Kawasaki 60ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93106-00113

60ZV-2

93106-00113 April 1, 2009

OPERATION & MAINTENANCE MANUAL WHEEL LOADER

60ZV-2

Printed in Japan (i) ( アメリカ用 )

93106-00113

©2009 KCM Corporation. All rights reserved.

NOTICE Powered by CUMMINS QSB4.5 Engine Serial No. 60C3-5001 and up

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

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 constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

"Perchlorate Material special handling may apply, See www.dtsc.ca.gov/hazardouswaste/perchlorate."

Applicable parts : MCU (Machine Control Unit) Applicable state : California

93106-00113 April 1, 2009

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 60ZV-2.

This manual contains safety, operation, transportation, maintenance and troubleshooting information. Read and understand the information in this manual carefully before operating or performing any maintenance of the machine. Failure to do so could result in personal injury or equipment failure. The safety of yourself and others depends upon your care and judgement in the operation and maintenance of this machine. Keep the manual with this machine at all times.

Kawasaki pursues a policy of continuing improvement in design and performance of this machine. The right is therefore reserved to vary specifications without prior notice or 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.

There may be an optional supplemental operation & maintenance manual, and this also should be referred to when operating machines that are equipped with special packages.

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

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

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

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

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

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

Always follow safe operating and maintenance practices.

Kawasaki cannot anticipate every possible circumstance, use, or misuse of the machine that might involve a potential hazard. The warnings in this Operation & Maintenance Manual and on the machine are therefore not all inclusive.

If an operation or maintenance procedure is not performed as specifically recommended by Kawasaki, you must satisfy yourself that it is safe for you and others. You should also ensure that the machine will not be damaged by the operation or maintenance procedure you choose.

Kawasaki makes every effort to supply machines which conform to every regulation applicable in your country / state. However, if your machine is not supplied through the authorized Kawasaki dealer, it may not be equipped as the regulations require. Kawasaki cannot be responsible for anything on that kind of machine.

Also, some local agencies or certain job sites may require special equipment that has not been provided. Contact your nearest Kawasaki dealer for further information or assistance.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible effort has been made to ensure it as complete and accurate as possible.

CONTENTS 1.SAFETY ...................................................................................................................................................... 1.1 SAFETY ..................................................................................................................................................... 1.2 Safe Operation..................................................................................................................................... 1.2 Safe Maintenance...............................................................................................................................1.11 Safety Signs....................................................................................................................................... 1.16 Safety Devices................................................................................................................................... 1.25 2.OPERATION ............................................................................................................................................... 2.1 COMPONENT NAME/LOCATION ............................................................................................................. 2.2 OPERATOR'S AREA ................................................................................................................................. 2.3 Pedals and Levers ............................................................................................................................... 2.3 Switches .............................................................................................................................................. 2.9 Indicators ........................................................................................................................................... 2.17 Seat ................................................................................................................................................... 2.23 Electrical Protection ........................................................................................................................... 2.25 Radio - AM / FM Cassette (24 Volt Type) (option) ............................................................................ 2.27 Heater or Air Conditioner (option) ...................................................................................................... 2.35 Ride Control (option).......................................................................................................................... 2.37 OPERATION ............................................................................................................................................ 2.38 Check before Operation..................................................................................................................... 2.38 Starting the Engine ............................................................................................................................ 2.48 Check after Starting the Engine ......................................................................................................... 2.50 Operating the Machine ...................................................................................................................... 2.55 Parking............................................................................................................................................... 2.58 Stopping the Engine........................................................................................................................... 2.59 Operating Techniques........................................................................................................................ 2.60 SPECIAL PROCEDURES ....................................................................................................................... 2.67 Adjustments ....................................................................................................................................... 2.67 Roading / Special Applications .......................................................................................................... 2.69 Booster Batteries / Jumper Cables .................................................................................................... 2.70 Towing................................................................................................................................................ 2.72 Transportation.................................................................................................................................... 2.73 Long Term Storage ............................................................................................................................ 2.75 Welding.............................................................................................................................................. 2.78

3.MAINTENANCE .......................................................................................................................................... 3.1 MAINTENANCE ......................................................................................................................................... 3.2 Serial Number Location ....................................................................................................................... 3.2 Inspection and Maintenance Table ...................................................................................................... 3.5 When Required Inspection and Maintenance ...................................................................................... 3.8 Every 10 Hours or Daily ..................................................................................................................... 3.17 Every 50 Hours or 1 Week................................................................................................................. 3.18 Every 250 Hours or 1 Month .............................................................................................................. 3.24 Every 500 Hours or 3 Months ............................................................................................................ 3.30 Every 1000 Hours or 6 Months .......................................................................................................... 3.35 Every 2000 Hours or 1 Year............................................................................................................... 3.41 Recommended Lubricants ................................................................................................................. 3.46 Coolant Specification ......................................................................................................................... 3.48 TROUBLESHOOTING............................................................................................................................. 3.49 SPECIFICATIONS ................................................................................................................................... 3.61

1.1

1.SAFETY

1.2 SAFETY Safe Operation

SAFETY Safe Operation Operator Safety

OM0026

Wear safe clothing: OM0001

Read and understand the Operation & Maintenance Manual.

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

- Protective clothing as required by the job or conditions for example: - Hard hat - Gloves - Steel-toe shoes - Do not wear jewelry that may catch on the equipment, controls or may short and cause burns if in contact with electrical components.

OM0180

Be aware of the location and meaning of safety signs (decals) on the machine. Report or replace any that are missing or unreadable.

Be alert and ready to operate the machine safely: - Do not operate if excessively tired.

- Do not operate if taking medication that causes drowsiness.

- Do not operate if under the influence of alcohol or drugs.

1.3 SAFETY Safe Operation

Mounting and Dismounting Safety

OM0012

OM0010

Face the machine when mounting or dismounting.

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

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

Climb and step only where steps and handrails are provided.

OM0181

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

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

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

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

Do not allow unauthorized personnel on the machine.

1.4 SAFETY Safe Operation

Before Starting Safety

OM0005 OM0006

Perform the normal daily maintenance.

Know the location of safety items and procedures: - Fire extinguishers - Fire blankets - First aid kits - Emergency phone numbers Walk around the machine to be sure no one is working or laying under the machine.

Lock

Inspect the machine for safety hazards and, if found, have them corrected: - Broken lights, mirrors, windows, etc.

- Fuel leaks, oil leaks, or debris build-up - Improper tire inflation or tire damage - Missing or unreadable safety signs (decals) Be sure the Roll Over Protective Structure (ROPS) is:

Unlock

60ZV 3701b

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

- Parking Brake -- Applied (See page 1.27) - Control Lever Lock -- Locked (See page 2.8)

- in place.

- properly attached (no bolts loose or missing).

- not damaged.

- not modified.

N

60ZV0002

- Transmission Shift Lever -- Neutral

1.5 SAFETY Safe Operation

Articulation Stopper "STORED"

OM0007

60ZV 3652

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

- Back-up Alarm -- Operational

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

Properly fasten the seat belt.

Securely lock the cab door either fully open or closed.

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

DANGER

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

DO NOT START MEN WORKING ON

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

MACHINERY SIGNED BY

Do not bring inflammable or explosive materials such as: - spray can - chemical cylinder Do not attach a suction cup on the window to avoid firing.

In case of fire during operation: - Turn off the starter switch and stop the engine.

- Extinguish fire with a fire extinguisher (Depend on the situation).

- With hand rails and steps, get off the machine and stay away from it.

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

DATE

OM0182

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

Do not operate the engine where there are or can be combustible vapors. These vapors can be drawn through the air intake system and cause engine overspeeding, which can result in a fire, and explosion.

1.6 SAFETY Safe Operation

Operational Safety SITE SAFETY: Consider the safety of the job site before operating the machine:

OM0011

- 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.

OM0021

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

Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

OM0183

Start the machine only from in the operator's seat.

- Do not reach through the window to start.

- Do not stand on the ground and start.

- Never attempt to start by shorting across the starter motor terminals since this can bypass the neutral start safety device.

If jumper cables are required to start the engine, follow the correct procedure in "Booster Batteries / Jumper Cables" page 2.70.

Do not operate the machine at work area close to fire or dry grass is.

Operate the machine slowly over rough ground and on a grade.

Do not operate on any grade that may be unstable (loose material, soft material, snow, or ice).

The range of temperature the machine is to be operated is between -35ºC ~ 45ºC (-31ºF ~ 113ºF).

1.7 SAFETY Safe Operation When working on a grade:

SAFETY DURING NORMAL OPERATIONS:

- Turn "OFF" the declutch switch.

- Keep the attachment low.

- Keep the attachment facing up the grade as often as possible.

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

- Stop when changing direction on a grade to maintain stability.

- Never coast down a grade.

- Select the same low gear to go down the grade as was selected to climb the grade. This provides some engine braking.

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

Know the machine limits and do not exceed them.

OM0013

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

OM0018

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

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

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

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

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

Do not expose the machine to flames.

approx. 40 cm (16 in) OM0016

- 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 allow.

- Know and follow all local laws that may require rotating beacon, slow moving vehicle (SMV) signs, width signs or flags, lead or chase vehicles, four-way flashers, or clearance lights, etc.

- If roading long distances (over 3 km (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.

OM0184

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

OM0020

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

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

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

1.9 SAFETY Safe Operation

SPECIAL OPERATING CONDITIONS:

70ZV OM 2665

OM0185

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

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

- Check for normal braking after leaving the water.

- Check differential gear oil for contamination.

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

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

- Use flashers or beacons (if equipped).

- Reduce speed.

- Periodically stop and inspect the job site.

- Take more frequent breaks to reduce fatigue.

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

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

- Use a cable that has appropriate pull hooks.

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

- Be sure the hitch pin is fully in its bore before applying tension.

- If brakes and steering are working on the towed vehicle, keep an operator in the operator's seat and have him control the vehicle.

- If brakes are not working on the towed vehicle, attach another vehicle of adequate size to the rear to act as a braking vehicle.

- Use the machine as a tow vehicle only for short distance.

1.10 SAFETY Safe Operation

Parking Safety

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

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

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

OM0025

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

- Block the tires.

- Apply the parking brake.

To prevent unauthorized use: - Remove the key.

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

- Install vandal covers (if equipped).

OM0186

Inspect the machine and report any needed repairs.

1.11 SAFETY Safe Maintenance

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

Perform maintenance and repairs only if trained.

Follow the Operation & Maintenance Manual or Shop Manual.

OM0002

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

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

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

OM0025

OM0026

Wear safe clothing to perform maintenance: - Close fitting clothing -- loose or baggy clothing can catch on equipment or controls.

- Protective clothing as required by the job or conditions -- for example: - Hard hat - Gloves - Steel-toe shoes - Eye / face protection - Approved respirator

Before performing any maintenance: - Park on level ground.

- Block the tires securely.

- Apply the parking brake.

- Lower the boom and attachment to the ground.

- Stop the engine (unless specified in the Operation & Maintenance Manual or Shop Manual).

Use a piece of cardboard or wood to find fluid leaks under pressure but do not use your bare hand. Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes and cause serious injury, blindness or death.

1.12 SAFETY Safe Maintenance

OM0029

OM0031

Never make repairs on pressurized components.

Release all trapped air and hydraulic pressure by:

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

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

- Moving the loading control levers back and forth.

- Turning the steering wheel right and left several times.

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

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

DANGER DO NOT START MEN WORKING ON MACHINERY SIGNED BY DATE

OM0182

Attach a "DO NOT START" or "DO NOT OPERATE" tag on the key switch or the steering wheel.

When working beneath the machine, use sturdy and stable supports to hold it up. Do not depend on hydraulic cylinders or attachment.

1.13 SAFETY Safe Maintenance

Explosion / Fire / Burn Prevention

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

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

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

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

Avoid contact with skin or eyes.

Pour all fuel and oil into appropriate containers.

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

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

Keep flame and sparks away from flammable and explosive materials such as: - Fuel - Oil - Antifreeze - Batteries - Wood chips - Straw, leaves, pine straw - Oily rags - Grease - Ether starting fluid

OM0032

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

OM0033

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

Never smoke while fueling a machine. Stop the engine before fueling.

- Fill oil at well ventilated place.

- Do not leave the machine when filling oil.

- Fasten the oil filler cap tightly.

Remove flammable materials from hot engine component areas (i.e.; muffler, manifold, etc.).

- Make sure wheel parts are correctly installed.

- Use a self attaching (locking) air chuck.

- Use a remotely located valve to turn air pressure on and off.

- Stand behind the tread not beside the rim.

- Do not inflate tires more than the recommended pressure.

- Use a safety cage for a repaired tire.

Serious injury may result from explosion of tire/rim assembly due to improper welding on the rim without first removing tire. Remove tire from rim when welding rim.

1.14 SAFETY Safe Maintenance Do not operate the engine where there are or can be combustible vapors. These vapors can be drawn through the air intake system and cause engine overspeeding, which can result in a fire, and explosion.

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

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

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

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

OM0008

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

Stop the engine before opening the engine access panel.

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

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

OM0188

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

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

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

Articulation Stopper "LOCKED"

60ZV 3652L

When transporting the machine on a truck or lifting the machine, lock the articulation stopper in the "LOCKED" position.

Used oil may cause skin disease if allowed to remain on the skin for extended periods. Wash skin completely to remove used oils.

Drain and discard of used oil and coolant properly to prevent environmental pollution.

Treat the oil and the coolant following the notes on the MSDS (Material Safety Data Sheet).

Dispose of the waste oil and the coolant following the law and/or local regulations.

When oil or fuel leaks from the high pressure rubber hose, it may cause an accident or fire by a wrong actuation. If something is wrong with the rubber hose, immediate repair is needed: - Correct them and fasten the rubber hose when a clamp, guard and cushion are loosen. Do not keep them loosen, or the rubber hose is damaged by vibrating or scratching other parts.

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

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

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

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

1.16 SAFETY Safety Signs

Safety Signs All safety signs which are on the machine are shown here. Read them and understand them thoroughly. They contain information which is important for the safe operation and the safe maintenance.

Follow the directions on the safety signs carefully.

It is very important that all safety signs be on the machine in the locations shown. If any sign is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct position.

NOTE The sample safety signs in this section have part numbers to help you and your dealer obtain the correct replacement.

1.17 SAFETY Safety Signs

1.

12.

DANGER

WARNING

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

Always keep ROPS in place.

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

44841-20870

CAUTION Improper brake oil or fluids can cause brake failure resulting in injury or death.

Use only approved oil such as: Mobil Delvac 1 or equivalent 44787-20871

Inside

Inside L.H, R.H

44787-24360

L.H, R.H

44787-24320

R.H

60ZV2 02597-1020PVa

5.

CAUTION

10.

Inside

WARNING

WARNING

44787-24410

44787-24440

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".

Machine will not turn with articulation stopper in locked position.

Unlock articulation stopper before operating machine.

44841-20650

44841-20630

1.18 SAFETY Safety Signs

4.

9.

11.

CAUTION

WARNING

DANGER

CAUTION

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

Avoid contact with skin or clothing.

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

44841-20690

Inside 44787-24420

44787-24370

44787-24330

60ZV2 02597-1020TVa

(With precleaner) 11.

13.

7.

Inside

8.

Inside

CAUTION

WARNING

CAUTION

WARNING

44787-24370

44787-24460

44787-24350

44787-24340

1.19 SAFETY Safety Signs

L.H, R.H

2.

WARNING

L.H, R.H

3.

WARNING

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

Do not clean or replace element while engine is running.

Clean only outer element.

Never clean inner element.

44787-20950

STOP

STOP

44787-24380

44787-24390

60ZV2 02597-1020RVa

(No precleaner) 6.

L.H, R.H

13.

WARNING

WARNING

44787-24400

44787-24460

1.20 SAFETY Safety Signs [ROPS Cab spec. (option)] 12.

WARNING

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

Always keep ROPS in place.

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

44841-20870

L.H

Inside L.H, R.H

44787-24320

R.H

50ZV02597-0759SVb 60ZV02597-0760ASa

Inside L.H

WARNING

FOR THE SAFETY OF WORK SITE PARSONNEL, THE BACK-UP ALARM MUST ALWAYS SOUND WHEN THIS MACHINE IS IN REVERSE. IF THERE IS NO SOUND, CHECK AND REPAIR THE BACK-UP ALARM IMMEDIATELY.

44787-24680

1.21 SAFETY Safety Signs 3.

1.

DANGER

WARNING

STOP 44787-24390

44787-24360

WARNING

DANGER No room in this area while turning machine.

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

Crushing will result in death or serious injury.

Stop engine before working in this area.

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

4.

2.

DANGER

WARNING

STOP 44787-24420 44787-24380

WARNING

DANGER

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

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

Keep all guards in place.

Before walking or working under raised boom:

Keep hands away from fan area.

- Securely block or brace boom.

- Remove key and tag "Do Not Operate."

- Release all trapped oil pressure before opening any piping.

1.22 SAFETY Safety Signs 7.

5.

WARNING

CAUTION

44787-24410

44787-24350

CAUTION

WARNING Apply articulation stopper when inspecting or servicing machine in articulation area.

When handling battery cable, you may get an electric shock.

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

6.

WARNING

44787-24400

WARNING Machine movement could result in death or serious injury.

Stay out of this machine.

1.23 SAFETY Safety Signs 9.

8.

WARNING

WARNING

44787-24340

44787-24330

WARNING

WARNING

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

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

Keep flames and sparks away.

Allow system to cool and vent pressure slowly before servicing.

Vent area before servicing.

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.

1.24 SAFETY Safety Signs 12.

10.

WARNING

WARNING

44787-24440

44787-24320

WARNING

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

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

- Do not start engine by shorting across starter terminals.

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

- 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.

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

13.

11.

CAUTION

WARNING

44787-24370

44787-24460

CAUTION You may fall from here.

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

Do not step on here.

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

1.25 SAFETY Safety Devices

Safety Devices

Control Lever Lock for Quick Coupler Lock Pin [3rd spool valve specification (option)]

Loading Control Lever Lock

DANGER

DANGER

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

During operation if operator accidentally move the control lever for the quick coupler lock pin, the lock pin moves accordingly, as a result there will be a possibility that the attachment falls. It causes serious injury or death.

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

Unless the hydraulic source to the attachment is needed on the machine equipped with the 3rd spool valve, make sure to lock the control lever (attachment lever) for the quick coupler lock pin.

This device prevents the attachment from falling in the following working condition.

When the attachment with no hydraulic source needed is installed on the 3rd spool valve specification machine, during operation if operator moves the control lever (attachment lever) for quick coupler lock pin, as a result the attachment falls.

Lock

Unlock

60ZV 3701b

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

Unlock Lock

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

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

65ZVUS3121Lc

Lock: 1. Place the control lever (attachment lever) for the quick coupler lock pin in the neutral position.

2. Loosen the screw for the lock plate.

3. Slide the lock plate to lock the control lever.

4. Tighten the screw to fix the lock plate.

1.26 SAFETY Safety Devices Unlock:

Articulation Stopper

1. Loosen the screw for the lock plate.

2. Slide the lock plate to unlock the control lever.

3. Tighten the screw to fix the lock plate.

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

60ZV 3652L

1. Align the front and rear chassis straight ahead.

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

3. Remove the clip pin and pin from the bracket on the rear chassis.

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

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

1.27 SAFETY Safety Devices

Parking Brake Lever

To unlock:

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

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

"STORED" position

60ZV 3652

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

2. Turn the link to the front chassis bracket.

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

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

Parking brake prevents the machine from accidentally moving when it is parked. When the parking brake lever is pulled up, the transmission is disengaged.

IMPORTANT Running machine with parking brake engaged may cause rapid brake pad wear and loss of parking brake force.

- Stop machine before engaging parking brake.

- Release parking brake lever when operating machine.

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.

Parking brake lever

60ZV 3701b

- Fully pull up the parking brake lever to engage the parking brake.

- Press the lever button and push down the parking brake lever to disengage the parking brake.

This will allow the transmission to re-engage.

1.28 SAFETY Safety Devices

ROPS (Roll Over Protective Structure)

WARNING Operating with damaged or improperly mounted ROPS could 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 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.

2.1

2.OPERATION

2.2 COMPONENT NAME/LOCATION

COMPONENT NAME/LOCATION 23

5

16

21

22

9

11

4

3 2 1

20 60ZV2 US COMPO

14

18

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

13 6

17

8

19 15 7

10

12

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

2.3 OPERATOR'S AREA Pedals and Levers

OPERATOR'S AREA Pedals and Levers

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

2

- Push the lever forward to move the machine forward.

10

1

3 7

9

8

60ZV5266

5

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

- Pull the lever backward to move the machine backward.

- The three forward and three reverse speeds shifting modes are selected by rotating the shift lever.

6

4

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

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

11

60ZV 3701c

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

2.4 OPERATOR'S AREA Pedals and Levers

3. High-Low Beam Lever / Turn Signal Lever (option)

4. Loading Control Lever Loading control lever is used to control the boom and attachment movement.

(b) (a)

(c) (d)

60ZV0003

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

- Lift the lever to turn the front lights (hi-beams) on momentarily (Flash position).

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

An indicator lamp on the panel will be turned on.

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

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

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

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

60ZV 3701b

(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 and bucket or attachment will stop 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 2.68.

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

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

2.5 OPERATOR'S AREA Pedals and Levers

5. Auxiliary Attachment Control Lever (option)

(e) (c)

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

(f)

(c) (a) (b) 60ZV 3701b

(e) Dump - Move the lever to right. The bucket or attachment will dump. (f) Roll Back - Move the lever to left. The bucket or attachment will roll back.

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

- For adjustment procedure refer to "Bucket / Attachment Leveler Adjustment" page 2.67.

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.

60ZV 3701c

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

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

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

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

2.6 OPERATOR'S AREA Pedals and Levers

6. Wrist Rest (adjustable)

7. Accelerator Pedal

60ZV 3701b

60ZV5266

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

Accelerator pedal is used to control the engine speed.

(High/Low) Unlock the lever to adjust the position.

- Step on the pedal to increase the engine speed.

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

- 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, step on one of the brake pedals or turn the starter switch to the "OFF" position.

2.7 OPERATOR'S AREA Pedals and Levers

8. Right Brake Pedal 9. Left Brake Pedal (Declutch Pedal)

the "ON" position. When the switch is "ON", a green indicator lamp on the dash will also be turned on.

CAUTION

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

- Do not use brake pedals as foot rest.

- Do not ride brakes.

- Use brake pedals only when applying brakes.

- Do not allow dirt and debris to build up around the pedals.

- Be sure the brake pedals move freely before using the machine.

60ZV5266

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

Right Brake Pedal: Applies the brakes only.

Left Brake Pedal (also called Declutch Pedal): May be used either of the following ways: 1. As a brake only pedal by turning the 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 declutch switch to

Declutch feature momentarily places transmission in neutral, which may allow machine to roll when on a grade.

Be sure to turn off declutch switch when operating on a grade.

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

2.8 OPERATOR'S AREA Pedals and Levers

10. Steering Column Telescopic Tilt Handle

11. Loading Control Lever Lock

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

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

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

Lock

Unlock

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

60ZV 3701b

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

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

- To unlock, push down the lock lever backward.

Release

Lock

97ZVOM0045

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

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

2.9 OPERATOR'S AREA Switches

Switches

4

6 7

15 10

8

20 30

20

40

5 0

0 0 0 0 0 0 1/10h

AUTO

5

N C

25

H

E

F

10 50

0 km/h

30

MPH

STOP

60ZV2 USA 0001

9 1 11

2

12

13 3

60ZV0004a

1. Starter Switch 2. Light Switch 3. High-Low Beam Lever / Turn Signal Lever (option) 4. Front Working Light Switch (Included in cab spec.) (option) 5. Rear Working Light Switch / Cab Rear Working Light Switch (option) 6. (FE) Fuel Efficient Mode Switch 7. Declutch Switch

10

60ZV 3701b

8. Ride Control Switch (option) 9. Four-Way Flasher Switch (option) 10. Downshift Button 11. Front Wiper Switch (Included in cab spec.)

12. Rear Wiper Switch (Included in cab spec.) (option) 13. 12 Volt Power-outlet Socket

2.10 OPERATOR'S AREA Switches

1. Starter Switch

PREHEAT

OFF

2. Light Switch

ON

START OFF

65ZV0074

OFF - Key can be either inserted or pulled out.

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

ON - Current flows to all circuits.

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

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

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

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

60ZV 5263

This is a three position switch.

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

2.11 OPERATOR'S AREA Switches

3. High-Low Beam Lever / Turn Signal Lever (option)

4. Front Working Light Switch (Included in cab spec.) (option)

Low beam position

60ZV2 USA 0002

High beam position

60ZV0003

OFF

This lever is used to change the head lights beam high and low, and to flash the dead lights. This lever also turns on the turn signals (option).

ON

- Lift the lever to turn the front lights (hi-beams) on momentarily (Flash position).

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

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

60ZV0003

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

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

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

switch-4

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

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

2.12 OPERATOR'S AREA Switches

5. Rear Working Light Switch / Cab Rear Working Light Switch (option)

6. (FE) Fuel Efficient Mode Switch

60ZV2 USA 0002 60ZV2 USA 0002

OFF OFF

ON ON

switch-3 switch-4

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

Engine Torque

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

Power Mode FE Mode

Engine Speed 90ZV2 5001

The operator can select either "Power" or "Fuel Efficient" (FE) engine mode.

Power mode provides added power for extreme applications.

Fuel efficient mode offers better fuel economy for standard applications.

When this switch is turned "ON" the switch lamp lights up and the engine power is reduced to provide better fuel economy.

2.13 OPERATOR'S AREA Switches

7. Declutch Switch

8. Ride Control Switch (option)

60ZV2 USA 0002

60ZV2 USA 0002

OFF

OFF

ON

ON

switch-3

Declutch switch is used to change the function of the left brake pedal.

Normally this switch should be "ON".

OFF - When a brake pedal is step on, the service brakes are engaged and the transmission directional clutch remains engaged. (brake only) ON - When the left brake pedal is step on, the service brakes are engaged and the transmission directional clutch is disengaged (brake and declutch).

The right pedal does not engage declutch.

Refer to "Left Brake Pedal (Declutch Pedal)" page 2.7 for the function of the left brake pedal.

CAUTION Declutch feature momentarily places transmission in neutral which may allow machine to roll when on a grade.

Do not turn declutch switch to "ON" when operating on a grade.

switch-3

When the ride control switch is ON, the ride control works. Refer to "Ride Control (option)" page 2.37.

2.14 OPERATOR'S AREA Switches

9. Four-Way Flasher Switch (option)

50ZV5012

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.

10. Downshift Button

60ZV 3701b

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

- When operating the machine in 2nd speed with the shift lever in [2] position, the transmission will shift down to 1st gear by pressing downshift button.

- Pressing downshift button again or the machine speed is more than 4 km/h (2.5 MPH) the transmission releases the 1st gear setting to return to 2nd gear.

2.15 OPERATOR'S AREA Switches

11. Front Wiper Switch (Included in cab spec.)

12. Rear Wiper Switch (Included in cab spec.) (option)

60ZV0004

60ZV0004

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

OFF

Rear wiper switch is used to wipe the rear windshield.

INT LOW HIGH

OFF

ON

PUSH

PUSH

OM0190

OM0189

OFF

:

OFF

:

INT

: Intermittent

ON

: Low speed

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

PUSH : Spraying solvent on the windshield

2.16 OPERATOR'S AREA Switches

13. 12 Volt Power-outlet Socket

12V PUSH

50ZV03126-0340

This is a power-outlet for 12 Volt. When using open the socket cap and insert a plug into the socket.

2.17 OPERATOR'S AREA Indicators

Indicators 1

19

20

4

16 18

17

21

8

3 9 10

15 10

20

40

5 0

AUTO

20 30

0 0 0 0 0 0 1/10h

11

N C

25

H

E

F

10 50

0 km/h

12

30

MPH

13 STOP

14 60ZV2 USA 0001

24 23 22

5

1. Speedometer 2. Engine Coolant Temperature Gauge 3. Fuel Level Gauge 4. Parking Brake Indicator Lamp (red) 5. Declutch Lamp (green) 6. Working Light Indicator Lamp (green) 7. Preheat Indicator Lamp (orange) 8. Central Warning Lamp (red) 9. MCU (Machine Control Unit) Warning Lamp (red) 10. Brake Oil Warning Lamp (red) 11. Engine Oil Pressure Warning Lamp (red) 12. Engine Coolant Temperature Warning Lamp (red) When the starter switch is turned to "ON", all warning lamps (8) ~ (15) and (22) light up for three seconds. This is the lamp (bulb) test period (lamp (15) lights up until engine starts).

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

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

7

6

15

2

13. Torque Converter Oil Temperature Warning Lamp (red) 14. Air Cleaner Warning Lamp (red) 15. Charge Lamp (red) 16. Turn Signal Indicator Lamp (Left) (green) 17. Turn Signal Indicator Lamp (Right) (green) 18. High Beam Indicator Lamp (blue) 19. Auto Shift Indicator Lamp 20. Neutral Indicator Lamp 21. Hour Meter 22. Secondary Steering Warning Lamp (red) (option) 23. Ride Control Indicator Lamp (green) (option) 24. Engine Warning Lamps

2.18 OPERATOR'S AREA Indicators

1. Speedometer

3. Fuel Level Gauge

15 10

20

30 40

5 0

E

20

F FUEL

25

10 50

0

30

km/h

MPH

65ZV0005 60ZV0005

Indicates the fuel amount in the fuel tank.

Indicates the machine ground speed in km/h and MPH.

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

2. Engine Coolant Temperature Gauge

4. Parking Brake Indicator Lamp (red)

C

P

H WATER TEMP

OM0052

97ZVOM0049

Indicates engine coolant temperature. It is normal when the indicator stays in the white zone (67~102ºC (153~216ºF)).

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

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.

5. Declutch Lamp (green)

- 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 3.49.

OM0054

Lights up when the declutch switch is "ON".

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

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

2.19 OPERATOR'S AREA Indicators

6. Working Light Indicator Lamp (green)

9. MCU (Machine Control Unit) Warning Lamp (red)

OM0057

OM0055

Lights up when working lights are on.

Lights up when MCU malfunction.

7. Preheat Indicator Lamp (orange)

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

10. Brake Oil Warning Lamp (red)

OM0176

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

8. Central Warning Lamp (red)

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

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

Lights up when brake oil level is lower than the specified or brake oil pressure in the front and rear circuits differ more than 1.5 MPa (210 psi).

The warning buzzer sounds when this lamp lights up.

OM0056

Lights up when any of the warning lamps come on.

OM0058

- If it lights up while operating, IMMEDIATELY stop the machine and check for leaks in the brake circuit.

- Refill the brake oil reservoir as needed.

Refer to "Check Brake Oil Level" page 2.41.

2.20 OPERATOR'S AREA Indicators

11. Engine Oil Pressure Warning Lamp (red)

13. Torque Converter Oil Temperature Warning Lamp (red) Lights up when transmission oil overheats. (Over 120±5ºC (248±9ºF))

OM0059

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

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

Refer to "TROUBLESHOOTING" page 3.49.

12. Engine Coolant Temperature Warning Lamp (red)

OM0061

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

- If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "TROUBLESHOOTING" page 3.52.

14. Air Cleaner Warning Lamp (red) OM0060

Lights up when coolant temperature overheats.

(Over 101ºC (214ºF)) - If it lights up while operating, slow the engine speed down to mid-range, shift to neutral, and wait until the lamp goes out. Check the coolant temperature gauge before resuming operation.

- If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "TROUBLESHOOTING" page 3.49.

CAUTION Hot coolant spray may cause burns.

Never open radiator cap when engine is hot.

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

OM0062

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 "Clean or Replace Air Cleaner Element" page 3.10.

2.21 OPERATOR'S AREA Indicators

15. Charge Lamp (red)

18. High Beam Indicator Lamp (blue)

OM0063

Lights up when alternator charge level is low.

OM0067

Lights up when headlights are switched to high beam.

- If it lights up, check the charging circuit.

Refer to "TROUBLESHOOTING" page 3.50.

19. Auto Shift Indicator Lamp 16. Turn Signal Indicator Lamp (Left) (green)

AUTO OM0068

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

OM0065

Flashes when the turn signal switch lever is moved forward.

20. Neutral Indicator Lamp

N

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

OM0069

Lights up when transmission is in neutral.

OM0066

21. Hour Meter Flashes when the turn signal switch lever is moved rearward.

0 0 0 0 0 0

1/10h OM0205

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

2.22 OPERATOR'S AREA Indicators

22. Secondary Steering Warning Lamp (red) (option)

24. Engine Warning Lamps Engine stop lamp

STOP OM0072

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

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

Red

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

OM0206

Yellow

Lights up when the ride control switch is ON. Refer to "Ride Control (option)" page 2.37.

OM0191

OM0192

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.

2.23 OPERATOR'S AREA Seat

Seat

Mechanical Suspension (If so equipped)

Seat Adjustment

- With seat pushed back half-way for easier access 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.

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.

1

2 Seat Belt

6 5

Tether

4

3

Air Suspension (If so equipped) - With the key turned "ON" push the knob (same location as 5) to increase the air pressure. This will raise the seat and make a firmer ride. Pull the knob 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.

70ZV0017

Forward / Backward Armrests - 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 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 handle (4) to the stop position. While holding handle (4) up, raise or push down on seat. Release handle (4) at one of three positions.

- Lift handle (6) and move the seat forward or backward.

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

2.24 OPERATOR'S AREA Seat

Seat Belt

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

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

- Always fasten seat belt when operating machine.

- 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.

OM0007

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.

2.25 OPERATOR'S AREA Electrical Protection

Electrical Protection

(1)

Fuse Boxes

2 1

(2) For the cab (option)

LIGHTING HEAD LIGHT

20A

SPARE

5A

R. WORK LIGHT

15A

SPARE

5A

BOOM KICKOUT BUCKET LEVELER

10A

R. WIPER / WASHER

5A

BACK LAMP STOP LAMP TURN SIGNAL

15A

F. WIPER / WASHER

10A

MCU (MACHINE)

10A

SPARE

10A

F. WORK LIGHT

15A

DC-DC CONVERTER

10A

AIR SUS SEAT (OPTION)

10A

RADIO

3A

SPARE

15A

SPARE

10A

SPARE

15A

SPARE

10A

4 WAY FLASHER HORN DOME LAMP RADIO BACK UP

15A

SPARE

5A

SPARE

10A

SPARE

5A

PREHEAT

15A

AIRCON (OPTION)

5A

BUZZER MONITOR

5A

AIRCON (OPTION)

20A

NEUTRAL RELAY

5A

AIRCON (OPTION)

20A

BATTERY RELAY ECM (ENGINE)

5A

SPARE

20A

60ZV 3684

3 60ZV2 9214

Main Fuse Boxes are located in the right hand side console and contain thirty fuses. Additional fuse box (3) is located in the engine compartment on the left hand side of the machine. It contains one fuse.

(3) ECM (ENGINE)

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.

30A

2.26 OPERATOR'S AREA Electrical Protection

Fusible Link Fusible link protects the main hot wire from short circuits.

60ZV2 9214

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

Fuse damaged

Problem (symptom) During engine operation

During engine stop

30A

- Engine will stop auto- - All the electrical circuit matically. will not function.

- All the power for all - Engine can not be electrical circuit will be started.

OFF.

70A (1)

- Horn [and opt. flasher] - The same conditions will operate. as "During engine - All the others will not operation" but engine operate and the can be started and machine can not be stopped. operated.

- Engine will not stop automatically but can be stopped with starter switch OFF.

70A (2)

- The machine can be - The same conditions operated but the batas "During engine teries can not be operation". charged and the batteries will be discharged soon.

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.

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

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

14

15

16

20

9 10 11

clarion

AM

ON OFF VOL

SLEEP

PUSH

AM/FM CASSETTE COMBINATION

CD

1

ST AUDIO MODE

2

ALARM

TIMER

TAPE

CD

AM FM

3

6

7

1 4

3

REW APC

5

6

SCAN

FF APC

DISP PS AS

M

H TUNE

RadioCassetteUSA

5

4 17

18

19

8

13

12

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

Symbol

Name of part Volume knob

Function

Operation method

Description

Turning power on/ off

PUSH

Push this SW to turn the power on or off.

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

Sleep timer

PUSH with ACC turned off

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

Sound volume adjustment MIN

Sound balance adjustment

MAX

Selected with audio mode button

1 L

Fader adjustment

R

Selected with audio mode button

REAR FRONT

Sound tone adjustment

Selected with audio mode button

Use this adjustment knob to adjust the sound volume.

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

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

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

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

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

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

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

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

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

CUT BOOST

MODE Audio mode button 2

Audio mode switching

PUSH

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

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

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

Remarks

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

Symbol

Name of part

Function Turning alarm ON/ OFF

Alarm button

3

PUSH

Alarm setting: Setting clock on the hour

Switching timer ON/ OFF One-touch timer button

Operation method

PUSH

Timer setting

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

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

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

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

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

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

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

4

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

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

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

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

The timer mark continues to light while the timer works.

TAPE 5

TAPE button CD

6

CD button

Cassette tape play/ stop

PUSH

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

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

CD changer play/stop

PUSH

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

The CD Changer is optional and not normally supplied.

Remarks

Alarm mark

Timer mark

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

Symbol

Name of part AM/FM

7

AM/FM band selector button

PS AS

Function

Operation method

Description

Band switching Turning on radio Setting clock on the hour

PUSH

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

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

Preset scan in radio mode

PUSH

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

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

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

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

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

Radio store button Auto store in radio mode

PUSH

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

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

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

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

Program scan in cassette tape mode

PUSH

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

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

Program scan in CD mode

PUSH

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

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

CD Changer is an option and is not normally offered.

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

8

Remarks

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

Symbol

Name of part

Function

Operation method

Description

Cassette tape ejection

PUSH

Push this button to eject the cassette tape.

This can be performed even with ACC off.

Display change

PUSH

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

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

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

Radio scanning

PUSH

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

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

9 Eject button DISP Display button

10

SCAN 11

SCAN button

Remarks

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

Symbol

Name of part

Function Manual tuning in radio mode

Operation method PUSH Upward

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

Downward Tuning button

for 0.5 sec. or less Seeking in radio mode

12

PUSH Upward Downward

13 for 0.5 sec. or less PUSH Downward

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

PUSH Upward

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

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: REW

PUSH

Push the button to rewind the cassette tape.

In CD mode: DISC DOWN

PUSH

Push the button to go down to the previous disc.

(Recalling the previous disc.)

In clock time setting mode "Hour" setting "Minute" setting

1

REW

Preset 1

14

REW button

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

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

Remarks

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

Symbol

Name of part 2 PRO Preset 2 Program button

15

3

FF

Preset 3 FF button 16

4

APC

Preset 4 APC button

Function

Operation method

Description

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: Program

PUSH

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

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

In CD mode: DISC UP

PUSH

Push the button to go to the next disc.

(Recalling the next disc.)

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: FF

PUSH

Push the button to wind forward the cassette tape quickly.

In CD mode: DISC UP

PUSH

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

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: APC REW

PUSH

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

In CD mode: TRACK DOWN

PUSH

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

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

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

17

REVIEW

Remarks

No beep sounds

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

Symbol

Name of part

5

18

Preset 5 Dolby button

6

APC

Preset 6 APC button

19

Function

Operation method

Description

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: Turning on/ off

PUSH

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

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: APC FF

PUSH

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

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

In CD mode: TRACK UP QUE

PUSH

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

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

No beep sounds

Auto metal

20

Tape insertion slot

Cassette tape insertion slot

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

21

LCD indicator

indicator

Displays time, frequency, etc.

Beep tone (guide tone)

Remarks

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

(Approx. 2 KHz, 50 ms)

2.35 OPERATOR'S AREA Heater or Air Conditioner (option)

Heater or Air Conditioner (option)

Switches Manual Heater Control

Ventilation Location and Mode 3

3

3

3 1

1

1 2

4

3

2 4

4 BERGSTROM H

4

4 Manual Combo Control 70ZV0014

VENT MODE

1

2

3

—

— —

—

: Open — : Close

1

2

—

3

4 BERGSTROM AC

—

— —

4

1. Mode Control 2. Heat/AC Control 3. Temperature Control 4. Blower Control

2.36 OPERATOR'S AREA Heater or Air Conditioner (option) Front Panel Controls Blower Control Turn the control fully counter clockwise to turn off the blower, or adjust the blower to the desired speed.

Temperature Control Adjusts the output temperature. This output is used to control the position of the water valve.

Heat/AC Control On the Combo control it enables/disables the AC function.

Air conditioner on Air conditioner off Mode Control Provides the signal to Adjust the mode doors to direct the air flow.

Panel Mode Provides air flow through door 1.

Bi-Level Mode Provides air flow through door 1 and 2.

Floor Mode Provides air flow through door 2.

Mix Mode Provides air flow through door 2 and 3.

Defrost Mode Provides air flow through door 3.

2.37 OPERATOR'S AREA Ride Control (option)

Ride Control (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 is installed.

Operation and Function

STOP

1

2

60ZV2 USA 0003

OFF

ON

switch-3

1. Before start the travelling machine, turn ride control switch (1) ON. Ride control pilot lamp (2) comes to ON. 2. Move the machine forward.

The ride control functions automatically when the machine travelling speed reaches more than 7 km/h (4.3 MPH).

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

2.38 OPERATION Check before Operation

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

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

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

What to Look for

Bucket / Attachment

Damage, missing bolts, leaks, and excessive wear

Bucket Control Linkage

Damage, missing bolts, excessive wear, and looseness

Lights

Broken bulbs, wires or lenses

Radiator Fins

Trash and dirt build-up

Cooling System

Leaks and trash build-up

Batteries

Loose terminals, dirt build up on top of the batteries

Steps and Handrails

Damage and cleanliness

Differentials (front and rear)

Leaks

Hydraulic System

Leaks

Final Drive (front and rear)

Leaks

Covers and Guards

Damage or missing

Transmission

Leaks

Instrument Panel

Broken gauges or indicator lights

Brake Lines

Damage and leaks

Engine Compartment

Leaks, debris build-up and flammable materials left

Seat belt restraint

Within date of expiration, loose seat or belt mounting bolts, worn or damaged belt, operation of seat belt retractor and buckle

Date:

Model-S/N:

Hours:

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

Inspector:

2.39 OPERATION Check before Operation

Greasing

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.

CAUTION Hot engine oil and components may cause burns.

Avoid contact with hot oil or engine components.

Lubricate until fresh grease is seen at each joint. Immediately replace or report any broken or defective grease fittings.

Refer to "Recommended Lubricants" page 3.46 for the correct grease.

Fill cap

Check

60ZV2 9197

60ZV2 9209

- Axle support (two places)

H (High)

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.

L (Low) OM0216

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

2.40 OPERATION Check before Operation 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 3.30.

NOTE Wait about fifteen 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

Check Hydraulic Oil Level

CAUTION Pressurized hydraulic tank is used for this machine.

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

Relieve all pressure by pressing down the filler cap.

Filler cap

Improper oil level may damage engine.

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

Check Level

Add or drain oil to keep proper oil level.

60ZV 5280

1. Lower the attachment to the ground.

2. Stop the engine.

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

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

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

Refer to "Recommended Lubricants" page 3.46 for the suitable viscosity of the oil according to the ambient temperature and oil type.

2.41 OPERATION Check before Operation

Check Engine Coolant Level

Check Brake Oil Level

CAUTION

WARNING

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

Lack of brake oil can cause loss of braking which could result in death or serious injury.

Avoid contact with skin and eyes to prevent injury.

If oil level drops quickly, check brake piping for leaks, and add proper oil.

FULL MAX

MIN LOW

60ZV2 9203

60ZV2 9202

1. Check the coolant level in the radiator subtank.

1. Check the brake oil level in the brake oil reservoir using the sight gauge.

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

2. It is normal if the oil level is near to "MAX" when machine is cold.

3. If needed, add the required amount of the coolant to the radiator sub-tank.

3. If needed, add required amount of the same brand oil as originally filled.

Refer to "Recommended Lubricants" page 3.46 for the suitable oil.

Refer to "Coolant Specification" page 3.48 for the correct mixture.

4. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 3.14.

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

WARNING Using wrong brake oil (vegetable oil, DOT 3 brake fluid, etc.) can cause loss of braking which could result in death or serious injury.

Use only brake oil as recommended in section "Recommended Lubricants" page 3.46.

2.42 OPERATION Check before Operation

Drain Water and Sediment from Fuel Filter

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 exchange it for new one.

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

60ZV2 9195

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

- Open the bleeder plug on the top of the fuel prefilter by using TORX T45 or 7/32 in hex (Allen) wrench.

- Dispose of the drained water and sediment properly.

CAUTION Escaping fuel is flammable and harmful to skin.

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

- Do not drain with engine running.

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

2.43 OPERATION Check before Operation

Articulation Stopper

Check Tire for Damage, Air and Tread Depth

60ZV 3652 OM0032

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

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

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

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

WARNING Overheated tire could explode causing serious injury or death.

If overheated tire is suspected, do not approach tire to distance of less than 15 m (50 ft).

Stay away until tire and rim cool down.

WARNING Serious injury may result from tire failure due to underinflation/overloading or excessive speed.

- Consult your tire dealer or Kawasaki dealer.

2.44 OPERATION Check before Operation

Tread Low Pressure

OK

High Pressure Side walls

Breakers Carcass

65ZV0008

Beads / Bead wire

OM0104

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

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

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

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

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

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

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

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

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

- Tire layers are separated.

- Radial cracks reach the carcass.

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

2.45 OPERATION Check before Operation

Check Drive Belt

Check Crankcase Breather Tube Inspect the crankcase breather tube for sludge or debris on or in the tube.

CAUTION Contact with moving belt or pulleys may cause injury.

Stop engine before opening engine access 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 access panel.

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

OK OK

OM0099

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

Inspect the tube more frequently in icy conditions.

2.46 OPERATION Check before Operation

Check Air Intake System

Check Cooling Fan

CAUTION Hot engine components may cause burns.

Avoid contact with hot engine components.

OK

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

OK OM0102

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

2. Open the engine rear grill.

3. Visually inspect the cooling fan for damage.

60ZV2 04063-0077

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.

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.

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

2.47 OPERATION Check before Operation

Check Horn Operation

Check Monitor Panel Operation

1. Push the horn button in the center of the steering wheel.

1. Turn the starter switch to the "ON" position.

2. The horn should sound loudly.

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

ROPS (Roll Over Protective Structure) (option)

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

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 mounting bolts.

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

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

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

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

4. The indicator lamps (green or blue) should come on respectively.

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

Refer to "Indicators" page 2.17.

Check Control Lever - Make sure the loading control lever is in the "HOLD" position. The levers should return to the "NEUTRAL" or "HOLD" position smoothly and naturally.

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

Check Seat Belt Restraint Check the following items.

- Within date of expiration - Loose seat or belt mounting bolts - Worn or damaged belt - Operation of seat belt retractor and buckle

2.48 OPERATION Starting the Engine

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

PREHEAT

OFF

ON

START

- Do not start engine by shorting across starer terminals.

- Do not start engine while standing on ground.

65ZV0075

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

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

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

Normal Start (Ambient temperature above 0ºC (32ºF))

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

1. Do not step on the accelerator pedal.

PREHEAT

OFF

ON

- The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "TROUBLESHOOTING" page 3.49.

START

IMPORTANT Low engine oil pressure may cause severe engine damage.

65ZV0076

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

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

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

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

Be sure engine oil pressure warning lamp goes out quickly.

2.49 OPERATION Starting the Engine

Cold Start

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

(Ambient temperature below 0ºC (32ºF)) 1. Do not step on the accelerator pedal.

PREHEAT

OFF

ON

- The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "TROUBLESHOOTING" page 3.49.

START

IMPORTANT Low engine oil pressure may cause engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

65ZV0077

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

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

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

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

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

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

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

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

2.50 OPERATION Check after Starting the Engine

Check after Starting the Engine

Check Warning Lamps

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

1. Check the warning lamps on the instrument panel.

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

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

IMPORTANT

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

Do not idle the engine for excessively long periods of time.

Long periods of idling (more than 10 minutes) can damage an engine because combustion chamber temperatures drop so low the fuel can not burn completely.

This will cause carbon to from in the injector spray holes and on the piston rings and can result in stuck valves.

2.51 OPERATION Check after Starting the Engine

Check Fuel Level

Check Transmission Oil Level

DANGER

E

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

Crushing will result in serious injury or death.

F FUEL

65ZV0005

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

When checking oil level: - Low attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

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

- Make sure nobody is on machine.

Check and Fill Tube

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

Refer to "Recommended Lubricants" page 3.46 for the proper fuel.

60ZV 5247

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.

"LOCKED" position

60ZV 3652L

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

Refer to "Articulation Stopper" page 1.26.

2.52 OPERATION Check after Starting the Engine 3. Check the oil level with engine at low idle.

Check Service Brake Operation Before testing be sure the area behind the loader is clear.

In hot

In cold

1. Turn "OFF" the declutch switch.

2. Firmly step on the right hand brake pedal.

Specified oil level

3. Release the parking brake.

4. Select the transmission shift lever 2nd and FORWARD. 97ZVOM0107

5. Slowly accelerate the engine to full speed.

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

6. The machine should not move.

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

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

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

Do not overfill.

Do not operate until problem has been corrected.

Refer to "Recommended Lubricants" page 3.46.

IMPORTANT

Check Parking Brake Operation

WARNING

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

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

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

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

4. Pull up the parking brake switch.

3. Stop the machine with the service brake.

5. Release the service brakes.

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.

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.

2.53 OPERATION Check after Starting the Engine

Check Steering Wheel Operation

Check Exhaust Gas

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.

Check Back-up Alarm Operation 60ZV 3712a

1. Apply the service brakes.

2. Release the parking brake.

3. Move the shift lever 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 3.50.

2.54 OPERATION Check after Starting the Engine

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.

- Turn parking brake switch to "ON".

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

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

2.55 OPERATION Operating the Machine

Operating the Machine

Starting the Machine

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

Do not stop engine while machine is moving.

WARNING

approx. 40 cm (16 in) OM0016

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

Be sure area is clear of personnel and obstructions.

IMPORTANT

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

2. Step on the brake pedal.

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

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

Do not operate machine on a grade over 30º.

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

60ZV5266

5. Release the brake pedal then step on 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 step on brake pedal before releasing parking brake.

2.56 OPERATION Operating the Machine

Starting the Machine on a Grade

Speed and Direction Change

1. Turn "OFF" the declutch switch.

2. Step on the left brake pedal.

60ZV0002a

60ZV5266

1. Select the proper gear shifting mode by rotating the transmission shift lever. Refer to the following tables on page 2.57 for the gear selection mode.

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

60ZV0002

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

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

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

2.57 OPERATION Operating the Machine

60ZV 3701b

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

4. Pressing the downshift button again or the machine speed more than 4 km/h (2.5 MPH) automatically returns to the 2nd gear from the 1st gear.

Refer to "Downshift Button" page 2.14.

Lever Position

Selected Gear

Operating Condition

[1]

1st

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

[2]

2nd

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

[3]

3rd

Carrying or roading

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

Use proper gear for each job.

2.58 OPERATION Parking

Parking

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

60ZV0017

WARNING

60ZV 3701b

4. Apply the parking brake.

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

Park machine in safe place on firm level ground.

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

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

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

N

60ZV5266

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

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

2.59 OPERATION Stopping the Engine

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

Do not stop engine while machine is moving.

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

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

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

PREHEAT

OFF

ON

START

65ZV0074

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

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

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

Prevent unauthorized operation.

When leaving machine for extended period of time, remove the starter key, lock cab doors (if equipped).

2.60 OPERATION Operating Techniques

Operating Techniques

Loading

IMPORTANT Machine damage may result from improper loading procedures.

- Do not dig or scoop with machine frame articulated.

- Do not drive machine into material at high speed.

30º Max. OM0194

IMPORTANT

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

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

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

Do not operate machine on a grade over 30º.

OM0111

1. Move the machine forward to the material.

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

OM0113

3. Lower the bucket parallel to the ground.

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

OM0112

OM0114

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

Reduce wheel slippage by slightly reducing engine speed.

OM0115

6. Move the loading 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 loading control lever to the "Roll Back" position.

8. When the loading control lever is released from the "Roll Back" to the position and the boom will rise.

9. Reverse the machine.

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

2.62 OPERATION Operating Techniques

Excavating

Dozing

1. Move the machine forward to the material.

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

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

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

Keep bucket or attachment bottom parallel to ground.

OM0119

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

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

Increase engine speed as the bucket digs deeper.

OM0120

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

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

OM0123

2.63 OPERATION Operating Techniques

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

OM0123

OM0121

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

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

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

Be sure to run machine backward when leveling ground.

OM0122

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

2.64 OPERATION Operating Techniques

Carrying

Dumping into Truck or Hopper

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

Do not make quick turns or abrupt braking when boom is raised. approx. 40 cm (16 in) OM0016

Keep boom low for best stability especially on slopes.

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

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

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

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

IMPORTANT

Refer to "Loading" or "Excavating" page 2.60, 2.62 for the loading procedure.

When carrying material over 450 m (500 yd) at high speed, tire overheating may occur.

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

OM0116

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

2. Use the declutch switch in the "ON" position if working on a level site.

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

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

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

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

Refer to "Boom Kickout Adjustment" page 2.68 for adjustment of the preset height.

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

OM0195

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

OM0196

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

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

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

2.66 OPERATION Operating Techniques

Typical Truck Loading Methods

T Cycle Operation

I Cycle Operation

OM0126

OM0124

This method is recommended where the working area is limited.

V or L Cycle Operation (L-cycle)

(V-cycle)

OM0125

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

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

2.67 SPECIAL PROCEDURES Adjustments

SPECIAL PROCEDURES Adjustments Bucket / Attachment Leveler Adjustment

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

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

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

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

4

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

Use safe sturdy platform to reach bucket leveler adjustment.

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

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

3 5±2 mm (1/8~1/4 in) OM0128

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

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

2 1 60ZV0007

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

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

5. Tighten bolts (1).

2.68 SPECIAL PROCEDURES Adjustments

Boom Kickout Adjustment 1

2

Adjustable

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

3

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

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

60ZV0008

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 loading control levers in the "Hold" position using the loading control lever lock.

7. Tighten 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 loading control lever to the "Raise" detent position to raise the boom.

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

3

2 5±2 mm (1/8~1/4 in) OM0128 OM0031

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

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

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

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

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

2.69 SPECIAL PROCEDURES Roading / Special Applications

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

If overheated tire is suspected during operation or servicing, do not approach tire to distance of less than 15 m (50 ft).

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 such as engine and transmission / torque converter may become extremely hot causing an explosion, early wear, or damage. 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 observed. Consult a tire dealer for the speed limit of the tires involved.

- Carefully watch the engine coolant temperature gauge and the torque converter oil temperature gauge on the operation panel not to exceed the white zone on them.

- After traveling a distance, 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.

2.70 SPECIAL PROCEDURES Booster Batteries / Jumper Cables

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

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

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

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

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

- Keep flames and sparks away from batteries.

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

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

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

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

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

2. Raise and lock the battery box covers.

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

+

+ -

Booster Batteries

-

+

+

-

Batteries being boosted

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

Rear chassis close to starter motor ground being jump started

It could shorten battery life or the battery could explode.

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

Keep the battery electrolyte level in the proper level.

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

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

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

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

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

OM0131

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

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

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

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

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

2.71 SPECIAL PROCEDURES Booster Batteries / Jumper Cables 11. Start the machine being boosted as described on "Starting the Engine" page 2.48.

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

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

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

2.72 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

60ZV 5312

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. 10 km/h) (6 MPH) 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.

2.73 SPECIAL PROCEDURES Transportation

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

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

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

5. Lower the bucket and lock each control lever using the loading control lever lock (page 1.25).

6. Apply the parking brake and set the articulation stopper in the "LOCKED" position (page 1.26).

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

65ZV0010

OM0132

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

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.

Cables or Chains

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

Front

Rear OM0207

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

65ZV0009

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

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

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

IMPORTANT Brake pipe runs on axle housing.

Do not fasten axle housing.

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

2.75 SPECIAL PROCEDURES Long Term Storage

Long Term Storage

IMPORTANT

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

2. Lubricate every greasing point described in "Greasing" section page 3.18 and 3.25.

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

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

5. Store the machine indoors and keep it dry.

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

OM0028

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

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

Refer to "Coolant Specification" page 3.48 for the mixing ratio.

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

If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the OFF position, it can corrupt the ECM program, which can disable the engine.

Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

2.76 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.

60ZV 3688d

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

1. Check the following points.

Refer to "Check before Operation" page 2.38 and "Check after Starting the Engine" page 2.50.

-

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

2. Operate the machine as follows.

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

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

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

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

3. Operate the air conditioner (option) as follows.

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

60ZV 5280

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

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

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

Refer to "Replace Engine Oil and Oil Filter Cartridge" page 3.30 and "Replace Transmission Oil" page 3.35.

4. Start the engine and check for any abnormalities.

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

2.77 SPECIAL PROCEDURES Long Term Storage

Cautions on Battery Replacement or Battery Cable Removal When battery or battery cable is removed, follow the procedure below to avoid miss throttle operation by ECM.

PREHEAT

OFF

ON

START

PREHEAT

OFF

ON

START

65ZV0074

3. Turn the starter switch key to OFF position.

4. Start the engine and check the max. engine speed.

65ZV0075

1. Turn the starter switch key to ON position.

Step on → Release (2sec.)

⇓ Step on → Release (2sec.)

⇓ Step on → Release (2sec.)

65ZV2 03153-0026

2. Slowly step on the accelerator pedal to the full stroke position 3 times.

(Keep it at the full stroke position 2 seconds and release it)

IMPORTANT Fully step on the accelerator pedal to the full stroke position. If the pedal is not step on fully enough, it causes that the max. engine speed does not reach the standard figure.

2.78 SPECIAL PROCEDURES Welding

Welding Cautions Regarding Welding Repair Service

low-conductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod.

6. Calibrate throttle pedal to ECM. (a) Turn the starter switch to "ON". (b) Fully step on and release the throttle pedal three times. (c) Turn the starter switch to "OFF".

Example 1:

Section to be welded

Hydraulic cylinder Ground this section. (correct grounding)

Do not ground this section.

Electric current may flow through the cylinders.

135ZV0052

Plated section (Mask this section.)

Example 2:

135ZV0054

Section to be welded

Do not ground this section.

Electric current may flow through the cylinders.

Pin section with pin temporarily inserted

Ground this section. (correct grounding) 135ZV0053

If welding is needed to repair the chassis, observe the following precautions to protect the hydraulic cylinders, hydraulic units, gear sets, and electrical units from possible damage.

1. Turn the starter switch OFF. 2. Remove the battery terminals both positive and negative sides from the battery.

3. Disconnect the connector for MCU (machine controller), ECM (engine controller) and air conditioner.

4. Ground the welder near the section to be welded.

5. To ground the welder, check that the electric current will not flow through the cylinders.

Cylinder head covers for some models have a

Pin

Plated section (Mask this section.)

135ZV0055

7. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes.

Be sure to mask these units and parts before welding.

- Plated section Cover the plated sections with heat-resistant cloth, such as glass wool or canvas.

2.79 SPECIAL PROCEDURES Welding NOTE The weld spattered on the plated sections causes corrosion.

1 m or more

Scrap material, etc.

Section to be welded

1 m or more 135ZV0056

- Cover the hydraulic units, electrical units, harnesses, hydraulic hoses, nylon tubes, etc. with heat-resistant cloth (glass wool or canvas) or scrap material to protect them from spatter.

Section to be welded Hydraulic hose, Nylon tube, or Harness Chassis

Remove and if necessary wrap 135ZV0057

- Hydraulic hoses, nylon tubes, or harnesses are easily damaged by the heat during welding. To protect them from the heat, remove them from the section to be welded to make enough clearance.

2.80

MEMO

3.1

3.MAINTENANCE

3.2 MAINTENANCE Serial Number Location

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

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

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

60ZV2 QSB4.5

2. Engine Serial Number

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

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

MODEL SERIAL NO. MODEL MADE IN JAPAN

SERIAL NO.

SN PLATE 41668-2006B

MADE IN JAPAN SN PLATE 41668-2063B

3. Transmission / Torque Converter Serial Number Model

1. Machine Serial Number

Serial Number Design Number

3.3 MAINTENANCE Serial Number Location

MANUFACTURED BY

J;B

COMPANY, INC

MODEL S/N P/N CAPACITY MADE IN U.S.A

BERGSTROM

OM0209

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

6. Air Conditioner and Heater Serial Number

SERIAL NO.

-

70ZV0004

70ZV0017

5. Seat Serial Number

7. Cab Serial Number Model Number Serial Number

3.4 MAINTENANCE Serial Number Location

Cab (L.H Inside) Seat

Bucket S/N

Heat & A/C

60ZV US SNa

Machine

T/M

E/G (R.H)

3.5 MAINTENANCE Inspection and Maintenance Table

Inspection and Maintenance Table

IMPORTANT Severe applications require more frequent maintenance.

Severe conditions include heavy dust, extremely abrasive material, caustic chemicals, extremely wet conditions or abnormally hot or cold ambient temperatures. : First time replacement or cleaning only

Section

Engine

Item for check

10

50

250

500

When Required 1000 2000

Page

Check Engine Oil Level

2.39

Check Engine Coolant Level

2.41

Check Warning Lamps

2.50

Check Exhaust Gas

2.53

Drain Water and Sediment from Fuel Filter

2.42

Check Fuel Level

2.51

Check Drive Belt

2.45

Check Crankcase Breather Tube

2.45

Check Air Intake System

2.46

Check Cooling Fan

2.46

Drain Water and Sediment from Fuel Tank

3.22

Replace Engine Oil and Oil Filter Cartridge

3.30

Replace Fuel Filter Cartridges

3.33

Inspect Automatic Belt Tensioner Pulley

3.40

Clean Fuel Tank

3.44

Check and Adjust Valve Lash Clearance

3.45

Clean or Replace Air Cleaner Element

3.10

Clean Radiator / Air cooler / Hydraulic oil cooler Fins

3.12

Clean or Replace Air Cleaner Element Replace Coolant Check Transmission Oil Level Transmission & Torque Converter

Operating hours

Replace Transmission Oil Filter Cartridge

After six cleanings or once a year

3.10

Every 2 years or 3000 hours

3.14 2.51 3.29, 3.32

Replace Transmission Oil

3.35

Clean or Replace Transmission Breather

3.37

3.6 MAINTENANCE Inspection and Maintenance Table

: First time replacement or cleaning only Section

Axle system

Steering system

Brake system

Loading system

Item for check

Operating hours 10

50

250

500

When Required 1000 2000

Page

Check Tire for Damage, Air and Tread Depth

2.43

Check Tire Air Pressure

3.21

Greasing (Axle support)

2.39

Check Differential Gear Oil

3.26

Greasing (2nd Propeller Shaft)

3.25

Greasing (3rd Propeller Shaft)

3.25

Check Tightness of Wheel Bolts

3.26

Replace Differential Gear Oil

3.43

Check Steering Wheel Operation

2.53

Greasing (Steering Cylinder)

3.20

Check Brake Oil Level

2.41

Check Service Brake Operation

2.52

Check Parking Brake Operation

2.52

Adjust Parking Brake Lining

3.38

Check Service Brake Disk Wear

3.45

Overhaul Brake Master Cylinder

3.45

Check Hydraulic Oil Level

2.40

Greasing

3.18

Replace Hydraulic Oil Return Filter

3.29, 3.37

Replace Hydraulic Oil, Clean Filter

3.41

Replace Filter in the Hydraulic Tank Cap

3.44

Replace Bucket Teeth (option)

3.8

Replace Cutting Edge (option)

3.9

3.7 MAINTENANCE Inspection and Maintenance Table

: First time replacement or cleaning only Section

Chassis

Electrical system

Item for check

Operating hours 10

50

250

500

When Required 1000 2000

Adjust and Check Rear View Mirrors

2.47

ROPS (Roll Over Protective Structure) (option)

2.47

Check Seat Belt Restraint

2.47

Greasing (Center Pin)

3.20

Check Ride Control Accumulator (option)

3.45

Replace Seat Belt and Tether

3.10

Check Windshield Washer Fluid

3.13

Check Bucket Stopper

3.16

Check Monitor Panel Operation

2.47

Check Horn Operation

2.47

Check Back-up Alarm Operation

2.53

Check Wiring Harnesses

2.42

Check Battery Electrolyte Level

3.23

Check or Replace Fuses

3.12

Check and Adjust Air Conditioner Belt (option) Clean Air Conditioner and Heater Filter Element (option) Air Conditioner (option)

3.27 3.28

Check Air Conditioner Refrigerant (option)

3.39

Replace Air Conditioner Filter Elements (option)

3.15

Clean Air Conditioner Condenser (option)

3.13

Replace Air Conditioner Receiver Dryer (option) Others

Page

Walk-Around Inspection

Every 3 years or 6000 hours

3.16 2.38

3.8 MAINTENANCE When Required Inspection and Maintenance

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

Replace Bucket Teeth (option) When the bucket teeth are worn, replace them as follows.

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

1

2

Block 97ZVOM0136

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

3. Stop the engine.

4. Remove bolts and nuts (1), then remove bucket teeth (2).

5. Install the new teeth on the bucket with new bolts.

3.9 MAINTENANCE When Required Inspection and Maintenance

Replace Cutting Edge (option) 1. Park the machine on level ground and apply the parking brake.

OM0188

WARNING Teeth and bucket edges are hardened steel which may chip when struck by steel hammer causing injury.

- Always wear eye protection.

- Use dead blow hammer or brass drift between hammer and tooth.

- Keep bystanders away from work area.

65ZV0011

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

3. Stop the engine.

6. To prevent any clearance between the tooth and the edge of the bucket, tighten the nut partially, then hit the top of the tooth.

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

7. Tighten the nuts to 451~539 N-m (330~400 ftlb).

5. If other side of the cutting edge is not worn, turn it around and install it so that the new side faces the front. If both sides are worn, install a new cutting edge.

8. Retighten them after operating the machine for a few hours.

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

6. Install all bolts and tighten them to 451~539 Nm (330~400 ft-lb).

7. Retighten them after a few hours operation.

3.10 MAINTENANCE When Required Inspection and Maintenance

Replace Seat Belt and Tether

Clean or Replace Air Cleaner Element When the warning monitor lamp lights up, clean or replace the air cleaner element.

IMPORTANT Seat Belt

Tether 70ZV0017

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

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

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

- Do not clean or replace air filters while engine is running.

- Clean only outer element. Never clean inner element.

- Clean or replace element only when indicator lamp comes on.

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

2

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

1 60ZV2 9194

2. Remove air cleaner cover (2) by releasing three cover latches (1).

3.11 MAINTENANCE When Required Inspection and Maintenance

5

3

4 95ZV2 Air Cleaner

3. Remove outer element (3) by slowly pulling it out.

4. Check the outer element, especially o-ring (4) fit in the cover correctly. If it is loose or deteriorated, replace it.

OM0139

6. Place a light inside the filter element. If the light spots are seen through the element, it must have cracks or pinholes. Replace it with a new element.

7. Check rubber seal (5), and if you find any damage, replace it with a new element.

8. Before installing the outer element, confirm that the inner element is seated properly, and then, reinstall the outer element.

9. Confirm that the o-ring fits properly, and secure the cover latches.

10. If the engine exhaust gas is not clean enough even after cleaning (still exhausting excessive black smoke), replace the element.

OM0138

5. Clean the element using dry compressed air (196 kPa (30 psi)) by applying from the inside of the element to blow off dirt and/or dust.

Apply the air along the length of the filter to avoid the damage to the paper element.

11. Be advised that the element cleaning should be effective up to 6 times. At the 7th maintenance or once a year as well as when you find any damage, replace both of the outer and inner elements.

3.12 MAINTENANCE When Required Inspection and Maintenance

Clean Radiator / Air cooler / Hydraulic oil cooler Fins

Check or Replace Fuses

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

60ZV 3684

60ZV 5312

2. Open the engine access panels on both the right hand side and the left hand side for clean the radiator.

IMPORTANT High pressure air or water may damage radiator fins.

60ZV2 9214

- When used for cleaning purposes, the pressure of compressed air should be at 196 kPa (30 psi) or less.

- When using high-pressure water, keep the nozzle a distance of at least 500 mm (20 in) away from the core surface, applying the water jet perpendicular to the core.

- Move nozzle from side to side; not up and down.

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

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

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

Refer to "Fuse Boxes" page 2.25.

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

2. Stop the engine and turn the starter switch key to the "OFF" position.

3. Open the covers of the main fuse box, cab fuse box and additional fuse box.

5. Determine the cause of the blown fuses and repair.

IMPORTANT

4. Reverse the direction to flush all debris from the radiator / air cooler / hydraulic oil cooler fins.

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

5. Close the engine access panels.

Never replace fuses with higher amperage rating.

3.13 MAINTENANCE When Required Inspection and Maintenance

Check Windshield Washer Fluid

Clean Air Conditioner Condenser (option) 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.

60ZV2 02507-0120

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

60ZV0011

2. Check the fluid level.

3. Replace the fluid if it is dirty.

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

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

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

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

The protective cover may be removed for cleaning. Reinstall the cover after cleaning.

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

4. If water is used for the cleaning, cover the electric condenser fan with plastic sheets. Remove the plastic sheets after cleaning.

IMPORTANT An excessively high air or water discharge pressure can damage the condenser fins.

- When used for cleaning purposes, the pressure of compressed air should be at 196 kPa (30 psi) or less.

- When cleaning with water, apply the water jet perpendicular to the core.

3.14 MAINTENANCE When Required Inspection and Maintenance

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.

- 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.

60ZV2 9209

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

5. Remove the drain plug and drain coolant (about 25 liters (6.6 gal)) into a suitable container.

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.

60ZV 5310a

6. Slowly open the radiator cap to drain coolant.

Follow the law and/or local regulations to properly dispose of or recycle the coolant.

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

Avoid contact with skin and eyes to prevent injury.

60ZV2 9203

3. Confirm the coolant in the radiator sub-tank is cool enough.

4. Remove the radiator sub-tank machine and drain coolant from it.

from the

7. Install the drain plug and fill the cooling system with clean water.

Do not install the radiator cap.

3.15 MAINTENANCE When Required Inspection and Maintenance 8. Operate the engine for one hour with the coolant temperature above 80ºC (180ºF). Then let the engine cool down naturally with the engine shut "OFF".

9. Stop the engine and remove the drain plug to drain the cooling system.

10. Install the drain plug and fill the cooling system with clean water.

Do not install the radiator cap or the new coolant filter.

Replace Air Conditioner Filter Elements (option) 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.

11. Operate the engine for five minutes with the coolant temperature above 80ºC (180ºF).

12. Stop the engine and remove the drain plug to drain the cooling system.

13. If the water being drained is still dirty, the system must be flushed again until the water is clean (step 7~13).

14. Install the drain plug and fill the system with the premixed coolant.

Refer to "Coolant Specification" page 3.48 for the mixing instruction.

15. Idle the engine for five minutes to purge air mixed into the coolant. (Leave the radiator cap off.)

135ZV0063

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.

16. Add coolant as necessary.

17. Reinstall the radiator cap.

For additional cold weather servicing information, refer to "Coolant Specification" page 3.48 for details.

135ZV0064

4. Remove the outer filter from the cab, and replace it with new one.

When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

3.16 MAINTENANCE When Required Inspection and Maintenance

Replace Air Conditioner Receiver Dryer (option) (Every 3 years or 6000 hours) - Contact your Kawasaki dealer.

Check Bucket Stopper 135ZV0063

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

Inner filter replacement

Inner filter Filter cover

70ZV0020

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 clean or replace with a new one.

(Part number BER525777) Filter may be washed with mild detergent.

Refer to "Clean Air Conditioner and Heater Filter Element (option)" page 3.28.

If the bucket roll back or dump stops are severely worn, clean and preheat the area to about 300ºF (150ºC) and use mild steel welding rod to build up the stop surfaces and grind them smoothly back down to the original stop height so that contact is evenly positioned. Be sure not to undercut the boom surface parent material while welding as this may contribute to cracking. Permit the boom to cool naturally at ambient room temperature of about 70ºF (20ºC).

3.17 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 2.38 and "Check after Starting the Engine" page 2.50.

3.18 MAINTENANCE Every 50 Hours or 1 Week

Every 50 Hours or 1 Week WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

Every 50 hours or 1 week, whichever comes first, perform the following inspection and maintenance in addition to the "Daily Inspection and Maintenance".

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

2. Lubricate fittings on the following components.

Wipe and clean all fittings before greasing.

Lubricate until fresh grease is seen at each joint. Immediately replace or report any broken or defective grease fittings.

Refer to "Recommended Lubricants" page 3.46 for the correct grease.

60ZV 5274

- Bucket-Boom (two places)

60ZV 5274

- Bucket-Rod (one place)

3.19 MAINTENANCE Every 50 Hours or 1 Week

60ZV 5257

60ZV 5274

- Bucket Cylinder-Front Chassis (one place)

- Lever-Rod (one place)

60ZV 5273

60ZV 5273

- Boom Cylinder-Boom (two places)

- Lever-Boom (one place)

60ZV 5273

- Bucket Cylinder-Lever (one place)

60ZV 5257

- Boom Cylinder-Front Chassis (two places)

3.20 MAINTENANCE Every 50 Hours or 1 Week

60ZV 5257

(upper)

60ZV 5250

- Boom-Front Chassis (two places)

(lower)

60ZV 5248

60ZV 5247

- Steering Cylinder (four places) L.H and R.H

- Center Pin (two places)

60ZV 5249

3.21 MAINTENANCE Every 50 Hours or 1 Week

Check Tire Air Pressure

Low Pressure

OK

High Pressure

60ZV0006

65ZV0008

WARNING

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

Explosive separation of tire and rim parts could result in death or serious injury.

- Low air pressure causes excessive deflection, heat, and accelerated wear.

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.

- 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 15 m (50 ft).

Stay away until tire and rim cool down.

OM0033

1. Before starting work and while the tires are still cool, measure the tire air pressure with the tire pressure gauge.

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.

3.22 MAINTENANCE Every 50 Hours or 1 Week Recommended Tire Air Pressure (Bias ply tire)

Size

Pattern

17.5-25-12PR

L2

15.5-25-12PR

L2

Drain Water and Sediment from Fuel Tank

Air pressure kPa (psi) Front

Rear

422~441 (61~64) 471~490 (68~71)

324~343 (47~50) 373~392 (54~57)

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

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

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.

60ZV 3688d

2. Prepare a suitable container.

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

4. Drain water and sediment along with fuel.

5. Close the drain cock or plug.

6. Dispose of the drained fuel and water properly.

7. Add fuel.

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

3.23 MAINTENANCE Every 50 Hours or 1 Week

Check Battery Electrolyte Level

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.

60ZV 5309

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

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

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

2. Clean the battery surface with a clean cloth or soft brush.

Keep the battery electrolyte level at the proper level.

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

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

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

Dispose of used batteries by recycling.

Low

OK

High OM0096

3. Check the battery electrolyte level in each cell.

Electrolyte should cover the cell plates.

4. If the level is low, add distilled water until it reaches the bottom of the filler neck.

NOTE If a maintenance free battery is used, step 3 and 4 of this inspection and maintenance is not required.

3.24 MAINTENANCE Every 250 Hours or 1 Month

Every 250 Hours or 1 Month WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

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.

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 3.46 for the correct grease. Use lithium base grease for universal joints.

3.25 MAINTENANCE Every 250 Hours or 1 Month

60ZV 5272

60ZV 3645

- 3rd Propeller Shaft (two places)

60ZV 3663

60ZV 3664

- 2nd Propeller Shaft (five places)

3.26 MAINTENANCE Every 250 Hours or 1 Month

Check Differential Gear Oil

Check Tightness of Wheel Bolts

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

CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

1. 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.

60ZV0006

2. Check the wheel bolts are tightened to 892 Nm (658 ft-lb).

2

3. Retighten if necessary.

1 60ZV 5279

2. Remove oil level plug (1) from the front axle housing, using a 12 mm hex (Allen) wrench.

3. If the oil level is lower than the level plug port, add the specified oil through filling plug port (2).

Refer to "Recommended Lubricants" page 3.46.

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

Dispose of the drained oil properly.

5. Install and tighten plugs (1) and (2).

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

3.27 MAINTENANCE Every 250 Hours or 1 Month

Check and Adjust Air Conditioner Belt (option)

Tension pulley

1

CAUTION Contact with moving belts or pulleys may cause injuries.

2

Stop engine before opening engine access panel.

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

2. Open the engine access panel.

OM0201

3. Visually inspect the compressor belt on both top and bottom sides for looseness and damage.

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

5. Measure the belt tension using a belt tension gauge so that it is applied 637±88 N.

Compressor pulley

Fan pulley 60ZV2 03033-0140

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

3.28 MAINTENANCE Every 250 Hours or 1 Month

Clean Air Conditioner and Heater Filter Element (option)

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.

Outer filter cleaning

7. After approximately 8~10 cleanings, replace the filter with new one. (Part number 4033060270)

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

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

Refer to "Replace Air Conditioner Filter Elements (option)" 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.

135ZV0063

135ZV0063

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

Turn the rings counterclockwise and then remove the cover.

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

Inner filter cleaning

Inner filter Filter cover

135ZV0064 70ZV0020

4. Remove the outer filter from the cab.

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

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 clean.

3.29 MAINTENANCE Every 250 Hours or 1 Month 2. Remove dust with compressed air. Use air pressure below 196 kPa (28 psi).

Replace Filter

3. After approximately 8~10 cleanings, replace the filters with new one. (Part number BER525777)

- Transmission Oil Filter Cartridge

Refer to "Replace Air Conditioner Filter Elements (option)" page 3.15.

4. 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.

(First time replacement or cleaning only)

Replace it first time only at 250 hours operation, after that replace it at every 500 hours operation.

Refer to "Every 500 Hours or 3 Months" page 3.32.

- Hydraulic Oil Return Filter Replace it first time only at 250 hours operation, after that replace it at every 1000 hours operation.

Refer to "Every 1000 Hours or 6 Months" page 3.37.

3.30 MAINTENANCE Every 500 Hours or 3 Months

Every 500 Hours or 3 Months WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

Every 500 hours or 3 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", and "250 hours" inspection and maintenance.

Replace Engine Oil and Oil Filter Cartridge

CAUTION Hot oil and engine components may cause burns.

Avoid contact with hot oil or engine components.

1. If the machine is cold operate the engine to bring the engine coolant temperature about 40ºC (105ºF). When the needle of the coolant temperature gauge reaches the middle of the white zone, the temperature is about 40ºC (105ºF).

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

60ZV 3688d

3. Loosen the drain plug.

4. Drain oil, about 12 liters (3.2 gal), into a suitable container.

3.31 MAINTENANCE Every 500 Hours or 3 Months

60ZV2 9206

5. Remove the oil filter and properly dispose of it.

Make sure the O-ring is removed with the filter.

Check

Fill cap 60ZV2 9197

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

Refer to "Recommended Lubricants" page 3.46 for the oil specifications. Total system capacity including the filter is 12 liters (3.3 gal).

6. Clean the oil filter head gasket surface.

7. Fill the new filter with clean engine oil.

Refer to "Recommended Lubricants" page 3.46 for the oil specifications.

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

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 filter.

CAUTION Used engine oil may cause skin disease or irritation.

OM0200

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

Refer to the instructions supplied with the filter.

IMPORTANT Do not over tighten the filter.

10. Retighten the oil drain plug, and tighten to 80 N-m (60 ft-lb) torque.

Do not allow used engine oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

3.32 MAINTENANCE Every 500 Hours or 3 Months

Replace Transmission Oil Filter Cartridge

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

CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

1. If the machine is cold, operate the machine to bring the torque converter oil temperature about 30~40ºC (85~105ºF).

2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

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.

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

60ZV 5247

60ZV 3694

4. Turn the filter counterclockwise to remove.

Properly dispose of the oil and filter.

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of the new filter.

7. Install the filter on the filter head. Turn it clockwise to tighten. Follow the instructions on the filter.

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

9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 2.51.

Add the specified oil as necessary to bring the oil level to the "H" (high) mark on the dipstick.

Refer to "Recommended Lubricants" page 3.46 for the specified oil.

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.

3.33 MAINTENANCE Every 500 Hours or 3 Months

Replace Fuel Filter Cartridges

7. Install the filters loosely on the filter head.

Turn the main filter until the gasket loosely contacts the filter head surface.

CAUTION Escaping fuel is flammable and harmful to skin.

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

- Do not drain with engine running.

- Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

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

OM0200

2. Place a small drain pan (about 1 liter (1 qt)) under the fuel filters.

1

8. Tighten prefilter (1) an additional one-half to three-fourths turn after the gasket contacts the filter head surface. Follow the instructions supplied with the filter.

IMPORTANT Do not over tighten the filter.

3

2 60ZV2 9195

3. Remove and properly dispose of prefilter (1) and fuel filter (2).

4

4. Clean the filter head gasket surface.

5. Apply a light film of clean engine oil to the gasket surface of the new filters.

6. Fill only prefilter (1) with clean fuel and leave main filter (2) empty.

Do not fill fuel filter (main filter) (2) with fuel before installation.

IMPORTANT Do not manually fill the fuel to prevent dust or dirt from being mixed into main filter (2).

A small amount of dirt could cause a serious problem with the fuel injection system.

60ZV2 9195

9. Open air bleeder plug (3) on the top of fuel prefilter (1) by using TORX T45 or 7/32 in hex (Allen) wrench.

10. Turn knob (4) on the prefilter head counterclockwise.

Be advised the lift pump comes out while loosening knob (4).

3.34 MAINTENANCE Every 500 Hours or 3 Months 11. Pump knob (4) push and pull until fuel comes out of air bleeder plug (3) without air bubbles, tighten plug and pump until fuel flows without air bubbles from main filter seal.

12. Tighten the main filter just as the prefilter was tightened.

13. Push and turn knob (4) clockwise to lock.

14. Wipe off any spilled fuel.

15. Turn the starter switch key to the START position to run the engine and check for leaks.

16. Properly dispose of the spilled fuel and oily rags.

NOTE If the engine does not start, is difficult to start, or does not run smoothly, stop the engine and bleed it again.

3.35 MAINTENANCE Every 1000 Hours or 6 Months

Every 1000 Hours or 6 Months WARNING

Replace Transmission Oil

WARNING

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

Accidental movement of machine 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 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.

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.

CAUTION Transmission oil may be hot and may cause burns.

Avoid contact with transmission oil.

1. If the machine is cold operate the machine for a few minutes to bring the transmission oil temperature about 30~40ºC (85~105ºF).

2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

1

60ZV0013

3. Remove drain plug (1) with a 17 mm wrench.

4. Drain oil into a suitable container (about 20 liters (5.3 gal)).

Properly dispose of or recycle the waste oil.

3.36 MAINTENANCE Every 1000 Hours or 6 Months

2 3 60ZV0014

5. Loosen four bolts (2) with a 14 mm wrench.

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

7. Remove the suction strainer from the flange, brush off any debris and clean with solvent.

It is normal for a few fine particles to be on the strainer. Large pieces or a large quantity of particles indicates a problem.

Reassemble the strainer and flange assembly.

Contact a Kawasaki dealer if you find excessive debris.

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

9. Tighten four bolts (2) to 68.6 N-m (51 ft-lb).

10. Fill with the specified oil.

Refer to "Recommended Lubricants" page 3.46.

11. Idle the engine and check for leaks.

60ZV 5247

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

Refer to "Check Transmission Oil Level" page 2.51 and "Recommended Lubricants" page 3.46.

3.37 MAINTENANCE Every 1000 Hours or 6 Months

Clean or Replace Transmission Breather

Replace Hydraulic Oil Return Filter

CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by slowly turning the filler cap 1/3 turn counterclockwise.

60ZV 5291

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

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

1

2. Remove the breather from the transmission case.

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

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

4. Install the breather onto the transmission case.

60ZV0015

2. Pull knob (1) beside the oil inlet cap and turn the cap slowly counterclockwise to relieve the tank pressure.

60ZV 3662

3. Place a small drain pan (about 1 liter (1 qt.)) under the filter.

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

3.38 MAINTENANCE Every 1000 Hours or 6 Months 5. Clean the filter head gasket surface.

Adjust Parking Brake Lining

6. Apply a light film of clean hydraulic oil to the new filter O-ring.

WARNING

7. Install the filter on the filter head and tighten it fully by hand.

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 a safe place on firm level ground and steer it fully to one side for easier access.

2. Lower the attachment to the ground and fully release the parking brake lever.

60ZV 3664

15º

1

OM0167a

3. Align inspection hole (1) with the adjuster wheel by turning the hole 15º clockwise from the top.

Do not enter the articulation area or under the machine.

3.39 MAINTENANCE Every 1000 Hours or 6 Months 4. Place wheel chocks in front of and behind the tires to prevent the machine from moving.

Check Air Conditioner Refrigerant (option)

5. Place a "DO NOT OPERATE" tag on the steering wheel.

Adjuster wheel

Screw driver

1 60ZV0011

60ZV0016

6. Turn the adjuster wheel fully downward to close the clearance between the brake drum and the brake lining (shoe). The adjuster wheel can be reached through the inspection hole.

7. Return the adjuster wheel eight clicks upward.

(Now the clearance is 0.23 mm (0.009 in)) 8. Check parking brake operation as described on page 2.52.

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

1. Apply the parking brake and lower the attachment to the ground.

2. Remove the cover.

3. Press the flow control switch to set maximum air flow.

4. Set the temperature control switch fully to the cool position and fully open the cab doors.

5. Slightly accelerate the engine to about the middle speed range. (compressor speed 1,500~1,800 min-1 (RPM)) 6. Compare the flow of bubbles in the sight glass of the receiver drier with the drawings in the following table.

The new receiver drier also has moisture sensor window with color code to indicate moisture in the system.

WARNING Overfilled refrigerant may cause dangerous high pressure and poor cooling action; and low refrigerant level may cause compressor damage.

Always maintain refrigerant in normal level.

3.40 MAINTENANCE Every 1000 Hours or 6 Months

Adjust of refrigerant

Normal

Appearance of the sight glass

Solutions

Inspect Automatic Belt Tensioner Pulley

Almost clear.

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

High

No bubble is seen.

Low

A flow of bubbles is visible.

Contact your local Kawasaki dealer for inspection and recharging refrigerant.

60ZV2 QSB4.5-2

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

2. Open the engine access panel.

3. Visually inspect the tensioner pulley and body for cracks. If any cracks are noticed, the tensioner pulley must be replaced.

4. Check the tensioner pulley for dirt buildup. If this condition exists, the tensioner pulley must be removed and steam-cleaned.

3.41 MAINTENANCE Every 2000 Hours or 1 Year

Every 2000 Hours or 1 Year WARNING

Replace Hydraulic Oil, Clean Filter

WARNING

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

Pressurized hydraulic tank is used for this machine.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.11 before performing any inspection or maintenance procedures.

Pressurized hot oil may cause injury or burns.

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.

Relieve all pressure by slowly turning the filler cap 1/3 turn counterclockwise.

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

2. Move the loading control lever back and forth to relieve the pressure.

2 1

60ZV0015

3. Pull knob (1) beside oil inlet cap (2) and turn the cap slowly 1/3 turn counterclockwise to relieve the tank pressure.

4. Remove the inlet cap.

CAUTION Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil.

5. Prepare a suitable container to catch the draining oil (about 87 liters (23 gal)).

3.42 MAINTENANCE Every 2000 Hours or 1 Year 15. Start the engine and allow the engine to idle for about five minutes.

16. Operate the bucket, boom, and steering cylinders for about five minutes, then lower the attachment to the ground.

4

17. Inspect for leaks.

18. Make sure hydraulic oil is to the center of the oil level gauge. Add hydraulic oil if necessary.

3

60ZV 5280

6. Remove drain plug (3) with a 12 mm Hex (Allen) wrench to drain oil.

7. Dispose of the waste oil properly.

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

CAUTION Compressed air may cause injury.

- Wear protective clothing and eye protection.

- Air pressure must be below 196 kPa (30 psi).

9. Remove the suction strainer. Inspect and clean them with solvent and compressed air.

A few small particles in the strainer is normal.

Large metal, rubber pieces, or a large amount of fine particles is abnormal. If found, contact your Kawasaki dealer.

10. Clean inside of the tank and magnet plug.

11. Install the suction strainer, new gasket (Part number 31990-20020) and inspection cover (2), and tighten the nuts. Do not overtighten.

12. Install and tighten the drain plug.

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

Refer to "Recommended Lubricants" page 3.46.

14. Close the oil inlet cap.

3.43 MAINTENANCE Every 2000 Hours or 1 Year

Replace Differential Gear Oil

CAUTION CAUTION

Used oil may cause skin disease.

Hot oil and components may cause burns.

Do not allow used oil to remain on skin for prolonged periods of time.

Avoid contact with hot oil or components.

1. If the machine is cold operate the machine for a few minutes to bring the differential gear oil temperature about 40ºC (105ºF).

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.

Clean skin thoroughly with soap and water.

NOTE While the oil is drained measure brake wear.

Refer to "Check Service Brake Disk Wear" page 3.45.

6. Install the drain plug.

7. Refill the recommended oil through the filling port until the oil comes out from the level hole.

Refer to "Recommended Lubricants" page 3.46.

8. Install and tighten the level and filling port plugs.

2

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

Required oil volume for the rear differential is about 20 liters (5.3 gal).

3

1 60ZV 5279

3. Remove level plug (1), filling port plug (2) and drain plug (3) from the front axle housing, with a 12 mm Hex (Allen) wrench.

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

Simply wipe it off.

4. Drain the oil (about 20 liters (5.3 gal)) into a suitable container.

5. Dispose of the waste oil properly.

3.44 MAINTENANCE Every 2000 Hours or 1 Year

Clean Fuel Tank

Replace Filter in the Hydraulic Tank Cap

CAUTION

CAUTION

Escaping fuel is flammable and harmful to skin.

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

- Do not drain with engine running.

- Do not allow fuel to remain on skin for an extended period of time. Wash thoroughly with soap and water.

Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before opening.

NOTE It is easiest to clean the fuel tank when the fuel is almost empty.

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

1 2 4

3

50ZV 38530-6001

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

1

2. Move the bucket and boom control levers back and forth to relieve the pressure.

2 60ZV 5319b

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

3. Pull knob (4) beside the oil inlet cap and turn the cap slowly 1/3 turn counterclockwise to relieve the tank pressure.

4. Remove the filter cap.

3. Drain the remaining fuel into a suitable container.

4. Remove the nuts with a 14 mm wrench to remove inspection cover (2) and clean inside of the tank.

5. Install the inspection cover with a new gasket.

(Part number 31990-20020) Tighten the nuts evenly. Do not overtighten.

6. Close the drain cock and fill the fuel tank.

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

5. Remove socket bolt (1) from the filter cap, using a 4 mm hex (Allen) wrench.

6. Remove cover (2) and filter element (3).

7. Replace element (3). (Part number 3098170010) 8. Install element and cover (2).

9. Install socket bolt (1) and tighten it with 0.007~0.009 N-m (0.005~0.007 ft-lb) torque.

3.45 MAINTENANCE Every 2000 Hours or 1 Year

Overhaul Brake Master Cylinder - Contact your nearest Kawasaki dealer.

Check Service Brake Disk Wear - Contact your Kawasaki dealer.

Check and Adjust Valve Lash Clearance - Contact your Kawasaki dealer or local ISUZU engine dealer.

Check Ride Control Accumulator (option)

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

Never service ride control accumulator unless trained properly.

Contact your nearest Kawasaki dealer.

3.46 MAINTENANCE Recommended Lubricants

Recommended Lubricants Ambient Temperature

Refill capacity (Approximate)

Kind of Oil

12 liter (3.2 gal)

Engine oil (CH4)

-22ºF -4 -30ºC -20

14 -10

32 0

50 10

68 20

86 30

104 40

Change Interval (Hours)

SAE10W

Engine

Transmission

Hydraulic tank

20 liter (5.3 gal)

∗1

ATF Engine oil (CD) Mobil TRANS HD-10 Valvoline DT10

SAE10W-30 SAE15W-40 SAE30 Multi-Purpose ATF SAE10W Mobil TRANS HD-10

Hydraulic oil

40 liter (10.5 gal)

Mobil TRANS HD30 Valvoline DT30

1,000

Valvoline DT10 ISO VG32

∗3 87 liter (23 gal)

∗2 500

ISO VG46

2,000

Mobil TRANS HD-30

Differential & Planetary

Valvoline DT30 Mobil TRANS HD-50

2,000

Valvoline DT50

Brake oil tank

∗4 0.35 liter (0.09 gal)

Engine oil

Fuel tank

175 liter (46 gal)

Diesel fuel

Mobil Delvac 1 ESP 5W40 ASTM D975 No.1 ASTM D975 No.2

Note: ∗1 shows "Hydraulic tank oil capacity at level gauge center." ∗4 shows "Brake oil tank capacity." 2 liter required for brake system totally.

daily

3.47 MAINTENANCE Recommended Lubricants

Engine

Use oil that meets engine oil classification API CH4 or CG4. ∗2. Change engine oil every 250 hours if CG4 is used.

Engine oil drain intervals need to be reduced by 50 % when fuel sulfur content exceeds 0.5 %.

Transmission

Use engine oil classification API "CD".

Mobil TRANS HD-10.

Valvoline DT10.

Multi-purpose Automatic Transmission Fluid.

Never mix engine oil, Mobil TRANS HD-10, Valvoline DT10 and/or ATF.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. ∗3. In a case that fire-resistant fluid is used in the hydraulic circuit, replace hydraulic pump every 6,000 hrs operation.

Differential & Planetary

Use Mobil TRANS HD-30, Valvoline DT30 or equivalent with 5 % "Antichatter" additive or friction modifier.

Brake oil

Use engine oil Mobil Delvac1 only.

Lubricating Grease

Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.

NLGI NO.1 or NO.0 grease for extremely low temperature.

Use lithium base grease for a needle bearing.

Diesel Fuel

Requirements for diesel fuel

Specifications Flash Point

ºC.

Grade No.1-D

min.

Water and Sediment % vol.

max

Distillation Temperature

90 % vol.

ºC

recovered

Kinematic Viscosity mm2/s at 40ºC

38

52

0.05

0.05

max.

288

338

min.

1.3

1.9

max.

Ash % mass

Grade No.2-D

max.

2.4

4.1

0.01

0.01

Sulfur % mass

max.

0.50

0.50

Cetane Number

min.

40

40

0.15

0.35

Carbon residue on 10 % distillation residue % mass

max.

3.48 MAINTENANCE Coolant Specification

Coolant Specification The machine is originally filled with Long Life Coolant (non-Amin type ethylene glycol) which need not be replaced for the first two years or 3000 hours.

Do not use Amin type Long Life Coolant in cooling system. It may cause a corrosion against radiator or heater core.

If standard antifreeze (not Long Life Coolant) is used for the replacement, it should be replaced every six months.

Recommended Mixture of Antifreeze Expected Minimum -35ºC -30ºC -25ºC -20ºC Ambient Temperature (-31ºF) (-22ºF) (-13ºF) (-4ºF)

-15ºC (5ºF)

Pure Water

liter (gal)

13.3 (3.5)

12.0 (3.2)

10.8 (2.8)

9.5 (2.5)

8.3 (2.2)

Antifreeze

liter (gal)

11.7 (3.1)

13.0 (3.4)

14.2 (3.8)

15.5 (4.1)

16.7 (4.4)

Mixture Ratio (%)

53

48

43

38

33

- Too much antifreeze in the coolant mixture may cause engine overheating.

Keep 33 % antifreeze mixture (same as the mixture for a minimum ambient temperature of -15 ºC (5ºF)) if the engine overheats in a high ambient temperature.

- Do not use hard water or water with high levels of calcium and magnesium ions as the coolant water.

IMPORTANT Do not mix different brands of antifreeze because they each contain special additives.

Careless mixing often diminishes the effect of these additives and causes packing damage or water leakage.

3.49 TROUBLESHOOTING

TROUBLESHOOTING This troubleshooting section is not intended to cover every condition, however many of the common possibilities are listed.

Following are example of problems and their solutions.

Contact your local Kawasaki dealer for the items marked with or your local authorized ISUZU ENGINE dealer for the items marked with to repair. kawasaki

ISUZU

ENGINE PROBLEM

Engine oil pressure warning lamp lights up, and buzzer sounds

POSSIBLE CAUSES Low engine oil level Wrong grade oil for weather conditions Clogging oil filter element Defective alarm switch Oil leakage from pipe or joint Clogging suction strainer Excessive engine wear Defective oil pump

Low engine coolant level Loose / slipping / broken fan belt Clogging radiator fins Coolant temp. warnScale or mineral build up inside radiator ing lamp lights up Defective alarm switch (gauge is in green) Low water pump flow Thermostat stuck or missing

SOLUTIONS

PAGE

Add oil Change oil Change filter and oil

kawasaki

or

2.39 3.30 3.30

ISUZU

Add coolant Adjust or replace belt Clean Flush or professionally clean kawasaki

or

ISUZU

Engine does not start when the starter motor is turning (Also see ELECTRICAL TROUBLESHOOTING)

Fuel filter element clogging Starter motor speed too low Defective engine shut off motor Fuel pump failure Incorrect fuel injection timing Compression pressure too low Defective injectors

Replace fuel filter Booster Battery may be used

Air in fuel lines Fuel filter element clogging Fuel pump failure Incorrect fuel injection timing

Tighten fuel connections and filter

Unstable (rough) idling

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

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

kawasaki

or

kawasaki

or

or

3.33 2.70

ISUZU

Replace fuel filter kawasaki

2.41 2.45 3.12 3.14

3.33 3.33

ISUZU

ISUZU

3.10 3.33 2.39

3.50 TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Use correct type of oil Correct oil level

3.46 2.39

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

kawasaki

kawasaki

kawasaki

or

or

or

ISUZU

3.33

ISUZU

3.10

ISUZU

ELECTRICAL PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Adjust or replace belt Replace battery

2.45

Charge lamp lights up

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

Starter motor does not turn when starter switch key is turned to "START"

Transmission not in NEUTRAL Insufficient battery charge Starter switch failure Defective wiring Starter motor failure

Shift to NEUTRAL Battery charge or booster

Starter motor turns engine slowly

Hydraulic control levers not in NEUTRAL Insufficient battery charging Engine oil viscosity too high (thick) Poor connection at batteries or ground Defective wiring Starter motor failure

Move levers to NEUTRAL Battery charge or booster Replace oil Clean and tighten all terminals

kawasaki

or

ISUZU

1.27 2.70

kawasaki

kawasaki

or

ISUZU

kawasaki kawasaki

or

ISUZU

2.4 2.70 3.30

3.51 TROUBLESHOOTING

STEERING PROBLEM

Hard steering

Will not steer

POSSIBLE CAUSES

SOLUTIONS

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 Orbitrol® failure Pump failure Relief valve failure Steering cylinder failure Excessively cold oil / wrong grade oil

Steering Drift Steering pilot valve failure

PAGE 3.21

kawasaki

1.26

kawasaki

Warm oil / Replace oil with proper viscosity for temperature

3.46

kawasaki

HYDRAULIC PROBLEM

Boom raises too slowly

Boom natural drift excessively

POSSIBLE CAUSES

SOLUTIONS

PAGE

Excessively cold oil Wrong grade oil Oil pressure too low Damaged cylinder piston or piston packing Pump flow too low Pilot pressure too low Engine RPM too low

Warm oil Replace with proper grade oil

3.46

Excessively cold oil / Wrong oil type

Warm oil / Replace oil with proper viscosity for temperature

kawasaki

Leakage from control valve plunger Damaged cylinder piston or piston packing

kawasaki

Leakage in pilot relief valve Bucket / Attachment floating or drifting

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

kawasaki

3.46

3.52 TROUBLESHOOTING

BRAKE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE 3.38

Parking brake does not work properly

Worn brake lining Defective linkage

Adjust or replace lining Remove or clean

Brake dragging

Dirt, debris under base of brake pedal Warped brake discs Master cylinder failure Brake oil level too low Air in brake oil circuit Master cylinder failure Brake piston seal leakage

Add oil and check for leaks

Braking power too low

kawasaki

kawasaki

2.41

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 MCU failure Defective electrical circuit

SOLUTIONS

PAGE

Warm oil / Replace oil with proper viscosity for temperature Release parking brake Add oil / Repair leak Clean strainer

3.46

kawasaki

Service or parking brake dragging Low oil level in transmission Suction strainer in transmission clogging Clutch oil pressure too low Torque converter oil pressure too low Transmission clutch failure

Inspect and correct Refill oil / Repair leak Clean or replace strainer

Oil leakage from transmission

Air breather clogged Seal damage (between engine and torque converter housing)

Clean and refill with oil

Torque converter overheat

Oil level too low Dozing, continuous pushing application Operating in too high a speed range Long downhill driving Radiator clogged: coolant temp also high Defective alarm switch (gauge is in green) Torque converter / Transmission failure Oil pressure too low

Add oil / Repair leak Reduce load Use lower gear Change application Clean radiator fins

Low power

2.51 3.35

2.51 3.35

kawasaki

3.37

kawasaki

kawasaki

2.51 2.56 3.12

3.53 TROUBLESHOOTING

AIR CONDITIONER (option) PROBLEM

Low cooling when A/C "ON"

Low heater out put

POSSIBLE CAUSES

SOLUTIONS

PAGE

Hot water continues to flow through heater core A/C not set for maximum cooling Condenser fins plugged A/C filters plugged A/C compressor belts slipping/broken A/C refrigerant charge low

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

2.35 3.13 3.28 3.27

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

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

kawasaki

kawasaki

2.35

3.54 TROUBLESHOOTING

QUANTUM FAULT CODE INFORMATION These codes show the fault codes for the engine failure displayed on the MODM error log monitor, or checked by the diagnostic switch (option).

EG111 Red

Engine Control Module (ECM) - critical internal failure.

EG113 Yellow

Engine Timing Actuator Circuit - shorted high.

EG114 Yellow

Engine Timing Actuator Circuit - shorted low.

EG115 Red

Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from the magnetic pickup sensor.

EG121 Yellow

Engine Speed / Position Sensor Circuit - lost one of two signals from the magnetic pickup sensor.

EG122 Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted high.

EG123 Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted low.

EG124 Yellow

Intake Manifold Pressure - above normal operation.

EG131 Red

Accelerator Pedal Position Sensor Circuit - shorted high.

EG132 Red

Accelerator Pedal Position Sensor Circuit - shorted low.

EG133 Red

Remote Accelerator Pedal Position Sensor Circuit - shorted high.

EG134 Red

Remote Accelerator Pedal Position Sensor Circuit - shorted low.

EG135 Yellow

Engine Oil Pressure Sensor Circuit - shorted high.

EG141 Yellow

Engine Oil Pressure Sensor Circuit - shorted low.

EG143 Yellow

Engine Oil Pressure Low - warning.

EG144 Yellow

Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted high.

EG145 Yellow

Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted low.

EG146 Yellow

Engine Coolant Temperature High - warning.

EG151 Red

Engine Coolant Temperature High - critical.

EG153 Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage above normal or shorted high.

EG154 Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage below normal or shorted low.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

Please note that not all are used in the 60ZV-2 machine application. Refer to Cummins Engine troubleshooting fault codes list for more information.

EG155 Red

Intake Manifold Air Temperature Sensor High - critical.

EG166 Yellow

Rack Position Sensor #1 Circuit - shorted high.

EG172 Red

Rack Actuator Position #1 Circuit - grounded circuit.

EG173 Yellow

Rack Actuator - mechanically stuck open.

EG184 Yellow

Engine Control Module Identification Input State Error.

EG185 Yellow

Engine Control Module Network Communication Error.

EG187 Yellow

Sensor Supply Voltage #2 Circuit - shorted low.

EG212 Yellow

Engine Oil Temperature Sensor Circuit - shorted high.

EG213 Yellow

Engine Oil Temperature Sensor Circuit - shorted low.

EG214 Red

Engine Oil Temperature High - Critical.

EG221 Yellow

Ambient Air Pressure Sensor Circuit - shorted high.

EG222 Yellow

Ambient Air Pressure Sensor Circuit - shorted low.

EG227 Yellow

Sensor Supply Voltage #2 Circuit - shorted high.

EG231 Yellow

Engine Coolant Pressure Sensor Circuit - shorted high.

EG232 Yellow

Engine Coolant Pressure Sensor Circuit - shorted low.

EG233 Yellow

Engine Coolant Pressure Low - warning.

EG234 Red

Engine Speed High - critical.

EG238 Yellow

Sensor Supply Voltage #3 Circuit - shorted low.

EG254 Red

Fuel Shutoff Valve Circuit - shorted low.

EG255 Yellow

Fuel Shutoff Valve Circuit - shorted high.

EG259 Red

Fuel Shutoff Valve - stuck open.

EG261 Yellow

Fuel Temperature High - warning.

EG263 Yellow

Fuel Temperature Sensor Circuit - shorted high.

EG265 Yellow

Fuel Temperature Sensor Circuit - shorted low.

EG266 Red

Engine Fuel Temperature - data valid but above normal operational range - most severe level.

EG271 Yellow

Fuel Control Actuator Circuit - shorted low.

EG272 Yellow

Fuel Control Actuator Circuit - shorted high.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

3.55 TROUBLESHOOTING

EG281 Yellow

Injection Pump Mechanical System - signal not in range from ECM.

EG284 Yellow

Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit shorted low.

EG285 Yellow

SAE J1939 Data Link Multiplexing PGN Timeout Error.

EG286 Yellow

SAE J1939 Data Link Multiplexing Configuration Error.

EG287 Red

SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.

EG295 Yellow

Ambient Air Pressure Sensor Circuit - data incorrect.

EG299 Yellow

Engine stopped not using Starter Switch.

EG311 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.

EG312 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.

EG313 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.

EG314 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.

EG315 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.

EG319 Yellow

Real Time Clock - power Interrupt.

EG321 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.

EG322 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - open circuit.

EG323 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - open circuit.

EG324 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - open circuit.

EG325 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - open circuit.

EG331 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - open circuit.

EG332 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - open circuit.

EG334 Yellow

Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.

EG341 Yellow

Engine Control Module - data lost.

EG342 Red

Engine Control Module - out of calibration.

EG343 Yellow

Engine Control Module - warning internal hardware failure.

EG346 Yellow

Engine Control Module - warning software error.

EG351 Yellow

Injector Power Supply.

EG352 Yellow

Sensor Supply Voltage #1 Circuit - shorted low.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

3.56 TROUBLESHOOTING

EG378 Yellow

Fueling Actuator #1 Circuit - open circuit.

EG379 Yellow

Fueling Actuator #1 Circuit - grounded circuit.

EG386 Yellow

Sensor Supply Voltage #1 Circuit - shorted high.

EG387 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.

EG394 Yellow

Timing Actuator #1 Circuit - open circuit.

EG395 Yellow

Timing Actuator #1 Circuit - grounded circuit.

EG396 Yellow

Fueling Actuator #2 Circuit - open circuit.

EG397 Yellow

Fueling Actuator #2 Circuit - grounded circuit.

EG398 Yellow

Timing Actuator #2 Circuit - open circuit.

EG399 Yellow

Timing Actuator #2 Circuit - grounded circuit.

EG415 Red

Engine Oil Pressure Low - critical.

EG418 Yellow

Water in Fuel Indicator High - maintenance.

EG419 Yellow

Intake Manifold Boost Pressure Imbalance.

EG423 Yellow

Fuel Timing Pressure or Timing Actuator Stuck.

EG428 Yellow

Water in Fuel Sensor Circuit - shorted high.

EG429 Yellow

Water in Fuel Sensor Circuit - shorted low.

EG431 Yellow

Accelerator Pedal Idle Validation Circuit - data incorrect.

EG432 Red

Accelerator Pedal Idle Validation Circuit - out of calibration.

EG433 Yellow

Intake Manifold Pressure Sensor Circuit - data incorrect.

EG434 Yellow

Voltage to ECM less than 6 V

EG435 Yellow

Engine Oil Pressure Switch Circuit - data incorrect.

EG441 Yellow

Battery #1 Voltage Low - warning.

EG442 Yellow

Battery #1 Voltage High - warning.

EG443 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.

EG449 Yellow

Fuel Pump Delivery Pressure High - warning.

EG451 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.

EG452 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

3.57 TROUBLESHOOTING

EG465 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted high.

EG466 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted low.

EG482 Yellow

Fuel Pressure Low - warning.

EG483 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.

EG484 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.

EG485 Yellow

Injector Metering Rail #2 Pressure High - warning.

EG486 Yellow

Injector Metering Rail #2 Pressure Low - warning.

EG488 Yellow

Intake Manifold Temperature High - warning.

EG491 Yellow

Turbocharger #2 Wastegate Control Circuit - shorted high.

EG492 Yellow

Turbocharger #2 Wastegate Control Circuit - shorted low.

EG496 Yellow

Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.

EG524 Yellow

OEM Alternate Droop Switch Validation - data incorrect.

EG527 Yellow

Auxiliary Input / Output #2 Circuit - shorted high.

EG528 Yellow

OEM Alternate torque validation switch - data incorrect.

EG529 Yellow

Auxiliary Input / Output #3 Circuit - shorted high.

EG546 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted high.

EG547 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted low.

EG551 Yellow

Accelerate Pedal Idle Validation Circuit - shorted low.

EG553 Yellow

Injector Metering Rail #1 Pressure High - warning level.

EG554 Yellow

Fuel Pressure Sensor Error.

EG559 Yellow

Injector Metering Rail #1 Pressure Low - data valid but below normal operational range - moderately severe level.

EG596 Yellow

Electrical Charging System Voltage High - warning level.

EG598 Red

Electrical Charging System Voltage Low - critical level.

EG689 Yellow

Crankshaft Engine Speed Signal Error.

EG731 Yellow

Mechanical Timing Misalignment.

EG753 Yellow

Crankshaft Position Sensor and Camshaft Position Sensor - data erratic, intermittent, or in correct.

EG757 Yellow

Electronic Control Module Data Lost.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

3.58 TROUBLESHOOTING

EG758 Yellow

Injector Metering Rail #2 Pressure Malfunction.

EG778 Yellow

Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.

EG951 None

Cylinder Power Imbalance Detected.

EG1117 None

Power Lost with Ignition ON - data erratic, intermittent, or incorrect.

EG1358 Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or Yellow shorted high.

EG1359 Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or Yellow shorted low.

EG1361 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below Yellow normal or shorted low.

EG1376 Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or Orange incorrect.

EG1595 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above Yellow normal or shorted high.

EG1597 Engine Control Module Critical Internal Failure - bad intelligent device or Orange component.

EG1845 Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to Orange high source.

EG1846 Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to Orange low source.

EG1852 Water in Fuel Indicator - data valid but above normal operational range Yellow moderately severe level.

EG1911 Yellow

Injector Metering Rail 1 Pressure - above normal operating range.

EG2185 Sensor Supply Voltage #4 Circuit - shorted high.

Yellow EG2186 Sensor Supply Voltage #4 Circuit - shorted low.

Yellow EG2215 Fuel Pump Delivery Pressure - data valid but below normal operational Yellow range - moderately severe level.

EG2249 Fuel Pump Delivery Pressure Sensor Circuit - shorted low.

Yellow EG2261 Fuel Pump Delivery Pressure - data valid but above normal operational Orange range - least severe level.

EG2262 Fuel Pump Delivery Pressure - data valid but below normal operational Orange range - least severe level.

EG2265 Fuel Priming Pump Control Signal Circuit - shorted high.

Yellow EG2266 Fuel Priming Pump Control Signal Circuit - shorted low.

Yellow EG2311 Yellow

Fueling Actuator #1 Circuit Error - condition exists.

EG2321 Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.

None EG2322 Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.

None EG2697 Accelerator Pedal Position Sensor Circuit and Idling Position Detection Orange Switch Circuit - data erratic, intermittent, or incorrect.

EG2963 Engine Coolant Temperature High - warning.

None

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

3.59 TROUBLESHOOTING

EG2964 Intake Manifold Temperature High - warning.

None EG2973 Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or Yellow incorrect.

(09D20E)

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

3.60 TROUBLESHOOTING

3.61 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.

Standard boom

High lift

General purpose General purpose Material handling Light material with bucket with bolt-on bucket with teeth bucket with bolt-on bolt-on cutting cutting edge cutting edge edge Capacity

Heaped

yd3 (m3)

2.2 (1.7)

2.1 (1.6)

2.5 (1.9)

2.2 (1.7)

Struck

yd3 (m3)

2.0 (1.5)

1.8 (1.4)

2.1 (1.6)

2.0 (1.5)

Maximum dumping clearance

ft-in (mm)

8'11 7/8" (2,740)

8'8 1/2" (2,655)

8'9 7/8" (2,690)

10' 1/8" (3,050)

Dumping reach (to front of bucket edge or tooth)

ft-in (mm)

3'3 3/4" (1,010)

3'6 3/8" (1,075)

3'5 3/4" (1,060)

3'3 3/8" (1,015)

Minimum turning radius at outside bucket 17'9 1/4" (5,415 mm) at center of outside tire 15'2 5/8" (4,640 mm) Full articulation angle 40º Tread

45º

6'1 1/4" (1,860 mm) Width (outside tire) 8' 1/2" (2,450 mm) Width (outside bucket) 7'5" (2,260 mm) Equipped with GSC bucket with bolt on cutting edge 17.5-25-12PR (L-2) Tire and ROPS Cab

11'8 1/2" (3,570)

10'2 5/8" (3,115)

9' 17/64" (2,750) 50º

1' 4" (405) 8'10 1/4" (2,700) 21'11 9/16" (6,695)

WL OPERATING SPEC EU

3.62 SPECIFICATIONS

Bucket Selection Chart Standard arm

Bucket size yd3 (m3)

2.1 (1.6) 2.2 (1.7) 2.5 (1.9) 2,200 2,300 2,400 2,500 2,600 2,700 2,800 2,900 3,000 3,100 3,200 3,300 3,400 3,500 3,600 3,700 Material density lbs/yd3 (m3) Bucket fill 115% 100% 95%

60ZV2 Bucket Selection Chart

Operating Weight

19,970 lb (9,060 kg)

Engine

Model Type

CUMMINS QSB4.5 Diesel 4 cycle, Water Cooled, Direct injection, Turbo charged & air cooled intercooler

Displacement

272 in3 (4.46 Liter)

Rated Power (Gross)

97 kW / 2,200 min-1 (130 HP / 2,200 rpm)

Tire

17.5-25-12PR(L-2)

Max. Running Speed (forward/reverse)

1st : 5.2 M PH ( 8.4 km/h) / 5.2 MPH ( 8.4 km/h) 2nd: 9.7 M PH (15.6 km/h) / 9.7 MPH (15.6 km/h) 3rd :20.5 M PH (33.0 km/h) / 20.5 MPH (33.0 km/h)

The weight and load figure includes optional counterweight, enclosed ROPS cab, air conditioner, GSC bucket with bolt-on cutting edge, 17.5-25-12PR (L-2) tires, full fuel tank and operator.

INDEX (FE) Fuel Efficient Mode Switch ................................2.12 12 Volt Power-outlet Socket ......................................2.16

A Accelerator Pedal ........................................................2.6 Adjust and Check Rear View Mirrors ........................2.47 Adjust Parking Brake Lining ......................................3.38 Adjustments ..............................................................2.67 After Storage .............................................................2.76 Air Cleaner Warning Lamp (red) ...............................2.20 Articulation Stopper ..........................................1.26, 2.43 Auto Shift Indicator Lamp ..........................................2.21 Auxiliary Attachment Control Lever (option) ................2.5

B Before Starting Safety .................................................1.4 Before Storage ..........................................................2.75 Boom Kickout Adjustment .........................................2.68 Booster Batteries / Jumper Cables ...........................2.70 Brake Oil Warning Lamp (red) ..................................2.19 Bucket / Attachment Leveler Adjustment ..................2.67

C Carrying .....................................................................2.64 Cautions on Battery Replacement or Battery Cable Removal .................................................................2.77 Cautions Regarding Welding Repair Service ............2.78 Central Warning Lamp (red) ......................................2.19 Charge Lamp (red) ....................................................2.21 Check after Starting the Engine ................................2.50 Check Air Conditioner Refrigerant (option) ...............3.39 Check Air Intake System ...........................................2.46 Check and Adjust Air Conditioner Belt (option) .........3.27 Check and Adjust Valve Lash Clearance ..................3.45 Check Back-up Alarm Operation ...............................2.53 Check Battery Electrolyte Level ................................3.23 Check before Operation ............................................2.38 Check Brake Oil Level ...............................................2.41 Check Bucket Stopper ..............................................3.16 Check Control Lever .................................................2.47 Check Cooling Fan ....................................................2.46 Check Crankcase Breather Tube ..............................2.45 Check Differential Gear Oil .......................................3.26 Check Drive Belt .......................................................2.45 Check Engine Coolant Level .....................................2.41 Check Engine Oil Level .............................................2.39 Check Exhaust Gas ..................................................2.53 Check Fuel Level ......................................................2.51 Check Horn Operation ..............................................2.47 Check Hydraulic Oil Level .........................................2.40 Check Monitor Panel Operation ................................2.47 Check or Replace Fuses ...........................................3.12 Check Parking Brake ................................................2.47 Check Parking Brake Operation ................................2.52 Check Ride Control Accumulator (option) .................3.45 Check Seat Belt Restraint .........................................2.47

Check Service Brake Disk Wear ...............................3.45 Check Service Brake Operation ................................2.52 Check Steering Wheel Operation .............................2.53 Check Tightness of Wheel Bolts ...............................3.26 Check Tire Air Pressure ............................................3.21 Check Tire for Damage, Air and Tread Depth ..........2.43 Check Transmission Oil Level ..................................2.51 Check Transmission Shift Lever ...............................2.47 Check Warning Lamps ..............................................2.50 Check Windshield Washer Fluid ...............................3.13 Check Wiring Harnesses ..........................................2.42 Clean Air Conditioner and Heater Filter Element (option) ..................................................................3.28 Clean Air Conditioner Condenser (option) ................3.13 Clean Fuel Tank ........................................................3.44 Clean or Replace Air Cleaner Element .....................3.10 Clean or Replace Transmission Breather .................3.37 Clean Radiator / Air cooler / Hydraulic oil cooler Fins ........................................................................3.12 Cold Start ..................................................................2.49 COMPONENT NAME/LOCATION ..............................2.2 Control Lever Lock for Quick Coupler Lock Pin [3rd spool valve specification (option)] ..................1.25 Coolant Specification ................................................3.48

D Declutch Lamp (green) .............................................2.18 Declutch Switch ........................................................2.13 Downshift Button .......................................................2.14 Dozing .......................................................................2.62 Drain Water and Sediment from Fuel Filter ..............2.42 Drain Water and Sediment from Fuel Tank ..............3.22 Dumping into Truck or Hopper ..................................2.64 During Storage ..........................................................2.76

E Electrical Protection ..................................................2.25 Engine Coolant Temperature Gauge ........................2.18 Engine Coolant Temperature Warning Lamp (red) .......................................................................2.20 Engine Oil Pressure Warning Lamp (red) .................2.20 Engine Warning Lamps .............................................2.22 Every 10 Hours or Daily ............................................3.17 Every 1000 Hours or 6 Months .................................3.35 Every 2000 Hours or 1 Year .....................................3.41 Every 250 Hours or 1 Month .....................................3.24 Every 50 Hours or 1 Week ........................................3.18 Every 500 Hours or 3 Months ...................................3.30 Excavating ................................................................2.62 Explosion / Fire / Burn Prevention ............................1.13

F Four-Way Flasher Switch (option) ............................2.14 Front Wiper Switch (Included in cab spec.) ..............2.15 Front Working Light Switch (Included in cab spec.) (option) ..................................................................2.11

Fuel Level Gauge ..................................................... 2.18 Fuse Boxes ............................................................... 2.25 Fusible Link ............................................................... 2.26

G General Inspection .................................................... 2.54 Greasing ................................................. 2.39, 3.18, 3.24 Ground Levelling ....................................................... 2.63

H Heater or Air Conditioner (option) ............................. 2.35 Switches ................................................................ 2.35 Ventilation Location and Mode .............................. 2.35 High Beam Indicator Lamp (blue) ............................. 2.21 High-Low Beam Lever / Turn Signal Lever (option) ....................................................................... 2.4, 2.11 Horn Button ................................................................. 2.3 Hour Meter ................................................................ 2.21

I Indicators .................................................................. 2.17 Inspect Automatic Belt Tensioner Pulley .................. 3.40 Inspection and Maintenance Table ............................. 3.5

L Left Brake Pedal (Declutch Pedal) .............................. 2.7 Light Switch .............................................................. 2.10 Loading ..................................................................... 2.60 Loading Control Lever ................................................ 2.4 Loading Control Lever Lock ............................... 1.25, 2.8 Long Term Storage ................................................... 2.75

M MAINTENANCE .......................................................... 3.2 MCU (Machine Control Unit) Warning Lamp (red) .............................................................................. 2.19 Mounting and Dismounting Safety .............................. 1.3

N Neutral Indicator Lamp ............................................. 2.21 Neutral Start System ................................................. 1.27 Normal Start .............................................................. 2.48

O Operating Techniques .............................................. 2.60 Operating the Machine ............................................. 2.55 OPERATION ............................................................. 2.38 Operational Safety ...................................................... 1.6 Operator Safety .......................................................... 1.2 OPERATOR'S AREA .................................................. 2.3 Other Maintenance Safety Concerns ........................ 1.14 Overhaul Brake Master Cylinder ............................... 3.45

P Parking ...................................................................... 2.58 Parking Brake Indicator Lamp (red) .......................... 2.18

Parking Brake Lever ................................................. 1.27 Parking Safety .......................................................... 1.10 Pedals and Levers ...................................................... 2.3 Preheat Indicator Lamp (orange) .............................. 2.19

R Radio - AM / FM Cassette (24 Volt Type) (option) .... 2.27 Rear Wiper Switch (Included in cab spec.) (option) .................................................................. 2.15 Rear Working Light Switch / Cab Rear Working Light Switch (option) .............................................. 2.12 Recommended Lubricants ........................................ 3.46 Recommended Mixture of Antifreeze ....................... 3.48 Replace Air Conditioner Filter Elements (option) ...... 3.15 Replace Air Conditioner Receiver Dryer (option) ...... 3.16 Replace Bucket Teeth (option) ................................... 3.8 Replace Coolant ....................................................... 3.14 Replace Cutting Edge (option) .................................... 3.9 Replace Differential Gear Oil .................................... 3.43 Replace Engine Oil and Oil Filter Cartridge .............. 3.30 Replace Filter ............................................................ 3.29 Replace Filter in the Hydraulic Tank Cap ................. 3.44 Replace Fuel Filter Cartridges .................................. 3.33 Replace Hydraulic Oil Return Filter .......................... 3.37 Replace Hydraulic Oil, Clean Filter ........................... 3.41 Replace Seat Belt and Tether ................................... 3.10 Replace Transmission Oil ......................................... 3.35 Replace Transmission Oil Filter Cartridge ................ 3.32 Ride Control (option) ................................................. 2.37 Ride Control Indicator Lamp (green) (option) ........... 2.22 Ride Control Switch (option) ..................................... 2.13 Right Brake Pedal ....................................................... 2.7 Roading / Special Applications ................................. 2.69 ROPS (Roll Over Protective Structure) ..................... 1.28 ROPS (Roll Over Protective Structure) (option) ....... 2.47

S Safe Operation ............................................................ 1.2 SAFETY ...................................................................... 1.2 Safety Devices .......................................................... 1.25 Safety Preparations Before Maintenance ................. 1.11 Safety Signs .............................................................. 1.16 Seat .......................................................................... 2.23 Seat Adjustment ....................................................... 2.23 Seat Belt ................................................................... 2.24 Secondary Steering Warning Lamp (red) (option) .............................................................................. 2.22 Serial Number Location .............................................. 3.2 SPECIAL PROCEDURES ........................................ 2.67 SPECIFICATIONS .................................................... 3.61 Speed and Direction Change .................................... 2.56 Speedometer ............................................................ 2.18 Starter Switch ........................................................... 2.10 Starting the Engine ................................................... 2.48 Starting the Machine ................................................. 2.55 Starting the Machine on a Grade .............................. 2.56 Steering Column Telescopic Tilt Handle ..................... 2.8 Stopping the Engine ................................................. 2.59 Switches ..................................................................... 2.9

T Torque Converter Oil Temperature Warning Lamp (red) .......................................................................2.20 Towing .......................................................................2.72 Transmission Shift Lever .............................................2.3 Transportation ...........................................................2.73 TROUBLESHOOTING ..............................................3.49 Turn Signal Indicator Lamp (Left) (green) .................2.21 Turn Signal Indicator Lamp (Right) (green) ...............2.21 Typical Truck Loading Methods ................................2.66

W Walk-Around Inspection ............................................2.38 Welding .....................................................................2.78 When Required Inspection and Maintenance .............3.8 Working Light Indicator Lamp (green) .......................2.19 Wrist Rest (adjustable) ................................................2.6

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