Kawasaki WHEEL LOADER 90ZV-2 OPERATION & MAINTENANCE MANUAL 93113 – PDF DOWNLOAD

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Kawasaki WHEEL LOADER 90ZV-2 OPERATION & MAINTENANCE MANUAL 93113 – PDF DOWNLOAD

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Kawasaki WHEEL LOADER 90ZV-2 OPERATION & MAINTENANCE MANUAL 93113 – PDF DOWNLOAD

Language :English
Pages :230
Downloadable : Yes
File Type : PDF

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Kawasaki WHEEL LOADER 90ZV-2 OPERATION & MAINTENANCE MANUAL 93113 – PDF DOWNLOAD

Powered by CUMMINS QSM11 Engine
Serial No. 90C5-5151 and up

FOREWORD

• Congratulations on your purchase of the Kawasaki Wheel Loader 90ZV-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. For additional details, for safe and efficient operation and maintenance of your Cummins engine, please refer to your Cummins operation & maintenance manual. There may be an optional supplemental operation & maintenance manual, and this also should be referred to when operating machines that are equipped with special packages. 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 WHEEL LOADER 90ZV-2 OPERATION & MAINTENANCE MANUAL 93113 – PDF DOWNLOAD

Powered by CUMMINS QSM11 Engine
Serial No. 90C5-5151 and up

CONTENTS 6
1SAFETY 8
SAFETY 9
Safe Operation 9
Operator Safety 9
Mounting and Dismounting Safety 10
Before Starting Safety 11
Operational Safety 14
Parking Safety 18
Safe Maintenance 19
Safety Preparations Before Maintenance 19
Explosion / Fire / Burn Prevention 22
Other Maintenance Safety Concerns 23
Safety Signs 25
Safety Devices 35
Loading Control Lever Lock 35
Control Lever Lock for Quick Coupler Lock Pin [3rd spool valve specification (option)] 35
K-Lever Steering System ON/OFF (option) 36
Articulation Stopper 37
Neutral Start System 38
Emergency Brake 38
Emergency Steering (option) 38
ROPS (Roll Over Protective Structure) Cab 39
2OPERATION 40
COMPONENT NAME/LOCATION 41
OPERATOR’S AREA 42
Pedals and Levers 42
1 Transmission Shift Lever 43
2 Horn Button 43
3 High-Low Beam Lever / Turn Signal Lever (option) 43
4 Boom Control Lever 44
5 Bucket Control Lever 45
6 Auxiliary Attachment Control Lever (option) 45
7 Wrist Rest 46
8 Accelerator Pedal 46
9 Brake Pedals 47
10 Steering Column Telescopic Tilt Handle 48
11 Loading Control Lever Lock 48
12 K-Lever (option) 49
Switches 50
1 Starter Switch 51
2 Parking Brake Switch 51
3 Light Switch 52
4 Front Working Light Switch 52
5 Rear Working Light Switch 53
6 (FE) Fuel Efficient Mode Switch 53
7 Front Wiper Switch 54
8 Rear Wiper Switch 54
9 12 Volt Power-outlet Socket 55
10 Downshift Button 55
11 Four-Way Flasher Switch (option) 56
12 MODM 56
13 Declutch ON/OFF and Adjustable Preset Switch 57
14 Kickout Control Switch 58
15 Efficient Loading System Switch 59
16 Selection Switch for Shift Lever or F/R Switch (option) 60
17 F/R Switch (option) 61
18 Reversal Fan Switch (option) 62
19 Ride Control Switch (option) 63
20 Shift Hold Switch (option) 63
21 K-Lever Switch (option) 64
22 Horn Button for K-Lever (option) 64
23 Forward / Reverse Changeover Switch for K-Lever (option) 65
24 Downshift Button on K-Lever (option) 65
Indicators 66
1 Tachometer 67
2 Engine Coolant Temperature Gauge 67
3 Torque Converter Oil Temperature Gauge 67
4 Fuel Gauge 67
5 Parking Brake Indicator Lamp (red) 68
6 Declutch Lamp (green) 68
7 Working Light Indicator Lamp (green) 68
8 Preheat Indicator Lamp (orange) 68
9 Central Warning Lamp (red) 68
10 MCU (Machine Control Unit) Warning Lamp (red) 68
11 Brake Pressure Warning Lamp (red) 69
12 Engine Oil Pressure Warning Lamp (red) 69
13 Engine Coolant Temperature Warning Lamp (red) 69
14 Torque Converter Oil Temperature Warning Lamp (red) 70
15 Air Cleaner Warning Lamp (red) 70
16 Charge Lamp (red) 70
17 Turn Signal Indicator Lamp (Left) (green) 70
18 Turn Signal Indicator Lamp (Right) (green) 70
19 High Beam Indicator Lamp (blue) 71
20 Auto Shift Indicator Lamp 71
21 Neutral Indicator Lamp 71
22 Transmission Status Monitor 71
23 Hour Meter 71
24 Emergency Steering Warning Lamp (red) (option) 72
25 Engine Warning Lamps 72
26 Reversal Fan Pilot Lamp (green)(option) 73
27 F/R Switch Indicator Lamp (green) (option) 73
28 Hydraulic Oil Level Warning Lamp (simultaneous flashing)(red)(11 24) 73
29 K-Lever Indicator Lamp (green) (option) 74
MODM 75
MODM function 75
Monitor Changeover 75
Information Monitor 76
Replacement Monitor 80
Error Log Monitor 82
Input/Output Monitor 83
Parameter Setting Monitor 84
Specification Setting Monitor 84
Seat 85
Seat Adjustment 85
Seat Belt 86
Electrical Protection 87
Fuse Boxes 87
Fusible Link 88
Radio – AM / FM Cassette (24 Volt Type) 89
Heater or Air Conditioner 97
Ventilation Location and Mode 97
Switches 97
Ride Control (option) 99
Operation and Function 99
OPERATION100
Check before Operation100
Walk-Around Inspection100
Greasing101
Check Engine Oil Level101
Check Hydraulic Oil Level102
Check Engine Coolant Level103
Drain Water and Sediment from Fuel Filter104
Check Wiring Harnesses105
Articulation Stopper105
Check Tire for Damage, Air and Tread Depth106
Check Drive Belt107
Check Crankcase Breather Tube107
Check Air Intake System108
Check Cooling Fan108
Check Horn Operation109
ROPS (Roll Over Protective Structure) Cab109
Adjust and Check Rear View Mirrors109
Check Parking Brake109
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
Parking121
Stopping the Engine122
Operating Techniques123
Loading123
Excavating125
Dozing125
Ground Levelling126
Carrying127
Dumping into Truck or Hopper127
Typical Truck Loading Methods129
SPECIAL PROCEDURES130
Adjustments130
Bucket / Attachment Leveler Adjustment130
Roading / Special Applications131
Booster Batteries / Jumper Cables132
Towing134
Transportation135
Long Term Storage137
Before Storage137
Battery removal / reinstallation procedure138
During Storage139
After Storage139
Cautions on Battery Replacement or Battery Cable Removal140
MEMO141
3MAINTENANCE142
MAINTENANCE143
Serial Number Location143
Inspection and Maintenance Table146
When Required Inspection and Maintenance149
Replace Bucket Teeth (option)149
Replace Cutting Edge (option)150
Check and/or Replace Seat Belt151
Clean or Replace Air Cleaner Element151
Clean Radiator / Air cooler / Hydraulic oil cooler Fins153
Check or Replace Fuses154
Check Windshield Washer Fluid155
Clean Air Conditioner Condenser156
Replace Coolant156
Replace Air Conditioner and Heater Filter Elements158
Replace Air Conditioner Receiver Dryer159
Greasing159
Every 10 Hours or Daily161
Every 50 Hours or 1 Week162
Greasing162
Drain Water and Sediment from Fuel Tank165
Check Battery Electrolyte Level165
Check Tire Air Pressure166
Every 250 Hours or 1 Month168
Greasing168
Check Differential Gear Oil169
Check Planetary Gear Oil170
Check Tightness of Wheel Bolts171
Adjust Belt Tension171
Replace DCA4 Coolant Filter Cartridge172
Replace Fuel Filter Cartridge174
Check and Adjust Air Conditioner Belt175
Clean Air Conditioner and Heater Filter Elements175
Replace Filter177
Every 500 Hours or 3 Months178
Replace Engine Oil and Oil Filter Cartridge178
Replace Transmission Oil Filter Cartridge180
Every 1000 Hours or 6 Months182
Replace Transmission Oil182
Clean or Replace Transmission Breather184
Replace Hydraulic Oil Return Filter184
Adjust Parking Brake Lining185
Check Air Conditioner Refrigerant186
Every 2000 Hours or 1 Year188
Greasing188
Replace Hydraulic Oil, Clean Filter189
Replace Differential Gear Oil190
Replace Planetary Gear Oil191
Clean Fuel Tank193
Check Vibration Damper194
Check Brake Accumulator195
Check Service Brake Disk Wear195
Check Water Pump195
Check Turbocharger195
Check Mounting Bolts195
Check and Adjust Injection Timing195
Check and Adjust Valve Lash Clearance195
Replace Filter in the Hydraulic Tank Cap196
Clean Filter for Brake Line196
Clean Filter for Orbitrol®197
Check Ride Control Accumulator (option)198
Recommended Lubricants199
Coolant Specification201
Recommended Mixture of Antifreeze201
TROUBLESHOOTING202
SPECIFICATIONS217
MEMO219
INDEX220
A220
B220
C220
D220
E220
F221
G221
H221
I221
K221
L221
M221
N221
O221
P221
R221
S222
T222
W222
Maintenance Log223
Notes227

S.M 3/2/2025