Kawasaki WHEEL LOADER 65TMV-2 OPERATION & MAINTENANCE MANUAL 93107-00442 (1)

65TMV-2

93107-00442 September 10, 2008

OPERATION & MAINTENANCE MANUAL WHEEL LOADER

65TMV-2

Printed in Japan (i) ( アメリカ用 )

93107-00442

©2008 Kawasaki Heavy Industries, Ltd. All rights reserved.

NOTICE Powered by ISUZU 4HK1X Engine Serial No. 65J4-4001 and up

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

WARNING CALIFORNIA PROPOSITION 65

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

WASH HANDS AFTER HANDLING !

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

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

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

93107-00442 September 10, 2008

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 65TMV-2.

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

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

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

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

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

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

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

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

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

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

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

Always follow safe operating and maintenance practices.

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

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

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

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

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

CONTENTS 1.SAFETY ...................................................................................................................................................... 1.1 SAFETY ..................................................................................................................................................... 1.2 Safe Operation..................................................................................................................................... 1.2 Safe Maintenance.............................................................................................................................. 1.12 Safety Signs....................................................................................................................................... 1.18 Safety Devices................................................................................................................................... 1.28 2.OPERATION ............................................................................................................................................... 2.1 COMPONENT NAME/LOCATION ............................................................................................................. 2.2 OPERATOR'S AREA ................................................................................................................................. 2.3 Pedals and Levers ............................................................................................................................... 2.3 Switches ............................................................................................................................................ 2.10 Indicators ........................................................................................................................................... 2.25 MODM ............................................................................................................................................... 2.33 Seat ................................................................................................................................................... 2.43 Electrical Protection ........................................................................................................................... 2.45 Radio - AM / FM Cassette (24 Volt Type)............................................................................................................................................... 2.47 Heater or Air Conditioner ................................................................................................................... 2.55 Ride Control (option).......................................................................................................................... 2.57 Grease Gun Holder............................................................................................................................ 2.58 OPERATION ............................................................................................................................................ 2.59 Check before Operation..................................................................................................................... 2.59 Starting the Engine ............................................................................................................................ 2.69 Check after Starting the Engine ......................................................................................................... 2.71 Operating the Machine ...................................................................................................................... 2.76 Parking............................................................................................................................................... 2.79 Stopping the Engine........................................................................................................................... 2.80 Operating Techniques........................................................................................................................ 2.81 SPECIAL PROCEDURES ....................................................................................................................... 2.93 Adjustments ....................................................................................................................................... 2.93 Roading / Special Applications .......................................................................................................... 2.94 Booster Batteries / Jumper Cables .................................................................................................... 2.95 Towing................................................................................................................................................ 2.97 Transportation.................................................................................................................................... 2.98 Long Term Storage .......................................................................................................................... 2.100

3.MAINTENANCE .......................................................................................................................................... 3.1 MAINTENANCE ......................................................................................................................................... 3.2 Serial Number Location ....................................................................................................................... 3.2 Inspection and Maintenance Table ...................................................................................................... 3.5 When Required Inspection and Maintenance ...................................................................................... 3.8 Every 10 Hours or Daily ..................................................................................................................... 3.20 Every 50 Hours or 1 Week................................................................................................................. 3.21 Every 250 Hours or 1 Month .............................................................................................................. 3.28 Every 500 Hours or 3 Months ............................................................................................................ 3.34 Every 1000 Hours or 6 Months .......................................................................................................... 3.40 Every 2000 Hours or 1 Year............................................................................................................... 3.46 Recommended Lubricants ................................................................................................................. 3.53 Coolant Specification ......................................................................................................................... 3.55 TROUBLESHOOTING............................................................................................................................. 3.56 SPECIFICATIONS ................................................................................................................................... 3.67

1.1

1.SAFETY

1.2 SAFETY Safe Operation

SAFETY Safe Operation Operator Safety

OM0026a

Wear safe clothing: OM0001

Read and understand the Operation & Maintenance Manual.

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

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

OM0180

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

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

- Do not operate if taking medication that causes drowsiness.

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

OM0002

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

1.3 SAFETY Safe Operation

Mounting and Dismounting Safety

OM0222

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

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

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

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

- Do not use compressed air for cleaning work.

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

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

OM0010

Face the machine when mounting or dismounting.

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

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

Climb and step only where steps and handrails are provided.

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

OM0181

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

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

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

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

1.4 SAFETY Safe Operation

Before Starting Safety

OM0012

OM0006

Do not allow unauthorized personnel on the machine.

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.

1.5 SAFETY Safe Operation

Articulation Stopper "STORED" OM0005

65ZV3061S

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

- Back-up Alarm -- Operational

Perform the normal daily maintenance.

Securely lock the cab door either fully open or closed.

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

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

Lock Unlock

65ZVUS3121c

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

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

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

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

Do not attach a suction cup on the window to avoid firing.

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

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

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

N

65ZV 5089

- Transmission Shift Lever -- Neutral

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

1.6 SAFETY Safe Operation

OM0007

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

Properly fasten the seat belt.

OM0011

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

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

DANGER DO NOT START MEN WORKING ON MACHINERY SIGNED BY DATE

OM0182

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

OM0183

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

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

- Do not reach through the window to start.

- Do not stand on the ground and start.

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

If jumper cables are required to start the engine, follow the correct procedure in "Booster Batteries / Jumper Cables" page 2.95.

1.7 SAFETY Safe Operation

Operational Safety

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

Before operating the machine, refer to "SPECIFICATIONS" listed on page 3.67.

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

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

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

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

The range of temperature the machine is to be operated is between -35ºC ~ 45ºC. When working on a grade: - Turn "OFF" the declutch switch.

- Keep the attachment low.

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

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

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

- Never coast down a grade.

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

OM0018

OM0021

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

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.

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.

1.8 SAFETY Safe Operation

SAFETY DURING NORMAL OPERATIONS:

When roading the machine:

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

- Travel in forward only.

- Travel only as fast as conditions and safety allow.

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

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

Know the machine limits and do not exceed them.

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

OM0013

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

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

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

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

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

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

OM0184

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

approx. 40 cm OM0016

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

1.9 SAFETY Safe Operation

SPECIAL OPERATING CONDITIONS:

OM0020

OM0185

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

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

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

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.

1.10 SAFETY Safe Operation

70ZV OM 2665

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

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

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

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

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

1.11 SAFETY Safe Operation

Parking Safety

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

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

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

OM0025

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

- Block the tires.

- Apply the parking brake.

To prevent unauthorized use: - Remove the key.

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

- Install vandal covers (if equipped).

OM0186

Inspect the machine and report any needed repairs.

1.12 SAFETY Safe Maintenance

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

Perform maintenance and repairs only if trained.

Follow the Operation & Maintenance Manual or Shop Manual.

OM0002

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

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

OM0026a

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

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

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

1.13 SAFETY Safe Maintenance

OM0025

OM0222

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

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

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

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

- Do not use compressed air for cleaning work.

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

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

Before performing any maintenance: - Park on level ground.

- Block the tires securely.

- Apply the parking brake.

- Lower the boom and attachment to the ground.

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

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

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

OM0029

Never make repairs on pressurized components.

Release all trapped air and hydraulic pressure by: - Stopping the engine after lowering the attachment to the ground.

- Moving the loading control levers back and forth.

- Turning the steering wheel right and left several times.

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

1.14 SAFETY Safe Maintenance

Support bar

DANGER DO

NOT

START MEN WORKING ON MACHINERY SIGNED BY DATE

OM0182 85ZV28463

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

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

70ZV27373

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

OM0031

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.

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

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

1.15 SAFETY Safe Maintenance

Explosion / Fire / Burn Prevention

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

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

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

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

Avoid contact with skin or eyes.

Pour all fuel and oil into appropriate containers.

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

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

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

OM0032

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

OM0033

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

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

- Fill oil at well ventilated place.

- Do not leave the machine when filling oil.

- Fasten the oil filler cap tightly.

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

- Make sure wheel parts are correctly installed.

- Use a self attaching (locking) air chuck.

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

- Stand behind the tread not beside the rim.

- Do not inflate tires more than the recommended pressure.

- Use a safety cage for a repaired tire.

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

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

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

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

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

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

OM0008

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

Stop the engine before opening the engine access panel.

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

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

OM0188

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

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

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

Articulation Stopper "LOCKED" 65ZV3061L

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

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

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

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

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

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

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

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

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

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

1.18 SAFETY Safety Signs

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

Follow the directions on the safety signs carefully.

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

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

1.19 SAFETY Safety Signs

1.

13.

DANGER

WARNING

WARNING

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

Always keep ROPS in place.

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

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

44787-24360

L.H, R.H

44841-20870

Inside L.H, R.H

44787-24680

44787-24440

Inside L.H

65TMV2 02597-1051PV

16.

L.H, R.H

WARNING

6.

R.H

CAUTION

WARNING

Inside

WARNING

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

Before checking transmission oil: Park on level ground.

Lower bucket to ground.

Place transmission in neutral.

Set parking brake.

Tag "Do Not Operate".

Machine will not turn with articulation stopper in locked position.

Unlock articulation stopper before operating machine.

44841-20640

44787-24480

44841-20630

44787-24470

1.20 SAFETY Safety Signs

4.

5.

11.

CAUTION

WARNING

DANGER

CAUTION

44787-24420

44787-24410

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

Avoid contact with skin or clothing.

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

44841-20690

44787-24370

Inside

65TMV2 02597-1051TV

17.

10.

8.

Inside

9.

Inside

WARNING

WARNING

CAUTION

WARNING

44787-24490

44787-24330

44787-24350

44787-24340

1.21 SAFETY Safety Signs

3.

2.

WARNING

WARNING

STOP

10.

18.

WARNING

STOP 44787-24460

44787-24390

L.H, R.H

44787-24380

L.H, R.H

65TMV2 02597-1051RV

7.

WARNING

L.H, R.H

WARNING

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

Do not clean or replace element while engine is running.

Clean only outer element.

Never clean inner element.

44787-20950

44787-24400

44787-24330

Inside

1.22 SAFETY Safety Signs

12.

Parking brake cylinder

WARNING

70ZV02597-0717EE 44787-24450

Inside of Cab

B B-B

70ZV02597-0717BSa

B

A A

70ZV02597-0717BS

A-A

70ZV02597-0717AS

15.

14.

WARNING

WARNING

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

Always keep ROPS in place.

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

44841-20870

44787-24430

44787-24320

1.23 SAFETY Safety Signs 3.

1.

DANGER

WARNING

STOP 44787-24390

44787-24360

WARNING

DANGER No room in this area while turning machine.

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

Crushing will result in death or serious injury.

Stop engine before working in this area.

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

4.

2.

DANGER

WARNING

STOP 44787-24420 44787-24380

WARNING

DANGER

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

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

Keep all guards in place.

Before walking or working under raised boom:

Keep hands away from fan area.

- Securely block or brace boom.

- Remove key and tag "Do Not Operate."

- Release all trapped oil pressure before opening any piping.

1.24 SAFETY Safety Signs 7.

5.

WARNING

WARNING

44787-24410

44787-24400

WARNING

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

Machine movement could result in death or serious injury.

Unlock articulation machine.

Stay out of this machine.

stopper

before

operating

8.

6.

WARNING

CAUTION

44787-24470

44787-24350

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

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

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

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

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

1.25 SAFETY Safety Signs 10.

9.

WARNING

WARNING

44787-24340

44787-24330

WARNING

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

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

Keep flames and sparks away.

Allow system to cool and vent pressure slowly before servicing.

Vent area before servicing.

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

Avoid contact with skin or clothing.

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

11.

CAUTION

44787-24370

CAUTION You may fall from here.

Do not step on here.

1.26 SAFETY Safety Signs 14.

12.

WARNING

WARNING

44787-24450

44787-24430

WARNING

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

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

Read Shop Manual before repairing this part.

Before checking transmission oil: - Park on level ground.

- Lower attachment to ground.

- Place transmission in neutral.

- Set parking brake.

- Tag "Do Not Operate."

13.

WARNING

44787-24440

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

- Do not start engine by shorting across starter terminals.

- Do not start engine while standing on ground.

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

1.27 SAFETY Safety Signs 17.

15.

WARNING

WARNING

44787-24320

44787-24490

WARNING

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

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

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

Allow system to cool and vent pressure slowly before servicing.

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

18.

16.

WARNING

WARNING

44787-24480

44787-24460

WARNING

WARNING

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

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

Allow system to cool and vent pressure slowly before servicing.

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

1.28 SAFETY Safety Devices

Safety Devices

Articulation Stopper

Loading Control Lever Lock

WARNING

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.

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

Do not lock Articulation Stopper during normal operation.

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

To lock:

Lock Unlock

65ZVUS3121c

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

"LOCKED" position

65ZV3061L

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

1. Align the front and rear chassis straight ahead.

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

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

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

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

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

1.29 SAFETY Safety Devices

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

To unlock:

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

"STORED" position

65ZV3061S

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

2. Turn the link to the rear chassis bracket.

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

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

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

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

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

Unlock

Lock

65ZVUS3121c

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

2. Loosen the screw for the lock plate.

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

4. Tighten the screw to fix the lock plate.

1.30 SAFETY Safety Devices Unlock:

Neutral Start System

1. Loosen the screw for the lock plate.

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

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

3. Tighten the screw to fix the lock plate.

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

97ZVOM0038

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

1.31 SAFETY Safety Devices

Emergency Steering (option)

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

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

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

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

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

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

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

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

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

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

ROPS (Roll Over Protective Structure) Cab

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

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

- Do not use ROPS Cab deformed.

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

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

1.32

MEMO

2.1

2.OPERATION

2.2 COMPONENT NAME/LOCATION

COMPONENT NAME/LOCATION 29 20

3

9 7

4

21 28 27 26

13 15

6

5

1

14 16 25

2

18

8 23

17

1. Bucket (Attachment) 2. Quick Coupler (option) 3. Boom 4. Lever 1 5. Lever 2 6. Rod 1 7. Rod 2 8. Boom Cylinders (2) 9. Bucket Cylinders (2) 10. Steering Cylinders (2) 11. Engine 12. Torque Converter & Transmission Ass'y 13. Radiator & Air Cooler (for engine intake air) 14. Torque Converter Oil Cooler 15. Hydraulic Oil Cooler 16. Fuel Tank

22 10 12

24

19

11

65TMV2 COMPO

17. Hydraulic Tank (Right hand side) 18. Front Axle / Differential Ass'y 19. Rear Axle / Differential Ass'y 20. Air Cleaner (Right hand side) 21. Precleaner 22. Parking Brake 23. 2nd Propeller Shaft 24. 3rd Propeller Shaft 25. Batteries (2) (one each side--two 12VDC=24VDC system) 26. Cooling Fan 27. Fan Motor (hydraulic type) 28. Exhaust Muffler 29. ROPS Cab 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.

2.3 OPERATOR'S AREA Pedals and Levers

OPERATOR'S AREA Pedals and Levers

1. Transmission Shift Lever

11

2

1

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

3

- 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.

8

9

8

7

97ZVOM0041

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

5 (option) 6 4

10 65ZVUS3121c

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

65ZV 5089

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

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

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

2.4 OPERATOR'S AREA Pedals and Levers

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

4. Loading Control Lever Loading control lever is used to control the boom / bucket movement.

[Boom Control] Low beam position

(b) (a)

(c) (d)

High beam position

97ZVOM0044

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

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

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

Lever lock released

65ZVUS3121c

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

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

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

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

97ZVOM0044

- 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.

- An automatic boom height positioner is provided which will automatically release the detent and return the lever to the "Hold" position when a preset boom height is reached. (c) Hold - Return the lever to the center position. The boom will stop and remain in that position. (d) Raise - Move the lever rearward. The boom is raised.

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

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

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

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

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

[Bucket Control]

(a) (b)

(c) (d)

65ZVUS3121c

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

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

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

when the bucket or attachment reaches to the preset angle.

- For adjustment procedure refer to "Bucket / Attachment Leveler Adjustment" page 2.93.

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

2.6 OPERATOR'S AREA Pedals and Levers

5. Auxiliary Attachment Control Lever (option)

6. Wrist Rest (adjustable)

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

(a)

Unlock

(b) (c)

Lock

65ZV4705

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

65ZVUS3121c

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

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

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

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

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

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

2.7 OPERATOR'S AREA Pedals and Levers

7. Accelerator Pedal

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.

97ZVOM0038

- Do not use brake pedals as foot rest.

- Do not ride brakes.

- Use brake pedals only when applying brakes.

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

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

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.

97ZVOM0038

- Be sure control pedals move freely before operating.

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

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

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

- Right Brake Pedal Applies the brake only.

Use this when working on slopes or ramps.

- Left Brake Pedal (also called Declutch Pedal) May be used either of two ways.

1. As a brake only pedal by turning the declutch switch (See page 2.17) to the "OFF" position.

Use this position when working on slopes or ramps.

2.8 OPERATOR'S AREA Pedals and Levers 2. Disengage the transmission while applying the brake. This is normally used when loading trucks. It allows higher engine speed to provide faster hydraulic operations.

To use this feature, turn the declutch switch to the "ON" position. When the switch is "ON", a green indicator lamp on the dash will also be turned on.

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

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

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

9. Steering Column Telescopic Tilt Handle

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

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

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

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

Release

Lock

97ZVOM0045

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

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

2.9 OPERATOR'S AREA Pedals and Levers

10. Loading Control Lever Lock

Lock Unlock

65ZVUS3121c

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

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

- To unlock, push down the lock lever backward.

2.10 OPERATOR'S AREA Switches

Switches

11

4

6

5

15

21 16 STOP

85ZV2 0001USc

7 8 9

12

3

2

70ZV0013a

65ZV5089d

20

10

19 14

17

18

13

1. Starter Switch 2. Parking Brake Switch 3. Light Switch 4. Front Working Light Switch 5. Rear Working Light Switch 6. (FE) Fuel Efficient Mode Switch 7. Front Wiper Switch 8. Rear Wiper Switch 9. 12 Volt Power-outlet Socket 10. Downshift Button 11. Four-Way Flasher Switch (option)

1

65ZVUS3121c

85ZV2 FR SWITCH

12. MODM 13. Declutch ON/OFF and Adjustable Preset Switch 14. Kickout Control Switch 15. Efficient Loading System Switch (option) 16. Selection Switch for Shift Lever or F/R Switch (option) 17. F/R Switch (option) 18. Reversal Fan Switch (option) 19. Ride Control Switch (option) 20. Bucket / Fork Leveler Switch 21. Quick Coupler Lock Pin Switch (option)

2.11 OPERATOR'S AREA Switches

1. Starter Switch

2. Parking Brake Switch

WARNING PREHEAT

OFF

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

ON

START

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

65ZV0074

OFF - Key can be either inserted or pulled out.

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

ON - Current flows to all circuits.

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

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

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

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

97ZVOM0038

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

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

2.12 OPERATOR'S AREA Switches

3. Light Switch

4. Front Working Light Switch

85ZV2 0002c

70ZV0013a

OFF

This is a three position switch.

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

ON

switch-4

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

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

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

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

2.13 OPERATOR'S AREA Switches

5. Rear Working Light Switch

6. (FE) Fuel Efficient Mode Switch

85ZV2 0002c

85ZV2 0002c

OFF

OFF

ON

ON

switch-4

switch-3

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

Engine Torque

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

Power Mode FE Mode

Engine Speed 90ZV2 5001

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

Power mode provides added power for extreme applications.

Fuel efficient mode offers better fuel economy for standard applications.

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

2.14 OPERATOR'S AREA Switches

7. Front Wiper Switch

8. Rear Wiper Switch

70ZV0013a

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

OFF

70ZV0013a

Rear wiper switch is used to wipe the rear windshield.

INT LOW HIGH

OFF

ON

PUSH

PUSH

OM0190

OM0189

OFF

:

OFF

:

INT

: Intermittent

ON

: Low speed

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

PUSH : Spraying solvent on the windshield

2.15 OPERATOR'S AREA Switches

9. 12 Volt Power-outlet Socket

10. Downshift Button

12V PUSH

PUSH

65ZV03126-0219

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

65ZVUS3121c

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

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

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

2.16 OPERATOR'S AREA Switches

11. Four-Way Flasher Switch (option)

12. MODM

85ZV2 0002c

65ZV5089d

OFF

The MODM has the following functions: - Information monitor

ON

switch-3

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

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

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

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

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

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

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

Refer to page 2.33 for the MODM operation.

2.17 OPERATOR'S AREA Switches

13. Declutch ON/OFF and Adjustable Preset Switch

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

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

Declutch OFF

Declutch preset

Adjustable Declutch Preset

Declutch ON 65ZVUS3121c

Hold

Declutch ON/OFF

Reset

OFF

switch-5

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

ON

switch-5

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

Normally this switch should be "ON".

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

Refer to "Brake Pedals" page 2.7 for the function of the brake pedals.

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

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

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

2.18 OPERATOR'S AREA Switches

14. Kickout Control Switch

position and the boom reaches at the preset height, the lower kickout automatically releases the detent and returns the boom control lever to "Hold" position.

NOTE - Float detent is ready to be reactivated 2 seconds just after the previous lower kickout operation. The bucket may hit the ground, if the boom leaves the clearance a bit higher above the lower kickout position.

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

65ZVUS3121c

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

(Upper)

(Lower)

Hold

Hold

Reset

Reset

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

switch-5

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

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

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

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

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

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

When the boom control lever is placed at "Float"

2.19 OPERATOR'S AREA Switches

15. Efficient Loading System Switch (option)

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

This improves loading efficiency and save fuels.

85ZV2 0002c

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

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

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

OFF

ON

switch-3

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

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

ELS system works under the following condition.

- ELS switch ON - Machine speed (Forward) under 5 km/h (3.1 MPH) - Boom control lever set at "Raise" position

FAST SLOW

90ZV2 5002

2.20 OPERATOR'S AREA Switches

16. Selection Switch for Shift Lever or F/R Switch (option)

STOP

85ZV2 0003c

OFF

ON

switch-4

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

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

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

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

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

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

2.21 OPERATOR'S AREA Switches

17. F/R Switch (option)

85ZV2 FR SWITCH

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

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

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

Operation

Shift lever position

F/R switch position

Selection switch

By F/R switch

Any position

N

ON

By shift lever

N

Any position

OFF

2.22 OPERATOR'S AREA Switches

18. Reversal Fan Switch (option)

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

65ZVUS3121c

OFF

ON

switch-3

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

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

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

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

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

2.23 OPERATOR'S AREA Switches

19. Ride Control Switch (option)

20. Bucket / Fork Leveler Switch

65ZVUS3121c

65ZVUS3121c

OFF

FORK

ON

BUCKET

switch-3

When the ride control switch is ON, the ride control works.

Refer to "Ride Control (option)" page 2.57.

switch-3

This machine has two positioners installed.

One is for the bucket leveler and other is for the attachment leveler.

This switch is to select these positioners.

When the bucket is installed on the machine, push the switch to "BUCKET".

When the attachment is installed on the machine, push the switch to "FORK".

2.24 OPERATOR'S AREA Switches

21. Quick Coupler Lock Pin Switch (option)

tion, and the quick coupler will be free to disconnect or reconnect.

During the operation of the switch, keep the bucket control lever in "Roll Back" position to operate coupler.

Refer to "How to Use Quick Coupler (option)" page 2.89.

85ZV2 0002c

Quick coupler lock pin switch is used to lock/unlock the quick coupler for 2-way piping specification machine with quick coupler.

Locked position

switch-7

( )The lock pin is fixed if fab is positioned to right.

This is the neutral or "OFF" position and coupler lock pin will remain engaged to the coupler when in this position.

Unlocked position

switch-8

( )When unlocked, the tab moved as shown, the coupler lock pin will go to the disconnectecd posi-

2.25 OPERATOR'S AREA Indicators

Indicators 20 5 17 19

21

1

18

9

2

23

4

10

11(28) 12 13 14 15 16

STOP

27

25

26

24 22 (28)

6

1. Tachometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Gauge 5. Parking Brake Indicator Lamp (red) 6. Declutch Lamp (green) 7. Working Light Indicator Lamp (green) 8. Preheat Indicator Lamp (orange) 9. Central Warning Lamp (red) 10. MCU (Machine Control Unit) Warning Lamp (red) 11. Brake Pressure Warning Lamp (red) 12. Engine Oil Pressure Warning Lamp (red) 13. Engine Coolant Temperature Warning Lamp (red) 14. Torque Converter Oil Temperature Warning Lamp (red) When the starter switch is turned to "ON", all warning lamps (9) ~ (16), (24) and (25) light up for three seconds. This is the lamp (bulb) test period (lamp (16) lights up until engine starts).

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

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

8

7

3

2

85ZV2 0004US

15. Air Cleaner Warning Lamp (red) 16. Charge Lamp (red) 17. Turn Signal Indicator Lamp (Left) (green) 18. Turn Signal Indicator Lamp (Right) (green) 19. High Beam Indicator Lamp (blue) 20. Auto Shift Indicator Lamp 21. Neutral Indicator Lamp 22. Transmission Status Monitor 23. Hour Meter 24. Emergency Steering Warning Lamp (red) (option) 25. Engine Warning Lamps 26. Reversal Fan Pilot Lamp (green) (option) 27. F/R Switch Indicator Lamp (green) (option) 28. Hydraulic Oil Level Warning Lamp (simultaneous flashing)(red)(11. 24.)

2.26 OPERATOR'S AREA Indicators

1. Tachometer

3. Torque Converter Oil Temperature Gauge 20

10

C

H T/C OIL TEMP

30

0 x100min -1

97ZVOM0050 97ZVOM0048

Indicates the engine revolutions per minutes.

2. Engine Coolant Temperature Gauge

C

Indicates the temperature of oil circulating through the torque converter and the transmission. It is normal if the indicator is in the white zone (56~125ºC (133~257ºF)) while operating.

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

H WATER TEMP

97ZVOM0049

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

Refer to "TROUBLESHOOTING" page 3.60.

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

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

4. Fuel Gauge

E

F FUEL

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

Refer to "TROUBLESHOOTING" page 3.56.

65ZV0005

Indicates the fuel amount in the fuel tank.

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

2.27 OPERATOR'S AREA Indicators

5. Parking Brake Indicator Lamp (red)

8. Preheat Indicator Lamp (orange)

P OM0176

OM0052

Lights up when the parking brake is applied.

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

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

9. Central Warning Lamp (red) 6. Declutch Lamp (green)

OM0056

Flashes when any of the warning lamps come on.

OM0054

Lights up when the 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).

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

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

OM0057

7. Working Light Indicator Lamp (green)

OM0055

Lights up when working lights are on.

Lights up when MCU malfunctions.

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

2.28 OPERATOR'S AREA Indicators

11. Brake Pressure Warning Lamp (red)

13. Engine Coolant Temperature Warning Lamp (red)

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

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

Brake Pressure Warning Lamp lights up and the warning buzzer sounds when the brake oil pressure is lower than 3.9 MPa (570 psi).

OM0058

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

Refer to "TROUBLESHOOTING" page 3.59.

OM0060

Lights up when coolant temperature overheats.

(Over 102ºC (215ºF)) - If it lights up while operating, slow the engine speed down to mid-range, shift to neutral, and wait until the lamp goes out. Check the coolant temperature gauge before resuming operation.

- If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "TROUBLESHOOTING" page 3.56.

CAUTION Hot coolant spray may cause burns.

Never open radiator cap when engine is hot.

12. Engine Oil Pressure Warning Lamp (red)

OM0059

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

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

Refer to "TROUBLESHOOTING" page 3.56.

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

2.29 OPERATOR'S AREA Indicators

14. Torque Converter Oil Temperature Warning Lamp (red)

16. Charge Lamp (red)

Lights up when transmission oil overheats. (Over 120±5ºC (248±9ºF))

OM0063

Lights up when alternator charge level is low.

OM0061

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

- If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause. Refer to "TROUBLESHOOTING" page 3.60.

15. Air Cleaner Warning Lamp (red)

- If it lights up, check the charging circuit.

Refer to "TROUBLESHOOTING" page 3.58.

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

OM0065

Flashes when the turn signal switch lever is moved forward.

OM0062

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

Lights up when air filter is clogged (25”hg).

- If it lights up while operating, stop the engine and clean or replace the air cleaner outer element.

Refer to "Clean or Replace Air Cleaner Element" page 3.10.

OM0066

Flashes when the turn signal switch lever is moved rearward.

2.30 OPERATOR'S AREA Indicators

19. High Beam Indicator Lamp (blue)

22. Transmission Status Monitor

4 3 2 1

OM0067

Lights up when headlights are switched to high beam.

OM0070

20. Auto Shift Indicator Lamp

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

AUTO

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

OM0068

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

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

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

21. Neutral Indicator Lamp 23. Hour Meter

N

1/10h OM0069

Lights up when transmission is in neutral.

OM0071

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

2.31 OPERATOR'S AREA Indicators

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

25. Engine Warning Lamps Engine stop lamp

STOP OM0072

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

Also the warning buzzer sounds.

Red

OM0191

If a stop (red) lamp comes on while the engine is in operation, the fault can be engine disabling. Stop the engine operation in a safe manner as soon as possible.

Engine warning lamp

Yellow

OM0192

If the yellow warning lamp illuminates, the engine can still be operated, but it can lose some system features that can sometimes result in a power loss.

The failure must be repaired as soon as convenient.

2.32 OPERATOR'S AREA Indicators

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

OM0223

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

OM0058

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

OM0072

27. F/R Switch Indicator Lamp (green) (option)

Flashes simultaneously when hydraulic oil level is lower than specified. Also the warning buzzer sounds.

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

OM0218

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

Refill the hydraulic tank with oil as needed.

Refer to "Check Hydraulic Oil Level" page 2.61.

2.33 OPERATOR'S AREA MODM

MODM

Monitor Changeover

(Machine Operation Diagnostic Module)

[ ]button

Display window

[

Replacement monitor

Error log monitor

Information monitor

Input/Output monitor

Specification setting monitor

Parameter setting monitor

]button

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

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

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

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

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

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

Change over the monitor using the following procedure: When the starter switch is ON, the information monitor is first displayed on initial monitor.

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

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

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

2.34 OPERATOR'S AREA MODM

Information Monitor

1. Outside air temperature

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

Every time the [

(step forward)] button is

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

Step forward

Step back

90ZV-262024

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

2. Machine speed and engine speed

Outside air temperature

90ZV-262025

Machine speed and engine speed

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

Engine coolant temperature

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

T/M oil temperature

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

Hydraulic oil temperature

Odometer

Cycle

Cylinder oil pressure

Voltage

Hour meter

85ZV2 0008

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

90ZV-262026

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

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

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

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

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

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

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

90ZV-262027

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

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

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

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

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

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

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

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

90ZV-262029 90ZV-262028

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

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

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

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

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

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

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

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

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

7. Number of cycles and cycle time

90ZV-262030

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

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

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

8. Hydraulic system oil pressure

90ZV-262031a

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

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

2.37 OPERATOR'S AREA MODM

Unit conversion and language selection

9. Voltage

Select the unit and language using the [ ] button.

90ZV-262032

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

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

Language selection

90ZV-262033

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

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

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

English is selected as the initial setting.

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

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

(step

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

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

2.38 OPERATOR'S AREA MODM

Replacement Monitor

Step forward

Step back

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

Engine oil filter

Fuel filter

90ZV-262034

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

Every time the [

(step forward)] button is

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

Coolant filter

T/C line filter

Hydraulic oil return filter

Engine oil

T/C and T/M oil

Axle gear oil

Hydraulic oil

85ZV2 0009

2.39 OPERATOR'S AREA MODM

Replacement interval set (timer reset)

Replacement pop-up

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

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

The timer reset screen displays the standard replacement interval.

90ZV-262038

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

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

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

Example: Engine oil

90ZV-262037

For setting the replacement interval other than the standard replacement interval, follow the procedure below: ∗∗∗∗ +50

90ZV-262039

∗∗∗∗ +100 (2 seconds or more) ∗∗∗∗ −50 ∗∗∗∗ −100 (2 seconds or more) Every time the [ (step forward)] button is pressed, "50" is added.

Every time the [ "50" is subtracted.

(step back)] button is pressed,

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

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

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

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

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

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

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

2.40 OPERATOR'S AREA MODM

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

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

Error codes are displayed from the latest one.

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

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

Clear error log Clear machine error log

Selection of machine error log and engine error log When the machine error log screen is displayed,

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

When the engine error log screen is displayed,

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

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

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

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

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

The machine error log screen and engine error log screen can be distinguished as follows:

Clear engine error log

press and hold the [ (step forward)] button for 2 seconds or more to display the engine error log screen which shows the latest engine error code.

Displayed error code: CN∗∗∗ ..... Machine error log screen EG∗∗∗ ..... Engine error log screen

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

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

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

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

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

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

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

2.41 OPERATOR'S AREA MODM

Active error (error pop up) When an error occurs, the corresponding error code is forcibly displayed on the screen.

When two or more active errors occur, up to 5 error codes are displayed repeatedly. (Up to 10 error codes for CN and EG total errors) Press one of the [ (step forward)] button, [ (step back)] button, [ ] button or [ ] button. The screen displayed before the active error codes appears again.

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

Press and hold Step forward

Press and hold Step back

Active error codes are displayed repeatedly, whenever the starter switch is ON, until the causes of errors are eliminated.

Input signal

IMPORTANT

Input sensor

Error log is important information for machine maintenance. Do not clear error log before figuring out cause.

Output signal

Continuous machine operation, with active error shown, may cause severe machine damage.

Current output

If active error shows, please contact Kawasaki dealer in your area.

85ZV2 0010

Refer to "TROUBLESHOOTING" page 3.61 for error code.

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

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

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

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

2.42 OPERATOR'S AREA MODM

Parameter Setting Monitor Display of parameter setting monitor This monitor allows check of the parameters currently set.

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

2.43 OPERATOR'S AREA Seat

Seat

Mechanical Suspension (If so equipped)

Seat Adjustment

- With seat pushed back half-way for easier access to 5, extend the crank lever from knob (5) and rotate Minus (−) direction for less support or Plus (+) for more support. Use indicator for approximate weight setting. Release crank lever.

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

1

2 Seat Belt

6 5

Tether

4

3

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

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

70ZV0017

Forward / Backward Armrests - Rotate control knob (1) to select desired angle.

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

Lumbar Support - Turn adjustment knob (2) for desired lumbar support.

Reclining - Lift handle (3) and allow the back cushion to angle forward, or lean backward into the cushion. Release the handle at desired position.

Seat Height - Remove your weight from seat while lifting handle (4) to the stop position. While holding handle (4) up, raise or push down on seat. Release handle (4) at one of three positions.

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

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

2.44 OPERATOR'S AREA Seat

Seat Belt

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

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

- Always fasten seat belt when operating machine.

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

OM0007

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

Keep buckle free of dirt and debris.

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

2.45 OPERATOR'S AREA Electrical Protection

Electrical Protection

(1) Left

Fuse Boxes 2

1

65TMV2 CONSOLE

3

(2) Left

SPARE

5A

LIGHTING HEAD LIGHT

SPARE

5A

R. WORK LIGHT

15A

R. WIPER / WASHER 5A

BOOM KICKOUT BUCKET LEVELER

10A

F. WIPER / WASHER 10A

TURN SIGNAL

15A

MODM

PARKING BRAKE MCU (MACHINE)

30A

DC-DC CONVERTER 15A

F. WORK LIGHT

15A

RADIO

3A

AIR SUS SEAT (option)

10A

SPARE

10A

SPARE

15A

SPARE

10A

SPARE

15A

AIRCON

20A

4 WAY FLASHER HORN DOME LAMP RADIO BACK UP

15A

SPARE

5A

SPARE

10A

SPARE

5A

PREHEAT

15A

SPARE

10A

BUZZER MONITOR

5A

AIRCON

20A

NEUTRAL RELAY

5A

SPARE

20A

BATTERY RELAY ECM (ENGINE)

5A

10A

20A

65TMV2 FUSE

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

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

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

Never replace fuses with higher amperage rating.

Right

Right

(3) ECM (ENGINE)

30A

2.46 OPERATOR'S AREA Electrical Protection

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

Spare

2

1

65TMV2 FUSE

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

Fuse damaged

Problem (symptom) During engine operation

During engine stop

30A

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

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

OFF.

70A (1)

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

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

70A (2)

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

CAUTION Contact with moving parts or engine components may result in injury or burns.

2. To check the cause and replace the fusible link, call your nearest Kawasaki dealer.

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

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

14

15

16

20

9 10 11

clarion

AM

ON OFF VOL

SLEEP

PUSH

AM/FM CASSETTE COMBINATION

CD

1

ST AUDIO MODE

2

ALARM

TIMER

TAPE

CD

AM FM

3

6

7

1 4

3

REW APC

5

6

SCAN

FF APC

DISP PS AS

M

H TUNE

RadioCassetteUSA

5

4 17

18

19

8

13

12

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

Symbol

Name of part Volume knob

Function

Operation method

Description

Turning power on/ off

PUSH

Push this SW to turn the power on or off.

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

Sleep timer

PUSH with ACC turned off

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

Sound volume adjustment MIN

Sound balance adjustment

MAX

Selected with audio mode button

1 L

Fader adjustment

R

Selected with audio mode button

REAR FRONT

Sound tone adjustment

Selected with audio mode button

Use this adjustment knob to adjust the sound volume.

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

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

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

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

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

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

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

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

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

CUT BOOST

MODE Audio mode button 2

Audio mode switching

PUSH

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

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

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

Remarks

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

Symbol

Name of part

Function Turning alarm ON/ OFF

Alarm button

3

PUSH

Alarm setting: Setting clock on the hour

Switching timer ON/ OFF One-touch timer button

Operation method

PUSH

Timer setting

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

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

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

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

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

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

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

4

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

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

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

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

The timer mark continues to light while the timer works.

TAPE 5

TAPE button CD

6

CD button

Cassette tape play/ stop

PUSH

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

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

CD changer play/stop

PUSH

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

The CD Changer is optional and not normally supplied.

Remarks

Alarm mark

Timer mark

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

Symbol

Name of part AM/FM

7

AM/FM band selector button

PS AS

Function

Operation method

Description

Band switching Turning on radio Setting clock on the hour

PUSH

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

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

Preset scan in radio mode

PUSH

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

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

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

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

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

Radio store button Auto store in radio mode

PUSH

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

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

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

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

Program scan in cassette tape mode

PUSH

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

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

Program scan in CD mode

PUSH

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

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

CD Changer is an option and is not normally offered.

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

8

Remarks

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

Symbol

Name of part

Function

Operation method

Description

Cassette tape ejection

PUSH

Push this button to eject the cassette tape.

This can be performed even with ACC off.

Display change

PUSH

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

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

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

Radio scanning

PUSH

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

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

9 Eject button DISP Display button

10

SCAN 11

SCAN button

Remarks

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

Symbol

Name of part

Function Manual tuning in radio mode

Operation method PUSH Upward

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

Downward Tuning button

for 0.5 sec. or less Seeking in radio mode

12

PUSH Upward Downward

13 for 0.5 sec. or less PUSH Downward

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

PUSH Upward

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

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: REW

PUSH

Push the button to rewind the cassette tape.

In CD mode: DISC DOWN

PUSH

Push the button to go down to the previous disc.

(Recalling the previous disc.)

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

1

REW

Preset 1

14

REW button

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

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

Remarks

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

Symbol

Name of part 2 PRO Preset 2 Program button

15

3

FF

Preset 3 FF button 16

4

APC

Preset 4 APC button

Function

Operation method

Description

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: Program

PUSH

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

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

In CD mode: DISC UP

PUSH

Push the button to go to the next disc.

(Recalling the next disc.)

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: FF

PUSH

Push the button to wind forward the cassette tape quickly.

In CD mode: DISC UP

PUSH

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

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: APC REW

PUSH

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

In CD mode: TRACK DOWN

PUSH

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

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

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

17

REVIEW

Remarks

No beep sounds

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

Symbol

Name of part

5

18

Preset 5 Dolby button

6

APC

Preset 6 APC button

19

Function

Operation method

Description

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: Turning on/ off

PUSH

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

In radio mode: Recalling and storing preset memories

PUSH

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

In cassette tape mode: APC FF

PUSH

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

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

In CD mode: TRACK UP QUE

PUSH

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

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

No beep sounds

Auto metal

20

Tape insertion slot

Cassette tape insertion slot

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

21

LCD indicator

indicator

Displays time, frequency, etc.

Beep tone (guide tone)

Remarks

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

(Approx. 2KHz, 50ms)

2.55 OPERATOR'S AREA Heater or Air Conditioner

Heater or Air Conditioner

Switches

Ventilation Location and Mode

Manual Heater Control

3

3

3 1

1

2

4

3

1

2 4

4

3

4

4 BERGSTROM H

Manual Combo Control 70ZV0014

VENT MODE

1

2

3

4

: Open : Close

1

2

3

4 BERGSTROM AC

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

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

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

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

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

Panel Mode Provides air flow through door 1.

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

Floor Mode Provides air flow through door 2.

Mix Mode Provides air flow through door 2 and 3.

Defrost Mode Provides air flow through door 3.

2.57 OPERATOR'S AREA Ride Control (option)

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

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

Operation and Function

65ZVUS3121c

OFF

ON

switch-3

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

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

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

2.58 OPERATOR'S AREA Grease Gun Holder

Grease Gun Holder

90ZV5009

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

2.59 OPERATION Check before Operation

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

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

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

What to Look for

Bucket / Attachment

Damage, missing bolts, leaks, and excessive wear

Bucket Control Linkage

Damage, missing bolts, excessive wear, and looseness

Lights

Broken bulbs, wires or lenses

Radiator Fins

Trash and dirt build-up

Cooling System

Leaks and trash build-up

Batteries

Loose terminals

Steps and Handrails

Damage and cleanliness

Differentials (front and rear)

Leaks

Hydraulic System

Leaks

Final Drive (front and rear)

Leaks

Covers and Guards

Damage or missing

Transmission

Leaks

Instrument Panel

Broken gauges or indicator lights

Brake Lines

Damage and leaks

Engine Compartment

Leaks, debris build-up and flammable materials left

Battery

Loose items, leaks and debris build-up

Date:

Model-S/N:

Hours:

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

Inspector:

2.60 OPERATION Check before Operation

Greasing

Check Engine Oil Level

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

2. Lubricate fittings on the following components.

Wipe and clean all fittings before greasing.

CAUTION Hot engine oil and components may cause burns.

Avoid contact with hot oil or engine components.

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

Check and fill tube

Refer to "Recommended Lubricants" page 3.53 for the correct grease.

65TMV2 EG OIL

65ZV2 9511

- Axle support (two places)

H

IMPORTANT Grease axle supports daily to avoid axle support wear.

Be sure to fully lubricate the trunnion-two fittings.

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

L OM0226

2.61 OPERATION Check before Operation 1. Check the oil level with the dipstick.

2. Keep the oil level between the "H" (high) mark and "L" (low) mark on the dipstick.

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

Refer to "Recommended Lubricants" page 3.53 for the suitable viscosity of the oil according to the ambient temperature.

Check Hydraulic Oil Level

CAUTION Pressurized hydraulic tank is used for this machine.

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

Relieve all pressure by pressing down the filler cap.

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

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

NOTE Wait about 10~20 minutes after stopping the engine to measure the oil level. The precise oil level cannot be measured immediately after stopping engine due to residual oil in the upper parts of the engine.

Check Level

IMPORTANT

65ZV2 9118

Improper oil level may damage engine.

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

Add or drain oil to keep proper oil level.

1. Lower the attachment to the ground.

2. Stop the engine.

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

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

2.62 OPERATION Check before Operation

Check Engine Coolant Level

CAUTION

Filler cap

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

Avoid contact with skin and eyes to prevent injury.

FULL 65ZV4989a

LOW

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

Refer to "Recommended Lubricants" page 3.53 for the suitable viscosity of the oil according to the ambient temperature.

65ZV2 9506

1. Check the coolant level in the radiator subtank.

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

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

Refer to "Coolant Specification" page 3.55 for the correct mixture.

4. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 3.15.

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

2.63 OPERATION Check before Operation

Drain Water and Sediment from Fuel Filter

Check Wiring Harnesses

CAUTION 3 4

4

Short circuit of wiring harnesses may cause fire.

2

- 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.

1

65ZV2 1299

Articulation Stopper - Open drain plugs (1) on the bottom of fuel main filter (2) and pre-filter (3) to allow water and sediment to drain into a suitable container.

- Open air bleeder plugs (4) on the top of both filters.

- After draining water, be sure to tighten drain plugs (1) and air bleeder plugs (4).

Be careful not to over-tighten the air bleeder plug.

Tightening torque: 7.9~11.7 N-m (5.8~8.6 ft-lb) For air bleeding of fuel, refer to "Replace Fuel Filter Elements" page 3.37 - Dispose of the drained water and sediment properly.

CAUTION Escaping fuel is flammable and harmful to skin.

- Do not smoke while draining water and sediment from fuel filter.

- Do not drain with engine running.

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

"STORED" position

65ZV3061S

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

2.64 OPERATION Check before Operation

Check Tire for Damage, Air and Tread Depth

Low Pressure

OK

High Pressure

97ZVOM0103

OM0032

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

WARNING

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

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

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

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

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

WARNING Overheated tire could explode causing serious injury or death.

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

Stay away until tire and rim cool down.

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

Consult your tire dealer or Kawasaki dealer.

Refer to "Check Tire Air Pressure" page 3.26 for the adjusting procedure.

2.65 OPERATION Check before Operation

Check and Adjust Drive Belt

Tread

CAUTION

Side walls

Breakers Carcass

Contact with moving belt or pulleys may cause injury.

Stop engine before opening engine side panel.

Inspection

Beads / Bead wire

OM0104

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

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

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

2. Open the engine access panel.

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

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

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

98 N (22 lb) Idle pulley Alternator pulley

6.1~6.9 mm (1/4~17/64 in)

- 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.

Crank pulley

OM0227

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

5. Apply pressure, approximately 98N (22 lb), to the center of the belt between the pulleys. Correctly adjusted belt will slack 6.1~6.9 mm (1/ 4~17/64 in).

NOTE The drive belt slack should be 5.0~5.8 mm (3/ 16~15/64 in) when the belt is replaced with new one.

2.66 OPERATION Check before Operation

Check Air Intake System

Adjustment

CAUTION

2 3

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.

1 65ZV2 9579

1. Loosen bolt (1) and nut (2).

2. Turn adjusting screw (3) to adjust the belt tension correctly.

3. Tighten bolts (1) and nut (2).

Tightening torque: Bolt (1) 127 N-m (94 ft-lb) Nut (2) 76 N-m (56 ft-lb) 4. If new belts are installed, check and adjust them again after one hour of operation.

65ZV2 04063-0076

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

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

IMPORTANT Severe engine damage may result from running with unfiltered air.

Do not operate engine if any leaks or defects are found on air intake system.

2.67 OPERATION Check before Operation

Check Cooling Fan

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

2. The horn should sound loudly.

OK ROPS (Roll Over Protective Structure) Cab

OK

WARNING OM0102

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

2. Open the engine rear grill.

3. Visually inspect the cooling fan for damage.

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

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

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

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

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

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

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

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

2.68 OPERATION Check before Operation

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

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

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

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

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

Refer to "Indicators" page 2.25.

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

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

2.69 OPERATION Starting the Engine

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

PREHEAT

OFF

ON

START

- Do not start engine by shorting across starer terminals.

- Do not start engine while standing on ground.

65ZV0075

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

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

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

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

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

1. Do not depress the accelerator pedal.

PREHEAT

OFF

ON

- The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "TROUBLESHOOTING" page 3.56.

START

IMPORTANT Low engine oil pressure may cause severe engine damage.

65ZV0076

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

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

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

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

Be sure engine oil pressure warning lamp goes out quickly.

2.70 OPERATION Starting the Engine

Cold Start

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

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

PREHEAT

OFF

ON

- The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "TROUBLESHOOTING" page 3.56.

START

IMPORTANT Low engine oil pressure may cause engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

65ZV0077

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

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

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

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

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

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

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

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

2.71 OPERATION Check after Starting the Engine

Check after Starting the Engine

Check Warning Lamps

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

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

IMPORTANT STOP

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

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

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

85ZV2 0004US

1. Check the warning lamps on the instrument panel.

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

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

2.72 OPERATION Check after Starting the Engine

Check Fuel Level

Check Transmission Oil Level

DANGER

E

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

Crushing will result in serious injury or death.

F FUEL

65ZV0005

When checking oil level: - Low attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

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

- Make sure nobody is on machine.

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

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

Check and fill tube

Refer to "Recommended Lubricants" page 3.53 for the proper fuel.

65ZV2 9112

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

2.73 OPERATION Check after Starting the Engine

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

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

"LOCKED" position

65ZV3061L

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

Refer to "Articulation Stopper" page 1.28 3. Check the oil level with engine at low idle.

In hot

In cold

Specified oil level

97ZVOM0107

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

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

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

Do not overfill.

Refer to "Recommended Lubricants" page 3.53.

IMPORTANT Never mix CD engine oil and auto transmission fluid.

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

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

2.74 OPERATION Check after Starting the Engine

Check Service Brake Operation

Check Steering Wheel Operation

1. Turn "OFF" the declutch switch.

1. Be sure the area is clear of bystanders.

2. Firmly depress the left hand brake pedal.

2. Release the brakes.

3. Release the parking brake.

3. Steer fully right and then left.

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

4. Steering should be smooth in both directions.

5. Slowly accelerate the engine to full speed.

6. The machine should not move.

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

Do not operate until problem has been corrected.

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

2. Release the parking brake.

3. Move the shift lever to "REVERSE".

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

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

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

3. Stop the machine with the service brake.

4. Pull up the parking brake switch.

5. Release the service brakes.

6. The machine should not move.

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

Do not operate until problem has been corrected.

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

Do not operate until problem has been corrected.

2.75 OPERATION Check after Starting the Engine

Check Exhaust Gas

General Inspection

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

When inspecting machine while engine is running:

70ZV OM 2590

1. Check the color of the exhaust gas.

Normal exhaust gas color is clear or light gray when engine is warm. White, black, or blue smoke during steady warm operation of the engine indicates a malfunction. (It is normal for some black smoke to occur during rapid acceleration.)

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

Refer to "TROUBLESHOOTING" page 3.57.

- Make sure nobody is on machine.

- Lower attachment to ground.

- Turn parking brake switch to "ON".

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

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

2.76 OPERATION Operating the Machine

Operating the Machine

Starting the Machine

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

Do not stop engine while machine is moving.

WARNING

approx. 40 cm (16 in) OM0016

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

Be sure area is clear of personnel and obstructions.

IMPORTANT

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

2. Depress the brake pedal.

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

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

Do not operate machine on a grade over 30º.

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

30º Max. OM0194 97ZVOM0038

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

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

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

2.77 OPERATION Operating the Machine

Starting the Machine on a Grade

Speed and Direction Change

1. Turn "OFF" the declutch switch.

2. Depress the left brake pedal.

65ZV 5089

97ZVOM0038

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

1. Select the proper gear shifting mode by rotating the transmission shift lever. Refer to the following tables on page 2.78 for the gear selection mode.

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

65ZV 5089

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

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

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

2.78 OPERATION Operating the Machine

65ZVUS3121c

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

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

Refer to "Downshift Button" page 2.15.

Lever Position

Selected Gear

Operating Condition

1st

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

[2]

2nd

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

[3]

3rd

Carrying or roading

[A]

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

Scooping, loading, carrying or roading

[1]

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

Use proper gear for each job.

2.79 OPERATION Parking

Parking

97ZVOM0038 OM0025

1. Release the accelerator pedal.

WARNING

2. Apply the service brake to stop the machine.

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

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

Park machine in safe place on firm level ground.

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

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

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

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

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

2.80 OPERATION Stopping the Engine

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

Do not stop engine while machine is moving.

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

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

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

PREHEAT

OFF

ON

START

65ZV0074

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

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

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

Prevent unauthorized operation.

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

2.81 OPERATION Operating Techniques

Operating Techniques

Loading

IMPORTANT Machine damage may result from improper loading procedures.

- Do not dig or scoop with machine frame articulated.

- Do not drive machine into material at high speed.

30º Max. OM0194

IMPORTANT

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

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

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

Do not operate machine on a grade over 30º.

OM0111

1. Move the machine forward to the material.

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

OM0113

3. Lower the bucket parallel to the ground.

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

OM0112

OM0114

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

Reduce wheel slippage by slightly reducing engine speed.

OM0115

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

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

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

9. Reverse the machine.

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

2.83 OPERATION Operating Techniques

Excavating

Dozing

1. Move the machine forward to the material.

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

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

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

Keep bucket or attachment bottom parallel to ground.

OM0119

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

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

Increase engine speed as the bucket digs deeper.

OM0120

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

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

OM0123

2.84 OPERATION Operating Techniques

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

OM0123

OM0121

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

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

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

Be sure to run machine backward when leveling ground.

OM0122

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

2.85 OPERATION Operating Techniques

Carrying

Dumping into Truck or Hopper

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

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

Keep boom low for best stability especially on slopes.

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

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

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

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

IMPORTANT

Refer to "Loading" or "Excavating" page 2.81, 2.83 for the loading procedure.

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

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

OM0116

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

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

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

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

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

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

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

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

OM0195

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

OM0196

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

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

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

2.87 OPERATION Operating Techniques

Typical Truck Loading Methods

T Cycle Operation

I Cycle Operation

OM0126

OM0124

This method is recommended where the working area is limited.

V or L Cycle Operation (L-cycle)

(V-cycle)

OM0125

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

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

2.88 OPERATION Operating Techniques

Pallet Forks

Extendable Boom

65TMV0007

1. Move the machine slowly forward into position and engage the load. The machine should be square with the load, with the forks spaced evenly between the pallet stringers and as far apart as the load permits.

2. Move the machine forward until the load touches the carriage.

3. Lift the load carefully.

4. Operate the machine in reverse, until the load is clear enough to lower.

5. Lower the cradled load to the travel position.

Travel with the load as low as possible, while still maintaining ground clearance.

Travel with the load uphill on upgrades and downgrades.

For better vision, travel in reverse with bulky loads.

65TMV0008

Remove the retainer pins from the arm to extend or retract the arm.

Lift the load close to the machine for best stability.

Move the machine slowly to avoid excessive load swing.

Do not apply side loads on hook and shackle.

Check the condition of hook, shackle and any lifting chains.

Any sign of unusual wear indicates that it is time to replace with new parts.

2.89 OPERATION Operating Techniques

How to Use Quick Coupler (option)

4. Attachment hook

NOTE - The procedure shown is for the JRB manufactured Quick Coupler. Other manufacturers' attachment procedures may vary. If your coupler is not identified on the ID plate as "JRB", contact manufacturer for correct procedures.

5. Lock pin holes

Before attaching

- Many attachments are available for the JRB Quick Coupler. The attachment procedure is the same for all JRB attachments.

- Reverse the procedures to release the attachment.

a

CAUTION Do not attempt to use other manufacturers' attachments on the JRB Quick Coupler unless they are specifically designed to work on that Coupler design. The attachment may fall off if not properly designed for this Quick Coupler causing death, injury or equipment damage.

Be sure the attachment is of the correct size and capacity for the loader. Attachments from larger loaders may adapt to this Quick Coupler but exceed its rated load. Loss of stability may result in death, injury, and/or equipment damage.

Component Identification

65TMV0010

- Be sure all hoses are clear of the attachment area - Be sure the coupler and attachment are parallel and level - Be sure the coupler pins are fully retracted. The pins can be seen from the operator's seat.

- Operate the Auxiliary attachment control lever (page 2.6) to retract the pins.

Note left hose (a) position. The pins will not retract if hose (a) is not attached as shown.

To attach

3 4

1. Use the Bucket Control Lever to tilt the Coupler frame forward.

1

2. Lower the boom until the coupler frame bar clears the coupler attachment hooks.

5

2 65TMV0009

1. Coupler frame 2. Hydraulic hose - 3rd function 3. Hydraulic hose - attachment side (only on some attachments)

2.90 OPERATION Operating Techniques

65TMV0011

3. Slowly drive forward as shown to engage the coupler frame and attachment hooks.

65ZVUS3121c

5. Operate the Auxiliary Attachment Control Lever (page 2.6) to extend and lock the pins into the attachment lock pin holes. Engagement of the pins into the holes can be seen from the operator's area.

If the pins do not extend the attachment may not be properly aligned. Rock the attachment using the bucket control lever while moving the Auxiliary Attachment Control Lever. This should align the holes allowing pin engagement.

CAUTION 65TMV0012

4. Tilt the coupler frame back and slightly raise the boom.

The attachment should be raised a few inches or centimeters above the ground.

- A loose attachment may fall off causing death, injury, or equipment damage.

- Be sure the coupler is locked to the attachment.

Test by reversing the Procedure 4~1. The attachment should not come off.

NOTE Refer to page 2.24 for 2-way piping specification machine.

2.91 OPERATION Operating Techniques

a

65TMV0013

65TMV0014

6. If the attachment requires hydraulic power (logforks, side dump bucket, broom, auger, etc.) attach the hoses following these steps: 6a. Lower the attachment to the ground.

6b. Put the transmission in Neutral and apply the parking brake.

6c. Stop the engine and release the trapped hydraulic oil pressure by operating the control levers several times in each direction.

6d. Move to the coupler area and remove any protective caps from the hoses.

a

65TMV0015

6e. Move hose (a) from the right connector to the left connector.

NOTE Keep the hydraulic system clean. Wipe clean the connectors and hose ends before attaching. Use the caps, covers or plugs to protect the connectors.

65TMV0015

6f. Remove the attachment hoses from their storage points or remove the plugs.

2.92 OPERATION Operating Techniques

65TMV0016

6g. Route the hoses so they are free to move throughout the dump and roll back of the attachment. Connect them to fittings as shown.

6h. Start the engine and operate the Auxiliary Attachment Control Lever. The pins will extend and lock the attachment to the attachment to the coupler frame.

Also the attachment should operate.

NOTE - If the attachment operates in the opposite direction it normally does, reverse the attachment hoses.

- If the attachment does not operate be sure the connectors are fully connected.

2.93 SPECIAL PROCEDURES Adjustments

SPECIAL PROCEDURES Adjustments Bucket / Attachment Leveler Adjustment

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

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

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

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

4

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

Use safe sturdy platform to reach bucket leveler adjustment.

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

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

3 5±2 mm (1/8~1/4 in) OM0128

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

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

1

2

65TMV0003

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

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

5. Tighten bolts (1).

2.94 SPECIAL PROCEDURES Roading / Special Applications

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

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

Stay away until tire and rim cool down.

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

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

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

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

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

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

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

2.95 SPECIAL PROCEDURES Booster Batteries / Jumper Cables

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

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

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

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

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

- Keep flames and sparks away from batteries.

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

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

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

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

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

2. Raise and lock the battery box covers.

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

+

+ -

Booster Batteries

-

+

+

-

Batteries being boosted

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

Rear chassis close to starter motor ground being jump started

It could cause to shorten the battery life or to emit sparks from the deterioration parts in the case, as a result the battery case could explode.

4. Move back the protective rubber covers (red) from the positive post (+) of the battery.

Keep the battery electrolyte level in the proper level.

WARNING Batteries contain lead, and acid which may cause burns.

Avoid contact with skin or clothing and wear hand, eye, and face protection when working on or around batteries.

If lead, or acid contacts skin or clothing, immediately wash with water.

NOTE This machine uses a 24VDC negative ground electrical system.

OM0131

5. Connect one end of the red jumper cable to the positive post (+) of the discharged battery.

6. Connect the other end of the red jumper cable to the 24 volt side of the booster battery set or power source.

7. Connect one end of the black jumper cable to the ground side of the booster battery set or power source.

8. The final connection should be the remaining end of the black jumper cable to the rear chassis close to starter motor ground being jump started.

9. Start the booster machine's engine or turn the auxiliary power source on.

10. Allow a few minutes to provide partial charge to the discharged batteries.

2.96 SPECIAL PROCEDURES Booster Batteries / Jumper Cables 11. Start the machine being boosted as described on "Starting the Engine" page 2.69.

12. As soon as the engine starts, disconnect the jumper cables in the reverse order (Step 8, Step 7, Step 6, Step 5).

13. Remove the damp cloth and replace the protective covers over the battery terminals and close the battery box covers.

14. Test the starting / charging system to determine the cause of the problem and correct it.

2.97 SPECIAL PROCEDURES Towing

Towing The following is for emergency case only to move a troubled machine to a short convenient location for repair.

WARNING Improper towing could result in death or serious injury.

Follow safety warnings found under "Safe Operation -- SPECIAL OPERATING CONDITIONS:" page 1.9.

This machine is equipped with a hitch on the rear end for towing a troubled machine.

1. Inspect the cable for damage. Never use a damaged cable.

Drawbar

70ZV OM 2665

2. Connect the cable to the drawbar. Make sure the drawbar and split pin are in the original position.

3. Connect the other end of the cable to the troubled machine.

4. If the service brake on the towed machine does not work; do not allow an operator on the towed machine, and attach another vehicle of adequate size to the rear to act as a braking vehicle.

5. Keep personnel away from between the towing machine and the towed machine.

6. Tow the machine slowly with gradual and smooth movement (Towing speed: Max.10 km/ h) (6 MPH).

7. Use flashing lights or other warning signals when towing.

If your machine must be towed, contact your nearest Kawasaki dealer for the necessary information or assistance.

2.98 SPECIAL PROCEDURES Transportation

Transportation When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc.

It is a good idea to obtain a special platform for loading and unloading the machine.

1. Park the trailer on flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.

5. Lower the bucket and lock each control lever using the loading control lever lock (page 1.28).

6. Apply the parking brake and set the articulation stopper in the "LOCKED" position (page 1.28).

7. Tape over the exhaust stack outlet to prevent turbo "Wind-milling" damage.

65ZV0010

OM0132

8. Place blocks in front of and behind the tires to prevent the machine from moving.

2. Properly apply the brakes of the trailer and place wheel chocks in front of and behind the tires to ensure that the trailer does not move.

Cables or Chains

3. Fix the ramp in line with the centers of the trailer and the machine.

Front

Rear OM0207

9. Fasten the machine to the trailer with chains or cables at lower part of the rear chassis.

65ZV0009

4. Determine the position of the ramp, then slowly load the machine onto the specified part of the trailer.

NOTE Have someone in clear view and in a safe position provide directions while loading.

Additional cables or chains may be used but do not damage brake lines or cylinder rods.

IMPORTANT Brake pipe runs on axle housing.

Do not fasten axle housing.

2.99 SPECIAL PROCEDURES Transportation 10. Determine the route for transporting the machine by taking into account the width, height and weight of the machine and truck.

2.100 SPECIAL PROCEDURES Long Term Storage

Long Term Storage

9. Securely cover the inlet and outlet ports of the air cleaner and muffler.

Before Storage 1. Wash and clean all parts of the machine and touch up the paint finish to avoid rusting.

2. Lubricate every greasing point described in "Greasing" section page 3.18, 3.21, 3.28 and 3.46.

3. Be sure to refuel in the fuel tank.

4. Replace engine oil, transmission oil, differential and planetary oil and hydraulic system oil.

5. Idle the engine for about 15 minutes so that fuel and lubricant circulate throughout the engine, transmission and torque converter.

6. Store the machine indoors and keep it dry.

Never leave it outdoors. If forced to leave it outdoors, choose a flat place, place the machine on wooden blocks and securely cover it with a canvas or plastic cover, etc.

The range of temperature the machine is to be stored is between -35ºC ~ 45ºC (-31ºF ~ 113ºF).

OM0028

7. Disconnect the cables from the batteries or if freezing temperatures are expected, remove the batteries from the machine and store separately in a heated area.

8. If freezing temperatures are expected, check and adjust the antifreeze/water mixture.

Refer to "Coolant Specification" page 3.55 for the mixing ratio.

2.101 SPECIAL PROCEDURES Long Term Storage

Battery removal / reinstallation procedure

WARNING Batteries produce explosive gases which could cause burns or blindness.

4

5 2 1

3

6

- Ventilate area to remove explosive gases.

- Wear eye or face protection when working on or around batteries.

8

7

85ZV28463

- Keep flames and sparks away from batteries.

- Keep cable ends from touching each other or machine to avoid sparks.

1. Remove bolt (1)(2) and remove the rear lamp with plate (3) from the battery box.

Hang the rear lamp with plate (3) temporarily up on the rear chassis by rope.

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.

2. Disconnect battery cables (4)(5) from the battery.

3. Loosen rod nuts (6)(7) and remove plate (8) from the battery.

4. Remove the battery not to give it a tilt from the battery box.

If possible remove the battery from the battery box by two persons.

For reinstallation, follow the above procedure in the reversed direction.

Carry on the same procedure for the other battery.

2.102 SPECIAL PROCEDURES Long Term Storage

During Storage

After Storage

Once a month remove the covers, run the engine, and move the machine a short distance to form a new oil film on the lubricated parts.

WARNING Batteries contain lead, and acid which may cause burns.

Avoid contact with skin or clothing and wear hand, eye, and face protection when working on or around batteries.

70ZV OM 2529 USb

If lead, or acid contacts skin or clothing, immediately wash with water.

1. Check the following points.

Refer to "Check before Operation" page 2.59 and "Check after Starting the Engine" page 2.71.

- Coolant level - Engine oil level - Hydraulic oil level - Transmission oil level - Brake function - Steering function 2. Operate the machine as follows.

- Run just the engine for about five minutes at low idle.

- Move all cylinders of the hydraulic system full stroke 2~3 times.

- Run the machine about 10 m in every gear and direction.

- Move the steering full stroke each way about 2~3 times.

3. Operate the air conditioner as follows.

- Operate the air conditioner with the engine low idle for several minutes once a month so that the lubricating oil in each part of the compressor is not eliminated.

65ZV 3098

1. Loosen the drain cock or plug of the fuel tank and the hydraulic tank to drain any water into a suitable container. Dispose of properly.

2. Remove the covers, connect the cables to the batteries and start the engine.

3. Replace engine and transmission oil with new specified oil after warming up both engine and transmission.

Refer to "Replace Engine Oil and Oil Filter Cartridge" page 3.34 and "Replace Transmission Oil" page 3.40.

4. Start the engine and check for any abnormalities.

5. Warm up the machine until all gauges reach the normal range.

3.1

3.MAINTENANCE

3.2 MAINTENANCE Serial Number Location

MAINTENANCE Before performing maintenance or repairs, read, understand and follow "Safe Maintenance" section page 1.12.

The maintenance or repair of the machine must be performed by well-Trained or experienced personnel only.

WARNING Do not open high pressure fuel system with engine running.

Engine operation causes high fuel pressure.

High pressure fuel spray can cause serious injury or death.

65ZV2 WSHK0185

2. Engine Serial Number

High pressure fuel

Serial Number Location When contacting Kawasaki dealer or the dealers of other products for servicing or repair, refer to the serial number found in the following locations. See next page for general location.

TRANSMISSION

For quick reference, record each serial number in the blanks below.

KAWASAKI HEAVY INDUSTRIES,LTD.

MODEL SERIAL NO. MADE IN JAPAN

If a component, like engine or transmission, is changed, record the new serial number here.

SN PLATE 41668-2006

3. Transmission / Torque Converter Serial Number Model MODEL

Serial Number

SERIAL NO.

KAWASAKI HEAVY INDUSTRIES,LTD. MADE IN JAPAN SN PLATE 41668-2063

1. Machine Serial Number

Design Number

3.3 MAINTENANCE Serial Number Location

MANUFACTURED BY

J;B

COMPANY, INC

MODEL S/N P/N CAPACITY MADE IN U.S.A

BERGSTROM

OM0209

4. Bucket or Attachment Serial Number (Appearance of serial number plate differs depending on the manufacturer.)

6. Air Conditioner and Heater Serial Number

SERIAL NO.

-

70ZV0017

5. Seat Serial Number

70ZV0004

7. Cab Serial Number Model Number Serial Number

3.4 MAINTENANCE Serial Number Location

Cab (R.H Inside)

Heat & A/C

Seat Bucket S/N

Machine (R.H)

T/M

65TMV2 COMPO

E/G (L.H)

3.5 MAINTENANCE Inspection and Maintenance Table

Inspection and Maintenance Table

IMPORTANT Severe applications require more frequent maintenance.

Severe conditions include heavy dust, extremely abrasive material, caustic chemicals, extremely wet conditions or abnormally hot or cold ambient temperatures.

Check and/or carry out the maintenance at intervals of the specified operating hours below or the calender date, whichever comes first.

: First time replacement or cleaning only Section

Engine

Item for check

Operating hours 10

50

250

500

When

1000 2000 Required

Page

Check Engine Oil Level

2.60

Check Engine Coolant Level

2.62

Check Warning Lamps

2.71

Check Exhaust Gas

2.75

Drain Water and Sediment from Fuel Filter

2.63

Check Fuel Level

2.72

Check and Adjust Drive Belt

2.65

Check Air Intake System

2.66

Check Cooling Fan

2.67

Drain Water and Sediment from Fuel Tank

3.24

Replace Engine Oil and Oil Filter Cartridge

3.34

Replace Fuel Filter Elements

3.37

Clean Electromagnetic Fuel Pump Filter

3.39

Clean Fuel Feed Pump Strainer

3.39

Check Engine Compression Pressure

3.45

Check and Adjust Valve Lash Clearance

3.45

Clean Fuel Tank

3.49

Replace Electromagnetic Fuel Pump Filter Element

3.51

Clean or Replace Air Cleaner Element

3.10

Clean Radiator / Air cooler / Hydraulic oil cooler Fins

3.12

Clean or Replace Air Cleaner Element Replace Coolant Check Transmission Oil Level

Transmission Replace Transmission Oil Filter Cartridge & Torque Replace Transmission Oil Converter Clean or Replace Transmission Breather

After six cleanings or once a year

3.10

Every 2 years or 3000 hours

3.15 2.72 3.33, 3.36

3.40 3.42

3.6 MAINTENANCE Inspection and Maintenance Table

: First time replacement or cleaning only Section

Item for check

Operating hours 10

50

250

500

Brake system

Loading system

Page

Check Tire for Damage, Air and Tread Depth

2.64

Greasing (Axle support)

2.60

Check Tire Air Pressure

3.26

Check Differential Gear Oil

3.29 3.28

Axle system Greasing (Pillow block bearing unit)

Steering system

When

1000 2000 Required

Check Tightness of Wheel Bolts

3.30

Greasing (2nd Propeller Shaft Spline)

3.46

Replace Differential Gear Oil

3.48

Greasing (2nd Propeller Shaft)

Every 12000 hours

3.19

Greasing (3rd Propeller Shaft)

Every 12000 hours

3.19

Check Steering Wheel Operation

2.74

Greasing (Steering Cylinder)

3.23

Check Service Brake Operation

2.74

Check Parking Brake Operation

2.74

Adjust Parking Brake Lining

3.43

Check Service Brake Disk Wear

3.50

Check Brake Accumulator

3.50

Clean Filter for Brake Line

3.33, 3.50

Check Hydraulic Oil Level

2.61

Greasing

3.21

Replace Hydraulic Oil Return Filter

3.33, 3.42

Replace Hydraulic Oil, Clean Filter

3.47

Replace Filter in the Hydraulic Tank Cap

3.51

Replace Bucket Teeth (option)

3.8

Replace Cutting Edge

3.9

3.7 MAINTENANCE Inspection and Maintenance Table

: First time replacement or cleaning only Section

Chassis

Electrical system

Air Conditioner

Item for check

10

50

250

500

When

1000 2000 Required

Page

Adjust and Check Rear View Mirrors

2.67

ROPS (Roll Over Protective Structure) Cab

2.67

Greasing (Center Pin)

3.24

Check Ride Control Accumulator (option)

3.52

Check and/or Replace Seat Belt

3.10

Check Windshield Washer Fluid

3.14

Check Monitor Panel Operation

2.68

Check Horn Operation

2.67

Check Back-up Alarm Operation

2.74

Check Wiring Harnesses

2.63

Check Battery Electrolyte Level

3.25

Check or Replace Fuses

3.13

Check and Adjust Air Conditioner Belt

3.30

Clean Air Conditioner and Heater Filter Element Check Air Conditioner Refrigerant

3.31

Replace Air Conditioner Filter Elements

3.17

Clean Air Conditioner Condenser

3.15

Replace Air Conditioner Receiver Dryer

Others

Operating hours

Walk-Around Inspection

3.44

Every 3 years or 6000 hours

3.18 2.59

3.8 MAINTENANCE When Required Inspection and Maintenance

When Required Inspection and Maintenance WARNING Improper inspection or maintenance could result in death or serious injury.

Replace Bucket Teeth (option) When the bucket teeth are worn, replace them as follows.

1. Park the machine on level ground and apply the parking brake.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

1

2

Block 97ZVOM0136

2. Raise the bucket to a convenient height and put blocks under the bucket to prevent it from coming down.

3. Stop the engine.

4. Remove bolts and nuts (1), then remove bucket teeth (2).

5. Install the new teeth on the bucket with new bolts.

3.9 MAINTENANCE When Required Inspection and Maintenance

Replace Cutting Edge 1. Park the machine on level ground and apply the parking brake.

OM0188

WARNING Teeth and bucket edges are hardened steel which may chip when struck by steel hammer causing injury.

- Always wear eye protection.

- Use dead blow hammer or brass drift between hammer and tooth.

- Keep bystanders away from work area.

65ZV0011

2. Raise the bucket to a convenient height and put blocks under the bucket to prevent it from coming down.

3. Stop the engine.

6. To prevent any clearance between the tooth and the edge of the bucket, tighten the nut partially, then hit the top of the tooth.

4. Remove the cutting edge. Clean all contact surfaces (bottom of bucket, top of cutting edge).

7. Tighten the nuts to 539 N-m (398 ft-fb).

5. If other side of the cutting edge is not worn, turn it around and install it so that the new side faces the front. If both sides are worn, install a new cutting edge.

8. Retighten them after operating the machine for a few hours.

NOTE For non-Kawasaki buckets or teeth, consult the manufacturer for the proper procedures.

6. Install all bolts and tighten them to 539 N-m (398 ft-fb).

7. Retighten them after a few hours operation.

3.10 MAINTENANCE When Required Inspection and Maintenance

Check and/or Replace Seat Belt

Clean or Replace Air Cleaner Element When the warning monitor lamp lights up, clean or replace the air cleaner element.

IMPORTANT

Seat Belt

Improper procedure of cleaning air cleaner may cause severe engine damage.

Tether

70ZV0017

1. Inspect the condition of the seat belt and all mounting hardware frequently.

2. Replace the seat belt or any part of the mounting hardware if it is damaged.

- Do not clean or replace air filters while engine is running.

- Clean only outer element. Never clean inner element.

- Clean or replace element only when indicator lamp comes on.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

3. Replace the seat belt every three years regardless of its condition or appearance.

1

1

2 65ZV2 9506

2. Remove air cleaner cover (2) by releasing four cover latches (1).

3.11 MAINTENANCE When Required Inspection and Maintenance

5

3

4 65ZV2 Air Cleaner

3. Remove outer element (3) by slowly pulling it out.

4. Check the outer element, especially o-ring (4) fit in the cover correctly. If it is loose or deteriorated, replace it.

OM0139

6. Place a light inside the filter element. If the light spots are seen through the element, it must have cracks or pinholes. Replace it with a new element.

7. Check rubber seal (5), and if you find any damage, replace it with a new element.

8. Before installing the outer element, confirm that the inner element is seated properly, and then, reinstall the outer element.

9. Confirm that the o-ring fits properly, and secure the cover latches.

10. If the engine exhaust gas is not clean enough even after cleaning (still exhausting excessive black smoke), replace the element.

OM0138

5. Clean the element using dry compressed air (196 kPa (30 psi)) by applying from the inside of the element to blow off dirt and/or dust.

Apply the air along the length of the filter to avoid the damage to the paper element.

11. Be advised that the element cleaning should be effective up to 6 times. At the 7th maintenance or once a year as well as when you find any damage, replace both of the outer and inner elements.

3.12 MAINTENANCE When Required Inspection and Maintenance

Clean Radiator / Air cooler / Hydraulic oil cooler Fins 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

70V2E44026a

4. Remove clean-out traps from bottom of radiator shroud.

70ZV OM 2665

IMPORTANT Clean-out traps must be reinstalled securely, or engine performance will be affected.

IMPORTANT High pressure air or water may damage radiator / air cooler / hydraulic oil cooler fins.

70ZV27735a

2. Open the engine access panels both the right hand side and left hand side.

3. Push the knob and open the radiator grill.

Open the hydraulic oil cooler using the lock lever for clean the radiator / air cooler / hydraulic oil cooler.

- When used for cleaning purposes, the pressure of compressed air should be at 196 kPa (30 psi) or less.

- When using high-pressure water, keep the nozzle a distance of at least 500 mm (20 in) away from the core surface, applying the water jet perpendicular to the core.

- Move nozzle from side to side; not up and down.

5. Blow off mud, dirt, or clogging debris from the radiator / air cooler / hydraulic oil cooler fins with compressed air. Use a pressure washer to remove harder debris.

Compressed air or water should be directed from rear toward the engine.

6. Reverse the direction to flush all debris from the radiator / air cooler / hydraulic oil cooler fins.

7. Reinstall clean-out traps.

8. Close the hydraulic oil cooler and the radiator grill.

3.13 MAINTENANCE When Required Inspection and Maintenance 9. Close the engine access panels both the right hand side and left hand side.

Check or Replace Fuses

65TMV2 CONSOLE

65TMV2 FUSE

1. Park the machine on level ground, apply the parking brake, and lower the attachment to the ground.

2. Stop the engine and turn the starter switch key to the "OFF" position.

3. Open the covers of the main fuse box, cab fuse box and additional fuse box.

4. Check the fuses. If any blown fuses are found, replace them with new ones.

Refer to "Fuse Boxes" page 2.45.

5. Determine the cause of the blown fuses and repair.

3.14 MAINTENANCE When Required Inspection and Maintenance

Check Windshield Washer Fluid

IMPORTANT Using wrong capacity fuse or bypassing fuse may cause electrical system damage.

Engine room R.H

Never replace fuses with higher amperage rating.

70ZV2 02507-0134

1. Park the machine on level ground, apply the parking brake, and lower the attachment to the ground.

2. Check the fluid level.

3. Replace the fluid if it is dirty.

4. If the level is low, add fluid to proper level.

5. Use windshield washer solvent for both better cleaning and to prevent freezing. Adjust the mixture according to the manufacturer's instructions.

3.15 MAINTENANCE When Required Inspection and Maintenance

Clean Air Conditioner Condenser

Replace Coolant

If mud, insects, or other debris are stuck to the air conditioner condenser, air flow through the condenser will be reduced causing decreased cooling ability.

- Since the Anti-Freeze "Long Life Coolant" (LLC) is originally used for the machine shipped from the factory, it is not necessary to replace the coolant for the first two years.

- If the cooling system conditioner (from a local supplier) is used at the time of last replacement, follow its instructions or contact your nearest Kawasaki dealer for the replacement interval.

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

70ZV OM 0005

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Inspect the condenser and replace it if any damage is found.

Stop engine and allow radiator and coolant to cool completely, then open cap slowly to relieve pressure.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Inspect all coolant hoses.

3. Clean its fins using compressed air, a pressure washer or a soft brush. Be sure the air pressure is below 196 kPa (30 psi). If a pressure washer is used, keep the nozzle about 50 cm (20 in) away from the fins to prevent fin damage.

Replace any that are cracked, swollen, or brittle.

4. If water is used for the cleaning, cover the electrical parts of the engine and the electric condenser fan with plastic sheets. Remove the plastic sheets after cleaning.

IMPORTANT An excessively high air or water discharge pressure can damage the condenser fins.

65ZV2 9506

- When used for cleaning purposes, the pressure of compressed air should be at 196 kPa (30 psi) or less.

- When cleaning with water, apply the water jet perpendicular to the core.

3. Confirm the coolant in the radiator sub-tank is cool enough.

4. Remove the radiator sub-tank machine and drain coolant from it.

from the

3.16 MAINTENANCE When Required Inspection and Maintenance 8. Operate the engine for one hour with the coolant temperature above 80ºC (180ºF). Then let the engine cool down naturally with the engine shut "OFF".

9. Stop the engine and remove the drain plug to drain the cooling system.

10. Install the drain plug and fill the cooling system with clean water.

70ZV OM 2529 USb

5. Remove the drain plug and drain coolant (about 30 liters (7.9 gal) into a suitable container.

Do not install the radiator cap or the new coolant filter.

11. Operate the engine for five minutes with the coolant temperature above 80ºC (180ºF).

12. Stop the engine and remove the drain plug to drain the cooling system.

13. If the water being drained is still dirty, the system must be flushed again until the water is clean (step 7~13).

14. Install the drain plug and fill the system with the premixed coolant.

Refer to "Coolant Specification" page 3.55 for the mixing instruction.

70ZV27397a

6. Slowly turn the radiator cap until it touches the stopper to release inner pressure.

15. Idle the engine for five minutes to purge air mixed into the coolant. (Leave the radiator cap off.)

16. Add coolant as necessary.

Pushing the cap, turn it to open.

17. Reinstall the radiator cap.

Follow the law and/or local regulations to properly dispose of or recycle the coolant.

For additional cold weather servicing information, refer to "Coolant Specification" page 3.55 for details.

CAUTION Cooling system conditioner contains alkali that may cause caustic burns or blindness.

Avoid contact with skin and eyes to prevent injury.

7. Install the drain plug and fill the cooling system with clean water and cooling system cleaner.

Follow the manufacturer's instructions.

Do not install the radiator cap.

3.17 MAINTENANCE When Required Inspection and Maintenance

Replace Air Conditioner Filter Elements Outer filter replacement 1. Park the machine on level ground, apply the parking brake and lower the attachment to the ground.

2. Turn the air conditioner "OFF" and stop the engine.

70ZV0018

5. Install the cover to the cab and turn the rings clockwise to fix the cover.

Inner filter replacement

Inner filter

70ZV0018

3. The cover for the outer filter is located at the right rear side of the cab.

Filter cover

Turn the rings counterclockwise and then remove the cover.

70ZV0020

1. The inner filter is located at the right behind the operator's seat.

Unscrew the turn knob to remove the filter cover.

Remove the filter and clean or replace with a new one.

(Part number BER525777) 70ZV0019

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.

Filter may be washed with mild detergent.

Refer to "Clean Air Conditioner and Heater Filter Element" page 3.31

3.18 MAINTENANCE When Required Inspection and Maintenance

Replace Air Conditioner Receiver Dryer

Greasing

(Every 3 years or 6000 hours)

(Every 12000 hours)

- Contact your Kawasaki dealer.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page 3.53 for the correct grease. Use lithium base grease for universal joints.

3.19 MAINTENANCE When Required Inspection and Maintenance

65ZV0019

65ZV0022

- 3rd Propeller Shaft (two places)

65ZV2 9114

65ZV2 9113

- 2nd Propeller Shaft (three places)

3.20 MAINTENANCE Every 10 Hours or Daily

Every 10 Hours or Daily WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

See "Check before Operation" page 2.59 and "Check after Starting the Engine" page 2.71.

3.21 MAINTENANCE Every 50 Hours or 1 Week

Every 50 Hours or 1 Week WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

Every 50 hours or 1 week, whichever comes first, perform the following inspection and maintenance in addition to the "Daily Inspection and Maintenance".

Greasing 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Lubricate fittings on the following components.

Wipe and clean all fittings before greasing.

Lubricate until fresh grease is seen at each joint. Immediately replace or report any broken or defective grease fittings.

Refer to "Recommended Lubricants" page 3.53 for the correct grease.

65TMV0004

- Bucket-Boom (two places)

65TMV0004

- Bucket-Rod 2 (two places)

3.22 MAINTENANCE Every 50 Hours or 1 Week

65TMV0004

65TMV0004

- Boom Cylinder-Boom (two places)

- Lever 2-Rod 2 (two places)

65TMV0005

65TMV0004

- Bucket Cylinder-Lever 1 (two places)

- Lever 2-Boom (two places)

65TMV0005

65TMV0004

- Bucket Cylinder-Rod 2 (two places)

- Lever 1-Boom (two places)

3.23 MAINTENANCE Every 50 Hours or 1 Week

65TMV0005

- Lever 1-Rod 1 (two places)

65TMV0005

- Boom Cylinder-Front Chassis (two places)

65TMV0005

- Boom-Front Chassis (two places)

- Steering Cylinder (four places) L.H and R.H

65TMV0005

- Rod 1-Front Chassis (two places)

65ZV2 9112

3.24 MAINTENANCE Every 50 Hours or 1 Week

Drain Water and Sediment from Fuel Tank

CAUTION Escaping fuel is flammable and harmful to skin.

65ZV2 9531a

- Do not smoke while draining moisture and sediment from fuel tank.

- Do not drain fuel with engine running.

- Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

65ZV2 9112

- Center Pin (two places) 70ZV OM 2529 USb

2. Prepare a suitable container.

3. Loosen the drain plug on the bottom of the fuel tank.

4. Drain water and sediment along with fuel.

5. Retighten up the drain cock.

6. Dispose of the drained fuel and water properly.

7. Add fuel.

NOTE To reduce water and sediment build up in the tank, refuel the machine at the end of each shift.

3.25 MAINTENANCE Every 50 Hours or 1 Week

Check Battery Electrolyte Level

WARNING Batteries produce explosive gases which could cause burns or blindness.

- Ventilate area to remove explosive gases.

- Wear eye or face protection when working on or around batteries.

- Keep flames and sparks away from batteries.

70ZV2 7743

WARNING If the batteries being used have insufficient battery electrolyte level, parts in the battery case could rapidly deteriorate.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

It could shorten battery life or the battery case could explode.

2. Clean the battery surface with a clean cloth or soft brush.

Keep the battery electrolyte level at the proper level.

WARNING Batteries contain lead, and acid which may cause burns.

Avoid contact with skin or clothing and wear hand, eye, and face protection when working on or around batteries.

If lead, or acid contacts skin or clothing, immediately wash with water.

Dispose of used batteries by recycling.

Low

OK

High OM0096

3. Check the battery electrolyte level in each cell.

Electrolyte should cover the cell plates.

4. If the level is low, add distilled water until it reaches the bottom of the filler neck.

NOTE If a maintenance free battery is used, step 3 and 4 of this inspection and maintenance is not required.

3.26 MAINTENANCE Every 50 Hours or 1 Week

Check Tire Air Pressure Low Pressure

OK

High Pressure

OM0032

97ZVOM0103

WARNING

Tire performance and its life depend greatly on the tire air pressure.

Explosive separation of tire and rim parts could result in death or serious injury.

- Low air pressure causes excessive deflection, heat, and accelerated wear.

When inflating tires; - Make sure wheel parts are correctly installed.

- Use self-attaching air chuck with remote shutoff valve.

- Stand behind tread of tire and keep all persons away from side of tire.

- Do not inflate tire more than recommended pressure.

- Use safety cage if available.

- High air pressure cause reduced traction, slippage, and possible blow outs.

It is important to keep the tire pressure at the recommended level.

Special applications, such as long load and carry operations, may require different pressures. Consult the tire manufacturer.

WARNING Overheated tire may explode causing serious injury or death.

If overheated tire is suspected, do not approach tire to distance of less than 15 m (50 ft).

Stay away until tire and rim cool down.

OM0033

1. Before starting work and while the tires are still cool, measure the tire air pressure with the tire pressure gauge.

2. Adjust air pressure according to the recommended pressures below.

When inflating a tire, stand behind the tread and use a self-attaching chuck with a remotely located valve to turn air pressure on and off.

3.27 MAINTENANCE Every 50 Hours or 1 Week Recommended Tire Air Pressure (Bias ply tire)

Size

Air pressure kPa (psi) Front

Rear

14.0-24-12PR

490~510 (71~74) 392~412 (57~60)

17.5-25-12PR

422~441 (61~64) 324~343 (47~50)

20.5-25-12PR

353~373 (51~54) 255~275 (37~40)

For radial tires, tires with other patterns, or special operating conditions consult the tire manufacturer.

For liquid tire ballast consult your Kawasaki dealer or the tire dealer.

3.28 MAINTENANCE Every 250 Hours or 1 Month

Every 250 Hours or 1 Month WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

Greasing 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page 3.53 for the correct grease. Use lithium base grease for universal joints.

Every 250 hours or 1 month, whichever comes first, perform the following inspection and maintenance in addition to the "Daily" and "50 hours" inspections and maintenance.

65ZV2 9531a

- Pillow block bearing unit (one place)

3.29 MAINTENANCE Every 250 Hours or 1 Month

Check Differential Gear Oil

4. If there is any sign of water in the oil, drain and replace the oil. Oil containing water looks milky.

CAUTION The axles are pressurized through the hydraulic tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Before removing the oil level check plug, push down on the hydraulic tank cap to release the air pressure inside the hydraulic tank.

Do not touch the parts or oil when it is hot.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

2

1 65ZV0015

2. Remove oil level plug (1) from the front axle housing, using a 12 mm hex (Allen) wrench.

3. If the oil level is lower than the plug, add the specified oil through filling plug port (2).

Refer to "Recommended Lubricants" page 3.53.

Dispose of the drained oil properly.

5. Install and tighten the level plug.

6. Check the rear axle oil level following the same steps.

3.30 MAINTENANCE Every 250 Hours or 1 Month

Check Tightness of Wheel Bolts

Check and Adjust Air Conditioner Belt

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine access panel.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine. Remove the key and page "Do Not Start" tag on the instrument panel.

2. Open the engine access panel.

65ZV0016

2. Check the wheel bolts are tightened to 892 Nm (658 ft-lb).

3. Retighten if necessary.

OM0201

3. Visually inspect the compressor belt on both top and bottom sides for looseness and damage.

4. If the belt is too stretched to permit adjustment or shows cuts or cracks, replace it and adjust the tension correctly.

5. Apply pressure approximately 98 N (22 lb) to the center of the belt between the pulleys; deflection of about 10 mm (0.39 in) is normal.

3.31 MAINTENANCE Every 250 Hours or 1 Month

Clean Air Conditioner and Heater Filter Element

1

2

Outer filter cleaning

3

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground.

1

2. Turn the air conditioner "OFF" and stop the engine.

65ZV2 9512

6. If the belt is too loose or tight, adjust the tension by loosening lock nuts (1)(2) and turning adjusting nut (3) under the compressor bracket.

70ZV0018

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.

70ZV0019

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. Use air pressure below 196 kPa (30 psi).

3.32 MAINTENANCE Every 250 Hours or 1 Month 6. To remove more stubborn debris, wash the filter with clean water. Leave them for five to seven days to dry out of direct sunlight.

7. After approximately 8~10 cleanings, replace the filter with new one. (Part number 4033060270) Refer to "Replace Air Conditioner Filter Elements" page 3.17.

2. Remove dust with compressed air. Use air pressure below 196 kPa (28 psi).

3. After approximately 8~10 cleanings, replace the filters with new one. (Part number BER525777) Refer to "Replace Air Conditioner Filter Elements" page 3.17.

4. Install the filter elements, install the filter cover.

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.

70ZV0018

9. Install the cover to the cab and turn the rings clockwise to fix the cover.

Inner filter cleaning

Inner filter Filter cover

70ZV0020

1. The inner filter is located at the right behind the operator's seat.

Unscrew the turn knob to remove the filter cover.

Remove the filter and clean.

NOTE It is recommended to have a second set of filters to use while another set is drying.

3.33 MAINTENANCE Every 250 Hours or 1 Month

Replace Filter (First time replacement or cleaning only) - Transmission Oil Filter Cartridge Replace it first time only at 250 hours operation, after that replace it at every 500 hours operation.

Refer to "Every 500 Hours or 3 Months" page 3.36.

After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

- Hydraulic Oil Return Filter Replace it first time only at 250 hours operation, after that replace it at every 1000 hours operation.

Refer to "Every 1000 Hours or 6 Months" page 3.42.

After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

- Brake Line Filter Clean it first time only at 250 hours operation, after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page 3.50.

3.34 MAINTENANCE Every 500 Hours or 3 Months

Every 500 Hours or 3 Months WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

Every 500 hours or 3 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", and "250 hours" inspection and maintenance.

Replace Engine Oil and Oil Filter Cartridge

CAUTION Hot oil and engine components may cause burns.

Avoid contact with hot oil or engine components.

1. If the machine is cold operate the engine to bring the engine coolant temperature about 40ºC (105ºF). When the needle of the coolant temperature gauge reaches the middle of the white zone, the temperature is about 40ºC (105ºF).

2. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

65ZV2 9511a

3. Loosen the drain plug.

4. Drain oil, about 16 liters (4.2 gal), into a suitable container.

3.35 MAINTENANCE Every 500 Hours or 3 Months

Check and fill tube

65TMV2 EG OIL

65ZV2 0226

5. Remove the oil filter and properly dispose of it.

Make sure the O-ring is removed with the filter.

11. Fill the engine with clean oil to the proper level.

Refer to "Recommended Lubricants" page 3.53 for the oil specifications. Total system capacity including the filter is 16 liters (4.2 gal).

6. Clean the oil filter head gasket surface.

7. Fill the new filter with clean engine oil.

Refer to "Recommended Lubricants" page 3.53 for the oil specifications.

8. Apply a light film of engine oil to the gasket surface of the new filter cartridge.

12. Idle the engine to inspect for leaks at the filter and the drain plug.

13. Stop the engine. Wait approximately 10~20 minutes to let the oil drain back to the oil pan.

14. Check the oil level again.

15. Add the specified oil if necessary to bring the oil level to the "H" (High) level on the dipstick.

16. Properly dispose of or recycle the waste oil.

17. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

OM0200

CAUTION

9. Install and tighten the filter until the gasket contacts filter head surface. Then tighten it using a filter wrench an additional one turn.

Used engine oil may cause skin disease or irritation.

Refer to the instructions supplied with the filter.

Do not allow used engine oil to remain on skin for prolonged periods of time.

10. Retighten the oil drain plug, and tighten to 80 N-m (60 ft-lb) torque.

Clean skin thoroughly with soap and water.

3.36 MAINTENANCE Every 500 Hours or 3 Months

Replace Transmission Oil Filter Cartridge

DANGER Accidental movement of machine could result in death or serious injury.

CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

1. If the machine is cold, operate the machine to bring the torque converter oil temperature about 30~40ºC (85~105ºF).

2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

When inspecting or servicing machine in articulation area: - Lower attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

- Make sure nobody is on machine.

- Place "DO NOT OPERATE" tag on steering wheel.

3. Place a suitable container (about 4 liters (1 gal)) under the transmission oil filter.

65ZV2 9112

65ZV 3098

4. Turn the filter counterclockwise to remove.

Properly dispose of the oil and filter.

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of the new filter.

7. Install the filter on the filter head. Turn it clockwise to tighten. Follow the instructions on the filter.

8. Idle the engine about ten minutes and inspect for leaks around the filter.

9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 2.72.

Add the specified oil as necessary to bring the oil level to the "H" (high) mark on the dipstick.

Refer to "Recommended Lubricants" page 3.53 for the specified oil.

10. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

CAUTION Used oil may cause skin disease.

Do not allow used oil to remain on skin for an extended period of time.

Clean skin thoroughly with soap and water.

3.37 MAINTENANCE Every 500 Hours or 3 Months

Replace Fuel Filter Elements

Main filter Air bleeder plug

CAUTION Escaping fuel is flammable and harmful to skin.

- Do not smoke while draining water and sediment from fuel filter.

- Do not drain with engine running.

- Do not allow diesel fuel to remain on skin for an extended period of time. Wash thoroughly with soap and water.

Cartridge Priming pump

Case Drain plug 65ZV2 IMWG0023

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 2 liter (0.5 gal)) under the fuel filters.

(65J4-4001~4016)

65ZV2 8980131700

3. Loosen drain plugs (1) and air bleeder plugs (2), and drain the fuel in the fuel filter.

65ZV2 0173b

(65J4-4017~)

4. Use a specified filter wrench (Part number 89801-3170-0) to remove the filter case.

5. Replace the cartridge.

2

6. Replace the O-ring of the filter case and apply fuel to the O-ring.

Turn the filter case until the O-ring contacts its sealed face.

Tightening torque: Filter case 29.4 N-m (21.7 ft-lb) Drain plug 1.5~2.5 N-m (1.1~1.8 ft-lb)

1

65ZV2 1299

Do not fill the fuel filter with fuel before installation.

3.38 MAINTENANCE Every 500 Hours or 3 Months 4. Start the engine with no acceleration pedal pushed.

IMPORTANT Do not manually fill the fuel into the fuel filter to prevent dust or dirt come into the fuel line.

A small amount of dirt could cause a serious problem with the fuel injection system.

7. After replacing the fuel filter elements, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

Fuel system air bleeding The entry of air into the fuel system may cause hard engine starting or engine malfunction.

When emptying the fuel tank, draining water from fuel or replacing fuel filter element, be sure to purge fuel line of air.

1

If the engine does not start this time, repeat the procedure from step 2.

5. After the engine starts, keep the idling engine speed for 5 minutes.

6. Slowly increase the engine speed and keep the speed for 3 minutes.

7. Operate the engine speed to the maximum.

Repeat this operation several times.

NOTE If the engine does not start, or it is difficult to start, or the engine does not run smoothly, stop the engine and bleed it again.

IMPORTANT Do not use an alcohol based fuel treatment.

Alcohol may crack or cloud visibility of plastic parts. This may result in low visibility of fuel level or fuel leakage.

IMPORTANT - To protect starter and battery, do not keep the starter switch in the "START" position for more than 20 seconds.

- Do not turn the starter switch key to the "START" position while the engine is running.

2 3

65ZV2 1299

1. Turn the starter switch key to the ON position to put the electromagnetic pump in the operating condition.

2. Loosen air bleeder plug (1) on fuel main filter (3) fully, and push priming pump (2) (20 times or more) until fuel comes out from air bleeder plug.

3. Tighten air bleeder plug (1) securely and wipe off fuel around vent area.

3.39 MAINTENANCE Every 500 Hours or 3 Months

Clean Electromagnetic Fuel Pump Filter

Clean Fuel Feed Pump Strainer

CAUTION Escaping fuel is flammable and harmful to skin.

- Do not smoke while draining water and sediment from fuel filter.

- Do not drain with engine running.

- Do not allow diesel fuel to remain on skin for an extended period of time. Wash thoroughly with soap and water.

65ZV2 4HK1X Fuel Pump

5 1 1

2

65ZV2 1301

3 2

4

4HK1X Fuel Pump

1. Place a suitable container under the feed pump and remove joint bolt (1).

1. Remove wiring (1) from cover (2) of the pump.

Then turn the cover to remove.

2. Remove strainer (2) from joint bolt. Properly clean the strainer and blow off dirt and/or dust.

CAUTION

CAUTION

When removing cover, place a container to drain oil to protect engine.

Remove flammable materials from engine component area.

Compressed air may cause injury.

2. Remove filter element (3), and clean it with diesel oil. Then blow off dust and dirt with the compressed air (196 kPa (30 psi)).

3. For installation, follow the above procedure in reverse order.

3. Replace gasket (4)(5) with new one, and assemble the filter element and cover.

IMPORTANT Hasten interval for cleaning according to fuel charge and resupply condition.

- Wear protective clothing and eye protection.

- Air pressure must be below 196kPa (30 psi).

After cleaning the strainer, be sure to purge fuel line of air. Refer to "Replace Fuel Filter Elements" page 3.37.

3.40 MAINTENANCE Every 1000 Hours or 6 Months

Every 1000 Hours or 6 Months WARNING

Replace Transmission Oil

WARNING

Improper inspection or maintenance could result in death or serious injury.

Accidental movement of machine could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

When inspecting or servicing machine in articulation area: - Lower attachment to ground.

- Put transmission shift lever in neutral.

- Apply parking brake.

- Make sure nobody is on machine.

- Place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel.

Every 1000 hours or 6 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", and "500 hours" inspection and maintenance.

CAUTION Transmission oil may be hot and may cause burns.

Avoid contact with transmission oil.

1. If the machine is cold operate the machine for a few minutes to bring the transmission oil temperature about 30~40ºC (85~105ºF).

2. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

1

65ZV2 9109

3. Remove drain plug (1) with a 17 mm wrench.

4. Drain oil into a suitable container (about 20 liters (5.3 gal)).

Properly dispose of or recycle the waste oil.

3.41 MAINTENANCE Every 1000 Hours or 6 Months 12. Check the oil level with the dipstick. Add the specified oil if necessary to maintain the proper oil level.

Refer to "Check Transmission Oil Level" page 2.72 and "Recommended Lubricants" page 3.53.

3

13. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

2 65ZV2 9107

Refer to "Replacement Monitor" page 2.38.

5. Loosen four bolts (2) with a 14 mm wrench.

6. Remove flange (3) together with the pipe and suction strainer.

7. Remove suction strainer from the flange, brush off any debris and clean with solvent.

It is normal for a few fine particles to be on the strainer. Large pieces or a large quantity of particles indicates a problem.

Contact a Kawasaki dealer.

8. Reinstall the drain plug and the strainer with a new gasket.

9. Tighten four bolts (2) to 68.6 N-m (50.6 ft-lb).

10. Fill with the specified oil.

Refer to "Recommended Lubricants" page 3.53.

11. Idle the engine and check for leaks.

65ZV2 9112

3.42 MAINTENANCE Every 1000 Hours or 6 Months

Clean or Replace Transmission Breather

Replace Hydraulic Oil Return Filter

CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler cap.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

65ZVOM3085

2. Open the access cover on the right deck.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Remove the breather from the transmission case.

2

1 Filler cap

3. Clean the breather in the cleaning oil tub, then spray dry compressed air from the bottom of the breather.

Even after cleaning, if the breather is not clean enough, replace the breather.

65ZV4989a

4. Install the breather onto the transmission case.

3. Press down the filler cap to relieve the tank pressure.

4. Clean around the top of filter cover (1).

5. Remove two bolts (2) with a 17 mm wrench and open filter cover (1).

Two bolts (2) may be used as "Jacking screws" to push up the cover. Install them into the two threaded holes in the cover. Screw them in equally to force the cover up evenly.

3.43 MAINTENANCE Every 1000 Hours or 6 Months

Adjust Parking Brake Lining

1

2

WARNING 3

When parking brake is released for adjusting brake lining, machine could move unexpectedly causing serious injury or death.

4 5

Make sure to lower attachment to ground, and put chocks under wheels.

6 97ZVOM0166

6. Remove O-ring (3), spring (4), and bypass valve (5) from the filter housing.

7. Remove and properly dispose of filter (6) and waste oil.

1. Park the machine in a safe place on firm level ground and steer it fully to one side for easier access.

2. Lower the attachment to the ground and turn "OFF" the parking brake switch.

8. Clean the inside of the filter housing.

9. Replace O-ring (3).

1

10. Apply a light film of clean hydraulic oil on the filter cover O-ring surface.

11. Install filter element (6), bypass valve (5), spring (4), new O-ring (3) and filter cover (1).

12. Close the access cover.

65ZV2 9109

13. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

1 8º

OM0167

3. Align inspection hole (1) with the adjuster wheel by turning the hole 8º counterclockwise from the bottom.

Do not enter the articulation area or under the machine.

3.44 MAINTENANCE Every 1000 Hours or 6 Months 4. Place wheel chocks in front of and behind the tires to prevent the machine from moving.

Check Air Conditioner Refrigerant

5. Place a "DO NOT OPERATE" tag on the steering wheel.

Engine room R.H

Adjuster wheel

1 70ZV2 03120-0117

Special Tool (Accessory) 97ZVOM0168

6. Remove a cap of inspection hole (1) on the brake drum.

7. Turn the adjuster wheel fully upward to close the clearance between the brake drum and the brake lining (shoe). The adjuster wheel can be reached through the inspection hole.

8. Return the adjuster wheel eight clicks downward. (Now the clearance is 0.23 mm (0.009 in)) 9. Check parking brake operation as described on page 2.74.

NOTE If the brake drum has been excessively hot (ie. burnt paint) or the parking brake will not adjust, contact your Kawasaki dealer.

1. Apply the parking brake and lower the attachment to the ground.

2. Remove the cover.

3. Press the flow control switch to set maximum air flow.

4. Set the temperature control switch fully to the cool position and fully open the cab doors.

5. Slightly accelerate the engine to about the middle speed range. (compressor speed 1,500~1,800 min-1 (RPM)) 6. Compare the flow of bubbles in the sight glass with the drawings in the following table.

The new receiver drier also has moisture sensor window with color code to indicate moisture in the system.

WARNING Overfilled refrigerant may cause dangerous high pressure and poor cooling action; and low refrigerant level may cause compressor damage.

Always maintain refrigerant in normal level.

3.45 MAINTENANCE Every 1000 Hours or 6 Months

Check Engine Compression Pressure Adjust of refrigerant Normal

Appearance of the sight glass

Solutions

Almost clear.

Any bubbles disappear if the engine speed is increased to 1,500 min-1.

High

No bubble is seen.

Low

A flow of bubbles is visible.

- Contact your Kawasaki dealer or local ISUZU engine dealer.

Check and Adjust Valve Lash Clearance Contact your local Kawasaki loader dealer for inspection and recharging refrigerant.

- Contact your Kawasaki dealer or local ISUZU engine dealer.

3.46 MAINTENANCE Every 2000 Hours or 1 Year

Every 2000 Hours or 1 Year WARNING Improper inspection or maintenance could result in death or serious injury.

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 1.12 before performing any inspection or maintenance procedures.

Every 2000 hours or 1 year, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", "500 hours", and "1000 hours" inspections and maintenance.

Greasing 1. Park the machine on level ground.

Lower the attachment to the lowest position and tilt back the bucket fully.

2. Steer the machine fully to the right or left, and stop the engine.

3. Lubricate the fitting on the sleeve yoke.

4. To lubricate the spline enough, start the engine and slowly turn the machine from side to side 2 or 3 times after greasing.

Refer to "Recommended Lubricants" page 3.53 for the correct grease. Use lithium base grease for universal joints.

65ZV2 9113

- 2nd Propeller Shaft Spline (one place)

IMPORTANT When greased with the machine in straight, remove the fitting on the sleeve yoke and follow the procedure above step 4.

3.47 MAINTENANCE Every 2000 Hours or 1 Year

Replace Hydraulic Oil, Clean Filter

WARNING Pressurized hydraulic tank is used for this machine.

2

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler cap.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Move the bucket and boom control levers back and forth to relieve the pressure.

1

65ZV 3098

7. Remove drain plug (1) using a 24 mm wrench to drain oil.

8. Dispose of the waste oil properly.

9. Remove the nuts with a 14 mm wrench to remove inspection cover (2).

CAUTION Compressed air may cause injury.

- Wear protective clothing and eye protection.

- Air pressure must be below 196 kPa (30 psi).

10. Remove the suction strainer. Inspect and clean them with solvent and compressed air.

65ZV4989a

3. Insert the key into the side of the filler cap and turn the key counterclockwise.

4. Press down the filler cap to relieve the tank pressure.

5. Remove the inlet cap.

CAUTION

A few small particles in the strainer is normal.

Large metal, rubber pieces, or a large amount of fine particles is abnormal. If found, contact your Kawasaki dealer.

11. Clean inside of the tank and magnet plug.

12. Install the suction strainer, new gasket (Part number 31990-20020) and inspection cover (2), and tighten the nuts. Do not overtighten.

Hydraulic oil may be hot and may cause burns.

13. Install and tighten the drain plug.

Avoid contact with hydraulic oil.

14. Add the specified hydraulic oil through the oil inlet hole.

6. Prepare a suitable container to catch the draining oil (about 70 liters (18.5 gal)).

Refer to "Recommended Lubricants" page 3.53.

15. Close the oil inlet cap.

3.48 MAINTENANCE Every 2000 Hours or 1 Year 16. Start the engine and allow the engine to idle for about five minutes.

17. Operate the bucket, boom, and steering cylinders for about five minutes, then lower the attachment to the ground.

18. Inspect for leaks.

19. Make sure hydraulic oil is to the center of the oil level gauge. Add hydraulic oil if necessary.

20. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

Replace Differential Gear Oil

CAUTION The axles are pressurized through the hydraulic tank.

When removing the oil level check plug a large volume of hot oil could spray out. It causes serious burns.

Before removing the oil level check plug, push down on the hydraulic tank cap to release the air pressure inside the hydraulic tank.

Do not touch the parts or oil when it is hot.

1. If the machine is cold operate the machine for a few minutes to bring the differential gear oil temperature about 40ºC (105ºF).

2. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

1 2

3 65ZV0015

3. Remove filling plug (1), level plug (2) and drain plug (3) from the front axle housing, with a 12 mm Hex (Allen) wrench.

Some fine metallic powder will normally stick to the magnet plugs.

Simply wipe it off.

3.49 MAINTENANCE Every 2000 Hours or 1 Year 4. Drain the oil (about 25 liters (6.6 gal)) into a suitable container.

Clean Fuel Tank

CAUTION

5. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease.

Do not allow used oil to remain on skin for prolonged periods of time.

Clean skin thoroughly with soap and water.

6. Install the drain plug.

7. Refill the recommended oil through filling plug hole (1) until the oil comes out from level plug hole (2).

Refer to "Recommended Lubricants" page 3.53.

8. Install and tighten plug (1) and (2).

Escaping fuel is flammable and harmful to skin.

- Do not smoke while draining moisture and sediment from tank.

- Do not drain with engine running.

- Do not allow fuel to remain on skin for an extended period of time. Wash thoroughly with soap and water.

NOTE It is easiest to clean the fuel tank when the fuel is almost empty.

1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2

9. Replace the rear axle gear oil following the same steps.

Required oil volume for the rear axle is about 25 liters (6.6 gal).

10. After replacing the filter and/or oil, reset the interval timer for the replacement. Go to the timer reset screen of the MODM, and reset the corresponding replacement interval.

Refer to "Replacement Monitor" page 2.38.

1 70ZV OM 2529 USb

2. Open drain cock (1) on the fuel tank.

3. Drain the remaining fuel into a suitable container.

4. Remove the nuts with a 14 mm wrench to remove inspection cover (2).

5. Clean inside of the tank.

6. Install the inspection cover with a new gasket.

(Part number 31990-20020) Tighten the nuts evenly. Do not overtighten.

7. Close the drain cock.

8. Fill the fuel tank.

9. Check for any leaks at the cover and plug.

3.50 MAINTENANCE Every 2000 Hours or 1 Year

Check Brake Accumulator

Clean Filter for Brake Line

Test the brake accumulator for proper pre-charge of nitrogen gas.

CAUTION Hot oil and components may cause burns.

WARNING Pressurized nitrogen gas in brake accumulator could explode causing serious injury or death.

Vent all pressure by pressing hydraulic cap down.

Avoid contact with hot oil or components.

Never service brake accumulator unless trained properly.

1. Park the machine on level ground, apply the parking brake, and lower the attachment to the ground.

1. Park the machine on level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

2. Run the engine at low idle for five minutes to fill the brake accumulator with oil.

3. Stop the engine.

4. Turn the key switch to the "ON" position.

5. Count the number of times you can depress the right hand brake pedal before the brake warning light comes on.

65ZV2 03248-0146

6. If the number counted is less than eight, there is some problem with the accumulator. Contact your nearest Kawasaki dealer.

Air blow

Check Service Brake Disk Wear FLOW

- Contact your Kawasaki dealer.

Filter case

Filter

Nipple

OM0212

2. Place a suitable container under the filter.

3. Remove the nipple with filter and properly clean the filter.

4. Install the nipple with filter and tighten it with 60~80 N-m (44~59 ft-lb) torque.

5. Idle the engine about ten minutes and inspect for leaks around the filter.

3.51 MAINTENANCE Every 2000 Hours or 1 Year

Replace Filter in the Hydraulic Tank Cap

Replace Electromagnetic Fuel Pump Filter Element

CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before opening.

1 65ZV2 4HK1X Fuel Pump

5 4 3 2

5 97ZVOM0170

1 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Move the bucket and boom control levers back and forth to relieve the pressure.

3. Insert the key into the side of filter cap (1) and turn the key counterclockwise.

4. Press down filter cap (1) to relieve the tank pressure.

3 2

4

4HK1X Fuel Pump

1. Remove wiring (1) from cover (2) of the pump.

Then turn the cover to remove.

CAUTION

5. Remove the filter cap.

When removing cover, place a container to drain oil to protect engine.

Remove flammable materials from engine component area.

6. Remove spiral snap ring (2), valve assy (3), spring (4), filter element (5).

2. Remove filter element (3), and gasket (4)(5).

7. Replace element (5). (Part number 3098170330)

3. Replace filter element (3) and gasket (4)(5) with new ones, and assemble the cover.

8. Install the element, spring, valve assy, and spiral snap ring.

3.52 MAINTENANCE Every 2000 Hours or 1 Year

Check Ride Control Accumulator (option)

WARNING Pressurized nitrogen gas in ride control accumulator could explode causing serious injury or death.

Never service ride control accumulator unless trained properly.

Contact your nearest Kawasaki dealer.

3.53 MAINTENANCE Recommended Lubricants

Recommended Lubricants

Engine

Transmission

Refill capacity (Approximate)

Kind of Oil

18.6 liter (4.9 gal)

Engine oil (CF4)

20 liter (5.3 gal)

ATF Engine oil (CD) Mobil TRANS HD-10 Valvoline DT10

Hydraulic tank

∗1 70 liter (18.5 gal)

∗2 Hydraulic oil

Differential & Planetary

Front: 25 liter (6.6 gal) Rear: 25 liter (6.6 gal)

Mobil TRANS HD-50 Valvoline DT50

Fuel tank

210 liter (55.5 gal)

Diesel fuel

Ambient Temperature (ºC) -30

-20

-10

0

10

20

30

40

Change Interval (Hours)

SAE10W-30 SAE15W-40

500

Multi-Purpose ATF SAE10W Mobil TRANS HD-10

1,000

Valvoline DT10 ISO VG32 ISO VG46

Mobil TRANS HD-50 Valvoline DT50 ASTM D975 No.1 ASTM D975 No.2

2,000

2,000

daily

Note: ∗1 shows "Hydraulic tank oil capacity at level gauge center."

Engine

Use oil that meets engine oil classification API CF4.

Transmission

Use engine oil classification API "CD".

Mobil TRANS HD-10.

Valvoline DT10.

Multi-purpose Automatic Transmission Fluid.

Never mix engine oil, Mobil TRANS HD-10, Valvoline DT10 and/or ATF.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure. ∗2. In a case that fire-resistant fluid is used in the hydraulic circuit, replace hydraulic pump every 6,000 hrs operation.

Differential & Planetary

Use Mobil TRANS HD-50, Valvoline DT50 or equivalent with 5% "Antichatter" additive or friction modifier.

Lubricating Grease

Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.

NLGI NO.1 or NO.0 grease for extremely low temperature.

Use lithium base grease for a needle bearing.

3.54 MAINTENANCE Recommended Lubricants

Diesel Fuel

Requirements for diesel fuel

Specifications Flash Point

ºC.

min.

Water and Sediment % vol.

max

Distillation Temperature

90 % vol.

ºC

recovered

Kinematic Viscosity mm2/s at 40ºC Ash % mass

max.

max.

Cetane Number

min.

Carbon residue on 10 % distillation residue % mass

Grade No.2-D

38

52

0.05

0.05

288

338

min.

1.3

1.9

max.

2.4

4.1

max.

Sulfur % mass

Grade No.1-D

max.

0.01

0.01

0.50

0.50

40

40

0.15

0.35

3.55 MAINTENANCE Coolant Specification

Coolant Specification The machine is originally filled with Long Life Coolant (non-Amin type ethylene glycol) which need not be replaced for the first two years or 3000 hours.

Do not use Amin type Long Life Coolant in cooling system. It may cause a corrosion against radiator or heater core.

If standard antifreeze (not Long Life Coolant) is used for the replacement, it should be replaced every six months.

Recommended Mixture of Antifreeze Expected Minimum -35ºC Ambient Temperature

-30ºC

-25ºC

-20ºC

-15ºC

Pure Water

liter (gal)

14.1 (3.7)

15.6 (4.1)

17.1 (4.5)

18.6 (4.9)

20.1 (5.3)

Antifreeze

liter (gal)

15.9 (4.2)

14.4 (3.8)

12.9 (3.4)

11.4 (3.0)

9.9 (2.6)

Mixture Ratio (%)

53

48

43

38

33

- Too much antifreeze in the coolant mixture may cause engine overheating.

Keep 33 % antifreeze mixture (same as the mixture for a minimum ambient temperature of -15 ºC (5ºF)) if the engine overheats in a high ambient temperature.

- Do not use hard water or water with high levels of calcium and magnesium ions as the coolant water.

IMPORTANT Do not mix different brands of antifreeze because they each contain special additives.

Careless mixing often diminishes the effect of these additives and causes packing damage or water leakage.

3.56 TROUBLESHOOTING

TROUBLESHOOTING This troubleshooting section is not intended to cover every condition, however many of the common possibilities are listed.

Following are example of problems and their solutions.

Contact your local Kawasaki dealer for the items marked with or your local authorized ISUZU ENGINE dealer for the items marked with to repair. kawasaki

ISUZU

ENGINE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Add oil Change oil Change filter and oil

2.60 3.34 3.34

Engine oil pressure warning lamp lights up, and buzzer sounds

Low engine oil level Wrong grade oil for weather conditions Clogging oil filter element Defective alarm switch Oil leakage from pipe or joint Clogging suction strainer Excessive engine wear Defective oil pump

2.62

Coolant temp. warning lamp lights up

Add coolant Low engine coolant level kawasaki Fan circuit pressure or flow too low Clean Clogging radiator fins Flush or professionally clean Scale or mineral build up inside radiator Defective alarm switch (gauge is in green) ISUZU kawasaki Low water pump flow or Thermostat stuck or missing

Engine does not start when the starter motor is turning (Also see ELECTRICAL TROUBLESHOOTING)

Fuel filter element clogging Starter motor speed too low Defective engine shut off solenoid Fuel pump failure Incorrect fuel injection timing Compression pressure too low Defective injectors

Replace fuel filter Booster Battery may be used

3.37 2.95

Air in fuel lines

Tighten fuel connections and filter Replace fuel filter

Unstable (rough) idling

Insufficient power

Fuel filter element clogging Fuel pump failure Incorrect fuel injection timing Air cleaner element clogging Fuel filter element clogging Throttle pedal electrical signal incorrect Engine oil level too high Incorrect valve clearance Piston ring wear Defective injectors Fuel pump failure Air cooler restricted

kawasaki

kawasaki

kawasaki

or

or

or

ISUZU

3.12 3.15

ISUZU

3.37 3.37

ISUZU

Clean or replace element Replace fuel filter

3.10 3.37

kawasaki

Check dipstick and correct level

kawasaki

or

ISUZU

2.60

3.57 TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Use correct type of oil Correct oil level

3.53 2.60

Unusual combustion noise or mechanical noise

Wrong type of oil Engine oil level too low or too high Defective injectors Incorrect valve clearance Main bearing / con-rod bearing wear Crankshaft uneven wear Connecting rod bent Timing gear wear Water pump bearing wear Failed turbo or muffler

White exhaust smoke (After engine has reached operating temp.)

Fuel being diluted with water Wrong grade fuel Incorrect fuel injection timing Compression pressure too low Turbo seal leakage Coolant ingestion

Replace with specified fuel and replace fuel filter

Clean or replace element

Black exhaust smoke

Air cleaner element clogging Turbo damage Incorrect fuel injection timing Fuel injection pump failure Defective injectors

kawasaki

kawasaki

kawasaki

or

or

or

ISUZU

3.37

ISUZU

ISUZU

3.10

3.58 TROUBLESHOOTING

ELECTRICAL PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Adjust or replace belt Replace battery

2.65

Charge lamp lights up

Broken or slipping alternator belt Defective battery Alternator failure Defective wiring Defective wiring to ground (short)

Starter motor does not turn when starter switch key is turned to "START"

Transmission not in NEUTRAL Insufficient battery charge Starter switch failure Defective wiring Starter motor failure

Shift to NEUTRAL Battery charge or booster

Starter motor turns engine slowly

Hydraulic control levers not in NEUTRAL Insufficient battery charging Engine oil viscosity too high (thick) Poor connection at batteries or ground Defective wiring Starter motor failure Steering valve failure

Move levers to NEUTRAL Battery charge or booster Replace oil Clean and tighten all terminals

POSSIBLE CAUSES

SOLUTIONS

kawasaki

or

ISUZU

1.30 2.95

kawasaki

kawasaki

or

ISUZU

2.4 2.95 3.34

kawasaki kawasaki

or

ISUZU

kawasaki

STEERING PROBLEM

Hard steering

Will not steer

Tires are under inflated Severe conditions (over loaded, deep mud, etc.)

Oil pressure too low Steering valve failure Steering cylinder failure Defective Orbitrol® Pump failure

Check/adjust tire pressure Change operation

Articulation stopper in locked position

Move articulation stopper to "STORED" position Reduce load

Excessive load on steering Orbitrol® failure Pump failure Relief valve failure Steering cylinder failure Excessively cold oil / wrong grade oil

Steering Drift Steering pilot valve failure

PAGE 3.26

kawasaki

1.28

kawasaki

Warm oil / Replace oil with proper viscosity for temperature kawasaki

3.53

3.59 TROUBLESHOOTING

HYDRAULIC PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Warm oil Replace with proper grade oil

3.53

Boom raises too slowly

Excessively cold oil Wrong grade oil Oil pressure too low Damaged cylinder piston or piston packing Pump flow too low Pilot pressure too low Engine RPM too low Excessively cold oil / Wrong oil type

Warm oil / Replace oil with proper viscosity for temperature

kawasaki

Boom natural drift excessively

Leakage from control valve plunger Damaged cylinder piston or piston packing Leakage in pilot relief valve

kawasaki

Bucket / Attachment floating or drifting

Over load relief pressure too low Control valve failure Natural drift of cylinder / packing

kawasaki

3.53

BRAKE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE 3.43

Worn brake lining Insufficient oil pressure (will not release) Failure of switch or solenoid valve Poor wiring or ground to switch or solenoid valve

Adjust or replace lining

Parking brake does not work properly

Dirt, debris under base of brake pedal Warped brake discs Air in brake oil circuit

Remove or clean

Brake dragging Braking power too low

Air in brake oil circuit Brake piston seal leakage Blocked screen filter

Brake pressure drops rapidly

Cracked or leaking brake line Brake valve failure Parking brake cylinder leakage Defective brake accumulator Defective brake seals

kawasaki

kawasaki

kawasaki

Clean filter

kawasaki

3.50

3.60 TROUBLESHOOTING

TORQUE CONVERTER & TRANSMISSION PROBLEM

POSSIBLE CAUSES Excessively cold oil / Wrong oil type

Engine is running but machine does not move

Parking brake is applied Transmission oil level too low Transmission suction strainer clogging Clutch oil pressure too low Transmission clutch failure MCU failure Defective electrical circuit

SOLUTIONS

PAGE

Warm oil / Replace oil with proper viscosity for temperature Release parking brake Add oil / Repair leak Clean strainer

3.53

kawasaki

Service or parking brake dragging Low oil level in transmission Suction strainer in transmission clogging Clutch oil pressure too low Torque converter oil pressure too low Transmission clutch failure

Inspect and correct Refill oil / Repair leak Clean or replace strainer

Oil leakage from transmission

Air breather clogged Seal damage (between engine and torque converter housing)

Clean and refill with oil

Torque converter overheat

Oil level too low Dozing, continuous pushing application Operating in too high a speed range Long downhill driving Radiator clogged: coolant temp also high Defective alarm switch (gauge is in green) Torque converter / Transmission failure Oil pressure too low

Add oil / Repair leak Reduce load Use lower gear Change application Clean radiator fins

Low power

2.72 3.40

2.72 3.40

kawasaki

3.42

kawasaki

2.72 2.77 3.12

kawasaki

AIR CONDITIONER PROBLEM

Low cooling when A/C "ON"

Low heater out put

POSSIBLE CAUSES

SOLUTIONS

Hot water continues to flow through heater core A/C not set for maximum cooling Condenser fins plugged A/C filters plugged A/C compressor belts slipping/broken A/C refrigerant charge low

Shut off valve in heater hose line at block Adjust controls/vents Clean Clean or replace Adjust/Replace

Engine not warmed up No hot water flow to heater core Air conditioner running Heater vents not adjusted properly Defective heater motor or switch

Warm up engine Open shut off valve on block Turn A/C off Adjust controls/vents

PAGE

2.55 3.15 3.31 3.30

kawasaki

kawasaki

2.55

3.61 TROUBLESHOOTING

MODM Error log monitor failure code (Input side) Code

Failure

Detection condition (In case of)

CN121

Shift lever F & R switch malfunction

Shift lever F & R contact ON at the same time Failure continues for more than 3 seconds

CN122

Shift lever 1•2•3•A switch malfunction (1)

Shift lever any of more than two 1•2•3•A contact ON at the same time Failure continues for more than 3 seconds

CN123

Shift lever 1•2•3•A switch malfunction (2)

All 1•2•3•A signal OFF continues for more than 3 seconds

CN141

Shift-up switch malfunction

Switch is ON for more than 10 seconds

CN142

Shift-down switch malfunction

Switch is ON for more than 10 seconds

CN143

Shift-up switch & shift-down switch malfunction

Shift-up switch & shift-down switch contact ON at the same time Failure continues for more than 3 seconds

CN145

Kick-down switch malfunction

Switch is ON for more than 10 seconds

CN151

T/M oil pressure switch malfunction (This applies to the model 115ZV-2 only)

Signal OFF continues for more than 10 seconds during engine running

CN152

T/M oil pressure sensor malfunction (This applies to the model 95ZV-2 only)

T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than 10 seconds during engine running

CN213

Inching sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN214

Inching sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN161

Machine speed sensor malfunction (1)

Input circuit is disconnected for more than 3 seconds

CN162

Machine speed sensor malfunction (2)

Input value is over 70 km/h (44 mile/h) for more than 3 seconds

CN163

E/G speed sensor 1 (ECM output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)

CN164

E/G speed sensor 1 (ECM output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is OFF

CN165

E/G speed sensor 2 (Sensor output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)

CN167

E/G speed sensor 2 (Sensor output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is ON

CN232

S/S potentiometer malfunction (1)

Voltage is lower than 0.1 V for more than 3 seconds

CN234

S/S potentiometer malfunction (2)

Voltage is larger than 4.9 V for more than 3 seconds

CN236

S/S shift switch (F & R contact) malfunction

Failure continues for more than 3 seconds

CN146

Shift hold switch malfunction

Switch is ON for more than 10 seconds

CN251

Emergency steering oil pressure sensor malfunction(1)

Voltage is lower than 0.2 V for more than 3 seconds

CN252

Emergency steering oil pressure sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN254

Low emergency steering oil pressure

Oil pressure sensor detects emergency steering oil pressure below 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine running

CN262

Kickout potentiometer malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN263

Kickout potentiometer malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN271

Efficient loading system hydraulic oil pressure senVoltage is lower than 0.2 V for more than 3 seconds sor malfunction (1)

CN272

Efficient loading system hydraulic oil pressure senVoltage is larger than 4.6 V for more than 3 seconds sor malfunction (2)

CN312

Brake oil pressure sensor 1 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN313

Brake oil pressure sensor 1 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN315

Brake oil pressure sensor 2 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN316

Brake oil pressure sensor 2 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN321

E/G coolant temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN323

E/G coolant temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN341

T/M oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN342

T/M oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

3.62 TROUBLESHOOTING

Code

Failure

Detection condition (In case of)

CN351

Hydraulic oil temperature sensor malfunction (1)

CN352

Hydraulic oil temperature sensor malfunction (2)

Input voltage is larger than 3.56 V for more than 3 seconds Input voltage is lower than 0.263 V for more than 3 seconds

CN381

Fuel level sensor malfunction

Input signal corresponds to "any other pattern" in fuel level indication table

CN391

Air temperature probe malfunction (1)

Input voltage is larger than 4.35 V for more than 3 seconds

CN392

Air temperature probe malfunction (2)

Input voltage is lower than 0.13 V for more than 3 seconds

CN412

Abnormal brake oil pressure (1)

Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/cm2) (592 psi) for more than 1 second during engine running

CN413

Abnormal brake oil pressure (2)

Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6 kgf/cm2) (592 psi) more than 1 second during engine running

CN414

Abnormal brake oil pressure difference

Brake oil pressure difference switch is in abnormal condition for more than 1 second

CN415

Abnormal brake oil amount

Brake oil amount switch is in abnormal condition for more than 1 second

CN421

Abnormal engine oil pressure

Engine oil pressure switch is OFF for more than 2 seconds during engine running

CN431

Abnormal engine coolant temperature (1)

Engine coolant temperature switch is ON for more than 2 seconds

CN432

Abnormal engine coolant temperature (2)

Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition for more than 2 seconds

CN451

Abnormal T/M oil temperature (1)

T/M oil temperature switch is ON for more than 2 seconds

CN452

Abnormal T/M oil temperature (2)

T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more than 2 seconds

CN461

Abnormal hydraulic oil temperature

Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for more than 2 seconds

CN471

Clogged T/M oil filter

30 minutes after starter switch is ON, T/M oil filter switch is ON for more than 2 seconds when T/M oil temperature sensor detects oil temperature more than 60 deg. C (140 deg. F)

CN481

Clogged air cleaner element

Air cleaner switch is ON for more than 2 seconds

CN491

Abnormal cooling water level in radiator

Radiator cooling water level switch is OFF for more than 2 seconds when the engine is off.

CN496

Abnormal hydraulic oil level

Hydraulic oil level switch is in abnormal condition for more than 30 seconds

CN497

Abnormal brake disc oil temperature

Brake disc oil temperature switch is ON for more than 1 second

CN498

Abnormal disc wear

Brake disc wear switch is ON for more than 1 second

CN912

Abnormal MCU voltage (1)

Voltage is larger than 30±1 V

CN913

Abnormal MCU voltage (2)

Voltage is lower than 22±0.5 V during engine running

3.63 TROUBLESHOOTING

Error log monitor failure code (Output side) Code

Failure

CN512

F solenoid valve malfunction

F solenoid valve is short-circuited or disconnected

Detection condition

CN514

R solenoid valve malfunction

R solenoid valve is short-circuited or disconnected

CN516

1st solenoid valve malfunction

1st solenoid valve is short-circuited or disconnected

CN518

2nd solenoid valve malfunction

2nd solenoid valve is short-circuited or disconnected

CN521

3rd solenoid valve malfunction

3rd solenoid valve is short-circuited or disconnected

CN524

4th solenoid valve malfunction

4th solenoid valve is short-circuited or disconnected

CN526

D solenoid valve malfunction

D solenoid valve is short-circuited or disconnected

CN528

H solenoid valve malfunction

H solenoid valve is short-circuited or disconnected

CN531

LU solenoid valve malfunction

LU solenoid valve is short-circuited or disconnected

CN534

Brake solenoid valve malfunction

Brake solenoid valve is short-circuited or disconnected

CN536

Speed change control solenoid valve malfunction (1)

Speed change control solenoid valve is short-circuited

CN537

Speed change control solenoid valve malfunction (2)

Speed change control solenoid valve is disconnected

CN621

S/S solenoid valve R malfunction (1)

S/S solenoid valve R is short-circuited

CN622

S/S solenoid valve R malfunction (2)

S/S solenoid valve R is disconnected

CN623

S/S solenoid valve L malfunction (1)

S/S solenoid valve L is short-circuited

CN624

S/S solenoid valve L malfunction (2)

S/S solenoid valve L is disconnected

CN631

Pressure increase solenoid valve malfunction

Pressure increase solenoid valve is short-circuited or disconnected

CN641

Ride control solenoid valve malfunction

Ride control solenoid valve is short-circuited or disconnected

CN681

Efficient loading system selection solenoid valve malfunction

Efficient loading system selection solenoid valve is short-circuited or disconnected

CN693

Lower kickout relay malfunction (1)

Lower kickout relay (coil) is short-circuited

CN694

Lower kickout relay malfunction (2)

Lower kickout relay (coil) is disconnected

CN712

Cooling fan solenoid valve malfunction (1)

Cooling fan solenoid valve is short-circuited

CN713

Cooling fan solenoid valve malfunction (2)

Cooling fan solenoid valve is disconnected

CN721

Hour meter drive malfunction

Hour meter drive is short-circuited

3.64 TROUBLESHOOTING

Diagnosis trouble code (DTC) information These codes show the fault codes for the engine failure displayed on the MODM error log monitor.

These codes are also quickly retrievable with Isuzu EMPS3 hand held analyzers.

DTC LAMP

Error

87 Red

No pump pressure feed (fuel leakage)

88 Red

Common rail pressure fault

89 Red

Common rail pressure fault (Excessive pressure feed in pump)

90 Red

SCV drive system open circuit +B short or ground short

107 Red

Barometric pressure sensor fault (low voltage fault)

108 Red

Barometric pressure sensor fault (high voltage fault)

112 Red

Intake air temperature sensor fault (low voltage fault)

113 Red

Intake air temperature sensor fault (high voltage fault)

117 Red

Engine coolant temperature sensor fault (low voltage fault)

118 Red

Engine coolant temperature sensor fault (high voltage fault)

182 Red

Fuel temperature sensor fault (low voltage fault)

183 Red

Fuel temperature sensor fault (high voltage fault)

192 Red

Common rail pressure sensor fault (low voltage fault)

193 Red

Common rail pressure sensor fault (high voltage fault)

201 Red

Open circuit in injection nozzle #1 drive system

202 Red

Open circuit in injection nozzle #2 drive system

203 Red

Open circuit in injection nozzle #3 drive system

204 Red

Open circuit in injection nozzle #4 drive system

205 Red

Open circuit in injection nozzle #5 drive system

206 Red

Open circuit in injection nozzle #6 drive system

219 Red

Engine speed abnormally high

237 Red

Boost pressure sensor fault (low voltage fault)

238 Red

Boost pressure sensor fault (high voltage fault)

335 Red

Crank sensor fault

336 Red

Crank sensor fault

3.65 TROUBLESHOOTING

DTC LAMP

Error

340 Red

Cam sensor (G sensor) fault

341 Red

Cam sensor (G sensor) fault

380 Red

Glow relay fault

487 Red

EGR position fault (Brushless specification)

488 Red

EGR valve control fault

522 Red

Engine oil pressure sensor fault (low voltage fault)

523 Red

Engine oil pressure sensor fault (high voltage fault)

601 Red

ROM fault

603 Red

EEPROM fault

606 Red

CPU fault

611 Red

Charge circuit fault (bank 1)

612 Red

Charge circuit fault (bank 2)

1093 Red

No pump pressure feed (fuel leakage)

1095 Red

Pressure limiter is opened

1112 Red

Boost temperature sensor fault (low voltage fault)

1113 Red

Boost temperature sensor fault (high voltage fault)

1173 Red

Overheat

1261 Red

Injection nozzle common 1 drive system fault

1262 Red

Injection nozzle common 2 drive system fault

1271 1277 1278 1282 1283

Accelerator sensor 1-2 comparison fault Accelerator sensor 1 fault (low voltage fault) Accelerator sensor 1 fault (high voltage fault) Accelerator sensor 2 fault (low voltage fault) Accelerator sensor 2 fault (high voltage fault)

1345 Red

Cam sensor out of phase

1625 Red

Main relay system fault (Not enter)

1630 Red

A/D conversion fault

1631 Red

Voltage fault i 5-V power supply 1

1632 Red

Voltage fault i 5-V power supply 2

3.66 TROUBLESHOOTING

DTC LAMP

Error

1633 Red

Voltage fault i 5-V power supply 3

1634 Red

Voltage fault i 5-V power supply 4

1635 Red

Voltage fault i 5-V power supply 5

3.67 SPECIFICATIONS

SPECIFICATIONS Specifications shown are for a machine equipped with standard features. Some options or special attachment will change the specifications shown.

Specifications subject to change without notice.

Bucket Data General purpose

Pin on

QGSC

QGST

GSC

GST

Heaped

yd3 (m3)

2.8 (2.1)

2.6 (2.0)

2.8 (2.1)

2.6 (2.0)

Struck

yd3 (m3)

2.3 (1.7)

2.2 (1.6)

2.3 (1.7)

2.2 (1.6)

Maximum dumping clearance

ft-in (mm)

9'8 1/8" (2,950)

9'4 63/64" (2,870)

9'8 15/16" (2,970)

9'5 25/32" (2,890)

Dumping reach (to front of bucket edge or tooth)

ft-in (mm)

3'7 1/8" (1,095)

3'9 9/32" (1,150)

3'6 1/8" (1,070)

3'8 19/64" (1,125)

Capacity

52º

Minimum turning radius at outside bucket 18'8 1/64" (5,690 mm) at center of outside tire 16'1 11/16" (4,920 mm)

45º

Full articulation angle 40º Tread

13' 11/16"

3'7 1/8" 9'8 1/8"

10'8 3/4"

6'1 5/8" (1,870 mm) Width (outside tire)

51º

7'10 11/16" (2,405 mm) Width (outside bucket) 8' 7/16" (2,450 mm)

45º 7'6 3/4" 7'11 1/16"

Equipped with GSC bucket with bolt on cutting edge

9'6 1/4"

5'11 1/4" 23'8 27/32"

TM BUCKET SPECa

20.5-25-12PR (L-2) Tire and ROPS Cab

3.68 SPECIFICATIONS

Bucket Selection Chart Standard arm

Bucket size yd3 (m3)

2.6 (2.0) 2.8 (2.1) 2,200 2,300 2,400 2,500 2,600 2,700 2,800 2,900 3,000 3,100 3,200 3,300 3,400 3,500 3,600 3,700 Material density lbs/yd3 Bucket fill

115%

100% 95%

65TMV2 Bucket Selection Chart

Operating Weight

24,410 lb (11,980 kg)

Engine

Model Type

ISUZU 4HK1X Diesel 4 cycle, Water Cooled, Direct injection, Turbo charged & air cooled intercooler

Displacement

317 in3 (5.193 Liter)

Rated Power (Gross)

115kW / 2,200 min-1 (154 HP / 2,200 rpm)

Tire (standard)

20.5-25-12PR(L-2)

Max. Running Speed (forward/reverse)

1st : 4.8 MPH ( 7.7 km/h) / 4.8 MPH ( 7.7 km/h) 2nd: 7.8 MPH (12.6 km/h) / 7.8 MPH (12.6 km/h) 3rd :12.4 MPH (20.0 km/h) / 12.4 MPH (20.0 km/h) 4th :22.3 MPH (35.8 km/h) / 22.3 MPH (35.8 km/h)

The weight and load figure includes optional counterweight, enclosed ROPS cab, air conditioner, GSC bucket with bolt-on cutting edge, 20.5-25-12PR (L-2) tires, full fuel tank and operator.

INDEX (FE) Fuel Efficient Mode Switch ................................2.13 12 Volt Power-outlet Socket ......................................2.15

Battery removal / reinstallation procedure ...............2.101 Before Starting Safety .................................................1.4 Before Storage ........................................................2.100 Booster Batteries / Jumper Cables ...........................2.95 Brake Pedals ...............................................................2.7 Brake Pressure Warning Lamp (red) ........................2.28 Bucket / Attachment Leveler Adjustment ..................2.93 Bucket / Fork Leveler Switch .....................................2.23

Check Steering Wheel Operation .............................2.74 Check Tightness of Wheel Bolts ...............................3.30 Check Tire Air Pressure ............................................3.26 Check Tire for Damage, Air and Tread Depth ..........2.64 Check Transmission Oil Level ..................................2.72 Check Transmission Shift Lever ...............................2.68 Check Warning Lamps ..............................................2.71 Check Windshield Washer Fluid ...............................3.14 Check Wiring Harnesses ..........................................2.63 Clean Air Conditioner and Heater Filter Element ......3.31 Clean Air Conditioner Condenser .............................3.15 Clean Electromagnetic Fuel Pump Filter ..................3.39 Clean Filter for Brake Line ........................................3.50 Clean Fuel Feed Pump Strainer ...............................3.39 Clean Fuel Tank ........................................................3.49 Clean or Replace Air Cleaner Element .....................3.10 Clean or Replace Transmission Breather .................3.42 Clean Radiator / Air cooler / Hydraulic oil cooler Fins ...............................................................................3.12 Cold Start ..................................................................2.70 COMPONENT NAME/LOCATION ..............................2.2 Control Lever Lock for Quick Coupler Lock Pin [3rd spool valve specification (option)] ..................1.29 Coolant Specification ................................................3.55

C

D

Carrying .....................................................................2.85 Central Warning Lamp (red) ......................................2.27 Charge Lamp (red) ....................................................2.29 Check after Starting the Engine ................................2.71 Check Air Conditioner Refrigerant ............................3.44 Check Air Intake System ...........................................2.66 Check and Adjust Air Conditioner Belt ......................3.30 Check and Adjust Drive Belt .....................................2.65 Check and Adjust Valve Lash Clearance ..................3.45 Check and/or Replace Seat Belt ...............................3.10 Check Back-up Alarm Operation ...............................2.74 Check Battery Electrolyte Level ................................3.25 Check before Operation ............................................2.59 Check Brake Accumulator .........................................3.50 Check Control Levers ................................................2.68 Check Cooling Fan ....................................................2.67 Check Differential Gear Oil .......................................3.29 Check Engine Compression Pressure ......................3.45 Check Engine Coolant Level .....................................2.62 Check Engine Oil Level .............................................2.60 Check Exhaust Gas ..................................................2.75 Check Fuel Level ......................................................2.72 Check Horn Operation ..............................................2.67 Check Hydraulic Oil Level .........................................2.61 Check Monitor Panel Operation ................................2.68 Check or Replace Fuses ...........................................3.13 Check Parking Brake ................................................2.67 Check Parking Brake Operation ................................2.74 Check Ride Control Accumulator (option) .................3.52 Check Service Brake Disk Wear ...............................3.50 Check Service Brake Operation ................................2.74

Declutch Lamp (green) .............................................2.27 Declutch ON/OFF and Adjustable Preset Switch ......2.17 Downshift Button .......................................................2.15 Dozing .......................................................................2.83 Drain Water and Sediment from Fuel Filter ..............2.63 Drain Water and Sediment from Fuel Tank ..............3.24 Dumping into Truck or Hopper ..................................2.85 During Storage ........................................................2.102

A Accelerator Pedal ........................................................2.7 Adjust and Check Rear View Mirrors ........................2.67 Adjust Parking Brake Lining ......................................3.43 Adjustments ..............................................................2.93 After Storage ...........................................................2.102 Air Cleaner Warning Lamp (red) ...............................2.29 Articulation Stopper ..........................................1.28, 2.63 Auto Shift Indicator Lamp ..........................................2.30 Auxiliary Attachment Control Lever (option) ................2.6

B

E Efficient Loading System Switch (option) ..................2.19 Electrical Protection ..................................................2.45 Emergency Brake .....................................................1.30 Emergency Steering (option) ....................................1.31 Emergency Steering Warning Lamp (red) (option) ...............................................................................2.31 Engine Coolant Temperature Gauge ........................2.26 Engine Coolant Temperature Warning Lamp (red) ...............................................................................2.28 Engine Oil Pressure Warning Lamp (red) .................2.28 Error Log Monitor ......................................................2.40 Every 10 Hours or Daily ............................................3.20 Every 1000 Hours or 6 Months .................................3.40 Every 2000 Hours or 1 Year .....................................3.46 Every 250 Hours or 1 Month .....................................3.28 Every 50 Hours or 1 Week ........................................3.21 Every 500 Hours or 3 Months ...................................3.34 Excavating ................................................................2.83 Explosion / Fire / Burn Prevention ............................1.15 Extendable Boom ......................................................2.88

F F/R Switch (option) ................................................... 2.21 F/R Switch Indicator Lamp (green) (option) .............. 2.32 Four-Way Flasher Switch (option) ............................ 2.16 Front Wiper Switch ................................................... 2.14 Front Working Light Switch ....................................... 2.12 Fuel Gauge ............................................................... 2.26 Fuse Boxes ............................................................... 2.45 Fusible Link ............................................................... 2.46

G General Inspection .................................................... 2.75 Grease Gun Holder ................................................... 2.58 Greasing ............................... 2.60, 3.18, 3.21, 3.28, 3.46 Ground Levelling ....................................................... 2.84

H Heater or Air Conditioner .......................................... 2.55 Switches ................................................................ 2.55 Ventilation Location and Mode .............................. 2.55 High beam Indicator Lamp (blue) ............................. 2.30 High-Low Beam Lever / Turn Signal Lever (option) ................................................................................ 2.4 Horn Button ................................................................. 2.3 Hour Meter ................................................................ 2.30 How to Use Quick Coupler (option) .......................... 2.89 Hydraulic Oil Level Warning Lamp (simultaneous flashing)(red)(11. 24.) ............................................ 2.32

I Indicators .................................................................. 2.25 Information Monitor ................................................... 2.34 Input/Output Monitor ................................................. 2.41 Inspection and Maintenance Table ............................. 3.5

K Kickout Control Switch .............................................. 2.18

L Light Switch .............................................................. 2.12 Loading ..................................................................... 2.81 Loading Control Lever ................................................ 2.4 Loading Control Lever Lock ............................... 1.28, 2.9 Long Term Storage ................................................. 2.100

M MAINTENANCE .......................................................... 3.2 MCU (Machine Control Unit) Warning Lamp (red) .............................................................................. 2.27 MODM ...................................................................... 2.33 MODM function ......................................................... 2.33 Monitor Changeover ................................................. 2.33 Mounting and Dismounting Safety .............................. 1.3

N Neutral Indicator Lamp ............................................. 2.30

Neutral Start System ................................................. 1.30 Normal Start .............................................................. 2.69

O Operating Techniques .............................................. 2.81 Operating the Machine ............................................. 2.76 OPERATION ............................................................. 2.59 Operation and Function ............................................ 2.57 Operational Safety ...................................................... 1.7 Operator Safety .......................................................... 1.2 OPERATOR'S AREA .................................................. 2.3 Other Maintenance Safety Concerns ........................ 1.16

P Pallet Forks ............................................................... 2.88 Parameter Setting Monitor ........................................ 2.42 Parking ...................................................................... 2.79 Parking Brake Indicator Lamp (red) .......................... 2.27 Parking Brake Switch ................................................ 2.11 Parking Safety .......................................................... 1.11 Pedals and Levers ...................................................... 2.3 Preheat Indicator Lamp (orange) .............................. 2.27

Q Quick Coupler Lock Pin Switch (option) ................... 2.24

R Radio - AM / FM Cassette (24 Volt Type) ................. 2.47 Rear Wiper Switch .................................................... 2.14 Rear Working Light Switch ....................................... 2.13 Recommended Lubricants ........................................ 3.53 Recommended Mixture of Antifreeze ....................... 3.55 Replace Air Conditioner Filter Elements ................... 3.17 Replace Air Conditioner Receiver Dryer ................... 3.18 Replace Bucket Teeth (option) ................................... 3.8 Replace Coolant ....................................................... 3.15 Replace Cutting Edge ................................................. 3.9 Replace Differential Gear Oil .................................... 3.48 Replace Electromagnetic Fuel Pump Filter Element .............................................................................. 3.51 Replace Engine Oil and Oil Filter Cartridge .............. 3.34 Replace Filter ............................................................ 3.33 Replace Filter in the Hydraulic Tank Cap ................. 3.51 Replace Fuel Filter Elements .................................... 3.37 Replace Hydraulic Oil Return Filter .......................... 3.42 Replace Hydraulic Oil, Clean Filter ........................... 3.47 Replace Transmission Oil ......................................... 3.40 Replace Transmission Oil Filter Cartridge ................ 3.36 Replacement Monitor ................................................ 2.38 Reversal Fan Pilot Lamp (green)(option) .................. 2.32 Reversal Fan Switch (option) .................................... 2.22 Ride Control (option) ................................................. 2.57 Ride Control Switch (option) ..................................... 2.23 Roading / Special Applications ................................. 2.94 ROPS (Roll Over Protective Structure) Cab .... 1.31, 2.67

S Safe Operation ............................................................ 1.2

SAFETY ......................................................................1.2 Safety Devices ..........................................................1.28 Safety Preparations Before Maintenance .................1.12 Safety Signs ..............................................................1.18 Seat ...........................................................................2.43 Seat Adjustment ........................................................2.43 Seat Belt ....................................................................2.44 Selection Switch for Shift Lever or F/R Switch (option) ...................................................................2.20 Serial Number Location ...............................................3.2 SPECIAL PROCEDURES .........................................2.93 Specification Setting Monitor .....................................2.42 SPECIFICATIONS ....................................................3.67 Speed and Direction Change ....................................2.77 Starter Switch ............................................................2.11 Starting the Engine ....................................................2.69 Starting the Machine .................................................2.76 Starting the Machine on a Grade ..............................2.77 Steering Column Telescopic Tilt Handle .....................2.8 Stopping the Engine ..................................................2.80 Switches ....................................................................2.10

T Tachometer ...............................................................2.26 Torque Converter Oil Temperature Gauge ...............2.26 Torque Converter Oil Temperature Warning Lamp (red) .......................................................................2.29 Towing .......................................................................2.97 Transmission Shift Lever .............................................2.3 Transmission Status Monitor .....................................2.30 Transportation ...........................................................2.98 TROUBLESHOOTING ..............................................3.56 Turn Signal Indicator Lamp (Left) (green) .................2.29 Turn Signal Indicator Lamp (Right) (green) ...............2.29 Typical Truck Loading Methods ................................2.87

W Walk-Around Inspection ............................................2.59 When Required Inspection and Maintenance .............3.8 Working Light Indicator Lamp (green) .......................2.27 Wrist Rest (adjustable) ................................................2.6

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes