This manual comes as three bound books, with part numbers 93211-00432, 93211-00441 and 93211-00450 on the covers. They cover the 85ZV-2 wheel loader from Serial No. 85C5-9001 and up, fitted with the Cummins QSC8.3 engine.
When the loader sits dead in the yard, there is usually nobody around who knows these machines. These books cover clutch pressure checks, relief settings for the loader valve and steering, brake accumulator charging and the articulation joint center pin. The wiring diagrams are split by serial range, so the harness you trace is the one on your machine.
The troubleshooting book starts from the symptom and works down to the part at fault. The chassis and Cummins fault codes shown on the MODM are listed with their meanings. Follow it through and the bucket goes back to work.
What's Inside This Kawasaki 85ZV-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-37 | Contents, How to Use Manual, Layout of Main Components, Maintenance Chart, Recommended Lubricants and Refill Capacity, Coolant, Weight of Main Components, Bolt Tightening Torque, Liquid Gasket |
| Measurement for Performance Check (Standard Values) | 38-43 | Engine Speeds, Clutch Pressure, Relief Valve Setting Pressures, Cycle Times |
| Chassis Group: Function, Structure and Adjustment | 44-59 | Center Pin, Front and Rear Axle, Axle Nut Tightening Procedure |
| Power Group: Cummins QSC8.3 Engine, Cooling and Drive Shafts | 60-91 | Engine Mount, Radiator, Fan Motor Line, Propeller Shaft, Engine Oil Pressure Measurement |
| Torque Converter and Transmission | 92-123 | Torque Converter, Clutch Solenoid Valve, Modulation, Trimmer Engagement, Clutch Pressure Check |
| Hydraulic Group: Function, Structure and Adjustment | 124-247 | Hydraulic Pumps, Multiple Control Valve, Pilot Valve, Orbitrol, Steering Valve, Ride Control Accumulator, Relief Valve Setting Pressures |
| Brake Group | 248-289 | Service Brake, Brake Valve, Accumulator, Unloader Valve, Parking Brake |
| Electrical Group | 290-403 | Fuse Box, Engine Start Circuit, Mcu, Modm, Engine Fault Codes, Error Codes |
| Operator Station Group | 404-487 | Cab, Air Conditioner, Steering Column, Operator Seat |
| Drawings and Diagrams (Index, Hydraulic Circuit, Wiring Diagrams, MODM) | 488-563 | Index, Axle and Transmission Drawings, Hydraulic & Brake Circuit, Electrical Wiring Diagrams by Serial Range, MODM Operation |
| Disassembly & Reassembly: General Information | 564-590 | Weight of Main Components, Bolt and Hose Band Tightening Torque, Welding Repair Cautions, Bearing Handling, Articulation Stopper |
| Disassembly & Reassembly: Chassis Group and Service Standard | 591-624 | Deck, Fuel Tank, Hydraulic Tank, Engine Room, Center Pin |
| Disassembly & Reassembly: Power Group and Service Standard | 625-692 | Engine Removal and Installation, Radiator, Front and Rear Axle, Differential |
| Disassembly & Reassembly: Torque Converter and Transmission | 693-746 | Transmission Assembly, Clutch Packs, Torque Converter Assembly Bolt Tightening Torque |
| Disassembly & Reassembly: Hydraulic Group and Service Standard | 747-824 | Hydraulic Pump Removal and Installation, Hydraulic Cylinders, Multiple Control Valve, Orbitrol |
| Disassembly & Reassembly: Brake Group and Service Standard | 825-862 | Service Brake Discs, Brake Valve, Unloader Valve Removing and Installing, Parking Brake |
| Disassembly & Reassembly: Operator Station and Index | 863-889 | Cab, Air Conditioner, Periodical Inspection/Servicing, Index |
| Troubleshooting | 890-948 | Quick Troubleshooting Tables (Torque Converter and Transmission, Hydraulic, Brake, Electrical), Error Codes for Chassis and Engine |
| Measurement for Performance Check (Procedures) and Maintenance Log | 949-1007 | Engine Speed, Clutch Pressure, Relief Pressure Setting, Accumulator Charging Time, Brake Pedal Applications, Maintenance Log |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Cummins QSC8.3 | p. 19 |
| Engine oil refill capacity | 33 liter (change every 500 hours) | p. 23 |
| Transmission oil refill capacity | 38 liter (change every 1,000 hours) | p. 23 |
| Hydraulic tank oil capacity | 130 liter (change every 2,000 hours) | p. 23 |
| Fuel tank capacity | 300 liter | p. 23 |
| Differential & planetary oil (front / rear) | 74 liter / 80 liter | p. 23 |
| Low idle / high idle (Normal) | 800±50 / 2,250±50 min-1 (rpm) | p. 40 |
| Torque converter stall speed | 2,250±100 (Normal) / 2,050±100 (Fuel efficient mode) min-1 | p. 40 |
| Loading line main relief pressure (HI) | 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi) | p. 41 |
| Loading line overload relief pressure (LI) | 23.5±0.5 MPa (240±5 kgf/cm2) (3,413±71 psi) | p. 41 |
| Steering line main relief pressure (HI) | 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi) | p. 41 |
Kawasaki 85ZV-2 Common Problems This Manual Covers
Machine does not move in any shift lever position
Start with the checks on page 902: parking brake released, MODM error code, transmission oil level, MCU fuses and the 70 A fusible link. If all of those pass, the table points to air drawn into the T/C pump suction line or a defective T/C pump. After that it lists a damaged torque converter, a sticking clutch pressure regulator valve, the inching pressure switch and the controller.
Manual Section: Troubleshooting - Torque Converter and Transmission (page 902) p. 902Torque converter oil overheating
Page 908 lists four causes: air drawn into the suction line of the torque converter, internal torque converter leakage, a damaged torque converter, and T/C pump discharge that is too small. Tighten and check the suction side first because it costs the least. Then run the clutch pressure check from the Measurement for Performance Check section before you split the converter.
Manual Section: Troubleshooting - Torque Converter and Transmission (page 908) p. 908Boom or bucket lifts slowly or lacks power
Page 913 covers internal damage to the steering pump or main pump, main relief valve leakage or a low setting, overload relief leakage on the bucket bottom, the cylinder itself, cold or thick oil, and suction air leaks. Put a gauge on the circuit and compare against page 41. The loading line main relief (HI) should read 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi).
Manual Section: Troubleshooting - Hydraulic Group (page 913); Relief Pressures (page 41) p. 913Brakes weak or accumulator pressure will not rise
Page 924 has you check the accumulator nitrogen gas pressure, brake piping leakage and the MODM error code first. Its listed causes are a worn brake disk, a defective accumulator, a sticking brake valve spool, a damaged brake oil pipe and brake piston seals. If pressure never builds, go to page 927. It covers low unloader valve switching pressure, a defective unloader valve, an internally damaged accumulator and a defective pilot pump.
Manual Section: Troubleshooting - Brake Group (pages 924 and 927) p. 924Frequently Asked Questions
How do I clear error codes on the Kawasaki 85ZV-2?
You clear fault codes from the MODM fault log screens; the Electrical Group section covers machine and engine fault log navigation and clearing (page 369). On 85ZV-2 S/N 9201 and thereafter, you need to enter a password to clear a fault code. Check your serial plate before you start pressing buttons, because the password step depends on it. p. 369
What are the bolt torque specs for the 85ZV-2?
The general torque table on page 28 lists values by bolt grade and size. A hexagon bolt M12 (C) 1.75 takes 90 N-m in 8.8 (8T) and 132 N-m in 10.9 (11T). An M16 (C) 2.0 takes 216 / 314 N-m. Read the grade stamp on the bolt head first. The axle nuts and torque converter assembly bolts have their own procedures in separate sections. p. 28
What do Kawasaki 85ZV-2 engine fault codes EG122 and EG131 mean?
EG codes are Cummins engine faults shown on the MODM, listed from page 317. EG122 Yellow is Intake Manifold Pressure Sensor #1 Circuit - shorted high. EG131 Red is Accelerator Pedal Position Sensor Circuit - shorted high. Both are circuit faults, so check the connector and harness before you order a sensor. p. 317
What does chassis error code CN121 mean on the 85ZV-2?
CN121 is the chassis code for Shift lever F & R switch malfunction (page 931). It points to the forward/reverse switch in the shift lever, not to the gearbox internals. Check the switch against the Electrical Wiring Diagram for your serial range before you pull the transmission apart. p. 931
What stall speed should the 85ZV-2 torque converter hit?
The standard values on page 40 give torque converter stall as 2,250±100 in Normal mode and 2,050±100 in Fuel efficient mode. High Idle is 2,250±50 and Low Idle is 800±50 min-1 (725 in hibernate mode). If you test in the wrong mode, a healthy converter will look tired. p. 40
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