Kawasaki WHEEL LOADER 80ZV Shop MANUAL 93211-00143 – PDF DOWNLOAD
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Kawasaki WHEEL LOADER 80ZV Shop MANUAL 93211-00143 – PDF DOWNLOAD
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DESCRIPTION:
Kawasaki WHEEL LOADER 80ZV Shop MANUAL 93211-00143 – PDF DOWNLOAD
General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSL9 ENGINE
Serial No. 85C4-9001 and up
Foreword
- To ensure good machine performance, reduce failures or problems, and prolong the service life of
each component, it is necessary to operate the machine as is directed in the Operator and
Maintenance Manual. - To effectively diagnose and repair the machine, it is important to follow the guidelines laid out
in this Shop Manual.
General Information Function and structure
- For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
- The purpose of this manual is to provide information on the product and the correct maintenance and
repair meth- ods. Please read this manual to ensure correct troubleshooting and good repair
service. - This manual will be periodically reviewed and revised for more satisfactory content. If
you have any opinion or requests, please inform us.
TABLE OF CONTENTS:
Kawasaki WHEEL LOADER 80ZV Shop MANUAL 93211-00143 – PDF DOWNLOAD
General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSL9 ENGINE
Serial No. 85C4-9001 and up
Foreword 2
Safety Symbols 3
CONTENTS 4
00 General Information 16
How to Use Manual 17
Safety precautions 17
Symbols 18
Outline 19
Layout of main components 19
Inspection and maintenance table 20
Recommended lubricants 23
Coolant 24
Coolant specification 24
Recommended mixture of antifreeze 24
Lubrication chart 25
Weight of main components 26
Bolt tightening torque 27
Hexagon bolt 27
Flanged hexagon bolt 30
Hose band tightening torque 31
Liquid gasket and screw lock agent 32
Cautions regarding parts removal 32
Cautions regarding reassembly 32
Screw lock agent application procedure 33
How to wind a seal tape 33
Cautions regarding welding repair service 34
Cautions 34
03 Measurement for Performance Check 36
Cautions on Safety 37
Standard Measurement Values for Performance Check 38
12 Function & Structure Chassis Group 40
Front Chassis 41
Loading linkage 41
Loading linkage pin 43
Rear Chassis 44
Fuel tank 44
Floor board mount 45
Floor board 45
Viscous mount 45
Center Pin 46
Upper center pin 46
Lower center pin 46
Dust seal 47
13 Check & Adjustment Chassis Group 48
Linkage Pin 49
Liner 49
Adjustment 50
Center Pin 51
Adjusting shim 51
Installing bearing cover 51
Installing bearing outer ring 52
22 Function & Structure Power Group 54
Power Line 55
Engine / Transmission 56
Engine / transmission mount 56
Radiator 57
Radiator mount 58
Propeller Shaft 59
Second propeller shaft assembly 60
Front differential – Transmission 60
Third propeller shaft assembly 61
Transmission – Rear differential 61
Axle Assembly 62
Axle Support 65
Differential Gear 69
Function of T P D 72
Difference in gear shapes 72
Contact between pinion and side gear 72
Operation of T P D 73
Differential Gear (Limited Slip Differential) 74
Structure 74
LSD function 77
LSD operation 77
23 Check & Adjustment Power Group 78
Engine 79
Measuring engine speed 79
Measurement instrument 79
Standard measurement value 79
Measuring engine oil pressure 79
Measurement instrument 79
Install position 79
Standard measurement value 79
Propeller Shaft 80
Propeller shaft phase 80
Second propeller shaft alignment 80
Tightening torque 81
Axle 82
Axle nut tightening procedure 82
Differential gear adjustment procedure 83
Preload adjustment 84
Bearing installation 84
Oil seal installation 84
Adjusting tooth contact 85
32 Function & Structure Torque Converter and Transmission Group 88
Torque Converter 89
Torque converter structure 89
Power flow path 89
Torque multiplication 89
Torque Converter Gear Pump 90
Gear pump specifications 90
Transmission 91
Clutch combination 91
Shift lever position 91
QUAD (Quick up and down shift) 91
Gear train and number of teeth 92
Clutch specifications 93
Friction plate: mm (in) 94
Clutch Pack 95
Forward and 3rd speed clutches 95
Reverse and 2nd speed clutches 96
1st speed clutch 97
4th speed clutch 98
Power Flow Path in the Transmission 99
Forward 99
Forward 1st speed 99
Forward 2nd speed 99
Forward 3rd speed 100
Forward 4th speed 100
Reverse 101
Reverse 1st speed 101
Reverse 2nd, 3rd, and 4th speeds 101
Hydraulic System Diagram 102
Hydraulic Circuit Diagram 103
Oil Flow 104
Oil flow in the torque converter line 104
From torque converter gear pump to torque converter 104
From torque converter to cooling circuit 104
From cooler to lubrication circuit 104
Oil flow to the clutch 104
To forward and reverse clutches 104
To speed clutch 104
T/C and T/M Oil Circulation 105
Control Valve 106
System diagram 107
Modulation Mechanism 108
Clutch control oil pressure curve 109
Traveling at forward 1st speed 110
Pressure holding 110
Changing from forward 1st speed to reverse 1st speed 111
Releasing forward clutch and feeding initial oil to reverse clutch 111
Trimmer engagement 112
Low-pressure holding 112
Clutch engagement starting 113
Pressure increase 113
Clutch Solenoid Valve 114
For forward/reverse and speed clutches 114
After power-off (clutch disengaged status) 114
After power-on (clutch engaged status) 115
For trimmer 116
After power-off (high clutch pressure status) 116
After power-on (just after switching clutch) 117
33 Check & Adjustment Torque Converter and Transmission Group 118
Clutch Oil Pressure 119
Measuring clutch oil pressure 119
42 Function & Structure Hydraulic Group 120
Flushing Hydraulic Circuit 121
Purpose of flushing 121
Cautions on Hydraulic Parts Replacement 122
Hydraulic Circuit Symbols 123
Hydraulic lines 123
Pumps & motors 123
Cylinders 123
Operation methods 124
Pressure control valve 124
Flow control valve 124
Directional control valve 125
Check valve 125
Miscellaneous hydraulic symbols 126
Hydraulic System Operation 127
Hydraulic system operation outline 127
Loading system 127
Steering system 128
Fan motor system 128
Vibration damper system (OPT) 128
Layout of Hydraulic Units 129
Hydraulic Tank 130
Hydraulic tank breather valve (tank cap) 132
Hydraulic tank specifications 133
Hydraulic oil level check 134
Hydraulic Pump 135
Hydraulic pump specifications 135
Hydraulic pump principle 136
Hydraulic pump wear plate 137
Hydraulic pump bushing lubrication 137
Hydraulic Cylinder 138
Boom cylinder 138
Bucket cylinder 139
Steering cylinder 139
Hydraulic cylinder specifications 140
Loading System 141
Reducing Valve (for Pilot Pressure) 142
Pilot valve (S/N 85C4-9001~9030) 143
Pilot valve operation 145
Pilot valve detent magnet solenoid 147
Detent adjustment procedure 147
Pilot valve (S/N 85C4-9031~) 148
Pilot valve operation 150
Pre-detent and detent magnet solenoid 152
Multiple Control Valve (KML35A/2T002) 153
Multiple control valve specifications 154
Multiple control valve main relief valve 155
Main relief valve operation 155
Adjusting set pressure 156
Multiple control valve overload relief valve 157
Overload relief valve operation 157
Adjusting set pressure 158
Multiple control valve make-up valve 158
Make-up valve operation 158
Multiple control valve bucket spool 159
Bucket spool operation 159
Multiple control valve boom spool 161
Boom spool operation 161
Adapter (Orifice) 164
Vibration Damper (OPT) 165
Vibration damper hydraulic circuit 165
Vibration damper function 165
Vibration damper operation 166
Preparation mode (vibration damper switch is OFF) 166
Running mode (vibration damper switch is ON) 167
Vibration damper valve assembly 168
Solenoid valve 171
Accumulator (for vibration damper) 173
Accumulator function 173
Vibration damper hydraulic line 174
Steering System 175
Orbitrol® 176
Orbitrol® specification 176
Orbitrol® structure 177
Valve part 177
Rotor part 177
Orbitrol® operation 178
Neutral 178
Turn 179
Orbitrol® feed-back mechanism operation 180
Steering speed and flow rate control 181
Hydraulic pump oil amount and steering force 181
Orbit rotor operation principle 182
Steering Valve (KVS25-A1 0/A3 0/20) 183
Steering valve operation 185
Neutral position 185
Left turn position 186
Steering plunger variable throttle 187
Steering valve flow control plunger 188
Steering valve main relief valve 189
When the pressure is at the preset value or less 189
When the pressure exceeds the preset value 190
Steering valve overload relief valve 191
Overload relief valve operation 192
Steering pilot circuit and its operation 193
Flow amplifier notch and pilot orifice 194
Stop Valve 195
Stop valve function 196
Stop valve operation 197
Reducing Valve (for Orbitrol®) 198
Steering Line Filter 199
Fan Motor System 200
Fan Motor Line 201
Fan Motor (GM20W-1T13T8-B70A61L) 204
Fan motor specifications 204
Thermo Sensing Valve 205
Thermo sensing valve specifications 205
Thermo sensing valve operation 206
Fan Motor Relief Valve Assembly 207
Fan motor relief valve 208
Fan motor check valve (Make-up valve) 208
Emergency Steering 209
Emergency steering circuit 209
Emergency steering operation 209
Machine speed signal 210
Emergency steering motor and pump 210
43 Check & Adjustment Hydraulic Group 212
Loading/Steering Circuit Relief Valve 213
Loading circuit relief valve setting pressures 213
Measurement instruments 213
Gauge port 213
Standard measurement value MPa (kgf/cm2) (psi) 214
Measuring loading circuit main relief pressure 214
Measuring loading circuit overload relief pressure 216
Measuring pilot circuit relief pressure 217
Steering circuit relief valve setting pressures 218
Measurement instruments 218
Gauge port 218
Standard measurement value MPa (kgf/cm2) (psi) 219
Measuring steering circuit main relief pressure 219
Measuring steering circuit overload relief pressure 221
Measuring pilot circuit relief pressure (reducing pressure) 222
Hydraulic Cylinder 223
Cylinder natural drift 223
Measurement instrument 223
Standard measurement value (mm/min) (in/min) 223
Measurement procedure 223
Stop Valve 225
Stop valve adjustment procedure 225
Fan Revolution 226
Fan maximum revolution measurement 227
Measurement instrument 227
Standard measurement value 227
Fan motor hydraulic circuit diagram 227
Measurement procedure 227
52 Function & Structure Brake Group 228
Brake System Outline 229
Service brake 229
Parking brake 229
Adjustment of axle internal pressure 229
Brake Units Layout 230
Unloader Valve 231
Unloader valve operation 232
Valve Unit 233
Accumulator 234
In-Line Filter 235
Brake Valve 237
Brake main valve (left pedal) 237
Brake pilot valve (right pedal) 238
Brake valve performance chart 239
Brake valve outline 241
Main valve (tandem type) operation 241
Pilot valve operation 242
Service Brake 243
Service brake operation 243
Service brake friction plate 244
Service brake steel plate 244
Service brake piston 245
Service brake pedal stroke adjusting mechanism (S/N 9001~9016) 247
Tolerance ring 248
Brake circuit air bleeding procedure 249
Bleeding air from the brake valves 250
Bleeding air from brake pipes and axle housing hubs 250
Parking Brake 251
Parking brake operation 252
Parking brake solenoid valve 253
Solenoid valve operation 253
Solenoid valve specifications 253
Parking Brake Manual Release 254
Parking Brake Spring Chamber 256
Brake Circuit Check Valve 257
Pressure Switch 258
Pressure switch (for stop lamp) 258
Pressure switch (for Declutch) 259
53 Check & Adjustment Brake Group 260
Brake Circuit Oil Pressure 261
Unloader valve setting pressure 261
Measurement procedure 262
Brake valve oil pressure 263
Measurement instrument 263
Gauge port 263
Measurement procedure 263
Brake valve performance 264
Service Brake 265
Service brake performance check 265
Condition 265
Standard measurement value 265
Service brake friction plate wear measurement 266
Measurement procedure 267
Cautions on installing brake discs (S/N 9001~9016 only) 267
Parking Brake 269
Parking brake performance check 269
Condition 269
Standard measurement value 269
Parking brake clearance adjustment 270
Adjustment procedure 270
Brake lining abrasion check 271
62 Function & Structure Electrical Group 272
How to Use Electrical Wiring Diagram 273
Utilisation des schémas des câblages électriques (FRANÇAIS) 274
Verwendung des elektrischen Schaltplans (DEUTSCH) 275
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) 276
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) 277
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) 278
Electrical Cable Color Codes 279
Electrical Circuit Symbols 280
Sensor Mount 281
Fuse 282
Fuse box location 282
Fuse box 283
Fusible link 284
Engine Start Circuit 285
Engine start circuit diagram 285
Neutral starter 285
Shift lever neutral (N) position 285
Shift lever forward/reverse (F/R) position 285
Starter switch 286
Battery relay 287
Battery relay operation 287
Alternator I terminal wire 287
Diode unit 288
Neutral relay 288
Magnet switch 289
Voltage relay 289
Power Generating/Charging Circuit 290
Alternator 290
ECM (Engine Controller) 291
Function of ECM 291
Connection diagram 291
Monitor lamp test 292
Failure diagnosis 293
Engine diagnostic switch (option) 293
Failure diagnostic chart 295
Engine idle revolution adjustment / failure history inspection switch (option) 296
Diag Inc/Dec switch assembly (option) 297
Quantum fault code information 299
Accelerator pedal 306
Accelerator pedal installation 307
Accelerator pedal 308
Accelerator pedal installation 309
Transmission Control Circuit and Monitor Circuit 310
Controller 310
LED inspection windows 311
Controller connection diagram 313
Controller function 314
Forward/reverse (F/R) shifting and speed change 314
Automatic shift 316
Machine speed sensor 317
Switching from automatic to manual 318
QUAD (downshift) switch operation 318
Transmission cut off (Declutch) 319
Pressure switch for inching (declutch) 320
Back-up alarm 321
Parking brake 322
Transmission controller failure warning 324
Emergency steering function 325
Monitoring system 326
Items to be monitored and operation condition 326
Operation monitor lamps 327
Instrument Panel and Switch 328
Instrument panel 328
Instrument panel rear surface 329
Gauge circuit 330
Temperature sensor 330
Fuel level sensor 331
Electrical Detent Circuit 332
Bucket leveler 332
Boom kick-out 333
Float 333
Proximity switch 333
Detent solenoid 334
Diode 335
Diode check method 336
Caution for diode check method 336
Continuity check mode 336
Diode check mode 336
Resistance check mode 337
Surge voltage and surge suppression diodes 338
Diagnostic System 339
Diagnostic system flow 339
Diagnostic failure history memory data 340
Warning monitor/control 340
Failure code 341
Malfunction mode symbol 342
Diagnostic (T/M controller) failure code detection condition 343
Diagnostic failure history indication and deletion 344
Failure history indication 344
Failure history deletion 344
Diagnostic switch 346
63 Check & Adjustment Electrical Group 348
Cautions Regarding Electric Circuit Check 349
Disconnecting or reinstalling connector 349
How to attach the probes of the circuit tester 351
Electrical Transmission Control System Troubleshooting Flowchart 352
Standard troubleshooting flowchart 352
Transmission Controller Abnormal Operation Judgment 353
Transmission controller check 353
When the “controller failure” monitor lamp lights: 353
When the output units (solenoid valve, etc ) do not operate properly: 353
If the input units or circuit are not defective 354
Transmission controller LED indicator 355
Electrical Circuit Check 357
Shift lever input electrical circuit check 357
Inching (Declutch) input electrical circuit check 359
QUAD switch input electrical circuit check 361
Machine speed sensor input electrical circuit check 362
Clutch solenoid valve output electrical circuit check 363
Transmission trimmer plug solenoid valve electrical circuit check 366
Neutral relay electrical circuit check 369
Parking brake electrical circuit check 370
Gauge circuit electrical circuit check 372
Bucket positioner electrical circuit check 374
72 Function & Structure Operator Station Group 376
Cabin 377
Glass 378
1 Part number 32011-21690 379
2 Part number 32011-21700 379
3 Part number 32011-21500 380
Wiper mount 381
Front wiper 381
Rear wiper 381
Wiper motor 382
Operator Seat 384
Steering and Transmission Shift Lever 385
Tilt case 386
Column shaft 387
Shift lever 387
Air Conditioner 388
Air conditioner components 388
Air conditioner specifications (system performance) 388
Air conditioner structure 389
Cooling unit 389
Heater and accessories 391
Air distributor (hood & defroster selection box) 391
Air compressor (with magnetic clutch) 392
Condenser unit 392
Control unit 393
Cooling mechanism 394
Principle of cooling 394
Refrigerant 394
Refrigerant characteristics 395
Cooling circuit 396
Electrical circuit 397
Control schematic drawing 397
Air conditioner functions of components 398
Control panel 398
Air conditioner unit 405
Compressor and magnetic clutch 414
Condenser unit 417
Receiver dryer 419
Sight glass 421
Pressure switches 421
Pressure relief valve 422
Relay A 423
Relay B 423
Refrigerant hose 424
Charge of refrigerant 425
Work procedure 426
Refrigerant charging tools 427
Refrigerant charging procedure 430
Troubleshooting using the gauge manifold 435
73 Check & Adjustment Operator Station Group 440
Air Conditioner 441
Adjustment of lubricating oil quantity when components of air conditioner are replaced 441
When the compressor is replaced 442
When the evaporator is replaced 443
When the condenser is replaced 443
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch 444
Compressor V-belt adjustment 445
Belt adjustment procedure 445
Belt adjustment value 445
Parts to be replaced periodically 446
Air filters 446
Receiver dryer 446
INDEX 448
Maintenance Log 453
Notes 457
92 Cross-section drawing & Diagrams 461
Axle Assembly 462
Torque Converter and Transmission 463
Loading/Steering Hydraulic Circuit 464
Brake Circuit 465
Electrical Wiring Diagram (1/2) (S/N 9001~9016) 466
Electrical Wiring Diagram (2/2) (S/N 9001~9016) 467
Electrical Wiring Diagram (1/2) (S/N 9017~) 468
Electrical Wiring Diagram (2/2) (S/N 9017~) 469
Electrical wiring diagram abbreviation chart 470
Electrical Wiring Diagram (CAB) 471
Electrical Connection Diagram (S/N 9001~9016) 474
Electrical Connection Diagram (S/N 9017~) 475
Electrical Equipment Layout 476
Electrical Circuit Diagram (Cabin Air Conditioner) 485
Electrical Wiring Diagram (Cabin Air Conditioner) 486
Equipment Operation Table (Cabin Air Conditioner) 487
S.M 5/2/2025