Kawasaki 80ZV-2 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 93109-00562 (1)

80ZV-2

93109-00562 May 16, 2012

OPERATION & MAINTENANCE MANUAL WHEEL LOADER

80ZV-2

Printed in Japan (K) ( オセアニア向 )

93109-00562

©2012 KCM Corporation. All rights reserved.

NOTICE

Powered by CUMMINS QSC8.3 Engine Serial No. 80C5-9201 and up

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

93109-00562 May 16, 2012

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

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.

Read and understand this manual before operating and save this manual on the machine.

If lost, damaged or unreadable, replace the manual immediately.

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.............................................................................................................................. 1.12 Safety Signs....................................................................................................................................... 1.18 Safety Devices................................................................................................................................... 1.28 2.OPERATION ............................................................................................................................................... 2.1 COMPONENT NAME/LOCATION ............................................................................................................. 2.2 OPERATOR'S AREA ................................................................................................................................. 2.3 Pedals and Levers ............................................................................................................................... 2.3 Switches ............................................................................................................................................ 2.10 Indicators ........................................................................................................................................... 2.25 MODM ............................................................................................................................................... 2.33 Seat ................................................................................................................................................... 2.42 Electrical Protection ........................................................................................................................... 2.45 Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009) .............................................. 2.47 Air Conditioner ................................................................................................................................... 2.55 Ride Control (option).......................................................................................................................... 2.62 Manual Box........................................................................................................................................ 2.63 Grease Gun Holder............................................................................................................................ 2.64 Quick Coupler (option)....................................................................................................................... 2.65 OPERATION ............................................................................................................................................ 2.69 Check before Operation..................................................................................................................... 2.69 Starting the Engine ............................................................................................................................ 2.79 Idling Management System ............................................................................................................... 2.81 Check after Starting the Engine ......................................................................................................... 2.82 Operating the Machine ...................................................................................................................... 2.87 Parking............................................................................................................................................... 2.90 Stopping the Engine........................................................................................................................... 2.91 Operating Techniques........................................................................................................................ 2.92

SPECIAL PROCEDURES...................................................................................................................... 2.100 Adjustments ..................................................................................................................................... 2.100 Roading / Special Applications......................................................................................................... 2.101 Booster Batteries / Jumper Cables .................................................................................................. 2.102 Towing.............................................................................................................................................. 2.104 Transportation .................................................................................................................................. 2.106 Long Term Storage........................................................................................................................... 2.108 Welding .............................................................................................................................................2.112 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 ..................................................................................................................... 3.20 Every 50 Hours or 1 Week ................................................................................................................. 3.21 Every 250 Hours or 1 Month .............................................................................................................. 3.27 Every 500 Hours or 3 Months ............................................................................................................ 3.34 Every 1000 Hours or 6 Months .......................................................................................................... 3.40 Every 2000 Hours or 1 Year............................................................................................................... 3.46 Recommended Lubricants ................................................................................................................. 3.58 Coolant Specification ......................................................................................................................... 3.60 TROUBLESHOOTING ............................................................................................................................. 3.61 SPECIFICATIONS ................................................................................................................................... 3.71

1.1

1.SAFETY

1.2 SAFETY Safe Operation

SAFETY Safe Operation Operator Safety

OM0026a

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 - Eye/face protection - Antidust mask or approved respirator

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.

OM0002

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

1.3 SAFETY Safe Operation

Mounting and Dismounting Safety

OM0222

The inhalation of asbestos-laden dust involves the risk of having an adverse health effect. At the wrecking site and the site handling industrial waste, there is a possibility of inhaling asbestos-laden dust.

It is requested that the following measures should be taken at the site where there is a possibility that asbestos-laden dust flies in all directions.

- The worker should wear protective equipment such as a dust-protective mask.

- Sprinkle water in order to prevent asbestos from flying in the air.

- Do not use compressed air for cleaning work.

- Do not allow any person other than workers to come near the working site.

- Observe strictly the laws, regulations and rules regarding the environmental standards at working sites.

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.

Asbestos is not used both in this product and genuine parts. However, as it is feared that asbestos may be used in non-genuine parts, please be sure to use our genuine parts for replacement.

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.

1.4 SAFETY Safe Operation

Before Starting Safety

OM0012 OM0006

Do not allow unauthorized personnel on the machine. Only the operator alone should be on the machine.

Know the location of safety items and procedures:

Do not carry person(s) with this machine like a passenger car.

- Fire extinguishers - Fire blankets - First aid kits - Emergency phone numbers

It is prohibited to raise person(s) put in bucket or attachment.

Walk around the machine to be sure no one is working or laying under the machine.

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

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

- properly attached (no bolts loose or missing).

- not damaged.

- not modified.

1.5 SAFETY Safe Operation

OM0005

Articulation Stopper "STORED"

85ZV0002

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

- Back-up Alarm -- Operational

Perform the normal daily maintenance.

Securely lock the cab door either fully open or closed.

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

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

Lock

Unlock

85ZV20005b

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

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

Do not bring inflammable or explosive materials such as: - spray can - chemical cylinder

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

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.

N

65ZV 5089

- Transmission Shift Lever -- Neutral

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

1.6 SAFETY Safe Operation

OM0007

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

Properly fasten the seat belt.

OM0011

Do not start to work in an enclosed area if adequate ventilation is not provided. Fumes could build up during operation that could cause drowsiness, injury, or death.

Blow the horn for a few seconds just before starting the engine to alert bystanders.

DANGER DO NOT START MEN WORKING ON MACHINERY SIGNED BY 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.

OM0183

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

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.

- 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 2.102.

1.7 SAFETY Safe Operation

Operational Safety Follow the regulations related to this machine, and drive carefully.

Before operating the machine, refer to "SPECIFICATIONS" listed on page 3.71.

Do not use the machine with excessive load than specified, to avoid a stack of the machine and/or any risk of injury caused by potential structural damage of the machine due to the overload.

Use the permitted attachments and optional parts provided, when needed, which are suitable for the operating conditions and job contents.

SITE SAFETY: Consider the safety of the job site before operating the machine: - Be aware of and avoid cliffs, ditches, trenches, overhead or underground wires, underground pipes, other equipment, and workers in the area.

- If required, be aware of hand signals that may be used by ground guides.

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 -25ºC ~ 35ºC. When working on a grade: - 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.

OM0018

OM0021

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

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.

Keep bystanders out of the work area.

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

Keep the work site as clean and flat as possible.

Do not expose the machine to flames.

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

Follow all local, federal or provincial laws and regulations regarding calling to locate underground hazards such as buried cables and pipes prior to digging.

Do not operate the machine under circumstances where toxic gas is generated or asbestos is flying in all directions.

1.8 SAFETY Safe Operation

SAFETY DURING NORMAL OPERATIONS:

When roading the machine:

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

- Travel in forward only.

- Travel only as fast as conditions and safety allow.

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

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

Know the machine limits and do not exceed them.

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

OM0013

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

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.

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.

OM0184

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

approx. 40 cm OM0016

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

1.9 SAFETY Safe Operation

SPECIAL OPERATING CONDITIONS:

OM0020

OM0185

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.

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

If entering water is unavoidable:

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

- 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.

1.10 SAFETY Safe Operation

80ZV0001

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

- Make sure to install the split pin into the hitch pin to avoid the hitch pin coming off.

- 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.

1.11 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.

1.12 SAFETY Safe Maintenance

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

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

OM0002

Perform maintenance and repairs only if trained.

Follow the Operation & Maintenance Manual or Shop Manual.

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

- 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.

OM0222

OM0026a

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 - Antidust mask or approved respirator

The inhalation of asbestos-laden dust involves the risk of having an adverse health effect. At the wrecking site and the site handling industrial waste, there is a possibility of inhaling asbestos-laden dust.

It is requested that the following measures should be taken at the site where there is a possibility that asbestos-laden dust flies in all directions.

- The worker should wear protective equipment such as a dust-protective mask.

- Sprinkle water in order to prevent asbestos from flying in the air.

- Do not use compressed air for cleaning work.

- Do not allow any person other than workers to come near the working site.

- Observe strictly the laws, regulations and rules regarding the environmental standards at working sites.

1.13 SAFETY Safe Maintenance Asbestos is not used both in this product and genuine parts. However, as it is feared that asbestos may be used in non-genuine parts, please be sure to use our genuine parts for replacement.

OM0029

Never make repairs on pressurized components.

Release all trapped air and hydraulic pressure by: OM0025

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.

- 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.

Always ask our authorized dealer in your area to repair or maintain on pressurized components.

1.14 SAFETY Safe Maintenance

Support bar

DANGER DO NOT START MEN WORKING ON MACHINERY SIGNED BY DATE

OM0182 85ZV28463

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.

70ZV27373

It may be a possibility that your hands or fingers are pinched with cover suddenly closed by mighty wind etc.

OM0031

Surely support the cover by support bar when carrying on inspection work keeping the cover open.

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

Pay attention not to pinch your fingers when you close door.

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

(The illustration above is shown the model 70ZV-2 engine room.)

1.15 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.

1.16 SAFETY Safe Maintenance

Other Maintenance Safety Concerns 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.

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.

1.17 SAFETY Safe Maintenance

Do not enter the articulation area when engine is running.

Articulation Stopper "LOCKED" 85ZV0001

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

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

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

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

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

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

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

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

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

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

1.18 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.

1.19 SAFETY Safety Signs

16.

1.

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

Always keep ROPS in place.

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

44841-20870

Inside L.H, R.H

44787-24020

44787-23880

L.H, R.H

L.H, R.H

80ZV02597-0722PVa

4.

5.

44787-23950

R.H

44787-23940

17.

6.

44787-24040

44787-24010

1.20 SAFETY Safety Signs

10.

8.

44787-23870

44787-23850

Inside

18.

11.

44787-24000

44787-23900

Inside

80ZV02597-0722TV

11.

10.

44787-23900

8.

44787-23850

Inside

44787-23870

9.

Inside

44787-23860

1.21 SAFETY Safety Signs

13.

2.

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 44787-23970

44787-23910

L.H, R.H

80ZV02597-0722REa

3.

L.H, R.H

7.

L.H, R.H

6.

STOP 44787-23920

44787-23930

44787-24010

1.22 SAFETY Safety Signs

12.

Parking brake cylinder

80ZV02597-0729EE

44787-23980

Inside of Cab

B B-B

70ZV02597-0717BSa

B

A A

70ZV02597-0717BS

A-A 70ZV02597-0717AS

15.

14.

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

44787-23960

44787-23840

1.23 SAFETY Safety Signs 3.

1.

STOP 44787-23880

44787-23920

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.

STOP 44787-23910

WARNING

44787-23950

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.

1.24 SAFETY Safety Signs 7.

5.

44787-23940

44787-23930

WARNING

WARNING Machine will not turn with articulation stopper in locked position.

Machine movement could result in death or serious injury.

Unlock articulation machine.

Stay out of this machine.

stopper

before

operating

8.

6.

44787-24010

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

Release the oil pressure from all brake circuit (and steering circuit for 65/70ZV-2 only) before removing any oil lines or piping.

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

44787-23870

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

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

1.25 SAFETY Safety Signs 10.

9.

44787-23860

44787-23850

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.

11.

44787-23900

CAUTION You may fall from here.

Do not step on here.

1.26 SAFETY Safety Signs 14.

12.

44787-23960

44787-23980

WARNING

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

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

Read Shop Manual before repairing this part.

Before checking transmission oil: - Park on level ground.

- Lower attachment to ground.

- Place transmission in neutral.

- Set parking brake.

- Tag "Do Not Operate."

13.

44787-23970

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

- Do not start engine by shorting across starter terminals.

- Do not start engine while standing on ground.

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

1.27 SAFETY Safety Signs 17.

15.

44787-24040

44787-23840

WARNING

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

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

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

Allow system to cool and vent pressure slowly before servicing.

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

18.

16.

44787-24000

44787-24020

WARNING

WARNING

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

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

Allow system to cool and vent pressure slowly before servicing.

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

1.28 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

85ZV20005b

Unlock

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

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.

70ZV0010d

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.

1.29 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 85ZV0001

1. Align the front and rear chassis straight ahead.

2. Using a 14 mm wrench remove the bolt that fixes the articulation stopper to the storage bracket on the front chassis.

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

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

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

1.30 SAFETY Safety Devices

Neutral Start System

To unlock:

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

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

"STORED" position

85ZV0002

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

2. Turn the link to the front chassis bracket.

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

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

97ZVOM0038

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

1.31 SAFETY Safety Devices

Secondary Steering

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

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

ROPS (Roll Over Protective Structure) Cab The ROPS Cab is equipped with a structure (ROPS) to prevent the cab from being crushed and protect the operator if the vehicle is overturned. Our ROPS Cab is also equipped with the FOPS function to protect the operator from a falling object.

WARNING

If the secondary steering works:

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

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

- Do not use ROPS Cab deformed.

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

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

1. Keep the starter switch in the "ON" position even when the engine unexpectedly stops.

ROPS and FOPS cannot comply with all overturning or falling-stone accidents.

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

In case of accidents beyond the following upper limit conditions, the operator may not be protected.

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

ROPS "A machine rolls on a solid clay ground slope tilted by 30º at 16 km/h or less travelling speed and overturns by 360º around an axis in back and forth direction." (from JIS A8910)

Secondary steering works automatically when the steering hydraulic pressure goes down or the engine stops while the machine is operating.

When the steering hydraulic pressure goes down while the engine is running, the steering hydraulic warning lamp lights up.

Refer to "Secondary Steering Warning Lamp (red)" page 2.31.

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

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

FOPS "Non-cutting 295.7 kg object falls freely from a 4 mheight point (or an equivalent potential energy level)." (based on JIS A8920) ROPS Cab deformed does not assure safety for operator as a protective cab.

1.32

MEMO

2.1

2.OPERATION

2.2 COMPONENT NAME/LOCATION

COMPONENT NAME/LOCATION 24 25 16 23

5

22 21

10

20

11

9

4

3 2 1

14

18

12,13 17

6

8

19

15

7 80ZV2 EU COMPO

1. Bucket (Attachment) 2. Boom 3. "Z" Lever 4. Boom Cylinders (2) 5. Bucket Cylinder 6. Steering Cylinders (2) 7. Engine 8. Torque Converter & Transmission Ass'y 9. Radiator & Torque Converter Cooler (Lower tank) 10. Air Cooler (for engine intake air) 11. Hydraulic Oil Cooler 12. Fuel Tank 13. Hydraulic Tank (Right hand side) NOTE When a component or an item location is given as "Left hand side" or "Right hand side", it is according to the operator's left side or right side when sitting in the seat.

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

2.3 OPERATOR'S AREA Pedals and Levers

OPERATOR'S AREA Pedals and Levers

1. Transmission Shift Lever

11

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

2 3

- Push the lever forward to move the machine forward.

1

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

- Pull the lever backward to move the machine backward.

9

6 (option) 4

10 9

8

97ZVOM0041

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

7

5

85ZV20005c

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

65ZV 5089

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

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

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

2.4 OPERATOR'S AREA Pedals and Levers

3. High-Low Beam Lever / Turn Signal Lever

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

Low beam position

(a)

(b)

(c) (d)

High beam position

97ZVOM0044

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

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

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

85ZV20005c

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

The boom will lower and move freely following the ground surface.

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

When held in this position, down pressure will be applied to the attachment.

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

97ZVOM0044

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

(c) Hold - Return the lever to the center position. The boom will stop and remain in that position.

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

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

When pulled fully back it is held in a detented position.

- 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.

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

2.5 OPERATOR'S AREA Pedals and Levers - For adjustment procedure Refer to "Kickout Control Switch" page 2.18.

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.

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

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

(b) (c)

(d)

(a)

85ZV20005c

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

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

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

- For adjustment procedure refer to "Bucket / Attachment Leveler Adjustment" page 2.100.

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.

2.6 OPERATOR'S AREA Pedals and Levers

6. Auxiliary Attachment Control Lever (option)

7. Wrist Rest

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

Unlock

(a)

(b) (c) Lock

65ZV4705

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

85ZV20005c

(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.

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

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

2.7 OPERATOR'S AREA Pedals and Levers

8. Accelerator Pedal

Effect on the machine The ECM is equipped with safety functions that are designed to limit engine speed in certain situations.

To avoid insufficient engine performance because of this safety function, the following steps are important.

1. Wait 1 second before turning the key from the "ON" to the "START" position.

(The safety function will turn "ON" 1 second after the key is set to the "ON" position.)

97ZVOM0038

Accelerator pedal is used to control the engine speed.

- Step on the pedal to increase the engine speed.

- Release the pedal to decrease the engine speed.

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

- Be sure control pedals move freely before operating.

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

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

2. Do not step on the pedal while the engine is starting, nor just after the engine starts.

(It takes about 3 seconds to complete the adjustment, and stepping on the pedal negatively affects the correct adjustment.)

If the safety function is activated, turn off the engine for about 30 seconds and then restart.

Engine Acceleration Control (Function) (Turbo Protection) When the engine coolant temperature is 10ºC or lower, the accelerator is not activated a few seconds and delays the response for acceleration.

2.8 OPERATOR'S AREA Pedals and Levers

9. Brake Pedals

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

- Do not use brake pedals as foot rest.

- Do not ride brakes.

- Use brake pedals only when applying brakes.

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

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

97ZVOM0038

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

Left and right Brake Pedals: May be used either of two ways: 1. As a brake only pedal by turning the declutch switch (See page 2.17) 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 the "ON" position. When the switch is "ON", a green indicator lamp on the dash will also be turned on.

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.

2.9 OPERATOR'S AREA Pedals and Levers

10. Steering Column Telescopic Tilt Handle

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

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

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

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

Release

Lock

97ZVOM0045

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

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

2.10 OPERATOR'S AREA Switches

Switches (80C5-9201~9350)

11

4

6

5

15 16 STOP

85ZV2 0001b

(80C5-9351~)

11

4

6

5

15 16

65ZV2 0001

3

2

12

9 7 65ZV5089c

10

8 65ZV 5088b

18 17

20 19 14 13

1

21 85ZV20006b

85ZV2 FR SWITCH a

2.11 OPERATOR'S AREA Switches 1. Starter Switch 2. Parking Brake Switch 3. Light Switch 4. Front Working Light Switch 5. Rear Working Light Switch 6. (FE) Fuel Efficient Mode Switch 7. Front Wiper Switch 8. Rear Wiper Switch 9. Cigarette Lighter 10. Downshift Button 11. Four-Way Flasher Switch 12. MODM 13. Declutch ON/OFF and Adjustable Preset Switch 14. Kickout Control Switch 15. Efficient Loading System Switch 16. Selection Switch for Shift Lever or F/R Switch 17. F/R Switch 18. Reversal Fan Switch (option) 19. Ride Control Switch (option) 20. Shift Hold Switch (option) 21. Quick Coupler Lock Pin Switch (option)

1. Starter Switch

PREHEAT

OFF

ON

START

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.

2.12 OPERATOR'S AREA Switches

2. Parking Brake Switch

3. Light Switch

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

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

65ZV 5088b

This is a three position switch.

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

97ZVOM0038

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

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

- 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.

2.13 OPERATOR'S AREA Switches

4. Front Working Light Switch

5. Rear Working Light Switch

85ZV2 0002b

85ZV2 0002b

OFF

OFF

ON

ON

switch-4

switch-4

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

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

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

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

2.14 OPERATOR'S AREA Switches

6. (FE) Fuel Efficient Mode Switch

7. Front Wiper Switch

85ZV2 0002b

65ZV 5088b

OFF

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

ON

switch-3

Engine Torque

OFF

INT LOW HIGH

PUSH

OM0189

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.

OFF

:

INT

: Intermittent

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

2.15 OPERATOR'S AREA Switches

8. Rear Wiper Switch

9. Cigarette Lighter

65ZV 5088b

Rear wiper switch is used to wipe the rear windshield.

65ZV 5088b

Cigarette lighter is used to light a cigarette or cigar.

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

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

OFF

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

ON

PUSH

OM0190

OFF

:

ON

: Low speed

PUSH : Spraying solvent on the windshield

2.16 OPERATOR'S AREA Switches

10. Downshift Button

11. Four-Way Flasher Switch

85ZV2 0002b

85ZV20005c

OFF

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] or [A] position, the transmission will shift down to 1st gear by pressing downshift button.

- Pressing downshift button again or moving the transmission shift lever to the opposite direction releases the 1st gear setting to return to 2nd gear.

ON

switch-3

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

2.17 OPERATOR'S AREA Switches

12. MODM

13. Declutch ON/OFF and Adjustable Preset Switch

Declutch OFF

Declutch preset

Declutch ON 65ZV5089c 85ZV20005c

The MODM has the following functions: - Information monitor

Declutch ON/OFF

- Displays outside air temperature, machine speed and engine speed, engine coolant temperature, transmission oil temperature, hydraulic oil temperature and miles driven etc.

- Replacement monitor Allows check of the replacement time for the parts and oil periodically replaced, allows setting of the replacement interval, and displays the replacement pop-ups.

OFF ON

switch-9

- Error log monitor Allows check of previous errors, and displays active errors.

- Input/Output monitor Displays the ON/OFF status of input and output signals.

- Parameter setting monitor Allows check and change of the parameter setting.

- Specification setting monitor Allows check and change of the specification setting.

Refer to page 2.33 for the MODM operation.

Declutch ON/OFF switch is used to change the function of the brake pedals.

Normally this switch should be "ON".

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

Refer to "Brake Pedals" page 2.8 for the function of the brake pedals.

2.18 OPERATOR'S AREA Switches

14. Kickout Control Switch

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

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

Adjustable Declutch Preset

85ZV20005c

(Upper)

Hold Reset

switch-10

Adjustable declutch preset switch is used to change the angle of the brake pedal to disengage the transmission clutch.

With the engine running, step on the brake pedal up to the desired angle, and press the switch to set the declutch pedal angle.

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

Be sure to stop machine and pull parking brake switch before adjusting brake pedal angle.

(Lower)

Hold

Hold

Reset

Reset

switch-5

Kickout control switch is used to set the desired upper and lower boom position.

- Raise the boom to desired position and press the left side of the switch for 1 second to set the upper kickout position.

After the buzzer sounds, the boom height is set at that position.

When the boom control lever is placed at "Raise" position and the boom reaches at the preset height, the lift kickout automatically releases the detent and returns the boom control lever to "Hold" position.

- Lower the boom to desired position and press the right side of the switch for 1 second to set the lower kickout position.

After the buzzer sounds, the boom height is set at that position.

When the boom control lever is placed at "Float"

2.19 OPERATOR'S AREA Switches position and the boom reaches at the preset height, the lower kickout automatically releases the detent and returns the boom control lever to "Hold" position.

15. Efficient Loading System Switch

NOTE - Float detent is ready to be reactivated 2 seconds just after the previous lower kickout operation. Use the float detent after 2 seconds or more later the lower kickout operates.

85ZV2 0002b

- The bucket may hit the ground, if the boom leaves the clearance a bit higher above the lower kickout position.

- Preset the lower kickout position at a higher point when it is cold due to the thicker oil.

OFF

WARNING ON

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

Be sure to stop machine and pull parking brake switch before adjusting boom position.

switch-3

ELS (Efficient Loading System) increases rim-pull power when digging while consuming less fuel.

It is useful to use the ELS for heavy duty digging application or fuel efficient engine mode.

ELS system works under the following condition.

- ELS switch ON - Machine speed (Forward) under 5 km/h - Boom control lever set at "Raise" position

FAST

SLOW

90ZV2 5002

2.20 OPERATOR'S AREA Switches When this switch is turned "ON", the switch lamp lights up and the hydraulic oil flow is optimized to increase digging power. As a result, the boom rises slower than it would in the non-ELS position from the ground to the ELS engagement boom setting height.

16. Selection Switch for Shift Lever or F/R Switch (80C5-9201~9350)

This improves loading efficiency and save fuels.

STOP

The boom height position at which the ELS engages is preset at the factory before delivery.

However it can be changed to engage at different positions by doing the following steps.

85ZV2 0003b

(80C5-9351~)

To change the ELS engagement boom height, raise the boom to the desired position and repeatedly turn the efficient loading system switch from "OFF" to "ON" three times. After the buzzer sounds, the boom is set to engage at that position.

65ZV2 0001

ON/OFF

switch-4

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

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

Regardless of the shift lever position, while the F/R switch is in N position, when pressing selection switch, the light turns ON. Changing direction for forward/reverse can be operated by F/R switch.

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

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

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

2.21 OPERATOR'S AREA Switches

17. F/R Switch

85ZV2 FR SWITCH a

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

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

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

Operation

Shift lever position

F/R switch position

Selection switch

By F/R switch

Any position

N

ON

By shift lever

N

Any position

OFF

2.22 OPERATOR'S AREA Switches

18. Reversal Fan Switch (option)

Functional Limitation When either one of the following temperatures exceeds the preset upper limit(s), the cooling fan reverse rotation function does not work: - Engine coolant temperature - Torque converter oil temperature - Hydraulic oil temperature

85ZV20006b

ON/OFF

switch-3

Engaging this switch reverses the rotation of the cooling fan for cleaning the radiator fins.

When pushing this switch for more than 2 seconds while the engine is running or with the starter switch at "ON" position, the switch turns "ON", the pilot lamp in instrument panel lights up and the cooling fan turns in reverse rotation for 1 minute, after which it returns to it's normal rotation.

The fan turns continuously in reverse direction for 1 minute at 30 minute intervals.

When the switch is pushed again for more than 2 seconds, the cooling fan reversal switch turns "OFF" and the pilot lamp in instrument panel turns "OFF". Then the cooling fan turns in the normal direction.

The cooling fan reversal switch can be operated any time the engine is running. It is not necessary to stop the machine to push the reversal cooling fan switch.

2.23 OPERATOR'S AREA Switches

19. Ride Control Switch (option)

20. Shift Hold Switch (option)

85ZV20006b

85ZV20006b

Shift hold switch is used to fix the gear when operating the machine with the transmission shift lever in [A] position.

Pressing shift hold switch again cancels the setting and the machine runs in [A] speed as before.

OFF

NOTE Even if the gear is fixed at the 4th position, it will automatically shift down to the 3rd gear position when machine speed becomes 3 km/h or slower to avoid knocking or engine stop.

ON

switch-3

When the ride control switch is ON, the ride control works. Refer to "Ride Control (option)" page 2.62.

2.24 OPERATOR'S AREA Switches

21. Quick Coupler Lock Pin Switch (option) Quick coupler lock pin switch is used to lock/unlock the quick coupler for 2-way piping specification machine with quick coupler.

85ZV20005d

85ZV2 35010-6035

( ) The lock pin is fixed. ( N ) In neutral position (when the switch is kept parallel.), the lock pin is held on the position. ( ) The lock pin is disconnected.

NOTE During the operation of the switch, keep the bucket control lever on the "Roll Back" position.

2.25 OPERATOR'S AREA Indicators

Indicators (80C5-9201~9350)

21

1

20 5 17 19

18

9

2

23

4

10

11(28) 12 13 14 15 16

STOP

27

25

26

24 22 (28)

6

8

7

85ZV2 0004

3

(80C5-9351~)

1

22

21 17 20 19 5 9 7 18

2

4

10

11(28) 12 13 14 15 25 24 23 27 (28)

26

8

6

3

65ZV2 0002

16

2.26 OPERATOR'S AREA Indicators 1. Speedometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Gauge 5. Parking Brake Indicator Lamp (red) 6. Declutch Lamp (green) 7. Working Light Indicator Lamp (green) 8. Preheat Indicator Lamp (orange) 9. Central Warning Lamp (red) 10. MCU (Machine Control Unit) Warning Lamp (red) 11. Brake Pressure Warning Lamp (red) 12. Engine Oil Pressure Warning Lamp (red) 13. Engine Coolant Temperature Warning Lamp (red) 14. Torque Converter Oil Temperature Warning Lamp (red) 15. Air Cleaner Warning Lamp (red) 16. Charge Lamp (red) 17. Turn Signal Indicator Lamp (Left) (green) 18. Turn Signal Indicator Lamp (Right) (green) 19. High Beam Indicator Lamp (blue) 20. Auto Shift Indicator Lamp 21. Neutral Indicator Lamp 22. Transmission Status Monitor 23. Hour Meter 24. Secondary Steering Warning Lamp (red) 25. Engine Warning Lamps 26. Reversal Fan Pilot Lamp (green)(option) 27. F/R Switch Indicator Lamp (green) 28. Hydraulic Oil Level Warning Lamp (simultaneous flashing)(red)(11. 24.)

When the starter switch is turned to "ON", all warning lamps (9) ~ (16), (24) and (25) light up for three seconds. This is the lamp (bulb) test period (lamp (16) lights up until engine starts).

1. Speedometer

20

30 40

10

50

0 km/h

70ZV0008

Indicates the machine ground speed in km/h.

2. Engine Coolant Temperature Gauge

C

H WATER TEMP

97ZVOM0049

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

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

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

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.

Refer to "TROUBLESHOOTING" page 3.61.

2.27 OPERATOR'S AREA Indicators

3. Torque Converter Oil Temperature Gauge

C

5. Parking Brake Indicator Lamp (red)

P

H T/C OIL TEMP

OM0052

97ZVOM0050

Lights up when the parking brake is applied.

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

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

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

6. Declutch Lamp (green)

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

Refer to "TROUBLESHOOTING" page 3.65.

OM0054

Lights up when the declutch switch is "ON".

4. Fuel Gauge

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

E

F

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

FUEL

65ZV0005

Indicates the fuel amount in the fuel tank.

7. Working Light Indicator Lamp (green)

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

OM0055

Lights up when working lights are on.

2.28 OPERATOR'S AREA Indicators

8. Preheat Indicator Lamp (orange)

11. Brake Pressure Warning Lamp (red)

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

OM0176

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

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

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

9. Central Warning Lamp (red)

OM0058 OM0056

Flashes when any of the warning lamps come on.

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

Refer to "TROUBLESHOOTING" page 3.64.

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

12. Engine Oil Pressure Warning Lamp (red)

OM0057

Lights up when MCU malfunctions.

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

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 3.61.

2.29 OPERATOR'S AREA Indicators

13. Engine Coolant Temperature Warning Lamp (red)

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

OM0060

Lights up when coolant temperature overheats.

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

- If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "TROUBLESHOOTING" page 3.61.

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 3.65.

CAUTION Hot coolant spray may cause burns.

15. Air Cleaner Warning Lamp (red) 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.

- 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.

2.30 OPERATOR'S AREA Indicators

16. Charge Lamp (red)

19. 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 3.63.

20. Auto Shift Indicator Lamp 17. Turn Signal Indicator Lamp (Left) (green)

AUTO OM0068

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

OM0065

Flashes when the turn signal switch lever is moved forward.

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

21. Neutral Indicator Lamp

N OM0069

Lights up when transmission is in neutral.

OM0066

Flashes when the turn signal switch lever is moved rearward.

2.31 OPERATOR'S AREA Indicators

22. Transmission Status Monitor

24. Secondary Steering Warning Lamp (red)

4 3 2 1

OM0072

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

OM0070

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

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

Also the warning buzzer sounds.

25. Engine Warning Lamps Engine stop lamp

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

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

STOP Red

OM0191

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.

23. Hour Meter

1/10h

Engine warning lamp

OM0071

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

Yellow

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.

2.32 OPERATOR'S AREA Indicators

26. Reversal Fan Pilot Lamp (green)(option)

28. Hydraulic Oil Level Warning Lamp (simultaneous flashing)(red)(11. 24.)

OM0223

OM0058

Lights up when the reversal fan switch is ON. Refer to "Reversal Fan Switch (option)" page 2.22.

OM0072

27. F/R Switch Indicator Lamp (green) Flashes simultaneously when hydraulic oil level is lower than specified. Also the warning buzzer sounds.

OM0218

Lights up when the selection switch for shift lever or F/R switch is ON. Refer to "Selection Switch for Shift Lever or F/R Switch" page 2.20.

When the lamp flashes simultaneously, IMMEDIATELY stop the machine and check for leaks in the hydraulic line.

Refill the hydraulic tank with oil as needed.

Refer to "Check Hydraulic Oil Level" page 2.71.

2.33 OPERATOR'S AREA MODM

MODM

Monitor Changeover

(Machine Operation Diagnostic Module)

[ ]button

Display window

[

Replacement monitor

Error log monitor

Information monitor

Input/Output monitor

Specification setting monitor

Parameter setting monitor

]button

[ (step back)] [ (step forward)] button button 90ZV-262001

Change over the monitor using the following procedure:

MODM function The MODM has the following functions: - Information monitor - Displays outside air temperature, machine speed and engine speed, engine coolant temperature, transmission oil temperature, hydraulic oil temperature and miles driven etc.

- Replacement monitor Allows check of the replacement time for the parts and oil periodically replaced, allows setting of the replacement interval, and displays the replacement pop-ups.

- Error log monitor Allows check of previous errors, and displays active errors.

- Input/Output monitor - Parameter setting monitor Allows check and change of the parameter setting.

- Specification setting monitor Allows check and change of the specification setting.

When the starter switch is ON, the information monitor is first displayed on initial monitor.

Press the [ (step back)] button and [ (step forward)] button at the same time to change over the monitor mode in sequence "Information monitor → Replacement monitor → Error log monitor → Input/Output monitor → Parameter setting monitor → Specification setting monitor → Information monitor".

However the monitor mode can not be changed in reverse such as "Information monitor → Specification setting monitor → Parameter setting monitor ....."

The display will not be changed to the next monitor when you hold the buttons.

2.34 OPERATOR'S AREA MODM

Information Monitor

1. Outside air temperature

Information monitor display When the starter switch is ON, the outside air temperature is displayed.

Every time the [ (step forward)] button is pressed or every time the [ (step back)] button is pressed, the displayed contents are changed over in sequence as below.

Step forward

Step back

90ZV-262024

The monitor displays the current outside air temperature when the starter switch is ON. Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

2. Machine speed and engine speed

Outside air temperature

Machine speed and engine speed

90ZV-262025

Engine coolant temperature

Press the [ ] button to change the display unit from "km/h" to "mile/h" Press the [ ] button again to return the display unit from "mile/h" to "km/h".

T/M oil temperature

For speed to be accurate, the correct tire size must be entered into the MCU via this MODM unit.

Hydraulic oil temperature

Odometer

Cycle

Cylinder oil pressure

Voltage

Hour meter

85ZV2 0008

2.35 OPERATOR'S AREA MODM 3. Current engine coolant temperature and maximum engine coolant temperature recorded (which can be reset)

90ZV-262026

The monitor displays the current engine coolant temperature and maximum engine coolant temperature recorded since the work on the day is started (that is, since the engine starter switch is ON).

Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum engine coolant temperature recorded on the day.

The maximum engine coolant temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off.

Immediately after reset, the engine coolant temperature at the time of reset is displayed as the maximum engine coolant temperature. In other words, the current engine coolant temperature is equivalent to the maximum engine coolant temperature.

Press the [ ] button to reset the maximum engine coolant temperature. Immediately after reset, the engine coolant temperature at the time of reset is displayed as the maximum engine coolant temperature.

Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

4. Current transmission oil temperature and maximum transmission oil temperature recorded (which can be reset)

90ZV-262027

The monitor displays the current transmission oil temperature and maximum transmission oil temperature recorded since the work on the day is started (that is, since the engine starter switch is ON).

Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum transmission oil temperature recorded on the day.

The maximum transmission oil temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off.

Immediately after reset, the transmission oil temperature at the time of reset is displayed as the maximum transmission oil temperature. In other words, the current transmission oil temperature is equivalent to the maximum transmission oil temperature.

Press the [ ] button to reset the maximum transmission oil temperature. Immediately after reset, the transmission oil temperature at the time of reset is displayed as the maximum transmission oil temperature.

Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

2.36 OPERATOR'S AREA MODM 5. Current hydraulic oil temperature and maximum hydraulic oil temperature recorded (which can be reset)

6. Odometer (total miles driven) and trip meter (which can be reset)

90ZV-262029 90ZV-262028

The monitor displays the current hydraulic oil temperature and maximum hydraulic oil temperature recorded since the work on the day is started (that is, since the engine starter switch to ON).

Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum hydraulic oil temperature recorded on the day.

The maximum hydraulic oil temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off.

Immediately after reset, the hydraulic oil temperature at the time of reset is displayed as the maximum hydraulic oil temperature. In other words, the current hydraulic oil temperature is equivalent to the maximum hydraulic oil temperature.

Press the [ ] button to reset the maximum hydraulic oil temperature. Immediately after reset, the hydraulic oil temperature at the time of reset is displayed as the maximum hydraulic oil temperature.

Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

The monitor displays the total number of miles driven in the upper line, and the trip meter in the lower line.

Press the [ ] button to reset the trip meter displayed in the lower line.

Press the [ ] button to change over the display unit from "km" to "mile". Press the [ ] button again to return the display unit from "mile" to "km".

7. Number of cycles and cycle time

90ZV-262030

The monitor displays the number of cycles in the upper line and the time required for one cycle (moving forward twice and moving backward twice) in the lower line.

Press the [ ] button to reset both the number of cycles and the cycle time.

After reset, the monitor displays newly the number of cycles in the upper line and the time required for one cycle in the lower line.

8. Hydraulic system oil pressure

90ZV-262031a

The monitor displays the unloader pressure of the efficient loading system (ELS).

Press the [ ] button to change over the display unit from "MPa" to "psi". Press the [ ] button again to return the display unit from "psi" to "MPa".

2.37 OPERATOR'S AREA MODM

Unit conversion and language selection

9. Voltage

Select the unit and language using the [ ] button.

90ZV-262032

10. Hour meter (total operating hours) and trip meter (which can be reset)

Unit conversion (for distance, temperature and pressure) Press the [ ] button once to change the display unit. Press the [ ] button again to return to the previous display unit.

Language selection 90ZV-262033

The monitor displays the total operating hours in the upper line, and the trip meter in the lower line.

Press the [ ] button to reset the trip meter displayed in the lower line.

Press and hold the [ ] button for 3 seconds or more to display the language selection screen.

English is selected as the initial setting.

Japanese, French, German, Italian and Spanish can be selected.

Press the [ (step forward)] button or [ (step back)] button to select the language.

For returning to the information monitor after selecting the language, press and hold the [ ] button for 2 seconds or more.

For returning to the information monitor without selecting the language, press the [ ] button.

2.38 OPERATOR'S AREA MODM

Replacement Monitor

Step forward

Step back

Replacement time check Press the [ (step forward)] button and [ (step back)] button at the same time to change over the screen from the information monitor to the replacement monitor.

Engine oil filter

Fuel filter

90ZV-262034

The display window displays the remaining time until next replacement of the engine oil filter cartridge to be changed.

Every time the [ (step forward)] button is pressed or every time the [ (step back)] button is pressed, the displayed contents are changed over in sequence as follows.

Coolant filter

T/C line filter

Hydraulic oil return filter

Engine oil

T/C and T/M oil

Axle gear oil

Hydraulic oil

85ZV2 0009

2.39 OPERATOR'S AREA MODM

Replacement interval set (timer reset)

Replacement pop-up

When the machine is shipped, the standard replacement interval is set as the initial setting.

Press and hold the [ ] button for 2 seconds or more on the replacement monitor screen to display the timer reset screen.

The timer reset screen displays the standard replacement interval.

90ZV-262038

When the remaining time until the next replacement reaches " 0 ", the replacement pop-up appears and flashes on the display window.

For setting the standard replacement interval, press the [ ] button.

Then, the standard replacement interval is set, and it returns to the replacement monitor screen again.

Example: Engine oil

90ZV-262037

For setting the replacement interval other than the standard replacement interval, follow the procedure below: ∗∗∗∗ +50 ∗∗∗∗ +100 (2 seconds or more) ∗∗∗∗ −50 ∗∗∗∗ −100 (2 seconds or more) Every time the [ (step forward)] button is pressed, "50" is added.

Every time the [ "50" is subtracted.

(step back)] button is pressed,

When the [ (step forward)] button is pressed and held for 2 seconds or more, "100" is added continuously.

When the [ (step back)] button is pressed and held for 2 seconds or more, "100" is subtracted continuously.

After setting the replacement interval, press and hold the [ ] button for 2 seconds or more, the replacement interval is reset, and it returns to the replacement monitor screen again.

90ZV-262039

When two or more replacement pop-ups occur at the same time, the corresponding items flash in turn.

After the remaining time for the next replacement reaches " 0 ", the corresponding pop-up appears up to three times when the starter switch is ON. (The outside air temperature is displayed for 3 seconds, and then the replacement pop-up flashes.)

When the [ (step forward)] button, [ (step back)] button, [ ] button or [ ] button is pressed, however, it returns to the previous screen again.

After replacing the corresponding filter or oil, return to the timer reset screen and set the replacement interval. Refer to the replacement interval set (timer reset) procedure above.

2.40 OPERATOR'S AREA MODM

Error Log Monitor Error log history check Up to 100 machine errors history and up to 100 engine errors history are recorded in the error log.

The error code and the date and time at the occurrence (in the format "year/month/day hour/minute/ second") are recorded in the error log.

Engine error log When two or more error codes are recorded, press the [ (step forward)] button to display the next latest error code.

Press the [ (step back)] button to display the error code in chronological order.

Clear error log Error codes are displayed from the latest one.

Clear machine error log

Selection of machine error log and engine error log When the machine error log screen is displayed, press and hold the [ (step forward)] button for 2 seconds or more to display the engine error log screen which shows the latest engine error code.

When the engine error log screen is displayed, press and hold the [ (step back)] button for 2 seconds or more to display the machine error log screen which shows the latest machine error code.

The machine error log screen and engine error log screen can be distinguished as follows: Displayed error code: CN∗∗∗ ..... Machine error log screen EG∗∗∗ ..... Engine error log screen

Machine error log When two or more error codes are recorded, press the [ (step forward)] button to display the next latest error code.

Press the [ (step back)] button to display the error code in chronological order.

Press and hold the [ ] button for 2 seconds or more to display the clear error log screen.

Press and hold the [ ] button for 2 seconds or more to clear the entire error log.

When there are two or more error codes recorded, all error codes recorded are cleared by performing the clear error log operation once.

Press the [ ] button not to clear the error log.

Then, the error log is not cleared, and it returns to the machine error log screen again.

Clear engine error log Press and hold the [ ] button for 2 seconds or more to display the clear error log screen.

Press and hold the [ ] button for 2 seconds or more to clear the entire error log.

When there are two or more error codes recorded, all error codes recorded are cleared by performing the clear error log operation once.

Press the [ ] button not to clear the error log.

Then, the error log is not cleared, and it returns to the engine error log screen again.

2.41 OPERATOR'S AREA MODM

Input/Output Monitor

Parameter Setting Monitor

Input/Output monitor display

Display of parameter setting monitor

Every time the [ (step forward)] button is pressed and held for 2 seconds or every time the [ (step back)] button is pressed and held for 2 seconds, the displayed contents are changed over in sequence as follows.

This monitor allows check of the parameters currently set.

Specification Setting Monitor Press and hold Step forward

Press and hold Step back

Specification setting monitor display This monitor allows check of the specifications currently set.

Input signal

Input sensor

Output signal

Current output

85ZV2 0010

1. Input signal monitor This monitor displays the ON/OFF status of the shift lever, setting switches, pressure switches, etc.

2. Input sensor monitor This monitor allows check of the input level of the brake pedal output oil pressure, steering oil pressure, boom angle etc.

3. Output signal monitor This monitor displays the ON/OFF status of the transmission forward/backward solenoid valves, speed range solenoid valves, indicator lamps and warning lamps on the instrument panel, etc.

4. Current output monitor This monitor allows check of the current output level of the cooling fan.

2.42 OPERATOR'S AREA Seat

Seat

Combined Height and Weight Adjuster

Seat Adjustment

1. Sit on the seat.

(KAB811)

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

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

WARNING

Clockwise to raise seat.

Anti-Clockwise to lower seat.

3. Check ride indicator (b) shows green.

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

Stop machine before adjusting seat position.

If red, readjust seat height.

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

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

3 Up-Stop Height Adjustment Control

2 1

c a

b 95ZV OM EU SEAT

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

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

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

Pivot up and parallel with backrest when not in use.

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

2.43 OPERATOR'S AREA Seat

Seat Adjustment

Combined Height and Weight Adjuster

(KAB851)

1. Sit on the seat.

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

2. Pull lever (4) up or push it down to adjust seat height.

3. Check ride indicator (5) shows green.

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

Stop machine before adjusting seat position.

If red, readjust seat height.

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

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

Armrests

2

7

3 1

4

Rotate controller (6) under armrest to select desired angle. Pivot up and parallel with backrest when not in use.

Lumber support

5

6

80ZV AIR SUS.SEAT

Reclining Pull control handle (1) upward and hold, select backrest angle, release control handle.

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

Up-Stop Height Adjustment Control To adjust the up-stop height, rotate control knob (3) clockwise to raise the seat unseated, rotate it counterclockwise to lower the seat unseated.

Rotate lumber support knob (7) counterclockwise to adjust the lumber support position.

5 adjusting positions are available.

IMPORTANT Always adjust the seat height when seated.

Adjusting the seat height should be done in 1 minute. Wait for 30 minutes for the next adjusting operation.

2.44 OPERATOR'S AREA Seat

Seat Belt

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

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

- Always fasten seat belt when operating machine.

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

1

3 2

OM0007

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

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

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

The tether is inside the seat boot.

No adjustment necessary.

2.45 OPERATOR'S AREA Electrical Protection

Electrical Protection

(1)

Fuse Boxes

2 1

(2) BATTERY RELAY ECM (ENGINE)

SPARE

20A

5A

AIRCON

20A

NEUTRAL RELAY

5A

AIRCON

10A

BUZZER MONITOR

5A

AIRCON

5A

PREHEAT

15A

AIRCON

5A

SPARE

10A

SPARE

20A

4 WAY FLASHER HORN DOME LAMP RADIO BACK UP

15A

SPARE

10A

SPARE

15A

SPARE

10A

SPARE

15A

RADIO

3A

AIR SUSPENSION SEAT (option)

10A

SPARE

15A

F. WORK LIGHT

15A

MODM CIGAR LIGHTER

10A

PARKING BRAKE MCU (MACHINE)

30A

F. WIPER / WASHER 10A

TURN SIGNAL

15A

R. WIPER / WASHER 5A

BOOM KICKOUT BUCKET LEVELER

10A

SPARE

5A

R. WORK LIGHT

15A

SPARE

5A

LIGHTING HEAD LIGHT

20A

85ZV28505

3

80ZV2 8729

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

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.

(3) ECM (ENGINE)

30A

2.46 OPERATOR'S AREA Electrical Protection

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

80ZV2 8729

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 will not function. matically.

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

70A

- Horn [and opt. flasher] - The same conditions as "During engine will operate. operation".

- All the others will not - Engine can be started. operate and the machine can not be operated.

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

70A (Alternator line)

- The same conditions - The machine can be as "During engine operated but the batoperation". teries can not be 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.

2.47 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009) 21

14

15

16

20

9 10 11

clarion

AM

ON OFF VOL

SLEEP

PUSH

AM/FM CASSETTE COMBINATION

CD

1

ST AUDIO MODE

2

TAPE

ALARM

CD

TIMER

AM FM

SCAN

1 4

3

REW APC

5

6

FF APC

DISP PS AS

M

H TUNE

RadioCassetteUSA

5

3

6

7

4 17

18

19

8

13

12

2.48 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

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

2.49 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

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

2.50 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

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

2.51 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

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

2.52 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Symbol

Name of part

Function Manual tuning in radio mode

Operation method PUSH Upward

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

Downward Tuning button

for 0.5 sec. or less Seeking in radio mode

12

PUSH Upward

Downward

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

PUSH Downward

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

PUSH Upward

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

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: REW

PUSH

Push the button to rewind the cassette tape.

In CD mode: DISC DOWN

PUSH

Push the button to go down to the previous disc.

(Recalling the previous disc.)

"Hour" setting "Minute" setting

1

REW

Preset 1

14

REW button

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

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

Remarks

2.53 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

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

2.54 OPERATOR'S AREA Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009)

Symbol

Name of part

5

18

Preset 5 Dolby button

6

APC

Preset 6 APC button

19

Function

Operation method

Description

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: Turning on/ off

PUSH

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

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: APC FF

PUSH

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

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

In CD mode: TRACK UP QUE

PUSH

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

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

No beep sounds

Auto metal

20

Tape insertion slot

Cassette tape insertion slot

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

21

LCD indicator

indicator

Displays time, frequency, etc.

Beep tone (guide tone)

Remarks

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

(Approx. 2KHz, 50ms)

2.55 OPERATOR'S AREA Air Conditioner

Air Conditioner

Switches

Ventilation Name and Location (d)

(d)

(d) (b)

1

2

3

4

5

Insolation sensor (d)

(b) 97ZVOM0093

6 (c) (c) (c)

(c)

(a)

(a)

(a)

97ZVOM0092

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

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

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

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

7

8

1. OFF switch 2. Blower switches 3. Temperature setting switches 4. Vent mode selector switch 5. AUTO switch 6. Inside/outside air selector switches 7. Liquid crystal display (LCD) unit 8. Air conditioner ON/Off switch While AUTO switch (5), inside/outside air selector switches (6) or air conditioner ON/OFF switch (8) is functioning, the LED lamp above each switch is lit.

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

When OFF switch (1) is pressed, the set temperature and the air blow quantity displayed on LCD unit (7) as well as the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) turned "off", and operation is stopped.

2.56 OPERATOR'S AREA Air Conditioner

Blower switches (2)

Vent mode selector switch (4)

These switches change over the air flow quantity in six steps.

This switch changes over the vent mode.

The air flow quantity is displayed on the LCD unit.

When the switch is pressed, the air flow quantity increases.

When the switch is pressed, the air flow quantity decreases.

In the automatic mode, the air flow quantity is automatically changed over. <Display on the LCD unit and the air blow quantity> LCD

Ventilation amount Air quantity "low" Air quantity "medium 1" Air quantity "medium 2" Air quantity "medium 3"

When vent mode selector switch (4) is pressed, the vent mode displayed on LCD unit (7) is changed over, and air is blown from the displayed vent positions.

In the automatic mode, the vent mode is automatically changed over.

Display on LCD unit

Vent positions Vent mode

Remarks (A) (B) (C) (D)

Face (blow-off to upper portion of body mainly during cooling)

O O

-

Face and foot

O O O

-

O

-

Foot (blow-off to feet mainly during heating) Foot and defroster

O

O O

This mode is not selected in automatic mode.

O

This mode is not selected in automatic mode.

Air quantity "medium 4" Air quantity "high"

Temperature setting switches (3)

Defroster

O

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

These switches set the temperature inside the cab in the range from 18.0~32.0ºC.

AUTO switch (5)

When the switch is pressed, the set temperature increases.

This switch automatically changes over the air blow quantity, the vent mode and the inside/outside air in accordance with the set temperature.

When the switch is pressed, the set temperature decreases.

Usually, set the temperature to 23.0~25.0ºC. <Display on the LCD unit and the function> Display on LCD unit 18.0ºC 18.5~31.5ºC 32.0ºC

When AUTO switch (5) is pressed, the indicator lamp above it lights.

Usually, press this switch, set the temperature by using temperature setting switches (3), and use the air conditioner in the automatic mode.

Set temperature Maximum cooling Temperature inside cab is controlled so that set temperature is realized.

Maximum heating

When the automatic mode is changed over to the manual mode, the indicator lamp above AUTO switch (5) is extinguished. In the manual mode, the air blow quantity, the vent mode and the inside/outside air can be changed over by manipulating each switch.

2.57 OPERATOR'S AREA Air Conditioner

Inside/outside air selector switches (6)

Operating Method (Normal Use)

These switches change over inside air circulation and outside air entry.

Automatic operation

When an either switch is pressed, the indicator lamp above it lights to indicate the selected air flow status.

3

5

In the automatic mode, outside air introduction and inside air circulation are automatically changed over.

97ZVOM0093

Inside air recirculation

Outside air entry

The outside air is shut down, and the air inside the cab is circulated.

Press this switch to rapidly cool or heat the air inside the cab or when the outside air is dirty.

The outside air enters the cab.

Press this switch to introduce clean air into the cab or defog the windows.

Liquid crystal display (LCD) unit (7) This LCD unit indicates the set temperature, the air flow quantity and the vent mode during operation.

When OFF switch (1) is pressed, the set temperature and the air flow quantity are extinguished and the operation is stopped.

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

When this switch (8) is pressed, the air conditioner is turned on and the indicator lamp above the switch lights. When this switch is pressed again, the air conditioner is turned off and the indicator lamp is extinguished.

However, the air conditioner is turned on only while the blower is operating (that is, while the air blow quantity is displayed on the LCD unit).

8 1. Set AUTO switch (5) to ON. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit, and that the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) are lit.

2. Adjust temperature setting switches (3), and set arbitrary temperature.

The air conditioner automatically changes over the air flow quantity, the vent mode and the inside/outside air to realize the set temperature.

NOTE When the vent mode is set to or in the automatic operation, if the engine water temperature is low, the air flow quantity is restricted to prevent blow-off of cold air.

Stopping the automatic operation

1

97ZVOM0093

Press OFF switch (1). Then, the set temperature and the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) are extinguished, and the operation is stopped.

2.58 OPERATOR'S AREA Air Conditioner

Operation Method (Other Uses)

Manual operation

2

3

4

Head cooling, feet heating (bi-level) operation In the bi-level operation, cool air is blown to the face and hot air is blown to the feet.

2

97ZVOM0093

6

3

4

5

8

1. Press blower switches (2), and adjust the air flow quantity.

Confirm that the set temperature and the air flow quantity are displayed on the LCD unit.

2. Set to ON air conditioner ON/OFF switch (8).

Confirm that the indicator lamp above the switch lights.

97ZVOM0093

6

8

3. Adjust temperature setting switches (3), and set arbitrary temperature.

1. Press blower switches (2), and adjust the air flow quantity.

Confirm that the set temperature and the air flow quantity are displayed on the LCD unit.

4. Press vent mode selector switch (4), and select arbitrary vent mode.

2. Press vent mode selector switch (4), and display the vent mode on the LCD unit.

5. Press an either inside/outside air selector switch (6) to select inside air circulation or outside air entry.

3. Set to ON air conditioner ON/OFF switch (8).

Confirm that the indicator lamp above the switch lights.

Stopping the manual operation

4. Arbitrarily set blower switches (2), temperature setting switches (3) and inside/outside air selector switches (6).

1 Then, the air conditioner realizes the bi-level operation in which cold air is blown to the head and hot air is blown to the feet.

97ZVOM0093

Press OFF switch (1). Then, the set temperature and the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) are extinguished, and the operation is stopped.

2.59 OPERATOR'S AREA Air Conditioner

Other Functions

Defroster operation

2

3

4

Self-diagnosis function Each sensor and equipment used in the air conditioner can be diagnosed for failure.

1

3

97ZVOM0093

6

8

1. Press blower switches (2), and adjust the air flow quantity.

Confirm that the set temperature and the air flow quantity are displayed on the LCD unit.

2. Press vent mode selector switch (4), and display the vent mode or on the LCD unit.

3. Set outside air introduction selector switch (6).

4. Press temperature setting switches (3), and display the set temperature "32.0" (maximum heating status) on the LCD unit.

Adjust the louver at each vent position so that air flow reaches the windows.

When defogging the windows or dehumidifying the air inside the cab in rainy season, set air conditioner ON/OFF switch (8) to ON.

97ZVOM0093

6 1. Press OFF switch (1) to stop the operation.

(The set temperature and the air blow quantity displayed on the LCD are extinguished.)

2. When both temperature setting switches " " and " " (3) are pressed and held together for 3 seconds or more, the failure mode is displayed on the LCD unit. <Display on the LCD unit and the failure mode> Display

Failure mode

EE11 E12 E13 E14 E15 E16 E18 E21 E22 E43 E44 E45 E51

No failure Wire breakage in inside air sensor Short-circuit in inside air sensor Wire breakage in outside air sensor Short-circuit in outside air sensor Wire breakage in water temperature sensor Short-circuit in water temperature sensor Short-circuit in insolation sensor Wire breakage in vent sensor Short-circuit in vent sensor Abnormality in vent damper Abnormality in air mixing damper Abnormality in inside/outside air Abnormality in refrigerant pressure

- If two or more failure are detected, the displayed contents can be scrolled through by pressing either one of temperature levels (3) " " or " ".

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

2.60 OPERATOR'S AREA Air Conditioner If a failure is detected by the self-diagnosis function, ask the dealer for inspection and repair.

For Efficient Use of the Air Conditioner

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

When the temperature inside the cabin should be cooled down rapidly

If not removed, the failure codes memorized in the computer continue to display on the LCD unit whenever diagnosing.

To delete the failure codes, press and hold both inside/outside air selector switches (6) for 3 seconds or more.

Refer to "TROUBLESHOOTING" page 3.61 for the failure and solution.

Celsius-Fahrenheit selector function for the set temperature display While the blower is operating, press and hold both temperature setting switches (3) " " and " " together for 5 seconds or more to change over the unit of the displayed value between Celsius and Fahrenheit. However, the unit type (C or F) itself is not displayed.

Only the set value is displayed.

Value displayed on LCD unit Celsius (ºC)

18.0~32.0

Fahrenheit (ºF)

65~90

When the machine is left under a scorching sun in the middle of summer, the temperature inside the cabin may be very hot.

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

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

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

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

2.61 OPERATOR'S AREA Air Conditioner

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

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

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

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

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

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

- Always keep the insolation sensor clean and free from adhesion of dusts so that the air conditioner can offer its auto function sufficiently.

Keep the area around the insolation sensor free from objects which may hinder the sensor function.

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

NOTE Any technician that operates a refrigerant recovery and recycling machine must first be certified through an EPA approved testing program.

2.62 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

85ZV20006b

OFF

ON

switch-3

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

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

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

2.63 OPERATOR'S AREA Manual Box

Manual Box

90ZV2 9690

Manual box is provided in the left rear of the driver seat to put in the Operation & Maintenance Manual.

2.64 OPERATOR'S AREA Grease Gun Holder

Grease Gun Holder

90ZV5009

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

2.65 OPERATOR'S AREA Quick Coupler (option)

Quick Coupler (option) Attachment Installation to Quick Coupler Regardless of the attachment types, the installation procedure is all the same.

For removing an attachment, follow the installation procedure in the reversed direction.

85ZV2 35010-6035

Component Name 1. Coupler frame 2. Hydraulic pressure hose (for 3-way piping spec. machine) 3. Hydraulic pressure connecting unit to attachment (One-touch operation type) 4. Hook 5. Lock pin support 6. Quick coupler lock pin switch (for 2-way piping spec. machine with quick coupler)

2 3

1

4 5 ATT0029

6

85ZV20005d

2.66 OPERATOR'S AREA Quick Coupler (option)

Installation Procedure

For 3-way piping spec. machine Lever Location

(b) (a)

(c)

ATT0031

1. In front of the attachment, lower the boom by the boom control lever and move the quick coupler to "Dump" position by the bucket control lever.

2. Move the machine forward to the hook of the attachment.

3. Insert the upper pipe of the coupler frame to the hook by operating boom control and bucket control levers.

85ZV20005a

(a) The lock pin is fixed. (b) In neutral position, the lock pin is held on the position. (c) The lock pin is disconnected.

Note After fixing the lock pin, confirm the indicator is at the right position.

DANGER 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.

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.

ATT0032

WARNING 4. Roll back the quick coupler to hang up the hook and lift the attachment.

5. For 3-way piping spec. machine, insert the quick coupler lock pin by operating the attachment control lever to fix the attachment.

For 2-way piping spec. machine with quick coupler, insert the quick coupler lock pin by operating the quick coupler lock pin switch on the control box, with the bucket control lever held on the "Roll Back" position. Then fix the attachment.

Your body or finger could be crushed by the lock pin when the lock pin moves.

Stay out of the lock pin area during lock pin operation.

2.67 OPERATOR'S AREA Quick Coupler (option)

For 2-way piping spec. machine with quick coupler

Hydraulic Pressure Hose & Electrical Wiring Connecting to Attachment

Switch Location

When 3-way piping spec. machine installs the attachment that needs the hydraulic pressure source, connect the hydraulic pressure hose from the quick coupler to the attachment side.

Regardless of the piping specifications, when the electrical power supply is needed to the attachment, connect the electrical wiring.

Regardless of the attachment types, the installation procedure is all the same.

Connecting Procedure 85ZV20005d

B A

85ZV2 35010-6035 ATT0033

( ) The lock pin is fixed. ( N ) In neutral position (when the switch is kept parallel.), the lock pin is held on the position. ( ) The lock pin is disconnected.

Note During the operation of the switch, keep the bucket control lever on the "Roll Back" position.

1. Stop the engine. Move the control lever back and forth and bleed the residual pressure in the hydraulic line.

2. Disconnect two hydraulic pressure hoses connected to the quick coupler at section A (Onetouch operation type).

3. Connect the disconnected hoses to section B at the attachment side (One-touch operation type).

Connect the hose at right side of the machine to right side of the attachment. Connect the hose at left side of the machine to left side of the attachment.

2.68 OPERATOR'S AREA Quick Coupler (option)

Dust cap

Quick coupler ATT0034

4. Cover the connecting hole disconnected from the quick coupler hose with the dust cap.

Electrical wiring connector

ATT0035

5. When the electrical power supply is needed to the attachment, connect the electrical wiring connector.

When disconnecting the connector, keep the waterproof cap.

IMPORTANT Cover the disconnected hydraulic pressure hose, hose connecting hole and electrical wiring connector with caps to protect them from dust and water.

2.69 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

Date:

Model-S/N:

Hours:

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

Inspector:

2.70 OPERATION Check before Operation

Check Engine Oil Level

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.

CAUTION Hot engine oil and components may cause burns.

Avoid contact with hot oil or engine components.

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

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

Refer to "Replace Engine Oil and Oil Filter Cartridge" page 3.34.

Check

Fill cap

85ZV28610

NOTE Wait about 15~20 minutes after stopping the engine to measure the oil level. The precise oil level cannot be measured immediately after stopping engine due to residual oil in the upper parts of the engine.

IMPORTANT Improper oil level may damage engine.

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

H L

Add or drain oil to keep proper oil level.

70ZV0011

2.71 OPERATION Check before Operation

Check Hydraulic Oil Level

(S/N 9201~9250)

Filler cap

CAUTION Pressurized hydraulic tank is used for this machine.

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

Relieve all pressure by pressing down the filler cap or the breather valve.

80ZV27801

Check Level

(S/N 9251~)

Breather valve

85ZVOM3230 80ZV27801a

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

2.72 OPERATION Check before Operation

Check Engine Coolant Level

Drain Water and Sediment from Fuel Filter

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

Avoid contact with skin and eyes to prevent injury.

85ZV28608

FULL LOW

85ZV28606

1. Check the coolant level in the radiator subtank.

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

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

Refer to "Coolant Specification" page 3.60 for the correct mixture.

4. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 3.15.

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

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

- 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.

2.73 OPERATION Check before Operation

Check Wiring Harnesses

Articulation Stopper

CAUTION Short circuit of wiring harnesses may cause fire.

- Keep the connection of wiring harnesses clean and tight.

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

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

"STORED" position

85ZV0002

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

2.74 OPERATION Check before Operation

Check Tire for Damage, Air and Tread Depth

Low Pressure

OK

High Pressure

97ZVOM0103

OM0032

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

WARNING

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

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

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

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

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

WARNING Overheated tire could explode causing serious injury or death.

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

Stay away until tire and rim cool down.

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

Consult your tire dealer or Kawasaki dealer.

Refer to "Check Tire Air Pressure" page 3.25 for the adjusting procedure.

2.75 OPERATION Check before Operation

Check Drive Belt

Tread

CAUTION Side walls Breakers

Carcass

Contact with moving belt or pulleys may cause injuries.

Stop engine before opening engine access panel.

Beads / Bead wire OM0104

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

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

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

2. Open the engine access panel.

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

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

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

OK OK

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

- Tire layers are separated.

- Radial cracks reach the carcass.

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

OM0099

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

2.76 OPERATION Check before Operation

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

Check Air Intake System

CAUTION Hot engine components may cause burns.

Inspect the tube more frequently in icy conditions.

Avoid contact with hot engine components.

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

85ZV28604

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.

2.77 OPERATION Check before Operation

Check Cooling Fan

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

2. The horn should sound loudly.

OK ROPS (Roll Over Protective Structure) Cab

OK

WARNING OM0102

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

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.

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

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

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

ROPS Cab deformed does not assure safety for operator as a protective cab.

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

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

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

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

2.78 OPERATION Check before Operation

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

2. All warning lamps (red) should come on for about three seconds. Refer to "Indicators" page 2.25.

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

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

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

Refer to "Indicators" page 2.25.

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

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

2.79 OPERATION Starting the Engine

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

PREHEAT

OFF

ON

START

- Do not start engine by shorting across starer terminals.

- Do not start engine while standing on ground.

65ZV0075

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

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

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

Normal Start (Ambient temperature above 0ºC)

NOTE - When the starter switch key is in the "ON" position, the engine itself will diagnose engine failure, if any, in 2 seconds.

1. Do not step on the accelerator pedal.

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

PREHEAT

OFF

ON

START

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

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

65ZV0076

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

3. 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.

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

- The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "TROUBLESHOOTING" page 3.61.

IMPORTANT Low engine oil pressure may cause severe engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

2.80 OPERATION Starting the Engine

Cold Start

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

(Ambient temperature below 0ºC) 1. Do not 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 3.61.

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.

2.81 OPERATION Idling Management System

Idling Management System

Hibernate Mode

Warm-up control

Mode ON:

Idle-up function

Decreases the engine idling speed from 800 min-1 to 725 min-1 under the following condition.

When the engine coolant temperature is 10ºC or lower, the engine idling speed increases from 800 min-1 to 1,000 min-1.

- When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min -1 or less for 10 seconds.

Fan low speed control When the engine coolant temperature is 60ºC or lower and the engine speed is 1,200 min-1 or less, the cooling fan retains its minimum speed regardless of the engine speed.

Engine Acceleration Control (Function) (Turbo Protection) When the engine coolant temperature is 10ºC or lower, the accelerator is not activated a few seconds and delays the response for acceleration.

Mode OFF: Returns to the normal engine speed under either one of the following conditions.

- When the transmission shift lever is placed other than in "N" position.

- When the engine speed is 950 min-1 or more - When the engine coolant temperature is 60ºC or lower

Forcible Mode OFF: When the generated power by the alternator lowers, the mode is OFF forcibly.

In this case turn off the starter switch and start the engine again to reset the hibernate mode.

2.82 OPERATION Check after Starting the Engine

Check after Starting the Engine

Check Warning Lamps

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

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

WARNING Do not open the engine access panel while the engine is running.

STOP

85ZV2 0004

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

IMPORTANT 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 form in the injector spray holes and on the piston rings and can result in stuck valves.

1. Check the warning lamps on the instrument panel.

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

3. Refer to "Indicators" page 2.25 for the meaning of each lamp and the correction.

2.83 OPERATION Check after Starting the Engine

Check Fuel Level

Check Transmission Oil Level

DANGER

E

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

Crushing will result in serious injury or death.

F FUEL

65ZV0005

When checking oil level: - Low attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

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

- Make sure nobody is on machine.

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

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

Refer to "Recommended Lubricants" page 3.58 for the proper fuel.

Check and Fill Tube 80ZVOM3271

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

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

In hot

In cold

Specified oil level

97ZVOM0107

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

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

Check Service Brake Operation

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

Do not overfill.

2. Firmly step on the left hand brake pedal.

Refer to "Recommended Lubricants" page 3.58.

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

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

IMPORTANT Never mix CD engine oil and auto transmission fluid.

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

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

1. Turn "OFF" the declutch switch.

3. Release the parking brake.

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

6. The machine should not move.

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

Do not operate until problem has been corrected.

Check Parking Brake Operation 1. If the service brakes work normally, test the parking brake.

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

3. Stop the machine with the service brake.

4. Pull up the parking brake switch.

5. Release the service brakes.

6. The machine should not move.

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

Do not operate until problem has been corrected.

2.85 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 95ZVOM2926

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 3.62.

2.86 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.

2.87 OPERATION Operating the Machine

Operating the Machine

Starting the Machine

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

Do not stop engine while machine is moving.

WARNING

approx. 40 cm OM0016

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

Be sure area is clear of personnel and obstructions.

IMPORTANT

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

2. 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.

30º Max. OM0194 97ZVOM0038

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.

2.88 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.

65ZV 5089

97ZVOM0038

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

1. Select the proper gear shifting mode by rotating the transmission shift lever. Refer to the following tables on page 2.89 for the gear selection mode.

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

65ZV 5089

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

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

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

2.89 OPERATION Operating the Machine

Running in Deep Mud or Water

Axle housing

A 85ZV20005c

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, moving the transmission shift lever to the neutral position, or operating the parking brake switch automatically returns to the 2nd gear from the 1st gear.

Refer to "Downshift Button" page 2.16.

Lever Position

Selected Gear

[1]

1st

[2]

2nd

[3]

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

[A]

Operating Condition 1. Excavating or scooping in a narrow space 2. Running downhill on a steep slope 1. Scooping or loading loose material 2. Running downhill on a slope Carrying or roading Scooping, loading, carrying or roading

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

Use proper gear for each job.

A=Maximum depth of water allowable during operation OM0109 (including waves).

Running the machine in mud, snow, or water at or near a level of A (even for a brief period of time) is considered a severe application.

1. Immediately after encountering this condition, check both differentials for water contamination in the oil. Water mixed with the oil will cause a milky or foamy appearance.

2. Drain and refill if water is found.

Refer to "Check Differential Gear Oil" page 3.28 and "Check Planetary Gear Oil" page 3.29 or consult the nearest Kawasaki dealer for further assistance.

2.90 OPERATION Parking

Parking

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

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

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

OM0025

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

Park machine in safe place on firm level ground.

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

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

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

97ZVOM0038

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

2.91 OPERATION Stopping the Engine

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

Do not stop engine while machine is moving.

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

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

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

PREHEAT

OFF

ON

START

65ZV0074

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

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

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

Prevent unauthorized operation.

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

2.92 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.

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

OM0112

OM0114

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

Reduce wheel slippage by slightly reducing engine speed.

OM0115

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

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

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

9. Reverse the machine.

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

2.94 OPERATION Operating Techniques

Excavating 1. Move the machine forward to the material.

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

OM0120

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

10 degrees or less

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

OM0118a

3. Lower the bucket parallel to the ground or dump it slightly forward (10 degrees or less).

OM0119

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

Increase engine speed as the bucket digs deeper.

2.95 OPERATION Operating Techniques

Dozing

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

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.

OM0121

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

OM0123

OM0122

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

2.96 OPERATION Operating Techniques

Carrying

OM0123

approx. 40 cm OM0016

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

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

Be sure to run machine backward when leveling ground.

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

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

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

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

2.97 OPERATION Operating Techniques

Dumping into Truck or Hopper

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

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.

Keep boom low for best stability especially on slopes.

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

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

WARNING

Refer to "Kickout Control Switch" page 2.18 for adjustment of the preset height.

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

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

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

Refer to "Loading" or "Excavating" page 2.92, 2.94 for the loading procedure.

OM0195

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

OM0116

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

2. Use the 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.

OM0196

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

2.98 OPERATION Operating Techniques

Typical Truck Loading Methods

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

I Cycle Operation

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

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.

2.99 OPERATION Operating Techniques

T Cycle Operation

OM0126

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

2.100 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 bucket control lever to the "Roll Back" detent position to rollback the attachment.

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

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

4

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

Use safe sturdy platform to reach bucket 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 OM0128

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

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

2

1 97ZVOM0127

3. Loosen 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).

2.101 SPECIAL PROCEDURES Roading / Special Applications

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

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

Stay away until tire and rim cool down.

When the machine travels at high speed or for a long distance, the tires or other components 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" 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.

2.102 SPECIAL PROCEDURES Booster Batteries / Jumper Cables

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

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

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

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

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

- Keep flames and sparks away from batteries.

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

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

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

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

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

2. Raise and lock the battery box covers.

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

+

+

-

+

-

+

-

Booster Batteries

Batteries being boosted

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

Rear chassis close to starter motor ground being jump started

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

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

Keep the battery electrolyte level in the proper level.

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

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

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

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

OM0131

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

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

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

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

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

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

2.103 SPECIAL PROCEDURES Booster Batteries / Jumper Cables

11. Start the machine being boosted as described on "Starting the Engine" page 2.79.

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.

2.104 SPECIAL PROCEDURES Towing

Towing

Allowable load: 33,720 N

WARNING

Towing speed: Less than 10 km/h

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.

Distance between the pulling vehicle and the towed vehicle: More than 5 m and the towed vehicle is able to stop safely.

IMPORTANT - When towing a machine be sure not to add load over the allowable load described on the draw hook or the sling hooks.

- When this machine is pulled out, rescued, by other machine, do not use the draw hook, always use the sling hooks.

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

95ZVOM2917

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

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

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

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

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

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

2.105 SPECIAL PROCEDURES Towing

Wire hooking position and range/ stretching impossible range/tolerance Hook tolerance Loads which can be applied to one position of the hook (one wire) Model

80ZV-2

Front side

Tolerance

[N]

223,000

Rear side

Tolerance

[N]

223,000

Hooking position

Rear side Front side

HOOKING POSITION

CAUTION - Be sure to hoist the loader at 4 points and lift it at 2 points.

- Hoisting/lifting angles are not limited in particular. (The tolerance is set to an acceptable level even if stretching it at any angle.)

- When lifting it, a wire interferes with the battery box, etc. which may cause damage (depending on the lifting direction).

2.106 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 1.28).

6. Apply the parking brake and set the articulation stopper in the "LOCKED" position (page 1.29).

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

65ZV0010 OM0132

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

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

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

OM0197

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

65ZV0009

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

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

IMPORTANT Brake pipe runs on axle housing.

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

Do not fasten axle housing.

2.107 SPECIAL PROCEDURES Transportation

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

BUCKET TSURI-1

GRAVITY CENTER

OM0198

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

Weight: 20 ton

BUCKET TSURI-2

BUCKET TSURI-3

Before hoisting the bucket, hook wire rope, etc. through the hole for hoisting the bucket.

2.108 SPECIAL PROCEDURES Long Term Storage

Long Term Storage

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

Before Storage 1. Wash and clean all parts of the machine and touch up the paint finish to avoid rusting.

2. Lubricate every greasing point described in "Greasing" section page 3.18, 3.21, 3.27 and 3.46.

3. Be sure to refuel in the fuel tank.

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

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

6. Store the machine indoors and keep it dry.

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

The range of temperature the machine is to be stored is between -25ºC ~ 35ºC.

OM0028

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

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

Refer to "Coolant Specification" page 3.60 for the mixing ratio.

2.109 SPECIAL PROCEDURES Long Term Storage

Battery removal / reinstallation procedure

WARNING Batteries produce explosive gases which could cause burns or blindness.

4

5 2 1

3

6

- Ventilate area to remove explosive gases.

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

8

7

85ZV28463

- Keep flames and sparks away from batteries.

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

WARNING

1. Remove bolt (1)(2) and remove the rear lamp with plate (3) from the battery box.

Hang the rear lamp with plate (3) temporarily up on the rear chassis by rope.

Batteries contain lead, and acid which may cause burns.

2. Disconnect battery cables (4)(5) from the battery.

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

3. Loosen rod nuts (6)(7) and remove plate (8) from the battery.

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

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the OFF position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

4. Remove the battery not to give it a tilt from the battery box.

If possible remove the battery from the battery box by two persons.

For reinstallation, follow the above procedure in the reversed direction.

Carry on the same procedure for the other battery.

2.110 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.

1. Check the following points.

Refer to "Check before Operation" page 2.69 and "Check after Starting the Engine" page 2.82.

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

85ZVOM3184

2. Operate the machine as follows.

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

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

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

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

3. Operate the air conditioner as follows.

- 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.

85ZVOM3230

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 3.34 and "Replace Transmission Oil" page 3.40.

4. Start the engine and check for any abnormalities.

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

2.111 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.

2.112 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.

2.113 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.

NOTE You must change the welding rod grade depending on the welding part and place. Should you have any question regarding the welding repair service, please contact KCM dealer in your area during business hours.

2.114

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 1.12.

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.

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

WARNING Do not open high pressure fuel system with engine running.

Engine operation causes high fuel pressure.

High pressure fuel spray can cause serious injury or death.

High pressure fuel

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

MODEL SERIAL NO.

Use KCM genuine parts for replacement.

MADE IN JAPAN SN PLATE 41668-2063B

MODEL

SERIAL NUMBER

TOTAL WEIGHT

FABRICATION YEAR

RATED POWER

kg

kW

PERMISSIBLE LOAD:FRONT AXLE

REAR AXLE

N TUG-HOOK MAX.PULL

N TUG-HOOK VERT.STRAIN

N

N

THIS PLATE MAY BE NEITHER ALTERED NOR REMOVED.

KCM Corporation 2680,Oka,Inami-Cho,Kako-gun, Hyogo Pref,675-1113,Japan

MADE IN JAPAN

P/N 41668-20840

SN PLATE 41668-20840

1. Machine Serial Number

3.3 MAINTENANCE Serial Number Location

SERIAL NO.

-

70ZV0004

85ZV27812

4. Cab Serial Number

2. Engine Serial Number

Model Number Serial Number

MODEL SERIAL NO. MADE IN JAPAN SN PLATE 41668-2006B

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

3.4 MAINTENANCE Serial Number Location

Cab (R.H Inside)

Machine (R.H)

Machine (L.H)

T/M

E/G (R.H) 80ZV2 EU COMPO

3.5 MAINTENANCE Inspection and Maintenance Table

Inspection and Maintenance Table Check and/or carry out the maintenance at intervals of the specified operating hours below or the calender date, whichever comes first.

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 Operating hours

Section

Item for check 10

Engine

50

250

500

When

1000 2000 Required

Page

Check Engine Oil Level

2.70

Check Engine Coolant Level

2.72

Check Warning Lamps

2.82

Check Exhaust Gas

2.85

Drain Water and Sediment from Fuel Filter

2.72

Check Fuel Level

2.83

Check Drive Belt

2.75

Check Crankcase Breather Tube

2.76

Check Air Intake System

2.76

Check Cooling Fan

2.77

Drain Water and Sediment from Fuel Tank

3.24

Replace DCA4 Coolant Filter Cartridge

3.38

Replace Engine Oil and Oil Filter Cartridge

3.34

Replace Fuel Filter Cartridges

3.37

Inspect Automatic Belt Tensioner Pulley

3.45

Clean Fuel Tank

3.52

Check and Adjust Valve Lash Clearance

3.53

Check Vibration Damper

3.52

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 Replace Transmission Oil Filter Cartridge & Torque Converter Replace Transmission Oil Clean or Replace Transmission Breather

After six cleanings or once a year

3.10

Every 2 years or 3000 hours

3.15 2.83 3.33, 3.36

3.40 3.42

3.6 MAINTENANCE Inspection and Maintenance Table

: First time replacement or cleaning only Operating hours Section

Item for check 10

Axle system

Steering system

Loading system

Chassis

250

500

When

1000 2000 Required

Page

Check Tire for Damage, Air and Tread Depth

2.74

Check Tire Air Pressure

3.25

Greasing (Axle support)

3.23

Check Differential Gear Oil

3.28

Check Planetary Gear Oil

3.29

Greasing (Pillow block bearing unit)

3.27

Check Tightness of Wheel Bolts

3.30

Greasing (2nd Propeller Shaft Spline)

3.46

Replace Differential Gear Oil

3.49

Replace Planetary Gear Oil

3.50

Greasing (2nd Propeller Shaft)

Every 12000 hours

3.18

Greasing (3rd Propeller Shaft)

Every 12000 hours

3.19

Check Steering Wheel Operation

2.85

Greasing (Steering Cylinder)

3.23

Clean Filter for Orbitrol®

Brake system

50

3.33, 3.55

Check Service Brake Operation

2.84

Check Parking Brake Operation

2.84

Adjust Parking Brake Lining

3.43

Check Service Brake Disk Wear

3.53

Check Brake Accumulator

3.53

Clean Filter for Brake Line

3.33, 3.55

Check Hydraulic Oil Level

2.71

Greasing

3.21

Replace Hydraulic Oil Return Filter

3.33, 3.42

Replace Hydraulic Oil, Clean Filter

3.47

Replace Filter in the Hydraulic Tank Cap (S/N 9201~9250) Replace Filter in the Hydraulic Tank Breather Valve (S/N 9251~)

3.56 3.57

Replace Bucket Teeth (option)

3.8

Replace Cutting Edge

3.9

Adjust and Check Rear View Mirrors

2.77

ROPS (Roll Over Protective Structure) Cab

2.77

Greasing (Center Pin)

3.23

Check Ride Control Accumulator (option)

3.57

Check and/or Replace Seat Belt

3.10

Check Windshield Washer Fluid

3.14

3.7 MAINTENANCE Inspection and Maintenance Table

: First time replacement or cleaning only Operating hours Section

Item for check 10

Electrical system

50

250

500

Page

Check Monitor Panel Operation

2.78

Check Horn Operation

2.77

Check Back-up Alarm Operation

2.85

Check Wiring Harnesses

2.73

Check Battery Electrolyte Level

3.24

Check or Replace Fuses

3.13

Check and Adjust Air Conditioner Belt

3.30

Clean Air Conditioner Filter Element

3.31 3.44

Check Air Conditioner Refrigerant Air Conditioner Replace Air Conditioner Filter Elements

3.54 3.15

Clean Air Conditioner Condenser Replace Air Conditioner Receiver Dryer

Others

When

1000 2000 Required

Walk-Around Inspection

Every 3 years or 6000 hours

3.17 2.69

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 1.12 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 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 696~834 N-m.

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

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

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

6. Install all bolts and tighten them to 696~834 Nm. 7. Retighten them after a few hours operation.

3.10 MAINTENANCE When Required Inspection and Maintenance

Check and/or Replace Seat Belt

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

Seat Belt

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

80ZV AIR SUS.SEAT

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

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

- 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.

- Never clean the elements by bumping or hitting them against a solid surface.

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

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

2

1

80ZV27818

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

85ZV YP7-233

3. Remove clean-out traps from bottom of radiator shroud.

IMPORTANT 95ZVOM2917

Clean-out traps and side cover doors must be reinstalled and closed securely, or engine performance will be affected.

IMPORTANT High pressure air or water may damage radiator / air cooler / hydraulic oil cooler fins.

90ZV5055

2. Push the knob and open the radiator grill.

Open covers on the radiator guard both the right hand side and the left hand side for clean the air cooler and hydraulic oil cooler.

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

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

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

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

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

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

6. Reinstall clean-out traps.

3.13 MAINTENANCE When Required Inspection and Maintenance 7. Close the engine access panels and covers.

Check or Replace Fuses

Be sure side cover doors are closed securely.

If the doors are not closed securely cooling air will leak out and cooling will be reduced.

85ZV28505

80ZV2 8729

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

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

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

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

Refer to "Fuse Boxes" page 2.45.

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

3.14 MAINTENANCE When Required Inspection and Maintenance

Check Windshield Washer Fluid

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

Never replace fuses with higher amperage rating.

80ZV27801

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

2. Check the fluid level.

3. Replace the fluid if it is dirty.

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

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

3.15 MAINTENANCE When Required Inspection and Maintenance

Clean Air Conditioner Condenser

Replace Coolant

If mud, insects, or other debris are stuck to the air conditioner condenser, air flow through the condenser will be reduced causing decreased cooling ability.

- Since the Anti-Freeze "Long Life Coolant" (LLC) is originally used for the machine shipped from the factory, it is not necessary to replace the coolant for the first two years.

- If the cooling system conditioner (from a local supplier) is used at the time of last replacement, follow its instructions or contact your nearest Kawasaki dealer for the replacement interval.

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

85ZVOM3179

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

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

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

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

2. Inspect all coolant hoses.

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

Replace any that are cracked, swollen, or brittle.

4. If water is used for the cleaning, cover the electrical parts of the engine and the electric condenser fan with plastic sheets. Remove the plastic sheets after cleaning.

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

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

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

85ZV28606

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

3.16 MAINTENANCE When Required Inspection and Maintenance

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

Avoid contact with skin and eyes to prevent injury.

7. Tighten the drain plugs and fill the cooling system with clean water.

1 85ZV28607

Do not install the radiator cap.

8. Operate the engine for one hour with the coolant temperature above 80ºC. Then let the engine cool down naturally with the engine shut "OFF".

9. Stop the engine and loosen the drain plugs to drain the cooling system.

2

10. Tighten the drain plugs and fill the cooling system with clean water.

85ZV2 2206

5. Loosen the drain plugs (1)(2) and drain coolant (about 63 liters) into a suitable container.

Do not install the radiator cap or the new coolant filter.

11. Operate the engine for five minutes with the coolant temperature above 80ºC. 12. Stop the engine and loosen the drain plugs 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 5~11).

3

14. Tighten the drain plugs and fill the system with the premixed coolant.

Refer to "Coolant Specification" page 3.60 for the mixing instruction.

85ZVOM3219

6. Slowly turn the radiator cap (3) until it touches the stopper to release inner pressure.

Pushing the cap, turn it to open.

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

15. Add three parts of DCA60L coolant additive at the same time.

16. Replace the DCA4 coolant filter (WF2071).

Refer to "Replace DCA4 Coolant Filter Cartridge" page 3.38 for the procedure.

17. Idle the engine for five minutes to purge air mixed into the coolant. (Leave the radiator cap off.)

3.17 MAINTENANCE When Required Inspection and Maintenance

Replace Air Conditioner Receiver Dryer 18. Add coolant as necessary.

19. Reinstall the radiator cap.

For additional cold weather servicing information, refer to "Coolant Specification" page 3.60 for details.

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

3.18 MAINTENANCE When Required Inspection and Maintenance

Greasing (Every 12000 hours) 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 3.58 for the correct grease. Use lithium base grease for universal joints.

85ZVOM3316

80ZVOM3314

95ZVOM2843

- 2nd Propeller Shaft (three places)

3.19 MAINTENANCE When Required Inspection and Maintenance

95ZVOM2901

- 3rd Propeller Shaft (two places)

3.20 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 1.12 before performing any inspection or maintenance procedures.

See "Check before Operation" page 2.69 and "Check after Starting the Engine" page 2.82.

3.21 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 1.12 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 3.58 for the correct grease.

85ZVOM3357

- Bucket-Boom (two places)

85ZVOM3357

- Bucket-Rod (one place)

3.22 MAINTENANCE Every 50 Hours or 1 Week

85ZVOM3357

80ZVOM3272

- Bucket Cylinder-Front Chassis (one place)

- Lever-Rod (one place)

85ZVOM3357

- Lever-Boom (one place)

85ZVOM3357

- Boom Cylinder-Boom (two places)

85ZVOM3357

- Bucket Cylinder-Lever (one place)

85ZVOM3353

- Boom Cylinder-Front Chassis (two places)

3.23 MAINTENANCE Every 50 Hours or 1 Week

85ZVOM3353

80ZVOM3272

- Boom-Front Chassis (two places)

80ZVOM3271

80ZVOM3271

- Steering Cylinder (four places) L.H and R.H

80ZV2 9728

- Axle support (two places)

- Center Pin (two places)

3.24 MAINTENANCE Every 50 Hours or 1 Week

Drain Water and Sediment from Fuel Tank

Check Battery Electrolyte Level

WARNING CAUTION Escaping fuel is flammable and harmful to skin.

Batteries produce explosive gases which could cause burns or blindness.

- Do not smoke while draining moisture and sediment from fuel tank.

- Do not drain fuel with engine running.

- Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

- Ventilate area to remove explosive gases.

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

- Keep flames and sparks away from batteries.

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

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

WARNING

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

Keep the battery electrolyte level at the proper level.

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

80ZVOM3269

2. Prepare a suitable container.

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

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.

4. Drain water and sediment along with fuel.

5. Retighten up the drain 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.

Do not handle batteries with general waste. When handling the used batteries follow the law and/or local regulation in your country, state, or province.

3.25 MAINTENANCE Every 50 Hours or 1 Week

Check Tire Air Pressure Low Pressure

OK

High Pressure

70ZV2 7743

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

2. Clean the battery surface with a clean cloth or soft brush.

70ZV0016

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

- Low air pressure causes excessive deflection, heat, and accelerated wear.

- High air pressure cause reduced traction, slippage, and possible blow outs.

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

Special applications, such as long load and carry operations, may require different pressures. Consult the tire manufacturer.

Low

OK

High OM0096

3. Check the battery electrolyte level in each cell.

Electrolyte should cover the cell plates.

4. If the level is low, add distilled water until it reaches the bottom of the filler neck.

WARNING Overheated tire may explode causing serious injury or death.

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

Stay away until tire and rim cool down.

NOTE If a maintenance free battery is used, step 3 and 4 of this inspection and maintenance is not required.

1. Before starting work and while the tires are still cool, measure the tire air pressure with the tire pressure gauge.

3.26 MAINTENANCE Every 50 Hours or 1 Week Recommended Tire Air Pressure Radial tire Size 20.5 R25 23.5 R25

Air pressure Front 471~490 kPa 471~490 kPa

Rear 373~392 kPa 373~392 kPa

Bias ply tire OM0032

Size

WARNING Explosive separation of tire and rim parts could result in death or serious injury.

When inflating tires; - Make sure wheel parts are correctly installed.

- Use self-attaching air chuck with remote shutoff valve.

- Stand behind tread of tire and keep all persons away from side of tire.

- Do not inflate tire more than recommended pressure.

- Use safety cage if available.

OM0033

2. Adjust air pressure according to the recommended pressures below.

When inflating a tire, stand behind the tread and use a self-attaching chuck with a remotely located valve to turn air pressure on and off.

20.5-25-20PR 23.5-25-16PR

Air pressure Front 520~539 kPa 392~412 kPa

Rear 422~441 kPa 294~314 kPa

3.27 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 1.12 before performing any inspection or maintenance procedures.

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

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page 3.58 for the correct grease.

Every 250 hours or 1 month, whichever comes first, perform the following inspection and maintenance in addition to the "Daily" and "50 hours" inspections and maintenance.

80ZVOM3271

- Pillow block bearing unit (one place)

3.28 MAINTENANCE Every 250 Hours or 1 Month

Check Differential Gear Oil

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

CAUTION The axles are pressurized through the hydraulic tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Before removing the oil level check plug, push down on the hydraulic tank cap or the breather valve to release the air pressure inside the hydraulic tank.

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

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

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

70ZV OM 2514

2. Remove the oil level plug from the front axle housing, using a 12 mm hex (Allen) wrench.

3. If the oil level is lower than the plug, add the specified oil through the level plug hole.

Refer to "Recommended Lubricants" page 3.58.

Dispose of the drained oil properly.

5. Install and tighten the level plug.

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

3.29 MAINTENANCE Every 250 Hours or 1 Month

Check Planetary Gear Oil

CAUTION The axles are pressurized through the hydraulic tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Before removing the oil level check plug, push down on the hydraulic tank cap or the breather valve to release the air pressure inside the hydraulic tank.

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

1. Check the oil level on all four wheels.

1 2

80ZVOM3340

2. Move the machine on level ground so that "TOP" mark (1) on the planetary gear housing comes top.

3. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

4. Remove oil level plug (2) on the housing, using a 12 mm hex (Allen) wrench.

5. If the oil level is lower than the plug, add the specified oil through the level plug hole.

Refer to "Recommended Lubricants" page 3.58.

6. Magnetic plugs are used for the planetary gear housing. Wipe off the small amount of fine metallic powder that normally sticks to the plugs. If abnormal debris is found, determine the cause and correct it.

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

Dispose of the drained oil properly.

8. Install and tighten the level plug.

3.30 MAINTENANCE Every 250 Hours or 1 Month

Check Tightness of Wheel Bolts

Check and Adjust Air Conditioner Belt

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

CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine 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.

80ZVOM3340

2. Check the wheel bolts are tightened to 892 Nm. 3. Retighten if necessary.

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 353±88 N (initial tension : 559±108 N).

3.31 MAINTENANCE Every 250 Hours or 1 Month

Clean Air Conditioner Filter Element

1

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

2

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

1 85ZV28612

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

97ZVOM0152

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

Turn the rings counterclockwise and then remove the cover.

97ZVOM0153

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. Use air pressure below 196 kPa. 6. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days for dry in the shade.

3.32 MAINTENANCE Every 250 Hours or 1 Month

7. After approximately 20 cleanings, replace the filter with new one.

2. Remove dust with compressed air. Use air pressure below 196 kPa.

Refer to "Replace Air Conditioner Filter Elements" page 3.54.

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

8. When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

4. After approximately 20 cleanings, replace the filters with new ones.

Refer to "Replace Air Conditioner Filter Elements" page 3.54.

5. Install the filter, install filter cover (3) and cover (1).

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

This filter is for dust, and has no effect on chemical substance like gas and asbestos etc.

97ZVOM0152

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

Inner filter cleaning

2

3

1 97ZVOM2473

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

Open unit cover (1) using screw driver.

Loosen screw (2) by fingers to remove cover (3).

Remove the filter and clean it.

3.33 MAINTENANCE Every 250 Hours or 1 Month

Replace Filter (First time replacement or cleaning only) - Transmission Oil Filter Cartridge Replace it first time only at 250 hours operation, after that replace it at every 500 hours operation.

Refer to "Every 500 Hours or 3 Months" page 3.36.

After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

- 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 3.42.

After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

- Brake Line Filter Clean it first time only at 250 hours operation, after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page 3.55.

- Orbitrol® Filter Clean it first time only at 250 hours operation, after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page 3.55.

3.34 MAINTENANCE Every 500 Hours or 3 Months

Every 500 Hours or 3 Months WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 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. When the needle of the coolant temperature gauge reaches the middle of the white zone, the temperature is about 40ºC. 2. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

85ZV28607

3. Loosen the drain plug.

4. Drain oil, about 33 liters, into a suitable container.

3.35 MAINTENANCE Every 500 Hours or 3 Months

Dip stick 85ZV28605

5. Remove the oil filter and properly dispose of it.

Make sure the O-ring is removed with the filter.

85ZV28610

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

Refer to "Recommended Lubricants" page 3.58 for the oil specifications. Total system capacity including the filter is 33 liters.

6. Clean the oil filter head gasket surface.

7. Fill the new filter with clean engine oil.

Refer to "Recommended Lubricants" page 3.58 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 15~20 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.

17. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

OM0200

CAUTION 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.

Used engine oil may cause skin disease or irritation.

Refer to the instructions supplied with the filter.

Do not allow used engine oil to remain on skin for prolonged periods of time.

10. Retighten the oil drain plug, and tighten to 80 N-m torque.

Clean skin thoroughly with soap and water.

3.36 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.

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.

2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

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

80ZVOM3271

85ZVOM3226

4. Turn the filter counterclockwise to remove.

Properly dispose of the oil and filter.

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of the new filter.

7. Install the filter on the filter head. Turn it clockwise to tighten. Follow the instructions on the filter.

Tightening torque: 30~40 N-m 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 2.83.

Add the specified oil as necessary to bring the oil level to the "H" (high) mark on the dipstick.

Refer to "Recommended Lubricants" page 3.58 for the specified oil.

10. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

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.

3.37 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) under the fuel filters.

8. Tighten the pre-filter (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.

9. Turn the starter switch key to the ON position and leave it about 20 seconds.

2

1

85ZV28608

10. Then, turn the starter switch key back to the OFF position and leave it about 15 seconds.

4. Clean the filter head gasket surface.

11. Repeat steps 9 and 10 three times.

The lift pump will automatically run to prime while the starter switch key is at ON position.

5. Apply a light film of clean engine oil to the gasket surface of the new filters.

12. Turn the starter switch key to the START position to run the engine

6. Fill only pre-filter (1) with clean fuel and leave main filter (2) empty.

Do not leave the key at the START position for 20 seconds or longer.

Do not fill fuel filter (main filter) (2) with fuel before installation.

13. If you failed to start the engine, repeat steps 9 through 12.

3. Remove and properly dispose of the fuel filters.

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.

14. After replacing the filter, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

3.38 MAINTENANCE Every 500 Hours or 3 Months

Replace DCA4 Coolant Filter Cartridge

CAUTION 2

Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

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

1 85ZV28605

CAUTION

3. Turn coolant shut-off valve (2).

Hot coolant and engine components can cause burns.

Avoid contact with coolant or engine components.

NOTE The filter WF2074 is initially installed when the machine is shipped from the factory. This filter can not be obtained as a spare parts.

4. Remove and properly dispose of coolant filter (1).

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of a new DCA4 coolant filter cartridge (WF2071).

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

OM0200

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

85ZVOM3219

2. Slowly open the radiator cap.

8. Open the coolant shut-off valves and install the radiator cap.

9. Run the engine and check for coolant leaks.

10. Idle the engine for about five minutes to purge all the air from the coolant.

11. After air has been purged from the system, stop the engine and check the coolant level again.

3.39 MAINTENANCE Every 500 Hours or 3 Months 12. If needed, add required amount of the coolant.

Refer to "Coolant Specification" page 3.60 for the correct mixture.

13. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

3.40 MAINTENANCE Every 1000 Hours or 6 Months

Every 1000 Hours or 6 Months

Replace Transmission Oil

WARNING

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

Every 1000 hours or 6 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", and "500 hours" inspection and maintenance.

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

When inspecting or servicing machine in articulation area: - Lower attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

- Make sure nobody is on machine.

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

CAUTION Transmission oil may be hot and may cause burns.

Avoid contact with transmission oil.

1. If the machine is cold operate the machine for a few minutes to bring the transmission oil temperature about 30~40ºC. 2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

3

1

2 95ZVOM2898

3. Remove drain plug (1) with a 36 mm wrench.

4. Drain oil into a suitable container (about 35 liters).

Properly dispose of or recycle the waste oil.

5. Loosen four bolts (2) with a 14 mm wrench.

3.41 MAINTENANCE Every 1000 Hours or 6 Months 6. Remove flange (3) together with the pipe and suction strainer.

Set screw

Flange

80ZVOM3271

Gasket Strainer 97ZVOM0164

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

8. Remove the suction strainer from the flange, brush off any debris and clean with solvent.

It is normal for a few fine particles to be on the strainer. Large pieces or a large quantity of particles indicates a problem.

Contact a Kawasaki dealer.

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

10. Tighten four bolts (2) to 53.0 N-m.

11. Fill with the specified oil.

Refer to "Recommended Lubricants" page 3.58.

12. Idle the engine and check for leaks.

13. 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 2.83 and "Recommended Lubricants" page 3.58.

14. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

3.42 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 pressing down the filler cap or the breather valve.

85ZVOM3250

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

2. Open the access cover on the right deck.

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

(S/N 9201~9250)

Filler cap

2

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.

1 80ZV27801

4. Install the breather onto the transmission case.

(S/N 9251~)

2 Breather valve

1 80ZV27801a

3. Press down the filler cap or the breather valve to relieve the tank pressure.

4. Clean around the top of filter cover (1).

3.43 MAINTENANCE Every 1000 Hours or 6 Months 5. Remove two bolts (2) with a 17 mm wrench and open filter cover (1).

Two bolts (2) may be used as "Jacking screws" to push up the cover. Install them into the two threaded holes in the cover. Screw them in equally to force the cover up evenly.

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

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

1

2

Adjust Parking Brake Lining

3

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

5

2. Lower the attachment to the ground and turn "OFF" the parking brake switch.

4

6 97ZVOM0166

1 6. Remove O-ring (3), spring (4), and bypass valve (5) from the filter housing.

7. Remove and properly dispose of filter (6) and waste oil.

8. Clean the inside of the filter housing.

9. Replace O-ring (3).

85ZV 3245

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

11. Install filter element (6), bypass valve (5), spring (4), new O-ring (3) and filter cover (1).

12. Close the access cover.

13. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

1

8º

Refer to "Replacement Monitor" page 2.38.

OM0167

3. Align inspection hole (1) with the adjuster wheel by turning the hole 8º counterclockwise from the bottom.

Do not enter the articulation area or under the machine.

3.44 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

5. Place a "DO NOT OPERATE" tag on the steering wheel.

Adjuster wheel

1 85ZV2829a

Special Tool (Accessory) 97ZVOM0168

6. Remove a cap of inspection hole (1) on the brake drum.

7. Turn the adjuster wheel fully upward to close the clearance between the brake drum and the brake lining (shoe). The adjuster wheel can be reached through the inspection hole.

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.

8. Return the adjuster wheel eight clicks downward. (Now the clearance is 0.23 mm)

5. Slightly accelerate the engine to about the middle speed range. (compressor speed 1,500~1,800 min-1)

9. Check parking brake operation as described on page 2.84.

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

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

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.

3.45 MAINTENANCE Every 1000 Hours or 6 Months

Adjust of refrigerant

Appearance of the sight glass

Normal

Almost clear.

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

Solutions

Inspect Automatic Belt Tensioner Pulley

High No bubble is seen.

Low A flow of bubbles is visible.

Contact your local Kawasaki dealer for inspection and recharging refrigerant.

85ZV28531

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.

3.46 MAINTENANCE Every 2000 Hours or 1 Year

Every 2000 Hours or 1 Year WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

Every 2000 hours or 1 year, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", "500 hours", and "1000 hours" inspections and maintenance.

Greasing 1. Park the machine on level ground.

Lower the attachment to the lowest position and tilt back the bucket fully.

2. Steer the machine fully to the right or left, and stop the engine.

3. Lubricate the fitting on the sleeve yoke.

4. To lubricate the spline enough, start the engine and slowly turn the machine from side to side 2 or 3 times after greasing.

Refer to "Recommended Lubricants" page 3.58 for the correct grease. Use lithium base grease for a propeller shaft spline.

95ZVOM2843

- 2nd Propeller Shaft Spline (one place)

IMPORTANT When greased with the machine in straight, remove the fitting on the sleeve yoke and follow the procedure above step 4.

3.47 MAINTENANCE Every 2000 Hours or 1 Year

Replace Hydraulic Oil, Clean Filter

Remove breather valve (S/N 9251~)

WARNING Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler cap or the breather valve.

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

2. Move the bucket and boom control levers back and forth to relieve the pressure.

80ZV27801a

6. Push down the top of the breather valve to relieve the tank pressure.

Remove oil inlet cap (S/N 9201~9250)

1

2

3

T4A breather valve2

80ZV27801

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

4. Press down the filler cap to relieve the tank pressure.

5. Remove the inlet cap.

CAUTION Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil.

7. Remove four bolts (1) to remove breather valve (2) and O-ring (3).

CAUTION Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil.

3.48 MAINTENANCE Every 2000 Hours or 1 Year Replace hydraulic oil 8. Prepare a suitable container to catch the draining oil (about 85 liters).

6

7

5

A 65DV2 02522-0436

4

85ZVOM3230

9. Remove drain plug (4) using a 24 mm wrench to drain oil.

12. Remove lock bolt (6) and suction strainer (7).

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. Dispose of the waste oil properly.

13. Clean inside of the tank and magnet plug.

11. Remove the nuts with a 14 mm wrench to remove inspection cover (5).

CAUTION Compressed air may cause injury.

- Wear protective clothing and eye protection.

- Air pressure must be below 196 kPa.

14. Apply lubrication oil to the threaded area (A) and install suction strainer (7). Tighten it with 155 N-m torque, and fix with lock bolt (6).

15. Install the new gasket and inspection cover (5), and tighten the nuts. Do not overtighten.

16. Install and tighten the drain plug.

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

Refer to "Recommended Lubricants" page 3.58.

18. Install the oil inlet cap or breather valve (2) and new O-ring (3).

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

20. Operate the bucket, boom, and steering cylinders for about five minutes, then lower the attachment to the ground.

21. Inspect for leaks.

22. Make sure hydraulic oil is to the center of the oil level gauge. Add hydraulic oil if necessary.

3.49 MAINTENANCE Every 2000 Hours or 1 Year 23. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

Replace Differential Gear Oil

CAUTION The axles are pressurized through the hydraulic tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Before removing the oil level check plug, push down on the hydraulic tank cap or the breather valve to release the air pressure inside the hydraulic tank.

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

1. If the machine is cold operate the machine for a few minutes to bring the differential gear oil temperature about 40ºC. 2. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

1

2

70ZV OM 2514

3. Remove level plug (1) and drain plug (2) from the front axle housing, with a 12 mm Hex (Allen) wrench.

Some fine metallic powder will normally stick to the magnet plugs.

Simply wipe it off.

3.50 MAINTENANCE Every 2000 Hours or 1 Year

Replace Planetary Gear Oil 4. Drain the oil (about 30 liters) into a suitable container.

5. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease.

Do not allow used oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

CAUTION The axles are pressurized through the hydraulic tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Before removing the oil level check plug, push down on the hydraulic tank cap or the breather valve to release the air pressure inside the hydraulic tank.

6. Install the drain plug.

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

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

Refer to "Recommended Lubricants" page 3.58.

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

1

8. Install and tighten the level plug.

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

2

Required oil volume for the rear differential is about 35 liters.

10. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

80ZVOM3340

2. Move the machine on level ground so that "TOP" mark (1) on the planetary gear housing comes to the top.

3. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

3.51 MAINTENANCE Every 2000 Hours or 1 Year 11. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

3 70ZV OM 2514

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

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

Simply wipe it off.

5. Drain the oil (about 12 liters) into a suitable container.

6. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease.

Do not allow used oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

7. Install and tighten the drain plug.

8. Refill the recommended oil through the level plug hole (2) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page 3.58.

9. Install and tighten the level plug.

10. Repeat these steps for all four planetaries.

3.52 MAINTENANCE Every 2000 Hours or 1 Year

Clean Fuel Tank

Check Vibration Damper

CAUTION Escaping fuel is flammable and harmful to skin.

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

- 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.

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.

80ZVUSA0003

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

2

OK

OK

1 80ZVOM3269

2. Remove drain plug (1) using a 24 mm wrench to drain oil.

3. Drain the remaining fuel into a suitable container.

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

5. Clean inside of the tank.

6. Install the inspection cover with a new gasket.

Tighten the nuts evenly. Do not overtighten.

7. Close the drain cock.

8. Fill the fuel tank.

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

80ZVUSA0004

3. If dents, cracks, or any deformations are found, contact your nearest Kawasaki dealer or Cummins Engine dealer for replacement.

3.53 MAINTENANCE Every 2000 Hours or 1 Year

Check Brake Accumulator

A

Test the brake accumulator for proper pre-charge of nitrogen gas.

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

C

B

65ZV0024

4. Check index lines (A) in vibration damper hub (B) and inertia member (C). If the lines are more than 1.59 mm out of alignment, replace the vibration damper.

Never service brake accumulator unless trained properly.

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

2. Run the engine at low idle for five minutes to fill the brake accumulator with oil.

3. Stop the engine.

OK

OK

4. Turn the key switch to the "ON" position.

5. Count the number of times you can step on the right hand brake pedal before the brake warning light comes on.

OK 65ZV0023

5. Inspect the rubber member for deterioration. If pieces of rubber are missing or if the elastic member is more than 3.18 mm below the metal surface, replace the damper.

Also, look for forward movement on the damper ring on the hub. Replace the vibration damper if any movement is detected.

6. If dents, cracks, or any deformations are found, contact your nearest Kawasaki dealer or Cummins Engine dealer for replacement.

6. If the number counted is less than eight, there is some problem with the accumulator. 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 Cummins engine dealer.

3.54 MAINTENANCE Every 2000 Hours or 1 Year

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

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

97ZVOM0152

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

Inner filter replacement

2 97ZVOM0152

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

Turn the rings counterclockwise and then remove the cover.

3

1 97ZVOM2473

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

Open unit cover (1) using screw driver.

Loosen screw (2) by fingers to remove cover (3).

Remove the filter and replace it with new one.

97ZVOM0153

4. Remove the outer filter from the cab, and replace it with new one.

When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

NOTE This filter is for dust, and has no effect on chemical substance like gas and asbestos etc.

3.55 MAINTENANCE Every 2000 Hours or 1 Year

Clean Filter for Orbitrol®

Clean Filter for Brake Line

CAUTION

CAUTION

Hot oil and components may cause burns.

Hot oil and components may cause burns.

Vent all pressure by pressing hydraulic cap or the breather valve down.

Vent all pressure by pressing hydraulic cap or the breather valve down.

Avoid contact with hot oil or components.

Avoid contact with hot oil or components.

1. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

1. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

2. Move the bucket and boom control levers back and forth to relieve the pressure.

Front

Center Pin C/L

3. Move the steering each way about 2~3 times to relieve the pressure.

Front Cross (Upper) 85ZV2 03261-0006

Front Chassis C/L

80ZV04033-02960

Air blow FLOW

Filter case

Filter

Nipple Air blow OM0212

2. Place a suitable container under the filter.

3. Remove the nipple with filter and properly clean the filter.

FLOW

Filter case

Filter

Nipple

OM0212

4. Install the nipple with filter and tighten it with 60~80 N-m torque.

4. Place a suitable container under the filter.

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

5. Remove the nipple with filter and properly clean the filter.

3.56 MAINTENANCE Every 2000 Hours or 1 Year 6. Install the nipple with filter and tighten it with 60~80 N-m torque.

Replace Filter in the Hydraulic Tank Cap (S/N 9201~9250)

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

CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before opening.

1 5 4 3 2 97ZVOM0170

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

2. Move the bucket and boom control levers back and forth to relieve the pressure.

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

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

5. Remove the filter cap.

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

7. Replace element (5).

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

3.57 MAINTENANCE Every 2000 Hours or 1 Year

Replace Filter in the Hydraulic Tank Breather Valve (S/N 9251~)

Check Ride Control Accumulator (option)

CAUTION

WARNING

Pressurized hydraulic tank is used for this machine.

Pressurized nitrogen gas in ride control accumulator could explode causing serious injury or death.

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing breather valve before opening.

Never service ride control accumulator unless trained properly.

Contact your nearest Kawasaki dealer.

1 2 3 4

T4A breather valve

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

2. Move the bucket and boom control levers back and forth to relieve the pressure.

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

4. Remove cap (1), nut (2), cover (3), and filter element (4).

5. Replace element (4).

6. Install the element, cover, nut, and cap.

Tightening torque: Nut (2) 8~10 N-m

3.58 MAINTENANCE Recommended Lubricants

Recommended Lubricants Refill capacity (Approximate)

Kind of Oil

Engine

33 liter

Engine oil (CH4 or CI4)

Transmission

35 liter

Engine oil (CD) or ATF

Hydraulic tank

∗1 85 liter

∗3 Hydraulic oil

Differential & Planetary

Front: 54 liter Rear: 59 liter

Engine oil (CD)

Fuel tank

290 liter

Diesel fuel

Ambient Temperature (ºC) -30

-20

-10

0

10

20

30

40

Change Interval (Hours)

SAE10W-30 SAE15W-40 SAE10W ATF ISO VG32 ISO VG46 Engine oil SAE40 or SAE50 ASTM D975 No.1 ASTM D975 No.2

∗2 500 1,000 2,000 2,000 daily

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

Engine

Use oil that meets engine oil classification API CH4, CI4 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 or A.T.F. (Auto Transmission Fluid).

Never mix engine oil and A.T.F.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure. ∗3. In a case that fire-resistant fluid is to be used in the hydraulic circuit, some hydraulic equipment must be replaced. Contact your Kawasaki dealer for service.

Be sure to use ISO VG32 when the temperature is below -15ºC. When replacing the hydraulic oil ISO VG46 with ISO VG32, the brakes must be bled to fully circulate the new oil, or brake problems could occur. Contact your Kawasaki dealer for service.

Differential & Planetary

Use class API CD engine oil with 5 % "Antichatter" additive or friction modifier.

Lubricating Grease

Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.

NLGI NO.1 or NO.0 grease for extremely low temperature.

Use lithium base grease for universal joints and a propeller shaft spline.

3.59 MAINTENANCE Recommended Lubricants

Diesel Fuel

Requirements for diesel fuel

Specifications Flash Point

ºC.

min.

Water and Sediment % vol.

max

Distillation Temperature

90% vol.

ºC

recovered

Kinematic Viscosity mm2

/s at 40ºC

Ash % mass

max.

Cetane Number

min.

Carbon residue on 10% distillation residue % mass

Grade No.2-D

38

52

0.05

0.05

max.

288

338

min.

1.3

1.9

max.

2.4

4.1

max.

Sulfur % mass

Grade No.1-D

max.

0.01

0.01

0.50

0.50

40

40

0.15

0.35

3.60 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 Ambient Temperature

-30ºC

-25ºC

-20ºC

-15ºC

Pure Water

(liter)

14.6

16.1

17.7

19.2

20.8

Antifreeze

(liter)

16.4

14.9

13.3

11.8

10.2

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) 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.

3.61 TROUBLESHOOTING

TROUBLESHOOTING This troubleshooting section is not intended to cover every condition, however many of the common possibilities are listed.

Following are example of problems and their solutions.

Contact your local Kawasaki dealer for the items marked with or your local authorized CUMMINS ENGINE dealer for the items marked with to repair. kawasaki

CUMMINS

ENGINE PROBLEM

POSSIBLE CAUSES

SOLUTIONS Add oil Change oil Change filter and oil

PAGE 2.70 3.34 3.34

Engine oil pressure warning lamp lights up, and buzzer sounds

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

2.72

Coolant temp. warning lamp lights up

Add coolant Low engine coolant level kawasaki Fan circuit pressure or flow too low Clean Clogging radiator fins Flush or professionally clean Scale or mineral build up inside radiator Defective alarm switch (gauge is in green) CUMMINS kawasaki Low water pump flow or Thermostat stuck or missing

Engine does not start when the starter motor is turning (Also see ELECTRICAL TROUBLESHOOTING)

Fuel filter element clogging Starter motor speed too low Defective engine shut off solenoid Fuel pump failure Incorrect fuel injection timing Compression pressure too low Defective injectors

Replace fuel filter Booster Battery may be used

3.37 2.102

Air in fuel lines

Tighten fuel connections and filter Replace fuel filter

Unstable (rough) idling

Insufficient power

Fuel filter element clogging Fuel pump failure Incorrect fuel injection timing Air cleaner element clogging Fuel filter element clogging Throttle pedal electrical signal incorrect Engine oil level too high Incorrect valve clearance Piston ring wear Defective injectors Fuel pump failure Air cooler restricted

kawasaki

kawasaki

kawasaki

or

or

or

CUMMINS

3.12 3.15

CUMMINS

3.37 3.37

CUMMINS

Clean or replace element Replace fuel filter

3.10 3.37

kawasaki

Check dipstick and correct level

kawasaki

or

CUMMINS

2.70

3.62 TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Use correct type of oil Correct oil level

3.58 2.70

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

CUMMINS

3.37

CUMMINS

CUMMINS

3.10

3.63 TROUBLESHOOTING

ELECTRICAL PROBLEM

SOLUTIONS

PAGE

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

Adjust or replace belt Replace battery

2.75

Starter motor does not turn when starter switch key is turned to "START"

Transmission not in NEUTRAL Insufficient battery charge Starter switch failure Defective wiring Starter motor failure

Shift to NEUTRAL Battery charge or booster

Starter motor turns engine slowly

Hydraulic control levers not in NEUTRAL Insufficient battery charging Engine oil viscosity too high (thick) Poor connection at batteries or ground Defective wiring Starter motor failure Steering valve failure

Move levers to NEUTRAL Battery charge or booster Replace oil Clean and tighten all terminals

POSSIBLE CAUSES

SOLUTIONS

Charge lamp lights up

POSSIBLE CAUSES

kawasaki

or

CUMMINS

1.30 2.102

kawasaki

kawasaki

or

CUMMINS

2.5 2.102 3.34

kawasaki kawasaki

or

CUMMINS

kawasaki

STEERING PROBLEM

Hard steering

Will not steer

Tires are under inflated Severe conditions (over loaded, deep mud, etc.)

Oil pressure too low Steering valve failure Steering cylinder failure Defective Orbitrol® Pump failure

Check/adjust tire pressure Change operation

Articulation stopper in locked position

Move articulation stopper to "STORED" position Reduce load

Excessive load on steering Steering valve failure Orbitrol® failure Pump failure Relief valve failure Steering cylinder failure Blocked screen filter Excessively cold oil / wrong grade oil

Steering Drift

Steering control valve failure Steering pilot valve failure

PAGE 3.25

kawasaki

1.29

kawasaki

Clean filter

3.55

Warm oil / Replace oil with proper viscosity for temperature

3.58

kawasaki

3.64 TROUBLESHOOTING

HYDRAULIC PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Warm oil Replace with proper grade oil

3.58

Boom raises too slowly

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 Excessively cold oil / Wrong oil type

Warm oil / Replace oil with proper viscosity for temperature

Boom natural drift excessively

Bucket / Attachment floating or drifting

kawasaki

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

kawasaki

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

kawasaki

3.58

BRAKE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE 3.43

Worn brake lining Insufficient oil pressure (will not release) Failure of switch or solenoid valve Poor wiring or ground to switch or solenoid valve

Adjust or replace lining

Parking brake does not work properly

Brake dragging

Wrong type of oil Dirt, debris under base of brake pedal Warped brake discs Air in brake oil circuit

Use correct type of oil Remove or clean

Braking power too low

Air in brake oil circuit Brake piston seal leakage Blocked screen filter

Brake pressure drops rapidly

Cracked or leaking brake line Brake valve failure Parking brake cylinder leakage Defective brake accumulator Defective brake seals

kawasaki

3.58

kawasaki

kawasaki

Clean filter

kawasaki

3.55

3.65 TROUBLESHOOTING

TORQUE CONVERTER & TRANSMISSION PROBLEM

POSSIBLE CAUSES Excessively cold oil / Wrong oil type

Engine is running but machine does not move

Parking brake is applied Transmission oil level too low Transmission suction strainer clogging Clutch oil pressure too low Transmission clutch failure 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

3.58

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

2.83 3.40

2.83 3.40

kawasaki

3.42

kawasaki

2.83 2.88 3.12

kawasaki

AIR CONDITIONER PROBLEM

Low cooling when A/C "ON"

Low heater out put

POSSIBLE CAUSES

SOLUTIONS

Hot water continues to flow through heater core A/C not set for maximum cooling Condenser fins plugged A/C filters plugged A/C compressor belts slipping/broken A/C refrigerant charge low

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

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

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

PAGE

2.55 3.15 3.31 3.30

kawasaki

kawasaki

2.55

3.66 TROUBLESHOOTING

AIR CONDITIONER FAILURE MODE FAILURE MODE

FAILURE

SOLUTIONS

E11 (Wire breakage in the inside air sensor)

- Breakage in the wire harness or loosen connector - Wire breakage in the inside air sensor (THI)

- Checking the wiring - Replacement

E12 (Short-circuit in the inside air sensor)

- Short-circuit in the wire harness - Short-circuit in the inside air sensor (THI)

- Checking the wiring - Replacement

E13 (Wire breakage in the outside air sensor)

- Breakage in the wire harness or loosen connector - Wire breakage in the outside air sensor (THAM)

- Checking the wiring - Replacement

E14 (Short-circuit in the outside air sensor)

- Short-circuit in the wire harness - Short-circuit in the outside air sensor (THAM)

- Checking the wiring - Replacement

E15 (Wire breakage in the water temperature sensor)

- Breakage in the wire harness or loosen connector - Wire breakage in the water temperature sensor (THW)

- Checking the wiring - Replacement

E16 (Short-circuit in the water temperature sensor)

- Short-circuit in the wire harness - Short-circuit in the water temperature sensor (THW)

- Checking the wiring - Replacement

E18 (Short-circuit in the insolation sensor)

- Short-circuit in the wire harness - Short-circuit in the insolation sensor (THI)

- Checking the wiring - Replacement

E21 (Wire breakage in the ventilation sensor)

- Breakage in the wire harness - Wire breakage in the ventilation sensor (THF)

- Checking the wiring - Replacement

E22 (Short-circuit in the ventilation sensor)

- Short-circuit in the wire harness - Short-circuit in the ventilation sensor (THF)

- Checking the wiring - Replacement

E43 (Abnormality in the ventilation servo motor)

- Defective wire harness or loosen connector - Defective servo motor - Stuck foreign material

- Checking the wiring - Replacement - Removing the foreign material

- Defective wire harness or loosen connector - Defective servo motor - Stuck foreign material

- Checking the wiring - Replacement - Removing the foreign material

- Defective wire harness or loosen connector - Defective servo motor - Stuck foreign material

- Checking the wiring - Replacement - Removing the foreign material

E44 (Abnormality in the air mixture damper motor) E45 (Abnormality in the inside/outside air switching motor)

3.67 TROUBLESHOOTING

FAILURE MODE

FAILURE - High pressure switch actuation - Outside air temperature is too high - Insufficient cooling of condenser - Defective fan motor - Clogging in condenser - Refrigerant overfilling

E51 (Abnormality in the refrigerant pressure)

- Aeration into refrigerant circuit - Low pressure switch actuation - Outside air temperature is too low - Insufficient refrigerant quantity - Gas leak

SOLUTIONS

- Motor replacement - Cleaning - Adjusting refrigerant quantity - Circuit evacuation & refilling

- Circuit evacuation & refilling - Repair leakage spot - Circuit evacuation & refilling

3.68 TROUBLESHOOTING

MODM Error log monitor failure code (Input side) Code

Failure

Detection condition (In case of)

CN121

Shift lever F & R switch malfunction

Shift lever F & R contact ON at the same time Failure continues for more than 3 seconds

CN122

Shift lever 1•2•3•A switch malfunction (1)

Shift lever any of more than two 1•2•3•A contact ON at the same time Failure continues for more than 30 seconds

CN123

Shift lever 1•2•3•A switch malfunction (2)

All 1•2•3•A signal OFF continues for more than 30 seconds

CN141

Shift-up switch malfunction

Switch is ON for more than 10 seconds

CN142

Shift-down switch malfunction

Switch is ON for more than 10 seconds

CN143

Shift-up switch & shift-down switch malfunction

Shift-up switch & shift-down switch contact ON at the same time Failure continues for more than 3 seconds

CN145

Kick-down switch malfunction

Switch is ON for more than 10 seconds

CN151

T/M oil pressure switch malfunction (This applies to the model 115ZV-2 only)

Signal OFF continues for more than 10 seconds during engine running

CN152

T/M oil pressure sensor malfunction (This applies to the model 95ZV-2 only)

T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than 10 seconds during engine running

CN213

Inching sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN214

Inching sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN161

Machine speed sensor malfunction (1)

Input circuit is disconnected for more than 3 seconds

CN162

Machine speed sensor malfunction (2)

Input value is over 70 km/h (44 mile/h) for more than 3 seconds

CN163

E/G speed sensor 1 (ECM output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)

CN164

E/G speed sensor 1 (ECM output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is OFF

CN165

E/G speed sensor 2 (Sensor output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)

CN167

E/G speed sensor 2 (Sensor output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is ON

CN232

S/S potentiometer malfunction (1)

Voltage is lower than 0.1 V for more than 3 seconds

CN234

S/S potentiometer malfunction (2)

Voltage is larger than 4.9 V for more than 3 seconds

CN236

S/S shift switch (F & R contact) malfunction

Failure continues for more than 3 seconds

CN146

Shift hold switch malfunction

Switch is ON for more than 10 seconds

CN251

Secondary steering oil pressure sensor malfunction(1)

Voltage is lower than 0.2 V for more than 3 seconds

CN252

Secondary steering oil pressure sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN254

Low secondary steering oil pressure

Oil pressure sensor detects secondary steering oil pressure below 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine running

CN262

Kickout potentiometer malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN263

Kickout potentiometer malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN271

Efficient loading system hydraulic oil pressure senVoltage is lower than 0.2 V for more than 3 seconds sor malfunction (1)

CN272

Efficient loading system hydraulic oil pressure senVoltage is larger than 4.6 V for more than 3 seconds sor malfunction (2)

CN312

Brake oil pressure sensor 1 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN313

Brake oil pressure sensor 1 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN315

Brake oil pressure sensor 2 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN316

Brake oil pressure sensor 2 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN321

E/G coolant temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN323

E/G coolant temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN341

T/M oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN342

T/M oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

3.69 TROUBLESHOOTING

Code

Failure

Detection condition (In case of)

CN351

Hydraulic oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN352

Hydraulic oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN381

Fuel level sensor malfunction

Input signal corresponds to "any other pattern" in fuel level indication table

CN391

Air temperature probe malfunction (1)

Input voltage is larger than 4.35 V for more than 3 seconds

CN392

Air temperature probe malfunction (2)

Input voltage is lower than 0.13 V for more than 3 seconds

CN412

Abnormal brake oil pressure (1)

Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/cm2) (592 psi) for more than 1 second during engine running

CN413

Abnormal brake oil pressure (2)

Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6 kgf/cm2) (592 psi) more than 1 second during engine running

CN414

Abnormal brake oil pressure difference

Brake oil pressure difference switch is in abnormal condition for more than 1 second

CN415

Abnormal brake oil amount

Brake oil amount switch is in abnormal condition for more than 1 second

CN421

Abnormal engine oil pressure

Engine oil pressure switch is OFF for more than 2 seconds during engine running

CN431

Abnormal engine coolant temperature (1)

Engine coolant temperature switch is ON for more than 2 seconds

CN432

Abnormal engine coolant temperature (2)

Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition for more than 2 seconds

CN451

Abnormal T/M oil temperature (1)

T/M oil temperature switch is ON for more than 2 seconds

CN452

Abnormal T/M oil temperature (2)

T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more than 2 seconds

CN461

Abnormal hydraulic oil temperature

Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for more than 2 seconds

CN471

Clogged T/M oil filter

30 minutes after starter switch is ON, T/M oil filter switch is ON for more than 2 seconds when T/M oil temperature sensor detects oil temperature more than 60 deg. C (140 deg. F)

CN481

Clogged air cleaner element

Air cleaner switch is ON for more than 2 seconds

CN491

Abnormal cooling water level in radiator

Radiator cooling water level switch is OFF for more than 2 seconds when the engine is off.

CN496

Abnormal hydraulic oil level

Hydraulic oil level switch is in abnormal condition for more than 30 seconds

CN497

Abnormal brake disc oil temperature

Brake disc oil temperature switch is ON for more than 1 second

CN498

Abnormal disc wear

Brake disc wear switch is ON for more than 1 second

CN801

CAN disconnect

CAN line is disconnected

CN802

Abnormal engine coolant temperature (CAN)

No engine coolant temperature data received for more than 3 seconds

CN912

Abnormal MCU voltage (1)

Voltage is larger than 30±1 V

CN913

Abnormal MCU voltage (2)

Voltage is lower than 22±0.5 V for more than 10 seconds during engine running

3.70 TROUBLESHOOTING

Error log monitor failure code (Output side) Code

Failure

Detection condition

CN512

F solenoid valve malfunction

F solenoid valve is short-circuited or disconnected

CN514

R solenoid valve malfunction

R solenoid valve is short-circuited or disconnected

CN516

1st solenoid valve malfunction

1st solenoid valve is short-circuited or disconnected

CN518

2nd solenoid valve malfunction

2nd solenoid valve is short-circuited or disconnected

CN521

3rd solenoid valve malfunction

3rd solenoid valve is short-circuited or disconnected

CN524

4th solenoid valve malfunction

4th solenoid valve is short-circuited or disconnected

CN526

D solenoid valve malfunction

D solenoid valve is short-circuited or disconnected

CN528

H solenoid valve malfunction

H solenoid valve is short-circuited or disconnected

CN531

LU solenoid valve malfunction

LU solenoid valve is short-circuited or disconnected

CN534

Auto brake solenoid valve malfunction

Auto brake solenoid valve is short-circuited or disconnected

CN536

Speed change control solenoid valve malfunction (1)

Speed change control solenoid valve is short-circuited

CN537

Speed change control solenoid valve malfunction (2)

Speed change control solenoid valve is disconnected

CN621

S/S solenoid valve R malfunction (1)

S/S solenoid valve R is short-circuited

CN622

S/S solenoid valve R malfunction (2)

S/S solenoid valve R is disconnected

CN623

S/S solenoid valve L malfunction (1)

S/S solenoid valve L is short-circuited

CN624

S/S solenoid valve L malfunction (2)

S/S solenoid valve L is disconnected

CN631

Pressure increase solenoid valve malfunction

Pressure increase solenoid valve is short-circuited or disconnected

CN641

Ride control solenoid valve malfunction

Ride control solenoid valve is short-circuited or disconnected

CN681

Efficient loading system selection solenoid valve malfunction

Efficient loading system selection solenoid valve is short-circuited or disconnected

CN693

Lower kickout relay malfunction (1)

Lower kickout relay (coil) is short-circuited

CN694

Lower kickout relay malfunction (2)

Lower kickout relay (coil) is disconnected

CN712

Cooling fan solenoid valve malfunction (1)

Cooling fan solenoid valve is short-circuited

CN713

Cooling fan solenoid valve malfunction (2)

Cooling fan solenoid valve is disconnected

CN721

Hour meter drive malfunction

Hour meter drive is short-circuited

3.71 SPECIFICATIONS

SPECIFICATIONS Intended use

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.

This product is designed for loading, excavation, grading, dozing and/or scooping.

Refer to "Operating Techniques" for further information.

Do not use the machine with excessive load than specified, to avoid getting stuck of the machine and/or any risk of injury caused by potential structural damage of the machine due to the overload.

Use the permitted attachments and optional parts provided, when needed, which are suitable for the operating conditions and job contents.

Bucket Data Kind of bucket

Hight Lift Spec. Bucket Hight Lift Spec. Bucket Hight Lift Spec. Bucket No Cutting Edge With Teeth With Cutting Edge

Bucket capacity (m3)

2.6

2.6

2.7

Dumping clearance (mm)

3,505

3,315

3,415

Dumping reach (mm)

1,915

2,030

1,960

Kind of bucket

General Purpose Bucket No Cutting Edge

General Purpose Bucket With Teeth

General Purpose Bucket With Cutting Edge

Bucket capacity (m3)

3.0

3.0

3.2

Dumping clearance (mm)

3,050

2,870

2,960

Dumping reach (mm)

1,080

1,190

1,130

Kind of bucket

Rock Bucket No Teeth Rock Bucket With Teeth

Rock Bucket With Cutting Edge

Bucket capacity (m3)

2.6

2.6

2.4

Dumping clearance (mm)

3,050

2,860

2,760

Dumping reach (mm)

1,080

1,195

1,265

Kind of bucket

Loose Material Bucket Loose Material Bucket Loose Material Bucket No Teeth With Teeth With Cutting Edge

Bucket capacity (m3)

3.4

3.4

3.6

Dumping clearance (mm)

2,960

2,780

2,875

Dumping reach (mm)

1,160

1,275

1,215

3.72 SPECIFICATIONS

Minimum turning radius at outside bucket 6,375 mm at center of outside tire 5,425 mm Full articulation angle 40º 45º

Tread

1,130

2,060 mm

4,095

Width (outside tire)

3,440

2,960

2,680 mm Width (outside bucket)

50º

2,800 mm 465

Equipped with GSC bucket with bolt on cutting edge

3,200 8,000

23.5 (L-3) Tire and ROPS Cab WL OPERATING SPEC EU

2.6 2.7 3.2 3.0 3.2 3.0

115%

95%

Material Density (kg/m3)

2450

2200

1950

1700

1450

2.6

1200

Standard Boom

Bucket Capacity (m3)

High Lift Boom

Bucket Selection Chart

3.73 SPECIFICATIONS

Operating Weight

17,830 kg

Tipping Load (Straight/Full turn)

13,880 / 11,880 kg

Engine

CUMMINS QSC8.3 Diesel 4 cycle, Water Cooled, Direct injection, Turbo charged & air cooled intercooler 8.26 Liter 152 kW / 2,200 min-1

Model Type Displacement Rated Power (Net)

Tire

23.5 R25

Max. Running Speed (forward/reverse)

1st : 7.1 / 7.3 km/h 2nd:12.0 / 12.2 km/h 3rd :21.2 / 21.6 km/h 4th :34.2 / 34.5 km/h

Sound Level 73dB (A) Continuous A-Weighted sound pressure level at workstation.

Measurement is obtained in accordance with ISO 6396.

Airborne sound power level 106dB (A) Measurement is obtained in accordance with ISO 6395.

Hand-arm vibration Less than 2.5 m/s2 The weighted root mean square acceleration value to which the hands/arms are subjected.

Measurements are obtained in accordance with ISO 5349.

Whole-body vibration Less than 0.5 m/s2 The weighted root mean square acceleration value to which the body is subjected.

Measurements are obtained in accordance with ISO 2631.

The weight and load figure include, enclosed ROPS cab, GSC bucket with bolt-on cutting edge, 23.5 R25 tires, full fuel tank and operator.

Safety regulations regarding safety of machinery including attachments: All rated capacities are determined on a condition that machines are placed on a horizontal and solid ground. If it is necessary to operate the machine on conditions other than above specified (for example, soft ground or irregular ground, inclined or slippery ground), the operator must consider the above conditions.

Outer filter for the air conditioner is for dust, and has no effect on chemical substance like gas and asbestos etc.

3.74 SPECIFICATIONS

Fork Loader Specifications Full turn tipping load

N

Tire

80,415 23.5 (L3) H3

ROPS Cab Air conditioner

H1

80

H2

180

H3

1,600

W1

235

W2

760

W3

2,160

W4

2,238

P

100

(kg)

1,629

H2

1,969

L1 L2 L3

P

L3

W2

1,775

W3

1,370

L2

W1

Weight

L1

W4

Dimensions (mm)

H1

Option weight

Fork assy

INDEX (FE) Fuel Efficient Mode Switch ................................2.14

A Accelerator Pedal ........................................................2.7 Adjust and Check Rear View Mirrors ........................2.77 Adjust Parking Brake Lining ......................................3.43 Adjustments ............................................................2.100 After Storage ...........................................................2.110 Air Cleaner Warning Lamp (red) ...............................2.29 Air Conditioner ..........................................................2.55 Action to be taken when the air conditioner is not used ................................................................2.61 For Efficient Use of the Air Conditioner .................2.60 Operating Method (Normal Use) ............................2.57 Operation Method (Other Uses) ............................2.58 Other Functions .....................................................2.59 Switches ................................................................2.55 Ventilation Name and Location ..............................2.55 Articulation Stopper ..........................................1.29, 2.73 Attachment Installation to Quick Coupler ..................2.65 Auto Shift Indicator Lamp ..........................................2.30 Auxiliary Attachment Control Lever (option) ................2.6

B Battery removal / reinstallation procedure ...............2.109 Before Starting Safety .................................................1.4 Before Storage ........................................................2.108 Boom Control Lever ....................................................2.4 Booster Batteries / Jumper Cables .........................2.102 Brake Pedals ...............................................................2.8 Brake Pressure Warning Lamp (red) ........................2.28 Bucket / Attachment Leveler Adjustment ................2.100 Bucket Control Lever ...................................................2.5 Bucket hoisting position ..........................................2.107

C Carrying .....................................................................2.96 Cautions on Battery Replacement or Battery Cable Removal .......................................2.111 Cautions Regarding Welding Repair Service ..........2.112 Central Warning Lamp (red) ......................................2.28 Charge Lamp (red) ....................................................2.30 Check after Starting the Engine ................................2.82 Check Air Conditioner Refrigerant ............................3.44 Check Air Intake System ...........................................2.76 Check and Adjust Air Conditioner Belt ......................3.30 Check and Adjust Valve Lash Clearance ..................3.53 Check and/or Replace Seat Belt ...............................3.10 Check Back-up Alarm Operation ...............................2.85 Check Battery Electrolyte Level ................................3.24 Check before Operation ............................................2.69 Check Brake Accumulator .........................................3.53 Check Control Levers ................................................2.78 Check Cooling Fan ....................................................2.77 Check Crankcase Breather Tube ..............................2.76 Check Differential Gear Oil .......................................3.28

Check Drive Belt .......................................................2.75 Check Engine Coolant Level .....................................2.72 Check Engine Oil Level .............................................2.70 Check Exhaust Gas ..................................................2.85 Check Fuel Level ......................................................2.83 Check Horn Operation ..............................................2.77 Check Hydraulic Oil Level .........................................2.71 Check Monitor Panel Operation ................................2.78 Check or Replace Fuses ...........................................3.13 Check Parking Brake ................................................2.77 Check Parking Brake Operation ...............................2.84 Check Planetary Gear Oil .........................................3.29 Check Ride Control Accumulator (option) .................3.57 Check Service Brake Disk Wear ...............................3.53 Check Service Brake Operation ................................2.84 Check Steering Wheel Operation .............................2.85 Check Tightness of Wheel Bolts ...............................3.30 Check Tire Air Pressure ............................................3.25 Check Tire for Damage, Air and Tread Depth ..........2.74 Check Transmission Oil Level ..................................2.83 Check Transmission Shift Lever ...............................2.78 Check Vibration Damper ...........................................3.52 Check Warning Lamps ..............................................2.82 Check Windshield Washer Fluid ...............................3.14 Check Wiring Harnesses ..........................................2.73 Cigarette Lighter .......................................................2.15 Clean Air Conditioner Condenser .............................3.15 Clean Air Conditioner Filter Element .........................3.31 Clean Filter for Brake Line ........................................3.55 Clean Filter for Orbitrol® ............................................3.55 Clean Fuel Tank ........................................................3.52 Clean or Replace Air Cleaner Element .....................3.10 Clean or Replace Transmission Breather .................3.42 Clean Radiator / Air cooler / Hydraulic oil cooler Fins ............................................................3.12 Cold Start ..................................................................2.80 COMPONENT NAME/LOCATION ..............................2.2 Control Lever Lock for Quick Coupler Lock Pin [3rd spool valve specification (option)] .................1.28 Coolant Specification ................................................3.60

D Declutch Lamp (green) .............................................2.27 Declutch ON/OFF and Adjustable Preset Switch ......2.17 Downshift Button .......................................................2.16 Dozing .......................................................................2.95 Drain Water and Sediment from Fuel Filter ..............2.72 Drain Water and Sediment from Fuel Tank ..............3.24 Dumping into Truck or Hopper ..................................2.97 During Storage ........................................................2.110

E Efficient Loading System Switch ...............................2.19 Electrical Protection ..................................................2.45 Emergency Brake .....................................................1.30 Engine Coolant Temperature Gauge ........................2.26

Engine Coolant Temperature Warning Lamp (red) ............................................. 2.29 Engine Oil Pressure Warning Lamp (red) ................. 2.28 Error Log Monitor ..................................................... 2.40 Every 10 Hours or Daily ............................................ 3.20 Every 1000 Hours or 6 Months ................................. 3.40 Every 2000 Hours or 1 Year ..................................... 3.46 Every 250 Hours or 1 Month .................................... 3.27 Every 50 Hours or 1 Week ....................................... 3.21 Every 500 Hours or 3 Months ................................... 3.34 Excavating ................................................................ 2.94 Explosion / Fire / Burn Prevention ............................ 1.15

F F/R Switch ................................................................ 2.21 Four-Way Flasher Switch ......................................... 2.16 Front Wiper Switch ................................................... 2.14 Front Working Light Switch ....................................... 2.13 Fuel Gauge ............................................................... 2.27 Fuse Boxes .............................................................. 2.45 Fusible Link .............................................................. 2.46

G General Inspection ................................................... 2.86 Grease Gun Holder .................................................. 2.64 Greasing ........................................ 3.18, 3.21, 3.27, 3.46 Ground Levelling ...................................................... 2.95

H Hibernate Mode ........................................................ 2.81 High beam Indicator Lamp (blue) ............................. 2.30 High-Low Beam Lever/Turn Signal Lever ................... 2.4 Horn Button ................................................................ 2.3 Hour Meter ............................................................... 2.31 Hydraulic Oil Level Warning Lamp (simultaneous flashing)(red)(11. 24.) ................... 2.32 Hydraulic Pressure Hose & Electrical Wiring Connecting to Attachment .................................... 2.67

M MAINTENANCE ......................................................... 3.2 Manual Box .............................................................. 2.63 MCU (Machine Control Unit) Warning Lamp (red) .............................................................................. 2.28 MODM ............................................................. 2.17, 2.33 MODM function ........................................................ 2.33 Monitor Changeover ................................................. 2.33 Mounting and Dismounting Safety ............................. 1.3

N Neutral Indicator Lamp ............................................. 2.30 Neutral Start System ................................................ 1.30 Normal Start ............................................................. 2.79

O Operating Techniques .............................................. 2.92 Operating the Machine ............................................. 2.87 OPERATION ............................................................ 2.69 Operation and Function ............................................ 2.62 Operational Safety ...................................................... 1.7 Operator Safety .......................................................... 1.2 OPERATOR'S AREA ................................................. 2.3 Other Maintenance Safety Concerns ....................... 1.16

P Parameter Setting Monitor ....................................... 2.41 Parking ..................................................................... 2.90 Parking Brake Indicator Lamp (red) ......................... 2.27 Parking Brake Switch ............................................... 2.12 Parking Safety .......................................................... 1.11 Pedals and Levers ...................................................... 2.3 Preheat Indicator Lamp (orange) ............................. 2.28

Q Quick Coupler (option) ............................................. 2.65 Quick Coupler Lock Pin Switch (option) ................... 2.24

I

R

Idling Management System ...................................... 2.81 Indicators .................................................................. 2.25 Information Monitor .................................................. 2.34 Input/Output Monitor ................................................. 2.41 Inspect Automatic Belt Tensioner Pulley .................. 3.45 Inspection and Maintenance Table ............................ 3.5

Radio - AM / FM Cassette (24Volt Type) (option) (~December, 2009) .............................................. 2.47 Rear Wiper Switch .................................................... 2.15 Rear Working Light Switch ....................................... 2.13 Recommended Lubricants ....................................... 3.58 Recommended Mixture of Antifreeze ....................... 3.60 Replace Air Conditioner Filter Elements .................. 3.54 Replace Air Conditioner Receiver Dryer .................. 3.17 Replace Bucket Teeth (option) ................................... 3.8 Replace Coolant ....................................................... 3.15 Replace Cutting Edge ................................................ 3.9 Replace DCA4 Coolant Filter Cartridge ................... 3.38 Replace Differential Gear Oil .................................... 3.49 Replace Engine Oil and Oil Filter Cartridge ............. 3.34 Replace Filter ........................................................... 3.33 Replace Filter in the Hydraulic Tank Breather Valve (S/N 9251~) ................................. 3.57

K Kickout Control Switch ............................................. 2.18

L Light Switch .............................................................. 2.12 Loading ..................................................................... 2.92 Loading Control Lever Lock ..................................... 1.28 Long Term Storage ................................................ 2.108

Replace Filter in the Hydraulic Tank Cap (S/N 9201~9250) ...........................................3.56 Replace Fuel Filter Cartridge ....................................3.37 Replace Hydraulic Oil Return Filter ...........................3.42 Replace Hydraulic Oil, Clean Filter ...........................3.47 Replace Planetary Gear Oil ......................................3.50 Replace Transmission Oil .........................................3.40 Replace Transmission Oil Filter Cartridge ................3.36 Replacement Monitor ................................................2.38 Reversal Fan Pilot Lamp (green)(option) ..................2.32 Reversal Fan Switch (option) ....................................2.22 Ride Control (option) .................................................2.62 Ride Control Switch (option) .....................................2.23 Roading / Special Applications ................................2.101 ROPS (Roll Over Protective Structure) Cab ....1.31, 2.77 Running in Deep Mud or Water .................................2.89

S Safe Operation ............................................................1.2 SAFETY ......................................................................1.2 Safety Devices ..........................................................1.28 Safety Preparations Before Maintenance .................1.12 Safety Signs ..............................................................1.18 Seat ...........................................................................2.42 Seat Adjustment ...............................................2.42, 2.43 Seat Belt ....................................................................2.44 Secondary Steering ...................................................1.31 Secondary Steering Warning Lamp (red) ..................2.31 Selection Switch for Shift Lever or F/R Switch ..........2.20 Serial Number Location ...............................................3.2 Shift Hold Switch (option) ..........................................2.23 SPECIAL PROCEDURES .......................................2.100 Specification Setting Monitor .....................................2.41 SPECIFICATIONS ....................................................3.71 Speed and Direction Change ....................................2.88 Speedometer .............................................................2.26 Starter Switch ............................................................2.11 Starting the Engine ....................................................2.79 Starting the Machine .................................................2.87 Starting the Machine on a Grade ..............................2.88 Steering Column Telescopic Tilt Handle .....................2.9 Stopping the Engine ..................................................2.91 Switches ....................................................................2.10

T Torque Converter Oil Temperature Gauge ...............2.27 Torque Converter Oil Temperature Warning Lamp (red) ..............................................2.29 Towing .....................................................................2.104 Transmission Shift Lever .............................................2.3 Transmission Status Monitor .....................................2.31 Transportation .........................................................2.106 TROUBLESHOOTING ..............................................3.61 Turn Signal Indicator Lamp (Left) (green) .................2.30 Turn Signal Indicator Lamp (Right) (green) ...............2.30 Typical Truck Loading Methods ................................2.98

W Walk-Around Inspection ............................................2.69

Warm-up control .......................................................2.81 Welding ...................................................................2.112 When Required Inspection and Maintenance .............3.8 Wire hooking position and range/stretching impossible range/tolerance .................................2.105 Working Light Indicator Lamp (green) .......................2.27 Wrist Rest ...................................................................2.6

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes

WHEEL LOADER 80ZV-2 OPERATION & MAINTENANCE MANUAL

Manual part number: 93109-00562

Manufacturer: KCM Corporation Address: 2680 Oka, Inami-cho, Kako-gun, Hyogo 675-1113 JAPAN URL: http://www.khi.co.jp/kenki/english/