Kawasaki WHEEL DOZER 135ZV OPERATION & MAINTENANCE MANUAL 93117-00035 - PDF DOWNLOAD

135ZV

93117-00035 February 1, 2006

OPERATION & MAINTENANCE MANUAL WHEEL LOADER

135ZV

Printed in Japan (i) ( アメリカ用 )

93117-00035

©2006 Kawasaki Heavy Industries, Ltd. All rights reserved.

NOTICE Powered by CUMMINS QST30-C Engine Serial No. 13C1-0201 and up

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

WARNING CALIFORNIA PROPOSITION 65

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

WASH HANDS AFTER HANDLING !

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

93117-00035 February 1, 2006

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 135ZV. This manual contains safety, operation, transportation, maintenance and troubleshooting information. Read and understand the information in this manual carefully before operating or performing any maintenance of the machine. Failure to do so could result in personal injury or equipment failure. The safety of yourself and others depends upon your care and judgement in the operation and maintenance of this machine. Keep the manual with this machine at all times.

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

This machine gives you, our customer, the maximum in performance and durability, state of the art technology and safety. Should you have any question regarding this machine or manual, please contact the Kawasaki dealer in your area during regular business hours. A satisfied customer is our goal.

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

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

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

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

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

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

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

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

Always follow safe operating and maintenance practices.

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

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

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

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

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

CONTENTS 1.SAFETY ...................................................................................................................................................... 1.1 SAFETY ..................................................................................................................................................... 1.2 Safe Operation..................................................................................................................................... 1.2 Safe Maintenance...............................................................................................................................1.11 Safety Signs....................................................................................................................................... 1.16 Safety Devices................................................................................................................................... 1.20 2.OPERATION ............................................................................................................................................... 2.1 COMPONENT NAME/LOCATION ............................................................................................................. 2.2 OPERATOR'S AREA ................................................................................................................................. 2.3 Pedals and Levers ............................................................................................................................... 2.3 Switches .............................................................................................................................................. 2.8 Indicators ........................................................................................................................................... 2.22 Seat ................................................................................................................................................... 2.30 Electrical Protection ........................................................................................................................... 2.32 Heater or Air Conditioner ................................................................................................................... 2.34 Ride Control System (option)............................................................................................................. 2.38 OPERATION ............................................................................................................................................ 2.39 Check before Operation..................................................................................................................... 2.39 Starting the Engine ............................................................................................................................ 2.48 Check after Starting the Engine ......................................................................................................... 2.50 Operating the Machine ...................................................................................................................... 2.56 Parking............................................................................................................................................... 2.60 Stopping the Engine........................................................................................................................... 2.61 Operating Techniques........................................................................................................................ 2.62 SPECIAL PROCEDURES ....................................................................................................................... 2.69 Adjustments ....................................................................................................................................... 2.69 Roading / Special Applications .......................................................................................................... 2.72 Booster Batteries / Jumper Cables .................................................................................................... 2.73 Long Term Storage ............................................................................................................................ 2.75 Welding .............................................................................................................................................. 2.78

3.MAINTENANCE .......................................................................................................................................... 3.1 MAINTENANCE......................................................................................................................................... 3.2 Serial Number Location ....................................................................................................................... 3.2 Inspection and Maintenance Table ...................................................................................................... 3.6 When Required Inspection and Maintenance ...................................................................................... 3.9 Every 10 Hours or Daily ..................................................................................................................... 3.18 Every 50 Hours or 1 Week................................................................................................................. 3.19 Every 250 Hours or 1 Month .............................................................................................................. 3.25 Every 500 Hours or 3 Months ............................................................................................................ 3.36 Every 1000 Hours or 6 Months .......................................................................................................... 3.40 Every 2000 Hours or 1 Year............................................................................................................... 3.48 Recommended Lubricants ................................................................................................................. 3.56 Coolant Specification ......................................................................................................................... 3.57 TROUBLESHOOTING ............................................................................................................................. 3.58 QUANTUM FAULT CODE INFORMATION FOR ENGINE ...................................................................... 3.63 SPECIFICATIONS ................................................................................................................................... 3.68 Standard Specifications...................................................................................................................... 3.68 High Lift Boom Specifications ............................................................................................................ 3.70

1.1

1.SAFETY

1.2 SAFETY Safe Operation

SAFETY Safe Operation Operator Safety

OM0026

Wear safe clothing: OM0001

Read and understand the Operation & Maintenance Manual.

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

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

OM0180

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

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

- Do not operate if taking medication that causes drowsiness.

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

1.3 SAFETY Safe Operation

Mounting and Dismounting Safety

OM0012

OM0010

Face the machine when mounting or dismounting.

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

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

Climb and step only where steps and handrails are provided.

OM0181

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

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

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

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

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

1.4 SAFETY Safe Operation

Before Starting Safety

OM0005 OM0006

Perform the normal daily maintenance.

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

Lock

Unlock

Inspect the machine for safety hazards and, if found, have them corrected:

135ZV1743

- 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 following safety devices work or are positioned properly.

Be sure the Roll Over Protective Structure (ROPS) is:

- Parking Brake Switch -- Applied (See page 2.9) - Loading Control Lever Lock -- Locked (See page 1.20)

- in place.

- properly attached (no bolts loose or missing).

- not damaged.

- not modified.

N F

R

95ZV0013

- Forward / Backward Changeover Switch -- Neutral

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

- Extinguish fire with a fire extinguisher. (Depend on the situation) - With hand rails and steps, get off the machine and stay away from it.

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

“STORED” position

"STORED" position 135ZV0022

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

- Back-up Alarm -- Operational Securely lock the cab door either fully open or closed.

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

OM0007

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

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

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

Properly fasten the seat belt.

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

Do not attach a suction cup on the window to avoid a fire hazard due to intense light magnification.

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 or controls.

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

1.6 SAFETY Safe Operation

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

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

OM0011

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

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

OM0021

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

Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

OM0183

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

- Do not reach through the window to start.

- Do not stand on the ground and start.

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

If jumper cables are required to start the engine, follow the correct procedure in "Booster Batteries / Jumper Cables" page 2.73.

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

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

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

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

1.7 SAFETY Safe Operation When working on a grade:

SAFETY DURING NORMAL OPERATIONS:

- Turn "OFF" the transmission cut-off selector switch.

- Keep the attachment low.

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

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

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

- Never coast down a grade.

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

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

Know the machine limits and do not exceed them.

OM0013

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

OM0018

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

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

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

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

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

Do not expose the machine to flames.

approx. 40cm (16in.)

OM0016

- The normal carry position is about 40cm (16in.) above the ground.

1.8 SAFETY Safe Operation When roading the machine: - Travel in forward only.

- Travel only as fast as conditions and safety allow.

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

- If roading long distances (over 3km (2miles)), periodically stop to allow tires, transmission, engine to cool down. Excessive tire heat caused by roading can cause blow-outs and loss of control.

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

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

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

OM0184

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

OM0020

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

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

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

1.9 SAFETY Safe Operation

SPECIAL OPERATING CONDITIONS:

Drawbar 80ZV0001

OM0185

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

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

- Check for normal braking after leaving the water.

- Check differential gear oil for contamination.

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

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

- Use flashers or beacons (if equipped).

- Reduce speed.

- Periodically stop and inspect the job site.

- Take more frequent breaks to reduce fatigue.

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

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

- Use a cable that has appropriate pull hooks.

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

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

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

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

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

1.10 SAFETY Safe Operation

Parking Safety

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

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

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

OM0025

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

- Block the tires.

- Apply the parking brake.

To prevent unauthorized use: - Remove the key.

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

- Install vandal covers (if equipped).

OM0186

Inspect the machine and report any needed repairs.

1.11 SAFETY Safe Maintenance

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

Perform maintenance and repairs only if trained.

Follow the Operation & Maintenance Manual or Shop Manual.

OM0002

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

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

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

OM0025

OM0026

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

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

Before performing any maintenance: - Park on level ground.

- Block the tires securely.

- Apply the parking brake.

- Lower the boom and attachment to the ground.

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

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

1.12 SAFETY Safe Maintenance

OM0029

OM0031

Never make repairs on pressurized components.

Release all trapped air and hydraulic pressure by:

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

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

- Moving the loading control levers back and forth.

- Moving the K-Lever right and left.

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

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

DANGER DO NOT START MEN WORKING ON MACHINERY SIGNED BY DATE

OM0182

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

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

1.13 SAFETY Safe Maintenance

Explosion / Fire / Burn Prevention

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

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

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

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

Avoid contact with skin or eyes.

Pour all fuel and oil into appropriate containers.

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

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

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

135ZV1684

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

135ZV1684a

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

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

- Fill oil at well ventilated place.

- Do not leave the machine when filling oil.

- Fasten the oil filler cap tightly.

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

- Make sure wheel parts are correctly installed.

- Use a self attaching (locking) air chuck.

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

- Stand behind the tread not beside the rim.

- Do not inflate tires more than the recommended pressure.

- Use a safety cage for a repaired tire.

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

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

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

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

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

OM0008

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

Stop the engine before opening the engine side panel.

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

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

OM0188

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

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

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

Articulation Stopper

"LOCKED"position "LOCKED" 135ZV0023

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.

When oil or fuel leaks from the high pressure rubber hose, it may cause an accident or fire. If something is wrong with the rubber hose, immediate repair is needed: - Correct them and fasten the rubber hose when a clamp, guard or cushion are loose. 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 loose.

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

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

1.16 SAFETY Safety Signs

Safety Signs All safety signs which are on the machine are shown below. 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, painted over, or worn, get a replacement from your Kawasaki dealer and install it in the correct position.

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

1.17 SAFETY Safety Signs

DANGER

CAUTION DANGER

No room in this area when turning.

Crushing will result in death or serious injury.

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

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

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

Before checking transmission oil: Park on level ground.

Lower bucket to ground.

Place transmission in neutral.

Set parking brake.

Tag "Do Not Operate".

44841-20630

High Temperature : hot surfaces could cause burns to fingers or hands.

Keep a safe distance or allow surfaces to cool before servicing.

44787-22950

L.H, R.H

44841-20600

Inside L.H, R.H

L.H, R.H

135ZV0024

WARNING

CAUTION

CAUTION

Machine will not turn with articulation stopper in locked position.

Unlock articulation stopper before operating machine.

44841-20640

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

Do not start engine by Machine will not turn starter with articulation shorting across stopper in locked position. terminals.

Unlock stopperwhile before Doarticulation noto start engine operating machine. standing on ground.

44841-20640 Make sure to start engine only from operator’s seat with transmission in neutral and parkingu brake applied.

44841-20660

Inside

Inside L.H, R.H

WARNING

WARNING

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

Stop engine before warking in this area.

44841-20700

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

Keep hands away from fan area.

Stop engine before opening door or rear grille.

44841-21100

1.18 SAFETY Safety Signs

WARNING

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

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

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

44841-20750

WARNING

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

Keep flames and sparks away.

Vent area before servicing.

44841-20680

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

Avoid contact with skin or clothing.

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

44841-20690

Inside

Inside

Inside

CAUTION

135ZV0025

Inside

DANGER

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

Before walking or working under raised boom.

Securely block orbrace boom.

Remove key and tag "Do Not Operate".

Relieve all trapped oil pressure before opening any piping.

44841-20620

WARNING

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

Read Shop Manual before repairing this part.

44841-20740

WARNING

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

Allow system to cool and vent pressure slowly before servicing.

44841-20720

1.19 SAFETY Safety Signs

Inside of Cab

A A

135ZV0026 135ZV0027

A-A

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

WARNING

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

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

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

44841-20610

1.20 SAFETY Safety Devices

Safety Devices

K-Lever Steering System On / Off

Loading Control Lever Lock

Raised position

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

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

PUSH PIN

115ZV5001

- Push the button and lift the arm rest to the fully raised position before getting off the machine.

Lock

- When the arm rest is fully raised the K-Lever system is turned off automatically. Then the green display lamp goes out.

Unlock

WARNING 135ZV1743

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

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

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

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

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

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

Operating position

115ZV5001

- Before operating the machine, lower the arm rest back to the operating position.

When the arm rest is completely lowered the K-

1.21 SAFETY Safety Devices Lever system is turned on automatically. Then the green display lamp comes on.

Articulation Stopper

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

"LOCKED"position 135ZV0023

1. Align the front and rear chassis straight ahead.

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

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

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

1.22 SAFETY Safety Devices

Neutral Start System

To unlock:

The transmission has a neutral start system which allows the engine to start only when the Forward/ Reverse Changeover switch is in NEUTRAL position.

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

“STORED” position

"STORED" position 135ZV0022

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

2. Turn the link to the rear chassis bracket.

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

135ZV1683

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

1.23 SAFETY Safety Devices

Emergency Steering (option)

ROPS (Roll Over Protective Structure)

WARNING

WARNING

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

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

- Whenever seated, fasten the seat belt.

- Do not modify ROPS, such as drilling or welding.

- Do not operate the machine if the ROPS has been damaged of deformed.

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

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

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

Emergency 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 "Emergency Steering Warning Lamp (red) (option)" page 2.28.

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

2. Immediately operate the K-Lever to bring the machine to a road shoulder or safe location.

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

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

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

1.24

MEMO

2.1

2.OPERATION

2.2 COMPONENT NAME/LOCATION

COMPONENT NAME/LOCATION 1

3

2

5

24

8

17

15

21

7

22

6

9

10 20 135ZV0028

13 18 4 16 11 23 12 19 14

1. Bucket (Attachment) 2. Boom 3. "Z" Lever 4. Boom Cylinders 5. Bucket Cylinders 6. Engine 7. Torque Converter 8. Transmission 9. Radiator, Air Cooler & Hydraulic Oil Cooler 10. Torque Converter Oil Cooler 11. Fuel Tank (Right hand side) 12. Hydraulic Oil Tank (Left hand side) 13. Front Axle / Differential Ass'y 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. Rear Axle / Differential Ass'y 15. Air Cleaner 16. Parking Brake 17. 1st Propeller Shaft 18. 2nd Propeller Shaft 19. 3rd Propeller Shaft 20. Batteries (two each side--two 12VDC=24VDC system) 21. Precleaner 22. Exhaust Mufflers 23. Steering Cylinders 24. ROPS

2.3 OPERATOR'S AREA Pedals and Levers

OPERATOR'S AREA Pedals and Levers

1. K-Lever 2. Loading Control Lever 3. Accelerator Pedal 4. Brake Pedals 5. Wrist Rests (adjustable)

2

1

3 4 135ZV1683

5

2

135ZV1744

1

5 N F

R

115ZV0037

2.4 OPERATOR'S AREA Pedals and Levers

1. K-Lever

2. Loading Control Lever L

R

Bucket control

Boom control

115ZV0039

- When the K-Lever is moved from the neutral (centered) position to the right, the machine articulates (steers) to the right.

Float (Detent) Lower

- When the K-Lever is returned to the neutral position the machine stops articulating.

- When the K-Lever is moved to the left the machine articulates to the left.

135ZV0029

Detent Bucket positioner

Roll Back

Hold

Dump

Raise

- The further the K-Lever is moved to the side the faster the machine articulates (proportional steering).

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

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

This type of damage is not covered by warranty policy.

Detent (Boom kickout)

Loading control lever is used to control the boom and bucket movement.

If the loading control lever is moved back and forth, the boom is controlled. The bucket is controlled if the lever is moved right and left. Both the boom and bucket are simultaneously controlled if the lever is moved diagonally.

Loading Control Lever will not move if the loading control lever lock is in the "Locked" position.

Refer to "Loading Control Lever Lock" page 1.20.

2.5 OPERATOR'S AREA Pedals and Levers

Boom Control

Bucket Control

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

Center position

(b)

(a)

Center position

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

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

While the boom soft landing switch is "ON", keep the boom lifted. By moving the lever to the float position, the boom is rapidly lowered to the set position, then it stops slowly. (b) Lower - Move the lever forward. The boom will lower.

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

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

- 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.

- For adjustment procedure refer to "Boom Kickout Adjustment" page 2.70.

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

(a) Dump - Move the lever away from you. The bucket will dump. (b) Hold - Return the lever to the center position. The bucket will stop and remain in that position. (c) Roll Back - Move the lever toward you. The bucket 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 reaches to the preset angle.

- For adjustment procedure refer to "Bucket / Attachment Positioner Adjustment" page 2.69 In case that the bucket does not stop moving even when the loading 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

3. Accelerator Pedal

4. Brake Pedals

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

- Do not use brake pedals as foot rest.

- Do not ride brakes.

- Use brake pedals only when applying brakes.

135ZV1683

Accelerator pedal is used to control the engine speed.

- Depress the pedal to increase the engine speed.

- Release the pedal to decrease the engine speed.

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

- Be sure control pedals move freely before operating.

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

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

135ZV1683

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

Left and right Brake Pedals: May be used either of two ways: 1. As a brake only pedal by turning the transmission cut-off (Declutch) switch (See page 2.13) to the "OFF" position. Use this position when working on slopes or ramps.

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

To use this feature, turn the transmission cutoff (Declutch) switch to the "ON" position.

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

2.7 OPERATOR'S AREA Pedals and Levers

5. Wrist Rests (adjustable)

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

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

Wrist rests are used to place the wrist or arm on while operating the loading control lever and KLever.

Both wrist rests are adjustable. Each way of adjustment is as follows :

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 Unlock

1

Lock

135ZV1747

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

- Pull up the lock lever (2) and adjust the loading control lever back and forth.

3 Unlock

4 Lock

135ZV1750

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

- Loosen the lock lever (4) and adjust the K-Lever back and forth.

2.8 OPERATOR'S AREA Switches

Switches 9 10 11 12

4 5 6 8

P

3

1

13

14

135ZV0040

2

19

25 18 15

16

17

24

135ZV1683a

23 135ZV1744

21 N F

R

20 22 7 115ZV0037

1. Starter Switch 2. Parking Brake Switch 3. Light Switch 4. Front Working Light Switch 5. Rear Working Light Switch 6. Ladder Light Switch 7. Ladder Light Switch 8. Boom Soft Landing Switch 9. Engine Mode Switch 10. Transmission Cut-Off (Declutch) Switch 11. Traction Control Switch 12. Ride Control Switch (option) 13. Front Wiper Switch

(Battery box)

135ZV0041

14. Rear Wiper Switch 15. Diagnostic Switch (option) 16. Increment / Decrement Switch (option) 17. Power Boost Switch 18. QUAD (Quick Up And Downshift) Switch 19. Horn Switch 20. Forward / Reverse Changeover Switch 21. Transmission Shift Switch 22. Engine Stop Switch 23. Traction Control Engine Adjust Switch 24. Boom Soft Landing Height Adjust Switch 25. 12 Volt Power-outlet Socket (S/N 0203~)

2.9 OPERATOR'S AREA Switches

1. Starter Switch

2. Parking Brake Switch

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

ON OFF

START

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

115ZV0041

- Key can be either inserted or pulled out.

Engine is stopped and most electrical circuits are turned off.

- Current flows to all circuits.

135ZV1683

- When the transmission changeover switch is in NEUTRAL, starter motor turns, starting the engine.

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

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

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

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

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

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

Call local Kawasaki dealer for repair.

2.10 OPERATOR'S AREA Switches

3. Light Switch

4. Front Working Light Switch

135ZV0042

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

135ZV1683

This is a four position switch.

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

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

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

- Front head lights are in the high beam position.

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

2.11 OPERATOR'S AREA Switches

5. Rear Working Light Switch

6. Ladder Light Switch 7. Ladder Light Switch

135ZV0042

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

135ZV0042

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

(Battery box)

135ZV0041

Ladder light switch is used for turning on and off the ladder lights. Each switch is installed in both the battery box and the cab.

2.12 OPERATOR'S AREA Switches

8. Boom Soft Landing Switch

9. Engine Mode Switch

135ZV0042

When the switch is ON, and the boom is lowered by moving the loading control lever to the float position, the boom is rapidly lowered till the designated height. Then the boom soft landing device works, and the boom stops slowly. The boom remains in that position.

135ZV0042

Engine mode switch is used to switch an engine power mode.

Three power modes are provided: N (Normal Mode) The engine power level is the lowest compared with other modes. The fuel consumption is the most economical setting.

However the max. rim-pull force is 10% lower than HD mode.

HD (Heavy Duty Mode) Compared with N mode, the engine power in any speed range is higher.

Especially this mode is suitable for heavier work such as digging rocks.

LC (Load and Carry Mode) The engine power in 2nd and 3rd speed range is higher than N mode.

Therefore acceleration performance is better.

2.13 OPERATOR'S AREA Switches

10. Transmission Cut-Off (Declutch) Switch

11. Traction Control Switch

135ZV0042 135ZV0042

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

Normally this switch should be "ON".

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

Refer to "Brake Pedals" page 2.6 for the function of both left and right brake pedals.

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

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

If the tire is ready to spin, by keeping the traction control switch ON, the engine speed is temporarily slowed down and tire spin is prevented. This increases tire life.

2.14 OPERATOR'S AREA Switches

12. Ride Control Switch (option)

13. Front Wiper Switch

135ZV0042

When the ride control switch is ON, the ride control system works. Refer to "Ride Control System (option)" page 2.38

135ZV1683

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

OFF

INT LOW HIGH

PUSH

OM0189

OFF

:

INT

: Intermittent

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

2.15 OPERATOR'S AREA Switches

14. Rear Wiper Switch

15. Diagnostic Switch (option)

?

115ZV0042

135ZV1683

Rear wiper switch is used to wipe the rear windshield.

This switch is used to check the engine failure when any one of the engine warning lamps (Refer to the page 2.28) is turned on.

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

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

OFF

ON ON OFF

START

PUSH

OM0190

OFF

:

ON

: Low speed

PUSH : Spraying solvent on the windshield

115ZV0043

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

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

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

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

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

2.16 OPERATOR'S AREA Switches The following steps show how to finish the diagnosis for the engine failure.

16. Increment / Decrement Switch (option)

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

115ZV0044

The switch is used for ; 1. Checking the history of the engine failures 2. Adjusting the engine idle revolution - Checking the history of the engine failures When the diagnostic switch is ON (Starter switch key "ON"), the lights will continue to flash the same fault code until the system is advanced to the next active fault code. To go to the second fault code, move the increment / decrement switch to "+", then release it. You can also go back to the previous fault code by moving the switch to "-", then releasing it . To check the third or fourth fault code, move the switch to "+", then release it when all active fault codes have been viewed. Moving the switch to "-" will go back to the first fault code.

Refer to the section of the "15.Diagnostic Switch (option)" for converting the flashing pattern to 3digit fault code.

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

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

The engine idle revolution can not be changed to over 825min-1 (rpm) or to below 775min-1

2.17 OPERATOR'S AREA Switches (rpm) even though this switch is moved to "+" or "-".

17. Power Boost Switch

135ZV1744

Power boost switch is used to give more power to hydraulic loading force. After the switch is pressed, main pressure in hydraulic circuit is increased from 31.4MPa (4551psi) to 34.4MPa (4978psi) about for five seconds. During increase of the main pressure, lifting force and digging force are increased.

2.18 OPERATOR'S AREA Switches

18. QUAD (Quick Up And Downshift) Switch

19. Horn Switch

135ZV1744 135ZV1744

Horn switch is used to blow the horn.

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

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

- By pressing QUAD switch again, setting the transmission shift switch to the neutral position (parallel) or operating the parking brake switch, the 1st gear is released and it returns to the 2nd gear.

2.19 OPERATOR'S AREA Switches

20. Forward / Reverse Changeover Switch

N F

21. Transmission Shift Switch

N F

R

R

115ZV0037 115ZV0037

Forward / reverse changeover switch is used to change direction.

Transmission shift switch is used to control machine speed.

R (Reverse) Pull the upper part of the trigger switch

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

N (Neutral) Keep the trigger switch parallel

Shift to lower speed (Shift Down)

F (Forward) Pull the lower part of the trigger switch

Refer to "Speed and Direction Change" page 2.57.

2.20 OPERATOR'S AREA Switches

22. Engine Stop Switch

ON

(Battery box)

23. Traction Control Engine Adjust Switch

OFF

135ZV0041 135ZV1744

Engine stop switch is used to stop engine, and it is installed in the left battery box. This switch is mainly used for emergency.

Engine does not start with the switch OFF. Return the switch to the position ON after using.

Traction control engine adjust switch is used for adjusting engine speed while the traction control system works.

- Turn the switch to PLUS (+), and engine speed is greatly reduced - Turn the switch to MINUS (-), and engine speed is slightly reduced Engine speed should be adjusted depending on the tire spin condition.

2.21 OPERATOR'S AREA Switches

24. Boom Soft Landing Height Adjust Switch

25. 12 Volt Power-outlet Socket (S/N 0203~)

12V PUSH

135ZV1744

Boom soft landing height adjust switch is used for adjusting boom stop position while the boom soft landing device works.

- Turn the switch to PLUS (+), and the boom stop position is raised - Turn the switch to MINUS (-), and the boom stop position is lowered Because of hydraulic oil temperature change, the boom stop position of the boom soft landing device is changeable.

Adjust the boom stop position depending on the ambient temperature and working condition.

PUSH

65ZV03126-0219

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

2.22 OPERATOR'S AREA Indicators

Indicators 1

23 22 21

6

5 10

20

2

24

4

11 12 13 14 15 16 17 18 19 135ZV0043

26

28 27 25

7 8 9

1. Tachometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Gauge 5. Parking Brake Indicator Lamp (red) 6. Auto Brake Indicator Lamp (red) 7. Transmission Cut-Off (Declutch) Lamp (green) 8. Working Light Indicator Lamp (green) 9. K-Lever Indicator Lamp 10. Central Warning Lamp (red) 11. Transmission Control Warning Lamp (red) 12. Brake Pressure Warning Lamp (red) 13. Brake Oil Temperature Warning and Brake Disk Wear Alarm Lamp (red) 14. Engine Oil Pressure Warning Lamp (red) 15. Engine Coolant Temperature Warning Lamp (red) When the starter switch is turned to "ON", all warning lamps (10) ~ (19), (25) and (26) light up for three seconds. This is the lamp (bulb) test period (lamp (14) lights up until engine starts).

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

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

3 16. Torque Converter Oil Temperature Warning Lamp (red) 17. Air Cleaner Warning Lamp (red) 18. Charge Lamp (red) 19. Transmission Oil Filter Warning Lamp (red) 20. High Beam Indicator Lamp (blue) 21. Auto Shift Indicator Lamp (green) 22. Neutral Indicator Lamp (green) 23. Transmission Status Monitor 24. Hour Meter 25. Emergency Steering Warning Lamp (red) (option) 26. Engine Warning Lamps 27. Ride Control Indicator Lamp (green) (option) 28. Engine Grid Air Heater Lamp (yellow) (For cold start)

2.23 OPERATOR'S AREA Indicators

1. Tachometer

3. Torque Converter Oil Temperature Gauge 20

10

C

H T/C OIL TEMP

30

0 x100min

-1

97ZVOM0050 97ZVOM0048

Indicates the engine revolutions per minutes.

2. Engine Coolant Temperature Gauge

C

Indicates the temperature of oil circulating through the torque converter and the transmission. It is normal if the indicator is in the white zone (50 ~ 120ºC (122 ~ 250ºF)) while operating.

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

H WATER TEMP

97ZVOM0049

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

Refer to "TROUBLESHOOTING" page 3.62.

Indicates engine coolant temperature. It is normal when the indicator stays in the white zone (70 ~ 95ºC (158 ~ 203ºF)).

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

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

Refer to "TROUBLESHOOTING" page 3.58.

4. Fuel Gauge

F

E FUEL

97ZVOM0051

Indicates the fuel amount in the fuel tank.

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

2.24 OPERATOR'S AREA Indicators

5. Parking Brake Indicator Lamp (red)

8. Working Light Indicator Lamp (green)

P OM0052 OM0055

Lights up when the parking brake is applied.

If the forward / reverse changeover switch is moved into "F" or "R" position while this lamp is on, an alarm sounds and the machine stays in neutral.

Lights up when working lights are on.

9. K-Lever Indicator Lamp 6. Auto Brake Indicator Lamp (red)

OM0218

OM0053

Lights up when the auto brake works.

- The green display lamp comes on when the KLever system is turned "ON". It goes out when the system is turned "OFF".

Refer to "Auto Brake" page 2.59 for the detail.

10. Central Warning Lamp (red) 7. Transmission Cut-Off (Declutch) Lamp (green)

OM0056

Flashes when any of the warning lamps come on.

OM0054

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

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

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

2.25 OPERATOR'S AREA Indicators

11. Transmission Control Warning Lamp (red)

13. Brake Oil Temperature Warning and Brake Disk Wear Alarm Lamp (red)

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

OM0057

Lights up when transmission controls malfunction.

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

Stop machine IMMEDIATELY and correct problem if brake oil temperature warning and brake disk wear alarm lamp lights up during operation.

Flashes when brake oil temperature overheats.

Also the buzzer sounds.

12. Brake Pressure Warning Lamp (red) OM0217

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

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

Brake Pressure Warning Lamp lights up and the warning buzzer sounds when the brake oil pressure is lower than 3.9MPa (570psi) or the pressure difference between the front and rear brake circuit is larger than 1.5MPa (213psi).

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

Lights up when brake discs wear out.

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

14. Engine Oil Pressure Warning Lamp (red)

OM0058

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

Refer to "TROUBLESHOOTING" page 3.61.

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 3.58.

2.26 OPERATOR'S AREA Indicators

15. Engine Coolant Temperature Warning Lamp (red)

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

OM0060

Lights up when coolant temperature overheats.

(Over 102ºC (215ºF)) - 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 3.58.

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 3.62.

CAUTION Hot coolant spray may cause burns.

Never open radiator cap when engine is hot.

17. Air Cleaner Warning Lamp (red)

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 3.11.

2.27 OPERATOR'S AREA Indicators

18. Charge Lamp (red)

21. Auto Shift Indicator Lamp (green)

AUTO OM0068

OM0063

Lights up when alternator charge level is low.

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

- If it lights up, check the charging circuit.

Refer to "TROUBLESHOOTING" page 3.60.

19. Transmission Oil Filter Warning Lamp (red)

22. Neutral Indicator Lamp (green)

N OM0069

Lights up when transmission is in neutral.

OM0064

23. Transmission Status Monitor Lights up when the transmission oil filter clogs.

- When lit, replace the transmission oil filter cartridges.

Refer to "Replace Transmission Oil Filter Elements" page 3.36.

20. High Beam Indicator Lamp (blue)

D

3 2 1 135ZV0065

- 1st Gear Lights up when the transmission is in 1st gear.

- 2nd Gear Lights up when the transmission is in 2nd gear.

OM0067

Lights up when headlights are switched to high beam.

- 3rd Gear Lights up when the transmission is in 3rd gear.

- D (Direct drive) Lights up when the transmission is in lock-up position (forward and 3rd gear).

2.28 OPERATOR'S AREA Indicators

24. Hour Meter

26. Engine Warning Lamps Engine stop lamp

0 0 0 0 0 0

1/10h OM0205

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

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

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.

Engine warning lamp

OM0072

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

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.

Engine protection lamp

Orange

OM0193

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

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

2.29 OPERATOR'S AREA Indicators

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

OM0206

Lights up when the ride control switch is ON. Refer to "Ride Control System (option)" page 2.38

28. Engine Grid Air Heater Lamp (yellow) (For cold start)

WAIT 135ZV0044

When the starter switch key is turned to "START" position at the ambient temperature below 0ºC (32ºF), it turns the engine grid heater to heat intake air and the lamp lights up. The heater only works when the engine is cold.

After the engine grid heater lamp goes out, then the engine will crank.

2.30 OPERATOR'S AREA Seat

Seat

Forward / Backward

Seat Adjustment

- Lift the handle (5) and move the seat forward or backward.

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

- Release the handle (5) at one of the several positions.

1

5

4

3

2 135ZV0045

Lumbar Support - Turn adjustment knob (1) for desired lumbar support.

Reclining - Lift the handle (2) and allow the back cushion to angle forward, or lean backward into the cushion. Release the handle at desired position.

Seat Height - Remove your weight from seat while lifting the handle (3) to the stop position. While holding the handle (3) up, raise or push down on seat.

Release handle (3) at one of three positions.

Air Suspension - With the key turned "ON" push the knob (4) to increase the air pressure. This will raise the seat and make a firmer ride. Pull the knob to reduce the air pressure (air will be vented). This will lower the seat and make a softer ride.

- When properly adjusted the seat will not "bottom out" over rough terrain.

2.31 OPERATOR'S AREA Seat

Seat Belt

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

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

- Always fasten seat belt when operating machine.

- Replace the seat belt and tether every three years regardless of appearance. Dirt can cut the fibers weakening the belt. The belt has a manufacture date to help decide when it should be replaced.

- Adjust tether so it is snug without the operator in the seat.

OM0007

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

Keep buckle free of dirt and debris.

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

2.32 OPERATOR'S AREA Electrical Protection

Electrical Protection

LIGHTING HEAD LIGHT

20A

RADIO

5A

R. WORK LIGHT

10A

VCM

5A

BOOM KICKOUT BUCKET POSITIONER BOOM SOFT LANDING RIDE CONTROL K-LEVER

10A

R. WIPER

5A

BACK LAMP STOP LAMP

15A

F. WIPER

10A

PARKING BRAKE CONTROLLER (MACHINE)

10A

CIGAR LIGHTER

10A

F. WORK LIGHT

15A

SPARE

10A

AIR SUS SEAT

10A

SPARE

3A

SPARE

15A

SPARE

10A

SPARE

15A

SPARE

10A

4 WAY FLASHER HORN ROOM LAMP RADIO BACKUP

15A

AIRCON (OPTION)

20A

IMPORTANT

SPARE

10A

SPARE

5A

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

SPARE

15A

SPARE

5A

BUZZER MONITOR (CONTROLLER)

5A

SPARE

10A

NEUTRAL RELAY

5A

AIRCON (OPTION)

20A

BATTERY RELAY ECM (ENGINE)

5A

STEP LIGHT

20A

Fuse Boxes

135ZV0036

Main fuse boxes are located in the right hand side console in the cab and contains thirty fuses.

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

Never replace fuses with higher amperage rating.

2.33 OPERATOR'S AREA Electrical Protection

Fusible Link Fusible links protect the main hot wire from short circuits.

135ZV0037

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

Problem (symptom) Fuse damaged

During engine operation

During engine stop

-Engine will stop.

-All the power for all electrical circuit will be OFF.

-Engine can not be started.

-All the power for all electrical circuit will be OFF.

70A (A)

-Except horn, all the power for all electrical circuit will be OFF and the machine can not be operated.

-The same conditions as "During engine operation".

70A (B)

-The machine can be operated but the batteries can not be charged and the batteries will discharge quickly.

-The same conditions as "During engine operation".

30A

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.

2.34 OPERATOR'S AREA Heater or Air Conditioner

Heater or Air Conditioner

Switches

(~October, 2005)

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

Ventilation Location and Mode 3

1

3

3

3

7

(A)

FAN ONLY

ON/ OFF

1

1 2

2 4

4

70ZV0015

(B)

4 135ZV0035

VENT MODE

2 8

1

2

3

4

○

―

―

○

―

○

―

○

○

―

○

○

○ : Open ―: Close

4

3

5

6

1. ON/OFF Switch 2. FAN ONLY Switch 3. TEMP UP/DOWN Switches (A) Temperature Display 4. FAN UP/DOWN Switches (B) Fan Speed Display 5. UPPER Mode Switch 6. LOWER Mode Switch 7. DEFROST Mode Switch 8. FAN ONLY Indicator LED

2.35 OPERATOR'S AREA Heater or Air Conditioner

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

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

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

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

4. FAN UP/DOWN Switches Allows the operator to adjust fan speed. The “FAN ONLY” Indicator LED (8) will be turned on.

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

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

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

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

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

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

2.36 OPERATOR'S AREA Heater or Air Conditioner

Switches

(November, 2005~)

Ventilation Location and Mode 3

Manual Heater Control

3

3

3 1

1

1

3

2

2 4

4

4 BERGSTROM H

4

Manual Combo Control 135ZV0035

VENT MODE

1

2

3

4

○

―

―

○

○

○

―

○

―

○

―

○

―

○

○

○

―

―

○

○

○ : Open ―: Close

1

2

3

4 BERGSTROM AC

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

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

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

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

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

Panel Mode Provides air flow through door 1.

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

Floor Mode Provides air flow through door 2.

Mix Mode Provides air flow through door 2 and 3.

Defrost Mode Provides air flow through door 3.

2.38 OPERATOR'S AREA Ride Control System (option)

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

The pitching motion is reduced when the ride control system is installed.

Operation and Function

P

1

2

135ZV0040a

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

The ride control system functions automatically when the machine travelling speed reaches more than 7km/h (4.3mph). The system automatically disengages below 5km/h (3.1mph).

The indicator lamp (2) will remain on regardless of the machine speed if the switch (1) is ON. NOTE When the bucket is fully tilted the ride control system does not work. Dump the bucket a bit when travelling.

2.39 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:

2.40 OPERATION Check before Operation

Check Engine Oil Level

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

Refer to "Replace Engine Oil Filter Cartridges" page 3.25 and "Replace Engine Oil" page 3.37 for the procedure.

135ZV0003

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

IMPORTANT Improper oil level may damage engine.

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

Add or drain oil to keep proper oil level.

H (High) L (Low) OM0177

1. Check the oil level with the dipstick.

2.41 OPERATION Check before Operation

Check Hydraulic Oil Level

Refer to "Recommended Lubricants" page 3.56.

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.

135ZV0008

1. Lower the attachment to the ground.

2. Stop the engine.

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

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

135ZV0009

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

2.42 OPERATION Check before Operation

Check Engine Coolant Level

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

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

OK

NG

NG

135ZV0046

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

Avoid contact with skin and eyes to prevent injury.

2. Check the coolant level by the sight gauge on the radiator through the hole on the left hand side of the engine room. Coolant level is normal when the gauge is filled with the coolant. If the surface of the coolant is seen in the sight gauge or no coolant is seen there, add coolant.

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

135ZV0047

135ZV0038

Radiator guard

Cap Neck pipe

Water surface

OM0095

3. Slowly open the cap of the radiator tank to release any remaining pressure.

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

2.43 OPERATION Check before Operation

Refer to "Coolant Specification" page 3.57 for the correct mixture.

Drain Water and Sediment from Fuel Filters

5. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 3.15.

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

135ZV0002

Following must be done with engine “OFF”.

- Open the drain cock on the bottom of the fuel filters 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.

2.44 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

"STORED" position 135ZV0022

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

2.45 OPERATION Check before Operation

Check Tire for Damage, Deformation and Wear

Low Pressure

OK

High Pressure

135ZV7532

135ZV1684

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

WARNING

- Low air pressure causes excessive deflection, heat, and accelerated wear.

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

- High air pressure cause reduced traction, slippage, and possible blow outs.

Do not service or change tires 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 15m (15yd).

Stay away until tire and rim cool down.

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

2.46 OPERATION Check before Operation

ROPS (Roll Over Protective Structure)

Tread

WARNING Side walls

Breakers Carcass

Beads / Bead wire

Operating without ROPS could cause serious injury or death.

Always keep ROPS in place while operating machine.

WARNING 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.

- 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.

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

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

- Whenever seated, fasten the seat belt.

- Do not modify ROPS, such as drilling or welding.

- Do not use ROPS if it is deformed.

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

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

- Inspect the ROPS mounting bolts.

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

- Tire layers are separated.

- Radial cracks reach the carcass.

Adjust and Check Rear View Mirrors

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

- 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.

2.47 OPERATION Check before Operation

Check Monitor Panel Operation

Greasing

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

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

2. All warning lamps (red) should come on for about three seconds. Refer to "Indicators" page 2.22.

3. Operate the transmission shift switch to each position, turn on the light switch to high beam position, and operate the rear working light switch and transmission cut-off (Declutch) switch.

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

2. Lubricate fittings on the following components.

Wipe and clean all fittings before greasing.

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

Refer to "Recommended Lubricants" page 3.56 for the correct grease.

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

Refer to "Indicators" page 2.22.

Check Control Levers - Make sure the loading control lever is in the "HOLD" position.

135ZV0006

Check K-Lever and Forward/Reverse Changeover Switch - Make sure the K-lever and Forward/Reverse Changeover Switch is in the neutral position.

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

2. The horn should sound loudly.

- Axle support (two places)

IMPORTANT Grease axle supports daily to avoid axle support wear.

Be sure to fully lubricate the trunnion-two fittings.

When fully lubricated grease will escape from the breather on the rear plate and from the top of the front support.

2.48 OPERATION Starting the Engine

Starting the Engine WARNING

ON

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

OFF

START

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

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

Normal Start

3. The turn the starter switch key to "START" position to "pre-lube" the engine. Keep the key in the "START" position during the pumping.

4. After several seconds delay, the starter motor will crank to start the engine.

(Ambient temperature above 0ºC (32ºF))

To protect starter and battery, do not keep the starter switch in the "START" position with the engine cranking for more than 25 seconds.

1. Do not depress the accelerator pedal.

5. 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.

ON OFF

115ZV0045

START

ON OFF

START

115ZV0043

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

115ZV0043

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

7. If the forward/reverse changeover switch is not in the "NEUTRAL" position, the engine will not crank.

2.49 OPERATION Starting the Engine

Cold Start Key position

Warning lamp

Condition

Time

1

ON

ON

stop

3 seconds

2

START

OFF

pre-lube runs

3-15 seconds

3

START

OFF

delay

5 seconds

4

START

OFF

starter crank

3-5 seconds

5

ON

OFF

engine start

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

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

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.

- 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 3.58.

IMPORTANT Low engine oil pressure may cause severe engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

(Ambient temperature below 0ºC (32ºF))

WAIT 135ZV0044

- This engine is equipped with the air grid starting aid system. When the starter key is turned to the "START" position, it turns on the engine grid air heater lamp (WAIT lamp) and the heater grid heats the intake air. After the WAIT lamp goes off, then engine will crank.

2.50 OPERATION Check after Starting the Engine

Check after Starting the Engine

Check Warning Lamps

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

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

135ZV0043a

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 2.22 for the meaning of each lamp and the correction.

2.51 OPERATION Check after Starting the Engine

Check Fuel Level

Check Transmission Oil Level

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

Crushing will result in serious injury or death.

F

E FUEL

97ZVOM0051

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

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

When checking oil level: - Lower attachment to ground.

- Put transmission changeover switch in neutral.

- Apply parking brake.

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

- Make sure nobody is on machine.

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

Refer to "Recommended Lubricants" page 3.56 for the proper fuel.

"LOCKED" position

"LOCKED"position 135ZV0023

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

Refer to "Articulation Stopper" page 1.21

2.52 OPERATION Check after Starting the Engine

IMPORTANT Never mix CD engine oil and auto transmission fluid.

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

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

135ZV7099

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

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

135ZV7099

5. If the oil level is lower than the specified, add recommended oil through the oil inlet hole while the engine is at idle. Do not overfill.

Refer to "Recommended Lubricants" page 3.56.

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

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

2.53 OPERATION Check after Starting the Engine

Check Service Brake Operation

Check Parking Brake Operation

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

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

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

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

2. Firmly depress the left brake pedal.

3. Stop the machine with the service brake.

3. Release the parking brake.

4. Pull up the parking brake switch.

4. Select the transmission changeover switch 1st and FORWARD.

5. Release the service brakes.

5. Slowly accelerate the engine to full speed.

6. The machine should not move.

6. The machine should not move.

IMPORTANT If machine moves when firmly depressing the brake pedal with transmission in 1st and FORWARD there is some problem with service brake.

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.

Do not operate until problem has been corrected.

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

2. Release the brakes.

3. Steer fully right and then left.

4. Steering should be smooth in both directions.

2.54 OPERATION Check after Starting the Engine

Check Back-up Alarm Operation

Check Exhaust Gas

1. Apply the service brakes.

2. Release the parking brake.

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

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

IMPORTANT If back-up alarm does not sound when parking brake is released and forward/reverse changeover switch is in REVERSE position, there is some problem with back-up alarm.

Do not operate until problem has been corrected.

135ZV0014

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 3.59.

2.55 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.

- Pull up 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 changeover switch in NEUTRAL, loading lever in NEUTRAL, and the attachment on the ground, walk around the machine and look for any problems, leaks, or signs of failure.

2.56 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. 40cm (16in.)

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 40cm (16in.) above the ground.

2. Depress the brake pedal.

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

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

Do not operate machine on a grade over 30º.

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

30º Max. OM0194 135ZV1683

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

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

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

2.57 OPERATION Operating the Machine

Starting the Machine on a Grade

Speed and Direction Change

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

2. Depress the left brake pedal.

Shift up Shift down N F

R

115ZV0037

135ZV1683

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

1. Select the proper gear shifting mode by pressing the transmission shift switch. Refer to the following tables on page 2.58 for the gear selection mode.

This machine is equipped with the automatic shifting system which selects the proper gear automatically using a micro computer to eliminate tiresome manual shifting. The automatic shift mode is engaged by pushing the “Shift Up” button until “AUTO” light comes on in dash panel.

Backward N F

R

Neutral

Forward

115ZV0037

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

2.58 OPERATION Operating the Machine

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

Status Monitor

Selected Gear

Operating Condition

[1]

1st

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

[2]

2nd

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

[3]

3rd

Carrying or roading

3rd and Direct drive (Lock up: only forward)

Carrying or roading

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

[3] [D]

135ZV1744

3. When the transmission is in the 2nd gear, it can be quickly shifted down to the 1st gear by pressing the Quick Up And Downshift (QUAD) switch.

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

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

Use proper gear for each job.

Shift up and shift down chart

AUTO

D

Refer to "QUAD (Quick Up And Downshift) Switch" page 2.18.

3

3

2

2 s

s 1

1 MANUAL

UP SHIFT SWITCH DOWN SHIFT SWITCH s

QUAD SWITCH

115ZV5004a

2.59 OPERATION Operating the Machine

Steering

Auto Brake L

R

135ZV0043a

115ZV0039

- When the K-Lever is moved from the neutral (centered) position to the right, the machine articulates (steers) to the right.

- When the K-Lever is returned to the neutral position the machine stops articulating.

- When the K-Lever is moved to the left the machine articulates to the left.

- The further the K-Lever is moved to the side the faster the machine articulates (proportional steering).

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

Auto Brake works under the following conditions: 1. If the machine runs above the following speeds forward or reverse; [1] : 15 / 17km/h ( 9.3 / 10.6mph) [2] : 29 / 32km/h (18 / 19.9mph) [3] : 32 / 34km/h (19.9 / 21.1mph) [D] : 36 / - km/h (22.4 / - mph) 2. When the direction is changed while running over 12km/h (7.5mph).

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

Be prepared. Wear seat belt.

2.60 OPERATION Parking

Parking

3. Shift the transmission shift 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.

135ZV1683

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

2.61 OPERATION Stopping the Engine

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

Do not stop engine while machine is moving.

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

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

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

ON OFF

START

115ZV0041

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).

2.62 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.

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

OM0112

OM0114

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

Reduce wheel slippage by slightly reducing engine speed.

OM0115

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

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

8. Release the loading 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.

2.64 OPERATION Operating Techniques

Excavating

Dozing

1. Move the machine forward to the material.

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

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

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

Keep bucket or attachment bottom parallel to ground.

OM0119

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

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

Increase engine speed as the bucket digs deeper.

OM0120

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

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

OM0123

2.65 OPERATION Operating Techniques

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

OM0123

OM0121

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

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

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

Be sure to run machine backward when leveling ground.

OM0122

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

2.66 OPERATION Operating Techniques

Carrying

Dumping into Truck or Hopper

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

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

OM0016

Keep boom low for best stability especially on slopes.

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

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

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

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

IMPORTANT

Refer to "Loading" or "Excavating" page 2.62, 2.64 for the loading procedure.

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

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

OM0116

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

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

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

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

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

Refer to "Boom Kickout Adjustment" page 2.70 for adjustment of the preset height.

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

OM0195

5. Move the loading control lever right to the "Dump" position to empty the bucket.

OM0196

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

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

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

2.68 OPERATION Operating Techniques

Typical Truck Loading Methods

T Cycle Operation

I Cycle Operation

OM0126

OM0124

This method is recommended where the working area is limited.

V or L Cycle Operation (L-cycle)

(V-cycle)

OM0125

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

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

2.69 SPECIAL PROCEDURES Adjustments

SPECIAL PROCEDURES Adjustments Bucket / Attachment Positioner Adjustment

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

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

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

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

4

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

3

Use safe sturdy platform to reach bucket positioner adjustment.

5 ± 2mm (1/8 ~ 1/4in)

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.

OM0128

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

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

2

1 97ZVOM0127

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

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

5. Tighten the bolts (1).

2.70 SPECIAL PROCEDURES Adjustments

Boom Kickout Adjustment

1

2

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

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

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

3 135ZV0049

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

Use safe sturdy platform to reach boom kickout adjustment.

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

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

3. Lock the loading control lever in the "Hold" position using the loading control lever lock.

7. Tighten the bolts (1).

8. Remove the support from the boom and linkage.

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

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

3

2

5 ± 2mm (1/8 ~ 1/4in) OM0128 OM0031

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

5. Loosen the two bolts (1).

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

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

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

2.71 SPECIAL PROCEDURES Adjustments

Boom Soft Landing Adjustment

3

2

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

1

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

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

135ZV0050

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

Use safe sturdy platform to reach boom kickout adjustment.

7. Tighten the bolts (1).

8. Remove the support from the boom and linkage.

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

9. To test the adjustment; start the engine, turn the boom soft landing switch to “ON”, lift the boom, and move the loading control lever to the "Float" detent position to lower the boom.

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

The boom is rapidly lowered to the set position, then it stops slowly.

3. Lock the loading control lever in the "Hold" position using the loading control lever lock.

3

2

5 ± 2mm (1/8 ~ 1/4in) OM0128

OM0031

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

5. Loosen the two bolts (1).

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

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

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

2.72 SPECIAL PROCEDURES Roading / Special Applications

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

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

Stay away until tire and rim cool down.

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

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

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

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

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

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

2.73 SPECIAL PROCEDURES Booster Batteries / Jumper Cables

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

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

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

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

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

- Keep flames and sparks away from batteries.

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

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

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

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

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

2. Raise and lock the battery box covers.

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

Booster batteries

Batteries being boosted

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

Engine block of machine being jump started

135ZV0051

It could shorten battery life or the battery could explode.

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

Keep the battery electrolyte level in the proper level.

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

WARNING

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

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.

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

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

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.

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

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.

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

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

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

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

2.75 SPECIAL PROCEDURES Long Term Storage

Long Term Storage

During Storage

Before Storage

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

1. Wash and clean all parts of the machine.

2. Lubricate every greasing point described in "Greasing" section page 3.19 and 3.54.

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

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

5. Store the machine indoors and keep it dry.

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

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

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

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

1. Check the following points.

Refer to "Check before Operation" page 2.39 and "Check after Starting the Engine" page 2.50.

-Coolant level -Engine oil level -Hydraulic oil level -Transmission oil level -Brake function -Steering function 2. Operate the machine as follows.

OM0028

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

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

Refer to "Coolant Specification" page 3.57 for the mixing ratio.

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

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

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

-Run the machine about 10m (30ft) in every gear and direction.

-Move the steering full stroke each way about 2 to 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.

2.76 SPECIAL PROCEDURES Long Term Storage

After 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.

ON OFF

START

135ZV0016

115ZV0043

1. Turn the starter switch key to ON position.

135ZV0008

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

Depress (2sec.)

Release

Depress (2sec.)

Release

Depress (2sec.)

Release

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 Filter Cartridges" page 3.25 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.

97ZV0002a

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

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

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

2.77 SPECIAL PROCEDURES Long Term Storage

ON OFF

START

115ZV0041

3. Turn the starter switch key to OFF position.

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

2.78 SPECIAL PROCEDURES Welding

Welding Cautions Regarding Welding Repair Service

Cylinder head covers for some models have a low-conductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod.

Example 1:

Hydraulic cylinder Section to be welded

Plated section (Mask this section.)

Ground this section. (correct grounding)

Do not ground this section.

Electric current may flow through the cylinders.

135ZV0054

135ZV0052

Example 2:

Pin section with pin temporarily inserted Pin

Section to be welded Do not ground this section.

Electric current may flow through the cylinders.

Ground this section. (correct grounding)

Plated section (Mask this section.)

135ZV0055

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. Leave the machine as it is more than 1 minute.

3. Remove the battery terminals both positive and negative sides from the battery.

4. The controller circuit breaker should be turned "OFF" .

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

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

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.

NOTE The weld spattered on the plated sections causes corrosion.

2.79 SPECIAL PROCEDURES Welding

1m or more

Scrap material, etc.

Section to be welded

1m or more 135ZV0056

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

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

Remove and if necessary wrap 135ZV0057

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

2.80

MEMO

3.1

3.MAINTENANCE

3.2 MAINTENANCE Serial Number Location

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

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

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

135ZV0058

2. Engine Serial Number

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

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

TRANSMISSION MODEL SERIAL

NO

KAWASAKI OM0211

3. Transmission Serial Number OM0219

1. Machine Serial Number

Model Serial Number Design Number

3.3 MAINTENANCE Serial Number Location

WARNING ANY ALTERNATION,MODIFICATION,CHANGE OR REPAIR OF THIS ROPS WITHOUT PRIOR WRITTEN AUTHORIZATION OF KAWASAKI HEAVY INDUSTRIES,LTD.WILL VOID PRODUCT CERTIFICATION AND WARRANTY.

FOPS AND ROPS CERTIFICATION THIS IS TO CERTIFY THAT THIS ROPS IS MANUFACTURED BY KAWASAKI HEAVY INDUSTRIES,LTD.,AND INSTALLED IN ACCORDANCE WITH SPECIFICATION OF KAWASAKI HEAVY INDUSTRIES,LTD.,AND COMPLIES WITH ISO 3449:1992,ISO 3471:1994,,SAE J231 JAN81,SAE J1040 MAY94

CERTIFICATION TEST W EIGHT

KAW ASAKI HEAVY INDUSTRIES, LTD. 4-1 HAMAMATU CHO 2 CHOME MINATO KU TOKYO JAPAN

135ZV0059

135ZV0060

6. ROPS Serial Number

4. Torque Converter Serial Number Model

ROPS:

TC650A01

Model Number

Serial Number

Serial Number

MODEL S/N PATENT NO.

SERIAL NO. ROCKLAND

ROCKLAND MFG. CO., BEDFORD, PA. USA

-

80ZVUSA0001

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

70ZV0004

7. CAB Serial Number

3.4 MAINTENANCE Serial Number Location

135ZV0045

8. Seat Serial Number

BERGSTROM

9. Air Conditioner and Heater Serial Number

3.5 MAINTENANCE Serial Number Location

CAB S/N

Heat & A/C S/N

ROPS S/N

Seat S/N

Engine S/N (R.H)

Bucket S/N

135ZV0028

Transmission S/N (R.H)

Torque converter S/N

Machine S/N

3.6 MAINTENANCE Inspection and Maintenance Table

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

Item for check

Operating hours 10

Transmission & Torque Converter

250

500

When 1000 2000 Required

Page

Check Engine Oil Level

○

2.40

Check Engine Coolant Level

○

2.42

Check Warning Lamps

○

2.50

Check Exhaust Gas

○

2.54

Drain Water and Sediment from Fuel Filters

○

2.43

Check Fuel Level

○

2.51

Drain Water and Sediment from Fuel Tank

Engine

50

3.21

○

Check and Adjust Belt Tension

○

3.30

Replace Engine Oil Filter Cartridges

○

3.25

Clean Crankcase Breather Tube

○

3.29

Check Air Intake System

○

3.31

Replace DCA4 Coolant Filter Cartridges

○

3.28

Replace Fuel Filters

○

3.27

Replace Engine Oil

○

3.37

Clean Fuel Prefilter

○

3.38

Check Engine Compression Pressure

○

3.44

Check Injection Pressure

○

3.44

Check and Adjust Injection Timing

○

3.44

Clean Fuel Tank

○

3.53

Check and Adjust Valve Lash Clearance

○

3.52

Check Vibration Damper

○

3.52

Greasing (Engine Trunnion Mount)

○

3.55

Clean or Replace Air Cleaner Element

○

3.11

Clean Radiator/Air cooler/Hydraulic oil cooler Fins

○

3.12

Clean or Replace Air Cleaner Element

After six cleanings or once a year

○

3.11

Replace Coolant

Every 2 years or 3000 hours

○

3.15

Check Transmission Oil Level

○

2.51

Replace Transmission Oil Filter Elements

△

Replace Transmission Oil Filter

△

3.36

○ ○

3.45

Replace Transmission Oil

○

3.40

Check and Replace Transmission and Torque Converter Breather Element

○

3.42

3.7 MAINTENANCE Inspection and Maintenance Table

△ : First time replacement or cleaning only Section

Item for check

Operating hours 10

Steering system

Brake system

Page 2.45

Greasing (Axle support)

○

2.47 3.23

○

Check Differential Gear Oil

○

3.31

Check Planetary Gear Oil

○

3.32

Check Tightness of Wheel Bolts

○

3.32

Greasing (Front Differential)

○

3.46

Greasing (Rear Differential)

○

3.46

Greasing (1st Propeller Shaft)

○

3.54

Greasing (2nd Propeller Shaft)

○

3.54

Greasing (3rd Propeller Shaft)

○

3.55

Replace Differential Gear Oil

○

3.50

Replace Planetary Gear Oil

○

3.51

Check Steering Wheel Operation

2.53

○

Greasing (Steering Cylinder)

3.21

○

Check Service Brake Operation

○

2.53

Check Parking Brake Operation

○

2.53

Check Brake Accumulators

○

3.52

Clean Filter for Brake Line

○

3.55 2.41

○

Greasing

3.19

○

Replace Hydraulic Oil Return Filter

△

Replace Filter in the Oil Tank Cap Replace Hydraulic Oil

○

3.42

○

3.47 3.48

○

Replace Bucket Teeth

Chassis

500

○

Check Hydraulic Oil Level

Loading system

250

Check Tire for Damage, Deformation and Wear

Check Tire Air Pressure

Axle system

50

When Required 1000 2000

○

3.9

Adjust and Check Rear View Mirrors

○

2.46

ROPS (Roll Over Protective Structure)

○

2.46

Greasing (Center Pin)

3.21

○

Check and/or Replace Seat Belt

○

3.10

Check Windshield Washer Fluid

○

3.13

3.8 MAINTENANCE Inspection and Maintenance Table

△ : First time replacement or cleaning only Section

Electrical system

Item for check

Operating hours 10

50

250

500

When Required 1000 2000

Check Monitor Panel Operation

○

2.47

Check Horn Operation

○

2.47

Check Back-up Alarm Operation

○

2.54

Check Wiring Harnesses

○

2.44

Check Battery Electrolyte Level

3.22

○

Check or Replace Fuses

Air Conditioner

○

3.13

Check and Adjust Air Conditioner Belt

○

3.33

Clean Air Conditioner and Heater Filter Element

○

3.34

Check Air Conditioner Refrigerant

3.43

○

Replace Air Conditioner Filter Elements

○

3.14

Clean Air Conditioner Condenser

○

3.14

Replace Air Conditioner Receiver Dryer Others

Page

Walk-Around Inspection

Every 3 years or 6000 hours ○ ○

3.17 2.39

3.9 MAINTENANCE When Required Inspection and Maintenance

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

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

Replace Bucket Teeth

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

- Always wear eye protection.

- Use deadblow hammer or brass drift between hammer and tooth.

- Keep bystanders away from work area.

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

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

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

3. Stop the engine.

Driving tool Tooth

Pin

95ZV0014

4. Remove the pin and tooth using a tool.

3.10 MAINTENANCE When Required Inspection and Maintenance

Check and/or Replace Seat Belt 1. Inspect the condition of the seat belt and all mounting hardware frequently.

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

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

Tooth adapter 95ZV0015

5. Install the tooth onto the tooth adapter.

Guide rib facing back

95ZV0016

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

2 to 4-poundhammer

95ZV0017

7. Tap the pin in flush ear using 2 to 4 pound hammer. (1 ~ 2kg) NOTE For non-Kawasaki buckets or teeth, consult the manufacturer for the proper procedures.

3.11 MAINTENANCE When Required Inspection and Maintenance

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

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

- 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.

OM0138

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

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

3

2

OM0139

1

135ZV0010

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

3. Remove the outer element.

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

6. If bright light spots are seen through the element, there are cracks or pinholes in the element. Replace it with a new element.

7. Inspect the rubber seal (3). If there is any damage to the seal, replace the element.

8. Confirm that the wing nut is tight and the inner element is properly seated, then reinstall the outer element, cover (2) and wing nut (1).

9. Even after cleaning, if the engine exhaust gas is not clean enough (excessive black smoke), replace the element.

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

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.

135ZV0015

IMPORTANT High pressure air or water may damage radiator / air cooler / hydraulic oil cooler fins.

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

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

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

2. Open covers on the radiator guard both the right hand side and the left hand side for clean the air cooler and hydraulic oil cooler.

3. 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.

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

NOTE If debris can become trapped between the hydraulic oil cooler and the radiator. The hydraulic cooler must be removed to completely clean and inspect.

3.13 MAINTENANCE When Required Inspection and Maintenance

Check or Replace Fuses

Check Windshield Washer Fluid

135ZV0036

135ZV0061

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

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

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

2. Check the fluid level.

3. Replace the fluid if it is dirty.

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

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

Refer to "Fuse Boxes" page 2.32.

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

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

Never replace fuses with higher amperage rating.

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

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

3.14 MAINTENANCE When Required Inspection and Maintenance

Clean Air Conditioner Condenser

Replace Air Conditioner Filter Elements

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.

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.

135ZV0062

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.

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

135ZV6484

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

Turn the rings counterclockwise and then remove the cover.

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

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 196kPa (30psi) or less.

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

70ZV0019

4. Remove the outer filter from the cab, and replace it with new one. (Part number 4033060270) When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

3.15 MAINTENANCE When Required Inspection and Maintenance

Replace Coolant - Since the Anti-Freeze "Long Life Coolant" (LLC) is originally used for the machine shipped from the factory, it is not necessary to replace the coolant for the first two years.

- If the cooling system conditioner (from a local supplier) is used at the time of last replacement, follow its instructions or contact your nearest Kawasaki dealer for the replacement interval.

135ZV6484

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

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

Inner filter replacement

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.

Inner filter Filter cover

2. Inspect all coolant hoses.

Replace any that are cracked, swollen, or brittle.

70ZV0020

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

Unscrew the turn knob to remove the filter cover.

Remove the filter and replace with a new one.

(Part number 40332-70100)

1 135ZV0047

3. Slowly open the radiator cap (1) to release any remaining pressure.

4. Remove the cap (1) slowly.

3.16 MAINTENANCE When Required Inspection and Maintenance 12. Stop the engine and open the drain cocks to drain the cooling system.

13. If the water being drained is still dirty, the system must be flushed again until the water is clean (step 7 ~ 13).

14. Close the drain cocks and fill the system with the premixed coolant.

3

2

Refer to "Coolant Specification" page 3.57 for the mixing instruction.

135ZV0004

5. Open the drain cocks (2), (3) and drain coolant about 270liters (71.3gal.) into a suitable container.

Do not remove the coolant filter.

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

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

Avoid contact with skin and eyes to prevent injury.

7. Close the drain cocks and fill the cooling system with clean water and cooling system cleaner. Follow the manufacturer's instructions.

Do not install the radiator cap.

8. Operate the engine for one hour with the coolant temperature above 80ºC (180ºF). Then let the engine cool down naturally with the engine shut “OFF”.

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

10. Close the drain cocks and fill the cooling system with clean water.

Do not install the radiator cap or the new coolant filter.

11. Operate the engine for five minutes with the coolant temperature above 80ºC (180ºF).

15. Add seven units of DCA65L coolant additive at the same time.

16. Replace the DCA4 coolant filter (WF2075).

Refer to "Replace DCA4 Coolant Filter Cartridges" page 3.28 for the procedure.

17. Idle the engine for five minutes to purge air mixed into the coolant. (Leave the radiator cap off.)

18. Add coolant as necessary.

19. Reinstall the radiator cap.

For additional cold weather servicing information, refer to "Coolant Specification" page 3.57 for details.

3.17 MAINTENANCE When Required Inspection and Maintenance

Replace Air Conditioner Receiver Dryer (Every 3 years or 6000 hours) - Contact your Kawasaki dealer.

3.18 MAINTENANCE Every 10 Hours or Daily

Every 10 Hours or Daily WARNING Improper inspection or maintenance could result in death or serious injury.

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

See "Check before Operation" page 2.39 and "Check after Starting the Engine" page 2.50.

3.19 MAINTENANCE Every 50 Hours or 1 Week

Every 50 Hours or 1 Week WARNING Improper inspection or maintenance could result in death or serious injury.

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

Every 50 hours or 1 week, whichever comes first, perform the following inspection and maintenance in addition to the "Daily Inspection and Maintenance".

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

2. Lubricate fittings on the following components.

Wipe and clean all fittings before greasing.

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

Refer to "Recommended Lubricants" page 3.56 for the correct grease.

90ZV0003

- Bucket-Boom (two places)

90ZV0003

- Bucket-Rod (two places)

3.20 MAINTENANCE Every 50 Hours or 1 Week

90ZV0004

- Lever-Rod (two places)

135ZV0006

- Bucket Cylinder-Front Chassis (two places)

135ZV0013

135ZV0012

- Lever-Boom (two places)

- Boom Cylinder-Boom (two places)

135ZV0012

- Bucket Cylinder-Lever (two places)

135ZV0006

- Boom Cylinder-Front Chassis (two places)

3.21 MAINTENANCE Every 50 Hours or 1 Week

Drain Water and Sediment from Fuel Tank

CAUTION Escaping fuel is flammable and harmful to skin.

135ZV0013

- Boom-Front Chassis (two places)

- Do not smoke while draining moisture and sediment from fuel tank.

- Do not drain fuel with engine running.

- Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

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

135ZV0006

- Steering Cylinder (four places)

135ZV0016

2. Prepare a suitable container.

3. Open the drain cock on the bottom of the fuel tank.

4. Drain water and sediment along with fuel.

5. Close the drain cock.

6. Properly dispose of the drained fuel and water.

7. Add fuel.

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

135ZV0006

- Center Pin (upper) (lower)

3.22 MAINTENANCE Every 50 Hours or 1 Week

Check Battery Electrolyte Level

WARNING Batteries produce explosive gases which could cause burns or blindness.

- Ventilate area to remove explosive gases.

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

- Keep flames and sparks away from batteries.

135ZV0017

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

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

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

2. Clean the battery surface with a clean cloth or soft brush.

Keep the battery electrolyte level 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.

Dispose of used batteries by recycling.

Low

OK

High OM0096

3. Check the battery electrolyte level in each cell.

Electrolyte should cover the cell plates.

4. If the level is low, add distilled water until it reaches the bottom of the filler neck.

NOTE If a maintenance free battery is used, step 3 and 4 of this inspection and maintenance is not required.

3.23 MAINTENANCE Every 50 Hours or 1 Week

Check Tire Air Pressure Low Pressure

OK

High Pressure

135ZV1684

135ZV7532

WARNING

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

Explosive separation of tire and rim parts could result in death or serious injury.

- Low air pressure causes excessive deflection, heat, and accelerated wear.

When inflating tires; - Make sure wheel parts are correctly installed.

- Use self-attaching air chuck with remote shutoff valve - Stand behind tread of tire and keep all persons away from side of tire.

- Do not inflate tire more than recommended pressure.

- Use safety cage if available.

- High air pressure cause reduced traction, slippage, and possible blow outs.

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

Special applications, such as long load and carry operations, may require different pressures. Consult the tire manufacturer.

WARNING Overheated tire may explode causing serious injury or death.

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

Stay away until tire and rim cool down.

135ZV1684a

1. Before starting work and while the tires are still cool, measure the tire air pressure with the tire pressure gauge.

2. Adjust air pressure according to the recommended pressures below.

When inflating a tire, stand behind the tread and use a self-attaching chuck with a remotely located valve to turn air pressure on and off.

3.24 MAINTENANCE Every 50 Hours or 1 Week Recommended Tire Air Pressure (Radial tire) Size 45 / 65 R39 (L-5)

Air pressure Front 471~490kPa (68~71psi)

Rear 373~392kPa (54~57psi)

Note Standard

3.25 MAINTENANCE Every 250 Hours or 1 Month

Every 250 Hours or 1 Month WARNING Improper inspection or maintenance could result in death or serious injury.

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

Every 250 hours or 1 month, whichever comes first, perform the following inspection and maintenance in addition to the "Daily" and "50 hours" inspections and maintenance.

Replace Engine Oil Filter Cartridges

CAUTION Hot oil and engine components may cause burns.

Avoid contact with hot oil or engine components.

1. If the machine is cold operate the engine to bring the engine coolant temperature about 60ºC (140ºF). When the needle of the coolant temperature gauge reaches the middle of the white zone, the temperature is about 60ºC (140ºF).

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

135ZV0001

3. Place a container under the filters to catch any spilled engine oil.

Remove the oil filters using an oil filter wrench and properly dispose of them. Make sure the O-ring is removed with the filter.

4. Clean the oil filter head gasket surface.

5. Fill the new filters with clean engine oil.

Refer to "Recommended Lubricants" page 3.56 for the oil specifications.

6. Apply a light film of engine oil to the gasket surface of the new filter cartridge (full-flow and bypass oil filters).

3.26 MAINTENANCE Every 250 Hours or 1 Month

CAUTION Used engine oil may cause skin disease or irritation.

Do not allow used engine oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

OM0200

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

Refer to the instructions supplied with the filter.

IMPORTANT Do not over tighten the filter.

8. Idle the engine to inspect for leaks at the filter.

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

135ZV0003

10. Check the oil level.

11. Add the specified oil if necessary to bring the oil level to the "H" (High) mark on the dipstick.

12. Properly dispose of the filters.

3.27 MAINTENANCE Every 250 Hours or 1 Month

Replace Fuel Filters

CAUTION Escaping fuel is flammable and harmful to skin.

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

Do not drain with engine running.

Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

OM0200

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

2. Place a small drain pan (about 1liter (1qt.)) under the fuel filters.

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

IMPORTANT Do not over tighten the filter.

135ZV6493

3. Remove and properly dispose of the fuel filters.

4. Clean the filter head gasket surface.

5. Apply a light film of clean engine oil to the gasket surface of the new filters.

6. Fill the filters with clean fuel.

7. Install the filter on the filter head.

Turn it until the gasket contacts the filter head surface.

3.28 MAINTENANCE Every 250 Hours or 1 Month

Replace DCA4 Coolant Filter Cartridges

CAUTION Pressurized radiator tank is used for this machine.

2

Spray of hot coolant may cause burns.

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

1 135ZV0003

CAUTION

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

Hot coolant and engine components can cause burns.

Avoid contact with coolant or engine components.

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

4. Remove and properly dispose of the coolant filters (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 cartridges (WF2075).

OM0200 135ZV0047

2. Slowly open the radiator cap to release any remaining pressure, and remove the cap slowly.

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

8. Open the coolant shut-off valve and install the radiator cap.

9. Run the engine and check for coolant leaks.

10. Idle the engine for about five minutes to purge all the air from the coolant.

11. After air has been purged from the system, stop the engine and check the coolant level again.

3.29 MAINTENANCE Every 250 Hours or 1 Month 12. If needed, add required amount of the coolant.

Clean Crankcase Breather Tube

Refer to "Coolant Specification" page 3.57 for the correct mixture.

135ZV0066

Every 250 hours or 6 months, check and clean the crankcase breather tube or hose.

The tube is to be removed and checked internally for obstructions or sludge buildup.

If the tube is blocked, it is to be cleaned or replaced to prevent excess crankcase pressure buildup.

3.30 MAINTENANCE Every 250 Hours or 1 Month

Check and Adjust Belt Tension

CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine side panel.

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

OM0201

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

Adjustment

1 4 6 5 OM0215

3

2. Open the engine side panel.

3. Visually inspect the fan belt 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.

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

2 135ZV0067

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

2. Turn the adjusting link (6) to adjust the belt tension correctly.

3. Tighten the bolts and nuts.

3.31 MAINTENANCE Every 250 Hours or 1 Month

Check Air Intake System

CAUTION Hot engine components may cause burns.

Avoid contact with hot engine components.

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

Check Differential Gear Oil 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.

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.

97ZVOM0159

2. Remove the oil level plug from the front axle housing, using a 12mm hex (Allen) wrench.

3. If the oil level is lower than the plug, add the specified oil through the level plug hole.

Refer to "Recommended Lubricants" page 3.56.

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

Dispose of the drained oil properly.

5. Install and tighten the level plug.

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

3.32 MAINTENANCE Every 250 Hours or 1 Month

Check Planetary Gear Oil

Check Tightness of Wheel Bolts

1. Check the oil level on all four wheels.

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

TOP

1

2

TOP

115ZV0027

2. Move the machine on level ground so that "TOP" mark (1) on the planetary gear housing comes top.

3. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

4. Remove the oil level plug (2) on the housing, using a 12mm hex (Allen) wrench.

5. If the oil level is lower than the plug, add the specified oil through the level plug hole.

Refer to "Recommended Lubricants" page 3.56.

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.

115ZV0027

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

3. Retighten if necessary.

3.33 MAINTENANCE Every 250 Hours or 1 Month

Check and Adjust Air Conditioner Belt

CAUTION Contact with moving belts or pulleys may cause injuries.

1

Stop engine before opening engine side panel.

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

2. Open the engine side panel.

2 135ZV0018

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

7. Tighten the lock bolts (1).

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 540 ~ 735N (121 ~ 165lb).

3.34 MAINTENANCE Every 250 Hours or 1 Month

Clean Air Conditioner and Heater Filter Element

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

Outer filter cleaning

7. After approximately 8~10 cleanings, replace the filter with new one. (Part number 4033060270)

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

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

Refer to "Replace Air Conditioner Filter Elements" page 3.14.

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.

135ZV6484

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

Turn the rings counterclockwise and then remove the cover.

135ZV6484

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

Inner filter cleaning

Inner filter Filter cover

70ZV0019 70ZV0020

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. Use air pressure below 196kPa (30psi).

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

Unscrew the turn knob to remove the filter cover.

Remove the filter and clean.

3.35 MAINTENANCE Every 250 Hours or 1 Month 2. Remove dust with compressed air. Use air pressure below 196kPa (28psi).

Replace Filter

3. After approximately 8~10 cleanings, replace the filters with new one. (Part number 4033270100)

- Transmission Oil Filter Elements

Refer to "Replace Air Conditioner Filter Elements" page 3.14.

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

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

(First time replacement or cleaning only)

Replace it first time only at 250 hours operation, after that replace it at every 500 hours operation.

Refer to "Every 500 Hours or 3 Months" page 3.36.

- Transmission Oil 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 3.45.

- 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.

3.36 MAINTENANCE Every 500 Hours or 3 Months

Every 500 Hours or 3 Months WARNING Improper inspection or maintenance could result in death or serious injury.

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

Every 500 hours or 3 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", and "250 hours" inspection and maintenance.

Replace Transmission Oil Filter Elements

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 to 40ºC (85 to 105ºF).

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 15liters (4gal.)) under the transmission oil filters.

135ZV0005

4. Remove the drain plugs from the bottom of the filter cases with 24mm wrench.

5. Remove the filter cases with 46mm wrench.

6. Replace the elements with new ones.

7. Replace the seals with new ones.

8. Clean the cases with solvent.

9. Clean the filter head gasket surface.

10. Apply a light film of clean engine oil to the seals surface of the new filters.

11. Reinstall the filters on the filter head.

12. Clean and install the oil drain plugs.

3.37 MAINTENANCE Every 500 Hours or 3 Months 13. Idle the engine about ten minutes and inspect for leaks around the filters.

Replace Engine Oil

CAUTION

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

When inspecting or servicing machine in articulation area: - Lower attachment to ground.

- Put transmission changeover switch in neutral.

- Apply parking brake.

- Make sure nobody is on machine.

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

Hot oil and 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 to about 60ºC (140ºF). When the needle of the coolant temperature gauge reaches the middle of the white zone, the temperature is about 60ºC (140ºF).

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

135ZV7099 135ZV0004

14. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 2.51.

Add the specified oil as necessary to bring the oil level to the middle of the level gauge.

Refer to "Recommended Lubricants" page 3.56 for the specified oil.

CAUTION Used oil may cause skin disease.

Do not allow used oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

3. Remove the drain plug from the drain port.

4. Drain oil, about 133liters (35.1gal.), into a suitable container.

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

3.38 MAINTENANCE Every 500 Hours or 3 Months

Clean Fuel Prefilter

WARNING Escaping fuel is flammable and harmful to skin.

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

- Do not drain with engine running.

- Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

135ZV0003

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

Refer to "Recommended Lubricants" page 3.56 for the oil specifications. Total system capacity including the filter is 133liters (35.1gal).

7. Idle the engine to inspect for leaks at the drain plug.

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

9. Check the oil level again.

10. Add the specified oil if necessary to bring the oil level to the "H" (High) mark on the dipstick.

11. Properly dispose of or recycle the waste oil.

CAUTION

135DV8426

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

2. Shut off valves to fuel tank.

Used engine oil may cause skin disease.

Engine

Do not allow used engine oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

1 2

Rear chassis R.H 135DV8397

3. Place a small drain pan (about 1 liter (1 qt.)) under the fuel prefilter (1).

4. Loosen the adapter (2). Remove the hose and remove the fuel prefilter (1).

5. Clean the fuel prefilter (1) by washing oil.

3.39 MAINTENANCE Every 500 Hours or 3 Months 6. Install the fuel prefilter (1) in the original place.

Install the hose.

7. Open valves at fuel tank.

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 1.11 before performing any inspection or maintenance procedures.

Every 1000 hours or 6 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", and "500 hours" inspection and maintenance.

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

When inspecting or servicing machine in articulation area: - Lower attachment to ground.

- Put transmission changeover switch 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 to 40ºC (85 to 105ºF).

2. Park the machine on level ground, turn “ON” the parking brake switch, lower the attachment to the ground, and stop the engine.

3

2

1

2

135ZV0020

3. Loosen the drain plug (1) with a 41mm wrench.

4. Drain oil into a suitable container (about 200liters (52.8gal)).

Properly dispose of or recycle the waste oil.

3.41 MAINTENANCE Every 1000 Hours or 6 Months 5. Loosen the eight bolts (2) with a 17mm wrench.

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

Set screw

Flange Gasket Strainer

97ZVOM0164

7. Remove the set screw from the strainer.

Remove the suction strainer from the flange.

Brush off any debris and clean with solvent.

It is normal for a few fine particles to be on the strainer. Large pieces or a large quantity of particles indicates a problem.

Contact a Kawasaki dealer.

8. Remove the magnet plate from the transmission bottom side, then clean it.

After cleaning, put the magnet plate in the transmission bottom side.

9. Reassemble the strainer and flange assembly.

10. Tighten the drain plug and reinstall the strainer with a new gasket.

11. Tighten the eight bolts (2) to 93.7N-m (69ft-lb).

12. Fill with the specified oil.

Refer to "Recommended Lubricants" page 3.56.

13. Idle the engine and check for leaks.

14. Check the oil level gauge. Add the specified oil if necessary to maintain the proper oil level.

Refer to "Check Transmission Oil Level" page

2.51 and "Recommended Lubricants" page 3.56.

3.42 MAINTENANCE Every 1000 Hours or 6 Months

Check and Replace Transmission and Torque Converter Breather Element

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.

135ZV6466

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 left deck.

3

2 1

2 135ZV7133

135ZV0009

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

2. Remove the breather for the transmission case and torque converter case.

2pcs on the transmission case 2pcs on the chassis left side.

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

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

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

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

4. Clean around the top of the filter cover (2).

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

The four bolts (3) 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.

3.43 MAINTENANCE Every 1000 Hours or 6 Months

Check Air Conditioner Refrigerant

2

3

4 5 6 7 97ZVOM0166

6. Remove the O-ring (4), spring (5), and bypass valve (6) from the filter housing.

7. Remove and properly dispose of the filter (7) and waste oil.

8. Clean the inside of the filter housing.

135ZV0062

1. Apply the parking brake and lower the attachment to the ground.

2. Remove the cap.

9. Replace the element (7) and O-ring (4).

3. Press the “FUN UP Arrow Switch” to set maximum air flow.

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

4. Set the temperature control switch fully to the cool position and fully open the cab doors.

11. Install the new filter element (7), bypass valve (6), spring (5), new O-ring (4) and filter cover (2).

5. Slightly accelerate the engine to about the middle speed range. (compressor speed 1500 ~ 1800min-1 (RPM))

12. Close the access cover.

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

The new receiver drier also has moisture sensor window with color code to indicate moisture in the system.

WARNING Overfilled refrigerant may cause dangerous high pressure and poor cooling action; and low refrigerant level may cause compressor damage.

Always maintain refrigerant in normal level.

3.44 MAINTENANCE Every 1000 Hours or 6 Months

Check Engine Compression Pressure Adjust of refrigerant

Normal

Appearance of the sight glass

Solutions

Almost clear.

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

Check Injection Pressure

High

No bubble is seen.

Low

A flow of bubbles is visible.

- Contact your Kawasaki dealer or local Cummins engine dealer.

Contact your local Kawasaki dealer for inspection and recharging refrigerant.

- Contact your Kawasaki dealer or local Cummins engine dealer.

Check and Adjust Injection Timing - Contact your Kawasaki dealer or local Cummins engine dealer.

3.45 MAINTENANCE Every 1000 Hours or 6 Months

Replace Transmission Oil Filter

DANGER 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 to 40ºC (85 to 105ºF).

2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

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.

- Set articulation stopper in "LOCKED" position.

- Make sure nobody is on machine.

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

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

135ZV7099

135ZV0005

4. Remove and properly dispose of the oil and filter.

5. Clean the filter head gasket surface.

9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 2.51.

If needed, add the required amount of the oil.

Refer to "Recommended Lubricants" page 3.56 for the specified oil.

CAUTION

6. Apply a light film of clean engine oil to the gasket surface of the new filter.

Used oil may cause skin disease.

7. Install the filter on the filter head. Follow the instructions on the filter.

Do not allow used oil to remain on skin for prolonged periods of time.

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

Clean skin thoroughly with soap and water.

3.46 MAINTENANCE Every 1000 Hours or 6 Months

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.

Before lubricating the seal with grease, remove the breather nipple (A).

Lubricate until the grease comes out from the breather installation hole.

After that, wipe it and install the breather nipple back again.

Refer to "Recommended Lubricants" page 3.56 for the correct grease. Use lithium base grease for universal joints.

A

135ZV0007

- Front Differential (one place)

A

115ZV0030

- Rear Differential (one place)

IMPORTANT Before lubricating the seal with grease, make sure to remove the breather nipple.

If fail to do this, it may cause the oil seal damage.

3.47 MAINTENANCE Every 1000 Hours or 6 Months

Replace Filter in the Oil Tank Cap

CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before opening.

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 loading control lever back and forth to relieve the pressure.

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

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

5. Remove the filter cap.

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

7. Replace element (5). (Part number 3098170330) 8. Install the element, spring, valve assy, and spiral snap ring.

3.48 MAINTENANCE Every 2000 Hours or 1 Year

Every 2000 Hours or 1 Year WARNING Improper inspection or maintenance could result in death or serious injury.

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

Every 2000 hours or 1 year, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", "500 hours", and "1000 hours" inspections and maintenance.

Replace Hydraulic Oil

WARNING Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler cap.

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

2. Move the loading control levers back and forth to relieve the pressure.

1

135ZV0009

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

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

5. Remove the filler cap (1).

CAUTION Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil.

6. Prepare a suitable container to catch the draining oil (about 310liters (81.9gal)).

3.49 MAINTENANCE Every 2000 Hours or 1 Year 15. Close the oil filler cap (1).

3

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

17. Operate the bucket, boom, and steering cylinders for about five minutes, then lower the attachment to the ground.

18. Inspect for leaks.

4 2

135ZV0008

7. Loosen the drain plug (2) with a 24mm wrench to drain oil.

8. Dispose of the waste oil properly.

9. Remove the nuts with a 14mm wrench to remove the inspection cover (3).

CAUTION Compressed air may cause injury.

- Wear protective clothing and eye protection.

- Air pressure must be below 196kPa (30psi).

10. Remove the set bolts in the suction strainers using a 8mm wrench. Remove the suction strainers. Inspect and clean them with solvent and compressed air.

A few small particles in the strainer is normal.

Large metal, rubber pieces, or a large amount of fine particles is abnormal. If found, contact your Kawasaki dealer.

11. Clean inside of the tank and magnet plug (4).

12. Install the suction strainers, new gasket (Part number 31990-25910) and inspection cover (3), and tighten the nuts evenly. Do not overtighten.

13. Tighten the drain plug (2).

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

Refer to "Recommended Lubricants" page 3.56.

19. Make sure hydraulic oil is to the center of the oil level gauge. Add hydraulic oil if necessary.

3.50 MAINTENANCE Every 2000 Hours or 1 Year

Replace Differential Gear Oil

CAUTION CAUTION

Used oil may cause skin disease.

Differential gear oil may be hot and may cause burns.

Avoid contact with differential gear oil.

Clean skin thoroughly with soap and water.

1. If the machine is cold operate the machine for a few minutes to bring the differential gear oil temperature about 40ºC (105ºF).

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

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

1

2 97ZVOM0159

3. Remove the level plug (1) and drain plug (2) from the front axle housing, with a 12mm Hex (Allen) wrench.

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

Simply wipe it off.

4. Drain the oil (about 220liters (58gal)) into a suitable container.

5. Dispose of the waste oil properly.

Do not allow used oil to remain on skin for prolonged periods of time.

6. Install the drain plug.

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

Refer to "Recommended Lubricants" page 3.56.

8. Install and tighten the level plug.

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

3.51 MAINTENANCE Every 2000 Hours or 1 Year

Replace Planetary Gear Oil

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

CAUTION Planetary gear oil may be hot and may cause burns.

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

Avoid contact with planetary gear oil.

Simply wipe it off.

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

1

5. Remove the drain plug (4) from the brake housing.

6. Drain the oil (about 50liters (13gal)) into a suitable container.

7. Dispose of the waste oil properly.

TOP

CAUTION Used oil may cause skin disease.

2

Do not allow used oil to remain on skin for prolonged periods of time.

115ZV0027

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.

4

3 97ZVOM0159

Clean skin thoroughly with soap and water.

8. Install and tighten the drain plugs.

9. Refill the recommended oil through the level plug hole (2) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page 3.56.

10. Install and tighten the level plug.

11. Repeat these steps for all four planetaries.

3.52 MAINTENANCE Every 2000 Hours or 1 Year

Check Vibration Damper

Check Brake Accumulators

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

Test the brake accumulators for proper pre-charge of nitrogen gas.

WARNING

OK

OK

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

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.

80ZVUSA0004

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

2. Run the engine at low idle for five minutes to fill the brake accumulators with oil.

3. Stop the engine.

4. Turn the key switch to the "ON" position.

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

5. Count the number of times you can depress the brake pedal before the brake warning light comes on.

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

Check and Adjust Valve Lash Clearance - Contact your Kawasaki dealer or local Cummins engine dealer.

3.53 MAINTENANCE Every 2000 Hours or 1 Year

Clean Fuel Tank

9. Check for any leaks at the cover and the drain cock (1).

CAUTION Escaping fuel is flammable and harmful to skin.

Do not smoke while draining moisture and sediment from tank.

Do not drain with engine running.

Do not allow fuel to remain on skin for an extended period of time. Wash thoroughly with soap and water.

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.

2

1

97ZVOM0145

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

3. Drain the remaining fuel into a suitable container.

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

5. Clean inside of the tank.

6. Install the inspection cover with a new gasket.

(Part number 31990-20020) Tighten the nuts evenly. Do not overtighten.

7. Close the drain cock (1).

8. Fill the fuel tank.

3.54 MAINTENANCE Every 2000 Hours or 1 Year

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 3.56 for the correct grease. Use lithium base grease for universal joints.

135ZV0007

135ZV0039

- 1st Propeller Shaft (two places)

135ZV0006

135ZV0006

- 2nd Propeller Shaft (five places)

3.55 MAINTENANCE Every 2000 Hours or 1 Year

Clean Filter for Brake Line

CAUTION Hot oil and components may cause burns.

Vent all pressure by pressing hydraulic cap down.

Avoid contact with hot oil or components.

115ZV0030

- 3rd Propeller Shaft (two places)

1. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

135ZV04053-0317

135ZV0021

- Engine Trunnion Mount (one place)

Air blow FLOW

Filter case

Filter

Nipple

OM0212

2. Place a suitable container under the filter.

3. Remove the nipple with filter and properly clean the filter.

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

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

3.56 MAINTENANCE Recommended Lubricants

Recommended Lubricants

Engine

Transmission

Ambient Temperature

Refill capacity (Approximate)

Kind of Oil

142liter (37.5gal.)

Engine oil (CH4)

200liter (52.8gal.)

ATF Engine oil (CD)

-22ºF -4 -30ºC -20

14 -10

32 0

50 10

68 20

86 30

104 40

SAE10W SAE10W-30 SAE15W-40

Change Interval (Hours) ∗2 500

Multi-Purpose ATF SAE10W

Mobil TRANS HD-10

Mobil TRANS HD-10

Valvoline DT10

Valvoline DT10

1,000

720liter (190.2gal.)

Hydraulic &

Brake system Differential & Planetary

∗1 [310liter refill (81.9gal.)]

Front: 317liter (83.7gal.)

Rear: 317liter (83.7gal.)

Fuel tank

1050liter (277.4gal.)

SAE10W

Engine oil (CD)

Gear Lubricant

Diesel fuel

Mobil TRANS HD-50 Valvoline DT50 ASTM D975 No.1 ASTM D975 No.2

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 or CG4. ∗2. Change engine oil every 250 hours unless CH4 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, SAE 10W Use Mobil TRANS HD-10, Valvoline DT10 or equivalent.

Multi-purpose Automatic Transmission Fluid.

Never mix engine oil, Mobil TRANS HD-10, Valvoline DT10 and/or ATF. TO-4 SAE30W or SAE15W-40 engine oil can be used for the machines operating in high ambient temperatures.

Hydraulic & Brake System

Use engine oil classification SAE 10W. Use industrial-type hydraulic oils which are certified by suppliers having antiwear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use.

Never mix engine oil and hydraulic oil.

Differential & Planetary

Use Mobil TRANS HD-50, Valvoline DT50 or equivalent with 5% “Antichatter” additive or friction modifier.

Lubricating Grease

Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.

NLGI NO.1 or NO.0 grease for extremely low temperature.

Use lithium base grease for a needle bearing.

3.57 MAINTENANCE Coolant Specification

Coolant Specification The machine is originally filled with Long Life Coolant which need not be replaced for the first two years or 3000 hours.

If Long Life Coolant (permanent type) is not used for the replacement, it should be replaced every six months.

Recommended Mixture of Antifreeze Expected Minimum -35ºC -30ºC -25ºC -20ºC Ambient Temperature (-31ºF) (-22ºF) (-13ºF) (-4ºF)

-15ºC (5ºF)

Pure Water

liter (gal)

127 (33.5)

140 (37)

154 (40.7)

167 (44.1)

181 (47.8)

Antifreeze

liter (gal)

143 (37.8)

130 (34.3)

116 (30.6)

103 (27.2)

89 (23.5)

53

48

43

38

33

Mixture Ratio (%)

- Too much antifreeze in the coolant mixture may cause engine overheating.

Keep 33% antifreeze mixture (same as the mixture for a minimum ambient temperature of -15 ºC (5ºF)) if the engine overheats in a high ambient temperature.

- Do not use hard water or water with high levels of calcium and magnesium ions as the coolant water.

IMPORTANT Do not mix different brands of antifreeze because they each contain special additives.

Careless mixing often diminishes the effect of these additives and causes packing damage or water leakage.

3.58 TROUBLESHOOTING

TROUBLESHOOTING This troubleshooting section is not intended to cover every condition, however many of the common possibilities are listed.

Following are example of problems and their solutions.

Contact your local Kawasaki dealer for the items marked with or your local authorized CUMMINS ENGINE dealer for the items marked with to repair. kawasaki

CUMMINS

ENGINE PROBLEM

Engine oil pressure warning lamp lights up, and buzzer sounds

POSSIBLE CAUSES Low engine oil level Wrong grade oil for weather conditions Clogging oil filter element Defective alarm switch Oil leakage from pipe or joint Excessive engine wear Defective oil pump

SOLUTIONS Add oil Change oil Change filter and oil

kawasaki

or

2.40 3.25 3.25

CUMMINS

Low engine coolant level Loose/slipping/broken fan belt Clogging radiator fins Coolant temp. warnScale or mineral build up inside radiator ing lamp lights up Defective alarm switch (gauge is in green) Low water pump flow Thermostat stuck or missing

Add coolant Adjust or replace belt Clean Flush or professionally clean

Engine does not start when the starter motor is turning (Also see ELECTRICAL TROUBLESHOOTING)

Fuel filter element clogging Starter motor speed too low Defective engine shut off solenoid Fuel pump failure Incorrect fuel injection timing Compression pressure too low Defective injectors

Replace fuel filter Booster Battery may be used

Air in fuel lines Fuel filter element clogging Fuel pump failure Incorrect fuel injection timing

Tighten fuel connections and filter

Unstable (rough) idling

Clean or replace element Replace fuel filter

Insufficient power

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

or

or

or

2.42 3.12 3.15

CUMMINS

3.27 2.73

CUMMINS

Replace fuel filter kawasaki

PAGE

3.27 3.27

CUMMINS

3.11 3.27

kawasaki

Check dipstick and correct level

kawasaki

or

CUMMINS

2.40

3.59 TROUBLESHOOTING

PROBLEM

SOLUTIONS

PAGE

Use correct type of oil Correct oil level

3.56 2.40

Unusual combustion noise or mechanical noise

Wrong type of oil Engine oil level too low or too high Defective injectors Incorrect valve clearance Main bearing / con-rod bearing wear Crankshaft uneven wear Connecting rod bent Timing gear wear Water pump bearing wear Failed turbo or muffler

White exhaust smoke (After engine has reached operating temp.)

Fuel being diluted with water Wrong grade fuel Incorrect fuel injection timing Compression pressure too low Turbo seal leakage Coolant ingestion

Replace with specified fuel and replace fuel filter

Clean or replace element

Black exhaust smoke

Air cleaner element clogging Turbo damage Incorrect fuel injection timing Fuel injection pump failure Defective injectors

Warning lamp lights up

POSSIBLE CAUSES

Engine failure

kawasaki

kawasaki

kawasaki

kawasaki

or

or

or

or

CUMMINS

3.27

CUMMINS

CUMMINS

CUMMINS

3.11

3.60 TROUBLESHOOTING

ELECTRICAL PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Adjust or replace belt Replace battery

3.30

Charge lamp lights up

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

Starter motor does not turn when starter switch key is turned to "START"

Transmission not in NEUTRAL Insufficient battery charge Starter switch failure Defective wiring Starter motor failure

Shift to NEUTRAL Battery charge or booster

Starter motor turns engine slowly

Hydraulic control levers not in NEUTRAL Insufficient battery charging Engine oil viscosity too high (thick) Poor connection at batteries or ground Defective wiring Starter motor failure Steering valve failure

Move levers to NEUTRAL Battery charge or booster Replace oil Clean and tighten all terminals

POSSIBLE CAUSES

SOLUTIONS

kawasaki

or

CUMMINS

1.22 2.73

kawasaki

kawasaki

or

CUMMINS

2.5 2.73 3.25

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 Excessively cold oil / wrong grade oil

Steering Drift

Steering control valve failure Steering pilot valve failure

PAGE 3.23

kawasaki

1.21

kawasaki

Warm oil / Replace oil with proper viscosity for temperature kawasaki

3.56

3.61 TROUBLESHOOTING

HYDRAULIC PROBLEM

Boom raises too slowly

Boom natural drift excessively

POSSIBLE CAUSES

SOLUTIONS

PAGE

Excessively cold oil Wrong grade oil Oil pressure too low Damaged cylinder piston or piston packing Pump flow too low Pilot pressure too low Engine RPM too low

Warm oil Replace with proper grade oil

3.56

Excessively cold oil / Wrong oil type

Warm oil / Replace oil with proper viscosity for temperature

kawasaki

3.56

Leakage from control valve plunger Damaged cylinder piston or piston packing

kawasaki

Leakage in pilot relief valve Bucket / Attachment floating or drifting

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

kawasaki

BRAKE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

Parking brake does not work properly

Insufficient oil pressure (will not release) Failure of switch or solenoid valve Poor wiring or ground to switch or solenoid valve

Brake dragging

Dirt, debris under base of brake pedal Warped brake discs Air in brake oil circuit

Braking power too low

Air in brake oil circuit Brake piston seal leakage

kawasaki

Brake pressure drops rapidly

Cracked or leaking brake line Brake valve failure Defective brake accumulator Defective brake seals

kawasaki

kawasaki

Remove or clean kawasaki

PAGE

3.62 TROUBLESHOOTING

TORQUE CONVERTER & TRANSMISSION PROBLEM

POSSIBLE CAUSES Excessively cold oil / Wrong oil type

Engine is running but machine does not move

Parking brake is applied Transmission oil level too low Transmission suction strainer clogging Clutch oil pressure too low Transmission clutch failure Transmission controller failure Defective electrical circuit

SOLUTIONS

PAGE

Warm oil / Replace oil with proper viscosity for temperature Release parking brake Add oil / Repair leak Clean strainer

3.56

kawasaki

Engine speed too low 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 Inspect and correct Refill oil / Repair leak Clean or replace strainer

Oil leakage from transmission

Air breather clogged Seal damage (between engine and torque converter housing)

Clean and refill with oil

Torque converter overheat

Oil level too low Dozing, continuous pushing application Operating in too high a speed range Long downhill driving Radiator clogged: coolant temp also high Defective alarm switch (gauge is in green) Torque converter / Transmission failure Oil pressure too low

Add oil / Repair leak Reduce load Use lower gear Change application Clean radiator fins

Low power

2.51 3.40

2.51 3.40

kawasaki

3.42

kawasaki

2.51 2.57 3.12

kawasaki

AIR CONDITIONER (option) 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

2.34 3.14 3.34 3.30

kawasaki

kawasaki

2.34

3.63 QUANTUM FAULT CODE INFORMATION FOR ENGINE

QUANTUM FAULT CODE INFORMATION FOR ENGINE These codes show the fault codes for the engine failure checked by the diagnostic switch.

FAULT CODE/ LAMP

REASON

EFFECT(Only when fault code is active) Engine will not start.

111 Red

Error internal to the Electronic Control Module (ECM) related to the memory hardware or internal microprocessor communications failures.

113 Yellow

More than 6.2amps detected at the timing No action by the ECM is taken. sleeve actuator circuit pin 6 of the engine har- The engine may have low power outputs, ness. loud combustion noise, and produce black smoke.

114 Yellow

No action by the ECM is taken.

Less than 1.0amp is detected at the timing sleeve actuator circuit pin 6 of the engine har- Engine emits white smoke and loses power. ness.

122 Yellow

More than 4.72volts is detected at the intake manifold air pressure sensor signal pin 45 of the engine harness.

Engine power derate to no-air setting.

123 Yellow

Less than 0.33volts is detected at the intake manifold air pressure sensor signal pin 45 of the engine harness.

Engine power derate to no-air setting.

131 Red

More than 4.20volts is detected at the throttle position signal pin 30 of the OEM interface harness.

Calibration-dependent power and speed derate.

132 Red

Less than 0.13volts is detected at throttle position signal pin 30 of the OEM interface harness.

Calibration-dependent power and speed derate.

133 Red

More than 4.82volts is detected at the remote throttle position signal pin 9 of the OEM interface harness.

Calibration-dependent power and speed derate.

134 Red

Less than 0.12volts is detected at the remote throttle position signal pin 9 of the OEM interface harness.

Calibration-dependent power and speed derate.

135 Yellow

More than 4.88volts is detected at oil pressure sensor signal pin 33 of the engine harness.

Engine protection for oil pressure is disabled.

141 Yellow

Less than 0.31volts is detected at the oil pres- Engine protection for oil pressure is disabled. sure sensor signal pin 33 of the engine harness.

3.64 QUANTUM FAULT CODE INFORMATION FOR ENGINE

FAULT CODE/ LAMP

REASON

143 Engine Protection

Low oil pressure has been detected. Voltage signal at oil pressure signal pin 33 of the engine harness indicates oil pressure lower than 69kPa [10psi] at engine speeds less than 800rpm; 155kPa [22.5psi] at 1200rpm; 241kPa [35psi] above 1600rpm.

Depending upon calibration, progressive power derate and engine shutdown with increasing time after alert.

144 Yellow

More than 4.95volts is detected at the coolant temperature signal pin 23 of the engine harness.

Engine protection for coolant temperature is disabled.

145 Yellow

Less than 0.21volts is detected at the coolant temperature signal pin 23 of the engine harness.

Engine protection for coolant temperature is disabled.

147 Red

A frequency of less than 150Hz has been detected at the frequency throttle signal, pin 14 of the engine harness.

Calibration dependent power and speed derate.

148 Red

A frequency of more than 400Hz has been detected at the frequency throttle signal, pin 14 of the engine harness.

Calibration dependent power and speed derate.

151 Engine Protection

High coolant temperature has been detected.

Voltage signal at coolant temperature signal pin 22 indicates coolant temperature above 100ºC [212ºF].

Calibration dependent progressive power and speed derate and engine shutdown as temperature increases over thresholds.

153 Yellow

More than 4.88volts is detected at intake manifold air temperature signal pin 34 of the engine harness.

Engine protection for intake manifold air temperature is lost.

154 Yellow

Less than 0.08volts is detected at intake man- Engine protection for intake manifold air temifold air temperature signal pin 34 of the perature is disabled. engine harness.

155 Engine Protection

High intake air manifold temperature has been detected. Voltage signal at intake manifold air temperature signal pin 34 indicates intake manifold air temperature above 104ºC [220ºF].

Depending on the calibration, a progressive power and speed derate and engine shutdown as the temperature increases over thresholds.

166 Yellow

The rack position sensor indicates that the rack position is greater than a calibrated threshold.

No action by the ECM is taken.

172 Red

Fuel control rack is stuck in a position commanding excessive fueling to the engine.

Engine shutdown.

173 Yellow

Fuel control rack is stuck in a position providing adequate, or less than adequate, fueling to the engine.

No action is taken by the ECM.

184 Red

Primary and / or secondary ECM identification error.

Module identification at powerup will fail, both modules will run as slaves.

EFFECT(Only when fault code is active)

3.65 QUANTUM FAULT CODE INFORMATION FOR ENGINE

FAULT CODE/ LAMP

REASON

EFFECT(Only when fault code is active)

221 Yellow

More than 4.78volts is detected at the ambient air pressure signal pin 32 of the engine harness.

No action is taken by the ECM.

222 Yellow

Less than 0.20volts is detected at the ambient air pressure signal pin 32 of the engine harness.

No action is taken by the ECM.

231 Yellow

More than 4.72volts is detected at the coolant pressure sensor signal pin 24 of the engine harness.

Engine protection for coolant pressure is disabled.

232 Yellow

Less than 0.33volts is detected at the coolant pressure sensor signal pin 24 of the engine harness.

Engine protection for coolant pressure is disabled.

233 Engine Protection

Low coolant pressure has been detected.

Voltage signal at coolant pressure signal pin 24 of the engine harness indicates coolant pressure lower than 28kPa [4psi] at 800rpm; 41kPa [6psi] at 1300rpm; 76kPa [11psi] at 1800rpm; 96kPa [14psi] at 2000rpm; and 103kPa [15psi] above 2100rpm.

Calibration dependent progressive power and speed derate and engine shutdown with increasing time after alert.

234 Red

Engine speed signals on pin 17 of the engine harness indicate an engine speed greater than 2650rpm.The EHAB (fuel shutoff valve) is de-energized, (closed).

The EHAB (fuel shutoff valve) is re-energized (opened) when engine speed falls below 2130rpm.

235 Engine Protection

Low coolant level has been detected. Voltage signal on the coolant level signal pin 37 of the engine harness indicates low radiator coolant level in the vehicle.

Calibration-dependent progressive power and speed derate, and engine shutdown with increasing time after alert.

252 Yellow

Low voltage detected at the lubricating oil level sensor supply pin 49 of the engine harness.

No action taken by the ECM.

253 Engine Protection

Voltage signal on the oil level signal pin 49 of the engine harness indicates low oil level in the engine.

Engine will not start.

254 Red

Less than 16.5volts detected at fuel shutoff valve solenoid supply pin 43 of the engine harness.

No action is taken by the ECM. Low voltage to the EHAB will cause it to stop fuel flow to the corresponding pump, and shut down that engine bank.

259 Red

EHAB (fuel shutoff valve) is open and will not close.

ECM commands rack position to zero, which stops fueling corresponding engine bank.

342 Red

The primary and secondary ECM calibrations do not match.

Engine will not start.

343 Yellow

Microprocessor communication error internal to the ECM.

Variable; performance will or will not be affected.

3.66 QUANTUM FAULT CODE INFORMATION FOR ENGINE

FAULT CODE/ LAMP

REASON

EFFECT(Only when fault code is active)

ECM power down internal data store error.

Power down data (which includes maintenance monitoring, current ECM / engine delta times, and past fault data) are lost.

415 Engine Protection

Very low oil pressure has been detected.

Voltage signal at oil pressure signal pin 33 of the engine harness indicates oil pressure lower than 34kPa [5psi] at engine speeds less than 800rpm; 121kPa [17.5psi] at 1200rpm; 207kPa [30psi] at engine speeds greater than 1600rpm.

Calibration dependent progressive power and speed derate and engine shutdown with increasing time after alert.

Voltage detected simultaneously on both the coolant level high and low signal pins 27 and 37 of the OEM interface harness, or no voltage detected on either pin.

No action taken by the ECM.

422 Yellow 431 Yellow

Voltage detected simultaneously on both the idle validation, off-idle, and idle-signal pins 25 and 26 of the OEM interface harness.

None on performance.

Engine will not respond to accelerator.

Engine will idle only.

432 Red

Voltage detected at idle validation on idle signal pins 26 of the OEM harness when voltage at accelerator position signal pin 30 of the OEM harness indicates pedal is not at idle, OR voltage detected at idle validation off-idle signal pin 25 of the OEM harness when voltage at accelerator position signal pin 30 of the OEM harness indicates pedal is at rest.

441 Yellow

Less than 9volts battery voltage detected at the engine harness.

ECM voltage supply approaching a level at which unpredictable operation will occur.

442 Yellow

More than 34volts battery voltage detected at ECM.

ECM damage will occur.

Voltage detected at pin 22 of the engine harness is out of range.

Droop setting defaults to switch position "1" (or normal) preprogrammed droop governor values.

Less than 17volts detected at solenoid supply pin 41 of the engine harness.

No action is taken by the ECM.

Voltage detected at pin 39 of the OEM interface harness is out of range.

Torque curve setting defaults to switch position 2 (or lowest) preprogrammed torque curve.

551 Yellow

No voltage detected simultaneously on both the idle validation off-idle and idle-signal pins 25 and 26 of the OEM interface harness.

Engine will default to zero percent throttle.

555 Engine Protection

High crankcase blowby pressure has been detected. Voltage signal at blowby pressure signal pin 25 indicates blowby pressure above 368mm H2O [14.5in H2O].

Calibration dependent progressive power and speed derate and engine shutdown as pressure increases over thresholds.

346 OFF

524 Yellow 527 Yellow 528 Yellow

3.67 QUANTUM FAULT CODE INFORMATION FOR ENGINE

FAULT CODE/ LAMP

REASON

EFFECT(Only when fault code is active)

719 Yellow

More than 4.94volts detected at the blowby pressure sensor signal pin 25 of the engine harness.

Engine protection for blowby flow rate is disabled.

729 Yellow

Less than 0.29volts detected at the crankcase blowby pressure sensor signal pin 25 of the engine harness.

Engine protection for blowby flow rate is disabled.

3.68 SPECIFICATIONS Standard Specifications

SPECIFICATIONS Standard Specifications

2 3/4" (4,945)

1/4" (2,140)

16'

1

5 1/16" (4,090)

7'

11 9/1 6" (9 ,740)

13'

19'

9 7/8" (6,040)

31'

26'

7 13/1 6" (8 ,120)

13'

14'

10" (4,520)

7 13/16" (4,160)

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.

15' 42'

9" (4,800)

4 1/16" (12,900) 135ZVUSA-OSV

3.69 SPECIFICATIONS Standard Specifications

Bucket Capacity

12.8yd3 (9.7m3) (Heaped) 10.5yd3 (8.0m3) (Struck)

Operating Weight

176,200lb (79,900kg)

Engine

CUMMINS QST30 -C 4 cycle, Water Cooled, Turbo charged direct injection 30.5L 537kW / 2,100min-1 (720HP / 2,100rpm) 3,300N-m / 1,000min-1 (2,434lb-ft / 1,000rpm)

Model Type Displacement Rated Power (Net) Max. Torque (NET)

Rock-V-Edge Bucket with Teeth (RVT) & Segments

Tire (standard)

45/65-R39-(L-5) Radial

Max. Running Speed (forward/reverse)

1st : 6.9 / 7.7km/h ( 4.3 / 4.8MPH) 2nd :12.8 / 14.3km/h ( 8.0 / 8.9MPH) 3rd :24.4 / 27.3km/h (15.2 / 17.0MPH) Lockup :30.0 / - km/h (18.6 / - MPH)

The weight and load figure includes counterweight, open ROPS and enclosed cab, air conditioner, RVT bucket with segments, 45/65-R39 (L-5) tires, full fuel tank and operator.

3.70 SPECIFICATIONS High Lift Boom Specifications

High Lift Boom Specifications

8 1/4 "

(9,960 )

16’

2

5 1/8"

(4,700)

2 3/4" (4,945)

7’ 11/16" (2,150)

15’

21’

8 5/16" (6,610)

32’

26’

7 13 /16"

(8,12 0)

13’

14’

7 13/16" (4,160)

6 1/16" (4,420)

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

15’

9" (4,800)

43’ 9 15/16" (13,355) 135ZVUSA-OSVa

3.71 SPECIFICATIONS High Lift Boom Specifications

Bucket Capacity

11.5yd3 (8.6m3) (Heaped) 10.2yd3 (7.6m3) (Struck)

Operating Weight

178,700lb (81,050kg)

Engine

CUMMINS QST30 -C 4 cycle, Water Cooled, Turbo charged direct injection 30.5L 537kW / 2,100min-1 (720HP / 2,100rpm) 3,300N-m / 1,000min-1 (2,434lb-ft / 1,000rpm)

Model Type Displacement Rated Power (Net) Max. Torque (NET)

Rock-V-Edge Bucket with Teeth (RVT) & Segments

Tire (standard)

45/65-R39-(L-5) Radial

Max. Running Speed (forward/reverse)

1st : 6.9 / 7.7km/h ( 4.3 / 4.8MPH) 2nd :12.8 / 14.3km/h ( 8.0 / 8.9MPH) 3rd :24.4 / 27.3km/h (15.2 / 17.0MPH) Lockup :30.0 / - km/h (18.6 / - MPH)

The weight and load figure includes counterweight, open ROPS and enclosed cab, air conditioner, RVT bucket with segments, 45/65-R39 (L-5) tires, full fuel tank and operator.

3.72

MEMO

INDEX 12 Volt Power-outlet Socket (S/N 0203~) ................2.21

A Accelerator Pedal ......................................................2.6 Adjust and Check Rear View Mirrors .......................2.46 Adjustments .............................................................2.69 After Storage ............................................................2.76 Air Cleaner Warning Lamp (red) ..............................2.26 Articulation Stopper .....................................1.21, 2.44 Auto Brake ...............................................................2.59 Auto Brake Indicator Lamp (red) ..............................2.24 Auto Shift Indicator Lamp (green) ............................2.27

B Before Starting Safety ................................................1.4 Before Storage .........................................................2.75 Boom Kickout Adjustment ........................................2.70 Boom Soft Landing Adjustment ...............................2.71 Boom Soft Landing Height Adjust Switch ................2.21 Boom Soft Landing Switch .......................................2.12 Booster Batteries / Jumper Cables ..........................2.73 Brake Oil Temperature Warning and Brake Disk Wear Alarm Lamp (red) ........................................2.25 Brake Pedals .............................................................2.6 Brake Pressure Warning Lamp (red) .......................2.25 Bucket / Attachment Positioner Adjustment .............2.69

C Carrying ...................................................................2.66 Cautions on Battery Replacement or Battery Cable Removal ...............................................................2.76 Cautions Regarding Welding Repair Service ..........2.78 Central Warning Lamp (red) ....................................2.24 Charge Lamp (red) ..................................................2.27 Check after Starting the Engine ...............................2.50 Check Air Conditioner Refrigerant ...........................3.43 Check Air Intake System .........................................3.31 Check and Adjust Air Conditioner Belt .....................3.33 Check and Adjust Belt Tension ................................3.30 Check and Adjust Injection Timing ..........................3.44 Check and Adjust Valve Lash Clearance ................3.52 Check and Replace Transmission and Torque Converter Breather Element .................................3.42 Check and/or Replace Seat Belt ..............................3.10 Check Back-up Alarm Operation .............................2.54 Check Battery Electrolyte Level ...............................3.22 Check before Operation ...........................................2.39 Check Brake Accumulators .....................................3.52 Check Control Levers ..............................................2.47 Check Differential Gear Oil ......................................3.31 Check Engine Compression Pressure .....................3.44 Check Engine Coolant Level ...................................2.42 Check Engine Oil Level ...........................................2.40 Check Exhaust Gas .................................................2.54 Check Fuel Level .....................................................2.51 Check Horn Operation .............................................2.47

Check Hydraulic Oil Level .......................................2.41 Check Injection Pressure .........................................3.44 Check K-Lever and Forward/Reverse Changeover Switch ...................................................................2.47 Check Monitor Panel Operation ..............................2.47 Check or Replace Fuses .........................................3.13 Check Parking Brake ...............................................2.46 Check Parking Brake Operation ..............................2.53 Check Planetary Gear Oil ........................................3.32 Check Service Brake Operation ..............................2.53 Check Steering Wheel Operation ............................2.53 Check Tightness of Wheel Bolts ..............................3.32 Check Tire Air Pressure ..........................................3.23 Check Tire for Damage, Deformation and Wear .....2.45 Check Transmission Oil Level .................................2.51 Check Vibration Damper .........................................3.52 Check Warning Lamps ............................................2.50 Check Windshield Washer Fluid ..............................3.13 Check Wiring Harnesses .........................................2.44 Clean Air Conditioner and Heater Filter Element ....3.34 Clean Air Conditioner Condenser ............................3.14 Clean Crankcase Breather Tube .............................3.29 Clean Filter for Brake Line .......................................3.55 Clean Fuel Prefilter ..................................................3.38 Clean Fuel Tank ......................................................3.53 Clean or Replace Air Cleaner Element ....................3.11 Clean Radiator/Air cooler/Hydraulic oil cooler Fins ................................................................................3.12 Cold Start .................................................................2.49 COMPONENT NAME/LOCATION ............................2.2 Coolant Specification ...............................................3.57

D Diagnostic Switch (option) .......................................2.15 Dozing .....................................................................2.64 Drain Water and Sediment from Fuel Filters ...........2.43 Drain Water and Sediment from Fuel Tank .............3.21 Dumping into Truck or Hopper ................................2.66 During Storage ........................................................2.75

E Electrical Protection .................................................2.32 Emergency Brake ....................................................1.22 Emergency Steering (option) ...................................1.23 Emergency Steering Warning Lamp (red) (option) ................................................................................2.28 Engine Coolant Temperature Gauge .......................2.23 Engine Coolant Temperature Warning Lamp (red) ................................................................................2.26 Engine Grid Air Heater Lamp (yellow) (For cold start) ................................................................................2.29 Engine Mode Switch ................................................2.12 Engine Oil Pressure Warning Lamp (red) ................2.25 Engine Stop Switch .................................................2.20 Engine Warning Lamps ...........................................2.28 Every 10 Hours or Daily ...........................................3.18

Every 1000 Hours or 6 Months ................................ 3.40 Every 2000 Hours or 1 Year .................................... 3.48 Every 250 Hours or 1 Month ................................... 3.25 Every 50 Hours or 1 Week ...................................... 3.19 Every 500 Hours or 3 Months .................................. 3.36 Excavating ............................................................... 2.64 Explosion / Fire / Burn Prevention ........................... 1.13

F Forward / Reverse Changeover Switch ................... 2.19 Front Wiper Switch .................................................. 2.14 Front Working Light Switch ..................................... 2.10 Fuel Gauge .............................................................. 2.23 Fuse Boxes ............................................................. 2.32 Fusible Link ............................................................. 2.33

Normal Start ............................................................ 2.48

O Operating Techniques ............................................. 2.62 Operating the Machine ............................................ 2.56 OPERATION ........................................................... 2.39 Operation of the Automatic Temperature Control unit ............................................................................... 2.35 Operational Safety ..................................................... 1.6 Operator Safety ......................................................... 1.2 OPERATOR'S AREA ................................................ 2.3 Other Maintenance Safety Concerns ...................... 1.14

P

General Inspection .................................................. 2.55 Greasing ...............................2.47, 3.19, 3.46, 3.54 Ground Levelling ..................................................... 2.65

Parking .................................................................... 2.60 Parking Brake Indicator Lamp (red) ........................ 2.24 Parking Brake Switch ................................................ 2.9 Parking Safety ......................................................... 1.10 Pedals and Levers ..................................................... 2.3 Power Boost Switch ................................................ 2.17

H

Q

Heater or Air Conditioner ......................................... 2.34 Switches ................................................... 2.34, 2.36 Ventilation Location and Mode ................. 2.34, 2.36 High Beam Indicator Lamp (blue) ............................ 2.27 Horn Switch ............................................................. 2.18 Hour Meter .............................................................. 2.28

QUAD (Quick Up And Downshift) Switch ................ 2.18

G

I Increment / Decrement Switch (option) ................... 2.16 Indicators ................................................................. 2.22 Inspection and Maintenance Table ........................... 3.6

K K-Lever ...................................................................... 2.4 K-Lever Indicator Lamp ........................................... 2.24 K-Lever Steering System On / Off ........................... 1.20

L Ladder Light Switch ................................................. 2.11 Light Switch ............................................................. 2.10 Loading .................................................................... 2.62 Loading Control Lever ............................................... 2.4 Boom Control ......................................................... 2.5 Bucket Control ....................................................... 2.5 Loading Control Lever Lock .................................... 1.20 Long Term Storage ................................................. 2.75

M MAINTENANCE ........................................................ 3.2 Mounting and Dismounting Safety ............................ 1.3

N Neutral Indicator Lamp (green) ............................... 2.27 Neutral Start System ............................................... 1.22

R Rear Wiper Switch ................................................... 2.15 Rear Working Light Switch ...................................... 2.11 Recommended Lubricants ...................................... 3.56 Recommended Mixture of Antifreeze ...................... 3.57 Replace Air Conditioner Filter Elements ................. 3.14 Replace Air Conditioner Receiver Dryer ................. 3.17 Replace Bucket Teeth ............................................... 3.9 Replace Coolant ...................................................... 3.15 Replace DCA4 Coolant Filter Cartridges ................. 3.28 Replace Differential Gear Oil ................................... 3.50 Replace Engine Oil .................................................. 3.37 Replace Engine Oil Filter Cartridges ....................... 3.25 Replace Filter .......................................................... 3.35 Replace Filter in the Oil Tank Cap .......................... 3.47 Replace Fuel Filters ................................................ 3.27 Replace Hydraulic Oil .............................................. 3.48 Replace Hydraulic Oil Return Filter ......................... 3.42 Replace Planetary Gear Oil ..................................... 3.51 Replace Transmission Oil ....................................... 3.40 Replace Transmission Oil Filter .............................. 3.45 Replace Transmission Oil Filter Elements .............. 3.36 Ride Control Indicator Lamp (green) (option) .......... 2.29 Ride Control Switch (option) .................................... 2.14 Ride Control System (option) .................................. 2.38 Roading / Special Applications ................................ 2.72 ROPS (Roll Over Protective Structure) ....... 1.23, 2.46

S Safe Operation .......................................................... 1.2 SAFETY .................................................................... 1.2 Safety Devices ........................................................ 1.20 Safety Preparations Before Maintenance ................ 1.11 Safety Signs ............................................................ 1.16

Seat .........................................................................2.30 Seat Adjustment ......................................................2.30 Seat Belt ..................................................................2.31 Serial Number Location .............................................3.2 SPECIAL PROCEDURES .......................................2.69 SPECIFICATIONS ...................................................3.68 Speed and Direction Change ...................................2.57 Starter Switch ............................................................2.9 Starting the Engine ..................................................2.48 Starting the Machine ................................................2.56 Starting the Machine on a Grade .............................2.57 Steering ...................................................................2.59 Stopping the Engine ................................................2.61 Switches ....................................................................2.8

T Tachometer ..............................................................2.23 Torque Converter Oil Temperature Gauge ..............2.23 Torque Converter Oil Temperature Warning Lamp (red) ......................................................................2.26 Traction Control Engine Adjust Switch ....................2.20 Traction Control Switch ............................................2.13 Transmission Control Warning Lamp (red) ..............2.25 Transmission Cut-Off (Declutch) Lamp (green) .......2.24 Transmission Cut-Off (Declutch) Switch ..................2.13 Transmission Oil Filter Warning Lamp (red) ............2.27 Transmission Shift Switch ........................................2.19 Transmission Status Monitor ...................................2.27 TROUBLESHOOTING .............................................3.58 Typical Truck Loading Methods ...............................2.68

W Walk-Around Inspection ...........................................2.39 Welding ....................................................................2.78 When Required Inspection and Maintenance ............3.9 Working Light Indicator Lamp (green) .....................2.24 Wrist Rests (adjustable) .............................................2.7

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes