Kawasaki KCM 115ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93116-00256

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Kawasaki KCM 115ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93116-00256 – PDF DOWNLOAD

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Kawasaki KCM 115ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93116-00256 – PDF DOWNLOAD

Language :English
Pages :205
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Kawasaki KCM 115ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93116-00256 – PDF DOWNLOAD

CUMMINS QSK19-C Engine
Serial No.
11C4-0121 and up
11C4-9011 and up

FOREWORD

• 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

TABLE OF CONTENTS:

Kawasaki KCM 115ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93116-00256 – PDF DOWNLOAD

CUMMINS QSK19-C Engine
Serial No.
11C4-0121 and up
11C4-9011 and up

FOREWORD 2
MACHINE SPECIFICATION 2
SAFETY NOTICE 3
CONTENTS 4
1 SAFETY 6
SAFETY 7
Safe Operation 7
Operator Safety 7
Mounting and Dismounting Safety 8
Before Starting Safety 9
Operational Safety 11
Parking Safety 15
Safe Maintenance 16
Safety Preparations Before Maintenance 16
Explosion / Fire / Burn Prevention 18
Other Maintenance Safety Concerns 19
Safety Signs 21
(For Standard Specification) 22
(For Europe Specification) 26
Safety Devices 34
Loading Control Lever Lock 34
Articulation Stopper 34
Neutral Start System 35
Emergency Brake 35
Emergency Steering (Option except Europe specification) 36
ROPS (Roll Over Protective Structure) (Option except Europe specification) 36
2 OPERATION 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 (Option except Europe specification) 41
4 Boom Control Lever 41
5 Bucket Control Lever 42
6 Auxiliary Attachment Control Lever (option) 42
7 Wrist Rest 43
8 Accelerator Pedal 43
9 Brake Pedals 44
10 Steering Column Telescopic Tilt Handle 45
Switches 46
1 Starter Switch 47
2 Parking Brake Switch 48
3 Light Switch 48
4 Front Working Light Switch 49
5 Rear Working Light Switch 49
6 Transmission Cut-Off Selector Switch 49
7 Cold Start (ether injection) Switch 50
8 Front Wiper Switch 50
9 Rear Wiper Switch 51
10 Cigarette Lighter 51
11 Power Up Switch 52
12 Four-way Flasher Switch (Option except Europe specification) 52
13 Engine Power Mode Switch 53
14 Ride Control Switch (option) 53
15 Selection Switch for Shift Lever or F/R Switch (option) 53
16 F/R Switch (option) 54
Indicators 55
1 Tachometer 56
2 Engine Coolant Temperature Gauge 56
3 Torque Converter Oil Temperature Gauge 57
4 Fuel Gauge 57
5 Parking Brake Indicator Lamp (red) 57
6 Auto Brake Indicator Lamp (red) 57
7 Transmission Cut-Off Selection Lamp (green) 57
8 Working Light Indicator Lamp (green) 58
9 Central Warning Lamp (red) 58
10 Transmission Control Warning Lamp (red) 58
11 Brake Pressure Warning Lamp (red) 58
12 Engine Oil Pressure Warning Lamp (red) 58
13 Engine Coolant Temperature Warning Lamp (red) 59
14 Torque Converter Oil Temperature Warning Lamp (red) 59
15 Air Cleaner Warning Lamp (red) 59
16 Charge Lamp (red) 60
17 Transmission Oil Filter Warning Lamp (red) 60
18 Turn Signal Indicator Lamp (Left) (green) (Option except Europe specification) 60
19 Turn Signal Indicator Lamp (Right) (green) (Option except Europe specification) 60
20 High Beam Indicator Lamp (blue) 60
21 Auto Shift Indicator Lamp 60
22 Neutral Indicator Lamp 61
23 Transmission Status Monitor 61
24 Hour Meter 61
25 Emergency Steering Warning Lamp (red) (Option except Europe specification) 61
26 Coolant Level Warning Lamp 61
27 Engine Warning Lamps 62
28 Ride Control Indicator Lamp (green) (option) 62
Seat 63
Seat Adjustment 63
Seat Belt 64
Electrical Protection 65
Fuse Boxes 65
Fusible Link 66
Radio – AM / FM Cassette (24Volt Type) (option) 67
Air Conditioner 75
Ventilation Name and Location 75
Switches 75
Operation Method (Normal Usage) 77
Operation Method (Other Usage) 78
Other Functions 79
For Efficient Use of the Air Conditioner 80
Action to be taken when the air conditioner is not used 81
Ride Control (option) 82
Operation and Function 82
Grease Gun Holder 83
OPERATION 84
Check before Operation 84
Walk-Around Inspection 84
Check Engine Oil Level 85
Check Hydraulic Oil Level 86
Check Engine Coolant Level 87
Drain Water and Sediment from Fuel Filter 88
Check Wiring Harnesses 88
Articulation Stopper 89
Check Tire for Damage, Air and Tread Depth 89
Check Drive Belt 91
Check Air Intake System 91
Check Cooling Fan 92
Check Horn Operation 92
ROPS (Roll Over Protective Structure) (Option except Europe specification) 92
Adjust and Check Rear View Mirrors 92
Check Parking Brake 92
Check Monitor Panel Operation 93
Check Control Levers 93
Check Transmission Shift Lever 93
Starting the Engine 94
Normal Start 94
Cold Start 95
Check after Starting the Engine 96
Check Warning Lamps 96
Check Fuel Level 97
Check Transmission Oil Level 97
Check Service Brake Operation 98
Check Parking Brake Operation 98
Check Steering Wheel Operation 99
Check Back-up Alarm Operation 99
Check Exhaust Gas 99
General Inspection 100
Operating the Machine 101
Starting the Machine 101
Starting the Machine on a Grade 102
Speed and Direction Change 102
Auto Brake 103
Running in Deep Mud or Water 104
Parking 105
Stopping the Engine 106
Operating Techniques 107
Loading 107
Excavating 109
Dozing 110
Ground Levelling 110
Carrying 111
Dumping into Truck or Hopper 112
Typical Truck Loading Methods 113
SPECIAL PROCEDURES 115
Adjustments 115
Bucket / Attachment Positioner Adjustment 115
Boom Kickout Adjustment 116
Roading / Special Applications 117
Booster Batteries / Jumper Cables 118
Towing 120
Transportation 121
Long Term Storage 123
Before Storage 123
During Storage 123
After Storage 124
Cautions on Battery Replacement or Battery Cable Removal 124
3 MAINTENANCE 126
MAINTENANCE 127
Serial Number Location 127
Inspection and Maintenance Table 129
When Required Inspection and Maintenance 132
Replace Bucket Teeth (option) 132
Replace Cutting Edge (option) 134
Check and/or Replace Seat Belt (Option except Europe specification) 134
Clean or Replace Air Cleaner Element 135
Clean Radiator / Air cooler / Fuel cooler Fins 136
Check or Replace Fuses 137
Check Windshield Washer Fluid 138
Clean Air Conditioner Condenser 138
Replace Coolant 139
Replace Ether Cylinder 140
Replace Air Conditioner Receiver Dryer 140
Every 10 Hours or Daily 141
Every 50 Hours or 1 Week 142
Greasing 142
Drain Water and Sediment from Fuel Tank 145
Check Battery Electrolyte Level 145
Check Tire Air Pressure 146
Every 250 Hours or 1 Month 148
Greasing 148
Replace Engine Oil and Oil Filter Cartridge 149
Replace Fuel Filter Cartridge 150
Replace DCA4 Coolant Filter Cartridge 151
Check Crankcase Breather 153
Adjust Belt Tension 153
Check Differential Gear Oil 154
Check Planetary Gear Oil 155
Check Tightness of Wheel Bolts 156
Check and Adjust Air Conditioner Belt 157
Clean Air Conditioner Filter Element 158
Replace Filter 159
Every 500 Hours or 3 Months 160
Replace Transmission Oil Filter Cartridge 160
Every 1000 Hours or 6 Months 162
Greasing 162
Replace Transmission Oil 163
Clean or Replace Transmission Breather 165
Replace Hydraulic Oil Return Filter 165
Adjust Parking Brake Lining 166
Check Air Conditioner Refrigerant 167
Check Engine Compression Pressure 168
Check Injection Pressure 168
Check and Adjust Injection Timing 168
Every 2000 Hours or 1 Year 169
Greasing 169
Replace Hydraulic Oil, Clean Filter 170
Replace Differential Gear Oil 172
Replace Planetary Gear Oil 173
Clean Fuel Tank 174
Check Vibration Damper 175
Check Brake Accumulators 175
Check Service Brake Disk Wear 175
Clean Filter for Brake Line 176
Clean Filter for Orbitrol® 176
Replace Filter in the Hydraulic Tank Cap (S/N 11C4-0121~0200, 11C4-9011~) 177
Replace Filter in the Hydraulic Tank Breather Valve (S/N 11C4-0201~) 178
Check Ride Control Accumulator (option) 178
Clean Crankcase Breather Tube 179
Replace Air Conditioner Filter Elements 179
Recommended Lubricants 181
Coolant Specification 183
Recommended Mixture of Antifreeze 183
TROUBLESHOOTING 184
SPECIFICATIONS 191
(For Europe Specification) 191
INDEX 194
Maintenance Log 197
Notes 201

S.M 6/2/2025