DOWNLOAD PDF : Kawasaki WHEEL LOADER 115ZV OPERATION & MAINTENANCE MANUAL 93116-00141 PDF

January 15, 2003

NOTICE

WARNING CALIFORNIA PROPOSITION 65

BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

WASH HANDS AFTER HANDLING !

CALIFORNIA Proposition 65 warning Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer, birth defects, and other reproductive harm.

93116-00141 January 15, 2003

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 115ZV. 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.

For additional details, for safe and efficient operation and maintenance of your Cummins engine, please refer to your Cummins operation & maintenance manual.

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 jobsites 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 ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・1.20 2.OPERATION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.1 COMPONENT NAME / LOCATION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.2 OPERATOR'S AREA・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.3 Pedals and Levers・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.3 Switches ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.9 Indicators ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.20 Seat ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.28 Electrical Protection (Fuses) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.30 Radio-AM/FM Cassette ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.32 Heater or Air Conditioner (option) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.40 Ride Control System (option) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.42 Grease Gun Holder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.43 OPERATION・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.44 Check Before Operation ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.44 Starting the Engine ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.55 Check after Starting the Engine・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.58 Operating the Machine ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.64 Parking ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.67 Stopping the Engine・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.68 Operating Techniques ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.69 SPECIAL PROCEDURES・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.76 Adjustments ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.76 Roading / Special Applications ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.79 Booster Batteries / Jumper Cables・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.80 Towing・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.82 Transportation ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.83 Long Term Storage・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.85

3.MAINTENANCE ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.1 MAINTENANCE ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.2 Serial Number Location ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.2 Inspection and Maintenance Table・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.5 When Required Inspection and Maintenance・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.8 Every 10 Hours or Daily・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.16 Every 50 Hours or 1 Week ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.17 Every 250 Hours or 1 Month ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.22 Every 500 Hours or 3 Months ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.34 Every 1000 Hours or 6 Months・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.36 Every 2000 Hours or 1 Year ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.43 Recommended Lubricants and Capacity ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.55 Coolant Specification ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.56 TROUBLESHOOTING ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.57 SPECIFICATIONS ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.62

INDEX

Maintenance log is in back of this manual.

1.1

1.SAFETY

1.2

SAFETY Safe Operation

SAFETY Safe Operation Operator Safety

Wear safe clothing: ・Close fitting clothing -- loose or baggy clothing can

Read and understand the Operation & Maintenance Manual.

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.

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

Face the machine when mounting or dismounting.

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

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

Climb and step only where steps and handrails are provided.

Use only the handrails provided to climb -- not use the 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 of that 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.

Only the operator alone should be on the machine.

1.4

SAFETY Safe Operation

Before Starting Safety

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.

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.

Lock Unlock

Be sure the following safety devices work or are positioned properly. ・Parking Brake -- Applied (See page 2.10) ・Control Lever Lock -- Locked (See page 2.8)

N F

R

・Forward / Backward Changeover Switch -- Neutral

1.5

SAFETY Safe Operation

"STORED" position

・Articulation Stopper -- Locked in the "STORED"

position. ・Back-up Alarm -- Operational

Adjust the seat, seat belt, 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

Do not leave butane cigarette lighters in the cab. The lighter may cause explosion from high temperature in the cab.

ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ ＳＩＧＮＥＤ ＢＹ

Do not bring inflammable or explosive materials such as : -spray can -chemical cylinder Do not attach suction cups to the windows to avoid a fire hazard due to intense light magnification.

In case of fire during operation : ・Turn off the starter switch and stop the engine. ・Extinguish fire with a fire extinguisher if possible. ・With hand rails and steps, get off the machine and

stay away from it.

・Call for emergency services to extinguish the fire if

necessary.

Depending on the situation, the way of evacuation will be changed. If necessary, periodic fire drill is needed at the work area.

ＤＡＴＥ

Do not start or operate the machine if a "DO NOT START" or a "DO NOT OPERATE" tag is on the key switch 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.

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.

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

Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

Do not operate the machine at work area close to fire.

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 2.80.

Operate the machine slowly over rough ground and/or 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 -35 ℃ ～ 45 ℃ (-31 ° F ～ 113 ° F).

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

Vision to the rear on any machine is limited. Always use special caution when backing up.

as possible.

・Drive directly up or down the grade -- never across

Know the machine limits and do not exceed them.

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.

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

Do not use the machine as a crane where the safety of the operator or other workers are involved.

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.

Properly counterweight and ballast the machine depending upon the bucket size and material or attachment application. Do not exceed the recommendations and limits.

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

Do not expose the machine to flames.

approx. 40cm (16in)

・The normal carry position is about 40 cm (16 in.)

above the ground.

1.8

SAFETY Safe Operation

When roading the machine: ・Travel in forward only. ・Travel only as fast as conditions and safety

allowed.

・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 (2 miles)), periodically stop to allow tires, transmission, engine to cool down. Excessive tire heat caused by roading can cause blow-outs and loss of 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.

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

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

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

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

1.9

SAFETY Safe Operation

SPECIAL OPERATING CONDITIONS:

Drawbar

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 running 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 running speed. ・Periodically stop the machine 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 drawbar 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

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.

Inspect the machine and report any needed repairs.

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

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).

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.

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

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

Wear safe clothing to perform maintenance: ・Close fitting clothing -- loose or baggy clothing can

catch on equipment or controls.

・Protective clothing as required by the job or

conditions -- for example:

-Hard hat -Gloves -Steel-toe shoes -Eye / face protection -Approved respirator

・Do not wear jewelry that may catch on equipment,

controls, or may short and cause burns if in contact with electrical components.

Before performing any maintenance: ・Park on level ground. ・Block the tires securely. ・Apply the parking brake. ・Lower the boom and attachment to the ground. ・Stop the engine (unless specified in the 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

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

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

to the ground. ・Moving the loading control levers back and forth. ・Moving the K-Lever right and left. ・Pushing down on hydraulic cap. Then turning the hydraulic oil tank cap 1/3 turn counterclockwise.

DANGER ＤＯ

ＮＯＴ

ＳＴＡＲＴ ＭＥＮ ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ ＳＩＧＮＥＤ ＢＹ ＤＡＴＥ

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 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

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

Tire and rim assemblies if improperly serviced can explode with deadly force. When inflating tires; ・Make sure wheel parts are correctly installed. ・Use a self attaching (locking) air chuck. ・Use a remotely located valve to turn air pressure

on and off.

Never smoke while fueling a machine. engine before fueling.

Stop the

・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.).

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

・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.

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.

1.14

SAFETY Safe Maintenance

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

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

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

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

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.

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"

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 used oil and coolant properly to prevent environmental pollution.

When oil or fuel leaks from the high pressure rubber hose, it may cause an accident or fire. If something is wrong with the rubber hose, immediate repair is needed : ・Correct it and tighten the rubber hose when a

clamp, guard or cushion are loose. Do not allow them to remain loose, or the rubber hose may be damaged by vibrating or scratching other parts. ・Fasten the rubber hose with proper torque when the connection is loose. ・Exchange the hose if it is damaged or deformed. ・Exchange the hose cover if it is damaged, cut or expanded.

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

DANGER

WARNING

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

Before checking transmission oil : Park on level ground. ・ Lower bucket to ground. ・ Place transmission in neutral. ・ Set parking brake. ・ Tag "Do Not Operate." ・ 44841-20630

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

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

L. H, R.H

L. H, R.H

Inside of Cab

WARNING

DANGER

CAUTION

WARNING L. H, R.H

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." ・ Relieve all trapped oil pressure before opening any piping.

44841-20880

Machine will not turn with articulation stopper in locked position.

Unlock articulation stopper before operating machine.

44841-20640

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

DANGER 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

Removal, damage or alteration of Roll Over Protective 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

1.18

SAFETY Safety Signs

WARNING

WARNING

CAUTION

CAUTION

FLAMMABLE

PART NAME : ETHER CYLINDER PART NO : 50401-03550 INGREDIENTS : ETHYL ETHER, CARBONIC ACIDGAS

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

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

Keep flames and sparks away.

Vent area before servicing.

44841-20680

CAUTIONS 1.DON'T APPLY TO THE HUMAN BODY 2.DON'T USE NEAR FIRE 3.DON'T STORE IN HOT PLACE OVER 40 ℃ 4.DON'T THROW EVEN EMPTY CYLINDER INTO FIRE 44770-49180

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

Inside

Inside

Inside

WARNING

WARNING

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 not start engine while ・ standing on ground.

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

44841-20660

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

Stop engine before working in this area.

44841-20700

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

Allow system to cool and vent pressure slowly before servicing.

44787-20720

1.19

SAFETY Safety Signs

WARNING

WARNING

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

Keep all guards in place.

Keep hands away from fan area.

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

Read Shop Manual before repairing this part.

44841-20740

Radiator

Parking brake cylinder

1.20

SAFETY Safety Devices

Safety Devices Loading Control Lever Lock

Auxilliary Attachment Control Lever Lock (option) Three Lever Type

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.

The auxiliary attachment control lever may be locked in the neutral position.

This prevents accidental movement of the attachment's auxiliary hydraulic function. If there is no auxiliary hydraulic function on the attachment this lock prevents accidental unlocking of the attachment.

To lock: Place the control lever in neutral and flip the lock tab down as shown.

Lock Unlock

This device locks the loading control levers to prevent accidental lowering of the attachment or boom. ・ To lock, set the loading control levers to "NEU-

TRAL" and pull-up the lock lever to forward.

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

During normal operation using the attachment's auxiliary hydraulic function the lever lock should be unlocked.

To unlock: Flip over the lock tab.

1.21

SAFETY Safety Devices

K-Lever Steering System On / Off

Operating position

Raised position

PUSH PIN

・ Before operating the machine, lower the arm rest ・ Push the button and lift the arm rest to the fully

raised position before getting off the machine.

・ When the arm rest is fully raised the K-Lever

system is turned off automatically. Then the green display lamp goes out.

WARNING Accidental movement of the stick while getting on or off the machine may cause unexpected movement of the machine resulting in an accident, injury, or death.

Always stop, and properly park the machine and turn off the K-Lever system while getting on or off the machine.

The K-Lever system will be turned off by fully raising the arm rest or turning off the key switch.

back to the operating position.

When the arm rest is completely lowered the K-Lever system is turned on automatically. Then the green display lamp comes on.

1.22

SAFETY Safety Devices

Articulation Stopper

To unlock:

WARNING 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:

"LOCKED" position

1. Align the front and rear chassis straight ahead.

2. Remove the clip pin and pin to remove the articulation stopper from the storage bracket under the hydraulic oil tank.

3. Turn the link and fix the end to the bracket on the front chassis (as shown).

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

"STORED" position

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

2. Turn the link to the rear chassis bracket.

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

1.23

SAFETY Safety Devices

Neutral Start System 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

Emergency Steering (option)

WARNING Operation without normal steering could cause loss of control and injury or death.

If emergency steering lamp lights up, steer machine IMMEDIATELY to safe location and stop it.

Emergency steering works if the steering hydraulic pressure decreases while the steering wheel is turned.

When the emergency steering is working, the monitor lamp lights up.

If the emergency steering works: 1. Keep the starter switch in the "ON" position even when the engine unexpectedly stops.

If the service brake does not work or a brake alarm occurs, the emergency brake can be applied manually; ・ Pull the emergency brake switch to engage the

emergency brake and disengage the transmission.

2. Immediately operate the steering wheel to bring the machine to a road shoulder or safe location.

3. Stop the machine. If necessary, use the service brakes, emergency brake or lower the attachment to stop the machine.

4. Place wheel chocks in front of and behind the tires to prevent the machine from moving.

5. Contact your local Kawasaki dealer for necessary testing and repair.

1.24

SAFETY Safety Devices

ROPS (Roll Over Protective Structure)

WARNING Operating with damaged or improperly mounted ROPS could cause serious injury or death. Be sure to observe the following. ・ Whenever seated,fasten the seat belt. ・ Do not modify ROPS, such as drilling or

welding.

・ Do not use ROPS if it has been deformed due

to an accident.

・ If any damage or loose bolts are found, do

not operate until repaired.

・ Never repair or modify ROPS without man-

ufacturer's approval and instructions.

2.1

2.OPERATION

2.2

COMPONENT NAME/LOCATION

COMPONENT NAME / LOCATION

１

３

２

５

４

９

１５

２０

２７ １８ １３，１４６ ２１ １９ １６ ２５ ２２ １２

1. Bucket (Attachment) 2. Boom 3. "Z" Lever (2) 4. Boom Cylinders (2) 5. Bucket Cylinders (2) 6. Steering Cylinders (2) 7. Engine 8. Torque Converter 9. Transmission 10. Radiator, Torque Converter Cooler (Lower tank), & Hydraulic Oil Cooler 11. Air Cooler (for engine intake air) 12. Fuel Cooler 13. Fuel Tank (Right hand side) 14. Hydraulic Oil Tank (Left hand side) 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.

８

２３

１７ ２６ ７ ２４ １１ １０

15. Front Axle / Differential Ass'y 16. Rear Axle / Differential Ass'y 17. Air Cleaner (Right hand side) 18. Parking Brake 19. 1st Propeller Shaft 20. 2nd Propeller Shaft 21. 3rd Propeller Shaft 22. Batteries (2) (one each side--two 12VDC=24VDC system) 23. Precleaner (2) 24. Cooling Fan 25. Fan Motor (hydraulic type) 26. Exhaust Muffler 27. Parking Brake Cylinder

2.3

OPERATOR'S AREA Pedals and Levers

OPERATOR'S AREA Pedals and Levers

1. K-Lever 2. Boom Control Lever 3. Bucket Control Lever 4. Auxiliary Attachment Control Lever (option) 5. Accelerator Pedal 6. Brake Pedals 7. Wrist Rests (adjustable) 8. Loading Control Lever Lock

１

５

６ ４ (option)

２

７

３ ８

７

１

2.4

OPERATOR'S AREA Pedals and Levers

1. K-Lever

2. Boom Control Lever L

R

Boom Control Lever is used to control the boom movement.

Boom Control Lever will not move if the loading control lever lock (10) is in the "Locked" position.

Refer to "Loading Control Lever Lock" page 1.20.

（ａ）

（ｂ） （ｃ） （ｄ）

・When the K-Lever is moved from the neutral

(centered) position to the right, the machine articulates (steers) to the right.

・When the K-Lever is returned to the neutral

position the machine stops articulating.

・When the K-Lever is moved to the left the machine

articulates to the left.

・The further the K-Lever is moved to the side the

faster the machine articulates (proportional steering).

IMPORTANT Excessive force will damage the K-Lever. Do not jam, slap or force the K-Lever beyond its normal range.

Avoid putting excessive force down on the arm rest. Never sit on the arm rest.

This type of damage is not covered by warranty policy.

Lever lock released

(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 moving and remain in that position. (d) Raise ・ Move the lever rearward. The boom is raised. ・ A boom kickout 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 2.77.

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.

2.5

OPERATOR'S AREA Pedals and Levers

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

Bucket control lever will not move if the loading control lever lock (10) is in the "Locked" position.

4. Auxiliary Attachment Control Lever (option) Auxiliary attachment control lever is used to control the auxiliary attachment such as log clamps, multipurpose buckets, etc..

Refer to "Loading Control Lever Lock" page 1.20.

（ａ）

（ａ）

（ｂ） （ｃ）

（ｂ）（ｃ）（ｄ）

(a) Normally this position will close the attachment. (a) Dump ・ Move the lever forward. attachment will dump.

The bucket or

(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 ・ 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 Positioner Adjustment" page 2.76.

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.

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

In case that the auxiliary attachement does not stop moving even when the auxiliary attachement 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

5. Accelerator Pedal

6. Brake Pedals

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 a foot rest. ・ Do not ride the brakes. ・ Use brake pedals only when applying brakes. ・ Do not allow dirt and debries to build up

around the pedals.

・ Be sure the brake pedals move freely before

using the machine.

Accelerator pedal is used to control the engine speed. ・Depress the pedal to increase the engine speed. ・Release the pedal to decrease the engine speed.

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.

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 (Declutch) switch (See page 2.13) 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 cut-off (Declutch) switch to the "ON" position. When the switch is "ON", a green indicator lamp on the dash will also be turned on.

2.7

OPERATOR'S AREA Pedals and Levers

CAUTION Transmission cut-off feature momentarily places transmission in neutral, which may allow machine to roll when on a grade with light brake pedal application.

Be sure to turn off transmission cut-off (Declutch) switch when operating on a grade.

7. Wrist Rests Wrist rests are used to place the wrist or arm on while operating the loading control lever and K-Lever.

Both wrist rests are adjustable. adjustment is as follows :

Each way of

２

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.

１

２

A. Loading control lever side - Loosen the two screws (1) and adjust the wrist rest up and down.

- Loosen the two screws (2) and adjust the loading control lever back and forth.

３

B. K-Lever side - Loosen the lock knob (3) and adjust the wrist rest up and down.

2.8

OPERATOR'S AREA Pedals and Levers

8. Loading Control Lever Lock

Lock Unlock

This device locks the loading control levers to prevent accidental lowering of the attachment or boom. ・ To lock, set the loading control levers to "NEU-

TRAL" and pull-up the lock lever forward.

・ To unlock, push down the lock lever backward.

2.9

OPERATOR'S AREA Switches

Switches

１６ ６ ７ １７

10

20

0 100r/min30

３ ８ ９

AUTO N 4 3 2 1

１

１０

0000001/10h

C

H

C

H

F E

４ ５ １８

２ １３ １２

１１ １４

１５

1. Starter Switch 2. Parking Brake Switch 3. Light Switch 4. Front Working Light Switch 5. Rear Working Light Switch 6. Transmission Cut-Off (Declutch) Switch 7. Cold Start Switch 8. Front Wiper Switch 9. Rear Wiper Switch

10. QUAD Switch 11. Horn Switch 12. Forward / Reverse Changeover Switch 13. Transmission Shift Switch 14. Diagnostic Switch (option) 15. Increment / Decrement Switch (option) 16. Four-way Flasher Switch (option) 17. Ride Control Switch (option) 18. Engine Power Mode Switch

2.10

OPERATOR'S AREA Switches

1. Starter Switch

2. Parking Brake Switch

ON OFF

START

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

OFF ( ) Key can be either inserted or pulled out.

Engine is stopped and most electrical circuits are turned off.

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

ON ( ) Current flows to all circuits.

START ( ) When the transmission changeover switch is in NEUTRAL, starter motor turns, starting the engine.

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

The 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.

If the parking brake does not work, use one of two foot brakes.

Should the directional changeover switch be moved into the forward or reverse position while the parking brake is applied and the engine is running, a warning buzzer will sound and the transmission will remain in Neutral.

2.11

OPERATOR'S AREA Switches

In case the service brake does not work, the parking brake can be used as an emergency brake.

3. Light Switch

If the electrical wiring in the line fuse / parking switch / solenoid valve malfunctions, the parking brake is applied automatically.

Call local Kawasaki dealer for repair.

This is a four position switch. : 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. : Front head lights are in the high beam position.

2.12

OPERATOR'S AREA Switches

4. Front Working Light Switch

5. Rear Working Light Switch

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

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

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

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

2.13

OPERATOR'S AREA Switches

6. Transmission Cut-Off (Declutch) Switch

7. Cold Start (ether injection) Switch

Transmission cut-off (Declutch) switch is used to change the function of the brake pedals.

Cold Start Switch is used for easy engine starting in cold weather. Ether is injected into the engine after turning this switch to "ON" and "OFF".

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" on page 2.6 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 with light brake pedal application.

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

Refer to "Cold Start" page 2.56 for proper use.

2.14

OPERATOR'S AREA Switches

8. Front Wiper Switch

9. Rear Wiper Switch

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

Rear wiper switch is used to wipe the rear windshield.

INT

LOW

OFF

OFF

ON

HIGH

PUSH PUSH

OFF

:

INT

: Intermittent

LOW

: Low speed

HIGH

: High speed

PUSH

: Spraying solvent on the windshield

OFF

:

ON

: Low speed

PUSH

: Spraying solvent on the windshield

2.15

OPERATOR'S AREA Switches

10. QUAD(Quick Up And Downshift)Switch

11. Horn Switch

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

Horn switch is used to blow the horn.

・When operating the machine in 2nd speed with the

shift switch in [2] or [A] position, the transmission will shift down to 1st gear by pressing QUAD switch.

・Pressing QUAD switch again, moving the trans-

mission shift lever to the neutral position, or operating the parking brake switch releases the 1st gear setting to return the transmission to 2nd gear.

・Press the button to blow the horn.

2.16

OPERATOR'S AREA Switches

12. Forward / Reverse Changeover Switch

N F

13. Transmission Shift Switch

R

Forward / reverse changeover switch is used to change direction.

R (Reverse) Pull the upper part of the trigger switch N (Neutral) Keep the trigger switch parallel F (Forward) Pull the lower part of the trigger switch

Transmission shift switch is used to control machine speed.

Shift to upper speed (Shift Up) ＊ ＊ Highest position up is the automatic mode.

Shift to lower speed (Shift Down) Refer to "Transmission Shift" page 2.65.

2.17

OPERATOR'S AREA Switches

14. Diagnostic Switch (option)

Step 1. Diagnostic switch "OFF" Step 2. Starter switch key "OFF"

?

This switch is used to check the engine failure when any one of the engine warning lamps (Refer to the page 40) is turned on.

The diagnosis for the engine failure should be done by the following steps.

Step 1. Starter switch key "OFF" Step 2. Diagnostic switch "ON" Step 3. Starter switch key "ON"

ON OFF

The following steps show how to finish the diagnosis for the engine failure.

START

If no active fault codes are recorded, all three lights will come on and stay on.

If active faults are recorded, all three lights will come on momentarily. The orange lamp will then be on.

The yellow and red lights will begin to flash the code of the recorded fault. The fault code will flash in the following sequence. First, the yellow lamp will flash.

There will be a short 1 second pause when both the yellow and red lights are off. Then the red light will flash the 3-digit number of the recorded fault code.

There will be a 1 second pause between each number. When the 3-digit number is done flashing, a yellow light will appear again. The 3-digit number will continue to flash the same fault code until the system is advanced to the next active fault code.

2.18

OPERATOR'S AREA Switches

15. Increment / Decrement Switch (option)

The switch is used for ; 1. Checking the history of the engine failures 2. Adjusting the engine idle revolution ・ Checking the history of the engine failures

When the diagnostic switch is ON (Starter switch key "ON"), the lights will continue to flash the same fault code until the system is advanced to the next active fault code. To go to the second fault code, move the increment / decrement switch to "+", then release it. You can also go back to the previous fault code by moving the switch to "-", then releasing it . To check the third or fourth fault code, move the switch to "+", then release it when all active fault codes have been viewed. Moving the switch to "-" will go back to the first fault code.

Refer to the section of the diagnostic switch (14) for converting the flashing pattern to 3-digit fault code. ・ Adjusting the engine idle revolution

When the diagnostic switch is OFF (Starter switch key "ON"), the engine idle revolution can be adjusted in 25min-1(rpm) by using the increment / decrement switch (775min-1(rpm) 奏 800min-1(rpm) 奏 825min-1(rpm)). Move the increment / decrement switch to "+", then release it, to increase the engine idle revolution to 825min-1(rpm).

To decrease the engine idle revolution, move this switch to "-", then release it. As a result the engine idle revolution is adjusted as 775min-1(rpm).

The engine idle revolution can not be changed to over 825min-1(rpm) or to below 775min-1(rpm) even though this switch is moved to "+" or "-".

16. Four-way Flasher Switch (option)

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.

2.19

OPERATOR'S AREA Switches

17. Ride Control Switch (option)

18. Engine Power Mode Switch

When the ride control switch is ON, the ride control system works. Refer to page 2.42 for handling of the ride control system.

Engine power mode switch is used to give more power to the torque converter.

When this switch is ON during the bucket, boom or steering system is being operated, it increases the rim-pull and the machine speed.

Please note the operator does not have the power up feeling the bucket lever, boom lever and steering system is in Neutral.

2.20

OPERATOR'S AREA Indicators

Indicators ２１ １

２２

１８ ５

９ １９ ２ ２０ ６ ７

２４

４ １０

20

10

0 100r/min30

２９

２７

２８ ２５

AUTO N 4 3 2 1

２３

1. Tachometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Level Gauge 5. Parking Brake Indicator Lamp 6. Auto Brake Indicator Lamp 7. Transmission Cut Off (Declutch) Lamp 8. Working Light Indicator Lamp 9. Central Warning Lamp 10. Transmission Control Warning Lamp 11. Brake Pressure Warning Lamp 12. Engine Oil Pressure Warning Lamp 13. Engine Coolant Temperature Warning Lamp 14.Torque Converter Oil Temperature Warning Lamp 15. Air Cleaner Warning Lamp When the starter switch is turned to "ON", all warning lamps (9) ～ (17), (25) and (26) light up for three seconds. This is the lamp (bulb) test period (lamp (16) lights up until engine starts). If coolant level warning lamp (26) remains on before the engine is started the coolant level is low.

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.

0000001/10h

C C

８ ３

H H

１１

F

１２

E

１３ １４ １５ １６ １７ ２６

16. Charge Lamp 17. Transmission Oil Filter Warning Lamp 18. Turn Signal Indicator Lamp (Left) (option) 19. Turn Signal Indicator Lamp (Right) (option) 20. High Beam Indicator Lamp 21. Auto Shift Indicator Lamp 22. Neutral Indicator Lamp 23. Transmission Status Monitor 24. Hour Meter 25. Emergency Steering Warning Lamp (option) 26. Coolant Level Warning Lamp 27. Engine Warning Lamps 28. Ride Control Indicator Lamp (option) 29. K-Lever Indicator Lamp

2.21

OPERATOR'S AREA Indicators

1.Tachometer

3.Torque Converter Oil Temperature Gauge

H

C T/C OIL TEMP -1

x100min

Indicates the engine revolutions per minute.

2.Engine Coolant Temperature Gauge

Indicates the temperature of oil circulating through the torque converter and the transmission. It is normal if the indicator is in the green zone (50 ～ 120° C (122～ 250 ° F)) while operating. ・ If the indicator enters the red zone while operating,

H

C WATER TEMP

slow the engine down to idle speed, shift to neutral, and wait until the indicator reaches the green zone.

・ If the indicator does not come back into the green

zone quickly, stop the engine and find the cause.

Indicates engine coolant temperature. It is normal when the indicator stays in the green zone (70 ～ 95° C (158～ 203° F)).

Refer to "Troubleshooting" page 3.61.

4.Fuel Level Gauge

・ If the indicator enters the red zone while operating,

slow the engine down to idle speed and wait until the indicator reaches the green zone.

F

・ 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 3.57.

E FUEL

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.

2.22

OPERATOR'S AREA Indicators

5.Parking Brake Indicator Lamp (red)

8.Working Light Indicator Lamp (green)

P Lights up when the parking brake is applied.

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.

Lights up when working lights are on.

9.Central Warning Lamp (red)

6.Auto Brake Indicator Lamp (red)

Flashes up when any of the warning lamps come on.

Lights up when the auto brake works.

Refer to "Auto Brake" page 2.66 for the detail.

10. Transmission Control Warning Lamp (red)

7.Transmission Cut-Off (Declutch) Lamp (green)

Lights up when transmission controls malfunction. ・ If it lights up while operating, stop the engine and

Lights up when the transmission cut-off (Declutch) switch is "ON". ・ 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

brake pedals are depressed.

contact your nearest Kawasaki dealer for necessary repair.

2.23

OPERATOR'S AREA Indicators

11. Brake Pressure Warning Lamp (red)

WARNING

13. Engine Coolant Temperature Warning Lamp (red)

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 3.9MPa (570psi) .

Lights up when coolant temperature overheats.

C (215° F)) (Over 102° ・ If it lights up while operating, slow the engine speed

down to idle, 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

・ If it lights up while operating, IMMEDIATELY stop

the machine and find the cause.

Refer to "Troubleshooting" page 3.60.

after resuming the operation, stop the engine and find the cause. Refer to "Troubleshooting" page 3.57.

CAUTION Hot coolant spray may cause burns.

Never open radiator cap when engine is hot.

12. Engine Oil Pressure Warning Lamp (red)

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

[Normal oil pressure ranges shown below.]

[0min-1 (rpm) / 0MPa (0psi), 600 / 0.1 (15), 800 / 0.13 (19), 1500 / 0.17 (24), 2100 / 0.2 (30), 2400 / 0.2 (30)] ・ If it lights up while operating, IMMEDIATELY stop

the engine and find the cause.

Refer to "Troubleshooting" page 3.57.

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

2.24

OPERATOR'S AREA Indicators

14. Torque Converter Oil Temperature Warning Lamp (red)

16. Charge Lamp (red)

Lights up when transmission oil overheats. (Over C (248±9° F)) 120±5°

Lights up when alternator charge level is low. ・ If it lights up, check the charging circuit. ・ If it lights up while operating, slow the engine speed

down to idle, shift to neutral, and wait until the lamp goes out. Check the torque converter oil temperature gauge before resuming the operation.

Refer to "Troubleshooting" page 3.58.

17. Transmission Oil Filter Warning Lamp (red)

・ 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 3.61.

15. Air Cleaner Warning Lamp (red) Lights up when the transmission oil filter clogs. ・ When lit, replace the transmission oil filter car-

tridge.

Lights up when air filter is clogged. (25 ″hg) ・ If it lights up while operating, stop the engine and

clean or replace the air cleaner outer element.

Refer to "Replace Transmission Oil Filter" page 3.34.

18.Turn Signal Indicator Lamp (Left) (green)(option)

Refer to "Clean or Replace Air Cleaner Element" page 3.11.

Flashes when the turn signal switch lever is moved forward.

2.25

OPERATOR'S AREA Indicators

19. Turn Signal Indicator Lamp (Right) (green) (option)

23. Transmission Status Monitor

4 3 2 1 Flashes when the turn signal switch lever is moved rearward.

20. High beam Indicator Lamp (blue)

・ 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. ・ 2nd Gear

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

Lights up when headlights are switched to high beam, or when the dimmer switch is pulled up to the "Flash" position.

21. Auto Shift Indicator Lamp

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

22. Neutral Indicator Lamp

N Lights up when transmission is in neutral.

・ 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.

24. Hour Meter 0 0 0 0 0 0

1/10h

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

2.26

OPERATOR'S AREA Indicators

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

27. Engine Warning Lamps Engine stop lamp

STOP Red Lights up when the steering hydraulic pressure downs below specified when the engine is running.

26. Coolant Level Warning Lamp

If a stop (red) lamp comes on while the engine is in operation, the fault can be engine disabling.

Stop the engine operation in a safe manner as soon as possible.

Engine warning lamp

Lights up when engine coolant level is lower than specified. ・ The coolant level is checked only with the starter

switch is in the "ON" position-engine off.

・ Once the engine is started this level check function

is turned off.

Yellow If the yellow warning lamp illuminates, the engine can still be operated, but it can lose some system features that can sometimes result in a power loss. The failure must be repaired as soon as convenient.

Engine protection lamp

Orange If the orange warning lamp comes on while driving, it means that a fault code has been recorded. The light will remain on as long as the fault is occurring.

The light will begin to flash if the condition continues to get worse. The engine power and/or speed will be gradually reduced. If the engine protection shutdown feature is enabled, the engine will shut down to prevent engine damage.

2.27

OPERATOR'S AREA Indicators

28. Ride Control Indicator Lamp (green) (option)

Lights up when the ride control switch is ON. Refer to "Ride Control System (option)" page 2.42.

29. K-Lever Indicator Lamp

・ The green indicator lamp comes on when the

K-Lever system is turned "ON". It goes out when the system is turned "OFF".

2.28

OPERATOR'S AREA Seat

Seat

Suspension (If so equipped)

Seat Adjustment

・With seat pushed back half-way for easier access

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

Armrests

to 5, extend the crank lever from knob (5) and rotate Minus(-) direction for less support or Plus(+) for more support. Use indicator for approximate weight setting. Release crank lever.

Suspension (If so equipped) ・With the key turned "ON" pull the knob (same

１ ２ Seat Belt

location as 5) out to increase the air pressure. This will raise the seat and make a firmer ride. Push the knob in to reduce the air pressure (air will be vented). This will lower the seat and make a softer ride.

・When properly adjusted the seat will not "bottom

out" over rough terrain.

６ ５

Tether

４

３

・Rotate control knob (1) to select desired angle.

The armrests will pivot up and parallel with backrest when not in use.

Lumbar Support ・Turn adjustment knob (2) for desired lumbar

support.

Reclining ・Lift the handle (3) and allow the back cushion to

angle forward, or lean backward into the cushion.

Release the handle at desired position.

Seat Height ・Remove your weight from seat while lifting the

handle (4) to the stop position. While holding the handle (4) up, raise or push down on seat.

Release handle (4) at one of three positions.

Forward / Backward ・Lift the handle (6) and move the seat forward or

backward.

Release the handle (6) at one of the several positions.

2.29

OPERATOR'S AREA Seat

Seat Belt

WARNING Improper use or maintenance of seat belt could result in death or serious injury. ・ Inspect seat belt tether, and mounting hard-

ware before operating machine and replace any defective components. ・ Always fasten seat belt when operating machine. ・ Replace the seat belt and tether every three years regardless of appearance. Dirt can cut the fibers weakening the belt. The belt has a manufacture date to help decide when it should be replaced. ・ Adjust tether so it is snug without the operator in the seat.

1. Fasten seat belt along your body without kinking or twisting it. The seat belt buckle should firmly "snap" when coupled.

Keep buckle free of dirt and debris.

2. For releasing the seat belt, push the red button where the belt attaches.

2.30

OPERATOR'S AREA Electrical Protection

Electrical Protection

(1)

Fuse Boxes

LIGHTING HEAD LIGHT

20A

RADIO

5A

R . WORK LIGHT

10A

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

SPARE

10A

F . WORK LIGHT

15A

SPARE

15A

AIR SUS SEAT (OPTION)

10A

SPARE

3A

SPARE

15A

SPARE

10A

SPARE

15A

SPARE

10A

4 WAY FLASHER (OPTION) HORN DOME LAMP RADIO BACK UP

15A

AIRCON (OPTION)

20A

SPARE

10A

SPARE

5A

COLD STARTER

15A

SPARE

5A

BUZZER MONITOR (CONTROLLER)

5A

SPARE

10A

NEUTRAL RELAY

5A

AIRCON (OPTION)

20A

BATTERY RELAY ECM (ENGINE)

5A

SPARE

20A

１

２

Main Fuse Boxes are located in the right hand side console in the cab and contain thirty fuses.

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

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

Never replace fuses with higher amperage rating.

(2)

Left

Right

Front

Rear

2.31

OPERATOR'S AREA Electrical Protection

Fusible Links

Problems caused by fused fusible link

Fusible links protect the main hot wire from short circuits. They are located left rear of machine.

Fuse damaged

1. If one of the fusible links is blown, the following symptom occurs.

Problem (symptom) During engine operation

During engine stop

30 A

・ Engine will be stopped. ・ All the power for all electrical circuit will be OFF.

・ None of the electrical circuits will function. ・ Engine can not be started.

70 A (A)

・ Engine can be stopped. ・ Horn will operate. ・ All the others will not operate and the machine can not be operated.

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

70 A (B)

・ 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".

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. Replacing the blown fusible link without correcting the problem may damage components or cause a fire.

2.32

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

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

１５

１４

２０

１６

９ １０ １１ １

２

５ ３

Symbol

Name of part

Volume knob

1

６ ４

Function

７

１７

１８

Operation method

１９

８

１３

１２

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

Use this adjustment knob to adjust the sound volume.

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

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

Selected with audio mode button

L

R

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.

Remarks

2.33

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

Symbol

Name of part

Function

Volume knob

Fader adjustment

Operation method

Selected with audio mode button

REAR FRONT

1 Sound tone adjustment

Selected with audio mode button

CUT

MODE Audio mode button

Audio mode switching

BOOST

PUSH

Remarks

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.

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.

2

Alarm button

3

Description

Turning alarm ON/OFF Alarm setting : Setting clock on the hour

PUSH

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.

Alarm mark

2.34

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

Symbol

Name of part

Onetouch timer button

Function

Switching timer ON/ OFF

Operation method

PUSH

Timer setting

Description

Remarks

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

↑

4

6:00

←

5:00

↓

←

4:00

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 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 CD button

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.

AM/FM

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.

TAPE

5

6

7

TAPE button

AM/FM band selector button

Timer mark

2.35

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

Symbol

Name of part

PS AS PS, AS button

Function

Operation method

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 currentlyselected band (AM or FM).

If 6 stations are not stored fully, the previously-tuned stations will remain as they

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.

Cassette tape ejection

PUSH

Push this button to eject the cassette tape.

This can be performed even with ACC off.

Preset Scan (PS) Auto Store (AS)

8

9 Eject button

Description

Remarks

2.36

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

Symbol

Name of part

DISP Display button

Function

Operation method

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.

Manual tuning in radio mode

PUSH Upward

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

10

SCAN

11

SCAN button

Description

Tuning button

Downward for 0.5 sec. or less

Seeking in radio mode

PUSH Upward

12

Downward

13

for 0.5 sec. or more In clock time setting mode "Hour" setting "Minute" setting

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

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.

Remarks

2.37

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

Symbol

Name of part

Function

2 PRO Preset 2 Program button

15

3

FF

Preset 3 FF button

16

Description

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.

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.)

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 REW mode : Recalling Preset 1 and storing preset REW memories button In cassette tape mode : REW

1

14

Operation method

Remarks

2.38

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

Symbol

Name of part

4

APC

Preset 4 APC button

17

Function

Operation method

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

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.)

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

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.

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.)

REVIEW

5

18

Preset 5 Dolby button

6

APC mode :

Preset 6 APC button

19

Description

Recalling and storing preset memories In cassette tape mode : APC FF

In CD PUSH mode : TRACK UP QUE

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.

Remarks

No beep sounds

No beep sounds

2.39

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

Symbol

Name of part

Function

20

Tape insertion slot

21

LCD indicator Beep tone (guide tone)

Operation method

Description

Remarks

Cassette tape insertion slot

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

Auto metal

Indicator

Displays time, frequency, etc.

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

(Approx. 2KHz, 50ms)

2.40

OPERATOR'S AREA Heater or Air Conditioner (Op-tion)

Heater or Air Conditioner (Option) Ventilation location and Mode ３ ３ ３

３ １

１

Switches Both the heater and the air conditioner (option) are controlled by the same Touch Pad Control Panel as shown below.

２

１

４

ＦＡＮ ＯＮＬＹ

ＯＮ／ ＯＦＦ

４

４

４ (B)

MODE

７

(A)

２

２

VENT

４

1

2

3

4

○

-

-

○

-

○

-

○

○

-

○

○

○ : Open

- : Close

３

1. ON/OFF Switch 2. FAN ONLY Switch 3. TEMP UP/DOWN Switches (A) Temperature Display 4. FAN UP/DOWN Switches (B) Fan Speed Display 5. UPPER Mode Switch 6. LOWER Mode Switch 7. DEFROST Mode Switch

５

６

2.41

OPERATOR'S AREA Heater or Air Conditioner (Op-tion)

Operation of the Automatic Temperature Control unit The ATC (automatic temperature control) front panel allows the operator to adjust the setpoint to a temperature between 60 and 90 degrees F (15 ℃ and 32 ℃ ). Once this temperature is set, the system automatically maintains that temperature. This setpoint will be maintained in memory and recalled each time the system is powered up. Switching to the Fan Only mode will disable the ATC mode and the temperature display will be blank, which disables the heating and cooling systems. Setting the temperature setting to 55 (13 ℃ ) (max cooling) or 95 (35 ℃ ) (max heating) will also disable the ATC mode.

Front Panel Controls 1. ON/OFF Switch Turns the unit on and off.

2. FAN ONLY Switch Switches the unit to the fan only mode and disables the Automatic Temperature Control.

3. TEMP UP/DOWN Switches Allows the operator to adjust the temperature setpoint.

4. FAN UP/DOWN Switches Allows the operator to adjust fan speed.

5. UPPER Mode Switch Switches the unit into the upper air mode.

6. LOWER Mode Switch Switches the unit into the lower air mode.

7. DEFROST Mode Switch Switches the unit into the defog mode and routes the air to the defrost vents.

NOTE Below about 32 degrees F (0 ℃ ) the A/C is turned off.

To change the display between degrees F and C, press the FAN DOWN and the TEMP UP keys simultaneously.

To display the current cab temperature, press the FAN UP and the TEMP DOWN keys simultaneously.

2.42

OPERATOR'S AREA Ride Control System (option)

Ride Control System (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 ride control system is installed and turned ON.

Operation and Function

１

10

20

0 100r/min30

AUTO N 4 3 2 1

000001/10h C H F E C H

２ 1. Before travelling, turn the ride control system switch (1) ON. The ride control system pilot lamp (2) turns ON. 2. Move the machine forward.

The ride control system functions automatically when the machine travelling speed reaches more than 7km/h (4.3mph). The system automatically disengages below 5km/h (3.1mph). The indicator lamp (2) will remain on regardless of the machine speed if the switch (1) is ON. NOTE When the bucket is fully tilted back the ride control system does not work. Roll the bucket forward slightly when travelling.

2.43

OPERATOR'S AREA Grease Gun Holder

Grease Gun Holder

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

2.44

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.

A. 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 (between Fan, Radiator or coolers)

□ Cooling System

Leaks and trash build-up

□ Batteries

Loose terminals, dirt build up on top of the batteries.

□ Steps and Handrails

Damage and cleanliness

□ Differentials (front and rear)

Leaks or loose bolts

□ Hydraulic System

Leaks and Fluid Level

□ 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 inside Belt condition

Date :

Model-S/N :

Hours :

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

Inspector :

2.45

OPERATION Check before Operation

B. Greasing

C. Check Engine Oil Level

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 or grease lines.

Refer to "Recommended Lubricants" page 3.55 for the correct grease.

CAUTION Hot engine oil and components may cause burns.

Avoid contact with hot oil or engine components.

・ Axle support (two places)

IMPORTANT Grease axle supports daily to avoid axle support wear.

Be sure to fully lubricate the trunnion-two fittings. When fully lubricated grease will escape from the breather on the rear plate and from the top of the front support.

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 3.55 for the suitable viscosity of the oil according to the ambient temperature.

2.46

OPERATION Check before Operation

D. Check Hydraulic Oil Level

H (High) L (Low)

CAUTION Pressurized hydraulic tank is used for this machine.

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

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

Refer to "Replace Engine Oil and Oil Filter Cartridge" page 3.23 for the procedure.

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

Relieve all pressure by pressing down the filler cap.

Check Level

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.

Add or drain oil to keep proper oil level.

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.

2.47

OPERATION Check before Operation

E. Check Engine Coolant Level

CAUTION Pressurized radiator tank is used for this machine.

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

Refer to "Recommended Lubricants" page 3.55 for the suitable viscosity of the oil according to the ambient temperature and oil type.

Spray of hot coolant could cause burns.

Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure.

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

Avoid contact with skin and eyes to prevent injury.

1. Stop the engine and allow the radiator and coolant to cool completely.

１

２

2. Lift the lever (1) on the cap (2) of the radiator tank to vent pressure and slowly open the cap (2) .

2.48

OPERATION Check before Operation

Radiator guard

F.Drain Water and Sediment from Fuel Filter

Cap

Neck pipe

Water surface

3. Check the coolant level.

4. Coolant level is normal if coolant is to the lower part of neck pipe.

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

Refer to "Coolant Specification" page 3.56 for the correct mixture.

6. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 3.48.

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

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.

Following must be done with engine "OFF". ・ Open the drain cock on the bottom of the fuel filter

to allow water and sediment to drain into a suitable container.

・ Dispose of properly.

2.49

OPERATION Check before Operation

G. Check Drive Belts

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 tag "Do Not Operate".

2. Open the engine side panel.

H. Check Air Intake System

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.

Cooler IN (Left) Cooler OUT (Right)

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

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

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

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

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.

2.50

OPERATION Check before Operation

I . Check Cooling Fan

J. Check Wiring Harnesses

CAUTION Short circuit of wiring harnesses may cause fire. ・ Keep the connection of wiring harnesses

clean and tight.

・ Repair the damaged wiring harness or ex-

change it for new one.

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

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 cooling fan for damage.

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

2.51

OPERATION Check before Operation

K. Articulation Stopper

L.Check Tire Air Pressure Low Pressure

OK

High Pressure

"STORED" position

・ Make sure the articulation stopper is secured in the

"STORED" position as shown.

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.

WARNING Overheated tire may explode causing serious injury or death.

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

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.

2.52

OPERATION Check before Operation

Recommended Tire Air Pressure (Bias ply tire) Size 35 / 65-33-24PR 29.5-29-28PR

Pattern L-4 L- 5 L-3 L-4

Air Pressure kPa (psi) 324～343 (47～ 50) 392～412 (57～ 60)

Same pressure for all four tires.

For radial tires, tires with other patterns, or special operating conditions consult the tire manufacturer.

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.

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.

For liquid tire ballast consult your Kawasaki dealer or the tire dealer.

2.53

OPERATION Check before Operation

M. Check Tire for Damage

Tread

Side walls Breakers Carcass

Beads / Bead wire

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

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

For the replacement contact Kawasaki loader dealer or a tire manufacturer's local dealer. ・ Bead wire is broken or bent, or the tire is greatly

deformed.

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

・ Wear is excessive and the carcass ply (including

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

・ Damage to the carcass exceeds 1/3 of the tire

WARNING Overheated tire could explode causing serious injury or death.

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

Stay away until tire and rim cool down.

breaker) is exposed for more than 1/4 of the circumference. width.

・ Tire layers are separated. ・ Radial cracks reach the carcass. ・ Deformation or damage which makes the tire

unsuitable for use.

2.54

OPERATION Check before Operation

N. ROPS (Roll Over Protective Structure)

O. Adjust and Check Rear View Mirrors

WARNING

・ Adjust and check the condition of the rear view

Operating without ROPS could cause serious injury or death.

・ If there is any dirt on or damage to the rear view

Always keep ROPS in place while operating machine.

WARNING Operating with damaged or improperly mounted ROPS could result in death or serious injury. Be sure to observe the following. ・ Whenever seated, fasten the seat belt. ・ Do not modify ROPS, such as drilling or

welding.

・ Do not use ROPS if it is deformed. ・ If any damage or loose bolts are found, do

not operate until repaired. ・ Never repair or modify ROPS without manufacturer's approval and instructions. ・ Inspect the ROPS and the ROPS Cab mounting bolts.

・ Check the condition of the ROPS and its mounting

bolts.

mirrors.

mirrors, clean or fix them.

P. Check Parking Brake

・ Make sure the parking brake switch is pulled up.

Q. 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 2.20.

If the coolant level lamp stays on the coolant level is low. Add coolant.

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 (Declutch) 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 2.20 ～ 2.27.

R. Check Control Levers ・ Make sure the boom and tilt control levers are in

the "HOLD" position. The levers should return to the "NEUTRAL" or "HOLD" position smoothly and naturally.

S. Check K-Lever and Forward / Reverse Changeover Switch ・ Make sure the K-Lever and Forward / Reverse

Changeover Switch 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.

ON OFF

START

・ Do not start engine by shorting across

starter terminals.

・ Do not start engine while standing on

ground.

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

Normal Start C (32 ° F)) (Ambient temperature above 0 ° 1. Do not depress the accelerator pedal.

ON OFF

3. Then 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.

START

ON OFF

START

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

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

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

2.56

OPERATION Starting the Engine

NOTE ・ When the starter switch key is in the "ON" position, the engine itself will diagnose engine failure, if any, in 3 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.

During this time, all of the engine warning lamp are being turned on. This checks the bulbs.

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

When the diagnosis is completed the engine warning lamps are turned off.

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

Before starting the engine, make sure all of the warning lamps are turned off. If the stop (red) lamp is turned on, do not start the engine.

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

・ Do not turn the starter switch key to the "START"

position while the engine is running.

・ 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 3.57.

IMPORTANT Low engine oil pressure may cause severe engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

Cold Start (Ambient temperature below 0 ° C (32 ° F)) 1. Do not depress the accelerator pedal.

WARNING Ether is very flammable and could cause serious injury or death. ・ Avoid heat, electric sparks and flames near

ether cylinder.

・ Do not store ether cylinders at temperature above 40° C (100° F). ・ Store ether cylinders out of children's reach. ・ When winter season is over (outside temperature is above 5° C (40° F)), remove ether

cylinder from machine and store it safely according to above instructions.

IMPORTANT Ether may cause serious engine damage.

Never attempt to inject ether into warm engine.

2. Turn the starter switch key to the "ON" position and press the cold start switch for two seconds.

(Here the ether is filled into a metering valve and measured.)

3.

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

Use ether only as specified in this manual.

2.57

OPERATION Starting the Engine

NOTE ・ Do not turn the starter switch key to the "START" position while the engine is running. ・ 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 3.57.

IMPORTANT Low engine oil pressure may cause engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

2.58

OPERATION Check after Starting the Engine

Check after Starting the Engine

A. 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.

10

20

0

30

AUTO N 4 3 2 1

000001/10h C

H

C

H

F E

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 2.20 for the meaning of each lamp and the correction.

2.59

OPERATION Check after Starting the Engine

B. Check Fuel Level

C. Check Transmission Oil Level

F

E FUEL

DANGER There is no room in articulation area when machine is turning.

Crushing will result in serious injury or death.

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

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

Refer to "Recommended Lubricants" page 3.55 for the proper fuel.

When checking oil level: ・ Lower 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.

"LOCKED" position

1. Park the machine on level ground, apply the parking brake, and lower the attachment to the ground. Verify that oil is up on the dipstick prior to starting.

2. Set the articulation stopper in the "LOCKED" position.

Refer to "Articulation Stopper" page 1.22.

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

2.60

OPERATION Check after Starting the Engine

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.

With hot oil

With cold oil

Specified oil level

4. At low oil temperature, use the side of dipstick marked at lower position. Normal oil level is within shaded area as shown.

5. At high oil temperature, use the side of dipstick marked at higher position. Normal oil level is within shaded area as shown.

6. If the oil level is lower than the specified, add recommended oil while the engine is at idle. Do not overfill.

Refer to "Recommended Lubricants" page 3.55.

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.

2.61

OPERATION Check after Starting the Engine

D. Check Service Brake Operation

E. Check Parking Brake Operation

Before testing be sure the area behind the loader is clear.

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

1. Turn "OFF" the clutch cut-off (Declutch) switch.

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

2. Firmly depress the right hand brake pedal.

3. Release the parking brake.

4. Select the transmission shift switch 2nd and REVERSE. 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 REVERS, there is some problem with service brake.

Do not operate until problem has been corrected.

3. Stop the machine with the service brake.

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.

F.Check Horn Operation 1. Press the horn button on the loading control lever.

2. The horn should sound loudly.

G. Check Steering 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.

2.62

OPERATION Check after Starting the Engine

H. Check Back-up Alarm Operation

I. Check Exhaust Gas

1. Apply the service brakes.

2. Release the parking brake.

3. Set the forward/reverse changeover switch to "REVERSE".

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

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.

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 3.58.

2.63

OPERATION Check after Starting the Engine

J.General Inspection

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

When inspecting machine while engine is running; ・ Make sure nobody is on machine. ・ Lower attachment to ground. ・ Pull up parking brake switch. ・ Do not enter or access hazardous areas of machine: -Articulation area -Under machine -Engine compartment, etc.

With the parking brake applied, transmission shift 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.

2.64

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

Be sure area is clear of personnel and obstructions.

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

Do not operate machine on a grade over 30 °

approx. 40cm (16in)

1. Raise the bucket to the carry position approximately 40cm (16in.) above the ground.

2. Depress the brake pedal.

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

4. Press the transmission shift switch to the desired travel speed mode and then shift to the desired direction.

30° Max.

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.

2.65

OPERATION Operating the Machine

Starting the Machine on a Grade

Speed and Direction Change Shift up Shift down N F

1. Turn "OFF" the clutch cut-off (Declutch) switch.

2. Depress the left brake pedal.

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

R

1. Select the proper gear shifting mode by pressing the transmission shift switch. Refer to the following tables on page 2.66 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. The automatic shift mode is engaged by pushing the "Shift Up" button until "AUTO" light comes on in dash panel.

Backward N F

R

Neutral

Forward

2. For a direction change, decelerate the machine then setting forward/reverse changeover switch 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.

2.66

OPERATION Operating the Machine

Shift up and shift down chart AUTO

4

s

3

3

2

2

1

1

s

MANUAL

3. When the transmission is in the 2nd gear, it can be quickly shifted down to the 1st gear by pressing the quick up and downshift (QUAD) switch.

4. By pressing the QUAD switch again, setting the forward / reverse changeover switch to the neutral position (parallel) or operating the parking brake switch, the 1st gear is released and it returns to 2nd gear.

s

UP SHIFT SWITCH DOWN SHIFT SWITCH QUAD SWITCH

Auto Brake

Refer to "QUAD Switch" page 2.15.

Lever Position Selected Gear 1st

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

1

2nd 2 3 A

Operating Condition

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

1.Scooping or loading loose material 2.Running downhill on a slope Carrying or roading Scooping, loading, carrying or roading

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

Use proper gear for each job.

10

20

0

30

AUTO N 4 3 2 1

000001/10h C

H

C

H

F E

Auto Brake feature protects the transmission from excessive speed. It applies the service brakes and turns on the warning buzzer. The auto brake monitor lamp also turns on.

Auto brake works under the following conditions: 1. If the machine runs above the following speeds forward or reverse; [1] : 15km/h (9.3mph) [2] : 22km/h (13.7mph) [3] or [A] : 36km/h (22.4mph) 2. When the direction is changed while running over 12km/h (7.5mph).

CAUTION When auto brake applies, machine may slow down suddenly.

Be prepared. Wear seat belt.

2.67

OPERATION Parking

Parking

1. Release the accelerator pedal.

WARNING

2. Apply the service brake to stop the machine.

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

3. Shift the transmission shift to "NEUTRAL".

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.

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.

2.68

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.

ON OFF

START

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.

In case that the engine does not stop even when the starter switch is in the "OFF" position, cut off the fuel supply to the engine manually.

2.69

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.

30° Max.

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 30 °

1. Move the machine forward to the material.

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

2.70

OPERATION Operating Techniques

3. Lower the bucket parallel to the ground.

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

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.

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.

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

2.71

OPERATION Operating Techniques

Excavating 1. Move the machine forward to the material.

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

Dozing

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

Keep bucket or attachment bottom parallel to ground.

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.

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.

2.72

OPERATION Operating Techniques

Ground Levelling 1. Keep the loaded bucket slightly above 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.

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

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

Be sure to run machine backward when leveling ground.

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

2.73

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. 40cm (16in)

Keep boom low for best stability especially on slopes.

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

2. Keep the bucket approximately 40cm (16in) above the ground when carrying.

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

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

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

Refer to "Loading" or "Excavating" page 2.69, 2.71 for the loading procedure.

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

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.

2.74

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 (option), 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 2.77 for adjustment of the preset height .

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

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

CAUTION 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.

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

2.75

OPERATION Operating Techniques

Typical Truck Loading Methods

T Cycle Operation

I Cycle Operation

This method is recommended where the working area is limited.

V or L Cycle Operation (L-cycle)

(V-cycle)

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

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

2.76

SPECIAL PROCEDURES Adjustments

SPECIAL PROCEDURES Adjustments Bucket / Attachment Positioner Adjustment

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

5. Tighten the bolts (1).

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.

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

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.

４

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

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.

２

１

3. Loosen the bolts (1) with a 19mm wrench.

３

5 ± 2mm (1/8～1/4in)

NOTE Clearance between the switch (4) and rod (3) should be about 5mm (0.2in).

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

2.77

SPECIAL PROCEDURES Adjustments

Boom Kickout (For North American Standard equipment) Adjustment

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.

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

１

２

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

Use safe sturdy platform to reach boom kickout adjustment.

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

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.

３

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

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

7. Tighten the bolts (1).

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.

2.78

SPECIAL PROCEDURES Adjustments

３

２

5 ± 2mm (1/8～1/4in)

NOTE Clearance between the switch (3) and plate (2) should be about 5mm (0.2in).

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

2.79

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 15m (50ft).

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" (Ton MPH) limitations must be obser-

ved. 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.

2.80

SPECIAL PROCEDURES Booster Batteries / Jumper Cables

Booster Batteries / Jumper Cables

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.

WARNING Improper procedure to start engine using jumper cables could cause battery case explosion. ・ Do this work with 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.

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

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.

WARNING If the batteries being used have insufficient battery electrolyte level, parts in the battery case could rapidly deteriorate.

It could shorter battery life or the battery case could explode.

Keep the battery electrolyte level at the proper level.

－

＋ Booster

＋

－

＋

－

＋

－

Batteries

Batteries being boosted

Rear chassis close to starter motor ground being jump started

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

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

2.81

SPECIAL PROCEDURES Booster Batteries / Jumper Cables

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.

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.

Refer to the Shop Manual for more information.

2.82

SPECIAL PROCEDURES Towing

Towing The following is for emergency case only to move a troubled machine to a short convenient location for repair.

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.

Drawbar

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. (Towing speed : Max. 10km/h) (6MPH) 7. Use flashing lights or other warning signals when towing.

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

2.83

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.

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.

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

5. Lower the bucket and lock each control lever using the loading control lever lock (page 1.20).

6. Apply the parking brake and set the articulation stopper in the "LOCKED" position (page 1.22).

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

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.

Cables or Chains

Front

Rear

9. Fasten the machine to the trailer with chains or cables at lower part of the rear chassis.

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

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

2.84

SPECIAL PROCEDURES Transportation

IMPORTANT Brake pipe runs on axle housing.

Do not fasten axle housing.

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

2.85

SPECIAL PROCEDURES Long Term Storage

Long Term Storage Before Storage 1. Wash and clean all parts of the machine.

2. Lubricate every greasing point described in "Greasing" section page 3.17 ～ 3.19, 3.22, 3.36 and 3.43.

3. Replace engine oil, transmission oil, differential and planetary oil, brake oil, and hydraulic system oil. For the engine and transmission, add 10% anticorrosive oil to new oil.

4. Add 10% anticorrosive oil to the fuel tank.

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

6. 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 -35 ℃ ～ 45 ℃ .

7. 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.

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

Refer to "Coolant Specification" page 3.56 for the mixing ratio.

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

2.86

SPECIAL PROCEDURES Long Term Storage

During Storage

After 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.

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.

1. Check the following points.

Refer to "Check before Operation" page 2.44 and "Check after Starting the Engine" page 2.58. ・ 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 to 3 times.

・ Run the machine about 10m (30ft) in every

gear and direction.

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

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 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" page 3.23 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.

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.

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.

2. Engine Serial Number

SERIAL NO. ASSEMBLED IN THE U.S.A. OF U.S. AND JAPANESE COMPONENT BY KAWASAKI CONSTRUCTION MACHINERY CORP. OF AMERICA

TRANSMISSION ＭＯＤＥＬ ＰＳ４００Ｃ０１ ＳＥＲＩＡＬ ＮＯ

KAWASAKI 1. Machine Serial Number 3. Transmission / Torque Converter Serial Number Model Serial Number Design Number

3.3

MAINTENANCE Serial Number Location

4. Torque Converter Serial Number Model

6. Seat Serial Number

TC400B01

Serial Number

MODEL SER. NO. PATEN NO.

ROCKLAND ROCKLAND MFG. CO., BEDFORD, PA. USA

5. Bucket or Attachment Serial Number (Appearance of serial number plate differs depending on the manufacturer.)

7. Air Conditioner and Heater Serial Number

3.4

MAINTENANCE Serial Number Location

Heat & A/C

Cab ROPS

Seat

Bucket

Machine

T/M

T/C

E/G

3.5

MAINTENANCE Inspection and Maintenance Table

Inspection and Maintenance Table △ : First time replacement only

○

Operating hours When Page 50 250 500 1000 2000 Required 2.45

Check coolant level

○

2.47

Check air filter (warning lamp)

○

2.58

Check exhaust gas color

○

2.62

Drain water from fuel filter

○

2.48

Check fuel level

○

2.59

Check drive belts

○

2.49

Check air intake system

○

2.49

Check cooling fan

○

2.50

Section

Items for check Check oil level

10

Drain water from fuel tank

Engine

3.20

○

Adjust belt tension

○

3.27

Replace oil

○

3.23

Replace oil filter cartridge

○

3.23

Check crankcase breather

○

3.27

Replace DCA coolant filter cartridge

○

3.25

Replace fuel filters

○

3.24

Check compression pressure

○

3.42

Check injection pressure

○

3.42

Check injection timing

○

3.42

Clean fuel tank

○

3.51

Check valve lash clearance

○

3.51

Check vibration damper

○

3.50

Replace coolant

Every 2 years or 3000 hours

Clean crankcase breather tube

○

3.48 3.53

○

Replace ether cylinder

○

3.14

Clean air cleaner element

○

3.11

Clean radiator fins

○

3.12

○

3.11

Replace air cleaner element Check oil level Transmission Replace oil filter cartridge & Torque Replace oil Converter Check and replace breather

After six cleanings or once a year

2.59

○ △

3.34

○ ○

3.37

○

3.38

3.6

MAINTENANCE Inspection and Maintenance Table

△ : First time replacement only

Section

○

Operating hours When Page 50 250 500 1000 2000 Required 2.51

Check tire for damage

○

2.53

Grease axle support

○

2.45

Items for check Check tire air pressure

10

Check oil level (diff. and planet.)

○

3.28 ・ 3.29

Axle system Grease pillow block bearing unit

○

3.22

○

3.30

Check tightness of wheel bolt Grease differential seals

Steering system

Brake system

Grease propeller shaft

○

3.43 ・ 3.44

Replace gear oil (diff. and planet.)

○

3.46 ・ 3.47

Check steering operation

2.61

○

Grease steering cylinder pins Replace filter for orbitrol

△

3.52

○

Check service brake operation

○

2.61

Check parking brake operation

○

2.61

Grease parking brake adjuster and shaft

3.22

○

Inspect and Adjust parking brake lining

3.40

○ ○

3.52

Check service brake disk wear

○

3.51

Check brake accumulators

○

3.50

Check hydraulic oil level

△

2.46

○

Grease pins

Chassis

3.19

○

Replace filter for brake line

Loading system

3.36

○

○

Replace return filter

3.17～3.19

△

3.39

○

Replace hydraulic oil, clean filter

○

3.44

Replace filter in the oil tank cap

○

3.53

Replace bucket teeth (option)

○

3.8

Replace cutting edge (option)

○

3.10

Check rear view mirrors

○

2.54

Check ROPS and mounting bolts

○

2.54

Grease center pins Check ride control accumulator (option)

3.19

○

3.54

○

Check seat belt

○

3.10

Check windshield washer fluid

○

3.13

3.7

MAINTENANCE Inspection and Maintenance Table

Section

Electrical system

Check monitor panel operation

○

Operating hours When Page 50 250 500 1000 2000 Required 2.54

Check horn operation

○

2.61

Check back-up alarm operation

○

2.62

Check wiring harnesses

○

2.50

Items for check

10

Check battery electrolyte level

3.20

○

Check fuses

○

3.13

Check compressor belt

○

3.30

Clean filter Air Check refrigerant Conditioner Replace filter elements (option) Clean condenser

○

3.31

Replace receiver dryer Others

Walk-around inspection

3.41

○

Every 3 years or 6000 hours ○

○

3.15

○

3.14

○

3.51 2.44

3.8

MAINTENANCE When Required Inspection and Maintenance

When Required Inspection and Maintenance

A. Replace Bucket Teeth (option)

CAUTION 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 bet-

ween hammer and tooth.

・ Keep bystanders away from work area.

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.

When the bucket teeth are worn, replace them as follows.

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

2. Raise the bucket to a convenient height and put blocks under the bucket to prevent it from coming down.

3. Stop the engine.

Driving tool

Tooth

Pin

4. Remove the pin and tooth using a tool.

3.9

MAINTENANCE When Required Inspection and Maintenance

NOTE For non-Kawasaki buckets or teeth, consult the manufacturer for the proper procedures.

Tooth adapter

5. Install the tooth onto the tooth adapter.

Guide rib facing back

6. Install the pin with the guide rib facing back.

2 to 4-pound hammer

7. Tap the pin in flush ear using 2 to 4 pound hammer. (1～ 2kg)

3.10

MAINTENANCE When Required Inspection and Maintenance

B. Replace Cutting Edge (option)

C. Check and/or Replace Seat Belt

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

Seat Belt

Tether

1. Inspect the condition of the seat belt and all mounting hardware frequently.

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 cutting edge. Clean all contact surfaces (bottom of bucket, top of cutting edge).

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.

6. Install all bolts and tighten them to 696～834N・m (514～ 615ft ・ lb).

7. Retighten them after a few hours operation.

2. Replace the seat belt or any part of the mounting hardware if it is damaged.

3. Replace the seat belt every three years regardless of its condition or apperance.

3.11

MAINTENANCE When Required Inspection and Maintenance

D. Clean or Replace Air Cleaner Element １

２

When the warning monitor lamp lights up, clean or replace the air cleaner element.

IMPORTANT Improper procedure of cleaning air cleaner may cause severe engine damage.

4. If the element is clogged by dirt or dust, spray dry compressed air (196kPa) (30psi) along the inside of the element up and down to blow off dust. Do not breathe the dust. If necessary wear a protective mask.

5. Insert a lamp inside of the element for checking a damaged element.

・ 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.

2. Remove the cover (2) by loosening wing nut (1).

3. Remove the outer 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. 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 with new one.

10. After six cleanings or once a year replace the outer element together with the inner element.

3.12

MAINTENANCE When Required Inspection and Maintenance

E. Clean Radiator Fins

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

2. Push the knob and open the radiator grill and side covers.

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

4. Blow off mud, dirt, or clogging debris from the radiator / air cooler / fuel cooler fins with compressed air. Use a pressure washer to remove harder debris.

High pressure air or water may damage radiator / air cooler / fuel cooler fins.

Compressed air or water should be directed from rear toward the engine.

・ Be sure pressure is below 196kPa. ・ Move nozzle from side to side; not up and

5. Reverse the direction to flush all debris from the radiator / air cooler / fuel cooler fins and remove from clean-out access traps.

down.

6. Reinstall clean-out traps.

7. Close the radiator grill and side 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.

3.13

MAINTENANCE When Required Inspection and Maintenance

F.Check or Replace Fuses

G. Check Windshield Washer Fluid

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. Open the covers of the main fuse box and cab fuse box.

4. If the level is low, add fluid to proper level.

4. Check the fuses. If any blown fuses are found, replace them with new ones.

Refer to "Fuse Box" page 2.30.

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.

3. Replace the fluid if it is dirty.

5. Use windshield washer solvent for both better cleaning and to prevent freezing. Adjust the mixture according to the manufacturer's instructions.

3.14

MAINTENANCE When Required Inspection and Maintenance

H. Clean Air Conditioner Condenser

I . Replace Ether Cylinder

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.

WARNING Ether is very flammable and can could serious injury or death if exploded.

Do not store new or used ether cylinder in C operators area or at temperatures above 40° (105° F).

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

Store new or used ether cylinder in cool place and out of children's reach.

Never dispose of cylinder by burning, crusing, or puncturing.

2. Inspect the condenser and replace it if any damage is found.

3. Clean its fins using compressed air, a pressure washer, steam cleaner, or a soft brush. Be sure the air pressure is below 196kPa (30psi). If a pressure washer or steam cleaner is used, keep the nozzle about 50cm (20in) away from the fins to prevent fin damage.

4. If high pressure water or steam is used for the cleaning, cover the electrical parts of the engine and the electric condenser fans with plastic sheets. Remove the plastic sheets after cleaning.

1. Remove the cover.

2. Loosen the clamp.

3. Remove (turn counterclockwise) the ether cylinder.

4. Install (turn clockwise) a new ether cylinder.

5. Tighten the clamp.

3.15

MAINTENANCE When Required Inspection and Maintenance

J. Replace Air Conditioner Filter Elements Outer filter replacement 1. Park the machine on level ground, apply the parking brake and lower the attachment to the ground.

2. Turn the air conditioner "OFF" and stop the engine.

5. Install the cover to the cab and turn the rings clockwise to fix the cover.

Inner filter replacement

3. The cover for the outer filter is located at the right rear side of the cab.

Inner filter Filter cover

Turn the rings counterclockwise and then remove the cover.

1. The inner filter is located at the right behind the operator's seat.

Unscrew the turn knob to remove the filter cover.

Remove the filter and replace with new one.

(Part number BER525777)

4. Remove the outer filter from the cab, and replace it with new one. (Part number 40330-60270) 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.

Filter may be washed with mild detergent. Refer to "Clean Air Conditioner and Heater Filter Element" page 3.31.

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 2.44 and "Check after Starting the Engine" page 2.58.

3.17

MAINTENANCE Every 50 Hours or 1 Week

Every 50 Hours or 1 Week

A. 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.

WARNING Improper inspection or maintenance could result in death or serious injury.

Lubricate until fresh grease is seen at each joint.

Immediately replace or report any broken or defective grease fittings.

Refer to "Recommended Lubricants" page 3.55 for the correct grease.

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".

・ Bucket-Boom (two places)

・ Bucket-Rod (two places)

3.18

MAINTENANCE Every 50 Hours or 1 Week

(L.H)

・ Lever-Rod (two places)

(R.H)

・ Bucket Cylinder-Front Chassis (two places) ・ Lever-Boom (two places)

・ Boom Cylinder-Boom (two places) ・ Bucket Cylinder-Lever (two places)

3.19

MAINTENANCE Every 50 Hours or 1 Week

・ Boom Cylinder-Front Chassis (two places)

・ Center Pin (lower)

・ Boom-Front Chassis (two places)

・ Steering Cylinder (four places)

Left hand and Right hand

・ Center Pin (upper)

3.20

MAINTENANCE Every 50 Hours or 1 Week

B. Drain Water and Sediment from Fuel Tank

C. Check Battery Electrolyte Level

CAUTION Escaping fuel is flammable and harmful to skin. ・ 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.

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

WARNING Batteries produce explosive gases which could cause burns or blindness. ・ Ventilate area to remove explosive gases. ・ Wear eye or face protection when working on

or around batteries.

・ Keep flames and sparks away from batteries.

WARNING If the batteries being used have insufficient battery electrolyte level, parts in the battery case could rapidly deteriorate.

It could shorter battery life or the battery case could explode.

Keep the battery electrolyte level at the proper level.

WARNING 2. Prepare a suitable container.

3. Loosen the plug on the bottom of the fuel tank.

4. Drain water and sediment along with some fuel.

5. Close the plug.

6. Properly dispose of the drained fuel and water.

7. Add fuel.

NOTE To reduce water and sediment build up in the tank, refuel the machine at the end of each shift.

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.

3.21

MAINTENANCE Every 50 Hours or 1 Week

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.

Low

OK

High

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.

3.22

MAINTENANCE Every 250 Hours or 1 Month

Every 250 Hours or 1 Month

A. 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 3.55 for the correct grease. Use lithium base grease for universal joints.

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 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. ・ Pillow block bearing unit (one place)

Adjuster

Shaft

Pillow block bearing unit

・ Parking Brake adjuster and shaft (two places)

3.23

MAINTENANCE Every 250 Hours or 1 Month

B. Replace Engine Oil and Oil Filter Cartridges

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 C the engine coolant temperature to about 40° F). When the needle of the coolant (105° temperature gauge reaches the middle of the C (105 white zone, the temperature is about 40° ° F).

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

3. Loosen the drain plug.

4. Drain oil, about 61liters (16.1gal.), into a suitable container.

5. Remove both oil filters and properly dispose of them. Make sure the O-ring is removed with the filter.

6. Clean the oil filter head gasket surface.

7. Fill the new filters with clean engine oil.

Refer to "Recommended Lubricants" page 3.55 for the oil specifications.

8. Apply a light film of engine oil to the gasket surface of new filter cartridge.

9. Install and tighten the filter until the gasket contacts filter head surface. Then tighten it by hand an additional three-fourths to one (3/4 to 1) turn.

Refer to the instructions supplied with the filter.

IMPORTANT Do not over tighten the filter.

3.24

MAINTENANCE Every 250 Hours or 1 Month

10. Clean and install the oil drain plug, and tighten to 80N ・ m (60ft-lbs) torque.

C. Replace Fuel Filters

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.

Oil Fill

Dipstick

11. Fill the engine with clean oil to the proper level.

Refer to "Recommended Lubricants" page 3.55 for the oil specifications. Total system capacity including the filter is 61liters (16.1gal).

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 (1qt.)) under the fuel filters.

12. Idle the engine to inspect for leaks at the filter and the drain plug.

13. Stop the engine. Wait approximately five minutes to let the oil drain back to the oil pan.

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 and filters.

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.

3. Remove and properly dispose of the fuel filters.

4. Clean the filter head gasket surface.

5. Apply a light film of clean engine oil to the gasket surface of each filter.

6. Fill the filters with clean fuel.

7. Install the filter on the filter head.

Turn it until the gasket contacts the filter head surface.

3.25

MAINTENANCE Every 250 Hours or 1 Month

D. Replace DCA4 Coolant Filter Cartridge

CAUTION Pressurized radiator tank is used for this machine.

8. Tighten each filter an additional one-half to three-fourths turn after the gasket contacts the filter head surface. Follow the instructions supplied with the filter.

IMPORTANT Clean fuel is critical to the proper operation of the QSK19-C. Filtration of the fuel must be to 10 microns. use only a filter of this rating like the Fleetguard # FS1000.

This filter may also be used on KT19-C engines but is not required.

IMPORTANT Do not over tighten the filter.

Spray of hot coolant may cause burns.

Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure.

CAUTION Hot coolant and engine components can cause burns.

Avoid contact with coolant or engine components.

NOTE The filter to be used here is WF2073 that is smaller than the filter initially installed when the machine is shipped from the factory.

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

3.26

MAINTENANCE Every 250 Hours or 1 Month

2. Lift the lever on the radiator tank cap to release any remaining pressure, and remove the cap slowly.

7. Install the filter firmly by hand. instructions supplied with the filter.

Follow the

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.

２

12. If needed, add required amount of the coolant.

１ 3. Turn the coolant shut-off valves (2) .

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 (WF2073).

Refer to "Coolant Specification" page 3.56 for the correct mixture.

3.27

MAINTENANCE Every 250 Hours or 1 Month

E. Check Crankcase Breather

F.Adjust Belt Tension

CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine side panel.

There are three breather elements on the top of the cylinder head cover. Clean all three.

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

６ １

Inspection 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 place "Do Not Operate" tag on the instrument panel.

２ ３ ４ ５ 2. Loosen the wing nut (6) and remove cover (1) and element (2) (3).

3. Clean the element (2) (3).

2. Open the engine side panel.

4. Inspect the element (2) (3) and rubber gasket (4).

Replace it if necessary.

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

5. Install a cleaned or new breather element.

Tighten the wing nut (6).

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

If multiple belts are used as a set, replace all of them.

3.28

MAINTENANCE Every 250 Hours or 1 Month

G. Check Differential Gear Oil (two places)

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 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.

5. Apply pressure approximately 98N (22lb) to the center of the belt between the pulleys; deflection of about 10mm (0.39in) is normal.

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

Adjustment

３

１

５ ４ ６ ２ 1. Loosen the bolts (1) (2) (3) and lock nut (5) (6).

2. Turn the adjusting bolt (4) to adjust the belt tension correctly.

3. Tighten the bolts and nuts.

Front Axle

2. Remove the oil level plug from the front axle housing, using a 12mm 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 3.55.

4. If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky.

5. Retighten the level plug.

6. Check the rear axle oil level following the same steps.

3.29

MAINTENANCE Every 250 Hours or 1 Month

H. Check Planetary Gear Oil (four places)

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 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.

TOP

１ ２

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 12mm 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 3.55.

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.

7. If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky.

8. Retighten the plug.

3.30

MAINTENANCE Every 250 Hours or 1 Month

I . Check Tightness of Wheel Bolts

J. Check and Adjust Air Conditioner Belt

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

CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine side panel.

2. Check the wheel bolts are tightened to 892N ・ m (658ft ・ lb).

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.

3. Retighten if necessary.

2. Open the engine side panel.

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 98N (22lb) to the center of the belt between the pulleys; deflection of about 8～ 10mm (0.31～ 0.39in) is normal.

3.31

MAINTENANCE Every 250 Hours or 1 Month

K. Clean Air Conditioner and Heater Filter Element １

Outer filter cleaning 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground.

2. Turn the air conditioner or heater "OFF" and stop the engine.

２ 6. If the belt is too loose or tight, adjust the tension by loosening the lock nuts (1) and turning the adjusting nut (2) on the compressor bracket.

3. The cover for the outer filter is located at the right rear side of the cab.

Turn the rings counterclockwise and then remove the cover.

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. pressure below 196kPa (28psi).

Use air

3.32

MAINTENANCE Every 250 Hours or 1 Month

6. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days to dry out of direct sunlight.

7. After approximately 8～ 10 cleanings, replace the filter with new one. (Part number 40330-60270) Refer to "Replace Air Conditioner Filter Elements" page 3.15.

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.

2. Remove dust with compressed air. pressure below 196kPa (28psi).

Use air

3. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days to dry out of direct sunlight.

4. After approximately 8～ 10 cleanings, replace the filter with new one. (Part number BER525777) Refer to "Replace Air Conditioner Filter Elements" page 3.15.

5. Install the filter elements, install the filter cover.

NOTE It is recommended to have a second set of filters to use while another set is drying.

9. Install the cover to the cab and turn the rings clockwise to fix the cover.

Inner filter cleaning

Inner filter Filter cover

1. The inner filter is located at the right behind the operator's seat.

Unscrew the turn knob to remove the filter cover.

Remove the filters and clean.

3.33

MAINTENANCE Every 250 Hours or 1 Month

L.Replace Filter (First time replacement only) ・ Transmission Oil Filter

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 Inspection and Maintenance" page 3.34. ・ 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 Inspection and Maintenance" page 3.36. ・ Brake Line Filter

Replace it first time only at 250 hours operation, after that replace it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year Inspection and Maintenance" page 3.43. ・ Orbitrol Filter

Replace it first time only at 250 hours operation, after that replace it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year Inspection and Maintenance" page 3.43.

3.34

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.

A. Replace Transmission Oil Filter

CAUTION Hot engine components may cause burns.

Avoid contact with hot engine components.

1. If the machine is cold, operate the machine to bring the torque converter oil temperature about C (85 to 105° F).

30 to 40° 2. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

3. Place a suitable container (about 4 liters (1gal.)) under the transmission oil filter.

4. Remove and properly dispose of the oil 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. Follow the instructions on the filter.

8. Idle the engine about ten minutes and inspect for leaks around the filter.

3.35

MAINTENANCE Every 500 Hours or 3 Months

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.

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.

9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 2.59.

Add the specified oil as necessary to bring the oil level to the marked at higher position on the dipstick.

Refer to "Recommended Lubricants" page 3.55 for the specified oil.

3.36

MAINTENANCE Every 1000 Hours or 6 Months

Every 1000 Hours or 6 Months

A. 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 3.55 for the correct grease.

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.

・ Differential seals (two places)

3.37

MAINTENANCE Every 1000 Hours or 6 Months

B. Replace Transmission Oil

１

２

WARNING

３

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

3. Remove the drain plug (1) with a 24mm wrench.

4. Drain oil into a suitable container (about 85 liters (22.5 gal.)).

Properly dispose of or recycle the waste oil.

5. Loosen the four bolts (2) with a 17mm wrench.

6. Remove the flange (3) together with the pipe and suction strainer.

Transmission oil may be hot and may cause burns.

Avoid contact with transmission oil.

Set screw

1. If the machine is cold operate the machine for a few minutes to bring the transmission oil temperC (85 to 105° F). ature about 30 to 40° 2. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

Flange Gasket Strainer

7. Remove the set screw using a 2.5mm hex (allen) wrench from the strainer. 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.

Reassemble the strainer and flange assembly.

Contact a Kawasaki dealer if you find excessive debris.

3.38

MAINTENANCE Every 1000 Hours or 6 Months

8. Reinstall the drain plug and the strainer with a new gasket.

C. Check and Replace Transmission and Torque Converter Breather Element

9. Tighten the four bolts (2) to 52.5N ・ m (39ft ・ lb).

10. Fill with the specified oil.

Refer to "Recommended Lubricants" page 3.55.

11. Idle the engine and check for leaks.

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 and torque converter case.

12. Check the oil level with the dipstick. Add the specified oil if necessary to maintain the proper oil level.

3. Clean the breather in the cleaning oil tub, then spray dry compressed air from the bottom of the breather.

Refer to "Check Transmission Oil Level" page 2.59 and "Recommended Lubricants" page 3.55.

Even after cleaning, if the breather is not clean enough, replace the breather.

4. Install the breather onto the transmission case and torque converter case.

3.39

MAINTENANCE Every 1000 Hours or 6 Months

D. Replace Hydraulic Oil Return Filter

6. Remove four bolts (3) with a 17mm wrench and open the filter covers (2).

The four bolts (3) may be used as "Jacking Screws" to push up the covers. Install them into the four threaded holes (4) in the covers. Screw them in equally to force the cover up evenly.

O-ring

CAUTION Pressurized hydraulic tank is used for this machine.

Spring

Pressurized hot oil may cause injury or burns.

Bypass valve

Relieve all pressure by pressing down the filler cap.

Filter element

３ 7. Remove the O-ring, spring, and bypass valve from the filter housing.

３

４ ２

8. Remove and properly dispose of the filter and waste oil.

9. Clean the inside of the filter housing.

１ ４

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

2. Open the cover on the left deck.

3. Insert the key into the side of the filler cap and turn the key counterclockwise.

4. Press down the filler cap (1) to relieve the tank pressure.

5. Clean around the top of the filter covers (2).

10. Replace the O-rings.

11. Apply a light film of clean hydraulic oil on the filter cover O-ring surface.

12. Install the new filter elements, bypass valves, springs, new O-rings and filter covers.

Tighten the four bolts (3) to 93.7N-m (69ft-lb) 13. Close the access cover.

3.40

MAINTENANCE Every 1000 Hours or 6 Months

E. Inspect and Adjust Parking Brake Lining

5. Check parking brake operation as described on page 2.61.

NOTE If the brake drum has been excessively hot (ie. burnt paint) or the parking brake will not adjust, contact your Kawasaki dealer.

WARNING When parking brake is released for adjusting brake lining, machine could move unexpectedly causing serious injury or death.

Make sure to lower attachment to ground, and put chocks under wheels.

1. Park the machine in safe place on firm level ground and steer it fully to one side for easier access.

2. Lower the attachment to the ground and push the parking brake switch to release the parking brake.

3. Turn the adjuster bolt clockwise to close the clearance between the brake drum and the brake lining (shoe).

4. Return the adjuster bolt counter-clockwise two or three clicks.

(Now the clearance is 0.3mm (0.012 in).)

3.41

MAINTENANCE Every 1000 Hours or 6 Months

F.Check Air Conditioner Refrigerant 1. Apply the parking brake and lower the attachment to the ground.

2. Remove the cover.

3. Press the "UP Arrow 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 1500 ～ 1800min-1 (RPM).]

6. Compare the flow of bubbles in the sight glass of the receiver drier with the drawings in the following table.

CAUTION 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.

Amount of refrigerant

Appearance of the sight glass

Normal

Almost clear.

Any bubbles disappear if the engine speed is increased to 1,500min-1.

High

No bubble is seen.

Low

A flow of bubbles is visible.

Solutions

Contact your local Kawasaki dealer for inspection and recharging refrigerant.

3.42

MAINTENANCE Every 1000 Hours or 6 Months

G. Check and Adjust Engine Contact your nearest Kawasaki dealer or local Cummins engine dealer for checking and adjusting the following items: ・ Engine Compression Pressure ・ Injection Pressure ・ Injection Timing

3.43

MAINTENANCE Every 2000 Hours or 1 Year

Every 2000 Hours or 1 Year

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

2. Lubricate fittings on the following components.

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.

Refer to "Recommended Lubricants" page 3.55 for the correct grease. Use lithium base grease for universal joints.

Lube

Lube 1st Prop Shaft

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. ・ 1st Propeller Shaft (two places)

3.44

MAINTENANCE Every 2000 Hours or 1 Year

B. Replace Hydraulic Oil

CAUTION 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

・ 2nd Propeller Shaft (four places)

3. Insert the key into the side of the filler cap (1) and turn the key counterclockwise.

4. Press down the filler cap (1) to relieve the tank pressure.

5. Remove the inlet cap (1) .

CAUTION Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil. ・ 3rd Propeller Shaft (two places)

6. Prepare a suitable container to catch the draining oil (about 225 liters (60gal.)).

3.45

MAINTENANCE Every 2000 Hours or 1 Year

16. Start the engine and allow the engine to idle for about five minutes.

３

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.

２ 7. Remove the drain plug (2) with a 12mm Hex (Allen) wrench to drain oil.

8. Dispose of the waste oil properly.

9. Remove the nuts with a 17mm wrench to remove the inspection cover (3).

10. Remove the set screws in the suction strainers using a 2.5mm hex (allen) wrench. Remove the suction strainers. 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.

CAUTION Compressed air may cause injury. ・ Wear protective clothing and eye protection. ・ Air pressure must be below 196kPa.

12. Install the suction strainers, set screws, new gasket, and inspection cover (3), and tighten the nuts evenly. Do not overtighten.

13. Install and tighten the drain plug (2).

14. Add the specified hydraulic oil through the oil inlet hole.

Refer to "Recommended Lubricants" page 3.55.

15. Close the oil inlet cap (1).

3.46

MAINTENANCE Every 2000 Hours or 1 Year

C. 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 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 C (105° F). temperature about 40° 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 3. Remove the level plug (1) and drain plug (2) from the front axle housing, using a 12mm Hex (Allen) wrench.

Some fine metallic powder will normally stick to the magnet plug (2).

Simply wipe it off.

4. Drain the oil (about 115 liters (30.4gal.)) into a suitable container.

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.

Clean skin thoroughly with soap and water.

NOTE While the oil is drained, request Kawasaki dealer to measure brake wear as described in item H. 6. Install the drain plug.

7. Refill the recommended oil through the level plug hole (1) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page 3.55.

8. Install and tighten the level plug.

9. Replace the rear differential oil following the same steps.

3.47

MAINTENANCE Every 2000 Hours or 1 Year

D. Replace Planetary 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 the hydraulic oil tank cap to release the air pressure inside the hydraulic oil tank.

３

Do not touch the parts or oil when it is hot.

1. Replace the planetary gear oil on all four wheels.

4. Remove the level plug (2) and drain plug (3) from the planetary gear housing, using a 12mm hex (Allen) wrench.

Some fine metallic powder will normally stick to the magnet plug (2).

TOP

Simply wipe it off.

１ ２

5. Drain the oil (about 32.5liters (8.6gal.)) into a suitable container.

6. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease.

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.

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 3.55.

9. Install and tighten the level plug.

10. Repeat these steps for all four planetaries.

3.48

MAINTENANCE Every 2000 Hours or 1 Year

E. Replace Coolant ・ 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.

１

・ 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.

２

3. Lift the lever (1) to release any remaining pressure.

4. Remove the cap (2) slowly.

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

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.

Replace any that are cracked, swollen, or brittle.

３ 5. Open the drain cocks (3) and drain coolant (about 122liters (32.2gal.)) into a suitable container.

Do not remove the coolant filter.

6. Follow local regulations to properly dispose of or recycle the coolant.

3.49

MAINTENANCE Every 2000 Hours or 1 Year

16. Replace the DCA4 coolant filter (WF2073).

Refer to "Replace DCA4 Coolant Filter" page 3.25 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 neccessary.

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.

7. Close the drain cocks 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 C (180° F). Then let the temperature above 80° engine cool down naturally with the engine shut "OFF".

9. Stop the engine and open the drain cocks to drain the cooling system.

10. Close the drain cocks 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 C (180° F). coolant temperature above 80° 12. Stop the engine and open the drain cocks 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. Close the drain cocks and fill the system with the premixed coolant.

Refer to "Coolant Specification" page 3.56 for the mixing instruction.

15. Add two pieces of DCA65L and three pieces of DCA60L coolant additive at the same time.

For additional cold weather servicing information, refer to "Coolant Specification" page 3.56 for details.

3.50

MAINTENANCE Every 2000 Hours or 1 Year

F.Check Vibration Damper

G. Check Brake Accumulators Test the brake accumulator for proper precharge of Nitrogen gas.

WARNING Pressurized nitrogen gas in brake accumulator could explode causing serious injury or death.

Never service brake trained properly.

accumulator

unless

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 accumulators 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 brake pedal before the brake warning light comes on.

6. If the number counted is less than ten, there is some problem with the accumulators. Contact your nearest Kawasaki dealer.

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

2. Check the damper on the fan end of the engine crankshaft.

3. If dents, cracks, mounting bolt looseness, or any deformations are found, contact your nearest Kawasaki dealer or Cummins engine dealer for replacement.

3.51

MAINTENANCE Every 2000 Hours or 1 Year

H. Check Service Brake Disk Wear ・ Contact your Kawasaki dealer.

K. Clean Fuel Tank

CAUTION

I . Check and Adjust Valve Lash Clearance

Escaping fuel is flammable and harmful to skin.

・ Contact your Kawasaki dealer or local Cummins

・ Do not smoke while draining moisture and

J. Replace Air Conditioner Receiver Dryer

・ Do not drain with engine running. ・ Do not allow fuel to remain on skin for an

engine dealer.

(Every 3 years or 6000 hours) ・ Contact your Kawasaki dealer.

sediment from tank.

extended period of time. Wash thoroughly with soap and water.

NOTE It is the 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.

２

１

2. Open the drain cock (1) on the bottom of the fuel tank.

3. Drain the remaining fuel into a suitable container.

4. Remove the nuts with a 14mm wrench to remove the inspection cover (2).

5. Clean inside of the tank.

6. Install the inspection cover with a new gasket.

(Part number 31990-20021) Tighten the nuts. Do not overtighten.

7. Close the drain cock.

8. Fill the fuel tank.

9. Check for any leaks at the cover and plug.

3.52

MAINTENANCE Every 2000 Hours or 1 Year

L.Replace Filter for Brake Line

CAUTION

M. Replace Filter for Orbitrol

CAUTION

Hot oil and components may cause burns.

Hot oil and components may cause burns.

Vent all pressure by pressing hydraulic cap down.

Vent all pressure by pressing hydraulic cap down.

Avoid contact with hot oil or components.

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.

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.

2. Place a suitable container under the filter.

3. Remove and properly dispose of the filter.

4. Install new filter, and tighten it with 60 ～ 80N-m (44～ 59ft-lb) torque.

5. Idle the engine about ten minutes and inspect for leaks around the filter.

4. Place a suitable container under the filter.

5. Remove and properly dispose of the filter.

6. Install new filter, and tighten it with 60 ～ 80N-m (44～ 59ft-lb) torque.

7. Idle the engine about ten minutes and inspect for leaks around the filter.

3.53

MAINTENANCE Every 2000 Hours or 1 Year

N. Clean Crankcase Breather Tube

O. Replace Filter in the Oil Tank Cap

Clean and check the crankcase breather tube.

CAUTION Wear protective goggles and mask to keep from breathing debris.

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.

１ ５ ４

３ 1. Remove the crankcase breather tube from the breather vent tube.

２ 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.

2. Use solvent to clean the inside of the crankcase breather tube, and dry with compressed air.

3. Use air pressure to blow through the vent tube.

Replace the vent tube if it is clogged.

6. Remove spiral snap ring (2), valve assy (3), spring (4), filter element (5).

7. Replace element (5).

8. Install the element, spring, valve assy, and spiral snap ring.

3.54

MAINTENANCE Every 2000 Hours or 1 Year

P. Check Ride Control Accumulator (option)

WARNING Pressurized nitrogen gas in brake accumulator could explode causing serious injury or death.

Never service brake trained properly.

accumulator

Contact your nearest Kawasaki dealer.

unless

3.55

MAINTENANCE Recommended Lubricants

Recommended Lubricants Kind of Oil

Refill Capacity (Approximate)

Engine

Engine oil (CH-4)

61liter (16.1gal.)

Transmission

Mobil TRANS HD-10 ATF

85liter (22.5gal.)

Hydraulic system

Hydraulic oil

Differential & Planetary Fuel tank

‐２２° －４°１４° ３２° ５０° ６８° ８６°Ｆ ‐３０°‐２０°－１０° ０°Ｃ １０° ２０° ３０°

SAE 10W-30 SAE 15W-40 Mobil TRANS HD-10 Multi-Purpose ATF

＊1

225liter (59.4gal.)

Gear Lubricant with Front :180liter (47.6gal.) friction modifier Rear :180liter (47.6gal.)

Diesel fuel

Ambient Temperature

ISO VG46 ISO VG32 MOBIL TRANS HD-50

670liter (177gal.)

ASTM D975 No.2 ASTM D975 No.1

Change Interval (Hours) 250 1,000 2,000 2,000 daily

Note : ＊1 shows "Hydraulic tank oil capacity at level gauge center."

Engine

Use oil that meets engine oil classification API CH-4.

Transmission

Mobil TRANS HD-10 or equivalent TO-4.

Multi-purpose Automatic Transmission Fluid.

Never mix engine oil, Mobil TRANS HD-10 and/or ATF.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use.

Differential & Planetary

Use Mobil TRANS HD-50 or equivalent 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.

3.56

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

-35 ° C (-31 ° F)

C -30 ° (-22 ° F)

C -25 ° (-13 ° F)

C -20 ° (-4 ° F)

C -15 ° (5 ° F)

Pure Water

(liter) (gal)

58.6 (15.5)

63.4 (16.7)

69.5 (18.4)

75.7 (20.0)

81.7 (21.6)

Antifreeze

(liter) (gal)

63.4 (16.7)

58.6 (15.5)

52.5 (13.8)

46.3 (12.2)

40.3 (10.6)

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 F)) for a minimum ambient temperature of -15 ℃ (5 ° 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 that causes the packing damage or water leakage.

3.57

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 loader dealer for items marked with or your local authorized CUMMINS ENGINE dealer for 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 Exessive engine wear Defective oil pump

SOLUTIONS Add oil Change oil Change filter and oil

Ｋａｗａｓａｋｉ

ｏｒ

ＣＵＭＭＩＮＳ

Low engine coolant level Fan circuit pressure or flow too low Clogging radiator fins Coolant temp. warning Scale or mineral build up inside radiator lamp lights up Defective alarm switch (gauge is in green) Low water pump flow Thermostat stuck or missing

Add coolant

Fuel filter element clogging Engine does not start Starter motor speed too low when the starter motor Defective engine shut off solenoid is turning Fuel pump failure (Also see Incorrect fuel injection timing ELECTRICAL Compression pressure too low TROUBLESHOOTING) Defective injectors

Replace fuel filter Booster Battery may be used

Air in fuel lines Fuel filter element clogging Unstable (rough) idling Fuel pump failure Incorrect fuel injection timing

Tighten fuel connections and filter

Insufficient power

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 or Fuel cooler restricted

2.47

Ｋａｗａｓａｋｉ

Clean Flush or professionally clean Ｋａｗａｓａｋｉ

Ｋａｗａｓａｋｉ

ｏｒ

ｏｒ

ｏｒ

ｏｒ

3.24 2.80

ＣＵＭＭＩＮＳ

3.24 3.24

ＣＵＭＭＩＮＳ

Clean or replace element Replace fuel filter Check and adjust linkage Check dipstick and correct level

Ｋａｗａｓａｋｉ

3.12 3.48

ＣＵＭＭＩＮＳ

Replace fuel filter Ｋａｗａｓａｋｉ

PAGE 2.45 3.23 3.23

ＣＵＭＭＩＮＳ

3.11 3.24 2.45

3.58

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Use correct type of oil Correct oil level

3.55 2.45

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

Warning lamp lights up

Refer to "Engine Warning Lamps"

ｏｒ

Ｋａｗａｓａｋｉ

ｏｒ

Ｋａｗａｓａｋｉ

ＣＵＭＭＩＮＳ

3.24

ＣＵＭＭＩＮＳ

Ｋａｗａｓａｋｉ

ｏｒ

ＣＵＭＭＩＮＳ

Ｋａｗａｓａｋｉ

ｏｒ

ＣＵＭＭＩＮＳ

3.11

2.26

ELECTRICAL PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Broken or slipping alternator belt Defective battery Alternator failure Defective wiring Defective wiring to ground (short)

Adjust or replace belt Replace battery

3.27

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

Charge lamp lights up

ｏｒ

Ｋａｗａｓａｋｉ

ＣＵＭＭＩＮＳ

2.16 2.80

Ｋａｗａｓａｋｉ

ｏｒ

Ｋａｗａｓａｋｉ

ＣＵＭＭＩＮＳ

Ｋａｗａｓａｋｉ Ｋａｗａｓａｋｉ Ｋａｗａｓａｋｉ

ｏｒ

ＣＵＭＭＩＮＳ

2.4 2.80 3.23

3.59

TROUBLESHOOTING

STEERING PROBLEM

Hard steering

Will not steer

POSSIBLE CAUSES Tires are underinflated Severe conditions (over loaded, deep mud, etc.)

Oil pressure too low Steering valve failure Steering cylinder failure Defective orbitrol Pump failure

Check/adjust tire pressure Change operation

Articulation stopper in locked position

Move articulation stopper to "STORED" position Reduce load

Excessive load on steering Steering valve failure Orbitroll failure Pump failure Relief valve failure Steering cylinder failure Blocked screen filter Excessively cold oil / Wrong grade oil

Steering drift

SOLUTIONS

Steering control valve failure Steering pilot valve failure

PAGE 2.51

Ｋａｗａｓａｋｉ

1.22

Ｋａｗａｓａｋｉ

Replace filter

3.52

Warm oil / Replace oil with proper viscosity for temperature

3.55

Ｋａｗａｓａｋｉ

HYDRAULIC PROBLEM

Boom raises too slowly

Boom natural drift excessively

Bucket / Attachment floating or drifting

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

3.55

Excessively cold oil / Wrong grade oil

Warm oil / Replace oil with proper viscosity for temperature

Ｋａｗａｓａｋｉ

Leakage from control valve plunger Damaged cylinder piston or piston packing Leakage in pilot relief valve

Ｋａｗａｓａｋｉ

Over load relief pressure too low Control valve failure Natural drift of cylinder / packing

Ｋａｗａｓａｋｉ

3.55

3.60

TROUBLESHOOTING

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

Air in brake oil circuit Braking power too low 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

Replace filter

3.52

Ｋａｗａｓａｋｉ

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

3.55

Release parking brake Add oil / Repair leak Clean strainer Ｋａｗａｓａｋｉ

2.59 3.37

3.61

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

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 Engine failure light on (in reduced power mode)

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 (QUAD) Change application Clean radiator fins

Low power

PAGE 2.59 3.37

Ｋａｗａｓａｋｉ

3.38

Ｋａｗａｓａｋｉ

2.59 2.65 3.12

Ｋａｗａｓａｋｉ

AIR CONDITIONER / HEATER (option) PROBLEM

POSSIBLE CAUSES

Hot water continues to flow through heater core A/C not set for maximum cooling Low cooling when A/C Condensor fins plugged "ON" A/C cab air filters plugged A/C compressor belts slipping/broken A/C refrigerant charge low

Low heater out put

Engine not warmed up No hot water flow to heater core Air conditioner running Heater vents not adjusted properly Defective heater motor or switch

SOLUTIONS

PAGE

Shut off valve in heater hose line at block Adjust controls/vents Clean Clean or replace Adjust/Replace

2.40 3.14

Ｋａｗａｓａｋｉ

Warm up engine Open shut off valve on block Turn A/C off Adjust controls/vents Ｋａｗａｓａｋｉ

2.40 2.40

3.62

SPECIFICATIONS

SPECIFICATIONS Specifications shown are for a machine equipped with standard features. Some options or special attachment will change the specifications shown. Specifications subject to change without notice.

3.63

SPECIFICATIONS

Bucket Capacity

8.3 yd3 (6.4 m3) (Heaped) 7.3 yd3 (5.6 m3) (Struck) Rock Bucket with Teeth (RVT)

Operating Weight

100,180 lb (45,440 kg) (with RVT bucket and standard tire)

Engine Model Type

Cummins QSK19 -C 4 cycle, Water Cooled, Direct injection, Turbo charged & air cooled intercooler 18,853 cm3(1,150 in3 ) 395 kW / 2,000 min-1 (RPM) [530 HP / 2000 min-1 (RPM)] 2,206 N-m / 1,300 min-1 (RPM) [1500 ft-lb / 1300 min-1 (RPM)]

Displacement Rated Power Max. Torque Tire (standard)

35/65-33-24 PR (L4)

Max. Running Speed MPH (km/h)

Forward

Reverse

1st 4.3 ( 7.0) 2nd 8.1 (13.0) 3rd13.2 (21.3) 4th 21.8 (35.1) 1st 4.7 ( 7.5) 2nd 8.6 (13.9) 3rd14.1 (22.7)

INDEX A Accelerator Pedal・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.6 Adjust and Check Rear View Mirrors ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.54 Adjust Belt Tension・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.27 Adjustments ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.76 Air Cleaner Warning Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.24 Articulation Stopper ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・1.22 To lock・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.22 To unlock ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.22 Articulation Stopper ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.51 Auto Brake・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.66 Auto Brake Indicator Lamp・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.22 Auto Shift Indicator Lamp・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.25 Auxiliary Attachment Control Lever (option) ・・・・・・・・・・・・・・・・・・・・ 2.5 Auxiliary Attachment Control Lever Lock (option)・・・・・・・・・・・・ 1.20

B Before Starting Safety ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.4 Boom Control Lever・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.4 Boom Kickout Adjustment ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.77 Booster Batteries/Jumper Cables ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.80 Brake Pressure Warning Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.23 Brake Pedals・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.6 Bucket/Attachment Positioner Adjustment ・・・・・・・・・・・・・・・・・・・・・2.76 Bucket Control Lever ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.5

C Carrying ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.73 Central Warning Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.22 Charge Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.24 Check after Starting the Engine・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.58 Check Air Conditioner Refrigerant ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.41 Check Air Intake System・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.49 Check and Adjust Air Conditioner Belt ・・・・・・・・・・・・・・・・・・・・・・・・・ 3.30 Check and Adjust Engine・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.42 Check and Adjust Valve Lash Clearance・・・・・・・・・・・・・・・・・・・・・・・3.51 Check and/or Replace Seat Belt・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.10 Check and Replace Transmission and Torque Converter Breather Element ・・・・・・・・・・・・・・・・・・・3.38 Check Back-up Alarm Operation ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.62 Check Battery Electrolyte Level・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.20 Check before Operation・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.44 Check Brake Accumulators ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.50 Check Control Levers・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.54 Check Cooling Fan・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.50 Check Crankcase Breather ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.27 Check Differential Gear Oil・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.28 Check Drive Belts・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.49 Check Engine Coolant Level ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.47 Check Engine Oil Level ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.45 Check Exhaust Gas ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.62 Check Fuel Level ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.59 Check Horn Operation・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.61 Check Hydraulic Oil Level ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.46 Check K-Lever and Forward / Reverse Changeover Switch ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.54

Check Monitor Panel Operation ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.54 Check or Replace Fuses・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.13 Check Parking Brake ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.54 Check Parking Brake Operation ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.61 Check Planetary Gear Oil ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.29 Check Ride Control Accumulator (option)・・・・・・・・・・・・・・・・・・・・・・3.54 Check Service Brake Disk Wear・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.51 Check Service Brake Operation ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.61 Check Steering Operation・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.61 Check Tightness of Wheel Bolts・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.30 Check Tire Air Pressure・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.51 Check Tire for Damage ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.53 Check Transmission Oil Level・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.59 Check Vibration Damper・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.50 Check Warning Lamps ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.58 Check Windshield Washer Fluid・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.13 Check Wiring Harnesses ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.50 Clean Air Conditioner and Heater Filter Element・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.31 Clean Air Conditioner Condenser ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.14 Clean Crankcase Breather Tube ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.53 Clean Fuel Tank ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.51 Clean or Replace Air Cleaner Element ・・・・・・・・・・・・・・・・・・・・・・・・ 3.11 Clean Radiator Fins・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.12 Cold Start (ether injection) Switch・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.13 COMPONENT NAME/LOCATION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.2 Coolant Specification ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.56 Coolant Level Warning Lamp・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.26

D Dozing ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.71 Drain Water and Sediment from Fuel Filter ・・・・・・・・・・・・・・・・・・・・2.48 Drain Water and Sediment from Fuel Tank ・・・・・・・・・・・・・・・・・・・・3.20 Dumping into Truck or Hopper ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.73 Diagnostic Switch (option)・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.17

E Electrical Protection・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.30 Emergency Brake・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・1.23 Emergency Steering (option) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.23 Emergency Steering Warning Lamp (red) (option)・・・・・・・・・・・ 2.26 Engine Coolant Temperature Gauge・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.21 Engine Coolant Temperature Warning Lamp ・・・・・・・・・・・・・・・・・2.23 Engine Oil Pressure Warning Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.23 Engine Power Mode Switch・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.19 Engine Warning Lamps ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.26 Every 10 Hours or Daily・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.16 Every 50 Hours or 1 Week ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.17 Every 250 Hours or 1 Month・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.22 Every 500 Hours or 3 Months ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.34 Every 1000 Hours or 6 Months・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.36 Every 2000 Hours or 1 Year ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.43 Excavating・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.71 Explosion/Fire/Burn Prevention ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.13

F

M

Forward / Reverse Changeover Switch・・・・・・・・・・・・・・・・・・・・・・・・ 2.16 Four-way Flasher Switch (option) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.18 Front Wiper Switch ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.14 Front Working Light Switch・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.12 Fuel Level Gauge・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.21 Fuse Boxes・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.30 Fusible Links・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.31

MAINTENANCE・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.2 Mounting and Dismounting Safety ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.3

Neutral Start System・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・1.23 Neutral Indicator Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.25

G

O

General Inspection ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.63 Grease Gun Holder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.43 Greasing ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.45 Greasing ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.17 Greasing ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.22 Greasing ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.36 Greasing ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.43 Ground Leveling ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.72

OPERATOR'S AREA ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.3 OPERATION・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.44 Operation and Function ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.42 Operational Safety・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.6 SITE SAFETY ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.6 SAFETY DURING NORMAL OPERATIONS ・・・・・・・・・・・・・・・・ 1.7 SPECIAL OPERATING CONDITIONS・・・・・・・・・・・・・・・・・・・・・・・・ 1.9 Operating the Machine ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.64 Operating Techniques・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.69 Other Maintenance Safety Concerns・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.14 Operator Safety ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.2

H Heater or Air Conditioner (option) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.40 Ventilation Location and Mode・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.40 Switches ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.40 Operation of the Automatic Temperature Control unit ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.41 High beam Indicator Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.25 Horn Switch ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.15 Hour Meter ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.25

N

P Parking Safety ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.10 Parking ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.67 Parking Brake Indicator Lamp・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.22 Parking Brake Switch・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.10 Pedals and Levers・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.3

I

Q

Increment / Decrement Switch (option) ・・・・・・・・・・・・・・・・・・・・・・・・ 2.18 Indicators ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.20 Inspect and Adjust Parking Brake Lining ・・・・・・・・・・・・・・・・・・・・・・・3.40 Inspection and Maintenance Table ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.5

QUAD (Quick Up and Downshift) Switch ・・・・・・・・・・・・・・・・・・・・・・・2.15

K K-Lever ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.4 K-Lever Indicator Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.27 K-Lever Steering System On/Off・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.21

L Light Switch ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.11 Long Term Storage・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.85 Before Storage ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.85 During Storage ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.86 After Storage・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.86 Loading・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.69 Loading Control Lever Lock・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.20 Loading Control Lever Lock・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.8

R Radio-AM / FM Cassette (24 Volt Type) ・・・・・・・・・・・・・・・・・・・・・・・・2.32 Rear Working Light Switch ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.12 Rear Wiper Switch・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.14 Recommended Lubricants ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.55 Recommended Mixture of Antifreeze・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.56 Replace Air Conditioner Filter Elements・・・・・・・・・・・・・・・・・・・・・・・・3.15 Replace Air Conditioner Receiver Dryer・・・・・・・・・・・・・・・・・・・・・・・・3.51 Replace Bucket Teeth (option)・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.8 Replace Coolant ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.48 Replace Cutting Edge (option) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.10 Replace DCA4 Coolant Filter Cartridge・・・・・・・・・・・・・・・・・・・・・・・・ 3.25 Replace Differential Gear Oil ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.46 Replace Engine Oil and Oil Filter Cartridges ・・・・・・・・・・・・・・・・・・3.23 Replace Ether Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.14 Replace Filter (First time replacement only) ・・・・・・・・・・・・・・・・・・・3.33 Replace Filter in the Oil Tank Cap ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.53 Replace Filter for Brake Line ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.52 Replace Filter for Orbitrol ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.52

Replace Fuel Filters・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.24 Replace Hydraulic Oil ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.44 Replace Hydraulic Oil Return Filter ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.39 Replace Planetary Gear Oil・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.47 Replace Transmission Oil ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.37 Replace Transmission Oil Filter・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.34 Ride Control Indicator Lamp (option)・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.27 Ride Control Switch (option) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.19 Ride Control System (option)・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.42 Roading/Special Applications ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.79 ROPS (Roll Over Protective Structure) ・・・・・・・・・・・・・・・・・・・・・・・・ 1.24 ROPS (Roll Over Protective Structure) ・・・・・・・・・・・・・・・・・・・・・・・・ 2.54

S Safe Operation ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.2 Safe Maintenance ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・1.11 SAFETY・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・1.2 Safety Devices ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.20 Safety Preparations Before Maintenance ・・・・・・・・・・・・・・・・・・・・・・1.11 Safety Signs・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1.16 Seat ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.28 Seat Adjustment ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.28 Seat Belt ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.29 Serial Number Location ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.2 SPECIAL PROCEDURES・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.76 SPECIFICATIONS・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.62 Speed and Direction Change・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.65 Starter Switch・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.10 Starting the Engine・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.55 Normal Start・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.55 Cold Start ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.56 Starting the Machine・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.64 Starting the Machine on a Grade ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.65 Stopping the Engine ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.68 Switches ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.9

T Tachometer ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.21 Torque Converter Oil Temparature Gauge ・・・・・・・・・・・・・・・・・・・・2.21 Torque Converter Oil Temperature Warning Lamp・・・・・・・・・・ 2.24 Towing・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.82 Transmission Control Warning Lamp・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.22 Transmission Cut-Off (Declutch) Lamp ・・・・・・・・・・・・・・・・・・・・・・・・ 2.22 Transmission Cut-Off (Declutch) Switch・・・・・・・・・・・・・・・・・・・・・・・・2.13 Transmission Oil Filter Warning Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・ 2.24 Transmission Shift Switch ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.16 Transmission Status Monitor ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.25 Transportation ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.83 TROUBLESHOOTING ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・3.57 ENGINE・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.57 ELECTRICAL・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.58 STEERING ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.59 HYDRAULIC ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.59 BRAKE ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3.60 TORQUE CONVERTER&TRANSMISSION ・・・・・・・・・・・・・・・・3.60

AIR CONDITIONER/HEATER (option)・・・・・・・・・・・・・・・・・・・・・・・3.61 Turn Signal Indicator Lamp(Left) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.24 Turn Signal Indicator Lamp(Right) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.25 Typical Truck Loading Methods・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.75

W Walk-Around Inspection・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・2.44 When Required Inspection and Maintenance ・・・・・・・・・・・・・・・・・・ 3.8 Working Light Indicator Lamp ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.22 Wrist Rests ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 2.7

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