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Kawasaki Wheel Loader 80Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual – PDF DOWNLOAD
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Kawasaki Wheel Loader 80Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
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Description
Kawasaki Wheel Loader 80Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
File Details:
Kawasaki Wheel Loader 80Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
Language : English
Pages : 500+
Size : 230 MB
Downloadable : Yes
Format : PDF
KAWASAKI WHEEL LOADER 80Z7 SERVICE MANUAL + PARTS MANUAL + WIRING DIAGRAMS + TROUBLESHOOTING MANUAL – PDF DOWNLOAD:
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Table of Contents:
Kawasaki Wheel Loader 80Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
INTRODUCTION..................................................................... 4 Safety Alert Symbol and Headline Notations................................... 5 Symbol and Abbreviation.......................................................... 6 SAFETY........................................................................... 8 Recognize Safety Information................................................. 8 Understand Signal Words...................................................... 8 Follow Safety Instructions................................................... 9 Prepare for Emergencies...................................................... 10 Wear Protective Clothing..................................................... 10 Protect Against Noise........................................................ 11 Inspect Machine.............................................................. 11 General Precautions for Cab.................................................. 12 Use Handrails and Steps...................................................... 13 Never Ride Attachment........................................................ 13 Adjust Operatorโs Seat....................................................... 13 Ensure Safety Before Rising from or Leaving Operatorโs Seat.................. 14 Fasten Your Seat Belt........................................................ 14 Move and Operate Machine Safely.............................................. 15 Handle Starting Aids Safely.................................................. 15 Operate Only from Operatorโs Seat............................................ 16 Jump Starting................................................................ 16 Investigate Job Site Beforehand.............................................. 17 Equipment of Head Guard, ROPS, FOPS.......................................... 18 Provide Signals for Jobs Involving Multiple Machines......................... 18 Keep Riders Off Machine...................................................... 19 Drive Safely................................................................. 19 Drive Machine Safely (Work Site)............................................. 20 Drive Safely with Bucket Loaded.............................................. 21 Drive on Snow Safely......................................................... 21 Travel on Public Roads Safely................................................ 22 Avoid Injury from Rollaway Accidents......................................... 22 Avoid Accidents from Backing Up and Turning.................................. 23 Avoid Positioning Bucket or Attachment Over Anyone........................... 24 Avoid Tipping................................................................ 24 Never Undercut a High Bank................................................... 25 Dig with Caution............................................................. 25 Perform Truck Loading Safely................................................. 25 Avoid Power Lines............................................................ 26 Precautions for Operation.................................................... 26 Precautions for Lightning.................................................... 26 Object Handling.............................................................. 27 Protect Against Flying Debris................................................ 27 Park Machine Safely.......................................................... 28 Store Attachments Safely..................................................... 28 Transport Safely............................................................. 29 Handle Fluids SafelyโAvoid Fires............................................. 30 Practice Safe Maintenance.................................................... 31 Warn Others of Service Work.................................................. 32 Support Machine Properly..................................................... 32 Stay Clear of Moving Parts................................................... 33 Support Maintenance Properly................................................. 33 Prevent Parts from Flying.................................................... 34 Prevent Burns................................................................ 34 Replace Rubber Hoses Periodically............................................ 35 Avoid High-Pressure Fluids................................................... 35 Prevent Fires................................................................ 36 Evacuating in Case of Fire................................................... 37 Beware of Exhaust Fumes...................................................... 38 Precautions for Welding and Grinding......................................... 38 Avoid Heating Near Pressurized Fluid Lines................................... 38 Avoid Applying Heat to Lines Containing Flammable Fluids..................... 39 Precautions for Handling Accumulator and Gas Damper.......................... 39 Precautions for Diesel Exhaust Fluid (DEF)................................... 39 Remove Paint Before Welding or Heating....................................... 40 Beware of Asbestos and Silicon Dust and Other Contamination.................. 40 Prevent Battery Explosions................................................... 41 Service Air Conditioning System Safely....................................... 41 Handle Chemical Products Safely.............................................. 42 Dispose of Waste Properly.................................................... 42 Notes for Aftertreatment Device.............................................. 43 Precautions for Communication Terminal....................................... 43 Precaution for Communication Terminal Equipment (Option)..................... 44 Articulation Stopper (Lock Bar).............................................. 45 SECTION 4 OPERATIONAL PERFORMANCE TEST TOC....................................... 46 1 Introduction................................................................... 48 Operational Performance Tests................................................ 48 Preparation for Performance Tests............................................ 49 2 Standard....................................................................... 50 Operational Performance Standard Table....................................... 50 Main Pump P-Q Diagram........................................................ 59 Sensor Activating Range...................................................... 61 3 Engine Test.................................................................... 62 Engine Speed................................................................. 62 Lubricant Consumption........................................................ 64 4 Machine Performance Test....................................................... 66 Travel Speed................................................................. 66 Service Brake Function Check................................................. 69 Service Brake Wear Amount.................................................... 71 Parking Brake Function Check................................................. 72 Bucket Stopper Clearance, Lever (Bell Crank) Stopper Clearance............... 73 Hydraulic Cylinder Cycle Time................................................ 75 Cylinder Drift Check......................................................... 77 Bucket Levelness............................................................. 78 Control Lever Operating Force................................................ 79 Control Lever Stroke......................................................... 81 5 Component Test................................................................. 82 Primary Pilot Pressure (Including Brake Circuit)............................. 82 Primary Pilot Pressure Adjustment Procedure.............................. 84 Secondary Pilot Pressure..................................................... 85 Solenoid Valve Set Pressure.................................................. 87 Solenoid Valve Adjustment Procedure...................................... 88 Main Pump Delivery Pressure.................................................. 89 Loading Circuit Main Relief Set Pressure..................................... 91 Main Relief Valve Pressure Adjustment Procedure.......................... 93 Steering Circuit Relief Set Pressure......................................... 95 Steering Relief Valve Pressure Adjustment Procedure...................... 96 Loading Overload Relief Valve Set Pressure................................... 97 Overload Relief Valve Pressure Adjustment Procedure (Reference).......... 98 Main Pump Flow Rate Measurement.............................................. 99 Regulator Adjustment.....................................................105 Service Brake Pressure (Front and Rear)......................................107 Parking Brake Release Pressure...............................................109 Brake Accumulator Pressure...................................................111 Brake Warning Pressure (Pressure-Decreasing).................................113 Brake Warning Pressure (Pressure-Increasing).................................115 Transmission Clutch Pressure.................................................117 6 Adjustment.....................................................................122 Rewrite of Aftertreatment Device Serial No...................................122 Clean DEF Tank...............................................................123 SECTION 5 TROUBLESHOOTING TOC...................................................124 1 Diagnosing Procedure...........................................................126 Introduction.................................................................126 Diagnosis Procedure..........................................................127 Electrical System Inspection.................................................130 Precautions for Inspection and Maintenance ..............................131 Instructions for Disconnecting Connectors................................133 Fuse Inspection..........................................................135 Fuse Box A...........................................................136 Fuse Box B...........................................................137 Fusible Link Inspection..................................................138 Battery Voltage Check....................................................139 Alternator Check.........................................................140 Continuity Check.........................................................141 Voltage and Current Measurement..........................................143 24-Volt Circuit......................................................143 5-Volt Circuit.......................................................149 Check by False Signal....................................................150 Test Harness.............................................................151 2 Monitor........................................................................154 Outline......................................................................154 Operating Procedures of Service Menu.........................................155 How to display service menu..............................................156 Monitoring...............................................................159 List of Monitoring Item..............................................161 Controller Version.......................................................169 Issued Warning Record....................................................170 List of Alarm........................................................171 Communication Terminal Status............................................175 Machine Setting..........................................................177 Aftertreatment Device No.................................................185 Engine Tachometer............................................................186 Transmission Oil Temperature Gauge and DEF / AdBlue Level Gauge..............187 Coolant Temperature Gauge....................................................188 3 e-Service......................................................................190 Outline......................................................................190 List of Operation Data.......................................................191 List of Daily Report Data................................................191 List of Frequency Distribution Data......................................193 List of Total Operating Hours............................................194 Snapshot Data................................................................195 Communication System.........................................................196 4 Component Layout...............................................................198 Main Component (Overview)....................................................198 Main Component...............................................................200 Electrical System (Overview).................................................202 Air Cleaner and Radiator Assembly............................................203 Radiator Assembly........................................................204 Battery Box..................................................................205 Hydraulic Oil Tank...........................................................206 Fuel Tank....................................................................207 Drive Unit...................................................................208 Front Axle...................................................................209 Cab..........................................................................210 Front Console............................................................211 Right Console............................................................212 Rear Console.............................................................213 Control Unit.............................................................214 Monitor Panel............................................................215 Engine.......................................................................216 Aftertreatment Device........................................................217 Fan Valve....................................................................218 Pump Device..................................................................219 Multiple Control Valve.......................................................219 Manifold Valve...............................................................220 Parking Brake Solenoid Valve.................................................220 Brake Charge Valve...........................................................220 2-Spool Solenoid Valve Unit..................................................220 Secondary Steering Block (Option) ...........................................221 Secondary Steering Pump (Option) ............................................221 Flow Regulator Valve.........................................................221 DEF Tank.....................................................................222 DEF Supply Module............................................................222 5 Troubleshooting A..............................................................224 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure....224 MPDr. Fault Code Reference Table.............................................226 MC Fault Code List...........................................................232 Controller Hardware Failure..............................................232 CAN Data Reception Failure...............................................233 Engine Failure...........................................................234 Pump Failure.............................................................235 Pilot Failure............................................................236 Proportional Solenoid Valve Failure......................................239 Learning Failure.........................................................241 Other Failures...........................................................242 Monitor Controller (Monitor) Fault Code List.................................244 Monitor Controller (Information) Fault Code List.............................245 Column Display Controller Fault Code List....................................248 Air Conditioner Controller Fault Code List...................................250 Communication Terminal Fault Code List.......................................251 ECM Fault Code List..........................................................252 TCU Fault Code List..........................................................282 CAN1 Harness Check...........................................................307 CAN3 (Engine) Harness Check..................................................311 CAN2 Harness Check...........................................................315 6 Troubleshooting B..............................................................342 Machine Diagnosis by Using Trouble Symptom...................................342 Relationship between Machine Trouble Symptoms and Related Parts..............344 Correlation between Trouble Symptoms and Part Failures.......................367 Engine System Troubleshooting............................................368 All Actuator System Troubleshooting......................................370 Front Attachment System Troubleshooting..................................373 Steering System Troubleshooting..........................................377 Travel System Troubleshooting............................................379 Brake System Troubleshooting.............................................382 Other System Troubleshooting.............................................383 Engine System Troubleshooting................................................387 All Actuator System Troubleshooting..........................................393 Front Attachment System Troubleshooting......................................398 Steering System Troubleshooting..............................................407 Travel System Troubleshooting................................................411 Brake System Troubleshooting.................................................420 Other System Troubleshooting.................................................423 Exchange Inspection..........................................................437 Air Bleeding Procedures for Brake (Axle).....................................439 7 Air Conditioner................................................................440 Outline......................................................................440 Component Layout.........................................................441 Functions of Main Parts......................................................443 Troubleshooting..............................................................448 Air Conditioner Controller Fault Code List...............................449 Air Conditioner Controller Fault Codes 11 to 22......................450 Air Conditioner Controller Fault Codes 43 to 92......................451 Faulty cooling ..........................................................453 Faulty heating...........................................................463 Others...................................................................466 Work after Replacing Components..............................................473 Refill Compressor Oil........................................................474 Charge Air Conditioner with Refrigerant......................................475 Hose and Pipe Tightening Torque..............................................483 INDEX............................................................................484
Description:
Kawasaki Wheel Loader 80Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
The service manual covers the following files:
80Z7(OCE-F&S)(93209-00640)Attachment.pdf
80Z7(OCE-F&S)-CoverKCM.pdf
80Z7(OCE-Trbl)(93209-00650).pdf
80Z7(OCE-Trbl)-CoverKCM.pdf
80Z7(US-DR)(93209-00600).pdf
80Z7(US-DR)-Cover.pdf
80Z7(US-F&S)-Cover.pdf
80Z7(US-Trbl)(93209-00590).pdf
80Z7(US-Trbl)-Cover.pdf
80Z7+Diagrams.pdf
80Z7+DR+US.pdf
80Z7B(F&S)(US)(93209-00700).pdf
80Z7B(F&S)(US)-TD.pdf
80Z7B_TS(US)(93209-00710).pdf
80Z7B+US+(93109-00660).pdf
93309-00432.?pdf.pdf
93309-00442.pdf
93309-00453.pdf
93309-00453+70,80Z7EG??.pdf
93309-00540 (1).pdf
93309-00540.pdf
93309-00550.pdf
93309-00560.pdf
93309-00561+(A4).pdf
93309-00561+(letter).pdf
-E-80Z7B+DR+US-1.pdf
-E-80Z7B+DR+US-2.pdf
T05-08+EN+book_ZW220-6.pdf
??80Z7B(USA)+ (1).pdf
??80Z7B(USA)+.pdf
??80Z7B+?????.pdf
??80Z7B??(USA)+.pdf
80Z7(OCE-F&S)(93209-00640).pdf
- Our shop manuals consist of the Technical Manual, the Workshop Manual and the Engine Manual.
๏ Information included in the Technical Manual: Technical information needed for machine pre-delivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures. Each page has a number, located on the center lower part of the page, and each number contains the following information: Example: ๏ Technical Manual: T 1-3-5 T Technical Manual 1 Section Number 3 Group Number 5 Consecutive Page Number for Each Group - ๏ Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assembly / disassembly procedures. ๏ Information included in the Engine Manual: Technical information needed for machine pre-delivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assembly / disassembly procedures
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contactย [email protected]
