Download Kawasaki 50ZIV-2 Wheel Loader with Cummins B3.9-C Engine Operation & Maintenance Manual.

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WiTH CUMMINS B3.9-C ENGINE SER!AL NUMBERS 50C2-010"I and up.

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R.EAD AND UNDER.ST.A.ND THIS M.ANUA,L

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MANU.AL ON THE MA.CHINE © 2005 Kawasaki Heavy Industries, ltd. All rights reserved.

Printed in Japan (I)

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THIS

WARNING CALIFORNIA PROPOSITION 65

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

WASH HANDS AFTER HANDLING !

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

93105-00053 October 25, 2005

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 50ZIV-2.

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

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

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

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

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 loader dealer, it may not be equipped as the regulations require. Kawasaki cannot be responsible for anything on that kind of machine. Also, some local agencies or certain jobsites may require special equipment that has not been provided. Contact your nearest Kawasaki dealer for further information or assistance.

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

CONTENTS SAFETY・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1 Safe Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1 Safe Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・10 Safety Signs・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・15 Safety Devices・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・22 COMPONENT NAME / LOCATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・25 OPERATOR'S AREA・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・26 Pedals and Levers・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・26 Indicators and Switches・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・31 Seat・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・37 Fuse Panel・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・39 Cab (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・40 Air conditioner (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・52 Vibration Damper (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・55 OPERATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・56 Check Before Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・56 Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・64 Check after Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・66 Operating the Machine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・70 Parking・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・73 Stopping the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・74 Operating Techniques・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・75 SPECIAL PROCEDURES・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・81 Adjustments・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・81 Roading / Special Applications・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・83 Booster Batteries / Jumper Cables・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・84 Towing・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・86 Transportation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・88 Long Term Storage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・90

MAINTENANCE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・92 Serial Number Location・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・92 Inspection and Maintenance Table・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・94 When Required Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・96 Daily Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・101 Every 50 Hours or 1 Week Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・102 Every 250 Hours or 1 Month Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・107 Every 500 Hours or 3 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・113 Every 1000 Hours or 6 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・115 Every 2000 Hours or 1 Year Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・122 Recommended Lubricants and Capacity・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・129 Coolant Specification・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・130 TROUBLESHOOTING・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・131

SAFETY

SAFETY Safe Operation Operator Safety Read and understand the Operation & Maintenance Manual.

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.

Wear safe clothing: ・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.

Mounting and Dismounting Safety Face the machine when mounting or dismounting.

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

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

Climb and step only where steps and handrails are provided.

1

SAFETY

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

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

Never jump from the machine regardless of that machine is moving or stopped.

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

Do not allow unauthorized personnel on the machine.

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

Inspect the machine for safety hazards and, if found, have them corrected: ・Broken lights, mirrors, windows, etc. ・Fuel leaks, oil leaks, or debris build-up ・Improper tire inflation or tire damage ・Missing or unreadable safety signs (decals) Be sure the Roll Over Protective Structure (ROPS) is: ・in place. ・properly attached (no bolts loose or missing). ・not damaged. ・not modified.

2

SAFETY

Perform the normal daily maintenance.

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

Parking brake lever

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

Control lever lock

・Transmission Shift Lever -- Neutral

・Articulation Stopper -- Locked in the "STORED" position. ・Back-up Alarm -- Operational

Articulation stopper "STORED"

Securely lock the cab door either fully open or closed.

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

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

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

3

SAFETY

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

In case of fire during operation : ・Turn off the starter switch and stop the engine. ・Extinguish fire with a fire extinguisher (Depend on the situation). ・With hand rails and steps, get off the machine and stay away from it.

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

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

Properly fasten the seat belt.

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

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

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.

4

DANGER ＤＯ ＮＯＴ ＳＴＡＲＴ ＭＥＮ ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ Ｓ ＩＧＮＥＤ ＢＹ ＤＡＴＥ

SAFETY

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

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 84.

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.

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

Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

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

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

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

The range of temperature the machine is to be operated is between −35 ℃ ~ 45 ℃ .

5

SAFETY

When working on a grade: ・Turn "OFF" the transmission cut-off (Declutch) switch. ・Keep the attachment low. ・Keep the attachment facing up the grade as often as possible. ・Drive directly up or down the grade -- never across the grade. ・Stop when changing direction on a grade to maintain stability. ・Never coast down a grade. ・Select the same low gear to go down the grade as was selected to climb the grade. This provides some engine braking.

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 expose the machine to flames.

SAFETY DURING NORMAL OPERATIONS: 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.

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

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

Properly counterweight and ballast the machine depending upon the bucket size and material or attachment application.

Do not exceed the recommendations and limits.

6

SAFETY

Maintain stability by carrying the load as low as possible throughout each cycle. ・The normal carry position is about 40 cm (16 in.) above the ground.

approx. 40cm (16in)

When roading the machine: ・Travel in forward only. ・Travel only as fast as conditions and safety allow. ・Know and follow all local laws that may require rotating beacon, slow moving vehicle (SMV) signs, width signs or flags, lead or chase vehicles, four-way flashers, or clearance lights, etc.. ・If roading long distances (over 3 km (2 miles)), periodically stop to allow tires, transmission, engine to cool down.

Excessive tire heat caused by roading can cause blow-outs and loss of control.

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

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

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

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

7

SAFETY

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.

SPECIAL OPERATING CONDITIONS: 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.

8

SAFETY

・Be sure the hitch pin is fully in its bore before applying tension. ・If brakes and steering are working on the towed vehicle, keep an operator in the operator's seat and have him control the vehicle. ・If brakes are not working on the towed vehicle, attach another vehicle of adequate size to the rear to act as a braking vehicle. ・Use the machine as a tow vehicle only for short distance.

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

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

If parking on a 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).

Inspect the machine and report any needed repairs.

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

9

SAFETY

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

Perform maintenance and repairs only if trained. Follow the Operation & Maintenance Manual or Shop Manual.

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

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

Wear safe clothing to perform maintenance: ・Close fitting clothing -- loose or baggy clothing can catch on equipment or controls. ・Protective clothing as required by the job or conditions -- for example: -Hard hat -Gloves -Steel-toe shoes -Eye / face protection -Approved respirator ・Do not wear jewelry that may catch on equipment, controls, or may short and cause burns if in contact with electrical components.

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

10

SAFETY

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.

Never make repairs on pressurized components. Release all trapped air and hydraulic pressure by: ・Stopping the engine after lowering the attachment to the ground. ・Moving the loading control levers back and forth. ・Turning the steering wheel right and left several times. ・Turning the hydraulic oil tank cap 1/3 turn counterclockwise.

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

DANGER

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

ＤＯ ＮＯＴ ＳＴＡＲＴ ＭＥＮ ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ Ｓ ＩＧＮＥＤ ＢＹ ＤＡＴＥ

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

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

Explosion / Fire / Burn Prevention Before removing any coolant hoses or plugs, relieve any trapped pressure in the cooling system.

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.

11

SAFETY

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 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.).

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

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

If overheated tire is suspected, never stand in front of the tire.

Stay away until the tire and rim cool down.

12

SAFETY

Tire and rim assemblies if improperly serviced can explode with deadly force. When inflating tires; ・Make sure wheel parts are correctly installed. ・Use a self attaching (locking) air chuck. ・Use a remotely located valve to turn air pressure on and off. ・Stand behind the tread not beside the rim. ・Do not inflate tires more than the recommended pressure. ・Use a safety cage for a repaired tire.

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

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.

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

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.

13

SAFETY

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.

Do not enter the articulation area when engine is running.

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 by a wrong actuation. If something is wrong with the rubber hose, immediate repair is needed : ・Correct them and fasten the rubber hose when a clamp, guard and cushion are loosen. Do not keep them loosen, or the rubber hose is damaged by vibrating or scratching other parts. ・Fasten the rubber hose with designated torgue when the connection is loosen. ・Exchange the hose base when it is damaged or deformed. ・Exchange the hose cover when it is damaged, cut or expanded. ・Exchange the moving contact of the rubber hose when it is twisted or bent.

14

Articulation stopper "LOCKED"

SAFETY

Safety Signs All safety signs which are on the machine are shown here.

Read them and understand them thoroughly. They contain information which is important for the safe operation and the safe maintenance. Therefore, it is very important that all safety signs be on the machine in the locations shown. If any sign is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct position.

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

DANGER

No room in this area when turning.

Crushing will cause serious injury or death.

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

44787 − 20810

15

SAFETY

W ith canopy

WARNING

Impriper operation or maintenance can cause serious injury ir death.

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

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

For replacement Operation & Maintenance Manual or safety signs,contact Kawasaki loader dealer.

44787 − 20760

W ith cab (option)

WARNING

Sudden or accidental movement of boom may cause injury or death.

Before walking or working under raised boom: ・Securely block or brace boom. ・Remove key and tag "Do Not Operate." ・Relieve all trapped oil pressure before opening any piping.

44787 − 20740

16

SAFETY

WARNING Check transmission oil level properly to avoid serious injury or death. ・Park on level ground. ・Lower bucket to ground. ・Place transmission in neutral. ・Set parking brake. ・Tag "Do Not Operate."

44787 − 20750

WARNING

Machine will not turn with articulation stopper in locked position.

Unlock articulation stopper before operating machine.

44787 − 21070

17

SAFETY

WARNING

Batteries produce explosive gases which can cause burns or blindness.

Keep flames and sparks away.

Vent area before servicing.

44787 − 20800

WARNING

Batteries contain lead, and acid which causes burns.

Avoid contact with skin or clothing.

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

44787 − 22890

18

SAFETY

CAUTION ＣＡＵＴ ＩＯＮ

Contact with moving belts or pullies will cause injuries.

Stop engine before working in this area.

44787 − 20860

CAUTION ＣＡＵＴ ＩＯＮ

Contact with fan will cause injury.

Keep all guards in place.

Keep hands away from fan area.

44787 − 20850

19

SAFETY

WARNING

Serious injury or death may result if engine starts in gear. ・Do not start engine by shorting across starter terminals. ・Do not start engine while standing on ground.

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

44787 − 20840

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

Use only approved oil such as: Mobil Delvac 1 or equivalent 44787 − 20870

20

SAFETY

CAUTION

Pressurized system: spray of hot fluid could cause burns.

Allow system to cool and vent pressure slowly before servicing.

44787 − 20820

ＦＡＬＬ ＩＮＧ

ＤＯＮ Ｔ ＳＴＥＰ ４４７８７−２２５００

21

SAFETY

Safety Devices Loading Control Lever Lock 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.

This device locks the loading control lever to prevent accidental lowering of the attachment or boom. ・ To lock, set the loading control lever to "NEUTRAL" and turn the lock lever clockwise to the vertical position. ・ To unlock, turn the lock lever counterclockwise to the horizontal position.

Articulation Stopper WARNING Machine will not turn with articulation stopper in locked position, which, while operating, could cause accident, injury or death.

Unlock articulation stopper before operating machine.

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

To lock: 1. Align the front and rear chassis straight ahead.

2. Remove the bolt from the bracket on the front chassis which holds the articulation stopper.

22

Lock

SAFETY

3. Turn the link and fix the end to the bracket on the rear chassis with the pin and clip pin. (This is the LOCKED position.)

4. Keep the bolt on the bracket.

"LOCKED" position

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

2. Turn and set the link on the front chassis bracket. Tighten the bolt to fix the link on the bracket. (This is the STORED position.)

"STORED" position

3. Insert the pin and clip pin.

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

23

SAFETY

Parking Brake Lever WARNING

Parking brake lever

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

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

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

IMPORTANT Running machine with parking brake engaged may cause rapid brake pad wear and loss of parking brake force. ・ Stop machine before engaging parking brake. ・ Release parking brake lever when operating machine.

・ Fully pull up the parking brake lever to engage the parking brake. ・ Press the lever button and push down the parking brake lever to disengage the parking brake. This will allow the transmission to re-engage.

ROPS (Roll Over Protective Structure)(option) WARNING Operating with damaged or improperly mounted ROPS could cause serious injury or death. Be sure to observe the following. ・ Whenever seated,fasten the seat belt. (If equipped) ・ Do not modify ROPS, such as drilling or welding. ・ Do not use ROPS deformed. ・ If any damage or loose bolts are found, do not operate until repaired. ・ Never repair or modify ROPS without manufacturer's

24

COMPONENT NAME / LOCATION

COMPONENT NAME / LOCATION

１２ ５

２ １７

４ ７

１

１０

９ １３ ６ ３

８

１５

１６

１１

１４

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.

1. Bucket (or Attachment) 2. Boom 3. Boom Cylinders 4. Bucket Cylinder 5. Engine 6. Torque Converter & Transmission Ass'y 7. Radiator and T/C Cooler (lower tank) 8. Fuel Tank

9 . Hydraulic Oil Tank (Right hand side) 10. Front Axle / Differential Ass'y 11. Rear Axle / Differential Ass'y 12. Air Cleaner (Right hand side) 13. Parking Brake 14. 2nd Propeller Shaft 15. 3rd Propeller Shaft 16. Batteries (one each side--two 12VDC=24VDC System) 17. "Z" Lever

25

OPERATOR'S AREA

OPERATOR'S AREA Pedals and Levers １

３

４

５

２

９

６ ８

７

1. Transmission Shift Lever 2. Horn Button 3. Light Switch 4. High-Low Beam / Turn Signal Lever (option) 5. Loading Control Lever 6. Accelerator Pedal 7. Right Brake Pedal 8. Left Brake Pedal (Declutch Pedal) 9. Loading Control Lever Lock

1. Transmission Shift Lever Transmission Shift Lever is used to control machine speed and direction. ・ Push the lever forward to move the machine forward. ・ When the lever is in NEUTRAL, the machine should not move on level ground. ・ Pull the lever backward to move the machine backward. ・ The three forward and three reverse speeds are selected by rotating the shift lever.

26

OPERATOR'S AREA

2. Horn Button Horn Button is used to blow the horn. ・ Press the button in the center of the steering wheel to blow the horn.

3. Light Switch This is a three position switch.

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

4. High-Low Beam / Turn Signal Lever (option) This lever is used to change the headlamp beam high and low, and to flash the headlights. It also turns on the turn signals (option). ・ Lift the lever to turn the front lights on momentarily (Flash position). ・ Set the light switch knob to ●● and lift the lever to turn the front hi-beams on. ・ The headlights are in the low beam position when the lever is pushed down (lowest position). ・ The light switch can be operated regardless of the lever position. ・ Push the lever forward to turn on the left turn signal. ・ Pull the lever backward to turn on the right turn signal. ・ Return the lever to the center position when the turn is completed. The lever does not return automatically when the steering wheel is returned to center.

27

OPERATOR'S AREA

5. Loading Control Lever Loading Control Lever is used to control the boom and attachment movement. (a) Float

(b) Lower

・Move the lever to full forward detent position.

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

（ｂ） （ａ）

・Move the lever forward. The boom will lower. ・When held in this position, down pressure will be applied to the boom and attachment.

(c) Raise

（ｆ） （ｃ）

（ｄ）

・Move the lever rearward. The boom is raised.

（ｆ）

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

（ｅ）

Raise

・For adjustment procedure refer to "Boom Kick-out Adjustment" page 82. (d) Dump

・Move the lever to right. attachment will dump.

The bucket or

(e) Roll Back ・Move the lever to left. attachment will roll back.

The bucket or

Lower

Roll back

・An automatic bucket leveler is provided which will automatically release the detent and return the lever to the "Hold" position when the bucket or attachment reaches to the preset angle. ・For adjustment procedure refer to "Bucket Positioner Adjustment" page 81. (f) Hold

・Return the lever to the center position. The boom and bucket or attachment will stop and remain in that position.

28

Dump

OPERATOR'S AREA

Auxiliary Attachment Control Lever (option).

(h) (g)

(g) Normally this position will close the attachment. (h) This center position will cause the attachment to stop and remain in that position. ( i ) Normally this position will open the attachment.

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

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

6. Accelerator Pedal 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.

7. 8.

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.

29

(i)

OPERATOR'S AREA

Brake Pedals are used to reduce the machine ground speed, stop the machine, or to hold the machine. ・ Right Brake Pedal・ ・ ・ ・ ・ ・ ・ ・Applies the brakes only. ・ Left Brake Pedal (also called Declutch Pedal)・ ・ ・ ・ ・ ・ ・ ・ ・May be used either of two ways: 1) As a brake only pedal by turning the transmission cut-off (Declutch) switch (See page 35) to the "OFF" position. Use this position when working on slopes or ramps.

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

To use this feature, turn the transmission cut-off (Declutch) switch to the "ON" position. When the switch is "ON", a green indicator light on the dash will also be turned on.

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

9. Loading Control Lever Lock WARNING Accidental movement of boom or machine could 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.

This device locks the loading control lever to prevent accidental lowering of the attachment or boom. ・ To lock, set the loading control lever to "NEUTRAL" and turn the lock lever clockwise to the vertical position. ・ To unlock, turn the lock lever counterclockwise to the horizontal position.

30

Lock

OPERATOR'S AREA

Indicators and Switches ３

２

１

１３

３０

２０

１４

ＴＥＭＰ

ＦＵＥＬ Ｈ

４０

Ｆ

１５

１０

１０

５０

１１

Ｃ

Ｅ

１６

０

１７

１２

Ｐ

４

５

６

７

８

９

１８

10. Pre-heat Lamp (orange) 11. Transmission Cut-Off (Declutch) Lamp (green) 12. Rear Working Light Indicator Lamp (green) 13. Turn Signal Indicator Lamp (green) 14. Hi-beam Indicator Lamp (blue) 15. Bulb Check Switch 16. Transmission Cut-Off (Declutch) Switch 17. Rear Working Light Switch 18. Starter Switch

1. Speedometer 2. Engine Coolant Temperature Gauge 3. Fuel Gauge 4. Engine Oil Pressure Lamp (red) 5. Transmission Oil Temperature Lamp (red) 6. Charge Lamp (red) 7. Brake Oil Lamp (red) 8. Air Filter Element Lamp (red) 9. Parking Brake Lamp (red)

31

OPERATOR'S AREA

IMPORTANT Operation of 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. ２０

３０

1.Speedometer

４０

Speedometer indicates the ground speed and accumulated travel mileage.

１０

５０ ０

2. Engine Coolant Temperature Gauge Indicates engine coolant temperature. It is normal when the indicator stays in the white zone. ・ If the indicator enters the red zone while operating, slow the engine down to midrange speed and wait until the indicator reaches the white zone.

ＴＥＭＰ

Ｈ

Ｃ

・ 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 131.

3. Fuel Gauge

ＦＵＥＬ

Indicates the fuel amount in the fuel tank. ・ When the indicator enters the red zone while operating, stop the machine, and add fuel.

Ｆ

Ｅ

・ Fill the fuel tank at the end of each day of operation to avoid condensation in the tank.

4. Engine Oil Pressure Lamp (red) 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 131.

32

E/G OIL PRESS

OPERATOR'S AREA

5. Transmission Oil Temperature Lamp (red) Lights up when transmission oil overheats.

(Over 120±5 ° C (248±9 ° F)) ・ If it lights up while operating, slow the engine speed down to midrange, shift to neutral, and wait until the lamp goes out.

T/M OIL TEMP

・ 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 134.

6. Charge Lamp (red) Lights up when the alternator charge level is low. ・ If it lights up, check the charging circuit.

Refer to "Troubleshooting" page 132.

7. Brake Oil Lamp (red)

CHARGE

Lights up when brake oil level is lower than specified .

The warning buzzer sounds when this lamp lights up.

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

Stop machine immediately and correct problem if brake oil lamp lights up.

BRAKE

・ If it lights up while operating, stop the machine immediately and check for leaks in the brake circuit. ・ Refill the brake oil reservoir as needed.

Refer to "Check Brake Oil Level" page 58.

8. Air Filter Element Lamp (red) Lights up when air filter is clogged. ・ If it lights up while operating, stop the engine and clean or replace the air cleaner element.

Refer to "Clean or Replace Air Cleaner Element" page 97.

AIR FILTER

33

OPERATOR'S AREA

9. Parking Brake Lamp (red) Lights up when the parking brake is applied.

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

P PARKING

10. Pre-heat Lamp (orange) Lights up when the starter switch is in "PREHEAT" position.

11. Transmission Cut-Off (Declutch) Lamp (green) 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 left brake pedal (declutch brake pedal). ・ When not lit, only the brakes are engaged as the left brake pedal is depressed.

12. Rear Working Light Lamp (green) Lights up when rear working lights are on.

13. Turn Signal Indicating Lamp (green) Flashes when the turn signal switch lever is moved forward or rearward (option) or the four way flasher switch is turned on (option).

TURN SIGNAL

14. High beam Indicator Lamp (blue) Lights up when headlights are switched to high beam.

HI BEAM

34

OPERATOR'S AREA

15. Bulb Check Switch When this switch is turned on while the starter switch is "ON", the red warning lamps ((5)(7) and (8): page 31) should light up.

If any warning lamps stay dark, replace the bulbs.

16. Transmission Cut-Off (Declutch) Switch 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"

Transmission Cut-Off (Declutch) Switch is used to change the function of the left brake pedal.

Normally this switch should be ON. "OFF"・ ・ ・When the left brake pedal (declutch brake pedal) is depressed, only the service brakes are engaged keeping the transmission directional clutch engaged (brake only).

"ON"・ ・ ・ ・ ・When the left brake pedal (declutch brake pedal) is depressed, the service brakes are engaged and the transmission directional clutch is disengaged (brake and declutch).

Refer to "Brake Pedals" on page 29 for the function of the left brake pedal.

17. Rear Working Light Switch Rear Working Light Switch is used for turning on and off the rear working lights.

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

35

OPERATOR'S AREA

18. Starter Switch "OFF" The key can be either inserted or pulled out. The engine is stopped and most electrical circuits are turned off.

ＰＲＥＨＥＡＴ

ＯＦＦ ＯＮ

ＳＴＡＲＴ

"ON" Current flows to all circuits. ＰＲＥＨＥＡＴ ＯＦＦ ＯＮ

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

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

"PREHEAT" Warms the engine intake air for cold weather starting.

Also the preheat lamp lights up.

The starter switch returns to the "OFF" position automatically if released.

ＰＲＥＨＥＡＴ

ＳＴＡＲＴ

ＯＦＦ ＯＮ ＳＴＡＲＴ

ＰＲＥＨＥＡＴ ＯＦＦ ＯＮ

Hour Meter (Service Meter) Hour Meter indicates accumulated total hours of engine operation.

Use to determine the timing of periodic inspection and maintenance service.

36

QUARTZ HOUR 1/10H

ＳＴＡＲＴ

OPERATOR'S AREA

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

Reclining Adjustment ・ Lift the lever (1) up to freely move the seat back angle.

２ １

Forward / Backward Adjustment ・ Shift the lever (2) to the right to move the seat forward or backward.

Body Weight Adjustment ・ Turn the knob (3) to suit the body weight: Right turn to the end (max): 120 kg Left turn to the end (min): 50 kg NOTE: An optional seat may be installed that may have slightly different adjustments.

Refer to the seat manufacturer's instructions.

Seat Belt (option) WARNING Improper use or maintenance of seat belt could result in death or serious injury. ・ Inspect seat belt and mounting hardware before operating machine and replace any defective components. ・ Always fasten seat belt when operating machine. ・ Properly adjust seat belt at beginning of each shift or when operator changes.

1. Fasten the seat belt along your body without kinking or twisting it.

37

３

OPERATOR'S AREA

2. Adjust the length of the seat belt on the belt end (3).

3. Hold the buckle (2) and insert the belt end (3) into buckle (2).

Be sure it locks securely.

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

NOTE: Be sure the tether (1) is securely attached to the seat and floor. When the seat is properly adjusted and no one is in the seat, tether should be snug or taut.

３ １ ２

38

OPERATOR'S AREA

Fuse Panel The fuse box contains nineteen (including five as spares) fuses to protect the electrical circuits of the machine.

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

Never replace fuses with higher amperage rating.

1 : 5A・ ・ ・ ・ ・ ・Monitor, Warning Buzzer, Gouges, Parking Switch, Inching Switch, Hour Meter 2 :15A・ ・ ・ ・ ・ ・Combination Switch, Stop Switch, Flasher Unit 3 :15A・ ・ ・ ・ ・ ・Rear Working Lights, Back-Up Lights and Alarm Relay 4 :10A・ ・ ・ ・ ・ ・RADIO (option), Cigarette Lighter (option), Front Working Lights (option) 5 : 5A・ ・ ・ ・ ・ ・Bucket Positioner, Boom Kick-Out (option) 6 :15A・ ・ ・ ・ ・ ・Front Wiper (option), Rear Wiper (option) 7 : 5A・ ・ ・ ・ ・ ・Airconditioner (option) 8 :20A・ ・ ・ ・ ・ ・Airconditioner (option) 9 :20A・ ・ ・ ・ ・ ・Airconditioner (option) 10 : 5A・ ・ ・ ・ ・ ・Battery Relay 11 : 5A・ ・ ・ ・ ・ ・Neutral Switch 12 :15A・ ・ ・ ・ ・ ・Horn 13 :15A・ ・ ・ ・ ・ ・Fuel Valve 14 :15A・ ・ ・ ・ ・ ・Front / Right Wiper (2 persons cab), Front / Left Wiper (2 persons cab) 15 :20A・ ・ ・ ・ ・ ・for spare 16 :20A・ ・ ・ ・ ・ ・for spare 17 :15A・ ・ ・ ・ ・ ・for spare 18 :10A・ ・ ・ ・ ・ ・for spare 19 : 5A・ ・ ・ ・ ・ ・for spare

１５ １４ １３ １２ １１ １０

１８

９ ８ ７ ６

１７

５ ４ ３ ２ １

39

１９

１６

OPERATOR'S AREA

Cab (option) Front Wiper Switch Front wiper switch is used to wipe the front windshield and spray solvent.

"OFF"

:

"INT"

: Intermittent

"LOW" : Low speed "HIGH" : High speed INT

"PUSH" : Spraying solvent on the windshield

LOW HIGH

OFF

PUSH

Rear Wiper Switch (option) Rear wiper switch is used to wipe the rear windshield.

"OFF"

:

"ON"

: Low speed

"PUSH" : Spraying solvent on the windshield

OFF

ON

PUSH

Cigarette Lighter (option) Cigarette Lighter is used to light a cigarette or cigar. ・ Push the lighter in and wait for a few seconds.

The lighter will spring back to be ready for lighting a cigarette or cigar. ・ The cigarette lighter power-outlet socket can be used as a power source with max. 24 volts 10 amperes in case of emergency.

40

OPERATOR'S AREA

Working Light Switch (option) Turns on the cab lights which are mounted to the outside of the cab. ２０ １０

０

３０

ＴＥＭＰ Ｈ

４０

５０

Ｃ

ＦＵＥＬ Ｆ

Ｅ

Ｐ

41

OPERATOR'S AREA

~September, 2005

Radio (option) 10

LCD Display Unit

9

8

7

1 ON/VOL pullBAL

ST FM AS AM PM

ch

DISP

TONE

PS AS

2

RESET

1 3

2

3

4

5

4

● [Operation Procedure] 1. Volume Knob Power ON/OFF : Each time this switch is depressed, power ON and OFF are repeated.

Volume Control (VOL) : Volume Control Knob By turning this knob clockwise, the sound volume is increased, and by turning it counterclockwise, the sound volume is reduced.

L/R Balance (BAL) : L/R Volume Balance Control Knob By pulling and turning this knob clockwise, the sound volume balance is controlled to the right side (R), and by turning it counterclockwise, the sound volume balance is controlled to the left side (L).

2. Tone Control Knob Tone Quality Adjustment : By turning this knob clockwise and counterclockwise, the low-pitched tone and high-pitched tone are emphasized respectively.

3. Tuning Button Manual Tuning : When the tuning button is depressed for less than 0.5 second, the manual tuning mode is selected: one-step up & down is carried out at FM 100 KHz (0.1 MHz) and AM 9 KHz.

42

6

BND

5

6

OPERATOR'S AREA

SEEK : When this button is depressed continuously for 0.5 second or more, the SEEK mode is selected: the system automatically searches radio waves, tuning in on the radio.

4. Preset Button (1 to 6) Preset memory call : By pushing and releasing this button in less than 2 seconds, recall mode is selected, and the frequency stored in memory in advance is selected.

Preset memory write : When this button is depressed continuously, the guide tone sounds in 2 seconds, and the frequency being received is written (stored) completely.

5. Traffic Information (HIGHWAY) Traffic information access : Each time this button is depressed, traffic information ON/OFF is repeated.

When this button is depressed during radio reception, the system enters the traffic information receiving condition, and the display is switched to "AM1620", the traffic information mark ( ) lighting up.

When the power is turned OFF during traffic information reception, or when the power is turned ON again with the starter switch "OFF", or when the starter switch is turned ON, the receiving frequency returns to the frequency before traffic information reception.

6. Band Selector Button (BND) Band selection : Each time when this button is depressed, the four receiving bands are changed over in the order as shown.

FM

AS FM

AM

AS AM

For each band specification, refer to the table.

FM

AS FM

Manual tuning

○

○

○

○

SEEK

○

○

○

○

○

○

○

○

○

○

○

○

×

○

×

○

Preset (1 to 6) Preset scan Automatic storing

43

AM AS AM

OPERATOR'S AREA

7. PS/AS Button PS (Preset Scanning) : The preset memory stations 1 to 6 are received in sequence for 5 seconds each.

By pressing this button once again during preset scanning (PS), PS is reset, and the radio continues to receive the station at that time. − A weak signal station is skipped. − During PS, the channel display flickers. − The present band is scanned. (No other bands are scanned.) − In the case of scanning from the preset memory station, scanning starts from the next station, and in the case of scanning from other stations, scanning starts from "ch1". − Each time the preset memory station changes, the guide tone sounds.

AS (Auto Store) : The six stronger wave stations are stored sequentially from a lower frequency radio station.

At this time : − In the case of 6 or less stations, the stations are stored from the lower order memory. − When one station has been searched, "AS" is reset. − When the Auto Store is performed in the FM (or AM) band, the receiving band is switched to the ASFM (or ASAM) band, and a station is to be stored automatically.

(The station being preset is stored to the new station.)

8. DISPLAY Button Display Switching (DISP) : Each time this button is depressed, the LCD display changes in the following sequence.

Present time

Alarm time

At this time, press this button : − During frequency display : 5 seconds − During alarm display : 15 seconds If no button is depressed, the LCD display unit returns to the present time display mode.

During alarm time display, the alarm mark ( ) flickers.

The display changes when the button is released.

44

Frequency (When the radio is turned ON)

OPERATOR'S AREA

Clock & alarm time setting (hour & minute) : By pressing the tuning button while pressing the DISPLAY button during clock display (or alarm time display), set the time.

The "hour" and "minute" can be set with the DISP button + " " button and DISP button + " " button respectively.

Clock time setting (Reset to "00") : Press 3 (preset) buttons while pressing the DISPLAY button during clock display to set the time.

Omit 30 minutes or less, and reckon 30 minutes and over as a unit to step up the time by one digit, then start counting from 00 second.

Example : 10:17 → 10:00 3:32 → 4:00

9. Timer Timer ON/OFF and setting time changeover : By pressing the timer button, the timer mark ( ) is displayed on the LCD display unit, and the timer setting mode is selected.

Each time the timer button is depressed, the setting time changes as shown below, and after the designated time, the alarm keeps on sounding for 2 minutes.

0:00 (OFF)

− The timer can be selected from 7 times : when the timer is 0:00, it is OFF. 3:00

1:00

2:00

When the setting time changes, the setting is completed, and the display flickers. By pressing other buttons, the timer setting mode is reset. − When it is desired to stop the alarm sound halfway, press any button : the alarm will be stopped. − The alarm sound is produced from both speakers.

Residual time display of timer : − By pressing the timer button when the timer is ON, the residual time is displayed. − By pressing other buttons, it is released.

45

0:30 1:30

0:15

OPERATOR'S AREA

10. Alarm Button Alarm (or Wake-up) ON/OFF : This button selects whether the Alarm/Wake-up function is actuated on the designated time.

Each time this button is depressed, "ON" and "OFF" are changed over.

When the mark ( ) is lighting up on the LCD display unit, the Alarm/Wake-up is "ON", and when it is going out, the Alarm/Wake-up is "OFF".

During alarm "ON", the Alarm or Wake-up preset function is performed when the designated time is reached.

Alarm/Wake-up Switching : By pressing the alarm button during alarm time display, the Alarm and Wake-up are changed over alternately.

In the Alarm mode, the "ch" display unit changes to [ ], and in the Wake-up mode, it changes to [ ].

Alarm Function - "ch" Display Unit [ ]: When the designated time (alarm time) is reached, the alarm continuously sounds for 2 minutes.

Wake-up Function - "ch" Display Unit [ ]: When the designated time (alarm time) is reached, the radio wakes up for sounding and stops sounding in one hour.

Where no station can be received (no broadcast is available) at the preset frequency with Wake-up "ON", the alarm sounds for 2 minutes.

Both Alarm and Wake-up functions are not turned OFF just by stopping the alarm. [The ( ) mark in the LCD display unit remains lit.]

The operation is carried out every day on the same time.

However, the Wake-up function is switched to the alarm mode once it is actuated.

Guide Tone : For one button whose function changes according to the button depressing time, the guide tone sounds when it is switched.

46

OPERATOR'S AREA

October, 2005~

Radio 10

LCD Display Unit

9

8

7

5

4

● [Operation Method] 1. Volume Knob Turning Power ON/OFF : Push this ＳＷ to turn the power on or off.

The SW alternately turns the power on or off every time you push the SW. Sound volume adjustment (VOL) : Use this adjustment knob to adjust the sound volume.

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

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

Sound balance adjustment (BAL) : Use this knob to adjust the blance between the left and right speakers.

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

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

Sleep timer Push this switch to turn on the power when the starter switch is turned off.

The unit continues to operate for one hour and then automatically turns it off. At this time, "Sleep" will be shown on the display panel.

If this switch is pushed again, this functinon is cancelled and the power is off.

47

2

6

1

3

OPERATOR'S AREA

2. Sound Tone Adjustment Use this knob to adjust bass / treble to the desired level.

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

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

3. Tuning Button Manual tuning : Push the tuning button for less 0.5 sec. to increase the frequency or to decrease the frequency.

SEEK : Pushing the button for 0.5 sec. or longer places the tuning condition in SEEK. The unit will seek radio stations automatically.

4. Preset Button (1 to 6) Preset memory recall : when this button is pushed for less than 2 seconds, the preset station stored before will be played.

Preset memory store : When this button is pushed for more than 2 seconds, the radio will generate a guide tone and will complete the frequency store currently received.

5. Traffic Report (HIGH WAY) Traffic report recall : Every time this bottun is pushed, the traffic report turns on or off alternately.

When the switch is pused while the radio is turned on, it turns to the traffic report receiving status and AM1620 is shown on the LCD display. At the same time the traffic report mark ( ) is lit.

When receiving the traffic report, if the power is turned off or the starter switch is turned off and again the power turns on or the starter switch turns on agaain, it returns to the frequency before receiving the traffic report.

When this button is pushed for less than 2 seconds, the frequency currently preset is recalled.

When this button is pused for 2 seconds or longer, the other frequency preset is recalled.

The frequency used for the traffic report is 1,620 kHz and 1,629 kHz. Initially 1,620 kHz is preset.

48

OPERATOR'S AREA

6. Band Switcing Button (AM/FM) Band switching : Every time this button is pushed, the radio band changes in order as follows.

- Push for less than 2 seconds AM1 FM1 AM2 FM2 - Push for 2 seconds or longer AM AM1 AM2 FM FM1 FM2

7. PS/AS Button PS (Preset Scanning) : When this button is pushed for less than 2 seconds, the mode will shift to the PS mode and the preset stations will be played sequentially for 5 sec.

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

Every time the station is shifted, a guide tone will be generated.

If the radio connot receive any stations in 2 rounds the preset stations will be automatically cancelled.

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

The channel indication flashes on and off during preset mode.

AS (Auto Store) : Six stations that have the strongest wave will be stored in frequency order from lower band.

In this case : − If 6 stations are not stored fully, the stations are stored from lower band in order. − This function is cancelled if you search one station. − As (Auto store) will work on the currently-selected band.

49

OPERATOR'S AREA

8. DISPLAY Button Display change (DISP) : Every time you push this button, the LED indication is changed in order as illusrated below.

Clock time and alarm setting (Hour / Min.) : During the current time is shown on the LCD display, push the display button for 2 seconds or more. Time indication on the LCD flanshes on and off and the mode is shifted to the current time setting mode.

During the alarm time is shown on the LCD display, push the display button for 2 seconds or more, The mode is shifted to the alarm time setting mode.

Push Push

button to adjust "hour". button to adjust "minute".

Push the button again to cancel this function.

This function is cancelled automatically if the button is not used for more than 15 seconds.

When or button is being pushed, the time indication does not flash on and off.

The colon on the LCD display in the current time setting mode and mark in the alarm time setting mode do not flash on and off.

Clock time adjustment (On hour) : When button is pushed in the clock time adjustment mode, any minutes below 30 minutes are rounded down and any minutes over 30 minutes are rounded up. One houre will be added to the hour value. Then the time count starts from 00 second.

When button is pushed, on hour adjustment is done.

Example : 10:17 → 10:00 3:32 → 4:00

50

OPERATOR'S AREA

9. Timer Switching timer ON/OFF and timer setting : When the timer button is pushed, the timer mark will be lit and the mode will shift to the timer setting mode.

In the timer set mode, every time you push the button, indications will be changed in the following order.

After setting the timer, alarm will sound for 3 minutes. − The timer turns off when the indication becomes 0:00. The timer mark ( ) is on during the timer works. − When the button is pushed for less 0.5 second. − When the button is pushed for 0.5 second or longer in the timer set mode, the timer setting time increases in 5-minute steps.

Setting time is changed, the time setting is completed. The indication on the LCD flashes on and off. The timer setting mode is cancelled when other button is pushed. − Push any button to stop alarm sound. − Alarm sound comes out from both speakers.

Timer residual time indication : The timer button is pushed while the timer is on, the residual time will be shown on the LCD display.

This function is cancelled when the other button is pushed.

10. Alarm Button Turning alarm ON/OFF : This is a selection button to work the alarm at the designated time.

Every time you push this button, alarm will be switched ON or OFF. When mark is displayed on the LCD display panel, alarm is ON. When no mark is displayed on the LCD display panel, alarm is OFF. Alarm works at the designated timer when alarm is ON. Guide Tone : A guide tone will be generated when functions are changed on the push time of the button.

51

OPERATOR'S AREA

Air Conditioner (option) Ventilation name and location DEF

DEF

DEF

FACE

FACE

FOOT FACE

Switches 4

5

3

A/C

OFF

HI

LO

2

1

1. Air Flow Control Switch Air flow control switch is used to control air flow supplied by blower for heating or cooling in four stages. It is also used as a main air conditioner switch. ・ Press the switch "LO", " flow.

", "

" or "HI" to control air

・ Select "OFF" to stop the fan and also air conditioner system.

2. Temperature Control Switch Temperature control switch is used to control the air temperature in the cab.

Press switch for higher temperature and press for lower temperature. ・ More green lights when the lower air temperature. ・ More red lights when the higher air temperature.

52

switch

OFF

LO

HI

OPERATOR'S AREA

3. Air Intake Control Switch Air intake control switch is used to select intake air, either outside air or recirculated air. ・ Press ( ) switch to allow filtered fresh air from outside the machine and pressurize the cab. ・ Press ( ) switch to recirculate and filter air inside the cab. The cab is heated or cooled more effectively with this mode.

4. Air Conditioner On-Off Switch Air conditioner on-off switch is used to turn on and off the air conditioner for cooling and dehumidifying function. ・ With the switch pressed, the air conditioner turns on. ・ Pressing the switch again will turn the air conditioner off.

5. Ventilation Mode Selecting Switches These switches are mode for selecting the ventilation mode.

Five selection mode are prepared such as FACE, FACE / FOOT, FOOT, FOOT / DEF, DEF. When pushing one of the ventilation selecting switches, a green indicator lamp lights and the ventilation location is shown on the switch.

Operation Cooling

・ For maximum cooling, open the vents FACE and close other vents. ・ If the air in the cab is very hot, ventilate the cab by opening the door and window before cooling. ・ In summer, the ideal air temperature is about 5 ° C (9 ° F) lower than the outside temperature.

53

Ａ／Ｃ

OPERATOR'S AREA

Dehumidifying ・ The air conditioner dries air regardless of the air temperature controlled by the temperature control switch. In very humid weather, dehumidifying can make more comfortable environment for the operator. ・ If the windows fog up in humid weather, push the ventilation selecting switch DEF or FOOT / DEF, then run the air conditioner for a short time.

Heating ・ Heating is not very effective until the engine has been fully warmed up. ・ For maximum heating, push the ventilation selecting switch FOOT.

CAUTION In dry environment cigarette smoke may irritate eyes.

Ventilate or use "

" position to take fresh air periodically.

NOTE: ・ When heating or cooling the cab for a long period, occasionally take fresh air in by setting air intake control switch in the position. ・ In seasons when the air conditioner is not used, run it for a few minutes two or three times a month in order to maintain an oil film on the compressor parts. At this time, also check that the refrigerant is not leaking.

Refer to "Check Air Conditioner Refrigerant" page 120.

54

OPERATOR'S AREA

Vibration Damper (option) Roading a wheel loader over rough terrain will cause fore and aft pitching motion to the machine. The pitching motion is reduced when the vibration damper is installed.

Operation and Function 1. Before start the travelling machine, turn the vibration damper main switch (1) ON.

２０

３０

ＴＥＭＰ Ｈ

４０

１０

５０

０

Ｃ

ＦＵＥＬ Ｆ

Ｅ

Ｐ

３ １ 2. The vibration damper can be operated by the vibration damper switch (2) on the hydraulic control lever grip.

ON (Push the switch)

: The vibration damper starts to operate and the pilot lamp (3) on the operation panel comes to ON.

OFF (Push the switch again) : The vibration damper stops operation (The machine comes to the standard status) and the pilot lamp (3) on the operation panel comes to OFF. NOTE: When the bucket is fully tilted the vibration damper does not work. Dump the bucket a bit when travelling.

55

２

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 level surface. Follow all the safety cautions mentioned in the safety section of this manual when checking the machine.

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

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

What to Look for

□Bucket / Attachment

Damage, missing bolts, leaks, and excessive wear

□Bucket Control Linkage

Damage, missing bolts, excessive wear, and looseness

□Lights

Broken bulbs, wires or lenses

□Radiator Fins

Trash and dirt build-up (between Fan and Radiator)

□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 and oil level

□Final Drive (front and rear)

Leaks

□Covers and Guards

Damage or missing

□Transmission

Leaks

□Instrument Panel

Broken gauges or indicator lights

□Brake Lines

Damage and leaks

□Engine Compartment

Leaks, debris build-up and flammable materials left

Date :

Model-S/N :

Hours :

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

56

Inspector :

OPERATION

B. Check Engine Oil Level CAUTION Hot oil and engine components may cause burns.

Avoid contact with hot oil or engine components.

1. Check the oil level with the dipstick.

2. Keep the oil level between the two round marks on the dipstick.

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

Refer to "Recommended Lubricants" page 129 for the suitable viscosity of the oil according to the ambient temperature.

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

Refer to "Replace Engine Oil and Oil Filter Cartridge" page 108 for the procedure.

NOTE: Wait about twenty 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 engine oil level may damage engine.

Do not operate engine with oil level below low mark or above high mark.

Add or drain oil to keep proper level.

57

ＨＬ

OPERATION

C. Check Brake Oil Level WARNING Lack of brake oil can cause loss of braking which could result in death or serious injury.

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

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

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

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

Refer to "Recommended Lubricants" page 129 for the suitable oil.

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

Use only brake oil as recommended in section"Recommended Lubricants" page 129.

D. Check Hydraulic Oil Level 1. Lower the attachment to the ground.

2. Stop the engine.

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

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

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

Refer to "Recommended Lubricants" page 129 for the suitable viscosity of the oil according to the ambient temperature.

58

OPERATION

CAUTION Pressurized hydraulic tank is used for this machine.

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

Vent all pressure by slowly turning cap 1/3 turn counterclockwise.

E. Check Engine Coolant Level 1. Check the engine coolant level in the radiator subtank.

2. It is normal if the coolant level is between the "LOW" and "FULL" mark.

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

Refer to "Coolant Specification" page 130 for the correct mixture.

4. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 123.

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

F. Drain Water from Fuel Filter 1. Loosen the drain plug to drain water.

2. Tighten both plugs.

G. Check Wiring Harnesses CAUTION Short circuit of wiring harnesses may cause fire. ・ Keep the connection of wiring harnesses clean and tight. ・ Repair the damaged wiring harness or exchange it for new one.

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

59

OPERATION

H. Articulation Stopper Make sure the articulation stopper is secured in the "STORED" position, as shown.

Articulation stopper "STORED"

I . ROPS (Roll Over Protective Structure)(option) WARNING Operating without ROPS could result in death or serious injury.

Always keep ROPS in place while operating machine.

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

Be sure to observe the following. ・Whenever seated, fasten the seat belt. ・Do not modify ROPS, such as drilling or welding. ・Do not use ROPS deformed. ・If any damage or loose bolts are found, do not operate until repaired. ・Never repair or modify ROPS without manufacturer' approval and instructions.

Check the condition of the ROPS and its mounting bolts.

J. Rear View Mirrors 1. Adjust and check the condition of the rear view mirrors.

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

K. Control Lever Make sure the Loading Control Lever is in the "Hold" position.

60

OPERATION

L. Parking Brake Lever Make sure the Parking Brake Lever is fully applied (pulled up).

M. Transmission Control Lever Make sure the Transmission Control Lever is in neutral position.

N. Tire Air Pressure Tire performance and its life depends greatly on the tire air pressure. ・ Low air pressure causes excessive deflection, heat, and accelerated wear. ・ High air pressure causes 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 could explode causing serious injury or death.

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

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

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

When inflating tires; ・ Make sure wheel parts are correctly installed. ・ Use self-attaching air chuck with remote shutoff valve. ・ Stand behind tread of tire and keep all persons away from side of tire. ・ Do not inflate tire more than recommended pressure. ・ Use safety cage if available.

61

Low pressure

OK

High pressure

OPERATION

2. Adjust air pressure according to the recommended pressures in the next page.

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.

SIZE

PATTERN

AIR PRESSURE kPa

16.9 − 24 − 10PR

L2

216〜235

15.5 − 25 − 8PR

L2

235〜255

12.0 − 24 − 8PR

L2

324〜343

Same pressure for all four tires.

For radial tires or tires with other patterns consult the tire manufacturer.

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

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

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

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

Tread Side walls

Breakers

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

62

Carcass

Beads

OPERATION

Contact your nearest Kawasaki dealer or local tire dealer for tire replacement.

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

2. The horn should sound loudly.

63

OPERATION

Starting the Engine WARNING If engine starts in gear due to bypassing neutral start device circuit from ground could result in death or serious injury. ・ Do not start engine by shorting across starter terminals. ・ Do not start engine while standing on ground.

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

Normal Start (Above 0 ° C (32 ° F))

1. Do not depress the accelerator pedal.

2. Turn the starter switch key to "START" position to start the engine.

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

ＰＲＥＨＥＡＴ

ＯＦＦ ＯＮ ＳＴＡＲＴ

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

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

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

NOTE

・ Do not turn the starter switch to "START" 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 131.

IMPORTANT Low engine oil pressure may cause severe engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

64

ＰＲＥＨＥＡＴ ＯＦＦ ＯＮ

ＳＴＡＲＴ

OPERATION

Cold Start (Below 0 ° C (32 ° F))

1. Do not depress the accelerator pedal.

2. Turn the starter switch key to "PREHEAT" position and hold it for about 20 seconds to warm intake air. ＰＲＥＨＥＡＴ ＯＦＦ ＯＮ

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

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

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

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

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

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

NOTE

・ Do not turn the starter switch to "START" 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 131.

IMPORTANT Low engine oil pressure may cause severe engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

65

ＳＴＡＲＴ

OPERATION

Check after Starting the Engine ・ 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.

A. Check Transmission Oil Level WARNING Accidenfal movement of machine could result in death or serious injury.

Before checking oil level: ・ 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 START" or "DO NOT OPERATE" tag on steering wheel.

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

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

Refer to "Safety Device" page 22.

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

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

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

6. If the oil level is lower than specified, add recommended oil while the engine is at idle. (Refer to "Recommended Lubricants" page 129.) Do not overfill.

7. Return the articulation stopper to the "STORED" position.

66

In hot

In cold

Specified oil level

OPERATION

IMPORTANT Never mix CD engine oil and A.T.F. Dexron .

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

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

B. Monitor Panel Operation 1. Check the monitor lamps by turning the bulb check switch ON. 2. If any monitor lamps do not light up, replace the bulb.

Refer to "Indicators and Switches" page 31.

C. Check Warning Lamp 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 and Switches" page 31 for the meaning of each lamp and the correction.

D. Check Fuel Level 1. Check the fuel level with the fuel gauge on the instrument panel 2. Add fuel to fill the tank if the gauge indicates the red zone.

Refer to "Recommended Lubricants" page 129 for the proper fuel.

E. Check Service Brake Operation 1. Turn "OFF" the clutch cut-off (Declutch) switch.

2. Firmly depress the right hand brake pedal.

3. Disengage the parking brake.

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

6. The machine should not move.

67

ＦＵＥＬ

Ｅ

Ｆ

OPERATION

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

Do not operate until problem has been corrected.

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

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

3. Stop the machine with the service brake.

4. Fully pull up the parking brake lever.

5. Release the service brakes.

6. The machine should not move.

IMPORTANT If machine moves when parking brake lever is fully pulled up, there is some problem with parking brake.

Do not operate until the problem has been corrected.

G. 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.

H. Check Back-up Alarm Operation 1. Apply the service brakes.

2. Release the parking brake.

3. Move the shift lever to "REVERSE".

68

OPERATION

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

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

I. Check Exhaust Gas 1. Check the color of the exhaust gas.

2. 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.)

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

J. General Inspection With the parking brake applied, transmission shift lever in NEUTRAL, loading lever in NEUTRAL, and the attachment on the ground, walk around the machine and look for any problems or sings of failure.

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

69

OPERATION

Operating the Machine WARNING Braking and steering force are reduced when engine is stopped.

Do not stop engine while driving machine.

If engine stops while driving, parking brake can be used together with service brake to stop immediately.

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

Be sure area is clear of personnel and obstructions.

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

2. Depress the brake pedal. approx. 40cm

3. Release the parking brake.

4. Turn the transmission shift lever to 1st or 2nd speed and then shift to the desired direction.

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

6. Shift up as ground speed increases.

70

OPERATION

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.

Starting the Machine on a Grade 1. Turn "OFF" the transmission cut-off (Declutch) switch.

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

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

Speed and Direction Change 1. Select the proper gear speed by rotating the transmission shift lever.

1st : Excavating or scooping Running downhill on a steep slope 2nd : Scooping or loading Running downhill on a slope 3rd : Carrying or roading

71

OPERATION

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

IMPORTANT Changing direction at high speed may cause serious transmission damage.

Never change direction at high speed.

When changing direction, slow down machine first.

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

Use proper gear for each job.

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

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

2. Drain and refill if water is found.

Refer to "Check Differential Gear Oil" page 110 or consult the nearest Kawasaki dealer for futher assistance.

72

Axle housing

A

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

OPERATION

Parking 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 in front of and behind wheels and dig attachment into ground.

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

Do not apply parking brake while machine is moving.

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

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

4. Apply the parking brake.

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

73

OPERATION

Stopping the Engine WARNING Braking and steering force are reduced when engine is stopped.

Do not stop engine while driving machine.

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

2. Turn the starter switch to "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, injury resulting in death or serious injury.

Prevent unauthorized operation.

When leaving machine for extended period of time, lock cab doors or lock vandal cover over dashboard (if equipped).

74

OPERATION

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.

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.

1. Move the machine forward to the material.

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

3. Lower the bucket parallel to the ground.

4. Drive the bucket straight into the material.

Use approximately 1/2-full engine speed.

75

OPERATION

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

Reduce wheel slippage by slightly reducing engine speed.

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

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

8. When the loading control lever is released from the "Rool Back" position, 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.

Excavating 1. Move the machine forward to the material.

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

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

76

OPERATION

4. Run the machine slowly in 1st speed.

Increase engine speed as the bucket digs deeper.

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.

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

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

Keep bucket bottom parallel to ground.

Ground Leveling 1. Keep the loaded bucket slightly above the gound.

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

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

77

OPERATION

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 on linkages.

Be sure to run machine backward when leveling ground.

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

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

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

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

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.

Keep boom low for best stability especially on slopes.

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

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

78

OPERATION

Refer to "Loading" or "Excavating" page 75~77 for the loading procedure.

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 selector switch in the "ON" position if working on a level site.

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

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

If the boom is equipped with the kickout device (option), the boom will automatically stop and the loading control lever will return to the "Hold" position when the bucket reaches the preset height. Holding the loading control lever in the "Raise" position will continue to raise the boom if required.

Refer to "Boom Kickout Adjustment" page 82 for adjustment of the present height.

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

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

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

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

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

79

OPERATION

7. For a truck loading you can choose one of the following methods of operation depending on the site condition.

Typical Truck Loading Methods I Cycle Operation This method is recommended where the working area is limited.

V or L Cycle Operation This is the most efficient operation for the shortest cycle time.

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

80

(L-cycle)

( V-cycle)

SPECIAL PROCEDURES

SPECIAL PROCEDURES Adjustments Bucket / Attachment Positioner Adjustment WARNING Accidental movement of machine could result in death or serious injury.

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

WARNING Standing on machine could cause accidents resulting in death or serious injury.

Use safe sturdy platform to reach bucket positioner adjustment.

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

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

3. Loosen the bolts (2) with a 19 mm wrench.

4. Move the bracket (1) forward to increase, or rearward to decrease the attachment preset angle.

5. Tighten the bolts (2).

１ 6. To test the adjustment; start the engine, raise the boom approximately half way, dump the attachment and move the loading control lever to Rollback 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.

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

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

81

３ ２

１

４

２

４

３

SPECIAL PROCEDURES

Boom Kickout (option) Adjustment DANGER Sudden or accidental movement of boom will result in death or serious injury.

Before walking or working under raised boom: ・ Securely block or brace boom. ・ Remove key and tag "Do Not Operate."

WARNING Standing on machine could 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.

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

5. Loosen the two bolts (1) using a 13 mm wrench. Align the plate (2) with the switch (3).

３ ２ １

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

7. Tighten the bolts (1).

8. Remove the support from the boom and linkage.

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

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

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

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

82

３

２ 5 ± 2mm

Adjustable

SPECIAL PROCEDURES

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

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

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 travelling for one hour, stop for 30 minutes 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 travelling. ・ Whenever possible use a lead and / or follow vehicle and all available warning devices even if not required by regulations.

83

SPECIAL PROCEDURES

Booster Batteries / Jumper Cables WARNING 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.

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

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

Keep the battery electrolyte level in the proper level.

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

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

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

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

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

84

SPECIAL PROCEDURES

・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 the battery box covers.

3. Move back the protective rubber cover (red) from the positive post (+) of the discharged battery. Connect one end of the red jumper cable to the positive post. −

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

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

6. The final connection should be the remaining end of the black jumper cable to the engine block or frame away from the battery compartment on the machine being jump started.

7. Start the booster machine's engine or turn the auxillary power source on.

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

9. Start the machine being boosted as described on "Starting the Engine" page 64.

10. As soon as the engine starts, disconnect the jumper cables in reverse order (Step 6, Step 5, Step 4, Step 3).

11. Replace the protective covers over the battery terminals and close the battery box covers.

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

85

＋

＋

−

Booster Batteries

−

＋

＋

−

Batteries being boosted

Engine block of machine being jump started

SPECIAL PROCEDURES

Towing WARNING Improper towing could result in death or serious injury.

Follow safety warnings found under "Safe Operation -SPECIAL OPERATING CONDITIONS" page 8.

・ This machine must not be towed except in emergencies. ・ Even in emergencies, the machine can be towed only a short distance to a convenient location for repair. ・ Do not allow operator on the machine being towed, unless the operator can control the steering and braking. ・ Inspect the cable for damage. Never use a damaged cable. ・ Connect the cable only to the hitch provided on the machine frame. ・ Keep personnel away from between the towing vehicle and towed machine. ・ Use flashing lights or other warning signals when towing.

When Engine Runs 1. Keep the engine running so that the steering and brakes work.

2. Keep an operator in the operator's seat.

3. Tow the machine at low speed, no faster than 2 km/h, with a gradual and smooth movement.

86

Cable hich point

SPECIAL PROCEDURES

When Engine Does not Run 1. Place wheel chocks in front of and behind the wheels.

2. Disconnect the front and rear drive shafts.

WARNING When drive shafts are removed, machine has no parking brake.

Machine could roll and cause serious injury or death.

Block wheels securely so that machine cannot move.

3. Disconnect the steering cylinder and steering linkage.

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

5. Remove the wheel chocks.

6. Tow the machine at low speed, no faster than 2 km/h, with a gradual and smooth movement.

7. Contact your nearest Kawasaki dealer for further assistance.

87

SPECIAL PROCEDURES

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

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

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

2. Properly apply the brakes of the trailer and insert blocks in front of and behind the tires to ensure that the trailer does not move.

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

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

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

5. Lower the bucket and lock the loading control lever. (Page 22) Apply the parking brake and set the articulation stopper in the "LOCKED" position. (Page 22) I

IMPORTANT

Machine may be equipped with turbocharger or altitude compensator.

Tape over exhaust stack outlet to prevent turbo "Windmilling" damage.

6. Place blocks (1) underneath the front and rear wheels to prevent the machine from moving.

88

SPECIAL PROCEDURES

7. Fasten the machine to the trailer with chains or cables by using lower part of the rear chassis (2).

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

Cables or Chains

Chocks1

2

Front

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

89

Rear

SPECIAL PROCEDURES

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

2. 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.

3. Disconnect the cables from the batteries or if freezing temperatures are expected remove the batteries from the machine and store separately.

4. When there is a possibility of the temperature going below 0° C (32° F), check and adjust the antifreeze / water mixture.

Refer to "Coolant Specification" page 130 for the mixing ratio.

5. When replacing oil for the engine and transmission, add 10% anticorrosive oil to new oil.

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

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

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

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

1. Check the following points.

Refer to "Check before Operation" page 56 and "Check after Starting the Engine" page 66. ・Coolant level ・Engine oil level ・Hydraulic oil level ・Brake oil level ・Transmission oil level

90

SPECIAL PROCEDURES

・Brake function ・Steering function 2. Operate the machine as follows. ・Run just the engine for five to ten minutes at low idle. ・Move all cylinders of the hydraulic system full stroke 10 to 15 times. ・Run the machine about 10 m in every gear and direction. ・Move the steering full stroke each way about ten times.

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

2. Remove the covers and start the engine.

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

Refer to "Replace Engine Oil and Oil Filter Cartridge" page 108 and "Replace Transmission Oil" page 116.

4. Start the engine and check for any abnormalities.

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

91

EVERY 50Hrs MAINTENANCE

MAINTENANCE Before performing maintenance or repairs, read, understand and follow "Safe Maintenance" section page 10.

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

For quick reference, record each Serial Number in the blanks below.

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

1. Machine Serial Number:

SELIAL No. HEAVY INDUSTORIES, LTD. MADE IN JAPAN

2. Engine Serial Number (Stamped on lower edge of the block):

3. Transmission / Torque Converter Serial Number:

Model

MODEL SERIAL DESIGN EXEDY Corporation

Serial Number Design Number

92

Serial Number Location

4. ROPS/EROPS Serial Number: SERIAL No.

Model Number Serial Number

Rops serial No.

Engine serial No.

Machine serial No.

Transmission serial No.

93

EVERY 50Hrs MAINTENANCE

Inspection and Maintenance Table Section

Items for check

Operating hours Daily

500

When 1000 2000 Required

Page

○

57

Check coolant level

○

59

Check air filter (warning lamp)

○

67

Check exhaust gas color

○

69

Drain water from fuel filter

○

59

Check fuel level

○

67 106

○

Replace oil

○

108

Replace oil filter cartridge

○

108

Check air intake hose

○

109

Replace fuel filter cartridge

113

○

Clean fuel tank

○

117

Clean feed pump strainer

○

119

Check fan belt, tensioner pulley and fan hub

○

121

Check valve lash clearance

○

126

Replace coolant

○

123

Clean air cleaner element

○

97

Clean radiator fins

○

98

Replace air cleaner element

After six cleanings or once a year

Check oil level Transmission Replace oil filter cartridge & Torque Replace oil Converter Replace breather

97

115

○ ○

116

○

117 61・62

○

Grease axle support

○

66

○

Check tire air pressure and damage

Axle system

250

Check oil level

Drain water from fuel tank

Engine

50

105

○

Check differential gear oil

○

110

Grease propeller shaft

○

107・108

Check tightness of wheel bolts

○

110

Replace differential gear oil

○

94

125

Inspection and Maintenance Table

Section

Items for check

Steering

Check steering wheel operation

system

Grease steering cylinder pins

Brake system

Operating hours Daily

Chassis

500

When 1000 2000 Required

Page 68 104

○

Check oil level

○

58

Check service brake operation

○

67

Check parking brake operation

○

68

Adjust parking brake lining

119

○

Overhaul brake master cylinder

○

126

Check service brake disk wear

○

126 58

○

Grease pins system

250

○

Check hydraulic oil level Loading

50

102-104

○

Replace return filter

118

○

Replace hydraulic oil

122

○

Replace bucket teeth (option)

○

96

Replace cutting edge (option)

○

97

Check rear view mirrors

○

60

Check ROPS and mounting bolts

○

60

Grease center pins

104

○

Check vibration damper accumulator

128

○

Check seat belt

○

97

Check window washer fluid

○

99

Check monitor panel operation

○

67

Check horn operation

○

63

Electrical

Check back-up alarm operation

○

68

system

Check wiring harnesses

○

59

Check battery electrolyte level

105

○

Check fuses

Air Conditioner (option)

○

Check compressor belt

○

111

Clean filter

○

111

Check refrigerant

120

○

Replace filter element

127

○

Clean condenser Replace receiver dryer Others

99

Walk around inspection

○

95

○

100

○ (6000)

127 56

WHEN REQUIRED 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 10 before performing any inspection or maintenance procedures.

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

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

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

3. Stop the engine.

4. Set the bucket so that the bottom is parallel to the ground.

5. Remove the bolts (1) and nuts (2), then remove the bucket teeth (3).

１，２

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

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

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.

8. Tighten the nuts to 451~539N-m.

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

96

３

Block

WHEN REQUIRED MAINTENANCE

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

B. Replace Cutting Edge (option) 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.

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

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

If both sides are worn, install a new cutting edge.

6. Install all bolts and tighten them to 451~539N-m.

7. Retighten them after a few hours operation.

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

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

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

２

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

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

2. Remove the cover (2) by flipping the clips (1).

97

１

WHEN REQUIRED MAINTENANCE

3. Remove the element.

4. If the element is clogged by dirt or dust, spray dry compressed air (196kPa) along the inside of the element up and down to blow off dust.

IMPORTANT Improper procedure of cleaning air cleaner element may cause severe engine damage. ・ Do not clean or replace air cleaner while engine is running. ・ Clean or replace element only when indicator light comes on.

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. If there is any damage to the seal, replace the element.

8. Reinstall the element, wing nut (1) and cover (2).

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

10. After six cleanings or once a year replace the element.

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

2. Blow off mud, dirt, or clogging debris from the radiator fins with compressed air.

3. Use a pressure washer or steam cleaner to remove harder debris.

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

98

WHEN REQUIRED MAINTENANCE

5. Reverse the direction to flush all debris from the radiator fins.

6. Move the nozzle from side to side; not up and down to prevent fin damage.

7. If necessary, the grill may be removed for a more complete cleaning.

F. Check or Replace Fuses 1. Park the machine on level ground, apply the parking brake, and lower the attachment to the ground.

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

3. Open the cover on outside of the right hand console. If a cab is equipped, open a cover on the cab which is located under the right side window.

4. Check the fuses. Refer to the Fuse Chart shown on page 39. If any blown fuses are found, replace them with new ones.

5. Determine the cause of the blown fuses.

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

Never replace fuses with higher amperage rating.

G. Check Window Washer Fluid (option) 1. Park the machine on level ground, apply the parking brake, and lower the attachment to the ground.

2. Check the fluid level.

3. Replace the fluid if it is dirty.

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

99

WHEN REQUIRED MAINTENANCE

5. Use windshield washer solvent for both better cleaning and to prevent freezing.

Adjust the mixture according to the manufacturer's instructions.

H. Clean Air Conditioner Condenser (option) If mud, insects, or other debris are stuck to the air conditioner condenser, air flow through the condenser will be reduced causing decreased cooling ability.

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.

The protective cover may be removed for cleaning.

Reinstall the cover after cleaning.

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

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

100

Daily Inspection and Maintenance

Daily Inspection and Maintenance See "Check before Operation" page 56 and "Check after Starting the Engine" page 56.

101

EVERY 50Hrs 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 10 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".

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

2. Lubricate fittings on the following components. Wipe and clean all fittings before.

Refer to "Recommended Lubricants" page 129 for the correct grease. ・Bucket-Boom (two places)

・Bucket-Rod (one place)

102

EVERY 50Hrs MAINTENANCE

・Lever-Rod (one place)

・Lever-Boom (one place)

・Bucket Cylinder-lever (one place)

・Bucket Cylinder-Front Chassis (one place)

・Boom Cylinder-Boom (two places)

103

EVERY 50Hrs MAINTENANCE

・Boom Cylinder-Front Chassis (two places)

・Boom-Front Chassis (two places)

・Center Pin (upper)

・Center Pin (lower)

・Steering Cylinder (four places)

104

EVERY 50Hrs MAINTENANCE

・Axle support (two places)

B. 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. ・ 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.

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

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

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.

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

105

EVERY 50Hrs MAINTENANCE

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

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, this inspection and maintenance is not required.

Low

C. Drain Water and Sediment from Fuel Tank CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from 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.

2. Prepare a suitable container.

3. Open the drain cock or remove the plug on the bottom of the fuel tank.

4. Drain water and sediment along with fuel.

5. Close the drain cock or replace the plug.

6. Dispose of the drained fuel and water properly.

7. Add fuel.

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

106

OK

High

EVERY 250Hrs 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 10 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" inspection and maintenance.

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

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page 129 for the correct grease.

Use lithium base grease for universal joints. ・2nd Propeller Shaft (five places)

107

EVERY 250Hrs MAINTENANCE

・ 3rd Propeller Shaft (two places)

B. Replace Engine Oil and Oil Filter Cartridge CAUTION Hot oil and engine components may cause burns.

Avoid contact with hot oil or engine components.

1. Operate the engine to bring the engine coolant temperature about 40° C (100° F).

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

3. Remove the drain plug (1) from the bottom of the oil drain hose.

4. Drain oil, about 11 liters, into a suitable container.

5. Remove the oil filter and properly dispose of it.

6. Clean the oil filter head gasket surface.

7. Apply a light film of engine oil to the gasket surface of the filter.

8. Install and tighten the filter until the gasket contacts filter head surface. Then tighten it an additional two-thirds turn.

108

１

EVERY 250Hrs MAINTENANCE

9. Clean and install the oil drain plug (1) on the bottom of the oil drain hose and tighten to 80N-m torque.

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

Refer to "Recommended Lubricants" page 129 for the oil specifications and capacity.

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

12. Stop the engine. Wait approximately twenty minutes to let the oil drain back to the oil pan.

13. Check the oil level again.

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

15. Properly dispose of or recycle the waste oil.

CAUTION Used engine oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

C. Check Air Intake Hose 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.

2. Check the engine intake hose and hose bands for damage and tightness.

3. If damaged hose or loose hose bands are found, replace or retighten or contact your nearest Kawasaki dealer.

109

EVERY 250Hrs MAINTENANCE

D. Check Differential Gear Oil CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

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

2. Remove the oil level plug from the front axle housing, using a 12 mm hex 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 129.

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

5. Retighten the level plug.

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

E. Check Tightness of Wheel Bolts 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Check the wheel bolts are tightened to 892N-m.

3. Retighten if necessary.

110

EVERY 250Hrs MAINTENANCE

F. Check and Adjust Air Conditioner Belt (option) CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine side panel.

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

2. Open the engine side panel.

3. Visually inspect the compressor belt on both top and bottom sides for looseness and damage.

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

98N 8〜10mm

5. Apply pressure approximately 98N to the center of the belt between the pulleys.

Correctly adjusted belts will deflect about 10 mm.

6. If the belt is too loose or tight, loosen the lock bolt (1) and adjust the tension by turning the adjusting screw (2) under the tension pully.

G. Clean Air Conditioner Filter Element (option) Outer filter cleaning 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground.

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

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

Turn the rings counterclockwise and then remove the cover.

4. Remove the outer filter from the cab.

111

１ ２

EVERY 250Hrs MAINTENANCE

5. Remove dust with compressed air. below 196kPa.

Use air pressure

6. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days for dry in the shade.

7. After approximately twenty times of cleanings, replace the filter with new one.

Refer to "Replace Air Conditioner Filter Elements" page 127.

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.

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

Inner filter cleaning 1. The inner filters (2pcs) are located at the right behind the operator's seat.

Open the unit cover and remove the cover (1) using screw driver.

Loosen the screw (2) by fingers to remove the cover (3).

Remove the filters and clean them.

1 2

2 2. Remove dust with compressed air. below 196kPa.

Use air pressure

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

4. After approximately twenty times of cleanings, replace the filters with new ones.

Refer to "Replace Air Conditioner Filter Elements" page 127.

5. Install the filter elements, install the filter cover (3) and cover (1).

NOTE: It is recommended to have a second set of filters to use while another set is being dried.

112

3

EVERY 500Hrs 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 10 before performing any inspection or maintenance procedures.

Every 500 hours or 3 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", and "250 hours" inspection and maintenance.

A. Replace Fuel Filters 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 fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

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

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

3. Remove and properly dispose of the fuel filters.

4. Clean the filter head gasket surface.

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

6. Fill the filters with clean fuel.

7. Install each filter on the filter head.

Turn it until the gasket contacts the filter head surface.

113

EVERY 500Hrs MAINTENANCE

8. Tighten the filter an additional two-thirds turn after the gasket contacts the filter head surface.

9. Turn the knob (1) on the priming pump of the injection pump counterclockwise.

10. Loosen the bleeder screw (2) on the fuel filter head.

11. Pump the knob (1) up and down until fuel comes out of the bleeder port without air bubbles.

２

３ １

12. Tighten the bleeder screw (2).

13. Loosen the bleeder screw (3) on the injection pump.

14. Pump the knob (1) up and down until fuel comes out of the bleeder port without air bubbles.

15. Tighten the bleeder screw (3).

16. Push down and turn the priming pump knob (1) to lock.

17. Wipe off any spilt fuel.

18. Start the engine and check for leaks.

19. Properly dispose of the spilled fuel and oily rags.

NOTE: If the engine will not start, is difficult to start, or does not run smoothly, stop the engine and bleed it again (steps 9-15).

114

EVERY 500Hrs MAINTENANCE

B. Replace Transmission Oil Filter CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

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

2. Place a suitable container under the filter (about 4 liters).

3. Remove and properly dispose of the oil filter.

4. Clean the filter head gasket surface.

5. Apply a light film of clean engine oil to the filter O-ring.

6. Install the filter on the filter head. Tighten it fully by hand.

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

8. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 66.

9. Add the specified oil as necessary to bring the oil level to the "H" (high) mark on the dipstick.

Refer to "Recommended Lubricants" page 129 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.

115

(50C2-0434~)

EVERY 1000Hrs 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 10 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.

A. Replace Transmission Oil WARNING Accidental movement of machine cold 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 START" or "DO NOT OPERATE" tag on steering wheel.

CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

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

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

3. Remove the drain plug (1) on the transmission with a 17 mm wrench.

4. Drain oil into a suitable container (about 20 liters).

116

１

EVERY 1000Hrs MAINTENANCE

5. Loosen the four bolts (2).

6. Remove the bolts and flange together with the suction strainer.

7. Remove the suction strainer from the flange, brush off any debris and clean with solvent.

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

9. Tighten the four bolts (2).

10. Fill with the specified oil (about 20 liters).

Refer to "Recommended Lubricants" page 129.

11. Idle the engine and check for leaks.

12. Check the oil level.

Refer to "Check Transmission Oil Level" page 66.

13. Add the specified oil if necessary to maintain the proper oil level.

Refer to "Recommended Lubricants" page 129.

14. Properly dispose of or recycle the waste oil.

15. Unlock the articulation stopper and secure it in the "STORED" position.

B. Replace Transmission Breather CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

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

2. Replace with a new breather assembly.

117

２

EVERY 1000Hrs MAINTENANCE

C. Replace Hydraulic Oil Return Filter CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by slowly turning cap 1/3 turn counterclockwise.

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

2. Pull the knob (1) beside the oil inlet cap and turn the cap slowly counterclockwise to relieve the tank pressure.

3. Place a small drain pan (about 1 liter) under the filter.

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

5. Clean the filter head gasket surface.

6. Apply a light film of clean hydraulic oil to the new filter O-ring.

7. Install the filter on the filter head and tighten it fully by hand.

D. Clean Fuel Tank 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 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.

118

１

EVERY 1000Hrs MAINTENANCE

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

2. Open the drain cock (1) on the fuel tank or remove the plug.

3. Discharge fuel into a suitable container (about 120 liters when full).

4. Remove the nuts on the cover (2) to remove the cover. ２

5. Clean inside of the tank.

6. Install the cover with a new gasket. Tighten the nuts but do not overtighten.

１

7. Close the drain cock or replace and tighten the plug.

8. Fill the fuel tank.

9. Check for any leaks at the cover, drain cock, or plug.

E. Clean Feed Pump Strainer 1. Remove the screw on the inlet port of the feed pump.

2. The strainer is in the screw and is not removable.

3. Clean the strainer with solvent. screw.

If necessary, replace

Screw

4. Install it on the feed pump.

F. Adjust Parking Brake Lining 1. Park the machine in safe place on firm level ground.

Steer it fully to one side for easier access.

2. Fully release the parking brake lever.

3. Align the inspection hole (1) on the brake drum with the adjuster wheel by turning the hole 15°clockwise from the top.

4. Use chocks under the wheels.

119

15 °

１

EVERY 1000Hrs MAINTENANCE

5. Lower the attachment to the ground and stop the engine.

Adjusting wheel

6. Place a "DO NOT OPERATE" tag on the steering wheel.

7. Turn the adjuster wheel fully downward to close the clearance between the brake drum and the brake lining (shoe).

8. Return the adjuster wheel eight clicks upward. (Now the clearance is 0.23 mm) 9. Check the parking brake operation as described in page 68.

NOTE: If the parking brake will not adjust or if the parking brake drum is burned contact your Kawasaki dealer.

G. Check Air Conditioner Refrigerant (Option) 1. Apply the parking brake and lower the attachment to the ground.

2. Remove the cover.

3. Press the "HI" flow control switch to set maximum air flow.

4. Set the temperature control switch fully to the cool position and fully open the cab doors.

5. Slightly accelerate the engine to about the middle speed -1 range (compressor speed 1500~1800min .)

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

CAUTION Overfilled refrigerant may cause dangerous high pressure and poor cooling action; and low refrigerant level may cause compressor damage.

Always maintain refrigerant in normal level.

120

Screw driver

1

EVERY 1000Hrs MAINTENANCE

Amount of refrigerant

Appearance of the sight glass

Normal

Almost clear.

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

High

No bubble is seen.

Solutions

Contact your local Kawasaki dealer for inspection and recharging refrigerant.

Low

A flow of bubbles is visible.

H. Check Fan Belt, Tensioner Pulley and Fan Hub 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Open the engine side panel.

3. Remove the fan belt.

4. Visually inspect the fan belt for damage.

5. Check the tensioner pulley.

NOTE: The tensioner pulley should spin freely with no rough spots detected under hand pressure.

6. Check the fan hub.

NOTE: The fan hub should spin freely without excessive end play.

7. Install the drive belt.

121

EVERY 2000Hrs 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 10 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" inspection and maintenance.

A. Replace Hydraulic Oil CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by slowly turning cap 1/3 turn counterclockwise.

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

2. Move the loading control lever back and forth to relieve the pressure.

3. Pull the knob (1) beside the oil inlet cap (2) and turn the cap slowly 1/3 turn counterclockwise to relieve the tank pressure.

4. Remove the inlet cap.

CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

5. Place a suitable container (about 75 liters) under the drain plug.

122

２ １

EVERY 2000Hrs MAINTENANCE

6. Remove the drain plug (3) to drain oil.

7. Remove the nuts on the side cover (4) to remove the side cover.

４

8. Clean inside of the tank and the magnet plug.

9. Install new gasket, and cover, and tighten the nuts. Do not overtighten the nuts.

10. Install and tighten the drain plug.

11. Add the specified hydraulic oil.

Refer to "Recommended Lubricants" page 129.

12. Close the oil inlet cap.

13. Start the engine and allow the engine idle for five minutes.

14. Operate the bucket, boom, and steering cylinder for about five minutes, then lower the attachment.

15. Inspect for leaks.

16. Make sure the hydraulic oil is to the center of the oil level gauge. Add hydraulic oil if necessary.

B. 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 or 3000 hours.

123

３

EVERY 2000Hrs MAINTENANCE

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

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

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

2. Inspect all coolant hoses.

Replace any that are cracked, swollen,or brittle.

3. Open the cap (1) of the radiator subtank.

１

4. Remove the radiator cap (2) slowly.

２

5. Prepare a suitable container (about 20 liters).

6. Remove the drain plug (3) to drain the coolant from the radiator.

３

124

EVERY 2000Hrs MAINTENANCE

7. Remove the drain plug cylinder block.

(4) to drain coolant from the

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

CAUTION

４

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

Avoid contact with skin and eyes to prevent personal injury.

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

10. Start the engine and run it at middle to high speed for about a half hour.

11. Stop the engine and remove the drain plug (3)again to drain water while pouring clean water.

12. When clear water starts coming out of the drain port, stop pouring water.

13. After the water is drained completely, install the drain plug (3) and fill the system with the premixed coolant.

Refer to page 130 for the mixing instruction.

14. Idle the engine for five minutes to purge air mixed into the coolant. (Leave the radiator cap off) 15. Reinstall the radiator cap.

16. Pour the coolant in the radiator subtank to the specified level and close the cap.

C. Replace Differential Gear Oil CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

125

EVERY 2000Hrs MAINTENANCE

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

2. Remove the level plug (1), filling port plug (2), and drain plug (3) from the front axle housing, using a 12 mm hex (Allen) wrench.

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

Simply wipe it off.

3. Drain oil (about 20 liters) into a suitable container.

CAUTION Used oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

NOTE: While the oil is drained measure brake disc wear as described in item E below.

4. Install the drain plug.

5. Refill the recommended oil (20 liters) through the filling port until the oil comes out from the level hole.

Refer to "Recommended Lubricants" page 129.

6. Clean and install the magnetic level and filling port plugs.

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

D. Overhaul Brake Master Cylinder ・ Contact your nearest Kawasaki dealer.

E. Check Service Brake Disk Wear ・ Contact your nearest Kawasaki dealer.

F. Check and Adjust Valve Lash Clearance ・ Contact your nearest Kawasaki dealer or local Cummins engine dealer.

126

２

３

１

EVERY 2000Hrs MAINTENANCE

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

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

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

Turn the rings counterclockwise and then remove the cover.

4. Remove the outer filter from the cab, and replace it with new one.

When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

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

Inner filter replacement 1. The inner filters (2pcs) are located at the right behind the operator's seat.

Open the unit cover and remove the cover (1) using screw driver.

Loosen the screw (2) by fingers to remoce the cover (3).

Remove the filters and replace them with new ones.

1 2

2

H. Replace Air Conditioner Receiver Dryer (option) (Every 3 years or 6000 hours) ・ Contact your nearest Kawasaki dealer.

127

3

EVERY 2000Hrs MAINTENANCE

I . Check Vibration Damper Accumulator (option) WARNING Pressurized nitrogen gas in brake accumulator could explode causing serious injury or death.

Never service brake accumulator unless trained properly.

Contact your nearest Kawasaki dealer.

128

Recommended Lubricants and Capacity

Recommended Lubricants and Capacity Ambient Temperature Kind of Oil

Capacity

Engine oil pan

Engine oil

11 liter

Transmission oil pan

Engine oil ATF Dexron Ⅱ.

Hydraulic oil tank

Hydraulic oil tank

Differential & Planetary

Gear oil

Brake oil tank Fuel tank

Engine oil Engine oil Mobil DELVAC 1 Diesel fuel

20 liter 75 liter 40 litier 2.1 liter

F ‑22°‑4° 14°32° 50°68°86° ‑30° ‑20° ‑10°0℃ 10° 20° 30° SAE 10W-30 SAE 15W-40 SAE 10W ATF Dexron Ⅱ ISO VG46 VG32 Gear oil SAE80 Engine oil SAE30 SAE 5W or SAE 5W-20 MOBIL DELVAC 1

120 liter

ASTM D975 No.2 ASTM D975 No.1

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

Engine Oil:

Use oil that meets engine service classification API "CD".

Transmission Oil:

Use engine oil classification API "CD" or A.T.F. (Automatic Transmission Fluid) Dexron Ⅱ .

Never mix engine oil and A.T.F. Dexron Ⅱ .

Hydraulic Oil:

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

Gear Oil: Brake Oil:

Use gear lubricant classification API "GL-5".

Use engine oil SAE 5W API "CD" class or Mobil DELVAC 1 only.

Lubricating Grease: Use multipurpose-type grease. NLGI NO.2 grease is suitable for most temperatures.

NLGI NO.1 or NO.0 grease for extremely low temperature.

129

Coolant Specification

Coolant Specification The machine is originally filled with Long Life Coolant which need not be replaced for the first two years or 3000 hours.

If Long Life Coolant (permanent type) is not used for the replacement, it should be replaced every six months.

Recommended mixture of antifreeze Expected Minimum Ambient Temperature

−35 ° C (−31 ° F)

−30 ° C (−22 ° F)

−25 ° C (−13 ° F)

−20 ° C (−4 ° F)

−15 ° C (5 ° F)

Pure Water

(liter)

9.4

10.4

11.4

12.4

13.4

Antifreeze

(liter)

10.6

9.6

8.6

7.6

6.6

53

48

43

38

33

Mixture Ratio (%)

・ Too much antifreeze in the coolant mixture may cause engine overheating.

Keep 33% antifreeze mixture (same as the mixture for a minimum ambient temperature of -15 ℃ (5 ° F)) if the engine overheats in a high ambient temperature. ・ Do not use hard water or water with high levels of calcium and magnesium ions as the coolant water.

IMPORTANT Do not mix different brands of antifreeze because they each contain special additives.

Careless mixing often diminishes the effect of these additives that causes the packing damage or water leakage.

130

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. ｋａｗａｓａｋ ｉ Contact your local Kawasaki dealer for items marked with ｃｕｍｍｉ ｎｓ Cummins Diesel dealer for items marked with to repair

or your local authorized

ENGINE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

Low engine oil level Wrong grade oil for weather conditions Clogging oil filter element Defective alarm switch Oil leakage from pipe or joint Clogging suction strainer Exessive engine wear Defective oil pump

Add oil Change oil Change filter and oil

Low engine coolant level Loose/slipping/broken fan belt Clogging radiator fins (engine side) Scale or mineral build up inside radiator 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

Unstable rough idling

Air in fuel lines Fuel filter element clogging Fuel pump failure Incorrect fuel injection or valve timing

Bleed air Replace fuel filter

Air cleaner element clogging Fuel line suction strainer clogging Fuel filter element clogging Incorrect valve clearance Incorrect fuel injection timing Piston ring wear Defective injectors Fuel pump failure

Clean or replace element Clean or replace suction strainer Clean or replace fuel filter

Engine oil pressure warning monitor lamp lights up, and buzzer sounds

Coolant temp. gauge needle is in red zone

Insufficient power

131

ｋａｗａｓａｋ

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ｏｒ

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ｏｒ

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ｃｕｍｍｉ ｎｓ

ｃｕｍｍｉ ｎｓ

ｃｕｍｍｉ ｎｓ

ｃｕｍｍｉ ｎｓ

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

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

Use correct type of oil Correct oil level

White exhaust smoke (After engine has reached operating temp.)

Fuel being diluted with water or wrong grade fuel Incorrect fuel injection timing Compression pressure too low

Replace with specified fuel and replace fuel filter

Clean or replace element

Black exhaust smoke

Air cleaner element clogging Incorrect fuel injection timing Fuel injection pump failure Defective injectors

Unusual combustion noise or mechanical noise

ｋａｗａｓａｋ

ｋａｗａｓａｋ

ｋａｗａｓａｋ

ｏｒ

ｏｒ

ｏｒ

ｃｕｍｍｉ ｎｓ

ｃｕｍｍｉ ｎｓ

ｃｕｍｍｉ ｎｓ

ELECTRICAL PROBLEM

Charge lamp lights up

Starter motor does not turn when starter is turned to "START"

Starter motor turns the engine slowly

POSSIBLE CAUSES

SOLUTIONS

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

Adjust or replace belt Replace alternator Replace battery

Transmission not in NEUTRAL Starter switch failure Insufficient battery charge Defective wiring Starter motor failure

Shift to NEUTRAL Replace starter switch Battery charge or booster

Poor connection at batteries or ground Insufficient battery charging Engine oil viscosity too high (thick) Hydraulic control lever not in NEUTRAL Defective wiring Starter motor failure

Clean and tighten all terminals Battery charge or booster Replace oil Move lever to NEUTRAL

132

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ｏｒ

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ｃｕｍｍｉ ｎｓ

ｃｕｍｍｉ ｎｓ

TROUBLESHOOTING

STEERING PROBLEM

Hard steering

Will not steer

POSSIBLE CAUSES

SOLUTIONS

Tires are underinflated Severe conditions (overloaded, deep mud, etc.)

Oil pressure too low Steering valve failure Steering cylinder failure

Check and 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 Pump failure Steering cylinder failure

ｋａｗａｓａｋ

ｋａｗａｓａｋ

HYDRAULIC PROBLEM

Boom raises too slowly

POSSIBLE CAUSES Excessively cold oil Wrong type oil Oil pressure too low Damaged cylinder piston packing or piston Pump flow too low Engine RPM too low

SOLUTIONS Warm oil Replace with proper type oil

ｋａｗａｓａｋ

Boom natural drift excessive

Leakage from control valve plunger Damage cylinder piston packing or piston

ｋａｗａｓａｋ

Bucket/Attachment floating or drifting

Over load relief pressure too low Control valve failure Internal cylinder / packing leaking Excessively worn linkages

ｋａｗａｓａｋ

BRAKE PROBLEM Parking brake does not work properly

Brake dragging

Braking power too low

POSSIBLE CAUSES

SOLUTIONS

Worn brake shoe Defective linkage

Adjust

Dirt, debris under base of brake pedal Master cylinder failure Warped discs

Remove or clean

Brake oil level too low Air in brake system Master cylinder failure Brake piston seal leakage

Add oil and check for leaks

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Bleed air or ｋａｗａｓａｋ

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TROUBLESHOOTING

TORQUE CONVERTER & TRANSMISSION PROBLEM

POSSIBLE CAUSES

SOLUTIONS

Parking brake is applied Transmission oil level too low Suction strainer in transmission clogging Clutch oil pressure too low Transmission clutch failure Defective electrical circuit

Release parking brake Add oil/Repair leak Clean strainer

Low oil level in transmission Suction strainer in transmission clogging Service or parking brake dragging Clutch oil pressure too low Torque converter oil pressure too low Transmission clutch failure

Refill oil/Repair leak Clean 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 Radiator clogged: coolant temp also high Defective alarm switch Torque converter/Transmission oil pressure too low

Adjust oil level Reduce load Use lower gear Clean radiator fins

Engine is running but machine does not move

Low power

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AIR CONDITIONER / HEATER (option) PROBLEM

Low cooling A/C on

POSSIBLE CAUSES

SOLUTIONS

Hot water continues to flow through heater core A/C not set for maximum cooling Condensor 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 ｋａｗａｓａｋ

Low Heater out put

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

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