Kawasaki 80ZIV-2 WHEEL LOADER SHOP MANUAL AAA-S80N3E00-00Z – PDF DOWNLOAD

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Kawasaki 80ZIV-2 WHEEL LOADER SHOP MANUAL AAA-S80N3E00-00Z – PDF DOWNLOAD

FILE DETAILS:

Kawasaki 80ZIV-2 WHEEL LOADER SHOP MANUAL AAA-S80N3E00-00Z – PDF DOWNLOAD

Language :English
Pages :336
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Kawasaki 80ZIV-2 WHEEL LOADER SHOP MANUAL AAA-S80N3E00-00Z – PDF DOWNLOAD

Powered by NISSAN NE6T14 Engine.
SERIAL NUMBERS
80N3-9001 and up.
General Information
Functions & Structure

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
Functions and structure
The purpose of this manual is to provide information on the product and the correct maintenance and repair methods.
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 opinions or
requests, please inform us.
Safety Precautions
The most important point in providing repair service is safety. To ensure safety, observe the general cautions
described below.
・This manual is intended for properly trained and equipped service technicians.
・Any work on the machine must be performed by the trained personnel only.
・Carefully read this manual to thoroughly understand the operation method before you operate or repair the
machine.
・Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles.
・Place the machine on a level and solid ground, and place chocks against the wheels to prevent movement.
・Remove the cable from the battery before starting the service work, and attach a “DO NOT OPERATE!” tag to the
steering wheel.
・Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant
pipe.
・Be sure to apply the articulation stopper before starting work.
・While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks.
・When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate
cribbing under the unit to prevent unexpected dropping.
・Do not start to work in an enclosed area if adequate ventilation is not provided.
・To remove a heavy unit (20kgf or more), be sure to use a crane or other lifting tool.
・Just after stopping operation, be careful not to directly touch a hot component. You may get burned.
・Contact tire manufacturer’s local dealer for tire servicing and changing.
・Always store the tools in good condition, and use them properly.
・Keep the work area clean. Clean up spills immediately.
・Avoid the use of flammable solvents and cleaners.
・When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud.
・Use safe work platforms to reach higher areas of the machine.

TABLE OF CONTENTS:

Kawasaki 80ZIV-2 WHEEL LOADER SHOP MANUAL AAA-S80N3E00-00Z – PDF DOWNLOAD

Powered by NISSAN NE6T14 Engine.
SERIAL NUMBERS
80N3-9001 and up.
General Information
Functions & Structure

FOREWORD 2
Safety Precautions 3
Safety Symbols 4
Symbols 5
OUTLINE 7
Layout of Main Components 8
Recommended Lubricants 9
Lubrication Chart 10
Weight of Main Components 11
Hexagon Bolt Tightening Torque 12
Flanged Hexagon Bolt Tightening Torque 14
Hose Band Tightening Torque 15
Liquid Gasket and Screw Lock Agent 16
Cautions regarding parts removal 16
Cautions regarding reassembly 16
Cautions Regarding Welding Repair Service 17
CHASSIS GROUP 19
Front Chassis 20
Loading system 20
Linkage 21
Rear Chassis 22
Fuel tank 22
Center Pin 23
Clearance Adjustment for Pin Section 24
Adjustment 24
Center Pin 25
Adjusting Shim(#5) 25
Installing bearing cover(#3) 25
Grease nipple installation direction 25
POWER GROUP 26
Outline of Power Line 27
Engine Mount 28
Radiator Mount 29
Propeller Shaft 30
Adjusting yoke direction (phase) at reinstallation 31
Adjusting yoke directions (second propeller shaft) 31
Axle Assembly 32
Construction 32
Front Axle Group 33
Rear Axle Support 34
Differential Gear 36
Fuel Control 41
Engine Oil Pressure 42
Engine Compression Pressure 43
Engine Valve Clearance 44
Engine Fuel Injection Pressure 45
Engine Fuel Injection Timing 46
TORQUE CONVERTER AND TRANSMISSION GROUP 47
Torque Converter and Transmission 48
Construction 48
Gear Arrangement 49
Torque Converter Operation 50
Clutch Pack 51
Clutch Plate 53
Gear Pump 54
Power Flow 55
Hydraulic System Diagram 58
Hydraulic Circuit Diagram 59
Control Valve 60
Construction 60
System Diagram 61
Solenoid Valve Operation 62
Modulation Mechanism 65
Measuring Clutch Oil Pressure 70
HYDRAULIC GROUP 71
Loading/Steering Hydraulic Line (S/N 80N3-9001～9100) 72
Loading/Steering Hydraulic Line (S/N 80N3-9101 73
Loading/Steering Hydraulic System Diagram (S/N 80N3-9001～9100) 74
Loading/Steering Hydraulic System Diagram (S/N 80N3-9101～） 75
Layout of Hydraulic Units 76
Hydraulic Tank 77
Hydraulic tank cap (with air breather) 78
Functions 78
Specifications of hydraulic tank 79
Hydraulic oil level check 80
Hydraulic Pump 81
Hydraulic Cylinder 82
Loading System 84
Operation 84
Pilot Valve 85
Function 86
Operation 86
Operation (Full pressure position) 87
Pilot Valve Filter 89
Function 89
Pilot Relief Valve Unit 90
Construction 90
Relief valve Function 91
When oil pressure is lower than the set point 91
When oil pressure exceeds the set point 91
Reduction valve Function 92
When pilot pressure drops 92
Pilot Relief Valve Unit 93
Construction 93
Relief valve 94
Operation 94
Check valve 94
Accumulator 95
Accumulator installation position 95
Construction 95
Specification 96
Operation 96
Maintenance 96
Multiple Control Valve (KVML) 97
Function 98
When the oil pressure is at the set point or below 98
When the oil pressure exceeds the set point 98
Function 104
Operation 104
Function 105
Operation 105
Slow Return Check Valve 106
Function 106
Adapter (with orifice) 107
Construction 107
Function 107
Steering System 108
Operation 108
Steering Gear Box 110
Structure 110
Checking and Adjusting Play of Steering Wheel 111
Checking and Adjusting Gear Box Oil Level 112
Gear Oil Replacement Procedure 112
Steering Valve (KVMT) 113
Operation 115
Construction 119
Operation 119
When the oil pressure is at the set point or below 120
When the oil pressure exceeds the set point 120
Operation as make-up valve 120
Emergency Steering 121
Operation condition 121
Oil flow 121
Standard Measurement Values for Performance Check 123
Cautions Regarding Replacement of Hydraulic Parts 124
Flushing Hydraulic Lines 125
Measuring Steering Wheel/Lever Operating Force WARNING moving Boom lever Bucket lever 129
BRAKE GROUP 130
Brake and Air Circuit 131
Layout of Brake and Air Units 133
Air Governor 134
Construction 135
Operation 135
Air Tank 136
Air tank mount 136
Construction 137
Check valve 140
Brake Valve 141
Construction 141
Operation 143
When problem occurs in secondary line 144
When problem occurs in primary line 144
Releasing air pressure 145
Air Pressure Switch (for inching) Construction 146
Double Check Valve 147
Construction 147
Operation 147
Air Master 148
Operation 149
When the brake pedal is pressed down 150
When the overstroke switch is actuated 150
Service Brake 151
Construction 151
Friction plate 152
Parking Brake 153
Construction 154
Solenoid Valve (for parking brake) 155
Installation position 155
Normal operation 155
Manual operation 156
Air Cylinder 157
Operation 157
Brake Oil Tank 158
Operation of level switch 158
Checking Braking Performance 159
Checking Air Line Setting Pressure 159
Checking Brake Valve 160
Checking Air Master 162
Checking Wear of Service Brake Friction Plate 164
Adjusting Parking Brake Clearance 165
Adjusting clearance 165
Brake Line Air Bleeding 166
ELECTRICAL GROUP 168
How to Use Electrical Wiring Diagram 170
Cable Color Codes 171
Electrical Wiring Diagram 172
Layout of Electrical Equipment 178
Electrical Connection Diagram 182
Layout of Electrical Equipment Inside Cab Control Box 184
Layout of Electrical Equipment Around Battery Relay 185
Fusible Link/Fuse 186
Fusible link 187
Engine Start Circuit 188
Neutral starting device 188
Shift lever neutral (N) position 188
Shift lever forward/reverse 「F 」「R 」position 188
Function 191
Operation 191
Construction 194
Operation 194
Alternator/Charge Circuit 195
Alternator 195
Construction 195
Engine Stop Circuit 197
Transmission Control and Monitor Circuit 199
Controller connection diagram 203
Forward/reverse(F/R)shifting and speed change 204
Shift lever 204
Input detection 204
Operation of solenoid valve 205
Automatic shift 205
Operation of PUS switch 206
PUS switch 207
Speed sensor 207
Clutch modulation chart 208
Inching 209
Instrument Panel 217
Gauge circuit 219
Electric Detent Circuit 221
Emergency Steering Circuit 223
Pilot valve 222
Emergency Steering Circuit 223
Cautions Regarding Electric Circuit Check 224
Flow Chart for Troubleshooting of Electrical Transmission Control System 226
Judgment of Transmission Controller Abnormal Operation 227
On/Off Statuses of Transmission Controller LED Indicator 228
Function of Diagnostic System for Controller 232
Checking Shift Lever Input Circuit 239
Checking Inching (declutch) Input Circuit 241
Checking Power Up Switch (PUS) Input Circuit 243
Checking Speed Sensor Input Circuit 244
Checking Clutch Solenoid Valve Output Circuit 245
Checking Trimmer Plug Solenoid Valve 247
Checking Neutral Relay Circuit 249
Checking Parking Brake Circuit 251
Checking Engine Stop Circuit 252
Checking Gauge Circuit 255
OPERATOR STATION GROUP 258
ROPS Cabin 259
Outline drawing 259
Connection diagram 260
Electrical wiring diagram (For inside cab) 261
Wiper motor 262
Rear (option) 263
Floor Board 264
Operator seat 265
Layout of meters, lamps and switches 266
Monitor symbols and actuation conditions 267
Error warning lamps (which are lit in red) 267
Operation indicator lamps 268
Control box 269
Viscous mount 270
Floor board mounting area 270
Steering and Transmission Shift Lever 271
Structure 271
Steering shaft assembly 272
Column bushing 272
Handle tilt adjustment lever assembly 273
Steering gear box 274
Structure 274
Checking and Adjusting Play of Steering Wheel: 275
Checking and Adjusting Gear Box Oil Level: 276
Transmission shift lever assembly 277
Transmission shift lever 278
Air Conditioner 279
Receiver dryer Control Air conditioner mount (S/N 80N3-9001～9100) 279
Air conditioner mount (S/N 80N3-9101～) 280
Specifications 281
Air conditioner line routing 281
Structure 282
Air conditioner unit 282
Air damper unit 283
Air duct unit 284
Compressor (with magnetic clutch) 284
Condenser unit 285
Control unit 285
Control panel 285
Cooling mechanism 286
Principle of cooling 286
Refrigerant 286
Refrigerant characteristics 287
Cooling circuit 288
Electrical circuit diagram 289
Electrical wiring diagram 290
Functions of components 291
Control unit 291
Control panel 291
Control amplifier 293
Troubleshooting the control unit 293
Air conditioner unit 294
Air mixing damper 294
Evaporator 295
Troubleshooting the evaporator 295
Expansion valve (box type) 296
Operation of expansion valve (box type) 297
Troubleshooting the expansion valve 297
Heater radiator 298
Troubleshooting the heater radiator 298
Water valve 298
Troubleshooting the water valve 298
Actuator for air mixing 299
Troubleshooting the actuator for air mixing 299
Duct for vent selection 300
Actuator for vent selection 301
Troubleshooting the actuator for vent selec-tion 301
Blower motor assembly 302
Troubleshooting the blower motor 302
Blower resistor 302
Troubleshooting the blower resistor 302
Thermistor 303
Troubleshooting the thermistor 303
Air filter and air damper box 304
Air damper box 304
Actuator for inside/outside air selection 305
Troubleshooting the actuator for inside/out-side air selection 305
Air filter 306
Troubleshooting the air filter 306
Compressor and magnetic clutch 307
Compressor 307
Magnetic clutch 307
Troubleshooting the compressor and mag-netic clutch 308
Condenser unit 309
Condenser 309
Condenser fan motor 309
Resistor 309
Troubleshooting the condenser unit 309
Receiver dryer 310
Receiver tank 310
Desiccant 310
Strainers 310
Troubleshooting the receiver tank 310
Access tube 311
Pressure switches 311
Troubleshooting the pressure switch 312
Sight glass 313
Relays 313
Relay A 314
Relay B 314
Troubleshooting the relay 314
Self-sealing coupling (S/N 80N3-9001~9100) 315
Refrigerant hose 316
Charge of refrigerant 317
Evacuation and Charging Procedures 318
Refrigerant charging tools 319
Refrigerant charging procedure 321
Troubleshooting using the gauge manifold 326
Adjustment of lubricating oil quantity when components of air conditioner are replaced 329
When the compressor is replaced 330
When the evaporator is replaced 331
When the condenser is replaced 331
When the receiver dryer is replaced 331
Adjustment of water valve and air mixing dampers 332
Adjustment of water valve 332
Adjustment of air mixing damper B 332
Adjustment of air gap (between hub and rotor) in compressor magnet clutch 333
Adjustment of V belt in compressor 334
Parts to be replaced periodically 335

S.M 7/2/2025