2. WARNING
BATTERY WARNING
CALIFORNIA PROPOSITION 65
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm.
WASH HANDS AFTER HANDLING !
CALIFORNIA
Proposition 65 warning
Diesel engine exhaust and some of its constituents are known to the
State of California to cause cancer, birth defects, and other reproductive harm.
"Perchlorate Material special handling may apply,
See www.dtsc.ca.gov/hazardouswaste/perchlorate."
Applicable parts : MCU (Machine Control Unit)
Applicable state : California
3. 93106-00113
April 1, 2009
FOREWORD
Congratulations on your purchase of the Kawasaki Wheel Loader 60ZV-2.
This manual contains safety, operation, transportation, maintenance and troubleshooting
information. Read and understand the information in this manual carefully before operating
or performing any maintenance of the machine. Failure to do so could result in personal
injury or equipment failure. The safety of yourself and others depends upon your care and
judgement in the operation and maintenance of this machine. Keep the manual with this
machine at all times.
Kawasaki pursues a policy of continuing improvement in design and performance of this
machine. The right is therefore reserved to vary specifications without prior notice or 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 Kawasaki dealer in your area during regular business hours. A
satisfied customer is our goal.
For additional details, for safe and efficient operation and maintenance of your Cummins
engine, please refer to your Cummins operation & maintenance manual.
There may be an optional supplemental operation & maintenance manual, and this also
should be referred to when operating machines that are equipped with special packages.
This manual is compiled for persons who understand English. If an operator or mainte-
nance person does not understand English, please translate what said in this manual into
his mother language.
4. SAFETY NOTICE
Whenever you see the symbols shown below in this manual or on the machine, read and understand their
messages.
Always follow safe operating and maintenance practices.
Kawasaki 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 Kawasaki, 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.
Kawasaki 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 Kawasaki dealer, it may not be
equipped as the regulations require. Kawasaki 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. Con-
tact your nearest Kawasaki 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.
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.
5. CONTENTS
1.SAFETY ...................................................................................................................................................... 1.1
SAFETY..................................................................................................................................................... 1.2
Safe Operation..................................................................................................................................... 1.2
Safe Maintenance...............................................................................................................................1.11
Safety Signs....................................................................................................................................... 1.16
Safety Devices................................................................................................................................... 1.25
2.OPERATION ............................................................................................................................................... 2.1
COMPONENT NAME/LOCATION............................................................................................................. 2.2
OPERATOR'S AREA ................................................................................................................................. 2.3
Pedals and Levers............................................................................................................................... 2.3
Switches .............................................................................................................................................. 2.9
Indicators ........................................................................................................................................... 2.17
Seat ................................................................................................................................................... 2.23
Electrical Protection........................................................................................................................... 2.25
Radio - AM / FM Cassette (24 Volt Type) (option) ............................................................................ 2.27
Heater or Air Conditioner (option)...................................................................................................... 2.35
Ride Control (option).......................................................................................................................... 2.37
OPERATION............................................................................................................................................ 2.38
Check before Operation..................................................................................................................... 2.38
Starting the Engine ............................................................................................................................ 2.48
Check after Starting the Engine ......................................................................................................... 2.50
Operating the Machine ...................................................................................................................... 2.55
Parking............................................................................................................................................... 2.58
Stopping the Engine........................................................................................................................... 2.59
Operating Techniques........................................................................................................................ 2.60
SPECIAL PROCEDURES ....................................................................................................................... 2.67
Adjustments ....................................................................................................................................... 2.67
Roading / Special Applications .......................................................................................................... 2.69
Booster Batteries / Jumper Cables .................................................................................................... 2.70
Towing................................................................................................................................................ 2.72
Transportation.................................................................................................................................... 2.73
Long Term Storage ............................................................................................................................ 2.75
Welding.............................................................................................................................................. 2.78
6. 3.MAINTENANCE.......................................................................................................................................... 3.1
MAINTENANCE......................................................................................................................................... 3.2
Serial Number Location ....................................................................................................................... 3.2
Inspection and Maintenance Table ...................................................................................................... 3.5
When Required Inspection and Maintenance...................................................................................... 3.8
Every 10 Hours or Daily..................................................................................................................... 3.17
Every 50 Hours or 1 Week................................................................................................................. 3.18
Every 250 Hours or 1 Month.............................................................................................................. 3.24
Every 500 Hours or 3 Months ............................................................................................................ 3.30
Every 1000 Hours or 6 Months .......................................................................................................... 3.35
Every 2000 Hours or 1 Year............................................................................................................... 3.41
Recommended Lubricants................................................................................................................. 3.46
Coolant Specification ......................................................................................................................... 3.48
TROUBLESHOOTING............................................................................................................................. 3.49
SPECIFICATIONS ................................................................................................................................... 3.61
8. 1.2
SAFETY
Safe Operation
SAFETY
Safe Operation
Operator Safety
Read and understand the Operation & Mainte-
nance Manual.
Be aware of the location and meaning of safety
signs (decals) on the machine. Report or replace
any that are missing or unreadable.
Be alert and ready to operate the machine safely:
- Do not operate if excessively tired.
- Do not operate if taking medication that causes
drowsiness.
- Do not operate if under the influence of alcohol
or drugs.
Wear safe clothing:
- 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
- Do not wear jewelry that may catch on the
equipment, controls or may short and cause
burns if in contact with electrical components.
OM0001
OM0180
OM0026
9. 1.3
SAFETY
Safe Operation
Mounting and Dismounting Safety
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.
Climb and step only where steps and handrails are
provided.
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.
Do not allow unauthorized personnel on the
machine.
OM0010
OM0181
OM0012
10. 1.4
SAFETY
Safe Operation
Before Starting Safety
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.
Perform the normal daily maintenance.
Be sure the following safety devices work or are
positioned properly.
- Parking Brake -- Applied (See page 1.27)
- Control Lever Lock -- Locked (See page 2.8)
- Transmission Shift Lever -- Neutral
OM0006
OM0005
60ZV 3701b
Lock
Unlock
60ZV0002
N
11. 1.5
SAFETY
Safe Operation
- 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.
Do not leave a lighter in the cab. The lighter may
cause explosion by high temperature in the cab.
Do not bring inflammable or explosive materials
such as:
- spray can
- chemical cylinder
Do not attach a suction cup on the window to avoid
firing.
In case of fire during operation:
- 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
needed at the work area.
Adjust the seat, seat belt and steering column, mir-
rors, etc.
Properly fasten the seat belt.
Do not start or operate the machine if a "DO NOT
START" or a "DO NOT OPERATE" tag is on the key
switch, steering wheel or controls.
Do not operate the engine where there are or can
be combustible vapors. These vapors can be
drawn through the air intake system and cause
engine overspeeding, which can result in a fire, and
explosion.
60ZV 3652
Articulation Stopper "STORED" OM0007
OM0182
DANGER
DO
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE
NOT
12. 1.6
SAFETY
Safe Operation
Do not start to work in an enclosed area if adequate
ventilation is not provided. Fumes could build up
during operation that could cause drowsiness,
injury, or death.
Blow the horn for a few seconds just before starting
the engine to alert bystanders.
Start the machine only from in the operator's seat.
- Do not reach through the window to start.
- Do not stand on the ground and start.
- Never attempt to start by shorting across the
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 2.70.
Operational Safety
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.
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).
The range of temperature the machine is to be
operated is between -35ºC ~ 45ºC (-31ºF ~ 113ºF).
OM0011
OM0183
OM0021
13. 1.7
SAFETY
Safe Operation
When working on a grade:
- Turn "OFF" the declutch 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.
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.
SAFETY DURING NORMAL OPERATIONS:
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.
Using the machine for purposes other than speci-
fied in the Operation & Maintenance Manual may
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.
- The normal carry position is about 40 cm (16 in)
above the ground.
OM0018
OM0013
OM0016
approx. 40 cm (16 in)
14. 1.8
SAFETY
Safe Operation
When roading the machine:
- 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 (2 miles)),
periodically stop to allow tires, transmission,
engine to cool down. Excessive tire heat caused
by roading can cause blow-outs and loss of con-
trol.
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
machine only when an emergency, like loss of brak-
ing occurs.
Be sure there are no bystanders under the raised
bucket or attachment.
Never position or move the load over the cab of a
truck or other vehicle.
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.
OM0184
OM0020
15. 1.9
SAFETY
Safe Operation
SPECIAL OPERATING CONDITIONS:
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.
- Be sure the hitch pin is fully in its bore before
applying tension.
- 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.
OM0185
70ZV OM 2665
16. 1.10
SAFETY
Safe Operation
Parking Safety
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.
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).
Inspect the machine and report any needed
repairs.
If parking near a road, be sure and erect safety bar-
riers and lights as required.
OM0025
OM0186
17. 1.11
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.
Air conditioner servicing and repair should be per-
formed by trained specialists since injury and/or
environmental pollution can result from improper
servicing.
Allow only properly trained tire mechanics with the
proper tools to service tires and rims.
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
- Approved respirator
- Do not wear jewelry that may catch on equip-
ment, controls, or may short and cause burns if
in contact with electrical components.
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.
OM0026
OM0002
OM0025
18. 1.12
SAFETY
Safe Maintenance
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.
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.
If working under the raised boom or attachment, be
sure to properly block or support boom.
Do not stand on tires. Use safe and sturdy working
platforms.
OM0029
OM0182
DANGER
DO
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE
NOT
OM0031
19. 1.13
SAFETY
Safe Maintenance
Explosion / Fire / Burn Prevention
Before removing any coolant hoses or plugs,
relieve any trapped pressure in the cooling system.
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
explosive materials such as:
- Fuel
- Oil
- Antifreeze
- Batteries
- Wood chips
- Straw, leaves, pine straw
- Oily rags
- Grease
- Ether starting fluid
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.).
Clean up all spills of coolant, fuel, oil, etc. to pre-
vent fire and slipping hazards.
Never use flammable solvents like gasoline or die-
sel fuel for cleaning parts.
If overheated tire is suspected, never stand in front
of the tire. Stay away until the tire and rim cool
down.
Tire and rim assemblies if improperly serviced can
explode with deadly force. When inflating tires;
- Make sure wheel parts are correctly installed.
- 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.
OM0187
OM0032
OM0033
20. 1.14
SAFETY
Safe Maintenance
Do not operate the engine where there are or can
be combustible vapors. These vapors can be
drawn through the air intake system and cause
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.
Other Maintenance Safety Concerns
Periodically check the ROPS bolts (if equipped) to
be sure they are in place and tight.
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.
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.
OM0008
OM0188
21. 1.15
SAFETY
Safe Maintenance
Do not enter the articulation area when engine is
running.
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.
60ZV 3652L
Articulation Stopper "LOCKED"
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23. 1.16
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 Kawasaki 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.
24. 1.17
SAFETY
Safety Signs
L.H, R.H
44787-24360
DANGER
1.
R.H
44787-24320
WARNING
12.
Inside L.H, R.H
44841-20870
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.
44787-20871
CAUTION
Improper brake oil or fluids can
cause brake failure resulting in
injury or death.
Use only approved oil such as:
Mobil Delvac 1 or equivalent
Inside
60ZV2 02597-1020PVa
44841-20650
CAUTION
Machine will not turn with articulation
stopper in locked position.
Unlock articulation stopper before
operating machine.
44841-20630
WARNING
Accidental movement of machine could
result in death or serious injury.
Before checking transmission oil:
Park on level ground.
Lower bucket to ground.
Place transmission in neutral.
Set parking brake.
Tag "Do Not Operate".
5.
44787-24410
WARNING
44787-24440
WARNING
10. Inside
