DOWNLOAD PDF Kawasaki WHEEL LOADER 135IV-2 CUMMINS QST30-C ENGINE Operation & Maintenance Manual

93117-00011

NOTICE

13C1-0102 and up.

SERIAL NUMBERS

WITH CUMMINS QST30-C ENGINE

93117-00011

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 135Z -2.

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

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

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

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

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

Copyright © 2000 Kawasaki Heavy Industries, Ltd. All rights reserved.

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

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

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

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

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

Always follow safe operating and maintenance practices.

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

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

Kawasaki makes every effort to supply machines which conform to every regulation applicable in your country / state or province. However, if your machine is not supplied through the authorized Kawasaki loader dealer, it may not be equipped as the regulations require. Kawasaki cannot be responsible for anything on that kind of machine. Also, some local agencies or certain jobsites may require special equipment that has not been provided. Contact your nearest Kawasaki loader dealer for further information or assistance.

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

CONTENTS SAFETY・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1 Safe Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1 Safe Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・11 Safety Signs・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・16 Safety Devices・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・21 COMPONENT NAME / LOCATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・24 OPERATOR'S AREA・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・25 Pedals and Levers・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・25 Switches・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・30 Indicators・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・40 Seat・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・48 Electrical Protection・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・50 Air Conditioner・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・52 Ride Control System (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・54 OPERATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・55 Check Before Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・55 Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・64 Check after Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・66 Operating the Machine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・71 Parking・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・75 Stopping the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・76 Operating Techniques・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・77 SPECIAL PROCEDURES・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・84 Adjustments・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・84 Roading / Special Applications・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・88 Booster Batteries / Jumper Cables・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・89 Long Term Storage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・91 Welding・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・93

MAINTENANCE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・95 Serial Number Location・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・95 Inspection and Maintenance Table・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・97 When Required Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・99 Daily Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・105 Every 50 Hours or 1 Week Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・106 Every 250 Hours or 1 Month Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・111 Every 500 Hours or 3 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・122 Every 1000 Hours or 6 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・126 Every 2000 Hours or 1 Year Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・134 Recommended Lubricants and Capacity・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・146 Coolant Specification・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・147 TROUBLESHOOTING・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・148 QUANTUM FAULT CODE INFORMATION FOR ENGINE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・153 SPECIFICATIONS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・158 INDEX・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・160

SAFETY

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

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

Be alert and ready to operate the machine safely: ・Do not operate if excessively tired. ・Do not operate if taking medication that causes drowsiness. ・Do not operate if under the influence of alcohol or drugs.

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

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

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

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

Climb and step only where steps and handrails are provided.

1

SAFETY

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

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

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

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

Do not allow unauthorized personnel on the machine.

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

Inspect the machine for safety hazards and, if found, have them corrected: ・Broken lights, mirrors, windows, etc. ・Fuel leaks, oil leaks, or debris build-up ・Improper tire inflation or tire damage ・Missing or unreadable safety signs (decals)

2

SAFETY

Be sure the Roll Over Protective Structure (ROPS) is: ・in place. ・properly attached (no bolts loose or missing). ・not damaged. ・not modified.

Perform the normal daily maintenance.

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

LOCK

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

UNLOCK

・Forward / Backward Changeover Switch -- Neutral N F

R

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

"STORED" position

3

SAFETY

Securely lock the cab door either fully open or closed.

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

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

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

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

In case of fire during operation : ・Turn off the starter switch and stop the engine. ・Extinguish fire with a fire extinguisher if possible. ・With hand rails and steps, get off the machine and stay away from it. ・Call for emergency services to extinguish the fire if necessary.

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

Adjust the seat, seat belt, mirrors, etc.

Properly fasten the seat belt.

4

SAFETY

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

DANGER

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

ＤＯ ＮＯＴ ＳＴＡＲＴ ＭＥＮ ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ Ｓ ＩＧＮＥＤ ＢＹ ＤＡＴＥ

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

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

Start the machine only from in the operator's seat. ・Do not reach through the window to start. ・Do not stand on the ground and start. ・Never attempt to start by shorting across the starter motor terminals since this can bypass the neutral start safety device.

If jumper cables are required to start the engine, follow the correct procedure in "Booster Batteries/Jumper Cables" page 89.

Operational Safety SITE SAFETY:

Consider the safety of the job site before operating the machine: ・Be aware of and avoid cliffs, ditches, trenches, overhead or underground wires, underground pipes, other equipment, and workers in the area. ・If required, be aware of hand signals that may be used by ground guides.

5

SAFETY

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

Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

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

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

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

The range of temperature the machine is to be operated is between -35 ℃ 〜 45 ℃ (-31 ° F 〜 113 ° F).

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

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

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

Do not expose the machine to flames.

SAFETY DURING NORMAL OPERATIONS: Vision to the rear on any machine is limited. Always use special caution when backing up.

Know the machine limits and do not exceed them.

6

SAFETY

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

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

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

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

approx. 40cm (16in)

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

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

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

7

SAFETY

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

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

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

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

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

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

SPECIAL OPERATING CONDITIONS: Avoid entering water deeper than the bottom of the wheel rim.

If entering water is unavoidable: ・Use caution that there are no hidden hazards -- (drop-offs, holes, rocks, logs, etc.). ・Check for normal braking after leaving the water. ・Check differential gear oil for contamination.

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

8

SAFETY

When darkness, fog, snow, dust, smoke, etc. reduce visibility, use the following precautions: ・Use adequate lighting. ・Use flashers or beacons (if equipped). ・Reduce running speed. ・Periodically stop the machine and inspect the job site. ・Take more frequent breaks to reduce fatigue.

If towing or pulling something is required: ・Keep helpers or bystanders away from between the machine and the towed vehicle or object. ・Use a cable of adequate capacity and in good condition. ・Use a cable that has appropriate pull hooks. ・Use only the hitch provided on the rear of the machine. ・Be sure the hitch pin is fully in its bore before applying tension. ・If brakes and steering are working on the towed vehicle, keep an operator in the operator's seat and have him control the vehicle. ・If brakes are not working on the towed vehicle, attach another vehicle of adequate size to the rear to act as a braking vehicle. ・Use the machine as a tow vehicle only for short distance.

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

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

If parking on a level ground is not possible, follow these precautions: ・Lower the attachment to the ground and apply some down pressure. ・Block the tires. ・Apply the parking brake.

9

SAFETY

To prevent unauthorized use: ・Remove the key. ・Close and lock all cab doors and windows (if equipped with a cab). ・Install vandal covers (if equipped).

Inspect the machine and report any needed repairs.

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

10

SAFETY

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

Perform maintenance and repairs only if trained.

Operation & Maintenance Manual or Shop Manual.

Follow the

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

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

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

11

SAFETY

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

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

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

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

DANGER

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

ＤＯ ＮＯＴ ＳＴＡＲＴ ＭＥＮ ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ Ｓ ＩＧＮＥＤ ＢＹ ＤＡＴＥ

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

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

12

SAFETY

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

Cooling system additives and cleaners may contain alkali that can cause caustic burns or blindness. Avoid contact with skin or eyes.

Pour all fuel and oil into appropriate containers. Leave the containers at well ventilated place where unauthorized persons are prohibited.

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

Keep flame and sparks away from flammable and explosive materials such as: -Fuel -Oil -Antifreeze -Batteries -Wood chips -Straw, leaves, pine straw -Oily rags -Grease -Ether starting fluid Never smoke while fueling a machine. Stop the engine before fueling. ・Fill oil at well ventilated place. ・Do not leave the machine when filling oil. ・Fasten the oil filler cap tightly.

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

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

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

13

SAFETY

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

Stay away until the tire and rim cool down.

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

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

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

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

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

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

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

14

SAFETY

Stop the engine before opening the engine side panel.

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

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

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

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

Do not enter the articulation area when engine is running.

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

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

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

When oil or fuel leaks from the high pressure rubber hose, it may cause an accident or fire. If something is wrong with the rubber hose, immediate repair is needed : ・Correct it and tighten the rubber hose when a clamp, guard or cushion are loose. Do not allow them to remain loose, or the rubber hose may be damaged by vibrating or scratching other parts. ・Fasten the rubber hose with proper torque when the connection is loose. ・Exchange the hose if it is damaged or deformed. ・Exchange the hose cover if it is damaged, cut or expanded.

15

Ａｒ ｔ ｉ ｃｕ ｌ ａ ｔ ｉ ｏｎ Ｓｔ ｏｐｐｅ ｒ ＬＯＣＫＥＤ

SAFETY

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

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

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

１４(Inside)

１

３

８

(Inside)

９

(Inside)

１２ １

１２

８

(Inside)

(Inside)

９

(Inside)

２ Ａ Ａ

Ａ−Ａ

７

７(L.H, R.H) １４(Inside)

１３(L.H, R.H, Inside) １０(L.H, R.H, Inside)

１１(L.H, R.H, Inside)

３

１

(L.H, R.H)

４， ５

(L.H)(L.H)

16

６(Inside)

SAFETY

2.

1.

WARNING

DANGER

Improper operation or maintenance can cause serious injury or death.

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

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

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

No room in this area when turning.

Crushing will cause serious injury or death.

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

44787-20810

loader dealer.

44787-20760

4.

3.

WARNING

WARNING

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

44787-20750

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

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

44787-20740

17

SAFETY

6.

5.

WARNING

WARNING

Machine will not turn with articulation stopper in locked position.

Unlock articulation stopper before operating machine.

44787-21060

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

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

44787-20840

7.

8.

WARNING

WARNING Serious injury or death may result if Roll Over Protective Structure (ROPS) is missing or damaged.

Always keep ROPS in place.

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

44787-20790

Batteries produce explosive gases which can cause burns or blindness.

Keep flames and sparks away.

Vent area before servicing.

44787-20800

18

SAFETY

10.

9.

WARNING

CAUTION

Batteries contain lead, and acid which causes burns.

Avoid contact with skin or clothing.

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

44787-22890

Contact with moving belts or pullies will cause injuries.

Stop engine before working in this area.

44787-20860

12.

11.

CAUTION

CAUTION

Contact with fan will cause injury.

Keep all guards in place.

Keep hands away from fan area.

44787-20850

Pressurized system: spray of hot fluid could cause burns.

Allow system to cool and vent pressure slowly before servicing.

44787-20820

19

SAFETY

14.

13.

CAUTION

CAUTION

Nitrogen accumulator contains compressed gas and fluid which can cause injuries.

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

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

44787-20880

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

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

44787-22950

20

SAFETY

Safety Devices Loading Control Lever Lock DANGER Accidental movement of boom or machine will result in death or serious injury.

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

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

LOCK

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

UNLOCK

・ To unlock, push down the lock lever.

K-Lever Steering System On / Off

Rised position

・ Push the button and lift the arm rest to the fully raised position before getting off the machine. ・ When the arm rest is fully raised the K-Lever system is turned off automatically. Then the green display lamp goes out.

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

PUSH

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

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

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

When the arm rest is completely lowered the K-Lever system is turned on automatically. Then the green display lamp comes on.

21

Operating position

SAFETY

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

Do not lock articulation stopper during normal operation.

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

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

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

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

"LOCKED" position

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

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

2. Turn the link to the rear chassis bracket.

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

"STORED" position

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

Emergency Brake If the service brake does not work or a brake alarm sounds, the emergency brake can be applied manually; ・ Pull the emergency brake switch to engage the emergency brake and disengage the transmission.

22

SAFETY

Emergency Steering (option) WARNING Operation without normal steering could cause loss of control and injury or death.

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

Emergency steering works if the steering hydraulic pressure extreamly decreases while steering the machine.

When the emergency steering is working, the monitor lamp on the center console comes on.

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

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

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

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

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

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

23

COMPONENT NAME/LOCATION

COMPONENT NAME / LOCATION １

３

２

５

２４

１３

１８ ４

１６ １１ ２３ １２

1. Bucket (Attachment) 2. Boom 3. "Z" Lever 4. Boom Cylinders 5. Bucket Cylinders 6. Engine 7. Torque Converter 8. Transmission 9. Radiator, Air Cooler & Hydraulic Oil Cooler 10. Torque Converter Oil Cooler 11. Fuel Tank (Right hand side) 12. Hydraulic Oil Tank (Left hand side) 13. Front Axle / Differential Ass'y

８ １７ １５ ２１ ７ ２２

１９

１４

６ ９

１０

２０

14. Rear Axle / Differential Ass'y 15. Air Cleaner 16. Parking Brake 17. 1st Propeller Shaft 18. 2nd Propeller Shaft 19. 3rd Propeller Shaft 20. Batteries (two each side--two 12VDC=24VDC system) 21. Precleaner 22. Exhaust Mufflers 23. Steering Cylinders 24. ROPS

NOTE: When a component or an item location is given as "Left hand side" or "Right hand side", it is according to the operator's left side or right side when sitting in the seat.

24

OPERATOR'S AREA

OPERATOR'S AREA Pedals and Levers ２

１

５

２ ４

５

３

１

1.

2.

3.

4.

5.

K-Lever Loading Control Lever Accelerator Pedal Brake Pedals Wrist Rests

1. K-Lever ・When the K-Lever is moved from the neutral (centered) position to the right, the machine articulates (steers) to the right. ・When the K-Lever is returned to the neutral position the machine stops articulating. ・When the K-Lever is moved to the left the machine articulates to the left. ・The further the K-Lever is moved to the side the faster the machine articulates (proportional steering).

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

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

This type of damage is not covered by warranty policy.

25

L

R

OPERATOR'S AREA

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

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

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

Refer to "Loading Control Lever Lock" page 21.

Bucket control

Boom control Float (Detent) Lower

Boom Control (a) Float

(b) Lower

(c) Hold

(d) Raise

・ Move the lever to full forward detent position.

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

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

When the lever is held in this position, down pressure will be applied to the attachment. ・ Return the lever to the center position. The boom will stop moving and remain in that position. ・ Move the lever rearward. The boom is raised. When pulled fully back it is held in a detented position. ・ An automatic boom height positioner is provided which will automatically release the detent and return the lever to the "Hold" position when a preset boom height is reached. ・ For adjustment procedure refer to "Boom Kickout Adjustment" page 85.

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

26

Detent Bucket positioner

Roll Back

Hold

Dump

Raise Detent (Boom kickout)

(a) (b)

(c) Center position

(d)

OPERATOR'S AREA

Bucket Control (a) Dump

・ Move the lever away from you. The bucket will dump.

(b) Hold

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

(c) Roll Back

・ Move the lever toward you. The bucket will roll back. ・ An automatic bucket or attachment leveler is provided which will automatically release the detent and return the lever to the "Hold" position when the bucket reaches to the preset angle. ・ For adjustment procedure refer to "Bucket Positioner Adjustment" page 84.

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

3. Accelerator Pedal Accelerator pedal is used to control the engine speed. ・Depress the pedal to increase the engine speed. ・Release the pedal to decrease the engine speed.

WARNING Control pedals which stick could cause loss of control and injury or death. ・ Be sure control pedals move freely before operating. ・ Do not allow dirt, mud, or debris to build up under or around pedals.

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

27

(c)

(b) Center position

(a)

OPERATOR'S AREA

4. Brake Pedals WARNING Continuous use of brake could cause rapid or abnormal brake disc wear and / or brake circuit malfunctions which could cause loss of control and injury or death. ・ Do not use brake pedals as foot rest. ・ Do not ride brakes. ・ Use brake pedals only when applying brakes.

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

Left and right brake pedals・ ・ ・ ・ ・ ・ ・May be used either of two ways: 1. As a brake only pedal by turning the transmission cut-off (Declutch) switch (See page 34) to the "OFF" position. Use this position when working on slopes or ramps.

2. As a brake and declutch pedal by turning the transmission cut-off (Declutch) switch to the "ON" position.

This disengages the transmission while applying the brakes.

This is normally used when loading trucks. It allows higher engine speed to provide faster hydraulic operations.

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

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

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

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

28

OPERATOR'S AREA

5. Wrist Rests Wrist rests are used to place the wrist or arm on while operating the loading control lever and K-Lever.

Both wrist rests are adjustable. Each way of adjustment is as follows : A. Loading control lever side - Loosen two lock knobs (1) and adjust the wrist rest up and down.

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

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

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

２

UNLOCK

１

LOCK

３ UNLOCK ４ LOCK

29

OPERATOR'S AREA

Switches

８ ９ １０ １１

４ ５ ６ ７

P

３ １２

１

２ １８

１３

１７ １６

１４ １５

２４ ２３

２０ １９ ２２ ２１ (Battery box)

13. Rear Wiper Switch 14. Diagnostic Switch (option) 15. Increment / Decrement Switch (option) 16. Power Boost Switch 17. QUAD Switch 18. Horn Switch 19. Forward / Reverse Changeover Switch 20. Transmission Shift Switch 21. Ladder Light Switch 22. Engine Stop Switch 23. Traction Control Engine Adjust Switch 24. Boom Soft Landing Height Adjust Switch

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

30

OPERATOR'S AREA

1. Starter Switch ・ ・Key can be either inserted or pulled out.

Engine is stopped and most electrical circuits are turned off.

ON OFF

・ ・Current flows to all circuits. ・ ・When the transmission changeover switch is in NEUTRAL, starter motor turns, starting the engine.

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

2. Parking Brake Switch WARNING Accidental movement of machine could result in death or serious injury.

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

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

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

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

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

31

START

OPERATOR'S AREA

3. Light Switch This is a four position switch. : Width (clearance) lamps (option), tail lamps, front head lights, and gauge lamps turn off. : Width (clearance) lamps (option), tail lamps, and gauge lamps turn on. : Width (clearance) lamps (option), tail lamps, front head lights, and gauge lamps turn on. : Front head lights are in the high beam position.

4. Front Working Light Switch Front working light switch is used for turning on and off the front working lights.

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

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

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

32

OPERATOR'S AREA

6. 21. Ladder Light Switch Ladder light switch is used for turning on and off the ladder lights.

Each switch is installed in both the battery box and the cab.

(Battery box)

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

8. Engine Mode Switch Engine mode switch is used to switch an engine power mode.

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

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

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

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

33

OPERATOR'S AREA

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

Therefore acceleration performance is better.

9. Transmission Cut-Off (Declutch) Switch Transmission cut-off (Declutch) switch is used to change the function of the brake pedal.

Normally this switch should be "ON".

"OFF"・ ・ ・When the brake pedal is depressed, only the service brakes are engaged keeping the transmission directional clutch engaged(brake only).

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

Refer to "Brake Pedals" page 28 for the function of the brake pedals.

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

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

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

34

OPERATOR'S AREA

11. Ride Control Switch (option) When the ride control switch is ON, the ride control system works. Refer to page 54 for handling of the ride control system.

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

"OFF"

:

"INT"

: Intermittent

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

"PUSH" : Spraying solvent on the windshield

LOW HIGH

OFF

PUSH

13. Rear Wiper Switch Rear wiper switch is used to wipe the rear windshield.

"OFF"

:

"ON"

: Low speed

"PUSH" : Spraying solvent on the windshield

OFF

ON

PUSH

35

OPERATOR'S AREA

14. Diagnostic Switch (option) This switch is used to check the engine failure when any one of the engine warning lamps (Refer to the page 40) is turned on.

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

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

?

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

If active faults are recorded, all three lights will come on momentarily. The orange lamp is being turned on. The yellow and red lights will begin to flash the code of the recorded fault.

The fault code will flash in the following sequence. First, the yellow lamp will flash. There will be a short 1 second pause when both the yellow and red lights are off. Then the red light will flash the 3-digit number of the recorded fault code. There will be a 1 second pause between each number. When the 3-digit number is done flashing, a yellow light will appear again. The 3-digit number will continue to flash the same fault code until the system is advanced to the next active fault code.

The following steps show how to finish the diagnosis for the engine failure.

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

36

ON OFF

START

OPERATOR'S AREA

15. Increment / Decrement Switch (option) The switch is used for ; 1. Checking the history of the engine failures 2. Adjusting the engine idle revolution ・ Checking the history of the engine failures When the diagnostic switch is ON (Starter switch key "ON"), the lights will continue to flash the same fault code until the system is advanced to the next active fault code.

To go to the second fault code, move the increment / decrement switch to "+", then release it. You can also go back to the previous fault code by moving the switch to "-", then releasing it . To check the third or fourth fault code, move the switch to "+", then release it when all active fault codes have been viewed. Moving the switch to "-" will go back to the first fault code.

Refer to the section of the diagnostic switch (14) for converting the flashing pattern to 3-digit fault code. ・ Adjusting the engine idle revolution When the diagnostic switch is OFF (Starter switch key "ON"), the engine idle revolution can be adjusted in 25min-1(rpm) by using the increment / decrement switch (775min-1(rpm) 800min-1(rpm) 825min-1(rpm)). Move the increment / decrement switch to "+", then release it, to increase the engine idle revolution to 825min-1(rpm).

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

The engine idle revolution can not be changed to over 825min-1(rpm) or to below 775min-1(rpm) even though this switch is moved to "+" or "-".

37

OPERATOR'S AREA

16. Power Boost Switch Power boost switch is used to give more power to hydraulic loading force. After the switch is pressed, main pressure in 2 hydraulic circuit is increased from 31.4MPa (320kgf/cm ) 2 (4551psi) to 34.4MPa (350kgf/cm ) (4978psi) about for five seconds. During increase of the main pressure, lifting force and digging force are increased.

17. QUAD (Quick Up And Downshift) Switch QUAD switch is used to quickly shift down the transmission from 2nd gear to 1st gear without moving the transmission shift switches. ・When operating the machine in 2nd speed with the shift switches in 2 or "AUTO" position, the transmission will shift down to 1st gear by pressing QUAD switch. ・By pressing QUAD switch again, setting the transmission shift switch to the neutral position (parallel) or operating the parking brake switch, the 1st gear is released and it returns to the 2nd gear.

18. Horn Switch Horn switch is used to blow the horn.

19. Forward / Reverse Changeover Switch Forward / reverse changeover switch is used to change direction.

R (Reverse)・ ・ ・ ・Pull the upper part of the trigger switch N (Neutral)・ ・ ・ ・ ・ ・Keep the trigger switch parallel F (Forward)・ ・ ・ ・ ・Pull the lower part of the trigger switch

38

N F

R

OPERATOR'S AREA

20. Transmission Shift Switch Transmission shift switch is used to control machine speed. ・ ・Shift to upper speed (Shift Up) ・ ・Shift to lower speed (Shift Down) Refer to "Transmission Shift" page 72.

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

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

ON

(Battery box)

23. Traction Control Engine Adjust Switch Traction control engine adjust switch is used for adjusting engine speed while the traction control system works.

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

24. Boom Soft Landing Height Adjust Switch Boom soft landing height adjust switch is used for adjusting boom stop position while the boom soft landing device works.

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

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

39

OFF

OPERATOR'S AREA

Indicators ２３２２２１ ６ ５１０ ２０

１

２ ２４

４ １１ １２ １３ １４ １５ １６ １７ １８ １９

２６

２８２７２５ ７ ８ ９ ３

1. Tachometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Level Gauge 5. Parking Brake Indicator Lamp 6. Auto Brake Indicator Lamp 7. Transmission Cut Off (Declutch) Lamp 8. Rear Working Light Indicator Lamp 9. K-Lever ON / OFF Display Lamp 10. Central Warning Lamp 11. Transmission Control Warning Lamp 12. Brake Pressure Warning Lamp 13. Brake Oil Temperature Warning Lamp and Brake Disk Wear Alarm 14. Engine Oil Pressure Warning Lamp

15. Engine Coolant Temperature Warning Lamp 16. Torque Converter Oil Temperature Warning Lamp 17. Air Cleaner Warning Lamp 18. Charge Lamp 19. Transmission Oil Filter Warning Lamp 20. High Beam Indicator Lamp 21. Auto Shift Indicator Lamp 22. Neutral Indicator Lamp 23. Transmission Status Monitor 24. Hour Meter 25. Steering Hydraulic Warning Lamp (option) 26. Engine Warning Lamps 27. Ride Control Lamp (option) 28. Engine Grid Air Heater Lamp

When the starter switch is turned to "ON", all warning lamps (10) 〜(19), (25) and (26) light up for three seconds. This is the lamp (bulb) test period (lamp (14) lights up until engine starts).

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

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

40

OPERATOR'S AREA

1. Tachometer Indicates the engine revolutions per minute.

x100r/min

2. Engine Coolant Temperature Gauge Indicates engine coolant temperature. It is normal when the indicator stays in the green zone (70〜95° C (158〜203° F)). ・ If the indicator enters the red zone while operating, slow the engine down to mid-range speed and wait until the indicator reaches the green zone.

H

C WATER TEMP

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

Refer to "Troubleshooting" page 148.

3. Torque Converter Oil Temperature Gauge Indicates the temperature of oil circulating through the torque converter and the transmission. It is normal if the indicator is in the green zone (50〜120° C (122〜250 ° F)) while operating.

H

C T/C OIL TEMP

・ If the indicator enters the red zone while operating, slow the engine down to mid-range speed, shift to neutral, and wait until the indicator reaches the green zone. ・ If the indicator does not come back into the green zone quickly, stop the engine and find the cause.

Refer to "Troubleshooting" page 152.

4. Fuel Level Gauge Indicates the fuel amount in the fuel tank. ・ Be sure to refuel at the end of each work day to avoid moisture condensation in the tank.

F

E FUEL

41

OPERATOR'S AREA

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

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

6. Auto Brake Indicator Lamp (red) Lights up when the auto brake works.

Refer to "Auto Brake" page 73 for details.

7. Transmission Cut-Off (Declutch) Lamp (green) Lights up when the transmission cut-off (Declutch) switch is "ON". ・ When lit, the service brakes are engaged and the transmission directional clutch is disengaged by depressing the brake pedals. ・ When not lit, only the brakes are engaged as the brake pedal is depressed.

8. Rear Working Light Indicator Lamp (green) Lights up when working lights are on.

9. K-Lever ON / OFF Display Lamp (green) ・ The green display lamp comes on when the K-Lever system is turned "ON". It goes out when the system is turned "OFF".

Refer to page 25 for details.

10. Central Warning Lamp (red) Flashes if any of the warning lamps come on.

42

P

OPERATOR'S AREA

11. Transmission Control Warning Lamp (red) Lights up if transmission controls malfunction. ・ If it lights up while operating, stop the engine and contact your nearest Kawasaki loader dealer for necessary repair.

12. Brake Pressure Warning Lamp (red) WARNING Loss of braking force could result in death or serious injury.

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

Brake pressure warning lamp lights up and the warning buzzer sounds when the brake oil pressure is lower than 3.9MPa(40kgf/cm2 )(570psi)or the pressure difference between the front and rear brake circuit is larger than 1.5MPa(15kgf/cm2 )(213psi). ・ If it lights up while operating, IMMEDIATELY stop the machine and find the cause.

Refer to "Troubleshooting" page 151.

13. Brake Oil Temperature Warning and Brake Disk Wear Alarm Lamp (red) WARNING Loss of braking force could result in death or serious injury.

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

Flashes if brake oil temperature overheats. sounds.

Also the buzzer

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

Lights up when brake discs wear out. ・If it lights up while operating, stop the engine and contact your nearest Kawasaki loader dealer for necessary repair.

43

OPERATOR'S AREA

14. Engine Oil Pressure Warning Lamp (red) Lights up when engine oil pressure is low. Also the warning buzzer sounds. ・ If it lights up while operating, IMMEDIATELY stop the engine and find the cause.

Refer to "Troubleshooting" page 148.

15. Engine Coolant Temperature Warning Lamp (red) Lights up if coolant temperature overheats. (Over 102° C (215 ° F)) ・ If it lights up while operating, slow the engine speed down to mid-range, shift to neutral, and wait until the lamp goes out.

Check the coolant temperature gauge before resuming operation. ・ If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause.

Refer to "Troubleshooting" page 148.

CAUTION Hot coolant spray may cause burns.

Never open radiator cap when engine is hot.

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

16. Torque Converter Oil Temperature Warning Lamp (red) Lights up if transmission oil overheats. (Over 120±5° C (248 ±9° F)) ・ If it lights up while operating, slow the engine speed down to mid-range, shift to neutral, and wait until the lamp goes out.

Check the torque converter oil temperature gauge before resuming the operation. ・ If the light does not go out quickly or lights up again after resuming the operation, stop the engine and find the cause.

Refer to "Troubleshooting" page 152.

44

OPERATOR'S AREA

17. Air Cleaner Warning Lamp (red) Lights up when air filters are clogged. ・ If it lights up while operating, stop the engine and clean or replace the air cleaner outer elements.

Refer to "Clean or Replace Air Cleaner Elements" page 100.

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

Refer to "Troubleshooting" page 149.

19. Transmission Oil Filter Warning Lamp (red) Lights up if the transmission oil filters are clogged. ・ When lit, replace the transmission oil filter cartridges.

Refer to "Replace Transmission Oil Filters" page 122.

20. High Beam Indicator Lamp (blue) Lights up when head lights are switched to high beam.

21. Auto Shift Indicator Lamp (green) Lights up when the transmission is in "AUTO" position.

AUTO 22. Neutral Indicator Lamp (green) Lights up when transmission is in neutral.

N 45

OPERATOR'S AREA

23. Transmission Status Monitor

・ 1st Gear

Lights up when the transmission is in 1st gear.

D 3 2 1

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

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

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

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

25. Steering Hydraulic Warning Lamp (red) (Option) Lights up if the steering hydraulic pressure goes down below the specified pressure when the engine is running.

This indicates a failure in the steering circuit.

Immediately stop the machine and have the problem corrected.

46

0 0 0 0 0 0

1/10h

OPERATOR'S AREA

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

STOP Red

If the yellow warning lamp illuminates, the engine can still be operated, but it can lose some system features that can sometimes result in a power loss. The failure must be repaired as soon as convenient.

Yellow

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

Orange

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

If any of these lights come on during normal operation, contact your nearest Kawasaki loader dealer or local Cummins engine dealer for checking the engine.

27. Ride Control Lamp (green) (option) Lights up when the ride control switch is ON. Refer to "Ride Control System (option)" page 54.

28. Engine Grid Air Heater Lamp (yellow) (For cold start) When the starter switch key is turned to "START" position at the ambient temperature below 0 ℃ (32 ° F), it turns the engine grid heater to heat intake air and the lamp lights up. The heater only works when the engine is cold.

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

47

WAIT

OPERATOR'S AREA

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

Lumbar Support ・Turn adjustment knob (1) for desired lumbar (middle of the back) support.

１

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

４

Seat Height ・The seat is lowered by pulling the knob (3) forward while the seat is raised by pushing the knob (3) backward.

Forward / Backward ・Lift the handle (4) and move the seat forward or backward.

Release the handle (4) at one of the several positions.

48

３

２

OPERATOR'S AREA

Seat Belt WARNING Improper use or maintenance of seat belt could result in death or serious injury. ・ Inspect seat belt and mounting hardware before operating machine and replace any defective components. ・ Always fasten seat belt when operating machine.

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

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

49

OPERATOR'S AREA

Electrical Protection Fuse Boxes Main fuse box is located in the side console and contains fifteen fuses.

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

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

Never replace fuses with higher amperage rating.

5A

BOOM KICKOUT BUCKET POSITIONER BOOM SOFT LANDING

R . WIPER

SPARE

3A

SPARE

R . WORK LIGHT (CAB)

10A 10A

VEHICLE CONTROL MODULE

BACK LAMP (BACK-UP LIGHTS, BACK-UP ALARM) STOP LAMP (BRAKE LIGHTS)

F . WORK LIGHT (CAB)

10A 10A 10A

PARKING BRAKE TRANS CONTROLLER

5A

5A

R . WORK LIGHT

15A 15A 15A 15A 15A

SPARE

5A

5A

TAIL LIGHTS INSTRUMENT PANEL LIGHTS HEAD LIGHTS

20A 10A 10A 15A 10A

SPARE

F . WIPER CIGAR LIGHTER

AIR SUSPENSION SEAT

SPARE SPARE

AIRCON AIRCON STEP LIGHT

RADIO BUZZER MONITOR (INSTRUMENT PANEL) NEUTRAL RELAY BATTERY RELAY ELECTRONIC CONTROL MODULE

5A

SPARE

5A

5A

ROOM LAMP (CAB LIGHT)

5A

K-LEVER RIDE CONTROL

20A 20A 20A

5A

4 WAY FLASHER HORN

5A

SPARE

50

OPERATOR'S AREA

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

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

Problems caused by fused fusible link Problem (symptom)

Fuse damaged

During engine operation

During engine stop

30A

・ Engine will stop. ・ All the power for all electrical circuit will be OFF.

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

70A (A)

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

・ The same conditions as "During engine operation".

70A (B)

・ The machine can be operated but the batteries will not charge and the batteries will discharge quickly.

・ The same conditions as "During engine operation".

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

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

51

OPERATOR'S AREA

Heater or Air Conditioner Ventilation Location and Mode ３

VENT

３

1

2

3

4

○

-

-

○

-

○

-

○

○

-

○

○

MODE

３

３ １

１

○ : Open - : Close

２

２ ４

４

４

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

２

１

ＯＮ／ ＯＦＦ

４

（Ａ）

７

ＦＡＮ ＯＮＬＹ

（Ｂ） 1. ON/OFF Switch 2. FAN ONLY Switch 3. TEMP UP/DOWN Switches (A) Temperature Display 4. FAN UP/DOWN Switches (B) Fan Speed Display

３

５

６

5. UPPER Mode Switch 6. LOWER Mode Switch 7. DEFROST Mode Switch

52

OPERATOR'S AREA

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

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

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

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

4. FAN UP/DOWN Switches・・・・・ Allows the operator to adjust fan speed.

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

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

7. DEFROST Mode Switch・・・・・・ Switches the unit into the defog mode. This mode locks on the AC and routes the air to the defrost vents.

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

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

53

OPERATOR'S AREA

Ride Control System (option) Roading a wheel loader over rough terrain will cause fore and aft pitching motion to the machine. The pitching motion is reduced when the ride control system is installed and operating.

Operation and Function 1. Before roading or traveling, turn the ride control system switch (1) ON. The ride control system pilot lamp (2) comes to ON. If the machine does not travel far during normal operation the system may be turned OFF.

１ 2. Move the machine forward.

The ride control system functions automatically when the machine traveling speed reaches more than 7 km/h (4 mph).

２ NOTE:

When the bucket is fully rolled back the ride control system does not work as well. Roll the bucket forward a bit when traveling.

54

OPERATION

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

A. Walk-Around Inspection

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

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

What to Look for

□Bucket / Attachment

Damage, missing bolts, leaks, and excessive wear

□Bucket Control Linkage

Damage, missing bolts, excessive wear, and looseness

□Lights

Broken bulbs, wires or lenses

□Radiator Fins

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

□Cooling System

Leaks and trash build-up

□Batteries

Loose terminals, dirt build up on top of the batteries

□Steps and Handrails

Damage and cleanliness

□Differentials (front and rear)

Leaks

□Hydraulic System

Leaks and Fluid Level

□Final Drive (front and rear)

Leaks

□Covers and Guards

Damage or missing

□Transmission

Leaks

□Instrument Panel

Broken gauges or indicator lights

□Brake Lines

Damage and leaks

□Engine Compartment

Leaks, debris build-up and flammable materials left

Date :

Model-S/N :

Hours :

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

55

Inspector :

OPERATION

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

Avoid contact with hot oil or engine components.

1. Check the oil level with the dipstick.

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

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

Refer to "Recommended Lubricants" page 146 for the suitable viscosity of the oil according to the ambient temperature.

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

Refer to "Replace Engine Oil Filter Cartridges" page 112 and "Replace Engine Oil"page 124 for the procedure.

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

IMPORTANT Improper oil level may damage engine.

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

Add or drain oil to keep proper oil level.

56

Ｈ （Ｈ ｉ ｇｈ） Ｌ （Ｌｏｗ）

OPERATION

C. Check Hydraulic Oil Level CAUTION Pressurized hydraulic tank is used for this machine.

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

Vent all pressure by pushing the cap down firmly.

1. Lower the attachment to the ground.

2. Stop the engine.

Level gauge

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

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

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

Refer to "Recommended Lubricants" page 146 for the suitable viscosity of the oil according to the ambient temperature.

D. Check Engine Coolant Level CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant could cause burns.

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

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

Avoid contact with skin and eyes to prevent injury.

57

10mm (0.4in)

Lowest position

OPERATION

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

2. Check the coolant level by the sight gauge on the radiator through the hole on the left hand side of the engine room.

Coolant level is normal when the gauge is filled with the coolant. If the surface of the coolant is seen in the sight gauge or no coolant is seen there, add coolant.

OK

NG

NG

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

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

Refer to "Coolant Specification" page 147 for the correct mixture.

5. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 138.

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

Ｒａｄ ｉ ａ ｔ ｏｒ ｇｕａｒ ｄ

Ｃａｐ

Ｎｅｃｋ ｐ ｉ ｐｅ Ｗａ ｔ ｅ ｒ ｓｕｒ ｆ ａｃｅ

E. Drain Water and Sediment from Fuel Filters ・ Open the drain cock on the bottom of the fuel filters to allow water and sediment to drain into a suitable container. ・ Dispose of properly.

58

OPERATION

CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from filter. ・ Do not drain with engine running. ・ Do not allow diesel fuel to remain on skin for an extended period of time.

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

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

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

"STORED" position

H. Check Tire Air Pressure Tire performance and tire life depend greatly on the tire air pressure. ・ Low air pressure causes excessive deflection, heat, and accelerated wear. ・ High air pressure cause reduced traction, slippage, and possible blow outs.

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

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

59

Low Pressure

OK

High Pressure

OPERATION

WARNING Overheated tire could explode causing serious injury or death.

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

Stay away until tire and rim cool down.

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

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

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

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

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

Recommended Tire Air Pressure Radial tire Size

Air Pressure Front

45 / 65-39-(L-5)

Note Rear

471〜490kPa 2 373〜392kPa 2 (4.8〜5.0kgf/cm ) (3.8〜4.0kgf/cm ) (68〜71 psi) (54〜57 psi)

60

Standard

OPERATION

I . Check Tire for Damage WARNING Improper servicing or changing tires and rims could cause explosion resulting in serious injury or death.

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

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

WARNING Overheated tire could explode causing serious injury or death.

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

Stay away until tire and rim cool down.

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

For the replacement contact Kawasaki loader dealer or a tire manufacturer's local dealer.

Tread Side walls

Breakers Carcass

・ Bead wire is broken or bent, or the tire is greatly deformed. ・ Wear is excessive and the carcass ply (including breaker) is exposed for more than 1/4 of the circumference. ・ Damage to the carcass exceeds 1/3 of the tire width. ・ Tire layers are separated. ・ Radial cracks reach the carcass. ・ Deformation or damage which makes the tire unsuitable for use.

61

Beads / Bead wire

OPERATION

J. ROPS (Roll Over Protective Structure) WARNING Operating without ROPS could cause serious injury or death.

Always keep ROPS in place while operating machine.

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

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

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

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

K. Adjust and Check Rear View Mirrors ・ Adjust and check the condition of the rear view mirrors. ・ If there is any dirt on, or damage to, the rear view mirrors, clean or fix them.

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

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

2. Eleven warning lamps (red) should come on for about three seconds. Refer to "Indicators" page 40.

3. Set the transmission shift switch to each position, rotate the light switch, and operate the working light switch and transmission cut-off selector switch.

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

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

Refer to "Indicators" page 40 〜 47.

62

OPERATION

N. Check Control Lever ・ Make sure the loading control lever is in the "HOLD" position.

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

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

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

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

Refer to "Recommended Lubricants" page 146 for the correct grease. ・ Axle support (two places)

63

OPERATION

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

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

Normal Start

(Ambient temperature above 0 ° C (32 ° F)) - Do not depress the accelerator pedal.

1. Turn the starter switch key to "ON" position and leave it there for 3 seconds.

ON START

OFF

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

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

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

ON OFF

START

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

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

ON

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

1 2 3 4 5

Key position ON START START START ON

Warning lamp ON OFF OFF OFF OFF

Condition stop pre-lube runs delay starter crank engine start

Time 3 seconds 3-15 seconds 5 seconds 3-5 seconds

64

OFF

START

OPERATION

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

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

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

Before starting the engine, make sure all of the warning lamps are turned off. If the stop (red) lamp remains on, do not start the engine. ・Do not turn the starter switch key to the "START" position while the engine is running. ・The engine oil pressure warning lamp should go out in less than ten seconds after the engine starts. If it remains on, stop the engine immediately and see "Troubleshooting" page 148.

IMPORTANT Low engine oil pressure may cause severe engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

Cold Start (Ambient temperature below 0 ℃ (32 ° F)) This engine is equipped with the air grid starting aid system.

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

65

WAIT

OPERATION

Check after Starting the Engine ・ Keep the engine running at low to medium speed and warm it up for about five minutes. ・ Do not subject the engine to sudden acceleration until the end of the warm-up period.

A. Check Warning Lamps 1. Check the warning lamps on the instrument panel.

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

3. Refer to "Indicators" page 40 for the meaning of each lamp and the correction.

B. Check Fuel Level 1. Check the fuel level with the fuel level indicator on the instrument panel.

F

2. Add fuel to fill the tank required.

Refer to "Recommended Lubricants" page 146 for the proper fuel.

E FUEL

C. Check Transmission Oil Level DANGER There is no room in articulation area when machine is turning.

Crushing will result in serious injury or death.

When checking oil level: - Lower attachment to ground.

- Put transmission shift switch in neutral.

- Apply parking brake.

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

- Make sure nobody is on machine.

66

OPERATION

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

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

Refer to "Articulation Stopper" page 22.

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

"LOCKED" position

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

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

Refer to "Recommended Lubricants" page 146.

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

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

IMPORTANT Never mix CD grade engine oil and A.T.F. Either may be used in transmission but they must not be mixed.

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

67

OPERATION

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

2. Firmly depress the left brake pedal.

3. Release the parking brake.

4. Select the transmission shift switch 1st and FORWARD. 5. Slowly accelerate the engine to full speed.

6. The machine should not move.

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

Do not operate until problem has been corrected.

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

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

3. Stop the machine with the service brake.

4. Pull up the parking brake switch.

5. Release the service brakes.

6. The machine should not move.

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

Do not operate until problem has been corrected.

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

2. The horn should sound loudly.

68

OPERATION

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

2. Release the brakes.

3. Steer fully right and then left.

4. Steering should be smooth in both directions.

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

2. Release the parking brake.

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

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

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

Do not operate until problem has been corrected.

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

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

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

Refer to "Troubleshooting" page 149.

69

OPERATION

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

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

When inspecting machine while engine is running; ・ Make sure nobody is on machine. ・ Lower attachment to ground. ・ Pull up parking brake switch. ・ Do not enter or access hazardous areas of machine: -Articulation area -Under machine -Engine compartment, etc.

70

OPERATION

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

Do not stop engine while machine is moving.

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

Be sure area is clear of personnel and obstructions.

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

Do not operate machine on a grade over 30 ° .

30°Max.

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

2. Depress the brake pedal.

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

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

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

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

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

71

approx. 40 cm (16 in)

OPERATION

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

2. Depress the left brake pedal.

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

Speed and Direction Change 1. Select the proper gear shifting mode by pressing the transmission shift switch. Refer to the following tables on page 73 for the gear selection mode.

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

Shift up Shift down N F

R

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

Backward N F

IMPORTANT

R

Neutral

Forward

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

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

3. When the transmission is in 2nd gear, it can be quickly shifted down to the 1st gear by pressing the quick up and downshift (QUAD) switch.

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

Refer to "QUAD Switch" page 38.

72

OPERATION

Selected Gear

Status Monitor

Operating Condition

1st

1

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

2nd

2

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

3rd

3

Carrying or roading

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

3

Carrying or roading

D

Shift up and shift down chart AUTO D 3

3

2

2 s

s 1

1

MANUAL

UP SHIFT SWITCH DOWN SHIFT SWITCH s

QUAD SWITCH

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

Use proper gear for each job.

73

OPERATION

Steering ・When the K-Lever is moved from the neutral (centered) position to the right, the machine articulates (steers) to the right. ・When the K-Lever is retumed to the neutral position the machine stops articulation. ・When the K-Lever is moved to the left the machine articulates to the left. ・The further the K-Lever is moved to the side the faster the machine articulates (proportional steering).

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

Auto brake works under the following conditions: 1. If the machine runs above the following speeds; (Forward / Reverse) ・15 / 17 km/h (9.3 / 10.6 mph) ・29 / 32 km/h (18 / 19.9 mph) ・32 / 34 km/h (19.9 / 21.1 mph) ・36 / 36 km/h (22.4 / 22.4 mph) 2. When the direction is changed while running over 12 km/h (7.5 mph).

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

Be prepared. Fasten seat belt.

74

L

R

OPERATION

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

Park machine in safe place on firm level ground.

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

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

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

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

3. Shift the transmission shift to "NEUTRAL".

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

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

75

OPERATION

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

Do not stop engine while machine is moving.

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

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

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

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

ON OFF

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

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

Prevent unauthorized operation.

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

In case that the engine does not stop even when the starter switch is in the "OFF" position, shut two valves on the fuel inlet and outlet hoses located in the chassis side of the fuel tank to cut off the fuel supply to the engine.

76

OPEN

SHUT

START

OPERATION

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

Do not operate machine on a grade over 30 ° .

30°Max.

Loading IMPORTANT Machine damage may result from improper loading procedures. ・ Do not dig or scoop with machine frame articulated. ・ Do not drive machine into material at high speed.

NOTE ・ When loading rocks or hardpacked material, the use of bucket teeth is recommended. ・ For loose stockpile material replaceable bolt-on cutting edges should be used.

1. Move the machine forward to the material.

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

3. Lower the bucket parallel to the ground.

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

77

OPERATION

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

Reduce wheel slippage by slightly reducing engine speed.

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

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

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

9. Reverse the machine.

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

Excavating 1. Move the machine forward to the material.

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

78

OPERATION

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

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

Increase engine speed as the bucket digs deeper.

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

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

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

Keep bucket or attachment bottom parallel to ground.

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

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

79

OPERATION

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

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

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

Be sure to run machine reverse when leveling ground.

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

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

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

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

80

OPERATION

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

Do not make quick turns or abrupt braking when boom is raised.

Keep boom low for best stability especially on slopes.

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

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

Refer to "Loading" or "Excavating" page 77, 78 for the loading procedure.

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

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

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

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

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

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

81

OPERATION

Refer to "Boom Kickout Adjustment" page 85 for adjustment of the preset height .

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

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

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

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

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

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

82

OPERATION

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

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

83

(L-cycle)

( V-cycle)

SPECIAL PROCEDURES

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

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

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

Use safe sturdy platform to reach bucket positioner adjustment.

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

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

3. Loosen the bolts (1) with a 19mm wrench.

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

5. Tighten the bolts (1).

２ １

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

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

84

SPECIAL PROCEDURES

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

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

4

3 5 ± 2mm (1/8〜1/4 in)

Boom Kickout Adjustment DANGER Sudden or accidental movement of boom resulting in death or serious injury.

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

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

Use safe sturdy platform to reach boom kickout adjustment.

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

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

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

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

85

SPECIAL PROCEDURES

5. Loosen the two bolts (1).

１

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

7. Tighten the bolts (1).

8. Remove the support from the boom and linkage.

３

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

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

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

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

Switch

Plate

5 ± 2mm (1/8〜1/4 in)

Boom Soft Landing Positioner Adjustment DANGER Sudden or accidental movement of boom resulting in death or serious injury.

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

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

Use safe sturdy platform to reach boom kickout adjustment.

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

86

２

SPECIAL PROCEDURES

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

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

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

5. Loosen the two bolts (1).

３

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

１

7. Tighten the bolts (1).

8. Remove the support from the boom and linkage.

２

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

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

Switch

Plate

5 ± 2mm (1/8〜1/4 in)

87

SPECIAL PROCEDURES

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

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

Stay away until tire and rim cool down.

When the machine travels at high speed or for a long distance, the tires or other components may become extremely hot causing an explosion or early wear. If the machine must be driven for a long distance, take the following precautions: ・ Follow the regulations related to this machine, and drive carefully. ・ The most suitable tire pressure, travel speed, or tire type differ according to the condition of the travel surface. Contact your nearest Kawasaki loader dealer or a tire dealer for information. ・ "Ton km/h" (Ton MPH) limitations must be observed. Consult a tire dealer for the speed limit of the tires involved. ・ After traveling for 30 minutes, stop the machine with engine running to allow the tires and components to cool. Check the tires and other parts for damage. ・ Do not put calcium chloride or dry ballast in the tires when traveling. ・ Whenever possible use a lead and/or follow vehicle and all available warning devices even if not required by regulations.

88

SPECIAL PROCEDURES

Booster Batteries / Jumper Cables WARNING Improper procedure to start engine using jumper cables could cause battery case explosion. ・ Do this work by two persons. While one person sits on the operator's seat, the other person connects jumper cables. ・ Wear eye or face protection when working on or around batteries. ・ The booster batteries should be of similar size and capacity as the batteries being boosted. ・ Do not allow the two machines to touch. This prevents possible sparks between or in the machines being used. ・ Keep flames and sparks away from batteries. ・ Keep jumper cable ends from touching each other or machine to avoid sparks. ・ Make last connection to grounded part of frame away from battery compartment.

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

It could shorten the battery life. It may also emit sparks from the deterioration parts in the case, as a result a battery explosion.

Keep the battery electrolyte level up to the proper level.

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

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

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

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

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

89

SPECIAL PROCEDURES

・ Be sure the problem is inadequate battery charge and not some other electrical problems. ・ Stop the engine of the boost machine or turn off the booster supply if using an auxiliary power source.

2. Raise and lock the battery box covers.

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

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

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

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

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

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

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

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

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

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

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

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

90

Booster batteries

Batteries being boosted

＋

＋

＋

＋

−

−

−

−

＋

＋

＋

＋

−

−

−

−

Engine block of machine being jump started

SPECIAL PROCEDURES

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

2. Lubricate every greasing point described in "Greasing" section page 106〜109, 111, 132, 144 and 145.

3. Replace engine oil, transmission oil, differential and planetary oil, brake oil, and hydraulic system oil. For the engine and transmission, add 10% anticorrosive oil to new oil.

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

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

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

The range of temperature the machine is to be stored is between -35 ℃ 〜 45 ℃ (-25 ° F〜110 ° F).

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

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

Refer to "Coolant Specification" page 147 for the mixing ratio.

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

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

91

−

＋

−

＋

SPECIAL PROCEDURES

1. Check the following points.

Refer to "Check before Operation" page 55 and "Check after Starting the Engine" page 66. ・ Coolant level ・ Engine oil level ・ Hydraulic oil level ・ Transmission oil level ・ Brake function ・ Steering function 2. Operate the machine as follows. ・ Run just the engine for about five minutes at low idle. ・ Move all cylinders of the hydraulic system full stroke 2 to 3 times. ・ Run the machine about 10m (30ft) in every gear and direction. ・ Move the steering full stroke each way about 2〜3 times.

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

Dispose of properly.

2. Remove the covers and start the engine.

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

Refer to "Replace Engine Oil" page 124 and "Replace Transmission Oil" page 126.

4. Start the engine and check for any abnormalities.

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

92

SPECIAL PROCEDURES

Welding Cautions Regarding Welding Repair Service If welding is needed to repair the chassis, observe the following precautions to protect the hydraulic cylinders, hydraulic units, gear sets, and electrical units from possible damage.

1) Turn the starter switch OFF. 2) Leave the machine as it is more than 1 minute.

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

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

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

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

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

Example 1:

Section to be welded Do not ground this section.

Electric current may flow through the cylinders.

Ground this section. (correct grounding)

Example 2:

Do not ground this section.

Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

93

SPECIAL PROCEDURES

7) The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins.

There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes.

Be sure to mask these units and parts before welding. a) Plated section Cover the plated sections with heat-resistant cloth, such as glass wool or canvas .

Note: The weld spattered on the plated sections causes corrosion.

Hydraulic cylinder

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

Scrap material, etc.

1m or more

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

Section to be welded

1m or more

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

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

Remove and if necessary Chassis wrap

94

Serial Number Location

MAINTENANCE Before performing maintenance or repairs, read, understand and follow "Safe Maintenance" section page 11.

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

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

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

1. Machine Serial Number

Standard specification

SERIAL No.

HEAVY INDUSTRIES, LTD. MADE IN JAPAN

2. Engine Serial Number

3. Transmission Serial Number

TRANSMISSION

Model

ＭＯＤＥＬ ＰＳ６５０Ａ０１ ＳＥＲＩＡＬ ＮＯ

Serial Number

KAWASAKI

Design Number

95

Serial Number Location

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

MODEL SER. NO. PATEN NO.

ROCKLAND ROCKLAND MFG. CO., BEDFORD, PA. USA

5. ROPS Serial Number

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

ROPS: Model Number Serial Number

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

CERTIFICATION TEST W EIGHT （ＭＯＤＥＬ）

（ＲＯＰＳ ＭＯＤＥＬ ＮＯ． ）

１３５ＺⅣ−２

ＲＰ１４

１３５ＺⅣ−３

（ｋｇ） ９０， ６００

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

6. CAB Serial Number

SERIAL NO.

OR-89

Engine S/N CAB S/N

ROPS S/N

Bucket S/N

Machine S/N

Transmission S/N

96

４４７８３−２１１５０

Inspection and Maintenance Table

Inspection and Maintenance Table Section

Items for check

Page

Check oil and water leak Check oil level

○

56

Check coolant level

○

57

Check air filter (warning lamp)

○

66

Check exhaust gas color

○

69

Drain water from fuel filter

○

58

Check fuel level

○

Drain water from fuel tank

Engine

Operating hours When 50 250 500 1000 2000 Required

Daily ○

55

66 109

○

Check and adjust belts

○

116

Replace oil filter cartridge

○

112

Clean crankcase breather tube

○

116

Check air intake system

○

117

Replace DCA coolant filter cartridges

○

114

Replace fuel filter cartridge

○

113

Replace oil

124

○

Check compression pressure

130

○

Check injection pressure

○

130

Check injection timing

○

130

Clean fuel tank

○

142

Check valve lash clearance

○

141

Check vibration damper

○

140

Replace coolant

○

138

Grease trunnion mount

○

145

Clean air cleaner element

○

100

Clean radiator fins

○

101

After six cleanings or once a year ○

100

Replace air cleaner element Check oil level

66

○

Replace oil filter elements (main)

122

○

Replace oil filter cartridge (for control valve)

○

130

Replace oil

○

126

Clean or replace breather

○

128

Check tire air pressure

○

59

Check tire for damage

○

61

○

63

Axle system Grease axle support Check oil level (diff. and planet.)

○

117

Check tightness of wheel bolt

○

118

97

Inspection and Maintenance Table

Section

Items for check

Operating hours Daily

50

250

Grease differential

When Required 500 1000 2000

Replace gear oil (diff. and planet.)

Steering system Brake system

Check steering operation

○

144

○

136,137 69

○

Grease steering cylinder pins

108

○

Check service brake operation

○

68

Check parking brake operation

○

68

Check brake accumulators Check hydraulic oil level

57

○

106〜108

○

Replace return filter

○

128

Clean filter for pilot pump control line

○

133

Replace hydraulic oil, Clean suction strainer

○

134

Replace filter for pilot pump control line

○

141

Replace bucket teeth

Chassis

Electrical system

○

Check rear view mirrors

○

Check ROPS and mounting bolts

○

Grease center pins

62 108

Check seat belt

○

100

Check windshield washer fluid

○

102

Check monitor panel operation

○

62

Check horn operation

○

68

Check back-up alarm operation

○

69

Check wiring harnesses

○

59 110

○

Check fuses

○

102

Check compressor belt

○

119

Clean filter

○

119

Check refrigerant

129

○

Replace filter elements

○

103

Clean condenser

○

103

(6000)

141

Replace receiver dryer Others

99 62

○

Check battery electrolyte level

Air Conditioner

140

○

Grease pins Loading system

132

○

Axle system Grease propeller shaft

Page

Walk-around inspection

○ ○

98

55

WHEN REQUIRED MAINTENANCE

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures.

A. Replace Bucket Teeth CAUTION Teeth and bucket edges are hardened steel which may chip when struck by steel hammer causing injury. ・ Always wear eye protection. ・ Use deadblow hammer or brass drift between hammer and tooth. ・ Keep bystanders away from work area.

Tooth

Pin

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

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

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

Tooth adapter

3. Stop the engine.

[ESCO "Vertalok" tooth shown] 4. Remove the pin and tooth using a tool.

Guide rib facing back

5. Install the tooth onto the tooth adapter.

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

7. Tap the pin in flush ear using 2 to 4 pound hammer.

NOTE:

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

99

2 to 4-pound hammer

WHEN REQUIRED MAINTENANCE

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

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

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

C. Clean or Replace Air Cleaner Elements When the warning monitor lamp lights up, clean or replace the air cleaner elements.

２

IMPORTANT Improper procedure of cleaning air cleaner may cause severe engine damage. ・ Do not clean or replace air cleaner while engine is running. ・ Clean only outer element. Never clean inner element. ・ Clean or replace element only when indicator lamp comes on. ・ Never clean the elements by bumping or hitting them against a solid surface.

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

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

3. Remove the outer element.

4. If the element is clogged by dirt or dust, move to an area away from the machine and spray dry compressed air (196kPa)(2kgf/cm2)(30psi) along the inside of the element up and down to blow off dust.

100

１

WHEN REQUIRED MAINTENANCE

5. Insert a lamp inside of the element for checking a damaged element. ３ 6. If bright light spots are seen through the element, there are cracks or pinholes in the element. Replace it with a new element.

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

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

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

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

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

2. Blow off mud, dirt, or clogging debris from the radiator fins with compressed air. Use a pressure washer or steam cleaner to remove harder debris.

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

IMPORTANT High pressure air, water, or steam may damage radiator fins.

2

・ Be sure pressure is below 196kPa(2kgf/cm )(30psi). ・ Move nozzle from side to side; not up and down.

2

If pressure exceeds 196kPa(2kgf/cm )(30psi), keep nozzle at least 50cm (20in) away from surface of radiator core.

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

101

WHEN REQUIRED MAINTENANCE

NOTE:

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

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

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

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

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

Refer to "Fuse Box" page 50.

5. Determine the cause of the blown fuses.

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

Never replace fuses with higher amperage rating.

F. Check Windshield Washer Fluid 1. Park the machine on a level ground, apply the parking brake, and lower the attachment to the ground.

2. Check the fluid level.

3. Replace the fluid if it is dirty.

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

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

102

WHEN REQUIRED MAINTENANCE

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

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

2. Inspect the condenser and replace it if any damage is found.

3. Clean its fins using compressed air, a pressure washer, steam cleaner, or a soft brush. Be sure the air pressure is below 196kPa(2kgf/cm2)(30psi). If a pressure washer or steam cleaner is used, keep the nozzle about 50cm (20in) away from the fins to prevent fin damage.

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

H. Replace Air Conditioner Filter Elements Outer filter replacement

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

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

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

Turn the rings counterclockwise and then remove the cover.

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

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

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WHEN REQUIRED MAINTENANCE

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

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

Unscrew the turn knob to remove the filter cover.

Remove the filter and replace with new one.

Inner filter Filter cover

104

DAILY MAINTENANCE

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures.

See "Check before Operation" page 55 and "Check after Starting the Engine" page 66.

105

EVERY 50Hrs MAINTENANCE

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures.

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

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

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

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

Refer to "Recommended Lubricants" page 146 for the correct grease. ・ Bucket-Boom (two places)

・ Bucket-Rod (two places)

106

EVERY 50Hrs MAINTENANCE

・ Lever-Rod (two places)

・ Lever-Boom (two places)

・ Bucket Cylinder-Lever (two places)

・ Bucket Cylinder-Front Chassis (two places)

・ Boom Cylinder-Boom (two places)

107

EVERY 50Hrs MAINTENANCE

・ Boom Cylinder-Front Chassis (two places)

・ Boom-Front Chassis (two places)

・ Steering Cylinder (four places)

・ Center Pin (upper) ・ Center Pin (lower)

108

EVERY 50Hrs MAINTENANCE

B. Drain Water and Sediment from Fuel Tank CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from fuel tank. ・ Do not drain fuel with engine running. ・ Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

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

2. Prepare a suitable container.

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

4. Drain water and sediment along with some fuel.

5. Close the drain cock.

6. Properly dispose of the drained fuel and water.

7. Add fuel.

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

109

EVERY 50Hrs MAINTENANCE

C. Check Battery Electrolyte Level WARNING Batteries produce explosive gases which could cause burns or blindness. ・ Ventilate area to remove explosive gases. ・ Wear eye or face protection when working on or around batteries. ・ Keep flames and sparks away from batteries.

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

It could shorten the battery life. It may also emit sparks from the deterioration parts in the case, as a result a battery explosion.

Keep the battery electrolyte level up to the proper level.

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

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

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

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

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

3. Check the battery electrolyte level in each cell. Electrolyte should cover the cell plates.

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

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

110

Low

OK

High

EVERY 250Hrs MAINTENANCE

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures.

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

A. Replace Engine Oil Filter Cartridges CAUTION Hot oil and engine components may cause burns.

Avoid contact with hot oil or engine components.

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

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

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

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

(The QST30 engine uses four full-flow and two bypass filters.)

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EVERY 250Hrs MAINTENANCE

4. Clean the oil filter head gasket surface.

5. Fill the new filters with clean engine oil.

Refer to "Recommended Lubricants" page 146 for the oil specifications.

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

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

Refer to the instructions supplied with the filter.

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

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

10. Check the oil level.

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

CAUTION Used engine oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

112

EVERY 250Hrs MAINTENANCE

B. Replace Fuel Filters CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from fuel filter. ・ Do not drain with engine running. ・ Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

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

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

3. Remove and properly dispose of the fuel filters.

4. Clean the filter head gasket surface.

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

6. Fill the filters with clean fuel.

7. Install the filter on the filter head.

Turn it until the gasket contacts the filter head surface.

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

113

EVERY 250Hrs MAINTENANCE

C. Replace DCA4 Coolant Filter Cartridges CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

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

CAUTION Hot coolant and engine components can cause burns.

Avoid contact with coolant or engine components.

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

2. Press the button on the radiator tank cap to release any remaining pressure, and remove the cap slowly.

ＰＵＳＨ

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

4. Remove and properly dispose of the coolant filters (1).

２

１ 5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of a new DCA4 coolant filter cartridges (WF2075).

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EVERY 250Hrs MAINTENANCE

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

Follow the instructions

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

9. Run the engine and check for coolant leaks.

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

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

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

Refer to "Coolant Specification" page 147 for the correct mixture.

D. Clean Crankcase Breather Tube Every 250 hours or 6 months, check and clean the crankcase breather tube or hose.

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

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

115

EVERY 250Hrs MAINTENANCE

E. Check and Adjust Belt Tension CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine side panel.

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

2. Open the engine side panel.

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

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

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

5. Apply pressure approximately 98N(10kgf)(22lb) to the center of the belt between the pulleys. Correctly adjusted belts will deflect one belt thickness per foot (30cm) of pulley center distance.

Adjustment 1. Loosen the bolts (1) (2) (3) and lock nut (5) (6).

１ ４

2. Turn the adjusting link (4) to adjust the belt tension correctly.

６

3. Tighten the bolts and nuts.

５ ３

116

２

EVERY 250Hrs MAINTENANCE

F. Check Air Intake System CAUTION Hot engine components may cause burns.

Avoid contact with hot engine components.

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

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

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

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

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

G. Check Differential Gear Oil 1. Park the machine on a level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Remove the oil level plug from the front axle housing, using a 12mm hex (Allen) wrench.

3. If the oil level is lower than the plug, add the specified oil through the level plug hole.

Refer to "Recommended Lubricants" page 146.

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

5. Retighten the level plug.

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

117

Front Axle

EVERY 250Hrs MAINTENANCE

H. Check Planetary Gear Oil 1. Check the oil level on all four wheels.

2. Move the machine on a level ground so that "TOP" mark (1) on the planetary gear housing comes top.

１

ＴＯＰ

3. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

２

4. Remove the oil level plug (2) on the housing, using a 12mm hex (Allen) wrench.

5. If the oil level is lower than the plug, add the specified oil through the level plug hole.

Refer to "Recommended Lubricants" page 146.

6. Magnetic plugs are used for the planetary gear housing.

Wipe off the small amount of fine metallic powder that normally sticks to the plugs. If abnormal debris is found, determine the cause and correct it.

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

8. Retighten the plug.

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

2. Check the wheel bolts are tightened to 892N-m(91kgf-m) (658ft-lb). ＴＯＰ

3. Retighten if necessary.

118

EVERY 250Hrs MAINTENANCE

J. Check and Adjust Air Conditioner Belt CAUTION Contact with moving belts or pulleys may cause injuries.

Stop engine before opening engine side panel.

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

2. Open the engine side panel.

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

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

5. Measure the belt tension using a belt tension gauge so that it is applied 637 ± 98N (65 ± 10kgf) (143 ± 22lb).

6. If the belt is too loose or tight, adjust the tension by loosening the four lock bolts (1) and turning the unt (2).

7. Tighten the lock bolts (1).

１

K. Clean Air Conditioner Filter Element Outer filter cleaning

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

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

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

Turn the rings counterclockwise and then remove the cover.

119

２

EVERY 250Hrs MAINTENANCE

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. Use air pressure below 196kPa(2kgf/cm2)(30 psi).

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

7. After approximately 20 cleanings, replace the filter with new one.

Refer to "Replace Air Conditioner Filter Elements" page 103.

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

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

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

Unscrew the turn knob to remove the filter cover.

Remove the filters and clean.

Inner filter Filter cover

120

EVERY 250Hrs MAINTENANCE

2. Remove dust with compressed air. Use air pressure below 196kPa(2kgf/cm2)(30 psi).

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

4. After approximately 20 cleanings, replace the filter with new one.

Refer to "Replace Air Conditioner Filter Elements" page 103.

5. Install the filter elements, install the filter cover.

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

121

EVERY 500Hrs MAINTENANCE

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures.

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

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

Avoid contact with hot oil or components.

1. If the machine is cold, operate the machine to bring the torque converter oil temperature about 30 to 40° C (85 to 105 ° F).

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

3. Place a suitable container (about 15 liters (4gal.)) under the transmission oil filters.

4. Remove the drain plugs from the bottom of the filter cases with 24mm wrench.

5. Remove the filter cases with 46mm wrench.

6. Replace the elements with new ones.

7. Replace the seals with new ones.

8. Clean the cases with solvent.

9. Clean the filter head gasket surface.

122

EVERY 500Hrs MAINTENANCE

10. Apply a light film of clean engine oil to the seals surface of the new filters.

11. Reinstall the filters on the filter head.

12. Clean and install the oil drain plugs.

13. Idle the engine about ten minutes and inspect for leaks around the filters.

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

When inspecting or servicing machine in articulation area: ・ Lower attachment to ground. ・ Put transmission shift lever in neutral. ・ Apply parking brake. ・ Make sure nobody is on machine. ・ Place "DO NOT OPERATE" tag on steering wheel.

9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 66.

If needed, add the required amount of the oil.

Refer to "Recommended Lubricants" page 146 for the specified oil.

CAUTION Used oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

123

EVERY 500Hrs MAINTENANCE

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

Avoid contact with hot oil or engine components.

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

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

3. Remove the drain plug from the drain port.

4. Drain oil, about 133liters (35.1gal.), into a suitable container.

5. Clean and install the oil drain plug, and tighten to 80N・m (8.2kgf-m)(60ft-lb) torque.

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

Refer to "Recommended Lubricants" page 146 for the oil specifications. Total system capacity including the filter is 133liters (35.1gal).

7. Idle the engine to inspect for leaks at the drain plug.

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

9. Check the oil level again.

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

124

EVERY 500Hrs MAINTENANCE

11. Properly dispose of or recycle the waste oil.

CAUTION Used engine oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

125

EVERY 1000Hrs MAINTENANCE

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures.

Every 1000 hours or 6 months, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", and "500 hours" inspection and maintenance.

A. Replace Transmission Oil WARNING Accidental movement of machine could result in death or serious injury.

When inspecting or servicing machine in articulation area: ・ Lower attachment to ground. ・ Put transmission shift switch in neutral. ・ Apply parking brake. ・ Make sure nobody is on machine. ・ Place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel.

CAUTION Transmission oil may be hot and may cause burns.

Avoid contact with hot transmission oil.

1. If the machine is cold operate the machine for a few minutes to bring the transmission oil temperature about 30 to 40° C (85 to 105° F).

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

126

EVERY 1000Hrs MAINTENANCE

3. Remove the drain plug (1) with a 24mm wrench.

３

4. Drain oil into a suitable container (about 200liters (52.8gal.)).

Properly dispose of or recycle the waste oil.

１

5. Loosen the eight bolts (2) with a 17mm wrench.

6. Remove the flange (3) together with the pipe and suction strainer.

7. Remove the set screw from the strainer. Remove the suction strainer from the flange. Brush off any debris and clean with solvent.

It is normal for a few fine particles to be on the strainer.

Large pieces or a large quantity of particles indicates a problem.

Contact a Kawasaki loader dealer.

8. Remove the magnet plate from the transmission bottom side, then clean it.

After cleaning, put the magnet plate in the transmission bottom side.

9. Reassemble the strainer and flange assembly.

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

11. Tighten the eight bolts (2) to 44N-m(4.5kgf-m)(33ft-lb).

12. Fill with the specified oil.

Refer to "Recommended Lubricants" page 146.

13. Idle the engine and check for leaks.

14. Check the oil level gauge. Add the specified oil if necessary to maintain the proper oil level.

Refer to "Check Transmission Oil Level" page 66 and "Recommended Lubricants" page 146.

127

２

２

Set screw

Flange Gasket Strainer

EVERY 1000Hrs MAINTENANCE

B. Check and Replace Transmission and Torque Converter Breather Element 1. Park the machine on level ground, apply the parking brake, lower the attachment to the ground, and stop the engine.

2. Remove the breather from the transmission case and torque converter case.

2pcs on the transmission case 1pc on torque converter case 3. Clean the breather with solvent, then spray with dry compressed air to dry.

Even after cleaning, if the breather is not clean enough, replace the breather.

4. Install the breather back onto the transmission case and torque converter case.

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

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before opening.

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

３

４ ２ １

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

3. Open the cover on the left deck.

４

4. Insert the key into the side of the filler cap and turn the key counterclockwise.

5. Press down firmly on the filler cap (1) to relieve the tank pressure.

6. Clean around the top of the filter covers (2).

128

２

EVERY 1000Hrs MAINTENANCE

7. Remove two bolts (3) with a 19mm wrench and open the filter cover (2).

The two bolts (3) may be used as "Jacking screws" to push up the cover. Install them into the two threaded holes (4) in the cover. Screw them in equally to force the cover up evenly.

8. Remove the O-ring, spring, and bypass valve from the filter housing.

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

O-ring

10. Clean the inside of the filter housing.

Spring

11. Replace the element and O-ring.

Bypass valve

12. Apply a light film of clean hydraulic oil on the filter cover O-ring surface.

13. Install the new filter element, bypass valve, spring, new O-ring, and filter cover.

14. Close the access cover.

D. Check Air Conditioner Refrigerant 1. Apply the parking brake and lower the attachment to the ground.

2. Remove the cap.

3. Press the "FAN UP Arrow Switch" to set maximum air flow.

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

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

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

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

Always maintain refrigerant in normal level.

129

Filter element

EVERY 1000Hrs MAINTENANCE

Amount of refrigerant

Appearance of the sight glass

Normal

Almost clear.

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

High

No bubbles are seen.

Solutions

Contact your local Kawasaki loader dealer for inspection and recharging refrigerant.

Low

A flow of bubbles is visible.

E. Check and Adjust Engine Contact your nearest Kawasaki loader dealer or local Cummins engine dealer for checking and adjusting the following items: ・ Engine Compression Pressure ・ Injection Pressure ・ Injection Timing

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

Avoid contact with hot oil or components.

1. If the machine is cold, operate the machine to bring the torque converter oil temperature about 30 to 40° C (85 to 105 ° F).

2. Park the machine on a level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

3. Place a suitable container (about 4 liters (1gal.)) under the transmission oil filter.

130

EVERY 1000Hrs MAINTENANCE

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

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of the new filter.

7. Install the filter on the filter head. Follow the instructions on the filter.

8. Idle the engine about ten minutes and inspect for leaks around the filter.

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

When inspecting or servicing machine in articulation area: ・ Lower attachment to ground. ・ Put transmission shift lever in neutral. ・ Apply parking brake. ・ Set articulation stopper in "LOCKED" position. ・ Make sure nobody is on machine. ・ Place "DO NOT OPERATE" tag on steering wheel.

9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page 66.

If needed, add the required amount of the oil.

Refer to "Recommended Lubricants" page 146 for the specified oil.

CAUTION Used oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

131

EVERY 1000Hrs MAINTENANCE

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

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page 146 for the correct grease. Use lithium base grease for universal joints. ・ Front Differential (one place) ・ Rear Differential (one place)

H. Replace Filter in the Oil Tank Cap CAUTION Pressurized hydraulic tank is used for this machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before opening.

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

１

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

５ ４

3. Insert the key into the side of the filter cap (1) and turn the key counterclockwise.

4. Press down the filter cap (1) to relieve the tank pressure.

5. Remove the filter cap.

３

6. Remove spiral snap ring (2), valve assy (3), spring (4), filter element (5).

7. Replace element (5).

8. Install the element, spring, valve assy, and spiral snap ring.

132

２

EVERY 1000Hrs MAINTENANCE

I . Clean Filter for Pilot Pump Control Line CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

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

2. Place a suitable container (about 2liters (0.5gal.)) under the oil filter.

3. Remove the filter case (5) with 24mm wrench.

4. Remove the element (3) and inspect and clean it by a toothbrush.

Remove the spring (4) and inspect and clean it with solvent and compressed air.

5. Install the element (3) , new O-ring (1), new backup ring (2) and spring (4) to the filter case (5).

6. Install and tighten the filter case (5) to 25 〜 34N-m (2.5 〜 3.5kgf-m)(18.1〜25.3ft-lb) on the filter head.

１ ２ ３

7. Check for oil leakage from the filter after installing the filter case (5).

４

Parts to be replaced Symbol

Part Name

Part Number

Q'ty

1

O-ring

47131-73540

1

2

Backup ring

47194-70800

1

CAUTION Used oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

133

５

EVERY 2000Hrs MAINTENANCE

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

Read, understand, and follow all warnings and instructions contained in "Safe Maintenance" page 11 before performing any inspection or maintenance procedures.

Every 2000 hours or 1 year, whichever comes first, perform the following inspection and maintenance in addition to the "Daily", "50 hours", "250 hours", "500 hours", and "1000 hours" inspections and maintenance.

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

Pressurized hot oil may cause injury or burns.

Vent all pressure counterclockwise.

by

slowly

turning

cap

1/3

turn

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

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

3. Insert the key into the side of the filler cap (1) and turn the key counterclockwise.

4. Press down firmly on the filler cap (1) to relieve the tank pressure.

5. Remove the filler cap (1) .

CAUTION Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil.

6. Prepare a suitable container to catch the draining oil (about 680liters (180gal.)).

134

１

EVERY 2000Hrs MAINTENANCE

7. Open the drain cock (2) with a 24mm wrench to drain oil.

３

8. Dispose of the waste oil properly.

9. Remove the nuts with a 17mm wrench to remove the inspection cover (3).

10. Remove the set screws in the suction strainers. Remove the suction strainers. Inspect and clean them with solvent and compressed air.

A few small particles in the strainer is normal. Large metal, rubber pieces, or a large amount of fine particles is abnormal. If found, contact your Kawasaki loader dealer.

２

４

11. Clean inside of the tank and magnet plug (4).

CAUTION Compressed air may cause injury. ・ Wear protective clothing and eye protection.

2 ・ Air pressure must be below 196kPa(2kgf/cm )(30psi).

12. Install the suction strainers, set screws, new gasket and inspection cover (3) and tighten the nuts evenly. Do not overtighten.

13. Close the drain cock (2).

14. Add the specified hydraulic oil through the oil inlet hole.

Refer to "Recommended Lubricants" page 146.

15. Close the oil filler cap (1).

16. Start the engine and allow the engine to idle for about five minutes.

17. Operate the bucket, boom, and steering cylinders for about five minutes, then lower the attachment to the ground.

Level gauge

18. Inspect for leaks.

19. Make sure hydraulic oil is to the lowest position of the oil level gauge. Add hydraulic oil if necessary.

10mm (0.4in)

Lowest position

135

EVERY 2000Hrs MAINTENANCE

B. Replace Differential Gear Oil CAUTION Differential gear oil may be hot and may cause burns.

Avoid contact with differential gear oil.

1. If the machine is cold operate the machine for a few minutes to bring the differential gear oil temperature about 40° C (105 ° F).

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

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

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

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

Simply wipe it off.

4. Drain the oil (about 220liters (58gal.)) into a suitable container.

5. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

Note: While the oil is drained measure brake wear as described in item H. 6. Install the drain plug.

7. Refill the recommended oil through the level plug hole (1) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page 146.

136

１

２

EVERY 2000Hrs MAINTENANCE

8. Install and tighten the level plug.

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

C. Replace Planetary Gear Oil CAUTION Planetary gear oil may be hot and may cause burns.

Avoid contact with planetary gear oil.

1. Move the machine on a level ground so that "TOP" mark (1) on the planetary gear housing comes to the top.

１ ＴＯＰ

2. Turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine. ２

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

3. Remove the level plug (2) and drain plug (3) from the planetary gear housing, using a 12mm hex (Allen) wrench.

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

Simply wipe it off.

4. Remove the drain plug(4) from the brake housing.

5. Drain the oil (about 50liters (13gal.)) into a suitable container.

6. Dispose of the waste oil properly.

CAUTION Used oil may cause skin disease.

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

Clean skin thoroughly with soap and water.

137

4

３

EVERY 2000Hrs MAINTENANCE

7. Install and tighten the drain plugs.

8. Refill the recommended oil through the level plug hole (2) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page 146.

9. Install and tighten the level plug.

10. Repeat these steps for all four planetaries.

D. Replace Coolant ・ Since the Anti-Freeze "Long Life Coolant" (LLC) is originally used for the machine shipped from the factory, it is not normally necessary to replace the coolant for the first two years. ・ If the cooling system conditioner (from a local supplier) is used at the time of last replacement, follow its instructions or contact your nearest Kawasaki loader dealer for the replacement interval.

CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant may cause burns.

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

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

2. Inspect all coolant hoses.

Replace any that are cracked, swollen, or brittle.

3. Press the button (1) to release any remaining pressure.

１

4. Remove the cap (2) slowly.

ＰＵＳＨ

２

138

EVERY 2000Hrs MAINTENANCE

5. Open the drain cocks (3), (4) and drain coolant (about 270liters (71.3gal.)) into a suitable container.

Do not remove the coolant filter.

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

４

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

Avoid contact with skin and eyes to prevent injury.

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

Do not install the radiator cap.

8. Operate the engine for one hour with the coolant temperature above 80° C (180° F).

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

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

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

11. Operate the engine for five minutes with the coolant temperature above 80° C (180° F).

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

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

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

Refer to "Coolant Specification" page 147 for the mixing instruction.

139

３

EVERY 2000Hrs MAINTENANCE

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

16. Replace the DCA4 coolant filter (WF2075).

Refer to "Replace DCA4 Coolant Filter" page 114 for the procedure.

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

18. Add coolant as neccessary.

19. Reinstall the radiator cap.

For additional cold weather servicing information, refer to "Coolant Specification" page 147 for details.

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

2. Check the damper on the fan end of the engine crankshaft.

3. If dents, cracks, or any deformations are found, contact your nearest Kawasaki loader dealer or Cummins engine dealer for replacement.

F. Check Brake Accumulators Test the brake accumulator for proper precharge of Nitrogen gas.

WARNING Pressurized Nitrogen gas in brake accumulator could explode causing serious injury or death.

Never service brake accumulator unless trained properly.

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

140

EVERY 2000Hrs MAINTENANCE

2. Run the engine at low idle for five minutes to fill the brake accumulators with oil.

3. Stop the engine.

4. Turn the key switch to the "ON" position.

5. Count the number of times you can depress the brake pedal before the brake warning light comes on.

6. If the number counted is less than five, there is some problem with the accumulators. Contact your nearest Kawasaki loader dealer.

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

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

I . Replace Filter for Pilot Pump Control Line CAUTION Hot oil and components may cause burns.

Avoid contact with hot oil or components.

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

2. Place a suitable container (about 2liters (0.5gal.)) under the oil filter.

3. Remove the filter case (5) with 24mm wrench.

4. Remove the element (3) and the spring (4). Inspect and clean the spring (4) with solvent and compressed air.

5. Install new element (3) , new O-ring (1), new backup ring (2) and spring (4) to the filter case (5).

6. Install and tighten the filter case (5) to 25 〜 34N-m (2.5 〜 3.5kgf-m)(18.1〜25.3ft-lb) on the filter head.

141

EVERY 2000Hrs MAINTENANCE

7. Check for oil leakage from the filter after installing the filter case (5).

Parts to be replaced Symbol

Part Name

Part Number

Q'ty

１

1

O-ring

47131-73540

1

２

2

Backup ring

47194-70800

1

3

Filter element

30981-70570

1

３ ４

CAUTION Used oil may cause skin disease.

５

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

Clean skin thoroughly with soap and water.

J. Clean Fuel Tank CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from tank. ・ Do not drain with engine running. ・ Do not allow fuel to remain on skin for extended period of time. Wash thoroughly with soap and water.

NOTE:

It is the easiest to clean the fuel tank when the fuel is almost empty.

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

２

2. Open the drain cock (1) on the bottom of the fuel tank.

3. Drain the remaining fuel into a suitable container.

１ 4. Remove the nuts with a 17mm wrench to remove the inspection cover (2).

142

EVERY 2000Hrs MAINTENANCE

5. Clean inside of the tank.

6. Install the inspection cover with a new gasket. Tighten the nuts. Do not overtighten.

7. Close the drain cock.

8. Fill the fuel tank.

9. Check for any leaks at the cover and the drain cock.

143

EVERY 2000Hrs MAINTENANCE

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

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page 146 for the correct grease. Use lithium base grease for universal joints. ・ 1st Propeller Shaft (two places)

・ 2nd Propeller Shaft (five places)

・ 3rd Propeller Shaft (two places)

144

EVERY 2000Hrs MAINTENANCE

・ Engine Trunnion Mount (one place)

145

Recommended Lubricants

Recommended Lubricants Ambient Temperature Kind of Oil

Engine

Engine oil (CE or CF4)

Capacity S/N~0104 147 liter (38.8gal.)

200 liter (52.8gal.)

ATF

Hydraulic & Brake system

Engine oil (CD)

Differential & Planetary

Gear Lubricant

Fuel tank

Diesel fuel

SAE 10W-30 SAE 15W-40

S/N0105~ 142 liter (37.5gal.)

Engine oil (CD) Transmission

‐２２° −４° １４° ３２° ５０° ６８° ８６°Ｆ ‐３０°‐２０°−１０° ０°Ｃ １０° ２０° ３０°

SAE 10W Mobil TRANS HD-10 Multi-Purpose ATF

720 liter (190.2gal.) ＊1 [310 liter refill (81.9gal.)]

Front :317 liter (83.7gal.)

Rear :317 liter (83.7gal.)

Change Interval (Hours)

500

1,000

SAE 10W

2,000

MOBIL TRANS HD-50

2,000

1050 liter (277.4gal.)

ASTM D975 No.2 ASTM D975 No.1

daily

Note : ＊1 shows "Hydraulic tank oil capacity at indication plate of level gauge with bucket on ground."

Engine

Use oil that meets engine oil classification "CE" or "CF4".

Transmission

Use engine oil classification "CD" SEA 10W or Mobil TRANS HD-10 or Multi-purpose Automatic Transmission Fluid.

Never mix engine oil, Mobil TRAMS HD-10 and/or ATF.

Hydraulic & Brake System

Use engine oil classification SAE 10W. Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use.

Never mix engine oil and hydraulic oil.

Differential & Planetary

Use Mobil TRANS HD-50 or equivalent.

Lubricating Grease

Use multipurpose-type molybdenum grease.

146

Coolant Specification

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

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

Recommended Mixture of Antifreeze Expected Minimum Ambient Temperature

-35 ° C (-31 ° F)

-30 ° C (-22 ° F)

-25 ° C (-13 ° F)

-20 ° C (-4 ° F)

-15 ° C (5 ° F)

Pure Water

liter (gal)

127 (33.5)

140 (37)

154 (40.7)

167 (44.1)

181 (47.8)

Antifreeze

liter (gal)

143 (37.8)

130 (34.3)

116 (30.6)

103 (27.2)

89 (23.5)

53

48

43

38

33

Mixture Ratio (%)

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

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

IMPORTANT Do not mix different brands of antifreeze because they each contain special additives. Careless mixing often diminishes the effect of these additives that causes the packing damage or water leakage.

147

TROUBLESHOOTING

TROUBLESHOOTING This troubleshooting section is not intended to cover every condition, however many of the common possibilities are listed.

Following are example of problems and their solutions.

Contact your local Kawasaki loader dealer for items marked with Ｋａｗａｓａｋｉ CUMMINS ENGINE dealer for items marked with ＣＵＭＭＩＮＳ to repair.

or your local authorized

ENGINE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

Low engine oil level Wrong grade oil for weather conditions Clogging oil filter element Engine oil pressure Defective alarm switch warning lamp lights up, and buzzer sounds Oil leakage from pipe or joint Exessive engine wear Defective oil pump

Add oil Change oil Change filter and oil

Low engine coolant level Loose/slipping/broken fan belt Clogging radiator fins Coolant temp. warning Scale or mineral build up inside radiator lamp lights up Defective alarm switch (gauge is in green) Low water pump flow Thermostat stuck or missing

Add coolant Adjust or replace belt Clean Flush or professionally clean

Fuel filter element clogging Engine does not start Starter motor speed too low when the starter motor Defective engine shut off solenoid is turning Fuel pump failure (Also see Incorrect fuel injection timing ELECTRICAL Compression pressure too low TROUBLESHOOTING) Defective injectors

Replace fuel filter Booster Battery may be used

Air in fuel lines Fuel filter element clogging Unstable (rough) idling Fuel pump failure Incorrect fuel injection timing

Tighten fuel connections and filter Replace fuel filter

Insufficient power

Air cleaner element clogging Fuel filter element clogging Throttle linkage adjustment wrong Engine oil level too high Incorrect valve clearance Piston ring wear Defective injectors Fuel pump failure

148

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

ｏｒ

ｏｒ

ｏｒ

ｏｒ

ｏｒ

56

112,124

ＣＵＭＭＩＮＳ

57 116 101 138

ＣＵＭＭＩＮＳ

113 89

ＣＵＭＭＩＮＳ

116 116

ＣＵＭＭＩＮＳ

Clean or replace element Replace fuel filter Check and adjust linkage Check dipstick and correct level Ｋａｗａｓａｋ ｉ

PAGE

ＣＵＭＭＩＮＳ

100 113 56

TROUBLESHOOTING

PROBLEM

SOLUTIONS

PAGE

Use correct type of oil Correct oil level

146 56

Unusual combustion noise or mechanical noise

Wrong type of oil Engine oil level too low or too high Defective injectors Incorrect valve clearance Main bearing / con-rod bearing wear Crankshaft uneven wear Connecting rod bent Timing gear wear Water pump bearing wear Failed turbo or muffler

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

Fuel being diluted with water Wrong grade fuel Incorrect fuel injection timing Compression pressure too low Turbo seal leakage

Replace with specified fuel and replace fuel filter

Clean or replace element

Black exhaust smoke

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

Warning lamp lights up

POSSIBLE CAUSES

Engine failure

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

ｏｒ

ｏｒ

ＣＵＭＭＩＮＳ

116

ＣＵＭＭＩＮＳ

Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

100

47

ELECTRICAL PROBLEM

Charge lamp lights up

POSSIBLE CAUSES

SOLUTIONS

PAGE

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

Adjust or replace belt Replace battery

116

Transmission not in NEUTRAL Starter motor does not Insufficient battery charge turn when starter Starter switch failure switch key is turned to Defective wiring "START"

Starter motor turns engine slowly

Hydraulic control levers not in NEUTRAL Insufficient battery charging Engine oil viscosity too high (thick) Poor connection at batteries or ground Defective wiring Starter motor failure 149

Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

Shift to NEUTRAL Battery charge or booster

22 89

Ｋａｗａｓａｋ ｉ Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

Move levers to NEUTRAL Battery charge or booster Replace oil Clean and tighten all terminals Ｋａｗａｓａｋ ｉ Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

26 89 124

TROUBLESHOOTING

STEERING PROBLEM

Hard steering

Will not steer

Steering drift

POSSIBLE CAUSES

SOLUTIONS

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

Oil pressure too low Steering valve failure Steering cylinder failure

Check/adjust tire pressure Change operation

Articulation stopper in locked position

Move articulation stopper to "STORED" position Reduce load

Excessive load on steering Steering valve failure Orbitroll failure Pump failure Relief valve failure Steering cylinder failure Excessively cold oil / Wrong grade oil

PAGE 59

Ｋａｗａｓａｋ ｉ

22

Ｋａｗａｓａｋ ｉ

Warm oil / Replace oil with proper viscosity for temperature

146

HYDRAULIC PROBLEM

Boom raises too slowly

Boom natural drift is excessive

Bucket / Attachment floating or drifting

POSSIBLE CAUSES

SOLUTIONS

PAGE

Excessively cold oil Wrong grade oil Oil pressure too low Damaged cylinder piston or piston packing Pump flow too low Pilot pressure too low Engine RPM too low

Warm oil Replace with proper grade oil

146

Excessively cold oil / Wrong grade oil

Warm oil / Replace oil with proper viscosity for temperature

Ｋａｗａｓａｋ ｉ

Leakage from control valve plunger Damaged cylinder piston or piston packing Leakage in pilot relief valve

Ｋａｗａｓａｋ ｉ

Over load relief pressure too low Control valve failure Natural drift of cylinder / packing

Ｋａｗａｓａｋ ｉ

150

146

TROUBLESHOOTING

BRAKE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

Parking brake does not work properly

Insufficient oil pressure (will not release) Failure of switch or solenoid valve Poor wiring or ground to switch or solenoid valve

Brake dragging

Dirt, debris under base of brake pedal Warped brake discs Air in brake oil circuit Auto-adjuster valve failure

Braking power too low

Air in brake oil circuit Brake piston seal leakage

Ｋａｗａｓａｋ ｉ

Brake pressure drops rapidly

Cracked or leaking brake line Brake valve failure Defective brake accumulator

Ｋａｗａｓａｋ ｉ

PAGE

Ｋａｗａｓａｋ ｉ

Remove or clean Ｋａｗａｓａｋ ｉ

TORQUE CONVERTER & TRANSMISSION PROBLEM

Engine is running but machine does not move

POSSIBLE CAUSES

SOLUTIONS

PAGE

Excessively cold oil / Wrong oil type

Warm oil / Replace oil with proper viscosity for temperature

146

Parking brake is applied Transmission oil level too low Transmission suction strainer clogging Clutch oil pressure too low Transmission clutch failure Transmission controller failure Defective electrical circuit

Release parking brake Add oil / Repair leak Clean strainer

151

Ｋａｗａｓａｋ ｉ

66 126

TROUBLESHOOTING

PROBLEM

Low power

POSSIBLE CAUSES Engine speed too low.

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

SOLUTIONS

PAGE

Inspect and correct Refill oil / Repair leak Clean or replace strainer

66 126

Ｋａｗａｓａｋ ｉ

Oil leakage from transmission

Air breather clogged Seal damage (between engine and torque converter housing)

Clean and refill with oil

Torque converter overheat

Oil level too low Dozing, continuous pushing application Operating in too high a speed range Long downhill driving Radiator clogged: coolant temp also high Defective alarm switch (gauge is in green) Torque converter / Transmission failure Oil pressure too low

Add oil / Repair leak Reduce load Use lower gear Change application Clean radiator fins

128

Ｋａｗａｓａｋ ｉ

66 72 101

Ｋａｗａｓａｋ ｉ

AIR CONDITIONER / HEATER PROBLEM

POSSIBLE CAUSES

SOLUTIONS

Low cooling when A/C "ON"

Hot water continues to flow through heater core A/C not set for maximum cooling Condensor fins plugged A/C filters plugged A/C compressor belts slipping/broken A/C refrigerant charge low

Shut off valve in heater hose line at block Adjust controls/vents Clean Clean or replace Adjust/Replace

Engine not warmed up No hot water flow to heater core Air conditioner running Heater vents not adjusted properly Defective heater motor or switch

Warm up engine Open shut off valve on block Turn A/C off Adjust controls/vents

Low heater out put

152

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

PAGE

QUANTUM FAULT CODE INFORMATION

These codes show the fault codes for the engine failure checked by the diagnostic switch.

FAULT CODE/ LAMP

REASON

EFFECT(Only when fault code is active)

111 Red

Error internal to the Electronic Control Module Engine will not start.

(ECM) related to the memory hardware or internal microprocessor communications failures.

113 Yellow

More than 6.2 amps detected at the timing sleeve actuator circuit pin 6 of the engine harness.

No action by the ECM is taken.

The engine may have low power outputs, loud combustion noise, and produce black smoke.

114 Yellow

Less than 1.0 amp is detected at the timing sleeve actuator circuit pin 6 of the engine harness.

No action by the ECM is taken.

Engine emits white smoke and loses power.

122 Yellow

More than 4.72 volts is detected at the intake Engine power derate to no-air setting. manifold air pressure sensor signal pin 45 of the engine harness.

123 Yellow

Less than 0.33 volts is detected at the intake Engine power derate to no-air setting. manifold air pressure sensor signal pin 45 of the engine harness.

131 Red

More than 4.20 volts is detected at the throttle position signal pin 30 of the OEM interface harness.

Calibration-dependent power and speed derate.

132 Red

Less than 0.13 volts is detected at throttle position signal pin 30 of the OEM interface harness.

Calibration-dependent power and speed derate.

133 Red

More than 4.82 volts is detected at the remote throttle position signal pin 9 of the OEM interface harness.

Calibration-dependent power and speed derate.

134 Red

Less than 0.12 volts is detected at the remote throttle position signal pin 9 of the OEM interface harness.

Calibration-dependent power and speed derate.

More than 4.88 volts is detected at oil pressure sensor signal pin 33 of the engine harness.

Engine protection for oil pressure is disabled.

Less than 0.31 volts is detected at the oil pressure sensor signal pin 33 of the engine harness.

Engine protection for oil pressure is disabled.

135 Yellow 141 Yellow

153

QUANTUM FAULT CODE INFORMATION

FAULT CODE/ LAMP

REASON

EFFECT(Only when fault code is active)

Depending upon calibration, progressive power Low oil pressure has been detected. Voltage signal at oil pressure signal pin 33 of the engine derate and engine shutdown with increasing 143 harness indicates oil pressure lower than 69 kPa time after alert.

Engine [10 psi] at engine speeds less than 800 rpm; 155 Protection kPa [22.5 psi] at 1200 rpm; 241 kPa [35 psi] above 1600 rpm.

144 Yellow

More than 4.95 volts is detected at the coolant Engine protection for coolant temperature is temperature signal pin 23 of the engine harness. disabled.

145 Yellow

Less than 0.21 volts is detected at the coolant Engine protection for coolant temperature is temperature signal pin 23 of the engine harness. disabled.

147 Red

A frequency of less than 150 Hz has been detected at the frequency throttle signal, pin 14 of the engine harness.

Calibration dependent power and speed derate.

148 Red

A frequency of more than 400 Hz has been detected at the frequency throttle signal, pin 14 of the engine harness.

Calibration dependent power and speed derate.

High coolant temperature has been detected.

Calibration dependent progressive power and speed derate and engine shutdown as temperature increases over thresholds.

151 Voltage signal at coolant temperature signal pin Engine 22 indicates coolant temperature above 100 ℃ Protection

[212 ° F].

153 Yellow

More than 4.88 volts is detected at intake manifold air temperature signal pin 34 of the engine harness.

Engine protection for intake manifold air temperature is lost.

154 Yellow

Less than 0.08 volts is detected at intake manifold air temperature signal pin 34 of the engine harness.

Engine protection for intake manifold air temperature is disabled.

High intake air manifold temperature has been

Depending on the calibration, a progressive power and speed derate and engine shutdown as the temperature increases over thresholds.

155 detected. Voltage signal at intake manifold air Engine temperature signal pin 34 indicates intake Protection

manifold air temperature above 104 ℃ [220 ° F].

166 Yellow

The rack position sensor indicates that the rack position is greater than a calibrated threshold.

No action by the ECM is taken.

172 Red

Fuel control rack is stuck in a position commanding excessive fueling to the engine.

Engine shutdown.

154

QUANTUM FAULT CODE INFORMATION

FAULT CODE/ LAMP

REASON

173 Yellow

Fuel control rack is stuck in a position providing adequate, or less than adequate, fueling to the engine.

No action is taken by the ECM.

184 Red

Primary and / or secondary ECM identification error.

Module identification at powerup will fail, both modules will run as slaves.

221 Yellow

More than 4.78 volts is detected at the ambient No action is taken by the ECM. air pressure signal pin 32 of the engine harness.

222 Yellow

Less than 0.20 volts is detected at the ambient No action is taken by the ECM. air pressure signal pin 32 of the engine harness.

231 Yellow

More than 4.72 volts is detected at the coolant pressure sensor signal pin 24 of the engine harness.

Engine protection for coolant pressure is disabled.

232 Yellow

Less than 0.33 volts is detected at the coolant pressure sensor signal pin 24 of the engine harness.

Engine protection for coolant pressure is disabled.

EFFECT(Only when fault code is active)

Calibration dependent progressive power and Low coolant pressure has been detected.

Voltage signal at coolant pressure signal pin 24 speed derate and engine shutdown with increasing time after alert. of the engine harness indicates coolant 233 pressure lower than 28 kPa [4 psi] at 800 rpm; Engine Protection 41 kPa [6 psi] at 1300 rpm; 76 kPa [11 psi] at 1800 rpm; 96 kPa [14 psi] at 2000 rpm; and 103 kPa [15 psi] above 2100 rpm.

234 Red

Engine speed signals on pin 17 of the engine harness indicate an engine speed greater than 2650 rpm.

The EHAB (fuel shutoff valve) is de-energized, (closed). The EHAB (fuel shutoff valve) is re-energized (opened) when engine speed falls below 2130 rpm.

Low coolant level has been detected. Voltage

Calibration-dependent progressive power and speed derate, and engine shutdown with increasing time after alert.

235 signal on the coolant level signal pin 37 of the Engine engine harness indicates low radiator coolant Protection

level in the vehicle.

252 Yellow

Low voltage detected at the lubricating oil level sensor supply pin 49 of the engine harness.

No action taken by the ECM.

Voltage signal on the oil level signal pin 49 of the Engine will not start.

253 engine harness indicates low oil level in the Engine Protection engine.

155

QUANTUM FAULT CODE INFORMATION

FAULT CODE/ LAMP

REASON

EFFECT(Only when fault code is active)

254 Red

Less than 16.5 volts detected at fuel shutoff valve solenoid supply pin 43 of the engine harness.

No action is taken by the ECM. Low voltage to the EHAB will cause it to stop fuel flow to the corresponding pump, and shut down that engine bank.

259 Red

EHAB (fuel shutoff valve) is open and will not close.

ECM commands rack position to zero, which stops fueling corresponding engine bank.

342 Red

The primary and secondary ECM calibrations do Engine will not start. not match.

343 Yellow

Microprocessor communication error internal to the ECM.

Variable; performance will or will not be affected.

ECM power down internal data store error.

Power down data (which includes maintenance monitoring, current ECM / engine delta times, and past fault data) are lost.

346 OFF

Calibration dependent progressive power and Very low oil pressure has been detected.

Voltage signal at oil pressure signal pin 33 of the speed derate and engine shutdown with 415 engine harness indicates oil pressure lower than increasing time after alert.

Engine 34 kPa [5 psi] at engine speeds less than 800 Protection rpm; 121 kPa [17.5 psi] at 1200 rpm; 207 kPa [30 psi] at engine speeds greater than 1600 rpm.

No action taken by the ECM.

422 Yellow

Voltage detected simultaneously on both the coolant level high and low signal pins 27 and 37 of the OEM interface harness, or no voltage detected on either pin.

431 Yellow

Voltage detected simultaneously on both the idle None on performance. validation, off-idle, and idle-signal pins 25 and 26 of the OEM interface harness.

432 Red

Voltage detected at idle validation on idle signal pins 26 of the OEM harness when voltage at accelerator position signal pin 30 of the OEM harness indicates pedal is not at idle, OR voltage detected at idle validation off-idle signal pin 25 of the OEM harness when voltage at accelerator position signal pin 30 of the OEM harness indicates pedal is at rest.

156

Engine will not respond to accelerator.

Engine will idle only.

QUANTUM FAULT CODE INFORMATION

FAULT CODE/ LAMP

REASON

EFFECT(Only when fault code is active)

441 Yellow

Less than 9 volts battery voltage detected at the ECM voltage supply approaching a level at engine harness. which unpredictable operation will occur.

442 Yellow

More than 34 volts battery voltage detected at ECM.

524 Yellow

Voltage detected at pin 22 of the engine harness Droop setting defaults to switch position "1" (or is out of range. normal) preprogrammed droop governor values.

527 Yellow

Less than 17 volts detected at solenoid supply pin 41 of the engine harness.

No action is taken by the ECM.

528 Yellow

Voltage detected at pin 39 of the OEM interface harness is out of range.

Torque curve setting defaults to switch position 2 (or lowest) preprogrammed torque curve.

551 Yellow

No voltage detected simultaneously on both the Engine will default to zero percent throttle. idle validation off-idle and idle-signal pins 25 and 26 of the OEM interface harness.

High crankcase blowby pressure has been

555 detected. Voltage signal at blowby pressure Engine signal pin 25 indicates blowby pressure above Protection

ECM damage will occur.

Calibration dependent progressive power and speed derate and engine shutdown as pressure increases over thresholds.

368mm H2O [14.5 in H2O].

719 Yellow

More than 4.94 volts detected at the blowby pressure sensor signal pin 25 of the engine harness.

Engine protection for blowby flow rate is disabled.

729 Yellow

Less than 0.29 volts detected at the crankcase blowby pressure sensor signal pin 25 of the engine harness.

Engine protection for blowby flow rate is disabled.

157

SPECIFICATIONS

SPECIFICATIONS

16 ′ 2 ″ (4,945)

7 ′ 1/4 ″ (2,140) 13 ′ 5 ″ (4,090)

19 ′ 9 3/4 ″ (6,040)

14 ′ 6 ″ (4,420)

13 ′ 7 3/4 ″ (4,160)

Specifications shown are for a machine equipped with standard features. Some options or special attachment will change the specifications shown. Specifications subject to change without notice.

15 ′ 9 ″ (4,800) 42 ′ 3 7/8 ″ (12,900)

158

SPECIFICATIONS

3

3

Bucket Capacity

12yd (9.2m ) (Heaped) 10.5yd3 (8.0m3) (Struck)

Operating Load

16,600kg (36,596 lb)

Operating Weight

174,384lb (79,100kg) (with RVT bucket and standard tire)

Engine Model Type Displacement Rated Power Max. Torque(NET)

Cummins QST30 -C 4 cycle, Water Cooled, Turbo charged direct injection 30.5L 537kW / 2,100min-1 (730ps / 2,100rpm) (720HP / 2,100rpm) 3,334N-m / 1,000min-1 (340kgf-m / 1,000rpm) (2,459lb-ft / 1,000rpm)

Tire (standard)

45/65-R39-(L-5) Radial

Max. Running Speed (forward/reverse)

1st 2nd 3rd Lockup

Rock Bucket with Teeth (RVT)

: 6.9/ 7.7km/h ( 4.3/ 4.8MPH) : 12.8/14.8km/h ( 8.0/ 8.9MPH) : 24.4/27.3km/h (15.2/ 17 MPH) : 30.0/ - km/h (18.6/ - MPH)

159

INDEX

INDEX A Accelerator Pedal・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・27

Check before Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・55

Adjust and Check Rear View Mirrors・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・62

Check Brake Accumulators・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・140

Air Cleaner Warning Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・45

Check Control Lever・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・63

Articulation Stopper・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・22

Check Differential Gear Oil・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・117

To lock・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・22

Check Engine Coolant Level・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・57

To unlock・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・22

Check Engine Oil Level・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・56

Articulation Stopper・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・59

Check Exhaust Gas・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・69

Auto Brake・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・74

Check Fuel Level・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・66

Auto Brake Indicator Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・42

Check Horn Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・68

Auto Shift Indicator Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・45

Check Hydraulic Oil Level・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・57 Check K-Lever and Forward/Backward Changeover Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・63 Check Monitor Panel Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・62 Check or Replace Fuses・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・102

B

Check Parking Brake・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・62

Before Starting Safety・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・2

Check Parking Brake Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・68

Boom Kickout Adjustment・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・85

Check Planetary Gear Oil・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・118

Boom Soft Landing Height Adjust Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・39

Check Service Brake Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・68

Boom Soft Landing Positioner Adjustment・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・86

Check Steering Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・69

Boom Soft Landing Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・33

Check Tightness of Wheel Bolts・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・118

Booster Batteries/Jumper Cables・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・89

Check Tire Air Pressure・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・59

Brake Oil Temperature Warning

Check Tire for Damage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・61

and BrakeDisk Wear Alarm Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・43

Check Transmission Oil Level・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・66

Brake Pressure Warning Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・43

Check Vibration Damper・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・140

Brake Pedals・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・28

Check Warning Lamps・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・66

Bucket/Attachment Positioner Adjustment・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・84

Check Windshield Washer Fluid・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・102 Check Wiring Harnesses・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・59 Clean Air Conditioner Condenser・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・103 Clean Air Conditioner Filter Element・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・119

C

Clean Crankcase Breather Tube・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・115

Carrying・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・80

Clean Filter for Pilot Pump Control Line・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・133

Central Warning Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・42 Charge Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・45

Clean Fuel Tank・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・142 Clean or Replace Air Cleaner Element・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・100

Check after Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・66

Clean Radiator Fins・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・101

Check Air Conditioner Refrigerant・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・129

COMPONENT NAME/LOCATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・24

Check Air Intake System・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・117

Coolant Specification・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・147

Check and Adjust Air Conditioner Belt・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・119 Check and Adjust Belt Tension・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・116

D

Check and Adjust Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・130 Check and Adjust Valve Lash Clearance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・141

Daily Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・105

Check and/or Replace Seat Belt・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・100

Diagnostic Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・36 Dozing・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・79

Check and Replace Transmission and Torque Converter Breather Element・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・128

Drain Water and Sediment from Fuel Filter・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・58

Check Back-up Alarm Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・69

Drain Water and Sediment from Fuel Tank・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・109

Check Battery Electrolyte Level・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・110

Dumping into Truck or Hopper・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・81 160

INDEX

E

H

Electrical Protection・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・50

Heater or Air Conditioner・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・52

Emergency Brake・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・22

Ventilation Location and Mode・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・52

Emergency Steering(option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・23

Switches・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・52

Engine Coolant Temperature Gauge・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・41

Operation of the Automatic Temperature

Engine Coolant Temperature Warning Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・44

Control unit・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・53

Engine Grid Air Heater Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・47

High beam Indicator Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・45

Engine Mode Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・33

Horn Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・38

Engine Oil Pressure Warning Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・44

Hour Meter・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・46

Engine Stop Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・39 Engine Warning Lamps ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・47

I

Every 50 Hours or 1 Week

Increment Decrement Switch ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・37

Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・106

Indicators・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・40

Every 250 Hours or 1 Month

Inspection and Maintenance Table・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・98

Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・111 Every 500 Hours or 3 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・122

K

Every 1000 Hours or 6 Months

K-Lever・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・25 K-Lever ON/OFF Display Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・42

Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・126 Every 2000 Hours or 1 Year

K-Lever Steering System Lock・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・21

Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・134 Excavating・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・78 Explosion/Fire/Burn Prevention・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・13

L Ladder Light Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・33

F

Light Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・32

Forward/Backward Changeover Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・38

Long Term Storage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・91

Front Wiper Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・35

Before Storage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・91

Front Working Light Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・32

During Storage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・91

Fuel Level Gauge・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・41

After Storage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・92

Fuse Boxes・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・50

Loading・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・77

Fusible Links・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・51

Loading Control Lever・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・26 Boom Control・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・26 Bucket Control・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・27

G

Loading Control Lever Lock・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・21

General Inspection・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・70 Greasing・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・63 Greasing・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・106

M

Greasing・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・132

MAINTENANCE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・95

Greasing・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・144

Mounting and Dismounting Safety・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1

Ground Leveling・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・79

N Neutral Start System・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・22 Neutral Indicator Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・45 161

INDEX

O 3OPERATOR'S AREA・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・25

Replace Hydraulic Oil Return Filter・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・128

OPERATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・55

Replace Planetary Gear Oil・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・137

Operational Safety・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・5

Replace Transmission Oil・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・126

SITE SAFETY・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・5

Replace Transmission Oil Filter Elements・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・122

SAFETY DURING NORMAL OPERATIONS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・6

Replace Transmission Oil Filter・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・130

SPECIAL OPERATING CONDITIONS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・8

Ride Control Lamp (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・47

Operating the Machine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・71

Ride Control Switch (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・35

Operating Techniques・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・77

Ride Control System (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・54

Other Maintenance Safety Concerns・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・14

Roading/Special Applications・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・88

Operator Safety・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1

ROPS(Roll Over Protective Structure)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・23 ROPS(Roll Over Protective Structure)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・62

P S

Parking Safety・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・9 Parking・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・75

Safe Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1

Parking Brake Indicator Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・42

Safe Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・11

Parking Brake Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・31

SAFETY・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1

Pedals and Levers・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・25

Safety Devices・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・21 Safety Preparations Before Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・11

Power Boost Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・38

Safety Signs・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・16 Seat・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・48

Q

Seat Adjustment・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・48

QUAD(Quick Up and Downshift)Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・38

Seat Belt・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・49

QUANTUM FAULT CODE INFORMATION

Serial Number Location・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・95

FOR ENGINE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・153

SPECIAL PROCEDURES・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・84 Adjustments・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・84 SPECIFICATIONS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・158

R

Speed and Direction Change・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・72

Rear Working Light Indicator Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・42

Starter Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・31

Rear Working Light Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・32

Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・64

Rear Wiper Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・35

Normal Start・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・64

Recommended Lubricants・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・146 Recommended Mixture of Antifreeze・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・147

Cold Start・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・65 Starting the Machine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・71

Replace Air Conditioner Filter Elements・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・103

Starting the Machine on a Grade・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・72

Replace Air Conditioner Receiver Dryer・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・141

Steering・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・74

Replace Bucket Teeth・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・99

Steering Hydraulic Warning Lamp(option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・46

Replace Coolant・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・138

Stopping the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・76

Replace DCA4 Coolant Filter Cartridges・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・114

Switches・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・30

Replace Differential Gear Oil・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・136 Replace Engine Oil・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・124 Replace Engine Oil Filter Cartridges・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・111 Replace Filter for Pilot Pump Control Line・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・141 Replace Filter in the Oil Tank Cap・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・132 Replace Fuel Filters・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・113 Replace Hydraulic Oil・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・134 162

INDEX

T Tachometer・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・41 Torque Converter Oil Temparature Gauge・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・41 Torque Converter Oil Temperature Warning Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・44 Traction Control Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・34 Traction Control Engine Adjust Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・39 Transmission Control Warning Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・43 Transmission Cut-Off Selection Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・42 Transmission Cut-Off Selector Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・34 Transmission Oil Filter Warning Lamp・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・45 Transmission Shift Switch・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・39 Transmission Status Monitor・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・46 TROUBLESHOOTING・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・148 ENGINE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・148 ELECTRICAL・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・149 STEERING・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・150 HYDRAULIC・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・150 BRAKE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・151 TORQUE CONVERTER&TRANSMISSION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・151 AIR CONDITIONER/HEATER・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・152 Typical Truck Loading Methods・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・82

W Walk-Around Inspection・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・55 When Required Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・99 Wrist Rests・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・29

163

WARNING CALIFORNIA PROPOSITION 65

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

WASH HANDS AFTER HANDLING !

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

135Z Ⅳ -2 OPERATION & MAINTENANCE MANUAL AAA-M13C1U01-008(93117-00010) 93117-00011

① 2000.11.30 ③ 2001.6.25

K

② 2001.5.10 ④ 2005.1.10

Construction Machinery Division Tokyo Head Office

W.T.C. Bldg., 2-4-1 Hamamatsu-cho Minato-ku, Tokyo 105-6116

Kobe Head Office

Kobe Crystal Tower, 1-1-3 Higashi Kawasaki-cho Chuo-ku, Kobe, Hyogo 650-8680

Banshu Works

2680 Oka Inami-cho Kako-gun, Hyogo 675-1113

All rights reserved. No copy allowed without written consent.