service repair manual

1. ©2016 KCM Corporation. All rights reserved. Printed in Japan (K)
( アメリカ用 )
93209-00700
March 2016
SHOP MANUAL
WHEEL LOADER
80Z7B
General Information
Function & Structure
Powered by CUMMINS QSB6.7 Engine
Serial No. 80C8-5001 and up
General
Information
80Z7B
SHOP
MANUAL
93209-00700
Function
&
Structure

2. ©2016 KCM Corporation. All rights reserved. Printed in Japan (K)
( アメリカ用 )
93209-00710
March 2016
SHOP MANUAL
WHEEL LOADER
80Z7B
Operational Performance Test
Troubleshooting
Powered by CUMMINS QSB6.7 Engine
Serial No. 80C8-5001 and up
Operational
Performance
Test
80Z7B
SHOP
MANUAL
93209-00710
Troubleshooting

3. ©2016 KCM Corporation. All rights reserved. Printed in Japan (K)
（アメリカ用）
93209-00720
November 2016
SHOP MANUAL
WHEEL LOADER
80Z7B
Disassembly & Reassembly
Powered by CUMMINS QSB6.7 ENGINE
Serial No. 80C8-5001 and up
Volume 1
80Z7B
SHOP
MANUAL
Disassembly
&
Reassembly
93209-00720

4. SECTION AND GROUP
CONTENTS
SHOP MANUAL
(Function & Structure)
All information, illustrations and
specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
93209-00700
SECTION 1 GENERAL
Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Controller
Group 2 Control System
Group 3 ECM System
Group 4 Hydraulic System
Group 5 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Control Valve
Group 3 Cooling Fan System
Group 4 Steering Pilot Valve
Group 5 Steering Valve
Group 6 Pilot Valve
Group 7 Brake Charge Valve/Manifold Valve
Group 8 Drive Unit
Group 9 Axle
Group 10 Brake Valve
Group 11 Others

5. SECTION AND GROUP
CONTENTS
SHOP MANUAL
(Troubleshooting)
All information, illustrations and
specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
SECTION 4 OPERATIONAL
PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner
93209-00710

6. SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
All information, illustrations and
specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Preparation
SECTION 2 MAINTENANCE STANDARD
Group 1 Body
Group 2 Front Attachment
SECTION 3 BODY
Group 1 Cab
Group 2 Counterweight
Group 3 Center Hinge
Group 4 Engine
Group 5 Radiator Assembly
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Pilot Valve
Group 11 Brake Charge Valve
Group 12 Manifold Valve
Group 13 Solenoid Valve
Group 14 Flow Regulator Valve
Group 15 Cooling Fan System
Group 16 Ride Control Device
Group 17 Battery Disconnect Switch
Group 18 Aftertreatment Device
Group 19 DEF Tank
Group 20 Coolant Control Valve
Group 21 DEF Supply Module
Group 22 Exterior Components
93209-00720
Volume 1

7. SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
All information, illustrations and
specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
SECTION 4 TRAVEL SYSTEM
Group 1 Tire
Group 2 Drive Unit
Group 3 Axle
Group 4 Propeller Shaft
Group 5 Brake Valve
Group 6 Steering Device
Group 7 Secondary Steering Device
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
93209-00720
Volume 2

8. 80Z7B F&S (US)
Group 1 Specifications
Specifications.......................................................................T1-1-1
Group 2 Component Layout
Main Component (Overview).........................................T1-2-1
Main Component................................................................T1-2-3
Electrical System (Overview) ..........................................T1-2-5
Air Cleaner and Radiator Assembly..............................T1-2-6
Radiator Assembly........................................................T1-2-7
Battery Box............................................................................T1-2-8
Hydraulic Oil Tank...............................................................T1-2-9
Fuel Tank ..............................................................................T1-2-10
Drive Unit.............................................................................T1-2-11
Front Axle.............................................................................T1-2-12
Cab.........................................................................................T1-2-13
Front Console................................................................T1-2-14
Right Console................................................................T1-2-15
Rear Console .................................................................T1-2-16
Control Unit...................................................................T1-2-17
Monitor Panel ...............................................................T1-2-18
Engine...................................................................................T1-2-19
Aftertreatment Device....................................................T1-2-20
Fan Valve ..............................................................................T1-2-21
Pump Device ......................................................................T1-2-22
Multiple Control Valve.....................................................T1-2-22
Manifold Valve....................................................................T1-2-23
Parking Brake Solenoid Valve.......................................T1-2-23
Brake Charge Valve...........................................................T1-2-23
2-Spool Solenoid Valve Unit..........................................T1-2-23
Secondary Steering Block (Option) ...........................T1-2-24
Secondary Steering Pump (Option) ..........................T1-2-24
Flow Regulator Valve.......................................................T1-2-24
DEF Tank...............................................................................T1-2-25
DEF Supply Module..........................................................T1-2-25
Group 3 Component Specifications
Engine.....................................................................................T1-3-1
Engine Performance Curve (QSB6.7)......................T1-3-4
Engine Accessories.............................................................T1-3-5
Hydraulic Component.......................................................T1-3-6
Electrical Component......................................................T1-3-12
SECTION 1
GENERAL
CONTENTS

9. T1-1-1
Group 1 Specifications
SECTION 1 GENERAL
Specifications
Model - 80Z7B
Bucket Capacity: heaped m3
(Y3
) 3.2 (4.2)
Operating Weight kg (lbs) 17650 (38912)
Tipping Load (straight) kg (lbs) 14900 (32849)
Engine CUMMINS QSB6.7
A: Overall Length mm (in) 8310 (327)
B: Overall Width (Bucket) mm (in) 2910 (115)
C: Overall Height mm (in) 3375 (133)
D: Wheel Base mm (in) 3300 (130)
E: Tread (front and rear tires) mm (in) 2160 (85)
F: Ground Clearance mm (in) 450 (18)
G: Bucket Hinge Height mm (in) 4090 (161)
H: Dumping Clearance (50 °) mm (in) 2890 (114)
I: Dumping Reach (50 °) mm (in) 1130 (44.5)
R1: Minimum Rotation Radius mm (in) 6325 (249)
R2: Minimum Rotation Radius mm (in) 6960 (274)
Travel Speed Forward/Reverse (at Power
mode)
km/h
(mph)
36.0 (36.0)/24.9 (26.2)
22.4 (22.4)/15.5 (16.3)
Transmission Speeds (F/R) - 5/3
Articulation Angle (Left/Right) deg ( ° ) 37
Tire Size - 23.5-25-16PR (L3)
fNOTE: These specifications are subject to change without notice.
B
G
C
37 °
R2
R1
E
H
50 °
I
F
D
A
MNEK-12-001-KC

10. T1-2-1
SECTION 1 GENERAL
Group 2 Component Layout
Main Component (Overview)
1- Bucket
2- Bucket Link
3- Bell Crank (Lever)
4- Bucket Cylinder
5- Front Combination Light
(Headlight, Turn Signal Light,
Clearance Light, Hazard Light)
(2 Used)
6- Horn (2 Used)
7- Front Work Light (2 Used)
8- Cab (Refer to T1-2-13.)
9- DEF Tank Box
10- Lift Arm Cylinder (2 Used)
11- Lift Arm
1
2
3
4
5
6
7 8
9
10
11
TNEK-01-02-007

11. T1-2-2
SECTION 1 GENERAL
Group 2 Component Layout
12
13
14
15
TNEK-01-02-008
12- Rear Work Light (2 Used) 13- Rain Cap/Pre-Cleaner (Option) 14- Battery Box (Refer to T1-2-8.) 15- Rear Combination Light (Turn
Signal Light, Hazard Light, Tail
Light, Brake Light) (2 Used)

12. T1-2-3
SECTION 1 GENERAL
Group 2 Component Layout
1- Air Cleaner and Radiator
Assembly (Refer to T1-2-6.)
2- Aftertreatment Device (Refer
to T1-2-20.)
3- Hydraulic Oil Tank (Refer to
T1-2-9.)
4- Parking Brake Solenoid Valve
(Refer to T1-2-23.)
5- Manifold Valve (Refer to T1-
2-23.)
6- Brake Valve
7- Steering Pilot Valve
8- Multiple Control Valve (Refer
to T1-2-22.)
9- 2-Spool Solenoid Valve Unit
(Refer to T1-2-23.)
10- Ride Control Accumulator
(Option)
11- Brake Charge Valve (Unloader
Valve) (Refer to T1-2-23.)
12- Pilot Filter
13- Service Brake Accumulator (2
Used)
14- Flow Regulator Valve (Refer to
T1-2-24.)
15- Pilot Valve
16- Engine (Refer to T1-2-19.)
Main Component
1 2 3 4 5 6
7
8
9
10
11
12
13
14
15
16
TNEK-01-02-001

13. T1-2-4
SECTION 1 GENERAL
Group 2 Component Layout
17- Front Axle (Refer to T1-2-12.)
18- Secondary Steering Block
(Option) (Refer to T1-2-24.)
19- Steering Accumulator (2 Used)
20- Stop Valve (2 Used)
21- Pump Device (Refer to T1-2-
22.)
22- Drive Unit (Refer to T1-2-11.)
23- Fuel Prefilter
24- Fuel Tank (Refer to T1-2-10.)
25- DEF Supply Module
26- DEF Tank
27- Torque Converter Cooler
Check Valve
28- Rear Axle
29- Rear (3rd) Propeller Shaft
30- Front (2nd) Propeller Shaft
31- Steering Cylinder (2 Used)
17 18 19 20 21 22
23
24
25
26
27
28
29
30
31
TNEK-01-02-002

14. T1-2-5
SECTION 1 GENERAL
Group 2 Component Layout
Electrical System (Overview)
1- Engine (Refer to T1-2-19.)
2- Hydraulic Oil Tank (Refer to
T1-2-9.)
3- Cab (Refer to T1-2-13.)
4- Bucket Proximity Switch
5- Lift Arm Proximity Switch
6- Battery Box (Refer to T1-2-8.)
7- Fuel Tank (Refer to T1-2-10.)
8- DEF Tank (Refer to T1-2-25.)
9- Backup Alarm (Option)
10- DEF Supply Module (Refer to
T1-2-25.)
3
2
1
7
6
10
9
8
5
4
TNEK-01-02-003

15. T1-2-6
SECTION 1 GENERAL
Group 2 Component Layout
Air Cleaner and Radiator Assembly
1- Air Cleaner
2- Radiator Assembly (Refer to
T1-2-7.)
3- Fan Valve (Refer to T1-2-21.)
4- Intercooler Outlet
Temperature Sensor
5- Reserve Tank
6- Air Filter Restriction Switch
7- TBAP Sensor
8- Coolant Level Sensor
2
1
5
6
1
7
3
A
View A
8
4
5
TNEK-01-02-012
TNEK-01-02-011

16. T1-2-7
SECTION 1 GENERAL
Group 2 Component Layout
Radiator Assembly
1
2
3
A
View A
4
5
1- Reserve Tank
2- Radiator
3- Oil Cooler
4- Intercooler
5- Torque Converter Cooler
6- Fan Motor
TNEK-01-02-009
6
TNEK-01-02-010
Machine Front Side
Machine Front Side

17. T1-2-8
SECTION 1 GENERAL
Group 2 Component Layout
Battery Box
1- Battery Box
2- Battery (2 Used)
3- Battery Disconnect Switch
4- Battery Relay
5- Fusible Link (70 A)
6- Fusible Link (140 A)
7- Fusible Link (65 A)
8- Fusible Link (45 A)
9- Fusible Link (65 A)
10- Starter Relay
11- Intake Air Heater Relay
1
2
2
3
5
4
6
7
8
9
10
A
Detail A
11
MNEK-01-015 TNEK-01-02-004

18. T1-2-9
SECTION 1 GENERAL
Group 2 Component Layout
Hydraulic Oil Tank
1- Hydraulic Oil Tank
2- Hydraulic Oil Level Sensor
3- Washer Fluid Tank 4- Hydraulic Oil Temperature
Sensor
5- Secondary Steering Pump
(Option) (Refer to T1-2-24.)
1 2
3
4
5
TNEG-01-02-014
Machine Front Side

19. T1-2-10
SECTION 1 GENERAL
Group 2 Component Layout
Fuel Tank
1
5
4
3
2 TNEK-01-02-013
1- Fuel Tank
2- Fuel Level Sensor
3- Fuel Pump 4- Water Separator Sensor
(Option)
5- Fuel Prefilter
Machine Front Side

20. T1-2-11
SECTION 1 GENERAL
Group 2 Component Layout
Drive Unit
View A
A
7
1
2
3
6
5
4
8
9
1- Transmission Intermediate
Shaft Sensor
2- Torque Converter Output
Speed Sensor
3- Transmission Oil Filter
4- Machine Speed Sensor
5- Transmission Oil Filter
Restriction Switch
6- Torque Converter Input Speed
Sensor
7- Breather
8- Torque Converter Oil
Temperature Sensor
9- Transmission Control Valve
10- Proportional Solenoid Valve
Y1 (For Fast-Speed Forward
Clutch)
11- Proportional Solenoid Valve Y2
(For Reverse Clutch)
12- Proportional Solenoid Valve Y3
(For 1st Speed Clutch)
13- Proportional Solenoid Valve Y4
(For 3rd Speed Clutch)
14- Proportional Solenoid Valve
Y5 (For Slow-Speed Forward
Clutch)
15- Proportional Solenoid Valve Y6
(For 2nd Speed Clutch)
10
15
14
13
11
12
TNEK-01-02-014
TNEK-01-02-015
TNEK-01-02-016
Machine Front Side

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22. T1-2-12
SECTION 1 GENERAL
Group 2 Component Layout
Front Axle
1- Pressure Sensor (Brake
Secondary Pressure)
2- Axle Oil Temperature Sensor
1
2
TNEE-01-02-018

23. T1-2-13
SECTION 1 GENERAL
Group 2 Component Layout
1- Radio
2- Upper Switch Panel (Option)
3- Speaker (2 Used)
4- Rear Wiper Motor
5- Accelerator Pedal Sensor
6- Brake Angle Sensor
7- Brake Light Switch
8- Front Wiper Motor
9- Front Wiper (1) Relay
10- Front Wiper (2) Relay
11- GPS Antenna (Option)
12- Communication Terminal
Antenna
a- Front Console (Refer to T1-2-
14.)
b- Right Console (Refer to T1-2-
15.)
c- Rear Console (Refer to T1-2-
16.)
e- Control Unit (Refer to T1-2-17.)
Detail D
View F
10
8
9
TNEG-01-02-041
TNEG-01-02-002
b
F
e
c
3
3 2
11 12
1
D
a
e
7 6 5
4
Cab
TNEK-01-02-017

24. T1-2-14
SECTION 1 GENERAL
Group 2 Component Layout
1- Hazard Light Switch
2- Work Light Switch
3- Parking Brake Switch
4- Neutral Lever Lock for
Forward/Reverse Lever
5- Steering Wheel
6- Monitor Panel (Refer to T1-
2-18.)
7- Horn
8- Accelerator Pedal
9- Brake/ Declutch Pedal (Both at
left and right are interlocked.)
10- Front/Rear Wiper Switch
11- Forward/Reverse Lever/Shift
Switch
12- Turn Signal Lever/Light
Switch/Dimmer Switch
13- Key Switch
14- Multi-Function Monitor/Air
Conditioner Control Panel
15- Cigar Lighter
Front Console
MNEC-01-038
MNEC-01-037
1 2 3 4 5 6 7
8
9
11
10
12 13
15
14
MNEC-01-036