You're about to tee a gauge into the loading line or count flashes off the engine warning lamp, and you need the standard value in front of you. This set covers the Kawasaki 90ZV-2 wheel loader, Serial No. 90C5-9001 and up, with the Cummins QSM11 engine. It comes as three bound books: 93213-00461, 93213-00471 and 93213-00450.
Every hour the loader sits with a slow boom or soft brakes, the pile doesn't move. The Troubleshooting book works through those faults one cause at a time, next to the chassis CN and engine EG code tables. Engine speeds are split by serial range, S/N 9001~9350 and S/N 9351~, and by Normal or Fuel efficient mode.
Put it on a tablet or phone and it goes wherever the machine is: in the cab, in the pump bay or out at the stockpile.
What's Inside This Kawasaki 90ZV-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-35 | Contents, Layout of Main Components, Maintenance Chart, Recommended Lubricants and Refill Capacity, Coolant, Weight of Main Components, Bolt Tightening Torque, Liquid Gasket, Welding Repair Cautions |
| Measurement for Performance Check (Standard Values) | 36-41 | Engine Speeds by Serial Range, Clutch Pressure, Relief Valve Setting Pressures, Cycle Times |
| Chassis Group: Function, Structure and Adjustment | 42-57 | Center Pin, Fuel Tank, Front and Rear Axle |
| Power Group: Cummins QSM11 Engine, Cooling and Drive Shafts | 58-89 | Radiator, Air Charge Cooler, Differential, Propeller Shaft, Engine Oil Pressure Measurement |
| Torque Converter and Transmission | 90-121 | Torque Converter, Hydraulic Circuit Diagram, Modulation, Clutch Pressure Check |
| Hydraulic Group: Function, Structure and Adjustment | 122-245 | Flushing Hydraulic Circuit, Multiple Control Valve, Orbitrol, Steering Valve, Ride Control, Relief Valve Setting Pressures |
| Brake Group | 246-293 | Service Brake, Brake Valve, Unloader Valve, Accumulator, Parking Brake |
| Electrical Group | 294-403 | Fuse Box, Mcu, Modm, Engine Fault Codes, Error Codes |
| Operator Station Group | 404-487 | Cab, Operator Seat, Air Conditioner |
| Index, Maintenance Log and Drawings & Diagrams | 488-553 | Index, Maintenance Log, Axle and Transmission Drawings, Hydraulic & Brake Circuit, Electrical Wiring Diagrams by Serial Range, MODM Operation |
| Disassembly & Reassembly: General Information | 554-580 | Weight of Main Components, Bolt Tightening Torque, Liquid Gasket, Welding Repair Cautions, Articulation Stopper |
| Disassembly & Reassembly: Chassis Group and Service Standard | 581-614 | Fuel Tank, Center Pin |
| Disassembly & Reassembly: Power Group and Service Standard | 615-684 | Engine Assembly Removal and Installation, Front and Rear Axle, Differential |
| Disassembly & Reassembly: Torque Converter and Transmission | 685-738 | Transmission Assembly, Clutch Pressure, Modulation |
| Disassembly & Reassembly: Hydraulic Group and Service Standard | 739-822 | Hydraulic Pumps, Hydraulic Cylinders, Multiple Control Valve, Orbitrol |
| Disassembly & Reassembly: Brake Group and Service Standard | 823-866 | Service Brake, Brake Valve, Unloader Valve, Parking Brake |
| Disassembly & Reassembly: Operator Station, Index and Maintenance Log | 867-893 | Cab, Periodical Inspection/Servicing, Index, Maintenance Log |
| Troubleshooting | 894-952 | Quick Troubleshooting Tables (Torque Converter and Transmission, Hydraulic, Brake, Electrical), Error Codes for Chassis and Engine |
| Measurement for Performance Check (Procedures) and Maintenance Log | 953-1011 | Engine Speed, Clutch Pressure, Relief Pressure Setting, Accumulator Charging, Cycle Time, Maintenance Log |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Cummins QSM11 | p. 19 |
| Engine oil refill capacity | 37 liter (change every 500 hours) | p. 23 |
| Transmission oil refill capacity | 38 liter (change every 1,000 hours) | p. 23 |
| Hydraulic tank refill capacity | 165 liter (change every 2,000 hours) | p. 23 |
| Differential & planetary oil (front / rear) | 74 liter / 80 liter | p. 23 |
| Fuel tank capacity | 370 liter | p. 23 |
| Low idle (S/N 9001~9350) | 800±50 min-1 (725 in hibernate mode) | p. 38 |
| High idle (S/N 9001~9350) | 2,250±50 min-1 | p. 38 |
| Torque converter stall (S/N 9001~9350, Normal / Fuel efficient) | 2,180±100 / 2,015±100 min-1 | p. 38 |
| Loading line main relief pressure (HI) | 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi) | p. 39 |
| Steering line overload relief pressure (LI) | 24.5 +1.0 MPa (250+10 kgf/cm2) (3,555+143 psi) | p. 39 |
Kawasaki 90ZV-2 Common Problems This Manual Covers
Machine does not move in forward or reverse
Start with the torque converter and transmission quick troubleshooting table (p906). It lists air drawn into the suction line of the torque converter pump, a defective torque converter pump, a damaged torque converter and a sticking clutch pressure regulator valve. Then run the clutch pressure check in Measurement for Performance Check (Procedures).
Manual Section: Troubleshooting / Quick troubleshooting (torque converter and transmission) p. 906Boom and bucket are slow under load
The hydraulic quick troubleshooting table (p917) starts with an internally damaged main pump, main relief valve leakage or low setting pressure. It also lists overload relief valve leakage, cold oil or wrong viscosity, and a suction side air leak. Before you pull the pump, gauge the loading line against main relief (HI) 20.6±0.5 MPa (p39).
Manual Section: Troubleshooting / Quick troubleshooting (hydraulic) p. 917Steering is hard or not possible
The hard steering table (p921) lists an internally damaged Orbitrol, a sticking stop valve spool and an internally damaged steering pump. It also names a defective main or overload relief valve and a defective steering cylinder. Check steering main (HI) 20.6±0.5 MPa (p39) first, because a gauge costs far less than an Orbitrol.
Manual Section: Troubleshooting / Quick troubleshooting (hydraulic) p. 921Brakes do not work well or accumulator pressure won't build
Before you open anything up, the Brake Group table has you check nitrogen gas pressure in the accumulator, look for leaks in the brake piping and read any error code on the MODM (p928). Then measure brake disk wear. If accumulator pressure stays low, p931 points to low unloader valve switching pressure or a defective unloader valve.
Manual Section: Troubleshooting / Quick troubleshooting (brake) p. 928Frequently Asked Questions
How do I clear an error code on a Kawasaki 90ZV-2?
On S/N 9351 and thereafter, you have to enter a password to clear a fault code on the MODM (p369). The book doesn't print the password. It comes from the Kawasaki Service Representative. Check your serial plate first, because the password requirement starts at S/N 9351. p. 369
How do I read engine fault codes on the 90ZV-2 without a laptop?
Watch the engine warning lamp. It flashes, and the Electrical Group shows how to convert the flashing pattern to the 3-digit fault code (p318). Then look that code up in the Quantum fault code information list (p321). p. 318
What do the CN and EG error codes mean on a Kawasaki 90ZV-2?
CN codes are chassis codes and EG codes are engine codes. Both are listed in the Troubleshooting Electrical Group tables, and the MODM only displays them. CN121 is a shift lever F & R switch malfunction (p935). EG111 Red means Engine Control Module (ECM) - critical internal failure, and EG113 Yellow means Engine Timing Actuator Circuit - shorted high (p938). p. 935
What are the bolt torque specs for the Kawasaki 90ZV-2?
The General Information torque table gives hexagon bolt values by grade, 8.8 (8T) / 10.9 (11T). An M12 (C) 1.75 bolt is 90 / 132 N-m, and an M16 (C) 2.0 is 216 / 314 N-m (p27). Read the head marking before you pick a column. p. 27
What should the relief valves be set to on a 90ZV-2?
Loading line main relief (HI) is 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi), and steering main (HI) is the same (p39). Loading overload (LI) is 23.5±0.5 (240±5) (3,413±71). Steering overload (LI) is 24.5 +1.0 (250+10) (3,555+143). With those numbers you can check a relief valve before you blame the pump, which makes the book worth having. p. 39
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