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Kawasaki 85Z7 WHEEL LOADER Service Repair Manual (Serial No. 85J1-8001 and up)

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Kawasaki 85Z7 WHEEL LOADER Service Repair Manual (Serial No. 85J1-8001 and up)

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  1. 93211-00660 April 2014 85Z7 SHOP MANUAL SHOP MANUAL WHEEL LOADER 85Z7 Function & Structure General Information General Information Function & Structure 93211-00660 Powered by ISUZU 6HK1 ENGINE ©2014 KCM Corporation. All rights reserved. Printed in Japan (K) ( オセアニア用 オセアニア用 ) Serial No. 85J1-8001 and up

  2. 93211-00660 April 2014 SHOP MANUAL (Function & Structure) INTRODUCTION ........................................................................................................................... IN-01~02 SECTION 1 GENERAL Group 1 Specifications ............................................................................................................. T1-1 Group 2 Component Layout ..................................................................................................... T1-2 Group 3 Component Specifications ......................................................................................... T1-3 SECTION 2 SYSTEM Group 1 Controller .................................................................................................................... T2-1 Group 2 Control System ........................................................................................................... T2-2 Group 3 ECM System .............................................................................................................. T2-3 Group 4 Hydraulic System ....................................................................................................... T2-4 Group 5 Electrical System........................................................................................................ T2-5 SECTION 3 COMPONENT OPERATION Group 1 Pump Device .............................................................................................................. T3-1 Group 2 Control Valve .............................................................................................................. T3-2 Group 3 Cooling Fan ................................................................................................................ T3-3 Group 4 Steering Pilot Valve (OrbitrolTM) ................................................................................. T3-4 Group 5 Steering Valve ............................................................................................................ T3-5 Group 6 Pilot Valve................................................................................................................... T3-6 Group 7 Charging Circuit ......................................................................................................... T3-7 Group 8 Drive Unit ................................................................................................................... T3-8 Group 9 Axle ............................................................................................................................ T3-9 Group 10 Brake Valve .............................................................................................................. T3-10 Group 11 Others ....................................................................................................................... T3-11 INDEX ATTACHMENT Hydraulic Circuit Diagram Electrical Connection Diagram Electrical Wiring Diagram - Front Chassis Electrical Wiring Diagram - Rear Chassis Electrical Wiring Diagram - Floor (Front Console) Electrical Wiring Diagram - Floor (Rear & Side Console) All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. Electrical Wiring Diagram - CAB 85Z7 OCE

  3. INTRODUCTION To The Reader This manual is written for trained and skilled technicians to provide technical information needed to maintain and repair this machine.  If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):  Be sure to thoroughly read this manual for correct product information and service procedures. Additional References Please refer to the other materials (Operation and Maintenance Manual, parts catalog, engine technical material and Kawasaki Shop Manual, etc.) in addition to this manual. Manual Composition This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.  Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assembly / disassembly procedures.  Information included in the Technical Manual: Technical information needed for machine pre-delivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.  Information included in the Engine Manual: Technical information needed for machine pre-delivery and delivery and maintenance and repair of the engine, operation and activation of all devices and systems, troubleshooting and assembly / disassembly procedures. Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T Technical Manual 1 Section Number 3 Group Number 5 Consecutive Page Number for Each Group  Workshop Manual: W 1-3-2-5 W Workshop Manual 1 Section Number 3 Group Number 2 Sub Group Number 5 Consecutive Page Number for Each Group IN-01

  4. INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or machine damage. d CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death. d This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts. IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. f NOTE: Indicates supplementary technical information. Units Used SI Units (International System of Units) are used in this manual. MKSA (Meter, Kirogram, Second, Ampere) system units and English units are also indicated in parentheses just behind SI units. Example: 24.5 MPa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes. Quantity Length To Convert From mm mm L L m3 kg N N N·m MPa MPa kW kW °C km/h min-1 L/min mL/rev Into in ft US gal US qt yd3 lb kgf lbf kgf·m kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 0.10197 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0 Volume Weight Force Torque Pressure Power Temperature Velocity Flow rate fNOTE: The numerical value in this manual might be different from the above-mentioned table. IN-02

  5. Symbol and Abbreviation Symbol and Abbreviation Symbol / Abbreviation TO TT W, W/M Name Explanation Technical manual (Operational principle) Technical manual (Troubleshooting) Workshop manual Technical manual (Operational Principle). Technical manual (Troubleshooting). Workshop manual (Removal and Installation, Disassembly and Assembly). Main controller. MC controls the engine, pump, and valve according to the machine operating condition. Engine controller. ECM controls fuel injection amount according to the machine operating condition. Variable turbo controller. VGS is an exhaust turbo charged system to supercharge the exhaust energy while running the engine at slow idle speed. VGS optimizes the turbine rotation, improves the performance at slow-speed torque and the acceleration, reduces fuel consumption, and reduces particulate matter (PM) by adjusting the nozzle opening of turbine housing. Transmission control unit. TCU control transmission according to the machine operating condition. Communication controller. GSM is a type of wireless communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone. Global positioning system. CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization). Air conditioner. Optional component. MPDr. is the independent software installed on a computer prepared for troubleshooting, monitoring, and adjustment. Warming-up. Slow idle engine speed. Transmission Torque Converter Attachment. MC Main Controller ECM Engine Control Module VGS Variable Geometry System controller TCU Transmission Control Unit GSM Global System for Mobile communications controller GPS CAN Global Positioning System Controller Area Network A/C OPT MPDr. Air Conditioner Option Maintenance Pro Dr. WU Li T/M T/C ATT Warming-Up Low (Slow) Idle Transmission Torque Converter Attachment SY-1

  6. Symbol and Abbreviation Symbol / Abbreviation DPF Name Explanation Diesel Particulate Filter DPF is a filter which removes particulate matter (PM) including the toxic substance of exhaust gas of the diesel engine. Exhaust particulate removal equipment. DPD is an exhaust emission control system, a type of DPF, which cleans up particulate matter (PM) of diesel engine exhaust gas. DPD is a ceramic filter which traps and filters PM of exhaust gas. DPD burns up accumulated PM when PM increases and regenerates the filter. Oxidation catalyst for the diesel engine. Diesel oxidation catalyst oxidizes unburnt fuel and raises exhaust temperature. Filter. The filter traps, burns, and remove particulate matter (PM) by using high-temperature-exhaust gas with diesel oxidation catalyst. Catalyst is applied onto the filter. This advances PM burning. Particulate matter. The EGR control re-circulates a part of exhaust gas in the intake manifold and combines it with intake-air. Therefore, combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled. DPD Diesel Particulate Diffuser DOC Diesel Oxidation Catalyst CSF Catalyzed Soot Filter PM EGR Particulate Matter Exhaust Gas Recirculation SY-2

  7. SECTION 1 GENERAL CONTENTS Group 1 Specifications Specifications .......................................................................T1-1-1 Group 2 Component Layout Main Component (Overview) .........................................T1-2-1 Main Component ................................................................T1-2-2 Main Component ................................................................T1-2-3 Electric Component Layout (Overview)......................T1-2-4 Electrical System (Cab) ......................................................T1-2-5 Controller and Relays ...................................................T1-2-6 Right Console ..................................................................T1-2-7 Monitor and Switches ..................................................T1-2-8 Monitor Panel .................................................................T1-2-9 Electrical System (Relays)..........................................T1-2-10 Electrical System (Around Hydraulic Oil Tank) ..T1-2-11 Electrical System (Around Fuel Tank) ...................T1-2-12 Engine and Fan Pump .....................................................T1-2-13 Exhaust Filter .................................................................T1-2-14 Hydraulic Pump .................................................................T1-2-15 Transmission and Torque Converter Assembly ......T1-2-15 Loading Control Valve .....................................................T1-2-16 Manifold Valve ....................................................................T1-2-17 Parking Brake Solenoid Valve .......................................T1-2-17 Brake Charge Valve ...........................................................T1-2-17 3-Spool Solenoid Valve Unit ..........................................T1-2-17 Steering Valve .....................................................................T1-2-18 Secondary Steering Pump (Option) ...........................T1-2-18 Flow Regulator Valve .......................................................T1-2-18 Group 3 Component Specifications Engine .....................................................................................T1-3-1 Engine Performance Curve (6HK1XZWT-01) .......T1-3-4 Engine Accessories .............................................................T1-3-5 Hydraulic Component .......................................................T1-3-7 Electrical Component ......................................................T1-3-12 85Z7(OCE)F&S

  8. SECTION 1 GENERAL Group 1 Specifications Specifications 45 ° I G C H E B 37 ° F D A R1 R2 MNEC-12-001 Bucket Capacity: heaped Operating Weight Tipping Load Rated Loading Weight Engine A:  Overall Length B: Overall Width (Bucket) C: Overall Height D: Wheel Base E: Tread F: Ground Clearance G: Bucket Hinge Height H: Dumping Clearance (45 °) I: Dumping Reach (45 °) R1: Minimum Rotation Radius R2: Minimum Rotation Radius Travel Speed Forward/Reverse Transmission Speeds (F/R) Articulation Angle (Left/Right) deg Tire Size fNOTE:  * BOC (Bolt-On Cutting Edge) m3 (Y3) kg (lbs) kg (lbs) kg (lbs) 3.7 (4.8) 20670 (45560) 16140 (35590) 6300 (13890) ISUZU 6HK1 Diesel 8460 (333) 3100 (122) 3460 (136) 3350 (132) 2260 (89) 480 (19) 4250 (167) 3000 (118) 1040 (41) 6150 (242) 7180 (283) 36.4/24.6 (22.6/15.3) 4/3 37 26.5-25-20PR (L3) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) km/h (mph) - ( ° ) -  These specifications are subject to change without notice. T1-1-1

  9. SECTION 1 GENERAL Group 2 Component Layout Main Component (Overview) 5 4 3 2 1 8 9 10 TNED-01-02-016 6 TNED-01-02-017 7 1- 2- 3- Bucket Bell Crank (Lever) Bucket Cylinder 4- Front Combination Light (Headlight, Turn Signal Light, Clearance Light, Hazard Light) Front Work Light Rear Work Light 7- Rear Combination Light (Turn Signal Light, Hazard Light, Tail Light, Brake Light, Backup Light) Lift Arm Cylinder 9- 10- Bucket Link Lift Arm 5- 6- 8- T1-2-1

  10. SECTION 1 GENERAL Group 2 Component Layout Main Component 11 12 13 14 15 10 9 8 7 6 5 4 3 2 1 16 17 18 19 20 TNED-01-02-025 28 27 26 25 24 23 22 21 1- 2- 3- 4- 5- 6- 7- 8- 9- Fan Motor Radiator Inter Charge Air Cooler Coolant Level and Surge Tank Exhaust Filter/Muffler Air Cleaner Service Brake Accumulator Parking Brake Solenoid Valve Brake Charge Valve 10- Manifold Valve 11- Brake Valve 12- Steering Pilot Valve 13- Pilot Valve 14- Steering Valve 15- Loading Control Valve 16- 3-Spool Solenoid Valve Unit 17- Ride Control Accumulator (Option) 18- Stop Valve 19- Flow Regulator Valve 20- Engine Oil Filter 21- Pilot Filter 22- Hydraulic Oil Tank 23- Engine 24- Fuel Filter 25- Fuel Pre-Filter 26- Fuel Tank 27- Torque Converter Cooler 28- Hydraulic Oil Cooler T1-2-2

  11. SECTION 1 GENERAL Group 2 Component Layout Main Component 1 2 3 4 5 6 9 8 7 TNED-01-02-027 1- 2- 3- Front Axle Propeller Shaft (Front) Steering Cylinder 4- 5- 6- Hydraulic Pump Transmission Rear Axle 7- 8- Propeller Shaft (Rear) Steering Accumulator 9- Pressure Sensor (Brake Secondary Pressure) T1-2-3

  12. SECTION 1 GENERAL Group 2 Component Layout Electric Component Layout (Overview) 4 5 3 2 1 6 7 8 10 9 11 TNED-01-02-028 1- 2- 3- 4- Bucket Proximity Switch Lift Arm Angle Sensor ECM (Engine Control Module) Components Related with Cab (Refer to T1-2-5) 5- Components Related with Hydraulic Oil Tank (Refer to T1-2-11) Components Related with Engine (Refer to T1-2-13) Back Buzzer Battery Components Related with Fuel Tank (Refer to T1-2-12) 10- Components Related with Hydraulic Pump (Refer to T1-2-15) 8- 9- 11- Secondary Steering Pump Delivery Pressure Sensor (Option) 6- 7- T1-2-4

  13. SECTION 1 GENERAL Group 2 Component Layout Electrical System (Cab) 1 2 3 10 4 5 9 8 TNED-01-02-029 6 7 1- 2- 3- 4- Radio Upper Switch Panel (Option) Speaker Rear Wiper Motor 5- Components Related with Right Console (Refer to T1-2-7) Components Related with Controllers and Relays (Refer to T1-2-6) 7- 8- 9- Outside Temperature Sensor Brake Lamp Switch Front Wiper Motor 10- Components Related with Monitor and Switches (Refer to T1-2-8) 6- T1-2-5

  14. SECTION 1 GENERAL Group 2 Component Layout Controller and Relays 30 29 28 5 TNED-01-02-029 12 11 10 9 8 17 16 15 14 13 6 22 21 20 19 18 27 26 25 24 23 7 2 TNED-01-02-009 3 1 4 TNED-01-02-030 1- TCU (Transmission Control Unit) Flasher Relay Air Conditioner Controller MC (Main Controller) ECM Main Relay Fuel Pump Relay Starter Cut Relay Head Light Relay (Left) (AR1) 9- 10- High-Beam Relay (AR3) 11- Bucket Leveler Relay (AR4) 12- Back Buzzer Relay (AR5) 13- Work Light (Front) Relay (AR6) 14- Work Light (Rear) Relay (AR7) 15- Right Turn Signal Light Relay (AR8) 16- Horn Relay (AR9) Head Light Relay (Right) (AR2) 17- Secondary Steering Relay (AR10) 18- Parking Brake Relay 1 (RBR1) 19- Parking Brake Relay 2 (BR2) 20- Pilot Shut-Off Relay (BR3) 21- Brake Light Relay (BR4) 22- Load Dump Relay (BR5) 23- Neutral Relay (BR6) 24- Left Turn Signal Light Relay (BR7) 25- Front Washer Relay (BR8) 26- Rear Wiper Relay (BR9) 27- Rear Washer Relay (BR10) 28- Fuse Box B 29- Fuse Box A 30- MPDr. Connector 2- 3- 4- 5- 6- 7- 8- T1-2-6

  15. SECTION 1 GENERAL Group 2 Component Layout Right Console 20 Fingertip Control Type 4 5 6 7 8 9 3 10 21 11 12 2 1 22 19 18 13 14 15 1716 MNEC-01-042 MNEC-01-041 Multi-Function Joystick Type (Option) 22 20 1 5 6 7 8 23 10 11 12 25 24 26 27 19 13 14 15 1716 MNEC-01-044 MNEC-01-043 1- Auxiliary Control Lever (Option) Bucket Control Lever Lift Arm Control Lever Forward/Reverse Switch (Option) Front Control Lever Lock Switch Declutch Position Switch Travel Mode Selector Switch Power Mode Switch Forward/Reverse Selector Switch (Option) 10- Fan Reverse Rotation Switch 11- Auxiliary 12- Hydraulic Coupler Switch (Option) 7- 8- 9- 13- Secondary Steering Operation Check Switch (Option) 14- Exhaust Filter Switch 15- Auxiliary 16- Auxiliary 17- Ride Control Switch (Option) 18- Hold Switch 19- Right Console Slide Lever 20- DSS (Down Shift Switch) 21- Horn Switch 22- Quick Power Switch 23- Forward/Reverse Selector Switch 24- Forward/Reverse Switch 25- Multi-Function Joystick Lever 26- Hold Switch (Under the Lever) 27- Horn Button (Under the Lever) 2- 3- 4- 5- 6- T1-2-7

  16. SECTION 1 GENERAL Group 2 Component Layout Monitor and Switches TNED-01-02-029 6 7 8 9 2 3 4 5 1 MNEC-01-037 MNEC-01-038 1- 2- 3- 4- Front/Rear Wiper Switch Hazard Switch Work Light Switch Parking Brake Switch 5- Forward/Reverse Lever/Shift Switch Monitor Panel (Refer to T1-2-9) 7- Turn Signal Lever/Light Switch/High-Low Beam (Dimmer) Switch 8- Multi-Function Monitor/Air Conditioner Switch Panel Key Switch 6- 9- T1-2-8

  17. SECTION 1 GENERAL Group 2 Component Layout Monitor Panel 21 22 1 2 3 4 5 20 6 19 7 8 9 18 10 17 11 16 15 12 13 14 MNEC-01-001 1- 2- 3- 4- 5- 6- Left Turn Signal Indicator High Beam Indicator Work Light Indicator Right Turn Signal Indicator Parking Brake Indicator Brake Oil Low Pressure Indicator Hydraulic Oil Level Indicator Low Steering Oil Pressure Indicator Transmission Warning Indicator 10- Control Lever Lock Indicator 11- Low Fuel Level Indicator 7- 8- 12- Discharge Warning Indicator 13- Fuel Gauge 14- Multi Function Monitor 15- Communication System Error Indicator 16- Coolant Temperature Gauge 17- Overheat Indicator 18- Engine Trouble Indicator 19- Engine Oil Low Pressure Indicator 20- Preheat Indicator 21- Air Filter Restriction (Clogging) Indicator 22- Clearance Light Indicator 9- T1-2-9

  18. SECTION 1 GENERAL Group 2 Component Layout Electrical System (Relays) 1 2 3 4 MNEC-01-082 5 1- 2- Battery Relay Fusible Link (100A) 3- 4- Fusible Link (65A) Starter Relay 1 5- Glow Plug Relay T1-2-10

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  20. SECTION 1 GENERAL Group 2 Component Layout Electrical System (Around Hydraulic Oil Tank) 2 3 4 6 View A TNED-01-02-024 A 1 5 TNED-01-02-023 1- 2- 3- MAF (Mass Air Flow) Sensor Air Cleaner Hydraulic Oil Level Sensor 4- Secondary Steering Pump (Option) Hydraulic Oil Tank 6- Hydraulic Oil Temperature Sensor 5- T1-2-11

  21. SECTION 1 GENERAL Group 2 Component Layout Electrical System (Around Fuel Tank) 1 3 2 TNED-01-02-031 5 4 1- Fuel Pump 2- Fan Pump Delivery Pressure Sensor 3- 4- Fan Motor Relief Valve Fuel Tank 5- Fuel Level Sensor T1-2-12

  22. SECTION 1 GENERAL Group 2 Component Layout Engine and Fan Pump 6 1 2 3 4 5 TNED-01-02-003 TNED-01-02-006 10 11 9 7 8 12 13 14 15 16 TNED-01-02-005 TNED-01-02-004 1- 2- 3- 4- EGR Valve Injector Boost Temperature Sensor Boost Pressure Sensor 5- 6- 7- 8- Glow Plug Cam Angle Sensor Turbocharger Overheat Switch 9- 10- Intake Throttle 11- Common Rail Pressure Sensor 12- Fuel Temperature Sensor Coolant Temperature Sensor 13- Supply Pump 14- Crank Revolution Sensor 15- Engine Oil Pressure Sensor 16- Fan Pump T1-2-13

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