service repair manual

1. ©2009 Kawasaki Heavy Industries, Ltd. All rights reserved. Printed in Japan (k)
( アメリカ用 )
93206-00111
January 2009
SHOP MANUAL
WHEEL LOADER
60ZV-2
General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSB4.5 Engine
Serial No. 60C3-5001~
General
Information
60ZV-2
SHOP
MANUAL
93206-00111
Function
&
Structure

2. 93206-00111
January 2009
Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.
General Information
Functions and structure
For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
The purpose of this manual is to provide information on the product and the correct maintenance and repair meth-
ods. Please read this manual to ensure correct troubleshooting and good repair service.
This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or
requests, please inform us.

3. Safety Symbols
An accident may occur if you disregard safety rules.
In this manual, several expressions are used according to levels of danger for inspection and repair work as shown
below. Read the work procedures and cautions described in this manual, and take preventive measures against
possible problems before starting service work.
We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that
is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing
service work.
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.

4. CONTENTS
60ZV-2 General Information .................................................................................................................................. 00-1
How to Use Manual ........................................................................................................................................... 00-2
Safety precautions ...................................................................................................................................... 00-2
Symbols ...................................................................................................................................................... 00-3
Outline ............................................................................................................................................................... 00-4
Layout of main components ........................................................................................................................ 00-4
Inspection and maintenance table .............................................................................................................. 00-5
Recommended lubricants ........................................................................................................................... 00-8
Coolant ..................................................................................................................................................... 00-10
Lubrication chart ........................................................................................................................................00-11
Weight of main components ..................................................................................................................... 00-12
Bolt tightening torque ................................................................................................................................ 00-13
Hose band tightening torque ..................................................................................................................... 00-17
Liquid gasket and screw lock agent .......................................................................................................... 00-18
Cautions regarding welding repair service ................................................................................................ 00-20
60ZV-2 Measurement for Performance Check ..................................................................................................... 03-1
Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
60ZV-2 Function & Structure Chassis Group ........................................................................................................ 12-1
Front Chassis .................................................................................................................................................... 12-2
Loading linkage ........................................................................................................................................... 12-2
Loading linkage pin ..................................................................................................................................... 12-3
Rear Chassis .................................................................................................................................................... 12-4
Fuel tank ..................................................................................................................................................... 12-4
Floor board mount ....................................................................................................................................... 12-5
Center Pin ......................................................................................................................................................... 12-6
Upper center pin ......................................................................................................................................... 12-6
Lower center pin ......................................................................................................................................... 12-6
Dust seal ..................................................................................................................................................... 12-7
60ZV-2 Check & Adjustment Chassis Group ........................................................................................................ 13-1
Linkage Pin ....................................................................................................................................................... 13-2
Liner ............................................................................................................................................................ 13-2
Center Pin ......................................................................................................................................................... 13-4
Adjusting shim ............................................................................................................................................. 13-4
Installing bearing cover ............................................................................................................................... 13-4

5. 60ZV-2 Function & Structure Power Group .......................................................................................................... 22-1
Power Line ........................................................................................................................................................ 22-2
Engine / Transmission ....................................................................................................................................... 22-3
Engine / transmission mount ....................................................................................................................... 22-3
Radiator ............................................................................................................................................................. 22-4
Propeller Shaft .................................................................................................................................................. 22-6
Second propeller shaft assembly ................................................................................................................ 22-7
Third propeller shaft assembly .................................................................................................................... 22-8
Axle Assembly ................................................................................................................................................... 22-9
Axle Support .................................................................................................................................................... 22-10
Differential Gear .............................................................................................................................................. 22-12
Function of T.P.D ....................................................................................................................................... 22-13
Operation of T.P.D ..................................................................................................................................... 22-14
60ZV-2 Check & Adjustment Power Group ........................................................................................................... 23-1
Engine ............................................................................................................................................................... 23-2
Measuring engine speed ............................................................................................................................. 23-2
Measuring engine oil pressure .................................................................................................................... 23-2
Propeller Shaft .................................................................................................................................................. 23-3
Propeller shaft phase .................................................................................................................................. 23-3
Second propeller shaft alignment ............................................................................................................... 23-3
Tightening torque ........................................................................................................................................ 23-4
Axle ................................................................................................................................................................... 23-5
Axle ............................................................................................................................................................. 23-5
Differential gear ........................................................................................................................................... 23-6
60ZV-2 Function & Structure Torque Converter and Transmission Group ........................................................... 32-1
Torque Converter .............................................................................................................................................. 32-2
Torque converter structure .......................................................................................................................... 32-2
Power flow path .......................................................................................................................................... 32-2
Torque multiplication ................................................................................................................................... 32-2
Torque Converter Gear Pump ........................................................................................................................... 32-3
Gear pump specifications ........................................................................................................................... 32-3
Transmission ..................................................................................................................................................... 32-4
Gear arrangement ....................................................................................................................................... 32-4
Clutch specifications ................................................................................................................................... 32-5
Valve location .............................................................................................................................................. 32-6

6. Clutch Pack ....................................................................................................................................................... 32-7
Forward and 2nd speed clutch .................................................................................................................... 32-7
Reverse and 1st speed clutch ..................................................................................................................... 32-8
3rd speed clutch .......................................................................................................................................... 32-9
Power Flow Path in the Transmission ............................................................................................................. 32-10
Hydraulic System Diagram ............................................................................................................................. 32-12
Hydraulic Circuit Diagram ............................................................................................................................... 32-13
Oil Flow ........................................................................................................................................................... 32-14
Oil flow in the torque converter line ........................................................................................................... 32-14
Oil flow to the clutch .................................................................................................................................. 32-14
T/C and T/M Oil Circulation ............................................................................................................................. 32-15
Control Valve ................................................................................................................................................... 32-16
System diagram ........................................................................................................................................ 32-18
Modulation Mechanism ................................................................................................................................... 32-19
Clutch control oil pressure curve ............................................................................................................... 32-19
Accumulator .................................................................................................................................................... 32-23
Accumulator for 1st speed clutch .............................................................................................................. 32-23
Clutch Solenoid Valve ..................................................................................................................................... 32-25
For forward/reverse and speed clutches ................................................................................................... 32-25
60ZV-2 Check & Adjustment Torque Converter and Transmission Group ........................................................... 33-1
Clutch Oil Pressure ........................................................................................................................................... 33-2
60ZV-2 Function & Structure Hydraulic Group ...................................................................................................... 42-1
Flushing Hydraulic Lines ................................................................................................................................... 42-2
Purpose of flushing ..................................................................................................................................... 42-2
Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3
Hydraulic Circuit Symbols ................................................................................................................................. 42-4
Hydraulic lines ............................................................................................................................................. 42-4
Pumps & motors ......................................................................................................................................... 42-4
Cylinders ..................................................................................................................................................... 42-4
Operation methods ..................................................................................................................................... 42-5
Pressure control valve ................................................................................................................................ 42-5
Flow control valve ....................................................................................................................................... 42-5
Directional control valve .............................................................................................................................. 42-6
Check valve ................................................................................................................................................ 42-6
Miscellaneous hydraulic symbols ................................................................................................................ 42-7

7. Layout of Hydraulic Units .................................................................................................................................. 42-8
Hydraulic Tank ................................................................................................................................................... 42-9
Hydraulic tank breather valve (tank cap) ................................................................................................... 42-10
Hydraulic tank specifications ......................................................................................................................42-11
Hydraulic oil level check .............................................................................................................................42-11
Hydraulic Pump ............................................................................................................................................... 42-12
Hydraulic pump specifications .................................................................................................................. 42-12
Hydraulic pump principle ........................................................................................................................... 42-13
Hydraulic pump wear plate ....................................................................................................................... 42-14
Hydraulic pump bushing lubrication .......................................................................................................... 42-14
Hydraulic Cylinder ........................................................................................................................................... 42-15
Boom cylinder ........................................................................................................................................... 42-15
Bucket cylinder .......................................................................................................................................... 42-15
Steering cylinder ....................................................................................................................................... 42-16
Hydraulic cylinder specifications ............................................................................................................... 42-17
Return Filter .................................................................................................................................................... 42-18
Loading System .............................................................................................................................................. 42-19
Relief Valve Assembly ..................................................................................................................................... 42-20
Relief valve operation ............................................................................................................................... 42-21
Check valve operation .............................................................................................................................. 42-21
Accumulator .................................................................................................................................................... 42-22
Accumulator specifications ....................................................................................................................... 42-22
Pilot Valve (TH40MS) ...................................................................................................................................... 42-23
Pilot valve specifications ........................................................................................................................... 42-24
Pilot valve performance chart ................................................................................................................... 42-24
Pilot valve operation .................................................................................................................................. 42-26
Multiple Control Valve (KVS-120H-2) .............................................................................................................. 42-28
Multiple control valve specifications .......................................................................................................... 42-29
Multiple control valve main relief valve ..................................................................................................... 42-30
Multiple control valve overload relief valve ............................................................................................... 42-32
Multiple control valve make-up valve ........................................................................................................ 42-33
Multiple control valve bucket spool ........................................................................................................... 42-34
Multiple control valve boom spool ............................................................................................................. 42-36
Elbow Adapter ................................................................................................................................................. 42-39
Pilot Valve Filter .............................................................................................................................................. 42-40

8. Steering System .............................................................................................................................................. 42-41
Priority Valve ................................................................................................................................................... 42-43
Priority valve specifications ....................................................................................................................... 42-43
Priority valve operation ............................................................................................................................. 42-44
Orbitrol®
.......................................................................................................................................................... 42-47
Orbitrol®
construction ................................................................................................................................ 42-47
Orbitrol®
specification ............................................................................................................................... 42-48
Orbitrol®
operation .................................................................................................................................... 42-49
Orbitrol®
feed-back mechanism operation ................................................................................................ 42-51
Steering speed and flow rate control ........................................................................................................ 42-52
Hydraulic pump oil amount and steering force .......................................................................................... 42-52
Orbit rotor operation principle ................................................................................................................... 42-53
Auxiliary valves ......................................................................................................................................... 42-54
Emergency check valve ............................................................................................................................ 42-56
Inlet check valve ....................................................................................................................................... 42-56
Cushion Valve ................................................................................................................................................. 42-57
Cushion valve specifications ..................................................................................................................... 42-58
Cushion valve operation ........................................................................................................................... 42-58
60ZV-2 Check & Adjustment Hydraulic Group ...................................................................................................... 43-1
Loading/Steering Circuit Relief Valve ................................................................................................................ 43-2
Loading circuit relief valve setting pressures .............................................................................................. 43-2
Steering circuit relief valve setting pressures .............................................................................................. 43-7
Hydraulic Cylinder ............................................................................................................................................43-11
Cylinder natural drift ...................................................................................................................................43-11
60ZV-2 Function & Structure Brake Group ........................................................................................................... 52-1
Brake Circuit ..................................................................................................................................................... 52-2
Brake Units Layout ............................................................................................................................................ 52-3
Hydraulic Servo Master Cylinder ...................................................................................................................... 52-4
Hydraulic servo master cylinder specifications ........................................................................................... 52-5
Performance diagram ................................................................................................................................. 52-5
Hydraulic servo master cylinder operation .................................................................................................. 52-6
Pressure Difference Switch ............................................................................................................................... 52-8
Service Brake .................................................................................................................................................... 52-9
Service brake operation .............................................................................................................................. 52-9
Service brake friction plate ........................................................................................................................ 52-10

9. Service brake steel plate ........................................................................................................................... 52-10
Brake circuit air bleeding procedure ..........................................................................................................52-11
Parking Brake .................................................................................................................................................. 52-12
Brake Control .................................................................................................................................................. 52-13
Service brake linkage ................................................................................................................................ 52-13
Parking brake linkage ............................................................................................................................... 52-14
Brake Oil Reservoir ......................................................................................................................................... 52-15
Brake oil reservoir specifications .............................................................................................................. 52-15
60ZV-2 Check & Adjustment Brake Group ........................................................................................................... 53-1
Hydraulic Servo Master ..................................................................................................................................... 53-2
Hydraulic servo master performance inspection ......................................................................................... 53-2
Service Brake .................................................................................................................................................... 53-4
Service brake performance check .............................................................................................................. 53-4
Service brake friction plate wear measurement .......................................................................................... 53-5
Parking Brake .................................................................................................................................................... 53-6
Parking brake performance check .............................................................................................................. 53-6
Parking brake clearance adjustment ........................................................................................................... 53-7
Brake Control .................................................................................................................................................... 53-9
Adjusting brake pedal and switch ............................................................................................................... 53-9
Parking brake linkage adjustment ..............................................................................................................53-11
60ZV-2 Function & Structure Electrical Group ...................................................................................................... 62-1
How to Use Electrical Wiring Diagram .............................................................................................................. 62-2
Electrical Cable Color Codes ............................................................................................................................ 62-3
Electrical Circuit Symbols .................................................................................................................................. 62-4
Sensor Mount .................................................................................................................................................... 62-5
Fuse .................................................................................................................................................................. 62-6
Fuse box ..................................................................................................................................................... 62-6
Fusible link .................................................................................................................................................. 62-8
Engine Start Circuit ........................................................................................................................................... 62-9
Engine start circuit diagram ........................................................................................................................ 62-9
Neutral starter ........................................................................................................................................... 62-10
Starter switch .............................................................................................................................................62-11
Battery relay .............................................................................................................................................. 62-12
Alternator I terminal wire ........................................................................................................................... 62-12
Diode unit .................................................................................................................................................. 62-12

10. Neutral relay .............................................................................................................................................. 62-13
Magnet switch ........................................................................................................................................... 62-14
Voltage relay ............................................................................................................................................. 62-15
Power Generating/Charging Circuit ................................................................................................................ 62-16
Alternator .................................................................................................................................................. 62-16
ECM (Engine Controller) ................................................................................................................................. 62-17
Function of ECM ....................................................................................................................................... 62-17
Connection diagram .................................................................................................................................. 62-17
Monitor lamp test ...................................................................................................................................... 62-18
Failure diagnosis ....................................................................................................................................... 62-19
Quantum fault code information ................................................................................................................ 62-22
Accelerator pedal ...................................................................................................................................... 62-29
Transmission Control Circuit and Monitor Circuit ............................................................................................ 62-31
Machine control unit (MCU) ...................................................................................................................... 62-31
Machine control unit (MCU) connection diagram ...................................................................................... 62-33
Machine control unit (MCU) function ......................................................................................................... 62-34
Monitoring system ..................................................................................................................................... 62-45
Instrument Panel and Switch .......................................................................................................................... 62-47
Instrument panel ....................................................................................................................................... 62-47
Instrument panel rear surface ................................................................................................................... 62-48
Gauge circuit ............................................................................................................................................. 62-49
Fuel level sensor ....................................................................................................................................... 62-51
Electrical Detent Circuit ................................................................................................................................... 62-52
Bucket leveler ........................................................................................................................................... 62-52
Boom kick-out ........................................................................................................................................... 62-52
Detent solenoid ......................................................................................................................................... 62-53
Diode ............................................................................................................................................................... 62-54
Diode check method ................................................................................................................................. 62-55
Caution for diode check method ............................................................................................................... 62-55
Surge voltage and surge suppression diodes ........................................................................................... 62-57
Diagnostic System .......................................................................................................................................... 62-58
Diagnostic system flow ............................................................................................................................. 62-58
Diagnostic failure history memory data ..................................................................................................... 62-59
Diagnostic failure history indication and deletion ...................................................................................... 62-63
Diagnostic switch ...................................................................................................................................... 62-65

11. 60ZV-2 Check & Adjustment Electrical Group ...................................................................................................... 63-1
Cautions Regarding Electric Circuit Check ....................................................................................................... 63-2
Disconnecting or reinstalling connector ...................................................................................................... 63-2
How to attach the probes of the circuit tester .............................................................................................. 63-4
Electrical Transmission Control System Troubleshooting Flowchart ................................................................ 63-5
Standard troubleshooting flowchart ............................................................................................................. 63-5
MCU Abnormal Operation Judgment ................................................................................................................ 63-6
MCU check ................................................................................................................................................. 63-6
MCU LED indicator ..................................................................................................................................... 63-8
Electrical Circuit Check ................................................................................................................................... 63-10
Shift lever input electrical circuit check ..................................................................................................... 63-10
Declutch input electrical circuit check ....................................................................................................... 63-12
Downshift button input electrical circuit check .......................................................................................... 63-14
Machine speed sensor input electrical circuit check ................................................................................. 63-15
Clutch solenoid valve output electrical circuit check ................................................................................. 63-16
Neutral relay electrical circuit check .......................................................................................................... 63-19
Checking parking brake circuit .................................................................................................................. 63-21
Gauge circuit electrical circuit check ......................................................................................................... 63-22
Bucket leveler electrical circuit check ....................................................................................................... 63-25
60ZV-2 Drawing & Diagrams ................................................................................................................................ 92-1
Axle Assembly ................................................................................................................................................... 92-2
Torque Converter and Transmission ................................................................................................................. 92-3
Loading/Steering Hydraulic Line ....................................................................................................................... 92-4
Brake Circuit ...................................................................................................................................................... 92-5
Electrical Wiring Diagram (1/2) ......................................................................................................................... 92-6
Electrical Wiring Diagram (2/2) ......................................................................................................................... 92-7
Electrical Wiring Diagram .................................................................................................................................. 92-8
Electrical wiring diagram abbreviation chart ............................................................................................... 92-8
Electrical Connection Diagram .......................................................................................................................... 92-9
Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-10
Electrical Equipment Layout ............................................................................................................................ 92-12

12. 00-1
60ZV-2 General Information
60ZV-2 General Information
How to Use Manual................................................. 00-2
Outline..................................................................... 00-4

13. 00-2
60ZV-2 General Information
How to Use Manual
How to Use Manual
Safety precautions
The most important point in providing repair service is
safety. To ensure safety, observe the general cautions
described below.
- This manual is intended for properly trained and
equipped service technicians.
- Any work on the machine must be performed by the
trained personnel only.
- Carefully read this manual to thoroughly understand
the operation method before you operate or repair
the machine.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles.
- Place the machine on level and solid ground, and
place chocks against the wheels to prevent move-
ment.
- Remove the cable from the battery before starting
the service work, and attach a "DO NOT OPER-
ATE!" tag to the steering wheel.
- Be sure to release the internal pressure before you
remove a pipe, such as the hydraulic oil, air, or
engine coolant pipe.
- Be sure to apply the articulation stopper before start-
ing work.
- While supporting the bottom of the chassis using a
jack, be sure to support the chassis using the blocks.
- When the boom or bucket is raised or when a unit is
lifted by a crane, be sure to place a stand or ade-
quate cribbing under the unit to prevent unexpected
dropping.
- Do not start to work in an enclosed area if adequate
ventilation is not provided.
- To remove a heavy unit (20 kgf (40 lbs) or more), be
sure to use a crane or other lifting device.
- Just after stopping operation, be careful not to
directly touch a hot component. You may get burned.
- Contact tire manufacturer's local dealer for tire ser-
vicing and changing.
- Always store the tools in good condition, and use
them properly.
- Keep the work area clean. Clean up spills immedi-
ately.
- Avoid the use of flammable solvents and cleaners.
- When working outdoors keep work areas, ladders,
steps, decks and work platforms clear of snow, ice,
and mud.
- Use safe work platforms to reach higher areas of the
machine.
- Any technician that operates a refrigerant recovery
and recycling machine must first be certified through
an EPA approved testing program.
More information is available at http://www.epa.gov/
ozone/title6/608/technicians/608certs.html.
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 program,
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.

14. 00-3
60ZV-2 General Information
How to Use Manual
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Abbreviation
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the follow-
ing abbreviation list. Additional abbreviations are listed on page 92-8.
Symbol Item Description
Reference
Shows the condition or procedure that will be useful
or efficient in doing service work.
Weight
Shows the weight of a part or unit. The weight
should be considered in selecting wire rope or cable
for slinging work or determining the working pos-
ture.
Tightening
torque
Shows the tightening torque of a section that should
be carefully tightened during assembly work.
Coating
Shows the type of coating or adhesive and the coat-
ing section.
Oil or
water
supply
Shows the oil or water supply port and the refill
amount.
Drainage
Shows the oil or water drain port and the drain
amount.
IMPORTANT
If the specified conditions are not satisfied or the specified procedure is not
observed, there is a strong possibility that the product will be damaged or the per-
formance of the product will be reduced.
The message shows the preventive measures.
E/G ........... Engine
T/C ........... Torque converter
T/M ........... Transmission
SOL ........... Solenoid valve
SW ........... Switch
F ........... Front or Forward
A/M ........... Auto/Manual
B ........... Battery
R ............Rear or Reverse
RH ............Right hand side
LH ............Left hand side
H ............High
L ............Low
GND............Ground
OPT ............Option
Assy ............Assembly
1st ............1st speed
2nd ............2nd speed
3rd ............3rd speed
4th ............4th speed
M/C ............Machine
min-1
............RPM
MCU ...........Machine control unit

15. 00-4
60ZV-2 General Information
Outline
Outline
Layout of main components
1. Engine assembly (Cummins QSB4.5)
2. Transmission/Torque converter assy
3. Hydraulic pump
4. Multiple (loader) control valve
5. Orbitrol®
6. Pilot valve (for loading)
7. Air cleaner
8. Muffler
9. Radiator
10. Front axle assembly
11. Rear axle assembly
12. 2nd propeller shaft
13. 3rd propeller shaft
14. T/C charging pump
15. Hydraulic oil cooler (air-to-oil type)
16. T/C oil cooler
17. Parking brake
60V2U00001
3 14
4 5 6 7 8 9
1
2
17
12
10 13 11 16 15

16. 00-5
60ZV-2 General Information
Outline
Inspection and maintenance table
: First time replacement or cleaning only
Section Item for check
Operating hours
When
Required
10 50 250 500 1000 2000
Engine
Check Engine Oil Level
Check Engine Coolant Level
Check Warning Lamps
Check Exhaust Gas
Drain Water and Sediment from Fuel Filter
Check Fuel Level
Check Drive Belt
Check Crankcase Breather Tube
Check Air Intake System
Check Cooling Fan
Drain Water and Sediment from Fuel Tank
Replace Engine Oil and Oil Filter Cartridge
Replace Fuel Filter Cartridges
Inspect Automatic Belt Tensioner Pulley
Clean Fuel Tank
Check and Adjust Valve Lash Clearance
Clean or Replace Air Cleaner Element
Clean Radiator / Air cooler / Hydraulic oil cooler Fins
Clean or Replace Air Cleaner Element After six cleanings or once a year
Replace Coolant Every 2 years or 3000 hours
Transmission &
Torque
Converter
Check Transmission Oil Level
Replace Transmission Oil Filter Cartridge
Replace Transmission Oil
Clean or Replace Transmission Breather
Axle system
Check Tire for Damage, Air and Tread Depth
Check Tire Air Pressure
Greasing (Axle support)
Check Differential Gear Oil
Greasing (2nd Propeller Shaft)
Greasing (3rd Propeller Shaft)
Check Tightness of Wheel Bolts
Replace Differential Gear Oil

17. 00-6
60ZV-2 General Information
Outline
: First time replacement or cleaning only
Section Item for check
Operating hours
When
Required
10 50 250 500 1000 2000
Steering system
Check Steering Wheel Operation
Greasing (Steering Cylinder)
Brake system
Check Brake Oil Level
Check Service Brake Operation
Check Parking Brake Operation
Adjust Parking Brake Lining
Check Service Brake Disk Wear
Overhaul Brake Master Cylinder
Loading system
Check Hydraulic Oil Level
Greasing
Replace Hydraulic Oil Return Filter
Replace Hydraulic Oil, Clean Filter
Replace Filter in the Hydraulic Tank Cap
Replace Bucket Teeth (option)
Replace Cutting Edge (option)
Chassis
Adjust and Check Rear View Mirrors
ROPS (Roll Over Protective Structure) (option)
Greasing (Center Pin)
Check Ride Control Accumulator (option)
Check and/or Replace Seat Belt
Check Windshield Washer Fluid
Electrical
system
Check Monitor Panel Operation
Check Horn Operation
Check Back-up Alarm Operation
Check Wiring Harnesses
Check Battery Electrolyte Level
Check or Replace Fuses

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19. 00-7
60ZV-2 General Information
Outline
: First time replacement or cleaning only
Section Item for check
Operating hours
When
Required
10 50 250 500 1000 2000
Air Conditioner
(option)
Check and Adjust Air Conditioner Belt (option)
Clean Air Conditioner and Heater Filter Element (option)
Check Air Conditioner Refrigerant (option)
Replace Air Conditioner Filter Elements (option)
Clean Air Conditioner Condenser (option)
Replace Air Conditioner Receiver Dryer (option) Every 3 years or 6000 hours
Others Walk-Around Inspection

20. 00-8
60ZV-2 General Information
Outline
Recommended lubricants
Refill capacity
(Approximate)
Kind of Oil
Ambient Temperature Change
Interval
(Hours)
Engine
12 liter
(3.2 gal)
Engine oil
(CH4)
∗2
500
Transmission
20 liter
(5.3 gal)
ATF
Engine oil (CD)
Mobil TRANS HD-10
Valvoline DT10
1,000
Hydraulic tank
∗1
87 liter (23 gal)
∗3
Hydraulic oil
2,000
Differential &
Planetary
40 liter
(10.5 gal)
Mobil TRANS HD-30
Valvoline DT30
2,000
Brake oil tank
2.1 liter
(0.5 gal)
Engine oil —
Fuel tank
175 liter
(46 gal)
Diesel fuel daily
Note: ∗1 shows "Hydraulic tank oil capacity at level gauge center."
-30ºC -20 -10 0 10 20 30
-22ºF -4 14 32 50 68 86
40
104
SAE10W-30
SAE15W-40
SAE10W
Mobil TRANS HD-10
Valvoline DT10
Multi-Purpose ATF
ISO VG46
ISO VG32
Mobil TRANS HD-30
Valvoline DT30
Mobil TRANS HD-50
Valvoline DT50
Mobil Delvac1 ESP 5W40
ASTM D975 No.2
ASTM D975 No.1
Engine Use oil that meets engine oil classification API CH4 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".
Mobil TRANS HD-10.
Valvoline DT10.
Multi-purpose Automatic Transmission Fluid.
Never mix engine oil, Mobil TRANS HD-10, Valvoline DT10 and/or ATF.
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 fail-
ure.
Differential &
Planetary
Use Mobil TRANS HD-30, Valvoline DT30 or equivalent with 5% "Antichatter" additive or
friction modifier.
Brake oil Use engine oil Mobil Delvac1 ESP 5W40 only.

21. 00-9
60ZV-2 General Information
Outline
Lubricating Grease Use multipurpose-type EP/MOLY grease for most applications.
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 a needle bearing.
Diesel Fuel
Specifications
Requirements for diesel fuel
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