Kawasaki 92ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93121-00034 PDF DOWNLOAD
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Kawasaki 92ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93121-00034 PDF DOWNLOAD
Language :English
Pages :230
Downloadable : Yes
File Type : PDF
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Kawasaki 92ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93121-00034 PDF DOWNLOAD
CUMMINS QSM11 Engine
Serial No. 92C1-9001 and up
FOREWORD
- Congratulations on your purchase of the Kawasaki Wheel Loader 92ZV-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 92ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93121-00034 PDF DOWNLOAD
CUMMINS QSM11 Engine
Serial No. 92C1-9001 and up
FOREWORD 2
SAFETY NOTICE 3
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
Control Lever Lock for Quick Coupler Lock Pin [3rd spool valve specification (option)] 33
Articulation Stopper 34
Neutral Start System 35
Emergency Brake 35
Secondary Steering 36
ROPS (Roll Over Protective Structure) Cab 36
2OPERATION 38
COMPONENT NAME/LOCATION 39
OPERATOR’S AREA 40
Pedals and Levers 40
1 Transmission Shift Lever 40
2 Horn Button 40
3 High-Low Beam Lever / Turn Signal Lever 41
4 Boom Control Lever 41
5 Bucket Control Lever 42
6 Auxiliary Attachment Control Lever (option) 43
7 Wrist Rest 43
8 Accelerator Pedal 44
9 Brake Pedals 45
10 Steering Column Telescopic Tilt Handle 46
11 Loading Control Lever Lock 46
Switches 47
1 Starter Switch 48
2 Parking Brake Switch 49
3 Light Switch 49
4 Front Working Light Switch 50
5 Rear Working Light Switch 50
6 (FE) Fuel Efficient Mode Switch 51
7 Front Wiper Switch 51
8 Rear Wiper Switch 52
9 Cigarette Lighter 52
10 Downshift Button 53
11 Four-Way Flasher Switch (option) 53
12 MODM 54
13 Declutch ON/OFF and Adjustable Preset Switch 54
14 Kickout Control Switch 55
15 Efficient Loading System Switch 56
16 Selection Switch for Shift Lever or F/R Switch 57
17 F/R Switch 58
18 Reversal Fan Switch (option) 59
19 Ride Control Switch (option) 60
20 Shift Hold Switch (option) 60
21 Quick Coupler Lock Pin Switch (option) 61
Indicators 62
1 Speedometer 63
2 Engine Coolant Temperature Gauge 63
3 Torque Converter Oil Temperature Gauge 64
4 Fuel Gauge 64
5 Parking Brake Indicator Lamp (red) 64
6 Auto Brake Indicator Lamp (red) 64
7 Declutch Lamp (green) 64
8 Working Light Indicator Lamp (green) 65
9 Preheat Indicator Lamp (orange) 65
10 Central Warning Lamp (red) 65
11 MCU (Machine Control Unit) Warning Lamp (red) 65
12 Brake Pressure Warning Lamp (red) 65
13 Engine Oil Pressure Warning Lamp (red) 66
14 Engine Coolant Temperature Warning Lamp (red) 66
15 Torque Converter Oil Temperature Warning Lamp (red) 66
16 Air Cleaner Warning Lamp (red) 66
17 Charge Lamp (red) 67
18 Turn Signal Indicator Lamp (Left) (green) 67
19 Turn Signal Indicator Lamp (Right) (green) 67
20 High Beam Indicator Lamp (blue) 67
21 Auto Shift Indicator Lamp 67
22 Neutral Indicator Lamp 67
23 Transmission Status Monitor 68
24 Hour Meter 68
25 Secondary Steering Warning Lamp (red) 68
26 Engine Warning Lamps 69
27 Reversal Fan Pilot Lamp (green) (option) 69
28 F/R Switch Indicator Lamp (green) 69
29 Hydraulic Oil Level Warning Lamp (simultaneous flashing) (red) (12 25) 70
MODM 71
MODM function 71
Monitor Changeover 71
Information Monitor 72
Replacement Monitor 76
Error Log Monitor 78
Input/Output Monitor 79
Parameter Setting Monitor 79
Specification Setting Monitor 79
Seat 80
Seat Adjustment 80
Seat Adjustment 81
Seat Belt 82
Electrical Protection 83
Fuse Boxes 83
Fusible Link 84
Air Conditioner 85
Ventilation Name and Location 85
Switches 85
Operating Method (Normal Use) 87
Operation Method (Other Uses) 88
Other Functions 89
For Efficient Use of the Air Conditioner 90
Action to be taken when the air conditioner is not used 91
Ride Control (option) 92
Operation and Function 92
Manual Box 93
Grease Gun Holder 94
Engine Access Panel 95
Open Engine Access Panel 95
Close Engine Access Panel 95
Quick Coupler (option) 96
Attachment Installation to Quick Coupler 96
Hydraulic Pressure Hose & Electrical Wiring Connecting to Attachment 98
OPERATION100
Check before Operation100
Walk-Around Inspection100
Check Engine Oil Level101
Check Hydraulic Oil Level102
Check Engine Coolant Level103
Drain Water and Sediment from Fuel Filter104
Check Wiring Harnesses104
Articulation Stopper105
Check Tire for Damage, Air and Tread Depth105
Check Drive Belt107
Check Crankcase Breather Tube107
Check Air Intake System107
Check Cooling Fan108
Check Horn Operation108
ROPS (Roll Over Protective Structure) Cab108
Adjust and Check Rear View Mirrors108
Check Parking Brake108
Check Monitor Panel Operation109
Check Control Levers109
Check Transmission Shift Lever109
Starting the Engine110
Normal Start110
Cold Start111
Idling Management System112
Warm-up control112
Hibernate Mode112
Check after Starting the Engine113
Check Warning Lamps113
Check Fuel Level114
Check Transmission Oil Level114
Check Service Brake Operation115
Check Parking Brake Operation115
Check Steering Wheel Operation116
Check Back-up Alarm Operation116
Check Exhaust Gas116
General Inspection117
Operating the Machine118
Starting the Machine118
Starting the Machine on a Grade119
Speed and Direction Change119
Auto Brake120
Running in Deep Mud or Water121
Parking122
Stopping the Engine123
Operating Techniques124
Loading124
Excavating126
Dozing127
Ground Levelling127
Carrying128
Dumping into Truck or Hopper129
Typical Truck Loading Methods130
SPECIAL PROCEDURES132
Adjustments132
Bucket / Attachment Leveler Adjustment132
Roading / Special Applications133
Booster Batteries / Jumper Cables134
Towing136
Wire hooking position and range/ stretching impossible range/tolerance137
Transportation138
Bucket hoisting position139
Long Term Storage140
Before Storage140
During Storage141
After Storage141
Cautions on Battery Replacement or Battery Cable Removal142
Welding143
Cautions Regarding Welding Repair Service143
3MAINTENANCE146
MAINTENANCE147
Serial Number Location147
Inspection and Maintenance Table150
When Required Inspection and Maintenance153
Replace Bucket Teeth (option)153
Replace Cutting Edge154
Check and/or Replace Seat Belt155
Clean or Replace Air Cleaner Element155
Clean Radiator / Air Cooler / Hydraulic Oil Cooler / Fuel Cooler Fins157
Check or Replace Fuses158
Check Windshield Washer Fluid159
Clean Air Conditioner Condenser159
Replace Coolant160
Replace Air Conditioner Receiver Dryer161
Greasing162
Every 10 Hours or Daily164
Every 50 Hours or 1 Week165
Greasing165
Drain Water and Sediment from Fuel Tank168
Check Battery Electrolyte Level168
Check Tire Air Pressure169
Every 250 Hours or 1 Month171
Greasing171
Check Differential Gear Oil172
Check Planetary Gear Oil173
Check Tightness of Wheel Bolts174
Adjust Belt Tension174
Replace Fuel Filter Cartridge175
Check and Adjust Air Conditioner Belt176
Clean Air Conditioner Filter Element177
Replace Filter178
Every 500 Hours or 3 Months179
Replace Engine Oil and Oil Filter Cartridge179
Replace Transmission Oil Filter Cartridge181
Replace DCA4 Coolant Filter Cartridge182
Every 1000 Hours or 6 Months184
Replace Transmission Oil184
Clean or Replace Transmission Breather186
Replace Hydraulic Oil Return Filter186
Check Air Conditioner Refrigerant187
Every 2000 Hours or 1 Year189
Greasing189
Replace Hydraulic Oil, Clean Filter190
Replace Differential Gear Oil192
Replace Planetary Gear Oil193
Clean Fuel Tank195
Check Vibration Damper196
Check Brake Accumulator197
Check Service Brake Disk Wear197
Check Water Pump197
Check Turbocharger197
Check Mounting Bolts197
Check and Adjust Injection Timing197
Check and Adjust Valve Lash Clearance197
Replace Filter in the Hydraulic Tank Cap (S/N 9001~9100)198
Replace Filter in the Hydraulic Tank Breather Valve (S/N 9101~)198
Clean Filter for Brake Line199
Clean Filter for Orbitrol®199
Replace Air Conditioner Filter Elements200
Check Ride Control Accumulator (option)201
Recommended Lubricants202
Coolant Specification204
Recommended Mixture of Antifreeze204
TROUBLESHOOTING205
SPECIFICATIONS215
INDEX218
Maintenance Log221
Notes225
S.M 3/2/2025