KCM WHEEL LOADER 45ZV-2 OPERATION & MAINTENANCE MANUAL 93104-00041 (1)

45ZV-2

93104-00041 October 25, 2012

OPERATION & MAINTENANCE MANUAL WHEEL LOADER

45ZV-2

Printed in Japan (H) ( アメリカ・オセアニア用 )

93104-00041

©2012 KCM Corporation. All rights reserved.

NOTICE Powered by Kubota V3307-DI-T Engine Serial No. 00193 and up

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

INTRODUCTION Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage.

This standard specification machine can be operated under the following conditions without being modified.

Atmospheric Temperature: -20 °C to 40 °C (-4 °F to 104 °F) Altitude: 0 m to 2000 m (0 ft to 6600 ft) In case the machine is used under conditions other than described above, consult your nearest Kawasaki dealer.

This manual should be considered a permanent part of your machine and should remain with the machine when you sell it.

This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.

Right-hand and left-hand sides are determined by facing in the direction of forward travel.

Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen.

Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine.

Warranty is provided as a part of Kawasaki’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you with the assurance that Kawasaki will back its products where defects appear within the warranty period. In some circumstances, Kawasaki also provides field improvements, often without charge to the customer, even if the product is out of warranty.

Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied.

Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

Only qualified, competent operators should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine.

Use only diesel fuel with quality specified in JIS K-2204, EN-590, ASTM D-975, GOST R52368 or GB252.

Failure to use diesel fuel with quality as specified above may allow the engine to emit exhaust gas which cleanness can not conform to the requests in various relevant regulations. In addition, serious damage to the engine may result. Consult with your nearest Kawasaki dealer for detailed information.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

93104-00041 October 25, 2012

CONTENTS ENGINE EMISSION CONTROL LABEL .......................................1 MACHINE NUMBERS .......................................................................3 SAFETY ..............................................................................................S-1 Recognize Safety Information ...................................................S-1 Understand Signal Words ............................................................S-1 Follow Safety Instructions ...........................................................S-2 Prepare for Emergencies ..............................................................S-3 Wear Protective Clothing .............................................................S-3 Protect Against Noise ...................................................................S-4 Inspect Machine .............................................................................S-4 General Precautions for Cab .......................................................S-5 Use Handrails and Steps ..............................................................S-6 Never Ride Attachment.................................................................S-6 Adjust Operator’s Seat ..................................................................S-6 Ensure Safety Before Rising from or Leaving Operator’s Seat ..........................................................S-7 Fasten Your Seat Belt .....................................................................S-7 Move and Operate Machine Safely ..........................................S-8 Handle Starting Aids Safely ........................................................S-8 Operate Only from Operator’s Seat .........................................S-9 Jump Starting ..................................................................................S-9 Investigate Job Site Beforehand ............................................ S-10 Equipment of Head Guard, ROPS, FOPS .............................. S-11 Provide Signals for Jobs Involving Multiple Machines ... S-11 Keep Riders Off Machine .......................................................... S-12 Drive Safely .................................................................................... S-12 Drive Machine Safely (Work Site) ........................................... S-13 Drive Safely with Bucket Loaded ........................................... S-14 Drive on Snow Safely .................................................................. S-14 Travel on Public Roads Safely .................................................. S-15 Avoid Injury from Rollway Accidents ................................... S-15 Avoid Accidents from Backing Up and Turning ............... S-16 Avoid Positioning Bucket or Attachment Over Anyone ................................................... S-17 Avoid Tipping ................................................................................ S-17 Never Undercut a High Bank ................................................... S-18 Dig with Caution .......................................................................... S-18 Perform Truck Loading Safely ................................................. S-18 Avoid Power Lines ....................................................................... S-19 Precautions for Operation ........................................................ S-19 Precautions for Lightning ......................................................... S-19 Object Handling .......................................................................... S-20 Protect Against Flying Debris ................................................. S-20 Park Machine Safely .................................................................... S-21 Store Attachments Safely ......................................................... S-21 Transport Safely ........................................................................... S-22 Handle Fluids Safely−Avoid Fires ........................................... S-23 Practice Safe Maintenance ....................................................... S-24 Warn Others of Service Work .................................................. S-25 Support Machine Properly ....................................................... S-25 Stay Clear of Moving Parts ....................................................... S-26 Support Maintenance Properly .............................................. S-26 Prevent Parts from Flying ......................................................... S-27 Prevent Burns ................................................................................ S-27 Replace Rubber Hoses Periodically ....................................... S-28

Avoid High-Pressure Fluids ...................................................... S-28 Prevent Fires .................................................................................. S-29 Evacuating in Case of Fire ......................................................... S-30 Beware of Exhaust Fumes ......................................................... S-30 Precautions for Welding and Grinding ................................ S-30 Avoid Heating Near Pressurized Fluid Lines ...................... S-31 Avoid Applying Heat to Lines Containing Flammable Fluids ................................................................... S-31 Remove Paint Before Welding or Heating .......................... S-31 Beware of Asbestos and Silicon Dust and Other Contamination......................................................................... S-32 Prevent Battery Explosions ...................................................... S-32 Service Air Conditioning System Safely .............................. S-33 Handle Chemical Products Safely .......................................... S-33 Dispose of Waste Properly ........................................................ S-34 SAFETY SIGNS ............................................................................. S-35 COMPONENTS NAME .................................................................1-1 Components Name .......................................................................1-1 Canopy Vehicle ..........................................................................1-1 Cab Vehicle (Optional) .............................................................1-2 OPERATOR’S STATION ................................................................1-3 Cab Features .....................................................................................1-3 Front Console ...................................................................................1-4 Right Console ...................................................................................1-5 Monitor Panel ..................................................................................1-6 Stop Indicator (Red) .......................................................................1-7 Service Indicator (Yellow) ............................................................1-7 Parking Brake Indicator (Red) .....................................................1-8 Brake Oil Low Level Indicator (Red) .........................................1-8 Discharge Warning Indicator (Red) ..........................................1-8 Overheat Indicator (Red) .............................................................1-9 Engine Oil Low Pressure Indicator (Red) ................................1-9 Air Filter Restriction Indicator (Red) .........................................1-9 HST Warning Indicator (Red) ......................................................1-9 Engine Coolant Temperature Gauge .................................... 1-10 Fuel Gauge...................................................................................... 1-10 Preheat Indicator (Yellow) ........................................................ 1-11 Turn Signal Indicator (Green) .................................................. 1-11 High Beam Indicator (Blue) ...................................................... 1-11 Work Light Indicator (Yellow) .................................................. 1-11 Clearance Light Indicator (Green) ......................................... 1-11 Monitor Display ............................................................................ 1-12 Forward/Reverse and Shift Position Indicator .................. 1-13 F-N-R (Forward/Reverse) Position Indicator ................. 1-13 Shift Position Indicator ......................................................... 1-13 Speedometer ................................................................................ 1-14 Ride Control Indicator (Optional) .......................................... 1-14 Machine Information Display .................................................. 1-15 Shifting Item to Be Indicated on Machine Information Display ....................................... 1-16 Hour Meter ............................................................................... 1-16 Odometer ................................................................................. 1-16 HST Error Code Readout Switch ............................................. 1-17 Error Code ...................................................................................... 1-18 Switches, Steering Wheel and Pedals ................................... 1-19

CONTENTS F-N-R Lever .................................................................................... 1-19 Neutral Lever Lock (F-N-R Lever) ............................................ 1-19 Steering ........................................................................................... 1-20 Horn Switch ................................................................................... 1-20 Turn Signal Lever ......................................................................... 1-20 Dimmer Switch ............................................................................. 1-20 Light Switch ................................................................................... 1-21 Hazard Switch ............................................................................... 1-22 Front and Rear Work Light Switch (Cab Vehicle) .............. 1-23 Hi-Lo Selector Switch ................................................................. 1-24 Parking Brake Switch .................................................................. 1-25 Wiper Operation .......................................................................... 1-26 Front Window Wiper Switch (Cab Vehicle) ......................... 1-27 Rear Window Wiper Switch (Cab Vehicle) ........................... 1-27 Accelerator Pedal ......................................................................... 1-28 Brake/inching Pedal ................................................................... 1-28 Right Console (Front Attachment) ........................................ 1-29 Loader Control Lever .................................................................. 1-30 Lever Locks .................................................................................... 1-31 Right Console/Switch Panel .................................................... 1-32 Key Switch ...................................................................................... 1-33 ECO Mode Switch ........................................................................ 1-33 Ride Control Switch (Optional) ............................................... 1-34 Ride Control Operation ........................................................ 1-34 Heater (Optional) Operation ................................................... 1-35 Heater Switch .......................................................................... 1-35 Vent ............................................................................................. 1-35 Adjusting Operator’s Seat (Standard Type) ........................ 1-36 Components Name ............................................................... 1-36 1. Damper Adjustment ......................................................... 1-36 2. Fore-Aft Position Adjustment ....................................... 1-36 Adjusting Operator’s Seat (Suspension Type) ................... 1-37 Components Name ............................................................... 1-37 1. Suspension adjustment .................................................. 1-37 2. Fore-Aft Position Adjustment ....................................... 1-38 3. Armrest Angle Adjustment ............................................ 1-38 4. Reclining Angle Adjustment ......................................... 1-38 Seat Belt .......................................................................................... 1-39 Seat Pocket (Suspension Seat)................................................. 1-39 Fuse Box .......................................................................................... 1-40 ROPS Cab (Optional) .................................................................. 1-42 Room Light .................................................................................... 1-44 Sun Visor (Optional) .................................................................... 1-44 Drink Holder .................................................................................. 1-44 Coat Hook ...................................................................................... 1-45 Rear View Mirror ........................................................................... 1-45 Room Rear View Mirror .............................................................. 1-45 FM/AM Radio (Optional) Operation ...................................... 1-46 Controls on the Radio ........................................................... 1-46 Tuning Procedures ................................................................ 1-47 Station Presetting Procedure ............................................. 1-47 Auto Station Presetting Procedure .................................. 1-48 Digital Clock Setting Procedure ........................................ 1-48 Alarm Setting Procedure ..................................................... 1-48 Upper Switch Panel (Optional) ............................................... 1-49

Rotary Beacon Switch (Optional) ........................................... 1-49 Cab Door ......................................................................................... 1-50 Door Lock Knob ........................................................................... 1-51 Door Open/Close Lever ............................................................. 1-51 Window Open/Close Levers .................................................... 1-51 When Fully Opening the Door ................................................ 1-52 Door Lock Disengage Lever ..................................................... 1-52 Articulation Lock Bar .................................................................. 1-53 Towing Pin ..................................................................................... 1-53 Engine Hood ................................................................................. 1-54 Maintenance Side Cover ........................................................... 1-54 Steps ................................................................................................. 1-55 Vandal Resistant Devices .......................................................... 1-55 BREAK-IN ..........................................................................................2-1 Observe Engine Operation Closely ..........................................2-1 OPERATING ENGINE ....................................................................3-1 Inspect Machine Daily Before Starting ...................................3-1 Check Before Starting ...................................................................3-3 Starting Engine ...............................................................................3-5 Check After Starting ......................................................................3-7 Using Booster Batteries ................................................................3-8 Warm Up Operation ................................................................... 3-10 Warm Up Operation in Cold Weather ................................... 3-11 Stopping Engine .......................................................................... 3-12 DRIVING MACHINE ......................................................................4-1 Driving Machine .............................................................................4-1 Starting to Move .............................................................................4-2 Parking Brake Switch .....................................................................4-4 Drive Speed Change ......................................................................4-5 Changing Forward/Reverse Drive Direction .........................4-5 Steering ..............................................................................................4-6 Stop and Restart of Travel ...........................................................4-7 Precautions for Travel on Slopes ...............................................4-9 Precautions to Be Taken if Machine Failure Occurs ......... 4-10 Precautions for Travel Speeds ................................................. 4-11 Stop .................................................................................................. 4-12 Parking ............................................................................................ 4-13 Emergency Evacuation .............................................................. 4-15 OPERATING MACHINE ................................................................5-1 Loader Control Lever .....................................................................5-1 Lever Locks .......................................................................................5-2 Adjustment of Bucket Auto Leveler .........................................5-3 Before Operation ............................................................................5-4 Precautions for Operation ...........................................................5-4 Ensure Safety When Operating on Road Shoulders ..........5-4 Avoid Overloading .........................................................................5-5 Avoid Rapid Steering Changes and/or Sudden Braking .........................................................................5-5 Avoid Operation with Biased Loads ........................................5-5 Excavation .........................................................................................5-6 Grading ..............................................................................................5-8 Loading ..............................................................................................5-9 Dozing ............................................................................................. 5-13

CONTENTS Scooping ........................................................................................ 5-13 Removing Snow ........................................................................... 5-14 Lifting Wheel Loader .................................................................. 5-14 Precautions for After Operation ............................................. 5-15 TRANSPORTING ............................................................................6-1 Transporting by Road ...................................................................6-1 Transporting by Trailer .................................................................6-1 Loading/Unloading on Trailer ....................................................6-2 Transporting .....................................................................................6-4 Transporting Wheel Loader (Urgent Situation) ...................6-5 Towing Method ...............................................................................6-9 Lifting Machine ............................................................................ 6-10 MAINTENANCE ..............................................................................7-1 Correct Maintenance and Inspection Procedures ..............7-1 Check the Hour Meter Regularly ...............................................7-2 Use Correct Fuels and Lubricants .............................................7-2 Layout .................................................................................................7-3 Maintenance Guide Table ............................................................7-4 Preparations for Inspection and Maintenance ....................7-5 Lock Frames ......................................................................................7-6 Maintenance Side Cover ..............................................................7-7 Engine Hood ....................................................................................7-8 Opening Engine Hood ............................................................7-8 Closing Engine Hood ...............................................................7-8 Periodic Replacement of Parts ...................................................7-9 Maintenance Guide .................................................................... 7-10 A. Greasing (See Page 7-19) ................................................ 7-10 B. Engine (See Page 7-22)..................................................... 7-11 C. Power Train (See Page 7-25) ........................................... 7-11 D. Hydraulic System (See Page 7-30) ............................... 7-12 E. Fuel System (See Page 7-42)........................................... 7-12 F. Air Cleaner (See Page 7-48) ............................................. 7-12 G. Cooling System (See Page 7-49)................................... 7-13 H. Electrical System (See Page 7-55) ................................ 7-13 I. Brake System (See Page 7-65) ......................................... 7-13 J. Tire (See Page 7-68) ............................................................ 7-14 K. Heater (Optional of Cab Vehicle) (See Page 7-74) .. 7-14 L. Miscellaneous (See Page 7-75) ...................................... 7-15 Kind of Oils ..................................................................................... 7-16 Grease ........................................................................................ 7-16 Engine Oil ................................................................................. 7-16 Brake Oil .................................................................................... 7-17 Transmission Oil, Axle Oil .................................................... 7-17 Hydraulic Oil ............................................................................ 7-17 Long-Life Coolant .................................................................. 7-18 A. Greasing ..................................................................................... 7-19 B. Engine ......................................................................................... 7-22 Check Engine Oil Level ......................................................... 7-22 Change Engine Oil ................................................................. 7-23 Replace Engine Oil Filter ...................................................... 7-24 C. Power Train ............................................................................... 7-25 Change Transmission Oil ..................................................... 7-25 Change Axle Oil ...................................................................... 7-26 Check Oil Level ........................................................................ 7-27 Clean Transmission Air Breather ....................................... 7-28

Check Surrounding Areas Around Axles and Covers for Oil Leaks ................................................. 7-29 Clean Axle Housing Air Breather ...................................... 7-29 D. Hydraulic System .................................................................... 7-30 Inspection and Maintenance of Hydraulic Equipment .. 7-30 Check Hydraulic Oil Level ................................................... 7-31 Change Hydraulic Oil/Clean Hydraulic Oil Tank .......... 7-32 Change/Cleaning ................................................................... 7-32 Bleed Air from the Hydraulic System .............................. 7-33 Procedures ................................................................................ 7-33 Clean Suction Filter ............................................................... 7-34 Replace HST Oil Filter Element .......................................... 7-35 Replace Return Filter ............................................................. 7-37 Replacement ............................................................................ 7-37 Check Hoses and Lines ........................................................ 7-39 Kinds of Hose/Line Fittings ................................................. 7-41 Precautions for Use ............................................................... 7-41 E. Fuel System ............................................................................... 7-42 Check Fuel Level ..................................................................... 7-42 Recommended Fuel .............................................................. 7-42 Refueling ................................................................................... 7-42 Drain Water and Sediment from Fuel Tank ................... 7-43 Check and Drain Water from Fuel Pre-Filter ................. 7-44 Fuel Pre-Filter Drain Procedures ....................................... 7-44 Clean Fuel Pre-Filter .............................................................. 7-45 Bleed Air from the Fuel System ......................................... 7-45 Replace Fuel Filter .................................................................. 7-46 Check Fuel Hoses ................................................................... 7-47 F. Air Cleaner .................................................................................. 7-48 Clean and Replace Air Cleaner Element ........................ 7-48 G. Cooling System ....................................................................... 7-49 Long Life Coolant (LLC) ........................................................ 7-49 Precautions for Handling Long Life Coolant (LLC) ..... 7-50 Check Coolant Level ............................................................. 7-51 Check Fan Belt ......................................................................... 7-52 Check Fan Belt Tension ........................................................ 7-52 Adjust Fan Belt Tension ........................................................ 7-52 Change Coolant ...................................................................... 7-53 Clean Radiator and Oil Cooler ........................................... 7-54 H. Electrical System ..................................................................... 7-55 Check Monitor Function and All Other Instrument Operation .................................. 7-55 Check Work Lights ................................................................. 7-56 Check Horn, Backup Buzzer and Backup Light ........... 7-56 Check Electrical Harnesses and Fuses ............................ 7-57 Check and Replace Fuse ...................................................... 7-57 Fuse Box .................................................................................... 7-58 Battery ........................................................................................ 7-59 Precautions for Handling Batteries .................................. 7-59 In Case the Batteries Were Discharged .......................... 7-61 Method to Recharge the Removed Battery .................. 7-62 Method to Replace with Charged Auxiliary Batteries ............................................................ 7-62 Check Electrolyte Level ........................................................ 7-63 Check Electrolyte Specific Gravity ................................... 7-64

CONTENTS I. Brake System .............................................................................. 7-65 Check Brake Oil Level ........................................................... 7-65 Check Right and Left Brake Interlocking Performance ............................................. 7-66 Check Brake Performance ................................................... 7-66 Check Play in Brake Pedal Stroke ..................................... 7-66 Check Parking Brake Force ................................................. 7-67 Check Brake Disc (Service and Parking) ......................... 7-67 Change Brake Oil .................................................................... 7-67 J. Tire ................................................................................................. 7-68 Check and Adjust Tire Pressure ......................................... 7-68 Check Tire Pressure ................................................................ 7-68 Check Tire for Damage ......................................................... 7-69 Check Wheel Bolt Torque .................................................... 7-69 Replace Tire .............................................................................. 7-69 Tire Sizes to Be Used ............................................................. 7-70 Tire Rotation ............................................................................ 7-71 Rotation Method .................................................................... 7-71 How to Check Wear Amount (Tread Design Groove Depth) ...................................... 7-71 Removal and Installation of Tire.............................................. 7-72 Tire Wheel ....................................................................................... 7-73 K. Heater (Optional of Cab Vehicle) ....................................... 7-74 Check Heater for Damage ................................................... 7-74 Check Heater Piping ............................................................. 7-74 L. Miscellaneous ........................................................................... 7-75 Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear ............................................. 7-75 Replacement............................................................................. 7-75 Check and Replace Seat Belt .............................................. 7-76 Check Canopy/Cab for Damage and Mounting Bolts for Tightness ....................................... 7-76 Check Windshield Washer Fluid Level (Cab Vehicle) ....................................................................... 7-76 Check Play in Steering Wheel Stroke .............................. 7-77 Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise ............................... 7-78 Exhaust Gas Color and Noise ............................................. 7-78 Check Outside and Inside Rearview Mirror .................. 7-79 Check Steps and Handrails for Damage and Tightness ................................................... 7-79 Clean Engine Compartment and Hood ......................... 7-79 Check and Adjust Valve Clearance ................................... 7-80 Check Sound Absorbing Mat Around Engine ............. 7-80 Check Fuel Injection Timing ............................................... 7-80 Check Engine Compression Pressure ............................. 7-81 Check and Clean Starter and Alternator ........................ 7-81 Retighten Front Axle, Rear Axle and Transmission Mounting Nuts .................................................................. 7-81 Tightening and Retightening Torque of Nuts and Bolts .................................................................... 7-82 Nut and Bolt Tightening Torque ....................................... 7-83 Tightening Torque ................................................................. 7-83

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS ...................................................................................9-1 Maintenance Under Special Environmental Conditions .....................................9-1 Precautions for Maintenance During Cold Weather Season ................................................9-2 STORAGE ....................................................................................... 10-1 Storing Machine .......................................................................... 10-1 Removing Machine from Storage ......................................... 10-2 TROUBLESHOOTING ................................................................ 11-1 Troubleshooting .......................................................................... 11-1 Engine .............................................................................................. 11-1 Hydraulic Control Lever ............................................................ 11-2 Hydraulic System ......................................................................... 11-3 Drive Function .............................................................................. 11-4 Others .............................................................................................. 11-5 SPECIFICATIONS ........................................................................ 12-1 Specifications ................................................................................ 12-1 OPTIONAL ATTACHMENTS .................................................... 13-1 Operating Quick Coupler (Mechanical Type) .................... 13-1 Operating Quick Coupler (Hydraulic Type) ........................ 13-3 INDEX ............................................................................................. 14-1

ENGINE EMISSION CONTROL LABEL EMISSION CONTROL LABEL: ENGINE LABEL (FOR EPA) Emission control label is attached on the cylinder head cover.

M4FG-00-003 M4FG-00-004

1

ENGINE EMISSION CONTROL LABEL MEMO ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... 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2

MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.

MACHINE TYPE: _______________________________ PRODUCT IDENTIFICATION NUMBER: ___________________________

PRODUCT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER: ___________________________ NOTE: *HFK4FG00A00000101*

M4FG-00-001

Label

Marks to indicate the start and end of the PIN

PRODUCT IDENTIFICATION NUMBER (PIN)

ENGINE M4FG-00-003

TYPE: _______________________________ MFG. NO.: ___________________________

3

MACHINE NUMBERS MEMO ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... 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4

SAFETY Recognize Safety Information x These are the SAFETY ALERT SYMBOLS. t 8IFO ZPV TFF UIFTF TZNCPMT PO ZPVS NBDIJOF PS JO UIJT manual, be alert to the potential for personal injury. t 'PMMPX SFDPNNFOEFE QSFDBVUJPOT BOE TBGF PQFSBUJOH practices.

SA-688

Understand Signal Words x On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. t DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. t WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. t CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. t DANGER or WARNING safety signs signs are located near specific hazards. General precautions are listed on CAUTION safety signs. t 4PNF TBGFUZ TJHOT EP OPU VTF BOZ PG UIF EFTJHOBUFE TJHOBM words above after the safety alert symbol has been used on this machine. x To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. x

f NOTE indicates an additional explanation for an element of information.

S-1

SA-1223

SAFETY Follow Safety Instructions x Carefully read and follow all safety signs on the machine and all safety messages in this manual. x Safety signs should be installed, maintained and replaced when necessary. t *G B TBGFUZ TJHO PS UIJT NBOVBM JT EBNBHFE PS NJTTJOH order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). x Learn how to operate the machine and its controls correctly and safely. x Allow only trained, qualified, authorized personnel to operate the machine. x Keep your machine in proper working condition. t 6OBVUIPSJ[FE NPEJGJDBUJPOT PG UIF NBDIJOF NBZ JNQBJS its function and / or safety and affect machine life. t %P OPU NPEJGZ BOZ NBDIJOF QBSUT XJUIPVU BVUIPSJ[BUJPO Failure to do so may deteriorate the part safety, function, and / or service life. In addition, personal accident, machine trouble, and / or damage to material caused by unauthorized modifications will void Kawasaki Warranty Policy. t %P OPU VTF BUUBDINFOUT BOE PS PQUJPOBM QBSUT PS equipment not authorized by Kawasaki. Failure to do so may deteriorate the safety, function, and / or service life of the machine. In addition, personal accident, machine trouble, and / or damage to material caused by using unauthorized attachments and / or optional parts or equipment will void Kawasaki Warranty Policy. x The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and / or your authorized dealer before operating or performing maintenance work on the machine.

S-2

SA-003

SAFETY Prepare for Emergencies x Be prepared if a fire starts or if an accident occurs. t ,FFQ B GJSTU BJE LJU BOE GJSF FYUJOHVJTIFS PO IBOE t 5IPSPVHIMZ SFBE BOE VOEFSTUBOE UIF MBCFM BUUBDIFE PO the fire extinguisher to use it properly. t 5P FOTVSF UIBU B GJSF FYUJOHVJTIFS DBO CF BMXBZT VTFE when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual. t &TUBCMJTI FNFSHFODZ QSPDFEVSF HVJEFMJOFT UP DPQF XJUI fires and accidents. t ,FFQ FNFSHFODZ OVNCFST GPS EPDUPST BNCVMBODF service, hospital, and fire department posted near your telephone.

SA-437

Wear Protective Clothing x Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask.

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

t "WPJE XFBSJOH MPPTF DMPUIJOH KFXFMSZ PS PUIFS JUFNT UIBU can catch on control levers or other parts of the machine. x Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

S-3

SAFETY Protect Against Noise x Prolonged exposure to loud noise can cause impairment or loss of hearing. t 8FBS B TVJUBCMF IFBSJOH QSPUFDUJWF EFWJDF TVDI BT earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

Inspect Machine x Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. t *O UIF XBML BSPVOE JOTQFDUJPO CF TVSF UP DPWFS BMM QPJOUT described in the “Inspect Machine Daily Before Starting” section in the operator’s manual.

SA-435

S-4

SAFETY General Precautions for Cab t #FGPSF FOUFSJOH UIF DBC UIPSPVHIMZ SFNPWF BMM EJSU BOE / or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and / or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. t %P OPU MFBWF QBSUT BOE PS UPPMT MZJOH BSPVOE UIF operator’s seat. Store them in their specified locations. t "WPJE TUPSJOH USBOTQBSFOU CPUUMFT JO UIF DBC %P OPU attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. t 3FGSBJO GSPN MJTUFOJOH UP UIF SBEJP PS VTJOH NVTJD headphones or mobile telephones in the cab while operating the machine. t ,FFQ BMM GMBNNBCMF PCKFDUT BOE PS FYQMPTJWFT BXBZ GSPN the machine. t "GUFS VTJOH UIF BTIUSBZ BMXBZT DPWFS JU UP FYUJOHVJTI UIF match and / or tobacco. t %P OPU MFBWF DJHBSFUUF MJHIUFST JO UIF DBC 8IFO UIF temperature in the cab increases, the lighter may explode.

S-5

SAFETY Use Handrails and Steps x Falling is one of the major causes of personal injury. t 8IFO ZPV HFU PO BOE PGG UIF NBDIJOF BMXBZT GBDF UIF machine and maintain a three-point contact with the steps and handrails. t %P OPU VTF BOZ DPOUSPMT BT IBOEIPMET t /FWFS KVNQ PO PS PGG UIF NBDIJOF /FWFS NPVOU PS dismount a moving machine. t #F DBSFGVM PG TMJQQFSZ DPOEJUJPOT PO QMBUGPSNT TUFQT BOE handrails when leaving the machine.

SA-439

Never Ride Attachment x Never allow anyone to ride attachment or the load. This is an extremely dangerous practice.

Adjust Operator’s Seat x A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperations. t 5IF TFBU TIPVME CF BEKVTUFE XIFOFWFS DIBOHJOH UIF operator for the machine. t 5IF PQFSBUPS TIPVME CF BCMF UP GVMMZ EFQSFTT UIF QFEBMT and to correctly operate the control levers with his back against the seat back. t *G OPU NPWF UIF TFBU GPSXBSE PS CBDLXBSE BOE DIFDL again. t "EKVTU UIF SFBS WJFX NJSSPS QPTJUJPO TP UIBU UIF CFTU SFBS visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

S-6

SA-462

SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat x Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the loader control lever lock to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death. t #FGPSF MFBWJOH UIF NBDIJOF CF TVSF UP GJSTU MPXFS UIF GSPOU attachment to the ground and then move the loader control lever lock to the LOCK position. Turn the key switch OFF to stop the engine. t #FGPSF MFBWJOH UIF NBDIJOF DMPTF BMM XJOEPXT EPPST BOE access covers and lock them up.

Fasten Your Seat Belt x If the machine should overturn, the operator may become injured and / or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. t 1SJPS UP PQFSBUJOH UIF NBDIJOF UIPSPVHIMZ FYBNJOF webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. t #F TVSF UP SFNBJO TFBUFE XJUI UIF TFBU CFMU TFDVSFMZ fastened at all times when the machine is in operation to minimize the chance of injury from an accident. t 8F SFDPNNFOE UIBU UIF TFBU CFMU CF SFQMBDFE FWFSZ UISFF years regardless of its apparent condition.

S-7

SA-237

SAFETY Move and Operate Machine Safely x Bystanders can be run over. t 5BLF FYUSB DBSF OPU UP SVO PWFS CZTUBOEFST $POGJSN UIF location of bystanders before moving, swinging, or operating the machine. t "MXBZT LFFQ UIF USBWFM BMBSN BOE IPSO JO XPSLJOH condition (if equipped). It warns people when the machine starts to move. t 6TF B TJHOBM QFSTPO XIFO NPWJOH PS PQFSBUJOH UIF machine in congested areas. Coordinate hand signals before starting the machine. t 6TF BQQSPQSJBUF JMMVNJOBUJPO $IFDL UIBU BMM MJHIUT BSF operable before operating the machine. If any faulty illumination is present, immediately repair it.

SA-398

Handle Starting Aids Safely Starting fluid: x Starting fluid is highly flammable. t ,FFQ BMM TQBSLT BOE GMBNF BXBZ XIFO VTJOH JU t ,FFQ TUBSUJOH GMVJE XFMM BXBZ GSPN CBUUFSJFT BOE DBCMFT t 3FNPWF DPOUBJOFS GSPN NBDIJOF JG FOHJOF EPFT OPU OFFE starting fluid. t 5P QSFWFOU BDDJEFOUBM EJTDIBSHF XIFO TUPSJOH B pressurized container, keep the cap on the container, and store it in a cool, well-protected location. t %P OPU JODJOFSBUF PS QVODUVSF B TUBSUJOH GMVJE DPOUBJOFS

S-8

SA-293

SAFETY Operate Only from Operator’s Seat x Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. t 4UBSU UIF FOHJOF POMZ XIFO TFBUFE JO UIF PQFSBUPShT TFBU t /&7&3 TUBSU UIF FOHJOF XIJMF TUBOEJOH PO UIF UJSF PS PO ground. t %P OPU TUBSU FOHJOF CZ TIPSUJOH BDSPTT TUBSUFS UFSNJOBMT t #FGPSF TUBSUJOH UIF FOHJOF DPOGJSN UIBU BMM DPOUSPM MFWFST are in neutral. t #FGPSF TUBSUJOH UIF FOHJOF DPOGJSN UIF TBGFUZ BSPVOE UIF machine and sound the horn to alert bystanders.

SA-431

Jump Starting x Battery gas can explode, resulting in serious injury. t *G UIF FOHJOF NVTU CF KVNQ TUBSUFE CF TVSF UP GPMMPX UIF instructions shown in the “OPERATING ENGINE” chapter in the operator’s manual. t 5IF PQFSBUPS NVTU CF JO UIF PQFSBUPS T TFBU TP UIBU UIF machine will be under control when the engine starts.

Jump starting is a two-person operation. t /FWFS VTF B GSP[FO CBUUFSZ t 'BJMVSF UP GPMMPX DPSSFDU KVNQ TUBSUJOH QSPDFEVSFT DPVME result in a battery explosion or a runaway machine.

S-9

SA-032

SAFETY Investigate Job Site Beforehand x When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. t *OWFTUJHBUF UIF DPOGJHVSBUJPO BOE HSPVOE DPOEJUJPOT PG the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing. t .BLF B XPSL QMBO 6TF NBDIJOFT BQQSPQSJBUF UP UIF XPSL and job site. t 3FJOGPSDF HSPVOE FEHFT BOE SPBE TIPVMEFST BT necessary. Keep the machine well back from the edges of excavations and road shoulders. t 8IFO XPSLJOH PO BO JODMJOF PS PO B SPBE TIPVMEFS employ a signal person as required. t $POGJSN UIBU ZPVS NBDIJOF JT FRVJQQFE XJUI B '014 DBC before working in areas where the possibility of falling stones or debris exist. t 8IFO UIF GPPUJOH JT XFBL SFJOGPSDF UIF HSPVOE CFGPSF starting work. t 8IFO XPSLJOH PO GSP[FO HSPVOE CF FYUSFNFMZ BMFSU "T ambient temperatures rise, footing becomes loose and slippery. t #FXBSF PG UIF QPTTJCJMJUZ PG GJSF XIFO PQFSBUJOH UIF machine near flammable objects such as dry grass.

S-10

SA-447

SAFETY Equipment of Head Guard, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performances and its certification will be lost.

ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-521

Provide Signals for Jobs Involving Multiple Machines x For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

SA-481

S-11

SAFETY Keep Riders Off Machine x Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. t 0OMZ UIF PQFSBUPS TIPVME CF PO UIF NBDIJOF ,FFQ SJEFST off. t 3JEFST BMTP PCTUSVDU UIF PQFSBUPS T WJFX SFTVMUJOH JO UIF machine being operated in an unsafe manner.

SA-427

Drive Safely x Beware of the possibility of slipping and / or turning over the machine when driving on a slope. t 8IFO ESJWJOH PO MFWFM HSPVOE IPME UIF CVDLFU BU NBSL (A) 300 to 400 mm (12 to 15 in) above the ground as illustrated. t "WPJE USBWFMJOH PWFS BOZ PCTUBDMFT t %SJWF UIF NBDIJOF TMPXMZ XIFO ESJWJOH PO SPVHI UFSSBJO t "WPJE RVJDL EJSFDUJPO DIBOHFT 'BJMVSF UP EP TP NBZ DBVTF the machine to turn over. t *G UIF FOHJOF TUPQT XIJMF ESJWJOH UIF TUFFSJOH GVODUJPO becomes inoperative. Immediately stop the machine by applying the brake to prevent personal accident.

S-12

SA-448

SAFETY Drive Machine Safely (Work Site) x Before driving the machine, always confirm that the steering wheel / and F-N-R lever (switch) direction corresponds to the direction you wish to drive. t #F TVSF UP EFUPVS BSPVOE BOZ PCTUSVDUJPOT

x Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

SA-449

t 8IFO ESJWJOH VQ PS EPXO B TMPQF LFFQ UIF CVDLFU GBDJOH the direction of travel, approximately 300 to 400 mm (approximately 12 to 15 in) (A) above the ground. t *G UIF NBDIJOF TUBSUT UP TLJE PS CFDPNFT VOTUBCMF immediately lower the bucket to the ground and stop.

x Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-450

WRONG

SA-451

S-13

SAFETY Drive Safely with Bucket Loaded x If the machine is operated incorrectly while driving with the bucket loaded, the machine may turn over. Be sure to follow all of the instructions indicated below. t 8IFO ESJWJOH UIF NBDIJOF PO B KPC TJUF XJUI UIF CVDLFU loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility. t %P OPU FYDFFE UIF SBUFE MPBE DBQBDJUZ "MXBZT PQFSBUF the machine within the rated load capacity. t "WPJE GBTU TUBSUT TUPQT BOE RVJDL UVSOT 'BJMVSF UP EP TP may result in personal injury and / or death. t "WPJE SBQJE ESJWF EJSFDUJPO DIBOHFT XIJDI DPVME QPTTJCMZ cause personal injury and / or death.

SA-400

Drive on Snow Safely x Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces. t 5IF NBDIJOF NBZ TMJQ NPSF FBTJMZ UIBO FYQFDUFE PO frozen snow surfaces even if the incline is small. Reduce speed when driving. Avoid fast starts, stops and quick turns. t 3PBE TIPVMEFS BOE PS TFU VQ VUJMJUJFT DPWFSFE XJUI TOPX are difficult to locate. Be sure where they are before removing snow. t #F TVSF UP VTF UJSF DIBJOT XIFO ESJWJOH PO TOPX t "WPJE BQQMZJOH UIF CSBLF GPS RVJDL TUPQT PO TOPX *G B quick stop is required, lower the bucket to the ground.

S-14

SA-452

SAFETY Travel on Public Roads Safely x This machine is not allowed to drive on public roads with the bucket loaded. t #F TVSF UP FNQUZ UIF CVDLFU t )PME UIF CVDLFU BU NBSL " UP NN UP JO above the road surface as illustrated.

SA-453

Avoid Injury from Rollway Accidents x Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollways: t 4FMFDU MFWFM HSPVOE XIFO QPTTJCMF UP QBSL NBDIJOF t %P OPU QBSL UIF NBDIJOF PO B HSBEF t -PXFS UIF CVDLFU UP UIF HSPVOE t 1VU UIF ' / 3 MFWFS TXJUDI JO OFVUSBM BOE QVMM VQ UIF park brake switch (lever) in the ON (parking brake) position. t 3VO UIF FOHJOF BU MPX JEMF TQFFE XJUIPVU MPBE GPS minutes to cool down the engine. t 4UPQ UIF FOHJOF BOE SFNPWF UIF LFZ GSPN UIF LFZ TXJUDI t 5VSO UIF MPBEFS DPOUSPM MFWFS MPDL UP -0$, QPTJUJPO t #MPDL CPUI UJSFT BOE MPXFS UIF CVDLFU UP UIF HSPVOE t 1PTJUJPO UIF NBDIJOF UP QSFWFOU SPMMJOH t 1BSL BU B SFBTPOBCMF EJTUBODF GSPN PUIFS NBDIJOFT

SA-457

SA-458

S-15

SAFETY Avoid Accidents from Backing Up and Turning x Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and / or death by being run over or entangled in the machine. t ,FFQ BMM QFSTPOOFM BXBZ GSPN UIF NBDIJOF CZ TPVOEJOH the horn and / or using hand signals. Use extra care to be sure no one is in from the articulation area before turning the machine. t ,FFQ XJOEPXT NJSSPST BOE MJHIUT JO HPPE DPOEJUJPO t 3FEVDF USBWFM TQFFE XIFO EVTU IFBWZ SBJO GPH FUD reduce the visibility. t *O DBTF HPPE WJTJCJMJUZ JT OPU PCUBJOFE VTF B TJHOBM QFSTPO to guide you.

SA-383

SA-312

S-16

SAFETY Avoid Positioning Bucket or Attachment Over Anyone x Never allow the bucket or attachment to pass over coworkers and / or the dump truck operator’s cab. Falling material from the bucket or contact with bucket or attachment may cause serious personal accidents and / or damage to the machine. t "WPJE DBSSZJOH UIF CVDLFU PS BUUBDINFOU PWFS UIF DP workers to ensure safe operation.

SA-518

Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE SA-463

FASTEN YOUR SEAT BELT x The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping: x Be extra careful before operating on a grade. t 1SFQBSF NBDIJOF PQFSBUJOH BSFB GMBU t ,FFQ UIF CVDLFU MPX UP UIF HSPVOE BOE DMPTF UP UIF machine. t 3FEVDF PQFSBUJOH TQFFET UP BWPJE UJQQJOH PS TMJQQJOH t "WPJE DIBOHJOH EJSFDUJPO XIFO USBWFMJOH PO HSBEFT t /&7&3 BUUFNQU UP USBWFM BDSPTT B HSBEF TUFFQFS UIBO degrees if crossing the grade is unavoidable. t 3FEVDF TQFFE BT OFDFTTBSZ XIFO TXJOHJOH MPBET x Be careful when working on frozen ground. t 5FNQFSBUVSF JODSFBTFT XJMM DBVTF UIF HSPVOE UP CFDPNF soft and make ground travel unstable.

S-17

SAFETY Never Undercut a High Bank x The edges could collapse or a land slide could occur causing serious injury or death.

SA-519

Dig with Caution x Accidental severing of underground cables or gas lines may cause an explosion and / or fire, possibly resulting in serious injury or death. t #FGPSF EJHHJOH DIFDL UIF MPDBUJPO PG DBCMFT HBT MJOFT BOE water lines. t ,FFQ UIF NJOJNVN EJTUBODF SFRVJSFE CZ MBX GSPN DBCMFT gas lines, and water lines. t *G B GJCFS PQUJD DBCMF TIPVME CF BDDJEFOUBMMZ TFWFSFE EP not look into the end. Doing so may result in serious eye injury. t $POUBDU ZPVS MPDBM iEJHHFST IPU MJOFw JG BWBJMBCMF JO ZPVS area , and / or the utility companies directly.

Have them mark all underground utilities.

SA-396

Perform Truck Loading Safely x Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and / or death. t %P OPU MPXFS UIF CVDLFU XJUI UIF MPBEFS DPOUSPM MFWFS in the FLOAT position. The bucket may free fall, possibly causing personal injury and / or death. t "MXBZT TFMFDU B MFWFM TVSGBDF GPS USVDL MPBEJOH SA-397

S-18

SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines.

Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length.

SA-455

Precautions for Operation x If the front attachment or any part of the machine comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result. t 5BLF DBSF UP BWPJE DPNJOH JO DPOUBDU XJUI PWFSIFBE obstacles with the bucket or arm during operation.

Precautions for Lightning x The machine is vulnerable to lightning strikes. t *O UIF FWFOU PG BO FMFDUSJDBM TUPSN JNNFEJBUFMZ TUPQ operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine. t "GUFS UIF FMFDUSJDBM TUPSN IBT QBTTFE DIFDL BMM PG UIF machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

S-19

SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED. x If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.

Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example). They may come off, causing the load to fall.

SA-132

Protect Against Flying Debris x If flying debris hit eyes or any other part of the body, serious injury may result. t (VBSE BHBJOTU JOKVSZ GSPN GMZJOH QJFDFT PG NFUBM PS EFCSJT wear goggles or safety glasses. t ,FFQ CZTUBOEFST BXBZ GSPN UIF XPSLJOH BSFB CFGPSF striking any object.

SA-432

S-20

SAFETY Park Machine Safely To avoid accidents: t 1BSL UIF NBDIJOF PO B GJSN MFWFM TVSGBDF t -PXFS CVDLFU UP UIF HSPVOE t 1VU UIF ' / 3 MFWFS TXJUDI JO OFVUSBM BOE UVSO UIF parking brake switch (lever) ON (parking brake) position. t 3VO UIF FOHJOF BU MPX JEMF TQFFE XJUIPVU MPBE GPS minutes. t 5VSO LFZ TXJUDI UP 0'' UP TUPQ FOHJOF t 3FNPWF UIF LFZ GSPN UIF LFZ TXJUDI t 5VSO UIF MPBEFS DPOUSPM MFWFS MPDL UP UIF -0$, QPTJUJPO t $MPTF XJOEPXT SPPG WFOU BOE DBC EPPS t -PDL BMM BDDFTT EPPST BOE DPNQBSUNFOUT

SA-456

Store Attachments Safely x Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. t 4FDVSFMZ TUPSF BUUBDINFOUT BOE JNQMFNFOUT UP QSFWFOU falling. Keep children and bystanders away from storage areas.

SA-034

S-21

SAFETY Transport Safely x Be careful because the machine may turn over when loading or unloading the machine on or off of a truck or trailer. t 0CTFSWF UIF SFMBUFE SFHVMBUJPOT BOE SVMFT GPS TBGF transportation. t 4FMFDU BO BQQSPQSJBUF USVDL PS USBJMFS GPS UIF NBDIJOF UP be transported. t #F TVSF UP VTF B TJHOBM QFSTPO t "MXBZT GPMMPX UIF GPMMPXJOH QSFDBVUJPOT GPS MPBEJOH PS unloading: 1. Select solid and level ground.

2. Always use a ramp or deck strong enough to support the machine weight.

3. Use a low speed gear.

4. Never steer the machine while being on the ramp. If the traveling direction must be changed while being on the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

5. After loading, install the lock bar to securely hold the articulation mechanism.

6. Chock the front and rear of tires. Securely hold the machine to the truck or trailer deck with heavy chains or wire cables.

Be sure to further follow the details described in the TRANSPORTING chapter.

S-22

Less than 15 ° SA-454

SAFETY Handle Fluids Safely−Avoid Fires x )BOEMF GVFM XJUI DBSF JU JT IJHIMZ GMBNNBCMF *G GVFM JHOJUFT an explosion and / or a fire may occur, possibly resulting in serious injury or death. t %P OPU SFGVFM UIF NBDIJOF XIJMF TNPLJOH PS XIFO OFBS open flame or sparks. t "MXBZT TUPQ UIF FOHJOF CFGPSF SFGVFMJOH UIF NBDIJOF t 'JMM UIF GVFM UBOL PVUEPPST

x All fuels, most lubricants, and some coolants are flammable. t 4UPSF GMBNNBCMF GMVJET XFMM BXBZ GSPN GJSF IB[BSET t %P OPU JODJOFSBUF PS QVODUVSF QSFTTVSJ[FE DPOUBJOFST t %P OPU TUPSF PJMZ SBHT UIFZ DBO JHOJUF BOE CVSO spontaneously. t 4FDVSFMZ UJHIUFO UIF GVFM BOE PJM GJMMFS DBQT

SA-018

SA-019

S-23

SAFETY Practice Safe Maintenance To avoid accidents: t 6OEFSTUBOE TFSWJDF QSPDFEVSFT CFGPSF TUBSUJOH XPSL t ,FFQ UIF XPSL BSFB DMFBO BOE ESZ t %P OPU TQSBZ XBUFS PS TUFBN JOTJEF DBC t /FWFS MVCSJDBUF PS TFSWJDF UIF NBDIJOF XIJMF JU JT NPWJOH t ,FFQ IBOET GFFU BOE DMPUIJOH BXBZ GSPN QPXFS ESJWFO parts.

Before servicing the machine: 1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Run the engine at low idle speed without load for 3 minutes.

SA-028

4. Turn the key switch to OFF to stop engine.

5. Relieve the pressure in the hydraulic system by moving the control levers several times.

6. Remove the key from the key switch.

7. Attach a “Do Not Operate” tag on the control lever.

8. Turn the loader control lever lock to the LOCK position.

9. Lock bar connects the front and rear frames.

10. Allow the engine to cool.

SA-312

t *G B NBJOUFOBODF QSPDFEVSF NVTU CF QFSGPSNFE XJUI UIF engine running, do not leave machine unattended. t /FWFS XPSL VOEFS B NBDIJOF SBJTFE CZ UIF MJGU BSN t *OTQFDU DFSUBJO QBSUT QFSJPEJDBMMZ BOE SFQBJS PS SFQMBDF BT necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual. t ,FFQ BMM QBSUT JO HPPE DPOEJUJPO BOE QSPQFSMZ JOTUBMMFE t 'JY EBNBHF JNNFEJBUFMZ 3FQMBDF XPSO PS CSPLFO QBSUT Remove any buildup of grease, oil, or debris. t 8IFO DMFBOJOH QBSUT BMXBZT VTF OPOGMBNNBCMF detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. t %JTDPOOFDU CBUUFSZ HSPVOE DBCMF ¦ CFGPSF NBLJOH adjustments to electrical systems or before performing welding on the machine.

SA-134

SA-527

S-24

SAFETY t 4VGGJDJFOUMZ JMMVNJOBUF UIF XPSL TJUF 6TF B NBJOUFOBODF work light when working under or inside the machine. t "MXBZT VTF B XPSL MJHIU QSPUFDUFE XJUI B HVBSE *O DBTF the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

Warn Others of Service Work x Unexpected machine movement can cause serious injury. t #FGPSF QFSGPSNJOH BOZ XPSL PO UIF NBDIJOF BUUBDI B i%P Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

SS2045102

Support Machine Properly x Never attempt to work on the machine without securing the machine first. t "MXBZT MPXFS UIF BUUBDINFOU UP UIF HSPVOE CFGPSF ZPV work on the machine. t *G ZPV NVTU XPSL PO B MJGUFE NBDIJOF PS BUUBDINFOU securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-527

S-25

SAFETY Stay Clear of Moving Parts x Entanglement in moving parts can cause serious injury. t 5P QSFWFOU BDDJEFOUT DBSF TIPVME CF UBLFO UP FOTVSF UIBU hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

Support Maintenance Properly x Explosive separation of a tire and rim parts can cause serious injury or death. t %P OPU BUUFNQU UP NPVOU B UJSF VOMFTT ZPV IBWF UIF proper equipment and experience to perform the job.

Have it done by your authorized dealer or a qualified repair service. t "MXBZT NBJOUBJO UIF DPSSFDU UJSF QSFTTVSF %0 /05 JOGMBUF tire above the recommended pressure. t 8IFO JOGMBUJOH UJSFT VTF B DIJQ PO DIVDL BOE FYUFOTJPO hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage if available. t *OTQFDU UJSFT BOE XIFFMT EBJMZ %P OPU PQFSBUF XJUI MPX pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts. t /FWFS DVU PS XFME PO BO JOGMBUFE UJSF PS SJN BTTFNCMZ )FBU from welding could cause an increase in pressure and may result in tire explosion.

S-26

SA-249

SAFETY Prevent Parts from Flying x Travel reduction gears are under pressure. t "T QJFDFT NBZ GMZ PGG CF TVSF UP LFFQ CPEZ BOE GBDF BXBZ from AIR RELEASE PLUG to avoid injury. t (&"3 0*- JT IPU 8BJU GPS (&"3 0*- UP DPPM UIFO HSBEVBMMZ loosen AIR RELEASE PLUG to release pressure.

SA-344

Prevent Burns Hot spraying fluids: x After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns. t "WPJE QPTTJCMF JOKVSZ GSPN IPU TQSBZJOH XBUFS %0 /05 remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. t 5IF IZESBVMJD PJM UBOL JT QSFTTVSJ[FE "HBJO CF TVSF UP release all pressure before removing the cap.

SA-039

Hot fluids and surfaces: x Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well. t 8BJU GPS UIF PJM BOE DPNQPOFOUT UP DPPM CFGPSF TUBSUJOH any maintenance or inspection work.

SA-225

S-27

SAFETY Replace Rubber Hoses Periodically x Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. t 1FSJPEJDBMMZ SFQMBDF UIF SVCCFS IPTFT 4FF UIF QBHF PG “Periodic replacement of parts” in the operator’s manual.) x Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

Avoid High-Pressure Fluids x Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. t "WPJE UIJT IB[BSE CZ SFMJFWJOH QSFTTVSF CFGPSF disconnecting hydraulic or other lines. t 5JHIUFO BMM DPOOFDUJPOT CFGPSF BQQMZJOH QSFTTVSF t 4FBSDI GPS MFBLT XJUI B QJFDF PG DBSECPBSE UBLF DBSF UP protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection. t *G BO BDDJEFOU PDDVST TFF B EPDUPS GBNJMJBS XJUI UIJT type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours, or gangrene may result.

SA-031

SA-292

SA-044

S-28

SAFETY Prevent Fires Check for Oil Leaks: x Fuel, hydraulic oil and lubricant leaks can lead to fires. t $IFDL GPS PJM MFBLT EVF UP NJTTJOH PS MPPTF DMBNQT LJOLFE hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. t 5JHIUFO SFQBJS PS SFQMBDF BOZ NJTTJOH MPPTF PS EBNBHFE clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. t %P OPU CFOE PS TUSJLF IJHI QSFTTVSF MJOFT t /FWFS JOTUBMM CFOU PS EBNBHFE MJOFT QJQFT PS IPTFT Check for Shorts: x Short circuits can cause fires. t $MFBO BOE UJHIUFO BMM FMFDUSJDBM DPOOFDUJPOT t $IFDL CFGPSF FBDI TIJGU PS BGUFS FJHIU UP UFO IPVST operation for loose, kinked, hardened or frayed electrical cables and wires. t $IFDL CFGPSF FBDI TIJGU PS BGUFS FJHIU UP UFO IPVST operation for missing or damaged terminal caps. t %0 /05 01&3"5& ."$)*/& JG DBCMF PS XJSFT BSF MPPTF kinked, etc.

Clean up Flammables: x Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. t 1SFWFOU GJSFT CZ JOTQFDUJOH BOE DMFBOJOH UIF NBDIJOF daily and by removing spilled or accumulated flammables immediately.

Check Key Switch: x If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key switch function before operating the machine every day: 1. Start the engine and run it at low idle.

2. Turn the key switch to the OFF position to confirm that the engine stops. t *G BOZ BCOPSNBMJUJFT BSF GPVOE CF TVSF UP SFQBJS UIFN before operating the machine.

Check Heat Shields: x Damaged or missing heat shields may lead to fires. t %BNBHFE PS NJTTJOH IFBU TIJFMET NVTU CF SFQBJSFE PS replaced before operating the machine.

S-29

SA-019

SAFETY Evacuating in Case of Fire x If a fire breaks out, evacuate the machine in the following way: t 4UPQ UIF FOHJOF CZ UVSOJOH UIF LFZ TXJUDI UP UIF 0'' position if there is time. t 6TF B GJSF FYUJOHVJTIFS JG UIFSF JT UJNF t &YJU UIF NBDIJOF

SA-393

Beware of Exhaust Fumes x Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. t *G ZPV NVTU PQFSBUF JO B CVJMEJOH CF TVSF UIFSF JT adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

SA-016

Precautions for Welding and Grinding x Welding may generate gas and / or small fires. t #F TVSF UP QFSGPSN XFMEJOH JO B XFMM WFOUJMBUFE BOE prepared area. Store flammable objects in a safe place before starting welding. t 0OMZ RVBMJGJFE QFSTPOOFM TIPVME QFSGPSN XFMEJOH Never allow an unqualified person to perform welding. x Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. x After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

S-30

SA-818

SAFETY Avoid Heating Near Pressurized Fluid Lines x Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. t %P OPU IFBU CZ XFMEJOH TPMEFSJOH PS VTJOH B UPSDI OFBS pressurized fluid lines or other flammable materials. t 1SFTTVSJ[FE MJOFT DBO CF BDDJEFOUBMMZ DVU XIFO IFBU HPFT beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-030

Avoid Applying Heat to Lines Containing Flammable Fluids x Do not weld or flame cut pipes or tubes that contain flammable fluids. t $MFBO UIFN UIPSPVHIMZ XJUI OPOGMBNNBCMF TPMWFOU before welding or flame cutting them.

Remove Paint Before Welding or Heating x Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. t Avoid potentially toxic fumes and dust. t %P BMM TVDI XPSL PVUTJEF PS JO B XFMM WFOUJMBUFE BSFB Dispose of paint and solvent properly. t 3FNPWF QBJOU CFGPSF XFMEJOH PS IFBUJOH 1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

SA-029

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

S-31

SAFETY Beware of Asbestos and Silicon Dust and Other Contamination x Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung cancer.

Inhalation of silicon dust and other contamination may cause sickness. t %FQFOEJOH PO UIF XPSL TJUF DPOEJUJPOT UIF SJTL PG inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air. t 8IFO PQFSBUJOH UIF NBDIJOF JO B XPSL TJUF XIFSF asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos. t ,FFQ CZTUBOEFST PVU PG UIF XPSL TJUF EVSJOH PQFSBUJPO t "TCFTUPT NJHIU CF QSFTFOU JO JNJUBUJPO QBSUT 6TF POMZ genuine Kawasaki Parts.

SA-029

Prevent Battery Explosions x Battery gas can explode. t ,FFQ TQBSLT MJHIUFE NBUDIFT BOE GMBNF BXBZ GSPN UIF top of battery. t /FWFS DIFDL CBUUFSZ DIBSHF CZ QMBDJOH B NFUBM PCKFDU across the posts. Use a voltmeter or hydrometer. t %P OPU DIBSHF B GSP[FO CBUUFSZ JU NBZ FYQMPEF 8BSN UIF battery to 16 °C (60 °F) first. t %P OPU DPOUJOVF UP VTF PS DIBSHF UIF CBUUFSZ XIFO electrolyte level is lower than specified. Explosion of the battery may result. t -PPTF UFSNJOBMT NBZ QSPEVDF TQBSLT 4FDVSFMZ UJHIUFO BMM terminals. x Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. t #F TVSF UP XFBS FZF QSPUFDUJPO XIFO DIFDLJOH FMFDUSPMZUF specific gravity.

S-32

SA-032

SAFETY Service Air Conditioning System Safely x If spilled onto skin, refrigerant may cause a cold contact burn. t 3FGFS UP UIF JOTUSVDUJPOT EFTDSJCFE PO UIF DPOUBJOFS GPS proper use when handling the refrigerant. t 6TF B SFDPWFSZ BOE SFDZDMJOH TZTUFN UP BWPJE MFBLJOH refrigerant into the atmosphere. t /FWFS UPVDI UIF SFGSJHFSBOU SA-405

Handle Chemical Products Safely x Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. t " .BUFSJBM 4BGFUZ %BUB 4IFFU .4%4 QSPWJEFT TQFDJGJD details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. t $IFDL UIF .4%4 CFGPSF ZPV TUBSU BOZ KPC VTJOH B hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. t 4FF ZPVS BVUIPSJ[FE EFBMFS GPS .4%4 T BWBJMBCMF POMZ JO English) on chemical products used with your machine.

S-33

SA-309

SAFETY Dispose of Waste Properly x Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Kawasaki equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. t 6TF MFBLQSPPG DPOUBJOFST XIFO ESBJOJOH GMVJET %P OPU VTF food or beverage containers that may mislead someone into drinking from them. t %P OPU QPVS XBTUF POUP UIF HSPVOE EPXO B ESBJO PS JOUP any water source. t "JS DPOEJUJPOJOH SFGSJHFSBOUT FTDBQJOH JOUP UIF BJS DBO damage the Earth’s atmosphere. Government regulations require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. t *ORVJSF PO UIF QSPQFS XBZ UP SFDZDMF PS EJTQPTF PG XBTUF from your local environmental or recycling center, or from your authorized dealer.

S-34

SA-226

SAFETY SIGNS All safety signs and their locations affixed on the machine are illustrated in this group. Make sure of the contents described in the safety signs through reading actual ones affixed on the machine to ensure safe machine operation. Always keep the safety signs clean. In case a safety sign is broken or lost, immediately obtain a new replacement and affix it again in position on the machine. Use the part No. indicated under the right corner of each safety sign illustration when placing an order for it to the Kawasaki dealer.

4

6

5

2

1

8

7

21 3 19 18

16

17

16

15

20

9 11

10

13 14

12 SS-4FGE-001

S-35

SAFETY SIGNS 1. Both sides of bucket

SS-4EK-017_E

SS-4FGE-002

t Sign indicates a hazard of falling. t Do not stand on this place.

2. Front Maintenance Access Cover for Front Frame

SS-4EK-019_E

t The front attachment may unexpectedly be lowered, possibly resulting in personal injury. Lower the front attachment to the ground before inspecting/maintaining the machine. In case inspection and/or maintenance work must unavoidably be performed with the front attachment raised, lock the front attachment control levers in position.

Then, securely support the front attachment with safety supports and/or blocks.

SS-4FGE-003

3. Both sides of Lift Arm

SS-4EK-020_E

S-36

SS-4FG-002

SAFETY SIGNS 4. Left Side of Front Console

SS-4EK-021_E

SS-4EK-005 E

5. Right Side of Front Console

SS-4EK-022_E SS-4EK-005 E

6. Left side of steering wheel support

t

WARNING: To minimize the injury due to an overturning accident, be sure to fasten the seat belt prior to operating the machine.

SS-4FGE-004 SS-4EK-023_E

S-37

SAFETY SIGNS 7. Steering wheel support

SS-4FGE-004

SS-4EK-026_E

8. Steering wheel support

SS-4FGE-004

SS-4EK-024_E

S-38

SAFETY SIGNS 9. Both Side Vicinity of Step’s

SS-4EK-027_E

SS-4FGE-005

SS-4FGE-006

10. Left Side of Fender

SS-4EK-028_E

t If the engine is started following an incorrect method, the machine suddenly may begin to move. Start the engine from the operator’s seat only.

S-39

SS-4FGE-007

SAFETY SIGNS 11. Vicinity of Battery

SS-4EK-029_E

SS-4FGE-008

t Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness. Take care not to touch electrolyte.

12. Vicinity of Radiator Cap

SS-4EK-031_E

SS-4FGE-007

t Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot. Allow radiator or hydraulic tank to cool before removing cap.

13. Vicinity of Radiator Cap

SS-4EK-032_E

t Avoid skin contact with highly heated parts such as the engine, muffer, etc. immediately after operation of the machine. Severe burns may result.

SS-4FGE-007

S-40

SAFETY SIGNS 14. Both Sides of Radiator Fan Guard

SS-4EK-033_E

t Side indicates a hazard of rotating parts, such as belt. Turn off before inspection and maintenance.

SS-4FGE-007

15. Vicinity of Brake Oil Tank

SS-4EK-035_E

SS-4FGE-007

16. Both Sides of Counterweight

SS-4EK-039_E

t Avoid machine reversing injuries. Keep everyone far away from the machine during operation.

S-41

SS-4FGE-009

SAFETY SIGNS 17. Left Side of Front Frame

SS-4EK-040_E

SS-4FGE-010

t The articulation area becomes a pinch point when steering the machine. Be sure to install the articulate lock bar during the inspection/maintenance work and transportation of the machine. Remove link when finished.

18. Both Sides of Front Fender

SS-4EK-041_E

t The articulation area becomes a pinch point when steering the machine. Keep all personnel away from the articulation area during operation of the machine.

SS-4FGE-011

19. Both Sides of Front Fender

SS-4EK-042_E

t Sign indicates a hazard of rotating parts, such as belt. Turn off before inspection and maintenance.

SS-4FGE-011

S-42

SAFETY SIGNS 20. Vicinity of Fuel Tank Cap

SS-4FGE-005 SS-4FGE-012

21. Both sides of Lift Arm

SS-4EK-043_E

S-43

SS-4FG-002

SAFETY SIGNS MEMO ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... ................................................................................................................................................................................................................................................... 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S-44

COMPONENTS NAME Components Name 9

Canopy Vehicle 8

1- Bolt-On Cutting Edge (BOC)

7

2- Bucket 6

3- Bucket Link

5 4

4- Bell Crank 3

5- Bucket Cylinder 6- Front Combination Lamp (Turn Signal/Clearance Light/Hazard Light) 7- Headlight 8- Outside Rear View Mirror 2

9- ROPS Canopy

11

1

10- Fuel Filler Port 11- Articulation Lock Bar

14

13

12

10 M4FGE-01-001

12- Front Fender 13- Lift Arm Cylinder 14- Lift Arm 15- Hydraulic Oil Tank 16- Counterweight 17- Rear Combination Lamp (Turn Signal/Hazard Light/Tail Light/Brake Light) 18- Back Light 19- Backup Alarm 20- Towing Pin 21- Radiator/Oil Cooler 21

15

20 19

M4FGE-01-002

18

1-1

17

16

COMPONENTS NAME Cab Vehicle (Optional) 1- Bolt-On Cutting Edge (BOC)

9

10

11

8

2- Bucket 3- Bucket Link

7

4- Bell Crank

6

5- Bucket Cylinder

5

6- Front Combination Lamp (Turn Signal/Clearance Light/ Hazard Light)

4 3

7- Headlight 8- Outside Rear View Mirror

2

9- Front Work Light 10- ROPS Cab 11- Rear Work Light

13

1

12- Fuel Filler Port

16

13- Articulation Lock Bar

15

12

14 M4FG-01-003

14- Front Fender 15- Lift Arm Cylinder 16- Lift Arm 17- Hydraulic Oil Tank 18- Counterweight 19- Rear Combination Lamp (Turn Signal/Hazard Light/Tail Light/Brake Light) 20- Backup Light 21- Towing Pin 22- Radiator/Oil Cooler

22

17 21

20

1-2

M4FG-01-004

19

18

OPERATOR’S STATION Cab Features 2

4

3

1

5

M4FG-01-005

1- Front Console 2- Right Console 3- Operator’s Seat 4- Fuse Box 5- Floor Mat

1-3

OPERATOR’S STATION Front Console

1

2

3

1- Steering Wheel 2- Horn switch 3- Monitor Panel 4- Accelerator Pedal

4

5- Brake/Inching Pedal (Both right and left sides are interlocked.)

6- Brake/Inching Pedal (Both right and left sides are interlocked.)

7- Neutral Lever Lock (F-N-R Lever) 8- F-N-R Lever 9- Hi-Lo Selector Switch 6

10- Front and Rear Work Light Switch (Cab Vehicle)

5

M4FG-01-006

11- Hazard Switch 12- Turn Signal Lever 13- Parking Brake Switch

11

14- Front Window Wiper Switch (Cab Vehicle)

10

15- Rear Window Wiper Switch (Cab Vehicle)

9

16- Light Switch

fNOTE: Cab vehicle is an optional.

8

7

M4FG-01-007

12

13

14

15 16 M4FG-01-008

1-4

OPERATOR’S STATION Right Console

1

2

Mono-Lever Type 3

1- Loader Control Lever

Front

4

2- Auxiliary Control Lever (Optional)

5

3- Auxiliary Control Lever Lock

6

4- Auxiliary (Optional)

7

5- Ride Control Switch (Optional) 6- eco Mode Switch 7- Heater Switch (Optional for Cab Vehicle) 8- Key Switch 9

9- Loader Control Lever Lock

8 M4FG-01-009

1-5

OPERATOR’S STATION Monitor Panel 1

2

3

4

5

6

7

8

9

10

11

22 12 21

20

19

18

17

16

15

14

13

1- Engine Coolant Temperature Gauge

12- Brake Oil Low Level Indicator

2- Left Turn Signal Indicator

13- Not Used

3- High Beam Indicator

14- Discharge Warning Indicator

4- Monitor Display

15- HST Error Code Readout Switch

5- Work Light Indicator (Optional)

16- Preheat Indicator

6- Right Turn Signal Indicator

17- Monitor Display Selector

7- Stop Indicator

18- Not Used

8- Service Indicator

19- Overheat Indicator

9- Parking Brake Indicator

20- Engine Oil Low Pressure Indicator

10- Clearance Light Indicator

21- Air Filter Restriction Indicator

11- Fuel Gauge

22- HST Warning Indicator

1-6

M4FG-01-010

OPERATOR’S STATION Stop Indicator (Red) Prevent possible casualty and/or machine d WARNING: damage. If the stop indicator flashes and the alarm buzzer sounds, immediately stop machine operation.

Then, check the section displaying the trouble.

Service the needed areas.

The stop indicator flashes and the alarm buzzer sounds if one of the following cases below occurs. Immediately, stop operating the machine. Move the machine to a safe area.

Park the machine and stop the engine. Contact your nearest Kawasaki dealer for machine inspection:

M4GB-01-010

t *G UIF FOHJOF PJM QSFTTVSF EFDSFBTFT t *G UIF FOHJOF DPPMBOU UFNQFSBUVSF BCOPSNBMMZ JODSFBTFT t *G UIF CSBLF PJM MFWFM EFDSFBTFT

Service Indicator (Yellow) The service indicator comes ON if one of the following cases as described below occurs. Immediately, stop the engine. Check the cause of the trouble. t *G UIF BMUFSOBUPS WPMUBHF EFDSFBTFT PS CFDPNFT FYDFTTJWFMZ high, t *G UIF BJS DMFBOFS JT SFTUSJDUFE t *G BOZ BCOPSNBMJUZ JT GPVOE JO )45 PQFSBUJPO t *G UIF JOEJDBUPS DPNFT 0/ XIFO UIF QBSLJOH CSBLF JT applied,

1-7

M4GB-01-011

OPERATOR’S STATION Parking Brake Indicator (Red) The parking brake indicator will light when the parking brake is applied.

Return the FNR lever to neutral (N) and release the parking brake.

M4GB-01-012

Brake Oil Low Level Indicator (Red) Stop the machine operation if the d WARNING: brake oil level lowers. Failure to do so may result in personal injury or death. If the red indicator comes ON, immediately stop the machine operation.

If the brake oil level lowers, the brake oil low level indicator will come ON, and the stop indicator will flash.

Immediately stop the machine operation and inspect the brake system for any brake oil leaks.

M4GB-01-014

Discharge Warning Indicator (Red) If any abnormality occurs in the battery charging system such as low alternator voltage, the discharge warning indicator and the service indicator will light. Inspect the alternator and the battery system. The alternator output voltage can be checked at the monitor in the operator’s station. Inspect the alternator and the battery system.

1-8

M4GB-01-018

OPERATOR’S STATION Overheat Indicator (Red) If the engine coolant temperature increases to an abnormally high range, the red indicator will light and the stop indicator will flash.

Stop machine operation and reduce the engine speed to the low idle range to cool the coolant temperature. Visually inspect coolant level in reservoir.

M4GB-01-020

Engine Oil Low Pressure Indicator (Red) If the engine is kept running with the d WARNING: engine oil pressure low, damage to the engine may result. Immediately stop machine operation and stop the engine if the indicator illuminates.

If the engine oil pressure becomes low, the engine oil low pressure indicator will illuminate and the stop indicator will flash.

Immediately stop machine operation and stop the engine.

Inspect the engine oil pressure system and the oil level for any abnormality.

M4GB-01-021

fNOTE: Cold oil temperature or operating on a steep slope may also cause the indicator to light.

Air Filter Restriction Indicator (Red) If the air cleaner is restricted, both the air filter restriction indicator and the service indicator come ON. Immediately stop the machine and the engine, check the air cleaner. Clean or replace the element as needed.

M4GB-01-023

HST Warning Indicator (Red) Caution is advised if any serious abnormality occurs in the HST or the HST relevant parts. If both the HST warning indicator and the service indicator come ON, immediately stop the machine and the engine in a safe position and then contact your nearest Kawasaki dealer.

1-9

M4GB-01-024

OPERATOR’S STATION Engine Coolant Temperature Gauge The engine coolant temperature is indicated with a needle.

When the needle stays in the blue range (1) during operation, the coolant temperature is normal.

If the engine coolant temperature becomes abnormally high, the stop indicator will flash. Stop machine operation and run the engine at low idle to lower the coolant temperature.

After the coolant temperature lowers, stop the engine for inspection. Visually inspect coolant level in reservoir. In case the needle does not swing at all, Error in the electrical system is suspected. Contact your nearest Kawasaki dealer for machine inspection.

1

M4GB-01-028

Fuel Gauge The remaining fuel amount is indicated by the needle.

Fuel the machine before the needle indicates the red range (E).

M4GB-01-030

1-10

OPERATOR’S STATION Preheat Indicator (Yellow) The preheat indicator lights when the key switch is turned to HEAT position, and it goes OFF when the engine preheating is completed.

M4GB-01-031

Turn Signal Indicator (Green) When the turn signal lever is operated, the turn signal and the indicator start flashing.

M4GB-01-032

High Beam Indicator (Blue) When the head lights are used at the high beam position, the indicator will light.

M4GB-01-033

Work Light Indicator (Yellow) When the work lights are turned ON, this indicator will come ON.

M4GB-01-034

Clearance Light Indicator (Green) When the clearance lights are turned ON, this indicator will come ON. M4GB-01-035

1-11

OPERATOR’S STATION Monitor Display

1

1- Monitor Display 2- HST Error Code Readout Switch 3- Monitor Display Selector 4- Not Used 5- Speedometer 6- Ride Control Indicator (Optional) 7- Machine Information Display

4

3

2

M4FG-01-011

8- Forward/Reverse and Shift Position Indicator 8

5

6

7

1-12

M4FG-01-012

OPERATOR’S STATION Forward/Reverse and Shift Position Indicator

1

F-N-R/Shift position indicator (1) displays the selected travel mode. t 'PSXBSE TUBHFT t 3FWFSTF TUBHFT

M4FG-01-012

F-N-R (Forward/Reverse) Position Indicator When F-N-R lever (4) is placed in forward (F), neutral (N), or reverse (R) position, F-N-R position indicator (2) indicates the selected F-N-R lever position by lightening the corresponding indicator in square ( ).

(F-N-R indicates the selected F-N-R lever position.)

2 3

Shift Position Indicator When F-N-R lever (4) is in either the forward or reverse position, shift position indicator (3) displays the shift stage selected by Hi - Lo selector switch (5).

M4FG-01-013

4

t )J "VUP 4IJGU 4QFFE .PEF t -P 4QFFE .PEF F N

R

5 M4FG-01-014

5

M4FG-01-056

1-13

OPERATOR’S STATION Speedometer Speedometer (1) indicates the present machine driving speed.

M4FG-01-011

1

Ride Control Indicator (Optional) Ride control indicator (2) lights when ride control switch (3) is turned ON.

2

1

M4FG-01-012

3

M4FG-01-015

1-14

OPERATOR’S STATION Machine Information Display When the key switch is turned ON, the machine information area (2) displays the machine information.

M4FG-01-011

1

When the key switch is turned ON, the machine information display indicates engine start-ready screen (3).

Each 0.5 seconds, the left most side indication is counted down as shown in display illustration (4).

Hour meter (5) will be displayed. Press monitor display selector (1) to shift the display item from the hour meter (5) to odometer on the machine information display.

2 1

M4FG-01-012

Engine Start-ready Screen (3)

Engine Start-ready Screen (4)

Hour Meter (5)

M4FG-01-016

1-15

OPERATOR’S STATION Shifting Item to Be Indicated on Machine Information Display Press monitor display selector (1) to shift the display item once at a time.

M4FG-01-011

1

Hour Meter

When monitor display selector (Δ) (1) is pressed once:

Indicates the total machine operating hours up to present.

In case the operating hour exceeds 99999.9 h, the meter restarts counting the hour from 0 hour. The hour meter will be locked after third round of 99999.9 h.

When this display is indicated, press monitor display selector (1) once to display the odometer.

Hour Meter

Press button

press button

Odometer

Odometer Indicates the total machine traveling distance up to present.

M4FG-01-017

1-16

OPERATOR’S STATION HST Error Code Readout Switch

2

Press HST error code readout switch (3) when HST warning indicator (1) and service indicator (2) light. HST warning indicator (1) flashes and troubles of HST related parts (Electrical system) are shown.

fNOTE: In case multiple faults are found, each time HST error

1

code readout switch (3) is pressed, the flashing state of HST warning indicator (1) changes according to the system faults.

3

M4FG-01-011

HST error code readout switch (3) detects only electrical system related faults. Several possible reasons other than the electrical system may occur, contact your nearest Kawasaki dealer for machine inspection.

Abnormality occurs at:

Flashing state of HST warning indicator (1)

Error Flashing Light Off Flashing Code (1 sec.)

(2 sec.)

(1 sec.)

Detecting Condition

Start-up condition

Once

o

Once

1-1

Low or high controller supply voltage

HST motor output

Twice

o

Once

2-1

Open circuit of HST motor solenoid output cable

HST pump output

Twice

o

Twice

2-2

Open circuit of HST pump solenoid output cable

Parking Brake

Twice

o

3-times

2-3

Open circuit of parking brake relay output cable

Overrunning Buzzer

Twice

o

4-times

2-4

Open circuit of overrunning buzzer output cable

Speed Sensor

3-times

o

Once

3-1

Speed sensor is abnormal

Engine Speed Sensor

3-times

o

Twice

3-2

Engine speed sensor is abnormal

Inching Sensor Low Voltage

3-times

o

3-times

3-3

Low voltage of inching sensor

Inching Sensor High Voltage

3-times

o

4-times

3-4

High voltage of inching sensor

F-N-R Lever

3-times

o

5-times

3-5

F-N-R Lever is abnormal

Low Voltage

4-times

o

Once

4-1

Low controller supply voltage (10 V or less)

High Voltage

4-times

o

Twice

4-2

High controller supply voltage (17 V or higher)

1-17

OPERATOR’S STATION Error Code

1

If the letters of “ERROR” are displayed on the machine information area (1), immediately stop operating the machine, move the machine to a safe area, park the machine and stop the engine. Contact your nearest Kawasaki dealer for machine inspection.

M4FG-01-011

2

M4FG-01-018

1-18

OPERATOR’S STATION Switches, Steering Wheel and Pedals Refer to page 1-4 for item locations.

F-N-R Lever

1

To ensure operator’s safety and ensure d WARNING: the longevity of the power train system, change the machine drive direction only after slowing the machine.

Changes the machine drive direction from forward to reverse and vice versa.

Move F-N-R lever (1) to the (F) position to travel the machine forward.

Move F-N-R lever (1) to the (R) position to drive the machine in reverse.

F N R

M4FG-01-014

When F-N-R lever (1) is placed in the (R) position, backup light (2) lights and the backup alarm sounds.

fNOTE: The engine will not start if the F-N-R lever (1) is not in the neutral (N) position.

2

M4FG-01-019

Neutral Lever Lock (F-N-R Lever) When the machine is parked or serviced, d WARNING: be sure to place the neutral lever lock in the LOCK position.

The neutral lever lock makes the F-N-R lever immovable so that the machine does not start moving even if a body part comes in contact with the F-N-R lever by mistake.

Before starting the engine, set neutral lever lock (3) in the LOCK position.

LOCK UNLOCK

Pull: UNLOCK Push: LOCK

3

1-19

M4FG-01-014

OPERATOR’S STATION Steering IMPORTANT:

When the steering wheel is fully turned, the front and the rear frames come in contact with the stoppers so that the steering wheel does not rotate further. If the steering wheel is forcibly turned more the engine may stall or malfunction of the steering system may result.

1

2

M4FG-04-002

Horn Switch Press horn switch (2) to sound the horn.

3

Turn Signal Lever Indicates the drive change direction to persons and/or other vehicles by operating turn signal lever (3).

Return turn signal lever (3) to neutral manually.

L

N

L : Left Turn R : Right Turn

R

Dimmer Switch

M4FG-01-020

The dimmer switch shifts the headlight beam high and low.

4

Travel the machine with the headlight d CAUTION: in the low beam position when other vehicles are present in the vicinity.

After turning the headlight ON, when turn signal lever (3) is lowered, the headlight beam is set in the high position and high beam indicator (4) comes ON. When the turn signal lever is raised, the headlight beam is set in the low position and high beam indicator turns OFF. M4FG-01-011

1-20

OPERATOR’S STATION Light Switch Light switch (1) has three positions, OFF, Small, and Main. As shown below, each light comes ON ( ) or OFF ( ) according to the selected position of the light switch.

2- Headlight 3- Turn Signal/Hazard Light/Clearance Light 4- Turn Signal/Hazard Light 5- Brake Light/Tail Light 1

Light Switch Position OFF

Headlight

Clearance Light

Tail Light

Monitor Panel Light

● ●● IMPORTANT:

M4FG-01-020

2

2

3

3

Take care not to use the below switch function for a long time. The batteries will be discharged.

fNOTE: Even though the key switch is turned OFF, as long as

M4FGE-01-021

the light switch is in (●) position, all lights except the headlight stay ON. This function is used as a parking light on a public road.

4

4 5

5 M4FGE-01-019

1-21

OPERATOR’S STATION Hazard Switch 1

IMPORTANT: Do not hold hazard switch (1) in the “ ” position for a long time with the engine stopped. The batteries will be discharged.

When a machine failure occurs, use this switch to inform other vehicles that the machine is in an emergency situation.

When the position marked with “ “ on hazard switch (1) is pressed, front and rear turn signals (hazard light) (2) on both right and left sides starts flashing.

Press the opposite side of hazard switch (1) to turn the hazard signals OFF.

M4FG-01-014

1

M4GB-01-065

2

2

M4FGE-01-021

2

2

M4FEG-01-019

1-22

OPERATOR’S STATION Front and Rear Work Light Switch (Cab Vehicle) Do not turn the work lights ON while d CAUTION: driving on a public road.

1

With the light switch in either (●) or (● ●) position, press side, front work lights (2) are turned ON. Rear switch (1) to work lights (3) stay OFF. Press switch (1) to side, front work lights (2) and rear work lights (3) turn ON.

M4FG-01-014

1

M4GB-01-067

3 2

2

3

M4FG-01-022

1-23

OPERATOR’S STATION Hi-Lo Selector Switch Hi-Lo selector switch (1) is used to shift the travel speed stage.

Select the position to match the desired travel/work mode.

Lo ..... Travel speed is restricted to the first stage.

0 to 14 km/h (8.7 mph) Hi ..... Travel speed is automatically shifted within the range of the first to 2nd speed stage by operating the accelerator pedal.

0 to 34 km/h (21 mph)

1

fNOTE: When eco mode switch (2) is in the ON position while Hi-Lo selector switch (1) is in the Hi position, the machine travels in speed shown below.

0 to 28 km/h (17 mph)

M4FG-01-014

1

M4FG-01-056

2

M4FG-01-015

1-24

OPERATOR’S STATION Parking Brake Switch To prevent the occurrence of accidents d WARNING: due to rolling of the machine, be sure to apply

1

the parking brake when parking the machine and before leaving the machine.

Do not apply the parking brake while the machine is moving, except in an emergency. Apply the parking brake only after the machine has stopped.

Failure to do so may cause sudden deceleration of the machine travel speed, possibly creating a dangerous situation. Premature wear and/or damage to the parking brake may result. After the parking brake has been applied in an emergency while traveling the machine, have the parking brake checked at your nearest Kawasaki dealer.

When parking brake switch (1) is turned ON, the parking brake is applied, and parking brake indicator (2) and service indicator (3) come ON. Press the OFF side of parking brake switch (1) to release the parking brake. Check that parking brake indicator (2) and service indicator (3) go OFF by pressing the switch twice.

f/05& t 5IF QBSLJOH CSBLF JT SFMFBTFE CZ IZESBVMJD QSFTTVSF only when the engine is running. t 5P FOTVSF TBGF PQFSBUJPO XIFO UIF QBSLJOH CSBLF is applied, even though the F-N-R lever is moved to forward (F) or reverse (R) position, the machine does not travel. t 5P FOTVSF TBGF PQFSBUJPO XIFO UIF FOHJOF JT stopped, the parking brake is applied even if parking brake switch (1) is in the OFF position.

Before starting the engine, check that the F-N-R lever is in the neutral (N) position. Then, turn the parking brake switch (1) ON.

1-25

M4FG-01-020

1

ON

OFF

M4EK-01-025A

3

2

M4FG-01-011

OPERATOR’S STATION Wiper Operation IMPORTANT:

The wiper may damage the glass surface, or the wiper blade, wiper motor and the relay may be damaged according to the condition of the glass surface such as snow coverage and freeze up.

x Before operating the wiper, remove snow and dust from the window. When the window becomes frozen, defrost the window pane by using the defroster. x Use nonfreezing washer fluid. x When the window pane is dry, operate the wiper after dispensing the washer fluid. With continuous operation of the wiper under the semiarid condition such as spatter of snow or rain, severe load may be applied to the wiper, possibly damaging to the wiper. Operate the wiper with intermittent mode or frequently turn the wiper on and off. x Do not operate heating wire in the window pane (If equipped) for a long time. The wiper blades may be burned.

1-26

OPERATOR’S STATION Front Window Wiper Switch (Cab Vehicle) IMPORTANT:

The washer motor may become damaged if washer fluid is continuously used for more than 20 seconds or the wiper switch is operated with no fluid in the washer tank.

Take care about the switch operation time and the fluid level in the washer tank.

1

Operate front window wiper switch (1) to move the windshield wiper.

2 M4FG-01-020

OFF ....... The wiper stops moving and the wiper blade is returned to the pre-start position.

LO .......... The wiper operates at slow speed.

HI ........... The wiper operates at fast speed.

PUSH..... As long as wiper switch (1) is depressed, the washer fluid is dispensed.

1

2 M4FG-01-044

Rear Window Wiper Switch (Cab Vehicle) IMPORTANT:

The washer motor may become damaged if washer fluid is continuously used for more than 20 seconds or the wiper switch is operated with no fluid in the washer tank.

Take care about the switch operation time and the fluid level in the washer tank.

Operate rear window wiper switch (2) to move the windshield wiper.

OFF ....... The wiper stops moving and the wiper blade is returned to the pre-start position.

LO .......... The wiper operates at slow speed.

PUSH..... As long as wiper switch (2) is depressed, the washer fluid is dispensed.

1-27

OPERATOR’S STATION Accelerator Pedal When accelerator pedal (1) is stepped on, the engine speed increases. When released, the engine speed decreases.

1

Brake/inching Pedal Avoid sudden brake application during d WARNING: travel operation, possibly creating a hazardous situation. The machine may lose its balance.

Unless necessary, do not place your foot on the brake pedal to prevent the brake discs from wearing out prematurely.

Keep the areas around the brake pedals clean to prevent dust and/or grit from accumulating. Failure to do so may cause the brake pedals to not fully release and become inoperable.

The machine brake is applied by stepping on the brake/ inching pedal (2) or (3).

When the brake pedal is stepped on, inching (4) operates and the HST pump destrokes to neutral, causing the travel speed to reduce. When the brake pedal is stepped on further, service brake (5) is activated, increasing braking force.

When the pedal is fully stroked, the machine stops regardless of the position of the F-N-R lever. Thus, the engine power is transmitted only to the working devices. Accordingly, when controlling the loader control lever while depressing accelerator pedal (1), the operator can concentrate on operating the front attachment.

1-28

2

3

M4FG-01-006

4 5

M4FG-01-043

OPERATOR’S STATION Right Console (Front Attachment)

1

2

Mono-Lever Type 3

1- Loader Control Lever 2- Auxiliary Control Lever (Optional) 3- Auxiliary Control Lever Lock 4- Loader Control Lever Lock

Front

4 M4FG-01-009

1-29

OPERATOR’S STATION Loader Control Lever

C B

Mono-Lever Type Is used to operate the lift arm and/or bucket.

(C) Float

E N

: The lift arm free falls and can be moved as loads are applied.

D G

A

(B) Lift Arm Lower (N) Hold

: The lift arm and bucket are stopped and held in that position.

Front

(A) Lift Arm Raise (E) Bucket Dump : The bucket is tilted forward to dump the bucket load.

(D) Bucket Tilt

: The bucket is tilted back, taking the transportation position.

(G) Detent (Auto level)

: When the loader control lever is moved from the bucket dump position to the bucket tilt position, the loader control lever is maintained in this position.

M4FG-01-023

fNOTE: After dumping the bucket, when loader control lever (1) is pulled further from the TILT position (D), the lever is held in that position (G). Then, as soon as the bucket is tilted up to the position set by the bucket auto-leveler, loader control lever (1) is automatically returned to the HOLD position (N).

C B

D

E N A M4GB-01-074

M4EJ-01-031A

1-30

OPERATOR’S STATION Lever Locks When locking the loader control lever d WARNING: and the auxiliary control lever (optional), securely

1

shift lever locks (2) and (4) to the LOCK position.

Unless lever locks (2), (4) are fully moved to the LOCK position, the control levers are not locked, possibly creating a hazardous situation.

LOCK

Before leaving the operator’s seat, be sure to stop the engine. Place the boom and bucket in a level, safe position. Then, move lever locks (2), (4) to the LOCK position.

Front

UNLOCK

2

Always check to be sure that the lever locks are moved to the LOCK position before: t 5SBOTQPSUJOH UIF NBDIJOF t -FBWJOH UIF NBDIJOF BU UIF FOE PG UIF TIJGU

M4FG-01-023

4

3

Refer to section 5-2 for details.

Lever locks (2), (4) are provided to prevent the machine is unexpectedly operated even if the operator mistakenly comes in contact with loader control lever (1) or auxiliary control lever (3) (optional) when getting on or off the machine. When loader control lever (1) and auxiliary control lever (3) (optional) are placed to the UNLOCK position, the levers become operable.

fNOTE: Auxiliary control lever (3) and lever lock (4) are optional.

UNLOCK

LOCK

Auxiliary Control Lever (Optional)

1-31

M4FG-01-024

OPERATOR’S STATION Right Console/Switch Panel 1- Auxiliary (Optional) 1

2- Ride Control Switch (Optional)

2

3- ECO Mode Switch

Front

3

4- Heater Switch (Cab Vehicle)

4

5- Key Switch

5

1-32

M4FG-01-023

OPERATOR’S STATION Key Switch Before starting the engine, return d WARNING: the F-N-R lever to neutral (N) position, apply the parking brake, and lock the loader control lever and the auxiliary control lever (optional). Refer to the descriptions in the “OPERATING ENGINE“ chapter for the detail information.

1

Never turn key switch (1) OFF while d WARNING: traveling the machine. Failure to do so may cause

M4FG-01-015

steering wheel and brakes to lose control, possibly creating a dangerous situation.

Failure in the electrical system and/or machine may result.

A : HEAT

(Preheat)

B : OFF

(Engine Off )

C : ON

(Engine On)

B A

C D

1

D : START (Engine Start)

M4EJ-01-025

ECO Mode Switch

2

When eco mode switch (2) is turned ON, HST pump and motor control programs are changed in order to prevent rapid increase of the engine speed.

This function helps to reduce fuel consumption.

When eco mode switch (2) is turned ON, orange light (3) comes ON.

M4FG-01-015

3

ON

2

OFF M4FG-01-045

1-33

OPERATOR’S STATION Ride Control Switch (Optional)

1

Ride control switch (1) dampens the fore and aft pitching movement of the machine during travel so that comfortable machine ride quality is obtained. As stable drive operation is achieved, bucket load spill can be reduced.

WARNING: When operating the machine with the front attachment in the float position (scooping, grading, or snow removal), always turn ride control switch (1) OFF. Failure to do so may allow the front attachment to unexpectedly move up or down when the ride control system is activated.

d

When operating the front attachment d WARNING: while the ride control is activated, reduce the

M4FG-01-015

1

machine travel speed. If impact loads are applied to the front attachment, high pressure may apply to the ride control accumulator, possibly resulting in N2 gas leakage.

Ride Control Operation

ON 2

OFF

To ensure safety, operate ride control d WARNING: switch (1) only after parking the machine with the

M4FG-01-025

bucket lowered to the ground.

When the ride control switch (1) is turned ON, the travel speed sensor and the controller is activated. Then, when the travel speed increases above 10 km/h (6.2 mph), the ride control system automatically operates. When the travel speed decreases below 8 km/h (5.0 mph), the ride control system turns OFF. When ride control switch (1) is turned ON, green lamp (2) of the switch and ride control indicator (3) on the monitor display illuminates.

When ride control switch (1) is turned OFF, green lamp (2) of the switch and ride control indicator (3) on the monitor display goes OFF and ride control does not operate.

When the key switch is in the OFF position, the ride control system does not operate even if ride control switch (1) is turned ON. When the engine is stopped while ride control switch (1) is ON, the ride control is turned OFF.

1-34

3

M4FG-01-012

OPERATOR’S STATION Heater (Optional) Operation

1

1- Heater Switch 2- Vent 3- Front Window Defroster Heater Switch Operate heater switch (1) to activate the heater.

M4FG-01-015

OFF .... The heater operation is stopped.

LO ....... Warm air volume decreases.

HI ........ Warm air volume increases.

Vent Manually open heater unit cover (2) to adjust heater operation.

1

f

NOTE: When the front window pane becomes frozen: If the front window pane becomes frozen in winter or when atmospheric temperature is low due to snow falling, close vent cover (2) and turn heater switch (1) to the HI position. Full warm air is blown out from three front window defrosters (3), allowing the frozen front window pane to be quickly defrosted.

M4EJ-01-060

2

M4FG-01-049

3

M4EK-01-060

1-35

OPERATOR’S STATION Adjusting Operator’s Seat (Standard Type) Adjust the seat position so that all the d CAUTION: pedals, levers and switches can be easily and correctly operated. Adjust the seat position while the machine is parked.

Components Name 1- Damper Adjustment 2- Slide Lever 2

M4FG-01-026

1

1. Damper Adjustment The damper stiffness can be adjusted in the range of full stroke 50 mm (2 in) in 5 steps in accordance with the type of work engaged in or the conditions of the road surface.

Pull up lever (1) and pull down at the proper point.

A: Soft (50 kg) (110 lb) B: Hard (120 kg) (265 lb)

A B 1

M4FG-01-027

2. Fore-Aft Position Adjustment Fore-after position of the seat adjustment allows for proper fitting to the operator. Pull up slide lever (2) to adjust the front/rear position of the seat assembly. The seat assembly position can be adjusted in the range of full stroke 160 mm (6.3 in) by 10 mm (0.4 in) interval. Return the lever to the original position after the seat assembly is moved to the desired position. Check that the seat assembly is locked in the desired position.

2

2

M4FG-01-028

1-36

OPERATOR’S STATION Adjusting Operator’s Seat (Suspension Type) Adjust the seat position so that all the d CAUTION: pedals, levers and switches can be easily and correctly operated. Adjust the seat position while the machine is parked.

3

Components Name 1- Suspension Handle 2- Slide Lever 3- Armrest 4- Reclining Adjusting Lever 5- Indicator

2

4 1 5

M4GB-01-155

1. Suspension adjustment Adjust the suspension to protect the operator.

Adjustment procedure 1. Sit on the operator’s seat.

2. Turn suspension handle (1) clockwise to raise the seat height, turn counterclockwise to lower the height.

1

3. Ensure that indicator (5) is in the green range. If the indicator is in red range, rotate the suspension handle and re-adjust the height.

The adjustable range: 50 kg (110 lb) to 120 kg (265 lb)

fNOTE: If the indicator is in upper red range, the seat stiffness is too hard and difficult to ride.

If the indicator is in lower red range, the seat stiffness is too soft and the seat may bottom out.

Red Green Red M4GB-01-156

1-37

OPERATOR’S STATION 2. Fore-Aft Position Adjustment Fore-after position of the seat adjustment allows for proper fitting to the operator. Pull up slide lever (2) to adjust the front/rear position of the seat assembly. The seat assembly position can be adjusted in the range of full stroke 160 mm by 10 mm interval. Return the lever to the original position after the seat assembly is moved to the desired position.

Check that the seat assembly is locked in the desired position.

2

M4GB-01-157

3. Armrest Angle Adjustment The angle of the armrest can be adjusted by turning knob (6) provided under the armrest.

A: Raise B: Lower

6

M4FG-01-046

4. Reclining Angle Adjustment The reclining angle can be adjusted up to 66 ° forward and 72 ° backward by pulling up reclining adjusting lever (4).

Return the reclining adjusting lever to the original position.

Check that the backrest is locked in the desired position.

4

1-38

M4FG-01-047

OPERATOR’S STATION Seat Belt

1

2

Always use the seat belt when operating d WARNING: the machine.

Before operating the machine, be sure to examine the seat belt and attaching hardware for any failure.

If any damage and/or wear is found, replace the part concerned.

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

3

1. Seat belt (1) on this machine is a recoiling type.

2. Confirm that seat belt (1) is not twisted. Securely insert the end of seat belt (1) into buckle (2).

M4FG-01-050

fNOTE: When trying to insert seat belt (1) into buckle (2), in

case the belt is suspended to extend and does not come out further, fully retract the belt to the original position and try to extend again.

3. Push button (3) on buckle (2) to unfasten seat belt (1).

Seat Pocket (Suspension Seat) A pocket is provided on the back of the operator’s seat. Use it as a storage space to keep goods such as the Operator’s Manual.

fNOTE: The seat pocket is not a water resistant type. For the

canopy vehicle, protect the seat pocket against water using a vinyl bag as needed.

M4GB-01-139

M4GB-01-160

1-39

OPERATOR’S STATION Fuse Box IMPORTANT:

If a fuse blows, turn the key switch OFF. After checking and correcting the cause of the trouble, replace the fuse with a new one.

The fuses function as a “safety valve” to prevent excess current from flowing in the electrical system. Slow blow fuses (2) are used.

Each fuse capacity differs depend on the corresponding circuit. Replace the fuse with one having the corresponding specific capacity.

When checking fuses, check the fuse (1) and slow blow fuses (2) (2 used) in this order.

1

M4FG-01-029

2

2: 100 A×2

M4FG-01-048

1-40

OPERATOR’S STATION Fuse Box No.

Ampere

1

10

HEAD LIGHT (LEFT)

2

10

HEAD LIGHT (RIGHT)

3

15

HEAD LIGHT (HI BEAM)

4

5

CLEARANCE LIGHT (LEFT), TAIL LIGHT (RIGHT)

5

5

CLEARANCE LIGHT (RIGHT), TAIL LIGHT (LEFT)

6

15

HST [F], [R] SOLENOID, PARKING BRAKE SOLENOID, BACKUP LIGHT, BACKUP BUZZER, RELAY [1], RELAY [2]

7

15

HORN, BRAKE LAMP

8

10

ENGINE STOP SOLENOID, FUEL PUMP

9

10

SAFETY RELAY, ALTERNATOR, ENGINE SPEED SENSOR, RELAY [3]

10

10

BUCKET AUTO LEVELER PROXIMITY SWITCH, CONTROL VALVE DETENT (TILT)

11

10

MONITOR

12

30

HEAD LIGHT, CLEARANCE LIGHT, TAIL LIGHT

13

15

HST CONTROLLER

14

10

MONITOR BACKUP POWER SUPPLY

15

−

OPTIONAL POWER

16

−

OPTIONAL POWER

17

−

OPTIONAL POWER

18

Corresponding Circuit

NOT USED

19

−

OPTIONAL POWER

20

15

HAZARD LIGHT, FLASHER UNIT

M4FG-07-047

1-41

OPERATOR’S STATION ROPS Cab (Optional)

1

ROPS Cab (1) is an optional equipment.

1- ROPS Cab 2- Room Light 3- Room Rear View Mirror 4- Sun Visor (Optional)

fNOTE: The ROPS cab may not be equipped for the special

M4FG-01-032

specification machine such as snow removal vehicles.

2

3

4

1-42

M4EK-01-030

M4FG-01-055

OPERATOR’S STATION 5- Radio (Optional)

5

6- Cab Switch Panel (Optional) 7- Drink Holder 8- Speaker (Optional) 9- Coat Hook

6

M4EK-01-031

8

7

9

1-43

M4EK-01-032

M4EK-01-033

OPERATOR’S STATION Room Light

1

When the switch knob is in the ON position, room light (1) comes ON. When the switch knob is in the OFF position, room light (1) turns OFF.

M4EK-01-030

ON

OFF

1

M4EK-01-034A

Sun Visor (Optional) Pull the sun visor down when blocking strong sun light radiation from the cab top side.

M4FG-01-055

Drink Holder IMPORTANT:

Be sure to put a plug or cap on a drink bottle when placing it on the drink bottle holder.

M4EK-01-032

1-44

OPERATOR’S STATION Coat Hook Use coat hook (1) for hanging up your jacket and hat.

1

M4EK-01-033

Rear View Mirror

d

3

WARNING: Do not travel the machine in reverse by relying on only the range of vision the rear view mirror (2) provides. Use the rear view mirror only as an assistant during travel operation. Be sure to confirm the safety by looking to the rear when traveling the machine in reverse.

2

2

After taking the seat, adjust the rear view mirror so that the good rearward visibility can be obtained.

Always keep the mirror clean.

Cab Vehicle

Canopy Vehicle M4FGE-01-033

Room Rear View Mirror Always keep room rear view mirror (3) clean.

1-45

OPERATOR’S STATION FM/AM Radio (Optional) Operation Controls on the Radio 1- Power/Volume Switch Each time switch (1) is pressed, electric power is turned ON or OFF alternately. Turn switch (1) clockwise to increase the sound volume. Turn switch (1) counterclockwise to decrease the sound volume. While pulling out switch (1), turn it clockwise to intensify the right side speaker volume, or turn it counterclockwise to intensify the left side speaker volume.

M4EK-01-031

3

2- Tone Adjusting Knob

2

1

Turn knob (2) clockwise to intensify high-pitched tone or turn knob (2) counterclockwise to intensify low-pitched tone.

3- Display 4

Displays time or frequency.

5

6

7

8

9

10 M4EK-01-036

4- Memory Button 5- AM/FM Switch Button Each time button (5) is pressed within an interval less than 5 seconds with the frequency kept displayed, the modulation mode is shifted in the order of AM1 o AM2 o FM1 o FM2.

fNOTE: When a stereo broadcasting is received, stereo

12

indicator (11) comes ON.

6- AS (Auto Station) Button Refer to “Auto Station Presetting Procedure“ page 1-48.

7- Search Button

11

8- Channel Button 9- Alarm Button

1-46

M4EK-01-038A

OPERATOR’S STATION Tuning Procedures x Manual Tuning Procedure Repeatedly press at intervals shorter than 0.5 seconds one of tuning buttons (7) until the desired station is reached.

Each time the tuning button is pressed, the frequency phase changes at the intervals of AM: 9 kHz and FM: 0.1 MHz. ) to increase the frequency.

Tap the tuning switch [UP] ( Tap the tuning switch [DOWN] ( ) to decrease the frequency. x Automatic Tuning Procedure Press and hold search button (7) for more than half a second. When a station is received, an electronic tone is heard and operation automatically stops. ) to increase the frequency.

Tap the tuning switch [UP] ( ) to decrease the Tap the tuning switch [DOWN] ( frequency.

7

7

M4EK-01-039

fNOTE: If the receiving radio waves are weak, i.e. such as

when the machine is located between high rising buildings, etc., use the manual tuning procedure to select the desired station.

Station Presetting Procedure 6 stations in each modulation mode (AM1, AM2, FM1 and FM2) can be preset (24 stations in total).

3

1. Press memory button (4) while receiving radio broadcasting. The channel No. indicated on display (3) starts blinking.

2. Select the station desired to preset by pressing channel button (8). Channel No. indicated on display (3) is shifted.

4

8

M4EK-01-036

3. After selecting the station, press memory button (4).

Then, the selected station is preset.

4. Each time when channel button (8) is pressed, stations stored in the preset memory (1 CH to 6 CH) can be received in order.

When required to change the preset station, repeat the same procedures as described in steps 1 to 4 above. x Deletion of Presetting Memory When the battery power is disconnected from the radio due to machine maintenance work or removal of the radio, memories stored by memory button (4) are deleted. Reset presetting.

1-47

M4EK-01-038A

OPERATOR’S STATION Auto Station Presetting Procedure AM/FM

Automatically received station is stored in the preset memory.

1. Select either AM or FM using AM/FM Switch button (5).

AS

CLOCK

2. Press and hold AS button (6) for longer than 2 seconds.

An electronic tone is heard and one of 6 stations is automatically stored at good sensitivity.

5

M4EK-01-040

6

Digital Clock Setting Procedure Set the clock with the key switch ON. 1. Press and hold AM/FM switch button (5) until an electronic tone is heard. A time display starts blinking so that time setting becomes ready. If no operation is made for 15 seconds afterwards, the clock setting mode is deactivated.

H

2. Press tuning button (7) to change the time. Press “H” button and “M” button to adjust “Hour” and “Minute” respectively.

7

M

7

M4EK-01-039

3. Press AM/FM switch button (5) to set the time.

fNOTE: When putting the clock by the time signal, press

memory button (4) with the clock display blinking.

Alarm Setting Procedure

4

Alarm can be set to emit at desired time. Each time alarm button (9) is pressed, alarm ON and OFF is repeatedly set.

9

M4EK-01-036

13

1. Press and hold alarm button (9) until an electronic tone is heard. Alarm mark (13) starts blinking so that alarm can be set. If no operation is made for 15 seconds afterwards, the alarm setting mode is deactivated.

M4EK-01-037

2. Press tuning button (7) to change the time. Press “H” button and “M” button to adjust “Hour” and “Minute” respectively.

3. When the set time arrives, the alarm continues to sound for 3 minutes. Press alarm button (9) to stop the alarm.

1-48

OPERATOR’S STATION Upper Switch Panel (Optional)

1

2

1- Rotary Beacon Switch (Optional) 2- Auxiliary

M4EK-01-031

Rotary Beacon Switch (Optional) 1

Press the ON side of rotary beacon switch (1) to turn the rotary beacon ON. Press the OFF side of rotary beacon switch (1) to turn rotary beacon OFF. When rotary beacon switch (1) turn ON, green light (3) on rotary beacon switch turns ON.

ON

3

OFF

M4FG-01-025

1-49

OPERATOR’S STATION Cab Door Securely close the door. If the door is d CAUTION: unexpectedly opened, a hazardous situation may be

1

created.

Before leaving the operator’s seat, fully open the cab door and lock the door in position.

2

1- Door Lock Key 2- Door Open/Close Lever M4EK-01-045

1-50

OPERATOR’S STATION Door Lock Knob

5

After closing the door, always check that d CAUTION: the door lock is securely engaged.

Depress door lock knob (5) to engage the door lock.

Door Open/Close Lever When opening the door, while lifting door lock knob (5), pull lever (6) to disengage the door lock.

6

Window Open/Close Levers

M4EK-01-046

7

When window open/close levers (7) on both sides are simultaneously pressed, the window is unlocked, allowing the windowpanes to move.

When window open/close levers (7) are released, stoppers are engaged in the nearest steps so that the window is locked in that position.

M4EK-01-047

7

LOCK UNLOCK

M4EK-01-048

1-51

OPERATOR’S STATION When Fully Opening the Door Push the door toward the outside of the cab to fully open the door (180 degrees).

M4EK-01-049

Door Lock Disengage Lever When keeping the door open, open the d CAUTION: door until latch (8) on the cab securely locks the

8

door.

When disengaging the door lock, push door lock disengage lever (9) or (10) downward.

M4EK-01-051

9

Left Door Lock Disengage Lever

M4EK-01-050

10 M4EK-01-032

Right Door Lock Disengage Lever

1-52

OPERATOR’S STATION Articulation Lock Bar Before servicing or transporting the d WARNING: machine, always be sure to engage articulation lock bar (1).

Before traveling or operating the machine, be sure to disengage articulation lock bar (1) from rear frame (4) and fasten it to the front frame (3) with ring pin (2).

3 2

1 M4FG-01-034

Articulation lock bar (1) locks the front and rear frames to prevent articulation between the front (4) and rear (5) frames when servicing or transporting the machine.

3

4

1

2 M4FG-01-035

Towing Pin

5

Since towing is a potentially dangerous d WARNING: operation, perform only when there is a emergency or crisis situation.

IMPORTANT:

Available towing forces by machine model are as follows. To prevent excessive wear of tires, avoid towing operation requiring more than the available towing force.

42.2 kN (4300 kgf ) (9480 lbf ) M4FG-01-036

Towing pin (5) is located on the back end of the base machine.

It is used for towing another machine or fastening the machine on a trailer deck for transportation.

1-53

OPERATOR’S STATION Engine Hood 1

Open/close engine hood (1) only after d WARNING: stopping the engine. Failure to do so may cause 2

personal injury or death due to entanglement into the engine fan.

Before using the machine, check that engine hood (1) does not open.

Opening Engine Hood Press lock key (2) of engine hood (1), engine hood (1) opens upward for daily check.

1

M4FG-01-039

3

Closing Engine Hood Pull band (3) down and slowly push engine hood (1) until it latches (a click sound is heard).

M4FG-01-040

Maintenance Side Cover Open/close side cover (4) only after d WARNING: stopping the engine. Failure to do so may create a

4

very dangerous situation such as entanglement with the rotating parts.

Be sure to install side cover (4) before travelling or operating the machine.

Remove bolts (5) (4 used) to open side cover (4).

5

M4FG-01-037

fNOTE: Side covers (4) are located at the left and right side

of the machine. Open left side cover (4) to check the engine oil level and to replace the engine oil filter.

M4FG-01-038

1-54

OPERATOR’S STATION Steps When getting on and off the machine, d WARNING: always maintain at least three points of contact.

Getting on and off the machine with less than three support points may cause you to slip, possibly resulting in a falling accident.

Although the steps are provided on both sides of the machine, mainly use the steps on the left side. The control levers are located on the right side, obstructing easy access.

M4FGE-01-052

1

Vandal-Resistant Devices A lock key can be installed to fuel tank cap (1) and engine hood (2).

M4FG-01-042

2

M4FG-01-054

1-55

OPERATOR’S STATION MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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.................................................................................................................................................................................................. ..................................................................................................................................................................................................

1-56

BREAK-IN Observe Engine Operation Closely IMPORTANT:

Be extra cautious during the first 100 hours, until you become thoroughly familiar with the sound and feel of your new machine.

1. While operating the machine, limit the maximum engine horsepower to about 80 % of full load.

2. Avoid excess engine idling.

3. Check indicator lights and gauges frequently during operation.

2-1

BREAK-IN MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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2-2

OPERATING ENGINE Inspect Machine Daily Before Starting The operator must perform the daily inspection before operating the machine.

Refer to MAINTENANCE chapter for more information.

Inspection Items 1. Brake system

2. Tire

3. Lighting system and turn signals 4. Rearview mirror 5. Machine identification plate 6. A device that was previously inoperable.

7. Engine

Inspection Criteria 1. Acceptable brake pedal stroke, good brake application, and brakes apply evenly.

2. The parking brake applies sufficiently.

3. Check the brake oil level. Check brake tubing for leaks.

1. Check tire pressure.

2. Check tires for cracks or damage.

3. Check for excessive wear.

4. Check for objects, such as stones or metal stuck in tire tread.

The lights operate normally. Lights clean and not damaged.

Rearview is normal.

Clean, legible and not damaged.

The device works normally.

1. Correct engine oil and coolant levels. Clean.

2. Check the alternator drive belt for damage and tension.

3. Starting ability, exhaust gas color, and noise are within allowable range.

4. Check the engine for oil and coolant leaks, check hoses and pipe lines for damage.

5. Check the radiator and oil cooler for clogging and damage.

6. Check bolts and nuts for loosening and dropping. (continued)

3-1

OPERATING ENGINE Inspection Items 8. Chassis

9. Working attachment

10. Others

Inspection Criteria 1. Check the transmission and axle for oil leaks.

2. Check fuel level. No leaks and foreign matter is found. Drain water from fuel tank.

3. Check hydraulic oil level. Check the tank for oil leaks.

4. Operation, play and control force of control levers are within allowable range.

5. Operation of hydraulics is normal. Check piping and hoses for oil leaks and damage.

6. Check each part for deformation, damage and abnormal noise.

7. Check windshield washer fluid level.

1. Check the cylinder, piping and hoses for oil leaks and damages.

2. Check the cutting edge for tightness, wear and missing parts.

3. Check the bucket for wear and damage.

4. Check linkage lubrication condition.

5. Check pin lock bolts, stoppers and links for damage.

6. Check bolts and nuts for tightness.

1. Check meters, switches and horn for operation condition.

2. Check ROPS cab for damage and deformation.

3. Check appearance of the machine.

4. Check the battery terminals for looseness.

5. Check the seat belt and tether for wear and damage.

6. Check the steps for damage.

3-2

OPERATING ENGINE Check Before Starting 1. Check that F-N-R lever (1) is in the neutral (N) position and that neutral lever lock (2) is in the lock position.

fNOTE: Unless forward/reverse lever (1) is in neutral (N), the engine will not start.

2. Check that parking brake switch (3) is ON. After starting the engine, check the indicator bulbs (Refer to page 3-3) and then check that parking brake indicator (4) is ON.

2

1

M4FG-01-014

3

M4FG-01-020

4

M4FG-01-011

3. Check that loader control lever (5) is in the neutral position.

5 LOCK

4. Check that loader control lever lock (6) is in the LOCK position.

UNLOCK

6

M4FG-01-015

3-3

OPERATING ENGINE 5. Adjust the position of outside rear view mirror (7) and room rear view mirror (8) (Cab vehicle) so that the best rear visibility can be obtained.

8

7

7

Cab Vehicle

Canopy Vehicle M4FGE-01-033

6. While seated on the operator’s seat with your back in contact with the backrest, adjust each function of the seat so that the brake pedal can be fully applied.

SA-462

7. Fasten seat belt.

SA-237

3-4

OPERATING ENGINE Starting Engine

1

Start the engine following the procedures below.

1. Check that parking brake switch (1) is in the ON position.

2. Check that F-N-R lever (2) is in neutral (N) position.

3. Check indicator bulbs When key switch (3) is turned ON, all indicators and the warning lights come and stay ON for 2 seconds. Then, they go OFF afterward. Any indicator and/or warning light that fails to light at this time is a burned bulb. After checking indicator bulbs, check that the six square segment marks displayed on the LCD will be sequentially erased one at a time. Charge warning indicator (4) will stay ON until the engine starts.

2

M4FG-01-007

4. Check that parking brake indicator (5) is ON and preheat indicator (6) turns OFF (Engine preheating is completed).

And then, sound the horn to clear any personnel away from the area surrounding the machine.

IMPORTANT:

3

Never operate the starter for more than 10 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for more than 30 seconds, then try again.

Prevent starter damage and/or battery discharge.

5. Turn key switch (3) to START position to rotate the starter. The engine should start and run.

M4FG-01-015

3

6. As soon as the engine starts, release the key switch. The key switch will automatically return to the ON position.

M4EJ-01-025

5

6

3-5

4

M4FG-01-011

OPERATING ENGINE Manual Starting in Cold Weather Preheating 1. Turn key switch (2) to HEAT position to preheat the engine. The coolant temperature sensor is activated so that the engine is automatically preheated.

2. Preheat indicator (1) should turn ON. As long as preheat indicator (1) stays ON, the engine is being heated.

fNOTE: Preheating time varies depending on the coolant

1

temperature.

M4FG-01-011

3. As soon as preheat indicator (1) turns OFF, turn key switch (2) to the START position to rotate the starter. As soon as the engine starts, release the key switch. The key switch will automatically return to the ON position.

After starting the engine, perform warm-up operation as described on page 3-8.

2 M4EJ-01-025

3-6

OPERATING ENGINE Check After Starting IMPORTANT:

1

2

If any abnormality is found in the monitor functions, immediately stop the engine and investigate the cause of the trouble.

Check the Monitor Operation

fNOTE: When the parking brake switch is ON, service

indicator (2) turns ON. When the parking brake is turned OFF, service indicator (2) turns OFF.

5

1. Check that stop indicator (1) and service indicator (2) turns OFF. 2. Check that discharge warning indicator (3) is OFF. In case the discharge warning indicator stays ON, immediately stop the engine. Inspect the alternator and battery system for problems.

3. Check that low engine oil pressure indicator (5) is OFF. In case low engine oil pressure indicator (5) stays ON, immediately stop the engine. Inspect the engine oil pressure system and the oil level.

4. Check that engine coolant temperature gauge (4) is within the blue range.

fNOTE: To check indicator bulbs, when the key switch is

turned ON, all monitor indicators including the service indicator, and stop indicator come ON and continue to stay ON for approx. 2 seconds.

Check Engine Noise and Exhaust Gas Color Check that the engine noise and exhaust gas color are normal.

fNOTE: Check the exhaust gas color as follows. (After warmup operation, run the engine with no loads.)

Exhaust gas color Engine operating condition Clear or light blue Normal (Perfect combustion) Black Abnormal (Imperfect combustion) Abnormal (Oil is leaking into the White combustion chamber.)

3-7

4

3

M4FG-01-011

OPERATING ENGINE Using Booster Batteries An explosive gas is produced while d DANGER: batteries are in use or being charged. Keep open flames and sparks away from the battery area.

Park the machine and a machine with the booster batteries on a dry or concrete surface, not on steel plates. If the machine is parked on steel plates, the machine is equivalent to a continuously grounded machine so that unexpected sparks may result.

When connecting the booster cables, never connect a positive terminal to a negative terminal, as a dangerous short circuit may occur.

IMPORTANT:

The machine electrical system is a 12 volt. Use only 12 volt booster batteries which have sufficient capacity to start the machine.

If the machine batteries are completely discharged so that when starting the engine using booster batteries is necessary, do the following procedure.

3-8

OPERATING ENGINE 1. Connecting the booster batteries 1.1 Stop the engine on the booster battery mounted machine.

1.2 Connect one end of red booster cable (1) to the positive (+) terminal of the machine batteries, and the other end to the positive (+) terminal of the booster batteries.

1.3 Connect one end of black booster cable (2) to the negative (-) terminal of the booster battery, and the other end to radiator mounting bolt on the machine.

In the last connection to the bracket, sparks may fly so keep the machine batteries as far away as possible from the bracket.

1.4 After securely connecting the booster cables, start the engine on the booster battery mounted machine.

1.5 Start the engine on the machine.

1.6 After the engine starts, disconnect booster cables (1 and 2) in the following steps.

2. Disconnecting the booster cables 2.1 Disconnect one end of black booster cable (2) from the radiator mounting bolt.

2.2 Disconnect the other end of black booster cable (2) from the negative terminal of the booster batteries.

2.3 Disconnect one end of red booster cable (1) from the positive terminal of the booster batteries.

2.4 Disconnect the other end of red booster cable (2) from the positive terminal of the machine batteries.

Chassis Ground Mounting Bolt

2 (Black)

Machine Battery

Booster Battery

(Red)

1 M4FG-03-001

3-9

OPERATING ENGINE Warm Up Operation 1

Operating the machine without warm d CAUTION: up the hydraulic system may cause engine seizure or damage and hydraulic system damage. Be sure to warm up to ensure safe operation so as to avoid accidents caused by unstable motion of hydraulic system.

N Tilt Front

If the machine is operated excessively with the hydraulic oil temperature below 20 °C (68 °F), damage to the hydraulic components may result. After starting the engine, warm up the hydraulic system as described below before operating the machine until the hydraulic temperature is above 20 °C (68 °F).

1. While slightly depressing accelerator pedal, run the engine at medium speed for about 5 minutes with no load.

2. Increase the engine at medium speed. Raise the bucket above the ground and move loader control lever (1) to the tilt position and neutral position. Repeat this for 10 seconds.

IMPORTANT:

Do not operate loader control lever (1) other than the tilt and neutral position at this time.

3-10

M4FG-01-023

OPERATING ENGINE Warm Up Operation in Cold Weather In case the hydraulic oil temperature is d CAUTION: low, perform warm-up. Operate the machine only after the loader boom and bucket operating speeds are normal. Operating the machine without warm-up may cause engine seizure or damaged and hydraulic system damage. Be sure to warm up to ensure safe operation so as to avoid accidents caused by unstable motion of hydraulic system.

1. Run the engine at low idle speed for more than 5 minutes.

2. Run the engine at medium speed for 5 minutes.

IMPORTANT:

Do not run the engine at fast speed at this time.

3. Fully extend the bucket cylinder.

IMPORTANT:

Do not continuously operate the loader control lever in tilt position for more than 10 seconds at this time.

4. Fully retract extend the bucket cylinder.

IMPORTANT:

Do not continuously operate the loader control lever in tilt position for more than 10 seconds at this time.

5. Repeat steps 2 to 4 above until the loader boom and bucket operating speeds are normal. When the atmospheric temperature is lower than 0 °C (32 °F), extend the warm-up time by running the engine at middle speed.

3-11

OPERATING ENGINE Stopping Engine Stop the engine in the following procedures.

1. Lower the bucket before stopping the engine.

IMPORTANT:

If the engine equipped with a turbocharger is stopped without first performing the cool down operation, the lubricant on the turbocharger bearing surfaces may dissipate due to the intense heat inside the turbocharger, possibly damaging the turbocharger.

1 M4EJ-01-025

Front

LOCK

2. Run the engine at low idle speed for 5 minutes to cool the engine. Do not idle for excessively long periods.

Observe local and federal engine idling regulations.

3. Turn key switch (1) to OFF position to stop the engine.

4. Be sure to move loader control lever lock (2) in forward and place it in the LOCK position.

UNLOCK

2 1

M4FG-01-015

3-12

DRIVING MACHINE Driving Machine Correct operation will result in extending the service life of each part and component as well as saving fuel and oil. Always be sure to safely and efficiently operate the machine while paying attention to the following points.

Precautions for Starting to Move 1. While checking the tires for abnormal air pressure and any obvious damage, make sure that there are no hazards and/or obstacles in and around the vicinity of the machine.

2. After raising the lift arm set the machine to the driving position, fully tilt the bucket backward.

3. Before driving on public roads, set the machine to the driving position as illustrated to the right. Be sure to place loader control lever lock (1) in the LOCK position so that the attachment will not move even if the control levers are accidentally operated.

A

Driving Position A: 300 to 400 mm (12 to 15 in)

M4FG-04-001

Front

LOCK

UNLOCK

1

M4FG-01-015

4-1

DRIVING MACHINE Starting to Move

1

2

3

Start to move the machine only after d WARNING: checking that no personnel and/or obstacles are present around the machine.

Never turn ride control switch (4) (Optional) to ON position while traveling the machine or raising the front attachment. Before turning the ride control switch ON, stop the machine and confirm safety around the bucket. If ride control switch (4) (Optional) is turned ON while traveling the machine, the lift arm will move upward or downward, possibly creating a dangerous situation.

M4FG-01-011

4

Front

Refer to page 1-35 for ride control switch (4) (Optional).

3

5

1. Check that none of the warning indicators except service indicator (2) and parking brake indicator (3) on the monitor panel (1) are ON. 2. Set the front attachment in the driving position by operating loader control lever (5).

3. Press neutral lever lock (6) to the UNLOCK position.

M4FG-01-015

A

Driving Position A: 300 to 400 mm (12 to 15 in)

M4FG-04-001

LOCK UNLOCK 6

4-2

M4FG-01-014

DRIVING MACHINE 4. Step on brake pedal (9) and depress parking brake switch (7) to the OFF position to release the parking brake. Check that at this time service indicator (2) and parking brake indicator (3) go OFF.

2

3

5. Move F-N-R lever (10) to either forward (F) or reverse (R) position.

6. Shift the travel speed stage by using Hi-Lo selector switch (11) to match the desired travel/work mode.

Hi-Lo Selector Switch

M4FG-01-011

Switch (11) is used to shift the travel speed stage. Auto shift 2-Speed mode or 1-Speed mode is selected.

7

Lo : To be used for excavation and loading work Hi : To be used for traveling the machine When traveling on rough terrain, slopes, d CAUTION: mud or snow, select the travel mode switch in Lo

8 10

position and drive the machine at slow speed.

7. Release brake pedal (9) and step on accelerator pedal (8).

9

9

M4FG-01-006

11

M4FG-01-014

4-3

DRIVING MACHINE Parking Brake Switch To prevent the occurrence of accidents d WARNING: due to runaway of the machine, be sure to apply the

ON OFF

parking brake when parking the machine and before leaving the machine.

Never apply the parking brake switch (1) while the machine is moving except in an emergency.

Premature wear and/or damage to the parking brake may result. If the parking brake was applied while traveling the machine because of an emergency, have the parking brake inspected by your nearest Kawasaki dealer.

1

M4FG-01-020

2

x Press the OFF side of parking brake switch (1) to release the parking brake. Check that parking brake indicator (5) and service indicator (4) go OFF by pressing the switch twice.

Press the ON side of parking brake switch (1) to apply the parking brake.

Operate the parking brake after parking the machine on level ground.

fNOTE: While running the engine, when the parking brake is applied with F-N-R lever (2) in neutral, parking brake indicator (5) and service indicator (4) come ON.

x While running the engine, when the parking brake is applied with F-N-R lever (2) in either the forward (F) or reverse (R) position, parking brake indicator (5) and service indicator (4) come ON, and the alarm buzzer sounds. The monitor display indicates (3) “N” not “F” and “R”. The monitor display will not indicate “F” and “R” until the parking brake is released. x In order to ensure safe operation, the parking brake is automatically applied when the engine is stopped even though parking brake switch (1) is OFF. In this case even after the engine is restarted, the parking brake will not be released. After starting the engine, push OFF position of parking brake switch (1) to release the parking brake.

4-4

M4FG-01-014

3

4

5

M4FG-01-011

DRIVING MACHINE Drive Speed Change Travel speed of this machine is automatically shifted.

Auto shift 2-Speed mode or 1-Speed mode is selected by using Hi-Lo selector switch (1).

Lo : 1-Speed mode. To be used for excavation and loading work Hi : Auto shift 2-Speed mode. To be used for traveling the machine.

IMPORTANT:

1 Lo Hi

While traveling at high speed, avoid quick deceleration by operating Hi-Lo selector switch (1). Change the travel speed only after the machine decelerates by releasing the accelerator pedal.

M4FG-01-014

Changing Forward/Reverse Drive Direction

2

Before changing the drive direction, d WARNING: confirm that the direction of travel is clear.

F

To ensure operator’s safety and ensure the longevity of the power train system, change the machine drive direction only after sufficiently reducing the drive speed.

N R

1. Pull neutral lever lock (3) to the UNLOCK position.

UNLOCK

2. Press the OFF position of parking brake switch (4).

3

3. Move F-N-R lever (2) to the desired position.

F: Forward Driving N: Neutral R: Reverse Driving

M4FG-01-014

4

M4FG-01-020

4-5

DRIVING MACHINE Steering Avoid sudden steering changes while d WARNING: driving at fast speed or on a slope.

Do not stop the engine while driving the machine.

If the engine is stopped, the steering becomes stiff.

Avoid sudden steering operation with the lift arm raised to a high position. Failure to do so may cause the machine to turn over.

IMPORTANT:

When the steering wheel is fully turned, the front and the rear frames come in contact with the stoppers so that the steering wheel does not rotate further. If the steering wheel is forcibly turned, the engine may stall or malfunction of the steering system may result.

Turn the steering wheel towards the direction you intend to steer the machine during drive operation.

fNOTE: The front and rear frames are coupled by a

connection pin (center pin) so that the rear wheels follow the tracks of the front wheels.

Turn the steering wheel smoothly so as to follow the motion of the machine.

4-6

M4FG-04-002

DRIVING MACHINE Stop and Restart of Travel Follow the tips described below when required to provisionally stop or restart driving.

1. Slowly release the accelerator pedal. Depress the service brake pedal to stop the machine.

2. Slowly depress the accelerator pedal while releasing service brake pedal to move the machine again.

3. When it is required to park the machine for a long period of time, return the F-N-R lever to neutral, and apply the parking brake to ensure safety operation.

4. During drive operation, the machine drive position may be changed due to inner hydraulic oil leaks. When required to rectify the drive position, stop machine, return the F-N-R lever to neutral, apply the parking brake by turning the parking brake switch ON. Then, after rectifying the drive position, begin driving the machine again. Always allow the machine to maintain correct drive position.

Precautions for Traveling During drive operation, observe the operation best practices and the precautions described below to ensure safe and correct operation.

Use care to the following points: d x WARNING: In case a tire becomes punctured while driving, securely hold the steering wheel and slowly reduce the drive speed.

If the brake is suddenly applied by strongly depressing the brake pedal, the operator may lose steering control, possibly creating a serious accident. Never apply the brake quickly if a tire is punctured. x Never mount or dismount a moving machine.

Never allow any personnel other than the operator to ride on the machine when driving.

4-7

DRIVING MACHINE t &WFO BGUFS CSFBL JO PQFSBUJPO JT DPNQMFUF BWPJE SVOOJOH the engine at fast speed under no load. t *G BOZ BCOPSNBM DPOEJUJPO TVDI BT BO BCOPSNBM OPJTF vibration, or smell is noticed during drive operation, immediately stop the engine and inspect the machine for any trouble. t "WPJE VTJOH TVEEFO TUFFSJOH PS CSBLJOH BT NVDI BT possible because not only your machine but also other machines may become involved in a hazardous condition. t %SJWJOH TQFFET PG UIJT NBDIJOF BSF MPXFS UIBO NPTU normal automobiles. Always give the right of way to automobiles. t .BLF JU B IBCJU UP QFSJPEJDBMMZ TDBO UIF HBVHFT and instruments. If any abnormality is recognized, immediately stop the machine and check the machine for the cause of the trouble. t 8IFO SFRVJSFE UP ESJWF PO UIF SPBE TIPVMEFS PS JO UJHIU spaces, use a signal person. t 4MPXMZ ESJWF JO PS UVSO B DSPTTJOH XIJMF QBZJOH BUUFOUJPO to the visibility ahead and of the opposite driving lane.

Traveling in Water or on Soft Ground IMPORTANT:

When driving/operating on muddy ground, mud can easily accumulate on the frame even if the frame is not heavily submerged in mud, check regularly and clean as necessary. Contact your nearest Kawasaki dealer.

t %P OPU TVCNFSHF UIF GSPOU BOE SFBS BYMFT USBOTNJTTJPO parking brake, or front and rear propeller shafts in water or mud. Avoid driving in water as much as possible. t *G ESJWJOH JO XBUFS PS NVE JT VOBWPJEBCMF EP OPU BMMPX the machine to be submerged deeper than allowable depth (A) (up to the bottom of the axle housing). Reduce the allowable depth in case the river bed is feared to be rugged or water is flowing fast. t 8IFO ESJWJOH PQFSBUJOH PO NVEEZ HSPVOE NVE DBO easily accumulate on the frame even if the frame is not heavily submerged in mud. Check regularly and clean as necessary.

fNOTE: After operation is complete, be sure to wash and lubricate all submerged areas.

4-8

A

M4EJ-04-004A

DRIVING MACHINE Precautions for Driving on Slopes When descending a slope with placing the d WARNING: F-N-R lever in neutral (N) position, the engine brake does not operate and malfunction or failure of the machine may result.

When descending a slope, use engine braking.

Apply the brakes only when absolutely required. If the brake is continuously used while descending a slope, the brake temperature will increase, possibly decreasing braking performance.

If overheating of the brake system is recognized, immediately park the machine in a safe location.

Restart and drive the machine only after the brake system is sufficiently cooled.

When steering on a slope, lower the front attachment to increase the machine stability. Do not steer on a steep slope.

Failure to do so may possibly cause the machine to turn over.

When descending a slope, place the Hi-Lo selector switch in Lo and using engine braking.

Do not drive the machine faster than its maximum travel speed.

In case the engine stalls on a slope, immediately step on the brake pedal as strongly as possible, lower the front attachment to the ground and stop the machine. The parking brake is automatically applied when the engine stops regardless of the position of the parking brake switch. Before restarting the engine, turn F-N-R lever in neutral (N) and push the parking brake switch to ON position. t #FGPSF EFTDFOEJOH B TMPQF DPOGJSN UIBU UIF CSBLF TZTUFN works normally by operating the brake pedal. t *O DBTF UIF IZESBVMJD PJM BOE MVCSJDBOU UFNQFSBUVSFT are low, the machine gradability may decrease. Before climbing a steep slope, sufficiently perform the warm up operation of the machine.

4-9

DRIVING MACHINE Precautions to Be Taken if Machine Failure Occurs x Remain alert. While paying attention to the vehicles following you, slowly reduce the travel speed and park the machine on the road shoulder as closely to the shoulder edge as possible. Turn the parking brake switch ON to apply the parking brake. When any machine failure is recognized in a short tunnel, park the machine outside the tunnel when possible. x Use a sign that indicates that the vehicle is disabled. Unless a sign is used, collision with a following vehicle from behind may result. Indicate that the machine is disabled by using one, or more of the following methods. t 6TF EJTBCMFE NBDIJOF USJBOHMFT t 5VSO UIF IB[BSE MJHIUT 0/ t 6TF BO FNFSHFODZ TJHOBM JOTUSVNFOU FNFSHFODZ TJHOBM light). t 6TF B SFE GMBH PS MJHIU x Check the failed section. If possible, repair the machine by yourself while ensuring safety and paying attention to the traffic conditions of other vehicles.

Do not spill oil on the road surface. Oil d WARNING: spillage may cause another vehicle to slide, possibly creating a serious accident. x In case the hydraulic oil leaks, immediately repair it. If the road surface is severely covered with oil, take the highest priority to notify the following vehicles of this danger. Then, recover the leaked oil as soon as possible. x In case the repairing the machine by yourself is impossible, contact your nearest Kawasaki dealer. x Repair work in the tunnel is very dangerous. Avoid working outside the vehicle even simple tasks.

4-10

DRIVING MACHINE Precautions for Travel Speeds Travel down a steep slope with the Hi-Lo d CAUTION: selector switch in Lo while applying engine brake sufficiently. Apply the service brakes only when absolutely required.

Traveling for a long time without reducing the speed will create the causes of various machine troubles.

When the machine travels faster than the warning travel speed, the service indicator and the HST warning indicator flash, the buzzer sounds. When the indicator flashes and the buzzer sounds, release the accelerator pedal in order to reduce the speed.

Speed Control Function This controls the speed in order to prevent from overrunning (faster than the warning setting speed).

Warning Setting Speed HST Warning Indicator Service Indicator 42 km/h (26 mph)

Flashing

Buzzer

Flashing

Continuous

fNOTE: If the machine travel speed exceeds the maximum

speed (36 km/h (22mph)), the speed control system will activate.

4-11

DRIVING MACHINE Stop

1

1. Avoid sudden deceleration. Smoothly reduce travel speed.

Release accelerator pedal (2) and step on brake pedal (3) to stop the machine.

2. Return F-N-R lever (5) to neutral (N).

Place neutral lever lock (4) to the LOCK position.

2

5

3. Turn parking brake switch (1) ON. 4. Level the bucket with the ground surface and lower the bucket to the ground by operating loader control lever (6).

5. Move the lock position of loader control lever lock (7).

IMPORTANT:

This machine is equipped with a turbocharged engine. Therefore if the engine is stopped without cooling down, the lubricant on the turbocharger bearing surfaces may dissipate due to the intense heat, possibly damaging to the turbocharger.

3

6

4

3

M4FG-01-006

Front

LOCK

UNLOCK 7

6. Run the engine at low idle speed to cool the engine for 5 minutes. Do not idle for excessively long periods.

Observe local and federal idling regulations.

M4FG-01-015

Stop and Parking Position

4-12

M4FG-04-003

DRIVING MACHINE Parking IMPORTANT:

When parking the machine with cab door and windows open, cab electrical components may be damaged by bad weather. Always close windows, roof vent and cab doors when parking the machine.

When parking a canopy vehicle, cover the electrical components and the operator’s seat with plastic covers to protect them from bad weather.

Stop and Parking Position

1. Stop and park the machine on level surface. Lower the bucket to the ground.

M4FG-04-003

1

2. Check that loader control lever (3) is in the neutral (N) position and that neutral lever lock (2) is in the lock position.

3. Turn parking brake switch (1) ON. 4. Level the bucket with the ground surface and lower the bucket to the ground by operating loader control lever (4).

LOCK

UNLOCK

5. Move the lock position of loader control lever lock (5).

IMPORTANT:

This machine is equipped with a turbocharged engine. Therefore if the engine is stopped without cooling down, the lubricant on the turbocharger bearing surfaces may dissipate due to the intense heat, possibly damaging to the turbocharger.

3 M4FG-01-007

2 4

Front

LOCK

UNLOCK

5

6. Run the engine at low idle speed to cool the engine for 5 minutes. Do not idle for excessively long periods.

Observe local and federal idling regulations.

M4FG-01-015

4-13

DRIVING MACHINE IMPORTANT:

If the key switch (6) is left in ON position, the batteries will discharge.

Be sure to turn key switch to OFF position before leaving the machine.

Front

7. Turn the key switch (6) to OFF position to stop the engine. Remove the key from the switch.

6

8. Before leaving the machine, close all access covers and lock them.

If the machine is equipped with the cab, close and lock all the windows, cab doors, and access covers and lock them before leaving the machine.

M4FG-01-015

6 M4EJ-01-025

4-14

DRIVING MACHINE Emergency Evacuation When the Engine Has Stalled During Driving The service brake applies by depressing the brake pedal and the pressurized oil in the master cylinder acts on the brake system.

If the machine does not stop even if the brake pedal is applied, press the parking brake switch ON side to stop the machine.

As the hydraulic system becomes deactivated, the steering system becomes very difficult to operate.

In the event any symptom mentioned above occurs, immediately trace the cause of the problem.

In case a complicated failure has occurred, consult your nearest Kawasaki dealer.

4-15

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4-16

OPERATING MACHINE Loader Control Lever

C B

Single-Lever Type Is used to operate the lift arm and/or bucket.

(C) Float

E 1

N

: The lift arm free falls and can be moved as loads are applied.

D G

A

(B) Lift arm Lower (N) Hold

: The lift arm and bucket are stopped and held in that position.

Front

(A) Lift arm Raise (E) Bucket Dump : The bucket is tilted forward to dump the bucket load.

(D) Bucket Tilt

: The bucket is tilted back, taking the transportation position.

(G) Detent (auto level)

: When the loader control lever is moved from the bucket dump position to the bucket tilt position, the loader control lever is maintained in this position.

M4FG-01-023

fNOTE: After dumping the bucket, when loader control lever

C

(1) is pulled further from the TILT position (D), the lever is held in that position (G). Then, as soon as the bucket is tilted up to the position set by the bucket auto-leveler, loader control lever (1) is automatically returned to the HOLD position (N).

B

D

E N A M4GB-01-074

M4EJ-01-031A

5-1

OPERATING MACHINE Lever Locks When locking the loader control lever and d WARNING: the auxiliary control lever (3) (optional), securely

1

shift lever locks (2), (4) to the LOCK position. Unless lever locks (2), (4) are fully moved to the LOCK position, the control levers are not locked, possibly creating a hazardous situation.

Before leaving the operator’s seat, be sure to stop the engine. Then, move lever locks (2), (4) to the LOCK position.

After completing operation of the machine or transporting the machine, be sure to move lever locks to the LOCK position.

Lever locks (2), (4) are provided to prevent the machine from being unexpectedly operated if the operator mistakenly comes in contact with loader control lever (1) or auxiliary control lever (3) (if equipped) when getting on or off the machine. When loader control lever (1) and auxiliary control lever (3) (optional) are placed in the UNLOCK position, the levers becomes operable.

LOCK Front

UNLOCK

2 M4FG-01-023

4

3

fNOTE: Auxiliary control lever (3) and lever lock (4) are

UNLOCK

optional.

Loader Control Lever Lock Operation

LOCK

t 8IFO MFBWJOH UIF PQFSBUPS T TFBU 1. Park the machine on solid level ground. Lower the bucket to the ground. Return all levers to neutral. Stop the engine.

2. Be sure to move lever lock (2) in the LOCK position.

Be sure to place lever lock (4) in the LOCK position when auxiliary control lever (3) is not in use. t #FGPSF TUBSUJOH PQFSBUJPO Before starting operation, check that lever lock (2) is in the UNLOCK position.

Be sure to place lever lock (4) in the UNLOCK position when auxiliary control lever (3) is in use.

5-2

Auxiliary Control Lever (Optional)

M4FG-01-024

OPERATING MACHINE Adjustment of Bucket Auto Leveler Be careful to avoid personal injury and/or dWARNING: death when adjusting the bucket auto leveler.

Stop the engine. Lower the loader front attachment to the ground to release the remaining pressure in the hydraulic circuits.

Apply the parking brake to prevent the machine from moving unexpectedly. Chock wheels with blocks. Keep bystanders away from the vicinity of the machine.

The bucket auto leveler automatically stops the bucket movement at the preset digging angle. (When the machine is shipped from the factory, the bucket positioner is preset so that the bucket is stopped with the bucket bottom parallel with the road surface.)

For example, after discharging the handling materials onto a truck or into a hopper, when loader control lever (4) is placed to detent position (G), the lever is held in that position. Then, when the bucket is returned to the preset angle position, the bucket is automatically stopped and the lever is returned to neutral (N).

The bucket auto leveler is preset so that the bucket is stopped when the bucket bottom becomes parallel with the road surface. Nevertheless, when tilting the bucket forward or backward more than the preset level position is needed, adjust the mounting position of the auto leveler proximity switch.

M4FG-05-004

N 4

D G

Front

M4FG-01-023

Adjustment Procedures IMPORTANT:

Do not operate the machine with the bucket dumped more than 10 degrees.

Avoid applying great downward force to the bucket cutting edge.

1. After moving the bucket to the desired digging angle, stop the engine.

2. Loosen lock nuts (2) (2 used) of proximity switch mounting bracket (1). Slide bracket (1) up to the end edge of leveler bar (3) moves to the center of the sensitive area (orange color) (5). Then, tighten lock nuts (2) (2 used).

3

5

1

3. After adjustment start the engine. Check that the bucket can be stopped at the preset angle position.

2

5-3

M4EJ-05-003

OPERATING MACHINE Before Operation Be sure to install only authorized buckets d WARNING: and other work tools on the front attachment.

Never modify or increase the capacity of the bucket or other work tools without first receiving authorization. Do not overload the machine by installing additional counterweights. Failure to do so may result in personal injury and/or machine trouble.

Precautions for Operation Confirm work site safety before starting d WARNING: operation. x Use the machine equipped with ROPS / FOPS cab if the machine is to be operated in the areas where the possibility of falling stones exists. x If operation on excessively soft ground is required, operate the machine only after reinforcing the ground. t #F TVSF UP XFBS DMPTF GJUUJOH DMPUIJOH BOE TBGFUZ equipment appropriate for the job, such as a hard hat, etc. when operating the machine. t $MFBS BMM QFSTPOT BOE PCTUBDMFT BXBZ GSPN UIF BSFB PG operation and machine movement. Always be aware of the area around the machine while operating.

Ensure Safety When Operating on Road Shoulders Reinforce the ground before operating the d CAUTION: machine on soft road shoulders.

5-4

OPERATING MACHINE Avoid Overloading Do not penetrate the bucket into piles d WARNING: of soil and/or gravel at fast travel speed to avoid accidents.

Avoid excavating or scooping loads when the machine is articulated, which could possibly cause the machine to turn over.

Avoid Rapid Steering Changes and/or Sudden Braking Always maintain a flat work site surface. d WARNING: Avoid rapid steering changes and sudden braking while raising the lift arm with the bucket loaded to prevent the machine from turning over.

Avoid Operation with Biased Loads Avoid machine abuse by allowing the d WARNING: bucket to receive biased loads at only one side.

Machine rollover or deformation of the lift arm may result.

5-5

OPERATING MACHINE Excavation Loading Accumulated Soil IMPORTANT:

Avoid operating the machine with the front wheels raised off the ground. Machine traction force is reduced and excessive loads are applied to the undercarriage.

Scoop load while traveling forward as described below. As load increases the wheels begin to slip, slightly raise the bucket to reduce the load.

M4EK-05-001

1. Level the bucket with the surface of the ground.

Penetrate the bucket into the accumulated soil while traveling forward.

2. After the bucket has sufficiently penetrated the soil, raise the lift arm while traveling forward further and occasionally tilt the bucket back to fill the bucket.

3. If it is difficult to penetrate the soil with the bucket, move the bucket back and forth and the bucket teeth up and down.

M4EK-05-002

4. Drive the machine with the bucket tilted backward fully and held at the lowest possible position.

M4EK-05-003

M4EK-05-004

5-6

OPERATING MACHINE Digging and Loading Level Ground IMPORTANT:

While excavating with the bucket or fork, never apply excessive force to the tooth tips with the bucket or fork tilted more than 10 degrees.

This may result in cracking or damaging the work tools.

M4EK-05-005

Slightly position the bucket teeth downward (0 to 10 degrees) and dig the ground while traveling forward as described below. Always take care not to apply loads to only to one side of the bucket.

1. Position the bucket teeth slightly downward.

2. While traveling forward, tilt the bucket so that the ground surface is gradually separated.

3. Adjust the digging depth by operating the lift arm.

M4EK-05-006

4. Carry material with the bucket tilted backward fully and held at the lowest possible position.

M4EK-05-007

M4EK-05-008

5-7

OPERATING MACHINE Grading IMPORTANT: Be sure to perform grading work while traveling in reverse. If grading work is performed by traveling forward, severe loads are applied to the front attachment, possibly creating cracks or damage to the front attachment.

M4EK-05-009

1. After filling soil into the bucket, dump the bucket gradually to disperse soil while traveling in reverse.

2. Lower the bucket teeth tips onto the ground. Grade and level the ground surface while traveling in reverse with the bucket teeth tips dragging.

3. After filling the bucket with a load such as soil, position the bucket level with the ground surface. Finish the ground surface utilizing the bucket weight.

At this time, traveling in reverse with the lift arm held in the FLOAT position.

M4EK-05-010

M4EK-05-011

5-8

OPERATING MACHINE Loading IMPORTANT:

Always maintain a clean travel surface.

Cleaning of materials such as soil spilled on the driving surface will reduce wear and/or damage on tires.

IMPORTANT:

When carrying loads in the bucket, pay attention to the travel surface conditions.

Travel at such speed so that the load will not spill out of the bucket, while positioning the bucket at the lowest possible height.

IMPORTANT:

Refrain from banging the bucket with the bucket stopper as much as possible when removing stuck material, like clay, from the bucket. Failure to do so may result in damage to the front attachment.

Remove material stuck to the bucket by washing with water.

Loading is dumping the handling material onto a truck or into a hopper.

Loading work is performed in either the load and carrying method or loader and dump truck method. Select either method depending on the work site conditions while taking the merits in cost and safety into account.

5-9

OPERATING MACHINE Load and Carrying Method Be sure to provide tire stopper (1) in front d WARNING: of the dumping port.

Before raising the lift arm, slightly tilt d WARNING: the bucket back and forth to stabilize the load in the bucket to avoid personal injury or damage to the machine due to material loss.

Raising the lift arm on the slope possibly result in personal injury.

1 M4FG-05-001

When approaching the machine to a d WARNING: hopper with the lift arm raised to a high enough position, travel slowly. Never steer the machine while approaching a hopper to prevent turning over.

A wheel loader performs work process of loading, carrying, and dumping in sequence. Generally, when the carrying distance is 30 to 100 m (33 to 109 yd), this method is employed.

Make an upgrade slope of approx. 3 degrees around a hopper when dumping into the hopper. Be sure to provide a level area 10 m apart from the hopper and tire stopper (1) at the hopper edge. Reduction in travel speed will assist operator’s braking effort.

5-10

OPERATING MACHINE Loader and Dump Track Combination Method Be aware of the following points: d x WARNING: Always maintain a flat work site surface. Avoid rapid swing and/or sudden braking while raising the lift arm with the bucket loaded to prevent the machine from tipping over. x Do not penetrate the bucket into a loading face at fast travel speeds, possibly resulting in an accident.

A loader carries out loading and carrying and dumping is carried out by a dump truck. Depending on the work site conditions encountered and matching with available trucks, select the most efficient method.

V-Shape Loading 1. Park a dump truck in a spot located at approx. 60 degrees angle toward the loading face. After loading material, travel the wheel loader in reverse and turn its direction so that the wheel loader faces the parked dump truck at a right angle. Then, travel forward to carry material onto the dump truck.

2. Position the wheel loader so that the material can be loaded around the center of the dump body. In case the dump body is longer than twice the bucket width, load from the front to rear position of the dump body in order.

3. Before raising the lift arm to the maximum height with the bucket full, lightly tap the bucket on the ground to stabilize the material in the bucket to prevent the material from spilling off the backside of the bucket.

5-11

M4EJ-05-016

OPERATING MACHINE I-Shape Loading Park a dump truck in a direction parallel to the loading face.

After loading material into the bucket, travel the wheel loader straight in reverse. Then, move a dump truck to a spot between the loading face and the wheel loader. Travel the wheel loader forward to load material onto the dump body.

Loading times become shorter using this loading method, reducing the total working cycle time and increasing work efficiency. Position the machine down the wind as much as possible. The engine will not only inhale as little dust as possible but also operator’s eyes will be protected from being contaminated.

5-12

M4EJ-05-017

OPERATING MACHINE Dozing IMPORTANT:

Never attempt to forcibly push piled material higher than the bucket capacity.

Premature wear of the tires due to slipping and/or waste of fuel may result.

IMPORTANT:

Do not perform dozing with the bucket dumped. Abnormal excessive stress will be increased on the front attachment, and the lever can bend, causing problems with the geometry.

IMPORTANT:

M4EJ-05-018

Never apply great force to the cutting edge with the cutting edge tilted forward more than 10 degrees. Failure to do so may result in cracking or damaging the work tools.

Dozing stands for a working method performed by a wheel loader using the wheel loader bucket in place of a bulldozer blade. This operation method is employed when reclaiming land or dumping material into a hopper that is below ground level.

Set the bucket bottom parallel with the ground surface and move the wheel loader forward.

Scooping Do not allow the machine to engage in d WARNING: piling up material on soft ground. It is import to be aware that steering operation on soft ground may easily cause the machine to tip over.

When piling up material with this d WARNING: machine, do not operate the machine in too steep an incline, as the counterweight can come in contact with the ground. The machine may become unstable, possibly causing the machine to turnover.

In addition, impact loads to be applied to the counterweight may cause the mounting bolts to become loose and/or to break.

5-13

M4EJ-05-019

OPERATING MACHINE Removing Snow Snow removal is in the same method as CAUTION: employed in general loading work. However, pay attention to slippage of tires and obstacles covered with snow.

Precautions for removing snow x Avoid sudden starting and stopping as well as rapid steering of the machine. x Use tire chains on all four wheels. x Pay attention to the presence of the utility facilities such a fire hydrant, a manhole, edge stones, roadside drains, etc.

M4EJ-05-020

Lifting Wheel Loader Be sure to use the specified lifting tools WARNING: (option) and set the articulation lock bar in the LOCK position. Never allow any person to ride on the machine to be lifted.

Never allow any person to enter below the lifted machine. Before fully lifting the machine above the ground, check that the hooks are securely attached to the machine and the machine is well balanced while lifting the machine slightly above the ground. Refer to the “Lifting Machine” in the “TRANSPORTING” chapter.

Lifting work of the machine may become necessary when loading the machine onto a ship or truck for repairing and/or transporting.

5-14

M4FG-05-002

OPERATING MACHINE Precautions for After Operation 1. After finishing operation, move the machine to firm, level ground where no possibility of falling stones, ground collapse, or floods are present.

Park the machine referring to the “Parking” in the “DRIVING MACHINE” chapter.)

2. Refill the fuel tank.

Wash the machine immediately after d CAUTION: operation and then coat rust-preventive oil to protect the machine from rusting. If the machine continues to be used with rust developing, oil leaks may occur.

3. Clean the machine.

4. Maintenance for long term machine storage after engaging in snow removal Anti-freeze agents such as salt (sodium chloride or calcium chloride) are scattered on snow roads. When the machine is stored for a long time after engaging in snow removal work, perform the following maintenance to protect the machine from being corroded and/or damaged by salt.

IMPORTANT:

Take care not to spray water directly to electrical parts except for kinds of lights such as the headlights, work lights, and turn signal lights.

4.1 Clean and dry the machine thoroughly.

Clean each cylinder rod (plated areas) and the radiator with extra care.

4.2 After positioning the machine for storage, carefully coat each cylinder rod (plated areas) and the control valve spools with rust-preventive oil.

4.3 Lubricate all pins while referring to “A. Greasing” in the ”MAINTENANCE” chapter.

5-15

OPERATING MACHINE When removing the batteries, first d CAUTION: disconnect the ground cable from the battery terminal.

4.4 Remove the batteries and store them in a dry cool place. Do not put the batteries on the ground.

When the batteries are not removed, disconnect the ground terminal cable.

Positive Side (Red Vinyl Cap)

Ground Side M4FG-07-042

5-16

TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations.

1. For transporting using a trailer, check the width, height, length and weight of the trailer when the machine is loaded.

2. Investigate beforehand the conditions of the route to be traveled, such as dimensional limits, weight limits, and traffic regulations.

In some cases, getting approval from the authority concerned, disassembling the machine to bring it within dimensional limits or weight limits of local regulations may be necessary.

Transporting by Trailer Provide an appropriate trailer while referring to the weight and dimensions shown in the specifications. When transporting the machine within the weight and dimensions shown in the specifications by a trailer, it is possible to transport the machine without disassembling. If the machine width, height or weight is enlarged due to installing an attachment, consult your nearest Kawasaki dealer.

6-1

TRANSPORTING Loading/Unloading on Trailer Be sure to use a loading dock or a ramp d WARNING: for loading/unloading.

Always load and unload the machine on a firm, level surface.

1

1

M4FG-06-001

Ramp/Loading Dock 1. Before loading, thoroughly clean the ramps, loading dock and flatbed. Dirty ramps, loading docks, and flatbeds with oil, mud, or ice on them are slippery and dangerous.

2. Chock (1) the trailer wheels so that the trailer does not move while using a ramp or loading dock.

3. Ramps must be sufficient in width, length, and strength.

Be sure that the incline of the ramp is less than 15 degrees.

4. Loading docks must be sufficient in width and strength to support the machine and have an incline of less than 15 degrees.

6-2

10 to 15 ° M4FG-06-002

TRANSPORTING Loading/Unloading Be aware of the following points: d x WARNING: NEVER steer while driving up or down a ramp as it is extremely dangerous and may cause the machine to turn over. If the travel direction must be changed on a slope, back the machine to flat ground. Then, after changing the travel direction, begin to move again.

Loading 1. Load the machine so that the machine width center aligns with the trailer deck width center.

2. Slowly drive the machine on the ramp.

3. Lower the bucket onto the trailer deck.

4. Stop the engine. Remove the key from the key switch.

5. Operate the loader control lever several strokes to relieve pressure in the cylinders.

6. Place the loader control lever lock in the LOCK position.

7. Cover the electrical components and the operator’s seat to protect them from bad weather. For the cab machine, close cab windows and doors to prevent entry of wind and water.

8. Install the articulation lock bar (1) to the rear frame side to prevent the machine from articulating.

6-3

Rear Frame Side

1

M4FG-01-035

TRANSPORTING Transporting Securely fasten the machine to the trailer CAUTION: flatbed with appropriate accessories (wire ropes/ chains, tighteners.)

Do not use the optional lifting tools.

The machine may move back and forth and/or laterally during transportation.

1. Apply the parking brake. Slowly rest the bucket on the trailer deck or load-carrying platform.

1

M4FG-06-003

2. Chock securely (1) behind each tire to fasten the machine in position.

3. Securely fasten the machine to the truck or trailer platform using appropriate accessories (wire ropes/ chains, tighteners.)

NOTE: When transporting the machine, it is necessary to

cover the exhaust pipe to prevent entry of anything into the exhaust pipe.

M4FG-06-008

6-4

TRANSPORTING Transporting Wheel Loader (Urgent Situation) When required to transport the wheel loader long distance, use a trailer.

Precautions for Towing Never attempt to tow the machine if the d WARNING: brake system is in need of repair. Ask your nearest Kawasaki dealer to repair the machine. Operate the machine only after repair is completed.

Avoid towing the machine as much as possible. If the machine is to be unavoidably towed, beware of the following points.

IMPORTANT:

Do not tow the machine with the parking brake applied. Damage to the parking brake may result.

x When the engine is operable: Keep the engine running to maintain the steering and brake systems operable and then, release the parking brake. x When the engine does not operate: t 8IFO JU JT JNQPTTJCMF GPS UIF QBSLJOH CSBLF UP CF SFMFBTFE manually release the parking brake. (Refer to the “Releasing Parking Brake” on page 6-7.)

And then, relieve the HST hydraulic pressure. (Refer to the “Relieving HST Hydraulic Pressure” on page 6-8.)

6-5

TRANSPORTING t *G UIF FOHJOF CFDPNFT JOPQFSBCMF TUFFSJOH PQFSBUJPO becomes impossible. Switch the hydraulic hose connections between the rod end side and the head end side on one of the steering cylinders. Articulation between the front frame and the rear frame will be easily performed while towing of the machine.

Steering Cylinder

fNOTE: Oil may pour out from the hose when disconnecting hoses. Be sure to catch the oil.

Hose

M4GB-06-007

t *O DBTF UIF CVDLFU JT CFJOH SFTUFE PO UIF HSPVOE SBJTF the bucket above the ground following the procedures below.

C

B

N

Front

LOCK

1. Place loader control lever (3) in FLOAT position (C).

UNLOCK

3

2. Using a jack or a crane, lift the bucket or the lift arm.

3. Move loader control lever (3) to neutral (N) position and loader control lever lock (4) to LOCK position to maintain the bucket in position above the ground.

4

M4FG-01-015

6-6

TRANSPORTING Releasing Parking Brake Once the parking brake is released, d WARNING: the machine becomes impossible to stop with the parking brake system, possibly resulting in personal injury or death.

Before releasing the parking brake, wedge the tire wheels.

As soon as towing operation is complete, d CAUTION: connect the parking brake.

Moving the machine by means of towing shall be made in a short distance until the machine reaches an appropriate location for inspection and/or maintenance. Do not tow the machine for a long distance.

Releasing the parking brake manually only when the parking brake switch becomes inoperable due to any abnormality or failure in the brake system (such as a pump).

1

Procedures

d x WARNING: Once the parking brake is manually released, the machine braking system is completely deactivated. x Before releasing the parking brake manually, chock all tires to prevent the machine from moving. x Before operating the machine again after releasing the parking brake manually, have the parking brake readjusted by your nearest Kawasaki dealer. t -PPTFO QMVHT VTFE PO UIF SJHIU TJEF PG UIF GSPOU axle center, remove the spacer, and then tighten plugs (1) (2 used) at the same time to release the parking brake.

6-7

1 M4FG-06-005

TRANSPORTING Relieving HST Hydraulic Pressure Do not tow the machine at travel speed d CAUTION: faster than 2 km/h (1.2 mph) and in a distance longer than 1 km.

The HST hydraulic pressure must be reset to the original set pressure after towing is complete.

Contact your nearest Kawasaki dealer for machine inspection:

1

Procedures

M4FG-06-007

The HST hydraulic pressure is manually relieved only when the machine must be towed with the engine inoperable.

d x WARNING: Before relieving the HST hydraulic pressure, chock

3

4

2

the tires to prevent the machine from moving.

Engine Side

x Before operating the machine again after resetting the HST hydraulic pressure, have the HST system readjusted by your nearest Kawasaki dealer.

1. If required to tow the machine with the engine inoperable, the hydraulic pressure in the HST pump/ motor closed circuit must be relieved.

4

2. Remove the floor mat and the maintenance access cover from the base of the operator’s seat. Wait for HST pump (1) to cool until it becomes touchable with a bare hand.

3. Remove caps from two high pressure relief valves on HST pump (1). Loosen lock nuts (2). Tighten adjust screws (hexagon socket head) (3) until the screw head becomes flush with the top surface of lock nuts (2).

4. Tighten lock nuts (2).

5. After towing is complete, return adjust screws (hexagon socket head) (3) to their original position and secure with lock nuts (2).

6-8

1

M4EJ-06-008

TRANSPORTING Towing Method Use wire rope having the strength more CAUTION: than approx. 150 % of the machine weight. x Towing from the front side of the machine; When using wire ropes, be sure to attach wire ropes to the front frame.

Always use soft material at the corners between the front frame and wire ropes to prevent damage to wire ropes. x Towing from the rear side of the machine; Be sure to attach wire ropes to the drawbar pin.

Always use the lock pin after completely inserting the drawbar pin to prevent the wire rope from coming off.

M4FG-07-015

x Do not use the optional lifting tools for towing.

Attach wire ropes to the machine as illustrated when the machine must be unavoidably towed, such cases when the machine can not be removed from soft ground under its own power.

M4FG-01-039

M4FG-01-036

6-9

TRANSPORTING Lifting Machine Be aware of the following points: x WARNING: The lifting tools are optional parts. Install specific lifting tools at your nearest Kawasaki dealer. x Use lifting cables and other lifting tools free from any damage and/or aging, and having sufficient strength. x Consult your nearest Kawasaki dealer for correct lifting procedures, and size and types of lifting cable and tools. x Before lifting the machine, move the loader control lever lock to the LOCK position to prevent the machine from moving unexpectedly. x Rigidly secure the front and rear frames using the articulation lock bar so that the machine front and rear frames can not articulate. x If the machine is incorrectly lifted or if lifting wire ropes are incorrectly attached to the machine, the machine may move when lifted, possibly resulting in an accident and/or damage to the machine. x Never apply impact loads to the lifting cables and tools. x Do not allow anyone to enter the area under the lifted machine.

6-10

TRANSPORTING Lifting 1. Straighten the machine and horizontally rest the bucket on the ground.

2. Move the loader control lever lock to the LOCK position.

3. Rigidly secure the front and rear frames using the articulation lock bar.

4. Stop the engine. Remove the key from the key switch.

5. Use cables long enough so that the cables come in contact with the machine chassis when the machine is lifted.

Cover the cables with cloth as needed to protect the machine from being damaged. Be sure to use the specified lifting tools (option).

6. Set a crane in an appropriate position.

7. Attach the cable to the front attachment and the lifting tools.

NOTE: The rear lifting tools are optional hooks to be

installed for the lifting purpose only. The hook must be securely tightened with mounting bolts and washers to the specified torque.

Tightening Torque: 423 to 460 N·m (43 to 47 kgf·m) (312 to 340 ft·lb)

6-11

M4FG-05-002a

TRANSPORTING MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. ..................................................................................................................................................................................................

6-12

MAINTENANCE Correct Maintenance and Inspection Procedures Learn how to service your machine correctly. Follow the correct maintenance and inspection procedures shown in this manual. Refer to page 3-1 for walk around inspection list.

Inspect machine daily before starting. t $IFDL DPOUSPMT BOE JOTUSVNFOUT t $IFDL DPPMBOU GVFM BOE PJM MFWFMT t $IFDL GPS MFBLT LJOLFE GSBZFE PS EBNBHFE IPTFT BOE lines. t 8BML BSPVOE NBDIJOF DIFDLJOH HFOFSBM BQQFBSBODF noise, heat, etc. t $IFDL GPS MPPTF PS NJTTJOH QBSUT SA-005

If there is any problem with your machine, repair it before operating or contact your authorized dealer. *.1035"/5 t 6TF POMZ SFDPNNFOEFE GVFM BOE lubricants.

t #F TVSF UP VTF POMZ HFOVJOF ,BXBTBLJ parts. Failure to do so may result in serious injury or death and/or machine breakdown.

t 'BJMVSF UP VTF SFDPNNFOEFE GVFM lubricants, and genuine Kawasaki parts will result in loss of Kawasaki product warranty.

t /FWFS BEKVTU FOHJOF HPWFSOPS PS IZESBVMJD system relief valve.

t 1SPUFDU FMFDUSJDBM QBSUT GSPN XBUFS BOE steam.

t /FWFS EJTBTTFNCMF FMFDUSJDBM DPNQPOFOUT such as main controller, sensors, etc.

7-1

MAINTENANCE Check the Hour Meter Regularly t *OUFSWBMT PO UIF QFSJPEJD NBJOUFOBODF DIBSU BSF GPS operating in normal conditions. If you operate your machine in more adverse conditions, you should service it at SHORTER INTERVALS. t -VCSJDBUF NBLF TFSWJDF DIFDLT BOE BEKVTUNFOUT BU intervals shown on periodic maintenance guide table (see page 7-4).

Use Correct Fuels and Lubricants IMPORTANT:

Always use recommended fuels and lubricants.

Failure to do so will result in machine damage and loss of Kawasaki product warranty.

7-2

MAINTENANCE Layout 3

4

5

6

7

8

9

10

11

12

13

14

15

16 17

2

1

29 28

18 27 19

26 30

25 24 23

22

21

20

1- Cutting Edge

16- Engine

2- Lift Arm Cylinder Pin

17- Radiator/Oil Cooler

3- Bucket

18- Backup Light

4- Bell Crank Pin

19- Battery

5- Bucket Cylinder Pin

20- Rear Combination Light

6- Bucket Auto-Leveler

21- Fuel Pre-Filter

7- Bucket Cylinder

22- Fuel Filter

8- Head Light/Front Combination Light

23- Air Cleaner

9- Lift Arm Pin

24- Rear Axle

10- Rear View Mirror

25- Transmission

11- ROPS Canopy

26- Front Propeller Shaft

12- HST Oil Filter

27- Fuel Tank

13- Return Filter

28- Steering Cylinder

14- Hydraulic Oil Tank/Suction Filter

29- Front Axle

15- Brake Oil Tank

30- Backup Alarm

7-3

M4FGE-07-001

MAINTENANCE Maintenance Guide Table The maintenance guide table is affixed under the operator’s seat. Lubricate and/or service the parts at the intervals as instructed in the table so that all necessary maintenance can be performed regularly.

M4FG-07-001_E

7-4

MAINTENANCE Preparations for Inspection and Maintenance Front

1

The lift arm may move up while holding d WARNING: ride control switch (1) in the ON position. Be sure

d

2

to turn the ride control switch OFF in order to avoid accidents due to unexpected movement of the lift arm.

CAUTION: If the machine is unexpectedly moved, a serious accident may result. Be sure to apply the parking brake when parking the machine.

LOCK

UNLOCK

Unless especially specified, park the machine by following the procedures below before beginning the inspection and/or maintenance work.

M4FG-01-015

1

1. Park the machine on solid level surface.

ON

2. Lower the working tools such as the bucket to the ground.

3. Turn ride control switch (1) (optional) OFF. 4. Place F-N-R lever (3) in neutral (N) and place neutral lever lock (4) to LOCK position (3).

OFF

5. Apply the parking brake by turning parking brake switch (5) ON.

M4FG-01-025

6. Chock the tires.

5

7. Run the engine for 5 minutes to cool the engine. Turn the key switch OFF and stop the engine. Remove the key from the switch. Fully move the loader control lever 3 to 4 strokes to release residual pressure in the hydraulic system.

8. Be sure to place loader control lever lock (2) in the LOCK position.

9. Begin to work only after attaching a “Do Not Operate” tag in a highly visible place such as on the cab door or the loader control lever.

LOCK

UNLOCK 3 M4FG-01-007

4

ON

OFF

5

7-5

M4EK-01-025A

MAINTENANCE Lock Frames Before beginning to work near the axle d WARNING: of frames (3), (4), install articulation lock bar (1) to securely lock and prohibit movement between the front and rear frames (3) and (4). Avoid accidents due to unexpected movement of the machine.

3

1. Align the front and rear frames (3) and (4) centers with each other.

2

1

2. Remove lock pin (2) and remove articulation lock bar (1) from the front side pin hole on front frame (3).

M4FG-01-034

3. Install one end of articulation lock bar (1) to the mounting pin of rear frame (4). Secure articulation lock bar (1) in position with lock pin (2).

3

4

1

2 M4FG-01-035

7-6

MAINTENANCE Maintenance Side Cover Open/close side cover (1) only after d WARNING: stopping the engine. Failure to do so may create a very dangerous situation such as entanglement with the rotating parts.

Be sure to install side cover (1) before travelling or operating the machine.

1

2

Remove bolts (2) (4 used) to open side cover (1).

fNOTE: Side covers (1) are located at the left and right side

M4FG-01-037

of the machine. Open left side cover (1) to check the engine oil level and to replace the engine oil filter.

M4FG-01-038

7-7

MAINTENANCE Engine Hood 1

Open/close engine hood (1) only after d WARNING: stopping the engine. Failure to do so may create a 2

very dangerous situation such as entanglement.

Before travelling the machine, check that engine hood (1) does not open.

Opening Engine Hood Press lock key (2) of engine hood (1), engine hood (1) opens upward for daily check.

1

M4FG-01-039

Closing Engine Hood Pull band (3) down and slowly push engine hood (1) until a click sound is heard.

fNOTE: Engine hood (1) can be locked with a key.

3

7-8

M4FG-01-040

MAINTENANCE Periodic Replacement of Parts To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval.

Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary.

Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary.

Consult your authorized dealer for correct replacement.

System/Equipment Engine Fuel Tank Brake valve Wet brake Brake system Brake piping Stop light Steering piping Steering Steering cylinder system Steering valve Pump Hydraulic System

Operator’s Seat

Working system

Seat belt

Replacement Part Hose Various seals (Rubber parts) Piston D-ring Hose Switch Hose Various seals (Rubber parts) Various seals (Rubber parts) Suction hose Delivery hose Bucket cylinder line hoses Lift arm cylinder line hose Hydraulic oil tank return hose Hydraulic oil cooler line hose Seat belt

Interval Every 2 years Every 1 year Every 4 years Every 2 years Every 2 years Every 2 years Every 4 years Every 2 years Every 4 years

Every 4 years

Every 3 years

fNOTE: When replacing hoses, replace O-rings, gaskets used for them at the same time.

7-9

MAINTENANCE Maintenance Guide Perform maintenance of items at the intervals shown by the shadowed areas in the table below.

A. Greasing (See Page 7-19) Parts Bucket Pin Bucket Link Pin Bucket Cylinder Pin Bucket Cylinder Rod Pin Bell Crank Pin Lift Arm Cylinder Rod Pin Lift Arm Cylinder Lift Arm Pivot Pin Steering Cylinder Rod Pin Steering Cylinder Pin Frame Center Hinge Pin Rear Axle Pin Propeller Shaft Universal Propeller Shaft Spline

Quantity 2 2 1 1 1 2 2 2 2 2 2 2 2 1

10 Daily ★ ★ ★ ★ ★ ★ ★ ★ ★ ★

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★ ★★★ ★★★

★: Add grease daily during first 50 hours of operation.

In case the machine is engaged in excavation in mud, water or snow, add grease after each work shift. ★★: After 50 hours of operation, add grease every 250 or every 3 months of operation.

Shorten greasing intervals when the machine is operated under severe working conditions or when the machine is continuously operated for a long period of time. ★★★: Shorten greasing intervals when the machine is operated under severe working conditions or when the machine is continuously operated for a long period of time.

7-10

MAINTENANCE B. Engine (See Page 7-22) IMPORTANT:

Be sure to use the specified oil. Change oil at the exactly specified intervals. If unspecified oil is used, or the oil change intervals are arbitrarily extended, serious engine failure or damage may result.

Parts

Quantity

1. Engine Oil

Check Oil Level

2. Engine Oil

Change

3. Engine Oil Filter

Change

10 Daily

50 —

— 11.2 L (3 gal)

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year ★ ★

★★

★: Only first time at every 100 hours or 1 month. ★★: Replace the engine oil filter when changing engine oil.

C. Power Train (See Page 7-25) IMPORTANT:

Be sure to use the specified oil. Change oil at the exactly specified intervals. If unspecified oil is used, or the oil change intervals are arbitrarily extended, serious transmission and/or axle failure or damage may result.

Parts

Quantity

1. Transmission Oil

Change

2. Axle Oil

Change (Front) Change (Rear)

3. Clean Transmission Air Breather 4. Check Oil Leaks Around Axle and/or Cover 5. Clean Axle Housing Air Breather

1.0 L (0.3 gal) 6.2 L (1.6 gal) 6.4 L (1.7 gal) 1 — 1 each in front and rear

★: Only first time at every 250 hours or 3 month.

7-11

10 Daily

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year ★ ★ ★

MAINTENANCE D. Hydraulic System (See Page 7-30) IMPORTANT:

Be sure to use the specified oil. Change oil at the exactly specified intervals. If unspecified oil is used, or the oil change intervals are arbitrarily extended, serious hydraulic system failure or damage may result.

Parts

Quantity

1. Check Oil Level in Hydraulic Oil Tank 2. Change Hydraulic Oil/Clean Hydraulic Oil Tank 3. Clean Suction Filter 4. Replace HST Oil Filter Element 5. Replace Return Filter Check Hoses and Lines For Leaks and 6. Tightness Check Hoses and Lines for Cracks and Bends

10 Daily

— 73 L (19.3 gal) 1 1 1

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year

When changing hydraulic oil ★ ★

— —

★: Only first time at every 100 hours or 1 month.

E. Fuel System (See Page 7-42) IMPORTANT:

Be sure to use the specified oil. Engine failure or damage may result.

Parts

Quantity

1. Check Fuel Level In Fuel Tank 2. Drain Water/Sediment from Fuel Tank 3. Check Fuel Pre-Filter and Drain Water 4. Clean Fuel Pre-Filter Element 5. Replace Fuel Filter Element Check Fuel Hoses for Leaks and Cracks 6.

Check Hoses for Cracks and Bends

10 Daily

50 —

— 1 1 1 1 — —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year

★

★: Only first time at every 100 hours or 1 month.

F. Air Cleaner (See Page 7-48) Intervals (Hours) Parts

1. Air Cleaner Element

Quantity Clean Replace

1 1

7-12

10 Daily

50 —

100 250 500 1000 1 Month 3 Months 6 Months 1 Year When indicator comes ON After cleaning 6 times or once per year

MAINTENANCE G. Cooling System (See Page 7-49) IMPORTANT:

Be sure to use the specified LLC. Change LLC at the exact specified intervals. If unspecified LLC is used, or the LLC change intervals are arbitrarily extended, serious engine failure or damage may result.

Intervals (Hours) Parts

1. Check Coolant Level 2. Check Drive Belt 3. Check Drive Belt Tension 4. Adjust Drive Belt Tension 5. Change Coolant 6. Clean Radiator and Oil Cooler

Quantity

10

50

Daily

—

100

250

500

1000

1 Month 3 Months 6 Months 1 Year

— — — — 10 L (2.6 gal) — (Or when clogged)

H. Electrical System (See Page 7-55) Intervals (Hours) Parts 1. Check Monitor for Malfunction and All Instruments for Inoperativeness 2. Check All Lights for Abnormality in Lightning and/or Blinking 3. Check Horn, Backup Buzzer and Backup Light for Malfunction 4. Check Electrical Circuits and Fuses for Abnormality 5. Check Electrolyte Level 6. Check Electrolyte Specific Gravity

Quantity

10 Daily

50 —

100 250 500 1000 1 Month 3 Months 6 Months 1 Year

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year Indicator comes ON

— — — — 1 1

I. Brake System (See Page 7-65)

Parts

Quantity

1. Check Brake Oil Level 2. Check Right and Left Brake Interlock Control Performance 3. Check Parking Brake Force 4. Check Brake Discs (Service And Parking for Abnormality)

—

5. Change Brake Oil

— — — 0.35 L (0.1 gal)

7-13

10 Daily

MAINTENANCE J. Tire (See Page 7-68) Intervals (Hours) Parts

Quantity

1. Adjust Tire Pressure 2. Check Tires for Damage 3. Check Wheel Nut Tightening Torque

Check Adjust Check Adjust

10 Daily

50 —

4 4 4 4

100 250 500 1000 1 Month 3 Months 6 Months 1 Year As needed

★

★: Only first 50 hours K. Heater/Air Conditioner (Optional of Cab Vehicle) (See Page 7-74) Parts Heater

Quantity

1. Heater unit 2. Check piping for damage 3. Circulation air filter Cleaning

10

50

Intervals (Hours) 100 250

Daily

-

1 Month

-

Every 6 months Every 6 months ★ Every 6 months Every 6 months Every 6 months Every 6 months Every 6 months Every 6 months Once a Year Once a Year

Replace

4. Check air conditioner unit 5. Check pipelines Air 6. Check air conditioner condenser Conditioner 7. Check air conditioner drive belt 8. Check refrigerant quantity 9. Check compressor and pulley 10. Check switch operation

1 1 1 1 -

★: Clean the element after 250 hours or 1 month of operation.

When the machine is operated in dusty work site, shorten intervals of cleaning and/or replacement.

7-14

500

3 Months 6 Months

1000 1 Year

MAINTENANCE L. Miscellaneous (See Page 7-75) Parts 1. Check Bucket Bolt-on-cutting Edge for Tightness and/or Wear 2. Check and Replace Seat Belt 3. Check Canopy/Cab Damage and Bolt Tightness 4. Check Windshield Washer Fluid Level 5. Check Play Amount In Steering Wheel Stroke 6. Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise 7. Check Rear View Mirror and Inside Rear View Mirror for Damage and Tightness 8. Check Steps and Hand Rails for Damage and Tightness 9. Clean Engine Compartment and Hood 10. Check and Adjust Valve Clearance* 11. Check Sound Absorbing Mat Around Engine for Damage 12. Check Fuel Injection Timing* 13. Measure Engine Compression Pressure* 14. Check and Clean Starter and Alternator* 15. Retighten Front Axle and Rear Axle Support Mounting Nuts

Quantity

10 Daily

50 —

Intervals (Hours) 100 250 500 1000 1 Month 3 Months 6 Months 1 Year

— 1

Every 4 years (Replace)

— — — — — — — — ★★ ★★

— — — ★

—

fNOTE: Contact your nearest Kawasaki dealer for maintenance of items with mark (*). ★: Only first 50 hours ★★: Every 1000 hours or 1 year whichever comes first

7-15

MAINTENANCE Kind of Oils IMPORTANT:

Be sure to use the specified lubricants. Change/add lubricants at the exact specified intervals. If unspecified lubricant is used, or the lubricant change intervals are arbitrarily extended, serious machine failure or damage may result.

Grease Kind of Grease Application Air Temp.

Manufacturer SHELL Oil

IDEMITSU Kosan JAPAN ENERGY COSMO Oil NIPPON Oil CALTEX Oil KIGNAS Oil MOBIL Oil GENERAL Oil

Grease (Lithium based) Front attachment joint pins, others -20 to 40 °C (-4 to 104 °F) * ALVANIA EP GREASE 2 DAPHNE EPONEX EP2 DAPHNE EPONEX No.2 JOMO LISONIC GREASE EP2 COSMO GREASE DYNAMAX EP2 EPINOC GREASE AP2 DIAMOND MULTIPURPOSE EP GREASE NO.2 MULTIFAX EP2 KIGNAS MPGREASE No.2 MOBILUX EP2 ZEMICO GREASE MP-2

fNOTE: Be sure to use a lithium-based grease. Use of other types of chassis grease may cause premature wear and/or noise.

The machine shipped from the factory is filled with grease marked with *.

Engine Oil IMPORTANT:

Be sure to use the specified engine oil. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.

Be noted that all engine failures caused by using engine oil other than specified are excluded from Kawasaki Warranty Policy. Consult your nearest Kawasaki dealer for any unclear points.

Kind of Oil Application Air Temp.

Standard

Manufacturer IDEMITSU Kosan

Engine Oil Engine crank case -20 to 30 °C (-4 to 86 °F) SAE 10W-30 Class CF or CI-4 * Apolloil Motive CF-M (10W-30)

fNOTE: The machine shipped from the factory is filled with engine oil marked with *.

Be careful that oil change intervals will differ according to the standard employed.

7-16

MAINTENANCE Brake Oil Kind of Oil Application Manufacturer IDEMITSU Kosan

Torque Converter Oil SAE5W (Mineral Oil) Brake System (Brake oil tank) * DAPHNE TORQUE OIL B

fNOTE: The machine shipped from the factory is filled with the oil marked with *.

Use the same oil (mineral oil). Use of other oil (vegetable oil) may cause the failure and/or malfunction of the brake.

Transmission Oil, Axle Oil Kind of Fluid Application Standard Manufacturer IDEMITSU Kosan COSMO Oil MOBIL Oil SHELL Oil ELF

Gear Oil Transmission and Axle API GL5, LSA, MIL2105B * Apolloil Gear TH Multi 75W-80 COSMO HI-GEAR OIL SP90TS MOBIL LUBE SHCLS 75W90 (FULL SYNTHETIC) MOBIL 1 SAE 75W90 LS(E.P.) SHELL SL90, SHELL SPIRAX HD 85W90 * SF3

fNOTE: The machine shipped from the factory is filled with gear oil marked with *. Use the same oil.

Use of other types of gear oil may cause axle failure and/or noise emission.

Hydraulic Oil Kind of Oil Application Change Interval

Manufacturer NIPPON Oil

IDEMITSU Kosan

Hydraulic Oil (ISO VG 46) Hydraulic system (Hydraulic oil tank) Every 1000 hours or 1 year HYRAND WIDE 46 HYRAND KENKI HP46 SUPER-HYDRO LW46 SUPER-HYDRO 46X SUPER-HYDRO WR46 * SUPER-HYDRO HN46

fNOTE: Select hydraulic oil appropriate to the atmospheric temperature. When the machine is operated in a low

temperature district, oil viscosity may increase due to low temperature so that the lubrication performance of hydraulic oil will decrease, possibly resulting in insufficient lubrication in hydraulic components. Change hydraulic oil appropriated to machine operation under cold weather conditions. In case atmospheric temperature becomes lower than -20 °C (-4 °F), consult your nearest Kawasaki dealer. The machine shipped from the factory is filled with the hydraulic oil marked with *.

7-17

MAINTENANCE Long-Life Coolant Kind of Coolant Application Standard Manufacturer TCM

LLC Mixing Ratio (%) 35

Long-Life Coolant (LLC) Radiator, Cooler JIS K 2234 (Class 2), SAE J814, SAE J 1034, ASTM D 3306 * TCM long-life coolant Total Capacity: 10 L (2.6 gal) LLC (L) Soft Water (L) 3.5 (0.9 gal) 6.5 (1.7 gal)

fNOTE: The machine shipped from the factory is filled with LLC marked with *.

The standard LLC mixing ratio is 35 %. When a machine is delivered to a cold weather district, the LLC mixing ratio is increased up to 50 %.

IMPORTANT:

If long life coolant (LLC) marked with * is unavailable, use LLC that meets following standards. t +*4 , t 4"& + t 4"& + t "45. % Dilute LLC with soft water.

Never mix LLC with different brand.

7-18

MAINTENANCE A. Greasing Apply the parking brake and hold the d WARNING: front and rear frames rigidly with the articulation lock bar.

fNOTE: During break-in operation more than 50 hours until initial operational break-in is finished, grease the machine every day.

In case excavations are performed in mud, water or snow, grease the machine after operation is complete.

fNOTE: Add high quality grease through the grease fittings.

After removing contamination around the grease fitting, add grease. After greasing, thoroughly wipe off old grease that was pushed out from the seals.

Bucket Link Pin (1) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours]

2

Bucket Link (2) [2 point] --- every 250 hours or 3 months [Daily during first 50 hours]

Bucket Cylinder Pin (3) [1 point] --- every 250 hours or 3 months [Daily during first 50 hours] 1

Bucket Cylinder Rod Pin (4) [1 point] --- every 250 hours or 3 months [Daily during first 50 hours]

M4FG-07-003

3 4

Bell Crank Pin (5) [1 point] --- every 250 hours or 3 months [Daily during first 50 hours] 5 M4FG-07-004

7-19

MAINTENANCE Lift Arm Cylinder Rod Pins (6) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours]

7

Lift Arm Cylinder Pins (7) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours]

6

Lift Arm Pivot Pins (8) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours]

8

M4FG-07-005

9, 10

M4FG-07-006

Steering Cylinder Rod Pin [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours] 12

9- Front-left 10- Front-right 11

Steering Cylinder Pin [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours] 11- Rear-left 12- Rear-right

Frame Center Hinge Pin [Each 1 point on the upper and lower sides] --- every 250 hours or 3 months 13

13- Upper side 14- Lower side

14 M4FG-07-006

7-20

MAINTENANCE Rear Axle Pins [Each 1 point on the front and rear pins] ---every 100 hours or 1 month 15- Front 15

16- Rear

16

M4FG-07-008

Propeller shaft universal (17) [2 points] ---every 500 hours or 6 months

fNOTE: When the machine is continuously operated under severe conditions for a long time, shorten the greasing intervals.

17

18

M4FG-07-009

17

Propeller Shaft Spline (18) [1 point] --- every 500 hours or 6 months

M4FG-07-010

7-21

MAINTENANCE B. Engine 1

Check Engine Oil Level --- every 10 hours (before starting the engine) Check the oil level before starting the engine. Remove dipstick (1). Check for mixing of foreign matter or contamination in the oil. Wipe oil off the dipstick with a clean cloth. Reinsert dipstick (1) and remove it again. Read level. Oil level must be within the specified range on dipstick (1).

If necessary, add the recommended engine oil via oil filler (2).

Recheck oil level after adding the oil.

2

M4FG-07-011

Specified Range M4EJ-07B-002

fNOTE: Before refilling oil or checking the oil level, be sure

machine is level. When checking the oil level after operating the machine, first stop the engine.

Wait for more than 15 minutes. Then check the oil level.

(This means that the oil level has become stabilized after all oil was delivered to respective lubrication area returns to the oil pan.) In case the oil color changes, severe contamination, and/or mixing of foreign matter is found, change the oil.

7-22

MAINTENANCE Change Engine Oil --- every 500 hours or 6 months (Only first time at 100 hours or 1 month) This interval applies only when using ultra low sulfur diesel fuel (ULSD). If ULSD is not used (with less than % 0.05 ppm), the change interval must be SHORTENED to 250 hrs or less.

Immediately after the machine was d WARNING: operated, all engine parts are hot. Wait for the

Clean Cloth Container

engine to cool before starting any maintenance work. Failure to do so may cause severe burns.

M4GB-07-020

IMPORTANT:

Consult a professional waste collector or your nearest Kawasaki dealer about disposal of waste oil and filters.

Dispose waste oil and filters according to local regulations while giving consideration to earth’s ecology.

Be sure to replace the engine oil filter when changing engine oil at the same time.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Clean the areas around the drain plug and the oil filter.

3. Arrange 12 liter (3.2 gal)-capacity container to receive the drain oil.

4. Remove drain plug (3) provided in the rear frame opening located at rear side of the fuel tank (on the left side of the base machine) to allow oil to drain.

5. Drain oil from the oil filter cartridge.

6. Allow oil to drain through clean cloth to check if any foreign matters such as metal pieces are not included in the oil.

7. Install new oil filter.

8. Securely tighten drain plug (3).

9. Remove the oil filler cap. Supply the specified amount of engine oil.

Oil refill quantity: 11.2 L (3 gal) 10. Check that the oil level is between the minimum and maximum level scales on the dipstick. Then, start the engine.

11. After starting the engine, check the sealing surfaces for any oil leakage.

12. Allow the engine to run at low idle speed for 5 minutes and stop the engine. About 15 minutes after, check the oil level. If necessary, add oil.

7-23

3 M4FG-07-012

MAINTENANCE Replace Engine Oil Filter --- every 500 hours or 6 months (Only first time at 100 hours or 1 month) Immediately after the machine was d WARNING: operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns.

fNOTE: Be sure to replace the engine oil filter when changing engine oil at the same time.

1

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

M4FG-01-038

2. Remove left side cover. Clean the area around the oil filter.

3. Before removing oil filter (1), loosen drain plug (2) to drain oil from the oil filter. The oil is drained through the drain hose. After draining the oil, tighten the drain plug.

4. Remove the spin-on type element from the filter head with a filter wrench. *.1035"/5 t 5BLF DBSF OPU UP BMMPX GPSFJHO NBUUFS TVDI as dirt to enter the oil filter.

t #F DBSFGVM OPU UP EBNBHF UIF PJM GJMUFS XIFO removing or installing the filter.

t /FWFS SFVTF UIF PJM GJMUFS 5. Fill the oil filter with clean engine oil.

6. After coating new oil filter gasket with engine oil, tighten the oil filter until the gasket comes in contact with the sealing surface. Take care that if the oil filter is overly tightened, the oil filter may become deformed.

fNOTE: When installing the element, take care not to allow gasket (4) to break due to twisting.

Check for oil leaks around the mounting surface of cartridge type element (2).

7-24

2 M4FG-07-012

MAINTENANCE C. Power Train

3

Change Transmission Oil --- every 1000 hours or 1 year (Only first time at 250 hours or 3 months) If the machine is unexpectedly moved, d WARNING: a serious accident may result. When parking the LOCK

machine, place F-N-R lever (1) in neutral and neutral lever lock (2) in the lock position. Then, apply parking brake (3) and stop the engine.

UNLOCK

Pay attention to the following points. d x WARNING: Immediately after the machine has been operated,

2

1

M4FG-01-007

all engine parts will be hot. Wait for the oil to cool before starting any maintenance work. x Secure the front and rear frames with articulation lock bar (4).

IMPORTANT:

Do not use transmission oils other than those listed in the table for “Kinds of oils”.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

4

2. Install articulation lock bar (4) to the front and rear of the frames by following the procedures described on page 7-6.

M4FG-01-035

3. Turn the key switch OFF to stop the engine. Leave the machine untouched for 10 minutes.

4. Clean areas around drain plug (5) and oil level plugs (6) (2 places).

6

5. Prepare a container of approximately 2 liter (0.5 gal) capacity to receive the drain oil.

6

6. Remove drain plug (5) from the transmission bottom to drain the oil. Dispose of the drain oil in the proper way.

5

7. Securely tighten drain plug (5).

8. Refill the specified amount of oil through either one of oil level plug (6) holes (2 places). Oil refill quantity: 1.0 L (0.3 gal) 9. Check that the oil level is at the position of oil level plug (6) hole. Add oil as necessary.

10. Install plug and check plugs for tightness.

fNOTE: Finally, check for any oil leakage around drain plug.

7-25

M4FG-07-013

MAINTENANCE Change Axle Oil --- every 1000 hours or 1 year (only first time at 250 hours or 3 months) Pay attention to the following points. d x WARNING: Immediately after the machine has been operated, all engine parts will be hot. Wait for the oil to cool before starting any maintenance work. x Secure the front and rear frames with the articulation lock bar and pins.

IMPORTANT:

Do not use axle oils other than those listed in the table for “Kinds of transmission oil“.

M4FG-07-032A

1

Change Axle Oil 1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

Park the machine so that each oil level plug (1) at left and right side of the axle is level.

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Clean the areas around drain plug (2) and oil level plugs (1) (2 places) and oil level plug (3) mounting area.

4. Arrange a container of approximately 10 liter (2.6 gal) capacity to receive the drain oil.

5. Remove drain plug (2) from axle bottom to drain the oil.

Dispose of the drain oil in the proper way.

IMPORTANT:

Do not wrap the drain plug with any seal tape. This may damage the case or may cause oil leakage.

6. After cleaning off oil and coating drain plug (2) with LOCTITE #572 or equivalent, securely retighten the drain plug.

IMPORTANT:

It takes time for oil to fully lubricate the overall front axle.

After installing the plug, allow the machine to drive for several minutes. Then, stop the engine and check the axle for any oil leaks.

7. Refill the specified amount of oil through oil level plugs (1) (2 places) and oil level plug (3).

Front Axle 6.2 L (1.6 gal)

Rear Axle 6.4 L (1.7 gal)

8. Install plug and tighten.

7-26

2

3

M4FG-07-015

MAINTENANCE Check Oil Level 1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

Park the machine so that each oil level plug (1) at left and right side of the axle is level.

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Clean the area around oil level plugs (1) (2 places) and oil level plug (3) mounting area.

M4FG-07-032A

1

4. Remove oil level pugs (1) (2 places) and oil level plug (3).

Check that the oil level is equal to the position of oil level plug holes.

Add oil as necessary.

5. Install plug and tighten.

3

7-27

M4FG-07-015

MAINTENANCE Clean Transmission Air Breather --- every 500 hours or 6 months

1

Be sure to wear safety glasses or goggles d CAUTION: when cleaning the air breather with compressed air.

1. Clean the vicinity around air breather (1) before removing the air breather.

2. Put a cover on the air breather port to prevent foreign matter from entering.

3. Clean air breather (1) using compressed air. If completely contaminated, wash the air breather with a cleaning solvent and reinstall it.

4. Take care not to allow foreign matter to enter into the transmission when reinstalling the air breather.

7-28

M4FG-07-016

MAINTENANCE Check Surrounding Areas Around Axles and Covers for Oil Leaks --- every 1000 hours or 1 year Check the surrounding areas around the axles and covers for oil leaks. If any oil leaks are found, check the bolts in the oil leaking area for tightness. Retighten as needed.

Clean Axle Housing Air Breather --- every 500 hours or 6 months

1

Be sure to wear safety glasses or goggles d CAUTION: when cleaning the air breather with compressed air.

1. Clean the vicinity around air breather (1) before removing the air breather.

2. Put a cover on the air breather port to prevent foreign matter from entering.

3. Clean air breather (1) using compressed air. If completely contaminated, wash the air breather with a cleaning solvent and reinstall it.

Front Axle

M4FG-07-017

1

4. Take care not to allow foreign matter to enter into the transmission when reinstalling the air breather.

Rear Axle

7-29

M4FG-07-018

MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment Always follow the following precautions d WARNING: for checking and maintaining the hydraulic system.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Begin servicing hydraulic components only after components, hydraulic oil and lubricants have completely cooled, and only after releasing residual pressure.

2.1 Operate all control levers several strokes to bleed off residual air pressure.

2.2 Immediately after operation, all hydraulic components and hydraulic oil or lubricants are hot and highly pressurized. Begin inspection and/or maintenance work only after the machine has cooled down.

Servicing heated and pressurized hydraulic components may cause plugs, screws and/or oil to fly off or escape suddenly, possibly resulting in personal injury. Hydraulic components may be pressurized even when cooled.

Keep body parts and face away from the front of plugs or screws when removing them. *.1035"/5 t 8IFO DPOOFDUJOH IZESBVMJD IPTFT BOE pipes, take special care to keep seal surfaces free from dirt and to avoid damaging them.

t 8BTI IPTFT QJQFT BOE UIF UBOL JOUFSJPS with a washing liquid and thoroughly wipe it out before reconnecting them.

t 0OMZ VTF 0 SJOHT UIBU BSF GSFF PG EBNBHF or defects. Be careful not to damage them during reassembly. Do not allow high pressure hoses to twist when connecting them. The life of twisted hoses will be shortened considerably.

t %P OPU VTF IZESBVMJD PJMT PUIFS UIBO MJTUFE in the “Brand Names of recommended Hydraulic Oil”.

t /FWFS TUBSU UIF FOHJOF XJUIPVU GJSTU supplying hydraulic oil.

7-30

MAINTENANCE Check Hydraulic Oil Level --- every 10 hours (daily) IMPORTANT:

If the oil level is not viewed in the level gauge, immediately refill hydraulic oil up to the appropriate level. Failure to do so may result in serious failure in the hydraulic system.

If the oil level is higher than the level gauge, remove oil down to the appropriate level.

1 M4FG-07-021

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

1

2. Check oil level with level gauge (1) at the side of the hydraulic oil tank. Oil must be within the gauge.

fNOTE: During cold weather season, check the oil level after warming up the hydraulic oil by referring to the instructions described in the “Warm Up Operation” section.

M4EJ-07D-002

7-31

MAINTENANCE Change Hydraulic Oil/Clean Hydraulic Oil Tank --- every 1000 hours or 1 year Change/Cleaning Hydraulic oil becomes hot and d WARNING: pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.

IMPORTANT:

1

Do not use hydraulic oils other than listed in the “Brand Names of recommended Hydraulic Oil”.

M4FG-01-035

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Install articulation lock bar (1) to the front and rear of the frames by following the procedures described on page 7-6.

2

3. Slowly loosen oil filler port plug (2) to relieve the air pressure from the hydraulic oil tank.

IMPORTANT:

When changing hydraulic oil, take care not to allow foreign matter such as dirt, water or soil to enter the hydraulic oil tank.

M4FG-07-021

4. Clean the vicinity of drain plug (4) on the bottom of hydraulic oil tank (3).

5. Arrange container of approx. 80 liters (21.1 gal) to receive the drain oil.

3

6. Remove drain plug (4) to drain hydraulic oil.

7. Remove cleaning cover (5) on the bottom of hydraulic oil tank (3). Clean the tank bottom with cleaning oil. Install cleaning cover (6) in its original position after cleaning.

4

8. Securely tighten drain plug (4).

7-32

5

M4FG-07-022

MAINTENANCE 9. Remove oil filler port plug (2). Refill hydraulic oil while checking oil level with level gauge (6).

Specified Oil Amount: Hydraulic Oil Tank 50 L (13.2 gal)

Hydraulic System 73 L (19.3 gal)

2

10. Install oil filler port plug (2).

11. Start the engine. Slowly raise or lower the arm and tilt the bucket forward and backward. Stop the engine.

Check for oil leaks. Check the oil level using level gauge (6).

6 M4FG-07-021

6

Bleed Air from the Hydraulic System After changing hydraulic oil or replacing the return filter, HST oil filter and/or suction filter, bleed air from the hydraulic system following the procedures below.

Procedures 1. After supplying oil, start the engine. Move the bucket and lift arm cylinders several times to bleed air mixed in the hydraulic circuit.

2. Rest the bucket on the ground to resume the hydraulic oil level check position.

3. Stop the engine. Check the oil level. Add oil as needed.

7-33

M4EJ-07D-002

MAINTENANCE Clean Suction Filter --- each time when hydraulic oil is changed

1

A suction filter is located on the bottom of the hydraulic oil tank. Clean the suction filter when changing hydraulic oil.

1. After draining the hydraulic oil, remove cleaning cover (3) on the bottom of hydraulic oil tank (1). Slowly remove suction filter (2) from the opening. Trapped debris will come from this filter.

2. Clean suction filter screen (2) and inside of the hydraulic oil tank with cleaning oil. Swab out cleaning oil with a lint free cloth.

2

4

3 M4FG-07-023

5

3. Install suction filter (2) in the hydraulic oil tank. Inspect O-ring seal for wear or for damage. Install cleaning cover (3) with bolts (6 used).

4. Refill hydraulic oil by the specified volume through the oil filler port while checking the oil level with oil gauge (5).

5. Start the engine. Slowly raise and lower the lift arm and tilt the bucket forward and backward to confirm that no abnormality is present. Stop the engine. Recheck the oil level with oil gauge (5).

7-34

M4EJ-07D-002

MAINTENANCE Replace HST Oil Filter Element --- every 1000 hours or 1 year (Only first time at 100 hours or 1 month) Hydraulic oil becomes hot and d WARNING: pressurized during operation. Severe burns may 1

result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.

Apply the parking brake and chock the tires before starting maintenance work.

M4FG-07-021

The HST oil filter is located at the front-left side of the HST pump.

Replace the element when changing hydraulic oil.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Before removing the filter, arrange a container and workshop towel to catch the drain oil and the element.

M4FG-07-025

4. Slowly loosen oil filler port plug (1) to relieve the air pressure from the hydraulic oil tank.

3

*.1035"/5 t %P OPU BMMPX GPSFJHO NBUUFS TVDI BT EJSU UP enter filter (2).

t 8IFO JOTUBMMJOH PS SFNPWJOH TQJO PO GJMUFS (2), be careful not to damage it.

t %P OPU SFVTF UIF FMFNFOU 5. Rotate the hexagonal section on the bottom of filter (2) counterclockwise with a wrench to remove the filter from filter head (3).

4

2

M4FG-07-029

7-35

MAINTENANCE 6. Pour new hydraulic oil into filter (2).

3

7. Coat O-ring (4) on new filter (2) with hydraulic oil. Install filter (2) to filter head (3) by turning the hexagonal section on the bottom of filter (2) with a wrench. After gasket (4) comes in contact with the seal surface on filter head (3), further tighten the element 3/4 turns.

4

fNOTE: When installing the filter, take care not to allow

O-ring (4) to break due to twisting.

Check for oil leaks around the mounting surface of filter (2).

8. After replacing the filter element, bleed air from the hydraulic system and check the oil level in the hydraulic oil tank.

(Refer to the descriptions for “Bleed Air from the Hydraulic System”. ) If the machine is operated without bleeding air from the hydraulic circuit, damage to the hydraulic pump may result.

fNOTE: Replace the filter at the regular intervals. The filter keeps hydraulic oil clean and extends hydraulic component life.

7-36

2

M4FG-07-029

MAINTENANCE Replace Return Filter --- every 1000 hours or 1 year (Only first time at 100 hours or 1 month) Replacement Hydraulic oil becomes hot and d WARNING: pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.

Apply the parking brake and chock the tires before starting maintenance work.

M4FG-07-026

The return filter is located at the front-right side of the HST pump.

Replace the filter when changing hydraulic oil.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

1

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

M4FG-07-021

3. Before removing the filter, arrange a container and workshop towel to catch the drain oil and the filter.

4. Slowly loosen oil filler port plug (1) to relieve the air pressure from the hydraulic oil tank.

3

*.1035"/5 t %P OPU BMMPX GPSFJHO NBUUFS TVDI BT EJSU UP enter filter (2).

t 8IFO JOTUBMMJOH PS SFNPWJOH TQJO PO GJMUFS (2), be careful not to damage it.

t %P OPU SFVTF UIF FMFNFOU 5. Rotate the filter(2) counterclockwise with a filter wrench to remove filter from filter head (3).

2

M4FG-07-030

7-37

MAINTENANCE 6. Pour new hydraulic oil into filter (2).

7. Coat O-ring (4) on new filter (2) with hydraulic oil. Install filter (2) to filter head (3) by turning the hexagonal section on the bottom of filter (2) with a wrench. After O-ring (4) comes in contact with the seal surface on filter head (3), further tighten the element by 3/4 turns. Take care not to damage filter (2) as it may become deformed if overly tightened.

fNOTE: When installing the filter, take care not to allow

O-ring (4) to break due to twisting.

Check for oil leaks around the mounting surface of filter (2).

8. After replacing the filter element, bleed air from the hydraulic system and check the oil level in the hydraulic oil tank.

(Refer to the description for “Bleed Air from the Hydraulic System”. ) If the machine is operated without bleeding air from the hydraulic circuit, damage to the hydraulic pump may result.

fNOTE: Replace the filter at the regular intervals. The filter keeps hydraulic oil clean and extends hydraulic component life.

7-38

3

4

2

M4FG-07-074

MAINTENANCE Check Hoses and Lines --- every 10 hours (daily)/every 250 hours or 3 months Escaping combustible fluid can cause d WARNING: fires. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, and oil leaks.

Escaping oil under pressure can penetrate the skin causing serious injury. To avoid this hazard, search for oil leaks with a piece of cardboard. Take care to protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor familiar with this type of injury immediately.

Tighten, repair or replace any missing, loose or damaged clamps, hoses, or lines.

Do not bend or strike high-pressure lines.

Never reinstall bent or damaged hoses or lines.

SA-031

According to the check points shown below, check hoses and lines for oil leaks and damage.

If any trouble is found, replace or retighten as instructed in the table.

SA-292

SA-044

Hose Interval Check Points (hours) Every 10 hours Hose covers Hose ends Fittings

3

Abnormalities Leak (1) Leak (2) Leak (3)

Remedies

2

Replace Replace Retighten or replace hose or O-ring

1 2 3 M4GB-07-053

3

2 1 2 3 M4GB-07-054

7-39

MAINTENANCE Interval (hours) Every 250 hours

4

Check Points

Abnormalities

Remedies

Hose covers Hose ends

Leak (4) Leak (5)

Replace Replace

Hose covers Hose covers

Exposed reinforcement (6) Blister (7)

Replace Replace

Hose

Bend (8), Collapse (9)

Replace

Hose ends and Fittings Deformation or corrosion (10)

5

M4GB-07-055

7 6

Replace

Lines Interval (hours) Daily

Every 250 hours

M4GB-07-056

Check Points

Abnormalities

Contact surfaces of flange joints Leak (11) Bolts Loose or leak (11) Welded surfaces on flange joints Leak (12) Flange joint neck Crack (13) Welded surfaces on flange joints Crack (12) Clamps Missing or deformation Loose bolts

8

Remedies Replace Retighten or replace O-ring Replace Replace Replace Replace or retighten

M4GB-07-057

9

10 M4GB-07-058

13

12 11 M4GB-07-059

13

12

M4GB-07-060

7-40

MAINTENANCE Kinds of Hose/Line Fittings Following joint is used for hose fittings.

1

2

3

4

5

1. Metal Face Seal Fittings Tight contact between metal flares on adaptor (1) and connector (3) of hose (5) prevents pressure oil leakage.

This type of fitting is used on smaller diameter joint.

M4GB-07-062

Precautions for Use Connect or disconnect fittings with care so as not to damage seat surfaces (2 and 4).

Tightening Torque Tighten fittings to the torque values shown below.

Wrench size (mm) (in) 19 (0.75) 22 (0.87) 27 (1.06) N·m 29 39 93 Tightening Torque (kgf·m) (3.0) (4.0) (9.5) (ft·lb) (22) (29) (69)

7-41

MAINTENANCE E. Fuel System Check Fuel Level --- every 10 hours (daily) Beware of fire. d DANGER: Fuel is flammable. Keep fuel away from fire hazards.

IMPORTANT:

Always fill the fuel tank with the specified diesel fuel. Failure to do so may cause engine trouble and may also make the engine difficult to start.

Do not use fuel additives as these can damage the fuel system.

1

M4GB-01-030

2 3

Recommended Fuel Use high quality DIESEL FUEL only (JIS K-2204) (ASTM D-975) (GOST-R 52368) (GB252). Kerosene must NOT be used.

(Sulfur content: Less than 15 ppm)

Refueling 1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Check the fuel level with gauge (1). Remove cap (2) on the fuel tank to add fuel as necessary.

3. Fill the tank at the end of operation in each day.

Fuel Tank Capacity : 82 L (21.7 gal) Add fuel, and be sure that fuel tank is not overfilled.

4. Immediately after fueling, install and lock fill cap (2) to prevent vandalism and loss.

fNOTE: When fueling, do not remove strainer (3) from the

filler port. Take care not to allow dirt and/or water to enter the fuel tank.

7-42

M4FG-07-027

MAINTENANCE Drain Water and Sediment from Fuel Tank --- every 1000 hours or 1 year Before starting to operate the machine, loosen drain plug (1) on the fuel tank bottom to drain water and/or sediment from the fuel tank.

Tighten plug when no more water is draining, and only fuel drainage is seen.

1

7-43

M4FG-07-028

MAINTENANCE Check and Drain Water from Fuel Pre-Filter --- every 10 hours (daily) Check before starting operation.

Fuel pre-filter (1) functions to separate water mixed in fuel.

There is float (9) inside filter cup (10). When water accumulates, float (9) rises.

Before float (9) rises up to the drain level (3) of filter cup (10), drain water from pre-filter.

Open the engine hood. Fuel pre-filter (1) is located on the left side of the radiator.

1

M4FG-07-031

Fuel Pre-Filter Drain Procedures 1. Turn cock (2) on fuel pre-filter (1) counterclockwise 90 ° to the close position.

2

2. Loosen retaining ring (4). Remove filter cup (10) from filter head (5). Get out float (9) and spring (8) from filter cup (10). Drain water.

Close

Catch water to protect the environment from being polluted.

Open

If any stain and/or debris are found inside filter cup (10), clean out the cup with clean fuel and a lint free cloth.

3

IMPORTANT:

Tighten retaining ring (4) by hand. If tightened with a tool, filter cup (10) may be damaged.

3. After draining, fill the cup with clean fuel, install filter cup (10) to filter head (5). Tighten retaining ring (4).

M4FG-07-065

5 6

4. Turn cock (2) to OPEN position.

7 8 9

10

4 M4FG-07-066

7-44

MAINTENANCE Clean Fuel Pre-Filter Element --- every 500 hours or 6 months Beware of fire. Fuel is flammable. Keep d DANGER: fuel away from fire hazards.

Wear goggles or safety glasses when using d CAUTION: compressed air [less than 0.2 MPa (2 kgf/cm²)

3 1

(29.1 PSI)].

IMPORTANT:

When cleaning/replacing the filter, take care not to allow foreign matter such as dirt to enter the filter. Engine failure or damage may result.

Remove fuel pre-filter element (1) following the same procedure as described in “ Check and Drain Water from Fuel Pre-Filter”.

Clean element (1) with light oil. Blow compressed air [less than 0.2 MPa (2 kgf/cm²) (30 PSI)] from the inner side of the filter element. If any stain and/or affixes are found inside filter cup (2), clean the cup. If element (1) is damaged, use new parts for replacement. Use new O-ring (3) when replacing element (1).

After element (1) is replaced, fill the cup with clean fuel and install it. Bleed air from the fuel system.

2

M4FG-07-066

Bleed Air from the Fuel System IMPORTANT:

Air in the fuel system may cause the engine to become difficult to start or other engine trouble.

In case the machine runs out of fuel in the fuel tank, after the fuel filter or fuel prefilter is drained, or the element is replaced, bleed air from the fuel system.

4 M4EJ-01-025

1. Turn key switch (4) to ON position. The electric fuel pump will operate and purge air.

2. Start the engine. Check the fuel system for fuel leaks.

7-45

MAINTENANCE Replace Fuel Filter --- every 500 hours or 6 months (Only first time at 100 hours or 1 month)

1

Beware of fire. Fuel is flammable. Keep fuel d DANGER: away from fire hazards.

IMPORTANT:

Consult a professional waste collector or your nearest Kawasaki dealer about disposal of waste oil and filters.

Dispose waste oil and filters according to local regulations while giving consideration to earth’s ecology.

When replacing the filter, take care not to allow foreign matter such as dirt to enter the filter. Engine failure or damage may result.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

M4FG-07-031

2

2. Remove cartridge filter (2) from fuel filter (1) by using a filter wrench.

Catch fuel to protect the environment from being polluted.

M4GB-07-066

3. Put a thin film of fuel on the gasket of new filter (2).

4. Tighten spin on filter (2) by hand until the gasket contacts the seal face.

5. Tighten the filter 2/3 turn more using the filter wrench.

Take care that the spin on filter (2) is not over tightened, as the filter may be damaged.

6. Bleed Air from the Fuel System After replacing the fuel filter, bleed mixed air from the fuel system.

(Refer to “Bleed Air from the Fuel System”.)

7-46

MAINTENANCE Check Fuel Hoses --- every 10 hours (daily)/250 hours or 3 months Fuel leaks can lead to fires that may result d WARNING: in serious injury.

Escaping combustible fluid can cause fires. Check for kinked hoses, hoses that rub against each other, and fuel leaks.

Repair or replace loose or damaged hoses.

Never reinstall bent or damaged hoses.

According to the check points shown below, check hoses and lines for oil leaks and damage.

If any trouble is found, replace or retighten as instructed in the table.

1

Hose Interval (hours) Every 10 hours Every 250 hours

Check Points

Abnormalities

Remedies

Hose ends

Leak (1)

Retighten or replace

Hose ends Hose Hose fittings

Crack (4) Bend (5), Collapse (6) Corrosion (7)

Replace Replace Replace

1 M4GB-07-071

4 M4GB-07-072

5

M4GB-07-073

6

7 M4GB-07-074

7-47

MAINTENANCE F. Air Cleaner

1

2

Clean and Replace Air Cleaner Element Cleaning --- when indicator comes ON Replacement --- after cleaning 6 times (or every 1 year) Clean and Replace Air Cleaner Element 3

Wear goggles or safety glasses when using d CAUTION: compressed air [less than 0.2 MPa (2 kgf/cm²) (30 PSI)].

IMPORTANT:

M4FG-07-033

To clean the element, avoid bumping or striking element with other objects.

When cleaning/replacing the element, take care not to allow foreign matter such as dirt to enter the engine.

Air cleaner (2) is comprised of double elements, outer element (5) and inner element (6). Clean outer element (5). In case severely contaminated, remove inner element (6) and clean it in the same cleaning method as the outer element. When outer element has been replaced 6 times or when damaged replace inner element.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

4

4

M4FC-07-037

5

6

2. Loosen clip band (3) and remove dust cap (1). Clean out dust from inside the cap.

3. Clean outer element (5) by blowing compressed air [less than 0.2 MPa (2 kgf/cm²) (30 PSI)] from the inner side of the filter element outward. After cleaning is complete, be sure to check outer element (5) for any damage. If any damage is found, replace the element with a new one.

4. In case the air cleaner restriction indicator lights soon after cleaning outer element (5) even if the cleaning intervals are less than 6 times, replace both outer and inner elements with new ones.

5. Install dust cap (1) in the original position so that arrow marks (4) (n TOP n) point upward.

6. After cleaning the element, run the engine at low idle speed. Check that the indicator on the monitor does not come ON.

7-48

M4FG-07-034

MAINTENANCE G. Cooling System IMPORTANT:

Cylinder Liner

Use only long life coolant (LLC) described in the “Brand Names of recommended LLC” .

Use fresh water or normal tap water. Do not use river-water, well-water or fountain– water which would have an adverse effect to the engine and radiator so that the cylinder liner would become corroded.

Soft water makes a lot of bubbles.

fNOTE: The machine shipped from the factory is filled with

coolant mixed with LLC. In this case, the coolant is usable through the year. Change the coolant at the earliest specified interval.

Normal

Long Life Coolant (LLC)

Corrosion/Rust M4GB-07-156

Dilute LLC with coolant. LLC mixing ratio is 35 %.

When refilling long life coolant (LLC), use the same brand product and the same mixture ratio as already used in the machine.

Change long life coolant (LLC) every 1000 hours or 1 year whichever comes first.

Change coolant only after cleaning the cooling system.

7-49

MAINTENANCE Precautions for Handling Long Life Coolant (LLC) Long life coolant (LLC) is poisonous. d x WARNING: If ingested by mistake, induce vomiting and get emergency medical attention immediately. x If antifreeze is accidentally splashed into eyes, freely flush with water and get emergency medical attention. x When storing LLC, be sure to keep it in a clearly marked container with a tight lid. Always keep LLC out of the reach of children. x Be careful of fire hazards. LLC is specified as a dangerous substance in the fire protection law. x When disposing of LLC, be sure to comply with all local regulations.

Air tempera ture (°C)

Long-Life Coolant (LLC) Mixture ratio (%)

Long-Life Coolant (LLC) (L) (gal)

Soft Water (L) (gal)

-15 °C or higher (5 °F)

30

3.0 (0.8)

7.0 (1.8)

-20 °C or higher (-4 °F)

35*

3.5 (0.9)

6.5 (1.7)

-25 °C or higher (-13 °F)

40

4.0 (1.1)

6.0 (1.6)

-35 °C or higher (-31 °F)

50

5.0 (1.3)

5.0 (1.3)

Total Capacity: 10 L (2.6 gal)

fNOTE: *The LLC mixture ratio filled for the machines shipped from the factory is 35 %.

In case a machine destination is nominated as a cold weather district, the mixture ratio is increased to 50 %.

7-50

MAINTENANCE Check Coolant Level --- every 10 hours (daily)

1

Do not remove radiator cap (1) until the d WARNING: coolant temperature in the radiator has cooled.

Hot steam and coolant may spout out, possibly causing severe burns. After the coolant temperature cools, slowly loosen cap (1) to release the inside air pressure before removing cap (4).

Check the coolant level at reservoir tank (2).

The normal coolant level is between the FULL and LOW marks on the side surface of reservoir tank (2).

M4FG-07-035

In case no coolant is present in reservoir tank (2), add the coolant mixture via the cap hole on reservoir tank (2).

2

t 8IFO SFGJMMJOH MPOH MJGF DPPMBOU --$ VTF UIF TBNF CSBOE product and the same mixture ratio as already used in the machine. (35 % Concentration) t *G POMZ XBUFS JT SFGJMMFE UIF NJYUVSF SBUJP JO UIF MPOH MJGF coolant (LLC) is diluted so that anti-rust and antifreeze effect in the coolant will deteriorate, and it will cause corrosion.

7-51

FULL

LOW M4FG-07-036a

MAINTENANCE Check Fan Belt --- every 10 hours (daily) Check the fan belt for any troubles. If any cracks are found, replace the belt with a new one.

Check Fan Belt Tension --- every 250 hours or 3 months IMPORTANT: Loose fan belt may result in insufficient battery charging, engine overheating, as well as premature belt wear. An excessively tight belt, however, can damage both water pump and alternator bearings and fan belts.

2 1

Check fan belt (1) tension by depressing the midpoint between alternator pulley (2) and crank pulley (3) with the thumb. Normal deflection must be 7 to 9 mm (0.3 to 0.35 in) with a depression force of approximately 98 N (10 kgf ) (22 lbf ).

Adjust Fan Belt Tension --- every 500 hours or 6 months (or whenever slack is found) 1. Loosen alternator (4) mounting bolts (5) (2 used).

3

M4FG-07-038

4

5

2. Adjust belt tension by moving alternator (4) forward or backward.

3. Tighten mounting bolts (5) (2 used).

fNOTE: When a new belt is installed, be sure to readjust the

belt tension after operating the machine for 3 to 5 minutes at low idle speed to be sure that the new belt is correctly seated.

7-52

5

M4FG-07-037

MAINTENANCE Change Coolant --- every 1000 hours or 1 year

1

Do not remove radiator cap (1) until the d WARNING: coolant temperature in the radiator has cooled.

Hot steam an coolant may spout out, possibly causing severe burns. After the coolant temperature cools, slowly loosen cap (1) to release the inside air pressure before removing cap (4).

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Install the articulation lock bar to the front and rear of the frames following the procedures described on page 7-5.

M4FG-07-035

2

3. Remove radiator cap (1). Loosen the radiator drain cock (2). Open the drain hole located at the left bottom of the rear frame and drain plug (3) at the engine water jacket to drain coolant. Remove impurities such as scale at the same time.

M4FG-07-042

M4FG-07-039

3 M4FG-07-040

7-53

MAINTENANCE Clean Radiator and Oil Cooler --- every 100 hours or 1 month or if the core becomes clogged When using compressed air pressure d CAUTION: [less than 0.2 MPa (2 kgf/cm²) (30 PSI)], wear safety glasses or goggles.

IMPORTANT:

IMPORTANT:

If compressed air with the pressure of more than 0.2 MPa (2 kgf/cm²) (30 PSI) or with high delivery pressurized tap water is used for cleaning, damage to the radiator/oil cooler fins may result.

Keep the nozzle away from the core surface more than 500 mm.

If the machine is operated with radiator/oil cooler are clogged, damage to the engine or radiator may result.

In case dirt and/or dust sticks to the radiator (1) and oil cooler (2) cores, clean them with compressed air [less than 0.2 MPa (2 kgf/cm²) (30 PSI)] or tap water to prevent a reduction in cooling system performance.

7-54

2

1

M4FG-07-041

MAINTENANCE H. Electrical System *.1035"/5 t *NQSPQFS SBEJP DPNNVOJDBUJPO FRVJQNFOU and associated parts, and/or improper installation of radio communication equipment may effect the machine’s electronic parts, causing involuntary movement of the machine.

Also, improper installation of electrical equipment may cause unexpected machine failure and/or fire on the machine.

Be sure to consult your nearest Kawasaki dealer when installing radio communication equipment or additional electrical parts.

t /FWFS BUUFNQU UP EJTBTTFNCMF PS NPEJGZ the electrical/electronic components.

If replacement or modification of such components is required, contact your nearest Kawasaki dealer.

Check Monitor Function and All Other Instrument Operation --- every 10 hours (daily) Run the engine at low idle speed when checking the instruments.

The monitor indicates alarm, caution and confirmation status in red, orange, and normal operative condition in blue or green respectively.

Check the needle movement of each gauge and meter with the key switch ON. The needle shall be moved to the blue range when normal and to the red range when abnormal.

Refer to the “Operator’s Station” for more information.

7-55

M4FG-01-011

MAINTENANCE Check Work Lights --- every 10 hours (daily) If any burned-out lights are found, d CAUTION: immediately replace it with a new one.

Visually check that all work lights normally light and/or blink from the front and rear sides of the machine.

M4FGE-01-021

M4FGE-01-019

Check Horn, Backup Buzzer and Backup Light --- every 10 hours (daily) Before checking the horn and/or the d WARNING: backup buzzer, always apply the parking brake and clear all personnel from the machine’s vicinity.

The horn switch button is located at the steering wheel center.

Horns (1) are located at the left and right side of the front work light bracket.

Check that the backup alarm (2) sound and backup light (3) turns ON when moving the FNR lever to reverse (R) position.

Backup light (3) is located at the right side of the weight center. Backup buzzer (2) is located of the weight center.

1

3

1

M4FGE-01-021

2

M4FGE-01-019

7-56

MAINTENANCE Check Electrical Harnesses and Fuses --- every 50 hours If dirt or dust sticks to the wiring and d CAUTION: relays, it may result in a fire.

1

Check the electrical harness and terminals of the batteries, battery relays, starter motor and alternator for loose connections and/or short circuit (broken shield). Clean any dirt and dust.

If any burned mark or an abnormal smell is noticed on a harness, consult your nearest Kawasaki dealer.

M4FG-01-029

Check and Replace Fuse 1. If any electrical equipment becomes inoperable, first check the fuses in base machine fuse box (1) located on the back of the operator’s seat.

2. One each spare fuse for each respective fuse size is provided in the fuse box.

3. Finally, check slow blow fuses (2) (2 used) located in the left front of the engine room.

2

Slow blow fuses (2): 100 A (2 used) M4FG-01-048

7-57

MAINTENANCE Fuse Box No. 1 2 3 4 5

Ampere 10 10 15 5 5

6

15

7 8 9 10 11 12 13 14 15 16 17 18 19 20

15 10 10 10 10 30 15 10 − − − − 15

Corresponding Circuit HEAD LIGHT (LEFT) HEAD LIGHT (RIGHT) HEAD LIGHT (HI BEAM) CLEARANCE LIGHT (LEFT), TAIL LIGHT (RIGHT) CLEARANCE LIGHT (RIGHT), TAIL LIGHT (LEFT) HST [F], [R] SOLENOID, PARKING BRAKE SOLENOID, BACKUP LIGHT, BACKUP BUZZER, RELAY [1], RELAY [2] HORN, BRAKE LAMP ENGINE STOP SOLENOID, FUEL PUMP SAFETY RELAY, ALTERNATOR, ENGINE SPEED SENSOR, RELAY [3] BUCKET AUTO LEVELER PROXIMITY SWITCH, CONTROL VALVE DETENT (TILT) MONITOR HEAD LIGHT, CLEARANCE LIGHT, TAIL LIGHT HST CONTROLLER MONITOR BACKUP POWER SUPPLY OPTIONAL POWER OPTIONAL POWER OPTIONAL POWER NOT USED OPTIONAL POWER HAZARD LIGHT, FLASHER UNIT

M4FG-07-047

7-58

MAINTENANCE Battery Explosive gas is generated during use d WARNING: and/or charging of batteries. Keep sparks and Open flames away from batteries.

Do not continue to use or charge the battery when electrolyte is lower than the specified level.

Explosion of the battery may result.

Charge the batteries in a well ventilated location.

Diluted sulfuric acid used for electrolyte is strong enough to burn skin and eats holes in clothing and metal. Always be careful when handling the batteries.

- wear protective goggles - wear protective clothing IMPORTANT:

If the battery is used with the electrolyte level lower than the specified lower level, the battery may deteriorate quickly.

IMPORTANT:

Do not refill electrolyte more than the specified upper level. Electrolyte may spill, damaging painted surfaces and/or corroding other machine parts.

SA-032

fNOTE: In case electrolyte solution is filled above the

specified upper level line or beyond the bottom end of the sleeve, remove the excess electrolyte until the electrolyte level is down to the bottom end of the sleeve, by using a pipette. After neutralizing the removed electrolyte solution with sodium bicarbonate, flush it with plenty of water, otherwise, consult the battery manufacturer.

SA-036

Precautions for Handling Batteries

fNOTE: A battery terminal (with a red cover) located at the

center of the counterweight is the positive terminal.

t *G FMFDUSPMZUF TPMVUJPO TQJMMT PO ZPVS TLJO BOE PS DMPUIFT immediately flush the skin and/or clothes with water and then wash with soap and water.

If splashed in eyes, flush with water for approximately 15 minutes and seek immediate medical attention.

7-59

M4FG-07-042

MAINTENANCE t "WPJE VTJOH GJSF IB[BSET TVDI BT NBUDIFT MJHIUFST BOE tobacco near the batteries. Do not cause sparks fly. t $IFDL BOE TFSWJDF UIF CBUUFSJFT POMZ BGUFS TUPQQJOH UIF engine, turning the key switch OFF and removing the battery caps. t 8PSLJOH BSPVOE UIF CBUUFSZ JNNFEJBUFMZ BGUFS PQFSBUJPO may cause personal injury.

Wait for the battery to cool. t 8IFO UIF CBUUFSZ JT SFDIBSHFE GMBNNBCMF IZESPHFO gas is created. Remove the battery from the machine.

Recharge the battery after removing the caps in a well ventilated area. t 8IFO EJTDPOOFDUJOH UIF CBUUFSZ UFSNJOBMT GJSTU disconnect the ground line [minus (-)] side terminal.

When connecting the battery terminals, connect the ground line [minus (-)] side terminal last. If a piece of metal, such as a tool comes in contact with the battery plus (+) side terminal and the vehicle frame when both terminals are connected, the electrical system may shortcircuit, possibly creating a dangerous situation. t -PPTF UFSNJOBM NBZ DBVTF TQBSLT UP GMZ 4FDVSFMZ UJHIUFO the terminals.

7-60

MAINTENANCE In Case the Batteries Were Discharged

d x WARNING: Hydrogen gas is generated from batteries.

Incorrect handling of the batteries may cause fires and/or explosion. Keep smoked tobacco and/or open flame away from the batteries. x If a metal tool is placed across the battery terminals and a vehicle component such as the engine block, sparks will fly, possibly resulting in fire and/or explosion. x If electrolyte solution spills on your skin, scalding and/or blindness may be caused. Wear safety glasses, rubber gloves and a rubber apron whenever handling batteries. x If electrolyte solution spills on your skin, immediately flush the skin with plenty of water and then seek immediate medical attention. x Before checking the batteries, turn the key switch OFF to stop the engine and turn all switches OFF or neutral.

- wear protective goggles - wear protective clothing When the batteries are removed, level the d CAUTION: bucket to the ground. Apply the parking brake. Turn the key switch OFF to stop the engine.

Be careful not to place metal tools on the batteries.

To prevent sparks from flying, first disconnect the negative side (ground line) terminal. When connecting the batteries, connect the negative side terminal last.

When disposing of batteries, consult d CAUTION: the shop where you purchased the batteries or a professional recycler. Do not dispose of the battery in a way that harms the environment.

7-61

MAINTENANCE Method to Recharge the Removed Battery t 5IPSPVHIMZ SFBE BOE VOEFSTUBOE UIF PQFSBUJPO manual for the battery charger and follow the manual instructions. t 8IFO DIBSHJOH UIF CBUUFSZ JOEPPST WFOUJMBUF UIF BSFB Remove the battery caps to allow gas to be released. t 8IFO DIBSHJOH UIF CBUUFSZ LFFQ GJSF IB[BSET BXBZ from the battery. Do not allow a metal piece to come in contact with battery terminals. t "GUFS UIF CBUUFSZ JT DIBSHFE DMFBO CBUUFSZ UFSNJOBMT and coat the terminals with grease before installing the battery on the base machine.

Method to Replace with Charged Auxiliary Batteries t 0ODF UIF CBUUFSZ IBT CFFO GVMMZ EJTDIBSHFE UIF TFSWJDF life of the battery is shortened. Replace such batteries with new ones at the earliest opportunity. t $PSSFDUMZ BOE TFDVSFMZ DPOOFDU CBUUFSZ QMVT QPTU UP cable plus (+) terminal and battery minus (-) post to cable minus (-) terminal respectively.

7-62

MAINTENANCE Check Electrolyte Level --- every 100 hours or 1 month Check the electrolyte level at least once a month.

U.L

1. Park the machine on level ground and stop the engine.

2. Check the electrolyte solution level.

2.1 When checking the level from the battery side: Clean around the level check lines with a wet towel.

Do not use a dry towel. Static electricity may cause the battery gas to explode.

Check if the electrolyte solution level is between U.L (Upper Level) and L.L (Low level). In case the electrolyte solution level is lower than the middle level between the U.L and L.L, immediately refill with distilled water or commercial battery fluid.

L.L

M4FGE-07-067 Filler Port

Sleeve

After refilling, securely tighten the filler plug.

Be sure to refill with distilled water before recharging (operating the machine).

2.2 When impossible to check the level from the battery side or no level check mark is indicated on the side: After removing the filler plug from the top of the battery, check the electrolyte level by viewing through the filler port. It is difficult to judge the accurate electrolyte solution level in this case. Therefore, when the electrolyte solution level is flush with the U.L, the level is correct. Referring to the illustrations to the right, check the level. When the electrolyte solution level is lower than the bottom end of the sleeve, refill with distilled water or commercial battery fluid up to the bottom end of the sleeve.

Separator Top

U.L L.L M4GB-07-093

Proper Since the electrolyte solution surface touches the bottom end of the sleeve, the electrolyte surface is raised due to surface tension so that the electrode ends are shown curved.

M4GB-07-094 Lower When the electrolyte solution surface is below the bottom end of the sleeve, the electrode ends are shown straight.

M4GB-07-095

After refilling, securely tighten the filler plug.

Be sure to refill with distilled water before recharging (operating the machine).

2.3 When an indicator is available to check the level, use this indicator to determine the fluid level.

3. Always keep the area around the battery terminals clean to prevent battery from discharging. Check terminals for looseness and/or corrosion.

Check terminals for looseness and/or corrosion. Coat the terminals with grease or petroleum jelly to prevent corrosion build up.

7-63

M4GB-07-096

MAINTENANCE Check Electrolyte Specific Gravity --- every 250 hours or 3 months The electrolyte specific gravity varies depending on the electrolyte temperature. The specific gravity should be kept within the range shown below. Charge the battery if the specific gravity is below the limit.

Recommended range of specific gravity by electrolyte temperature 40 °C (104 °F) 20 °C (68 °F)

Fluid temp.

Working Range

0 °C (32 °F) –20 °C (–4 °F) –40 °C (–40 °F)

1.21

1.22

1.23

1.24

1.25

1.26

1.27

Specific gravity of battery fluid

fNOTE: Measure the electrolyte solution specific gravity

when the electrolyte temperature is equal to the atmospheric temperature. Do not check the electrolyte solution specific gravity immediately after operation as the correct value can not be obtained.

7-64

1.28

1.29

1.30

1.31

1.32

1.33 M104-07-054

MAINTENANCE I. Brake System Check Brake Oil Level --- every 10 hours (daily) or when the brake oil indicator comes ON If brake oil low level indicator (1) on d WARNING: the monitor comes ON, immediately stop machine 1

operation, check brake oil tank (2) level and the brake system. Do not continue to operate the machine with the brake oil level reduced, possibly resulting in personal injury or death.

M4FG-01-011

2

IMPORTANT:

When the oil level in brake oil tank (2) becomes lower than [MIN] level, brake oil low level indicator (1) on the monitor comes ON. Immediately stop the machine.

Check the brake system for any leaks, and then refill the specified brake oil up to the appropriate level.

IMPORTANT:

Refill brake oil with the same brand of oil as described in the “kind of oils”.

If oil other than those described in the “kind of oils” is used, malfunction or failure of the brake may result.

Automotive brake fluids will swell rubber parts and cause brake system failure.

Use the correct brake oil.

1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work.

2. Brake oil tank (2) is located at the left front of the engine room. When the brake oil level is correct, it should be between MAX and MIN marks on brake oil tank (2).

3. If the oil level is lower than MIN mark on brake oil tank (2), open cap (3) of brake oil tank (2) and refill specified brake oil up to the appropriate level.

After refilling, securely tighten the filler plug.

4. Check that brake oil low level indicator (1) on the monitor does not come ON before operating the machine.

7-65

M4FG-01-030

2

3

MAX MIN

M4EK-07I-002

MAINTENANCE Check Right and Left Brake Interlocking Performance --- every 10 hours (daily)

1

1

Put up a No Entrance notice 100 m d WARNING: (110 yd) ahead of the machine forward travel direction. Arrange a safety monitor person.

Do not allow dust and/or soil to d WARNING: accumulate in vicinity (3) of the brake pedal. The brake may lose traction.

While stepping on brake pedal (1), check the pedal movement, the brake performance and the play in the pedal stroke for any abnormality.

If dust and/or soil accumulate in vicinity of the brake pedal, remove the accumulated dust and/or soil.

3

3

M4FG-07-045

Check Brake Performance The machine must be stopped within 5 m (16’ 5” ft·in) range after the brake is applied while driving at the speed of 15 km/h (9.3 mph) on a flat dry paved surface road.

2

Check Play in Brake Pedal Stroke Measure the pedal stroke at pedal tip by pressing the pedal with your hand until you feel an intermittent feed back force from the pedal.

Correct play (2): Approx. 10 mm (0.4 in) If the play is outside the specified range, or abnormal pedal operation and/or performance is noticed, consult your nearest Kawasaki dealer.

Get the machine checked and repaired.

M4FG-07-046

7-66

MAINTENANCE Check Parking Brake Force --- every 10 hours (daily) Check the machine in a place where no d WARNING: one is present or ahead in the traveling direction.

1

Keep bystanders away from the machine.

Condition : Empty bucket Park the machine with no load applied on a 15 ° inclined dry surface slope. The machine must not move with the parking brake switch (1) ON. Should the machine move during inspection, consult your nearest Kawasaki dealer. Get the brake system checked and repaired.

M4FG-01-008

Check Brake Disc (Service and Parking) --- every 1000 hours or 1 year Wet disc type service brake and parking brake are mounted in the front axle.

Consult your nearest Kawasaki dealer for checking.

M4FG-06-005

Change Brake Oil --- every 1000 hours or 1 year Consult your nearest Kawasaki dealer for changing brake oil.

M4FG-01-030

7-67

MAINTENANCE J. Tire Check and Adjust Tire Pressure Check appearance --- every 10 hours (daily) Check tire pressure when appearance is questionable or each week (50 hrs.)

Adjust --- as necessary Secure the front and rear frames with the d WARNING: articulation lock bar and ring pins.

When inflating tires, stand behind the tire tread and use the self-attaching chuck.

Avoid welding near tires and never weld rims, which could potentially cause the tires to explode.

If the machine catches fire, tires may explode due to emission of heat if any sign of abnormality such as tire smoking, abnormal increase in tire temperature, or the air smells of rubber or tire bead burning is found.

IMPORTANT:

Always maintain the correct tire pressure.

Even if only one tread pattern has worn out, replace the tire with a new one. Before operating the machine, check the tires for any breaks, damage or foreign matter.

When replacing one tire, use a new tire having the same tread pattern, diameter and specification as the other tires.

Check Tire Pressure Pay attention not to allow tires to be d WARNING: used with excessively high or low pressure, possibly causing abnormal operation of the machine when traveling. In addition, cracks of the tires and cracks of the rims may result.

1. Measure air pressure when the tires are cool before operating the machine.

Standard Tire Size

Standard Air Pressure

17.5/65-20-10PR

240 kPa (2.4 kgf/cm²) (34 PSI)

2. Check tires for any damage and/or excessive wear.

7-68

SA-249

MAINTENANCE Check Tire for Damage --- every 10 hours (daily) If tire has external damaged such as a d WARNING: score, an accident due to puncture or burst of the tire may occur, possibly resulting in personal injury or death.

Check the external appearance of tires for any damage.

Check Wheel Bolt Torque --- every 500 hours or 6 months (Only first time at 50 hours) Be sure to check the wheel bolt torque by turning the bolt in the tightening direction.

Tightening Torque: 494 to 604 N·m (50.4 to 61.6 kgf·m) (364 to 445 ft·lb) Replace Tire Secure the front and rear frames with the d WARNING: articulation lock bar and pins.

IMPORTANT:

Allover height of the machine may change according to the type of tires installed.

Do not change the specifications of the registered machine.

1. Lower the bucket and lift arm to the ground. Apply the parking brake.

2. Secure the front and rear frames with the articulation lock bar and pins following the procedures described on page 7-6.

3. Loosen all wheel nuts one turn.

Note which way the tread pattern is facing.

4. After jacking up the machine, securely support the machine with blocks.

5. Remove the wheel nuts. Replace the tire.

1

6. With the tire raised off the ground, lightly tighten the wheel nuts in the order as illustrated to the right.

7. Lower the machine to the ground. Retighten the wheel bolts to the specified torque value in the order as illustrated to the right.

6

7

4

3

8

5 2

7-69

M4FG-07-032

MAINTENANCE Tire Sizes to Be Used

fNOTE: Consult with your nearest Kawasaki dealer about the optional tire patterns.

The machine may vibrate depending on tire pattern.

This is caused by resonance of the machine with the tire pattern, not by failure.

TIRE Standard Size Standard Tire Standard Air Pressure Optional

Bias

17.5/65-20-10PR

Bias

17.5/65-20-10PR L2

Bias Bias (Snow)

17.5/65-20-10PR L2 240 kPa (2.4 kgf/cm²) (34 PSI) 17.5/65-20-10PR 240 kPa (2.4 kgf/cm²) (34 PSI)

fNOTE: Regardless of tire patterns to be used, inflate the tire with the pressure shown above application instructions are below.

Adjust tire pressure conforming with the work mode the machine is engaged in.

Consult your nearest Kawasaki dealer for more detailed information. t %SJWJOH PO QVCMJD SPBET 4UBOEBSE QSFTTVSF t -PBEJOH FYDBWBUJPO PO OPSNBM HSPVOE TVSGBDF 4UBOEBSE or slightly higher than standard pressure t )FBWZ EVUZ FYDBWBUJPO )JHIFS QSFTTVSF JO UIF TUBOEBSE pressure range t 0QFSBUJPO PO TPGU PS TBOEZ UFSSBJO 4MJHIUMZ MPXFS UIBO standard pressure Tire Pressure Adjustment Range: 240 to 260 kPa (2.4 to 2.6 kgf/cm²) (34 to 37 PSI)

7-70

MAINTENANCE Tire Rotation Rotate tires when uneven or abnormal wear is recognized on either front or rear, or right and left tire. Tire rotation is recommended to achieve uniformity of wear on tires or equalization of tire service life.

Rotation Method

Correct

Incorrect

Install tire with no external damage such d WARNING: as scoring or abnormal wear.

Failure to do so may cause a puncture or tire blowout, possibly resulting in personal injury or death since tire load is increased when the machine is loaded or stopped when operated. x Switch tires only between the front and rear positions. Do not switch the tires between diagonal positions. x Align the tire rotation direction with the tire tread design pattern. The traction design pattern (optional) will affect not only economy of the tire but also safety of operation.

Front

M4EJ-07J-001

How to Check Wear Amount (Tread Design Groove Depth) IMPORTANT:

If the machine is operated with tires at either rear or front being extremely worn or different in type, construction, or size, the travel driving system such as axles or transmission will be adversely affected in their performance and/or usable life.

Avoid operating the machine under such conditions.

When replacing tires, be sure to use the same tires in type, construction and size on all four wheels. It is recommended to replace all four tires at the same time.

Measure the groove depth at position of 1/4 tread width [shown with X mark (1) in the figure].

Use limit of the groove depth shall be approx. 85 % of the new tire groove depth. In case extreme uneven wear or exposed treads (or wires if radical tires are used) are found, replace the tire even before reaching 85 %.

7-71

Tread Width

1

1/2

× ×

1/4

× × Groove Depth

× × 1/4 1/2 Tread Width M4EJ-07J-002

MAINTENANCE Removal and Installation of Tire Tire rim is a very heavy part so that d WARNING: removal and installation of tire is hazardous and difficult work. In addition, a crane to lift the tire is required when removing or installing the tire to the wheel. Consult your nearest Kawasaki dealer or professional tire sales shop for tire removal and installation work.

In case jacking up the machine is required, be sure to observe the following points. x Select dry, solid and level ground for work site. x Work in groups of more than two personnel. One person shall mainly engage in the repair work and others shall work as assistants and/or to ensure safety. x Do not use the bucket to raise the front wheels. x Do not raise the machine off the ground more than necessary. x Chock tires as required. x After the machine is raised off ground, be sure to block the machine using rigid supports. Never leave the machine supported only by jacks. x The rear wheels oscillate. Insert wooden blocks between the axle and the frame to stop oscillation. x When removing the wheel nuts, lift the wheel with a crane. The wheel nut remaining at the top position should be the last to be removed. x Refer to Check Wheel Bolt Torque for the wheel bolt tightening torque value.

7-72

MAINTENANCE Tire Wheel When a tire must be dismounted from the d WARNING: rim, ask a professional tire shop to do so.

Allow only an authorized tire shop to inflate a tire after the tire was installed onto the wheel.

Remove rust from the wheel. Severe rust may caused cracks, possibly resulting in the machine and/or personal accident. Rim cracks may be shown by development of rust.

7-73

MAINTENANCE K. Heater (Optional of Cab Vehicle) Check Heater for Damage --- every 6 months Check the heater mounting and hoses for any damage.

fNOTE: Heater is an optional of the cab vehicle.

When the cold season approaching, check the heater before it is actually required to be sure it is operable at any time.

When the heater is not used for a long period of time, use heater once a week to keep it operational.

M4FG-01-049

Check Heater Piping --- every 6 months If any water leak is found, repair or replace d CAUTION: the corresponding parts.

Check the heater piping for any abnormal deformation and/or damage.

If a pipe joint become contaminated, check the joint for water leaks.

M4FG-07-072

7-74

MAINTENANCE L. Miscellaneous Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear --- every 10 hours (daily) Check the bucket cutting edge for wear and tightness.

1

Replacement Guard against injury from flying pieces of d WARNING: metal.

3

Wear protection such as safety glasses and a hard hat when servicing the machine.

2

1. Raise the bucket to an appropriate height with the bucket bottom supported with blocks.

fNOTE: Raise the bucket so that the bucket bottom is level.

2. Remove bolts (2) and nuts (1). Remove cutting edge (3).

3. Install new cutting edge (3). If the reverse side of cutting edge is not worn much, use it again with the unused edge forward. If both sides are worn out, replace with a new one.

Tighten nuts (1) to specified torque.

Tightening torque: 245 to 300 N·m (24.9 to 30.6 kgf·m) (180 to 221 ft·lb) 4. Retighten the mounting nuts after several hours of operation.

7-75

M4FG-07-062

MAINTENANCE Check and Replace Seat Belt Check --- every 10 hours (daily) Replace --- every 3 years Examine seat belt tongue (1), buckle (2) and seat belt. Replace the damaged or worn parts. Check if the seat belt is correctly reeled in.

Replace the seat belt every 3 years, regardless of appearance.

1 2

M4FG-07-068

Check Canopy/Cab for Damage and Mounting Bolts for Tightness --- every 10 hours (daily) Check the appearance of the canopy resin roof and cab for any abnormal damage or deformation. Check mounting bolts (3) for tightness.

3

M4FG-07-063

Check Windshield Washer Fluid Level (Cab Vehicle) --- every 10 hours (daily) IMPORTANT: Keep all dirt, dust and other foreign materials out of the tank.

Use antifreeze washer fluid in cold weather district.

Check the fluid level. If necessary, add fluid.

M4FG-07-069

7-76

MAINTENANCE Check Play in Steering Wheel Stroke --- every 10 hours (daily) When the steering wheel is turned, d WARNING: clearance between the front and rear frames becomes narrower, possibly creating a pinchpoint hazard. Keep all personnel away from the articulation joint during inspection.

Check that play (1) in steering wheel stroke is correct.

In addition, check that the rear chassis contacts steering stopper when the steering wheel is fully turned and that the steering cylinders operate normally.

1. Start the engine.

Turn the parking brake switch ON. 2. Slightly lift the bucket above the ground.

Place the loader control lever lock in the LOCK position.

3. While running the engine at slow speed, slightly rotate the steering wheel knob both clockwise and counterclockwise. Measure the moving distance along the steering wheel circumference until both right and left steering cylinders start moving (check the movement of the bucket and/or tires).

Correct play (1): 20 to 40 mm (0.8 to 1.6 in)

fNOTE: If steering wheel play is excessively large or if steering wheel does not move smoothly, consult your nearest Kawasaki dealer for inspection.

7-77

1

M4EJ-07L-004

MAINTENANCE Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise --- every 10 hours (daily)

d

1

WARNING: Move the F-N-R lever to neutral. Apply the parking brake. After leveling and resting the bucket on the ground, set the wheel chock blocks.

While slowly stepping on accelerator pedal (1), check if the engine speed smoothly increases. Then, while slowly returning accelerator pedal (1), check if the engine speed smoothly decreases.

If dust and/or soil accumulate in vicinity of accelerator pedal (1), remove the accumulated dust and/or soil.

Exhaust Gas Color and Noise Check exhaust gas color and noise.

Ventilate the shop with fresh air when d DANGER: carrying out warm-up operation indoors. Failure to do so may cause inhalation of the exhaust gas, possibly resulting in death or severe injury.

IMPORTANT:

The engine mounted on this machine meets Tier 3 emission requirements. Modification of the engine inlet and exhaust system is prohibited by low.

Exhaust gas color is normally transparent or light blue.

Although exhaust gas becomes a light black color immediately after the engine is started or quickly accelerated, this symptom is not abnormal.

If the exhaust gas color becomes black, white, brown, or gray, check the engine oil level and the fuel supply system for abnormality. In addition, check that no abnormal noise is heard coming from the engine or the muffler.

7-78

M4FG-07-045

MAINTENANCE Check Outside and Inside Rearview Mirrors --- every 10 hours (daily) Check that inside rearview mirror (1) and outside rearview mirror (2) (on the cab vehicle) are facing in the correct direction and check for dirt or damage.

2

1

1

Cab Vehicle

Canopy Vehicle M4FGE-01-033

Check Steps and Handrails for Damage and Tightness --- every 10 hours (daily) Check steps (3) and handrails (4) for damage, tightness and contamination. If any slippery matter such as machine lubricants or mud sticks to the steps and/or handrails, remove such contaminants. If the steps and/or handrails become damaged or loosened so that getting on and off the machine is difficult, immediately tighten or replace.

4

4

3

M4FGE-01-052

Clean Engine Compartment and Hood --- every 10 hours (daily) Debris or chips accumulated in the engine d CAUTION: compartment or around the hood may come in contact with high temperature sections near the engine or hood, possibly causing fires.

Open the hood and check if debris and/or chips are accumulated in the engine compartment and/or the areas above the engine. Remove the accumulated debris and chips from under the hood.

M4FG-01-040

7-79

MAINTENANCE Check and Adjust Valve Clearance --- every 1000 hours or 1 year Consult your nearest Kawasaki dealer for inspection and repair.

Check Sound Absorbing Mat Around Engine --- every 1000 hours or 1 year If the sound absorbing mat in the engine d CAUTION: compartment loosens, the mat may come in contact with the high temperature sections of the engine, possibly resulting in fires.

Check if the sound absorbing mat around the engine has loosened. If any part of the mat is found loose, immediately contact your nearest Kawasaki dealer for repair.

M4EK-01-056

Check Fuel Injection Timing --- every 1000 hours (or 1 year whichever comes first) Consult your nearest Kawasaki dealer for inspection and repair.

7-80

MAINTENANCE Check Engine Compression Pressure --- every 1000 hours (or 1 year whichever comes first) Consult your nearest Kawasaki dealer for inspection and repair.

Check and Clean Starter and Alternator --- every 1000 hours or 1 year Consult your nearest Kawasaki dealer for inspection and repair.

Retighten Front Axle, Rear Axle and Transmission Mounting Nuts --- every 1000 hours (Only first time at 50 hours) Check the front/rear axle and the transmission support mounting nuts for tightness.

Tightening torque values of the front/rear axle and the transmission support mounting nuts Front axle mounting nuts (1), (2) (1) 207 to 253 N·m (21.1 to 25.8 kgf·m) (153 to 187 ft·lb) (2) 259 to 316 N·m (26.4 to 32.2 kgf·m) (191 to 233 ft·lb)

Rear Axle and Transmission mounting nuts 491 to 600 N·m (50.0 to 61.2 kgf·m) (362 to 443 ft·lb)

fNOTE: The front axle is mounted with double nuts such as lock nut (1) and nut (2).

7-81

MAINTENANCE Tightening and Retightening Torque of Nuts and Bolts Tighten or retighten nuts and bolts used on this machine in accordance with the torque values shown in the following table. Check nuts and bolts for tightness and verification that they are in place before and after operation. If any loose or missing nuts and/or bolts are found, retighten or supply replacement parts. The nuts and bolts other than those shown in the table below shall be tightened in accordance with the torque values shown in the table on page 7-83.

Use LOCTITE #262 and apply torque values shown with mark *.

Bolt Wrench Size Torque Values Quantity diameter mm (in) N·m (kgf·m) (ft·lb) Front axle mounting Lock nut 8 207 to 253 (21.1 to 25.8) (153 to 187) 1 18 27 (1.06) Nut 8 * 259 to 316 (26.4 to 32.2) (191 to 233) nut 2 Rear axle and transmission mounting nuts 20 4 30 (1.18) * 491 to 600 (50.0 to 61.2) (362 to 443) 3 Wheel rim mounting nuts 22 32 32 (1.26) 494 to 604 (50.4 to 61.6) (364 to 445) 4 Propeller shaft mounting bolt 10 16 17 (0.67) * 58 to 71 (5.9 to 7.2) (43 to 52) 5 HST motor mounting bolt 16 4 24 (0.94) 186 to 227 (19 to 23) (137 to 166) 6 HST Pump mounting bolt 18 4 27 (1.06) 265 to 314 (27 to 32) (195 to 231) Front side 12 8 19 (0.75) * 83 to 93 (8.5 to 9.5) (61 to 69) Engine mounting 7 bolt, Bracket Rear side 14 8 22 (0.87) * 122 to 149 (12.4 to 15.2) (90 to 110) 8 Engine mounting bolt, Rubber cushion 18 4 27 (1.06) 343 to 412 (34.9 to 42.0 ) (252 to 304) Muffler mounting Lock nut 4 20 to 24 (2.0 to 2.4) (14 to 17) 9 10 17 (0.67) Nut 4 44 to 54 (4.5 to 5.5) (33 to 40) nuts 10 Counterweight mounting bolt 20 4 30 (1.18) 423 to 460 (43.1 to 46.9) (312 to 339) Mounting nuts 24 1 36 (1.42) * 255 to 314 (26.0 to 32.0) (188 to 231) Retainer fixing nuts 12 4 19 (0.75) * 77 to 94 (7.9 to 9.6) (57 to 69) 11 Upper center pin Lock nuts 12 1 19 (0.75) * 77 to 94 (7.9 to 9.6) (57 to 69) 12 Lower center pin locking 12 1 19 (0.75) 77 to 94 (7.9 to 9.6) (57 to 69) 13 Loader front pin locking 12 13 19 (0.75) 77 to 94 (7.9 to 9.6) (57 to 69) 14 Steering cylinder pin locking 12 4 19 (0.75) 77 to 94 (7.9 to 9.6) (57 to 69) 19/17 77 to 94 (7.9 to 9.6) (57 to 69)/ 15 Radiator frame mounting bolt 12/10 4/8 (0.75/0.67) 44 to 54 (4.5 to 5.5) (33 to 40) 16 Cutting edge mounting nut 16 7 24 (0.94) 245 to 300 (24.9 to 30.6) (180 to 221) 17 Canopy mounting bolt 16 6 24 (0.94) 188 to 229 (19.2 to 23.4) (139 to 169) 18 Cab rubber cushion 16 10 24 (0.94) 188 to 229 (19.2 to 23.4) (139 to 169) Tightening location

7-82

MAINTENANCE Nut and Bolt Tightening Torque *.1035"/5 t 3FNPWF TPJM EVTU BOE PS EJSU GSPN UIF OVU and bolt thread surfaces before tightening.

t 5JHIUFO OVUT BOE CPMUT UP TQFDJGJDBUJPOT If tightened with excessively low or high torque, loss or breakage of nuts and/or bolts may result.

When checking the machine parts, if loose nuts and bolts are found, retighten them to the torque values shown in the table below.

Tightening Torque Hexagon head bolt Bolt M4FG-07-073 M4GB-07-122 M4GB-07-123 Wrench Dia. Standard size Standard Standard mm torque Allowable torque range torque Allowable torque range torque Allowable torque range mm (in) kgf·m kgf·m kgf·m N·m N·m kgf·m N·m N·m kgf·m N·m N·m kgf·m (ft·lb) (ft·lb) (ft·lb) 4

1.27

5

2.55

6

4.31

8

10.2

10

19.7

12

34.5

14

54.3

16

83.9

18

116

20

168

22

221

24

280

27

346

30

475

0.13 (1) 0.26 (2) 0.44 (3) 1.04 (8) 2.01 (15) 3.52 (25) 5.54 (40) 8.56 (62) 11.8 (85) 17.1 (124) 22.5 (163) 28.6 (207) 35.3 (255) 48.4 (350)

0.43 0.33 3.82 to 4.61 0.39 to 0.47 2.94 to 3.53 0.30 to 0.36 4.22 (3) (2) 0.84 0.64 7.45 to 9.02 0.76 to 0.92 5.69 to 6.86 0.58 to 0.70 8.24 0.23 to 0.29 6.28 (6) (5) 1.45 1.11 12.8 to 15.7 1.31 to 1.60 9.80 to 12.0 1.00 to 1.22 1.45 0.40 to 0.48 10.9 (10) (8) 3.38 2.59 29.8 to 36.5 3.04 to 3.72 22.8 to 27.9 2.33 to 2.85 33.1 0.94 to 1.14 25.4 (24) (19) 6.55 5.01 57.9 to 70.7 5.90 to 7.21 44.2 to 54.0 4.51 to 5.51 64.2 1.81 to 2.21 49.1 (47) (36) 11.4 8.75 101 to 123 10.3 to 12.5 77.2 to 94.4 7.88 to 9.63 112 3.17 to 3.87 85.8 (82) (63) 18.0 13.8 159 to 194 16.2 to 19.8 122 to 149 12.4 to 15.2 177 4.99 to 6.09 135 (130) (100) 27.8 21.3 245 to 300 25.0 to 30.6 188 to 229 19.2 to 23.4 273 7.70 to 9.42 209 (201) (154) 29.3 38.3 10.6 to 13.0 287 338 to 413 34.5 to 42.1 259 to 316 26.4 to 32.2 376 (277) (212) 55.6 42.6 490 to 600 50.0 to 61.2 376 to 460 38.3 to 46.9 545 15.4 to 18.8 418 (402) (308) 73.2 56.0 646 to 789 65.9 to 80.5 494 to 604 50.4 to 61.6 718 20.3 to 24.8 549 (529) (405) 93.0 71.3 821 to 1000 83.7 to 102 630 to 769 64.2 to 78.4 912 25.7 to 31.5 699 (673) (516) 115 87.9 1020 to 1245 104 to 127 775 to 948 79.0 to 96.7 1128 31.8 to 38.8 862 (832) (636) 157 121 1383 to 1697 141 to 173 1069 to 1304 109 to 133 1540 43.6 to 53.2 1187 (1135) (875)

1.18 to 1.37 0.12 to 0.14 3.24 2.26 to 2.84 3.92 to 4.71 9.22 to 11.2 17.8 to 21.7 31.1 to 38.0 48.9 to 59.7 75.5 to 92.4 104 to 127 151 to 184 199 to 243 252 to 309 312 to 380 428 to 522

* Tightening torque of strength criteria 10.9 is used for socket bolts.

7-83

7 (0.28) 8 (0.31) 10 (0.39) 13 (0.51) 17 (0.67) 19 (0.75) 22 (0.87) 24 (0.94 ) 27 (1.06) 30 (1.18) 32 (1.26) 36 (1.42) 41 (1.61) 46 (1.81)

MAINTENANCE 1. Front axle mounting nut Bolt diameter Quantity

18 16

M4FG-07-050

2. Rear Axle and Transmission mounting nuts Bolt diameter Quantity

16 4

M4FG-07-051

3. Wheel rim mounting nuts Bolt diameter Quantity

18 32

M4FG-07-032

7-84

MAINTENANCE 4. Propeller shaft mounting bolt Bolt diameter Quantity

12 16

M4FG-07-052

M4FG-07-070

5. HST motor mounting bolt Bolt diameter Quantity

16 4

M4FG-07-053

6. HST Pump mounting bolt Bolt diameter Quantity

18 4

M4FG-07-054

7-85

MAINTENANCE 7. Engine mounting bolt, Bracket Bolt diameter Quantity

Front side 12 8

Rear side 14 8

M4FG-07-071

8. Engine mounting bolt, Rubber cushion Bolt diameter Quantity

18 4

M4FG-07-071

9. Muffler mounting nuts Bolt diameter Quantity

10 8

M4FG-07-056

7-86

MAINTENANCE 10. Counterweight mounting bolt Bolt diameter Quantity

20 4

M4FGE-01-019

11. Upper center pin Bolt diameter Quantity

Mounting nuts 24 1

Bolt diameter Quantity

Lock nuts 12 1

Retainer fixing nuts 12 4

M4FG-07-057

M4FG-07-058

12. Lower center pin locking Bolt diameter Quantity

12 1

M4FG-07-057

7-87

MAINTENANCE 13. Loader front pin locking Bolt diameter Quantity

12 13

M4FG-07-059

14. Steering cylinder pin locking Bolt diameter Quantity

10 4

M4FG-07-060

15. Radiator frame mounting bolt Bolt diameter Quantity

10 4

M4FG-07-061

7-88

MAINTENANCE 16. Cutting edge mounting nut Bolt diameter Quantity

16 7

M4FG-07-062

17. Canopy mounting bolt Bolt diameter Quantity

16 6

M4FG-07-063

18. Cab rubber cushion Bolt diameter Quantity

16 6

M4FG-07-064

7-89

MAINTENANCE MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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7-90

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions

d WARNING:

t #FGPSF PQFSBUJOH UIF NBDIJOF JO B SJWFS DIFDL the riverbed conditions in advance. t "WPJE ESJWJOH UIF NBDIJOF JOUP B SJWFS XIFSF the riverbed is steep and deep or the stream is rapid.

Operating Conditions Precautions for Maintenance Muddy Soil, Rainy or Before Operation : Check tightness of plugs and all drain cocks.

Snowy Weather After Operation : Clean the machine and check for cracks and damage. Check for loose or missing bolts and nuts. Lubricate all necessary parts.

If the machine should be submerged in water, water may get into the brake device (like the parking brake), resulting in poor braking performance.

Watch out when starting/stopping the machine.

Near the Ocean Before Operation : Check tightness of plugs and all drain cocks.

After Operation : Thoroughly clean the machine with fresh water to wash off salt. Service electrical equipment often to prevent corrosion.

Dusty Air Cleaner : Clean the element regularly at shorter service intervals. : Clean the oil cooler screen to prevent clogging of the radiator.

Atmosphere Radiator : Clean the filter element and strainer regularly at shorter service intervals.

Fuel System : Clean them regularly, in particular, the commutator surface of the alternator Electrical and starter.

Equipment Rocky Ground Chassis : Check for damage on tires, for loose, cracked, worn, and damaged bolts and Front Attachment : nuts.

Standard attachment may be damaged when digging rocky ground.

Use a heavy duty bucket.

9-1

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Precautions for Maintenance During Cold Weather Season Before the atmospheric temperature lowers below -0 °C (32 °F), note the following points. t Water and oil in the machine will freeze. t Road surfaces will freeze so that tires may slip.

Keeping the above points in mind, follow the advisement below: 1. Refill fluids such as water and lubricants prior to operation.

2. Mix LLC (long life coolant) in the radiator (coolant). When this machine is shipped from the factory, LLC is supplied.

3. Change the engine oil in the engine crankcase to cold weather type oil.

4. Use fuel (diesel-#1) of an antifreeze type. To prevent condensation in the fuel tank, fully refill the fuel tank with #1 diesel fuel after each shift.

5. If the electrolyte solution in the battery case freezes, damage to the battery case may result. Maintain the batteries at fully charged condition. After completing work, turn all lights OFF. Run cooling cycle for five minutes.

Another option is to, dismount the batteries and store them in a warm place. When it is possible to measure and adjust the specific gravity of the electrolyte solution, increase the specific gravity of the electrolyte up to 1.280. Do not increase more than 1.280.

6. Use anti-freeze type washer fluid. After taking the measures as recommended above, start operation of the machine.

d WARNING: Ventilate the shop with fresh air when

carrying out warm-up operation indoor. Failure to do so may cause intoxication by exhaust gas, possibly resulting in death or serious injury.

7. After preheating the engine, start the engine. Perform warm-up.

9-2

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 8. After warming up the engine, cycle the front attachment system. Slowly operate the loader control lever to move the cylinders full stroke several times.

9. Road surfaces covered with snow, especially when snow has been compacted, will be frozen. Use tire chains on four wheels.

10. Take anti-freeze measures after completing operation. t $PWFS UIF LFZIPMF CZ TUJDLJOH B UBQF PO t 3VCCFS QBSUT TVDI BT XJQFST NBZ GSFF[F ,FFQ PUIFS QBSUT away from the rubber parts. Thoroughly heat cab prior to operating machine. t 3FNPWF QBDLFE TOPX GSPN BSPVOE UIF VOEFSDBSSJBHF BOE inside the machine with a bar or brush. Be careful not to damage electrical wiring. t *O DBTF JU JT JNQPTTJCMF UP TUPSF UIF NBDIJOF JOEPPST QBSL the machine on a level dry surface and cover overall the machine with a large machine cover.

9-3

MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO .................................................................................................................................................................................................................................................... .................................................................................................................................................................................................................................................... .................................................................................................................................................................................................................................................... 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9-4

STORAGE Storing Machine In case lubrication is performed indoors, WARNING: open windows and doors to maintain good air ventilation to prevent asphyxiation.

Apply the parking brake while storing.

If the machine is to be stored for more than one month, observe the following precautions so that its function will not be impaired during storage.

Precaution Items for Long-Time Storage Wash Machine Supply Oil and Grease

Battery Coolant

Prevention of Dust and Moisture Tools Lubrication No-load Operation at a Slow Speed for Several Minutes IMPORTANT:

Contents of Work Wash the machine and dry to remove mud and/or dust.

Check for low level/contamination of lubricating oil.

Grease all joints.

Apply a thin coat of oil to parts susceptible to rust (i.e. cylinder rods etc.)

Remove and fully charge the battery, then store it in a warm place.

Supply a rust preventive agent . If there is a possibility of freezing, also use an antifreeze solution or fully drain the coolant. In this case, be sure to attach a “No Water in Radiator” sign in the operator’s cab.

Also, clean and dry the radiator thoroughly.

Store the machine in a dry garage and cover it.

Inspect and repair, then store.

If the oil films of the parts are broken and parts are rusted, they will cause damage when operated. To prevent this, operate the machine at least once a month to lubricate the parts.

At this time, check the coolant and lubrication oil levels.

Operating the machine without lubrication operation may cause the engine to seize or be damaged and hydraulic system to be damaged.

NOTE Lubrication operation means that a series of

operations such as drive, and loader front operation are repeated a few times after performing the warm-up operation. Before operating the loader front attachment and steering wheel, remove rust prevention oil coated on the hydraulic cylinder rods.

ALL electronic settings, such as radio station settings and HVAC system controller settings must be reset due to battery removal.

10-1

STORAGE Removing Machine from Storage In case lubrication is performed indoors, d WARNING: open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored and not run. Check all lubricants before operating the machine after bring stored. Apply the parking brake while stored.

IMPORTANT:

Lubricants will deteriorate during storage of the machine. Thoroughly check coolant, lubricants and adequately perform lubrication operation before resuming operation. Avoid quick operation. Failure to do so may cause damage to the engine, hydraulic equipment, transmission, axle, etc. due to insufficient lubrication or coolant.

1. Remove grease from the cylinder rods if coated.

2. Adjust alternator and fan belt tension.

3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels.

4. Start the engine.

Run the engine at half speed for several minutes until operating temperature is reached before full load operation.

5. Cycle all hydraulic functions several times, being careful not to fully stroke cylinders.

6. Carefully check all systems before operating the machine at full load.

fNOTE: When the machine has been stored for a long time,

be sure to perform the following steps as well: (a) Check condition of all hoses and connections. (b) Warm up the engine. (c) Stop the engine. (d) Install new fuel filters. Replace the engine oil filter and fill the engine oil to the full mark on the oil level dipstick.

Before operating, check the machine in accordance with the descriptions on “Check Before Starting” on page 3-1 and warm-up.

10-2

TROUBLESHOOTING Troubleshooting If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary measures to prevent the reoccurrence of the same trouble. In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest Kawasaki dealer. Never attempt to adjust, disassemble, or repair the hydraulic and/or electrical/electronic parts/components.

Engine Consult the nearest Kawasaki dealer for the engine troubleshooting.

Engine Auxiliaries Problem Batteries will not charge.

Batteries discharge quickly after being charged.

Coolant temperature is too high.

Cause Broken battery separator Faulty regulator Faulty ground line Faulty alternator Shorted cable Shorted battery separator Increased sediment in battery Low coolant level Loose engine fan V-belt Damaged rubber hose Faulty thermostat Faulty coolant temperature gauge Cooling system passages dirty Radiator core or oil cooler core plugged Radiator screen plugged

Items with * mark: Consult your nearest Kawasaki dealer.

11-1

Solution Replace * Adjust or replace * Repair * Repair or replace * Repair or replace * Replace * Replace Add * Adjust * Replace * Replace * Replace Flush cooling system Clean radiator and oil cooler Clean screen

TROUBLESHOOTING Engine does not Start Symptom The starter does not turn.

Although the starter turns, the engine does not start.

Engine speed does not increase.

Cause Reduced battery voltage High resistance in the starter circuit

Faulty key switch Damaged wire harness Faulty battery relay Blown slow blow fuse link The F-N-R lever is in either the forward or reverse position.

Faulty starter Use of poor quality fuel, insufficient fuel, lack of fuel Faulty glow plug Air mixed in the fuel supply line Faulty injection pump or nozzle Reduced compression pressure The accelerator pedal function is abnormal.

Although the engine cranks, running Deteriorated engine oil speed is low and easy to stall.

Contaminated injection nozzle Clogged fuel filter Clogged fuel pre-filter Air mixed in the fuel supply line Poor fuel quality

Solution Charge the batteries. Replace. * Clean and/or retighten the battery terminals and starter terminals * Replace * Repair or replace * Replace * Replace Return to neutral. * Repair or replace Change fuel. Refill tank with good quality fuel. * Replace glow plug Bleed air * Repair or replace * Repair or replace Replace accelerator pedal or parts.

Change engine oil. * Replace Replace Replace Bleed air Replace

Items with * mark: Consult your nearest Kawasaki dealer.

Hydraulic Control Lever Symptom Hard to move Does not move smoothly Does not return to neutral The lever is tilted in the neutral position due to increase in play.

The lever is not held with magnetic detent.

Cause Rusted joint Worn pusher Worn pusher Faulty control valve Faulty control valve Worn joint Faulty control valve Faulty magnetic solenoid Faulty sensor

Items with * mark: Consult your nearest Kawasaki dealer.

11-2

Solution * Lubricate or repair * Replace * Repair or replace * Replace * Replace * Repair or replace * Replace * Replace * Replace

TROUBLESHOOTING Hydraulic System After the machine has been kept stored for a long time, air in the oil may be separated and accumulate in the upper section in the cylinder, causing slow response time in operation or reducing cylinder power. In case these symptoms appear, repeatedly operate all actuators several times.

Problem Front attachment is inoperable (Hydraulic pump noise level increases).

All actuators have no power.

Only one actuator is inoperable.

Only one cylinder is inoperable or has no power.

Oil overheats Oil leak from low pressure hose

Cause Faulty hydraulic pump Lack of hydraulic oil Broken suction pipe and/or hose Malfunction due to worn hydraulic pump Decrease in set pressure of main relief valve in control valve Lack of hydraulic oil Trapped foreign matter in hydraulic oil tank suction filter Aeration in suction side Broken control valve spool Trapped foreign matter in valve spool Broken pipe and/or hose Loose pipe line joint Broken O-ring at pipe line joint Broken actuator Broken oil seal in cylinder Oil leak due to damage to cylinder rod Clogged oil cooler Weak tension of engine fan V-belt Loose clamp Faulty suction manifold

Items with * mark: Consult your nearest Kawasaki dealer.

11-3

Solution * Repair, Replace Refill * Repair, Replace * Replace * Clean and Adjust Refill Clean or Replace Retighten * Replace * Repair, Replace * Repair, Replace Retighten * Replace * Repair, Replace * Repair, Replace * Repair, Replace Clean or Replace Adjust Retighten * Repair, Replace

TROUBLESHOOTING Drive Function Steering Wheel Problem Steering wheel is heavy to operate.

Steering wheel turns in unexpected direction.

Cause Faulty hydraulic pump Faulty steering device Relief valve set pressure reduction Faulty steering column Low tire air pressure Faulty steering device

Solution * Repair, Replace * Repair, Replace * Adjust * Repair, Replace * Inflate * Repair, Replace

Items with * mark: Consult your nearest Kawasaki dealer.

Accelerator Pedal Problem Accelerator pedal is heavy to operate.

Accelerator pedal play is excessive.

Rusted joint

Cause

Solution * Lubricate, Repair

Worn joint

* Replace, Repair

Items with * mark: Consult your nearest Kawasaki dealer.

Parking Brake Problem Parking brake The brake does not release (sticking, dragging).

Parking brake Does not work properly.

Cause Oil leak due to failure of D-ring on the parking brake piston Faulty brake disk Damaged disk brake spring Faulty disk brake Scored or seized piston or worn disk

Solution * Repair or replace * Repair or replace * Replace * Replace * Repair or replace

Items with * mark: Consult your nearest Kawasaki dealer.

Service Brake Problem Service brake does not work properly.

Service brake is dragging.

Service brake fluid loss.

Cause Solution Malfunction of brake master cylinder * Repair or replace Oil leak from brake line, Air mixing * Repair. Bleed air Malfunction of brake master cylinder * Repair or replace Faulty brake pedal * Repair or replace Corrosion of brake pedal parts Clean and lubricate Pebbles in area of brake pedals Remove-clean area Oil leak from brake line and/or hose connector * Retighten or repair Oil leak due to brake piston seal (Inside of * Repair front axle)

Items with * mark: Consult your nearest Kawasaki dealer.

11-4

TROUBLESHOOTING Transmission Problem Transmission is noisy.

Cause Lack or deterioration of gear oil Worn out transmission parts Broken gear or bearing

Solution Refill, replace * Repair, Replace * Repair, Replace

Items with * mark: Consult your nearest Kawasaki dealer.

Propeller Shaft Problem Propeller shaft vibrates.

Propeller shaft is noisy.

Cause Bent propeller shaft Loosened parts, Loss of balance Excessively worn spline Worn or seized spider bearing Loosened parts Insufficient greasing

Solution * Replace * Retighten, Adjust or Replace * Replace * Replace * Retighten Grease

Items with * mark: Consult your nearest Kawasaki dealer.

Front and/or Rear Axle Problem Front and/or rear axle is noisy.

Front and/or rear axle does not transmit power.

Cause Worn or broken gears Lack or deterioration of gear oil Worn bearings, Excess play Excess play on shaft spline Broken axle Broken gears

Items with * mark: Consult your nearest Kawasaki dealer.

Others The machine may have a noise, excessive vibration, and abnormal smell when any trouble occurs. Always beware of the machine conditions during operation.

11-5

Solution * Replace Refill, Replace * Replace * Repair, Replace * Repair * Repair

TROUBLESHOOTING MEMO .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. .................................................................................................................................................................................................. 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11-6

SPECIFICATIONS Specifications

M4FGE-12-001

Model Bucket Type Bucket Capacity (heaped) Operating Weight (Canopy/Cab) Static Tipping Load Straight Full 40 degree turn Engine A: Overall Length B: Overall Width (Bucket) C: Overall Height (Canopy/Cab) D: Wheel Base E: Tread F: Ground Clearance G: Bucket Hinge Height H: Dumping Clearance (45 °) I: Dumping Reach (45 °) R1: Minimum Rotation Radius Outer Ring Center R2: Minimum Rotation Radius End of Bucket Travel Speed Forward/Reverse Transmission Speeds (F/R) Articulation Angle (Left/Right) deg Tire Size

—

45ZV-2 Pin Type

mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in)

Coupler Type 0.9 (1.17) 5245/5405 (11570/11920) 5380/5540 (11860/12220) 4260 (9390) 3695 (8150) 3620 (7980) 3120 (6880) Kubota V3307-DI-T 45.6 kW/2200 rpm (62 PS/2200 rpm) (61 HP/2200 rpm) 5220 (17’ 2”) 5380 (17’ 8”) 2860 (6’ 3”) 2790/2850 (9’ 2”/9’ 4”) 2200 (7’ 3”) 1470 (4’ 10”) 340 (1’ 1”) 3160 (10’ 4”) 2500 (8’ 2”) 2390 (7’ 10”) 880 (2’ 11”) 990 (3’ 3”)

mm (ft·in)

3795 (12’ 5”)

m³ (yd³) kg (lb) kgf (lbf ) kgf (lbf ) —

mm (ft·in)

4475 (14’ 8”)

km/h (mph) — (°) —

4540 (14’ 11”) 34/34 (21/21) 2/2 40 17.5/65-20-10PR

fNOTE: The specifications can change at any time.

12-1

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12-2

OPTIONAL ATTACHMENTS Operating Quick Coupler (Mechanical Type) During work, keep personnel away from d WARNING: the machine.

The quick coupler is a system with which a front attachment work tool such as a bucket can be easily replaced with other work tool.

When installing an additionally purchased bucket or your own bucket with the quick coupler, the bucket may not be fit on due to misaligned stopper. Contact your nearest Kawasaki dealer for adjustment.

20 cm

M4EK-13-001 Install Remove

Removal

2

1

Apply the parking brake before leaving d WARNING: the machine.

Disconnect all hydraulic hoses routed to the attachment cylinders except for the bucket and lift arm cylinders. (Refer to page 13-6 for “Disconnection/Connection Hydraulic Hoses”.)

If possible, place the bucket (attachment) to be removed on a pallet.

1. Raise the bucket (attachment) level, about 20 cm (8 in) above the pallet.

4

3

3

M4EK-13-002

3

2. Remove quick coupler lock pin (1). Pull up lever (2) to the removal position and remove coupler pins (3) (right and left).

3. Check that coupler pins (3) (right and left) are removed.

Install lock pin (1) in hole (4) to fix lock lever (2) in position.

4. Place the bucket (attachment) as close to the rear of the pallet as possible so that the quick coupler can be easily removed.

5. While tilting the bucket forward, slightly lower the arm.

The bucket (attachment) is able to be removed from the quick coupler. Take your time and proceed with care.

13-1

M4EK-13-003

OPTIONAL ATTACHMENTS Installation Be sure to complete installation work only d WARNING: after checking that coupler pins (5) (both right and

d d

left) have been completely installed and locked in position.

Crushing Hazard: Failure to fully engage the quick coupler lock can lead to attachment loss, and injury or death.

Be sure it is fully engaged in the locked position.

WARNING: Apply the parking brake before leaving the machine.

IMPORTANT:

5

5

6

6

M4EJ-13-004

Apply grease onto coupler pins (5) to prevent seizing and rust before installing the attachment.

7

1. After checking that coupler pins (5) have been removed.

Slowly approach the machine to the bucket (attachment) hooks (6) until the hooks are inserted into the quick coupler.

M4EK-13-004

2. Slightly raise lift arm (7) to slowly allow the bucket (attachment) to tilt backward until stopper (8a) on the bucket comes in contact with quick coupler stopper (8b).

3. Remove lock pin (9). Turn lever (10) to the installation position and install coupler pins (5) (right and left).

4. After checking that coupler pins (5) (right and left) have been securely installed, set lock pin (9) in the original position.

8a

8b

If installed attachment uses additional hydraulic cylinder other than the bucket or the lift arm, connect the hydraulic hoses to the attachment.

M4EK-13-005 Install Remove

10

9 6

5

5

M4EK-13-002

13-2

OPTIONAL ATTACHMENTS Operating Quick Coupler (Hydraulic Type) During work, keep other persons away d WARNING: from the machine.

The quick coupler is a system with which a front attachment work tool such as a bucket can be easily replaced with other work tool.

When installing an additionally purchased bucket or your own bucket with the quick coupler, the bucket may not be fit on due to misaligned stopper. Contact your nearest Kawasaki dealer for adjustment.

Removal Apply the parking brake before leaving d WARNING: the machine.

Disconnect all hydraulic hoses routed to the attachment cylinders except for the bucket and lift arm cylinders.

Connect the removed hydraulic hoses to the coupler. (Refer to page 13-6 for “Disconnection/Connection Hydraulic Hoses”.)

If possible, place the bucket (attachment) to be removed on a pallet.

20 cm (8 in)

M4EK-13-001

1. Raise the bucket (attachment) level about 20 cm (8 in) above the pallet.

1

2

3

2. Check that the hydraulic hoses (2, 3) from the machine are connected to coupler cylinder (1) .

fNOTE: Connecting hydraulic hoses (2, 3) from the machine with coupler cylinder (1) of the quick coupler allows operator to install/remove the attachment by controlling auxiliary control lever (5).

4

4

M4EK-PLOW-065

Remove

5

Install

M4EK-PLOW-063

13-3

OPTIONAL ATTACHMENTS 3. Move auxiliary control lever (5) forward (Remove) to remove coupler cylinder pins (4) (left and right).

Remove

4. Slightly lower the arm and tilt the bucket forward, the bucket (attachment) is able to be removed from the quick coupler. Take your time and proceed with care.

5

Install

M4EK-PLOW-063

4

M4EK-13-003

13-4

OPTIONAL ATTACHMENTS Installation Be sure to complete installation work only d WARNING: after checking that coupler pins (6) (both right and

d d

6

6

left) have been completely installed and locked in position.

Crushing Hazard: Failure to fully engage the quick coupler lock can lead to attachment loss, and injury or death.

Be sure it is fully engaged in the locked position.

WARNING: Apply the parking brake before leaving the machine.

IMPORTANT:

M4EK-PLOW-066

8b

Apply grease onto coupler pins (6) to prevent seizing and rust before installing the attachment.

7

1. After checking that coupler pins (6) have been removed.

Slowly approach the machine to the bucket (attachment) hooks until the hooks are inserted into the quick coupler.

IMPORTANT:

8a

Take care not to pinch hydraulic hoses between the quick coupler and the attachment.

M4EK-13-004

2. Slightly raise lift arm (7) to slowly allow the bucket (attachment) to tilt backward until stopper (8a) on the bucket comes in contact with quick coupler stopper (8b).

3. Move auxiliary control lever (9) reverse (Install) to install coupler cylinder pins (6) (left and right).

fNOTE: Disconnect hydraulic hoses from the coupler cylinder

of the quick coupler, connect them to the attachment cylinder.

M4EK-13-005

Remove

9

Install

M4EK-PLOW-063

13-5

OPTIONAL ATTACHMENTS Disconnecting/Connecting Hydraulic Hose Quick Connectors When activating an attachment with a hydraulic cylinder other than the lift arm cylinder or bucket cylinder using the machine hydraulic pressure oil, hydraulic quick connectors must be connected or disconnected. At this time, connect or disconnect the hydraulic hoses following the procedures below.

Procedures

Plug (Male)

Sleeve (Female)

When connecting hoses, insert the plug while pulling the sleeve. When the sleeve is returned, the hose connectors are automatically locked and connected.

Before starting to work, apply the parking d CAUTION: brake and stop the engine. Operate the attachment

M4GB-13-007

control lever several strokes to release any hydraulic oil pressure remaining in the circuits.

IMPORTANT:

Thoroughly remove dirt and oil from the hydraulic hose connectors.

x Connect the attachment hydraulic hoses to the machine

hydraulic pipe lines. x After connecting the hydraulic hoses, start the engine.

While operating the attachment control lever, slowly move the attachment. Check for oil leaks from the hydraulic hose connectors. x When the attachment is removed, joint the attachment hose female end to the male end. Put dust caps on the machine hydraulic pipe line female and male ends to prevent the pipe line ends from becoming contaminated.

When disconnecting the hoses, pull the sleeve.

The connectors are instantaneously separated.

M4GB-13-008

Dust cap

Sleeve (Female)

When installing the dust cap to or removing the dust cap from the female type hose end, pull on the sleeve.

M4GB-13-009

When installing the dust cap to the male type hose end, just connect it to the hose end.

M4GB-13-010

13-6

INDEX A Accelerator Pedal ......................................................................... 1-28 Adjust Fan Belt Tension ............................................................. 7-52 Adjust Operator’s Seat ..................................................................S-6 Adjusting Operator’s Seat (Standard Type) ........................ 1-36 Adjusting Operator’s Seat (Suspension Type) ................... 1-37 Adjustment of Bucket Auto Leveler .........................................5-3 Air Cleaner .......................................................................... 7-12, 7-48 Air Filter Restriction Indicator (Red) .........................................1-9 Alarm Setting Procedure .......................................................... 1-48 Armrest Angle Adjustment ...................................................... 1-38 Articulation Lock Bar .................................................................. 1-53 Auto Station Presetting Procedure ....................................... 1-48 Avoid Accidents from Backing Up and Turning ............... S-16 Avoid Applying Heat to Lines Containing Flammable Fluids ................................................................... S-31 Avoid Heating Near Pressurized Fluid Lines ...................... S-31 Avoid High-Pressure Fluids ...................................................... S-28 Avoid Injury from Rollway Accidents ................................... S-15 Avoid Operation with Biased Loads ........................................5-5 Avoid Overloading .........................................................................5-5 Avoid Positioning Bucket or Attachment Over Anyone ............................................................................ S-17 Avoid Power Lines ....................................................................... S-19 Avoid Rapid Steering Changes and/ or Sudden Braking ....................................................................5-5 Avoid Tipping ................................................................................ S-17 B Battery ............................................................................................. 7-59 Before Operation ............................................................................5-4 Beware of Asbestos and Silicon Dust and Other Contamination......................................................................... S-32 Beware of Exhaust Fumes ......................................................... S-30 Bleed Air from the Fuel System .............................................. 7-45 Bleed Air from the Hydraulic System ................................... 7-33 Brake Oil .......................................................................................... 7-17 Brake Oil Low Level Indicator (Red) .........................................1-8 Brake System ...................................................................... 7-13, 7-65 Brake/inching Pedal ................................................................... 1-28 BREAK-IN ............................................................................................2-1 C Cab Door ......................................................................................... 1-50 Cab Features .....................................................................................1-3 Cab Vehicle (Optional) ..................................................................1-2 Canopy Vehicle ................................................................................1-1 Change Axle Oil ............................................................................ 7-26 Change Brake Oil ......................................................................... 7-67 Change Coolant ........................................................................... 7-53 Change Engine Oil ...................................................................... 7-23 Change Hydraulic Oil/Clean Hydraulic Oil Tank ............... 7-32 Change Transmission Oil .......................................................... 7-25 Change/Cleaning ........................................................................ 7-32

Changing Forward/Reverse Drive Direction .........................4-5 Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise .................................... 7-78 Check After Starting ......................................................................3-7 Check and Adjust Tire Pressure .............................................. 7-68 Check and Adjust Valve Clearance ........................................ 7-80 Check and Clean Starter and Alternator ............................. 7-81 Check and Drain Water from Fuel Pre-Filter ....................... 7-44 Check and Replace Fuse ........................................................... 7-57 Check and Replace Seat Belt ................................................... 7-76 Check Before Starting ...................................................................3-3 Check Brake Disc (Service and Parking) .............................. 7-67 Check Brake Oil Level ................................................................. 7-65 Check Brake Performance ........................................................ 7-66 Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear ............................................................................. 7-75 Check Canopy/Cab for Damage and Mounting Bolts for Tightness ................................................................. 7-76 Check Coolant Level ................................................................... 7-51 Check Electrical Harnesses and Fuses .................................. 7-57 Check Electrolyte Level ............................................................. 7-63 Check Electrolyte Specific Gravity ......................................... 7-64 Check Engine Compression Pressure ................................... 7-81 Check Engine Oil Level .............................................................. 7-22 Check Fan Belt .............................................................................. 7-52 Check Fan Belt Tension .............................................................. 7-52 Check Fuel Hoses ......................................................................... 7-47 Check Fuel Injection Timing .................................................... 7-80 Check Fuel Level .......................................................................... 7-42 Check Heater for Damage ........................................................ 7-74 Check Heater Piping ................................................................... 7-74 Check Horn, Backup Buzzer and Backup Light ................. 7-56 Check Hoses and Lines .............................................................. 7-39 Check Hydraulic Oil Level ......................................................... 7-31 Check Monitor Function and All Other Instrument Operation .................................................................................. 7-55 Check Oil Level ............................................................................. 7-27 Check Outside and Inside Rearview Mirror ........................ 7-79 Check Parking Brake Force ....................................................... 7-67 Check Play in Brake Pedal Stroke ........................................... 7-66 Check Play in Steering Wheel Stroke .................................... 7-77 Check Right and Left Brake Interlocking Performance ............................................................................ 7-66 Check Sound Absorbing Mat Around Engine ................... 7-80 Check Steps and Handrails for Damage and Tightness .......................................................................... 7-79 Check Surrounding Areas Around Axles and Covers for Oil Leaks ............................................................... 7-29 Check the Hour Meter Regularly ...............................................7-2 Check Tire for Damage .............................................................. 7-69 Check Tire Pressure ..................................................................... 7-68 Check Wheel Bolt Torque .......................................................... 7-69 Check Windshield Washer Fluid Level (Cab Vehicle) ....... 7-76 Check Work Lights ....................................................................... 7-56 Clean and Replace Air Cleaner Element .............................. 7-48

14-1

INDEX Clean Axle Housing Air Breather ............................................ 7-29 Clean Engine Compartment and Hood ............................... 7-79 Clean Fuel Pre-Filter .................................................................... 7-45 Clean Radiator and Oil Cooler ................................................. 7-54 Clean Suction Filter ..................................................................... 7-34 Clean Transmission Air Breather ............................................ 7-28 Clearance Light Indicator (Green) ......................................... 1-11 Closing Engine Hood ....................................................................7-8 Coat Hook ...................................................................................... 1-45 Components Name .................................................1-1, 1-36, 1-37 Hydraulic Control Lever ............................................................ 11-2 Controls on the Radio ................................................................ 1-46 Cooling System ................................................................. 7-13, 7-49 Correct Maintenance and Inspection Procedures ..............7-1 D Damper Adjustment .................................................................. 1-36 Dig with Caution .......................................................................... S-18 Digital Clock Setting Procedure ............................................. 1-48 Dimmer Switch ............................................................................. 1-20 Discharge Warning Indicator (Red) ..........................................1-8 Dispose of Waste Properly ........................................................ S-34 Door Lock Disengage Lever ..................................................... 1-52 Door Lock Knob ........................................................................... 1-51 Door Open/Close Lever ............................................................. 1-51 Dozing ............................................................................................. 5-13 Drain Water and Sediment from Fuel Tank ........................ 7-43 Drink Holder .................................................................................. 1-44 Drive Function .............................................................................. 11-4 Drive Machine Safely (Work Site) ........................................... S-13 Drive on Snow Safely .................................................................. S-14 Drive Safely .................................................................................... S-12 Drive Safely with Bucket Loaded ........................................... S-14 Drive Speed Change ......................................................................4-5 DRIVING MACHINE .........................................................................4-1 Driving Machine .............................................................................4-1 E ECO Mode Switch ........................................................................ 1-33 Electrical System ............................................................... 7-13, 7-55 Emergency Evacuation .............................................................. 4-15 Engine ........................................................................ 7-11, 7-22, 11-1 Engine Coolant Temperature Gauge .................................... 1-10 ENGINE EMISSION CONTROL LABEL ............................................1 Engine Hood .........................................................................1-54, 7-8 Engine Oil ....................................................................................... 7-16 Engine Oil Low Pressure Indicator (Red) ................................1-9 Ensure Safety Before Rising from or Leaving Operator’s Seat ..........................................................................S-7 Ensure Safety When Operating on Road Shoulders ..........5-4 Equipment of Head Guard, ROPS, FOPS .............................. S-11 Error Code ...................................................................................... 1-18 Evacuating in Case of Fire ......................................................... S-30 Excavation .........................................................................................5-6 Exhaust Gas Color and Noise .................................................. 7-78

F Fasten Your Seat Belt .....................................................................S-7 FM/AM Radio (Optional) Operation ...................................... 1-46 F-N-R (Forward/Reverse) Position Indicator ...................... 1-13 F-N-R Lever .................................................................................... 1-19 Follow Safety Instructions ...........................................................S-2 Fore-Aft Position Adjustment ...................................... 1-36, 1-38 Forward/Reverse and Shift Position Indicator .................. 1-13 Front and Rear Work Light Switch (Cab Vehicle) .............. 1-23 Front Console ...................................................................................1-4 Front Window Wiper Switch (Cab Vehicle) ......................... 1-27 Fuel Gauge...................................................................................... 1-10 Fuel Pre-Filter Drain Procedures ............................................. 7-44 Fuel System ......................................................................... 7-12, 7-42 Fuse Box ............................................................................... 1-40, 7-58 G General Precautions for Cab .......................................................S-5 Grading ..............................................................................................5-8 Grease .............................................................................................. 7-16 Greasing................................................................................ 7-10, 7-19 H Handle Chemical Products Safely .......................................... S-33 Handle Fluids Safely−Avoid Fires ........................................... S-23 Handle Starting Aids Safely ........................................................S-8 Hazard Switch ............................................................................... 1-22 Heater (Optional of Cab Vehicle) ................................ 7-14, 7-74 Heater (Optional) Operation ................................................... 1-35 Heater Switch ................................................................................ 1-35 High Beam Indicator (Blue) ...................................................... 1-11 Hi-Lo Selector Switch ................................................................. 1-24 Horn Switch ................................................................................... 1-20 Hour Meter ..................................................................................... 1-16 How to Check Wear Amount (Tread Design Groove Depth) ........................................... 7-71 HST Error Code Readout Switch ............................................. 1-17 HST Warning Indicator (Red) ......................................................1-9 Hydraulic Oil .................................................................................. 7-17 Hydraulic System ................................................... 7-12, 7-30, 11-3 I In Case the Batteries Were Discharged ................................ 7-61 Inspect Machine .............................................................................S-4 Inspect Machine Daily Before Starting ...................................3-1 Inspection and Maintenance of Hydraulic Equipment ............................................................ 7-30 Investigate Job Site Beforehand ............................................ S-10 J Jump Starting ..................................................................................S-9 K Keep Riders Off Machine .......................................................... S-12

14-2

INDEX Key Switch ...................................................................................... 1-33 Kind of Oils ..................................................................................... 7-16 Kinds of Hose/Line Fittings ...................................................... 7-41 L Layout .................................................................................................7-3 Lever Locks ............................................................................1-31, 5-2 Lifting Machine ............................................................................ 6-10 Lifting Wheel Loader .................................................................. 5-14 Light Switch ................................................................................... 1-21 Loader Control Lever .................................................................. 1-30 Loader Control Lever .....................................................................5-1 Loading ..............................................................................................5-9 Loading/Unloading on Trailer ....................................................6-2 Lock Frames ......................................................................................7-6 Long Life Coolant (LLC) ............................................................. 7-49 Long-Life Coolant ........................................................................ 7-18 M Machine Information Display .................................................. 1-15 MACHINE NUMBERS ..........................................................................3 MAINTENANCE ................................................................................7-1 Maintenance Guide .................................................................... 7-10 Maintenance Guide Table ............................................................7-4 Maintenance Side Cover ...................................................1-54, 7-7 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS ...............................................................................9-1 Method to Recharge the Removed Battery ....................... 7-62 Method to Replace with Charged Auxiliary Batteries .... 7-62 Miscellaneous .................................................................... 7-15, 7-75 Monitor Display ............................................................................ 1-12 Monitor Panel ..................................................................................1-6 Move and Operate Machine Safely ..........................................S-8 N Neutral Lever Lock (F-N-R Lever) ............................................ 1-19 Never Ride Attachment.................................................................S-6 Never Undercut a High Bank ................................................... S-18 Nut and Bolt Tightening Torque ............................................. 7-83 O Object Handling .......................................................................... S-20 Observe Engine Operation Closely ..........................................2-1 Odometer ....................................................................................... 1-16 Opening Engine Hood ..................................................................7-8 Operate Only from Operator’s Seat .........................................S-9 OPERATING ENGINE .......................................................................3-1 OPERATING MACHINE ...................................................................5-1 Operating Quick Coupler (Hydraulic Type) ........................ 13-3 Operating Quick Coupler (Mechanical Type) .................... 13-1 OPERATOR’S STATION ...................................................................1-3 OPTIONAL ATTACHMENTS ....................................................... 13-1 Others .............................................................................................. 11-5 Overheat Indicator (Red) .............................................................1-9

P Park Machine Safely .................................................................... S-21 Parking ............................................................................................ 4-13 Parking Brake Indicator (Red) .....................................................1-8 Parking Brake Switch ..........................................................1-25, 4-4 Perform Truck Loading Safely ................................................. S-18 Periodic Replacement of Parts ...................................................7-9 Power Train ......................................................................... 7-11, 7-25 Practice Safe Maintenance ....................................................... S-24 Precautions for After Operation ............................................. 5-15 Precautions for Handling Batteries ....................................... 7-59 Precautions for Handling Long Life Coolant (LLC) .......... 7-50 Precautions for Lightning ......................................................... S-19 Precautions for Maintenance During Cold Weather Season .........................................................................9-2 Precautions for Operation ................................................S-19, 5-4 Precautions for Travel on Slopes ...............................................4-9 Precautions for Travel Speeds ................................................. 4-11 Precautions for Use ..................................................................... 7-41 Precautions for Welding and Grinding ................................ S-30 Precautions to Be Taken if Machine Failure Occurs ......... 4-10 Preheat Indicator (Yellow) ........................................................ 1-11 Preparations for Inspection and Maintenance ....................7-5 Prepare for Emergencies ..............................................................S-3 Prevent Battery Explosions ...................................................... S-32 Prevent Burns ................................................................................ S-27 Prevent Fires .................................................................................. S-29 Prevent Parts from Flying ......................................................... S-27 Procedures ..................................................................................... 7-33 Protect Against Flying Debris ................................................. S-20 Protect Against Noise ...................................................................S-4 Provide Signals for Jobs Involving Multiple Machines ... S-11 R Rear View Mirror ........................................................................... 1-45 Rear Window Wiper Switch (Cab Vehicle) ........................... 1-27 Reclining Angle Adjustment ................................................... 1-38 Recognize Safety Information ...................................................S-1 Recommended Fuel ................................................................... 7-42 Refueling ........................................................................................ 7-42 Removal and Installation of Tire.............................................. 7-72 Remove Paint Before Welding or Heating .......................... S-31 Removing Machine from Storage ......................................... 10-2 Removing Snow ........................................................................... 5-14 Replace Engine Oil Filter ........................................................... 7-24 Replace Fuel Filter ....................................................................... 7-46 Replace HST Oil Filter Element ................................................ 7-35 Replace Return Filter .................................................................. 7-37 Replace Rubber Hoses Periodically ....................................... S-28 Replace Tire ................................................................................... 7-69 Replacement....................................................................... 7-37, 7-75 Retighten Front Axle, Rear Axle and Transmission Mounting Nuts ............................................. 7-81 Ride Control Indicator (Optional) .......................................... 1-14 Ride Control Operation ............................................................. 1-34 Ride Control Switch (Optional) ............................................... 1-34

14-3

INDEX Right Console ...................................................................................1-5 Right Console (Front Attachment) ........................................ 1-29 Right Console/Switch Panel .................................................... 1-32 Room Light .................................................................................... 1-44 Room Rear View Mirror .............................................................. 1-45 ROPS Cab (Optional) .................................................................. 1-42 Rotary Beacon Switch (Optional) ........................................... 1-49 Rotation Method ......................................................................... 7-71 S SAFETY ...............................................................................................S-1 SAFETY SIGNS ............................................................................... S-35 Scooping ........................................................................................ 5-13 Seat Belt .......................................................................................... 1-39 Seat Pocket (Suspension Seat)................................................. 1-39 Service Air Conditioning System Safely .............................. S-33 Service Indicator (Yellow) ............................................................1-7 Shift Position Indicator .............................................................. 1-13 Shifting Item to Be Indicated on Machine Information Display ............................................ 1-16 SPECIFICATIONS ........................................................................... 12-1 Speedometer ................................................................................ 1-14 Starting Engine ...............................................................................3-5 Starting to Move .............................................................................4-2 Station Presetting Procedure .................................................. 1-47 Stay Clear of Moving Parts ....................................................... S-26 Steering ...................................................................................1-20, 4-6 Steps ................................................................................................. 1-55 Stop .................................................................................................. 4-12 Stop and Restart of Travel ...........................................................4-7 Stop Indicator (Red) .......................................................................1-7 Stopping Engine .......................................................................... 3-12 STORAGE ......................................................................................... 10-1 Store Attachments Safely ......................................................... S-21 Storing Machine .......................................................................... 10-1 Sun Visor (Optional) .................................................................... 1-44 Support Machine Properly ....................................................... S-25 Support Maintenance Properly .............................................. S-26 Suspension adjustment ............................................................ 1-37 Switches, Steering Wheel and Pedals ................................... 1-19

Transporting by Trailer .................................................................6-1 Transporting Wheel Loader (Urgent Situation) ...................6-5 Travel on Public Roads Safely .................................................. S-15 TROUBLESHOOTING ................................................................... 11-1 Tuning Procedures ...................................................................... 1-47 Turn Signal Indicator (Green) .................................................. 1-11 Turn Signal Lever ......................................................................... 1-20 U Understand Signal Words ............................................................S-1 Upper Switch Panel (Optional) ............................................... 1-49 Use Correct Fuels and Lubricants .............................................7-2 Use Handrails and Steps ..............................................................S-6 Using Booster Batteries ................................................................3-8 V Vandal Resistant Devices .......................................................... 1-55 Vent .................................................................................................. 1-35 W Warm Up Operation ................................................................... 3-10 Warm Up Operation in Cold Weather ................................... 3-11 Warn Others of Service Work .................................................. S-25 Wear Protective Clothing .............................................................S-3 When Fully Opening the Door ................................................ 1-52 Window Open/Close Levers .................................................... 1-51 Wiper Operation .......................................................................... 1-26 Work Light Indicator (Yellow) .................................................. 1-11

T Tightening and Retightening Torque of Nuts and Bolts ......................................................................... 7-82 Tightening Torque ....................................................................... 7-83 Tire ......................................................................................... 7-14, 7-68 Tire Rotation .................................................................................. 7-71 Tire Sizes to Be Used ................................................................... 7-70 Tire Wheel ....................................................................................... 7-73 Towing Method ...............................................................................6-9 Towing Pin ..................................................................................... 1-53 Transmission Oil, Axle Oil ......................................................... 7-17 Transport Safely ........................................................................... S-22 TRANSPORTING ...................................................................... 6-1, 6-4 Transporting by Road ...................................................................6-1

14-4

Write Down Your Loader Data Here Write Down Your Loader Data Here

LOADER MODEL LOADER SERIAL NO. ENGINE SERIAL NO. SUPERVISER’S NAME

DATE OF PURCHASE DEALER’S NAME

WORKSHOP’S NAME

PHONE

Memo

Maintenance Log

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Maintenance Log Date

Machine hours

Service performed

Serviced by (name)

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Maintenance Log Date

Machine hours

Service performed

Serviced by (name)

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Maintenance Log Date

Machine hours

Service performed

Serviced by (name)

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Maintenance Log Date

Machine hours

Service performed

Serviced by (name)

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Notes

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Notes

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Memo