Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00312 – PDF DOWNLOAD

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Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00312 – PDF DOWNLOAD

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Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00312 – PDF DOWNLOAD

Language :English
Pages :215
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00312 – PDF DOWNLOAD

Powered by CUMMINS QSC8.3 Engine
Serial No. 80C5-9001 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 93109-00312 – PDF DOWNLOAD

Powered by CUMMINS QSC8.3 Engine
Serial No. 80C5-9001 and up

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
Articulation Stopper 33
Neutral Start System 34
Emergency Brake 34
Emergency Steering 35
ROPS (Roll Over Protective Structure) Cab 35
2OPERATION 36
COMPONENT NAME/LOCATION 37
OPERATOR’S AREA 38
Pedals and Levers 38
1 Transmission Shift Lever 38
2 Horn Button 38
3 High-Low Beam Lever / Turn Signal Lever 39
4 Boom Control Lever 39
5 Bucket Control Lever 40
6 Auxiliary Attachment Control Lever (option) 41
7 Wrist Rest 41
8 Accelerator Pedal 42
9 Brake Pedals 42
10 Steering Column Telescopic Tilt Handle 43
Switches 44
1 Starter Switch 45
2 Parking Brake Switch 45
3 Light Switch 46
4 Front Working Light Switch 46
5 Rear Working Light Switch 47
6 Fuel Efficient Mode Switch 47
7 Front Wiper Switch 48
8 Rear Wiper Switch 48
9 Cigarette Lighter 49
10 Downshift Button 49
11 Four-Way Flasher Switch 50
12 MODM (Serial No 80C5-9001~9039) 50
13 MODM (Serial No 80C5-9040~9100) 50
14 Adjustable Declutch Preset Switch 51
15 Kickout Control Switch 52
16 Efficient Loading System Switch 52
17 Declutch Switch 53
18 Selection Switch for Shift Lever or F/R Switch 54
19 F/R Switch 55
20 Reversal Fan Switch (option) 56
21 Ride Control Switch (option) 56
22 Shift Hold Switch (option) 57
Indicators 58
1 Speedometer 59
2 Engine Coolant Temperature Gauge 59
3 Torque Converter Oil Temperature Gauge 59
4 Fuel Gauge 59
5 Parking Brake Indicator Lamp (red) 60
6 Declutch Lamp (green) 60
7 Working Light Indicator Lamp (green) 60
8 Preheat Indicator Lamp (orange) 60
9 Central Warning Lamp (red) 60
10 Controller Warning Lamp (red) 60
11 Brake Pressure Warning Lamp (red) 61
12 Engine Oil Pressure Warning Lamp (red) 61
13 Engine Coolant Temperature Warning Lamp (red) 61
14 Torque Converter Oil Temperature Warning Lamp (red) 62
15 Air Cleaner Warning Lamp (red) 62
16 Charge Lamp (red) 62
17 Turn Signal Indicator Lamp (Left) (green) 62
18 Turn Signal Indicator Lamp (Right) (green) 62
19 High Beam Indicator Lamp (blue) 63
20 Auto Shift Indicator Lamp 63
21 Neutral Indicator Lamp 63
22 Transmission Status Monitor 63
23 Hour Meter 63
24 Emergency Steering Warning Lamp (red) 64
25 Engine Warning Lamps 64
26 Reversal Fan Pilot Lamp (green)(option) 65
27 F/R Switch Indicator Lamp (green) 65
28 Hydraulic Oil Level Warning Lamp (simultaneous flashing)(red)(11 24) 65
MODM 66
MODM function 66
Monitor Changeover 66
Information Monitor 67
Replacement Monitor 71
Error Log Monitor 73
Input/Output Monitor 74
Parameter Setting Monitor 75
Specification Setting Monitor 75
Seat 76
Seat Adjustment 76
Seat Belt 77
Electrical Protection 78
Fuse Boxes 78
Fusible Link 79
Air Conditioner 80
Ventilation Name and Location 80
Switches 80
Operation Method (Normal Usage) 82
Operation Method (Other Usage) 83
Other Functions 84
For Efficient Use of the Air Conditioner 85
Action to be taken when the air conditioner is not used 86
Ride Control (option) 87
Operation and Function 87
Grease Gun Holder 88
Quick Coupler (option) 89
Attachment Installation to Quick Coupler 89
Hydraulic Pressure Hose & Electrical Wiring Connecting to Attachment 91
OPERATION 92
Check before Operation 92
Walk-Around Inspection 92
Check Engine Oil Level 93
Check Hydraulic Oil Level 94
Check Engine Coolant Level 95
Drain Water and Sediment from Fuel Filter 95
Check Wiring Harnesses 96
Articulation Stopper 96
Check Tire for Damage, Air and Tread Depth 97
Check Drive Belt 98
Check Crankcase Breather Tube 99
Check Air Intake System 99
Check Cooling Fan100
Check Horn Operation100
ROPS (Roll Over Protective Structure) Cab100
Adjust and Check Rear View Mirrors100
Check Parking Brake100
Check Monitor Panel Operation101
Check Control Levers101
Check Transmission Shift Lever101
Starting the Engine102
Normal Start102
Cold Start103
Idling Management System104
Warm-up control104
Hibernate Mode104
Check after Starting the Engine105
Check Warning Lamps105
Check Fuel Level106
Check Transmission Oil Level106
Check Service Brake Operation107
Check Parking Brake Operation107
Check Steering Wheel Operation108
Check Back-up Alarm Operation108
Check Exhaust Gas108
General Inspection109
Operating the Machine110
Starting the Machine110
Starting the Machine on a Grade111
Speed and Direction Change111
Parking113
Stopping the Engine114
Operating Techniques115
Loading115
Excavating117
Dozing117
Ground Levelling118
Carrying119
Dumping into Truck or Hopper119
Typical Truck Loading Methods121
SPECIAL PROCEDURES122
Adjustments122
Bucket / Attachment Leveler Adjustment122
Roading / Special Applications123
Booster Batteries / Jumper Cables124
Towing126
Transportation127
Long Term Storage129
Before Storage129
Battery removal / reinstallation procedure130
During Storage131
After Storage131
Cautions on Battery Replacement or Battery Cable Removal132
MEMO133
3MAINTENANCE134
MAINTENANCE135
Serial Number Location135
Inspection and Maintenance Table137
When Required Inspection and Maintenance140
Replace Bucket Teeth (option)140
Replace Cutting Edge141
Check and/or Replace Seat Belt142
Clean or Replace Air Cleaner Element142
Clean Radiator / Air cooler / Hydraulic oil cooler Fins144
Check or Replace Fuses145
Check Windshield Washer Fluid146
Clean Air Conditioner Condenser147
Replace Coolant147
Replace Air Conditioner Receiver Dryer149
Greasing149
Every 10 Hours or Daily151
Every 50 Hours or 1 Week152
Greasing152
Drain Water and Sediment from Fuel Tank155
Check Battery Electrolyte Level155
Check Tire Air Pressure156
Every 250 Hours or 1 Month158
Greasing158
Check Differential Gear Oil159
Check Planetary Gear Oil160
Check Tightness of Wheel Bolts161
Check and Adjust Air Conditioner Belt161
Replace DCA4 Coolant Filter Cartridge162
Clean Air Conditioner Filter Element164
Replace Filter165
Every 500 Hours or 3 Months166
Replace Engine Oil and Oil Filter Cartridge166
Replace Transmission Oil Filter Cartridge168
Replace Fuel Filter Cartridges169
Every 1000 Hours or 6 Months170
Replace Transmission Oil170
Clean or Replace Transmission Breather171
Replace Hydraulic Oil Return Filter172
Adjust Parking Brake Lining173
Check Air Conditioner Refrigerant174
Inspect Automatic Belt Tensioner Pulley175
Every 2000 Hours or 1 Year176
Greasing176
Replace Hydraulic Oil, Clean Filter177
Replace Differential Gear Oil178
Replace Planetary Gear Oil179
Clean Fuel Tank181
Check Vibration Damper181
Check Brake Accumulator182
Check Service Brake Disk Wear182
Check and Adjust Valve Lash Clearance182
Replace Air Conditioner Filter Elements183
Clean Filter for Brake Line184
Clean Filter for Orbitrol®184
Replace Filter in the Hydraulic Tank Cap185
Check Ride Control Accumulator (option)186
Recommended Lubricants187
Coolant Specification189
Recommended Mixture of Antifreeze189
TROUBLESHOOTING190
SPECIFICATIONS200
MEMO203
INDEX204
A204
B204
C204
D204
E204
F205
G205
H205
I205
K205
L205
M205
N205
O205
P205
Q205
R205
S206
T206
W206
Maintenance Log207
Notes211

S.M 3/2/2025