Kawasaki 80ZV-2 WHEEL LOADER SHOP MANUAL 93209-00460 – PDF DOWNLOAD

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Kawasaki 80ZV-2 WHEEL LOADER SHOP MANUAL 93209-00460 – PDF DOWNLOAD

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Kawasaki 80ZV-2 WHEEL LOADER SHOP MANUAL 93209-00460 – PDF DOWNLOAD

Language :English
Pages :118
Downloadable : Yes
File Type : PDF

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Kawasaki 80ZV-2 WHEEL LOADER SHOP MANUAL 93209-00460 – PDF DOWNLOAD

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 Operation and Maintenance Manual.
• To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.

Troubleshooting
Measurement for Performance check

• 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 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 opinion 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 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 (20 kgf (40 lbs) or more), be sure to use a crane or other lifting device.
– 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 80ZV-2 WHEEL LOADER SHOP MANUAL 93209-00460 – PDF DOWNLOAD

Foreword 2
Safety Precautions 3
Safety Symbols 4
Symbols 5
CONTENTS 6
Troubleshooting 01 8
Cautions Regarding Troubleshooting 10
How to Use Quick Troubleshooting Table 11
Safety Precautions 12
Torque Converter and Transmission Group 13
1 Machine dose not move in any shift lever position 13
2 Machine dose not move at a certain shift lever position (OR:Machine moves only in a certain shift lever position) 14
3 Machine moves at the neutral position (Example: Machine moves forward at the neutral position) 15
4 Large shock at starting or changing speed / direction 16
5 Large time lag at starting or changing speed / direction 17
6 Low power (Defective torque converter or transmission) 18
7 Torque converter oil is overheating 19
8 Machine moves reverse when starting to climb up on a slope using inching brake 20
9 Automatic speed change is not possible 21
10 Downshift button does not work 22
Hydraulic Group 23
1 Boom and/or bucket do not move 23
2 Boom and/or bucket have low power, or move too slowly 24
3 Excessive cylinder drift 25
4 Boom and/or bucket are spongy (Holding bucket against the ground is not possible-front wheels off the ground) 26
5 Bucket leveler does not work Boom lift kickout and lower kickout does not work 27
6 Steering is not possible or hard to steer 28
7 Machine sways, or has a shock during steering 29
8 ELS (Efficient Loading System) does not work (Excavating and scooping tractive power does not become up during ELS working condition) 30
9 Ride control does not work 31
10 Fan motor rotates abnormally or does not rotate 32
11 Abnormal noise in hydraulic system 33
12 Others 34
Brake Group 35
1 Brake does not work well (In the worst case, the brake does not work at all) 35
2 Brake is dragging when released 36
3 Stepping on the brake pedal sounds the buzzer 37
4 Accumulator pressure does not rise, or too slow in rising 38
5 Parking brake does not work (or: Releasing the parking brake is not possible) 39
Electrical Group 40
1 Instrument panel does not indicate properly 40
2 Fuse for controller is blown 41
Error code (for chassis) 42
Error code (for engine) 45
Operator Station Group 52
Air conditioner 52
Measurement for Performance Check 03 60
Cautions on Safety 62
Standard Measurement Values for Performance Check (S/N 9001~9200) 63
Standard Measurement Values for Performance Check (S/N 9201~) 66
Preparation for Performance Check 69
Engine 71
Measuring engine speed 71
Measurement instrument 71
Standard measurement value 71
Clutch Oil Pressure 75
Measuring clutch oil pressure 75
Hydraulic Cylinder 76
Cylinder natural drift 76
Measurement instrument 76
Standard measurement value (mm/min) (in/min) 76
Measurement procedure 76
Boom Rising Time 78
Measurement instrument 78
Warm-up the engine before measuring boom rising time 78
Standard measurement value (sec) 78
Measurement procedure 78
Full Steering Cycle Time 80
Measurement instrument 80
Warm-up the engine before measuring full steering time 80
Standard measurement value (sec) 80
Measurement procedure 80
Loading/Steering Circuit Relief Valve 82
Loading circuit relief valve setting pressures 82
Measurement instruments 82
Gauge port 82
Standard measurement value MPa (kgf/cm2) (psi) 83
Measuring loading circuit main relief pressure 83
Measuring loading circuit overload relief pressure 85
Measuring pilot circuit relief pressure 86
Steering circuit relief valve setting pressures 87
Measurement instruments 87
Gauge port 87
Standard measurement value MPa (kgf/cm2) (psi) 88
Measuring steering circuit main relief pressure 88
Measuring steering circuit overload relief pressure 90
Measuring pilot circuit relief pressure (reducing pressure) 91
Stop Valve 92
Stop valve adjustment procedure 92
Fan Revolution 93
Measurement instrument 93
Measuring number of fan maximum revolutions 94
Service Brake 95
Service brake performance check 95
Condition 95
Standard measurement value 95
Service brake friction plate wear measurement 96
Measurement procedure 97
Cautions on installing brake discs 97
Parking Brake 98
Parking brake performance check 98
Condition 98
Standard measurement value 98
Parking brake clearance adjustment 99
Adjustment procedure 99
Brake lining abrasion check100
Brake Circuit Oil Pressure101
Unloader valve setting pressure101
Measurement instrument102
Gauge port102
Standard measurement value102
Measurement procedure102
Brake valve oil pressure104
Measurement instrument104
Gauge port104
Measurement procedure104
Brake valve performance105
Accumulator Circuit Charging Time106
Measurement instrument106
Gauge installation position106
Standard measurement valve (sec)107
Measurement procedure107
Number of Brake Pedal Applications108
Standard measurement value108
Measurement procedure108
Possible causes of extremely low measurement value and solution108
Declutch Engagement109
Measurement instrument109
Warm-up the engine before measuring declutch engagement109
Standard measurement value109
Cause of extremely high measurement value and solution109
Measurement procedure109
Maintenance Log111
Notes115

S.M 3/2/2025