93116-00483

January 24, 2016

FOREWORD
Congratulations on your purchase of the KCM Wheel Loader 115ZV-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.

KCM 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 obliga-
tion.

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 authorized 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 mainte-
nance 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.
SAFETY NOTICE
Whenever you see the symbols shown below in this manual or on the machine, read and understand their
messages.

DANGER
This danger symbol identifies special warnings or
procedures which, if not strictly observed, will result
in death or serious injury.

WARNING
This warning symbol identifies special warnings or
procedures which, if not strictly observed, could result
in death or serious injury.

CAUTION
This caution symbol identifies special instructions or
procedures which, if not strictly observed, may result
in minor or moderate injury.

IMPORTANT
This important symbol identifies special instructions
or procedures which, if not correctly followed, may
result in serious machine damage.

Always follow safe operating and maintenance practices.

KCM cannot anticipate every possible circumstance, use, or misuse of the machine that might involve a
potential hazard. The warnings in this Operation & Maintenance Manual and on the machine are therefore not
all inclusive.
If an operation or maintenance procedure is not performed as specifically recommended by KCM, you must
satisfy yourself that it is safe for you and others. You should also ensure that the machine will not be damaged
by the operation or maintenance procedure you choose.

KCM makes every effort to supply machines which conform to every regulation applicable in your country /
state. However, if your machine is not supplied through the authorized authorized dealer, it may not be
equipped as the regulations require. KCM cannot be responsible for anything on that kind of machine. Also,
some local agencies or certain job sites may require special equipment that has not been provided. Contact
your nearest authorized dealer for further information or assistance.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
effort has been made to ensure it as complete and accurate as possible.
CONTENTS
1.SAFETY ...................................................................................................................................................... 1.1
SAFETY ..................................................................................................................................................... 1.2
Safe Operation..................................................................................................................................... 1.2
Safe Maintenance.............................................................................................................................. 1.12
Safety Signs....................................................................................................................................... 1.18
Safety Devices................................................................................................................................... 1.28
2.OPERATION ............................................................................................................................................... 2.1
COMPONENT NAME/LOCATION ............................................................................................................. 2.2
OPERATOR'S AREA ................................................................................................................................. 2.3
Pedals and Levers ............................................................................................................................... 2.3
Switches ............................................................................................................................................ 2.10
Indicators ........................................................................................................................................... 2.26
MODM ............................................................................................................................................... 2.36
Seat ................................................................................................................................................... 2.46
Electrical Protection ........................................................................................................................... 2.48
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009) .............................................. 2.50
Air Conditioner ................................................................................................................................... 2.58
Ride Control (option).......................................................................................................................... 2.65
Grease Gun Holder............................................................................................................................ 2.66
OPERATION ............................................................................................................................................ 2.67
Check before Operation..................................................................................................................... 2.67
Starting the Engine ............................................................................................................................ 2.77
Idling Management System ............................................................................................................... 2.80
Check after Starting the Engine ......................................................................................................... 2.81
Operating the Machine ...................................................................................................................... 2.86
Parking............................................................................................................................................... 2.90
Stopping the Engine........................................................................................................................... 2.91
Operating Techniques........................................................................................................................ 2.92
 SPECIAL PROCEDURES...................................................................................................................... 2.100
Adjustments ..................................................................................................................................... 2.100
Roading / Special Applications......................................................................................................... 2.101
Booster Batteries / Jumper Cables .................................................................................................. 2.102
Towing.............................................................................................................................................. 2.104
Transportation .................................................................................................................................. 2.105
Long Term Storage........................................................................................................................... 2.107
Welding .............................................................................................................................................2.110
3.MAINTENANCE .......................................................................................................................................... 3.1
MAINTENANCE ......................................................................................................................................... 3.2
Serial Number Location ....................................................................................................................... 3.2
Inspection and Maintenance Table ...................................................................................................... 3.4
When Required Inspection and Maintenance ...................................................................................... 3.7
Every 10 Hours or Daily ..................................................................................................................... 3.19
Every 50 Hours or 1 Week ................................................................................................................. 3.20
Every 250 Hours or 1 Month .............................................................................................................. 3.26
Every 500 Hours or 3 Months ............................................................................................................ 3.37
Every 1000 Hours or 6 Months .......................................................................................................... 3.42
Every 2000 Hours or 1 Year............................................................................................................... 3.49
Recommended Lubricants ................................................................................................................. 3.62
Coolant Specification ......................................................................................................................... 3.64
TROUBLESHOOTING ............................................................................................................................. 3.65
SPECIFICATIONS ................................................................................................................................... 3.75
 1.1

1.SAFETY
1.2
SAFETY
Safe Operation

SAFETY

Safe Operation
Operator Safety

OM0026a

Wear safe clothing:

OM0001 - Close fitting clothing -- loose or baggy clothing

can catch on equipment or controls.

Read and understand the Operation & Mainte- - Protective clothing as required by the job or con-
nance Manual. ditions for example:

- Hard hat
- Gloves
- Steel-toe shoes
- Eye/face protection
- Antidust mask or approved respirator

OM0180

Be aware of the location and meaning of safety

signs (decals) on the machine. Report or replace
any that are missing or unreadable.
OM0002
Be alert and ready to operate the machine safely:

- Do not operate if excessively tired. - Do not wear jewelry that may catch on the
equipment, controls or may short and cause
- Do not operate if taking medication that causes burns if in contact with electrical components.
drowsiness.

- Do not operate if under the influence of alcohol

or drugs.
 1.3
SAFETY
Safe Operation

Mounting and Dismounting Safety

OM0222

The inhalation of asbestos-laden dust involves the
risk of having an adverse health effect. At the
wrecking site and the site handling industrial waste,
there is a possibility of inhaling asbestos-laden
dust.
It is requested that the following measures should
be taken at the site where there is a possibility that
asbestos-laden dust flies in all directions.
OM0010
Face the machine when mounting or dismounting.
Maintain three points of contact when climbing (two
hands and one foot, or two feet and one hand).
When mounting or dismounting, never carry tools
or other objects in your hands.

- The worker should wear protective equipment Climb and step only where steps and handrails are
such as a dust-protective mask. provided.
- Sprinkle water in order to prevent asbestos from
flying in the air.
- Do not use compressed air for cleaning work.
- Do not allow any person other than workers to
come near the working site.
- Observe strictly the laws, regulations and rules
regarding the environmental standards at work-
ing sites.

Asbestos is not used both in this product and genu-

ine parts. However, as it is feared that asbestos
may be used in non-genuine parts, please be sure
to use our genuine parts for replacement.
OM0181

Use only the handrails provided to climb -- do not

use the steering wheel, shift lever, mirror brackets,
or control lever.

Use extra caution mounting and dismounting when

slippery conditions exist (oil, ice, snow, mud, or wet
conditions).

Never jump from the machine regardless if

machine is moving or stopped.

Report or replace any damaged or missing steps,

handrails, or anti-skid material.
1.4
SAFETY
Safe Operation

Before Starting Safety

OM0012
OM0006

Do not allow unauthorized personnel on the

machine. Know the location of safety items and procedures:

- Fire extinguishers
- Fire blankets
- First aid kits
- Emergency phone numbers

Walk around the machine to be sure no one is

working or laying under the machine.

Inspect the machine for safety hazards and, if

found, have them corrected:

- Broken lights, mirrors, windows, etc.

- Fuel leaks, oil leaks, or debris build-up
- Improper tire inflation or tire damage
- Missing or unreadable safety signs (decals)

Be sure the Roll Over Protective Structure (ROPS)

is:

- in place.
- properly attached (no bolts loose or missing).
- not damaged.
- not modified.
 1.5
SAFETY
Safe Operation

"STORED" position

OM0005 115ZV0002a

Perform the normal daily maintenance. - Articulation Stopper -- Locked in the "STORED"
position.
- Back-up Alarm -- Operational

Securely lock the cab door either fully open or

closed.

Secure any loose items inside the cab (lunch

boxes, tools, vacuum bottles, etc.).

After using the ashtray, close the ashtray cap to

avoid fire.
Lock
Do not leave a lighter in the cab. The lighter may
Unlock 115ZV2 9296 cause explosion by high temperature in the cab.

Do not bring inflammable or explosive materials

Be sure the following safety devices work or are
such as:
positioned properly.
- spray can
- Parking Brake -- Applied
- chemical cylinder
- Control Lever Lock -- Locked
Do not attach a suction cup on the window to avoid
firing.

In case of fire during operation:

N - Turn off the starter switch and stop the engine.

- Extinguish fire with a fire extinguisher (Depend
on the situation).
- With hand rails and steps, get off the machine
and stay away from it.

Depending on the situation, the way of evacuation

will be changed. If necessary, periodic fire drill is
65ZV 5089
needed at the work area.

- Transmission Shift Lever -- Neutral

1.6
SAFETY
Safe Operation

OM0007 OM0011

Adjust the seat, seat belt and steering column, mir- Do not start to work in an enclosed area if adequate
rors, etc. ventilation is not provided. Fumes could build up
during operation that could cause drowsiness,
Properly fasten the seat belt. injury, or death.

Blow the horn for a few seconds just before starting

the engine to alert bystanders.

DANGER

DO NOT
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE

OM0182

Do not start or operate the machine if a "DO NOT OM0183

START" or a "DO NOT OPERATE" tag is on the key
switch, steering wheel or controls.
Start the machine only from in the operator's seat.
Do not operate the engine where there are or can
be combustible vapors. These vapors can be - Do not reach through the window to start.
drawn through the air intake system and cause - Do not stand on the ground and start.
engine overspeeding, which can result in a fire, and - Never attempt to start by shorting across the
explosion. starter motor terminals since this can bypass the
neutral start safety device.

If jumper cables are required to start the engine,

follow the correct procedure in "Booster Batteries /
Jumper Cables" page 2.102.

Operational Safety
Before operating the machine, refer to "SPECIFI-
CATIONS" listed on page 3.75.
Do not use the machine with excessive load than
specified, to avoid a stack of the machine and/or
any risk of injury caused by potential structural
damage of the machine due to the overload.
Use the permitted attachments and optional parts
provided, when needed, which are suitable for the
operating conditions and job contents.
SITE SAFETY:
Consider the safety of the job site before operating
the machine:
- Be aware of and avoid cliffs, ditches, trenches,
overhead or underground wires, underground
pipes, other equipment, and workers in the area.
- If required, be aware of hand signals that may
be used by ground guides.
OM0021
Avoid working under or near overhanging material
that could fall on the machine.
Keep bystanders out of the work area.
Keep the work site as clean and flat as possible.
Do not operate the machine at work area close to
fire or dry grass is.
Operate the machine slowly over rough ground and
on a grade.
Do not operate on any grade that may be unstable
(loose material, soft material, snow, or ice).
1.7
SAFETY
Safe Operation
The range of temperature the machine is to be
operated is between -25ºC ~ 35ºC.
When working on a grade:
- Turn "OFF" the declutch ON/OFF switch.
- Keep the attachment low.
- Keep the attachment facing up the grade as
often as possible.
- Drive directly up or down the grade -- never
across the grade.
- Stop when changing direction on a grade to
maintain stability.
- Never coast down a grade.
- Select the same low gear to go down the grade
as was selected to climb the grade. This pro-
vides some engine braking.
OM0018
Before crossing a bridge, make sure that the
capacity of the bridge is greater than the weight of
the machine and any load it may be carrying.
Check for enough clearance before entering a
building, doorway, tunnel, under wires or other
structures.
Do not expose the machine to flames.
Follow all local, federal or provincial laws and regu-
lations regarding calling to locate underground haz-
ards such as buried cables and pipes prior to
digging.
1.8
SAFETY
Safe Operation

SAFETY DURING NORMAL OPERATIONS: When roading the machine:

Vision to the rear on any machine is limited. Always
use special caution when backing up.
Know the machine limits and do not exceed them.
- Travel in forward only.
- Travel only as fast as conditions and safety
allow.
- Know and follow all local laws that may require
rotating beacon, slow moving vehicle (SMV)
signs, width signs or flags, lead or chase vehi-
cles, four-way flashers, or clearance lights, etc.
- If roading long distances (over 3 km), periodi-
cally stop to allow tires, transmission, engine to
cool down. Excessive tire heat caused by road-
ing can cause blow-outs and loss of control.

Stop the machine motion immediately if any failure

occurs that causes reduced control (e.g.; engine,
pump, or brake system failures).

Lower the bucket or attachment to stop the

OM0013 machine only when an emergency, like loss of brak-
ing occurs.
Using the machine for purposes other than speci-
Be sure there are no bystanders under the raised
fied in the Operation & Maintenance Manual may
bucket or attachment.
create hazards that are not mentioned in this man-
ual.

Do not use the machine as a crane where the

safety of the operator or other workers are involved.

Properly counterweight and ballast the machine

depending upon the bucket size and material or
attachment application. Do not exceed the recom-
mendations and limits.

Maintain stability by carrying the load as low as

possible throughout each cycle.
OM0184

Never position or move the load over the cab of a

truck or other vehicle.

approx. 40 cm
OM0016

- The normal carry position is about 40 cm above

the ground.

OM0020
Never use the "Float" position to lower the boom
since it will fall rapidly.
Drive into a load at a medium speed. Do not run
into the material at high speed.
Always be alert for abnormal noises, odors, vibra-
tions, heat, etc.
1.9
SAFETY
Safe Operation
SPECIAL OPERATING CONDITIONS:
OM0185
Avoid entering water deeper than the bottom of the
wheel rim.
If entering water is unavoidable:
- Use caution that there are no hidden hazards --
(drop-offs, holes, rocks, logs, etc.).
- Check for normal braking after leaving the
water.
- Check differential gear oil for contamination.
Reduce speed and avoid rapid steering movement
when traction is poor -- mud, snow, ice, etc. Use tire
chains if necessary.
When darkness, fog, snow, dust, smoke, etc.
reduce visibility, use the following precautions:
- Use adequate lighting.
- Use flashers or beacons (if equipped).
- Reduce speed.
- Periodically stop and inspect the job site.
- Take more frequent breaks to reduce fatigue.
If towing or pulling something is required:
- Keep helpers or bystanders away from between
the machine and the towed vehicle or object.
- Use a cable of adequate capacity and in good
condition.
- Use a cable that has appropriate pull hooks.
- Use only the hitch provided on the rear of the
machine.
1.10
SAFETY
Safe Operation

80ZV0001

- Be sure the hitch pin is fully in its bore before

applying tension.
- Make sure to install the split pin into the hitch pin
to avoid the hitch pin coming off.
- If brakes and steering are working on the towed
vehicle, keep an operator in the operator's seat
and have him control the vehicle.
- If brakes are not working on the towed vehicle,
attach another vehicle of adequate size to the
rear to act as a braking vehicle.
- Use the machine as a tow vehicle only for short
distance.
 1.11
SAFETY
Safe Operation

Parking Safety If parking near a road, be sure and erect safety bar-
riers and lights as required.
Stop the machine on level ground with the service
brakes -- not the parking brake.

Lower the attachment to the ground and apply the

parking brake.

OM0025

If parking on level ground is not possible, follow

these precautions:

- Lower the attachment to the ground and apply

some down pressure.
- Block the tires.
- Apply the parking brake.

To prevent unauthorized use:

- Remove the key.

- Close and lock all cab doors and windows (if
equipped with a cab).
- Install vandal covers (if equipped).

OM0186

Inspect the machine and report any needed

repairs.
1.12
SAFETY
Safe Maintenance

Safe Maintenance
Safety Preparations Before Mainte-
nance

Do not rush. Walk, do not run. Avoid shortcuts that

may cause accidents.

Perform maintenance and repairs only if trained.

Follow the Operation & Maintenance Manual or
Shop Manual.
OM0002

Air conditioner servicing and repair should be per-

formed by trained specialists since injury and/or
environmental pollution can result from improper - Do not wear jewelry that may catch on equip-
servicing. ment, controls, or may short and cause burns if
in contact with electrical components.
Allow only properly trained tire mechanics with the
proper tools to service tires and rims.

OM0026a

Wear safe clothing to perform maintenance:

- Close fitting clothing -- loose or baggy clothing

can catch on equipment or controls.
- Protective clothing as required by the job or con-
ditions -- for example:

- Hard hat
- Gloves
- Steel-toe shoes
- Eye / face protection
- Antidust mask or approved respirator

OM0222
The inhalation of asbestos-laden dust involves the
risk of having an adverse health effect. At the
wrecking site and the site handling industrial waste,
there is a possibility of inhaling asbestos-laden
dust.
It is requested that the following measures should
be taken at the site where there is a possibility that
asbestos-laden dust flies in all directions.
- The worker should wear protective equipment
such as a dust-protective mask.
- Sprinkle water in order to prevent asbestos from
flying in the air.
- Do not use compressed air for cleaning work.
- Do not allow any person other than workers to
come near the working site.
- Observe strictly the laws, regulations and rules
regarding the environmental standards at work-
ing sites.
Asbestos is not used both in this product and genu-
ine parts. However, as it is feared that asbestos
may be used in non-genuine parts, please be sure
to use our genuine parts for replacement.
1.13
SAFETY
Safe Maintenance
OM0025
Before performing any maintenance:
- Park on level ground.
- Block the tires securely.
- Apply the parking brake.
- Lower the boom and attachment to the ground.
- Stop the engine (unless specified in the Opera-
tion & Maintenance Manual or Shop Manual).
Use a piece of cardboard or wood to find fluid leaks
under pressure but do not use your bare hand. Die-
sel fuel or hydraulic fluid under pressure can pene-
trate skin or eyes and cause serious injury,
blindness or death.
OM0029
Never make repairs on pressurized components.
Release all trapped air and hydraulic pressure by:
- Stopping the engine after lowering the attach-
ment to the ground.
- Moving the loading control levers back and
forth.
- Turning the steering wheel right and left several
times.
- Turning the hydraulic tank cap 1/3 turn counter-
clockwise.
1.14
SAFETY
Safe Maintenance

Support bar

DANGER

DO NOT
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE
85ZV28463
OM0182

Attach a "DO NOT START" or "DO NOT OPER-

ATE" tag on the key switch or the steering wheel.

When working beneath the machine, use sturdy

and stable supports to hold it up. Do not depend on
hydraulic cylinders or attachment.

70ZV27373

It may be a possibility that your hands or fingers are

pinched with cover suddenly closed by mighty wind
etc.

Surely support the cover by support bar when car-

OM0031 rying on inspection work keeping the cover open.

Pay attention not to pinch your fingers when you

If working under the raised boom or attachment, be close door.
sure to properly block or support boom.
(The illustration above is shown the model 70ZV-2
Do not stand on tires. Use safe and sturdy working engine room.)
platforms.
 1.15
SAFETY
Safe Maintenance

Explosion / Fire / Burn Prevention Clean up all spills of coolant, fuel, oil, etc. to pre-
vent fire and slipping hazards.
Before removing any coolant hoses or plugs,
relieve any trapped pressure in the cooling system. Never use flammable solvents like gasoline or die-
sel fuel for cleaning parts.
Cooling system additives and cleaners may contain
alkali that can cause caustic burns or blindness.
Avoid contact with skin or eyes.

Pour all fuel and oil into appropriate containers.

Leave the containers at well ventilated place where
unauthorized persons are prohibited.

Hot oils or coolant and components can cause

burns. Allow components to cool to a safe tempera-
ture before servicing.

Keep flame and sparks away from flammable and OM0032

explosive materials such as:

- Fuel If overheated tire is suspected, never stand in front

- Oil of the tire. Stay away until the tire and rim cool
- Antifreeze down.
- Batteries
- Wood chips
- Straw, leaves, pine straw
- Oily rags
- Grease
- Ether starting fluid

OM0033

Tire and rim assemblies if improperly serviced can

explode with deadly force. When inflating tires;

OM0187 - Make sure wheel parts are correctly installed.

Never smoke while fueling a machine. Stop the
engine before fueling.
- Fill oil at well ventilated place.
- Do not leave the machine when filling oil.
- Fasten the oil filler cap tightly.
Remove flammable materials from hot engine com-
ponent areas (i.e.; muffler, manifold, etc.).
- Use a self attaching (locking) air chuck.
- Use a remotely located valve to turn air pres-
sure on and off.
- Stand behind the tread not beside the rim.
- Do not inflate tires more than the recommended
pressure.
- Use a safety cage for a repaired tire.
Serious injury may result from explosion of tire/rim
assembly due to improper welding on the rim with-
out first removing tire. Remove tire from rim when
welding rim.
1.16
SAFETY
Safe Maintenance

Other Maintenance Safety Concerns

Do not operate the engine where there are or can
be combustible vapors. These vapors can be Periodically check the ROPS bolts (if equipped) to
drawn through the air intake system and cause be sure they are in place and tight.
engine overspeeding, which can result in a fire, and
explosion.

To prevent ignition, use the luminaire when check-

ing oil, cooling water, fuel and battery electrolyte
level.

Move ignitable things to a safe place when grinding

welding or gas cutting.

Charge a battery at well ventilated place and keep

fire away from it during charging.

OM0008

Never weld, drill or in any way modify the ROPS

without approval from the manufacturer.

Stop the engine before opening the engine access

panel.
Contact with belts, pulleys, or other moving parts
will cause injuries.

During servicing, inspect the wiring harnesses, con-

nections and wires and replace any that may be
chafed, or tighten any that may be loose.

OM0188

Keep the area clear of bystanders and wear eye

protection when striking pins, teeth, or cutting
edges during removal or installation. Metal pieces
can fly off and cause injury. Use a brass drift or a
dead blow hammer as required by the job.

Keep the area clear of bystanders and wear proper

eye protection and protective clothing when grind-
ing or welding.
 1.17
SAFETY
Safe Maintenance

Do not enter the articulation area when engine is

running.

Articulation Stopper
"LOCKED"

115ZV0001a

When transporting the machine on a truck or lifting

the machine, lock the articulation stopper in the
"LOCKED" position.

Used oil may cause skin disease if allowed to

remain on the skin for extended periods. Wash skin
completely to remove used oils.

Drain and discard of used oil and coolant properly

to prevent environmental pollution.

Treat the oil and the coolant following the notes on

the MSDS (Material Safety Data Sheet).

Dispose of the waste oil and the coolant following

the law and/or local regulations.

When oil or fuel leaks from the high pressure rub-

ber hose, it may cause an accident or fire by a
wrong actuation. If something is wrong with the rub-
ber hose, immediate repair is needed:

- Correct them and fasten the rubber hose when

a clamp, guard and cushion are loosen. Do not
keep them loosen, or the rubber hose is dam-
aged by vibrating or scratching other parts.
- Fasten the rubber hose with designated torque
when the connection is loosen.
- Exchange the hose base when it is damaged or
deformed.
- Exchange the hose cover when it is damaged,
cut or expanded.
- Exchange the moving contact of the rubber
hose when it is twisted or bent.
1.18
SAFETY
Safety Signs

Safety Signs
All safety signs which are on the machine are
shown here. Read them and understand them thor-
oughly. They contain information which is important
for the safe operation and the safe maintenance.
Follow the directions on the safety signs carefully.

It is very important that all safety signs be on the

machine in the locations shown. If any sign is miss-
ing, damaged, or worn, get a replacement from
your authorized dealer and install it in the correct
position.

NOTE
The sample safety signs in this section have part
numbers to help you and your dealer obtain the
correct replacement.
 1.19
SAFETY
Safety Signs

1. 15.

WARNING

DANGER
Removal, damage or alteration
of Roll Over Protctive Structure
(ROPS) will result in death or
Serious injury.
Always keep ROPS in place.
FOR THE SAFETY OF
WORK SITE PARSONNEL, Do not operate this machine if
THE BACK-UP ALARM ROPS has been removed,
MUST ALWAYS SOUND
WHEN THIS MACHINE IS
damaged, or altered.
IN REVERSE. 44841-20870

IF THERE IS NO SOUND, L.H, R.H

CHECK AND REPAIR THE
BACK-UP ALARM
IMMEDIATELY.

44787-23880 44787-24020 44787-24680

L.H, R.H L.H, R.H Inside L.H

115ZV2 02597-0982PV

4. 5. L.H 16.

44787-23950 44787-23940 44787-24040

1.20
SAFETY
Safety Signs

6. 8. 9. 11.

44787-24010 44787-23870 44787-23860 44787-23900

Inside Inside Inside

115ZV2 02597-0982TV

11. 8. Inside 9. Inside 10. Inside

44787-23900 44787-23870 44787-23860 44787-23850

 1.21
SAFETY
Safety Signs

3. 2.

IMPORTANT
Improper procedure of cleaning
air cleaner element can cause
severe engine damage.
Do not clean or replace
element while engine is
running.
Clean only outer element.
Never clean inner element.
44787-20950

STOP STOP

44787-23920 44787-23910
L.H, R.H L.H, R.H

115ZV2 02597-0982RE

7. L.H, R.H 12. 6.

44787-23930 44787-23970 44787-24010

1.22
SAFETY
Safety Signs

Inside of Cab

B A

70ZV02597-0717BSa
B A 70ZV02597-0717BS
B-B A-A
70ZV02597-0717AS

13. 14.

DANGER
Removal, damage or alteration
of Roll Over Protctive Structure
(ROPS) will result in death or
Serious injury.
Always keep ROPS in place.
Do not operate this machine if
ROPS has been removed,
damaged, or altered.
44841-20870

44787-23960 44787-23840
 1.23
SAFETY
Safety Signs

1. 3.

STOP

44787-23880 44787-23920

DANGER WARNING

No room in this area while turning machine. Contact with moving belts or pulleys could result in
death or serious injury.
Crushing will result in death or serious injury.
Stop engine before working in this area.
Stay out of this area when machine could move or
turn.

2. 4.

STOP

44787-23910 44787-23950

WARNING DANGER

Contact with moving fan could result in death or Sudden or accidental movement of boom will result
serious injury. in death or serious injury.

Keep all guards in place. Before walking or working under raised boom:

Keep hands away from fan area. - Securely block or brace boom.

- Remove key and tag "Do Not Operate."

- Release all trapped oil pressure before opening

any piping.
1.24
SAFETY
Safety Signs

5. 7.

44787-23940 44787-23930

WARNING WARNING

Machine will not turn with articulation stopper in Machine movement could result in death or serious
locked position. injury.

Unlock articulation stopper before operating Stay out of this machine.

machine.

6. 8.

44787-24010 44787-23870

WARNING CAUTION

Nitrogen accumulator contains compressed gas When handling battery cable, you may get an elec-
and fluid which could result in death or serious tric shock.
injury.
Read, understand, and follow Operation & Mainte-
Release the oil pressure from all brake circuit (and nance Manual before servicing machine.
steering circuit for 65/70ZV-2 only) before removing
any oil lines or piping.

Do not attempt to service or repair accumulator

unless properly trained and equipped.
 1.25
SAFETY
Safety Signs

9. 10.

44787-23860 44787-23850

WARNING WARNING

Batteries produce explosive gases which could Pressurized system: spray of hot fluid could result
result in death or serious injury. in death or serious injury.

Keep flames and sparks away. Allow system to cool and vent pressure slowly
before servicing.
Vent area before servicing.

Batteries contain lead, and acid which may result in

minor or moderate injury.

Avoid contact with skin or clothing.

If lead, or acid contacts skin or clothing, immedi-

ately wash with water.

11.

44787-23900

CAUTION

You may fall from here.

Do not step on here.

1.26
SAFETY
Safety Signs

12. 13.

44787-23970 44787-23960

WARNING WARNING

Machine movement, if engine starts in gear, could Accidental movement of machine could result in
result in death or serious injury. death or serious injury.

- Do not start engine by shorting across starter Before checking transmission oil:
terminals. - Park on level ground.
- Lower attachment to ground.
- Do not start engine while standing on ground. - Place transmission in neutral.
- Set parking brake.
Make sure to start engine only from operator's seat - Tag "Do Not Operate."
with transmission in neutral and parking brake
applied.
14.

44787-23840

WARNING

Improper operation or maintenance could result in

death or serious injury.

Read, understand, and follow Operation & Mainte-

nance Manual before operating or servicing
machine.

Follow all safety signs and instructions in Operation

& Maintenance Manual or on machine.
 1.27
SAFETY
Safety Signs

15.

44787-24020

WARNING

Pressurized system: spray of hot fluid could result

in death or serious injury.

Allow system to cool and vent pressure slowly

before servicing.

16.

44787-24040

WARNING

Pressurized system: spray of hot fluid could result

in death or serious injury.

Allow system to cool and vent pressure slowly

before servicing.
1.28
SAFETY
Safety Devices
Safety Devices
Loading Control Lever Lock
DANGER
Accidental movement of boom or machine will
result in death or serious injury.
When parking or leaving machine, or when per-
forming maintenance on it, always lower attach-
ment to ground and lock loading control levers.
Lock
Unlock 115ZV2 9296
This device locks the loading control levers to pre-
vent accidental lowering of the attachment or boom.
- To lock, set the loading control levers to "NEU-
TRAL" and pull-up the lock lever to forward.
- To unlock, push down the lock lever to back-
ward.
Articulation Stopper
WARNING
With articulation stopper in LOCKED position,
machine will not steer; which, while operating,
could cause an accident, injury or death.
Do not lock Articulation Stopper during normal
operation.
Articulation stopper locks the front and rear chassis
to prevent them from sudden articulation during
inspection or transportation.
To lock:
"LOCKED" position
115ZV0001a
1. Align the front and rear chassis straight ahead.
2. Using a 14 mm wrench remove the bolt that
fixes the articulation stopper to the storage
bracket on the rear chassis.
3. Remove the clip pin and pin from the end of
the Articulation Stopper.
4. Turn the link and fix the end to the bracket on
the front chassis (as shown).
5. Insert the pin and clip pin. (This is the LOCKED
position.)
 1.29
SAFETY
Safety Devices

To unlock: Neutral Start System

The transmission has a neutral start system which

allows the engine to start only when the transmis-
sion shift lever is in NEUTRAL position.

Emergency Brake

"STORED" position When the service brake does not work, emergency
brake can be applied manually.

115ZV0002a

1. Remove the clip pin and pin from the end of

the articulation stopper on the front chassis
bracket.

2. Turn the link to the rear chassis bracket.

3. Insert the pin and clip pin. (This is the

STORED position.)

4. Tighten the bolt to fix the articulation stopper 97ZVOM0038

on the bracket.

- Pull the emergency brake switch to engage the

emergency brake and disengage the transmis-
sion.
1.30
SAFETY
Safety Devices

Secondary Steering (option) ROPS (Roll Over Protective Structure)

WARNING
Operation without normal steering could cause
loss of control and injury or death.
If secondary steering lamp lights up, steer
machine IMMEDIATELY to safe location and
stop it.
Secondary steering works automatically when the
steering hydraulic pressure goes down or the
engine stops while the machine is operating.
When the steering hydraulic pressure goes down
while the engine is running, the steering hydraulic
warning lamp lights up.
WARNING
Operating with damaged or improperly mounted
ROPS could serious injury or death. Be sure to
observe the following.
- Whenever seated, fasten the seat belt. (If
equipped)
- Do not modify ROPS, such as drilling or weld-
ing.
- Do not use ROPS deformed.
- If any damage or loose bolts are found, do not
operate until repaired.
- Never repair or modify ROPS without manu-
facturer’s approval and instructions.

Refer to "Secondary Steering Warning Lamp (red)

(option)" page 2.33.

If the secondary steering works:

1. Keep the starter switch in the "ON" position

even when the engine unexpectedly stops.

2. Immediately operate the steering wheel to

bring the machine to a road shoulder or safe
location.

3. Stop the machine. If necessary, use the emer-

gency brake or lower the attachment to stop
the machine.

4. Place wheel chocks in front of and behind the

tires to prevent the machine from moving.

5. Contact your local authorized dealer for neces-

sary testing and repair.
 2.1

2.OPERATION
2.2
COMPONENT NAME/LOCATION

COMPONENT NAME/LOCATION

9 27 8 18 17 26 25 24
11

10
5 4
3
2

7 23 12
115ZV2 EU COMPO

15 19 21 13,14 6 22 20 16

1. Bucket (Attachment) 15. Front Axle / Differential Ass'y

2. Boom 16. Rear Axle / Differential Ass'y
3. "Z" Lever 17. Air Cleaner (Right hand side)
4. Boom Cylinders (2) 18. Precleaner (2) (option)
5. Bucket Cylinders (2) (1pc. for log loader) 19. Parking Brake
6. Steering Cylinders (2) 20. 1st Propeller Shaft
7. Engine 21. 2nd Propeller Shaft
8. Torque Converter 22. 3rd Propeller Shaft
9. Transmission Ass'y 23. Batteries (2)
10. Radiator & Torque Converter Cooler (one each side--two 12VDC=24VDC system)
(Lower tank) 24. Cooling Fan
11. Air Cooler (for engine intake air) 25. Fan Motor (hydraulic type)
12. Hydraulic Oil Cooler 26. Exhaust Muffler
13. Fuel Tank (Right hand side) 27. ROPS
14. Hydraulic Tank (Left hand side)

NOTE
When a component or an item location is given as
"Left hand side" or "Right hand side", it is according
to the operator's left side or right side when sitting
in the seat.
 2.3
OPERATOR'S AREA
Pedals and Levers

OPERATOR'S AREA

Pedals and Levers 1. Transmission Shift Lever

Transmission Shift Lever is used to control machine

11 speed and direction.
2
3 - Push the lever forward to move the machine for-
1 ward.

- When the lever is in NEUTRAL, the machine

should not move on level ground.

- Pull the lever backward to move the machine

backward.

9 10 9 8 97ZVOM0041 - The four forward and three reverse speed shift-

ing modes are selected by rotating the shift
lever.

6 (option)
7

5
115ZV2 9296

65ZV 5089

1. Transmission Shift Lever

2. Horn Button [1]: 1st speed (fixed)
3. High-Low Beam Lever / Turn Signal Lever
(option) [2]: 2nd speed (fixed)
4. Boom Control Lever
5. Bucket Control Lever [3]: 3rd speed (fixed)
6. Auxiliary Attachment Control Lever (option)
7. Wrist Rest [A]: 2nd, 3rd and 4th speed is automatically
8. Accelerator Pedal selected for the machine running condition.
9. Brake Pedals
10. Steering Column Telescopic Tilt Handle

2. Horn Button

Horn Button is used to blow the horn.

- Press the button in the center of the steering

wheel to blow the horn.
2.4
OPERATOR'S AREA
Pedals and Levers

3. High-Low Beam Lever / Turn Signal 4. Boom Control Lever

Lever (option)
Boom control lever is used to control the boom
movement.

Low beam position

(c) (d)
(b)
(a)

High beam position

97ZVOM0044

115ZV2 9296
This lever is used to change the head lights beam
high and low. This lever also turns on the turn sig-
nals. (a) Float
- Move the lever to full forward detent position.
- The head lights are in the high beam position The boom will lower and move freely following
when the lever is pushed down (low position). the ground surface.

- The light switch can be operated regardless of - An automatic boom height positioner is provided
the lever position. which will automatically release the detent and
return the lever to the "Hold" position when a
preset boom height is reached.

(b) Lower
- Move the lever forward. The boom will lower.
When held in this position, down pressure will
be applied to the attachment.

- An automatic boom height positioner is provided

which will automatically release the detent and
return the lever to the "Hold" position when a
preset boom height is reached.

97ZVOM0044 (c) Hold

- Push the lever forward to turn on the left turn
signal.
- Pull the lever backward to turn on the right turn
signal.
- Return the lever to the center position when the
turn is completed. The lever does not return
automatically when the steering wheel is
returned to center.
- Return the lever to the center position. The
boom will stop and remain in that position.
(d) Raise
- Move the lever rearward. The boom is raised.
When pulled fully back it is held in a detonated
position.
- An automatic boom height positioner is provided
which will automatically release the detent and
return the lever to the "Hold" position when a
preset boom height is reached.
 2.5
OPERATOR'S AREA
Pedals and Levers

- For adjustment procedure Refer to "Kickout 5. Bucket Control Lever

Control Switch" page 2.18.
Bucket control lever is used to control the bucket or
In case that the boom does not stop moving even
attachment movement.
when the boom control lever is in the HOLD posi-
tion, turn the starter switch to the "OFF" position to
stop the engine.

IMPORTANT
If the engine stops by some trouble, lower the (d)
boom and place the bucket on the ground imme- (b) (c)
diately. (a)

115ZV2 9296

(a) Dump
- Move the lever forward. The bucket or attach-
ment will dump.

(b) Hold
- Return the lever to the center position. The
bucket or attachment will stop and remain in that
position.

(c) Roll Back (Dual Motion)

- Move the lever rearward half way. The bucket or
attachment will roll back slowly.
- When the boom control lever is in the "Raise"
detent position, both bucket or attachment and
boom will move slowly.

(d) Roll Back (Detent)

- Move the lever rearward. The bucket or attach-
ment will roll back.
- An automatic bucket or attachment leveler is
provided which will automatically release the
detent and return the lever to the "Hold" position
when the bucket or attachment reaches to the
preset angle.
- For adjustment procedure refer to "Bucket /
Attachment Leveler Adjustment" page 2.100.

In case that the bucket does not stop moving even

when the bucket control lever is in the HOLD posi-
tion, turn the starter switch to the "OFF" position to
stop the engine.
2.6
OPERATOR'S AREA
Pedals and Levers

6. Auxiliary Attachment Control Lever 7. Wrist Rest

(option)

Auxiliary attachment control lever is used to control

the auxiliary attachment such as log clamps, multi-
purpose buckets, etc.

Unlock

(b) (c)
(a) Lock

65ZV4705

Wrist rest is used to put on the wrist or arm while

operating the bucket/boom control levers.

115ZV2 9296 (High/Low)

(a) Normally this position will close the attach-
ment.
(b) This center position will cause the attachment
to stop and remain in that position.
Pull the lever out and turn, bringing back to the orig-
inal position, to adjust the height.
(Front/Rear)
Loosen the screws to adjust the position.

(c) Normally this position will open the attachment.

In case that the auxiliary attachment does not stop

moving even when the auxiliary attachment control
lever is in the HOLD position, turn the starter switch
to the "OFF" position to stop the engine.

NOTE
If equipped with attachments other than the stan-
dard bucket, consult the attachment supplier for
specific instructions.

IMPORTANT
KCM will not accept any liability for any attach-
ments and spare parts not approved by KCM.

8. Accelerator Pedal
97ZVOM0038
Accelerator pedal is used to control the engine
speed.
- Step on the pedal to increase the engine speed.
- Release the pedal to decrease the engine
speed.
WARNING
Control pedals which stick could cause loss of
control and injury or death.
- Be sure control pedals move freely before
operating.
- Do not allow dirt, mud, or debris to build up
under or around pedals.
In case that the accelerator pedal does not release,
step on one of the brake pedals or turn the starter
switch to the "OFF" position.
2.7
OPERATOR'S AREA
Pedals and Levers
Effect on the machine
The ECM is equipped with safety functions that are
designed to limit engine speed in certain situations.
To avoid insufficient engine performance because
of this safety function, the following steps are
important.
1. Wait 1 second before turning the key from the
"ON" to the "START" position.
(The safety function will turn "ON" 1 second
after the key is set to the "ON" position.)
2. Do not step on the pedal while the engine is
starting, nor just after the engine starts.
(It takes about 3 seconds to complete the
adjustment, and stepping on the pedal nega-
tively affects the correct adjustment.)
If the safety function is activated, turn off the engine
for about 30 seconds and then restart.
Engine Acceleration Control (Function)
(Turbo Protection)
When the engine coolant temperature is 10ºC or
lower, the accelerator is not activated a few sec-
onds and delays the response for acceleration.
2.8
OPERATOR'S AREA
Pedals and Levers

9. Brake Pedals
WARNING
Continuous use of brake could cause rapid or
abnormal brake disc wear and / or brake circuit
malfunctions which could cause loss of control
and injury or death.
- Do not use brake pedals as foot rest.
- Do not ride brakes.
- Use brake pedals only when applying brakes.
CAUTION
Declutch feature momentarily places transmis-
sion in neutral, which may allow machine to roll
when on a grade.
Be sure to turn off declutch ON/OFF switch when
operating on a grade.
In case the brake does not work, pull the parking
brake switch to apply the emergency brake. The
parking brake can be used as the emergency
brake.

97ZVOM0038

Brake pedals are used to reduce the machine

ground speed, stop the machine, or to hold the
machine.

Left and right Brake Pedals: May be used either of

two ways:

1. As a brake only pedal by turning the declutch

ON/OFF switch (See page 2.17) to the "OFF"
position. Use this position when working on
slopes or ramps.

2. Disengage the transmission while applying the

brakes. This is normally used when loading
trucks. It allows higher engine speed to provide
faster hydraulic operations.

To use this feature, turn the declutch ON/OFF

switch to the "ON" position. When the switch is
"ON", a green indicator lamp on the dash will
also be turned on.
 2.9
OPERATOR'S AREA
Pedals and Levers

10. Steering Column Telescopic Tilt

Handle

WARNING
Unexpected movement of steering column could
cause loss of control and result in death or seri-
ous injury.

- Stop machine before adjusting steering wheel

height and angle of steering column.
- Be sure to push down fully the telescopic tilt
handle lock lever before operating machine.

Steering column telescopic tilt handle is used to

adjust the steering wheel up and down, and to tilt
the steering column forward or backward for opera-
tor's comfort.

Release

Lock

97ZVOM0045

1. Pull up the telescopic tilt handle lock lever and

move the steering wheel to the desired posi-
tion.

2. Push down the telescopic tilt handle lock lever

fully to lock the steering wheel in position.
2.10
OPERATOR'S AREA
Switches

Switches
(11C5-0151~0250)

11 4
6 10 20 5
F

15
E
0 30
16 x100min -1 17

STOP

115ZV2 0002a

(11C5-0251~)

11 4
6 5
15
16 17

115ZV2 0013

2 378
12 9

65ZV5089c
65ZV 5088e

10 19
21
22
20
14
1 18
13 115ZV2 9296 85ZV2 FR SWITCH a
 2.11
OPERATOR'S AREA
Switches

1. Starter Switch
1. Starter Switch
2. Parking Brake Switch
3. Light Switch
4. Front Working Light Switch
5. Rear Working Light Switch
6. Fuel Efficient Mode Switch OFF ON
START
7. Front Wiper Switch
8. Rear Wiper Switch
9. Cigarette Lighter
10. Downshift Button
11. Four-Way Flasher Switch (option)
12. MODM
13. Declutch ON/OFF and Adjustable Preset
Switch 97ZVOM0074
14. Kickout Control Switch
15. Efficient Loading System Switch
16. Cold Start (ether injection) Switch OFF
17. Selection Switch for Shift Lever or F/R Switch - Key can be either inserted or pulled out.
(option)
18. F/R Switch (option) - Engine is stopped and most electrical circuits
19. Reversal Fan Switch (option) are turned off.
20. Ride Control Switch (option)
21. Traction Control Switch ON
22. Alternate Throttle for Traction Control - Current flows to all circuits.

START
- When the transmission shift lever is in NEU-
TRAL, starter motor turns, starting the engine.

- When released the key will automatically return

to the "ON" position.
2.12
OPERATOR'S AREA
Switches

2. Parking Brake Switch 3. Light Switch

WARNING
Accidental movement of machine could result in
death or serious injury.

Be sure to pull parking brake switch when park-

ing or leaving machine, and during maintenance
or transportation.

65ZV 5088e

This is a three position switch.

OFF
- Width (clearance) lamps (option), tail lamps,
front head lights, and gauge lamps turn off.

97ZVOM0038 - Width (clearance) lamps (option), tail lamps, and

gauge lamps turn on.
Parking brake switch is used for parking the
machine. When the switch is pulled, the parking
brake is applied and the transmission is disen- - Width (clearance) lamps (option), tail lamps,
gaged. When the switch is pushed, the parking front head lights, and gauge lamps turn on.
brake is released.

Should the directional shift lever be moved into the

forward or reverse position while the parking brake
is applied and the engine is running, a warning
buzzer will sound.
 2.13
OPERATOR'S AREA
Switches

4. Front Working Light Switch 5. Rear Working Light Switch

115ZV2 0003a 115ZV2 0003a

OFF OFF

ON ON

switch-4 switch-4

Front working light switch is used for turning on and Rear working light switch is used for turning on and
off the front working lights. off the rear working lights.

Turn off the front working lights when roading to Turn off the rear working lights when roading to pre-
prevent blinding the driver in front of you. vent blinding the driver behind you.
2.14
OPERATOR'S AREA
Switches

6. Fuel Efficient Mode Switch 7. Front Wiper Switch

115ZV2 0003a

65ZV 5088e
OFF

Front wiper switch is used to wipe the front wind-

shield and spray solvent.
ON

switch-3
INT LOW
OFF HIGH
Engine Torque

PUSH

OM0189
Power Mode

FE Mode OFF :

INT : Intermittent
Engine Speed
90ZV2 5001
LOW : Low speed

The operator can select either "Power" or "Fuel Effi- HIGH : High speed
cient" engine mode.
PUSH : Spraying solvent on the windshield
Power mode provides added power for extreme
applications.

Fuel efficient mode offers better fuel economy for

standard applications.

When this switch is turned "ON" the switch lamp

lights up and the engine power is reduced to pro-
vide better fuel economy.
 2.15
OPERATOR'S AREA
Switches

8. Rear Wiper Switch 9. Cigarette Lighter

65ZV 5088e 65ZV 5088e

Rear wiper switch is used to wipe the rear wind-
shield.
Cigarette lighter is used to light a cigarette or cigar.
- Push the lighter in and wait for a few seconds.
The lighter will spring back to be ready for light-
ing a cigarette or cigar.

- The cigarette lighter power-outlet socket can be

used as a power source with max. 24 volts 10
OFF ON
amperes in case of emergency.

PUSH

OM0190

OFF :

ON : Low speed

PUSH : Spraying solvent on the windshield

2.16
OPERATOR'S AREA
Switches

10. Downshift Button 11. Four-Way Flasher Switch (option)

115ZV2 0003

115ZV2 9296
OFF

Downshift button is used to quickly shift down the

transmission from 2nd gear to 1st gear without
moving the transmission shift lever. ON

- When operating the machine in 2nd speed with

the shift lever in [2] or [A] position, the transmis-
sion will shift down to 1st gear by pressing switch-3
downshift button.

- Pressing downshift button again or moving the
transmission shift lever to the opposite direction
releases the 1st gear setting to return to 2nd
gear.
The two front and two rear turn signal lights will
flash when four-way flasher switch is ON.
This is used in emergency, when parking on the
road, etc. to warn other vehicles.
 2.17
OPERATOR'S AREA
Switches

12. MODM 13. Declutch ON/OFF and Adjustable

Preset Switch

Declutch
Declutch OFF preset

65ZV5089c
Declutch ON 115ZV2 9296

The MODM has the following functions:

- Information monitor Declutch ON/OFF

- Displays outside air temperature, machine

speed and engine speed, engine coolant tem-
perature, transmission oil temperature, hydrau-
lic oil temperature and miles driven etc.

- Replacement monitor

Allows check of the replacement time for the OFF

parts and oil periodically replaced, allows setting ON
of the replacement interval, and displays the
replacement pop-ups.

switch-9
- Error log monitor

Allows check of previous errors, and displays Declutch ON/OFF switch is used to change the
active errors. function of the brake pedals.

- Input/Output monitor Normally this switch should be "ON".

Displays the ON/OFF status of input and output OFF

signals. - When the brake pedals are step on, only the
service brakes are engaged keeping the trans-
- Parameter setting monitor mission directional clutch engaged. (brake only)

Allows check and change of the parameter set- ON

ting. - When the brake pedal is step on, the service
brakes are engaged and the transmission direc-
- Specification setting monitor tional clutch is disengaged (brake and declutch).

Allows check and change of the specification Refer to "Brake Pedals" page 2.8 for the function of
setting. the brake pedals.

Refer to page 2.36 for the MODM operation.

2.18
OPERATOR'S AREA
Switches

14. Kickout Control Switch

CAUTION
Declutch feature momentarily places transmis-
sion in neutral which may allow machine to roll
when on a grade.

Do not turn declutch ON/OFF switch to "ON"

when operating on a grade.

Adjustable Declutch Preset

115ZV2 9296

(Upper) (Lower)

Hold
Hold Hold
Reset

Reset Reset
switch-10

Adjustable declutch preset switch is used to

change the angle of left brake pedal (declutch
pedal) to disengage the transmission clutch.
With the engine running, step on the left brake
pedal (declutch pedal) up to the desired angle, and
press the switch to set the declutch pedal angle.
switch-5
Kickout control switch is used to set the desired
upper and lower boom position.
- Raise the boom to desired position and press
the left side of the switch to set the upper kick-
out position.
When the boom control lever is placed at
"Raise" position and the boom reaches at the
preset height, the lift kickout automatically
releases the detent and returns the boom con-
trol lever to "Hold" position.

- Lower the boom to desired position and press

the right side of the switch to set the lower kick-
out position.
When the boom control lever is placed at "Float"
position and the boom reaches at the preset
height, the lower kickout automatically releases
the detent and returns the boom control lever to
"Hold" position.
 2.19
OPERATOR'S AREA
Switches

NOTE 15. Efficient Loading System Switch

- Float detent is ready to be reactivated 2 sec-
onds just after the previous lower kickout opera-
tion. Use the float detent after 2 seconds or
more later the lower kickout operates.

- The bucket may hit the ground, if the boom

leaves the clearance a bit higher above the
lower kickout position.
115ZV2 0003a

- Preset the lower kickout position at a higher

point when it is cold due to the thicker oil.

WARNING
Accidental movement of machine could result in OFF
death or serious injury.

Be sure to stop machine and pull parking brake

switch before adjusting boom position. ON

switch-3

ELS (Efficient Loading System) increases rim-pull

power when digging while consuming less fuel.

It is useful to use the ELS for heavy duty digging

application or fuel efficient engine mode.

ELS system works under the following condition.

- ELS switch ON
- Machine speed (Forward) under 5 km/h
- Boom control lever set at "Raise" position

FAST

SLOW

90ZV2 5002
2.20
OPERATOR'S AREA
Switches

When this switch is turned "ON", the switch lamp 16. Cold Start (ether injection) Switch
lights up and the hydraulic oil flow is optimized to
increase digging power. As a result, the boom rises
slower than it would in the non-ELS position from
the ground to the ELS engagement boom setting
height.

This improves loading efficiency and save fuels.

115ZV2 0003a
The boom height position at which the ELS
engages is preset at the factory before delivery.
However it can be changed to engage at different
positions by doing the following steps.

To change the ELS engagement boom height, raise

the boom to the desired position and repeatedly OFF
turn the efficient loading system switch from "OFF"
(Automatically
to "ON" three times. After the buzzer sounds, the reset)
boom is set to engage at that position.
ON
NOTE
As an alternative method of operation to the above
method, the efficient loading system also works
when engine revolutions are lower than 1,000 min-1 switch-3
(RPM), even if the efficient loading system switch is
in the "OFF" position.
Cold Start Switch is used for easy engine starting in
In this type of situation, when the engine revolu- cold weather. Ether is injected into the engine after
tions rise above 1,300 min-1 (RPM), it stops work- turning this switch to "ON" and "OFF".
ing.
Refer to "Cold Start" page 2.78 for proper use.
 2.21
OPERATOR'S AREA
Switches

17. Selection Switch for Shift Lever or

F/R Switch (option)

STOP

115ZV2 0004a

ON/OFF

switch-4

Selection switch for shift lever or F/R switch is used

to switch the forward/reverse function by using from
the shift lever to the F/R switch (option).

The F/R switch has three positions (F, N, R).

Regardless of the shift lever position, while the F/R

switch is in N position, when pressing selection
switch, the light turns ON. Changing direction for
forward/reverse can be operated by F/R switch.

Pressing selection switch again, the light goes out,

and the function of F/R switch is cancelled.

The shift lever can be used to move the machine

forward or reverse.

However for safety purposes, place the shift lever

in the neutral position before pressing selection
switch again.
2.22
OPERATOR'S AREA
Switches

18. F/R Switch (option)

85ZV2 FR SWITCH a

F/R switch is used to move the machine forward

and reverse.

Place the F/R switch in F position to move the

machine forward, and in R position to move the
machine reverse.

The machine does not move either way when the

F/R switch is in N position.

Operation Shift lever position F/R switch position Selection switch

By F/R switch Any position N ON
By shift lever N Any position OFF
 2.23
OPERATOR'S AREA
Switches

19. Reversal Fan Switch (option) Function Limitation

When either one of the following temperatures

exceeds the preset upper limit(s), the cooling fan
reverse rotation function does not work:

- Engine coolant temperature

- Torque converter oil temperature
- Hydraulic oil temperature

115ZV2 9296

ON/OFF

switch-3

Engaging this switch reverses the rotation of the

cooling fan for cleaning the radiator fins.

When pushing this switch for more than 2 seconds

while the engine is running or with the starter switch
at "ON" position, the switch turns "ON", the pilot
lamp on the switch lights up and the cooling fan
turns in reverse rotation for 1 minute, after which it
returns to it's normal rotation.

The fan turns continuously in reverse direction for 1

minute at 30 minute intervals.

When the switch is pushed again for more than 2

seconds, the cooling fan reversal switch turns
"OFF" and the pilot lamp in instrument panel turns
"OFF". Then the cooling fan turns in the normal
direction.

The cooling fan reversal switch can be operated

any time the engine is running. It is not necessary
to stop the machine to push the reversal cooling fan
switch.
2.24
OPERATOR'S AREA
Switches

20. Ride Control Switch (option) 21. Traction Control Switch

115ZV2 9296 115ZV2 9296

OFF OFF

ON ON

switch-3 switch-3

When the ride control switch is ON, the ride control If the tire is ready to spin, by keeping the traction
system works. Refer to "Ride Control (option)" page control switch ON, the engine speed is temporarily
2.65. slowed down and tire spin is reduced. This
increases tire life.

When the traction control is reducing the wheel

spin, the green light in the switch flashes.

The engine speed reduction level can be adjusted

using the alternate throttle for traction control.
Refer to the following section.
 2.25
OPERATOR'S AREA
Switches

22. Alternate Throttle for Traction Con- 4. Repeat steps 2 and 3 to find the desired
trol engine speed reduction level.

115ZV2 9296

Alternate throttle for traction control is used for

adjusting engine speed while the traction control
system works.

Engine speed should be adjusted depending on the

tire spin condition.

Adjustment procedure:

1. Turn the rotary switch fully clockwise.

The engine speed will be reduced dramatically
for 1~2 seconds when wheel spin starts and
further spinning is stopped.

Max. Engine
Max.Engine Normal
Normal Traction
Traction
Speed
Speed Reduction
Reduction Control
Control Range
Range

Alternate throttle

2. Slightly turn the rotary switch counterclock-

wise.
The middle position is suggested.

3. Operate the machine under the condition

where the tires are slipping, and check the
engine speed reduction level.
2.26
OPERATOR'S AREA
Indicators

Indicators
(11C5-0151~0250)

1 23 22 5 19 21 20 9 6 2 25 4 10

0 0 0 0 0 0 1/10h
11(30)
AUTO
20 12
10 N
C H F
4 13
3 E
0 30 2 14
x100r/min
1
C H
15
16
17
115ZV2 0008 18
29 27 28 26 24 7 8 3
(30)

(11C5-0251~)

1 24 23 19 22 21 9 5 8 6 20 2 12 10 11(30)

13
14
27

17
115ZV2 0012
26 25 29 28 7 3 15 16 18
(30)
 2.27
OPERATOR'S AREA
Indicators

1. Tachometer 1. Tachometer
2. Engine Coolant Temperature Gauge
3. Torque Converter Oil Temperature Gauge
4. Fuel Gauge
5. Parking Brake Indicator Lamp (red) 20
10
6. Auto Brake Indicator Lamp (red)
7. Declutch Lamp (green)
8. Working Light Indicator Lamp (green) 0 30
9. Central Warning Lamp (red)
x100min -1
10. MCU (Machine Control Unit) Warning Lamp
(red) 97ZVOM0048

11. Brake Pressure Warning Lamp (red)

12. Engine Oil Pressure Warning Lamp (red) Indicates the engine revolutions per minutes.
13. Engine Coolant Temperature Warning Lamp
(red)
14. Torque Converter Oil Temperature Warning
Lamp (red) 2. Engine Coolant Temperature Gauge
15. Air Cleaner Warning Lamp (red)
16. Charge Lamp (red)
17. Transmission Oil Filter Warning Lamp (red)
18. Coolant Level Warning Lamp C H

19. Turn Signal Indicator Lamp (Left) (green) WATER

TEMP
20. Turn Signal Indicator Lamp (Right) (green)
21. High Beam Indicator Lamp (blue)
22. Auto Shift Indicator Lamp 97ZVOM0049

23. Neutral Indicator Lamp

24. Transmission Status Monitor Indicates engine coolant temperature. It is normal
25. Hour Meter when the indicator stays in the white zone
26. Secondary Steering Warning Lamp (red) (67~102ºC).
(option)
27. Engine Warning Lamps - If the indicator enters the red zone while operat-
28. Reversal Fan Pilot Lamp (green) (option) ing, slow the engine down to mid-range speed
29. F/R Switch Indicator Lamp (green) (option) and wait until the indicator reaches the white
30. Hydraulic Oil Level Warning Lamp (simulta- zone.
neous flashing) (red) (11. 26.)
- If the gauge stays in the red zone, stop the
When the starter switch is turned to "ON", indicator engine and allow it to cool naturally. After cool-
lamp (6) and all warning lamps (9) ~ (18), (26) and ing, check the cooling system.
(27) light up for three seconds. This is the lamp
(bulb) test period (lamp (16) lights up until engine Refer to "TROUBLESHOOTING" page 3.65.
starts).

IMPORTANT
Operating machine while any of red lamps are
ON may cause injury or damage to machine.

Stop machine and correct problems if any red

lamps come on.
2.28
OPERATOR'S AREA
Indicators

3. Torque Converter Oil Temperature 5. Parking Brake Indicator Lamp (red)

Gauge

C
T/C OIL
H
P
TEMP

OM0052

97ZVOM0050
Indicates the temperature of oil circulating through
the torque converter and the transmission. It is nor-
mal if the indicator is in the white zone (56~125ºC)
while operating.
Lights up when the parking brake is applied.
If the transmission shift lever is moved into "F" or
"R" position while this lamp is on, an alarm sounds
and the machine stays in neutral.

- If the indicator enters the red zone while operat-

ing, slow the engine down to mid-range speed,
6. Auto Brake Indicator Lamp (red)
shift to neutral, and wait until the indicator
reaches the white zone.
(11C5-0151~0250)
- If the indicator does not come back into the
white zone quickly, stop the engine and find the
cause.

Refer to "TROUBLESHOOTING" page 3.69.

OM0053

(11C5-0251~)
4. Fuel Gauge

OM0228

E
FUEL
97ZVOM0051
Lights up when the auto brake works.

Refer to "Auto Brake" page 2.88 for the detail.

Indicates the fuel amount in the fuel tank.

- Be sure to refuel at the end of each work day to

avoid condensation in the tank.
 2.29
OPERATOR'S AREA
Indicators

7. Declutch Lamp (green) 10. MCU (Machine Control Unit) Warn-

ing Lamp (red)

OM0054

OM0057

Lights up when the declutch ON/OFF switch is

"ON". Lights up when MCU malfunctions.

- When lit, the service brakes are engaged and - If it lights up while operating, stop the engine
the transmission directional clutch is disen- and contact your nearest authorized dealer for
gaged by step on the brake pedals. necessary repair.

- When not lit, only the brakes are engaged as the

brake pedal is step on.
11. Brake Pressure Warning Lamp (red)

8. Working Light Indicator Lamp WARNING

(green) Loss of braking force could result in death or
serious injury.

Stop machine IMMEDIATELY and correct prob-

lem if brake pressure warning lamp lights up dur-
ing operation.

OM0055
Brake Pressure Warning Lamp lights up and the
warning buzzer sounds when the brake oil pressure
Lights up when working lights are on. is lower than 3.9±0.5 MPa.

9. Central Warning Lamp (red)

OM0058

- If it lights up while operating, IMMEDIATELY

stop the machine and find the cause.
OM0056
Refer to "TROUBLESHOOTING" page 3.68.
Flashes when any of the warning lamps come on.
2.30
OPERATOR'S AREA
Indicators

12. Engine Oil Pressure Warning Lamp 13. Engine Coolant Temperature Warn-
(red) ing Lamp (red)

OM0059 OM0060

Lights up when engine oil pressure is low. Also the Lights up when coolant temperature overheats.
warning buzzer sounds. (Over 101±2ºC)

- If it lights up while operating, IMMEDIATELY - If it lights up while operating, slow the engine
stop the engine and find the cause. speed down to mid-range, shift to neutral, and
wait until the lamp goes out. Check the coolant
Refer to "TROUBLESHOOTING" page 3.65. temperature gauge before resuming operation.

- If the light does not go out quickly or lights up

again after resuming the operation, stop the
engine and find the cause. Refer to "TROUBLE-
SHOOTING" page 3.65.

CAUTION
Hot coolant spray may cause burns.

Never open radiator cap when engine is hot.

Stop engine and allow radiator and coolant to

cool completely before opening cap slowly to
relieve pressure.
 2.31
OPERATOR'S AREA
Indicators

14. Torque Converter Oil Temperature 16. Charge Lamp (red)

Warning Lamp (red)

Lights up when transmission oil overheats. (Over

120±5ºC)

OM0063

Lights up when alternator charge level is low.

OM0061 - If it lights up, check the charging circuit.

- If it lights up while operating, slow the engine Refer to "TROUBLESHOOTING" page 3.67.
speed down to mid-range, shift to neutral, and
wait until the lamp goes out. Check the torque
converter oil temperature gauge before resum-
ing the operation. 17. Transmission Oil Filter Warning
Lamp (red)
- If the light does not go out quickly or lights up
again after resuming the operation, stop the
engine and find the cause. Refer to "TROUBLE-
SHOOTING" page 3.69.

OM0064
15. Air Cleaner Warning Lamp (red)
Lights up when the transmission oil filter clogs.

- When lit, replace the transmission oil filter car-

tridge.

Refer to "Replace Transmission Oil Filter" page

OM0062
3.39.

Lights up when air filter is clogged.

- If it lights up while operating, stop the engine

and clean or replace the air cleaner outer ele-
ment.

Refer to "Clean or Replace Air Cleaner Element"

page 3.10.
2.32
OPERATOR'S AREA
Indicators

18. Coolant Level Warning Lamp 21. High Beam Indicator Lamp (blue)

OM0073 OM0067

Lights up when engine coolant level is lower than Lights up when headlights are switched to high
specified. beam.

- The coolant level is checked only with the

starter switch is in the "ON" position-engine off.
22. Auto Shift Indicator Lamp
- Once the engine is started this level check func-
tion is turned off.

19. Turn Signal Indicator Lamp (Left) AUTO

(green) OM0068

Lights up when the transmission control lever is in

the [A] position.

OM0065 23. Neutral Indicator Lamp

Flashes when the turn signal switch lever is moved

forward.

20. Turn Signal Indicator Lamp (Right)

N OM0069
(green)
Lights up when transmission is in neutral.

OM0066

Flashes when the turn signal switch lever is moved

rearward.
 2.33
OPERATOR'S AREA
Indicators

24. Transmission Status Monitor 26. Secondary Steering Warning Lamp

(red) (option)

4
3
2
OM0072

1
OM0070 Lights up when the steering hydraulic pressure is
lower than specified when the engine is running.
- 1st Gear
Lights up when the shift lever is in [1] position Also the warning buzzer sounds.
and transmission is in 1st gear. Machine stays
in this gear until manually shifted.

- 2nd Gear
Lights up when the shift lever is in [2] or [A]
position and transmission is in 2nd gear.

- 3rd Gear
Lights up when the shift lever is in [3] or [A]
position and transmission is in 3rd gear.

- 4th Gear
Lights up when the shift lever is in [A] position
and transmission is in 4th gear.

25. Hour Meter

1/10h

OM0071

Hour meter indicates the accumulated total hours

of engine operation. Use to determine the timing of
periodic inspection and maintenance service.
2.34
OPERATOR'S AREA
Indicators

27. Engine Warning Lamps 28. Reversal Fan Pilot Lamp (green)
(option)
Engine stop lamp

STOP
OM0223

OM0191
Red
Lights up when the reversal fan switch is ON.
If a stop (red) lamp comes on while the engine is in
Refer to "Reversal Fan Switch (option)" page 2.23.
operation, the fault can be engine disabling. Stop
the engine operation in a safe manner as soon as
possible.
29. F/R Switch Indicator Lamp (green)
(option)
Engine warning lamp

OM0218
OM0192
Yellow
Lights up when the selection switch for shift lever or
If the yellow warning lamp illuminates, the engine F/R switch is ON.
can still be operated, but it can lose some system
features that can sometimes result in a power loss. Refer to "Selection Switch for Shift Lever or F/R
The failure must be repaired as soon as conve- Switch (option)" page 2.21.
nient.

Engine protection lamp

OM0193
Orange

If the orange warning lamp comes on while driving,

it means that a fault code has been recorded. The
light will remain on as long as the fault is occurring.

The light will begin to flash if the condition contin-

ues to get worse. The engine power and/or speed
will be gradually reduced. If the engine protection
shutdown feature is enabled, the engine will shut
down to prevent engine damage.
 2.35
OPERATOR'S AREA
Indicators

30. Hydraulic Oil Level Warning Lamp

(simultaneous flashing) (red)
(11. 26.)

OM0058

OM0072

Flashes simultaneously when hydraulic oil level is

lower than specified. Also the warning buzzer
sounds.

- When the lamp flashes simultaneously, IMME-

DIATELY stop the machine and check for leaks
in the hydraulic line.

Refill the hydraulic tank with oil as needed.

Refer to "Check Hydraulic Oil Level" page 2.69.
2.36
OPERATOR'S AREA
MODM

MODM Monitor Changeover

(Machine Operation Diagnostic Module)

Replacement Error log

monitor monitor
[ ]button [ ]button

Information Input/Output
monitor monitor

Specification Parameter
setting monitor setting monitor
Display window [ (step back)] [ (step forward)]
button button

90ZV-262001
MODM function
The MODM has the following functions:
- Information monitor
- Displays outside air temperature, machine
speed and engine speed, engine coolant tem-
perature, transmission oil temperature, hydrau-
lic oil temperature and miles driven etc.
Change over the monitor using the following proce-
dure:
When the starter switch is ON, the information
monitor is first displayed on initial monitor.
Press the [ (step back)] button and [ (step
forward)] button at the same time to change over
the monitor mode in sequence "Information monitor
 Replacement monitor  Error log monitor 
Input/Output monitor  Parameter setting monitor
 Specification setting monitor  Information
monitor".

- Replacement monitor However the monitor mode can not be changed in

Allows check of the replacement time for the
parts and oil periodically replaced, allows setting
of the replacement interval, and displays the
replacement pop-ups.
- Error log monitor
reverse such as "Information monitor  Specifica-
tion setting monitor  Parameter setting monitor
....."
The display will not be changed to the next monitor
when you hold the buttons.

Allows check of previous errors, and displays

active errors.

- Input/Output monitor

- Parameter setting monitor

Allows check and change of the parameter set-

ting.

- Specification setting monitor

Allows check and change of the specification

setting.
 2.37
OPERATOR'S AREA
MODM

Information Monitor 1. Outside air temperature

Information monitor display

90ZV-262024
When the starter switch is ON, the outside air tem-
perature is displayed.
The monitor displays the current outside air temper-
Every time the [ (step forward)] button is ature when the starter switch is ON.
pressed or every time the [ (step back)] button
is pressed, the displayed contents are changed Press the [ ] button to change over the display
over in sequence as below. unit from "ºC" to "ºF". Press the [ ] button again to
return the display unit from "ºF" to "ºC".
Step forward Step back

2. Machine speed and engine speed

Outside air temperature

90ZV-262025
Machine speed and engine speed

Press the [ ] button to change the display unit

from "km/h" to "mile/h"
Engine coolant temperature
Press the [ ] button again to return the display unit
from "mile/h" to "km/h".

T/M oil temperature For speed to be accurate, the correct tire size must
be entered into the main MCU via this MODM unit.

Hydraulic oil temperature

Odometer

Cycle

Cylinder oil pressure

Voltage

Hour meter

85ZV2 0008
2.38
OPERATOR'S AREA
MODM
3. Current engine coolant temperature and
maximum engine coolant temperature
recorded (which can be reset)
90ZV-262026
The monitor displays the current engine coolant
temperature and maximum engine coolant temper-
ature recorded since the work on the day is started
(that is, since the engine starter switch is ON).
Even if the engine is stopped once and then started
again, if the time is before 24:00, the monitor dis-
plays the maximum engine coolant temperature
recorded on the day.
The maximum engine coolant temperature is auto-
matically reset everyday at 24:00, whether the
engine starter switch is turned on or off.
Immediately after reset, the engine coolant temper-
ature at the time of reset is displayed as the maxi-
mum engine coolant temperature. In other words,
the current engine coolant temperature is equiva-
lent to the maximum engine coolant temperature.
Press the [ ] button to reset the maximum engine
coolant temperature. Immediately after reset, the
engine coolant temperature at the time of reset is
displayed as the maximum engine coolant temper-
ature.
Press the [ ] button to change over the display
unit from "ºC" to "ºF". Press the [ ] button again to
return the display unit from "ºF" to "ºC".
4. Current transmission oil temperature and
maximum transmission oil temperature
recorded (which can be reset)
90ZV-262027
The monitor displays the current transmission oil
temperature and maximum transmission oil tem-
perature recorded since the work on the day is
started (that is, since the engine starter switch is
ON).
Even if the engine is stopped once and then started
again, if the time is before 24:00, the monitor dis-
plays the maximum transmission oil temperature
recorded on the day.
The maximum transmission oil temperature is auto-
matically reset everyday at 24:00, whether the
engine starter switch is turned on or off.
Immediately after reset, the transmission oil tem-
perature at the time of reset is displayed as the
maximum transmission oil temperature. In other
words, the current transmission oil temperature is
equivalent to the maximum transmission oil temper-
ature.
Press the [ ] button to reset the maximum trans-
mission oil temperature. Immediately after reset,
the transmission oil temperature at the time of reset
is displayed as the maximum transmission oil tem-
perature.
Press the [ ] button to change over the display
unit from "ºC" to "ºF". Press the [ ] button again to
return the display unit from "ºF" to "ºC".

5. Current hydraulic oil temperature and maxi-
mum hydraulic oil temperature recorded
(which can be reset)
90ZV-262028
The monitor displays the current hydraulic oil tem-
perature and maximum hydraulic oil temperature
recorded since the work on the day is started (that
is, since the engine starter switch to ON).
Even if the engine is stopped once and then started
again, if the time is before 24:00, the monitor dis-
plays the maximum hydraulic oil temperature
recorded on the day.
The maximum hydraulic oil temperature is automat-
ically reset everyday at 24:00, whether the engine
starter switch is turned on or off.
Immediately after reset, the hydraulic oil tempera-
ture at the time of reset is displayed as the maxi-
mum hydraulic oil temperature. In other words, the
current hydraulic oil temperature is equivalent to
the maximum hydraulic oil temperature.
Press the [ ] button to reset the maximum hydrau-
lic oil temperature. Immediately after reset, the
hydraulic oil temperature at the time of reset is dis-
played as the maximum hydraulic oil temperature.
Press the [ ] button to change over the display
unit from "ºC" to "ºF". Press the [ ] button again to
return the display unit from "ºF" to "ºC".
2.39
OPERATOR'S AREA
MODM
6. Odometer (total miles driven) and trip meter
(which can be reset)
90ZV-262029
The monitor displays the total number of miles
driven in the upper line, and the trip meter in the
lower line.
Press the [ ] button to reset the trip meter dis-
played in the lower line.
Press the [ ] button to change over the display
unit from "km" to "mile". Press the [ ] button again
to return the display unit from "mile" to "km".
7. Number of cycles and cycle time
90ZV-262030
The monitor displays the number of cycles in the
upper line and the time required for one cycle (mov-
ing forward twice and moving backward twice) in
the lower line.
Press the [ ] button to reset both the number of
cycles and the cycle time.
After reset, the monitor displays newly the number
of cycles in the upper line and the time required for
one cycle in the lower line.
8. Hydraulic system oil pressure
90ZV-262031a
The monitor displays the unloader pressure of the
efficient loading system (ELS).
Press the [ ] button to change over the display
unit from "MPa" to "psi". Press the [ ] button again
to return the display unit from "psi" to "MPa".
2.40
OPERATOR'S AREA
MODM

9. Voltage Unit conversion and language selection

Select the unit and language using the [ ] button.

Unit conversion (for distance, temperature and

90ZV-262032
pressure)

Press the [ ] button once to change the display

10. Hour meter (total operating hours) and trip unit. Press the [ ] button again to return to the pre-
meter (which can be reset) vious display unit.

90ZV-262033
The monitor displays the total operating hours in
the upper line, and the trip meter in the lower line.
Press the [ ] button to reset the trip meter dis-
played in the lower line.
Language selection
Press and hold the [ ] button for 3 seconds or
more to display the language selection screen.
English is selected as the initial setting.
Japanese, French, German, Italian and Spanish
can be selected.
Press the [ (step forward)] button or [ (step
back)] button to select the language.

For returning to the information monitor after select-

ing the language, press and hold the [ ] button for
2 seconds or more.

For returning to the information monitor without

selecting the language, press the [ ] button.
 2.41
OPERATOR'S AREA
MODM

Replacement Monitor Step forward Step back

Replacement time check

Engine oil filter
Press the [ (step forward)] button and [
(step back)] button at the same time to change over
the screen from the information monitor to the
replacement monitor. Fuel filter

Coolant filter
90ZV-262034

The display window displays the remaining time

T/C line filter
until next replacement of the engine oil filter car-
tridge to be changed.

Every time the [ (step forward)] button is Hydraulic oil return filter
pressed or every time the [ (step back)] button
is pressed, the displayed contents are changed
over in sequence as follows.
Engine oil

T/C and T/M oil

Axle gear oil

Hydraulic oil

85ZV2 0009
2.42
OPERATOR'S AREA
MODM

Replacement interval set (timer reset) Replacement pop-up

When the machine is shipped, the standard

replacement interval is set as the initial setting.
90ZV-262038
Press and hold the [ ] button for 2 seconds or
more on the replacement monitor screen to display
the timer reset screen. When the remaining time until the next replacement
The timer reset screen displays the standard reaches " 0 ", the replacement pop-up appears and
replacement interval. flashes on the display window.

For setting the standard replacement interval, press

the [ ] button.
Then, the standard replacement interval is set, and
it returns to the replacement monitor screen again.

Example: Engine oil

90ZV-262037

For setting the replacement interval other than the

standard replacement interval, follow the procedure
below:

 50 90ZV-262039

 100 (2 seconds or more)
 50
 100 (2 seconds or more)
Every time the [ (step forward)] button is
pressed, "50" is added.
Every time the [ (step back)] button is pressed,
"50" is subtracted.
When the [ (step forward)] button is pressed
and held for 2 seconds or more, "100" is added
continuously.
When the [ (step back)] button is pressed and
held for 2 seconds or more, "100" is subtracted
continuously.
After setting the replacement interval, press and
hold the [ ] button for 2 seconds or more, the
replacement interval is reset and it returns to the
replacement monitor screen again.
When two or more replacement pop-ups occur at
the same time, the corresponding items flash in
turn.
After the remaining time for the next replacement
reaches " 0 ", the corresponding pop-up appears up
to three times when the starter switch is ON.
(The outside air temperature is displayed for 3 sec-
onds, and then the replacement pop-up flashes.)
When the [ (step forward)] button, [ (step
back)] button, [ ] button or [ ] button is pressed,
however, it returns to the previous screen again.
After replacing the corresponding filter or oil, return
to the timer reset screen and set the replacement
interval. Refer to the replacement interval set (timer
reset) procedure above.

Error Log Monitor
Error log history check
Up to 100 machine errors history and up to 100
engine errors history are recorded in the error log.
The error code and the date and time at the occur-
rence (in the format "year/month/day hour/minute/
second") are recorded in the error log.
Error codes are displayed from the latest one.
Selection of machine error log and engine
error log
When the machine error log screen is displayed,
press and hold the [ (step forward)] button for 2
seconds or more to display the engine error log
screen which shows the latest engine error code.
When the engine error log screen is displayed,
press and hold the [ (step back)] button for 2
seconds or more to display the machine error log
screen which shows the latest machine error code.
The machine error log screen and engine error log
screen can be distinguished as follows:
Displayed error code:
CN ..... Machine error log screen
EG ..... Engine error log screen
Machine error log
When two or more error codes are recorded, press
the [ (step forward)] button to display the next
latest error code.
Press the [ (step back)] button to display the
error code in chronological order.
2.43
OPERATOR'S AREA
MODM
Engine error log
When two or more error codes are recorded, press
the [ (step forward)] button to display the next
latest error code.
Press the [ (step back)] button to display the
error code in chronological order.
Clear error log
Clear machine error log
Press and hold the [ ] button for 2 seconds or
more to display the clear error log screen.
Press and hold the [ ] button for 2 seconds or
more to clear the entire error log.
When there are two or more error codes recorded,
all error codes recorded are cleared by performing
the clear error log operation once.
Press the [ ] button not to clear the error log.
Then, the error log is not cleared, and it returns to
the machine error log screen again.
Clear engine error log
Press and hold the [ ] button for 2 seconds or
more to display the clear error log screen.
Press and hold the [ ] button for 2 seconds or
more to clear the entire error log.
When there are two or more error codes recorded,
all error codes recorded are cleared by performing
the clear error log operation once.
Press the [ ] button not to clear the error log.
Then, the error log is not cleared, and it returns to
the engine error log screen again.
2.44
OPERATOR'S AREA
MODM

Active error (error pop up) Input/Output Monitor

When an error occurs, the corresponding error
Input/Output monitor display
code is forcibly displayed on the screen.
When two or more active errors occur, up to 5 error Every time the [ (step forward)] button is
codes are displayed repeatedly. (Up to 10 error pressed and held for 2 seconds or every time the
codes for CN and EG total errors) [ (step back)] button is pressed and held for 2
seconds, the displayed contents are changed over
Press one of the [ (step forward)] button, [ in sequence as follows.
(step back)] button, [ ] button or [ ] button. The
screen displayed before the active error codes Press and hold Press and hold
appears again. Step forward Step back

Active error codes are displayed repeatedly, when-

ever the starter switch is ON, until the causes of
errors are eliminated. Input signal

IMPORTANT
Input sensor
Error log is important information for machine
maintenance. Do not clear error log before figur-
ing out cause.
Output signal
Continuous machine operation, with active error
shown, may cause severe machine damage.

If active error shows, please contact authorized Current output

dealer in your area.

85ZV2 0010
Refer to "TROUBLESHOOTING" page 3.72 for
error code.
1. Input signal monitor

This monitor displays the ON/OFF status of the

shift lever, setting switches, pressure switches,
etc.

2. Input sensor monitor

This monitor allows check of the input level of

the brake pedal output oil pressure, steering oil
pressure, boom angle etc.

3. Output signal monitor

This monitor displays the ON/OFF status of the

transmission forward/backward solenoid
valves, speed range solenoid valves, indicator
lamps and warning lamps on the instrument
panel, etc.

4. Current output monitor

This monitor allows check of the current output

level of the cooling fan.
 2.45
OPERATOR'S AREA
MODM

Parameter Setting Monitor

Display of parameter setting monitor

This monitor allows check of the parameters cur-

rently set.

Specification Setting Monitor

Specification setting monitor display

This monitor allows check of the specifications cur-

rently set.
2.46
OPERATOR'S AREA
Seat

Seat Combined Height and Weight Adjuster

Seat Adjustment 1. Sit on the seat.

(KAB811) 2. Turn handle (a) to adjust seat height.
Adjust the seat for comfort and so that the pedals Clockwise to raise seat.
may be pushed fully down when the operator's
back is fully back. Anti-Clockwise to lower seat.

WARNING 3. Check ride indicator (b) shows green.

Unexpected movement of seat could result in
If red, readjust seat height.
death or serious injury.
Within the green band of the ride indicator there is
Stop machine before adjusting seat position.
75 mm of height adjustment for any driver.

NOTE
The seat is designed so that it is unnecessary to
make any adjustment for the driver weight.
3
Up-Stop Height Adjustment Control
2
To adjust the up-stop height, rotate hand wheel (c)
clockwise to raise the seat unseated, rotate it
1 counter-clockwise to lower the seat unseated.
c

a b
95ZV OM EU SEAT

Reclining

Rotate control handle (1) forward and hold, select

backrest angle, release control handle.

Forward / Backward

Lift lever (2) up and hold, slide seat to desired posi-

tion, release handle.

Armrests

Rotate control knob (3) to select desired angle.

Pivot up and parallel with backrest when not in use.
 2.47
OPERATOR'S AREA
Seat

Seat Belt

WARNING
Improper use or maintenance of seat belt could
result in death or serious injury.

- Inspect seat belt and mounting hardware

before operating machine and replace any
defective components.

- Always fasten seat belt when operating

machine.

- Properly adjust seat belt at beginning of each

shift or when operator changes.

1 3
2

OM0007

1. Pull at seat belt (1) and fasten it along your

body without kinking or twisting it.

2. Hold buckle (2) and insert belt end (3) into

buckle (2). Be sure it locks securely.

3. For releasing the seat belt, press the "press

button" in buckle (2) and remove belt end (3)
from buckle (2).

The tether is inside the seat boot.

No adjustment necessary.
2.48
OPERATOR'S AREA
Electrical Protection

Electrical Protection
(1) (2)
BATTERY RELAY
Fuse Boxes SPARE 20A
ECM (ENGINE)
5A

AIRCON 20A NEUTRAL RELAY 5A

2 AIRCON 10A
BUZZER
5A
1 MONITOR

AIRCON 5A COLD STARTER 15A

AIRCON 5A SPARE 10A

4 WAY FLASHER
HORN
SPARE 20A 15A
DOME LAMP
RADIO BACK UP
SPARE 10A SPARE 15A
85ZV28505

SPARE 10A SPARE 15A

Main Fuse Boxes are located in the right hand side
AIR SUS SEAT
console in the cab and contain thirty fuses. RADIO 3A 10A
(option)

SPARE 15A F. WORK LIGHT 15A

IMPORTANT
When replacing fuse, be sure to turn the starter PARKING BRAKE
CIGAR LIGHTER 10A 30A
MCU (MACHINE)
switch to "OFF" position.
F. WIPER / WASHER 10A TURN SIGNAL 15A

IMPORTANT R. WIPER / WASHER 5A

BOOM KICKOUT
10A
BUCKET LEVELER
Using wrong capacity fuse or bypassing fuse
may cause electrical system damage. SPARE 5A R. WORK LIGHT 15A

LIGHTING
Never replace fuses with higher amperage rat- SPARE 5A 20A
HEAD LIGHT
ing.
 2.49
OPERATOR'S AREA
Electrical Protection

Fusible Link

Fusible link protects the main hot wire from short

circuits.

115ZV0005

1. If the fusible link is blown, the following prob-

lem occurs.

Problem (symptom)
Fuse
damaged
During engine operation During engine stop

- Engine will stop auto- - All the electrical circuit

matically. will not function.
30A - All the power for all - Engine can not be
electrical circuit will be started.
OFF.

- Horn [and opt. flasher] - The same conditions

will operate. as "During engine
- All the others will not operation".
operate and the - Engine can be started.
machine can not be
70A
operated.
- Engine will not stop
automatically but can
be stopped with starter
switch OFF.

- The machine can be - The same conditions

operated but the bat- as "During engine
70A
teries can not be operation".
(Alterna-
charged and the batter-
tor line)
ies will be discharged
soon.

CAUTION
Contact with moving parts or engine components
may result in injury or burns.

2. To check the cause and replace the fusible

link, call your nearest authorized dealer.
2.50
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Radio - AM / FM Cassette
(24Volt Type) (option) (~Decem-
ber, 2009)

21 14 16
15 20 9 10 11
clarion
ON OFF VOL
AM SLEEP
AM/FM CASSETTE COMBINATION PUSH
CD 1
ST

SCAN
AUDIO MODE ALARM TIMER 3
1 DISP
REW FF
H M
PS
2 AM
4
APC
5 6
APC AS
TAPE CD FM
TUNE

RadioCassetteUSA

5 3 6 7 4 17 18 19 8
13 12
 2.51
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Name of Operation
Symbol Function Description Remarks
part method

Volume Turning PUSH Push this SW to turn the power on or off.

knob power on/ The SW alternately turns the power on or off every
off time you push the SW.
Sleep timer PUSH with To use the sleep timer, push this SW with the ACC
ACC turned turned off. This function causes the unit to continue
off to operate for one hour and then automatically
turns it off. At this time, "Sleep" will be shown on
the display panel.
Sound vol- Use this adjustment knob to adjust the sound vol-
ume ume.
adjustment To increase the sound volume, turn this knob clock-
MIN MAX wise to the desired volume level.
To decrease the sound volume, turn this knob
counterclockwise to the desired volume level.
Sound bal- Selected with Use this knob to adjust the balance between the
ance audio mode left and right speakers.
adjustment button When turning the knob clockwise, with BALANCE
mode, the sound volume from the left speakers will
1 decrease, and the sound will be shifted to the right.
When turning the knob counterclockwise, the
L R sound volume from the right speakers will
decrease, and the sound will be shifted to the left.
Fader Selected with Use this knob to adjust the balance between the
adjustment audio mode front and rear speakers. When turning the knob
button clockwise, with FADER mode, the sound volume
from the rear speakers will decrease, and the
sound will be shifted to the front. When turning the
knob counterclockwise, the sound volume from the
REAR FRONT front speakers will decrease, and the sound will be
shifted to the rear.
Sound tone Selected with Use this knob to adjust bass / treble to the desired
adjustment audio mode level.
button When turning the knob clockwise, with BASS/TRE-
BLE mode, the sound will be boosted up.
When turning the knob counterclockwise, the
sound will be cut.
CUT BOOST

MODE Audio PUSH Every time you push this SW, the audio mode will
mode be changed in the following order.
Audio switching
mode but- BASS  TREBLE  FADER
ton  
VOLUME  BALANCE
2
No operation for 10 sec. or longer will return the
mode to VOLUME. (Indication varies according to
the audio source.)
When each mode is selected, the corresponding
mode will be shown on the LCD display. However,
turning the VOL knob, the mode stops showing and
each level will be shown on the LCD display.
2.52
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Name of Operation
Symbol Function Description Remarks
part method

Turning PUSH Every time you push this button, alarm will be
alarm ON/ switched ON or OFF. (This function works with the
OFF ACC turned on or while the sleep timer is ON.)
Alarm but- The alarm mark will be lit while the alarm is set.
ton Alarm set- When the time reaches the set time, you hear the Alarm
ting: alarm sound for 3 min. To stop the alarm sound, mark
Setting push any button.
clock on Continuing to push the button for 2 sec. or more will
3
the hour cause the mode to shift to the alarm setting mode.
Push the button in the clock set mode to set the
clock on the hour and reset the mode. If the minute
value of the current time is less than 30, the min-
utes will be rounded down and the seconds will be
reset. If the minutes value is more than 30, the min-
utes will be rounded up, one hour will be added to
the hour value, and the seconds will be reset.
Switching PUSH When the timer button is pushed, the timer mark
timer ON/ will be lit and the mode will shift to the timer setting
OFF mode. At this time "0:00" will be shown on the dis-
One-touch play. However, if the timer has been set before-
timer but- Timer set- hand, the residual time will be shown on the Timer
ton ting display. (While the timer is running, the residual mark
time decreases gradually.)
In the timer set mode, every time you push the but-
ton, indications will be changed in the following
order. (When the button is released, the indication
will be changed.)

0:15  0:30  1:00  2:00

 
0:00 3:00
4  
6:00  5:00  4:00

When pushing the button for a long period in the

timer set mode, the timer setting time increases in
5-minute steps. (Speed: 5 min./sec.)
"0:00" indicates that the timer is set to "OFF". At
this time, the timer setting mode will be canceled
unless you start to set the timer within 15 sec.
When performing operations other than timer set-
ting in the timer setting mode, the current time will
be set and the timer setting mode will be canceled.
When the residual time reaches 0, you hear the
alarm sound for 3 min.
The timer mark continues to light while the timer
works.
TAPE Cassette PUSH When the tape is loaded, push this button to play or
tape play/ stop the operation of the cassette tape.
5
TAPE but- stop In FF/REW/APC -FF/APC-REW, the mode will shift
ton to "Play".
CD CD PUSH When the CD changer is loaded, push this button
changer to play or stop the operation of the CD changer.
6
CD button play/stop The CD Changer is optional and not normally sup-
plied.
 2.53
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Name of Operation
Symbol Function Description Remarks
part method

AM/FM Band PUSH While the radio is turned on, push this button to
switching change the radio frequency band. If a mode other
AM/FM Turning on than the radio is selected, push this button to turn
band radio on the radio at the last-tuned station.
7 selector Setting Push this button for less than 2 sec. to change the
button clock on radio frequency band from AM to FM or from FM to
the hour AM. If this button is pushed for 2 sec. or longer, a
beep sound will be generated and the bands 1 and
2 will be switched with each other.
PS Preset PUSH When this button is pushed for less than 2 sec-
AS scan in onds, the mode will shift to the PS mode and the
radio mode preset stations will be played sequentially for 5 sec.
PS, AS To stop the scan feature, push the button again
button and the radio will remain set to the last station. If
the radio wave of the preset station is weak, the
Preset station will be skipped.
Scan (PS) Every time the station is shifted, a beep sound will
be generated.
Auto Store If the radio cannot receive any stations, 2 times the
(AS) preset stations will be automatically cancelled.
The preset scan will work on the currently-selected
band (AM or FM).
Radio store PUSH When this button is pushed for 2 sec. or longer, the
button radio will generate a beep sound and the mode is
Auto store shifted to the AS. Then the radio will search sta-
in radio tions upward from the lower band end and auto-
mode matically store them in the preset memory. The six
stations that have the strongest wave will be stored
in frequency order.
(AS will stop at the upper band end and the stron-
8 gest station will be called up.)
Auto store (AS) will work on the currently-selected
band (AM or FM).
If 6 stations are not stored fully, the previously-
tuned stations will remain as they are.
Program PUSH Program scan will be performed in cassette tape
scan in mode. The beginning of each music track will be
cassette sequentially played for 10 sec.
tape mode When the button is pushed again in PS mode, the
PS feature will be canceled and the currently
selected music track will be played in full without
skipping to the next music.
Program PUSH Program scan will be performed in CD mode. The
scan in CD beginning of each track of the loaded CDs will be
mode sequentially played for 10 sec.
When the button is pushed again in PS mode, the
PS feature will be canceled and the currently
selected music track will be played in full without
skipping to the next music.
CD Changer is an option and is not normally
offered.
2.54
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Name of Operation
Symbol Function Description Remarks
part method

Cassette PUSH Push this button to eject the cassette tape.

tape ejec- This can be performed even with ACC off.
tion
9

Eject but-
ton
DISP Display PUSH Push this button to switch the indications shown on
change the display panel. Each time you push this button,
Display the current time, alarm time, frequency (in radio
button mode), track No. and disc NO. indications (in CD
changer mode), and cassette tape EQ position indi-
cation (in cassette tape mode) will be shifted to
sequentially.
While the current time is shown on the display
10
panel, pushing the button for 2 sec. or more will
generate a beep sound. Then the indication will
blink, and the mode will be shifted to the clock set-
ting mode.
While the alarm time is shown on the display panel,
pushing the button for 2 sec. or more will generate
a beep sound and the mode will shift to the alarm
setting mode.
SCAN Radio PUSH Pushing this button will change the mode to Auto
scanning Tuning mode and will play each station for 5 sec.
11 SCAN but- To stop the scan feature and listen the currently
ton tuned station continuously, push the button again
while the station is tuned in and is being played.
 2.55
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Name of Operation
Symbol Function Description Remarks
part method

Manual PUSH Push the button for less 0.5 sec. to increase the fre-
tuning in Upward quency or to decrease the frequency.
radio mode

Downward

Tuning but-
for 0.5 sec. or
ton
less
Seeking in PUSH Pushing the button for 0.5 sec. or longer will gener-
radio mode Upward ate a beep sound.
While SEEK UP, SEEK DOWN or ILLUMI OFF is
selected, the unit will seek radio stations in DX
12 Downward mode. While ILLUMI ON is selected, the unit will
seek radio stations in Local mode. (However, seek
13
functions only in AM mode.)
for 0.5 sec. or
less
In clock PUSH Push the button once for less 0.5 sec. to increase
time set- Downward the current hour value by one hour. Push the button
ting mode for 0.5 sec. or longer to increase hours continu-
ously.
"Hour" set-
ting
"Minute" PUSH Push the button once for less 0.5 sec. to increase
setting Upward the minutes value by one minute. Push the button
for 0.5 sec. or longer to increase minutes continu-
ously.

In radio PUSH Push the button for less 2 sec. to recall preset sta-
1 mode: tions. Pushing the button for 2 sec. or longer will
REW
Recalling generate a beep sound and the currently tuned sta-
Preset 1 and storing tion will be stored.
preset
REW but- memories
ton
14 In cassette PUSH Push the button to rewind the cassette tape.
tape mode:
REW
In CD PUSH Push the button to go down to the previous disc.
mode: (Recalling the previous disc.)
DISC
DOWN
2.56
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Name of Operation
Symbol Function Description Remarks
part method

2 PRO In radio PUSH Push the button for less 2 sec. to recall preset sta-
mode: tions. Pushing the button for 2 sec. or longer will
Preset 2 Recalling generate a beep sound and the currently tuned sta-
and storing tion will be stored.
Program preset
button memories
15 In cassette PUSH Push the button to program the tape. (Switching
tape mode: forward or reverse modes.)
Program Pushing the button in FF, REW (APC) mode will
play the cassette tape.
In CD PUSH Push the button to go to the next disc.
mode: (Recalling the next disc.)
DISC UP
In radio PUSH Push the button for less 2 sec. to recall preset sta-
3 mode: tions. Pushing the button for 2 sec. or longer will
FF
Recalling generate a beep sound and the currently tuned sta-
Preset 3 and storing tion will be stored.
FF button preset
memories
16
In cassette PUSH Push the button to wind forward the cassette tape
tape mode: quickly.
FF
In CD PUSH Push the button to go to the next disc. (Recalling
mode: the next disc.)
DISC UP
In radio PUSH Push the button for less 2 sec. to recall preset sta-
4 mode: tions. Pushing the button for 2 sec. or longer will
APC
Recalling generate a beep sound and will store the currently
Preset 4 and storing tuned station.
APC but- preset
ton memories
In cassette PUSH Push the button to search for the beginning of the
tape mode: currently-played music track. Pushing the button
APC REW again in APC REW mode will search for the begin-
17 ning of the previous music. (Every time it is pushed
after that, the number of music tracks to search for
will be increased by 1.)
In CD PUSH Push the button for less 2 sec. to search for the No beep
mode: beginning of the currently-played track. sounds
TRACK (If the button is pushed at the beginning of the
DOWN music track, the beginning of the previous music
track will be searched for.)
REVIEW Push the button for 2 sec. or longer to rewind the
CD fast.)
 2.57
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Name of Operation
Symbol Function Description Remarks
part method

In radio PUSH Push the button for less 2 sec. to recall preset sta-
5 mode: tions. Pushing the button for 2 sec. or longer will
Recalling generate a beep sound and the currently tuned sta-
Preset 5 and storing tion will be stored.
Dolby but- preset
18 ton memories
In cassette PUSH Every time the button is pushed, DOLBY will be
tape mode: turned on or off alternately. Pushing the button for 2
Turning on/ sec. or longer will generate a beep sound and the
off currently tuned station will be stored.
In radio PUSH Push the button for less 2 sec. to recall preset sta-
6 mode: tions. Pushing the button for 2 sec. or longer will
APC
Recalling generate a beep sound and the currently tuned sta-
Preset 6 and storing tion will be stored.
APC but- preset
ton memories
In cassette PUSH Push the button to search for the beginning of the
tape mode: next music track. In APC FF mode, pushing the
19 APC FF button again will search for the next-alternate
music.
(Every time the button is pushed after that, the
number of music tracks to search for will be
increased by 1.)
In CD PUSH Push the button for less 2 sec. to search for the No beep
mode: next music track. sounds
TRACK UP Push the button for 2 sec. or longer to wind forward
QUE the music.
Tape Cassette Insert the cassette tape with the open side of the Auto
20 insertion tape inser- cassette tape faced rightward to play the cassette metal
slot tion slot tape.
LCD indi- indicator Displays time, frequency, etc.
21
cator
Beep tone A beep sound will be generated when functions are
(guide changed depending on the push time of the button.
tone) (Approx. 2KHz, 50ms)
2.58
OPERATOR'S AREA
Air Conditioner

Air Conditioner Switches

Ventilation Name and Location 1 2 3 4 5

(d) (d) Insolation sensor

(d) (d)

(b) (b)

97ZVOM0093

6 7 8

(c) (c) (c) (c)

1. OFF switch
(a) (a) (a)
2. Blower switches
3. Temperature setting switches
4. Vent mode selector switch
97ZVOM0092 5. AUTO switch
6. Inside/outside air selector switches
7. Liquid crystal display (LCD) unit
(a) Rear ventilation and defroster port 8. Air conditioner ON/Off switch
(b) Face ventilation port
(c) Foot ventilation port While AUTO switch (5), inside/outside air selector
(d) Defroster port switches (6) or air conditioner ON/OFF switch (8) is
functioning, the LED lamp above each switch is lit.
The wind direction from the ventilation ports (a) (b)
can be changed arbitrarily by manipulating the lou-
ver. OFF switch (1)

Rear ventilation ports (a) can be used as defroster
ports for the rear window glass by manipulating the
direction of the louver.
This switch stops the operation of the blower and
the air conditioner.
When OFF switch (1) is pressed, the set tempera-
ture and the air blow quantity displayed on LCD unit
(7) as well as the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
turned "off", and operation is stopped.
 2.59
OPERATOR'S AREA
Air Conditioner

Blower switches (2) Vent mode selector switch (4)

These switches change over the air flow quantity in This switch changes over the vent mode.
six steps.
When vent mode selector switch (4) is pressed, the
The air flow quantity is displayed on the LCD unit. vent mode displayed on LCD unit (7) is changed
over, and air is blown from the displayed vent posi-
When the switch is pressed, the air flow quan- tions.
tity increases.
In the automatic mode, the vent mode is automati-
When the switch is pressed, the air flow quan- cally changed over.
tity decreases.
Display Vent positions
In the automatic mode, the air flow quantity is auto- on LCD Vent mode Remarks
matically changed over. unit (A) (B) (C) (D)
Face (blow-off to
<Display on the LCD unit and the air blow quantity> upper portion of
body mainly dur-
O O -
LCD Ventilation amount
ing cooling)
Air quantity "low" Face and foot O O O -
Air quantity "medium 1" Foot (blow-off to
feet mainly dur- O -
ing heating)
Air quantity "medium 2" This mode
is not
Foot and
Air quantity "medium 3" defroster
O O O selected in
automatic
mode.
Air quantity "medium 4"
This mode
is not
Air quantity "high" Defroster O O selected in
automatic
mode.
Temperature setting switches (3) Air is blown from the ventilation ports marked with "O".

These switches set the temperature inside the cab

AUTO switch (5)
in the range from 18.0~32.0ºC
This switch automatically changes over the air blow
When the switch is pressed, the set tempera-
quantity, the vent mode and the inside/outside air in
ture increases.
accordance with the set temperature.
When the switch is pressed, the set tempera-
When AUTO switch (5) is pressed, the indicator
ture decreases.
lamp above it lights.
Usually, set the temperature to 23.0~25.0ºC.
Usually, press this switch, set the temperature by
<Display on the LCD unit and the function> using temperature setting switches (3), and use the
air conditioner in the automatic mode.
Display on LCD
Set temperature
unit
18.0ºC Maximum cooling
When the automatic mode is changed over to the
manual mode, the indicator lamp above AUTO
Temperature inside cab is controlled so
18.5~31.5ºC switch (5) is extinguished. In the manual mode, the
that set temperature is realized.
32.0ºC Maximum heating air blow quantity, the vent mode and the inside/out-
side air can be changed over by manipulating each
switch.
2.60
OPERATOR'S AREA
Air Conditioner

Inside/outside air selector switches (6) Operating Method (Normal Use)

These switches change over inside air circulation
and outside air entry. Automatic operation

When an either switch is pressed, the indicator 3 5

lamp above it lights to indicate the selected air flow
status.

In the automatic mode, outside air introduction and

inside air circulation are automatically changed
over.
97ZVOM0093

Inside air recirculation The outside air is shut down, and the 8
air inside the cab is circulated.
Press this switch to rapidly cool or
heat the air inside the cab or when
the outside air is dirty. 1. Set AUTO switch (5) to ON. Confirm that the
set temperature and the air flow quantity are
Outside air entry
The outside air enters the cab. displayed on the LCD unit, and that the indica-
Press this switch to introduce clean
air into the cab or defog the windows.
tor lamps above AUTO switch (5) and air con-
ditioner ON/OFF switch (8) are lit.

2. Adjust temperature setting switches (3), and

Liquid crystal display (LCD) unit (7)
set arbitrary temperature.
The air conditioner automatically changes over
This LCD unit indicates the set temperature, the air
the air flow quantity, the vent mode and the
flow quantity and the vent mode during operation.
inside/outside air to realize the set tempera-
ture.
When OFF switch (1) is pressed, the set tempera-
ture and the air flow quantity are extinguished and
NOTE
the operation is stopped.
When the vent mode is set to or in
the automatic operation, if the engine water tem-
Air conditioner ON/Off switch (8) perature is low, the air flow quantity is restricted to
prevent blow-off of cold air.
This switch turns on and off the air conditioner
(cooling or dehumidification/heating).
Stopping the automatic operation
When this switch (8) is pressed, the air conditioner
is turned on and the indicator lamp above the 1
switch lights. When this switch is pressed again,
the air conditioner is turned off and the indicator
lamp is extinguished.

However, the air conditioner is turned on only while

the blower is operating (that is, while the air blow
97ZVOM0093
quantity is displayed on the LCD unit).

Press OFF switch (1). Then, the set temperature

and the air flow quantity displayed on the LCD unit
are extinguished, the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
are extinguished, and the operation is stopped.

Manual operation
2 3 4 Head cooling, feet heating (bi-level) opera-
97ZVOM0093
6 8
1. Press blower switches (2), and adjust the air
flow quantity.
Confirm that the set temperature and the air
flow quantity are displayed on the LCD unit.
2. Set to ON air conditioner ON/OFF switch (8).
Confirm that the indicator lamp above the
switch lights.
3. Adjust temperature setting switches (3), and
set arbitrary temperature.
4. Press vent mode selector switch (4), and
select arbitrary vent mode.
5. Press an either inside/outside air selector
switch (6) to select inside air circulation or out-
side air entry.
Stopping the manual operation
1
97ZVOM0093
Press OFF switch (1). Then, the set temperature
and the air flow quantity displayed on the LCD unit
are extinguished, the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
are extinguished, and the operation is stopped.
2.61
OPERATOR'S AREA
Air Conditioner
Operation Method (Other Uses)
tion
In the bi-level operation, cool air is blown to the
face and hot air is blown to the feet.
2 3 4 5
97ZVOM0093
6 8
1. Press blower switches (2), and adjust the air
flow quantity.
Confirm that the set temperature and the air
flow quantity are displayed on the LCD unit.
2. Press vent mode selector switch (4), and dis-
play the vent mode on the LCD unit.
3. Set to ON air conditioner ON/OFF switch (8).
Confirm that the indicator lamp above the
switch lights.
4. Arbitrarily set blower switches (2), temperature
setting switches (3) and inside/outside air
selector switches (6).
Then, the air conditioner realizes the bi-level opera-
tion in which cold air is blown to the head and hot
air is blown to the feet.
2.62
OPERATOR'S AREA
Air Conditioner

Defroster operation Other Functions

2 3 4 Self-diagnosis function

Each sensor and equipment used in the air condi-

tioner can be diagnosed for failure.

1 3
97ZVOM0093

6 8

1. Press blower switches (2), and adjust the air

flow quantity.
Confirm that the set temperature and the air 97ZVOM0093

flow quantity are displayed on the LCD unit. 6

2. Press vent mode selector switch (4), and dis-
play the vent mode or on the
LCD unit.
3. Set outside air introduction selector switch (6).
4. Press temperature setting switches (3), and
display the set temperature "32.0" (maximum
heating status) on the LCD unit.
1. Press OFF switch (1) to stop the operation.
(The set temperature and the air blow quantity
displayed on the LCD are extinguished.)
2. When both temperature setting switches " "
and " " (3) are pressed and held together
for 3 seconds or more, the failure mode is dis-
played on the LCD unit.

Adjust the louver at each vent position so that air <Display on the LCD unit and the failure mode>
flow reaches the windows. Display Failure mode
E- No failure
When defogging the windows or dehumidifying the E11 Wire breakage in inside air sensor
air inside the cab in rainy season, set air condi- E12 Short-circuit in inside air sensor
tioner ON/OFF switch (8) to ON. E13 Wire breakage in outside air sensor
E14 Short-circuit in outside air sensor
E15 Wire breakage in water temperature sensor
E16 Short-circuit in water temperature sensor
E18 Short-circuit in insolation sensor
E21 Wire breakage in vent sensor
E22 Short-circuit in vent sensor
E43 Abnormality in vent damper
E44 Abnormality in air mixing damper
E45 Abnormality in inside/outside air
E51 Abnormality in refrigerant pressure

- If two or more failure are detected, the displayed

contents can be scrolled through by pressing
either one of temperature levels (3) " " or
" ".

- Press OFF switch (1) again to finish the self

diagnosis function and return to the normal dis-
play.

If a failure is detected by the self-diagnosis func-
tion, ask the dealer for inspection and repair.
After completing the inspection and/or the repair,
delete the failure codes memorized in the com-
puter.
If not removed, the failure codes memorized in the
computer continue to display on the LCD unit
whenever diagnosing.
To delete the failure codes, press and hold both
inside/outside air selector switches (6) for 3 sec-
onds or more.
Refer to "TROUBLESHOOTING" page 3.65 for the
failure and solution.
Celsius-Fahrenheit selector function for the
set temperature display
While the blower is operating, press and hold both
temperature setting switches (3) " " and "
together for 5 seconds or more to change over the
unit of the displayed value between Celsius and
Fahrenheit. However, the unit type (C or F) itself is
not displayed.
Only the set value is displayed.
Value displayed on LCD unit
Celsius (ºC) 18.0~32.0
Fahrenheit (ºF) 65~90
2.63
OPERATOR'S AREA
Air Conditioner
For Efficient Use of the Air Conditioner
When the temperature inside the cabin
should be cooled down rapidly
When the machine is left under a scorching sun in
the middle of summer, the temperature inside the
cabin may be very hot.
In order to rapidly cool down the cabin in such a
case, completely close the windows and doors first,
drive hot air out of the cabin, then operate the air
conditioner.
Start up the engine, press AUTO switch (5), then
set the temperature to "18.0" by manipulating tem-
perature setting switches (3). In this status, run the
engine for 2~3 minutes with high revolution, then
close the windows.
When the temperature inside the cabin is decreas-
ing, set the arbitrary temperature.
"
When the windows are misted
In the rainy season, etc., if the humidity inside the
cabin is high and the inner surfaces of the windows
are misted, mist can be removed by operating the
air conditioner. Or if the humidity of the outside air
is high, the temperature inside the cabin may be
too low and the outer surfaces of the windows may
be misted. In such a case, properly control the tem-
perature inside the cabin by controlling the set tem-
perature, stopping the air conditioner, etc.
2.64
OPERATOR'S AREA
Air Conditioner

Action to be taken when the air condi- NOTE

tioner is not used Any technician that operates a refrigerant recovery
and recycling machine must first be certified
through an EPA approved testing program.
Even if the air conditioner is not used, operate the
air conditioner with the engine low idle for several
minutes at least once a month so that the lubricat-
ing oil in each part of the compressor is not elimi-
nated (running-in of the air conditioner).

If the temperature inside the cabin is low in winter,

the air conditioner may be disabled. In such a case,
increase the temperature inside the cabin by using
the heater, then perform running-in of the air condi-
tioner.

IMPORTANT
- If the air conditioner is not operated for a long
time, the lubricating oil inside the compressor
may be eliminated, and the compressor may
be seized or damaged. Make sure to operate
the air conditioner once or twice a month even
while the air conditioner is not necessary or
while the machine is stored for a long time.
- During running - in of the air conditioner, make
sure to start it up with the engine low idle.
Never start up the air conditioner with the
engine high idle: Such start up may damage
the air conditioner.
- If water enters the control panel or the insola-
tion sensor, unexpected failure may be
caused. Pay attention so that water does not
enter. In addition, make sure to keep fire off
the control panel and the insolation sensor.
- Always keep the insolation sensor clean and
free from adhesion of dusts so that the air con-
ditioner can offer its auto function sufficiently.
Keep the area around the insolation sensor
free from objects which may hinder the sensor
function.
- Special tools and instruments are required to
fill the refrigerant (gas) and perform other ser-
vicing. Make sure to let such works be per-
formed in a service shop with required
facilities specified by our company.
 2.65
OPERATOR'S AREA
Ride Control (option)

Ride Control (option)

Roading a wheel loader over rough terrain will
cause fore and aft pitching motion to the machine.
The pitching motion is reduced when the ride con-
trol is installed.

Operation and Function

115ZV2 9296

OFF

ON

switch-3

1. Before start the travelling machine, turn the

ride control switch ON.

The ride control pilot lamp comes to ON.

2. Move the machine forward.

The ride control functions automatically when

the machine travelling speed reaches more
than 7 km/h.

NOTE
When the bucket is fully tilted the ride control does
not work. Dump the bucket a bit when travelling.
2.66
OPERATOR'S AREA
Grease Gun Holder

Grease Gun Holder

90ZV5009

Grease gun holder is provided in the left side bat-

tery box. It is used for keeping the grease gun on
the machine when not in use.
 2.67
OPERATION
Check before Operation

OPERATION

Check before Operation

Before performing the following checks, make sure
the parking brake is engaged, the attachment is on
the ground, the engine is shut off, and the machine
is on a level surface. Follow all the safety cautions
mentioned in the safety section of this manual
when checking the machine.

Walk-Around Inspection

For your own safety and maximum service life of

the machine, make a thorough walk-around inspec-
tion before mounting the machine to start the
engine. Report or correct any problems found dur-
ing the Walk-Around inspection.

Items to Check and What to Look for:

Items to Check What to Look for

Bucket / Attachment Damage, missing bolts, leaks, and excessive wear
Bucket Control Linkage Damage, missing bolts, excessive wear, and looseness
Lights Broken bulbs, wires or lenses
Radiator Fins Trash and dirt build-up
Cooling System Leaks and trash build-up
Batteries Loose terminals, dirt build up on top of the batteries
Steps and Handrails Damage and cleanliness
Differentials (front and rear) Leaks
Hydraulic System Leaks
Final Drive (front and rear) Leaks
Covers and Guards Damage or missing
Transmission Leaks
Instrument Panel Broken gauges or indicator lights
Brake Lines Damage and leaks
Engine Compartment Leaks, debris build-up and flammable materials left
Date: Model-S/N: Hours: Inspector:
You may wish to copy this page and use it as a daily check list.
2.68
OPERATION
Check before Operation

Check Engine Oil Level 4. If the oil is particularly dirty or contains water
(milky appearance), replace the oil.

CAUTION Refer to "Replace Engine Oil and Oil Filter Car-

Hot engine oil and components may cause
burns.
Avoid contact with hot oil or engine components.
tridge" page 3.37.
NOTE
Wait about 15~20 minutes after stopping the
engine to measure the oil level. The precise oil
level cannot be measured immediately after stop-
ping engine due to residual oil in the upper parts of
the engine.

IMPORTANT
Improper oil level may damage engine.

Do not operate engine with oil level below "L"

(low) mark or above "H" (high) mark.

Add or drain oil to keep proper oil level.

115ZV2196

H (High)
L (Low)

OM0225

1. Check the oil level with the dipstick.

2. Keep the oil level between the "H" (high) mark

and "L" (low) mark on the dipstick.

3. If needed, add the required amount of the

same brand and viscosity oil as originally used
through the refill port.

Refer to "Recommended Lubricants" page

3.62 for the suitable viscosity of the oil accord-
ing to the ambient temperature.
 2.69
OPERATION
Check before Operation

Check Hydraulic Oil Level (S/N 0151~0200)

CAUTION
Pressurized hydraulic tank is used for this
machine.

Pressure may throw tank cap and hot oil out of

tank causing injury or burns.

Relieve all pressure by pressing down the filler

cap or the breather valve.
115ZV2195

Check Level (S/N 0201~)

115ZV0008
115ZV2195a

1. Lower the attachment to the ground.

5. If needed, add the required amount of the oil.
2. Stop the engine.
Refer to "Recommended Lubricants" page
3. Check the oil level gauge on the side of the 3.62 for the suitable viscosity of the oil accord-
hydraulic tank. ing to the ambient temperature.

4. The oil level is OK if the oil reaches the middle

of the level gauge.
2.70
OPERATION
Check before Operation

Check Engine Coolant Level

Radiator guard Cap
Neck pipe
CAUTION
Pressurized radiator tank is used for this
machine.

Spray of hot coolant may cause burns. Water surface

Stop engine and allow radiator and coolant to

cool completely, then open cap slowly to relieve
pressure.
OM0095

CAUTION 3. Check the coolant level.

Cooling system conditioner contains alkali that
could caustic burns or blindness.
Avoid contact with skin and eyes to prevent
injury.
1. Stop the engine and allow the radiator and
coolant to cool completely.
4. Coolant level is normal if coolant is to the lower
part of neck pipe.
5. If needed, add the required amount of the cool-
ant.
Refer to "Coolant Specification" page 3.64 for
the correct mixture.

6. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 3.14.

7. If the coolant contains oil, diagnose the prob-

1
lem and correct it immediately.

115ZV2 7212

2. Lift lever (1) on cap (2) of the radiator tank to

vent pressure and slowly open cap (2).
 2.71
OPERATION
Check before Operation

Drain Water and Sediment from Fuel Check Wiring Harnesses

Prefilter
CAUTION
Short circuit of wiring harnesses may cause fire.

- Keep the connection of wiring harnesses

clean and tight.
- Repair the damaged wiring harness or
exchange it for new one.

Be sure the wiring harnesses are not damaged and

the connection is kept clean and tight.

115ZV2 FUEL FILTER

- Open the drain cock on the bottom of the fuel

prefilter to allow water and sediment to drain
into a suitable container.

- Dispose of the drained water and sediment

properly.

CAUTION
Escaping fuel is flammable and harmful to skin.

- Do not smoke while draining moisture and

sediment from filter.
- Do not drain with engine running.
- Do not allow diesel fuel to remain on skin for
an extended period of time.
2.72
OPERATION
Check before Operation

Articulation Stopper Check Tire for Damage, Air and Tread

Depth

"STORED" position

115ZV0002

OM0032

- Make sure the articulation stopper is secured in

the "STORED" position as shown.
WARNING
Improper service or changing tires and rims
could cause explosion resulting in serious injury
or death.

Do not service or change tire and rims unless

properly trained and equipped.

Contact your nearest authorized dealer or tire

manufacturer’s local dealer for tire servicing or
changing.

WARNING
Overheated tire could explode causing serious
injury or death.

If overheated tire is suspected, do not approach

tire to distance of less than 15 m.

Stay away until tire and rim cool down.

WARNING
Serious injury may result from tire failure due to
underinflation/overloading or excessive speed.

Consult your tire dealer or authorized dealer.

 2.73
OPERATION
Check before Operation

Tread
Low Pressure OK High Pressure

Side walls
Breakers

Carcass

Beads / Bead wire

97ZVOM0103 OM0104

Tire performance and its life depend greatly on the If the following defects are found in tires, for safety
tire air pressure. reasons the tires should be replaced with new tires.

It is important to keep the tire pressure at the rec- For the replacement contact authorized dealer or a
ommended level. tire manufacturers local dealer.

Under the abnormal condition, check and adjust the - Bead wire is broken or bent, or the tire is greatly
air pressure to the standard value. deformed.

Refer to "Check Tire Air Pressure" page 3.24 for - Wear is excessive and the carcass ply (includ-
the adjusting procedure. ing breaker) is exposed for more than 1/4 of the
circumference.

- Damage to the carcass exceeds 1/3 of the tire

width.

- Tire layers are separated.

- Radial cracks reach the carcass.

- Deformation or damage which makes the tire

unsuitable for use.
2.74
OPERATION
Check before Operation

Check Drive Belt Check Air Intake System

CAUTION
Contact with moving belt or pulleys may cause
injuries.
Stop engine before opening engine access
panel.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine. Remove the key
and tag "Do Not Operate".
CAUTION
Hot engine components may cause burns.
Avoid contact with hot engine components.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
Cooler IN (Left)
Cooler OUT (Right)

2. Open the engine access panel.

3. Visually inspect the drive belt for looseness

and damage.

OK
115ZV2 0001

OK
2. Check the engine intake hose, intake pipes,
pipe clamps and hose bands for damage and
tightness.

3. If damaged or loose, replace or retighten or

OM0099
contact your nearest authorized dealer.

4. If the belt is too stretched to permit adjustment

IMPORTANT
or shows cuts or cracks, replace it. Severe engine damage may result from running
with unfiltered air.

Do not operate engine if any leaks or defects are

found on air intake system.

Check Cooling Fan
OK
OK
OM0102
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine. Remove the key
and tag "Do Not Operate".
2. Open the engine rear grill.
3. Visually inspect the cooling fan for damage.
4. If the fan shows cracks, loose rivets, bent or
loose blades, replace it.
2.75
OPERATION
Check before Operation
Check Horn Operation
1. Push the horn button in the center of the steer-
ing wheel.
2. The horn should sound loudly.
ROPS (Roll Over Protective Structure)
WARNING
Operating with damaged or improperly mounted
ROPS could result in death or serious injury.
If any damage or loose bolts are found, do not
operate until repaired.
Never repair or modify ROPS without manufac-
turer’s approval and instructions.
- Check the condition of the ROPS and its mount-
ing bolts.
Adjust and Check Rear View Mirrors
- Adjust and check the condition of the rear view
mirrors.
- If there is any dirt on or damage to the rear view
mirrors, clean or fix them.
Check Parking Brake
- Make sure the parking brake switch is pulled up.
2.76
OPERATION
Check before Operation

Check Monitor Panel Operation

1. Turn the starter switch to the "ON" position.

2. All warning lamps (red) should come on for

about three seconds. Refer to "Indicators"
page 2.26.

3. Rotate and move the transmission shift lever to

each position, pull the high-low beam lever,
and operate the rear working light switch and
declutch ON/OFF switch.

4. The transmission status monitor lamps (green)

and the indicator lamps (green or blue) should
come on respectively.

5. If any lamps do not light up, replace the bulbs.

Refer to "Indicators" page 2.26.

Check Control Levers

- Make sure the boom and tilt control levers are in

the "HOLD" position.

Check Transmission Shift Lever

- Make sure the transmission shift lever is in the

neutral position.
 2.77
OPERATION
Starting the Engine

Starting the Engine

WARNING OFF ON
START
If engine starts in gear due to bypassing neutral
start device from ground could result in death or
serious injury.

- Do not start engine by shorting across starer

terminals.
- Do not start engine while standing on ground.
97ZVOM0076
Make sure to start engine only from operator’s
seat with transmission in neutral and parking
brake applied. 3. The turn the starter switch key to "START"
position to start the engine.

To protect starter and battery, do not keep the

Normal Start starter switch in the "START" position for more
(Ambient temperature above 0ºC) than 20 seconds.

1. Do not step on the accelerator pedal. 4. If the engine fails to start, wait about two min-
utes before trying to restart. This allows the
starter motor to cool which prevents starter
motor damage.

OFF ON
START

97ZVOM0075

2. Turn the starter switch key to "ON" position

and leave it there for 3 seconds. Check the
indicator lamps.
2.78
OPERATION
Starting the Engine
Cold Start
(Ambient temperature below 0ºC)
OFF ON
START
97ZVOM0075
5. After the engine starts, release the key and it
will return to the "ON" position.
6. If the transmission shift lever is not in the
"NEUTRAL" position, the engine will not crank.
NOTE
- When the starter switch key is in the "ON" posi-
tion, the engine itself will diagnose engine fail-
ure, if any, in 2 seconds.
During this time, all of the engine warning lamp
are being turned on. This checks the bulbs.
When the diagnosis is completed the engine
warning lamps are turned off.
Before starting the engine, make sure all of the
warning lamps are turned off. If the stop (red)
lamp remains on, do not start the engine.
- Do not turn the starter switch key to the
"START" position while the engine is running.
- The engine oil pressure warning lamp should go
out in less than ten seconds after the engine
starts. If it remains on, stop the engine immedi-
ately and see "TROUBLESHOOTING" page
3.65.
IMPORTANT
Low engine oil pressure may cause severe
engine damage.
Be sure engine oil pressure warning lamp goes
out quickly.
1. Do not step on the accelerator pedal.
115ZV2 0003
2. Turn the starter switch key to the "ON" position
and press the cold start switch for two sec-
onds. (Here the ether is filled into a metering
valve and measured.)
3. Turn the starter switch key to the "START"
position to start the engine and release the
cold start switch. To protect starter and battery,
do not keep the starter switch in the "START"
position for more than 20 seconds.
4. If the engine fails to start, wait about two min-
utes before trying to restart. This allows the
starter motor to cool which prevents starter
motor damage.
5. After the engine starts, release the key and it
will return to the "ON" position.
6. If the transmission shift lever is not in the
"NEUTRAL" position, the engine will not crank.
7. In case the engine does not start on the first
attempt, repeat the above procedures after
intervals of about one to two minutes.
WARNING
Ether is very flammable and could cause serious
injury or death.
- Avoid heat, electric sparks and flames near
ether cylinder.
- Do not store ether cylinders at temperature
above 40ºC.
- Store ether cylinders out of children's reach.
- When winter season is over (outside tempera-
ture is above 5ºC), remove ether cylinder from
machine and store it safely according to
above instructions.
 2.79
OPERATION
Starting the Engine

IMPORTANT
Ether may cause serious engine damage.

Never attempt to inject ether into warm engine.

Use ether only as specified in this manual.

NOTE
- Do not turn the starter switch key to the
"START" position while the engine is running.

- The engine oil pressure warning lamp should go

out in less than ten seconds after the engine
starts. If it remains on, stop the engine immedi-
ately and see "TROUBLESHOOTING" page
3.65.

IMPORTANT
Low engine oil pressure may cause engine dam-
age.

Be sure engine oil pressure warning lamp goes

out quickly.
2.80
OPERATION
Idling Management System

Idling Management System Hibernate Mode

Warm-up control Mode ON:

Idle-up function
When the engine coolant temperature is 10ºC or
lower, the engine idling speed increases from 925
min-1 to 1,000 min-1.
Decreases the engine idling speed from 925 min-1
to 775 min-1 under the following condition.
- When the transmission shift lever is placed in
"N" position, the engine coolant temperature is
higher than 60ºC, and the engine speed is held
at 950 min-1 or less for 10 seconds.

Fan low speed control

When the engine coolant temperature is 60ºC or Mode OFF:

lower and the engine speed is 1,200 min-1 or less,
the cooling fan retains its minimum speed regard- Returns to the normal engine speed under either
less of the engine speed. one of the following conditions.

- When the transmission shift lever is placed

other than in "N" position.
Engine Acceleration Control (Function)
(Turbo Protection) - When the engine speed is 950 min-1 or more

When the engine coolant temperature is 10ºC or - When the engine coolant temperature is 60ºC or
lower, the accelerator is not activated a few sec- lower
onds and delays the response for acceleration.

Forcible Mode OFF:

When the generated power by the alternator low-

ers, the mode is OFF forcibly.

In this case turn off the starter switch and start the
engine again to reset the hibernate mode.
 2.81
OPERATION
Check after Starting the Engine

Check after Starting the Engine Check Warning Lamps

(11C5-0151~0250)
- Keep the engine running at low to medium
speed and warm it up for about five minutes.

- Do not subject the engine to sudden accelera-

tion until the end of the warm-up period.
0 0 0 0 0 0 1/10h
AUTO
20
10 N

IMPORTANT 4
3
C H F

E
0 30
Do not idle the engine for excessively long peri- x100r/min
2
1
C H
ods of time.

Long periods of idling (more than 10 minutes)

115ZV2 0008
can damage an engine because combustion
chamber temperatures drop so low the fuel can
not burn completely.
(11C5-0251~)
This will cause carbon to form in the injector
spray holes and on the piston rings and can
result in stuck valves.

115ZV2 0012

1. Check the warning lamps on the instrument

panel.

2. If any red lamp (except for "PARKING") is on,

do not operate the machine.

3. Refer to "Indicators" page 2.26 for the meaning

of each lamp and the correction.
2.82
OPERATION
Check after Starting the Engine

Check Fuel Level Check Transmission Oil Level

DANGER
There is no room in articulation are when
machine is turning.
Crushing will result in serious injury or death.
F

When checking oil level:

- Low attachment to ground.
E
FUEL - Put transmission shift lever in neutral.
97ZVOM0051
- Apply parking brake.
- Place "DO NOT OPERATE" tag on steering
wheel.
- Make sure nobody is on machine.

1. Check the fuel level with the fuel gauge on the
instrument panel.
2. Add fuel to fill the tank if the gauge shows
below "F".
1. Park the machine on level ground, apply the
parking brake, and lower the attachment to the
ground.

Refer to "Recommended Lubricants" page

3.62 for the proper fuel.

"LOCKED" position

115ZV0001

2. Set the articulation stopper in the "LOCKED"

position.

Refer to "Articulation Stopper" page 1.28.

3. Check the oil level with engine at low idle.

 2.83
OPERATION
Check after Starting the Engine

Sight Gauge
IMPORTANT
Fill Tube
Never mix CD engine oil and auto transmission
fluid.
Either may be used in transmission but they
must not be mixed.

Determine what type of oil is in transmission and

use only that type.

115ZV0011a

HOT

COLD

97ZV2 0002

4. At low oil temperature, check if the oil surface

level is within the "COLD" window of the sight
gauge.

5. At high oil temperature, check if the oil surface

level is within the "HOT" window of the sight
gauge.

6. If the oil level is lower than the specified, add

recommended oil while the engine is at idle.
Do not overfill.

Refer to "Recommended Lubricants" page

3.62.

WARNING
With articulation stopper in "LOCKED" position,
machine will not steer which, while operating,
could cause an accident result in death or seri-
ous injury.

Return articulation stopper to "STORED" posi-

tion after checking transmission oil level.
2.84
OPERATION
Check after Starting the Engine

Check Service Brake Operation Check Steering Wheel Operation

Before testing be sure the area behind the loader is 1. Be sure the area is clear of bystanders.
clear.
2. Release the brakes.
1. Turn "OFF" the declutch ON/OFF switch.
3. Steer fully right and then left.
2. Firmly step on the left hand brake pedal.
4. Steering should be smooth in both directions.
3. Release the parking brake.

4. Select the transmission shift lever 2nd and

REVERSE. Check Back-up Alarm Operation
5. Slowly accelerate the engine to full speed. 1. Apply the service brakes.

6. The machine should not move. 2. Release the parking brake.

IMPORTANT 3. Move the shift lever to "REVERSE".

If machine moves when firmly step on right hand 4. The back-up alarm should sound and be heard
brake with transmission in 2nd and FORWARD, in the operator's seat.
there is some problem with service brake.

Do not operate until problem has been corrected. IMPORTANT

If back-up alarm does not sound when parking
brake is released and shift lever is in REVERSE
position, there is some problem with back-up
Check Parking Brake Operation alarm.

Do not operate until problem has been corrected.

1. If the service brakes work normally, test the
parking brake.

2. Move the machine to a safe open place on a

slope.

3. Stop the machine with the service brake.

4. Pull up the parking brake switch.

5. Release the service brakes.

6. The machine should not move.

IMPORTANT
If machine moves when parking brake switch is
pulled, there is some problem with parking
brake.

Do not operate until problem has been corrected.


Check Exhaust Gas
115ZV2262a
1. Check the color of the exhaust gas.
Normal exhaust gas color is clear or light gray
when engine is warm. White, black, or blue
smoke during steady warm operation of the
engine indicates a malfunction. (It is normal for
some black smoke to occur during rapid accel-
eration.)
2. If abnormal exhaust gas color occurs, have the
machine checked immediately.
Refer to "TROUBLESHOOTING" page 3.66.
2.85
OPERATION
Check after Starting the Engine
General Inspection
WARNING
Accidental movement of machine could result in
death or serious injury.
When inspecting machine while engine is run-
ning:
- Make sure nobody is on machine.
- Lower attachment to ground.
- Turn parking brake switch to "ON".
- Do not enter or access hazardous areas of
machine:
- Articulation area
- Under machine
- Engine compartment, etc.
With the parking brake applied, transmission shift
lever in NEUTRAL, loading levers in NEUTRAL,
and the attachment on the ground, walk around the
machine and look for any problems, leaks, or signs
of failure.
2.86
OPERATION
Operating the Machine

Operating the Machine Starting the Machine

WARNING
Stopping engine while machine is moving will
cause loss of steering control which could cause
serious injury or death.

Do not stop engine while machine is moving.

WARNING approx. 40 cm
OM0016
Moving machine in congested areas could result
in death or serious injury.

Be sure area is clear of personnel and obstruc-

tions. 1. Raise the bucket to the carry position approxi-
mately 40 cm above the ground.

IMPORTANT 2. Step on the brake pedal.

Operating machine on a grade may cause lack
of lubrication resulting in severe engine or com-
ponents damage.
Do not operate machine on a grade over 30º.
3. Push the parking brake switch to release the
parking brake.
4. Turn the transmission shift lever to the desired
travel speed mode and then shift to the desired
direction.

30º Max.

OM0194
97ZVOM0038

5. Release the brake pedal then step on the

accelerator pedal to drive the machine.

WARNING
When parking brake is released, machine could
roll on a grade unexpectedly causing injury or
death.

When starting machine on a grade, firmly step

on brake pedal before releasing parking brake.
 2.87
OPERATION
Operating the Machine

Starting the Machine on a Grade Speed and Direction Change

1. Turn "OFF" the declutch ON/OFF switch.

2. Step on the left brake pedal (declutch brake

pedal).

65ZV 5089

1. Select the proper gear shifting mode by rotat-

ing the transmission shift lever. Refer to the fol-
lowing tables on page 2.88 for the gear
97ZVOM0038
selection mode.

3. Step on the accelerator pedal while releasing This machine is equipped with the automatic
the left brake pedal to start the machine off shifting system which selects the proper gear
slowly. automatically using a micro computer to elimi-
nate tiresome manual shifting.

65ZV 5089

2. For a direction change, decelerate the

machine then move the transmission shift lever
to forward or reverse.

IMPORTANT
Changing direction with transmission in 3rd or
4th gear may cause serious transmission dam-
age.

Slow down machine and shift transmission to 1st

or 2nd gear when changing direction.
2.88
OPERATION
Operating the Machine

Auto Brake

(11C5-0151~0250)

0 0 0 0 0 0 1/10h
AUTO
20
10 N
C H F
4
3 E
0 30 2
x100r/min
1
C H

115ZV2 9296 115ZV2 0008

3. When the transmission is in the 2nd gear, it (11C5-0251~)

can be quickly shifted down to the 1st gear by
pressing the downshift button.

4. Pressing the downshift button again, moving

the transmission shift lever to the neutral posi-
tion, or operating the parking brake switch
automatically returns to the 2nd gear from the
1st gear.

Refer to "Downshift Button" page 2.16. 115ZV2 0012

Lever Auto Brake feature protects the transmission from

Selected Gear Operating Condition
Position excessive speed. It applies the service brakes and
1. Excavating or turns on the warning buzzer. The Auto Brake moni-
scooping in a nar- tor lamp also turns on.
[1] 1st row space
2. Running downhill
In case of the direction change, the warning buzzer
on a steep slope
1. Scooping or load-
does not turn on, only the service brakes are
ing loose material applied and the auto brake monitor lamp turns on.
[2] 2nd
2. Running downhill
on a slope Auto Brake works under the following conditions:
[3] 3rd Carrying or roading
2nd, 3rd or 4th Scooping, loading, 1. If the machine runs above the following speeds
[A] (automatically carrying or roading forward or reverse;
shifted)
Forward Reverse
[1] : 13 km/h 12 km/h
IMPORTANT [2] : 22 km/h 24 km/h
Using too high gear for job may cause torque [3] : 36 km/h 36 km/h
converter overheating. [4] : 39 km/h —

Use proper gear for each job. NOTE

When the machine speed reaches the specified
machine maximum speed at the 4th speed range,
the engine speed automatically reduces before the
Auto Brake is applied to keep within the safety
speed limit.

Still the Auto Brake should operate if the machine

 2.89
OPERATION
Operating the Machine

speed exceeds the speed mentioned above or Running in Deep Mud or Water
higher at each speed range.

2. When the direction is changed while running

over 12 km/h. Axle housing

CAUTION
When auto brake applies, machine may slow
down suddenly.
A
Be prepared. Wear seat belt.

A=Maximum depth of water allowable during operation

OM0109
(including waves).

Running the machine in mud, snow, or water at or

near a level of A (even for a brief period of time) is
considered a severe application.

1. Immediately after encountering this condition,

check both differentials for water contamina-
tion in the oil. Water mixed with the oil will
cause a milky or foamy appearance.

2. Drain and refill if water is found.

Refer to "Check Differential Gear Oil" page
3.30 and "Check Planetary Gear Oil" page
3.31 or consult the nearest authorized dealer
for further assistance.
2.90
OPERATION
Parking

Parking
3. Shift the transmission shift lever to "NEU-
TRAL".

4. Pull up the parking brake switch to apply the

parking brake.

5. Lower the attachment to the ground and apply

a small amount of down pressure.

OM0025

WARNING
Unexpected movement of machine could result
in death or serious injury.

Park machine in safe place on firm level ground.

If machine has to be parked on a grade, place

wheel chocks under wheels and dig attachment
into ground.

IMPORTANT
Applying parking brake while moving may cause
rapid brake lining wear and loss of parking brak-
ing force.

Except for emergency do not apply parking

brake while machine is moving.

97ZVOM0038

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

 2.91
OPERATION
Stopping the Engine

Stopping the Engine

WARNING
Stopping engine while machine is moving will
cause loss of steering control and braking force
which may cause serious injury or death.

Do not stop engine while machine is moving.

IMPORTANT
Failure to allow engine to cool down before stop-
ping may cause premature turbocharger failure.

Run engine at low idle speed for about five min-

utes before stopping engine.

1. Let the engine idle for about five minutes

before stopping.

OFF ON
START

97ZVOM0074

2. Turn the starter switch to the "OFF" position to

stop the engine.

3. After stopping the engine, remove the key and

store it in a safe place.

WARNING
Unauthorized operation could cause accidents
resulting in death or serious injury.

Prevent unauthorized operation.

When leaving machine for extended period of

time, remove the starter key, lock cab doors or
lock vandal cover over dashboard and right hand
console (if equipped).
2.92
OPERATION
Operating Techniques

Operating Techniques Loading

IMPORTANT
Machine damage may result from improper load-
ing procedures.

- Do not dig or scoop with machine frame artic-

ulated.
- Do not drive machine into material at high
speed.

30º Max. NOTE

- When loading rocks or hardpacked material, the
OM0194 use of bucket teeth is recommended.

- For loose stockpile material replaceable bolt-on

IMPORTANT cutting edges should be used.
Operating machine on a grade may cause lack
of lubrication resulting in severe damage on
engine or other components.

Do not operate machine on a grade over 30º.

NOTE
Refer to "Traction Control Switch" page 2.24 for
effective operation.

OM0111

1. Move the machine forward to the material.

2. Steer the machine in a straight ahead position

when entering the material.

OM0113

3. Lower the bucket parallel to the ground.

 2.93
OPERATION
Operating Techniques

4. Drive the bucket straight into the material. Use

approximately 1/2 - full engine speed.

OM0112

OM0114 10. On later passes, aim the center of the bucket

at the protruding portion of the material.

5. Move the boom control lever to the "Raise"

detent position and run the machine forward
slowly in 1st or 2nd speed.

Reduce wheel slippage by slightly reducing

engine speed.

OM0115

6. Move the bucket control lever to the "Roll

Back" and the "Hold" position several times to
get more material in the bucket.

7. When the bucket is filled, move the bucket

control lever to the "Roll Back" position.

8. Release the bucket control lever to the "Hold"

position and the boom will rise.

9. Reverse the machine.

2.94
OPERATION
Operating Techniques

Excavating

1. Move the machine forward to the material.

2. Steer the machine in a straight ahead position

when entering the material.

OM0120

5. When the bucket is filled, move the bucket

control lever to the "Roll Back" position.
10 degrees or less
6. Move the boom control lever to the "Raise"
position to clear the ground.
OM0118a

3. Lower the bucket parallel to the ground or

dump it slightly forward (10 degrees or less).

OM0119

4. Run the machine slowly in 1st or 2nd speed.

Increase engine speed as the bucket digs

deeper.
 2.95
OPERATION
Operating Techniques

Dozing Ground Levelling

1. Keep the loaded bucket slightly above the

IMPORTANT ground.
Dozing or pushing with dumped bucket or attach-
ment may cause severe damage to linkages.

It may also cause engine over-heating and

torque converter over-heating.

Keep bucket or attachment bottom parallel to

ground.

OM0121

2. While running the machine backward, dump

the bucket little by little to evenly spread mate-
rial on the ground.

OM0123

OM0122

3. Dump the bucket, allow the cutting edge to

contact the ground, and run the machine back-
ward.
2.96
OPERATION
Operating Techniques
OM0123
4. To get smoother surface, put some material in
the bucket, place the bucket parallel to the
ground, run the machine backward with the
boom control lever in the "Float" position.
IMPORTANT
Pushing material with dumped bucket may
cause severe damage to linkages.
Be sure to run machine backward when leveling
ground.
Carrying
approx. 40 cm
OM0016
1. Fully roll back the loaded bucket before carry-
ing to prevent spillage.
2. Keep the bucket approximately 40 cm above
the ground when carrying.
IMPORTANT
When carrying material over 450 m at high
speed, tire overheating may occur.
Follow tire manufacturer's instructions for tire
inflation on this type of application.

Dumping into Truck or Hopper
WARNING
When boom is raised, machine stability is
reduced and could cause machine to tip over
causing serious injury or death.
Do not make quick turns or abrupt braking when
boom is raised.
Keep boom low for best stability especially on
slopes.
WARNING
Machine contact with overhead wires or other
objects could result in death or serious injury.
Be sure there are no overhead wires or obstruc-
tions before raising boom to full height.
Refer to "Loading" or "Excavating" page 2.92, 2.94
for the loading procedure.
OM0116
1. Move the boom control lever to the "Raise"
position to raise the loaded bucket while
approaching the truck or the hopper.
2. Use the declutch ON/OFF switch in the "ON"
position if working on a level site.
When the left brake pedal (declutch pedal) is
step on, the transmission is placed automati-
cally in neutral and the boom rises faster.
2.97
OPERATION
Operating Techniques
3. Return the boom control lever to the "Hold"
position when the bucket reaches the enough
height to clear the truck or hopper sideboards.
If the boom is equipped with the kickout
device, the boom will automatically stop and
the boom control lever will return to the "Hold"
position when the bucket reaches the preset
height.
Holding the boom control lever in the "Raise"
position will continue to raise the boom if
required.
Refer to "Kickout Control Switch" page 2.18 for
adjustment of the preset height.
4. Position the machine in the center of the truck
body or hopper to dump the load.
OM0195
5. Push the bucket control lever forward to the
"Dump" position to empty the bucket.
OM0196
6. Roll back the bucket to clear the truck or hop-
per sideboards and lower the boom while
reversing the machine.
2.98
OPERATION
Operating Techniques

Typical Truck Loading Methods

WARNING
Fast boom lowering motion may cause machine I Cycle Operation
rear wheels to jump up, reducing stability and
control.

Do not lower boom using detented "Float" posi-

tion especially when bucket is full.

OM0124

This method is recommended where the working

area is limited.

V or L Cycle Operation

(L-cycle) (V-cycle)

OM0125

This is the most efficient operation for the shortest

cycle time.
 2.99
OPERATION
Operating Techniques

T Cycle Operation

OM0126

This method is effective for the sites where trucks

continuously come and go.
2.100
SPECIAL PROCEDURES
Adjustments

SPECIAL PROCEDURES

Adjustments 6. To test the adjustment; start the engine, raise

the boom approximately half way, dump the
attachment, and move the bucket control lever
Bucket / Attachment Leveler Adjust-
to the "Roll Back" detent position to rollback
ment the attachment.

WARNING When the preset angle is reached, the bucket

control lever should return to the "Hold" posi-
Accidental movement of machine could result in tion. Lower the attachment to the ground and
death or serious injury. confirm the proper angle has been set.

Apply parking brake and use wheel chocks to

prevent sudden movement of machine.
4

WARNING
Standing on tire, boom or linkage could cause
accidents resulting in death or serious injury.
3
Use safe sturdy platform to reach bucket leveler
adjustment.
5±2 mm

1. Park the machine on level ground and apply OM0128

the parking brake.

2. Lower the attachment to the ground, adjust it to NOTE

the desired angle, set the bucket control lever Clearance between switch (4) and rod (3) should
to the hold position, and stop the engine. be about 5 mm.

The switch may be adjusted in or out to set this

clearance.

2
1
97ZVOM0127

3. Loosen bolts (1) with a 17 mm wrench.

4. Move bracket (2) forward to increase, or rear-

ward to decrease the attachment preset angle.

5. Tighten bolts (1).

 2.101
SPECIAL PROCEDURES
Roading / Special Applications

Roading / Special Applications

WARNING
Overheated tire could explode causing serious
injury or death.

If overheated tire is suspected during operation

or servicing, do not approach tire to distance of
less than 15 m.

Stay away until tire and rim cool down.

When the machine travels at high speed or for a

long distance, the tires or other components such
as engine and transmission / torque converter may
become extremely hot causing an explosion, early
wear, or damage. If the machine must be driven for
a long distance, take the following precautions:

- Follow the regulations related to this machine,

and drive carefully.

- The most suitable tire pressure, travel speed, or

tire type differ according to the condition of the
travel surface. Contact your nearest authorized
dealer or a tire dealer for information.

- "Ton km/h" limitations must be observed. Con-

sult a tire dealer for the speed limit of the tires
involved.

- Carefully watch the engine coolant temperature

gauge and the torque converter oil temperature
gauge on the operation panel not to exceed the
white zone on them.

- After traveling a distance, stop the machine with

engine running to allow the tires and compo-
nents to cool. Check the tires and other parts for
damage.

- Do not put calcium chloride or dry ballast in the

tires when traveling.

- Whenever possible use a lead and/or follow

vehicle and all available warning devices even if
not required by regulations.
2.102
SPECIAL PROCEDURES
Booster Batteries / Jumper Cables
Booster Batteries / Jumper
Cables
DANGER
Improper procedure to start engine using jumper
cables could cause battery case explosion.
- Do this work by two persons. While one per-
son sits on the operator's seat, the other per-
son connects jumper cables.
- Wear eye or face protection when working on
or around batteries.
- The booster batteries should be of similar size
and capacity as the batteries being boosted.
- Do not allow the two machines to touch. This
prevents possible sparks between or in the
machines being used.
- Keep flames and sparks away from batteries.
- Keep jumper cable ends from touching each
other or machine to avoid sparks.
- Make last connection to grounded part of
frame away from battery compartment.
WARNING
If the battery is being used with insufficient bat-
tery electrolyte level, the deterioration on the
parts in the case could be in the advanced stage.
It could cause to shorten the battery life or to
emit sparks from the deterioration parts in the
case, as a result the battery case could explode.
Keep the battery electrolyte level in the proper
level.
WARNING
Batteries contain lead, and acid which may
cause burns.
Avoid contact with skin or clothing and wear
hand, eye, and face protection when working on
or around batteries.
If lead, or acid contacts skin or clothing, immedi-
ately wash with water.
NOTE
This machine uses a 24VDC negative ground elec-
trical system.
1. Before connecting jumper cables:
- The booster cables must be of the heavy duty
type and in good condition.
- Be sure the problem is inadequate battery
charge and not some other electrical problems.
- Stop the engine of the boost machine or turn off
the booster supply if using an auxiliary power
source.
2. Raise and lock the battery box covers.
3. Be sure vent caps are tight and level. Place
damp cloth over vent caps on both batteries.
- + - +
+ - + -
Booster Batteries Batteries being boosted
Rear chassis close to starter motor ground being jump started
OM0131
4. Move back the protective rubber covers (red)
from the positive post (+) of the battery.
5. Connect one end of the red jumper cable to the
positive post (+) of the discharged battery.
6. Connect the other end of the red jumper cable
to the 24 volt side of the booster battery set or
power source.
7. Connect one end of the black jumper cable to
the ground side of the booster battery set or
power source.
8. The final connection should be the remaining
end of the black jumper cable to the rear chas-
sis close to starter motor ground being jump
started.
9. Start the booster machine's engine or turn the
auxiliary power source on.
10. Allow a few minutes to provide partial charge
to the discharged batteries.
 2.103
SPECIAL PROCEDURES
Booster Batteries / Jumper Cables

11. Start the machine being boosted as described

on "Starting the Engine" page 2.77.

12. As soon as the engine starts, disconnect the

jumper cables in the reverse order (Step 8,
Step 7, Step 6, Step 5).

13. Remove the damp cloth and replace the pro-

tective covers over the battery terminals and
close the battery box covers.

14. Test the starting / charging system to deter-

mine the cause of the problem and correct it.
2.104
SPECIAL PROCEDURES
Towing

Towing
If your machine must be towed, contact your near-
est authorized dealer for the necessary information
WARNING or assistance.

Improper towing could result in death or serious

injury.

Follow safety warnings found under "Safe Oper-

ation -- SPECIAL OPERATING CONDITIONS:"
page 1.9.

This machine is equipped with a hitch on the rear

end for towing a troubled machine.

1. Inspect the cable for damage. Never use a

damaged cable.

Drawbar

115ZV2 03174-0145

2. Connect the cable to the drawbar. Make sure

the drawbar and split pin are in the lower posi-
tion.

3. Connect the other end of the cable to the trou-

bled machine.

4. If the service brake on the towed machine

does not work;

do not allow an operator on the towed

machine, and attach another vehicle of ade-
quate size to the rear to act as a braking vehi-
cle.

5. Keep personnel away from between the towing

machine and the towed machine.

6. Tow the machine slowly with gradual and

smooth movement.

7. Use flashing lights or other warning signals

when towing.
 2.105
SPECIAL PROCEDURES
Transportation

Transportation
5. Lower the bucket and lock each control lever
using the loading control lever lock (page
When transporting the machine, observe the vari- 1.28).
ous road rules, road transportation vehicle laws
and vehicle limit ordinances, etc. 6. Apply the parking brake and set the articulation
It is a good idea to obtain a special platform for stopper in the "LOCKED" position (page 1.28).
loading and unloading the machine.
7. Tape over the exhaust stack outlet to prevent
1. Park the trailer on flat firm roadbed. Keep a turbo "Wind-milling" damage.
fairly long distance between the road shoulder
and the machine.

97ZVOM0134

OM0132
8. Place blocks in front of and behind the tires to
prevent the machine from moving.
2. Properly apply the brakes of the trailer and
place wheel chocks in front of and behind the
tires to ensure that the trailer does not move.

3. Fix the ramp in line with the centers of the

trailer and the machine.

OM0197

9. Fasten the machine to the trailer with chains or

cables at 4 fixing points (red painted) provided
on the machine.
97ZVOM0133
Additional cables or chains may be used but
do not damage brake lines or cylinder rods.
4. Determine the position of the ramp, then slowly
load the machine onto the specified part of the
trailer. IMPORTANT
Brake pipe runs on axle housing.
NOTE
Have someone in clear view and in a safe position Do not fasten axle housing.
provide directions while loading.
2.106
SPECIAL PROCEDURES
Transportation

10. Determine the route for transporting the

machine by taking into account the width,
height and weight of the machine and truck.

OM0198
GRAVITY CENTER

11. In the case that it is necessary to lift the

machine, sling the machine at 4 fixing points
(red painted) provided on the machine as
shown.

Weight: 47 ton
 2.107
SPECIAL PROCEDURES
Long Term Storage

Long Term Storage
Before Storage
1. Wash and clean all parts of the machine and
touch up the paint finish to avoid rusting.
2. Lubricate every greasing point described in
"Greasing" section page 3.17, 3.20, 3.26, 3.42
and 3.49.
3. Be sure to refuel in the fuel tank.
9. Securely cover the inlet and outlet ports of the
air cleaner and muffler.
IMPORTANT
If a battery terminal is removed from a machine
in less than 30 seconds after the key is put into
the OFF position, it can corrupt the ECM pro-
gram, which can disable the engine.
Always wait 1 full minute to be sure to be past
this "write to memory function" prior to removing
battery terminals.

4. Replace engine oil, transmission oil, differential

and planetary oil and hydraulic system oil.

5. Idle the engine for about 15 minutes so that

fuel and lubricant circulate throughout the
engine, transmission and torque converter.

6. Store the machine indoors and keep it dry.

Never leave it outdoors. If forced to leave it
outdoors, choose a flat place, place the
machine on wooden blocks and securely cover
it with a canvas or plastic cover, etc.

The range of temperature the machine is to be

stored is between -25ºC ~ 35ºC.

OM0028

7. Disconnect the cables from the batteries or if

freezing temperatures are expected, remove
the batteries from the machine and store sepa-
rately in a heated area.

8. If freezing temperatures are expected, check

and adjust the antifreeze/water mixture.

Refer to "Coolant Specification" page 3.64 for

the mixing ratio.
2.108
SPECIAL PROCEDURES
Long Term Storage

During Storage After Storage

Once a month remove the covers, run the engine,

and move the machine a short distance to form a
new oil film on the lubricated parts.

1. Check the following points.

Refer to "Check before Operation" page 2.67

and "Check after Starting the Engine" page
2.81.

- Coolant level
- Engine oil level
- Hydraulic oil level 97ZVOM0145

- Transmission oil level

- Brake function
- Steering function

2. Operate the machine as follows.

- Run just the engine for about five minutes at

low idle.

- Move all cylinders of the hydraulic system full

stroke 2~3 times.

- Run the machine about 10 m in every gear

and direction. 115ZV0008

- Move the steering full stroke each way about

2~3 times. 1. Loosen the drain cock or plug of the fuel tank
and the hydraulic tank to drain any water into a
3. Operate the air conditioner as follows. suitable container. Dispose of properly.

- Operate the air conditioner with the engine
low idle for several minutes once a month so
that the lubricating oil in each part of the
compressor is not eliminated.
2. Remove the covers, connect the cables to the
batteries and start the engine.
3. Replace engine and transmission oil with new
specified oil after warming up both engine and
transmission.

Refer to "Replace Engine Oil and Oil Filter Car-

tridge" page 3.37 and "Replace Transmission
Oil" page 3.43.

4. Start the engine and check for any abnormali-

ties.

5. Warm up the machine until all gauges reach

the normal range.
 2.109
SPECIAL PROCEDURES
Long Term Storage

Cautions on Battery Replacement or

Battery Cable Removal

When battery or battery cable is removed, follow OFF ON

START
the procedure below to avoid miss throttle opera-
tion by ECM.

OFF ON
START 97ZVOM0074

3. Turn the starter switch key to OFF position.

4. Start the engine and check the max. engine

speed.

97ZVOM0075

1. Turn the starter switch key to ON position.

Step on
 Release
(2sec.)

Step on
 Release
(2sec.)

Step on
 Release
(2sec.)

65ZV2 03153-0026

2. Slowly step on the accelerator pedal to the full

stroke position 3 times.
(Keep it at the full stroke position 2 seconds
and release it)

IMPORTANT
Fully step on the accelerator pedal to the full
stroke position. If the pedal is not step on fully
enough, it causes that the max. engine speed
does not reach the standard figure.
2.110
SPECIAL PROCEDURES
Welding

Welding low-conductive metal that will cause spark if

the welding current flows. The spark may dam-
age the cylinder rod.
Cautions Regarding Welding Repair
Service 6. Calibrate throttle pedal to ECM.

Example 1: (a) Turn the starter switch to "ON".

(b) Fully step on and release the throttle pedal
three times.
Section to be welded (c) Turn the starter switch to "OFF".

Ground this section.
(correct grounding)
Hydraulic cylinder
Do not ground this section.
Electric current may flow
through the cylinders.
135ZV0052

Plated section (Mask this section.)

Example 2:

135ZV0054

Section to be welded
Pin section with pin
Do not ground this section. temporarily inserted
Ground this section.
Electric current may flow (correct grounding)
through the cylinders. Pin
135ZV0053

If welding is needed to repair the chassis, observe

the following precautions to protect the hydraulic
cylinders, hydraulic units, gear sets, and electrical Plated section (Mask this section.)
units from possible damage. 135ZV0055

1. Turn the starter switch OFF.
2. Remove the battery terminals both positive
and negative sides from the battery.
3. Disconnect the connector for MCU (machine
controller), ECM (engine controller) and air
conditioner.
7. The weld spattered on the hydraulic cylinders
and on the plated sections of pins will damage
the cylinders and pins. There are other parts
that may be damaged by the spatter; hydraulic
units, harnesses, hydraulic hoses, and nylon
tubes.
Be sure to mask these units and parts before
welding.

4. Ground the welder near the section to be - Plated section

welded. Cover the plated sections with heat-resistant
cloth, such as glass wool or canvas.
5. To ground the welder, check that the electric
current will not flow through the cylinders.
Cylinder head covers for some models have a
 2.111
SPECIAL PROCEDURES
Welding

NOTE
The weld spattered on the plated sections causes
corrosion.

Scrap material, etc.

1 m or more

Section to
be welded

1 m or more

135ZV0056

- Cover the hydraulic units, electrical units, har-

nesses, hydraulic hoses, nylon tubes, etc. with
heat-resistant cloth (glass wool or canvas) or
scrap material to protect them from spatter.

Section to
be welded

Hydraulic hose,
Nylon tube, or
Harness
Remove
and if
Chassis necessary
wrap

135ZV0057

- Hydraulic hoses, nylon tubes, or harnesses are

easily damaged by the heat during welding. To
protect them from the heat, remove them from
the section to be welded to make enough clear-
ance.

NOTE
You must change the welding rod grade depending
on the welding part and place. Should you have
any question regarding the welding repair service,
please contact KCM dealer in your area during
business hours.
2.112

MEMO
 3.1

3.MAINTENANCE
3.2
MAINTENANCE
Serial Number Location

MAINTENANCE
Before performing maintenance or repairs, read,
understand and follow "Safe Maintenance" section
page 1.12.

The maintenance or repair of the machine must be

performed by well-Trained or experienced person-
nel only.

WARNING
Do not open high pressure fuel
system with engine running.
115ZV0036
Engine operation causes high fuel
pressure.
High pressure fuel spray can
2. Engine Serial Number
cause serious injury or death.

High pressure fuel

Serial Number Location

When contacting authorized dealer or the dealers
of other products for servicing or repair, refer to the
serial number found in the following locations. See MODEL
next page for general location. SERIAL NO.

For quick reference, record each serial number in

MADE IN JAPAN
the blanks below.
SN PLATE 41668-2006B

If a component, like engine or transmission, is

changed, record the new serial number here.

3. Transmission / Torque Converter Serial Num-

ber

Model
MODEL
SERIAL NO. Serial Number

Design Number
MADE IN JAPAN

SN PLATE 41668-2063B

1. Machine Serial Number

 3.3
MAINTENANCE
Serial Number Location

SERIAL NO.
-

115ZV2 37430-2118 70ZV0004

4. Torque Converter Serial Number 5. Cab Serial Number

Model TC400B01 Model Number

Serial Number Serial Number

Cab (R.H Inside)

T/C

115ZV2 EU COMPO

T/M
Machine (L.H) E/G (L.H)
3.4
MAINTENANCE
Inspection and Maintenance Table

Inspection and Maintenance

Table
Check and/or carry out the maintenance at inter-
vals of the specified operating hours below or the
calender date, whichever comes first.
IMPORTANT
Severe applications require more frequent main-
tenance.
Severe conditions include heavy dust, extremely
abrasive material, caustic chemicals, extremely
wet conditions or abnormally hot or cold ambient
temperatures.

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required
Check Engine Oil Level 2.68
Check Engine Coolant Level 2.70
Drain Water and Sediment from Fuel Pre-
2.71
filter
Check Drive Belt 2.74
Check Air Intake System 2.74
Check Cooling Fan 2.75
Check Warning Lamps 2.81
Check Fuel Level 2.82
Check Exhaust Gas 2.85
Drain Water and Sediment from Fuel Tank 3.23
Replace Fuel Filter Cartridge 3.27
Replace DCA4 Coolant Filter Cartridge 3.40
Clean Crankcase Breather Tube 3.29
Engine Adjust Belt Tension 3.29
Replace Engine Oil and Oil Filter Cartridge 3.37
Check and Adjust Injection Timing 3.47
Check Engine Compression Pressure 3.47
Check Injection Pressure 3.47
Replace Fuel Tank Breather 3.48
Clean Fuel Tank 3.56
Check Vibration Damper 3.56
Clean Crankcase Breather 3.61
Clean or Replace Air Cleaner Element 3.10
Clean Radiator / Air cooler / Hydraulic oil
3.11
cooler / Fuel cooler Fins
Replace Ether Cylinder 3.16
Clean or Replace Air Cleaner Element After six cleanings or once a year 3.10
Replace Coolant Every 2 years or 3000 hours 3.14
 3.5
MAINTENANCE
Inspection and Maintenance Table

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required

Check Transmission Oil Level 2.82

Transmission Replace Transmission Oil Filter 3.36, 3.39
& Torque
Converter Replace Transmission Oil 3.43
Clean or Replace Transmission Breather 3.45
Check Tire for Damage, Air and Tread
2.72
Depth
Check Tire Air Pressure 3.24
Greasing (Axle support) 3.22
Greasing (Pillow block bearing unit) 3.26
Check Differential Gear Oil 3.30
Check Planetary Gear Oil 3.31
Check Tightness of Wheel Bolts 3.33
Axle system
Greasing (Differential seals) 3.42
Greasing (2nd Propeller Shaft Spline) 3.49
Replace Differential Gear Oil 3.52
Replace Planetary Gear Oil 3.53
Greasing (1st Propeller Shaft) Every 12000 hours 3.17
Greasing (2nd Propeller Shaft) Every 12000 hours 3.17
Greasing (3rd Propeller Shaft) Every 12000 hours 3.18
Check Steering Wheel Operation 2.84
Steering
Greasing (Steering Cylinder) 3.22
system
Clean Filter for Orbitrol® 3.36, 3.59

Check Service Brake Operation 2.84

Check Parking Brake Operation 2.84
Check Parking Brake Oil 3.32
Brake system Clean Filter for Brake Line 3.36, 3.58

Replace Parking Brake Oil 3.55

Check Service Brake Disk Wear 3.57
Check Brake Accumulator 3.57
Check Hydraulic Oil Level 2.69
Greasing 3.20
Replace Hydraulic Oil Return Filter 3.36, 3.45
Loading Replace Hydraulic Oil, Clean Filter 3.50
system
Replace Filter in the Hydraulic Tank Cap
3.60
(S/N 0151~0200)
Replace Bucket Teeth (option) 3.7
Replace Cutting Edge (option) 3.9
3.6
MAINTENANCE
Inspection and Maintenance Table

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required

Adjust and Check Rear View Mirrors 2.75

ROPS (Roll Over Protective Structure) 2.75
Greasing (Center Pin) 3.22
Chassis
Check Ride Control Accumulator (option) 3.61
Check and/or Replace Seat Belt 3.9
Check Windshield Washer Fluid 3.13
Check Wiring Harnesses 2.71
Check Horn Operation 2.75
Electrical Check Monitor Panel Operation 2.76
system Check Back-up Alarm Operation 2.84
Check Battery Electrolyte Level 3.23
Check or Replace Fuses 3.13
Check and Adjust Air Conditioner Belt 3.33
Clean Air Conditioner Filter Element 3.34
Air Check Air Conditioner Refrigerant 3.46
Conditioner Replace Air Conditioner Filter Elements 3.57
Clean Air Conditioner Condenser 3.14
Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours 3.16
Others Walk-Around Inspection 2.67
 3.7
MAINTENANCE
When Required Inspection and Maintenance

When Required Inspection and Replace Bucket Teeth (option)

Maintenance
When the bucket teeth are worn, replace them as
follows.
WARNING
1. Park the machine on level ground and apply
Improper inspection or maintenance could result the parking brake.
in death or serious injury.

Read, understand, and follow all warnings and

instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or
maintenance procedures.

Block

97ZVOM0136

2. Raise the bucket to a convenient height and

put blocks under the bucket to prevent it from
coming down.

3. Stop the engine.

3.8
MAINTENANCE
When Required Inspection and Maintenance

NOTE
For non-KCM buckets or teeth, consult the manu-
facturer for the proper procedures.

OM0188

WARNING
Teeth and bucket edges are hardened steel
which may chip when struck by steel hammer
causing injury.

- Always wear eye protection.

- Use dead blow hammer or brass drift between
hammer and tooth.
- Keep bystanders away from work area.

3 1
2

1
3
2 115ZV0013

4. To remove locking pin (3), drive pin through

tooth (2) with drift pin and hammer. Remove
tooth (2) from adapter nose (1).

5. Clean all nose and surfaces with knife or other

cleaning tool. Remove all cemented dirt depos-
its.

6. Replace tooth, and drive pin into slot until flush

with top surface of point. When reversing
tooth, invert pin so recesses on unworn end
mate properly. Use a new pin with a new tooth.
 3.9
MAINTENANCE
When Required Inspection and Maintenance

Replace Cutting Edge (option) Check and/or Replace Seat Belt

1. Park the machine on level ground and apply 1. Inspect the condition of the seat belt and all
the parking brake. mounting hardware frequently.

2. Replace the seat belt or any part of the mount-

ing hardware if it is damaged.

3. Replace the seat belt every three years regard-

less of its condition or appearance.

95ZV0022

2. Raise the bucket to a convenient height and

put blocks under the bucket to prevent it from
coming down.

3. Stop the engine.

4. Remove the cutting edge. Clean all contact

surfaces (bottom of bucket, top of cutting
edge).

5. If other side of the cutting edge is not worn,

turn it around and install it so that the new side
faces the front. If both sides are worn, install a
new cutting edge.

6. Install all bolts and tighten them to 696~834 N-

m.

7. Retighten them after a few hours operation.

3.10
MAINTENANCE
When Required Inspection and Maintenance

Clean or Replace Air Cleaner Element

When the warning monitor lamp lights up, clean or

replace the air cleaner element.

IMPORTANT
Improper procedure of cleaning air cleaner may
cause severe engine damage.

- Do not clean or replace air filters while engine

is running.
OM0138
- Clean only outer element. Never clean inner
element.
- Clean or replace element only when indicator 4. Clean the element using dry compressed air
lamp comes on. (196 kPa) by applying from the inside of the
- Never clean the elements by bumping or hit- element to blow off dirt and/or dust. Apply the
ting them against a solid surface. air along the length of the filter to avoid the
damage to the paper element.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.

1
3

OM0139

97ZVOM0137
5. Place a light inside the filter element. If the light
spots are seen through the element, it must
2. Remove cover (2) by loosening wing nut (1). have cracks or pinholes. Replace it with a new
element.
3. Remove the outer element.
6. Check rubber seal (3), and if you find any dam-
age, replace it with a new element.

7. Before installing the outer element, confirm

that the inner element is seated properly, and
then, reinstall the outer element.

8. Confirm that the o-ring fits properly, and secure

the cover latches.

9. If the engine exhaust gas is not clean enough

even after cleaning (still exhausting excessive
black smoke), replace the element.

10. Be advised that the element cleaning should
be effective up to 6 times. At the 7th mainte-
nance or once a year as well as when you find
any damage, replace both of the outer and
inner elements.
3.11
MAINTENANCE
When Required Inspection and Maintenance
Clean Radiator / Air cooler / Hydraulic
oil cooler / Fuel cooler Fins
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
115ZV2 03174-0145
97ZVOM0140
2. Push the knob and open the radiator grill.
Open covers on the radiator guard both the
right hand side and the left hand side for clean
the air cooler and hydraulic oil cooler.
3.12
MAINTENANCE
When Required Inspection and Maintenance

7. Close the engine access panels and covers.

Be sure side cover doors are closed securely.

If the doors are not closed securely cooling air
will leak out and cooling will be reduced.

115ZV2 7200

3. Remove clean-out trap from bottom of radiator

shroud.

IMPORTANT
Clean-out trap and side cover doors must be
reinstalled and closed securely, or engine perfor-
mance will be affected.

IMPORTANT
High pressure air or water may damage radiator
/ air cooler / hydraulic oil cooler fins.

- When used for cleaning purposes, the pres-

sure of compressed air should be at 196 kPa
or less.
- When using high-pressure water, keep the
nozzle a distance of at least 500 mm away
from the core surface, applying the water jet
perpendicular to the core.
- Move nozzle from side to side; not up and
down.

4. Blow off mud, dirt, or clogging debris from the

radiator / air cooler / hydraulic oil cooler fins
with compressed air. Use a pressure washer to
remove harder debris.

Compressed air or water should be directed

from rear toward the engine.

5. Reverse the direction to flush all debris from

the radiator / air cooler / hydraulic oil cooler
fins.

6. Reinstall clean-out trap.


Check or Replace Fuses
85ZV28505
1. Park the machine on level ground, apply the
parking brake, and lower the attachment to the
ground.
2. Stop the engine and turn the starter switch key
to the "OFF" position.
3. Open the covers of the main fuse box, cab
fuse box.
4. Check the fuses. If any blown fuses are found,
replace them with new ones.
Refer to "Fuse Boxes" page 2.48.
5. Determine the cause of the blown fuses and
repair.
IMPORTANT
Using wrong capacity fuse or bypassing fuse
may cause electrical system damage.
Never replace fuses with higher amperage rat-
ing.
3.13
MAINTENANCE
When Required Inspection and Maintenance
Check Windshield Washer Fluid
115ZV2195
1. Park the machine on level ground, apply the
parking brake, and lower the attachment to the
ground.
2. Check the fluid level.
3. Replace the fluid if it is dirty.
4. If the level is low, add fluid to proper level.
5. Use windshield washer solvent for both better
cleaning and to prevent freezing. Adjust the
mixture according to the manufacturer's
instructions.
3.14
MAINTENANCE
When Required Inspection and Maintenance

Clean Air Conditioner Condenser Replace Coolant

If mud, insects, or other debris are stuck to the air - Since the Anti-Freeze "Long Life Coolant" (LLC)
conditioner condenser, air flow through the con- is originally used for the machine shipped from
denser will be reduced causing decreased cooling the factory, it is not necessary to replace the
ability. coolant for the first two years.

- If the cooling system conditioner (from a local

supplier) is used at the time of last replacement,
follow its instructions or contact your nearest
authorized dealer for the replacement interval.

CAUTION
Pressurized radiator tank is used for this
machine.

Spray of hot coolant may cause burns.

115ZV2229a Stop engine and allow radiator and coolant to

cool completely, then open cap slowly to relieve
pressure.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine. 1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
2. Inspect the condenser and replace it if any ground, and stop the engine.
damage is found.
2. Inspect all coolant hoses.
3. Clean its fins using compressed air, a pressure
washer or a soft brush. Be sure the air pres- Replace any that are cracked, swollen, or brit-
sure is below 196 kPa. If a pressure washer is tle.
used, keep the nozzle about 50 cm away from
the fins to prevent fin damage.

4. If water is used for the cleaning, cover the elec-

trical parts of the engine and the electric con-
denser fan with plastic sheets. Remove the
plastic sheets after cleaning.
1
IMPORTANT 2
An excessively high air or water discharge pres-
sure can damage the condenser fins.

- When used for cleaning purposes, the pres- 115ZV2 7212

sure of compressed air should be at 196 kPa
or less. 3. Lift lever (1) to release any remaining pres-
- When cleaning with water, apply the water jet sure.
perpendicular to the core.
4. Remove cap (2) slowly.
 3.15
MAINTENANCE
When Required Inspection and Maintenance

13. If the water being drained is still dirty, the sys-

tem must be flushed again until the water is
clean (step 7~13).

14. Tighten the drain cock and fill the system with
the premixed coolant.

Refer to "Coolant Specification" page 3.64 for

the mixing instruction.

3 15. Add four parts of DCA65L coolant additive at

115ZV0014a the same time.

16. Replace the DCA4 coolant filter (WF2076).

5. Loosen drain plug (3) and drain coolant about
155 liters into a suitable container.
Refer to "Replace DCA4 Coolant Filter Car-
tridge" page 3.40 for the procedure.
Do not remove the coolant filter.
17. Idle the engine for five minutes to purge air
6. Follow local regulations to properly dispose of
mixed into the coolant. (Leave the radiator cap
or recycle the coolant.
off.)

CAUTION 18. Add coolant as necessary.

Cooling system conditioner contains alkali that
may cause caustic burns or blindness. 19. Reinstall the radiator cap.

Avoid contact with skin and eyes to prevent For additional cold weather servicing information,
injury. refer to "Coolant Specification" page 3.64 for
details.

7. Tighten the drain plug and fill the cooling sys-

tem with clean water.

Do not install the radiator cap.

8. Operate the engine for one hour with the cool-

ant temperature above 80ºC. Then let the
engine cool down naturally with the engine
shut "OFF".

9. Stop the engine and loosen the drain plug to

drain the cooling system.

10. Tighten the drain cock and fill the cooling sys-
tem with clean water.

Do not install the radiator cap or the new cool-

ant filter.

11. Operate the engine for five minutes with the

coolant temperature above 80ºC.

12. Stop the engine and loosen the drain plug to

drain the cooling system.
3.16
MAINTENANCE
When Required Inspection and Maintenance

Replace Ether Cylinder Replace Air Conditioner Receiver Dryer

(Every 3 years or 6000 hours)

WARNING
Ether is very flammable and can could serious - Contact your authorized dealer.
injury or death if exploded.

Do not store new or used ether cylinder in opera-

tors area or at temperatures above 40ºC.

Store new or used ether cylinder in cool place

and out of children's reach.
Never dispose of cylinder by burning, crusing, or
puncturing.

115ZV2 F.FILTER&ETHER CY

1. Remove the cover.

2. Loosen the clamp.

3. Remove (turn counterclockwise) the cylinder.

4. Install (turn clockwise) a new ether cylinder.

5. Tighten the clamp.

 3.17
MAINTENANCE
When Required Inspection and Maintenance

Greasing

(Every 12000 hours)

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page

3.62 for the correct grease. Use lithium base
115ZV2 7225
grease for universal joints.

- 1st Propeller Shaft

(two places)

95ZV28779

115ZV2 7182

- 2nd Propeller Shaft

(three places)
3.18
MAINTENANCE
When Required Inspection and Maintenance

115ZV2 7224

- 3rd Propeller Shaft

(two places)
 3.19
MAINTENANCE
Every 10 Hours or Daily

Every 10 Hours or Daily

WARNING
Improper inspection or maintenance could result
in death or serious injury.

Read, understand, and follow all warnings and

instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or
maintenance procedures.

See "Check before Operation" page 2.67 and

"Check after Starting the Engine" page 2.81.
3.20
MAINTENANCE
Every 50 Hours or 1 Week

Every 50 Hours or 1 Week Greasing

1. Park the machine on level ground, apply the

WARNING parking brake, lower the attachment to the
Improper inspection or maintenance could result ground, and stop the engine.
in death or serious injury.
2. Lubricate fittings on the following components.
Read, understand, and follow all warnings and Wipe and clean all fittings before greasing.
instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or Lubricate until fresh grease is seen at each
maintenance procedures. joint. Immediately replace or report any broken
or defective grease fittings.

Every 50 hours or 1 week, whichever comes first, Refer to "Recommended Lubricants" page
perform the following inspection and maintenance 3.62 for the correct grease.
in addition to the "Daily Inspection and Mainte-
nance".

90ZV0003

- Bucket-Boom
(two places)

90ZV0003

- Bucket-Rod
(two places) (1pc. for log loader)
 3.21
MAINTENANCE
Every 50 Hours or 1 Week

(L.H)

90ZV0004a 115ZV0017a

- Lever-Rod
(R.H)
(two places) (1pc. for log loader)

115ZV0018

- Bucket Cylinder-Front Chassis

(two places) (1pc. for log loader)
115ZV2 02643-0207

- Lever-Boom
(two places) (1pc. for log loader)

115ZV0019a

- Boom Cylinder-Boom
(two places)
115ZV2 02643-0207

- Bucket Cylinder-Lever
(two place) (1pc. for log loader)
3.22
MAINTENANCE
Every 50 Hours or 1 Week

115ZV0020
97ZVOM0151

- Boom Cylinder-Front Chassis - Axle support

(two places) (two places)

115ZV0019a 115ZV0017a

- Boom-Front Chassis
(two places)

115ZV0017a

- Center Pin
(two places)
115ZV0017a

- Steering Cylinder
(four places) L.H and R.H

Drain Water and Sediment from Fuel
Tank
CAUTION
Escaping fuel is flammable and harmful to skin.
- Do not smoke while draining moisture and
sediment from fuel tank.
- Do not drain fuel with engine running.
- Do not allow fuel to remain on skin for
extended period of time. Wash thoroughly with
soap and water.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
97ZVOM0145a
2. Prepare a suitable container.
3. Loosen the drain plug on the bottom of the fuel
tank.
4. Drain water and sediment along with fuel.
5. Retighten up the drain plug.
6. Dispose of the drained fuel and water properly.
7. Add fuel.
NOTE
To reduce water and sediment build up in the tank,
refuel the machine at the end of each shift.
3.23
MAINTENANCE
Every 50 Hours or 1 Week
Check Battery Electrolyte Level
WARNING
Batteries produce explosive gases which could
cause burns or blindness.
- Ventilate area to remove explosive gases.
- Wear eye or face protection when working on
or around batteries.
- Keep flames and sparks away from batteries.
WARNING
If the batteries being used have insufficient bat-
tery electrolyte level, parts in the battery case
could rapidly deteriorate.
It could shorten battery life or the battery case
could explode.
Keep the battery electrolyte level at the proper
level.
WARNING
Batteries contain lead, and acid which may
cause burns.
Avoid contact with skin or clothing and wear
hand, eye, and face protection when working
on or around batteries.
If lead, or acid contacts skin or clothing, immedi-
ately wash with water.
Dispose of used batteries by recycling.
Do not handle batteries with general waste. When
handling the used batteries follow the law and/or
local regulation in your country, state, or province.
3.24
MAINTENANCE
Every 50 Hours or 1 Week

Check Tire Air Pressure

Low Pressure OK High Pressure

115ZV0007

1. Park the machine on level ground, apply the 97ZVOM0103

parking brake, lower the attachment to the

ground, and stop the engine.
2. Clean the battery surface with a clean cloth or
soft brush.
Tire performance and its life depend greatly on the
tire air pressure.
- Low air pressure causes excessive deflection,
heat, and accelerated wear.

- High air pressure cause reduced traction, slip-

page, and possible blow outs.

It is important to keep the tire pressure at the rec-

ommended level.

Special applications, such as long load and carry

operations, may require different pressures. Con-
sult the tire manufacturer.
Low OK High

OM0096
3. Check the battery electrolyte level in each cell.
Electrolyte should cover the cell plates.
4. If the level is low, add distilled water until it
reaches the bottom of the filler neck.
NOTE
If a maintenance free battery is used, step 3 and 4
of this inspection and maintenance is not required.
WARNING
Overheated tire may explode causing serious
injury or death.
If overheated tire is suspected, do not approach
tire to distance of less than 15 m.
Stay away until tire and rim cool down.
1. Before starting work and while the tires are still
cool, measure the tire air pressure with the tire
pressure gauge.
 3.25
MAINTENANCE
Every 50 Hours or 1 Week

Recommended Tire Air Pressure

Radial tire

Air pressure
Size
Front Rear
35/65 R33 471~490 kPa 373~392 kPa

Bias ply tire

Air pressure
OM0032 Size
Front Rear
29.5-29-28PR 520~539 kPa 422~441 kPa

WARNING 35/65-33-24PR 422~441 kPa 324~343 kPa

Explosive separation of tire and rim parts could

result in death or serious injury.

When inflating tires;

- Make sure wheel parts are correctly installed.
- Use self-attaching air chuck with remote shut-
off valve.
- Stand behind tread of tire and keep all per-
sons away from side of tire.
- Do not inflate tire more than recommended
pressure.
- Use safety cage if available.

OM0033

2. Adjust air pressure according to the recom-

mended pressures below.

When inflating a tire, stand behind the tread

and use a self-attaching chuck with a remotely
located valve to turn air pressure on and off.
3.26
MAINTENANCE
Every 250 Hours or 1 Month

Every 250 Hours or 1 Month Greasing

1. Park the machine on level ground, apply the

WARNING parking brake, lower the attachment to the
Improper inspection or maintenance could result ground, and stop the engine.
in death or serious injury.
2. Lubricate fittings on the following components.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance" Refer to "Recommended Lubricants" page
page 1.12 before performing any inspection or 3.62 for the correct grease.
maintenance procedures.

Every 250 hours or 1 month, whichever comes first,

perform the following inspection and maintenance
in addition to the "Daily" and "50 hours" inspections
and maintenance.

115ZV0018

- Pillow block bearing unit

(one place)
 3.27
MAINTENANCE
Every 250 Hours or 1 Month

Replace Fuel Filter Cartridge

CAUTION
Escaping fuel is flammable and harmful to skin.
- Do not smoke while draining moisture and
sediment from fuel filter.
- Do not drain with engine running.
- Do not allow fuel to remain on skin for
extended period of time. Wash thoroughly with
soap and water.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
2. Place a suitable drain pan (about 4 liter) under
the fuel filters.
3. Loosen vent cap (B) to break the air lock in the
filter.
4. Open the drain valve and drain the fuel level
below the collar, then close the drain valve.
5. Using the Collar/Vent Cap Wrench (Fleetguard
part number 3944451 S), remove clear cover
(D) from the fuel processor by removing collar
(A).
Remove the o-ring from the base of the cover.
(A new o-ring is supplied with the new filter.)
Remove filter element (F) by pulling upward
and twisting slightly.
Be sure the sealing grommet is removed from
the center stud.

COLLAR

VENT
CAP
115ZV2 F.Filter Collar, Vent Cap Wrench

6. Install the new filter element (supplied with a

sealing grommet already inserted into the ele-
ment) on the processor center stud by pushing
115ZV2 F.FILTER&ETHER CY
down and twisting slightly.

After checking to make sure the new o-ring

(supplied with the filter) at the base of the
A cover is in place, install cover (D) and collar
B (A).
C
Hand tighten collar (A) until seated. Do not use
D tools to tighten.
E
7. Remove vent cap (B) from the top of the clear
Sealing cover by turning the vent cap counterclock-
grommet
wise.
F
O-ring Fill the clear cover with enough clean fuel to
Drain valve 115ZV2 F.FILTER ELEMENT
cover the bottom half of the filter element.

A: Collar Make sure the new o-ring (supplied with the fil-
B: Vent Cap (Vent Cap and Assembly) ter) is installed on the vent cap.
C: Vent Seal (Vent Cap and Assembly)
D: Cover Reinstall the vent cap and tighten by hand only.
E: Filter Spring
F: Filter Element (Includes Grommet and O-Rings)
3.28
MAINTENANCE
Every 250 Hours or 1 Month

8. Start the engine. When the lubrication system

reaches its normal operating pressure,
increase engine speed for one minute.

After the air is purged, loosen vent cap (B) until

the fuel level lowers to just above the collar.
Tighten the vent cap by hand only.

NOTE
The clear filter cover will not fill completely during
engine operation. It will gradually fill over time and
the fuel level will rise as the filter becomes clogged.
OM0200

9. Hand tighten the collar again while the engine

is running. To avoid damage, do not use tools
to tighten the collar.
Cartridge type fuel filter (2pcs)
10. Remove and properly dispose of the fuel filters.
11. Clean the filter head gasket surface.
12. Apply a light film of clean engine oil to the gas-
ket surface of the new filters.
13. Do not fill the fuel filters with fuel before instal-
lation.
IMPORTANT
Do not manually fill the fuel to prevent dust or dirt
from being mixed into the fuel filters.
A small amount of dirt could cause a serious
problem with the fuel injection system.
15. Tighten the filter an additional one-half to
three-fourths turn after the gasket contacts the
filter head surface. Follow the instructions sup-
plied with the filter.
IMPORTANT
Do not over tighten the filter.
16. Turn the starter switch key to the ON position
and leave it about 2 minutes.
17. Then, turn the starter switch key back to the
OFF position and leave it about 15 seconds.
18. Repeat steps 16 and 17 twice.
The lift pump will automatically run to prime
while the starter switch key is at ON position.
Visually confirm that the fuel comes up into
clear cover (D).

19. Turn the starter switch key to the START posi-

14. Install the filter on the filter head.
tion to run the engine.
Do not leave the key at the START position for
Turn it until the gasket contacts the filter head
20 seconds of longer.
surface.
20. If you failed to start the engine, repeat steps 16
through 19.

21. After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.41.

 3.29
MAINTENANCE
Every 250 Hours or 1 Month

Clean Crankcase Breather Tube Adjust Belt Tension

Clean and check the crankcase breather tube.

CAUTION
Contact with moving belts or pulleys may cause
CAUTION injuries.
Wear protective goggles and mask to keep from
breathing debris. Stop engine before opening engine access
panel.

Inspection

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine. Remove the key
OK and place "Do Not Operate" tag on the instru-
ment panel.

115ZV Breather tube

1. Remove the crankcase breather tube from the

breather vent tube.

OM0215

2. Open the engine access panel.

OK 3. Visually inspect the fan belt for looseness and

damage.

OM0173 4. If the belt is too stretched to permit adjustment

2. Use solvent to clean the inside of the crank-
case breather tube, and dry with compressed
air.
or shows cuts or cracks, replace it and adjust
the tension correctly.
If multiple belts are used as a set, replace all of
them.

3. Use air pressure to blow through the vent tube.

Replace the vent tube if it is clogged.
3.30
MAINTENANCE
Every 250 Hours or 1 Month

Check Differential Gear Oil

CAUTION
The axles are pressurized through the hydraulic
tank.

When removing the oil level check plug a large

volume of hot oil could spray out. It causes seri-
ous burns.

Before removing the oil level check plug, push

OM0201
down on the hydraulic tank cap to release the air
pressure inside the hydraulic tank.
5. Apply pressure approximately 98 N to the cen-
ter of the belt between the pulleys; deflection of Do not touch the parts or oil when it is hot.
about 10 mm is normal.
1. Park the machine on level ground, apply the
Adjustment parking brake, lower the attachment to the
ground, and stop the engine.

3 1 WARNING
If the boom is raised to ease access securely
5 block or brace the boom to prevent accidental
lowering.
4

2
115ZV0026

1. Loosen bolts (1)(2)(3) and lock nut (5)(6).

2. Turn adjusting bolt (4) to adjust the belt tension

correctly.
115ZV0023
3. Tighten the bolts and nuts.

2. Remove the oil level plug from the front axle

housing, using a 12 mm hex (Allen) wrench.

3. If the oil level is lower than the plug, add the

specified oil through the level plug hole.

Refer to "Recommended Lubricants" page

3.62.
 3.31
MAINTENANCE
Every 250 Hours or 1 Month

4. If there is any sign of water in the oil, drain and Check Planetary Gear Oil
replace the oil. Oil containing water looks
milky.
CAUTION
Dispose of the drained oil properly. The axles are pressurized through the hydraulic
tank.
5. Install and tighten the level plug.
When removing the oil level check plug a large
6. Check the rear axle oil level following the same volume of hot oil could spray out. It causes seri-
steps. ous burns.

Before removing the oil level check plug, push

down on the hydraulic tank cap to release the air
pressure inside the hydraulic tank.

Do not touch the parts or oil when it is hot.

1. Check the oil level on all four wheels.

TOP

2 1

115ZV0027

2. Move the machine on level ground so that

"TOP" mark (1) on the planetary gear housing
comes top.

3. Turn "ON" the parking brake switch, lower the

attachment to the ground, and stop the engine.

4. Remove oil level plug (2) on the housing, using

a 12 mm hex (Allen) wrench.

5. If the oil level is lower than the plug, add the

specified oil through the level plug hole.

Refer to "Recommended Lubricants" page

3.62.

6. Magnetic plugs are used for the planetary gear

housing. Wipe off the small amount of fine
metallic powder that normally sticks to the
plugs. If abnormal debris is found, determine
the cause and correct it.
3.32
MAINTENANCE
Every 250 Hours or 1 Month

Check Parking Brake Oil

7. If there is any sign of water in the oil, drain and
replace the oil. Oil containing water looks
milky. CAUTION
Do not touch the parts or oil when it is hot.
Dispose of the drained oil properly.

8. Install and tighten the level plug. 1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.

2
1

95ZV28773

2. Remove plug (1) and (2) for oil level check,

using a 12 mm hex (Allen) wrench.

3. Fill the oil from plug (2) until oil comes out from
plug (1).

Refer to "Recommended Lubricants" page

3.62.

4. Install and tighten plug (1) and (2).

 3.33
MAINTENANCE
Every 250 Hours or 1 Month

Check Tightness of Wheel Bolts Check and Adjust Air Conditioner Belt

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
CAUTION
ground, and stop the engine. Contact with moving belts or pulleys may cause
injuries.

Stop engine before opening engine access

panel.
TOP

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine. Remove the key
and page "Do Not Start" tag on the instrument
panel.

2. Open the engine access panel.

115ZV0027

2. Check the wheel bolts are tightened to 892 N-

m.

3. Retighten if necessary.

OM0201

3. Visually inspect the compressor belt on both

top and bottom sides for looseness and dam-
age.

4. If the belt is too stretched to permit adjustment

or shows cuts or cracks, replace it and adjust
the tension correctly.

5. Measure the belt tension using a belt tension

gauge so that it is applied 353±88 N (initial ten-
sion: 559±108 N).
3.34
MAINTENANCE
Every 250 Hours or 1 Month

Clean Air Conditioner Filter Element

Outer filter cleaning

1 1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground.

2. Turn the air conditioner "OFF" and stop the

engine.
2
115ZV0028

6. If the belt is too loose or tight, adjust the ten-

sion by loosening lock nuts (1) and turning
adjusting nut (2) on the compressor bracket.

97ZVOM0152

3. The cover for the outer filter is located at the

left rear side of the cab.

Turn the rings counterclockwise and then

remove the cover.

97ZVOM0153

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. Use air

pressure below 196 kPa.

6. To remove more stubborn debris, wash the fil-

ter with clean water. Leave them for five to
seven days for dry in the shade.
 3.35
MAINTENANCE
Every 250 Hours or 1 Month

7. After approximately 20 cleanings, replace the 2. Remove dust with compressed air. Use air
filter with new one. pressure below 196 kPa.

Refer to "Replace Air Conditioner Filter Ele-
ments" page 3.57.
8. When installing the outer filter into the cab, be
sure to align the air flow arrow on the outer fil-
ter to point toward the cab.
3. To remove more stubborn debris, wash the fil-
ter with clean water. Leave them for five to
seven days for dry.
4. After approximately 20 cleanings, replace the
filters with new ones.

Refer to "Replace Air Conditioner Filter Ele-

ments" page 3.57.

5. Install the filter, install filter cover (3) and cover

(1).

NOTE
It is recommended to have a second set of filters to
use while another set is being dried.

97ZVOM0152

9. Install the cover to the cab and turn the rings

clockwise to fix the cover.

Inner filter cleaning

1
97ZVOM2473

1. The inner filter is located at behind the opera-

tor's seat.

Open unit cover (1) using screw driver.

Loosen screw (2) by fingers to remove cover

(3).

Remove the filter and clean it.

3.36
MAINTENANCE
Every 250 Hours or 1 Month

Replace Filter

(First time replacement or cleaning only)

- Transmission Oil Filter Cartridge

Replace it first time only at 250 hours operation,

after that replace it at every 500 hours opera-
tion.

Refer to "Every 500 Hours or 3 Months" page

3.39.

After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.41.

- Hydraulic Oil Return Filter

Replace it first time only at 250 hours operation,

after that replace it at every 1000 hours opera-
tion.

Refer to "Every 1000 Hours or 6 Months" page

3.45.

After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.41.

- Brake Line Filter

Clean it first time only at 250 hours operation,

after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page

3.58.

- Orbitrol® Filter

Clean it first time only at 250 hours operation,

after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page

3.59.

Every 500 Hours or 3 Months
WARNING
Improper inspection or maintenance could result
in death or serious injury.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or
maintenance procedures.
Every 500 hours or 3 months, whichever comes
first, perform the following inspection and mainte-
nance in addition to the "Daily", "50 hours", and
"250 hours" inspection and maintenance.
3.37
MAINTENANCE
Every 500 Hours or 3 Months
Replace Engine Oil and Oil Filter Car-
tridge
CAUTION
Hot oil and engine components may cause
burns.
Avoid contact with hot oil or engine components.
1. If the machine is cold operate the engine to
bring the engine coolant temperature about
40ºC. When the needle of the coolant tempera-
ture gauge reaches the middle of the white
zone, the temperature is about 40ºC.
2. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
115ZV0022
3. Loosen the drain plug.
4. Drain oil, about 66 liters, into a suitable con-
tainer.
3.38
MAINTENANCE
Every 500 Hours or 3 Months
115ZV2 7203
5. Remove the oil filter and properly dispose of it.
Make sure the O-ring is removed with the filter.
6. Clean the oil filter head gasket surface.
7. Fill the new filter with clean engine oil.
Refer to "Recommended Lubricants" page
3.62 for the oil specifications.
8. Apply a light film of engine oil to the gasket sur-
face of the new filter cartridge.
OM0200
9. Install and tighten the filter until the gasket con-
tacts filter head surface. Then tighten it by
hand an additional three-fourths to one turn.
Refer to the instructions supplied with the filter.
10. Close the oil drain plug, and tighten to 80 N-m
torque.
Oil fill
Dip stick
115ZV2196
11. Fill the engine with clean oil to the proper level.
Refer to "Recommended Lubricants" page
3.62 for the oil specifications. Total system
capacity including the filter is 66 liters.
12. Idle the engine to inspect for leaks at the filter
and the drain plug.
13. Stop the engine. Wait approximately 15~20
minutes to let the oil drain back to the oil pan.
14. Check the oil level again.
15. Add the specified oil if necessary to bring the
oil level to the "H" (High) mark on the dipstick.
16. Properly dispose of or recycle the waste oil
and filter.
17. After replacing the filter and/or oil, reset the
interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.
Refer to "Replacement Monitor" page 2.41.
CAUTION
Used engine oil may cause skin disease or irrita-
tion.
Do not allow used engine oil to remain on skin
for prolonged periods of time.
Clean skin thoroughly with soap and water.

Replace Transmission Oil Filter
CAUTION
Hot oil and components may cause burns.
Avoid contact with hot oil or components.
1. If the machine is cold, operate the machine to
bring the torque converter oil temperature
about 30~40ºC.
2. Park the machine on level ground, turn "ON"
the parking brake switch, lower the attachment
to the ground, and stop the engine.
3. Place a suitable container (about 4 liters)
under the transmission oil filter.
115ZV2 7185
4. Remove the drain plugs from the bottom of the
filter cases with 24 mm wrench.
5. Remove the filter cases with 46 mm wrench.
6. Replace the elements with new ones.
7. Replace the seals with new ones.
8. Clean the cases with solvent.
9. Clean the filter head gasket surface.
10. Apply a light film of clean engine oil to the
seals surface of the new filters.
11. Reinstall the filters on the filter head.
Tightening torque: 98±9.8 N-m
3.39
MAINTENANCE
Every 500 Hours or 3 Months
12. Clean and install the oil drain plugs.
Tightening torque: 58.8±4.9 N-m
13. Idle the engine about ten minutes and inspect
for leaks around the filter.
DANGER
Accidental movement of machine could result in
death or serious injury.
When inspecting or servicing machine in articu-
lation area:
- Lower attachment to ground.
- Put transmission shift lever in neutral.
- Apply parking brake.
- Make sure nobody is on machine.
- Place "DO NOT OPERATE" tag on steering
wheel.
115ZV0011a
14. Check transmission oil level.
Refer to "Check Transmission Oil Level" page
2.82.
Add the specified oil as necessary so the oil
level is within the "HOT" window of the sight
gauge.
Refer to "Recommended Lubricants" page
3.62 for the specified oil.
15. After replacing the filter and/or oil, reset the
interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.
Refer to "Replacement Monitor" page 2.41.
3.40
MAINTENANCE
Every 500 Hours or 3 Months

Replace DCA4 Coolant Filter Cartridge

CAUTION
Used oil may cause skin disease.
Do not allow used oil to remain on skin for pro-
longed periods of time.
Clean skin thoroughly with soap and water.
CAUTION
Pressurized radiator tank is used for this
machine.
Spray of hot coolant may cause burns.
Stop engine and allow radiator and coolant to
cool completely, then open cap slowly to relieve
pressure.

CAUTION
Hot coolant and engine components can cause
burns.

Avoid contact with coolant or engine compo-

nents.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

115ZV2 7212

2. Lift the lever on the radiator tank cap to release

any remaining pressure, and remove the cap
slowly.
 3.41
MAINTENANCE
Every 500 Hours or 3 Months

12. If needed, add required amount of the coolant.

Refer to "Coolant Specification" page 3.64 for

the correct mixture.

13. After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
2 corresponding replacement interval.

Refer to "Replacement Monitor" page 2.41.

1 115ZV2196

3. Turn coolant shut-off valves (2).

4. Remove and properly dispose of coolant filter

(1).

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gas-

ket surface of a new DCA4 coolant filter car-
tridge (WF2076).

OM0200

7. Install the filter firmly by hand. Follow the

instructions supplied with the filter.

8. Open the coolant shut-off valves and install the

radiator cap.

9. Run the engine and check for coolant leaks.

10. Idle the engine for about five minutes to purge

all the air from the coolant.

11. After air has been purged from the system,

stop the engine and check the coolant level
again.
3.42
MAINTENANCE
Every 1000 Hours or 6 Months
Every 1000 Hours or 6 Months
WARNING
Improper inspection or maintenance could result
in death or serious injury.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or
maintenance procedures.
Every 1000 hours or 6 months, whichever comes
first, perform the following inspection and mainte-
nance in addition to the "Daily", "50 hours", "250
hours", and "500 hours" inspection and mainte-
nance.
Greasing
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
2. Lubricate fittings on the following components.
Before lubricating the seal with grease, remove
breather nipple (A).
Lubricate until the grease comes out from the
breather installation hole.
After that, wipe it and install the breather nipple
back again.
Refer to "Recommended Lubricants" page
3.62 for the correct grease.
95ZV28779
115ZV2 7224
- Differential seals
(two places)
 3.43
MAINTENANCE
Every 1000 Hours or 6 Months

Replace Transmission Oil

IMPORTANT
Before lubricating the seal with grease, make WARNING
sure to remove the breather nipple. Accidental movement of machine could result in
If fail to do this, it may cause the oil seal damage. death or serious injury.

When inspecting or servicing machine in articu-

lation area:
- Lower attachment to ground.
- Put transmission shift lever in neutral.
- Apply parking brake.
- Make sure nobody is on machine.
- Place "DO NOT START" or "DO NOT OPER-
ATE" tag on steering wheel.

CAUTION
Transmission oil may be hot and may cause
burns.

Avoid contact with transmission oil.

1. If the machine is cold operate the machine for

a few minutes to bring the transmission oil tem-
perature about 30~40ºC.

2. Park the machine on level ground, turn "ON"

the parking brake switch, lower the attachment
to the ground, and stop the engine.

2
1

115ZV2244

3. Remove drain plug (1) with a 41 mm wrench.

4. Drain oil into a suitable container (about 70

liters).

Properly dispose of or recycle the waste oil.

5. Loosen four bolts (2) with a 14 mm wrench.

3.44
MAINTENANCE
Every 1000 Hours or 6 Months

6. Remove flange (3) together with the pipe and

suction strainer.

Set screw

Flange
115ZV0011a
Gasket

Strainer
97ZVOM0164
7. Remove the set screw using a 2.5 mm hex
(allen) wrench from the strainer.
8. Remove the suction strainer from the flange,
brush off any debris and clean with solvent.
Reassemble the strainer and flange assembly.
It is normal for a few fine particles to be on the
strainer. Large pieces or a large quantity of
particles indicates a problem.
13. Check the oil level with the sight gauge. Add
the specified oil if necessary to maintain the
proper oil level.
Refer to "Check Transmission Oil Level" page
2.82 and "Recommended Lubricants" page
3.62.
14. After replacing the filter and/or oil, reset the
interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.
Refer to "Replacement Monitor" page 2.41.

Contact a authorized dealer if you find exces-

sive debris.

9. Reinstall the drain plug and the strainer with a

new gasket.

10. Tighten four bolts (2) to 53.0 N-m.

11. Fill with the specified oil.

Refer to "Recommended Lubricants" page

3.62.

12. Idle the engine and check for leaks.

 3.45
MAINTENANCE
Every 1000 Hours or 6 Months

Clean or Replace Transmission Replace Hydraulic Oil Return Filter

Breather
CAUTION
Pressurized hydraulic tank is used for this
machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler

cap or the breather valve.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.
115ZV2 02641-0351

2. Open the access cover on the left deck.

1. Park the machine on level ground, apply the
parking brake, lower the attachment to the (S/N 0151~0200)
ground, and stop the engine.
1
2. Remove the breather from the transmission
case. 2
3. Clean the breather in the cleaning oil tub, then
spray dry compressed air from the bottom of
the breather.

Even after cleaning, if the breather is not clean Filler cap

enough, replace the breather.
115ZV2195

4. Install the breather onto the transmission case.

(S/N 0201~)

Breather
valve
115ZV2195a

3. Press down the filler cap or the breather valve

to relieve the tank pressure.

4. Clean around top of the filter cover (1).

3.46
MAINTENANCE
Every 1000 Hours or 6 Months

5. Remove two bolts (2) with a 17 mm wrench Check Air Conditioner Refrigerant
and open filter cover (1).

Two bolts (2) may be used as "Jacking screws"

to push up the cover. Install them into the two
threaded holes in the cover. Screw them in
equally to force the cover up evenly.

1
2

3
4 115ZV2229a

5
1. Apply the parking brake and lower the attach-
6 ment to the ground.

97ZVOM0166 2. Remove the cover.

3. Press the flow control switch to set maximum

6. Remove O-ring (3), spring (4), and bypass air flow.
valve (5) from the filter housing.
4. Set the temperature control switch fully to the
7. Remove and properly dispose of filter (6) and cool position and fully open the cab doors.
waste oil.
5. Slightly accelerate the engine to about the mid-
8. Clean the inside of the filter housing. dle speed range.
(compressor speed 1,500~1,800 min-1)
9. Replace O-ring (3).
6. Compare the flow of bubbles in the sight glass
10. Apply a light film of clean hydraulic oil on the with the drawings in the following table.
filter cover O-ring surface.

11. Install filter element (6), bypass valve (5), WARNING

spring (4), new O-ring (3) and filter cover (1). Overfilled refrigerant may cause dangerous high
pressure and poor cooling action; and low refrig-
12. Close the access cover. erant level may cause compressor damage.

13. After replacing the filter and/or oil, reset the Always maintain refrigerant in normal level.
interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.41.

 3.47
MAINTENANCE
Every 1000 Hours or 6 Months

Check Engine Compression Pressure

Adjust of Appearance of the
Solutions
refrigerant sight glass - Contact your authorized dealer or local Cum-
Normal Almost clear. mins engine dealer.
Any bubbles dis-
appear if the
engine speed is
increased to
1,500 min-1.
Check Injection Pressure
High
- Contact your authorized dealer or local Cum-
No bubble is mins engine dealer.
seen. Contact your local
authorized dealer
for inspection and
Low recharging refrig-
Check and Adjust Injection Timing
A flow of bubbles erant.
is visible.
- Contact your authorized dealer or local Cum-
mins engine dealer.
3.48
MAINTENANCE
Every 1000 Hours or 6 Months

Replace Fuel Tank Breather

115ZV0012a

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

2. Remove the breather from the fuel tank, and

replace it with new one.

Every 2000 Hours or 1 Year
WARNING
Improper inspection or maintenance could result
in death or serious injury.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or
maintenance procedures.
Every 2000 hours or 1 year, whichever comes first,
perform the following inspection and maintenance
in addition to the "Daily", "50 hours", "250 hours",
"500 hours", and "1000 hours" inspections and
maintenance.
3.49
MAINTENANCE
Every 2000 Hours or 1 Year
Greasing
1. Park the machine on level ground.
Lower the attachment to the lowest position
and tilt back the bucket fully.
2. Steer the machine fully to the right or left, and
stop the engine.
3. Lubricate the fitting on the sleeve yoke.
4. To lubricate the spline enough, start the engine
and slowly turn the machine from side to side 2
or 3 times after greasing.
Refer to "Recommended Lubricants" page
3.62 for the correct grease. Use lithium base
grease for a propeller shaft spline.
115ZV2 7182
- 2nd Propeller Shaft Spline
(one place)
IMPORTANT
When greased with the machine in straight,
remove the fitting on the sleeve yoke and follow
the procedure above step 4.
3.50
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Hydraulic Oil, Clean Filter Remove breather valve (S/N 0201~)

WARNING
Pressurized hydraulic tank is used for this
machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler

cap or the breather valve.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the 115ZV2195a
ground, and stop the engine.

2. Move the bucket and boom control levers back 6. Push down the top of the breather valve to
and forth to relieve the pressure. relieve the tank pressure.

Remove oil inlet cap (S/N 0151~0200)

2 1

T4A breather valve2

115ZV2195 7. Remove four bolts (1) to remove breather

valve (2) and O-ring (3).
3. Insert the key into the side of the filler cap and
turn the key counterclockwise. CAUTION
4. Press down the filler cap to relieve the tank Hydraulic oil may be hot and may cause burns.
pressure.
Avoid contact with hydraulic oil.
5. Remove the inlet cap.

CAUTION
Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil.


Replace hydraulic oil
8. Prepare a suitable container to catch the drain-
ing oil (about 225 liters).
5
4 115ZV0008
9. Remove drain plug (4) using a 24 mm wrench
to drain oil.
10. Dispose of the waste oil properly.
11. Remove the nuts with a 14 mm wrench to
remove inspection cover (5).
CAUTION
Compressed air may cause injury.
- Wear protective clothing and eye protection.
- Air pressure must be below 196 kPa.
3.51
MAINTENANCE
Every 2000 Hours or 1 Year
A
6
7 97ZV2 02522-0478
12. Remove lock bolt (6) and suction strainer (7).
Inspect and clean them with solvent and com-
pressed air.
A few small particles in the strainer is normal.
Large metal, rubber pieces, or a large amount
of fine particles is abnormal. If found, contact
your authorized dealer.
13. Clean inside of the tank and magnet plug.
14. Apply lubrication oil to the threaded area (A)
and install suction strainer (7). Tighten it with
190 N-m torque, and fix with lock bolt (6).
15. Install the new gasket and inspection cover (5),
and tighten the nuts. Do not overtighten.
16. Install and tighten the drain plug.
17. Add the specified hydraulic oil through the oil
inlet hole.
Refer to "Recommended Lubricants" page
3.62.
18. Install the oil inlet cap or breather valve (2) and
new O-ring (3).
19. Start the engine and allow the engine to idle for
about five minutes.
20. Operate the bucket, boom, and steering cylin-
ders for about five minutes, then lower the
attachment to the ground.
21. Inspect for leaks.
22. Make sure hydraulic oil is to the center of the
oil level gauge. Add hydraulic oil if necessary.
3.52
MAINTENANCE
Every 2000 Hours or 1 Year

23. After replacing the filter and/or oil, reset the Replace Differential Gear Oil
interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval. CAUTION
The axles are pressurized through the hydraulic
Refer to "Replacement Monitor" page 2.41. tank.

When removing the oil level check plug a large

volume of hot oil could spray out. It causes seri-
ous burns.

Before removing the oil level check plug, push

down on the hydraulic tank cap to release the air
pressure inside the hydraulic tank.

Do not touch the parts or oil when it is hot.

1. If the machine is cold operate the machine for

a few minutes to bring the differential gear oil
temperature about 40ºC.

2. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

WARNING
If the boom is raised to ease access securely
block or brace the boom to prevent accidental
lowering.

2 115ZV0023

3. Remove level plug (1) and drain plug (2) from

the front axle housing, with a 12 mm Hex
(Allen) wrench.

Some fine metallic powder will normally stick to

the magnet plugs.

Simply wipe it off.


4. Drain the oil (about 115 liters) into a suitable
container.
5. Dispose of the waste oil properly.
CAUTION
Used oil may cause skin disease.
Do not allow used oil to remain on skin for pro-
longed periods of time.
Clean skin thoroughly with soap and water.
6. Install the drain plug.
7. Refill the recommended oil through level plug
hole (1) until the oil comes out from the hole.
Refer to "Recommended Lubricants" page
3.62.
8. Install and tighten the level plug.
9. Replace the rear differential oil following the
same steps.
Required oil volume for the rear differential is
about 115 liters.
10. After replacing the filter and/or oil, reset the
interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.
Refer to "Replacement Monitor" page 2.41.
3.53
MAINTENANCE
Every 2000 Hours or 1 Year
Replace Planetary Gear Oil
CAUTION
The axles are pressurized through the hydraulic
tank.
When removing the oil level check plug a large
volume of hot oil could spray out. It causes seri-
ous burns.
Before removing the oil level check plug, push
down on the hydraulic tank cap to release the air
pressure inside the hydraulic tank.
Do not touch the parts or oil when it is hot.
1. Replace the planetary gear oil on all four
wheels.
1
TOP
2
115ZV0027
2. Move the machine on level ground so that
"TOP" mark (1) on the planetary gear housing
comes to the top.
3. Turn "ON" the parking brake switch, lower the
attachment to the ground, and stop the engine.
WARNING
If the boom is raised to ease access securely
block or brace the boom to prevent accidental
lowering.
3.54
MAINTENANCE
Every 2000 Hours or 1 Year

11. After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.41.

3 115ZV0023

4. Remove level plug (2) and drain plug (3) from

the planetary gear housing, using a 12 mm hex
(Allen) wrench.

Some fine metallic powder will normally stick to

magnet plug (2).

Simply wipe it off.

5. Drain the oil (about 32.5 liters) into a suitable

container.

6. Dispose of the waste oil properly.

CAUTION
Used oil may cause skin disease.

Do not allow used oil to remain on skin for pro-

longed periods of time.

Clean skin thoroughly with soap and water.

7. Install and tighten the drain plug.

8. Refill the recommended oil through level plug

hole (2) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page

3.62.

9. Install and tighten the level plug.

10. Repeat these steps for all four planetaries.

 3.55
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Parking Brake Oil 6. Refill the recommended oil through oil filling
port (2) until the oil comes out from oil level
check port (1).
CAUTION
Do not touch the parts or oil when it is hot. Refer to "Recommended Lubricants" page
3.62.

1. Park the machine on level ground, apply the 7. Install and tighten port plugs (1) and (2).
parking brake, lower the attachment to the
ground, and stop the engine.

3 95ZV28773

2. Remove the port plugs for oil level check (1),

oil filling (2) and drain (3), using a 12 mm Hex
(Allen) wrench.

Some fine metallic powder will normally stick to

the magnet plugs.

Simply wipe it off.

3. Drain the oil (about 3 liters) into a suitable con-

tainer.

4. Dispose of the waste oil properly.

CAUTION
Used oil may cause skin disease.

Do not allow used oil to remain on skin for pro-

longed periods of time.

Clean skin thoroughly with soap and water.

5. Install drain plug (3).

3.56
MAINTENANCE
Every 2000 Hours or 1 Year

Clean Fuel Tank Check Vibration Damper

1. Park the machine on level ground, apply the

CAUTION parking brake, lower the attachment to the
Escaping fuel is flammable and harmful to skin. ground, and stop the engine.

- Do not smoke while draining moisture and

sediment from tank.
- Do not drain with engine running.
- Do not allow fuel to remain on skin for an
extended period of time. Wash thoroughly with
soap and water.

NOTE
It is easiest to clean the fuel tank when the fuel is
almost empty.

1. Park the machine on level ground, apply the

115ZV2201
parking brake, lower the attachment to the
ground, and stop the engine.

OK OK
2

80ZVUSA0004
1 97ZVOM0145a

2. Check the damper on the fan end of the engine

2. Remove drain plug (1) using a 24 mm wrench crankshaft.
to drain oil.
3. If dents, cracks, mounting bolt looseness, or
3. Drain the remaining fuel into a suitable con- any deformations are found, contact your near-
tainer. est authorized dealer or Cummins Engine
dealer for replacement.
4. Remove the nuts with a 14 mm wrench to
remove inspection cover (2).

5. Clean inside of the tank.

6. Install the inspection cover with a new gasket.

Tighten the nuts evenly. Do not overtighten.

7. Install and tighten the drain plug.

8. Fill the fuel tank.

9. Check for any leaks at the cover and plug.

 3.57
MAINTENANCE
Every 2000 Hours or 1 Year

Check Brake Accumulator Replace Air Conditioner Filter Elements

Test the brake accumulator for proper pre-charge of

Outer filter replacement
nitrogen gas.
1. Park the machine on level ground, apply the
WARNING parking brake and lower the attachment to the
ground.
Pressurized nitrogen gas in brake accumulator
could explode causing serious injury or death.
2. Turn the air conditioner "OFF" and stop the
engine.
Never service brake accumulator unless trained
properly.

1. Park the machine on level ground, apply the

parking brake, and lower the attachment to the
ground.

2. Run the engine at high idle for 1 minute to fill

the brake accumulator with oil.

3. Stop the engine.

4. Turn the key switch to the "ON" position.

97ZVOM0152
5. Count the number of times you can step on the
right hand brake pedal before the brake warn-
3. The cover for the outer filter is located at the
ing light comes on.
left rear side of the cab.
6. If the number counted is less than eleven,
Turn the rings counterclockwise and then
there is some problem with the accumulator.
remove the cover.
Contact your nearest authorized dealer.

Check Service Brake Disk Wear

- Contact your authorized dealer.

97ZVOM0153

4. Remove the outer filter from the cab, and

replace it with new one.

When installing the outer filter into the cab, be

sure to align the air flow arrow on the outer fil-
ter to point toward the cab.
3.58
MAINTENANCE
Every 2000 Hours or 1 Year

Clean Filter for Brake Line

CAUTION
Hot oil and components may cause burns.

Vent all pressure by pressing hydraulic cap

down.

Avoid contact with hot oil or components.

97ZVOM0152 1. Park the machine on level ground, turn "ON"

the parking brake switch, lower the attachment
to the ground, and stop the engine.
5. Install the cover to the cab and turn the rings
clockwise to fix the cover.

L.H
Inner filter replacement
Front

2
Center Pin C/L

3
115ZV2 03274-0006

1
97ZVOM2473

Air blow
The inner filter is located at behind the operator's FLOW
seat.

Open unit cover (1) using screw driver.

Filter case Filter Nipple

Loosen screw (2) by fingers to remove cover (3).

OM0212
Remove the filter and replace it with new one.

2. Place a suitable container under the filter.

3. Remove the nipple with filter and properly

clean the filter.

4. Install the nipple with filter and tighten it with

60~80 N-m torque.

5. Idle the engine about ten minutes and inspect

for leaks around the filter.
 3.59
MAINTENANCE
Every 2000 Hours or 1 Year

Clean Filter for Orbitrol® 6. Install the nipple with filter and tighten it with
60~80 N-m torque.

CAUTION 7. Idle the engine about ten minutes and inspect

Hot oil and components may cause burns. for leaks around the filter.

Vent all pressure by pressing hydraulic cap

down.

Avoid contact with hot oil or components.

1. Park the machine on level ground, turn "ON"

the parking brake switch, lower the attachment
to the ground, and stop the engine.

2. Move the bucket and boom control levers back

and forth to relieve the pressure.

3. Move the steering each way about 2~3 times

to relieve the pressure.

L.H
Center Pin C/L

Front

115ZV2 03272-0004

Air blow
FLOW

Filter case Filter Nipple

OM0212

4. Place a suitable container under the filter.

5. Remove the nipple with filter and properly

clean the filter.
3.60
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Filter in the Hydraulic Tank Replace Filter in the Hydraulic Tank
Cap (S/N 0151~0200) Breather Valve (S/N 0201~)

CAUTION CAUTION
Pressurized hydraulic tank is used for this Pressurized hydraulic tank is used for this
machine. machine.

Pressurized hot oil may cause injury or burns. Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before open- Vent all pressure by pressing breather valve
ing. before opening.

1 1
2
5
3
4

3 4
2
97ZVOM0170
T4A breather valve

1. Park the machine on level ground, apply the 1. Park the machine on level ground, apply the
parking brake, lower the attachment to the parking brake, lower the attachment to the
ground, and stop the engine. ground, and stop the engine.

2. Move the bucket and boom control levers back 2. Move the bucket and boom control levers back
and forth to relieve the pressure. and forth to relieve the pressure.

3. Insert the key into the side of filter cap (1) and 3. Press down cap (1) to relieve the tank pres-
turn the key counterclockwise. sure.

4. Press down filter cap (1) to relieve the tank 4. Remove cap (1), nut (2), cover (3), and filter
pressure. element (4).

5. Remove the filter cap. 5. Replace element (4).

6. Remove spiral snap ring (2), valve assy (3), 6. Install the element, cover, nut, and cap.
spring (4), filter element (5).
Tightening torque: Nut (2) 8~10 N-m
7. Replace element (5).

8. Install the element, spring, valve assy, and spi-

ral snap ring.
 3.61
MAINTENANCE
Every 2000 Hours or 1 Year

Check Ride Control Accumulator Clean Crankcase Breather

(option)

WARNING
Pressurized nitrogen gas in ride control accumu-
lator could explode causing serious injury or
death.

Never service ride control accumulator unless

trained properly.

Contact your nearest authorized dealer.

115ZV2225

There are three breather elements on the top of the

cylinder head cover. Clean all three.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

1
2
3
4
5

QSK19 Crankcase breather

2. Loosen wing nut (1) and remove cover (2) and

element (3)(4)(5).

3. Clean element (3)(4)(5).

4. Inspect element (3)(4)(5). Replace it if neces-

sary.

5. Install a cleaned or new breather element.

Tighten wing nut (1).
3.62
MAINTENANCE
Recommended Lubricants

Recommended Lubricants

Refill capacity Ambient Temperature (ºC) Change Interval

Kind of Oil -30 -20 -10 0 10 20 30 40
(Approximate) (Hours)

Engine oil SAE10W-30 2

Engine 66 liter SAE15W-40
(CH4 or CI4) 500

Engine oil (CD) or SAE10W

Transmission 90 liter 1,000
ATF ATF

1 3 ISO VG32
Hydraulic tank ISO VG46
2,000
225 liter Hydraulic oil
Differential & Front: 180 liter
Planetary Rear: 180 liter Engine oil SAE40 or SAE50
Engine oil (CD) 2,000
Parking brake 3 liter
ASTM D975 No.1
Fuel tank 660 liter Diesel fuel ASTM D975 No.2 daily

Note: 1 shows "Hydraulic tank oil capacity at level gauge center."

Engine Use oil that meets engine oil classification API CH4, CI4 or CG4.
2. Change engine oil every 250 hours if CG4 is used.
Engine oil drain intervals need to be reduced by 50 % when fuel sulfur content
exceeds 0.5 %.

Transmission Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid).
Never mix engine oil and A.T.F.

Hydraulic System Use industrial-type hydraulic oils which are certified by suppliers having anti-wear,
anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use.
Use of the wrong viscosity of oil can cause improper operation of hydraulic
functions or premature pump failure.
3. In a case that fire-resistant fluid is to be used in the hydraulic circuit, some
hydraulic equipment must be replaced. Contact your authorized dealer for ser-
vice.
Be sure to use ISO VG32 when the temperature is below -15ºC. When replac-
ing the hydraulic oil ISO VG46 with ISO VG32, the brakes must be bled to fully
circulate the new oil, or brake problems could occur. Contact your authorized
dealer for service.

Differential & Use class API CD engine oil with 5 % "Antichatter" additive or friction modifier.
Planetary

Lubricating Use multipurpose-type EP/MOLY grease for most applications.

Grease NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for universal joints and a propeller shaft spline.
 3.63
MAINTENANCE
Recommended Lubricants

Diesel Fuel Requirements for diesel fuel

Specifications
Grade No.1-D Grade No.2-D
Flash Point ºC. min. 38 52
Water and Sediment % vol. max 0.05 0.05
Distillation Temperature ºC 90 % vol. recovered max. 288 338
Kinematic Viscosity mm2 /s at 40ºC min. 1.3 1.9
max. 2.4 4.1
Ash % mass max. 0.01 0.01
Sulfur % mass max. 0.50 0.50
Cetane Number min. 40 40
Carbon residue on 10 % distillation residue % mass max. 0.15 0.35
3.64
MAINTENANCE
Coolant Specification

Coolant Specification
The machine is originally filled with Long Life Cool-
ant (non-Amin type ethylene glycol) which need not
be replaced for the first two years or 3000 hours.

Do not use Amin type Long Life Coolant in cooling

system. It may cause a corrosion against radiator
or heater core.

If standard antifreeze (not Long Life Coolant) is

used for the replacement, it should be replaced
every six months.

Recommended Mixture of Antifreeze

Expected Minimum
-35ºC -30ºC -25ºC -20ºC -15ºC
Ambient Temperature
Pure Water (liter) 72.8 80.6 88.3 96.1 103.8
Antifreeze (liter) 82.2 74.4 66.7 58.9 51.2
Mixture Ratio (%) 53 48 43 38 33

- Too much antifreeze in the coolant mixture may

cause engine overheating.

Keep 33 % antifreeze mixture (same as the mix-

ture for a minimum ambient temperature of -15
ºC) if the engine overheats in a high ambient
temperature.

- Do not use hard water or water with high levels

of calcium and magnesium ions as the coolant
water.

IMPORTANT
Do not mix different brands of antifreeze
because they each contain special additives.
Careless mixing often diminishes the effect of
these additives and causes packing damage or
water leakage.
 3.65
TROUBLESHOOTING

TROUBLESHOOTING
This troubleshooting section is not intended to
cover every condition, however many of the com-
mon possibilities are listed.
Following are example of problems and their solu-
tions.
Contact your local authorized dealer for the items
marked with KCM
or your local authorized CUM-
MINS ENGINE dealer for the items marked with
to repair.
CUMMINS

ENGINE

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Low engine oil level Add oil 2.68
Wrong grade oil for weather conditions Change oil 3.37
Engine oil pres- Clogging oil filter element Change filter and oil 3.37
sure warning lamp Defective alarm switch
lights up, and Oil leakage from pipe or joint
buzzer sounds Clogging suction strainer KCM or CUMMINS

Excessive engine wear

Defective oil pump
Low engine coolant level Add coolant 2.70
Fan circuit pressure or flow too low KCM

Coolant temp. Clogging radiator fins Clean 3.11

warning lamp Scale or mineral build up inside radiator Flush or professionally clean 3.14
lights up Defective alarm switch (gauge is in green)
Low water pump flow KCM or CUMMINS

Thermostat stuck or missing

Engine does not Fuel filter element clogging Replace fuel filter
start when the Starter motor speed too low Booster Battery may be used 2.102
starter motor is Defective engine shut off solenoid
turning Fuel pump failure
(Also see ELEC- Incorrect fuel injection timing KCM or CUMMINS

TRICAL TROU- Compression pressure too low

BLESHOOTING) Defective injectors
Air in fuel lines Tighten fuel connections and fil- 3.27
ter
Unstable (rough)
Fuel filter element clogging Replace fuel filter 3.27
idling
Fuel pump failure
Incorrect fuel injection timing
KCM or CUMMINS

Air cleaner element clogging Clean or replace element 3.10

Fuel filter element clogging Replace fuel filter
Throttle pedal electrical signal incorrect KCM

Engine oil level too high Check dipstick and correct level 2.68
Insufficient power Incorrect valve clearance
Piston ring wear
Defective injectors KCM or CUMMINS

Fuel pump failure

Air cooler restricted
3.66
TROUBLESHOOTING

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Wrong type of oil Use correct type of oil 3.62
Engine oil level too low or too high Correct oil level 2.68
Defective injectors
Incorrect valve clearance
Unusual combus-
Main bearing / con-rod bearing wear
tion noise or
Crankshaft uneven wear
mechanical noise KCM or CUMMINS
Connecting rod bent
Timing gear wear
Water pump bearing wear
Failed turbo or muffler
Fuel being diluted with water Replace with specified fuel and
White exhaust
Wrong grade fuel replace fuel filter
smoke
Incorrect fuel injection timing
(After engine has
Compression pressure too low
reached operating KCM or CUMMINS
Turbo seal leakage
temp.)
Coolant ingestion
Air cleaner element clogging Clean or replace element 3.10
Turbo damage
Black exhaust
Incorrect fuel injection timing
smoke KCM or CUMMINS
Fuel injection pump failure
Defective injectors
 3.67
TROUBLESHOOTING

ELECTRICAL

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Broken or slipping alternator belt Adjust or replace belt 2.74
Defective battery Replace battery
Charge lamp lights
Alternator failure
up
Defective wiring KCM or CUMMINS

Defective wiring to ground (short)

Starter motor does Transmission not in NEUTRAL Shift to NEUTRAL 1.29
not turn when Insufficient battery charge Battery charge or booster 2.102
starter switch key Starter switch failure KCM

is turned to Defective wiring

"START" Starter motor failure
KCM or CUMMINS

Hydraulic control levers not in NEUTRAL Move levers to NEUTRAL 2.5

Insufficient battery charging Battery charge or booster 2.102
Engine oil viscosity too high (thick) Replace oil 3.37
Starter motor turns
Poor connection at batteries or ground Clean and tighten all terminals
engine slowly
Defective wiring KCM

Starter motor failure KCM

or CUMMINS

Steering valve failure KCM

STEERING

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Tires are under inflated Check/adjust tire pressure 3.24
Severe conditions (over loaded, deep Change operation
mud, etc.)
Oil pressure too low
Hard steering Steering valve failure
Steering cylinder failure KCM

Defective Orbitrol®
Pump failure
Articulation stopper in locked position Move articulation stopper to 1.28
"STORED" position
Excessive load on steering Reduce load
Steering valve failure
Will not steer Orbitrol® failure
Pump failure KCM

Relief valve failure

Steering cylinder failure
Blocked screen filter Clean filter 3.59
Excessively cold oil / wrong grade oil Warm oil / Replace oil with 3.62
proper viscosity for temperature
Steering Drift
Steering control valve failure
KCM
Steering pilot valve failure
3.68
TROUBLESHOOTING

HYDRAULIC

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Excessively cold oil Warm oil 3.62
Wrong grade oil Replace with proper grade oil
Oil pressure too low
Boom raises too Damaged cylinder piston or piston pack-
slowly ing
KCM
Pump flow too low
Pilot pressure too low
Engine RPM too low
Excessively cold oil / Wrong oil type Warm oil / Replace oil with 3.62
proper viscosity for temperature
Boom natural drift Leakage from control valve plunger
excessively Damaged cylinder piston or piston pack-
KCM
ing
Leakage in pilot relief valve
Bucket / Attach- Over load relief pressure too low
ment floating or Control valve failure KCM

drifting Natural drift of cylinder / packing

BRAKE

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Worn brake friction plates
Insufficient oil pressure (will not release)
Parking brake
Failure of parking brake switch or parking
does not work KCM
brake solenoid valve
properly
Poor wiring or ground to parking brake
switch or parking brake solenoid valve
Dirt, debris under base of brake pedal Remove or clean
Brake dragging Warped brake discs
KCM
Air in brake oil circuit
Air in brake oil circuit
Braking power too KCM
Brake piston seal leakage
low
Blocked screen filter Clean filter 3.58
Cracked or leaking brake line
Brake pressure Brake valve failure
KCM
drops rapidly Defective brake accumulator
Defective brake piston seals
 3.69
TROUBLESHOOTING

TORQUE CONVERTER & TRANSMISSION

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Excessively cold oil / Wrong oil type Warm oil / Replace oil with 3.62
proper viscosity for temperature
Parking brake is applied Release parking brake
Engine is running Transmission oil level too low Add oil / Repair leak 2.82
but machine does Transmission suction strainer clogging Clean strainer 3.43
not move Clutch oil pressure too low
Transmission clutch failure
KCM
MCU failure
Defective electrical circuit
Service or parking brake dragging Inspect and correct
Low oil level in transmission Refill oil / Repair leak 2.82
Suction strainer in transmission clogging Clean or replace strainer 3.43
Low power
Clutch oil pressure too low
Torque converter oil pressure too low KCM

Transmission clutch failure

Air breather clogged Clean and refill with oil 3.45
Oil leakage from
Seal damage (between engine and torque
transmission KCM
converter housing)
Oil level too low Add oil / Repair leak 2.82
Dozing, continuous pushing application Reduce load
Operating in too high a speed range Use lower gear 2.87
Torque converter Long downhill driving Change application
overheat Radiator clogged: coolant temp also high Clean radiator fins 3.11
Defective alarm switch (gauge is in green)
Torque converter / Transmission failure KCM

Oil pressure too low

AIR CONDITIONER

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Hot water continues to flow through Shut off valve in heater hose
heater core line at block
A/C not set for maximum cooling Adjust controls/vents 2.58
Low cooling when
Condenser fins plugged Clean 3.14
A/C "ON"
A/C filters plugged Clean or replace 3.34
A/C compressor belts slipping/broken Adjust/Replace
A/C refrigerant charge low KCM

Engine not warmed up Warm up engine

No hot water flow to heater core Open shut off valve on block
Low heater out put Air conditioner running Turn A/C off
Heater vents not adjusted properly Adjust controls/vents 2.58
Defective heater motor or switch KCM
3.70
TROUBLESHOOTING

AIR CONDITIONER FAILURE MODE

FAILURE MODE FAILURE SOLUTIONS

E11 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the inside air sensor) - Wire breakage in the inside air sensor (THI) - Replacement
E12 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
inside air sensor) - Short-circuit in the inside air sensor (THI) - Replacement
E13 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the outside air sensor) - Wire breakage in the outside air sensor (THAM) - Replacement
E14 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
outside air sensor) - Short-circuit in the outside air sensor (THAM) - Replacement
E15 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the water temperature - Wire breakage in the water temperature sensor - Replacement
sensor) (THW)
E16 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
water temperature sen- - Short-circuit in the water temperature sensor (THW) - Replacement
sor)
E18 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
insolation sensor) - Short-circuit in the insolation sensor (THI) - Replacement
E21 (Wire breakage in - Breakage in the wire harness - Checking the wiring
the ventilation sensor) - Wire breakage in the ventilation sensor (THF) - Replacement
E22 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
ventilation sensor) - Short-circuit in the ventilation sensor (THF) - Replacement
- Defective wire harness or loosen connector - Checking the wiring
E43 (Abnormality in the - Defective servo motor - Replacement
ventilation servo motor) - Stuck foreign material - Removing the
foreign material
- Defective wire harness or loosen connector - Checking the wiring
E44 (Abnormality in the
- Defective servo motor - Replacement
air mixture damper
- Stuck foreign material - Removing the
motor)
foreign material
- Defective wire harness or loosen connector - Checking the wiring
E45 (Abnormality in the
- Defective servo motor - Replacement
inside/outside air
- Stuck foreign material - Removing the
switching motor)
foreign material
 3.71
TROUBLESHOOTING

FAILURE MODE FAILURE SOLUTIONS

- High pressure switch actuation
- Outside air temperature is too high
- Insufficient cooling of condenser
- Defective fan motor - Motor replacement
- Clogging in condenser - Cleaning
- Refrigerant overfilling - Adjusting refriger-
ant quantity
- Aeration into refrigerant circuit - Circuit evacuation
E51 (Abnormality in the
& refilling
refrigerant pressure)
- Low pressure switch actuation
- Outside air temperature is too low
- Insufficient refrigerant quantity - Circuit evacuation
& refilling
- Gas leak - Repair leakage
spot
- Circuit evacuation
& refilling
3.72
TROUBLESHOOTING

MODM
Error log monitor failure code (Input side)

Code Failure Detection condition (In case of)

Shift lever F & R contact ON at the same time
CN121 Shift lever F & R switch malfunction
Failure continues for more than 3 seconds
Shift lever any of more than two 1•2•3•A contact ON at the same time
CN122 Shift lever 1•2•3•A switch malfunction (1)
Failure continues for more than 30 seconds
CN123 Shift lever 1•2•3•A switch malfunction (2) All 1•2•3•A signal OFF continues for more than 30 seconds
CN141 Shift-up switch malfunction Switch is ON for more than 10 seconds
CN142 Shift-down switch malfunction Switch is ON for more than 10 seconds
Shift-up switch & shift-down switch contact ON at the same time
CN143 Shift-up switch & shift-down switch malfunction
Failure continues for more than 3 seconds
CN145 Kick-down switch malfunction Switch is ON for more than 10 seconds
T/M oil pressure switch malfunction
CN151 Signal OFF continues for more than 10 seconds during engine running
(This applies to the model 115ZV-2 only)
T/M oil pressure sensor malfunction T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more
CN152
(This applies to the model 95ZV-2 only) than 10 seconds during engine running
CN213 Inching sensor malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
CN214 Inching sensor malfunction (2) Voltage is larger than 4.6 V for more than 3 seconds
CN161 Machine speed sensor malfunction (1) Input circuit is disconnected for more than 3 seconds
CN162 Machine speed sensor malfunction (2) Input value is over 70 km/h (44 mile/h) for more than 3 seconds
No E/G speed sensor input for more than 3 seconds when E/G speed
CN163 E/G speed sensor 1 (ECM output) malfunction (1)
sensor selection is OFF (Input circuit is disconnected)
Input value is more than 3,000 min-1 for more than 3 seconds when
CN164 E/G speed sensor 1 (ECM output) malfunction (2)
E/G speed sensor selection is OFF
E/G speed sensor 2 (Sensor output) malfunction No E/G speed sensor input for more than 3 seconds when E/G speed
CN165
(1) sensor selection is ON (Input circuit is disconnected)
E/G speed sensor 2 (Sensor output) malfunction Input value is more than 3,000 min-1 for more than 3 seconds when
CN167
(2) E/G speed sensor selection is ON
CN232 S/S potentiometer malfunction (1) Voltage is lower than 0.1 V for more than 3 seconds
CN234 S/S potentiometer malfunction (2) Voltage is larger than 4.9 V for more than 3 seconds
CN236 S/S shift switch (F & R contact) malfunction Failure continues for more than 3 seconds
CN146 Shift hold switch malfunction Switch is ON for more than 10 seconds
Secondary steering oil pressure sensor malfunc-
CN251 Voltage is lower than 0.2 V for more than 3 seconds
tion(1)
Secondary steering oil pressure sensor malfunc-
CN252 Voltage is larger than 4.6 V for more than 3 seconds
tion (2)
Oil pressure sensor detects secondary steering oil pressure below
CN254 Low secondary steering oil pressure 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine
running
CN262 Kickout potentiometer malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
CN263 Kickout potentiometer malfunction (2) Voltage is larger than 4.6 V for more than 3 seconds
Efficient loading system hydraulic oil pressure sen-
CN271 Voltage is lower than 0.2 V for more than 3 seconds
sor malfunction (1)
Efficient loading system hydraulic oil pressure sen-
CN272 Voltage is larger than 4.6 V for more than 3 seconds
sor malfunction (2)
CN312 Brake oil pressure sensor 1 malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
CN313 Brake oil pressure sensor 1 malfunction (2) Voltage is larger than 4.6 V for more than 3 seconds
CN315 Brake oil pressure sensor 2 malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
CN316 Brake oil pressure sensor 2 malfunction (2) Voltage is larger than 4.6 V for more than 3 seconds
CN321 E/G coolant temperature sensor malfunction (1) Input voltage is larger than 3.56 V for more than 3 seconds
CN323 E/G coolant temperature sensor malfunction (2) Input voltage is lower than 0.263 V for more than 3 seconds
CN341 T/M oil temperature sensor malfunction (1) Input voltage is larger than 3.56 V for more than 3 seconds
CN342 T/M oil temperature sensor malfunction (2) Input voltage is lower than 0.263 V for more than 3 seconds
 3.73
TROUBLESHOOTING

Code Failure Detection condition (In case of)

CN351 Hydraulic oil temperature sensor malfunction (1) Input voltage is larger than 3.56 V for more than 3 seconds
CN352 Hydraulic oil temperature sensor malfunction (2) Input voltage is lower than 0.263 V for more than 3 seconds
Input signal corresponds to "any other pattern" in fuel level indication
CN381 Fuel level sensor malfunction
table
CN391 Air temperature probe malfunction (1) Input voltage is larger than 4.35 V for more than 3 seconds
CN392 Air temperature probe malfunction (2) Input voltage is lower than 0.13 V for more than 3 seconds
Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6
CN412 Abnormal brake oil pressure (1)
kgf/cm2) (592 psi) for more than 1 second during engine running
Brake oil pressure sensor 2 detects pressure below 4,081 kPa for
CN413 Abnormal brake oil pressure (2)
(41.6 kgf/cm2) (592 psi) more than 1 second during engine running
Brake oil pressure difference switch is in abnormal condition for more
CN414 Abnormal brake oil pressure difference
than 1 second
Brake oil amount switch is in abnormal condition for more than 1 sec-
CN415 Abnormal brake oil amount
ond
Engine oil pressure switch is OFF for more than 2 seconds during
CN421 Abnormal engine oil pressure
engine running
CN431 Abnormal engine coolant temperature (1) Engine coolant temperature switch is ON for more than 2 seconds
Engine coolant temperature sensor is in 101 deg. C (214 deg. F) con-
CN432 Abnormal engine coolant temperature (2)
dition for more than 2 seconds
CN451 Abnormal T/M oil temperature (1) T/M oil temperature switch is ON for more than 2 seconds
T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for
CN452 Abnormal T/M oil temperature (2)
more than 2 seconds
Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condi-
CN461 Abnormal hydraulic oil temperature
tion for more than 2 seconds
30 minutes after starter switch is ON, T/M oil filter switch is ON for
CN471 Clogged T/M oil filter more than 2 seconds when T/M oil temperature sensor detects oil tem-
perature more than 60 deg. C (140 deg. F)
CN481 Clogged air cleaner element Air cleaner switch is ON for more than 2 seconds
Radiator cooling water level switch is OFF for more than 2 seconds
CN491 Abnormal cooling water level in radiator
when the engine is off.
Hydraulic oil level switch is in abnormal condition for more than 30 sec-
CN496 Abnormal hydraulic oil level
onds
CN497 Abnormal brake disc oil temperature Brake disc oil temperature switch is ON for more than 1 second
CN498 Abnormal disc wear Brake disc wear switch is ON for more than 1 second
CN801 CAN disconnect CAN line is disconnected
CN802 Abnormal engine coolant temperature (CAN) No engine coolant temperature data received for more than 3 seconds
CN912 Abnormal MCU voltage (1) Voltage is larger than 30±1 V
Voltage is lower than 22±0.5 V for more than 10 seconds during
CN913 Abnormal MCU voltage (2)
engine running
3.74
TROUBLESHOOTING

Error log monitor failure code (Output side)

Code Failure Detection condition

CN512 F solenoid valve malfunction F solenoid valve is short-circuited or disconnected
CN514 R solenoid valve malfunction R solenoid valve is short-circuited or disconnected
CN516 1st solenoid valve malfunction 1st solenoid valve is short-circuited or disconnected
CN518 2nd solenoid valve malfunction 2nd solenoid valve is short-circuited or disconnected
CN521 3rd solenoid valve malfunction 3rd solenoid valve is short-circuited or disconnected
CN524 4th solenoid valve malfunction 4th solenoid valve is short-circuited or disconnected
CN526 D solenoid valve malfunction D solenoid valve is short-circuited or disconnected
CN528 H solenoid valve malfunction H solenoid valve is short-circuited or disconnected
CN531 LU solenoid valve malfunction LU solenoid valve is short-circuited or disconnected
CN534 Auto brake solenoid valve malfunction Auto brake solenoid valve is short-circuited or disconnected
Speed change control solenoid valve malfunction
CN536 Speed change control solenoid valve is short-circuited
(1)
Speed change control solenoid valve malfunction
CN537 Speed change control solenoid valve is disconnected
(2)
CN621 S/S solenoid valve R malfunction (1) S/S solenoid valve R is short-circuited
CN622 S/S solenoid valve R malfunction (2) S/S solenoid valve R is disconnected
CN623 S/S solenoid valve L malfunction (1) S/S solenoid valve L is short-circuited
CN624 S/S solenoid valve L malfunction (2) S/S solenoid valve L is disconnected
CN631 Pressure increase solenoid valve malfunction Pressure increase solenoid valve is short-circuited or disconnected
CN641 Ride control solenoid valve malfunction Ride control solenoid valve is short-circuited or disconnected
Efficient loading system selection solenoid valve Efficient loading system selection solenoid valve is short-circuited or
CN681
malfunction disconnected
CN693 Lower kickout relay malfunction (1) Lower kickout relay (coil) is short-circuited
CN694 Lower kickout relay malfunction (2) Lower kickout relay (coil) is disconnected
CN712 Cooling fan solenoid valve malfunction (1) Cooling fan solenoid valve is short-circuited
CN713 Cooling fan solenoid valve malfunction (2) Cooling fan solenoid valve is disconnected
CN721 Hour meter drive malfunction Hour meter drive is short-circuited

Fuel level display table

Input Output
1/8 1/4 1/2 3/4 F E 1/4 1/2 3/4 F
x x x x x — — — —
x x x x — — — —
x x x — — — —
x x — — — —
x — — — —
— — — —
Other than above — — — — —
: No input signal given : Lamp on : Lamp flashing
x : Input signal given — : Lamp off
 3.75
SPECIFICATIONS

SPECIFICATIONS
Specifications shown are for a machine equipped
with standard features. Some options or special
attachment will change the specifications shown.
Specifications subject to change without notice.

Bucket Data

Rock Straight General Purpose

V-edged Rock General Purpose Hight Lift Spec.
Kind of bucket Edge Bucket With Bucket With Cut-
Bucket With Teeth Bucket With Teeth Bucket With Teeth
Teeth ting Edge
Bucket capacity
6.1 5.9 6.6 6.8 5.0
(m3)
Dumping clearance
3,290 3,450 3,380 3,580 3,800
(mm)
Dumping reach
1,995 1,835 1,910 1,770 2,020
(mm)

Bucket Selection Curve

Hight Lift
Boom
Bucket Capacity (m3)

5.0
Standard Boom

6.8
6.6
5.9
6.1
1,400

1,600

1,800

2,000

2,200

Material Density (kg/m3)

115% 95%

Operating Weight 45,700 kg (with ROPS canopy, cabin and Rock bucket with teeth)

Engine Model CUMMINS QSK19 Diesel

Type 4 cycle, Water Cooled, Direct injection, Turbo charged & air cooled
intercooler
Displacement 19 Liter
Rated Power 377 kW / 1,800 min-1
(Gross)

Tire 35/65-33-24PR (L4)

Max. Running Speed 1st : 7.4 / 8.2 km/h

(forward/reverse) 2nd:13.5 / 14.8 km/h
3rd :21.6 / 23.6 km/h
4th :36.0 / — km/h
3.76
SPECIFICATIONS

Hand-arm vibration Less than 2.5 m/s2

The weighted root mean square acceleration value to which the hands/arms are subjected.
Measurements are obtained in accordance with ISO 5349.

Whole-body vibration Less than 0.5 m/s2

The weighted root mean square acceleration value to which the body is subjected.
Measurements are obtained in accordance with ISO 2631.

The weight and load figure include enclosed ROPS cab, GSC bucket with bolt-on cutting edge, 35/65-33-
24PR (L4) tires, full fuel tank and operator.
INDEX
A Check Engine Oil Level .............................................2.68
Accelerator Pedal ........................................................2.7
Adjust and Check Rear View Mirrors ........................2.75
Adjust Belt Tension ...................................................3.29
Adjustments ............................................................2.100
After Storage ...........................................................2.108
Air Cleaner Warning Lamp (red) ...............................2.31
Air Conditioner ..........................................................2.58
Action to be taken when the air conditioner is
not used ................................................................2.64
For Efficient Use of the Air Conditioner .................2.63
Operating Method (Normal Use) ............................2.60
Operation Method (Other Uses) ............................2.61
Other Functions .....................................................2.62
Switches ................................................................2.58
Ventilation Name and Location ..............................2.58
Alternate Throttle for Traction Control .......................2.25
Articulation Stopper ..........................................1.28, 2.72
Auto Brake ................................................................2.88
Auto Brake Indicator Lamp (red) ...............................2.28
Auto Shift Indicator Lamp ..........................................2.32
Auxiliary Attachment Control Lever (option) ................2.6
B Check Wiring Harnesses ..........................................2.71
Before Starting Safety .................................................1.4
Before Storage ........................................................2.107
Boom Control Lever ....................................................2.4
Booster Batteries / Jumper Cables .........................2.102
Brake Pedals ...............................................................2.8
Brake Pressure Warning Lamp (red) ........................2.29
Bucket / Attachment Leveler Adjustment ................2.100
Bucket Control Lever ...................................................2.5
C Clean or Replace Transmission Breather .................3.45
Carrying .....................................................................2.96
Cautions on Battery Replacement or
Battery Cable Removal .......................................2.109
Cautions Regarding Welding Repair Service ..........2.110
Central Warning Lamp (red) ......................................2.29
Charge Lamp (red) ....................................................2.31
Check after Starting the Engine ................................2.81
Check Air Conditioner Refrigerant ............................3.46
Check Air Intake System ...........................................2.74
Check and Adjust Air Conditioner Belt ......................3.33
Check and Adjust Injection Timing ............................3.47
Check and/or Replace Seat Belt .................................3.9
Check Back-up Alarm Operation ...............................2.84
Check Battery Electrolyte Level ................................3.23
Check before Operation ............................................2.67
Check Brake Accumulator .........................................3.57
Check Control Levers ................................................2.76
Check Cooling Fan ....................................................2.75
Check Differential Gear Oil .......................................3.30
Check Drive Belt .......................................................2.74
Check Engine Compression Pressure ......................3.47
Check Engine Coolant Level .....................................2.70
Check Exhaust Gas ..................................................2.85
Check Fuel Level ......................................................2.82
Check Horn Operation ..............................................2.75
Check Hydraulic Oil Level .........................................2.69
Check Injection Pressure ..........................................3.47
Check Monitor Panel Operation ................................2.76
Check or Replace Fuses ...........................................3.13
Check Parking Brake ................................................2.75
Check Parking Brake Oil ...........................................3.32
Check Parking Brake Operation ...............................2.84
Check Planetary Gear Oil .........................................3.31
Check Ride Control Accumulator (option) .................3.61
Check Service Brake Disk Wear ...............................3.57
Check Service Brake Operation ................................2.84
Check Steering Wheel Operation .............................2.84
Check Tightness of Wheel Bolts ...............................3.33
Check Tire Air Pressure ............................................3.24
Check Tire for Damage, Air and Tread Depth ..........2.72
Check Transmission Oil Level ..................................2.82
Check Transmission Shift Lever ...............................2.76
Check Vibration Damper ...........................................3.56
Check Warning Lamps ..............................................2.81
Check Windshield Washer Fluid ...............................3.13
Cigarette Lighter .......................................................2.15
Clean Air Conditioner Condenser .............................3.14
Clean Air Conditioner Filter Element .........................3.34
Clean Crankcase Breather ........................................3.61
Clean Crankcase Breather Tube ..............................3.29
Clean Filter for Brake Line ........................................3.58
Clean Filter for Orbitrol® ............................................3.59
Clean Fuel Tank ........................................................3.56
Clean or Replace Air Cleaner Element .....................3.10
Clean Radiator / Air cooler / Hydraulic oil cooler /
Fuel cooler Fins ....................................................3.11
Cold Start ..................................................................2.78
Cold Start (ether injection) Switch .............................2.20
COMPONENT NAME/LOCATION ..............................2.2
Coolant Level Warning Lamp ....................................2.32
Coolant Specification ................................................3.64
D
Declutch Lamp (green) .............................................2.29
Declutch ON/OFF and Adjustable Preset Switch ......2.17
Downshift Button .......................................................2.16
Dozing .......................................................................2.95
Drain Water and Sediment from Fuel Prefilter ..........2.71
Drain Water and Sediment from Fuel Tank ..............3.23
Dumping into Truck or Hopper ..................................2.97
During Storage ........................................................2.108
E
Efficient Loading System Switch ...............................2.19
Electrical Protection ..................................................2.48
Emergency Brake ..................................................... 1.29
Engine Coolant Temperature Gauge ....................... 2.27
Engine Coolant Temperature Warning Lamp (red)
.............................................................................. 2.30
Engine Oil Pressure Warning Lamp (red) ................. 2.30
Error Log Monitor ..................................................... 2.43
Every 10 Hours or Daily ............................................ 3.19
Every 1000 Hours or 6 Months ................................. 3.42
Every 2000 Hours or 1 Year ..................................... 3.49
Every 250 Hours or 1 Month .................................... 3.26
Every 50 Hours or 1 Week ....................................... 3.20
Every 500 Hours or 3 Months ................................... 3.37
Excavating ................................................................ 2.94
Explosion / Fire / Burn Prevention ............................ 1.15
F O
F/R Switch (option) ................................................... 2.22
F/R Switch Indicator Lamp (green) (option) .............. 2.34
Four-Way Flasher Switch (option) ............................ 2.16
Front Wiper Switch ................................................... 2.14
Front Working Light Switch ....................................... 2.13
Fuel Efficient Mode Switch ....................................... 2.14
Fuel Gauge ............................................................... 2.28
Fuse Boxes .............................................................. 2.48
Fusible Link .............................................................. 2.49
G Parameter Setting Monitor ....................................... 2.45
General Inspection ................................................... 2.85
Grease Gun Holder .................................................. 2.66
Greasing ............................... 3.17, 3.20, 3.26, 3.42, 3.49
Ground Levelling ...................................................... 2.95
H
Hibernate Mode ........................................................ 2.80
High beam Indicator Lamp (blue) ............................. 2.32
High-Low Beam Lever / Turn Signal Lever (option)
................................................................................ 2.4
Horn Button ................................................................ 2.3
Hour Meter ............................................................... 2.33
I Replace Air Conditioner Receiver Dryer .................. 3.16
Idling Management System ...................................... 2.80
Indicators .................................................................. 2.26
Information Monitor .................................................. 2.37
Input/Output Monitor ................................................. 2.44
Inspection and Maintenance Table ............................ 3.4
K Replace Ether Cylinder ............................................ 3.16
Kickout Control Switch ............................................. 2.18
L Replace Filter in the Hydraulic Tank Cap
Light Switch .............................................................. 2.12
Loading ..................................................................... 2.92
Loading Control Lever Lock ..................................... 1.28
Long Term Storage ................................................ 2.107
M
MAINTENANCE ......................................................... 3.2
MCU (Machine Control Unit) Warning Lamp (red)
.............................................................................. 2.29
MODM ............................................................. 2.17, 2.36
MODM function ........................................................ 2.36
Monitor Changeover ................................................. 2.36
Mounting and Dismounting Safety ............................. 1.3
N
Neutral Indicator Lamp ............................................. 2.32
Neutral Start System ................................................ 1.29
Normal Start ............................................................. 2.77
Operating Techniques .............................................. 2.92
Operating the Machine ............................................. 2.86
OPERATION ............................................................ 2.67
Operation and Function ............................................ 2.65
Operational Safety ...................................................... 1.7
Operator Safety .......................................................... 1.2
OPERATOR'S AREA ................................................. 2.3
Other Maintenance Safety Concerns ....................... 1.16
P
Parking ..................................................................... 2.90
Parking Brake Indicator Lamp (red) ......................... 2.28
Parking Brake Switch ............................................... 2.12
Parking Safety .......................................................... 1.11
Pedals and Levers ...................................................... 2.3
R
Radio - AM / FM Cassette (24Volt Type) (option)
(~December, 2009) .............................................. 2.50
Rear Wiper Switch .................................................... 2.15
Rear Working Light Switch ....................................... 2.13
Recommended Lubricants ....................................... 3.62
Recommended Mixture of Antifreeze ....................... 3.64
Replace Air Conditioner Filter Elements .................. 3.57
Replace Bucket Teeth (option) ................................... 3.7
Replace Coolant ....................................................... 3.14
Replace Cutting Edge (option) ................................... 3.9
Replace DCA4 Coolant Filter Cartridge ................... 3.40
Replace Differential Gear Oil .................................... 3.52
Replace Engine Oil and Oil Filter Cartridge ............. 3.37
Replace Filter ........................................................... 3.36
Replace Filter in the Hydraulic Tank Breather Valve
(S/N 0201~) ......................................................... 3.60
(S/N 0151~0200) ................................................. 3.60
Replace Fuel Filter Cartridge ................................... 3.27
Replace Fuel Tank Breather .................................... 3.48
Replace Hydraulic Oil Return Filter .......................... 3.45
Replace Hydraulic Oil, Clean Filter .......................... 3.50
Replace Parking Brake Oil ....................................... 3.55
Replace Planetary Gear Oil ......................................3.53 Welding ...................................................................2.110
Replace Transmission Oil .........................................3.43 When Required Inspection and Maintenance .............3.7
Replace Transmission Oil Filter ................................3.39 Working Light Indicator Lamp (green) .......................2.29
Replacement Monitor ................................................2.41 Wrist Rest ...................................................................2.6
Reversal Fan Pilot Lamp (green) (option) .................2.34
Reversal Fan Switch (option) ....................................2.23
Ride Control (option) .................................................2.65
Ride Control Switch (option) .....................................2.24
Roading / Special Applications ................................2.101
ROPS (Roll Over Protective Structure) ............1.30, 2.75
Running in Deep Mud or Water .................................2.89

S
Safe Maintenance .....................................................1.12
Safe Operation ............................................................1.2
SAFETY ......................................................................1.2
Safety Devices ..........................................................1.28
Safety Preparations Before Maintenance .................1.12
Safety Signs ..............................................................1.18
Seat ...........................................................................2.46
Seat Adjustment ........................................................2.46
Seat Belt ....................................................................2.47
Secondary Steering (option) .....................................1.30
Secondary Steering Warning Lamp (red) (option)
...............................................................................2.33
Selection Switch for Shift Lever or
F/R Switch (option) ...............................................2.21
Serial Number Location ...............................................3.2
SPECIAL PROCEDURES .......................................2.100
Specification Setting Monitor .....................................2.45
SPECIFICATIONS ....................................................3.75
Speed and Direction Change ....................................2.87
Starter Switch ............................................................2.11
Starting the Engine ....................................................2.77
Starting the Machine .................................................2.86
Starting the Machine on a Grade ..............................2.87
Steering Column Telescopic Tilt Handle .....................2.9
Stopping the Engine ..................................................2.91
Switches ....................................................................2.10

T
Tachometer ...............................................................2.27
Torque Converter Oil Temperature Gauge ...............2.28
Torque Converter Oil Temperature
Warning Lamp (red) ..............................................2.31
Towing .....................................................................2.104
Traction Control Switch .............................................2.24
Transmission Oil Filter Warning Lamp (red) .............2.31
Transmission Shift Lever .............................................2.3
Transmission Status Monitor .....................................2.33
Transportation .........................................................2.105
TROUBLESHOOTING ..............................................3.65
Turn Signal Indicator Lamp (Left) (green) .................2.32
Turn Signal Indicator Lamp (Right) (green) ...............2.32
Typical Truck Loading Methods ................................2.98

W
Walk-Around Inspection ............................................2.67
Warm-up control ........................................................2.80
Maintenance Log

Date Machine hours Service performed

Date Machine hours Service performed
Date Machine hours Service performed
Date Machine hours Service performed
Notes
 K
WHEEL LOADER 115ZV-2
OPERATION & MAINTENANCE MANUAL

Manual part number: 93116-00483

Manufacturer:
KCM Corporation
Address: 2680 Oka, Inami-cho, Kako-gun, Hyogo 675-1113 JAPAN
URL: http://www.khi.co.jp/kenki/english/