Kawasaki 80ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00273 – PDF DOWNLOAD
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Kawasaki 80ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00273 – PDF DOWNLOAD
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Kawasaki 80ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00273 – PDF DOWNLOAD
Powered by CUMMINS 6CTAA8.3 Engine
Serial No. 80C4-8001 and up
FOREWORD
- 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 obliga- tion.
- 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 mainte- nance person does not understand English, please translate what said in this manual into his mother language.
TABLE OF CONTENTS:
Kawasaki 80ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00273 – PDF DOWNLOAD
Powered by CUMMINS 6CTAA8.3 Engine
Serial No. 80C4-8001 and up
FOREWORD 2
SAFETY NOTICE 3
CONTENTS 4
1 SAFETY 1 1 4
SAFETY 1 2 4
Safe Operation 1 2 4
Safe Maintenance 1 11 4
Safety Signs 1 16 4
Safety Devices 1 21 4
2 OPERATION 2 1 4
COMPONENT NAME/LOCATION 2 2 4
OPERATOR’S AREA 2 3 4
Pedals and Levers 2 3 4
Switches 2 9 4
Indicators 2 17 4
Seat 2 24 4
Electrical Protection 2 26 4
Radio – AM / FM Cassette (24Volt Type) (option) 2 28 4
Air Conditioner 2 36 4
Vibration Damper (option) 2 43 4
Grease Gun Holder 2 44 4
OPERATION 2 45 4
Check before Operation 2 45 4
Starting the Engine 2 55 4
Check after Starting the Engine 2 57 4
Operating the Machine 2 62 4
Parking 2 65 4
Stopping the Engine 2 66 4
Operating Techniques 2 67 4
SPECIAL PROCEDURES 2 74 4
Adjustments 2 74 4
Roading / Special Applications 2 77 4
Booster Batteries / Jumper Cables 2 78 4
Towing 2 80 4
Transportation 2 81 4
Long Term Storage 2 83 4
3 MAINTENANCE 3 1 5
MAINTENANCE 3 2 5
Serial Number Location 3 2 5
Inspection and Maintenance Table 3 4 5
When Required Inspection and Maintenance 3 7 5
Every 10 Hours or Daily 3 16 5
Every 50 Hours or 1 Week 3 17 5
Every 250 Hours or 1 Month 3 23 5
Every 500 Hours or 3 Months 3 33 5
Every 1000 Hours or 6 Months 3 37 5
Every 2000 Hours or 1 Year 3 43 5
Coolant Specification 3 55 5
TROUBLESHOOTING 3 56 5
1 SAFETY 6
SAFETY 7
Safe Operation 7
Operator Safety 7
Mounting and Dismounting Safety 8
Before Starting Safety 9
Operational Safety 11
Parking Safety 15
Safe Maintenance 16
Safety Preparations Before Maintenance 16
Explosion / Fire / Burn Prevention 18
Other Maintenance Safety Concerns 19
Safety Signs 21
Safety Devices 26
Loading Control Lever Lock 26
Articulation Stopper 26
Neutral Start System 27
Emergency Brake 27
ROPS (Roll Over Protective Structure) Cab 28
MEMO 29
2 OPERATION 30
COMPONENT NAME/LOCATION 31
OPERATOR’S AREA 32
Pedals and Levers 32
1 Transmission Shift Lever 32
2 Horn Button 32
3 High-Low Beam Lever / Turn Signal Lever 33
4 Boom Control Lever 33
5 Bucket Control Lever 34
6 Auxiliary Attachment Control Lever (option) 34
7 Wrist Rest 35
8 Accelerator Pedal 35
9 Brake Pedals 36
10 Steering Column Telescopic Tilt Handle 37
Switches 38
1 Starter Switch 39
2 Parking Brake Switch 39
3 Light Switch 40
4 Front Working Light Switch 40
5 Rear Working Light Switch 41
6 Transmission Cut-Off Selector Switch 41
7 Front Wiper Switch 42
8 Rear Wiper Switch 42
9 Cigarette Lighter 43
10 Power Up Switch 43
11 Four-way Flasher Switch 44
12 Selection Switch for Shift Lever or F/R Switch (option) 44
13 F/R Switch (option) 45
Indicators 46
1 Speedometer 47
2 Engine Coolant Temperature Gauge 47
3 Torque Converter Oil Temperature Gauge 47
4 Fuel Gauge 47
5 Parking Brake Indicator Lamp (red) 48
6 Transmission Cut-Off Selection Lamp (green) 48
7 Working Light Indicator Lamp (green) 48
8 Preheat Indicator Lamp (orange) 48
9 Central Warning Lamp (red) 48
10 Transmission Control Warning Lamp (red) 48
11 Brake Pressure Warning Lamp (red) 49
12 Engine Oil Pressure Warning Lamp (red) 49
13 Engine Coolant Temperature Warning Lamp (red) 49
14 Torque Converter Oil Temperature Warning Lamp (red) 50
15 Air Cleaner Warning Lamp (red) 50
16 Charge Lamp (red) 50
17 Turn Signal Indicator Lamp (Left) (green) 50
18 Turn Signal Indicator Lamp (Right) (green) 50
19 High Beam Indicator Lamp (blue) 51
20 Auto Shift Indicator Lamp 51
21 Neutral Indicator Lamp 51
22 Transmission Status Monitor 51
23 Hour Meter 51
24 Vibration Damper Pilot Lamp (green) (option) 52
25 Emergency Steering Warning Lamp (red) (option) 52
Seat 53
Seat Adjustment 53
Seat Belt 54
Electrical Protection 55
Fuse Boxes 55
Fusible Link 56
Radio – AM / FM Cassette (24Volt Type) (option) 57
Air Conditioner 65
Ventilation Name and Location 65
Switches 65
Operation Method (Normal Usage) 67
Operation Method (Other Usage) 68
Other Functions 69
For Efficient Use of the Air Conditioner 70
Action to be taken when the air conditioner is not used 71
Vibration Damper (option) 72
Operation and Function 72
Grease Gun Holder 73
OPERATION 74
Check before Operation 74
Walk-Around Inspection 74
Check Engine Oil Level 75
Check Hydraulic Oil Level 76
Check Engine Coolant Level 77
Drain Water and Sediment from Fuel Filter 77
Check Wiring Harnesses 78
Articulation Stopper 78
Check Tire for Damage, Air and Tread Depth 79
Check Drive Belt 80
Check Air Intake System 81
Check Cooling Fan 82
Check Horn Operation 82
ROPS (Roll Over Protective Structure) Cab 82
Adjust and Check Rear View Mirrors 82
Check Parking Brake 82
Check Monitor Panel Operation 83
Check Control Levers 83
Check Transmission Shift Lever 83
Starting the Engine 84
Normal Start 84
Cold Start 85
Check after Starting the Engine 86
Check Warning Lamps 86
Check Fuel Level 87
Check Transmission Oil Level 87
Check Service Brake Operation 88
Check Parking Brake Operation 89
Check Steering Wheel Operation 89
Check Back-up Alarm Operation 89
Check Exhaust Gas 90
General Inspection 90
Operating the Machine 91
Starting the Machine 91
Starting the Machine on a Grade 92
Speed and Direction Change 92
Parking 94
Stopping the Engine 95
Operating Techniques 96
Loading 96
Excavating 98
Dozing 98
Ground Levelling 99
Carrying 100
Dumping into Truck or Hopper 100
Typical Truck Loading Methods 102
SPECIAL PROCEDURES 103
Adjustments 103
Bucket / Attachment Positioner Adjustment 103
Boom Kickout Adjustment 104
Roading / Special Applications 106
Booster Batteries / Jumper Cables 107
Towing 109
Transportation 110
Long Term Storage 112
Before Storage 112
During Storage 112
After Storage 113
3 MAINTENANCE 114
MAINTENANCE 115
Serial Number Location 115
Inspection and Maintenance Table 117
When Required Inspection and Maintenance 120
Replace Bucket Teeth (option) 120
Replace Cutting Edge 121
Check and/or Replace Seat Belt 122
Clean or Replace Air Cleaner Element 122
Clean Radiator / Air cooler / Hydraulic oil cooler Fins 123
Check or Replace Fuses 125
Check Windshield Washer Fluid 125
Clean Air Conditioner Condenser 126
Replace Coolant 126
Replace Air Conditioner Receiver Dryer 128
Every 10 Hours or Daily 129
Every 50 Hours or 1 Week 130
Greasing 130
Drain Water and Sediment from Fuel Tank 133
Check Battery Electrolyte Level 133
Check Tire Air Pressure 134
Every 250 Hours or 1 Month 136
Greasing 136
Replace Engine Oil and Oil Filter Cartridge 137
Check Differential Gear Oil 138
Check Planetary Gear Oil 139
Check Tightness of Wheel Bolts 140
Replace DCA4 Coolant Filter Cartridge 141
Check and Adjust Air Conditioner Belt 142
Clean Air Conditioner Filter Element 143
Replace Filter 145
Every 500 Hours or 3 Months 146
Replace Transmission Oil Filter Cartridge 146
Replace Fuel Filter Cartridge 147
Clean Fuel Prefilter 148
Every 1000 Hours or 6 Months 150
Replace Transmission Oil 150
Clean or Replace Transmission Breather 151
Replace Hydraulic Oil Return Filter 152
Adjust Parking Brake Lining 153
Check Air Conditioner Refrigerant 154
Inspect Automatic Belt Tensioner Pulley 155
Every 2000 Hours or 1 Year 156
Greasing 156
Replace Hydraulic Oil, Clean Filter 158
Replace Differential Gear Oil 159
Replace Planetary Gear Oil 160
Clean Fuel Tank 161
Check Vibration Damper 162
Check Brake Accumulator 163
Check Service Brake Disk Wear 163
Check and Adjust Valve Lash Clearance 163
Replace Air Conditioner Filter Elements 163
Clean Filter for Brake Line 164
Clean Filter for Orbitrol® 165
Check Vibration Damper Accumulator (option) 166
Replace Filter in the Oil Tank Cap 166
Coolant Specification 168
Recommended Mixture of Antifreeze 168
TROUBLESHOOTING 169
INDEX 176
A 176
B 176
C 176
D 176
E 176
F 177
G 177
H 177
I 177
L 177
M 177
N 177
O 177
P 177
R 177
S 177
T 177
V 178
W 178
Maintenance Log 179
Notes 183
SAFETY NOTICE 3
CONTENTS 4
1 SAFETY 1 1 4
SAFETY 1 2 4
Safe Operation 1 2 4
Safe Maintenance 1 11 4
Safety Signs 1 16 4
Safety Devices 1 21 4
2 OPERATION 2 1 4
COMPONENT NAME/LOCATION 2 2 4
OPERATOR’S AREA 2 3 4
Pedals and Levers 2 3 4
Switches 2 9 4
Indicators 2 17 4
Seat 2 24 4
Electrical Protection 2 26 4
Radio – AM / FM Cassette (24Volt Type) (option) 2 28 4
Air Conditioner 2 36 4
Vibration Damper (option) 2 43 4
Grease Gun Holder 2 44 4
OPERATION 2 45 4
Check before Operation 2 45 4
Starting the Engine 2 55 4
Check after Starting the Engine 2 57 4
Operating the Machine 2 62 4
Parking 2 65 4
Stopping the Engine 2 66 4
Operating Techniques 2 67 4
SPECIAL PROCEDURES 2 74 4
Adjustments 2 74 4
Roading / Special Applications 2 77 4
Booster Batteries / Jumper Cables 2 78 4
Towing 2 80 4
Transportation 2 81 4
Long Term Storage 2 83 4
3 MAINTENANCE 3 1 5
MAINTENANCE 3 2 5
Serial Number Location 3 2 5
Inspection and Maintenance Table 3 4 5
When Required Inspection and Maintenance 3 7 5
Every 10 Hours or Daily 3 16 5
Every 50 Hours or 1 Week 3 17 5
Every 250 Hours or 1 Month 3 23 5
Every 500 Hours or 3 Months 3 33 5
Every 1000 Hours or 6 Months 3 37 5
Every 2000 Hours or 1 Year 3 43 5
Coolant Specification 3 55 5
TROUBLESHOOTING 3 56 5
1 SAFETY 6
SAFETY 7
Safe Operation 7
Operator Safety 7
Mounting and Dismounting Safety 8
Before Starting Safety 9
Operational Safety 11
Parking Safety 15
Safe Maintenance 16
Safety Preparations Before Maintenance 16
Explosion / Fire / Burn Prevention 18
Other Maintenance Safety Concerns 19
Safety Signs 21
Safety Devices 26
Loading Control Lever Lock 26
Articulation Stopper 26
Neutral Start System 27
Emergency Brake 27
ROPS (Roll Over Protective Structure) Cab 28
MEMO 29
2 OPERATION 30
COMPONENT NAME/LOCATION 31
OPERATOR’S AREA 32
Pedals and Levers 32
1 Transmission Shift Lever 32
2 Horn Button 32
3 High-Low Beam Lever / Turn Signal Lever 33
4 Boom Control Lever 33
5 Bucket Control Lever 34
6 Auxiliary Attachment Control Lever (option) 34
7 Wrist Rest 35
8 Accelerator Pedal 35
9 Brake Pedals 36
10 Steering Column Telescopic Tilt Handle 37
Switches 38
1 Starter Switch 39
2 Parking Brake Switch 39
3 Light Switch 40
4 Front Working Light Switch 40
5 Rear Working Light Switch 41
6 Transmission Cut-Off Selector Switch 41
7 Front Wiper Switch 42
8 Rear Wiper Switch 42
9 Cigarette Lighter 43
10 Power Up Switch 43
11 Four-way Flasher Switch 44
12 Selection Switch for Shift Lever or F/R Switch (option) 44
13 F/R Switch (option) 45
Indicators 46
1 Speedometer 47
2 Engine Coolant Temperature Gauge 47
3 Torque Converter Oil Temperature Gauge 47
4 Fuel Gauge 47
5 Parking Brake Indicator Lamp (red) 48
6 Transmission Cut-Off Selection Lamp (green) 48
7 Working Light Indicator Lamp (green) 48
8 Preheat Indicator Lamp (orange) 48
9 Central Warning Lamp (red) 48
10 Transmission Control Warning Lamp (red) 48
11 Brake Pressure Warning Lamp (red) 49
12 Engine Oil Pressure Warning Lamp (red) 49
13 Engine Coolant Temperature Warning Lamp (red) 49
14 Torque Converter Oil Temperature Warning Lamp (red) 50
15 Air Cleaner Warning Lamp (red) 50
16 Charge Lamp (red) 50
17 Turn Signal Indicator Lamp (Left) (green) 50
18 Turn Signal Indicator Lamp (Right) (green) 50
19 High Beam Indicator Lamp (blue) 51
20 Auto Shift Indicator Lamp 51
21 Neutral Indicator Lamp 51
22 Transmission Status Monitor 51
23 Hour Meter 51
24 Vibration Damper Pilot Lamp (green) (option) 52
25 Emergency Steering Warning Lamp (red) (option) 52
Seat 53
Seat Adjustment 53
Seat Belt 54
Electrical Protection 55
Fuse Boxes 55
Fusible Link 56
Radio – AM / FM Cassette (24Volt Type) (option) 57
Air Conditioner 65
Ventilation Name and Location 65
Switches 65
Operation Method (Normal Usage) 67
Operation Method (Other Usage) 68
Other Functions 69
For Efficient Use of the Air Conditioner 70
Action to be taken when the air conditioner is not used 71
Vibration Damper (option) 72
Operation and Function 72
Grease Gun Holder 73
OPERATION 74
Check before Operation 74
Walk-Around Inspection 74
Check Engine Oil Level 75
Check Hydraulic Oil Level 76
Check Engine Coolant Level 77
Drain Water and Sediment from Fuel Filter 77
Check Wiring Harnesses 78
Articulation Stopper 78
Check Tire for Damage, Air and Tread Depth 79
Check Drive Belt 80
Check Air Intake System 81
Check Cooling Fan 82
Check Horn Operation 82
ROPS (Roll Over Protective Structure) Cab 82
Adjust and Check Rear View Mirrors 82
Check Parking Brake 82
Check Monitor Panel Operation 83
Check Control Levers 83
Check Transmission Shift Lever 83
Starting the Engine 84
Normal Start 84
Cold Start 85
Check after Starting the Engine 86
Check Warning Lamps 86
Check Fuel Level 87
Check Transmission Oil Level 87
Check Service Brake Operation 88
Check Parking Brake Operation 89
Check Steering Wheel Operation 89
Check Back-up Alarm Operation 89
Check Exhaust Gas 90
General Inspection 90
Operating the Machine 91
Starting the Machine 91
Starting the Machine on a Grade 92
Speed and Direction Change 92
Parking 94
Stopping the Engine 95
Operating Techniques 96
Loading 96
Excavating 98
Dozing 98
Ground Levelling 99
Carrying 100
Dumping into Truck or Hopper 100
Typical Truck Loading Methods 102
SPECIAL PROCEDURES 103
Adjustments 103
Bucket / Attachment Positioner Adjustment 103
Boom Kickout Adjustment 104
Roading / Special Applications 106
Booster Batteries / Jumper Cables 107
Towing 109
Transportation 110
Long Term Storage 112
Before Storage 112
During Storage 112
After Storage 113
3 MAINTENANCE 114
MAINTENANCE 115
Serial Number Location 115
Inspection and Maintenance Table 117
When Required Inspection and Maintenance 120
Replace Bucket Teeth (option) 120
Replace Cutting Edge 121
Check and/or Replace Seat Belt 122
Clean or Replace Air Cleaner Element 122
Clean Radiator / Air cooler / Hydraulic oil cooler Fins 123
Check or Replace Fuses 125
Check Windshield Washer Fluid 125
Clean Air Conditioner Condenser 126
Replace Coolant 126
Replace Air Conditioner Receiver Dryer 128
Every 10 Hours or Daily 129
Every 50 Hours or 1 Week 130
Greasing 130
Drain Water and Sediment from Fuel Tank 133
Check Battery Electrolyte Level 133
Check Tire Air Pressure 134
Every 250 Hours or 1 Month 136
Greasing 136
Replace Engine Oil and Oil Filter Cartridge 137
Check Differential Gear Oil 138
Check Planetary Gear Oil 139
Check Tightness of Wheel Bolts 140
Replace DCA4 Coolant Filter Cartridge 141
Check and Adjust Air Conditioner Belt 142
Clean Air Conditioner Filter Element 143
Replace Filter 145
Every 500 Hours or 3 Months 146
Replace Transmission Oil Filter Cartridge 146
Replace Fuel Filter Cartridge 147
Clean Fuel Prefilter 148
Every 1000 Hours or 6 Months 150
Replace Transmission Oil 150
Clean or Replace Transmission Breather 151
Replace Hydraulic Oil Return Filter 152
Adjust Parking Brake Lining 153
Check Air Conditioner Refrigerant 154
Inspect Automatic Belt Tensioner Pulley 155
Every 2000 Hours or 1 Year 156
Greasing 156
Replace Hydraulic Oil, Clean Filter 158
Replace Differential Gear Oil 159
Replace Planetary Gear Oil 160
Clean Fuel Tank 161
Check Vibration Damper 162
Check Brake Accumulator 163
Check Service Brake Disk Wear 163
Check and Adjust Valve Lash Clearance 163
Replace Air Conditioner Filter Elements 163
Clean Filter for Brake Line 164
Clean Filter for Orbitrol® 165
Check Vibration Damper Accumulator (option) 166
Replace Filter in the Oil Tank Cap 166
Coolant Specification 168
Recommended Mixture of Antifreeze 168
TROUBLESHOOTING 169
INDEX 176
A 176
B 176
C 176
D 176
E 176
F 177
G 177
H 177
I 177
L 177
M 177
N 177
O 177
P 177
R 177
S 177
T 177
V 178
W 178
Maintenance Log 179
Notes 183
S.M 5/2/2025