Within the hour you might be teeing a 30 MPa gauge into the bucket cylinder bottom side, or reading CN codes off the monitor of an 80ZV-2 that quit mid-shift. This set covers serial 80C5-900x and up. That means the Cummins QSC8.3, the MCU/ECM electronics and the full loader hydraulics.
Every hour the loader sits, a pile doesn't get moved and a truck waits at the face. These are the numbers you actually set to: 20.6±0.5 MPa loading main relief, 11.8±0.5 MPa accumulator cut-out, and clutch pressure at idle and full throttle.
Book 93209-00442 holds function, checks and the wiring diagrams by serial range. Book 93209-00451 is teardown and service standards. Book 93209-00460 is troubleshooting by symptom, so a drifting boom takes you straight to its causes.
What's Inside This Kawasaki 80ZV-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information (Book 93209-00442) | 1-37 | Safety, Symbols, Recommended Lubricants, Coolant Mixture, Bolt Tightening Torque Tables, Liquid Gasket and Screw Lock Agents |
| Measurement for Performance Check | 38-43 | Standard Measurement Values, Clutch Time Lag, Engine Speed and Pressure Checks |
| Chassis Group: Function, Structure, Check & Adjustment | 44-59 | Front and Rear Chassis, Loading Linkage, Center Pin, Fuel Tank |
| Power Group: Function, Structure, Check & Adjustment | 60-91 | Engine and Transmission Mounts, Propeller Shafts, Axles, Differential Gear, T.P.D |
| Torque Converter and Transmission Group | 92-123 | Torque Converter Gear Pump, Power Flow Paths by Speed, Hydraulic Circuit, Clutch Oil Pressure Measurement |
| Hydraulic Group: Function & Structure | 124-229 | Hydraulic Circuit Flushing, Multiple Control Valve, Pilot Reducing Valve, Steering, Fan Motor System, Efficient Loading System |
| Hydraulic Group: Check & Adjustment | 230-245 | Loading Circuit Main and Overload Relief Pressure, Pilot Circuit Relief, Cylinder Natural Drift |
| Brake Group: Function, Structure, Check & Adjustment | 246-285 | Brake Valve, Accumulator Charge Cut-In and Cut-Out, Parking Brake |
| Electrical Group: Function & Structure | 286-399 | MCU and ECM Functions, Fuses and Fusible Link, Monitor and Fault Log, CN/EN Failure Codes, Solenoid Valves |
| Operator Station Group | 400-498 | Cabin, Operator Seat, Denso Air Conditioner with R134a, A/C Troubleshooting |
| Drawings & Diagrams | 499-560 | Hydraulic and Brake Circuit, Electrical Wiring Diagrams by Serial Range, Electrical Equipment Layout, MODM |
| Disassembly & Reassembly: General Information (Book 93209-00451) | 561-587 | Foreword, Contents, General Cautions |
| Disassembly & Reassembly: Chassis Group and Service Standards | 588-623 | Cab, Linkage, Center Pin Removal and Installation |
| Disassembly & Reassembly: Power Group and Service Standards | 624-691 | Engine Removal, Axles, Differential, Propeller Shafts |
| Disassembly & Reassembly: Torque Converter and Transmission | 692-747 | Torque Converter and Transmission Assembly Overhaul, Service Standards |
| Disassembly & Reassembly: Hydraulic Group | 748-823 | Hydraulic Cylinders, Pilot Valve, Orbitrol, Control Valve, Service Standards |
| Disassembly & Reassembly: Brake Group | 824-861 | Brake Components Overhaul and Service Standards |
| Disassembly & Reassembly: Operator Station Group | 862-888 | Cab Components and Service Standards |
| Troubleshooting (Book 93209-00460) | 889-949 | Hydraulic, Steering and Brake Symptoms with Causes Such As Relief Valve Leakage and Cylinder Seal Leakage |
| Measurement for Performance Check (Book 93209-00460) | 950-1006 | Safety Cautions, Measurement Procedures and Record Sheets |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | CUMMINS QSC8.3 | p. 1 |
| Loading line main relief pressure (at maximum speed) | 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi) | p. 231 |
| Pilot reducing valve set pressure | 3.5 MPa (36 kgf/cm2) (512 psi) | p. 146 |
| Brake accumulator cut-out pressure | 11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi) | p. 276 |
| Brake accumulator cut-in pressure | 6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi) | p. 276 |
| Clutch oil pressure | 1.3±0.2 MPa (13±2 kgf/cm2) (185±28 psi) at engine idling speed (LI); 1.5±0.2 MPa (15±2 kgf/cm2) (213±28 psi) at engine maximum speed (HI) | p. 123 |
| Torque converter gear pump theoretical displacement | 64.5 cc/rev (3.9 in3/rev) | p. 94 |
| Torque converter gear pump maximum operation speed | 2,400 min-1 (rpm) | p. 94 |
| Clutch time lag, Neutral to Forward 1st (engine 1,500 rpm) | 0.3±0.1 sec | p. 40 |
| Coolant antifreeze in hot climates | 33 % antifreeze mixture | p. 25 |
| Air conditioner refrigerant | R134a | p. 419 |
Kawasaki 80ZV-2 Common Problems This Manual Covers
Boom or bucket cylinders drift down with the loader valve in neutral
Measure the drift first, using the cylinder natural drift procedure in Hydraulic Group Check & Adjustment. The troubleshooting book points to internal leakage past the boom cylinder piston seal or inside the multiple control valve. Seal kits and control valve overhaul are in the Hydraulic Group disassembly section, along with service standards.
Manual Section: Hydraulic Group: Check & Adjustment; Troubleshooting (Book 93209-00460) p. 913A/C blows air that never gets properly cold
Make sure the system holds the specified R134a and nothing else. Then work through the Denso A/C troubleshooting in the Operator Station Group. It covers evaporator gas leaks, blockage and freezing, the usual reasons a cab stays hot in summer.
Manual Section: Operator Station Group: Air Conditioner Troubleshooting p. 419Engine runs hot in high ambient temperatures
The General Information book specifies a 33 % antifreeze mixture for hot climates, so test the coolant before replacing parts. The Hydraulic Group explains how the hydraulic fan motor system works, so you can check the fan drive once the coolant mix is right.
Manual Section: General Information: Coolant Mixture; Hydraulic Group: Fan Motor System p. 25New debris or sticking spools after replacing a pump, cylinder or hydraulic oil
The Hydraulic Group says to flush the hydraulic circuit after replacing oil or parts, so debris is cleared out of the valves, cylinders and pipes. Follow that flushing procedure. Then recheck the 3.5 MPa pilot reducing valve setting and the loading circuit relief pressures before going back to work.
Manual Section: Hydraulic Group: Function & Structure, Hydraulic Circuit Flushing p. 125Frequently Asked Questions
The 80ZV-2 won't crank at all. What should I check before pulling the starter?
Look at the shift lever first. The engine will not start with the lever in forward or reverse, so put it in neutral and try again. If it still won't crank, the Electrical Group covers the MCU, ECM, fuses and fusible link. p. 107
How do I read and clear the fault codes on the monitor?
Codes starting with CN are machine faults, and codes starting with EN are engine faults. To clear them, open the engine fault or machine fault screen and hold the [x] button for more than 2 seconds. Brake oil pressure sensor codes CN312, CN313, CN315 and CN316 mean the sensor voltage stayed below 0.2 V for more than 3 seconds. p. 365
The lift arms and bucket feel weak and slow. How do I check the loader relief?
Fit a 30 MPa gauge to the bucket cylinder bottom side and turn the declutch switch on. Hold the bucket lever in roll back and read the gauge at maximum engine speed. Spec is 20.6±0.5 MPa. The troubleshooting book also lists internal leakage at the bucket rod side overload relief valve as one cause. p. 233
Why does the transmission drop to neutral when I apply the brake?
The machine is built to do that. Applying the parking brake or the declutch brake switches off the F or R clutch solenoid valve. You can confirm it on the Output signal monitor, which shows the ON/OFF state of the direction and speed range solenoids. Knowing this one fact can save you an unnecessary transmission teardown. p. 330
What brake accumulator pressures should I see?
The charge should cut out at 11.8±0.5 MPa (1,706±71 psi) and cut back in at 6.9±1.0 MPa (995±142 psi). The Brake Group check and adjustment section walks through the measurement. It also covers the brake valve and the parking brake. p. 276
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