Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00562 – PDF DOWNLOAD
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Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00562 – PDF DOWNLOAD
Language :English
Pages :237
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File Type : PDF
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Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00562 – PDF DOWNLOAD
Powered by CUMMINS QSC8.3 Engine
Serial No. 80C5-9201 and up
FOREWORD
- Congratulations on your purchase of the Kawasaki Wheel Loader 80ZV-2. This manual contains safety, operation, transportation, maintenance and troubleshooting information. Read and understand the information in this manual carefully before operating or performing any maintenance of the machine. Failure to do so could result in personal injury or equipment failure.
- The safety of yourself and others depends upon your care and judgement in the operation and maintenance of this machine. Keep the manual with this machine at all times. Kawasaki pursues a policy of continuing improvement in design and performance of this machine. The right is therefore reserved to vary specifications without prior notice or obligation. This machine gives you, our customer, the maximum in performance and durability, state of the art technology and safety.
- Should you have any question regarding this machine or manual, please contact the Kawasaki dealer in your area during regular business hours. A satisfied customer is our goal. This manual is compiled for persons who understand English. If an operator or maintenance person does not understand English, please translate what said in this manual into his mother language. Read and understand this manual before operating and save this manual on the machine. If lost, damaged or unreadable, replace the manual immediately.
TABLE OF CONTENTS:
Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00562 – PDF DOWNLOAD
Powered by CUMMINS QSC8.3 Engine
Serial No. 80C5-9201 and up
FOREWORD 2
SAFETY NOTICE 3
CONTENTS 4
1SAFETY 6
SAFETY 7
Safe Operation 7
Operator Safety 7
Mounting and Dismounting Safety 8
Before Starting Safety 9
Operational Safety 12
Parking Safety 16
Safe Maintenance 17
Safety Preparations Before Maintenance 17
Explosion / Fire / Burn Prevention 20
Other Maintenance Safety Concerns 21
Safety Signs 23
Safety Devices 33
Loading Control Lever Lock 33
Control Lever Lock for Quick Coupler Lock Pin [3rd spool valve specification (option)] 33
Articulation Stopper 34
Neutral Start System 35
Emergency Brake 35
Secondary Steering 36
ROPS (Roll Over Protective Structure) Cab 36
2OPERATION 38
COMPONENT NAME/LOCATION 39
OPERATOR’S AREA 40
Pedals and Levers 40
1 Transmission Shift Lever 40
2 Horn Button 40
3 High-Low Beam Lever / Turn Signal Lever 41
4 Boom Control Lever 41
5 Bucket Control Lever 42
6 Auxiliary Attachment Control Lever (option) 43
7 Wrist Rest 43
8 Accelerator Pedal 44
9 Brake Pedals 45
10 Steering Column Telescopic Tilt Handle 46
Switches 47
1 Starter Switch 48
2 Parking Brake Switch 49
3 Light Switch 49
4 Front Working Light Switch 50
5 Rear Working Light Switch 50
6 (FE) Fuel Efficient Mode Switch 51
7 Front Wiper Switch 51
8 Rear Wiper Switch 52
9 Cigarette Lighter 52
10 Downshift Button 53
11 Four-Way Flasher Switch 53
12 MODM 54
13 Declutch ON/OFF and Adjustable Preset Switch 54
14 Kickout Control Switch 55
15 Efficient Loading System Switch 56
16 Selection Switch for Shift Lever or F/R Switch 57
17 F/R Switch 58
18 Reversal Fan Switch (option) 59
19 Ride Control Switch (option) 60
20 Shift Hold Switch (option) 60
21 Quick Coupler Lock Pin Switch (option) 61
Indicators 62
1 Speedometer 63
2 Engine Coolant Temperature Gauge 63
3 Torque Converter Oil Temperature Gauge 64
4 Fuel Gauge 64
5 Parking Brake Indicator Lamp (red) 64
6 Declutch Lamp (green) 64
7 Working Light Indicator Lamp (green) 64
8 Preheat Indicator Lamp (orange) 65
9 Central Warning Lamp (red) 65
10 MCU (Machine Control Unit) Warning Lamp (red) 65
11 Brake Pressure Warning Lamp (red) 65
12 Engine Oil Pressure Warning Lamp (red) 65
13 Engine Coolant Temperature Warning Lamp (red) 66
14 Torque Converter Oil Temperature Warning Lamp (red) 66
15 Air Cleaner Warning Lamp (red) 66
16 Charge Lamp (red) 67
17 Turn Signal Indicator Lamp (Left) (green) 67
18 Turn Signal Indicator Lamp (Right) (green) 67
19 High Beam Indicator Lamp (blue) 67
20 Auto Shift Indicator Lamp 67
21 Neutral Indicator Lamp 67
22 Transmission Status Monitor 68
23 Hour Meter 68
24 Secondary Steering Warning Lamp (red) 68
25 Engine Warning Lamps 68
26 Reversal Fan Pilot Lamp (green)(option) 69
27 F/R Switch Indicator Lamp (green) 69
28 Hydraulic Oil Level Warning Lamp (simultaneous flashing)(red)(11 24) 69
MODM 70
MODM function 70
Monitor Changeover 70
Information Monitor 71
Replacement Monitor 75
Error Log Monitor 77
Input/Output Monitor 78
Parameter Setting Monitor 78
Specification Setting Monitor 78
Seat 79
Seat Adjustment 79
Seat Adjustment 80
Seat Belt 81
Electrical Protection 82
Fuse Boxes 82
Fusible Link 83
Radio – AM / FM Cassette (24Volt Type) (option) (~December, 2009) 84
Air Conditioner 92
Ventilation Name and Location 92
Switches 92
Operating Method (Normal Use) 94
Operation Method (Other Uses) 95
Other Functions 96
For Efficient Use of the Air Conditioner 97
Action to be taken when the air conditioner is not used 98
Ride Control (option) 99
Operation and Function 99
Manual Box100
Grease Gun Holder101
Quick Coupler (option)102
Attachment Installation to Quick Coupler102
Hydraulic Pressure Hose & Electrical Wiring Connecting to Attachment104
OPERATION106
Check before Operation106
Walk-Around Inspection106
Check Engine Oil Level107
Check Hydraulic Oil Level108
Check Engine Coolant Level109
Drain Water and Sediment from Fuel Filter109
Check Wiring Harnesses110
Articulation Stopper110
Check Tire for Damage, Air and Tread Depth111
Check Drive Belt112
Check Crankcase Breather Tube113
Check Air Intake System113
Check Cooling Fan114
Check Horn Operation114
ROPS (Roll Over Protective Structure) Cab114
Adjust and Check Rear View Mirrors114
Check Parking Brake114
Check Monitor Panel Operation115
Check Control Levers115
Check Transmission Shift Lever115
Starting the Engine116
Normal Start116
Cold Start117
Idling Management System118
Warm-up control118
Hibernate Mode118
Check after Starting the Engine119
Check Warning Lamps119
Check Fuel Level120
Check Transmission Oil Level120
Check Service Brake Operation121
Check Parking Brake Operation121
Check Steering Wheel Operation122
Check Back-up Alarm Operation122
Check Exhaust Gas122
General Inspection123
Operating the Machine124
Starting the Machine124
Starting the Machine on a Grade125
Speed and Direction Change125
Running in Deep Mud or Water126
Parking127
Stopping the Engine128
Operating Techniques129
Loading129
Excavating131
Dozing132
Ground Levelling132
Carrying133
Dumping into Truck or Hopper134
Typical Truck Loading Methods135
SPECIAL PROCEDURES137
Adjustments137
Bucket / Attachment Leveler Adjustment137
Roading / Special Applications138
Booster Batteries / Jumper Cables139
Towing141
Wire hooking position and range/ stretching impossible range/tolerance142
Transportation143
Bucket hoisting position144
Long Term Storage145
Before Storage145
Battery removal / reinstallation procedure146
During Storage147
After Storage147
Cautions on Battery Replacement or Battery Cable Removal148
Welding149
Cautions Regarding Welding Repair Service149
3MAINTENANCE152
MAINTENANCE153
Serial Number Location153
Inspection and Maintenance Table156
When Required Inspection and Maintenance159
Replace Bucket Teeth (option)159
Replace Cutting Edge160
Check and/or Replace Seat Belt161
Clean or Replace Air Cleaner Element161
Clean Radiator / Air cooler / Hydraulic oil cooler Fins163
Check or Replace Fuses164
Check Windshield Washer Fluid165
Clean Air Conditioner Condenser166
Replace Coolant166
Replace Air Conditioner Receiver Dryer168
Greasing169
Every 10 Hours or Daily171
Every 50 Hours or 1 Week172
Greasing172
Drain Water and Sediment from Fuel Tank175
Check Battery Electrolyte Level175
Check Tire Air Pressure176
Every 250 Hours or 1 Month178
Greasing178
Check Differential Gear Oil179
Check Planetary Gear Oil180
Check Tightness of Wheel Bolts181
Check and Adjust Air Conditioner Belt181
Clean Air Conditioner Filter Element182
Replace Filter184
Every 500 Hours or 3 Months185
Replace Engine Oil and Oil Filter Cartridge185
Replace Transmission Oil Filter Cartridge187
Replace Fuel Filter Cartridges188
Replace DCA4 Coolant Filter Cartridge189
Every 1000 Hours or 6 Months191
Replace Transmission Oil191
Clean or Replace Transmission Breather193
Replace Hydraulic Oil Return Filter193
Adjust Parking Brake Lining194
Check Air Conditioner Refrigerant195
Inspect Automatic Belt Tensioner Pulley196
Every 2000 Hours or 1 Year197
Greasing197
Replace Hydraulic Oil, Clean Filter198
Replace Differential Gear Oil200
Replace Planetary Gear Oil201
Clean Fuel Tank203
Check Vibration Damper203
Check Brake Accumulator204
Check Service Brake Disk Wear204
Check and Adjust Valve Lash Clearance204
Replace Air Conditioner Filter Elements205
Clean Filter for Brake Line206
Clean Filter for Orbitrol®206
Replace Filter in the Hydraulic Tank Cap (S/N 9201~9250)207
Replace Filter in the Hydraulic Tank Breather Valve (S/N 9251~)208
Check Ride Control Accumulator (option)208
Recommended Lubricants209
Coolant Specification211
Recommended Mixture of Antifreeze211
TROUBLESHOOTING212
SPECIFICATIONS222
INDEX226
Maintenance Log229
Notes233
S.M 3/2/2025
