DOWNLOAD PDF : Kawasaki 80ZV WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00273

80ZV

93109-00273 May 16, 2007

OPERATION & MAINTENANCE MANUAL WHEEL LOADER

80ZV

Printed in Japan (i) ( オーストラリア用 )

93109-00273

©2007 Kawasaki Heavy Industries, Ltd. All rights reserved.

NOTICE Powered by CUMMINS 6CTAA8.3 Engine Serial No. 80C4-8001 and up

READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING AND SAVE THIS MANUAL ON THE MACHINE

93109-00273 May 16, 2007

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 80ZV. 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 obligation.

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.

This manual is compiled for persons who understand English. If an operator or maintenance person does not understand English, please translate what said in this manual into his mother language.

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

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

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

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

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

Always follow safe operating and maintenance practices.

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. Contact 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.

CONTENTS 1.SAFETY ...................................................................................................................................................... 1.1 SAFETY ..................................................................................................................................................... 1.2 Safe Operation..................................................................................................................................... 1.2 Safe Maintenance...............................................................................................................................1.11 Safety Signs....................................................................................................................................... 1.16 Safety Devices ................................................................................................................................... 1.21 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 ................................................................................................................................................... 2.24 Electrical Protection ........................................................................................................................... 2.26 Radio - AM / FM Cassette (24Volt Type) (option) .............................................................................. 2.28 Air Conditioner ................................................................................................................................... 2.36 Vibration Damper (option).................................................................................................................. 2.43 Grease Gun Holder............................................................................................................................ 2.44 OPERATION ............................................................................................................................................ 2.45 Check before Operation..................................................................................................................... 2.45 Starting the Engine ............................................................................................................................ 2.55 Check after Starting the Engine ......................................................................................................... 2.57 Operating the Machine ...................................................................................................................... 2.62 Parking............................................................................................................................................... 2.65 Stopping the Engine........................................................................................................................... 2.66 Operating Techniques ........................................................................................................................ 2.67 SPECIAL PROCEDURES ....................................................................................................................... 2.74 Adjustments ....................................................................................................................................... 2.74 Roading / Special Applications .......................................................................................................... 2.77 Booster Batteries / Jumper Cables .................................................................................................... 2.78 Towing................................................................................................................................................ 2.80 Transportation.................................................................................................................................... 2.81 Long Term Storage ............................................................................................................................ 2.83

3.MAINTENANCE .......................................................................................................................................... 3.1 MAINTENANCE ......................................................................................................................................... 3.2 Serial Number Location ....................................................................................................................... 3.2 Inspection and Maintenance Table ...................................................................................................... 3.4 When Required Inspection and Maintenance ...................................................................................... 3.7 Every 10 Hours or Daily ..................................................................................................................... 3.16 Every 50 Hours or 1 Week ................................................................................................................. 3.17 Every 250 Hours or 1 Month .............................................................................................................. 3.23 Every 500 Hours or 3 Months ............................................................................................................ 3.33 Every 1000 Hours or 6 Months .......................................................................................................... 3.37 Every 2000 Hours or 1 Year............................................................................................................... 3.43 Coolant Specification ......................................................................................................................... 3.55 TROUBLESHOOTING ............................................................................................................................. 3.56

1.1

1.SAFETY

1.2 SAFETY Safe Operation

SAFETY Safe Operation Operator Safety

OM0026

Wear safe clothing: OM0001

Read and understand the Operation & Maintenance Manual.

- Close fitting clothing -- loose or baggy clothing can catch on equipment or controls.

- Protective clothing as required by the job or conditions 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.

OM0180

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.

1.3 SAFETY Safe Operation

Mounting and Dismounting Safety

OM0012

OM0010

Face the machine when mounting or dismounting.

Maintain three points of contact when climbing (two hands and one foot, or two feet and one hand).

When mounting or dismounting, never carry tools or other objects in your hands.

Climb and step only where steps and handrails are provided.

OM0181

Use only the handrails provided to climb -- do not use the steering wheel, shift lever, mirror brackets, or control lever.

Use extra caution mounting and dismounting when slippery conditions exist (oil, ice, snow, mud, or wet conditions).

Never jump from the machine regardless if machine is moving or stopped.

Report or replace any damaged or missing steps, handrails, or anti-skid material.

Do not allow unauthorized personnel on the machine.

1.4 SAFETY Safe Operation

Before Starting Safety

OM0005 OM0006

Perform the normal daily maintenance.

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.

Lock

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.

Unlock

70ZV0009

Be sure the following safety devices work or are positioned properly.

- Parking Brake -- Applied - Control Lever Lock -- Locked

N

65ZV 5089

- Transmission Shift Lever -- Neutral

1.5 SAFETY Safe Operation

Articulation Stopper "STORED"

OM0007

85ZV0002

- Articulation Stopper -- Locked in the "STORED" position.

- Back-up Alarm -- Operational

Adjust the seat, seat belt and steering column, mirrors, etc.

Properly fasten the seat belt.

Securely lock the cab door either fully open or closed.

Secure any loose items inside the cab (lunch boxes, tools, vacuum bottles, etc.).

DANGER

After using the ashtray, close the ashtray cap to avoid fire.

DO NOT START MEN WORKING ON

Do not leave a lighter in the cab. The lighter may cause explosion by high temperature in the cab.

MACHINERY SIGNED BY

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.

DATE

OM0182

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.

1.6 SAFETY Safe Operation

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.

OM0011

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.

OM0021

Avoid working under or near overhanging material that could fall on the machine.

Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

OM0183

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 2.78.

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.

1.7 SAFETY Safe Operation When working on a grade:

SAFETY DURING NORMAL OPERATIONS:

- Turn "OFF" the transmission cut-off selector 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 provides some engine braking.

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.

OM0013

Using the machine for purposes other than specified in the Operation & Maintenance Manual may create hazards that are not mentioned in this manual.

OM0018

Before crossing a bridge, make sure that the capacity of the bridge is greater than the weight of the machine and any load it may be carrying.

Check for enough clearance before entering a building, doorway, tunnel, under wires or other structures.

Do not 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 recommendations and limits.

Maintain stability by carrying the load as low as possible throughout each cycle.

Do not expose the machine to flames.

approx. 40 cm OM0016

- The normal carry position is about 40 cm above the ground.

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 vehicles, four-way flashers, or clearance lights, etc.

- If roading long distances (over 3 km), periodically stop to allow tires, transmission, engine to cool down. Excessive tire heat caused by roading can cause blow-outs and loss of control.

Stop the machine motion immediately if any failure occurs that causes reduced control (e.g.; engine, pump, or brake system failures).

Lower the bucket or attachment to stop the machine only when an emergency, like loss of braking occurs.

Be sure there are no bystanders under the raised bucket or attachment.

OM0184

Never position or move the load over the cab of a truck or other vehicle.

OM0020

Never use the "Float" position to lower the boom since it will fall rapidly.

Drive into a load at a medium speed. Do not run into the material at high speed.

Always be alert for abnormal noises, odors, vibrations, heat, etc.

1.9 SAFETY Safe Operation

SPECIAL OPERATING CONDITIONS:

80ZV0001 OM0185

Avoid entering water deeper than the bottom of the wheel rim.

If entering water is unavoidable: - Use caution that there are no hidden hazards -(drop-offs, holes, rocks, logs, etc.).

- Check for normal braking after leaving the water.

- Check differential gear oil for contamination.

Reduce speed and avoid rapid steering movement when traction is poor -- mud, snow, ice, etc. Use tire chains if necessary.

When darkness, fog, snow, dust, smoke, etc. reduce visibility, use the following precautions: - Use adequate lighting.

- Use flashers or beacons (if equipped).

- Reduce speed.

- Periodically stop and inspect the job site.

- Take more frequent breaks to reduce fatigue.

If towing or pulling something is required: - Keep helpers or bystanders away from between the machine and the towed vehicle or object.

- Use a cable of adequate capacity and in good condition.

- Use a cable that has appropriate pull hooks.

- Use only the hitch provided on the rear of the machine.

- 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.

1.10 SAFETY Safe Operation

Parking Safety

If parking near a road, be sure and erect safety barriers and lights as required.

Stop the machine on level ground with the service brakes -- not the parking brake.

Lower the attachment to the ground and apply the parking brake.

OM0025

If parking on level ground is not possible, follow these precautions: - Lower the attachment to the ground and apply some down pressure.

- Block the tires.

- Apply the parking brake.

To prevent unauthorized use: - Remove the key.

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

- Install vandal covers (if equipped).

OM0186

Inspect the machine and report any needed repairs.

1.11 SAFETY Safe Maintenance

Safe Maintenance Safety Preparations Before Maintenance Do not rush. Walk, do not run. Avoid shortcuts that may cause accidents.

Perform maintenance and repairs only if trained.

Follow the Operation & Maintenance Manual or Shop Manual.

OM0002

Air conditioner servicing and repair should be performed by trained specialists since injury and/or environmental pollution can result from improper servicing.

- Do not wear jewelry that may catch on equipment, controls, or may short and cause burns if in contact with electrical components.

Allow only properly trained tire mechanics with the proper tools to service tires and rims.

OM0025

OM0026

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 conditions -- for example: - Hard hat - Gloves - Steel-toe shoes - Eye / face protection - Approved respirator

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 Operation & 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. Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes and cause serious injury, blindness or death.

1.12 SAFETY Safe Maintenance

OM0029

OM0031

Never make repairs on pressurized components.

Release all trapped air and hydraulic pressure by:

If working under the raised boom or attachment, be sure to properly block or support boom.

- Stopping the engine after lowering the attachment to the ground.

- Moving the loading control levers back and forth.

- Turning the steering wheel right and left several times.

- Turning the hydraulic oil tank cap 1/3 turn counterclockwise.

Do not stand on tires. Use safe and sturdy working platforms.

DANGER DO NOT START MEN WORKING ON MACHINERY SIGNED BY DATE

OM0182

Attach a "DO NOT START" or "DO NOT OPERATE" 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.

1.13 SAFETY Safe Maintenance

Explosion / Fire / Burn Prevention

Clean up all spills of coolant, fuel, oil, etc. to prevent fire and slipping hazards.

Before removing any coolant hoses or plugs, relieve any trapped pressure in the cooling system.

Never use flammable solvents like gasoline or diesel fuel for cleaning parts.

Cooling system additives and cleaners may contain alkali that can cause caustic burns or blindness.

Avoid contact with skin or eyes.

Pour all fuel and oil into appropriate containers.

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

Hot oils or coolant and components can cause burns. Allow components to cool to a safe temperature 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

OM0032

If overheated tire is suspected, never stand in front of the tire. Stay away until the tire and rim cool down.

OM0033

Tire and rim assemblies if improperly serviced can explode with deadly force. When inflating tires; OM0187

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 component areas (i.e.; muffler, manifold, etc.).

- Make sure wheel parts are correctly installed.

- Use a self attaching (locking) air chuck.

- Use a remotely located valve to turn air pressure 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.

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.

Other Maintenance Safety Concerns Periodically check the ROPS bolts (if equipped) to be sure they are in place and tight.

To prevent ignition, use the luminaire when checking oil, cooling water, fuel and battery electrolyte level.

Move ignitable things to a safe place when grinding welding or gas cutting.

Charge a battery at well ventilated place and keep fire away from it during charging.

OM0008

Never weld, drill or in any way modify the ROPS without approval from the manufacturer.

Stop the engine before opening the engine side panel.

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

During servicing, inspect the wiring harnesses, connections and wires and replace any that may be chafed, or tighten any that may be loose.

OM0188

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

Keep the area clear of bystanders and wear proper eye protection and protective clothing when grinding or welding.

1.15 SAFETY Safe Maintenance Do not enter the articulation area when engine is running.

Articulation Stopper "LOCKED" 85ZV0001

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 rubber hose, it may cause an accident or fire by a wrong actuation. If something is wrong with the rubber 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 damaged by vibrating or scratching other parts.

- Fasten the rubber hose with designated torque when the connection is loosen.

- Exchange the hose base when it is damaged or deformed.

- Exchange the hose cover when it is damaged, cut or expanded.

- Exchange the moving contact of the rubber hose when it is twisted or bent.

1.16 SAFETY Safety Signs

Safety Signs All safety signs which are on the machine are shown here. Read them and understand them thoroughly. 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 missing, 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.

1.17 SAFETY Safety Signs

WARNING

WARNING

WARNING

Contact with moving fan could result in death or serious injury.

Keep hands away from fan area.

Stop engine before opening door or rear grille.

44841-21100

Contact with moving belts or pullies could result in death or serious injury.

Stop engine before warking in this area.

44841-20700

Inside

Inside

DANGER Removal, damage or alteration of Roll Over Protctive Structure (ROPS) will result in death or Serious injury.

Always keep ROPS in place.

Do not operate this machine if ROPS has been removed, damaged, or altered.

44841-20870

Inside L.H, R.H

Nitrogen accumulator contains compressed gas and fluid which could result in death or serious injury.

Release all brake circuit oil pressure before removing any oil lines or piping.

Do not attempt to service or repair accumulator unless properly trained and equipped.

44841-20750

L.H, R.H

80ZV02597-0722PV

L.H, R.H

L.H, R.H

DANGER

R.H

WARNING

WARNING

Pressurized system: spray of hot fluid could result in death or serious injury.

Allow system to cool and vent pressure slowly before servicing.

44841-20950

Pressurized system: spray of hot fluid could result in death or serious injury.

Allow system to cool and vent pressure slowly before servicing.

44841-20720

CAUTION

No room in this area when turning.

Crushing will result in death or serious injury.

Stay out of this area when machine could move or turn.

44841-20600

Machine will not turn with articulation stopper in locked position.

Unlock articulation stopper before operating machine.

44841-20640

1.18 SAFETY Safety Signs

WARNING

Pressurized system: spray of hot fluid could result in death or serious injury.

Allow system to cool and vent pressure slowly before servicing.

44841-20720

WARNING

DO NOT USE ETHER. THIS ENGINE EQUIPPED WITH ELECTRIC HEATER STARTING AID. USE OF ETHER COULD CAUSE EXPLOSION AND COULD RESULT IN DEATH OR SERIOUS INJURY.

WARNING

Batteries produce explosive gases which could result in death or serious injury.

Keep flames and sparks away.

Vent area before servicing.

44841-20680

44787-23780

CAUTION

Batteries contain lead, and acid which may result in minor or moderate injury.

Avoid contact with skin or clothing.

If lead, or acid contacts skin or clothing, immediately wash with water.

44841-20690

Inside

Inside

80ZV02597-0722TV

Inside

DANGER

Sudden or accidental movement of boom will result in death or serious injury.

Before walking or working under raised boom.

Securely block orbrace boom.

Remove key and tag "Do Not Operate".

Relieve all trapped oil pressure before opening any piping.

44841-20880

WARNING

Pressurized system: spray of hot fluid could result in death or serious injury.

Allow system to cool and vent pressure slowly before servicing.

44841-20720

WARNING

Batteries produce explosive gases which could result in death or serious injury.

Keep flames and sparks away.

Vent area before servicing.

44841-20680

Inside

CAUTION

Batteries contain lead, and acid which may result in minor or moderate injury.

Avoid contact with skin or clothing.

If lead, or acid contacts skin or clothing, immediately wash with water.

44841-20690

1.19 SAFETY Safety Signs

WARNING

WARNING

Contact with moving belts or pullies could result in death or serious injury.

Stop engine before warking in this area.

44841-20700

Contact with moving fan could result in death or serious injury.

Keep hands away from fan area.

Stop engine before opening door or rear grille.

44841-21100

Inside

Inside

L.H, R.H

80ZV02597-0722RE

Inside

WARNING

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

Do not start engine by shorting across starter terminals.

Do noto start engine while standing on ground.

Make sure to start engine only from operator’s seat with transmission in neutral and parkingu brake applied.

44841-20660

WARNING

Pressurized system: spray of hot fluid could result in death or serious injury.

Allow system to cool and vent pressure slowly before servicing.

44841-20720

1.20 SAFETY Safety Signs

Parking brake cylinder

WARNING

Compressed spring may accidently be released and could result in death or serious injury.

Read Shop Manual before repairing this part.

80ZV02597-0729EE

44841-20740

Inside of Cab

A A

A-A

70ZV02597-0717BS

70ZV02597-0717AS

WARNING DANGER Removal, damage or alteration of Roll Over Protctive Structure (ROPS) will result in death or Serious injury.

Always keep ROPS in place.

Do not operate this machine if ROPS has been removed, damaged, or altered.

44841-20870

Improper operation or maintenance could result in death or serious injury.

Read, understand, and follow Operation & Maintenance Manual before operating or servicing machine.

Follow all safety signs in Operation & Maintenance Manual or on machine.

44841-20610

1.21 SAFETY Safety Devices

Safety Devices

Articulation Stopper

Loading Control Lever Lock

WARNING

DANGER Accidental movement of boom or machine will result in death or serious injury.

When parking or leaving machine, or when performing maintenance on it, always lower attachment to ground and lock loading control levers.

With articulation stopper in LOCKED position, machine will not steer; which, while operating, could cause an accident, injury or death.

Do not lock Articulation Stopper during normal operation.

Articulation stopper locks the front and rear chassis to prevent them from sudden articulation during inspection or transportation.

To lock:

Lock Unlock

70ZV0009

This device locks the loading control levers to prevent accidental lowering of the attachment or boom.

"LOCKED" position 85ZV0001

- To lock, set the loading control levers to "NEUTRAL" and pull-up the lock lever to forward.

1. Align the front and rear chassis straight ahead.

- To unlock, push down the lock lever to backward.

2. Using a 13 mm wrench remove the bolt that fixes the articulation stopper to the storage bracket on the front chassis.

3. Remove the clip pin and pin from the end of the Articulation Stopper.

4. Turn the link and fix the end to the bracket on the rear chassis (as shown).

5. Insert the pin and clip pin. (This is the LOCKED position.)

1.22 SAFETY Safety Devices

Neutral Start System

To unlock:

The transmission has a neutral start system which allows the engine to start only when the transmission shift lever is in NEUTRAL position.

Emergency Brake When the service brake does not work, emergency brake can be applied manually.

"STORED" position

85ZV0002

1. Remove the clip pin and pin from the end of the articulation stopper on the rear chassis bracket.

2. Turn the link to the front chassis bracket.

3. Insert the pin and clip pin. (This is the STORED position.)

4. Tighten the bolt to fix the articulation stopper on the bracket.

97ZVOM0038

- Pull the emergency brake switch to engage the emergency brake and disengage the transmission.

1.23 SAFETY Safety Devices

ROPS (Roll Over Protective Structure) Cab

WARNING Operating with damaged or improperly mounted ROPS Cab could serious injury or death. Be sure to observe the following.

- Whenever seated, fasten the seat belt. (If equipped) - Do not modify ROPS Cab, such as drilling or welding.

- Do not use ROPS Cab deformed.

- If any damage or loose bolts are found, do not operate until repaired.

- Never repair or modify ROPS Cab without manufacturer’s approval and instructions.

1.24

MEMO

2.1

2.OPERATION

2.2 COMPONENT NAME/LOCATION

COMPONENT NAME/LOCATION 24

5

16

23

22

21

10

9

4

3 2 1

20

11 80ZV OM COMPO

14

18

12,13 17

1. Bucket (Attachment) 2. Boom 3. "Z" Lever 4. Boom Cylinders (2) 5. Bucket Cylinder 6. Steering Cylinders (2) 7. Engine 8. Torque Converter & Transmission Ass'y 9. Radiator & Torque Converter Cooler (Lower tank) 10. Air Cooler (for engine intake air) 11. Hydraulic Oil Cooler 12. Fuel Tank NOTE When a component or an item location is given as "Left hand side" or "Right hand side", it is according to the operator's left side or right side when sitting in the seat.

6

8

19

15

7

13. Hydraulic Oil Tank (Right hand side) 14. Front Axle / Differential Ass'y 15. Rear Axle / Differential Ass'y 16. Air Cleaner (Right hand side) 17. Parking Brake 18. 2nd Propeller Shaft 19. 3rd Propeller Shaft 20. Batteries (2) (one each side--two 12VDC=24VDC system) 21. Cooling Fan 22. Fan Motor (hydraulic type) 23. Exhaust Muffler 24. ROPS Cab

2.3 OPERATOR'S AREA Pedals and Levers

OPERATOR'S AREA Pedals and Levers

1. Transmission Shift Lever

11

2

1

Transmission Shift Lever is used to control machine speed and direction.

3

- Push the lever forward to move the machine forward.

- When the lever is in NEUTRAL, the machine should not move on level ground.

- Pull the lever backward to move the machine backward.

9 6 (option)

10

9

8

97ZVOM0041

- The four forward and four reverse speed shifting modes are selected by rotating the shift lever.

7

4

5

70ZV0010

1. Transmission Shift Lever 2. Horn Button 3. High-Low Beam Lever / Turn Signal Lever 4. Boom Control Lever 5. Bucket Control Lever 6. Auxiliary Attachment Control Lever (option) 7. Wrist Rest 8. Accelerator Pedal 9. Brake Pedals 10. Steering Column Telescopic Tilt Handle 11. Steering Wheel

65ZV 5089

[1]: 1st speed (fixed) [2]: 2nd speed (fixed) [3]: 3rd speed (fixed) [A]: 2nd, 3rd and 4th speed is automatically selected for the machine running condition.

2. Horn Button Horn Button is used to blow the horn.

- Press the button in the center of the steering wheel to blow the horn.

2.4 OPERATOR'S AREA Pedals and Levers

3. High-Low Beam Lever / Turn Signal Lever

4. Boom Control Lever Boom control lever is used to control the boom movement.

Low beam position

(a)

(b)

(c) (d)

High beam position

97ZVOM0044

This lever is used to change the head lights beam high and low. This lever also turns on the turn signals.

- The head lights are in the high beam position when the lever is pushed down (low position).

- The light switch can be operated regardless of the lever position.

70ZV0010

(a) Float - Move the lever to full forward detent position.

- The boom will lower and move freely following the ground surface. (b) Lower - Move the lever forward. The boom will lower.

- When held in this position, down pressure will be applied to the attachment. (c) Hold - Return the lever to the center position. The boom will stop and remain in that position.

97ZVOM0044

- Push the lever forward to turn on the left turn signal.

- Pull the lever backward to turn on the right turn signal.

- Return the lever to the center position when the turn is completed. The lever does not return automatically when the steering wheel is returned to center.

(d) Raise - Move the lever rearward. The boom is raised.

- An automatic boom height positioner (option) is provided which will automatically release the detent and return the lever to the "Hold" position when a preset boom height is reached.

- For adjustment procedure refer to "Boom Kickout Adjustment" page 2.75.

In case that the boom does not stop moving even when the boom control lever is in the HOLD position, turn the starter switch to the "OFF" position to stop the engine.

IMPORTANT If the engine stops by some trouble, lower the boom and place the bucket on the ground immediately.

2.5 OPERATOR'S AREA Pedals and Levers

5. Bucket Control Lever

6. Auxiliary Attachment Control Lever (option)

Bucket control lever is used to control the bucket or attachment movement.

(a)

(b) (c)

(d)

Auxiliary attachment control lever is used to control the auxiliary attachment such as log clamps, multipurpose buckets, etc.

(a)

(b) (c)

70ZV0010

(a) Dump - Move the lever forward. The bucket or attachment will dump. (b) Hold - Return the lever to the center position. The bucket or attachment will stop and remain in that position. (c) Roll Back (Dual Motion) - Move the lever rearward half way. The bucket or attachment will roll back slowly.

- When the boom control lever is in the "Raise" detent position, both bucket or attachment and boom will move slowly. (d) Roll Back (Detent) - Move the lever rearward. The bucket or attachment will roll back.

- An automatic bucket or attachment leveler is provided which will automatically release the detent and return the lever to the "Hold" position when the bucket or attachment reaches to the preset angle.

- For adjustment procedure refer to "Bucket / Attachment Positioner Adjustment" page 2.74.

In case that the bucket does not stop moving even when the bucket control lever is in the HOLD position, turn the starter switch to the "OFF" position to stop the engine.

70ZV0010

(a) Normally this position will close the attachment. (b) This center position will cause the attachment to stop and remain in that position. (c) Normally this position will open the attachment.

In case that the auxiliary attachment does not stop moving even when the auxiliary attachment control lever is in the HOLD position, turn the starter switch to the "OFF" position to stop the engine.

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

IMPORTANT Kawasaki will not accept any liability for any attachments and spare parts not approved by Kawasaki.

2.6 OPERATOR'S AREA Pedals and Levers

7. Wrist Rest

8. Accelerator Pedal

Unlock

Lock

65ZV4705

97ZVOM0038

Wrist rest is used to put on the wrist or arm while operating the bucket/boom control levers.

Accelerator pedal is used to control the engine speed.

To adjust the position (High/Low or Front/Rear loosen the screws.

- Depress the pedal to increase the engine speed.

(High/Low) Pull the lever out and turn, bringing back to the original position, to adjust the height.

- Release the pedal to decrease the engine speed.

(Front/Rear) Loosen the screws to adjust the position.

WARNING Control pedals which stick could cause loss of control and injury or death.

- Be sure control pedals move freely before operating.

- Do not allow dirt, mud, or debris to build up under or around pedals.

In case that the accelerator pedal does not release, depress one of the brake pedals or turn the starter switch to the "OFF" position.

2.7 OPERATOR'S AREA Pedals and Levers

9. Brake Pedals

CAUTION WARNING Continuous use of brake could cause rapid or abnormal brake disc wear and / or brake circuit malfunctions which could cause loss of control and injury or death.

- Do not use brake pedals as foot rest.

- Do not ride brakes.

- Use brake pedals only when applying brakes.

97ZVOM0038

Brake pedals are used to reduce the machine ground speed, stop the machine, or to hold the machine.

Left and right Brake Pedals: May be used either of two ways: 1. As a brake only pedal by turning the transmission cut-off selector switch (See page 2.12) to the "OFF" position. Use this position when working on slopes or ramps.

2. Disengage the transmission while applying the brakes. This is normally used when loading trucks. It allows higher engine speed to provide faster hydraulic operations.

To use this feature, turn the transmission cutoff selector switch to the "ON" position. When the switch is "ON", a green indicator lamp on the dash will also be turned on.

Transmission cut-off feature momentarily places transmission in neutral, which may allow machine to roll when on a grade.

Be sure to turn off transmission cut-off selector switch when operating on a grade.

In case the brake does not work, pull the parking brake switch to apply the emergency brake. The parking brake can be used as the emergency brake.

2.8 OPERATOR'S AREA Pedals and Levers

10. Steering Column Telescopic Tilt Handle

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

- Stop machine before adjusting steering wheel height and angle of steering column.

- Be sure to push down fully the telescopic tilt handle lock lever before operating machine.

Steering column telescopic tilt handle is used to adjust the steering wheel up and down, and to tilt the steering column forward or backward for operator's comfort.

Release

Lock

97ZVOM0045

1. Pull up the telescopic tilt handle lock lever and move the steering wheel to the desired position.

2. Push down the telescopic tilt handle lock lever fully to lock the steering wheel in position.

2.9 OPERATOR'S AREA Switches

Switches

11

4

6

20

30

5

N 40

10

0 0 0 0 0 0 1/10h

AUTO

4

C

H

C

H

E

F

3 0

50 km/h

2 1

80ZV0002

3

2

13

10

1

12

9 7

8

65ZV 5088

1. Starter Switch 2. Parking Brake Switch 3. Light Switch 4. Front Working Light Switch 5. Rear Working Light Switch 6. Transmission Cut-Off Selector Switch 7. Front Wiper Switch

70ZV0010

65ZV FR SWITCH

8. Rear Wiper Switch 9. Cigarette Lighter 10. Power Up Switch 11. Four-way Flasher Switch 12. Selection Switch for Shift Lever or F/R Switch (option) 13. F/R Switch (option)

2.10 OPERATOR'S AREA Switches

1. Starter Switch

2. Parking Brake Switch

WARNING PREHEAT

OFF

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

ON

START

Be sure to pull parking brake switch when parking or leaving machine, and during maintenance or transportation.

65ZV0074

OFF - Key can be either inserted or pulled out.

- Engine is stopped and most electrical circuits are turned off.

ON - Current flows to all circuits.

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

- When released the key will automatically return to the "ON" position.

PREHEAT - This position is used when it is too cold to start the engine.

- Intake air will be heated and the preheat lamp comes on. When released the key will automatically return to the "ON" position.

97ZVOM0038

Parking brake switch is used for parking the machine. When the switch is pulled, the parking brake is applied and the transmission is disengaged. When the switch is pushed, the parking brake is released.

Should the directional shift lever be moved into the forward or reverse position while the parking brake is applied and the engine is running, a warning buzzer will sound.

2.11 OPERATOR'S AREA Switches

3. Light Switch

4. Front Working Light Switch

70ZV0006

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

65ZV 5088

This is a three position switch.

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

- Width (clearance) lamps (option), tail lamps, and gauge lamps turn on.

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

Turn off the front working lights when roading to prevent blinding the driver in front of you.

2.12 OPERATOR'S AREA Switches

5. Rear Working Light Switch

6. Transmission Cut-Off Selector Switch

70ZV0006 70ZV0006

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

Turn off the rear working lights when roading to prevent blinding the driver behind you.

Transmission cut-off selector switch is used to change the function of the brake pedals.

Normally this switch should be "ON".

OFF - When the brake pedals are depressed, only the service brakes are engaged keeping the transmission directional clutch engaged. (brake only) ON - When the brake pedals are depressed, the service brakes are engaged and the transmission directional clutch is disengaged (brake and declutch).

Refer to "Brake Pedals" page 2.7 for the function of both left and right brake pedals.

CAUTION Transmission cut-off feature momentarily places transmission in neutral which may allow machine to roll when on a grade.

Do not turn transmission cut-off selector switch to "ON" when operating on a grade.

2.13 OPERATOR'S AREA Switches

7. Front Wiper Switch

8. Rear Wiper Switch

65ZV 5088

Front wiper switch is used to wipe the front windshield and spray solvent.

OFF

65ZV 5088

Rear wiper switch is used to wipe the rear windshield.

INT LOW HIGH

OFF

ON

PUSH

PUSH

OM0190

OM0189

OFF

:

OFF

:

INT

: Intermittent

ON

: Low speed

LOW : Low speed HIGH : High speed PUSH : Spraying solvent on the windshield

PUSH : Spraying solvent on the windshield

2.14 OPERATOR'S AREA Switches

9. Cigarette Lighter

10. Power Up Switch

65ZV 5088

Cigarette lighter is used to light a cigarette or cigar.

- Push the lighter in and wait for a few seconds.

The lighter will spring back to be ready for lighting a cigarette or cigar.

- The cigarette lighter power-outlet socket can be used as a power source with max. 24 volts 10 amperes in case of emergency.

70ZV0010

Power up switch is used to quickly shift down the transmission from 2nd gear to 1st gear without moving the transmission shift lever.

- When operating the machine in 2nd speed with the shift lever in [2] or [A] position, the transmission will shift down to 1st gear by pressing power up switch.

- Pressing power up switch again, moving the transmission shift lever to the neutral position, or operating the parking brake switch releases the 1st gear setting to return the transmission to 2nd gear.

2.15 OPERATOR'S AREA Switches

11. Four-way Flasher Switch

12. Selection Switch for Shift Lever or F/R Switch (option)

70ZV0006

The two front and two rear turn signal lights will flash when four-way flasher switch is ON. This is used in emergency, when parking on the road, etc. to warn other vehicles.

65ZV FR SWITCH

Selection switch for shift lever or F/R switch is used to switch the forward/reverse function by using from the shift lever to the F/R switch.

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

Regardless of the shift lever position, while the F/R switch is in N position, when pressing Selection switch, the switch turns ON, and the changing for forward/reverse can be operated by F/R switch.

Pressing Selection switch again, the light goes out, and the function of F/R switch is cancelled.

The shift lever can be used to move the machine forward or reverse.

However for safety purposes, place the shift lever in the neutral position before pressing Selection switch again.

2.16 OPERATOR'S AREA Switches

13. F/R Switch (option)

65ZV FR SWITCH

F/R switch is used to move the machine forward and reverse.

Place the F/R switch in F position to move the machine forward, and in R position to move the machine reverse.

The machine does not move either way when the F/R switch is in N position.

Operation

Shift lever position

F/R switch position

Selection switch

By F/R switch

Any position

N

ON

By shift lever

N

Any position

OFF

2.17 OPERATOR'S AREA Indicators

Indicators 20

21

5

17 19

18

9

23

4

1 10

20 10 0

N

40

11

0 0 0 0 0 0 1/10h

AUTO

30

C

4

H

12

F

E

13

3

km/h

50

2 1

C

14

H

15 16 65ZV5003

24 25 22

6

1. Speedometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Gauge 5. Parking Brake Indicator Lamp (red) 6. Transmission Cut-Off Selection Lamp (green) 7. Working Light Indicator Lamp (green) 8. Preheat Indicator Lamp (orange) 9. Central Warning Lamp (red) 10. Transmission Control Warning Lamp (red) 11. Brake Pressure Warning Lamp (red) 12. Engine Oil Pressure Warning Lamp (red) 13. Engine Coolant Temperature Warning Lamp (red) When the starter switch is turned to "ON", all warning lamps (9) ~ (16), (24) and (25) light up for three seconds. This is the lamp (bulb) test period (lamp (16) lights up until engine starts).

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

Stop machine and correct problems if any red lamps come on.

8

7

3

2

14. Torque Converter Oil Temperature Warning Lamp (red) 15. Air Cleaner Warning Lamp (red) 16. Charge Lamp (red) 17. Turn Signal Indicator Lamp (Left) (green) 18. Turn Signal Indicator Lamp (Right) (green) 19. High Beam Indicator Lamp (blue) 20. Auto Shift Indicator Lamp 21. Neutral Indicator Lamp 22. Transmission Status Monitor 23. Hour Meter 24. Vibration Damper Pilot Lamp (green) (option) 25. Emergency Steering Warning Lamp (red) (option)

2.18 OPERATOR'S AREA Indicators

1. Speedometer

20

3. Torque Converter Oil Temperature Gauge 30 40

10

C

H T/C OIL TEMP

50

0

km/h 97ZVOM0050 70ZV0008

Indicates the machine ground speed in km/h.

2. Engine Coolant Temperature Gauge

C

H WATER TEMP

97ZVOM0049

Indicates engine coolant temperature. It is normal when the indicator stays in the white zone (67~102ºC).

- If the indicator enters the red zone while operating, slow the engine down to mid-range speed and wait until the indicator reaches the white zone.

- If the gauge stays in the red zone, stop the engine and allow it to cool naturally. After cooling, check the cooling system.

Refer to "TROUBLESHOOTING" page 3.56.

Indicates the temperature of oil circulating through the torque converter and the transmission. It is normal if the indicator is in the white zone (56~125ºC) while operating.

- If the indicator enters the red zone while operating, slow the engine down to mid-range speed, shift to neutral, and wait until the indicator reaches the white zone.

- If the indicator does not come back into the white zone quickly, stop the engine and find the cause.

Refer to "TROUBLESHOOTING" page 3.60.

4. Fuel Gauge

E

F FUEL

65ZV0005

Indicates the fuel amount in the fuel tank.

- Be sure to refuel at the end of each work day to avoid condensation in the tank.

2.19 OPERATOR'S AREA Indicators

5. Parking Brake Indicator Lamp (red)

8. Preheat Indicator Lamp (orange)

P OM0052

Lights up when the parking brake is applied.

OM0176

Lights up when the starter switch is in the "PREHEAT" position.

If the transmission shift lever is moved into "F" or "R" position while this lamp is on, an alarm sounds and the machine stays in neutral.

9. Central Warning Lamp (red) 6. Transmission Cut-Off Selection Lamp (green)

OM0056

Flashes when any of the warning lamps come on.

OM0054

Lights up when the transmission cut-off selector switch is "ON".

10. Transmission Control Warning Lamp (red)

- When lit, the service brakes are engaged and the transmission directional clutch is disengaged by depressing the brake pedals.

- When not lit, only the brakes are engaged as the left brake pedal is depressed.

OM0057

Lights up when transmission controls malfunction.

7. Working Light Indicator Lamp (green)

OM0055

Lights up when working lights are on.

- If it lights up while operating, stop the engine and contact your nearest Kawasaki dealer for necessary repair.

2.20 OPERATOR'S AREA Indicators

11. Brake Pressure Warning Lamp (red)

13. Engine Coolant Temperature Warning Lamp (red)

WARNING Loss of braking force could result in death or serious injury.

Stop machine IMMEDIATELY and correct problem if brake pressure warning lamp lights up during operation.

Brake Pressure Warning Lamp lights up and the warning buzzer sounds when the brake oil pressure is lower than 3.9 MPa.

OM0058

- If it lights up while operating, IMMEDIATELY stop the machine and find the cause.

Refer to "TROUBLESHOOTING" page 3.59.

OM0060

Lights up when coolant temperature overheats.

(Over 102ºC) - If it lights up while operating, slow the engine speed down to mid-range, shift to neutral, and wait until the lamp goes out. Check the coolant temperature gauge before resuming operation.

- If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "TROUBLESHOOTING" page 3.56.

CAUTION Hot coolant spray may cause burns.

Never open radiator cap when engine is hot.

12. Engine Oil Pressure Warning Lamp (red)

OM0059

Lights up when engine oil pressure is low. Also the warning buzzer sounds.

- If it lights up while operating, IMMEDIATELY stop the engine and find the cause.

Refer to "TROUBLESHOOTING" page 3.56.

Stop engine and allow radiator and coolant to cool completely before opening cap slowly to relieve pressure.

2.21 OPERATOR'S AREA Indicators

14. Torque Converter Oil Temperature Warning Lamp (red)

16. Charge Lamp (red)

Lights up when transmission oil overheats. (Over 120±5ºC)

OM0063

Lights up when alternator charge level is low.

OM0061

- If it lights up while operating, slow the engine speed down to mid-range, shift to neutral, and wait until the lamp goes out. Check the torque converter oil temperature gauge before resuming the operation.

- If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "TROUBLESHOOTING" page 3.60.

15. Air Cleaner Warning Lamp (red)

- If it lights up, check the charging circuit.

Refer to "TROUBLESHOOTING" page 3.58.

17. Turn Signal Indicator Lamp (Left) (green)

OM0065

Flashes when the turn signal switch lever is moved forward.

OM0062

18. Turn Signal Indicator Lamp (Right) (green)

Lights up when air filter is clogged.

- If it lights up while operating, stop the engine and clean or replace the air cleaner outer element.

Refer to "Clean or Replace Air Cleaner Element" page 3.9.

OM0066

Flashes when the turn signal switch lever is moved rearward.

2.22 OPERATOR'S AREA Indicators

19. High Beam Indicator Lamp (blue)

22. Transmission Status Monitor

4 3 2 1

OM0067

Lights up when headlights are switched to high beam.

OM0070

20. Auto Shift Indicator Lamp

- 1st Gear Lights up when the shift lever is in [1] position and transmission is in 1st gear. Machine stays in this gear until manually shifted.

AUTO

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

OM0068

Lights up when the transmission control lever is in the [A] position.

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

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

21. Neutral Indicator Lamp 23. Hour Meter

N

1/10h OM0069

Lights up when transmission is in neutral.

OM0071

Hour meter indicates the accumulated total hours of engine operation. Use to determine the timing of periodic inspection and maintenance service.

2.23 OPERATOR'S AREA Indicators

24. Vibration Damper Pilot Lamp (green) (option)

OM0206

Lights up when the ride control switch is ON. Refer to "Vibration Damper (option)" page 2.43.

25. Emergency Steering Warning Lamp (red) (option)

OM0072

Lights up when the steering hydraulic pressure is lower than specified when the engine is running.

2.24 OPERATOR'S AREA Seat

Seat

Combined Height and Weight Adjuster

Seat Adjustment

1. Sit on the seat.

(KAB811)

2. Turn handle (a) to adjust seat height.

Adjust the seat for comfort and so that the pedals may be pushed fully down when the operator's back is fully back.

WARNING

Clockwise to raise seat.

Anti-Clockwise to lower seat.

3. Check ride indicator (b) shows green.

Unexpected movement of seat could result in death or serious injury.

Stop machine before adjusting seat position.

If red, readjust seat height.

Within the green band of the ride indicator there is 75 mm of height adjustment for any driver.

NOTE The seat is designed so that it is unnecessary to make any adjustment for the driver weight.

3

Up-Stop Height Adjustment Control

2 1

c a

b 95ZV OM EU SEAT

Reclining Rotate control handle (1) forward and hold, select backrest angle, release control handle.

Forward / Backward Lift lever (2) up and hold, slide seat to desired position, release handle.

Armrests Rotate control knob (3) to select desired angle.

Pivot up and parallel with backrest when not in use.

To adjust the up-stop height, rotate the handwheel (c) clockwise to raise the seat unseated, rotate it counter-clockwise to lower the seat unseated.

2.25 OPERATOR'S AREA Seat

Seat Belt

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

- Inspect seat belt and mounting hardware before operating machine and replace any defective components.

- Always fasten seat belt when operating machine.

- Properly adjust seat belt at beginning of each shift or when operator changes.

1

3

2

OM0007

1. Pull at the seat belt (1) and fasten it along your body without kinking or twisting it.

2. Hold buckle (2) and insert belt end (3) into buckle (2). Be sure it locks securely.

3. For releasing the seat belt, press the "press button" in the buckle (2) and remove the belt end (3) from the buckle (2).

The tether is inside the seat boot.

No adjustment necessary.

2.26 OPERATOR'S AREA Electrical Protection

Electrical Protection

(1) Left

Fuse Boxes 2 1

View from top cover

(80C4-8031~)

97ZVOM0086

2

1

View from top cover

80ZV8214

(2) Front

LIGHTING HEAD LIGHT

20A

SPARE

5A

R. WORK LIGHT

15A

SPARE

5A

BOOM KICKOUT BUCKET POSITIONER

10A

R. WIPER / WASHER

5A

BACK LAMP STOP LAMP TURN SIGNAL

15A

F. WIPER / WASHER

10A

PARKING BRAKE CONTROLLER (MACHINE)

10A

CIGAR LIGHTER

10A

F. WORK LIGHT

15A

SPARE

15A

SPARE

10A

RADIO

3A

SPARE

15A

SPARE

10A

SPARE

15A

SPARE

10A

4 WAY FLASHER HORN DOME LAMP RADIO BACK UP

15A

SPARE

20A

SPARE

10A

AIRCON

5A

PREHEAT

15A

AIRCON

5A

BUZZER MONITOR (CONTROLLER)

5A

AIRCON

10A

NEUTRAL RELAY

5A

AIRCON

20A

BATTERY RELAY

5A

SPARE

20A

Right

3

Rear

(3) FUEL SOLENOID RELAY

View from side cover

65ZVOM3131

Main Fuse Boxes are located in the right hand side console in the cab and contain thirty fuses. The additional fuse box (3) is also located in the right hand side console in the cab. It contains one fuse.

3A

2.27 OPERATOR'S AREA Electrical Protection

Fusible Link

IMPORTANT When replacing fuse, be sure to turn the starter switch to "OFF" position.

Fusible link protects the main hot wire from short circuits.

IMPORTANT Using wrong capacity fuse or bypassing fuse may cause electrical system damage.

Never replace fuses with higher amperage rating.

80ZVOM3288

1. If the fusible link is blown, the following problem occurs.

Problem (symptom) Fuse damaged

During engine operation

30A

-Horn will not operate.

-Flasher unit (Hazard-operation) will not operate.

-Engine will stop

-All the electrical circuit will not function.

-(Engine can not be started.)

70A (BR line)

-Horn will not operate.

-Flasher unit (Hazard-option) -All the others will not operate but engine can be stopped.

-The same conditions as "During engine operation" but engine can be started and stopped.

70A (Alternator line)

-The machine can be operated but the batteries can not be charged and the batteries will be discharged soon.

-The same conditions as "During engine operation".

During engine stop

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

2. To check the cause and replace the fusible link, call your nearest Kawasaki dealer.

2.28 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option)

Radio - AM / FM Cassette (24Volt Type) (option) 21

14

15

16

20

9 10 11

clarion

AM

ON OFF VOL

SLEEP

PUSH

AM/FM CASSETTE COMBINATION

CD

1

ST AUDIO MODE

2

TAPE

ALARM

CD

TIMER

AM FM

1 4

3

REW APC

5

6

SCAN

FF APC

DISP PS AS

M

H TUNE

RadioCassetteUSA

5

3

6

7

4 17

18

19

8

13

12

2.29 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option)

Symbol

Name of part Volume knob

Function

Operation method

Description

Turning power on/ off

PUSH

Push this SW to turn the power on or off.

The SW alternately turns the power on or off every time you push the SW.

Sleep timer

PUSH with ACC turned off

To use the sleep timer, push this SW with the ACC turned off. This function causes the unit to continue to operate for one hour and then automatically turns it off. At this time, "Sleep" will be shown on the display panel.

Sound volume adjustment MIN

Sound balance adjustment

MAX

Selected with audio mode button

1 L

Fader adjustment

R

Selected with audio mode button

REAR FRONT

Sound tone adjustment

Selected with audio mode button

Use this adjustment knob to adjust the sound volume.

To increase the sound volume, turn this knob clockwise to the desired volume level.

To decrease the sound volume, turn this knob counterclockwise to the desired volume level.

Use this knob to adjust the balance between the left and right speakers.

When turning the knob clockwise, with BALANCE mode, the sound volume from the left speakers will decrease, and the sound will be shifted to the right.

When turning the knob counterclockwise, the sound volume from the right speakers will decrease, and the sound will be shifted to the left.

Use this knob to adjust the balance between the front and rear speakers. When turning the knob clockwise, with FADER mode, the sound volume from the rear speakers will decrease, and the sound will be shifted to the front. When turning the knob counterclockwise, the sound volume from the front speakers will decrease, and the sound will be shifted to the rear.

Use this knob to adjust bass / treble to the desired level.

When turning the knob clockwise, with BASS/TREBLE mode, the sound will be boosted up.

When turning the knob counterclockwise, the sound will be cut.

CUT BOOST

MODE Audio mode button 2

Audio mode switching

PUSH

Every time you push this SW, the audio mode will be changed in the following order.

BASS → TREBLE → FADER ↑ ↓ VOLUME ← BALANCE No operation for 10 sec. or longer will return the mode to VOLUME. (Indication varies according to the audio source.)

When each mode is selected, the corresponding mode will be shown on the LCD display. However, turning the VOL knob, the mode stops showing and each level will be shown on the LCD display.

Remarks

2.30 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option)

Symbol

Name of part

Function Turning alarm ON/ OFF

Alarm button

3

PUSH

Alarm setting: Setting clock on the hour

Switching timer ON/ OFF One-touch timer button

Operation method

PUSH

Timer setting

Description Every time you push this button, alarm will be switched ON or OFF. (This function works with the ACC turned on or while the sleep timer is ON.) The alarm mark will be lit while the alarm is set.

When the time reaches the set time, you hear the alarm sound for 3 min. To stop the alarm sound, push any button.

Continuing to push the button for 2 sec. or more will cause the mode to shift to the alarm setting mode.

Push the button in the clock set mode to set the clock on the hour and reset the mode. If the minute value of the current time is less than 30, the minutes will be rounded down and the seconds will be reset. If the minutes value is more than 30, the minutes will be rounded up, one hour will be added to the hour value, and the seconds will be reset.

When the timer button is pushed, the timer mark will be lit and the mode will shift to the timer setting mode. At this time "0:00" will be shown on the display. However, if the timer has been set beforehand, the residual time will be shown on the display. (While the timer is running, the residual time decreases gradually.)

In the timer set mode, every time you push the button, indications will be changed in the following order. (When the button is released, the indication will be changed.)

0:15 → 0:30 → 1:00 → 2:00 ↑ ↓ 0:00 3:00 ↑ ↓ 6:00 ← 5:00 ← 4:00

4

When pushing the button for a long period in the timer set mode, the timer setting time increases in 5-minute steps. (Speed: 5 min./sec.)

"0:00" indicates that the timer is set to "OFF". At this time, the timer setting mode will be canceled unless you start to set the timer within 15 sec.

When performing operations other than timer setting in the timer setting mode, the current time will be set and the timer setting mode will be canceled.

When the residual time reaches 0, you hear the alarm sound for 3 min.

The timer mark continues to light while the timer works.

TAPE 5

TAPE button CD

6

CD button

Cassette tape play/ stop

PUSH

When the tape is loaded, push this button to play or stop the operation of the cassette tape.

In FF/REW/APC -FF/APC-REW, the mode will shift to "Play".

CD changer play/stop

PUSH

When the CD changer is loaded, push this button to play or stop the operation of the CD changer.

The CD Changer is optional and not normally supplied.

Remarks

Alarm mark

Timer mark

2.31 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option)

Symbol

Name of part AM/FM

7

AM/FM band selector button

PS AS

Function

Operation method

Description

Band switching Turning on radio Setting clock on the hour

PUSH

While the radio is turned on, push this button to change the radio frequency band. If a mode other than the radio is selected, push this button to turn on the radio at the last-tuned station.

Push this button for less than 2 sec. to change the radio frequency band from AM to FM or from FM to AM. If this button is pushed for 2 sec. or longer, a beep sound will be generated and the bands 1 and 2 will be switched with each other.

Preset scan in radio mode

PUSH

When this button is pushed for less than 2 seconds, the mode will shift to the PS mode and the preset stations will be played sequentially for 5 sec.

To stop the scan feature, push the button again and the radio will remain set to the last station. If the radio wave of the preset station is weak, the station will be skipped.

Every time the station is shifted, a beep sound will be generated.

If the radio cannot receive any stations, 2 times the preset stations will be automatically cancelled.

The preset scan will work on the currently-selected band (AM or FM).

Radio store button Auto store in radio mode

PUSH

When this button is pushed for 2 sec. or longer, the radio will generate a beep sound and the mode is shifted to the AS. Then the radio will search stations upward from the lower band end and automatically store them in the preset memory. The six stations that have the strongest wave will be stored in frequency order.

(AS will stop at the upper band end and the strongest station will be called up.)

Auto store (AS) will work on the currently-selected band (AM or FM).

If 6 stations are not stored fully, the previouslytuned stations will remain as they are.

Program scan in cassette tape mode

PUSH

Program scan will be performed in cassette tape mode. The beginning of each music track will be sequentially played for 10 sec.

When the button is pushed again in PS mode, the PS feature will be canceled and the currently selected music track will be played in full without skipping to the next music.

Program scan in CD mode

PUSH

Program scan will be performed in CD mode. The beginning of each track of the loaded CDs will be sequentially played for 10 sec.

When the button is pushed again in PS mode, the PS feature will be canceled and the currently selected music track will be played in full without skipping to the next music.

CD Changer is an option and is not normally offered.

PS, AS button Preset Scan (PS) Auto Store (AS)

8

Remarks

2.32 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option)

Symbol

Name of part

Function

Operation method

Description

Cassette tape ejection

PUSH

Push this button to eject the cassette tape.

This can be performed even with ACC off.

Display change

PUSH

Push this button to switch the indications shown on the display panel. Each time you push this button, the current time, alarm time, frequency (in radio mode), track No. and disc NO. indications (in CD changer mode), and cassette tape EQ position indication (in cassette tape mode) will be shifted to sequentially.

While the current time is shown on the display panel, pushing the button for 2 sec. or more will generate a beep sound. Then the indication will blink, and the mode will be shifted to the clock setting mode.

While the alarm time is shown on the display panel, pushing the button for 2 sec. or more will generate a beep sound and the mode will shift to the alarm setting mode.

Radio scanning

PUSH

Pushing this button will change the mode to Auto Tuning mode and will play each station for 5 sec.

To stop the scan feature and listen the currently tuned station continuously, push the button again while the station is tuned in and is being played.

9 Eject button DISP Display button

10

SCAN 11

SCAN button

Remarks

2.33 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option)

Symbol

Name of part

Function Manual tuning in radio mode

Operation method PUSH Upward

Description Push the button for less 0.5 sec. to increase the frequency or to decrease the frequency.

Downward Tuning button

for 0.5 sec. or less Seeking in radio mode

12

PUSH Upward Downward

13 for 0.5 sec. or less In clock time setting mode

PUSH Downward

Push the button once for less 0.5 sec. to increase the current hour value by one hour. Push the button for 0.5 sec. or longer to increase hours continuously.

PUSH Upward

Push the button once for less 0.5 sec. to increase the minutes value by one minute. Push the button for 0.5 sec. or longer to increase minutes continuously.

In radio mode: Recalling and storing preset memories

PUSH

Push the button for less 2 sec. to recall preset stations. Pushing the button for 2 sec. or longer will generate a beep sound and the currently tuned station will be stored.

In cassette tape mode: REW

PUSH

Push the button to rewind the cassette tape.

In CD mode: DISC DOWN

PUSH

Push the button to go down to the previous disc.

(Recalling the previous disc.)

"Hour" setting "Minute" setting

1

REW

Preset 1

14

REW button

Pushing the button for 0.5 sec. or longer will generate a beep sound.

While SEEK UP, SEEK DOWN or ILLUMI OFF is selected, the unit will seek radio stations in DX mode. While ILLUMI ON is selected, the unit will seek radio stations in Local mode. (However, seek functions only in AM mode.)

Remarks

2.34 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option)

Symbol

Name of part 2 PRO Preset 2 Program button

15

3

FF

Preset 3 FF button 16

4

APC

Preset 4 APC button

Function

Operation method

Description

In radio mode: Recalling and storing preset memories

PUSH

Push the button for less 2 sec. to recall preset stations. Pushing the button for 2 sec. or longer will generate a beep sound and the currently tuned station will be stored.

In cassette tape mode: Program

PUSH

Push the button to program the tape. (Switching forward or reverse modes.)

Pushing the button in FF, REW (APC) mode will play the cassette tape.

In CD mode: DISC UP

PUSH

Push the button to go to the next disc.

(Recalling the next disc.)

In radio mode: Recalling and storing preset memories

PUSH

Push the button for less 2 sec. to recall preset stations. Pushing the button for 2 sec. or longer will generate a beep sound and the currently tuned station will be stored.

In cassette tape mode: FF

PUSH

Push the button to wind forward the cassette tape quickly.

In CD mode: DISC UP

PUSH

Push the button to go to the next disc. (Recalling the next disc.)

In radio mode: Recalling and storing preset memories

PUSH

Push the button for less 2 sec. to recall preset stations. Pushing the button for 2 sec. or longer will generate a beep sound and will store the currently tuned station.

In cassette tape mode: APC REW

PUSH

Push the button to search for the beginning of the currently-played music track. Pushing the button again in APC REW mode will search for the beginning of the previous music. (Every time it is pushed after that, the number of music tracks to search for will be increased by 1.)

In CD mode: TRACK DOWN

PUSH

Push the button for less 2 sec. to search for the beginning of the currently-played track.

(If the button is pushed at the beginning of the music track, the beginning of the previous music track will be searched for.)

Push the button for 2 sec. or longer to rewind the CD fast.)

17

REVIEW

Remarks

No beep sounds

2.35 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option)

Symbol

Name of part

5

18

Preset 5 Dolby button

6

APC

Preset 6 APC button

19

Function

Operation method

Description

In radio mode: Recalling and storing preset memories

PUSH

Push the button for less 2 sec. to recall preset stations. Pushing the button for 2 sec. or longer will generate a beep sound and the currently tuned station will be stored.

In cassette tape mode: Turning on/ off

PUSH

Every time the button is pushed, DOLBY will be turned on or off alternately. Pushing the button for 2 sec. or longer will generate a beep sound and the currently tuned station will be stored.

In radio mode: Recalling and storing preset memories

PUSH

Push the button for less 2 sec. to recall preset stations. Pushing the button for 2 sec. or longer will generate a beep sound and the currently tuned station will be stored.

In cassette tape mode: APC FF

PUSH

Push the button to search for the beginning of the next music track. In APC FF mode, pushing the button again will search for the next-alternate music.

(Every time the button is pushed after that, the number of music tracks to search for will be increased by 1.)

In CD mode: TRACK UP QUE

PUSH

Push the button for less 2 sec. to search for the next music track.

Push the button for 2 sec. or longer to wind forward the music.

No beep sounds

Auto metal

20

Tape insertion slot

Cassette tape insertion slot

Insert the cassette tape with the open side of the cassette tape faced rightward to play the cassette tape.

21

LCD indicator

indicator

Displays time, frequency, etc.

Beep tone (guide tone)

Remarks

A beep sound will be generated when functions are changed depending on the push time of the button.

(Approx. 2KHz, 50ms)

2.36 OPERATOR'S AREA Air Conditioner

Air Conditioner

Switches

Ventilation Name and Location

(d)

(d)

(d)

1

2

3

4

5

Insolation sensor (d)

(b)

(b)

97ZVOM0093

6 (c)

(c) (c)

(c)

(a)

(a)

(a)

97ZVOM0092

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

Rear ventilation and defroster port Face ventilation port Foot ventilation port Defroster port

The wind direction from the ventilation ports (a) (b) can be changed arbitrarily by manipulating the louver.

The rear ventilation ports (a) can be used as defroster ports for the rear window glass by manipulating the direction of the louver.

7

8

1. OFF switch 2. Fan switch 3. Temperature control switch 4. Ventilation mode selecting switch 5. Auto switch 6. Air intake control switch 7. Liquid crystal display (LCD) 8. Air conditioner ON/Off Switch While the auto switch (5), the air intake control switches (6) or the air control ON/OFF switch (8) is functioning, the LED lamp above each switch is lit.

OFF switch (1) This switch stops the operation of the fan and the air conditioner.

When the OFF switch (1) is pressed, the set temperature and the ventilation amount displayed on the LCD (7) go blank, the LED lamps above the auto switch (5) and the air conditioner ON/OFF switch (8) also go blank, then the operation is stopped.

2.37 OPERATOR'S AREA Air Conditioner

Fan switch (2)

Ventilation mode selecting switch (4)

These switches control the ventilation amount in six steps.

This switch changes over the ventilation ports.

The ventilation amount is displayed on the LCD (7).

Press the

switch to increase the ventilation

amount. Press the tilation amount.

switch to decrease the ven-

During the auto operation, the ventilation amount is automatically changed over

During the auto operation, the ventilation ports are automatically changed over.

LCD

Ventilation mode

−

Air amount "weak"

Face and foot

−

Foot (blow to the feet mainly during heating)

−

Air amount "medium 2" Air amount "medium 3" Air amount "medium 4"

Foot and defroster

This mode is not selected during the auto operation.

Defroster

This mode is not selected during the auto operation

Air amount "strong"

Temperature control switch (3) These switches set the temperature inside the cab.

The temperature can be set in the range from 18.0ºC to 32.0ºC Press the

switch to increase the temperature.

Press the

switch to decrease the temperature.

Set the temperature to 25.0ºC usually. <Display on the LCD and the function> 18.0 18.5~31.5 32.0

Remarks

Ventilation amount

Air amount "medium 1"

LCD

Ventilation ports (A) (B) (C) (D)

Face (blow to the upper part of the body mainly during cooling)

<Display on the LCD and the ventilation amount> LCD

When this switch is pressed, the display on the LCD (7) is changed over, and air is blown from the displayed ventilation ports.

Set temperature Maximum cooling Controls the temperature inside the cab to reach the set temperature Maximum heating

Air is blown from the ventilation ports marked with "O".

Auto switch (5) This switch selects the auto mode in which the ventilation amount, the ventilation ports and the air intake status are automatically changed over in accordance with the set temperature.

When the auto switch (5) is pressed and set to ON, the LED lamp above the switch lights.

Usually, set this switch to ON, set the arbitrary temperature by using the temperature control switches (3), then use the air conditioner in the auto mode.

In the manual mode, the ventilation amount, the ventilation ports and the air intake status can be changed over by manipulating each switch. In the manual mode, the LED lamp above the auto switch (5) go blank.

2.38 OPERATOR'S AREA Air Conditioner

Air intake control switch (6)

Operation Method (Normal Usage)

These switches change over the air intake status between inside air circulation and outside air suction.

Auto operation

3

When an either switch is pressed, the LED lamp above the switch lights to indicate the air intake status.

During the auto operation, the air intake status is automatically changed over.

Inside air circulation

Outside air suction

The outside air is shut down, and the air inside the cabin is circulated. Press this switch when the air inside the cabin should be rapidly cooled or heated or when the outside air is dirty.

The outside air is sucked into the cabin. Press this switch to suck clean outside air or to remove mist from the windows.

Liquid crystal display (LCD) (7) This LCD displays the set temperature, the ventilation amount and the ventilation port status during operation.

When the OFF switch (1) is pressed, the displayed set temperature and ventilation amount disappear, and the operation is stopped.

Air conditioner ON/Off Switch (8) This switch turns on and off the air conditioner (cooling/defrost and heating).

When the air conditioner ON/OFF switch (8) is pressed once, the air conditioner is turned on and the LED lamp above the switch lights. When this switch is pressed once more, the air conditioner is turned off and the LED lamp goes blank.

5

97ZVOM0093

8 1. Set to ON the auto switch (5). Confirm that the set temperature and the ventilation amount are displayed on the LCD, and that the LED lamps above the auto switch (5) and the air conditioner ON/OFF switch (8) are lit.

2. Manipulate the temperature control switches (3) to set the arbitrary temperature.

Then, the auto operation is performed. The ventilation amount, the ventilation ports and the air intake status are automatically controlled to reach the set temperature.

NOTE During the auto operation, if the ventilation mode is set to to and the engine water temperature is low, the ventilation amount is limited to prevent blowout of cool air.

Stopping the auto operation

1

The air conditioner is turned on only while the fan is operating (that is, while the ventilation amount is displayed on the LCD).

97ZVOM0093

Press the OFF switch (1).

The set temperature and the ventilation amount displayed on the LCD disappear, the LED lamps above the auto switch (5) and the air conditioner ON/OFF switch (8) go blank, and the operation is stopped.

2.39 OPERATOR'S AREA Air Conditioner

Operation Method (Other Usage)

Manual operation

2

3

4

Bi-level operation In the bi-level operation, cool air is blown to the face and hot air is blown to the feet.

2

3

4

5

97ZVOM0093

6

8

1. Manipulate the fan switches (2) to control the ventilation amount. Confirm that the set temperature and the ventilation amount are displayed on the LCD. 2. Set to ON the air conditioner ON/OFF switch (8). Confirm that the LED lamp above the switch is lit.

3. Manipulate the temperature control switches (3) to set the arbitrary temperature.

4. Press the ventilation mode selecting switch (4) to select the arbitrary ventilation mode.

5. Press the air intake control switches (6) to select inside air circulation or outside air suction.

Stopping the manual operation

1

97ZVOM0093

8

6

1. Manipulate the fan switches (2) to control the ventilation amount. Confirm that the set temperature and the ventilation amount are displayed on the LCD. 2. Press the ventilation mode selecting switch (4) to display on the LCD. 3. Set to ON the air conditioner ON/OFF switch (8). Confirm that the LED lamp above the switch is lit.

4. Arbitrarily set the fan switches (2), the temperature control switches (3) and the air intake control switches (6).

Defroster operation

2

3

4

97ZVOM0093

Press the OFF switch (1).

The set temperature and the ventilation amount displayed on the LCD disappear, the LED lamps above the auto switch (5) and the air conditioner ON/OFF switch (8) go blank, and the operation is stopped.

97ZVOM0093

6

8

1. Manipulate the fan switches (2) to control the ventilation amount. Confirm that the set temperature and the ventilation amount are displayed on the LCD. 2. Press the ventilation mode selecting switch (4) to display or on the LCD.

2.40 OPERATOR'S AREA Air Conditioner 3. Manipulate the air intake control switches (6) to select the outside air suction status.

Other Functions

4. Manipulate the temperature control switches (3) to display "32.0"

Self-diagnosis function

Manipulate the louver at each ventilation port so that the wind reaches the window glass.

Each sensor and equipment used in the air conditioner can be diagnosed for failure.

1

In the rainy season, etc., set to ON the air conditioner ON/OFF switch (8) to remove mist from the window glass or dehumidify the cabin.

3

97ZVOM0093

6 1. Press the OFF switch (1). The set temperature and the ventilation amount displayed on the LCD disappear, and the operation is stopped.

2. Press and hold both temperature control switches (3) and for 3 seconds or more to display the failure mode on the LCD. <Display on the LCD and the failure mode> Display

Failure mode

E-

No failure

E11

Wire breakage in the inside air sensor

E12

Short-circuit in the inside air sensor

E13

Wire breakage in the outside air sensor

E14

Short-circuit in the outside air sensor

E15

Wire breakage in the water temperature sensor

E16

Short-circuit in the water temperature sensor

E18

Short-circuit in the insolation sensor

E21

Wire breakage in the ventilation sensor

E22

Short-circuit in the ventilation sensor

E43

Abnormality in the ventilation servo motor

E44

Abnormality in the air mixture damper motor

E45

Abnormality in the inside/outside air switching motor

E51

Abnormality in the refrigerant pressure

2.41 OPERATOR'S AREA Air Conditioner - If two or more failures are detected, press either temperature control switch (3) or to change over the displayed failures in turn.

- Press the OFF switch (1) again to finish the selfdiagnosis function and return to the normal display.

If a failure is detected by the self-diagnosis function, ask the dealer for inspection and repair.

After completing the inspection and/or the repair, delete the failure codes memorized in the computer.

If fail to do it, the failure codes memorized in the computer continue to display on the LCD whenever diagnosing.

To delete the failure codes, press and hold both air intake control switches (6) for 3 seconds or more.

Refer to "TROUBLESHOOTING" page 3.56 for the failure and solution.

For Efficient Use of the Air Conditioner When the temperature inside the cabin should be cooled down rapidly When the machine is left under a scorching sun in the middle of summer, the temperature inside the cabin may be very hot.

In order to rapidly cool down the cabin in such a case, completely close the windows and doors first, drive hot air out of the cabin, then operate the air conditioner.

Start up the engine, press the auto switch (5), then set the temperature to "18.0" by manipulating the temperature control switches (3). In this status, run the engine for 2~3 minutes with high revolution, then close the windows.

When the temperature inside the cabin is decreasing, set the arbitrary temperature.

When the windows are misted Set temperature display (Centigrade/Fahrenheit) selecting function The set temperature display can be changed over between centigrade and Fahrenheit.

While the fan is operating, press and hold both temperature control switches (3) and for 5 seconds or more to change over the set temperature display between centigrade and Fahrenheit.

(However, the unit is not displayed.)

LCD Centigrade (ºC)

18.0~32.0

Fahrenheit (ºF)

63~91

In the rainy season, etc., if the humidity inside the cabin is high and the inner surfaces of the windows are misted, mist can be removed by operating the air conditioner. Or if the humidity of the outside air is high, the temperature inside the cabin may be too low and the outer surfaces of the windows may be misted. In such a case, properly control the temperature inside the cabin by controlling the set temperature, stopping the air conditioner, etc.

2.42 OPERATOR'S AREA Air Conditioner

Action to be taken when the air conditioner is not used Even if the air conditioner is not used, operate the air conditioner with the engine low idle for several minutes at least once a month so that the lubricating oil in each part of the compressor is not eliminated (running-in of the air conditioner).

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

IMPORTANT - If the air conditioner is not operated for a long time, the lubricating oil inside the compressor may be eliminated, and the compressor may be seized or damaged. Make sure to operate the air conditioner once or twice a month even while the air conditioner is not necessary or while the machine is stored for a long time.

- During running - in of the air conditioner, make sure to start it up with the engine low idle.

Never start up the air conditioner with the engine high idle: Such start up may damage the air conditioner.

- If water enters the control panel or the insolation sensor, unexpected failure may be caused. Pay attention so that water does not enter. In addition, make sure to keep fire off the control panel and the insolation sensor.

- Always keep the insolation sensor clean and free from adhesion of dusts so that the air conditioner can offer its auto function sufficiently. Keep the area around the insolation sensor free from objects which may hinder the sensor function.

- Special tools and instruments are required to fill the refrigerant (gas) and perform other servicing. Make sure to let such works be performed in a service shop with required facilities specified by our company.

2.43 OPERATOR'S AREA Vibration Damper (option)

Vibration Damper (option) Roading a wheel loader over rough terrain will cause fore and aft pitching motion to the machine.

The pitching motion is reduced when the vibration damper is installed.

Operation and Function

20

N 40

10

0 0 0 0 0 0 1/10h

AUTO

30

4

C

H

C

H

E

F

3 0

50

2

km/h

1

STOP

70ZV0005

1

2

1. Before start the travelling machine, turn the vibration damper switch (1) ON. The vibration damper pilot lamp (2) comes to ON. 2. Move the machine forward.

The vibration damper functions automatically when the machine travelling speed reaches more than 7 km/h.

NOTE When the bucket is fully tilted the vibration damper does not work. Dump the bucket a bit when travelling.

2.44 OPERATOR'S AREA Grease Gun Holder

Grease Gun Holder

80ZV7175

Grease gun holder is provided in the left side battery box. It is used for keeping the grease gun on the machine when not in use.

2.45 OPERATION Check before Operation

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

Walk-Around Inspection For your own safety and maximum service life of the machine, make a thorough walk-around inspection before mounting the machine to start the engine. Report or correct any problems found during the Walk-Around inspection.

Items to Check and What to Look for: Items to Check

What to Look for

Bucket / Attachment

Damage, missing bolts, leaks, and excessive wear

Bucket Control Linkage

Damage, missing bolts, excessive wear, and looseness

Lights

Broken bulbs, wires or lenses

Radiator Fins

Trash and dirt build-up

Cooling System

Leaks and trash build-up

Batteries

Loose terminals

Steps and Handrails

Damage and cleanliness

Differentials (front and rear)

Leaks

Hydraulic System

Leaks

Final Drive (front and rear)

Leaks

Covers and Guards

Damage or missing

Transmission

Leaks

Instrument Panel

Broken gauges or indicator lights

Brake Lines

Damage and leaks

Engine Compartment

Leaks, debris build-up and flammable materials left

Battery

Loose items, leaks and debris build-up

Date:

Model-S/N:

Hours:

You may wish to copy this page and use it as a daily check list.

Inspector:

2.46 OPERATION Check before Operation

Check Engine Oil Level

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

CAUTION Hot engine oil and components may cause burns.

Avoid contact with hot oil or engine components.

Refer to "Replace Engine Oil and Oil Filter Cartridge" page 3.24.

NOTE Wait about five minutes after stopping the engine to measure the oil level. The precise oil level cannot be measured immediately after stopping engine due to residual oil in the upper parts of the engine.

IMPORTANT Improper oil level may damage engine.

Do not operate engine with oil level below "L" (low) mark or above "H" (high) mark.

Check

Fill cap

80ZVOM3300

H L

70ZV0011

1. Check the oil level with the dipstick.

2. Keep the oil level between the "H" (high) mark and "L" (low) mark on the dipstick.

3. If needed, add the required amount of the same brand and viscosity oil as originally used through the refill port.

Refer to "Recommended Lubricants" page 3.54 for the suitable viscosity of the oil according to the ambient temperature.

Add or drain oil to keep proper oil level.

2.47 OPERATION Check before Operation

Check Hydraulic Oil Level

Filler cap

CAUTION Pressurized hydraulic tank is used for this machine.

Pressure may throw tank cap and hot oil out of tank causing injury or burns.

Relieve all pressure by pressing down the filler cap.

80ZVOM3305

5. If needed, add the required amount of the oil.

Check Level

Refer to "Recommended Lubricants" page 3.54 for the suitable viscosity of the oil according to the ambient temperature.

85ZVOM3230

1. Lower the attachment to the ground.

2. Stop the engine.

3. Check the oil level gauge on the side of the hydraulic oil tank.

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

2.48 OPERATION Check before Operation

Check Engine Coolant Level

Drain Water and Sediment from Fuel Filter

CAUTION Cooling system conditioner contains alkali that could caustic burns or blindness.

Avoid contact with skin and eyes to prevent injury.

FULL LOW 80ZVOM3298

- Open the drain cock on the bottom of the fuel filter to allow water and sediment to drain into a suitable container.

80ZVOM3286

1. Check the coolant level in the radiator subtank.

2. Coolant level is normal if it is between FULL and LOW lines.

3. If needed, add the required amount of the coolant to the subtank.

Refer to "Coolant Specification" page 3.55 for the correct mixture.

4. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 3.13.

5. If the coolant contains oil, diagnose the problem and correct it.

- Dispose of the drained water and sediment properly.

CAUTION Escaping fuel is flammable and harmful to skin.

- Do not smoke while draining moisture and sediment from filter.

- Do not drain with engine running.

- Do not allow diesel fuel to remain on skin for an extended period of time.

2.49 OPERATION Check before Operation

Check Wiring Harnesses

Articulation Stopper

CAUTION Short circuit of wiring harnesses may cause fire.

- Keep the connection of wiring harnesses clean and tight.

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

Be sure the wiring harnesses are not damaged and the connection is kept clean and tight.

85ZV0002

- Make sure the articulation stopper is secured in the "STORED" position as shown.

2.50 OPERATION Check before Operation

Check Tire for Damage, Air and Tread Depth

Low Pressure

OK

High Pressure

97ZVOM0103

OM0032

Tire performance and its life depend greatly on the tire air pressure.

WARNING

It is important to keep the tire pressure at the recommended level.

Improper service or changing tires and rims could cause explosion resulting in serious injury or death.

Under the abnormal condition, check and adjust the air pressure to the standard value.

Do not service or change tire and rims unless properly trained and equipped.

Contact your nearest Kawasaki loader dealer or tire manufacturer’s local dealer for tire servicing or changing.

WARNING Overheated tire could explode causing serious injury or death.

If overheated tire is suspected, do not approach tire to distance of less than 15 m.

Stay away until tire and rim cool down.

Refer to "Check Tire Air Pressure" page 3.21 for the adjusting procedure.

2.51 OPERATION Check before Operation

Check Drive Belt

Tread

CAUTION

Side walls

Breakers Carcass

Beads / Bead wire

Contact with moving belt or pulleys may cause injuries Stop engine before opening engine side panel.

OM0104

If the following defects are found in tires, for safety reasons the tires should be replaced with new tires.

For the replacement contact Kawasaki dealer or a tire manufacturers local dealer.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and tag "Do Not Operate".

2. Open the engine side panel.

3. Visually inspect the drive belt for looseness and damage.

- Bead wire is broken or bent, or the tire is greatly deformed.

- Wear is excessive and the carcass ply (including breaker) is exposed for more than 1/4 of the circumference.

OK OK

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

- Tire layers are separated.

OM0099

- Radial cracks reach the carcass.

- Deformation or damage which makes the tire unsuitable for use.

4. If the belt is too stretched to permit adjustment or shows cuts or cracks, replace it.

2.52 OPERATION Check before Operation

Check Air Intake System

3. If damaged or loose, replace or retighten or contact your nearest Kawasaki dealer.

CAUTION Hot engine components may cause burns.

Avoid contact with hot engine components.

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

80ZVOM3286

80ZVOM3303

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

IMPORTANT Severe engine damage may result from running with unfiltered air.

Do not operate engine if any leaks or defects are found on air intake system.

2.53 OPERATION Check before Operation

Check Cooling Fan

Check Horn Operation 1. Push the horn button in the center of the steering wheel.

2. The horn should sound loudly.

OK ROPS (Roll Over Protective Structure) Cab

OK

WARNING OM0102

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and tag "Do Not Operate".

2. Open the engine rear grill.

Operating with damaged or improperly mounted ROPS Cab could result in death or serious injury.

If any damage or loose bolts are found, do not operate until repaired.

Never repair or modify ROPS Cab without manufacturer’s approval and instructions.

3. Visually inspect the cooling fan for damage.

4. If the fan shows cracks, loose rivets, bent or loose blades, replace it.

- Check the condition of the ROPS Cab and its mounting bolts.

Adjust and Check Rear View Mirrors - Adjust and check the condition of the rear view mirrors.

- If there is any dirt on or damage to the rear view mirrors, clean or fix them.

Check Parking Brake - Make sure the parking brake switch is pulled up.

2.54 OPERATION Check before Operation

Check Monitor Panel Operation 1. Turn the starter switch to the "ON" position.

2. All warning lamps (red) should come on for about three seconds. Refer to "Indicators" page 2.17.

3. Rotate and move the transmission shift lever to each position, pull the high-low beam lever, and operate the rear working light switch and transmission cut-off selector switch.

4. The transmission status monitor lamps (green) and the indicator lamps (green or blue) should come on respectively.

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

Refer to "Indicators" page 2.17.

Check Control Levers - Make sure the boom and tilt control levers are in the "HOLD" position.

Check Transmission Shift Lever - Make sure the transmission shift lever is in the neutral position.

2.55 OPERATION Starting the Engine

Starting the Engine WARNING If engine starts in gear due to bypassing neutral start device from ground could result in death or serious injury.

PREHEAT

OFF

ON

START

- Do not start engine by shorting across starer terminals - Do not start engine while standing on ground.

65ZV0075

Make sure to start engine only from operator’s seat with transmission in neutral and parking brake applied.

5. After the engine starts, release the key and it will return to the "ON" position.

6. If the transmission shift lever is not in the "NEUTRAL" position, the engine will not crank.

Normal Start (Ambient temperature above 0ºC)

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

1. Do not depress the accelerator pedal.

PREHEAT

OFF

ON

- The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "TROUBLESHOOTING" page 3.56.

START

IMPORTANT Low engine oil pressure may cause severe engine damage.

65ZV0076

2. Turn the starter switch key to "ON" position and leave it there for 3 seconds. Check the indicator lamps.

3. The turn the starter switch key to "START" position to start the engine.

To protect starter and battery, do not keep the starter switch in the "START" position for more than 20 seconds.

4. If the engine fails to start, wait about two minutes before trying to restart. This allows the starter motor to cool which prevents starter motor damage.

Be sure engine oil pressure warning lamp goes out quickly.

2.56 OPERATION Starting the Engine

Cold Start

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

(Ambient temperature below 0ºC) 1. Do not depress the accelerator pedal.

PREHEAT

OFF

ON

- The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "TROUBLESHOOTING" page 3.56.

START

IMPORTANT Low engine oil pressure may cause engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

65ZV0077

2. The turn the starter switch key to the "PREHEAT" position for about fifteen seconds.

3. Turn the starter switch key to the "START" position to start the engine. To protect starter and battery, do not keep the starter switch in the "START" position for more than 20 seconds.

4. If the engine fails to start, wait about two minutes before trying to restart. This allows the starter motor to cool which prevents starter motor damage.

5. After the engine starts, release the key and it will return to the "ON" position.

6. If the transmission shift lever is not in the "NEUTRAL" position, the engine will not crank.

7. In case the engine does not start on the first attempt, repeat the above procedures after intervals of about one to two minutes.

WARNING Use of ether could cause explosion and could result in death or serious injury.

- Do not use ether. This engine equipped with electric heater starting aid.

2.57 OPERATION Check after Starting the Engine

Check after Starting the Engine

Check Warning Lamps

- Keep the engine running at low to medium speed and warm it up for about five minutes.

- Do not subject the engine to sudden acceleration until the end of the warm-up period.

20

N 40

10

0 0 0 0 0 0 1/10h

AUTO

30

4

C

H

C

H

E

F

3 0

50 km/h

2 1

STOP

70ZV0007

1. Check the warning lamps on the instrument panel.

2. If any red lamp (except for "PARKING") is on, do not operate the machine.

3. Refer to "Indicators" page 2.17 for the meaning of each lamp and the correction.

2.58 OPERATION Check after Starting the Engine

Check Fuel Level

Check Transmission Oil Level

DANGER

E

There is no room in articulation are when machine is turning.

Crushing will result in serious injury or death.

F FUEL

65ZV0005

When checking oil level: - Low attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

- Place "DO NOT OPERATE" tag on steering wheel.

- Make sure nobody is on machine.

1. Check the fuel level with the fuel gauge on the instrument panel.

2. Add fuel to fill the tank if the gauge shows below "F".

Refer to "Recommended Lubricants" page 3.54 for the proper fuel.

Check and Fill Tube 80ZVOM3271

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

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

In hot

In cold

Specified oil level

97ZVOM0107

3. At low oil temperature, use the side of dipstick marked "COLD". Normal oil level is within shaded area as shown.

2.59 OPERATION Check after Starting the Engine 4. At high oil temperature, use the side of dipstick marked "HOT". Normal oil level is within shaded area as shown.

Check Service Brake Operation

5. If the oil level is lower than the specified, add recommended oil while the engine is at idle.

Do not overfill.

2. Firmly depress the right hand brake pedal.

Refer to "Recommended Lubricants" page 3.54.

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

Return articulation stopper to "STORED" position after checking transmission oil level.

IMPORTANT Never mix CD engine oil and auto transmission fluid.

Either may be used in transmission but they must not be mixed.

Determine what type of oil is in transmission and use only that type.

1. Turn "OFF" the clutch cut-off selector switch.

3. Release the parking brake.

4. Select the transmission shift lever 2nd and FORWARD. 5. Slowly accelerate the engine to full speed.

6. The machine should not move.

IMPORTANT If machine moves when firmly depressing right hand brake with transmission in 2nd and FORWARD, there is some problem with service brake.

Do not operate until problem has been corrected.

2.60 OPERATION Check after Starting the Engine

Check Parking Brake Operation

Check Back-up Alarm Operation

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

1. Apply the service brakes.

2. Release the parking brake.

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

3. Stop the machine with the service brake.

3. Move the shift lever to "REVERSE".

4. The back-up alarm should sound and be heard in the operator's seat.

4. Pull up the parking brake switch.

5. Release the service brakes.

6. The machine should not move.

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

Do not operate until problem has been corrected.

Check Steering Wheel Operation 1. Be sure the area is clear of bystanders.

2. Release the brakes.

3. Steer fully right and then left.

4. Steering should be smooth in both directions.

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

Do not operate until problem has been corrected.

2.61 OPERATION Check after Starting the Engine

Check Exhaust Gas

General Inspection

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

When inspecting machine while engine is running:

95ZVOM2926

1. Check the color of the exhaust gas.

Normal exhaust gas color is clear or light gray when engine is warm. White, black, or blue smoke during steady warm operation of the engine indicates a malfunction. (It is normal for some black smoke to occur during rapid acceleration.)

2. If abnormal exhaust gas color occurs, have the machine checked immediately.

Refer to "TROUBLESHOOTING" page 3.57.

- Make sure nobody is on machine.

- Lower attachment to ground.

- Turn parking brake switch to "ON".

- Do not enter or access hazardous areas of machine: - Articulation area - Under machine - Engine compartment, etc.

With the parking brake applied, transmission shift lever in NEUTRAL, loading levers in NEUTRAL, and the attachment on the ground, walk around the machine and look for any problems, leaks, or signs of failure.

2.62 OPERATION Operating the Machine

Operating the Machine

Starting the Machine

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

Do not stop engine while machine is moving.

WARNING

approx. 40 cm OM0016

Moving machine in congested areas could result in death or serious injury.

Be sure area is clear of personnel and obstructions.

IMPORTANT

1. Raise the bucket to the carry position approximately 40 cm above the ground.

2. Depress the brake pedal.

Operating machine on a grade may cause lack of lubrication resulting in severe engine or components damage.

3. Push the parking brake switch to release the parking brake.

Do not operate machine on a grade over 30º.

4. Turn the transmission shift lever to the desired travel speed mode and then shift to the desired direction.

30º Max. OM0194 97ZVOM0038

5. Release the brake pedal then depress the accelerator pedal to drive the machine.

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

When starting machine on a grade, firmly depress brake pedal before releasing parking brake.

2.63 OPERATION Operating the Machine

Starting the Machine on a Grade

Speed and Direction Change

1. Turn "OFF" the clutch cut-off selector switch.

2. Depress the left brake pedal (declutch brake pedal).

65ZV 5089

97ZVOM0038

3. Depress the accelerator pedal while releasing the left brake pedal to start the machine off slowly.

1. Select the proper gear shifting mode by rotating the transmission shift lever. Refer to the following tables on page 2.64 for the gear selection mode.

This machine is equipped with the automatic shifting system which selects the proper gear automatically using a micro computer to eliminate tiresome manual shifting.

65ZV 5089

2. For a direction change, decelerate the machine then move the transmission shift lever to forward or reverse.

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

Slow down machine and shift transmission to 1st or 2nd gear when changing direction.

2.64 OPERATION Operating the Machine

IMPORTANT Using too high gear for job may cause torque converter overheating.

Use proper gear for each job.

70ZV0010

3. When the transmission is in the 2nd gear, it can be quickly shifted down to the 1st gear by pressing the power up switch.

4. Pressing the power up switch again, moving the transmission shift lever to the neutral position, or operating the parking brake switch releases the 1st gear setting to return the transmission to the 2nd gear.

Refer to "Power Up Switch" page 2.14.

Lever Position

Selected Gear

Operating Condition

[1]

1st

1. Excavating or scooping in a narrow space 2. Running downhill on a steep slope

[2]

2nd

1. Scooping or loading loose material 2. Running downhill on a slope

[3]

3rd

Carrying or roading

[A]

2nd, 3rd or 4th (automatically shifted)

Scooping, loading, carrying or roading

2.65 OPERATION Parking

Parking

3. Shift the transmission shift lever to "NEUTRAL".

4. Pull up the parking brake switch to apply the parking brake.

5. Lower the attachment to the ground and apply a small amount of down pressure.

OM0025

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

Park machine in safe place on firm level ground.

If machine has to be parked on a grade, place wheel chocks under wheels and dig attachment into ground.

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

Except for emergency do not apply parking brake while machine is moving.

97ZVOM0038

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

2.66 OPERATION Stopping the Engine

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

Do not stop engine while machine is moving.

IMPORTANT Failure to allow engine to cool down before stopping may cause premature turbocharger failure.

Run engine at low idle speed for about five minutes before stopping engine.

1. Let the engine idle for about five minutes before stopping.

PREHEAT

OFF

ON

START

65ZV0074

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

3. After stopping the engine, remove the key and store it in a safe place.

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

Prevent unauthorized operation.

When leaving machine for extended period of time, remove the starter key, lock cab doors or lock vandal cover over dashboard and right hand console (if equipped).

2.67 OPERATION Operating Techniques

Operating Techniques

Loading

IMPORTANT Machine damage may result from improper loading procedures.

- Do not dig or scoop with machine frame articulated.

- Do not drive machine into material at high speed.

30º Max. OM0194

IMPORTANT

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

- For loose stockpile material replaceable bolt-on cutting edges should be used.

Operating machine on a grade may cause lack of lubrication resulting in severe damage on engine or other components.

Do not operate machine on a grade over 30º.

OM0111

1. Move the machine forward to the material.

2. Steer the machine in a straight ahead position when entering the material.

OM0113

3. Lower the bucket parallel to the ground.

2.68 OPERATION Operating Techniques 4. Drive the bucket straight into the material. Use approximately 1/2 - full engine speed.

OM0112

OM0114

5. Move the boom control lever to the "Raise" detent position and run the machine forward slowly in 1st or 2nd speed.

Reduce wheel slippage by slightly reducing engine speed.

OM0115

6. Move the bucket control lever to the "Roll Back" and the "Hold" position several times to get more material in the bucket.

7. When the bucket is filled, move the bucket control lever to the "Roll Back" position.

8. Release the bucket control lever to the "Hold" position and the boom will rise.

9. Reverse the machine.

10. On later passes, aim the center of the bucket at the protruding portion of the material.

2.69 OPERATION Operating Techniques

Excavating

Dozing

1. Move the machine forward to the material.

2. Steer the machine in a straight ahead position when entering the material.

IMPORTANT Dozing or pushing with dumped bucket or attachment may cause severe damage to linkages.

It may also cause engine over-heating and torque converter over-heating.

Keep bucket or attachment bottom parallel to ground.

OM0119

3. Lower the bucket parallel to the ground or dump it slightly forward.

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

Increase engine speed as the bucket digs deeper.

OM0120

5. When the bucket is filled, move the bucket control lever to the "Roll Back" position.

6. Move the boom control lever to the "Raise" position to clear the ground.

OM0123

2.70 OPERATION Operating Techniques

Ground Levelling 1. Keep the loaded bucket slightly above the ground.

OM0123

OM0121

2. While running the machine backward, dump the bucket little by little to evenly spread material on the ground.

4. To get smoother surface, put some material in the bucket, place the bucket parallel to the ground, run the machine backward with the boom control lever in the "Float" position.

IMPORTANT Pushing material with dumped bucket may cause severe damage to linkages.

Be sure to run machine backward when leveling ground.

OM0122

3. Dump the bucket, allow the cutting edge to contact the ground, and run the machine backward.

2.71 OPERATION Operating Techniques

Carrying

Dumping into Truck or Hopper

WARNING When boom is raised, machine stability is reduced and could cause machine to tip over causing serious injury or death.

Do not make quick turns or abrupt braking when boom is raised. approx. 40 cm OM0016

Keep boom low for best stability especially on slopes.

WARNING 1. Fully roll back the loaded bucket before carrying to prevent spillage.

Machine contact with overhead wires or other objects could result in death or serious injury.

2. Keep the bucket approximately 40 cm above the ground when carrying.

Be sure there are no overhead wires or obstructions before raising boom to full height.

IMPORTANT

Refer to "Loading" or "Excavating" page 2.67, 2.69 for the loading procedure.

When carrying material over 450 m at high speed, tire overheating may occur.

Follow tire manufacturer's instructions for tire inflation on this type of application.

OM0116

1. Move the boom control lever to the "Raise" position to raise the loaded bucket while approaching the truck or the hopper.

2. Use the transmission cut-off selector switch in the "ON" position if working on a level site.

When the left brake pedal (declutch pedal) is depressed, the transmission is placed automatically in neutral and the boom rises faster.

2.72 OPERATION Operating Techniques 3. Return the boom control lever to the "Hold" position when the bucket reaches the enough height to clear the truck or hopper sideboards.

If the boom is equipped with the kickout device, the boom will automatically stop and the boom control lever will return to the "Hold" position when the bucket reaches the preset height.

Holding the boom control lever in the "Raise" position will continue to raise the boom if required.

Refer to "Boom Kickout Adjustment" page 2.75 for adjustment of the preset height.

4. Position the machine in the center of the truck body or hopper to dump the load.

OM0196

6. Roll back the bucket to clear the truck or hopper sideboards and lower the boom while reversing the machine.

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

Do not lower boom using detented "Float" position especially when bucket is full.

OM0195

5. Push the bucket control lever forward to the "Dump" position to empty the bucket.

2.73 OPERATION Operating Techniques

Typical Truck Loading Methods

T Cycle Operation

I Cycle Operation

OM0126

OM0124

This method is recommended where the working area is limited.

V or L Cycle Operation (L-cycle)

(V-cycle)

OM0125

This is the most efficient operation for the shortest cycle time.

This method is effective for the sites where trucks continuously come and go.

2.74 SPECIAL PROCEDURES Adjustments

SPECIAL PROCEDURES Adjustments Bucket / Attachment Positioner Adjustment

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

6. To test the adjustment; start the engine, raise the boom approximately half way, dump the attachment, and move the bucket control lever to the "Roll Back" detent position to rollback the attachment.

When the preset angle is reached, the bucket control lever should return to the "Hold" position. Lower the attachment to the ground and confirm the proper angle has been set.

Apply parking brake and use wheel chocks to prevent sudden movement of machine.

4

WARNING Standing on tire, boom or linkage could cause accidents resulting in death or serious injury.

Use safe sturdy platform to reach bucket positioner adjustment.

1. Park the machine on level ground and apply the parking brake.

2. Lower the attachment to the ground, adjust it to the desired angle, set the bucket control lever to the hold position, and stop the engine.

3 5±2 mm OM0128

NOTE Clearance between the switch (4) and rod (3) should be about 5 mm.

The switch may be adjusted in or out to set this clearance.

2

1

97ZVOM0127

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

4. Move the bracket (2) forward to increase, or rearward to decrease the attachment preset angle.

5. Tighten the bolts (1).

2.75 SPECIAL PROCEDURES Adjustments

Boom Kickout Adjustment

1

2

DANGER Sudden or accidental movement of boom will result in death or serious injury.

Before walking or working under raised boom: - Securely block or brace boom.

- Remove key and tag "Do Not Operate" on the - steering wheel.

3 97ZVOM0129

WARNING Standing on tire can cause accidents resulting in death or serious injury.

5. Loosen the two bolts (1). Align the plate (2) with the switch (3).

Use safe sturdy platform to reach boom kickout adjustment.

6. Move the plate (2) clockwise to decrease, or counterclockwise to increase the boom lift kickout height.

1. Park the machine on level ground and apply the parking brake.

7. Tighten the bolts (1).

2. Raise the boom to the desired height and stop the engine.

3. Lock the bucket and boom control levers in the "Hold" position using the loading control lever lock.

8. Remove the support from the boom and linkage.

9. To test the adjustment; start the engine, slowly lower the boom to the ground, and move the boom control lever to the "Raise" detent position to raise the boom.

When the preset height is reached, the boom control lever should return to the "Hold" position.

3

2 OM0031

4. Block the boom and linkage from falling down using a proper support.

5±2 mm OM0128

NOTE Clearance between the switch (3) and plate (2) should be about 5 mm.

2.76 SPECIAL PROCEDURES Adjustments The switch may be adjusted in or out to set this clearance.

2.77 SPECIAL PROCEDURES Roading / Special Applications

Roading / Special Applications WARNING Overheated tire could explode causing serious injury or death.

If overheated tire is suspected during operation or servicing, do not approach tire to distance of less than 15 m.

Stay away until tire and rim cool down.

When the machine travels at high speed or for a long distance, the tires or other components may become extremely hot causing an explosion or early wear. If the machine must be driven for a long distance, take the following precautions: - Follow the regulations related to this machine, and drive carefully.

- The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your nearest Kawasaki dealer or a tire dealer for information.

- "Ton km/h" limitations must be observed. Consult a tire dealer for the speed limit of the tires involved.

- After traveling for 30 minutes, stop the machine with engine running to allow the tires and components to cool. Check the tires and other parts for damage.

- Do not put calcium chloride or dry ballast in the tires when traveling.

- Whenever possible use a lead and/or follow vehicle and all available warning devices even if not required by regulations.

2.78 SPECIAL PROCEDURES Booster Batteries / Jumper Cables

Booster Batteries / Jumper Cables DANGER Improper procedure to start engine using jumper cables could cause battery case explosion.

- Do this work by two persons. While one person sits on the operator's seat, the other person connects jumper cables.

- Wear eye or face protection when working on or around batteries.

- The booster batteries should be of similar size and capacity as the batteries being boosted.

- Do not allow the two machines to touch. This prevents possible sparks between or in the machines being used.

- Keep flames and sparks away from batteries.

- Keep jumper cable ends from touching each other or machine to avoid sparks.

- Make last connection to grounded part of frame away from battery compartment.

1. Before connecting jumper cables: - The booster cables must be of the heavy duty type and in good condition.

- Be sure the problem is inadequate battery charge and not some other electrical problems.

- Stop the engine of the boost machine or turn off the booster supply if using an auxiliary power source.

2. Raise and lock the battery box covers.

3. Be sure vent caps are tight and level. Place damp cloth over vent caps on both batteries.

+

+

-

+

-

+

-

Booster Batteries

Batteries being boosted

WARNING If the battery is being used with insufficient battery electrolyte level, the deterioration on the parts in the case could be in the advanced stage.

Rear chassis close to starter motor ground being jump started

It could cause to shorten the battery life or to emit sparks from the deterioration parts in the case, as a result the battery case could explode.

4. Move back the protective rubber covers (red) from the positive post (+) of the battery.

Keep the battery electrolyte level in the proper level.

WARNING Batteries contain lead, and acid which may cause burns.

Avoid contact with skin or clothing and wear hand, eye, and face protection when working on or around batteries.

If lead, or acid contacts skin or clothing, immediately wash with water.

NOTE This machine uses a 24VDC negative ground electrical system.

OM0131

5. Connect one end of the red jumper cable to the positive post (+) of the discharged battery.

6. Connect the other end of the red jumper cable to the 24 volt side of the booster battery set or power source.

7. Connect one end of the black jumper cable to the ground side of the booster battery set or power source.

8. The final connection should be the remaining end of the black jumper cable to the rear chassis close to starter motor ground being jump started.

9. Start the booster machine's engine or turn the auxiliary power source on.

10. Allow a few minutes to provide partial charge to the discharged batteries.

2.79 SPECIAL PROCEDURES Booster Batteries / Jumper Cables 11. Start the machine being boosted as described on "Starting the Engine" page 2.55.

12. As soon as the engine starts, disconnect the jumper cables in the reverse order (Step 8, Step 7, Step 6, Step 5).

13. Remove the damp cloth and replace the protective covers over the battery terminals and close the battery box covers.

14. Test the starting / charging system to determine the cause of the problem and correct it.

2.80 SPECIAL PROCEDURES Towing

Towing

If your machine must be towed, contact your nearest Kawasaki dealer for the necessary information or assistance.

WARNING Improper towing could result in death or serious injury.

Follow safety warnings found under "Safe Operation -- SPECIAL OPERATING CONDITIONS:" page 1.9.

This machine is equipped with a hitch on the rear end for towing a troubled machine.

1. Inspect the cable for damage. Never use a damaged cable.

95ZVOM2917

2. Connect the cable to the drawbar. Make sure the drawbar and split pin are in the original position.

3. Connect the other end of the cable to the troubled machine.

4. If the service brake on the towed machine does not work; do not allow an operator on the towed machine, and attach another vehicle of adequate size to the rear to act as a braking vehicle.

5. Keep personnel away from between the towing machine and the towed machine.

6. Tow the machine slowly with gradual and smooth movement.

7. Use flashing lights or other warning signals when towing.

2.81 SPECIAL PROCEDURES Transportation

Transportation When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc.

It is a good idea to obtain a special platform for loading and unloading the machine.

1. Park the trailer on flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.

5. Lower the bucket and lock each control lever using the loading control lever lock (page 1.21).

6. Apply the parking brake and set the articulation stopper in the "LOCKED" position (page 1.21).

7. Tape over the exhaust stack outlet to prevent turbo "Wind-milling" damage.

65ZV0010 OM0132

2. Properly apply the brakes of the trailer and place wheel chocks in front of and behind the tires to ensure that the trailer does not move.

8. Place blocks in front of and behind the tires to prevent the machine from moving.

3. Fix the ramp in line with the centers of the trailer and the machine.

OM0197

9. Fasten the machine to the trailer with chains or cables at 4 fixing points (red painted) provided on the machine.

65ZV0009

4. Determine the position of the ramp, then slowly load the machine onto the specified part of the trailer.

NOTE Have someone in clear view and in a safe position provide directions while loading.

Additional cables or chains may be used but do not damage brake lines or cylinder rods.

IMPORTANT Brake pipe runs on axle housing.

Do not fasten axle housing.

2.82 SPECIAL PROCEDURES Transportation 10. Determine the route for transporting the machine by taking into account the width, height and weight of the machine and truck.

GRAVITY CENTER

OM0198

11. In the case that it is necessary to lift the machine, sling the machine at 4 fixing points (red painted) provided on the machine as shown.

Weight: 20 ton

2.83 SPECIAL PROCEDURES Long Term Storage

Long Term Storage

During Storage

Before Storage

Once a month remove the covers, run the engine, and move the machine a short distance to form a new oil film on the lubricated parts.

1. Wash and clean all parts of the machine.

2. Lubricate every greasing point described in "Greasing" section page 3.17, 3.23 and 3.44.

3. Replace engine oil, transmission oil, differential and planetary oil and hydraulic system oil.

4. Idle the engine for about 15 minutes so that fuel and lubricant circulate throughout the engine, transmission and torque converter.

5. Store the machine indoors and keep it dry.

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

The range of temperature the machine is to be stored is between -35ºC ~ 45ºC.

1. Check the following points.

Refer to "Check before Operation" page 2.45 and "Check after Starting the Engine" page 2.57.

-

Coolant level Engine oil level Hydraulic oil level Transmission oil level Brake function Steering function

2. Operate the machine as follows.

- Run just the engine for about five minutes at low idle.

- Move all cylinders of the hydraulic system full stroke 2~3 times.

- Run the machine about 10 m in every gear and direction.

- Move the steering full stroke each way about 2~3 times.

3. Operate the air conditioner as follows.

OM0028

6. Disconnect the cables from the batteries or if freezing temperatures are expected, remove the batteries from the machine and store separately in a heated area.

7. If freezing temperatures are expected, check and adjust the antifreeze/water mixture.

Refer to "Coolant Specification" page 3.55 for the mixing ratio.

8. Securely cover the inlet and outlet ports of the air cleaner and muffler.

- Operate the air conditioner with the engine low idle for several minutes once a month so that the lubricating oil in each part of the compressor is not eliminated.

2.84 SPECIAL PROCEDURES Long Term Storage

After Storage

80ZVOM3269

85ZVOM3230

1. Loosen the drain cock or plug of the fuel tank and the hydraulic oil tank to drain any water into a suitable container. Dispose of properly.

2. Remove the covers, connect the cables to the batteries and start the engine.

3. Replace engine and transmission oil with new specified oil after warming up both engine and transmission.

Refer to "Replace Engine Oil and Oil Filter Cartridge" page 3.24 and "Replace Transmission Oil" page 3.37.

4. Start the engine and check for any abnormalities.

5. Warm up the machine until all gauges reach the normal range.

3.1

3.MAINTENANCE

3.2 MAINTENANCE Serial Number Location

MAINTENANCE Before performing maintenance or repairs, read, understand and follow "Safe Maintenance" section page 1.11.

The maintenance or repair of the machine must be performed by well-Trained or experienced personnel only.

Serial Number Location When contacting Kawasaki dealer or the dealers of other products for servicing or repair, refer to the serial number found in the following locations. See next page for general location.

80ZVOM3344

2. Engine Serial Number

For quick reference, record each serial number in the blanks below.

If a component, like engine or transmission, is changed, record the new serial number here.

TRANSMISSION MODEL SERIAL

NO

KAWASAKI OM0211

OM0219

1. Machine Serial Number

3. Transmission / Torque Converter Serial Number Model Serial Number Design Number

3.3 MAINTENANCE Serial Number Location

SERIAL NO.

-

70ZV0004

4. Cab Serial Number Model Number Serial Number

Cab (R.H Inside)

80ZV OM COMPO

Machine (R.H)

T/M

E/G (R.H)

3.4 MAINTENANCE Inspection and Maintenance Table

Inspection and Maintenance Table △ : First time replacement or cleaning only Section

Item for check

Operating hours 10

250

500

○

2.46

Check Engine Coolant Level

○

2.48

Check Warning Lamps

○

2.57

Check Exhaust Gas

○

2.61

Drain Water and Sediment from Fuel Filter

○

2.48

Check Fuel Level

○

2.58

Check Drive Belt

○

2.51

Check Air Intake System

○

2.52

Check Cooling Fan

○

2.53 3.20

○

Replace Engine Oil and Oil Filter Cartridge

○

3.24

Replace DCA4 Coolant Filter Cartridge

○

3.28

Clean Fuel Prefilter

○

3.35

Replace Fuel Filter Cartridge

○

3.34

Inspect Automatic Belt Tensioner Pulley

3.42

○

Clean Fuel Tank

○

3.48

Check and Adjust Valve Lash Clearance

○

3.50

Check Vibration Damper

○

3.49

Clean or Replace Air Cleaner Element

○

3.9

Clean Radiator / Air cooler / Hydraulic oil cooler Fins

○

3.10

Clean or Replace Air Cleaner Element Replace Coolant Transmission & Torque Converter

Page

Check Engine Oil Level

Drain Water and Sediment from Fuel Tank Engine

50

When Required 1000 2000

Check Transmission Oil Level Replace Transmission Oil Filter Cartridge

After six cleanings or once a year ○

3.9

Every 2 years or 3000 hours ○

3.13 2.58

○ △

3.32, 3.33

○

Replace Transmission Oil

○

3.37

Clean or Replace Transmission Breather

○

3.38

3.5 MAINTENANCE Inspection and Maintenance Table

△ : First time replacement or cleaning only Section

Item for check Check Tire for Damage, Air and Tread Depth

Axle system

10

50

When 1000 2000 Required

Page 2.50

○

3.21

Greasing (Axle support)

○

3.19

Check Differential Gear Oil

○

3.25

Check Planetary Gear Oil

○

3.26

Greasing (Pillow block bearing unit)

○

3.23

Check Tightness of Wheel Bolts

○

3.27

Greasing (2nd Propeller Shaft)

○

3.44

Greasing (3rd Propeller Shaft)

○

3.44

Replace Differential Gear Oil

○

3.46

Replace Planetary Gear Oil

○

3.47 2.60

○

Greasing (Steering Cylinder)

3.19

○ △

3.32, 3.52

○

Check Service Brake Operation

○

2.59

Check Parking Brake Operation

○

2.60

Adjust Parking Brake Lining

3.40

○

Check Service Brake Disk Wear

○

3.50

Check Brake Accumulator

○

3.50

○

3.32, 3.51

Clean Filter for Brake Line Check Hydraulic Oil Level Greasing Replace Hydraulic Oil Return Filter Loading system

500

○

Clean Filter for Orbitrol®

Brake system

250

Check Tire Air Pressure

Check Steering Wheel Operation Steering system

Operating hours

△

2.47

○

3.17

○ △

3.32, 3.39

○

Replace Hydraulic Oil, Clean Filter

○

3.45

Replace Filter in the Oil Tank Cap

○

3.53

Replace Bucket Teeth (option)

○

3.7

Replace Cutting Edge

○

3.8

3.6 MAINTENANCE Inspection and Maintenance Table

△ : First time replacement or cleaning only Section

Chassis

Electrical system

Item for check

Operating hours 10

50

250

500

When 1000 2000 Required

Adjust and Check Rear View Mirrors

○

2.53

ROPS (Roll Over Protective Structure) Cab

○

2.53

Greasing (Center Pin)

3.19

○

Check Vibration Damper Accumulator (option) Check and/or Replace Seat Belt

○

3.9

Check Windshield Washer Fluid

○

3.12

Check Monitor Panel Operation

○

2.54

Check Horn Operation

○

2.53

Check Back-up Alarm Operation

○

2.60

Check Wiring Harnesses

○

2.49 3.20

○

Check or Replace Fuses

○

3.12

Check and Adjust Air Conditioner Belt

○

3.29

Clean Air Conditioner Filter Element

○

3.30

Check Air Conditioner Refrigerant

3.41

○

Replace Air Conditioner Filter Elements

○

Replace Air Conditioner Receiver Dryer Walk-Around Inspection

3.50

○

Clean Air Conditioner Condenser

Others

3.53

○

Check Battery Electrolyte Level

Air Conditioner

Page

Every 3 years or 6000 hours ○ ○

3.13 3.15 2.45

3.7 MAINTENANCE When Required Inspection and Maintenance

When Required Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury.

Replace Bucket Teeth (option) When the bucket teeth are worn, replace them as follows.

1. Park the machine on level ground and apply the parking brake.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

1

2

Block 97ZVOM0136

2. Raise the bucket to a convenient height and put blocks under the bucket to prevent it from coming down.

3. Stop the engine.

4. Remove the bolts and nuts (1), then remove the bucket teeth (2).

5. Install the new teeth on the bucket with new bolts.

3.8 MAINTENANCE When Required Inspection and Maintenance

Replace Cutting Edge 1. Park the machine on level ground and apply the parking brake.

OM0188

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

- Always wear eye protection.

- Use deadblow hammer or brass drift between hammer and tooth.

- Keep bystanders away from work area.

65ZV0011

2. Raise the bucket to a convenient height and put blocks under the bucket to prevent it from coming down.

3. Stop the engine.

6. To prevent any clearance between the tooth and the edge of the bucket, tighten the nut partially, then hit the top of the tooth.

4. Remove the cutting edge. Clean all contact surfaces (bottom of bucket, top of cutting edge).

7. Tighten the nuts to 696~834 N-m.

5. If other side of the cutting edge is not worn, turn it around and install it so that the new side faces the front. If both sides are worn, install a new cutting edge.

8. Retighten them after operating the machine for a few hours.

NOTE For non-Kawasaki buckets or teeth, consult the manufacturer for the proper procedures.

6. Install all bolts and tighten them to 696~834 Nm. 7. Retighten them after a few hours operation.

3.9 MAINTENANCE When Required Inspection and Maintenance

Check and/or Replace Seat Belt

Clean or Replace Air Cleaner Element

1. Inspect the condition of the seat belt and all mounting hardware frequently.

When the warning monitor lamp lights up, clean or replace the air cleaner element.

2. Replace the seat belt or any part of the mounting hardware if it is damaged.

WARNING

3. Replace the seat belt every three years regardless of its condition or appearance.

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

- Do not clean or replace air filters while engine is running.

- Clean only outer element. Never clean inner element.

- Clean or replace element only when indicator lamp comes on.

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

1

2

65ZV0012

2. Remove the cover (2) by loosening wing nut (1).

3. Remove the outer element.

3.10 MAINTENANCE When Required Inspection and Maintenance

Clean Radiator / Air cooler / Hydraulic oil cooler Fins 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

OM0138

4. If the element is clogged by dirt or dust, spray dry compressed air (196 kPa) along the inside of the element up and down to blow off dust.

95ZVOM2917

3

OM0139

5. Insert a lamp inside of the element for checking a damaged element.

6. If bright light spots are seen through the element, there are cracks or pinholes in the element. Replace it with a new element.

7. Inspect the rubber seal (3). If there is any damage to the seal, replace the element.

8. Confirm that the wing nut is tight and the inner element is properly seated, then reinstall the outer element, cover (2) and wing nut (1).

9. Even after cleaning, if the engine exhaust gas is not clean enough (excessive black smoke), replace the element.

10. After six cleanings or once a year replace the outer element together with the inner element.

90ZV5055

2. Push the knob and open the radiator grill.

Open covers on the radiator guard both the right hand side and the left hand side for clean the air cooler and hydraulic oil cooler.

3.11 MAINTENANCE When Required Inspection and Maintenance 7. Close the engine side panels and covers.

Be sure side cover doors are closed securely.

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

85ZV YP7-233

3. Remove clean-out traps from bottom of radiator shroud.

IMPORTANT Clean-out traps and side cover doors must be reinstalled and closed securely, or engine performance will be affected.

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

- When used for cleaning purposes, the pressure of compressed air should be at 196 kPa or less.

- When using high-pressure water, keep the nozzle a distance of at least 500 mm away from the core surface, applying the water jet perpendicular to the core.

- Move nozzle from side to side; not up and down.

4. Blow off mud, dirt, or clogging debris from the radiator / air cooler / hydraulic oil cooler fins with compressed air. Use a pressure washer to remove harder debris.

Compressed air or water should be directed from rear toward the engine.

5. Reverse the direction to flush all debris from the radiator / air cooler / hydraulic oil cooler fins.

6. Reinstall clean-out traps.

3.12 MAINTENANCE When Required Inspection and Maintenance

Check or Replace Fuses

Check Windshield Washer Fluid

97ZVOM0086

80ZVOM3330

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

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

2. Stop the engine and turn the starter switch key to the "OFF" position.

2. Check the fluid level.

3. Replace the fluid if it is dirty.

3. Open the covers of the main fuse box, cab fuse box.

4. Check the fuses. If any blown fuses are found, replace them with new ones.

Refer to "Fuse Boxes" page 2.26.

5. Determine the cause of the blown fuses and repair.

IMPORTANT Using wrong capacity fuse or bypassing fuse may cause electrical system damage.

Never replace fuses with higher amperage rating.

4. If the level is low, add fluid to proper level.

5. Use windshield washer solvent for both better cleaning and to prevent freezing. Adjust the mixture according to the manufacturer's instructions.

3.13 MAINTENANCE When Required Inspection and Maintenance

Clean Air Conditioner Condenser

Replace Coolant

If mud, insects, or other debris are stuck to the air conditioner condenser, air flow through the condenser will be reduced causing decreased cooling ability.

- Since the Anti-Freeze "Long Life Coolant" (LLC) is originally used for the machine shipped from the factory, it is not necessary to replace the coolant for the first two years.

- If the cooling system conditioner (from a local supplier) is used at the time of last replacement, follow its instructions or contact your nearest Kawasaki dealer for the replacement interval.

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

85ZVOM3179

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

2. Inspect the condenser and replace it if any damage is found.

Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure.

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

2. Inspect all coolant hoses.

3. Clean its fins using compressed air, a pressure washer or a soft brush. Be sure the air pressure is below 196 kPa. If a pressure washer is used, keep the nozzle about 50 cm away from the fins to prevent fin damage.

Replace any that are cracked, swollen, or brittle.

4. If water is used for the cleaning, cover the electrical parts of the engine and the electric condenser fan with plastic sheets. Remove the plastic sheets after cleaning.

IMPORTANT An excessively high air or water discharge pressure can damage the condenser fins.

- When used for cleaning purposes, the pressure of compressed air should be at 196 kPa or less.

- When cleaning with water, apply the water jet perpendicular to the core.

80ZVOM3286

3. Confirm the coolant in the radiator subtank is cool enough.

4. Remove the subtank from the machine and drain coolant from it.

3.14 MAINTENANCE When Required Inspection and Maintenance 9. Stop the engine and remove the drain plug to drain the cooling system.

10. Install the drain plug and fill the cooling system with clean water.

Do not install the radiator cap or the new coolant filter.

11. Operate the engine for five minutes with the coolant temperature above 80ºC. 80ZVOM3294

5. Remove the drain plug and drain coolant (about 59 liters) into a suitable container.

12. Stop the engine and remove the drain plug to drain the cooling system.

13. If the water being drained is still dirty, the system must be flushed again until the water is clean (step 7~13).

14. Install the drain plug and fill the system with the premixed coolant.

Refer to "Coolant Specification" page 3.55 for the mixing instruction.

15. Add one piece of DCA65L and two pieces of DCA60L coolant additive at the same time.

16. Replace the DCA4 coolant filter (WF2071).

85ZVOM3219

6. Slowly open the radiator cap to drain coolant.

Follow the law and/or local regulations to properly dispose of or recycle the coolant.

Refer to "Replace DCA4 Coolant Filter Cartridge" page 3.28 for the procedure.

17. Idle the engine for five minutes to purge air mixed into the coolant. (Leave the radiator cap off.)

CAUTION

18. Add coolant as necessary.

Cooling system conditioner contains alkali that may cause caustic burns or blindness.

19. Reinstall the radiator cap.

Avoid contact with skin and eyes to prevent injury.

For additional cold weather servicing information, refer to "Coolant Specification" page 3.55 for details.

7. Install the drain plug and fill the cooling system with clean water and cooling system cleaner.

Follow the manufacturer's instructions.

Do not install the radiator cap.

8. Operate the engine for one hour with the coolant temperature above 80ºC. Then let the engine cool down naturally with the engine shut "OFF".

3.15 MAINTENANCE When Required Inspection and Maintenance

Replace Air Conditioner Receiver Dryer (Every 3 years or 6000 hours) - Contact your Kawasaki dealer.

3.16 MAINTENANCE Every 10 Hours or Daily

Every 10 Hours or Daily WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

See "Check before Operation" page 2.45 and "Check after Starting the Engine" page 2.57.

3.17 MAINTENANCE Every 50 Hours or 1 Week

Every 50 Hours or 1 Week WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

Every 50 hours or 1 week, whichever comes first, perform the following inspection and maintenance in addition to the "Daily Inspection and Maintenance".

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

2. Lubricate fittings on the following components.

Wipe and clean all fittings before greasing.

Lubricate until fresh grease is seen at each joint. Immediately replace or report any broken or defective grease fittings.

Refer to "Recommended Lubricants" page 3.54 for the correct grease.

85ZVOM3357

- Bucket-Boom (two places)

85ZVOM3357

- Bucket-Rod (one place)

3.18 MAINTENANCE Every 50 Hours or 1 Week

85ZVOM3357

- Lever-Rod (one place)

80ZVOM3272

- Bucket Cylinder-Front Chassis (one place)

85ZVOM3357

- Lever-Boom (one place)

85ZVOM3357

- Boom Cylinder-Boom (two places)

85ZVOM3357

- Bucket Cylinder-Lever (one place)

85ZVOM3353

- Boom Cylinder-Front Chassis (two places)

3.19 MAINTENANCE Every 50 Hours or 1 Week

85ZVOM3353

80ZVOM3272

- Boom-Front Chassis (two places)

80ZVOM3271

80ZVOM3271

- Steering Cylinder (four places) L.H and R.H

80ZVOM3266

- Axle support (two places)

- Center Pin (two places)

3.20 MAINTENANCE Every 50 Hours or 1 Week

Drain Water and Sediment from Fuel Tank

Check Battery Electrolyte Level

WARNING

CAUTION Escaping fuel is flammable and harmful to skin.

Batteries produce explosive gases which could cause burns or blindness.

- Do not smoke while draining moisture and sediment from fuel tank.

- Do not drain fuel with engine running.

- Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

- Ventilate area to remove explosive gases.

- Wear eye or face protection when working on or around batteries.

- Keep flames and sparks away from batteries.

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

If the batteries being used have insufficient battery electrolyte level, parts in the battery case could rapidly deteriorate.

WARNING

It could shorten battery life or the battery case could explode.

Keep the battery electrolyte level at the proper level.

WARNING Batteries contain lead, and acid which may cause burns.

80ZVOM3269

2. Prepare a suitable container.

3. Open the drain cock on the bottom of the fuel tank.

4. Drain water and sediment along with fuel.

5. Close the drain cock.

6. Dispose of the drained fuel and water properly.

7. Add fuel.

NOTE To reduce water and sediment build up in the tank, refuel the machine at the end of each shift.

Avoid contact with skin or clothing and wear hand, eye, and face protection when working on or around batteries.

If lead, or acid contacts skin or clothing, immediately wash with water.

3.21 MAINTENANCE Every 50 Hours or 1 Week

Check Tire Air Pressure Low Pressure

OK

High Pressure

95ZVOM2913

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

2. Clean the battery surface with a clean cloth or soft brush.

70ZV0016

Tire performance and its life depend greatly on the tire air pressure.

- Low air pressure causes excessive deflection, heat, and accelerated wear.

- High air pressure cause reduced traction, slippage, and possible blow outs.

It is important to keep the tire pressure at the recommended level.

Special applications, such as long load and carry operations, may require different pressures. Consult the tire manufacturer.

Low

OK

High OM0096

3. Check the battery electrolyte level in each cell.

Electrolyte should cover the cell plates.

4. If the level is low, add distilled water until it reaches the bottom of the filler neck.

NOTE If a maintenance free battery is used, step 3 and 4 of this inspection and maintenance is not required.

WARNING Overheated tire may explode causing serious injury or death.

If overheated tire is suspected, do not approach tire to distance of less than 15 m.

Stay away until tire and rim cool down.

1. Before starting work and while the tires are still cool, measure the tire air pressure with the tire pressure gauge.

3.22 MAINTENANCE Every 50 Hours or 1 Week Recommended Tire Air Pressure Radial tire Size

Air pressure Front

Rear

20.5 R25 ☆

471~490 kPa

373~392 kPa

23.5 R25 ☆

471~490 kPa

373~392 kPa

Bias ply tire OM0032

Size

WARNING Explosive separation of tire and rim parts could result in death or serious injury.

When inflating tires; - Make sure wheel parts are correctly installed.

- Use self-attaching air chuck with remote shutoff valve - Stand behind tread of tire and keep all persons away from side of tire.

- Do not inflate tire more than recommended pressure.

- Use safety cage if available.

OM0033

2. Adjust air pressure according to the recommended pressures below.

When inflating a tire, stand behind the tread and use a self-attaching chuck with a remotely located valve to turn air pressure on and off.

Air pressure Front

Rear

20.5-25-16PR

422~441 kPa

324~343 kPa

23.5-25-16PR

392~412 kPa

294~314 kPa

3.23 MAINTENANCE Every 250 Hours or 1 Month

Every 250 Hours or 1 Month WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

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

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page 3.54 for the correct grease. Use lithium base grease for universal joints.

Every 250 hours or 1 month, whichever comes first, perform the following inspection and maintenance in addition to the "Daily" and "50 hours" inspections and maintenance.

80ZVOM3271

- Pillow block bearing unit (one place)

3.24 MAINTENANCE Every 250 Hours or 1 Month

Replace Engine Oil and Oil Filter Cartridge

CAUTION Hot oil and engine components may cause burns.

Avoid contact with hot oil or engine components.

1. If the machine is cold operate the engine to bring the engine coolant temperature about 40ºC. When the needle of the coolant temperature gauge reaches the middle of the white zone, the temperature is about 40ºC. 2. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

80ZVOM3285

5. Remove the oil filter and properly dispose of it.

Make sure the O-ring is removed with the filter.

6. Clean the oil filter head gasket surface.

7. Fill the new filter with clean engine oil.

Refer to "Recommended Lubricants" page 3.54 for the oil specifications.

8. Apply a light film of engine oil to the gasket surface of the new filter cartridge.

80ZVOM3294

3. Loosen the drain plug.

4. Drain oil, about 22 liters, into a suitable container.

OM0200

9. Install and tighten the filter until the gasket contacts filter head surface. Then tighten it by hand an additional three-fourths to one turn.

Refer to the instructions supplied with the filter.

10. Retighten the oil drain plug, and tighten to 80 N-m torque.

3.25 MAINTENANCE Every 250 Hours or 1 Month

Check Differential Gear Oil

CAUTION The axles are pressurized through the hydraulic oil tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Dipstick Oil Fill

80ZVOM3300

11. Fill the engine with clean oil to the proper level.

Refer to "Recommended Lubricants" page 3.54 for the oil specifications. Total system capacity including the filter is 22 liters.

Before removing the oil level check plug, push down on the hydraulic oil tank cap to release the air pressure inside the hydraulic oil tank.

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

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

12. Idle the engine to inspect for leaks at the filter and the drain plug.

WARNING

13. Stop the engine. Wait approximately five minutes to let the oil drain back to the oil pan.

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

14. Check the oil level again.

15. Add the specified oil if necessary to bring the oil level to the "H" (High) mark on the dipstick.

16. Properly dispose of or recycle the waste oil.

CAUTION Used engine oil may cause skin disease or irritation.

Do not allow used engine oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

70ZV OM 2514

2. Remove the oil level plug from the front axle housing, using a 12 mm hex (Allen) wrench.

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

Refer to "Recommended Lubricants" page 3.54.

4. If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky.

Dispose of the drained oil properly.

3.26 MAINTENANCE Every 250 Hours or 1 Month 5. Install and tighten the level plug.

Check Planetary Gear Oil

6. Check the rear axle oil level following the same steps.

CAUTION The axles are pressurized through the hydraulic oil tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Before removing the oil level check plug, push down on the hydraulic oil tank cap to release the air pressure inside the hydraulic oil tank.

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

1. Check the oil level on all four wheels.

1 2

80ZVOM3340

2. Move the machine on level ground so that "TOP" mark (1) on the planetary gear housing comes top.

3. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

4. Remove the oil level plug (2) on the housing, using a 12 mm hex (Allen) wrench.

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

Refer to "Recommended Lubricants" page 3.54.

6. Magnetic plugs are used for the planetary gear housing. Wipe off the small amount of fine metallic powder that normally sticks to the plugs. If abnormal debris is found, determine the cause and correct it.

3.27 MAINTENANCE Every 250 Hours or 1 Month 7. If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky.

Dispose of the drained oil properly.

Check Tightness of Wheel Bolts 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

8. Install and tighten the level plug.

80ZVOM3340

2. Check the wheel bolts are tightened to 892 Nm. 3. Retighten if necessary.

3.28 MAINTENANCE Every 250 Hours or 1 Month

Replace DCA4 Coolant Filter Cartridge 2

CAUTION

1

Pressurized radiator tank is used for this machine.

2

Spray of hot coolant may cause burns.

Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure.

80ZVOM3285

CAUTION

3. Close the coolant shut-off valves (2).

Hot coolant and engine components can cause burns.

Avoid contact with coolant or engine components.

NOTE The filter WF2073 is initially installed when the machine is shipped from the factory. This filter can not be obtained as a spare parts.

4. Remove and properly dispose of the coolant filter (1).

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of a new DCA4 coolant filter cartridge (WF2071).

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

OM0200

7. Install the filter firmly by hand. Follow the instructions supplied with the filter.

85ZVOM3219

2. Slowly open the radiator cap.

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

9. Run the engine and check for coolant leaks.

10. Idle the engine for about five minutes to purge all the air from the coolant.

11. After air has been purged from the system, stop the engine and check the coolant level again.

3.29 MAINTENANCE Every 250 Hours or 1 Month 12. If needed, add required amount of the coolant.

Refer to "Coolant Specification" page 3.55 for the correct mixture.

Check and Adjust Air Conditioner Belt

CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine side panel.

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

2. Open the engine side panel.

OM0201

3. Visually inspect the compressor belt on both top and bottom sides for looseness and damage.

4. If the belt is too stretched to permit adjustment or shows cuts or cracks, replace it and adjust the tension correctly.

5. Apply pressure approximately 98 N to the center of the belt between the pulleys; deflection of about 8~10 mm is normal.

3.30 MAINTENANCE Every 250 Hours or 1 Month

Clean Air Conditioner Filter Element Outer filter cleaning

2 3

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

1

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

80ZVOM3304

6. If the belt is too loose or tight, adjust the tension by loosening the lock bolts (1) and nut (2), turning the adjusting nut (3) on the compressor bracket.

97ZVOM0152

3. The cover for the outer filter is located at the left rear side of the cab.

Turn the rings counterclockwise and then remove the cover.

97ZVOM0153

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. Use air pressure below 196 kPa. 6. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days for dry in the shade.

3.31 MAINTENANCE Every 250 Hours or 1 Month 7. After approximately 20 cleanings, replace the filter with new one.

2. Remove dust with compressed air. Use air pressure below 196 kPa.

Refer to "Replace Air Conditioner Filter Elements" page 3.50.

3. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days for dry.

8. When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

4. After approximately 20 cleanings, replace the filters with new ones.

Refer to "Replace Air Conditioner Filter Elements" page 3.50.

5. Install the filter, install the filter cover (3) and cover (1).

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

97ZVOM0152

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

Inner filter cleaning

2

3

1 97ZVOM2473

1. The inner filter is located at behind the operator's seat.

Open the unit cover (1) using screw driver.

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

Remove the filter and clean it.

3.32 MAINTENANCE Every 250 Hours or 1 Month

Replace Filter (First time replacement or cleaning only) - Transmission Oil Filter Cartridge Replace it first time only at 250 hours operation, after that replace it at every 500 hours operation.

Refer to "Every 500 Hours or 3 Months" page 3.33.

- Hydraulic Oil Return Filter Replace it first time only at 250 hours operation, after that replace it at every 1000 hours operation.

Refer to "Every 1000 Hours or 6 Months" page 3.39.

- Brake Line Filter Clean it first time only at 250 hours operation, after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page 3.51.

- Orbitrol® Filter Clean it first time only at 250 hours operation, after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page 3.52.

3.33 MAINTENANCE Every 500 Hours or 3 Months

Every 500 Hours or 3 Months WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

Every 500 hours or 3 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", and "250 hours" inspection and maintenance.

Replace Transmission Oil Filter Cartridge

CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

1. If the machine is cold, operate the machine to bring the torque converter oil temperature about 30~40ºC. 2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

3. Place a suitable container (about 4 liters) under the transmission oil filter.

85ZVOM3226

4. Turn the filter counterclockwise to remove.

Properly dispose of the oil and filter.

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of the new filter.

7. Install the filter on the filter head. Turn it clockwise to tighten. Follow the instructions on the filter.

8. Idle the engine about ten minutes and inspect for leaks around the filter.

3.34 MAINTENANCE Every 500 Hours or 3 Months

Replace Fuel Filter Cartridge

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

When inspecting or servicing machine in articulation area: - Lower attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

- Make sure nobody is on machine.

- Place "DO NOT OPERATE" tag on steering wheel.

CAUTION Escaping fuel is flammable and harmful to skin.

Do not smoke while draining moisture and sediment from fuel filter.

Do not drain with engine running.

Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

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

2. Place a small drain pan (about 1 liter) under the fuel filters.

80ZVOM3271

9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 2.50.

Add the specified oil as necessary to bring the oil level to the "H" (high) mark on the dipstick.

Refer to "Recommended Lubricants" page 3.54 for the specified oil.

CAUTION

80ZVOM3298

3. Remove and properly dispose of the fuel filters.

4. Clean the filter head gasket surface.

Used oil may cause skin disease.

5. Apply a light film of clean engine oil to the gasket surface of the new filters.

Do not allow used oil to remain on skin for prolonged periods of time.

6. Fill the filter with clean fuel.

Clean skin thoroughly with soap and water.

7. Install the filter on the filter head.

Turn it until the gasket contacts the filter head surface.

3.35 MAINTENANCE Every 500 Hours or 3 Months

Clean Fuel Prefilter

WARNING Escaping fuel is flammable and harmful to skin.

- Do not smoke while draining moisture and sediment from filter.

- Do not drain with engine running.

- Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

OM0200

8. Tighten the filter an additional one-half to three-fourths turn after the gasket contacts the filter head surface. Follow the instructions supplied with the filter.

1

3

2

3

Front

(R.H) 80ZV04042-0188

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

2. Place a small drain pan (about 1 liter (1 qt.)) under the fuel prefilter (1).

3. Loosen the hose bands (2). Remove the hoses (3) and remove the fuel prefilter (1).

4. Clean the fuel prefilter (1) by washing oil.

5. Install the fuel prefilter (1) in the original place.

Install the hoses (3) and tighten the hose bands (2).

3.36 MAINTENANCE Every 500 Hours or 3 Months

To fuel filter

From fuel tank

50ZV0001

NOTE When installing the fuel prefilter, the arrow on the fuel prefilter should be directed as shown in the figure.

3.37 MAINTENANCE Every 1000 Hours or 6 Months

Every 1000 Hours or 6 Months

Replace Transmission Oil

WARNING

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

Every 1000 hours or 6 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", and "500 hours" inspection and maintenance.

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

When inspecting or servicing machine in articulation area: - Lower attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

- Make sure nobody is on machine.

- Place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel.

CAUTION Transmission oil may be hot and may cause burns.

Avoid contact with transmission oil.

1. If the machine is cold operate the machine for a few minutes to bring the transmission oil temperature about 30~40ºC. 2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

3

1

2 95ZVOM2898

3. Remove the drain plug (1) with a 32 mm wrench.

4. Drain oil into a suitable container (about 35 liters).

Properly dispose of or recycle the waste oil.

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

3.38 MAINTENANCE Every 1000 Hours or 6 Months 6. Remove the flange (3) together with the pipe and suction strainer.

Clean or Replace Transmission Breather

7. Remove the suction strainer from the flange, brush off any debris and clean with solvent.

It is normal for a few fine particles to be on the strainer. Large pieces or a large quantity of particles indicates a problem.

Contact a Kawasaki dealer.

8. Reinstall the drain plug and the strainer with a new gasket.

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

80ZVOM3267

10. Fill with the specified oil.

Refer to "Recommended Lubricants" page 3.54.

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

2. Remove the breather from the transmission case.

11. Idle the engine and check for leaks.

3. Clean the breather in the cleaning oil tub, then spray dry compressed air from the bottom of the breather.

Even after cleaning, if the breather is not clean enough, replace the breather.

4. Install the breather onto the transmission case.

80ZVOM3271

12. Check the oil level with the dipstick. Add the specified oil if necessary to maintain the proper oil level.

Refer to "Check Transmission Oil Level" page 2.58 and "Recommended Lubricants" page 3.54.

3.39 MAINTENANCE Every 1000 Hours or 6 Months

Replace Hydraulic Oil Return Filter

1

2

CAUTION Pressurized hydraulic tank is used for this machine.

3 4 5

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler cap.

6 97ZVOM0166

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

2. Open the access cover on the right deck.

6. Remove the O-ring (3), spring (4), and bypass valve (5) from the filter housing.

7. Remove and properly dispose of the filter (6) and waste oil.

Filler cap

8. Clean the inside of the filter housing.

9. Replace the O-ring (3).

2

10. Apply a light film of clean hydraulic oil on the filter cover O-ring surface.

11. Install the filter element (6), bypass valve (5), spring (4), new O-ring (3) and filter cover (1).

1

80ZVOM3305

3. Press down the filler cap to relieve the tank pressure.

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

5. Remove two bolts (2) with a 17 mm wrench and open the filter cover (1).

The two bolts (2) may be used as "Jacking screws" to push up the cover. Install them into the two threaded holes in the cover. Screw them in equally to force the cover up evenly.

12. Close the access cover.

3.40 MAINTENANCE Every 1000 Hours or 6 Months

Adjust Parking Brake Lining

4. Place wheel chocks in front of and behind the tires to prevent the machine from moving.

WARNING When parking brake is released for adjusting brake lining, machine could move unexpectedly causing serious injury or death.

5. Place a "DO NOT OPERATE" tag on the steering wheel.

Make sure to lower attachment to ground, and put chocks under wheels.

Adjuster wheel

1. Park the machine in a safe place on firm level ground and steer it fully to one side for easier access.

1

2. Lower the attachment to the ground and turn "OFF" the parking brake switch.

Special Tool (Accessory) 97ZVOM0168

1

6. Remove a cap of the inspection hole (1) on the brake drum.

7. Turn the adjuster wheel fully upward to close the clearance between the brake drum and the brake lining (shoe). The adjuster wheel can be reached through the inspection hole.

8. Return the adjuster wheel eight clicks downward. (Now the clearance is 0.23 mm)

85ZV 3245

9. Check parking brake operation as described on page 2.60.

NOTE If the brake drum has been excessively hot (ie. burnt paint) or the parking brake will not adjust, contact your Kawasaki dealer.

1 8º

OM0167

3. Align the inspection hole (1) with the adjuster wheel by turning the hole 8º counterclockwise from the bottom.

Do not enter the articulation area or under the machine.

3.41 MAINTENANCE Every 1000 Hours or 6 Months

Check Air Conditioner Refrigerant

Adjust of refrigerant

Normal

Appearance of the sight glass

Solutions

Almost clear.

Any bubbles disappear if the engine speed is increased to 1,500 min-1.

High

No bubble is seen.

85ZV2829

Low

1. Apply the parking brake and lower the attachment to the ground.

2. Remove the cover.

3. Press the flow control switch to set maximum air flow.

4. Set the temperature control switch fully to the cool position and fully open the cab doors.

5. Slightly accelerate the engine to about the middle speed range. (compressor speed 1,500~1,800 min-1) 6. Compare the flow of bubbles in the sight glass with the drawings in the following table.

WARNING Overfilled refrigerant may cause dangerous high pressure and poor cooling action; and low refrigerant level may cause compressor damage.

Always maintain refrigerant in normal level.

A flow of bubbles is visible.

Contact your local Kawasaki loader dealer for inspection and recharging refrigerant.

3.42 MAINTENANCE Every 1000 Hours or 6 Months

Inspect Automatic Belt Tensioner Pulley

80ZVUSA0003

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and tag "Do Not Start".

2. Open the engine side panel.

3. Visually inspect the tensioner pulley and body for cracks. If any cracks are noticed, the tensioner pulley must be replaced.

4. Check the tensioner pulley for dirt buildup. If this condition exists, the tensioner pulley must be removed and steam-cleaned.

3.43 MAINTENANCE Every 2000 Hours or 1 Year

Every 2000 Hours or 1 Year WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

Every 2000 hours or 1 year, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", "500 hours", and "1000 hours" inspections and maintenance.

Greasing 1. Park the machine on level ground.

Lower the attachment to the lowest position and tilt back the bucket fully.

2. Steer the machine fully to the right or left, and stop the engine.

3. Lubricate the fitting on the following components.

Refer to "Recommended Lubricants" page 3.54 for the correct grease. Use lithium base grease for universal joints.

3.44 MAINTENANCE Every 2000 Hours or 1 Year

85ZVOM3316

95ZVOM2901

- 3rd Propeller Shaft (two places)

IMPORTANT - To lubricate the spline enough, start the engine and slowly turn the machine from side to side 2 or 3 times after greasing.

80ZVOM3314

95ZVOM2843

- 2nd Propeller Shaft (four places)

- When greased with the machine in straight, remove the fitting on the sleeve yoke and follow the procedure above.

3.45 MAINTENANCE Every 2000 Hours or 1 Year

Replace Hydraulic Oil, Clean Filter 2

WARNING Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler cap.

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

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

1

85ZVOM3230

7. Remove the drain plug (1) with a 12 mm Hex (Allen) wrench to drain oil.

8. Dispose of the waste oil properly.

9. Remove the nuts with a 17 mm wrench to remove the inspection cover (2).

CAUTION Compressed air may cause injury.

- Wear protective clothing and eye protection.

- Air pressure must be below 196 kPa. 10. Remove the set bolt in the suction strainers using a 8 mm wrench. (80C4-8053~) 80ZVOM3305

3. Insert the key into the side of the filler cap and turn the key counterclockwise.

4. Press down the filler cap to relieve the tank pressure.

5. Remove the inlet cap.

CAUTION Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil.

6. Prepare a suitable container to catch the draining oil (about 85 liters).

Remove the suction strainer. Inspect and clean them with solvent and compressed air.

A few small particles in the strainer is normal.

Large metal, rubber pieces, or a large amount of fine particles is abnormal. If found, contact your Kawasaki dealer.

11. Clean inside of the tank and magnet plug.

12. Install the suction strainer, new gasket and inspection cover (2), and tighten the nuts. Do not overtighten.

13. Install and tighten the drain plug.

14. Add the specified hydraulic oil through the oil inlet hole.

Refer to "Recommended Lubricants" page 3.54.

3.46 MAINTENANCE Every 2000 Hours or 1 Year 15. Close the oil inlet cap.

16. Start the engine and allow the engine to idle for about five minutes.

17. Operate the bucket, boom, and steering cylinders for about five minutes, then lower the attachment to the ground.

18. Inspect for leaks.

19. Make sure hydraulic oil is to the center of the oil level gauge. Add hydraulic oil if necessary.

Replace Differential Gear Oil

CAUTION The axles are pressurized through the hydraulic oil tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Before removing the oil level check plug, push down on the hydraulic oil tank cap to release the air pressure inside the hydraulic oil tank.

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

1. If the machine is cold operate the machine for a few minutes to bring the differential gear oil temperature about 40ºC. 2. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

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

1

2

70ZV OM 2514

3. Remove the level plug (1) and drain plug (2) from the front axle housing, with a 12 mm Hex (Allen) wrench.

Some fine metallic powder will normally stick to the magnet plugs.

Simply wipe it off.

3.47 MAINTENANCE Every 2000 Hours or 1 Year 4. Drain the oil (about 30 liters) into a suitable container.

Replace Planetary Gear Oil

CAUTION

5. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease.

Do not allow used oil to remain on skin for prolonged periods of time.

The axles are pressurized through the hydraulic oil tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Clean skin thoroughly with soap and water.

Before removing the oil level check plug, push down on the hydraulic oil tank cap to release the air pressure inside the hydraulic oil tank.

6. Install the drain plug.

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

7. Refill the recommended oil through the level plug hole (1) until the oil comes out from the hole.

1. Replace the planetary gear oil on all four wheels.

Refer to "Recommended Lubricants" page 3.54.

8. Install and tighten the level plug.

1 2

9. Replace the rear differential oil following the same steps.

Required oil volume for the rear differential is about 35 liters.

80ZVOM3340

2. Move the machine on level ground so that "TOP" mark (1) on the planetary gear housing comes to the top.

3. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

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

3.48 MAINTENANCE Every 2000 Hours or 1 Year

Clean Fuel Tank

CAUTION Escaping fuel is flammable and harmful to skin.

3

Do not smoke while draining moisture and sediment from tank.

Do not drain with engine running.

Do not allow fuel to remain on skin for an extended period of time. Wash thoroughly with soap and water.

70ZV OM 2514

4. Remove the level plug (2) and drain plug (3) from the planetary gear housing, using a 12 mm hex (Allen) wrench.

Some fine metallic powder will normally stick to the magnet plug (2).

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

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

Simply wipe it off.

5. Drain the oil (about 12 liters) into a suitable container.

2

6. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease.

Do not allow used oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

7. Install and tighten the drain plug.

8. Refill the recommended oil through the level plug hole (2) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page 3.54.

1 80ZVOM3269

2. Open the drain cock (1) on the fuel tank.

3. Drain the remaining fuel into a suitable container.

4. Remove the nuts with a 17 mm wrench to remove the inspection cover (2).

5. Clean inside of the tank.

9. Install and tighten the level plug.

6. Install the inspection cover with a new gasket.

Tighten the nuts evenly. Do not overtighten.

10. Repeat these steps for all four planetaries.

7. Close the drain cock.

8. Fill the fuel tank.

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

3.49 MAINTENANCE Every 2000 Hours or 1 Year

Check Vibration Damper

A

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

C

B

65ZV0024

4. Check the index lines (A) in the vibration damper hub (B) and the inertia member (C). If the lines are more than 1.59 mm out of alignment, replace the vibration damper.

80ZVUSA0003

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

OK

OK

OK

OK

OK 65ZV0023

80ZVUSA0004

3. If dents, cracks, or any deformations are found, contact your nearest Kawasaki dealer or Cummins Engine dealer for replacement.

5. Inspect the rubber member for deterioration. If pieces of rubber are missing or if the elastic member is more than 3.18 mm below the metal surface, replace the damper.

Also, look for forward movement on the damper ring on the hub. Replace the vibration damper if any movement is detected.

6. If dents, cracks, or any deformations are found, contact your nearest Kawasaki dealer or Cummins Engine dealer for replacement.

3.50 MAINTENANCE Every 2000 Hours or 1 Year

Check Brake Accumulator Test the brake accumulator for proper pre-charge of nitrogen gas.

Replace Air Conditioner Filter Elements Outer filter replacement

WARNING

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

Pressurized nitrogen gas in brake accumulator could explode causing serious injury or death.

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

Never service brake accumulator unless trained properly.

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

2. Run the engine at low idle for five minutes to fill the brake accumulator with oil.

3. Stop the engine.

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

5. Count the number of times you can depress the right hand brake pedal before the brake warning light comes on.

6. If the number counted is less than nine, there is some problem with the accumulator. Contact your nearest Kawasaki dealer.

97ZVOM0152

3. The cover for the outer filter is located at the left rear side of the cab.

Turn the rings counterclockwise and then remove the cover.

Check Service Brake Disk Wear - Contact your Kawasaki dealer.

Check and Adjust Valve Lash Clearance - Contact your Kawasaki dealer or local Cummins engine dealer.

97ZVOM0153

4. Remove the outer filter from the cab, and replace it with new one.

When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

3.51 MAINTENANCE Every 2000 Hours or 1 Year

Clean Filter for Brake Line

CAUTION Hot oil and components may cause burns.

Vent all pressure by pressing hydraulic cap down.

Avoid contact with hot oil or components.

97ZVOM0152

5. Install the cover to the cab and turn the rings clockwise to fix the cover.

1. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

Inner filter replacement

2 Front

3 (R.H) 80ZV03148-06300

1 97ZVOM2473

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

Air blow FLOW

Open the unit cover (1) using screw driver.

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

Remove the filter and replace it with new one.

Filter case

Filter

Nipple

OM0212

2. Place a suitable container under the filter.

3. Remove the nipple with filter and properly clean the filter.

4. Install the nipple with filter and tighten it with 60~80 N-m torque.

5. Idle the engine about ten minutes and inspect for leaks around the filter.

3.52 MAINTENANCE Every 2000 Hours or 1 Year

Clean Filter for Orbitrol®

6. Install the nipple with filter and tighten it with 60~80 N-m torque.

CAUTION Hot oil and components may cause burns.

Vent all pressure by pressing hydraulic cap down.

Avoid contact with hot oil or components.

1. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

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

3. Move the steering each way about 2~3 times to relieve the pressure.

Front Cross (Upper)

Front Chassis C/L

80ZV04033-02960

Air blow FLOW

Filter case

Filter

Nipple

OM0212

4. Place a suitable container under the filter.

5. Remove the nipple with filter and properly clean the filter.

7. Idle the engine about ten minutes and inspect for leaks around the filter.

3.53 MAINTENANCE Every 2000 Hours or 1 Year

Check Vibration Damper Accumulator (option)

WARNING Pressurized nitrogen gas in vibration damper accumulator could explode causing serious injury or death.

Never service vibration damper accumulator unless trained properly.

Replace Filter in the Oil Tank Cap

CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before opening.

Contact your nearest Kawasaki dealer.

1 5 4 3 2 97ZVOM0170

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

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

3. Insert the key into the side of the filter cap (1) and turn the key counterclockwise.

4. Press down the filter cap (1) to relieve the tank pressure.

5. Remove the filter cap.

6. Remove spiral snap ring (2), valve assy (3), spring (4), filter element (5).

7. Replace element (5). (Part number 3098160030) 8. Install the element, spring, valve assy, and spiral snap ring.

3.54 MAINTENANCE Every 2000 Hours or 1 Year

Recommended Lubricants Refill capacity (Approximate)

Kind of Oil

21 liter

Engine oil (CF4SG)

Ambient Temperature (ºC) -30

-20

-10

0

10

20

30

40

Change Interval (Hours)

SAE10W

Engine

250

SAE10W-30 SAE15W-40

Transmission

35 liter

Engine oil (CD) or ATF

Hydraulic tank

∗1 85 liter

Hydraulic oil

Differential & Planetary

Front: 54 liter Rear: 59 liter

Engine oil (CD)

Fuel tank

290 liter

Diesel fuel

SAE10W

1,000

ATF ISO VG32

2,000

ISO VG46 Engine oil SAE40 or SAE50

2,000

ASTM D975 No.1

daily

ASTM D975 No.2

Note: ∗1 shows "Hydraulic tank oil capacity at level gauge center."

Engine

Use oil that meets engine oil classification API CF4SG.

Transmission

Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid).

Never mix engine oil and A.T.F.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure.

Differential & Planetary

Use class API CD engine oil with 5 % "Antichatter" additive or friction modifier.

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

Requirements for diesel fuel

Specifications Flash Point

ºC.

Grade No.1-D

min.

Water and Sediment % vol.

max

Distillation Temperature

90 % vol.

ºC

recovered

Kinematic Viscosity mm2/s at 40ºC

38

52

0.05

0.05

max.

288

338

min.

1.3

1.9

max.

Ash % mass

Grade No.2-D

max.

2.4

4.1

0.01

0.01

Sulfer % mass

max.

0.50

0.50

Cetane Number

min.

40

40

0.15

0.35

Carbon residue on 10 % distillation residue % mass

max.

3.55 MAINTENANCE Coolant Specification

Coolant Specification The machine is originally filled with Long Life Coolant which need not be replaced for the first two years or 3000 hours.

If Long Life Coolant (permanent type) is not used for the replacement, it should be replaced every six months.

Recommended Mixture of Antifreeze Expected Minimum Ambient Temperature

-35ºC

-30ºC

-25ºC

-20ºC

-15ºC

Pure Water

(liter)

27.7

30.7

33.6

36.6

39.5

Antifreeze

(liter)

31.3

28.3

25.4

22.4

19.5

53

48

43

38

33

Mixture Ratio (%)

- Too much antifreeze in the coolant mixture may cause engine overheating.

Keep 33 % antifreeze mixture (same as the mixture for a minimum ambient temperature of -15 ºC) if the engine overheats in a high ambient temperature.

- Do not use hard water or water with high levels of calcium and magnesium ions as the coolant water.

IMPORTANT Do not mix different brands of antifreeze because they each contain special additives.

Careless mixing often diminishes the effect of these additives and causes packing damage or water leakage.

3.56 TROUBLESHOOTING

TROUBLESHOOTING This troubleshooting section is not intended to cover every condition, however many of the common possibilities are listed.

Following are example of problems and their solutions.

Contact your local Kawasaki dealer for the items marked with or your local authorized CUMMINS ENGINE dealer for the items marked with to repair. kawasaki

CUMMINS

ENGINE PROBLEM

Engine oil pressure warning lamp lights up, and buzzer sounds

POSSIBLE CAUSES Low engine oil level Wrong grade oil for weather conditions Clogging oil filter element Defective alarm switch Oil leakage from pipe or joint Clogging suction strainer Excessive engine wear Defective oil pump

SOLUTIONS Add oil Change oil Change filter and oil

kawasaki

or

2.46 3.24 3.24

CUMMINS

Low engine coolant level Add coolant kawasaki Fan circuit pressure or flow too low Clogging radiator fins Clean Coolant temp. warnScale or mineral build up inside radiator Flush or professionally clean ing lamp lights up Defective alarm switch (gauge is in green) or kawasaki CUMMINS Low water pump flow Thermostat stuck or missing Engine does not start when the starter motor is turning (Also see ELECTRICAL TROUBLESHOOTING)

Fuel filter element clogging Starter motor speed too low Defective engine shut off solenoid Fuel pump failure Incorrect fuel injection timing Compression pressure too low Defective injectors

Replace fuel filter Booster Battery may be used

Air in fuel lines Fuel filter element clogging Fuel pump failure Incorrect fuel injection timing

Tighten fuel connections and filter

Unstable (rough) idling

kawasaki

or

or

2.48 3.10 3.13

3.34 2.78

CUMMINS

Replace fuel filter kawasaki

PAGE

CUMMINS

3.34 3.34

3.57 TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

Air cleaner element clogging Fuel filter element clogging Throttle linkage adjustment wrong Engine oil level too high Incorrect valve clearance Piston ring wear Defective injectors Fuel pump failure Air cooler restricted

Clean or replace element Replace fuel filter

Use correct type of oil Correct oil level

Unusual combustion noise or mechanical noise

Wrong type of oil Engine oil level too low or too high Defective injectors Incorrect valve clearance Main bearing / con-rod bearing wear Crankshaft uneven wear Connecting rod bent Timing gear wear Water pump bearing wear Failed turbo or muffler

White exhaust smoke (After engine has reached operating temp.)

Fuel being diluted with water Wrong grade fuel Incorrect fuel injection timing Compression pressure too low Turbo seal leakage Coolant ingestion

Replace with specified fuel and replace fuel filter

Clean or replace element

Black exhaust smoke

Air cleaner element clogging Turbo damage Incorrect fuel injection timing Fuel injection pump failure Defective injectors

Insufficient power

PAGE 3.9 3.34

kawasaki

Check dipstick and correct level

kawasaki

kawasaki

kawasaki

kawasaki

or

or

or

or

2.46

CUMMINS

3.54 2.46

CUMMINS

3.34

CUMMINS

CUMMINS

3.9

3.58 TROUBLESHOOTING

ELECTRICAL PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Adjust or replace belt Replace battery

2.51

Charge lamp lights up

Broken or slipping alternator belt Defective battery Alternator failure Defective wiring Defective wiring to ground (short)

Starter motor does not turn when starter switch key is turned to "START"

Transmission not in NEUTRAL Insufficient battery charge Starter switch failure Defective wiring Starter motor failure

Shift to NEUTRAL Battery charge or booster

Starter motor turns engine slowly

Hydraulic control levers not in NEUTRAL Insufficient battery charging Engine oil viscosity too high (thick) Poor connection at batteries or ground Defective wiring Starter motor failure Steering valve failure

Move levers to NEUTRAL Battery charge or booster Replace oil Clean and tighten all terminals

POSSIBLE CAUSES

SOLUTIONS

kawasaki

or

CUMMINS

1.22 2.78

kawasaki

kawasaki

or

CUMMINS

2.5 2.78 3.24

kawasaki kawasaki

or

CUMMINS

kawasaki

STEERING PROBLEM

Hard steering

Tires are underinflated Severe conditions (over loaded, deep mud, etc.)

Oil pressure too low Steering valve failure Steering cylinder failure

Check/adjust tire pressure Change operation

PAGE 3.21

kawasaki

®

Defective Orbitrol Pump failure

Articulation stopper in locked position Excessive load on steering Steering valve failure Will not steer

Orbitrol® failure Pump failure Relief valve failure Steering cylinder failure Blocked screen filter Excessively cold oil / wrong grade oil

Steering Drift

Steering control valve failure Steering pilot valve failure

Move articulation stopper to "STORED" position Reduce load

1.21

kawasaki

Clean filter

3.52

Warm oil / Replace oil with proper viscosity for temperature

3.54

kawasaki

3.59 TROUBLESHOOTING

HYDRAULIC PROBLEM

Boom raises too slowly

Boom natural drift excessively

POSSIBLE CAUSES

SOLUTIONS

PAGE

Excessively cold oil Wrong grade oil Oil pressure too low Damaged cylinder piston or piston packing Pump flow too low Pilot pressure too low Engine RPM too low

Warm oil Replace with proper grade oil

3.54

Excessively cold oil / Wrong oil type

Warm oil / Replace oil with proper viscosity for temperature

kawasaki

3.54

Leakage from control valve plunger Damaged cylinder piston or piston packing

kawasaki

Leakage in pilot relief valve Bucket / Attachment floating or drifting

Over load relief pressure too low Control valve failure Natural drift of cylinder / packing

kawasaki

BRAKE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Adjust or replace lining

3.40

Parking brake does not work properly

Worn brake lining Insufficient oil pressure (will not release) Failure of switch or solenoid valve Poor wiring or ground to switch or solenoid valve

Remove or clean

Brake dragging

Dirt, debris under base of brake pedal Warped brake discs Air in brake oil circuit

Braking power too low

Air in brake oil circuit Brake piston seal leakage Blocked screen filter

Brake pressure drops rapidly

Cracked or leaking brake line Brake valve failure Parking brake cylinder leakage Defective brake accumulator Defective brake seals

kawasaki

kawasaki

kawasaki

Clean filter

kawasaki

3.51

3.60 TROUBLESHOOTING

TORQUE CONVERTER & TRANSMISSION PROBLEM

POSSIBLE CAUSES Excessively cold oil / Wrong oil type

Engine is running but machine does not move

Parking brake is applied Transmission oil level too low Transmission suction strainer clogging Clutch oil pressure too low Transmission clutch failure Transmission controller failure Defective electrical circuit

SOLUTIONS

PAGE

Warm oil / Replace oil with proper viscosity for temperature Release parking brake Add oil / Repair leak Clean strainer

3.54

kawasaki

Service or parking brake dragging Low oil level in transmission Suction strainer in transmission clogging Clutch oil pressure too low Torque converter oil pressure too low Transmission clutch failure

Inspect and correct Refill oil / Repair leak Clean or replace strainer

Oil leakage from transmission

Air breather clogged Seal damage (between engine and torque converter housing)

Clean and refill with oil

Torque converter overheat

Oil level too low Dozing, continuous pushing application Operating in too high a speed range Long downhill driving Radiator clogged: coolant temp also high Defective alarm switch (gauge is in green) Torque converter / Transmission failure Oil pressure too low

Add oil / Repair leak Reduce load Use lower gear Change application Clean radiator fins

Low power

2.58 3.37

2.58 3.37

kawasaki

3.38

kawasaki

2.58 2.63 3.10

kawasaki

AIR CONDITIONER PROBLEM

Low cooling when A/C "ON"

Low heater out put

POSSIBLE CAUSES

SOLUTIONS

Hot water continues to flow through heater core A/C not set for maximum cooling Condenser fins plugged A/C filters plugged A/C compressor belts slipping/broken A/C refrigerant charge low

Shut off valve in heater hose line at block Adjust controls/vents Clean Clean or replace Adjust/Replace

Engine not warmed up No hot water flow to heater core Air conditioner running Heater vents not adjusted properly Defective heater motor or switch

Warm up engine Open shut off valve on block Turn A/C off Adjust controls/vents

PAGE

2.36 3.13 3.30 3.29

kawasaki

kawasaki

2.36

3.61 TROUBLESHOOTING

AIR CONDITIONER FAILURE MODE FAILURE MODE

FAILURE

SOLUTIONS

E11 (Wire breakage in the inside air sensor)

- Breakage in the wire harness or loosen connector - Wire breakage in the inside air sensor (THI)

- Checking the wiring - Replacement

E12 (Short-circuit in the inside air sensor)

- Short-circuit in the wire harness - Short-circuit in the inside air sensor (THI)

- Checking the wiring - Replacement

E13 (Wire breakage in the outside air sensor)

- Breakage in the wire harness or loosen connector - Wire breakage in the outside air sensor (THAM)

- Checking the wiring - Replacement

E14 (Short-circuit in the outside air sensor)

- Short-circuit in the wire harness - Short-circuit in the outside air sensor (THAM)

- Checking the wiring - Replacement

E15 (Wire breakage in the water temperature sensor)

- Breakage in the wire harness or loosen connector - Wire breakage in the water temperature sensor (THW)

- Checking the wiring - Replacement

E16 (Short-circuit in the water temperature sensor)

- Short-circuit in the wire harness - Short-circuit in the water temperature sensor (THW)

- Checking the wiring - Replacement

E18 (Short-circuit in the insolation sensor)

- Short-circuit in the wire harness - Short-circuit in the insolation sensor (THI)

- Checking the wiring - Replacement

E21 (Wire breakage in the ventilation sensor)

- Breakage in the wire harness - Wire breakage in the ventilation sensor (THF)

- Checking the wiring - Replacement

E22 (Short-circuit in the ventilation sensor)

- Short-circuit in the wire harness - Short-circuit in the ventilation sensor (THF)

- Checking the wiring - Replacement

E43 (Abnormality in the ventilation servo motor)

- Defective wire harness or loosen connector - Defective servo motor - Stuck foreign material

- Checking the wiring - Replacement - Removing the foreign material

- Defective wire harness or loosen connector - Defective servo motor - Stuck foreign material

- Checking the wiring - Replacement - Removing the foreign material

- Defective wire harness or loosen connector - Defective servo motor - Stuck foreign material

- Checking the wiring - Replacement - Removing the foreign material

E44 (Abnormality in the air mixture damper motor) E45 (Abnormality in the inside/outside air switching motor)

3.62 TROUBLESHOOTING

FAILURE MODE

FAILURE - High pressure switch actuation - Outside air temperature is too high - Insufficient cooling of condenser - Defective fan motor - Clogging in condenser - Refrigerant overfilling

E51 (Abnormality in the refrigerant pressure)

- Aeration into refrigerant circuit - Low pressure switch actuation - Outside air temperature is too low - Insufficient refrigerant quantity - Gas leak

SOLUTIONS

- Motor replacement - Cleaning - Adjusting refrigerant quantity - Circuit evacuation & refilling

- Circuit evacuation & refilling - Repair leakage spot - Circuit evacuation & refilling

INDEX A

Before Starting Safety ................................................1.4 Before Storage .........................................................2.83 Boom Control Lever ...................................................2.4 Boom Kickout Adjustment ........................................2.75 Booster Batteries / Jumper Cables ..........................2.78 Brake Pedals .............................................................2.7 Brake Pressure Warning Lamp (red) .......................2.20 Bucket / Attachment Positioner Adjustment .............2.74 Bucket Control Lever .................................................2.5

Check or Replace Fuses .........................................3.12 Check Parking Brake ...............................................2.53 Check Parking Brake Operation ..............................2.60 Check Planetary Gear Oil ........................................3.26 Check Service Brake Disk Wear .............................3.50 Check Service Brake Operation ..............................2.59 Check Steering Wheel Operation ............................2.60 Check Tightness of Wheel Bolts ..............................3.27 Check Tire Air Pressure ..........................................3.21 Check Tire for Damage, Air and Tread Depth .........2.50 Check Transmission Oil Level .................................2.58 Check Transmission Shift Lever ..............................2.54 Check Vibration Damper .........................................3.49 Check Vibration Damper Accumulator (option) .......3.53 Check Warning Lamps ............................................2.57 Check Windshield Washer Fluid ..............................3.12 Check Wiring Harnesses .........................................2.49 Cigarette Lighter ......................................................2.14 Clean Air Conditioner Condenser ............................3.13 Clean Air Conditioner Filter Element .......................3.30 Clean Filter for Brake Line .......................................3.51 Clean Filter for Orbitrol® ...........................................3.52 Clean Fuel Prefilter ..................................................3.35 Clean Fuel Tank ......................................................3.48 Clean or Replace Air Cleaner Element ......................3.9 Clean or Replace Transmission Breather ................3.38 Clean Radiator / Air cooler / Hydraulic oil cooler Fins .............................................................................3.10 Cold Start .................................................................2.56 COMPONENT NAME/LOCATION ............................2.2 Coolant Specification ...............................................3.55

C

D

Accelerator Pedal ......................................................2.6 Adjust and Check Rear View Mirrors .......................2.53 Adjust Parking Brake Lining .....................................3.40 Adjustments .............................................................2.74 After Storage ............................................................2.84 Air Cleaner Warning Lamp (red) ..............................2.21 Air Conditioner .........................................................2.36 Action to be taken when the air conditioner is not used ......................................................................2.42 For Efficient Use of the Air Conditioner ................2.41 Operation Method (Normal Usage) ......................2.38 Operation Method (Other Usage) .........................2.39 Other Functions ....................................................2.40 Switches ...............................................................2.36 Ventilation Name and Location ............................2.36 Articulation Stopper ..................................... 1.21, 2.49 Auto Shift Indicator Lamp ........................................2.22 Auxiliary Attachment Control Lever (option) ..............2.5

B

Carrying ...................................................................2.71 Central Warning Lamp (red) ....................................2.19 Charge Lamp (red) ..................................................2.21 Check after Starting the Engine ...............................2.57 Check Air Conditioner Refrigerant ...........................3.41 Check Air Intake System .........................................2.52 Check and Adjust Air Conditioner Belt .....................3.29 Check and Adjust Valve Lash Clearance ................3.50 Check and/or Replace Seat Belt ................................3.9 Check Back-up Alarm Operation .............................2.60 Check Battery Electrolyte Level ...............................3.20 Check before Operation ...........................................2.45 Check Brake Accumulator .......................................3.50 Check Control Levers ..............................................2.54 Check Cooling Fan ..................................................2.53 Check Differential Gear Oil ......................................3.25 Check Drive Belt ......................................................2.51 Check Engine Coolant Level ...................................2.48 Check Engine Oil Level ...........................................2.46 Check Exhaust Gas .................................................2.61 Check Fuel Level .....................................................2.58 Check Horn Operation .............................................2.53 Check Hydraulic Oil Level ........................................2.47 Check Monitor Panel Operation ...............................2.54

Dozing .....................................................................2.69 Drain Water and Sediment from Fuel Filter .............2.48 Drain Water and Sediment from Fuel Tank .............3.20 Dumping into Truck or Hopper ................................2.71 During Storage ........................................................2.83

E Electrical Protection .................................................2.26 Emergency Brake ....................................................1.22 Emergency Steering Warning Lamp (red) (option) .............................................................................2.23 Engine Coolant Temperature Gauge .......................2.18 Engine Coolant Temperature Warning Lamp (red) .............................................................................2.20 Engine Oil Pressure Warning Lamp (red) ................2.20 Every 10 Hours or Daily ...........................................3.16 Every 1000 Hours or 6 Months ................................3.37 Every 2000 Hours or 1 Year ....................................3.43 Every 250 Hours or 1 Month ....................................3.23 Every 50 Hours or 1 Week ......................................3.17 Every 500 Hours or 3 Months ..................................3.33 Excavating ...............................................................2.69 Explosion / Fire / Burn Prevention ...........................1.13

F F/R Switch (option) ................................................. 2.16 Four-way Flasher Switch ......................................... 2.15 Front Wiper Switch .................................................. 2.13 Front Working Light Switch ..................................... 2.11 Fuel Gauge ............................................................. 2.18 Fuse Boxes ............................................................. 2.26 Fusible Link ............................................................. 2.27

G General Inspection .................................................. 2.61 Grease Gun Holder ................................................. 2.44 Greasing ..........................................3.17, 3.23, 3.43 Ground Levelling ..................................................... 2.70

H High beam Indicator Lamp (blue) ............................ 2.22 High-Low Beam Lever/Turn Signal Lever ................. 2.4 Horn Button ............................................................... 2.3 Hour Meter .............................................................. 2.22

I Indicators ................................................................ 2.17 Inspect Automatic Belt Tensioner Pulley ................. 3.42 Inspection and Maintenance Table ........................... 3.4

L Light Switch ............................................................. 2.11 Loading ................................................................... 2.67 Loading Control Lever Lock .................................... 1.21 Long Term Storage ................................................. 2.83

Power Up Switch ..................................................... 2.14 Preheat Indicator Lamp (orange) ............................ 2.19

R Radio - AM / FM Cassette (24Volt Type) (option) ............................................................................. 2.28 Rear Wiper Switch .................................................. 2.13 Rear Working Light Switch ...................................... 2.12 Recommended Lubricants ...................................... 3.54 Recommended Mixture of Antifreeze ...................... 3.55 Replace Air Conditioner Filter Elements ................. 3.50 Replace Air Conditioner Receiver Dryer ................. 3.15 Replace Bucket Teeth (option) ................................. 3.7 Replace Coolant ..................................................... 3.13 Replace Cutting Edge ............................................... 3.8 Replace DCA4 Coolant Filter Cartridge .................. 3.28 Replace Differential Gear Oil .................................. 3.46 Replace Engine Oil and Oil Filter Cartridge ............ 3.24 Replace Filter .......................................................... 3.32 Replace Filter in the Oil Tank Cap .......................... 3.53 Replace Fuel Filter Cartridge .................................. 3.34 Replace Hydraulic Oil Return Filter ......................... 3.39 Replace Hydraulic Oil, Clean Filter ......................... 3.45 Replace Planetary Gear Oil .................................... 3.47 Replace Transmission Oil ....................................... 3.37 Replace Transmission Oil Filter Cartridge .............. 3.33 Roading / Special Applications ............................... 2.77 ROPS (Roll Over Protective Structure) Cab ..................................................................1.23, 2.53

S

Operating Techniques ............................................. 2.67 Operating the Machine ............................................ 2.62 OPERATION ........................................................... 2.45 Operational Safety .................................................... 1.6 Operator Safety ......................................................... 1.2 OPERATOR'S AREA ................................................ 2.3 Other Maintenance Safety Concerns ...................... 1.14

Safe Operation .......................................................... 1.2 SAFETY .................................................................... 1.2 Safety Devices ........................................................ 1.21 Safety Preparations Before Maintenance ............... 1.11 Safety Signs ............................................................ 1.16 Seat ......................................................................... 2.24 Seat Adjustment ...................................................... 2.24 Seat Belt ................................................................. 2.25 Selection Switch for Shift Lever or F/R Switch (option) ............................................................................. 2.15 Serial Number Location ............................................ 3.2 SPECIAL PROCEDURES ...................................... 2.74 Speed and Direction Change .................................. 2.63 Speedometer .......................................................... 2.18 Starter Switch .......................................................... 2.10 Starting the Engine ................................................. 2.55 Starting the Machine ............................................... 2.62 Starting the Machine on a Grade ............................ 2.63 Steering Column Telescopic Tilt Handle ................... 2.8 Stopping the Engine ................................................ 2.66 Switches .................................................................... 2.9

P

T

Parking .................................................................... 2.65 Parking Brake Indicator Lamp (red) ........................ 2.19 Parking Brake Switch .............................................. 2.10 Parking Safety ......................................................... 1.10 Pedals and Levers .................................................... 2.3

Torque Converter Oil Temperature Gauge ............. 2.18 Torque Converter Oil Temperature Warning Lamp (red) ..................................................................... 2.21 Towing .................................................................... 2.80 Transmission Control Warning Lamp (red) ............. 2.19

M MAINTENANCE ........................................................ 3.2 Mounting and Dismounting Safety ............................ 1.3

N Neutral Indicator Lamp ............................................ 2.22 Neutral Start System ............................................... 1.22 Normal Start ............................................................ 2.55

O

Transmission Cut-Off Selection Lamp (green) ........2.19 Transmission Cut-Off Selector Switch .....................2.12 Transmission Shift Lever ...........................................2.3 Transmission Status Monitor ...................................2.22 Transportation ..........................................................2.81 TROUBLESHOOTING .............................................3.56 Turn Signal Indicator Lamp (Left) (green) ................2.21 Turn Signal Indicator Lamp (Right) (green) .............2.21 Typical Truck Loading Methods ...............................2.73

V Vibration Damper (option) ........................................2.43 Vibration Damper Pilot Lamp (green) (option) .........2.23

W Walk-Around Inspection ...........................................2.45 When Required Inspection and Maintenance ............3.7 Working Light Indicator Lamp (green) .....................2.19 Wrist Rest ..................................................................2.6

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes