service repair manual download

1. ©2012 KCM Corporation. All rights reserved. Printed in Japan (K)
( アメリカ用 )
93211-00581
November 2012
SHOP MANUAL
WHEEL LOADER
85Z7
General Information
Function & Structure
Powered by ISUZU 6HK1 ENGINE
Serial No. 85J1-5001 and up
General
Information
85Z7
SHOP
MANUAL
93211-00581
Function
&
Structure

2. 93211-00581
November 2012
85Z7
SHOP MANUAL (Function & Structure)
INTRODUCTION........................................................................................................................... IN-01~02
Symbol and Abbreviation...............................................................................................................SY-1~2
SECTION 1 GENERAL
Group 1 Specifications ..........................................................................................................T1-1-1
Group 2 Component Layout..................................................................................................T1-2-1
Group 3 Component Specifications ......................................................................................T1-3-1
SECTION 2 SYSTEM
Group 1 Controller.................................................................................................................T2-1-1
Group 2 Control System........................................................................................................T2-2-1
Group 3 ECM System ...........................................................................................................T2-3-1
Group 4 Hydraulic System ....................................................................................................T2-4-1
Group 5 Electrical System.....................................................................................................T2-5-1
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device...........................................................................................................T3-1-1
Group 2 Control Valve...........................................................................................................T3-2-1
Group 3 Cooling Fan System................................................................................................T3-3-1
Group 4 Steering Pilot Valve .................................................................................................T3-4-1
Group 5 Steering Valve .........................................................................................................T3-5-1
Group 6 Pilot Valve................................................................................................................T3-6-1
Group 7 Charging Circuit ......................................................................................................T3-7-1
Group 8 Drive Unit.................................................................................................................T3-8-1
Group 9 Axle .........................................................................................................................T3-9-1
Group 10 Brake Valve ...........................................................................................................T3-10-1
Group 11 Others....................................................................................................................T3-11-1
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.

3. 93211-00590
March 2012
85Z7
SHOP MANUAL
(Operational Performance Test & Troubleshooting)
INTRODUCTION........................................................................................................................... IN-01~02
Symbol and Abbreviation...............................................................................................................SY-1~2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction .............................................................................................................T4-1-1
Group 2 Standard..................................................................................................................T4-2-1
Group 3 Engine Test..............................................................................................................T4-3-1
Group 4 Machine Performance Test .....................................................................................T4-4-1
Group 5 Component Test......................................................................................................T4-5-1
Group 6 Adjustment ..............................................................................................................T4-6-1
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure ............................................................................................T5-1-1
Group 2 Monitor ....................................................................................................................T5-2-1
Group 4 Component Layout..................................................................................................T5-4-1
Group 5 Troubleshooting A ...................................................................................................T5-5-1
Group 6 Troubleshooting B...................................................................................................T5-6-1
Group 7 Air Conditioner ........................................................................................................T5-7-1
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.

4. INTRODUCTION
IN-01
To The Reader
Additional References
Manual Composition
Page Number
This manual is written for trained and skilled technicians
to provide technical information needed to maintain and
repair this machine.
y Be sure to thoroughly read this manual for correct
product information and service procedures.
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.
This manual consists the Technical Manual, the Workshop
Manual and the Engine Manual.
y 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.
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
y Technical Manual: T 1-3-5
T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
y 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.):
y 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.
y 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.
y 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

5. INTRODUCTION
IN-02
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.
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.
CAUTION:
Indicated potentially hazardous situation which could, if
not avoided, result in personal injury or death.
IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information.
Units Used
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3
yd3
1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
NOTE: The numerical value in this manual might be
different from the above-mentioned table.
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.

6. Symbol and Abbreviation
SY-1
Symbol and Abbreviation
Symbol /
Abbreviation
Name Explanation
TO Technical manual (Operational principle) Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
VGS Variable Geometry System controller 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.
TCU Transmission Control Unit Transmission control unit. TCU control transmission
according to the machine operating condition.
GSM Global System for Mobile communications
controller
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.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment.

7. Symbol and Abbreviation
SY-2
Symbol /
Abbreviation
Name Explanation
DPF 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 Diesel Particulate Diffuser 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.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter 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.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation 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.

8. 85Z7 FS
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
Electric Component Layout (Overview) .....T1-2-4
Electrical System (Cab) ............................T1-2-5
Electrical System
(Around Hydraulic Oil Tank)................. T1-2-11
Electrical System (Around Fuel Tank) .....T1-2-12
Engine and Fan Pump............................T1-2-13
Hydraulic Pump......................................T1-2-15
Transmission and Torque Converter
Assembly ............................................T1-2-15
Loading Control Valve ............................T1-2-16
Manifold Valve........................................T1-2-17
Brake Charge Valve................................T1-2-17
Parking Brake Solenoid Valve.................T1-2-17
3-Spool Solenoid Valve Unit....................T1-2-17
Steering Valve ........................................T1-2-18
Flow Regualtor Valve..............................T1-2-18
Secondary Steering Pump ......................T1-2-18
Group 3 Component Specifications
Engine ..................................................... T1-3-1
Engine Accessories ................................. T1-3-5
Hydraulic Component .............................. T1-3-7
Electrical Component............................. T1-3-12

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

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

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

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

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

14. 5
6
3
2
1
T1-2-5
SECTION 1 GENERAL
Group 2 Component Layout
Electrical System (Cab)
Radio
1-
Upper Switch Panel (Optional)
2-
Speaker
3-
Rear Wiper Motor
4-
Components Related with
5-
Right Console (Refer to T1-2-7)
Components Related with
6-
Controllers and Relays (Refer
to T1-2-6)
Outside Temperature Sensor
7-
Brake Lamp Switch
8-
Front Wiper Motor
9-
Components Related with
10-
Monitor and Switches (Refer
to T1-2-8)
9
10
8
4
7 TNED-01-02-029

15. 11 10 9 8
6
5
7
T1-2-6
SECTION 1 GENERAL
Group 2 Component Layout
Controller and Relays
1- TCU (Transmission Control
Unit)
2- Flasher Relay
3- Air Conditioner Controller
4- MC (Main Controller)
5- ECM Main Relay
6- Fuel Pump Relay
7- Starter Cut Relay
8- Head Light Relay (Left) (AR1)
9- Head Light Relay (Right) (AR2)
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)
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
3
4
2
1
28
30
29
12
17
22
27
16
21
26
15
20
25
14
19
24
13
18
23
TNED-01-02-009
TNED-01-02-029
TNED-01-02-030

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

17. T1-2-8
SECTION 1 GENERAL
Group 2 Component Layout
Monitor and Switches
1- Front/Rear Wiper Switch
2- Hazard Switch
3- Work Light Switch
4- Parking Brake Switch
5- Forward/Reverse Lever/Shift
Switch
6- 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
9- Key Switch
5 6 7 8 9
4
3
2
1
MNEC-01-038
MNEC-01-037
TNED-01-02-029

18. T1-2-9
SECTION 1 GENERAL
Group 2 Component Layout
1- Left Turn Signal Indicator
2- High Beam Indicator
3- Work Light Indicator
4- Right Turn Signal Indicator
5- Parking Brake Indicator
6- Brake Oil Low Pressure
Indicator
7- Hydraulic Oil Level Indicator
8- Low Steering Oil Pressure
Indicator
9- Transmission Warning
Indicator
10- Control Lever Lock Indicator
11- Fuel Level Indicator
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
Monitor Panel
MNEC-01-001
4
5
6
7
8
10
9
3
2
1
22
21
20
19
18
17
16
14 13
11
12
15

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

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

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

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

24. T1-2-14
SECTION 1 GENERAL
Group 2 Component Layout
Exhaust Filter
DOC Exhaust Temperature
1-
Sensor
CSF Exhaust Temperature
2-
Sensor
Differential Pressure Sensor
3-
1 2 3
TNED-02-03-001