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KCM WHEEL LOADER 30ZV-240ZV-2A42ZV-2 OPERATION & MAINTENANCE MANUAL 93103-00012
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KCM WHEEL LOADER 30ZV-240ZV-2A42ZV-2 OPERATION & MAINTENANCE MANUAL 93103-00012 – PDF DOWNLOAD
93103-00012
Powered by Kubota V2403-M-DI-EDM Engine
Serial No. 30ZV-2A 05001 and up
40ZV-2A 05001 and up
42ZV-2A 05001 and up
Serial No. 30ZV-2A 05001 and up
40ZV-2A 05001 and up
42ZV-2A 05001 and up
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Description
KCM WHEEL LOADER 30ZV-240ZV-2A42ZV-2 OPERATION & MAINTENANCE MANUAL 93103-00012 – PDF DOWNLOAD
FILE DETAILS:
KCM WHEEL LOADER 30ZV-240ZV-2A42ZV-2 OPERATION & MAINTENANCE MANUAL 93103-00012 – PDF DOWNLOAD
Language :English
Pages :267
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPRION:
KCM WHEEL LOADER 30ZV-240ZV-2A42ZV-2 OPERATION & MAINTENANCE MANUAL 93103-00012 – PDF DOWNLOAD
93103-00012
Powered by Kubota V2403-M-DI-EDM Engine
Serial No. 30ZV-2A 05001 and up
40ZV-2A 05001 and up
42ZV-2A 05001 and up
Serial No. 30ZV-2A 05001 and up
40ZV-2A 05001 and up
42ZV-2A 05001 and up
FOREWORD
- Read this manual carefully before starting and operating the machine for the first time to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage
- This standard specification machine can be operated under the following conditions without being modified. Atmospheric Temperature: -20 °C to 45 °C (-4 °F to 113 °F) Altitude: 0 m to 2000 m (0 ft to 6600 ft)
- In case the machine is used under conditions other than described above, consult your nearest authorized dealer.
- This manual should be considered a permanent part of your machine and should remain with the machine when you sell it. Replace immediately if missing, damaged or not readable.
- This machine is of metric design. Measurements in this manual are metric. American standard measurements are included when appropriate. Use only metric hardware and tools as specified
- Right-hand and left-hand sides are determined by facing in the direction of forward travel. Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.
- Use only diesel fuel with quality specified in JIS K-2204, EN-590 or ASTM D-975 which contents 15 ppm or lower sulfur. Also use fuel that complies with solid contamination level of class 18/16/13 of ISO4406-1999 (solid contamination includes dust). If the fuel specified above is not used, exhaust gas that exceeds the regulation values may be discharged, causing serious problem on the engine. Consult your nearest authorized dealer.
TABLE OF CONTENTS:
KCM WHEEL LOADER 30ZV-240ZV-2A42ZV-2 OPERATION & MAINTENANCE MANUAL 93103-00012 – PDF DOWNLOAD
93103-00012
Powered by Kubota V2403-M-DI-EDM Engine
Serial No. 30ZV-2A 05001 and up
40ZV-2A 05001 and up
42ZV-2A 05001 and up
Serial No. 30ZV-2A 05001 and up
40ZV-2A 05001 and up
42ZV-2A 05001 and up
FOREWORD 3
INDEX 4
CONTENTS 6
MACHINE NUMBERS 11
ENGINE EMISSION CONTROL LABEL 10
SAFETY 12
Recognize Safety Information 12
Understand Signal Words 12
Follow Safety Instructions 13
Prepare for Emergencies 14
Wear Protective Clothing 14
Protect Against Noise 15
Inspect Machine 15
General Precautions for Cab 16
Use Handrails and Steps 17
Never Ride Attachment 17
Adjust Operator’s Seat 17
Ensure Safety Before Rising from or Leaving Operator’s Seat 18
Fasten Your Seat Belt 18
Move and Operate Machine Safely 19
Handle Starting Aids Safely 19
Operate Only from Operator’s Seat 20
Jump Starting 20
Investigate Job Site Beforehand 21
Equipment of Head Guard, ROPS, FOPS 22
Provide Signals for Jobs Involving Multiple Machines 22
Keep Riders Off Machine 23
Drive Safely 23
Drive Machine Safely (Work Site) 24
Drive Safely with Bucket Loaded 25
Drive on Snow Safely 25
Travel on Public Roads Safely 26
Avoid Injury from Rollaway Accidents 26
Avoid Accidents from Backing Up and Turning 27
Avoid Positioning Bucket Over Anyone 28
Avoid Tipping 28
Never Undercut a High Bank 29
Dig with Caution 29
Perform Truck Loading Safely 29
Avoid Power Lines 30
Precautions for Operation 30
Precautions for Lightning 30
Object Handling 31
Protect Against Flying Debris 31
Park Machine Safely 32
Store Attachments Safely 32
Transport Safely 33
Handle Fluids Safely−Avoid Fires 34
Practice Safe Maintenance 35
Warn Others of Service Work 36
Support Machine Properly 36
Stay Clear of Moving Parts 37
Support Maintenance Properly 37
Prevent Parts from Flying 38
Prevent Burns 38
Replace Rubber Hoses Periodically 39
Avoid High-Pressure Fluids 39
Prevent Fires 40
Evacuating in Case of Fire 41
Beware of Exhaust Fumes 42
Precautions for Welding and Grinding 42
Avoid Heating Near Pressurized Fluid Lines 43
Avoid Applying Heat to Lines Containing Flammable Fluids 43
Precautions for Handling Accumulator and Gas Damper 43
Remove Paint Before Welding or Heating 44
Beware of Asbestos and Silicon Dust and Other Contamination 44
Prevent Battery Explosions 45
Service Air Conditioning System Safely 45
Handle Chemical Products Safely 46
Dispose of Waste Properly 46
SAFETY SIGNS 47
1-1 COMPONENTS NAME 56
Components Name 81
1-2 GETTING ON/OFF THE MACHINE 57
Getting ON/OFF the Machine 57
OPERATOR’S STATION 58
1-3 OPERATOR’S STATION 58
Features 58
Front Console 59
Right Console 75
Monitor Panel 61
Parking Brake Indicator 62
Brake Oil Low Level Indicator 62
Discharge Warning Indicator 62
Engine Oil Low Pressure Indicator 62
Engine Coolant Temperature Gauge 63
Fuel Gauge 63
Hour Meter 63
Preheat Indicator 64
Turn Signal Indicator 64
Forward/Reverse Indicator 64
Switches, Steering Wheel and Pedals 65
Forward/Reverse Lever 66
Neutral Lever Lock (Forward/Reverse Lever) 66
Steering 67
Horn Switch 67
Turn Signal Lever 67
Light Switch 68
Hazard Switch (Optional) 69
Front Work Light Switch (Cab) 70
Rear Work Light Switch (Cab, Optional) 71
Parking Brake Switch 72
Front Window Wiper Switch (Cab) 73
Rear Window Wiper Switch (Cab) 73
Accelerator Pedal 74
Brake/Inching Pedal 74
1-20 Right Console 75
Loader Control Lever 76
Loader Control Lever Lock 77
Key Switch 78
Driving Mode Switch 79
Heater (Optional) Operation 80
Heater Switch 80
Venthole 80
1-26 Air Conditioner (Optional) Operation 81
Components Name 81
Control Panel Arrangement 81
Control Panel Switch Designation and Function 82
Tips for Optimal Air Conditioner Usage 83
Adjusting Operator’s Seat (Standard Type) 84
Seat Belt 85
Seat Pocket 85
Fuse Box 87
Fuse Box 87
1-33 ROPS/FOPS Cab (Optional) 88
Room Light 90
Sun Visor (Optional) 90
Drink Holder 90
Coat Hook 91
Rear View Mirror 91
Room Rear View Mirror 91
Cab Switch Panel (Optional) 92
Cab Door 93
Door Lock Knob 94
Door Open/Close Lever 94
Window Open/Close Levers 94
1-41 Articulation Lock Bar 96
Towing Pin 96
Engine Hood 97
Steps 97
Vandal-Proof Devices 98
2 BREAK-IN100
Observe Engine Operation Closely 100
3 OPERATING THE ENGINE102
Check Before Starting 102
Starting Engine 104
Starting in Cold Weather 105
Check After Starting 106
Check Monitor Operation106
Check Engine Noise and Exhaust Gas Color 106
Using Booster Batteries 107
Warming Up Operation 109
Warming Up Operation in Cold Weather 110
Stopping Engine 111
4 DRIVING THE MACHINE112
Driving Machine 112
Precautions for Starting to Move112
Starting to Move 113
Parking Brake Switch 115
Changing Travel Speed 116
Changing Forward/Reverse Drive Direction 116
Steering 117
Provisional Stop and Restart of Driving 118
Precautions for Traveling 118
Driving in Water or on Soft Ground 119
Precautions for Driving on Slopes 120
Precautions to Be Taken If the Machine Failure Occurs 121
Stop/Parking 122
Emergency Occasions 124
If the Engine Stalls During Traveling 124
5 OPERATING THE MACHINE126
Loader Control Lever 126
Single-Lever Type126
Adjustment of Bucket Auto Leveler 128
Before Operation 129
Precautions for Operation 129
Ensure Safety When Operating on Road Shoulders 129
Avoid Overloading130
Avoid Rapid Steering Changes and/or Sudden Braking130
Excavation131
Loading Accumulated Soil131
Digging and Loading Level Ground132
Grading133
Loading134
Load and Carrying Method134
Loader and Dump Track Combination Method135
V-Shape Loading135
I-Shape Loading135
Dozing136
Scooping136
Removing Snow137
Lifting Wheel Loader137
Precautions for After Operations138
6 TRANSPORTING140
Transporting by Road 140
Transporting by Trailer 140
Loading/Unloading on Trailer 140
Ramp/Loading Dock140
Loading/Unloading141
Transporting142
Transporting Wheel Loader (Urgent Situation)143
Precautions for Towing144
Removal of Propeller Shafts145
Relieving HST Hydraulic Pressure146
Releasing Parking Brake147
Towing Method 148
Lifting Machine 149
7 MAINTENANCE150
Correct Maintenance and Inspection Procedures 150
Check the Hour Meter Regularly 151
Use Correct Fuels and Lubricants 151
Layout (42ZV-2)152
Maintenance Guide Table 153
Preparations for Inspection and Maintenance 154
Lock Frames 155
Engine Hood 156
Periodic Replacement of Parts157
Maintenance Guide 158
Kind of Oils 164
Grease164
Engine Oil164
Brake Oil165
Transmission Oil165
Axle Oil165
Hydraulic Oil166
Long-Life Coolant166
A Greasing167
B Engine171
1 Check Engine Oil Level171
2 Change Engine Oil172
3 Replace Engine Oil Filter173
C Power Train174
1 Change Transmission Oil174
2 Change Axle Oil175
Change Axle Oil175
Check Oil Level176
3 Clean Transmission Air Breather177
4 Check Surrounding Areas Around Axles and Covers for Oil Leaks178
5 Clean Axle Housing Air Breather178
D Hydraulic System179
Inspection and Maintenance of Hydraulic Equipment179
1 Check Hydraulic Oil Level180
2 Change Hydraulic Oil/Clean Hydraulic Oil Tank181
Bleed Air from the Hydraulic System182
3 Clean Suction Filter183
4 Replace HST Oil Filter Element184
5 Replace Return Filter186
6 Check Hoses and Lines188
Service Recommendations for Hydraulic Fittings190
E Fuel System191
1 Check Fuel Level191
Recommended Fuel191
Refueling191
2 Drain Water and Sediment from Fuel Tank192
3 Check and Drain Water from Fuel Filter193
Fuel Filter Drain Procedures193
Bleed Air from the Fuel System194
4 Replace Fuel Filter Element195
5 Check and Drain Water from Water Separator196
Water Separator Drain Procedures196
6 Clean Water Separator Screen197
7 Check Fuel Hose198
F Air Cleaner199
1 Check Air Cleaner for Clogging199
2 Clean and Replace Air Cleaner Element200
G Cooling System201
Kinds of Antifreeze201
Precautions for Handling Long Life Coolant (LLC)202
1 Check Coolant Level203
2 Check Fan Drive Belt204
3 Check Fan Belt Tension204
4 Adjust Fan Belt Tension204
5 Change Coolant205
6 Clean Radiator and Oil Cooler206
H Electrical System207
1 Check Monitor Function and All Other Instrument Operation207
2 Check Work Lights208
3 Check Horn, Backup Alarm and Backup Light208
4 Check Electrical Harnesses, Fuses, and Battery209
Replace Fuse209
Fuse Box 210
Battery211
Precautions for Handling Batteries211
In Case the Batteries Were Discharged213
Method to Recharge the Removed Battery213
Method to Replace with Charged Auxiliary Batteries214
5 Check Electrolyte Level215
6 Check Electrolyte Specific Gravity216
I Brake System217
1 Check Brake Oil Level217
2 Check Right and Left Brake Interlocking Performance218
Check Brake Performance218
Check Play in Brake Pedal Stroke218
3 Check Parking Brake Force219
4 Check Brake Disc (Service and Parking)219
5 Change Brake Oil219
J Tire220
1 Check and Adjust Tire Pressure220
Check Tire Pressure220
2 Check Tire for Damage221
3 Check Wheel Bolt Torque221
Replace Tire221
Tire Size To Be Used222
Tire Rotation223
How to Check Wear Amount (Tread Design Groove Depth)223
Removal and Installation of Tire224
Tire Wheel224
K Heater/Air Conditioner225
1 Check Heater for Any Damage 225
2 Check Heater Piping225
3 Clean and Replace Air Conditioner Circulation Air Filter226
Clean Circulation Air Filter226
4 Check Air Conditioner Unit227
High Temperature Pressure Cleaning (Steam Cleaning)227
5 Check Pipelines227
6 Check Air Conditioner Condenser228
7 Check Air Conditioner Drive Belt228
Adjusting Compressor Drive Belt Tension228
8 Check Refrigerant Quantity229
9 Check Compressor and Pulley229
10 Check Switch Operation229
L Miscellaneous230
1 Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear230
2 Check and Replace Seat Belt231
3 Check Canopy/Cab for Damage and Mounting Bolts for Tightness231
4 Check Windshield Washer Fluid Level (Cab Equipped Unit)231
5 Check Play in Steering Wheel Stroke232
6 Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise 233
Exhaust Gas Color and Noise233
7 Check Rearview Mirror and Inside Rearview Mirror234
8 Check Steps and Handrails for Damage and Tightness234
9 Clean Engine Compartment and Hood234
10 Check and Adjust Valve Clearance 235
11 Check Sound Absorbing Mat Around Engine 235
12 Check Fuel Injection Timing 235
13 Check Engine Compression Pressure236
14 Check and Clean Starter and Alternator236
15 Retighten Front Axle and Rear Axle Support Mounting Bolts236
16 Tightening and Retightening Torque of Nuts and Bolts237
Nuts and Bolts Tightening Torque238
9 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS244
Maintenance Under Special Environmental Conditions244
Precautions for Maintenance During Cold Weather Season245
10 STORAGE248
Storing the Machine 248
Removing the Machine from Storage249
11 TROUBLESHOOTING250
Troubleshooting250
12 SPECIFICATIONS254
Specifications (30ZV-2/40ZV-2A)254
Specifications (42ZV-2)255
13 OPTIONAL ATTACHMENTS256
Operating Quick Coupler (Mechanical Type) 256
Coupler Switch 256
Caution to take when using attachment 257
Caution to take during operation 257
Removal258
Reinstalling259
Disconnecting/connecting hydraulic hose quick connectors260
14 INDEX262
INDEX 4
CONTENTS 6
MACHINE NUMBERS 11
ENGINE EMISSION CONTROL LABEL 10
SAFETY 12
Recognize Safety Information 12
Understand Signal Words 12
Follow Safety Instructions 13
Prepare for Emergencies 14
Wear Protective Clothing 14
Protect Against Noise 15
Inspect Machine 15
General Precautions for Cab 16
Use Handrails and Steps 17
Never Ride Attachment 17
Adjust Operator’s Seat 17
Ensure Safety Before Rising from or Leaving Operator’s Seat 18
Fasten Your Seat Belt 18
Move and Operate Machine Safely 19
Handle Starting Aids Safely 19
Operate Only from Operator’s Seat 20
Jump Starting 20
Investigate Job Site Beforehand 21
Equipment of Head Guard, ROPS, FOPS 22
Provide Signals for Jobs Involving Multiple Machines 22
Keep Riders Off Machine 23
Drive Safely 23
Drive Machine Safely (Work Site) 24
Drive Safely with Bucket Loaded 25
Drive on Snow Safely 25
Travel on Public Roads Safely 26
Avoid Injury from Rollaway Accidents 26
Avoid Accidents from Backing Up and Turning 27
Avoid Positioning Bucket Over Anyone 28
Avoid Tipping 28
Never Undercut a High Bank 29
Dig with Caution 29
Perform Truck Loading Safely 29
Avoid Power Lines 30
Precautions for Operation 30
Precautions for Lightning 30
Object Handling 31
Protect Against Flying Debris 31
Park Machine Safely 32
Store Attachments Safely 32
Transport Safely 33
Handle Fluids Safely−Avoid Fires 34
Practice Safe Maintenance 35
Warn Others of Service Work 36
Support Machine Properly 36
Stay Clear of Moving Parts 37
Support Maintenance Properly 37
Prevent Parts from Flying 38
Prevent Burns 38
Replace Rubber Hoses Periodically 39
Avoid High-Pressure Fluids 39
Prevent Fires 40
Evacuating in Case of Fire 41
Beware of Exhaust Fumes 42
Precautions for Welding and Grinding 42
Avoid Heating Near Pressurized Fluid Lines 43
Avoid Applying Heat to Lines Containing Flammable Fluids 43
Precautions for Handling Accumulator and Gas Damper 43
Remove Paint Before Welding or Heating 44
Beware of Asbestos and Silicon Dust and Other Contamination 44
Prevent Battery Explosions 45
Service Air Conditioning System Safely 45
Handle Chemical Products Safely 46
Dispose of Waste Properly 46
SAFETY SIGNS 47
1-1 COMPONENTS NAME 56
Components Name 81
1-2 GETTING ON/OFF THE MACHINE 57
Getting ON/OFF the Machine 57
OPERATOR’S STATION 58
1-3 OPERATOR’S STATION 58
Features 58
Front Console 59
Right Console 75
Monitor Panel 61
Parking Brake Indicator 62
Brake Oil Low Level Indicator 62
Discharge Warning Indicator 62
Engine Oil Low Pressure Indicator 62
Engine Coolant Temperature Gauge 63
Fuel Gauge 63
Hour Meter 63
Preheat Indicator 64
Turn Signal Indicator 64
Forward/Reverse Indicator 64
Switches, Steering Wheel and Pedals 65
Forward/Reverse Lever 66
Neutral Lever Lock (Forward/Reverse Lever) 66
Steering 67
Horn Switch 67
Turn Signal Lever 67
Light Switch 68
Hazard Switch (Optional) 69
Front Work Light Switch (Cab) 70
Rear Work Light Switch (Cab, Optional) 71
Parking Brake Switch 72
Front Window Wiper Switch (Cab) 73
Rear Window Wiper Switch (Cab) 73
Accelerator Pedal 74
Brake/Inching Pedal 74
1-20 Right Console 75
Loader Control Lever 76
Loader Control Lever Lock 77
Key Switch 78
Driving Mode Switch 79
Heater (Optional) Operation 80
Heater Switch 80
Venthole 80
1-26 Air Conditioner (Optional) Operation 81
Components Name 81
Control Panel Arrangement 81
Control Panel Switch Designation and Function 82
Tips for Optimal Air Conditioner Usage 83
Adjusting Operator’s Seat (Standard Type) 84
Seat Belt 85
Seat Pocket 85
Fuse Box 87
Fuse Box 87
1-33 ROPS/FOPS Cab (Optional) 88
Room Light 90
Sun Visor (Optional) 90
Drink Holder 90
Coat Hook 91
Rear View Mirror 91
Room Rear View Mirror 91
Cab Switch Panel (Optional) 92
Cab Door 93
Door Lock Knob 94
Door Open/Close Lever 94
Window Open/Close Levers 94
1-41 Articulation Lock Bar 96
Towing Pin 96
Engine Hood 97
Steps 97
Vandal-Proof Devices 98
2 BREAK-IN100
Observe Engine Operation Closely 100
3 OPERATING THE ENGINE102
Check Before Starting 102
Starting Engine 104
Starting in Cold Weather 105
Check After Starting 106
Check Monitor Operation106
Check Engine Noise and Exhaust Gas Color 106
Using Booster Batteries 107
Warming Up Operation 109
Warming Up Operation in Cold Weather 110
Stopping Engine 111
4 DRIVING THE MACHINE112
Driving Machine 112
Precautions for Starting to Move112
Starting to Move 113
Parking Brake Switch 115
Changing Travel Speed 116
Changing Forward/Reverse Drive Direction 116
Steering 117
Provisional Stop and Restart of Driving 118
Precautions for Traveling 118
Driving in Water or on Soft Ground 119
Precautions for Driving on Slopes 120
Precautions to Be Taken If the Machine Failure Occurs 121
Stop/Parking 122
Emergency Occasions 124
If the Engine Stalls During Traveling 124
5 OPERATING THE MACHINE126
Loader Control Lever 126
Single-Lever Type126
Adjustment of Bucket Auto Leveler 128
Before Operation 129
Precautions for Operation 129
Ensure Safety When Operating on Road Shoulders 129
Avoid Overloading130
Avoid Rapid Steering Changes and/or Sudden Braking130
Excavation131
Loading Accumulated Soil131
Digging and Loading Level Ground132
Grading133
Loading134
Load and Carrying Method134
Loader and Dump Track Combination Method135
V-Shape Loading135
I-Shape Loading135
Dozing136
Scooping136
Removing Snow137
Lifting Wheel Loader137
Precautions for After Operations138
6 TRANSPORTING140
Transporting by Road 140
Transporting by Trailer 140
Loading/Unloading on Trailer 140
Ramp/Loading Dock140
Loading/Unloading141
Transporting142
Transporting Wheel Loader (Urgent Situation)143
Precautions for Towing144
Removal of Propeller Shafts145
Relieving HST Hydraulic Pressure146
Releasing Parking Brake147
Towing Method 148
Lifting Machine 149
7 MAINTENANCE150
Correct Maintenance and Inspection Procedures 150
Check the Hour Meter Regularly 151
Use Correct Fuels and Lubricants 151
Layout (42ZV-2)152
Maintenance Guide Table 153
Preparations for Inspection and Maintenance 154
Lock Frames 155
Engine Hood 156
Periodic Replacement of Parts157
Maintenance Guide 158
Kind of Oils 164
Grease164
Engine Oil164
Brake Oil165
Transmission Oil165
Axle Oil165
Hydraulic Oil166
Long-Life Coolant166
A Greasing167
B Engine171
1 Check Engine Oil Level171
2 Change Engine Oil172
3 Replace Engine Oil Filter173
C Power Train174
1 Change Transmission Oil174
2 Change Axle Oil175
Change Axle Oil175
Check Oil Level176
3 Clean Transmission Air Breather177
4 Check Surrounding Areas Around Axles and Covers for Oil Leaks178
5 Clean Axle Housing Air Breather178
D Hydraulic System179
Inspection and Maintenance of Hydraulic Equipment179
1 Check Hydraulic Oil Level180
2 Change Hydraulic Oil/Clean Hydraulic Oil Tank181
Bleed Air from the Hydraulic System182
3 Clean Suction Filter183
4 Replace HST Oil Filter Element184
5 Replace Return Filter186
6 Check Hoses and Lines188
Service Recommendations for Hydraulic Fittings190
E Fuel System191
1 Check Fuel Level191
Recommended Fuel191
Refueling191
2 Drain Water and Sediment from Fuel Tank192
3 Check and Drain Water from Fuel Filter193
Fuel Filter Drain Procedures193
Bleed Air from the Fuel System194
4 Replace Fuel Filter Element195
5 Check and Drain Water from Water Separator196
Water Separator Drain Procedures196
6 Clean Water Separator Screen197
7 Check Fuel Hose198
F Air Cleaner199
1 Check Air Cleaner for Clogging199
2 Clean and Replace Air Cleaner Element200
G Cooling System201
Kinds of Antifreeze201
Precautions for Handling Long Life Coolant (LLC)202
1 Check Coolant Level203
2 Check Fan Drive Belt204
3 Check Fan Belt Tension204
4 Adjust Fan Belt Tension204
5 Change Coolant205
6 Clean Radiator and Oil Cooler206
H Electrical System207
1 Check Monitor Function and All Other Instrument Operation207
2 Check Work Lights208
3 Check Horn, Backup Alarm and Backup Light208
4 Check Electrical Harnesses, Fuses, and Battery209
Replace Fuse209
Fuse Box 210
Battery211
Precautions for Handling Batteries211
In Case the Batteries Were Discharged213
Method to Recharge the Removed Battery213
Method to Replace with Charged Auxiliary Batteries214
5 Check Electrolyte Level215
6 Check Electrolyte Specific Gravity216
I Brake System217
1 Check Brake Oil Level217
2 Check Right and Left Brake Interlocking Performance218
Check Brake Performance218
Check Play in Brake Pedal Stroke218
3 Check Parking Brake Force219
4 Check Brake Disc (Service and Parking)219
5 Change Brake Oil219
J Tire220
1 Check and Adjust Tire Pressure220
Check Tire Pressure220
2 Check Tire for Damage221
3 Check Wheel Bolt Torque221
Replace Tire221
Tire Size To Be Used222
Tire Rotation223
How to Check Wear Amount (Tread Design Groove Depth)223
Removal and Installation of Tire224
Tire Wheel224
K Heater/Air Conditioner225
1 Check Heater for Any Damage 225
2 Check Heater Piping225
3 Clean and Replace Air Conditioner Circulation Air Filter226
Clean Circulation Air Filter226
4 Check Air Conditioner Unit227
High Temperature Pressure Cleaning (Steam Cleaning)227
5 Check Pipelines227
6 Check Air Conditioner Condenser228
7 Check Air Conditioner Drive Belt228
Adjusting Compressor Drive Belt Tension228
8 Check Refrigerant Quantity229
9 Check Compressor and Pulley229
10 Check Switch Operation229
L Miscellaneous230
1 Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear230
2 Check and Replace Seat Belt231
3 Check Canopy/Cab for Damage and Mounting Bolts for Tightness231
4 Check Windshield Washer Fluid Level (Cab Equipped Unit)231
5 Check Play in Steering Wheel Stroke232
6 Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise 233
Exhaust Gas Color and Noise233
7 Check Rearview Mirror and Inside Rearview Mirror234
8 Check Steps and Handrails for Damage and Tightness234
9 Clean Engine Compartment and Hood234
10 Check and Adjust Valve Clearance 235
11 Check Sound Absorbing Mat Around Engine 235
12 Check Fuel Injection Timing 235
13 Check Engine Compression Pressure236
14 Check and Clean Starter and Alternator236
15 Retighten Front Axle and Rear Axle Support Mounting Bolts236
16 Tightening and Retightening Torque of Nuts and Bolts237
Nuts and Bolts Tightening Torque238
9 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS244
Maintenance Under Special Environmental Conditions244
Precautions for Maintenance During Cold Weather Season245
10 STORAGE248
Storing the Machine 248
Removing the Machine from Storage249
11 TROUBLESHOOTING250
Troubleshooting250
12 SPECIFICATIONS254
Specifications (30ZV-2/40ZV-2A)254
Specifications (42ZV-2)255
13 OPTIONAL ATTACHMENTS256
Operating Quick Coupler (Mechanical Type) 256
Coupler Switch 256
Caution to take when using attachment 257
Caution to take during operation 257
Removal258
Reinstalling259
Disconnecting/connecting hydraulic hose quick connectors260
14 INDEX262
S.M 1/2/25
