Kawasaki WHEEL LOADER 95ZIV-3 OPERATION & MAINTENANCE MANUAL AAA-M97C3E01-006 (1)

AAA-M97C3E01-006 (93115-00092)

OPERATION & MAINTENANCE MANUAL WHEEL LOADER

95Z -3 WITH CUMMINS N14-C ENGINE

SERIAL NUMBERS 97C3-1001 and up.

97C3-9001 and up.

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

FOREWORD Congratulations on your purchase of the Kawasaki Wheel Loader 95ZIV-3.

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.

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

MACHINE SPECIFICATION Specification

Serial numbers

Remarks

Standard specification

97C3 -1001 and up

Europe specification

97C3 -9001 and up

With CUMMINS N14 -C Engine

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. 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・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・24 COMPONENT NAME / LOCATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・27 OPERATOR'S AREA・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・28 Pedals and Levers・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・28 Switches・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・34 Indicators・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・39 Seat・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・46 Electrical Protection・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・48 Air Conditioner (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・50 Vibration Damper (option)・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・53 Grease Gun Holder・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・53 OPERATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・54 Check Before Operation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・54 Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・62 Check after Starting the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・65 Operating the Machine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・69 Parking・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・72 Stopping the Engine・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・73 Operating Techniques・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・74 SPECIAL PROCEDURES・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・80 Adjustments・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・80 Roading / Special Applications・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・83 Booster Batteries / Jumper Cables・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・84 Towing・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・86 Transportation・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・87 Long Term Storage・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・89

MAINTENANCE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・91 Serial Number Location・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・91 Inspection and Maintenance Table・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・93 When Required Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・95 Daily Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・101 Every 50 Hours or 1 Week Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・102 Every 250 Hours or 1 Month Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・107 Every 500 Hours or 3 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・120 Every 1000 Hours or 6 Months Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・122 Every 2000 Hours or 1 Year Inspection and Maintenance・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・129 Recommended Lubricants and Capacity・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・140 Coolant Specification・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・141 TROUBLESHOOTING・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・142 SPECIFICATIONS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・147 PERIODICAL REPLACEMENT PARTS LIST・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・149

SAFETY

SAFETY Safe Operation Operator Safety

Read and understand the Operation & Maintenance Manual.

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

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

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

Mounting and Dismounting Safety

Face the machine when mounting or dismounting.

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

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

Climb and step only where steps and handrails are provided.

1

SAFETY

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

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

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

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

Do not allow unauthorized personnel on the machine.

Before Starting Safety

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

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

2

SAFETY

Perform the normal daily maintenance.

Be sure the following safety devices work or are positioned properly. ・Parking Brake -- Applied ・Control Lever Lock -- Locked Ｌｏｃｋ Ｕｎ ｌ ｏｃｋ

・Transmission Shift Lever -- Neutral

Ｎ

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

Securely lock the cab door either fully open or closed.

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

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

3

SAFETY

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

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

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

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

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

Properly fasten the seat belt.

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

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

4

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

SAFETY

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 84.

Operational Safety SITE SAFETY:

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

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

Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

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

5

SAFETY

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

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

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

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.

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

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

6

SAFETY

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

Do not exceed the recommendations and limits.

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

approx. 40cm (16in)

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

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

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

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

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

7

SAFETY

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

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

8

SAFETY

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.

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).

9

SAFETY

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. Follow the Operation & Maintenance Manual or Shop Manual.

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

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

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

Before performing any maintenance: ・Park on 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).

11

SAFETY

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

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

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

DANGER

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

ＤＯ ＮＯＴ ＳＴＡＲＴ ＭＥＮ ＷＯＲＫＩＮＧ ＯＮ ＭＡＣＨＩＮＥＲＹ Ｓ ＩＧＮＥＤ ＢＹ ＤＡＴＥ

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

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

Explosion / Fire / Burn Prevention

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

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

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

12

SAFETY

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

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

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

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

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

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

Stay away until the tire and rim cool down.

13

SAFETY

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

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

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

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

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

Other Maintenance Safety Concerns

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

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

Stop the engine before opening the engine side panel.

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

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

14

SAFETY

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

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

Do not enter the articulation area when engine is running.

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

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

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

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

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 here.

Read them and understand them thoroughly. They contain information which is important for the safe operation and the safe maintenance. Follow the directions on the safety signs carefully.

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

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

DANGER

No room in this area when turning.

Crushing will cause serious injury or death.

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

44787-20810

16

SAFETY

WARNING

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 loader dealer.

44787-20760

WARNING

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

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

44787-20740

17

SAFETY

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

44787-20750

WARNING

Machine will not turn with articulation stopper in locked position.

Unlock articulation stopper before operating machine.

44787-21060

18

SAFETY

WARNING

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

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

44787-20840

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

19

SAFETY

WARNING

Batteries produce explosive gases which can cause burns or blindness.

Keep flames and sparks away.

Vent area before servicing.

44787-20800

WARNING

Batteries contain lead, and acid which causes burns.

Avoid contact with skin or clothing.

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

44787-20770

20

SAFETY

CAUTION

Contact with moving belts or pullies will cause injuries.

Stop engine before working in this area.

44787-20860

CAUTION

Contact with fan will cause injury.

Keep all guards in place.

Keep hands away from fan area.

44787-20850

21

SAFETY

CAUTION

Pressurized system: spray of hot fluid could cause burns.

Allow system to cool and vent pressure slowly before servicing.

44787-20820

22

SAFETY

CAUTION

Compressed spring may accidently be released and cause injury.

Read Shop Manual before repairing this part.

44787-20830

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

23

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 levers to prevent accidental lowering of the attachment or boom. ・ To lock, set the loading control levers to "NEUTRAL" and pull-up the lock lever to forward. ・ To unlock, push down the lock lever to backward.

Ｌｏｃｋ Ｕｎ ｌ ｏｃｋ

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

Do not lock Articulation Stopper during normal operation.

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

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

2. Using a 14mm wrench remove the bolt that fixes the articulation stopper to the storage bracket under the hydraulic oil tank.

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

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

24

"LOCKED" position

SAFETY

5. 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.)

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

Neutral Start System

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

Emergency Brake

When the service brake does not work, emergency brake can be applied manually. ・ Pull the emergency brake switch to engage the emergency brake and disengage the transmission.

25

“ＳＴＯＲＥＤ”ｐｏｓ ｉ ｔ ｉ ｏｎ

SAFETY

Emergency Steering (Option except Europe specification) WARNING Operation without normal steering could cause loss of control and injury or death.

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

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

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

Refer to "Steering Hydraulic Warning Lamp" page 45.

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

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

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

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

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

ROPS (Roll Over Protective Structure) (Option except Europe specification) WARNING Operating with damaged or improperly mounted ROPS could cause serious injury or death. Be sure to observe the following. ・ Whenever seated,fasten the seat belt. (If equipped) ・ Do not modify ROPS, such as drilling or welding. ・ Do not use ROPS deformed. ・ If any damage or loose bolts are found, do not operate until

repaired.

・ Never repair or modify ROPS without manufacturer's

approval and instructions.

26

COMPONENT NAME/LOCATION

COMPONENT NAME / LOCATION １８ １３

４ ３

１

６

８

５

２

１１

１５

１４

1. Bucket (Attachment) 2. Boom 3. "Z" Lever 4. Boom Cylinders 5. Bucket Cylinders 6. Engine 7. Torque Converter & Transmission Ass'y 8. Radiator, Torque Converter Cooler (Lower tank), & Hydraulic Oil Cooler 9. Fuel Tank (Right hand side)

９，１０ ７ １６

１２

１７

10. Hydraulic Oil Tank (Left hand side) 11. Front Axle / Differential Ass'y 12. Rear Axle / Differential Ass'y 13. Air Cleaner (Right hand side) 14. Parking Brake 15. 2nd Propeller Shaft 16. 3rd Propeller Shaft 17. Batteries (one each side--two 12VDC=24VDC system) 18. ROPS (Option except Europe specification)

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.

27

OPERATOR'S AREA

OPERATOR'S AREA Pedals and Levers 11

2

1

3

4

6 （ｏｐｔｉｏｎ） 7

5 9

10 9 8

1. Transmission Shift Lever 2. Horn Button 3. High-Low Beam Lever / Turn Signal Lever (option) 4. Boom Control Lever 5. Bucket Control Lever 6. Auxiliary Attachment Control Lever (option) 7. Wrist Rest 8. Accelerator Pedal 9. Brake Pedals 10. Steering Column Tilt Handle 11. Steering Wheel

1. Transmission Shift Lever

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

28

OPERATOR'S AREA

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

2. Horn Button

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

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

29

Flash position

High beam position

OPERATOR'S AREA

4. Boom Control Lever

Boom control lever is used to control the boom movement. (a) Float

・ Move the lever to full forward detent position.

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

(b) Lower

・ Move the lever forward. The boom will lower.

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

(c) Hold

・ Return the lever to the center position.

The boom will stop and remain in that position.

(d) Raise

・ Move the lever rearward. The boom is raised. ・ An automatic boom height positioner (option) 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 81.

（ｃ（ ）ｄ） （ｂ） （ａ）

5. Bucket Control Lever

Bucket control lever is used to control the bucket or attachment movement. (a) Dump

・ Move the lever forward. The bucket or attachment will dump.

(b) Hold

・ Return the lever to the center position.

The bucket or attachment will stop and remain in that position.

(c) Roll Back ・ Move the lever rearward half way. The (Dual Motion) bucket or attachment will roll back slowly. ・ When the boom control lever is in the "Raise" detent position, both bucket or attachment and boom will move slowly.

30

（ｃ） （ｄ） （ｂ） （ａ）

OPERATOR'S AREA

(d) Roll Back

・ Move the lever rearward. The bucket or attachment will roll back. ・ An automatic bucket or attachment leveler is provided which will automatically release the detent and return the lever to the "Hold" position when the bucket or attachment reaches to the preset angle. ・ For adjustment procedure refer to "Bucket Positioner Adjustment" page 80.

6. Auxiliary Attachment Control Lever (option)

Auxiliary attachment control lever is used to control the auxiliary attachment such as log clamps, multi-purpose buckets, etc.. (a) Normally this position will close the attachment. (b) This center position will cause the attachment to stop and remain in that position. (c) Normally this position will open the attachment.

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

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

7. Wrist Rest

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

To adjust the position (High/Low or Front/Rear loosen the screws.

31

（ｂ） （ｃ） （ａ）

OPERATOR'S AREA

8. 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.

9. 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 selector switch (See page 36) to the "OFF" position. Use this position when working on slopes or ramps.

2. Disengage the transmission while applying the brakes.

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

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

32

OPERATOR'S AREA

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 selector switch when operating on a grade.

10. Steering Column Tilt Handle WARNING Unexpected movement of steering column could cause loss of control and result in death or serious injury. ・ Stop machine before adjusting angle of steering column. ・ Be sure to pull up fully the tilt handle before operating

machine.

Steering column tilt handle is used to tilt the steering column forward or backward for operator's comfort.

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

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

33

Release Lock

OPERATOR'S AREA

Switches

６ ７

20

10

0 100min-130

C

H

C

H

F E

１

１０８ ９

１１

１２ ３

２

1. Starter Switch 2. Parking Brake Switch 3. Light Switch 4. Front Working Light Switch ( ＊ ) 5. Rear Working Light Switch 6. Transmission Cut-Off Selector Switch

４ ５

0000001/10h

AUTO N 4 3 2 1

7. Cold Start (ether infection) Switch 8. Front Wiper Switch ( ＊ ) 9. Rear Wiper Switch ( ＊ ) 10. Cigarette Lighter ( ＊ ) 11. Power Up Switch ( ＊ ) 12. Cab Electrical Mirror Switch (option) ( ＊ : Option except Europe specification)

1. Starter Switch "OFF"

"ON"

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・Key can be either inserted or pulled out.

Engine is stopped and most electrical circuits are turned off. ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・Current flows to all circuits.

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

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

34

ＯＦＦ ＯＮ ＳＴＡＲＴ

OPERATOR'S AREA

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

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

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

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

3. Light Switch

This is a three position switch.

"OFF"

: 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.

4. Front Working Light Switch (Option except Europe specification) 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.

35

OPERATOR'S AREA

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.

6. Transmission Cut-Off Selector Switch

Transmission cut-off selector switch is used to change the function of the brake pedals.

Normally this switch should be "ON".

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

Refer to "Brake Pedals" page 32 for the function of the left brake pedal.

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 selector switch to "ON" when operating on a grade.

7. Cold Start (ether injection) Switch

Cold Start Switch is used for easy engine starting in cold weather. Ether is injected into the engine after turning this switch to "ON" and "OFF".

Refer to "Cold Start" page 63 for proper use.

36

OPERATOR'S AREA

8. Front Wiper Switch (Option except Europe specification) Front wiper switch is used to wipe the front windshield and spray solvent.

"OFF"

:

"INT"

: Intermittent

"LOW"

: Low speed INT

"HIGH" : High speed

LOW

OFF

HIGH

"PUSH" : Spraying solvent on the windshield PUSH

9. Rear Wiper Switch (Option except Europe specification) Rear wiper switch is used to wipe the rear windshield.

"OFF"

:

"ON"

: Low speed

"PUSH" : Spraying solvent on the windshield

OFF

ON

PUSH

10. Cigarette Lighter (Option except Europe specification) Cigarette lighter is used to light a cigarette or cigar. ・ Push the lighter in and wait for a few seconds.

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

37

OPERATOR'S AREA

11. Power Up Switch (Option except Europe specification) Power up switch is used to quickly shift down the transmission from 2nd gear to 1st gear without moving the transmission shift lever. ・ When operating the machine in 2nd speed with the shift lever in 2 or A position, the transmission will shift down to 1st gear by pressing power up switch. ・ Pressing power up switch again, moving the transmission shift lever to the neutral position, or operating the parking brake switch releases the 1st gear setting to return the transmission to 2nd gear.

12. Cab Electrical Mirror Switch (option)

This switch is to adjust the cab mirror direction electrically.

Before pushing the see-saw switch, decide which cab mirror should be adjusted. ・ Push the see-saw switch R to adjust the right mirror, on the other hand push the see-saw switch L to adjust the left mirror.

toggle switch

L

R see-saw switch

・ Move the toggle switch up / down / right / left to adjust the disignated mirror direction.

38

OPERATOR'S AREA

Indicators

２２

２１ ５ １８ ２０９ ６１９７

２４ １０

１ ４

AUTO

N

２

P

4 3 2 1

x100min-1

２６

２５

Ｆ Ｅ

２３ ８

1. Tachometer 2. Engine Coolant Temperature Gauge 3. Torque Converter Oil Temperature Gauge 4. Fuel Gauge 5. Parking Brake Indicator Lamp 6. Auto Brake Indicator Lamp 7. Transmission Cut Off Selection Lamp 8. Working Light Indicator Lamp 9. Central Warning Lamp 10. Transmission Control Warning Lamp 11. Brake Pressure Warning Lamp 12. Engine Oil Pressure Warning Lamp 13. Engine Coolant Temperature Warning Lamp

３

１２ １３ １４ １５ １６ １７

14. Torque Converter Oil Temperature Warning Lamp 15. Air Cleaner Warning Lamp 16. Charge Lamp 17. Transmission Oil Filter Warning Lamp 18. Turn Signal Indicator Lamp (Left) (option) 19. Turn Signal Indicator Lamp (Right) (option) 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. Coolant Level Warning Lamp

When the starter switch is turned to "ON", all warning lamps (9) ～ (17), (25) and (26) light up for three seconds. This is the lamp (bulb) test period (lamp (16) lights up until engine starts).

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

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

39

１１

OPERATOR'S AREA

1.Tachometer

Indicates the engine revolutions per minute.

x100min-1

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)). °

H

C WATER TEMP

・ 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. ・ 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 141.

3.Torque Converter Oil Temperature Gauge

Indicates the temperature of oil circulating through the torque converter and the transmission. It is normal if the C (122 ～ 203 ° F)) indicator is in the green zone (50 ～ 95° 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 145.

4.Fuel Gauge

Indicates the fuel amount in the fuel tank.

F

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

E FUEL

40

OPERATOR'S AREA

5.Parking Brake Indicator Lamp (red)

Lights up when the parking brake is applied.

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

6.Auto Brake Indicator Lamp (red)

Lights up when the auto brake works.

Reger to "Auto Brake" page 71 for the detail.

7.Transmission Cut-Off Selection Lamp (green)

Lights up when the transmission cut-off selector 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 left brake pedal is depressed.

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

9.Central Warning Lamp (red)

Lights up when any of the warning lamps come on.

41

P

OPERATOR'S AREA

10. Transmission Control Warning Lamp (red) Lights up when transmission controls malfunction.

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

11. 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 ) or the pressure difference between the front and rear brake circuit is larger than 1.5MPa(15kgf/cm2 ). ・ If it lights up while operating, IMMEDIATELY stop the machine and find the cause.

Refer to "Troubleshooting" page 144.

12. Engine Oil Pressure Warning Lamp (red) Lights up when engine oil pressure is low. warning buzzer sounds.

Also the

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

Refer to "Troubleshooting" page 141.

13. Engine Coolant Temperature Warning Lamp (red) Lights up when coolant temperature overheats. (Over C (215° F)) 102° ・ 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 141.

42

OPERATOR'S AREA

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.

14. Torque Converter Oil Temperature Warning Lamp (red) Lights up when transmission oil overheats. (Over 120±5° C F)) (248±9° ・ 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 145.

15. Air Cleaner Warning Lamp (red) Lights up when air filter is clogged.

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

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

16. Charge Lamp (red)

Lights up when alternator charge level is low.

・ If it lights up, check the charging circuit.

Refer to "Troubleshooting" page 142.

17. Transmission Oil Filter Warning Lamp (red) Lights up when the transmission oil filter cloggs.

・ When lit, replace the transmission oil filter cartridge.

Refer to "Replace Transmission Oil Filter" page 120.

43

OPERATOR'S AREA

18.Turn Signal Indicator Lamp (Left) (green)(option) Flashes when the turn signal switch lever is moved forward.

19. Turn Signal Indicator Lamp (Right) (green) (option) Flashes when the turn signal switch lever is moved rearward.

20. High beam Indicator Lamp (blue)

Lights up when headlights are switched to high beam.

21. Auto Shift Indicator Lamp

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

22. Neutral Indicator Lamp

AUTO

N

Lights up when transmission is in neutral.

23. Transmission Status Monitor

・ 1st Gear

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

・ 2nd Gear Lights up when the shift lever is in 2 or A position and transmission is in 2nd gear. ・ 3rd Gear Lights up when the shift lever is in 3 or A position and transmission is in 3rd gear.

・ 4th Gear

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

44

4 3 2 1

OPERATOR'S AREA

24. Hour Meter

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

25. Steering Hydraulic Warning Lamp (red)

Lights up when the steering hydraulic pressure downs below specified when the engine is running.

26. Coolant Level Warning Lamp

Lights up when engine coolant level is lower than specified.

45

0 0 0 0 0 0

1/10h

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.

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

Stop machine before adjusting seat position.

Reclining

Rotate control handle (1) forward and hold, select backrest angle, release control handle.

Forward / Backward

Lift lever (2) up and hold, slide seat to desired position, release handle.

Suspension

Rotate handwheel (3) until your body weight is selected on indicator for maximum suspension performance. If the seat suspension is set below your body weight, excessive bouncing will occur. This will result in premature seat suspension wear and/or failure.

Seat Height

Lift front handle (4) or rear handle (5) up and hold to release lock for spring loaded seat. Adjust to desired position by adding or removing your body weight to front or rear of seat cushion. Release handles to lock.

Armrests

・Rotate control knob (6) to select desired angle. Pivot up and parallel with backrest when not in use.

Seat Belt (Option except Europe specification) WARNING Improper use or maintenance of seat belt could result in death or serious injury. ・ Inspect seat belt and mounting hardware before operating

machine and replace any defective components. ・ Always fasten seat belt when operating machine. ・ Properly adjust seat belt at beginning of each shift or when operator changes.

46

６ １ ３ ２

４ ５

OPERATOR'S AREA

1. Fasten Seat Belt along your body without kinking or twisting it.

2. Adjust the length of the seat belt on both buckle (2) and belt end (3) so that both come to the midpoint of your body front.

3. Hold buckle (2) and insert belt end (3) into buckle (2). Be sure it locks securely.

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

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

３ ２

47

１

OPERATOR'S AREA

Electrical Protection Fuse Boxes

Fuse box is located in the side console and contains thirty 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.

2 PERSONS CAB F . WIPER (LH) (OPTION)

LIGHTING HEAD LIGHT

2 PERSONS CAB F . WIPER (RH) (OPTION)

R . WORK LIGHT

R . WIPER

BOOM KICKOUT BUCKET POSITIONER

F . WIPER

BACK LAMP STOP LAMP TURN SIGNAL

CIGARETTE LIGHTER

PARKING BRAKE CONTROLLER

F . WORK LIGHT

BUZZER MONITOR

RADIO

COLD STARTER

SPARE

SPARE

SPARE

SPARE (Standard spec.)

R.WINDOW HEATING (Europe spec.)

SPARE

4 WAY FLASHER HORN

SPARE

SPARE

AIRCON (OPTION)

SPARE

AIRCON (OPTION)

FUEL VALVE

AIRCON (OPTION)

NEUTRAL RELAY

SPARE

BATTERY RELAY

48

OPERATOR'S AREA

Fusible Link

Fusible link protects the main hot wire from short circuits.

1. If the fusible link is blown, the horn will not sound.

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

Use extra caution when stopping engine by manually operate engine stop lever.

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

49

OPERATOR'S AREA

Air Conditioner (Options) Ventilation name and location DEF

DEF

DEF

FACE

FACE

FOOT FACE

Switches ４

５

３

A/C

OFF

HI

LO

２

１

1. Air Flow Control Switch

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

", "

" or "HI" to control air

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

2. Temperature Control Switch

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

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

50

switch

OFF

LO

HI

OPERATOR'S AREA

3. Air Intake Control Switch

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

4. Air Conditioner On-Off Switch

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

5. Ventilation Mode Selecting Switches

These switches are mode for selecting the ventilation mode.

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

Operation Cooling

・ For maximum cooling, open the vents FACE and close other vents. ・ If the air in the cab is very hot, ventilate the cab by opening the door and window before cooling.

C (9 ° F) ・ In summer, the ideal air temperature is about 5 ° lower than the outside temperature.

Dehumidifying

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

51

Ａ／Ｃ

OPERATOR'S AREA

Heating

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

CAUTION In dry environment cigarette smoke may irritate eyes.

Ventilate or use "

" position to take fresh air periodically.

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

Refer to "Check Air Conditioner Refrigerant" page 127.

52

OPERATOR'S AREA

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

Operation and Function

1. Before start the travelling machine, turn the vibration damper switch (1) ON. The vibration damper pilot lamp (2) comes to ON.

1 2. Move the machine forward.

The vibration damper functions automatically when the machine travelling speed reaches more than 7 km/h.

AUTO N 4 3 2 1

x100min-1

2 NOTE:

When the bucket is fully tilted the vibration damper does not work. Dump the bucket a bit when travelling.

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

53

0000001/10h Ｆ Ｅ

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

□Steps and Handrails

Damage and cleanliness

□Differentials (front and rear)

Leaks

□Hydraulic System

Leaks

□Final Drive (front and rear)

Leaks

□Covers and Guards

Damage or missing

□Transmission

Leaks

□Instrument Panel

Broken gauges or indicator lights

□Brake Lines

Damage and leaks

□Engine Compartment

Leaks, debris build-up and flammable materials left

□Battery

Loose items, leaks and debris build-up

Date :

Model-S/N :

Hours :

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

54

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 139 for the suitable viscosity of the oil according to the ambient temperature.

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

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

NOTE: Wait about 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.

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 slowly turning cap 1/3 turn counterclockwise.

55

ＭＡＸ ＭＩＮ

OPERATION

1. Lower the attachment to the ground.

2. Stop the engine.

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

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

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

Refer to "Recommended Lubricants" page 139 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 caustic burns or blindness.

Avoid contact with skin and eyes to prevent injury.

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

2. Push the button (1) on the cap (2) of the radiator tank and slowly open the cap (2).

１

3. Check the coolant level. ＰＵＳＨ

4. Coolant level is normal if coolant is to the lower part of neck pipe.

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

Refer to "Coolant Specification" page 140 for the correct mixture.

56

２

OPERATION

6. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 132.

Ｒａｄ ｉ ａ ｔ ｏｒ ｇｕａｒ ｄ

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

Ｃａｐ

Ｎｅｃｋ ｐ ｉ ｐｅ Ｗａ ｔ ｅ ｒ ｓｕｒ ｆ ａｃｅ

E. Drain Water and Sediment from Fuel Filter

・ Open the drain cock on the bottom of the fuel filter to allow water and sediment to drain into a suitable container. ・ Dispose of properly.

CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from

filter.

・ Do not drain with engine running. ・ Do not allow diesel fuel to remain on skin for an extended

period of time.

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 connection is kept clean and tight.

G. Articulation Stopper

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

57

OPERATION

H. Check Tire Air Pressure

Tire performance and its 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.

WARNING Overheated tire may explode causing serious injury or death.

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

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.

58

Low Pressure

OK

High Pressure

OPERATION

Recommended Tire Air Pressure Radial tire

29.5 R25 ☆

Air Pressure Note Front Rear 471～490kPa 373～392kPa (4.8～5.0kgf/cm2) (3.8～4.0kgf/cm2) Standard

26.5 R25 ☆

471～490kPa (4.8～5.0kgf/cm2)

373～392kPa (3.8～4.0kgf/cm2)

Pattern

Air Pressure

Note

392～412kPa (4.0 ～ 4.2kgf/cm2)

Optional

324～343kPa (3.3 ～ 3.5kgf/cm2)

Optional

Size

Optional

Bias ply tire Size 26.5-25-24PR 29.5-25-22PR

L3 L4 L5 L3 L4 L5

Same pressure for all four tires.

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.

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 manufacturers 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.

59

Beads / Bead wire

OPERATION

・ 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.

J. Check Horn Operation

1. Push the horn button in the center of the steering wheel.

2. The horn should sound loudly.

K. ROPS (Roll Over Protective Structure) (Option except Europe specification) 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.

L. 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.

M. Check Parking Brake

・ Make sure the parking brake switch is pulled up.

N. 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 39.

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

60

OPERATION

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 39 ～ 45.

O. Check Control Levers

・ Make sure the boom and tilt control levers are in the "HOLD" position.

P. Check Transmission Shift Lever

・ Make sure the transmission shift lever is in the neutral position.

61

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)) 1. Do not depress the accelerator pedal.

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

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

ＯＦＦ ＯＮ

ＳＴＡＲＴ

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

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

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

NOTE・ Do not turn the starter switch 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 141.

IMPORTANT Low engine oil pressure may cause severe engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

62

ＯＦＦ ＯＮ

ＳＴＡＲＴ

OPERATION

Cold Start(Ambient temperature below 0 ° C (32 ° F)) 1. Do not depress the accelerator pedal.

2. The turn the starter switch key to the "ON" position and press the cold start switch for two seconds. (Here the ether is filled into a metering valve and measured.)

3.

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

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

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

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

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

WARNING Ether is very flammable and could cause serious injury or death. ・ Avoid heat, electric sparks and flames near ether cylinder. ・ Do not store ether cylinders at temperature above 40° C (100° F). ・ Store ether cylinders out of children's reach. ・ When winter season is over (outside temperature is above 5° C (40° F)), remove ether cylinder from machine and store it

safely according to above instructions.

IMPORTANT Ether may cause serious engine damage.

Never attempt to inject ether into warm engine.

Use ether only as specified in this manual.

63

OPERATION

NOTE・ 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 141.

IMPORTANT Low engine oil pressure may cause engine damage.

Be sure engine oil pressure warning lamp goes out quickly.

64

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 39 for the meaning of each lamp and the correction.

10

20

0

30 100r/min

0000001/10h

AUTO N 4 3 2 1

C H C H

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 if the indicator shows below "F".

Refer to "Recommended Lubricants" page 139 for the proper 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 lever in neutral. ・ Apply parking brake. ・ Place "DO NOT OPERATE" tag on steering wheel. ・ Make sure nobody is on machine.

65

E FUEL

F E

OPERATION

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

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

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

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

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

Refer to "Recommended Lubricants" page 139.

In hot

In cold

Specified oil level

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 engine oil and auto transmission fluid.

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

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

D. Check Service Brake Operation

1. Firmly depress the right hand brake pedal.

2. Release the parking brake.

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

5. The machine should not move.

66

OPERATION

IMPORTANT If machine moves when firmly depressing right hand brake with transmission in 2nd and REVERS, 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 slope.

3. Stop the machine with the service brake.

4. Pull up the parking brake switch.

5. Release the service brakes.

6. The machine should not move.

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

Do not operate until problem has been corrected.

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

2. Release the brakes.

3. Steer fully right and then left.

4. Steering should be smooth in both directions.

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

2. Release the parking brake.

67

OPERATION

3. Move the shift lever 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 shift lever is in REVERSE position, there is some problem with back-up alarm.

Do not operate until problem has been corrected.

H. 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 142.

I . General Inspection

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

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. ・ Turn parking brake switch to "ON". ・ Do not enter or access hazardous areas of machine:

-Articulation area -Under machine -Engine compartment, etc.

68

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 above the ground.

2. Depress the brake pedal.

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

4. Turn the transmission shift lever 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.

69

approx. 40 cm

OPERATION

Starting the Machine on a Grade

1. Turn "OFF" the clutch cut-off selector switch.

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

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

Speed and Direction Change

1. Select the proper gear shifting mode by rotating the transmission shift lever. Refer to the following tables on page 70 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.

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

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

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

3. When the transmission is in the 2nd gear, it can be quickly shifted down to the 1st gear by pressing the power up switch (Option except Europe specification).

4. Pressing the power up switch again, moving the transmission shift lever to the neutral position, or operating the parking brake switch releases the 1st gear setting to return the transmission to the 2nd gear.

Refer to "Power Up Switch" page 38.

70

OPERATION

Lever

Selected Gear 1 □ 2 □ 3 □ A □

Operating Condition

1st

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

2nd

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

3rd

Carrying or roading

2nd, 3rd or 4th (automatically

Scooping, loading, carrying or roading

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

Use proper gear for each job.

Auto Brake

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

Auto Brake works under the following conditions: 1. If the machine runs above the following speeds; 1 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15km/h 2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 22km/h 3 or A ・ ・ ・ 36km/h 2. When the direction is changed while running over 11km/h.

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

Be prepared. Wear seat belt.

71

10

20

0

30 100r/min

AUTO N 4 3 2 1

0000001/10h C H C H

F E

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 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 lever 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.

72

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.

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

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

Prevent unauthorized operation.

When leaving machine for extended period of time, remove the starter key, lock cab doors or lock vandal cover over dashboard and right hand console (if equipped).

73

ＯＦＦ ＯＮ 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.

74

OPERATION

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

Reduce wheel slippage by slightly reducing engine speed.

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

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

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

9. Reverse the machine.

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

Excavating

1. Move the machine forward to the material.

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

75

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 bucket control lever to the "Roll Back" position.

6. Move the boom 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 backward, dump the bucket little by little to evenly spread material on the ground.

76

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 boom control lever in the "Float" position.

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

Be sure to run machine backward when leveling ground.

Carrying

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

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

IMPORTANT

approx. 40cm

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

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

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

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

Keep boom low for best stability especially on slopes.

77

OPERATION

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 74, 75 for the loading procedure.

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

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

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

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

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

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

Refer to "Boom Kickout Adjustment" page 86 for adjustment of the preset height .

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

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

78

OPERATION

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.

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.

79

(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).

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

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

80

２

１

SPECIAL PROCEDURES

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

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

４

３ 5 ± 2mm

Boom Kickout Adjustment (Option except Europe specification) DANGER Sudden or accidental movement of boom will result in death or serious injury.

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

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

Use safe sturdy platform to reach boom kickout adjustment.

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

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

3. Lock the bucket and boom control levers in the "Hold" position using the loading control lever lock.

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

81

SPECIAL PROCEDURES

5. Loosen the two bolts (1). Align the plate (2) with the switch (3).

１

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

7. Tighten the bolts (1).

３

8. Remove the support from the boom and linkage.

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

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

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

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

３

２ 5 ± 2mm

82

２

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.

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" 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.

83

SPECIAL PROCEDURES

Booster Batteries / Jumper Cables WARNING Improper procedure to start engine using jumper cables could cause battery case explosion. ・ Do this work by two persons. While one person sits on the

operator's seat, the other person connects jumper cables.

・ Wear eye or face protection when working on or around

batteries. ・ The booster batteries should be of similar size and capacity as the batteries being boosted. ・ Do not allow the two machines to touch. This prevents possible sparks between or in the machines being used. ・ Keep flames and sparks away from batteries. ・ Keep jumper cable ends from touching each other or machine to avoid sparks. ・ Make last connection to grounded part of frame away from battery compartment.

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

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

Keep the battery electrolyte level in the proper level.

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

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

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

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

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

84

SPECIAL PROCEDURES

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

2. Raise 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 61 .

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.

85

－

＋

＋

－

＋

－

＋

－

Booster Batteries Batteries being boosted Engine block of machine being jump started

SPECIAL PROCEDURES

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

Follow safety warnings found under "Safe Operation -Special Operating Conditions" page 8.

This machine is equipped with a hitch on the rear end for towing a troubled machine.

1. Inspect the cable for damage. Never use a damaged cable.

2. Pull the handle to open the radiator grill.

3. Connect the cable to the drawbar. Make sure the drawbar and split pin are in the original position.

4. Close the radiator grill.

5. Connect the other end of the cable to the troubled machine.

6. If the service brake on the towed machine does not work; do not allow an operator on the towed machine, and attach another vehicle of adequate size to the rear to act as a braking vehicle.

7. Keep personnel away from between the towing machine and the towed machine.

8. Tow the machine slowly with gradual and smooth movement.

9. Use flashing lights or other warning signals when towing.

If your machine must be towed, contact your nearest Kawasaki loader dealer for the necessary information or assistance.

86

SPECIAL PROCEDURES

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

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

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

2. Properly apply the brakes of the trailer and place wheel chocks in front of and behind the tires to ensure that the trailer does not move.

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

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

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

5. Lower the bucket and lock each control lever using the loading control lever lock (page 24).

6.

Apply the parking brake and set the articulation stopper in the "LOCKED" position (page 24).

7. Tape over the exhaust stack outlet to prevent turbo "Wind-milling" damage.

8. Place blocks in front of and behind the tires to prevent the machine from moving.

87

SPECIAL PROCEDURES

9. Fasten the machine to the trailer with chains or cables at 4 fixing points (red painted for Europe specification machine) provided on the machine.

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

IMPORTANT Brake pipe runs on axle housing.

Do not fasten axle housing.

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

11. In the case that it is necessary to lift the machine, sling the machine at 4 fixing points (red painted for Europe specification machine) provided on the machine as shown. ・ ・ ・34ton : Europe specification Weight・ 30ton : Standard specification ＧＲＡＶ Ｉ ＴＹ ＣＥＮＴＥＲ

88

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 102 and 107.

3. Replace engine oil, transmission oil, differential and planetary 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 ℃ .

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 140 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.

89

SPECIAL PROCEDURES

1. Check the following points.

Refer to "Check before Operation" page 55 and "Check after Starting the Engine" page 65. ・ 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 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 108 and "Replace Transmission Oil" page 122.

4. Start the engine and check for any abnormalities.

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

90

Serial Number Location

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

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

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

Europe specification ＨＥＡＶＹ ＩＮＤＵＳＴＲＩＥＳ， ＬＴＤ． ＳＥＲＩＡＬ ＮＵＭＢＥＲ

ＭＯＤＥＬ ＴＯＴＡＬ ＷＥＩＧＨＴ

ＦＡＢＲＩＣＡＴ ＩＯＮ ＤＡＴＥ

ＲＡＴＥＤＰＯＷＥＲ

ｋｇ

ｋＷ ＲＥＡＲ ＡＸＬＥ

ＰＥＲＭＩＳＳＩＢＬＥ ＬＯＡＤ：ＦＲＯＮＴ ＡＸＬＥ

Ｎ

Ｎ ＴＵＧ－ＨＯＯＫ ＶＥＲＴ． ＳＴＲＡＩＮ

ＴＵＧ－ＨＯＯＫ ＭＡＸ． ＰＵＬＬ

Ｎ

Ｎ

ＴＨＩＳ ＰＬＡＴＥ ＭＡＹ ＢＥ ＮＥＩ ＴＨＥＲＫＡＷＡＳＡＫ Ｉ ＨＥＡＶＹ ＩＮＤＵＳＴＲＩＥＳ， ＬＴＤ． ＡＬＴＥＲＥＤ ＮＯＲ ＲＥＭＯＶＥＤ． ４－１ ＨＡＭＡＭＡＴＵ ＣＨＯ ２ＣＨＯＭＥ ＭＩＮＡＴＯ ＫＵ ＴＯＫＹＯ ＪＡＰＡＮ ＭＡＤＥ ＩＮ ＪＡＰＡＮ Ｐ／Ｎ ４１６６８－２０３８０

Standard specification

SERIAL No.

KAWASAKI HEAVY INDUSTRIES, LTD. MADE IN JAPAN

2. Engine Serial Number

Ｄａ ｔ ａｐ ｌ ａ ｔ ｅ

91

Serial Number Location

3. Transmission / Torque Converter Serial Number

TRANSMISSION

Model

ＭＯＤＥＬ ＰＴ３１５Ｂ０１ ＳＥＲＩＡＬ ＮＯ

Serial Number

KAWASAKI

Design Number 4. ROPS Cab Serial Number (Option except Europe specification) SERIAL NO. Model Number Serial Number

Engine S/N

ROPS S/N (option)

Machine S/N (Right hand) Transmission S/N

92

Inspection and Maintenance Table

Inspection and Maintenance Table Section

Items for check

Daily

Check oil level Check coolant level Check air filter (warning lamp) Check exhaust gas color Drain water from fuel filter Check fuel level Drain water from fuel tank Check and adjust belts (fan,alternater,water pump) Replace oil Replace oil filter cartridge Clean crankcase breather Check air intake system Engine Replace DCA coolant filter cartridge Replace fuel filter cartridge Clean fuel tank Check compression pressure Check injection pressure Check injection timing Check valve lash clearance Check vibration damper Replace coolant Replace ether cylinder Clean air cleaner element Clean radiator fins Replace air cleaner element Check oil level Transmission Replace oil filter cartridge & Torque Replace oil Converter Clean or Replace breather Check tire air pressure Check tire for damage Axle system Grease axle support Check oil level (diff. and planet.)

Grease propeller shaft

○ ○ ○ ○ ○ ○

Operating hours When Page 50 250 500 1000 2000 Required 55 56 65 68 57 65 ○ 105 ○

113～115

○

108 108 112 115 111 110 125 127 127 127 136 135 132 100 97 98 97 65 120 122 123 58 59 105 116 107, 108

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

After six cleanings or once a year ○ ○ ○ ○ ○ ○ ○ ○ ○

93

○

Inspection and Maintenance Table

Section Axle system Steering system Brake system

Loading system

Operating hours

Items for check

Daily

Check tightness of wheel nuts Replace gear oil (diff. and planet.)

Check steering wheel operation Grease steering cylinder pins Check service brake operation Check parking brake operation Adjust parking brake lining Overhaul auto adjuster valve Check service brake disk wear Check brake accumulator Check hydraulic oil level Grease pins Replace return filter Clean filter for pilot pump control line Replace hydraulic oil Replace filter in the oil tank cap

50

250 ○

○ ○ ○ ○

○

When Page Required 500 1000 2000 117 ○ 130, 131 67 104 66 67 ○ 126 ○ 136 ○ 136 ○ 135 55

○

102～104

○ ○ ○ ○

Replace filter for pilot pump control line

Chassis

○

Replace bucket teeth (option) Replace cutting edge (option) Check rear view mirrors

○

Check ROPS and mounting bolts (option)

○

○ ○

Grease center pins

○ ○

Check vibration damper accumulator (option)

Check seat belt

○

Check windshield washer fluid (option)

○

Check monitor panel operation Check horn operation Check back-up alarm operation Electrical system Check wiring harnesses Check battery electrolyte level Check fuses Check compressor belt Clean filter Air Check refrigerant Conditioner Replace filter elements (option) Clean condenser Replace receiver dryer Others Walk-around inspection

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ (3000) ○ 94

124 128 129 137 138 95 96 60 60 108 138 96 99 60 60 67 57 106 98 117 118 127 136 99 137 54

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 (option)

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.

1

3. Stop the engine.

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

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

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.

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

7. Tighten the nuts to 1314N・m(134kgf・m).

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

NOTE:

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

95

2

Block

WHEN REQUIRED MAINTENANCE

B. Replace Cutting Edge (option)

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.

3. Stop the engine.

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

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

6. Install all bolts and tighten them to 1314N・m(134kgf・m).

7. Retighten them after a few hours operation.

C. Check and/or Replace Seat Belt (Option except Europe specification) 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.

96

WHEN REQUIRED MAINTENANCE

D. Clean or Replace Air Cleaner Element

When the warning monitor lamp lights up, clean or replace the air cleaner element.

IMPORTANT

１

２

Improper procedure of cleaning air cleaner may cause severe engine damage. ・ Do not clean or replace cleaner while engine is running. ・ Clean only outer element. Never clean inner element. ・ Clean or replace element only when indicator lamp comes

on.

1. Park the machine on 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, spray dry compressed air (196kPa[2kgf/cm2]) along the inside of the element up and down to blow off dust.

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

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

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

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

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

97

３

WHEN REQUIRED MAINTENANCE

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

E. 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. Pull the knob and open the radiator grill.

3. 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. ・ Be sure pressure is below 196kPa(2kgf/cm2). ・ Move nozzle from side to side; not up and down.

If pressure exceeds 196kPa(2kgf/cm2), keep nozzle at least 50cm away from surface of radiator core.

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

5. Close the radiator grill.

F. 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 48.

5. Determine the cause of the blown fuses.

98

WHEN REQUIRED MAINTENANCE

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

Never replace fuses with higher amperage rating.

G. Check Windshield Washer Fluid (option)

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.

H. Clean Air Conditioner Condenser (option)

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

1. Park the machine on 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). If a pressure washer or steam cleaner is used, keep the nozzle about 50cm 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 fan with plastic sheets. Remove the plastic sheets after cleaning.

99

WHEN REQUIRED MAINTENANCE

I . Replace Ether Cylinder WARNING Ether is very flammable and could cause serious injury or death if exploded.

Do not store new or used ether cylinder in operators area or at temperatures above 40° C (105° F).

Store new or used ether cylinder in cool place and out of children's reach.

Never dispose of cylinder by burning, crusing, or puncturing.

1. Remove the cover.

2. Loosen the clamp.

3. Remove (turn counterclockwise) the cylinder.

4. Install (turn clockwise) a new ether cylinder.

5. Tighten the clamp.

100

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 54 and "Check after Starting the Engine" page 65.

101

EVERY 50Hrs MAINTENANCE

Every 50 Hours or 1 Week 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.

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 139 for the correct grease.

・ Bucket-Boom (two places)

・ Bucket-Rod (two places)

102

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)

103

EVERY 50Hrs MAINTENANCE

・ Boom Cylinder-Front Chassis (two places)

・ Boom-Front Chassis (two places)

・ Steering Cylinder (four places)

L.H. and R.H.

・ Axle support (two places)

104

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 on the bottom of the fuel tank.

4. Drain water and sediment along with fuel.

5. Close the drain cock.

6. Dispose of the drained fuel and water properly.

7. Add fuel.

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

105

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

Keep the battery electrolyte level in the proper level.

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

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

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

1. Park the machine on 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.

106

Low

OK

High

EVERY 250Hrs MAINTENANCE

Every 250 Hours or 1 Month 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.

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. 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 139 for the correct grease. Use lithium base grease for universal joints.

・ 2nd Propeller Shaft (five places)

107

EVERY 250Hrs MAINTENANCE

・ 3rd Propeller Shaft (two places)

・ Center Pin (two places)

(lower)

(upper)

B. Replace Engine Oil and 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 C (105° F). When engine coolant temperature about 40° the needle of the coolant temperature gauge reaches the C middle of the white zone, the temperature is about 40° F).

(105° 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 43 liters, into a suitable container.

108

EVERY 250Hrs MAINTENANCE

5. Remove the oil filter and properly dispose of them. Make sure the O-ring is removed with the filter.

6. Clean the oil filter head gasket surface.

7. Fill the new filter with clean engine oil.

Refer to "Recommended Lubricants" page 139 for the oil specifications.

8. Apply a light film of engine oil to the gasket surface of the new filter cartridge.

9. Install and tighten the filter until the gasket contacts filter head surface. Then tighten it by hand an additional three-fourths to one turn.

Refer to the instructions supplied with the filter.

10. Clean and install the oil drain plug, and tighten to 80N ・ m(8.2kgf-m) torque.

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

Refer to "Recommended Lubricants" page 139 for the oil specifications. Total system capacity including the filter is 43 liters.

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

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

14. Check the oil level again.

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

16. 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.

109

EVERY 250Hrs MAINTENANCE

C. 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) under the fuel filter.

3. Remove and properly dispose of the fuel filter.

4. Clean the filter head gasket surface.

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

6. Fill the filter with clean fuel.

7. Install the filter on the filter head.

Turn it until the gasket contacts the filter head surface.

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

Follow the instructions supplied with the filter.

110

EVERY 250Hrs MAINTENANCE

D. Replace DCA4 Coolant Filter Cartridge CAUTION Pressurized radiator tank is used for this machine.

Spray of hot coolant can 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.

NOTE: The filter to be used here is WF2073 that is smaller than the filter initially installed when the machine is shipped from the factory.

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).

２

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

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 cartridge (WF2073).

111

EVERY 250Hrs MAINTENANCE

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

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

9. Run the engine and check for coolant leaks.

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

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

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

Refer to "Coolant Specification" page 140 for the correct mixture.

E. Clean Crankcase Breather There are three breather elements on the top of the cylinder head cover. Clean all three.

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

2. Loosen the wing nut (6) and remove cover (1) and element (2).

６ １

3. Clean the element (2).

4. Inspect the element (2) and rubber gasket (4). Replace it if necessary.

5. Install a cleaned or new breather element.

Tighten the wing nut (6).

２ ３ ４ ５

112

EVERY 250Hrs MAINTENANCE

F. Check and Adjust Fan Belt 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 tag "Do Not Operate".

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), to the center of the belt between the pulleys. Correctly adjusted belts will deflect one belt thickness per 30cm of pulley center distance.

Adjustment

1. Loosen the three capscrews (1) which secure the fan hub shaft to the bracket.

2. Loosen the lock nut (3).

２

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

4. Tighten the lock nut (3).

5. Tighten the three capscrews to 108N・m(11kgf・m).

6. Loosen the adjusting screw 1/2 turn to prevent breakage.

113

１

３

EVERY 250Hrs MAINTENANCE

G. Check and Adjust Alternator Drive Belt 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 tag "Do Not Operate".

2. Open the engine side panel.

3. Visually inspect the alternator drive 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.

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

Adjustment

1. Loosen the bolts (1), (2) and (3) which secure the alternator to the bracket.

１

2. Shift the alternator outward to increase the belt tension.

２

3. Tighten the bolts.

３

H.Check and Adjust Water Pump Belt 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 tag "Do Not Operate".

114

EVERY 250Hrs MAINTENANCE

2. Open the engine side panel.

3. Visually inspect the water pump drive 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.

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

Adjustment

1. Loosen the lock nut (1) which secures the idler pulley to the water pump.

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

3. Secure the idler pulley in position by tightening the lock nut (1) to 69N・m(7kgf・m).

4. Loosen the adjusting screw (2) 1/2 turn to prevent breakage.

I . 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.

115

２ １

EVERY 250Hrs MAINTENANCE

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.

J. 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 139.

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

Ｆｒ ｏｎ ｔ Ａｘ ｌ ｅ

5. Retighten the level plug.

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

K. 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.

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

116

２

EVERY 250Hrs MAINTENANCE

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

Refer to "Recommended Lubricants" page 139.

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.

L. Check Tightness of Wheel Nuts

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 wheel bolts are tightened to 892N・m (91kgf ・ m). ＴＯＰ

3. Retighten if necessary.

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

Stop engine before opening engine side panel.

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

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.

117

EVERY 250Hrs MAINTENANCE

5. Measure the belt tension using a belt tension gauge so that it is applied 637 ± 98N (65 ± 10kgf).

6. If the belt is too loose or tight, adjust the tension by loosening the lock nuts (1) and turning the adjusting nut (2) under the compressor bracket.

１

7. Tighten the lock nuts (1).

１ ２

N. Clean Air Conditioner Filter Element (option) 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.

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. below 196kPa(2kgf/cm2).

Use air pressure

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

118

EVERY 250Hrs MAINTENANCE

7. After approximately 20 cleanings, replace the filter with new one.

Refer to "Replace Air Conditioner Filter Elements" page 136.

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

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

Inner filter cleaning

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

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

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

Remove the filters and clean them.

１ ２

２ 2. Remove dust with compressed air. below 196kPa(2kgf/cm2).

Use air pressure

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

4. After approximately 20 cleanings, replace the filters with new ones.

Refer to "Replace Air Conditioner Filter Elements" page 136.

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

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

119

３

EVERY 500Hrs MAINTENANCE

Every 500 Hours or 3 Months 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.

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 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 C (85 to torque converter oil temperature about 30 to 40° F).

105° 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) under the transmission oil filter.

4. Turn the filter counterclockwise to remove. dispose of the oil and filter.

Properly

5. Clean the filter head gasket surface.

6. Apply a light film of clean engine oil to the gasket surface of the new filter.

7. Install the filter on the filter head. Turn it clockwise to tighten. Follow the instructions on the filter.

8. Idle the engine about ten minutes and inspect for leaks around the filter.

120

EVERY 500Hrs MAINTENANCE

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 64.

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

Refer to "Recommended Lubricants" page 139 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.

121

EVERY 1000Hrs MAINTENANCE

Every 1000 Hours or 6 Months 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.

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 lever in neutral. ・ Apply parking brake. ・ Make sure nobody is on machine. ・ Place "DO NOT START" or "DO NOT OPERATE" tag on

steering wheel.

CAUTION Transmission oil may be hot and may cause burns.

Avoid contact with transmission oil.

1. If the machine is cold operate the machine for a few minutes to bring the transmission oil temperature about C (85 to 105° F).

30 to 40° 2. Park the machine on a level ground, turn "ON" the parking brake switch, lower the attachment to the ground, and stop the engine.

122

EVERY 1000Hrs MAINTENANCE

3. Remove the drain plug (1) with a 12mm wrench.

4. Drain oil into a suitable container (about 55 liters).

Properly dispose of or recycle the waste oil.

5. Loosen the four bolts (2) with a 17mm wrench.

6. Remove the flange (3) together with the pipe and suction strainer.

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

9. Tighten the four bolts (2) to 44N・m(4.5kgf・m).

10. Fill with the specified oil.

Refer to "Recommended Lubricants" page 139.

11. Idle the engine and check for leaks.

12. Check the oil level with the dipstick. Add the specified oil if necessary to maintain the proper oil level.

Refer to "Check Transmission Oil Level" page 65 and "Recommended Lubricants" page 139.

B. Clean or Replace Transmission Breather

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 breather from the transmission case.

3. Clean the breather in the cleaning oil tub, then spray dry compressed air from the bottom of the breather.

Even after cleaning, if the breather is not clean enough, replace the breather.

4. Install the breather onto the transmission case.

123

１

３

２

EVERY 1000Hrs MAINTENANCE

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

Pressurized hot oil may cause injury or burns.

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

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

2. Open the access cover on the left deck.

3. Press down the filler cap to relieve the tank pressure.

4. Clean around the top of the filter cover (1).

２

5. Remove two bolts (2) with a 19mm wrench and open the filter cover (1).

The two bolts (3) may be used as "Jacking screws" to push up the cover. Install them into the two threaded holes in the cover. Screw them in equally to force the cover up evenly.

１

6. Remove the O-ring (3), spring (4), and bypass valve (5) from the filter housing.

２ １

7. Remove and porperly dispose of the filter (6) and waste oil.

３

8. Clean the inside of the filter housing.

４

9. Replace the gaskets and seals.

５

10. Apply a light film of clean hydraulic oil on the filter cover O-ring surface.

11. Install the filter element (6), bypass valve (5), spring (4), new O-ring (3), and filter cover (1).

12. Close the access cover.

124

６

EVERY 1000Hrs MAINTENANCE

D. Clean Fuel Tank CAUTION Escaping fuel is flammable and harmful to skin. ・ Do not smoke while draining moisture and sediment from

tank.

・ Do not drain with engine running. ・ Do not allow fuel to remain on skin for an extended period

of time. Wash thoroughly with soap and water.

NOTE: It is easiest to clean the fuel tank when the fuel is almost empty.

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

2. Open the drain cock (1) on the bottom of the fuel tank.

3. Drain the remaining fuel into a suitable container.

4. Remove the nuts with a 17mm wrench to remove the inspection cover (2).

２

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 plug.

125

１

EVERY 1000Hrs MAINTENANCE

E. Adjust Parking Brake Lining WARNING When parking brake is released for adjusting brake lining, machine could move unexpectedly causing serious injury or death.

Make sure to lower attachment to ground, and put chocks under wheels.

1. Park the machine in a safe place on firm level ground and steer it fully to one side for easier access.

１

2. Lower the attachment to the ground and turn "OFF" the parking brake switch.

3. Align the inspection hole (1) with the adjuster wheel by turning the hole 8° counterclockwise from the bottom.

Do not enter the articulation area or under the machine.

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

１

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

6. Remove a cap of the inspection hole (1) on the brake drum.

7. Turn the adjuster wheel fully upward to close the clearance between the brake drum and the brake lining (shoe). The adjuster wheel can be reached through the inspection hole.

8. Return the adjuster wheel eight clicks downward. (Now the clearance is 0.23mm) 9. Check parking brake operation as described on page 67.

NOTE: If the brake drum has been excessively hot (ie. burnt paint) or the parking brake will not adjust, contact your Kawasaki loader dealer.

126

8°

Adjuster wheel

１ Special Tool (Accessory)

EVERY 1000Hrs MAINTENANCE

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

2. Remove the cover.

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

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

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

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

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

Always maintain refrigerant in normal level.

Amount of refrigerant

Appearance of the sight glass

Normal

Almost clear.

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

High

No bubble is seen.

Low

A flow of bubbles is visible.

G. 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

127

Solutions

Contact your local Kawasaki loader dealer for inspection and recharging refrigerant.

EVERY 1000Hrs MAINTENANCE

H. 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 2 L) 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) on the filter head.

7. Check for oil leakage from the filter after installing the filter case (5).

１ ２ ３ 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.

128

５

EVERY 2000Hrs MAINTENANCE

Every 2000 Hours or 1 Year 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.

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.

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

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 bucket and boom control levers back and forth to relieve the pressure.

3. Insert the key into the side of the filler cap and turn the key counterclockwise. (Europe specification) 4. Press down the filler cap to relieve the tank pressure.

5. Remove the inlet cap.

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 150 liters).

129

EVERY 2000Hrs MAINTENANCE

7. Remove the drain plug (1) with a 12mm Hex (Allen) wrench to drain oil.

２

8. Dispose of the waste oil properly.

9. Remove the nuts with a 17mm wrench to remove the inspection cover (2).

１

CAUTION Compressed air may cause injury. ・ Wear protective clothing and eye protection. ・ Air pressure must be below 196kPa(2kgf/cm2).

10. Clean inside of the tank and magnet plug.

11. Install the new gasket, and inspection cover (2), and tighten the nuts. Do not overtighten.

12. Install and tighten the drain plug.

13. Add the specified hydraulic oil through the oil inlet hole.

Refer to "Recommended Lubricants" page 139.

14. Close the oil inlet cap.

15. Start the engine and allow the engine to idle for about five minutes.

16. Operate the bucket, boom, and steering cylinders for about five minutes, then lower the attachment to the ground.

17. Inspect for leaks.

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

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 C (105° F). about 40°

130

EVERY 2000Hrs MAINTENANCE

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, with a 12mm Hex (Allen) wrench.

Some fine metallic powder will normally stick to the magnet plugs.

Simply wipe it off.

１

4. Drain the oil (about 55 liters) into a suitable container.

２

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 139.

8. Install and tighten the level plug.

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

Required oil volume for the rear differential is about 60 liters.

C. Replace Planetary Gear Oil CAUTION Planetary gear oil may be hot and may cause burns.

Avoid contact with planetary gear oil.

131

EVERY 2000Hrs MAINTENANCE

1. Replace the planetary gear oil on all four wheels.

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

１ ＴＯＰ

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

WARNING If the boom is raised to ease access securely block or brace the boom to prevent accidental lowering.

２

4. 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 magnet plugs.

Simply wipe it off.

5. Drain the oil (about 20 liters) 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.

7. Install and tighten the drain plug.

8. Refill the recommended oil through the level plug hole (2) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page 139.

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 necessary to replace the coolant for the first two years.

132

３

EVERY 2000Hrs MAINTENANCE

・ 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 pressrue.

１

4. Remove the cap (2) slowly.

ＰＵＳＨ

２ 5. Open the drain cocks (3) and (4) and drain coolant (about 100 liters) into a suitable container.

Do not remove the coolant filter.

３

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

４

133

EVERY 2000Hrs MAINTENANCE

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 C (180° F). temperature above 80° 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 C (180° F). temperature above 80° 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 140 for the mixing instruction.

15. Add two pieces of DCA65L and one piece of DCA60L coolant additive at the same time.

16. Replace the DCA4 coolant filter (WF2073).

Refer to "Replace DCA4 Coolant Filter" page 111 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.

134

EVERY 2000Hrs MAINTENANCE

19. Reinstall the radiator cap.

For additional cold weather servicing information, refer to "Coolant Specification" page 140 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 Accumulator

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.

2. Run the engine at low idle for five minutes to fill the brake accumulator with oil.

3. Stop the engine.

4. Turn the key switch to the "ON" position.

5. Count the number of times you can depress the right hand brake pedal before the brake warning light comes on.

6. If the number counted is less than five, there is some problem with the accumulator. Contact your nearest Kawasaki loader dealer.

135

EVERY 2000Hrs MAINTENANCE

G. Overhaul Auto-adjuster Valve Contact your Kawasaki loader dealer.

H. Check Service Brake Disk Wear

Contact your Kawasaki loader dealer or local Cummins engine dealer.

I . Check and Adjust Valve Lash Clearance

Contact your Kawasaki loader dealer or local Cummins engine dealer.

J.Replace Air Conditioner Filter Elements(option) 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.

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

136

EVERY 2000Hrs MAINTENANCE

Inner filter replacement

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

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

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

Remove the filters and replace them with new ones.

１ ２

２

３

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

L. 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 bucket and boom control levers 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).

２

7. Replace element (5).

8. Install the element, spring, valve assy, and spiral snap ring.

137

EVERY 2000Hrs MAINTENANCE

M. 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 2 L) 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) on the filter head.

１ ２

7. Check for oil leakage from the filter after installing the filter case (5).

３

Parts to be replaced

４

Symbol

Part Name

Part Number

Q'ty

1

O-ring

47131-73540

1

2

Backup ring

47194-70800

1

3

Filter element

30981-70570

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.

138

５

EVERY 2000Hrs MAINTENANCE

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

Never service brake accumulator unless trained properly.

Contact your nearest Kawasaki loader dealer.

139

Recommended Lubricants

Recommended Lubricants Ambient Temperature Kind of Oil

Refill capacity

Engine

Engine oil (CE or CF4)

43 liter

Transmission

Engine oil ATF

55 liter

Hydraulic tank

Hydraulic oil

Differential & Planetary

Gear oil (GL-5) Engine oil (CD)

Front : 95 liter Rear :100 liter

Fuel tank

Diesel fuel

405 liter

＊1

150 liter

‐４° １４° ３２° ５０° ６８° ８６°１０４°Ｆ ‐２０°‐１０° ０°Ｃ １０° ２０° ３０° ４０°

SAE 10W-30 SAE15W-40 SAE10W ATF ISO VG46 ISOVG32 Gear oil SAE90 Engine oil SAE40 or SAE50 ASTM D975 No.2 ASTM D975 No. 1

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

Note : ＊1 shows "Hydraulic tank oil capacity at level gauge center."

Engine

Use oil that meets engine oil classification API CE or CF4.

Transmission

Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid).

Never mix engine oil and A.T.F.

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure.

Differential & Planetary

Use class GL-5 gear oil or class API CD engine oil.

Lubricating Grease

Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.

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

Use lithium base grease for a needle bearing.

Diesel Fuel

Requirements for diesel fuel Grade No.1-D Grade No.2-D 38 52

Specifications Flash Point

℃.

min.

Water and Sediment

% vol.

max.

Distillation Temperature ℃ 90% vol.

Kinematic Viscosity mm2/s at 40 ℃ Ash % mass

recovered max. min. max.

max.

Sulfer % mass Cetane Number

max. min.

Carbon residue on 10% distillation residue % mass

140

max.

0.05

0.05

288 1.3 2.4 0.01

338 1.9 4.1 0.01

0.50

0.50

40

40

0.15

0.35

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)

C -30 ° (-22 ° F)

C -25 ° (-13 ° F)

C -20 ° (-4 ° F)

C -15 ° (5 ° F)

Pure Water

(liter)

47.0

52.0

57.0

62.0

67.0

Antifreeze

(liter)

53.0

48.0

43.0

38.0

33.0

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.

141

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 the items marked with Ｋａｗａｓａｋｉ or your local Ｃ ＵＭＭ Ｉ Ｎ Ｓ authorized CUMMINS ENGINE dealer for the items marked with to repair.

ENGINE PROBLEM

Engine oil pressure warning lamp lights up, and buzzer sounds

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

SOLUTIONS Add oil Change oil Change filter and oil

Ｋａｗａｓａｋ ｉ

ｏｒ

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

Tightenfuel connections andfilter 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

142

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

ｏｒ

ｏｒ

ｏｒ

ｏｒ

56 113 98 132

ＣＵＭＭＩＮＳ

110 84

ＣＵＭＭＩＮＳ

110 110

ＣＵＭＭＩＮＳ

Clean or replace element Replace fuel filter Check and adjust linkage Check dipstick and correct level Ｋａｗａｓａｋ ｉ

55 108 108

ＣＵＭＭＩＮＳ

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

Ｋａｗａｓａｋ ｉ

PAGE

ＣＵＭＭＩＮＳ

97 110 55

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Use correct type of oil Correct oil level

139 55

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

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

ｏｒ

ｏｒ

ｏｒ

ＣＵＭＭＩＮＳ

110

ＣＵＭＭＩＮＳ

97

ＣＵＭＭＩＮＳ

ELECTRICAL PROBLEM

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

113

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

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

Shift to NEUTRAL Battery charge or booster

Starter motor turns engine slowly

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

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

Charge lamp lights up

143

Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

28 84

Ｋａｗａｓａｋ ｉ Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

Ｋａｗａｓａｋ ｉ Ｋａｗａｓａｋ ｉ

ｏｒ

ＣＵＭＭＩＮＳ

30 84 108

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

PAGE 58

Ｋａｗａｓａｋ ｉ

24

Ｋａｗａｓａｋ ｉ

Warm oil / Replace oil with proper viscosity for temperature

139

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

139

Excessively cold oil / Wrong oil type

Warm oil / Replace oil with proper viscosity for temperature

Excessively cold oil / wrong grade oil

HYDRAULIC PROBLEM

Boom raises too slowly

Boom natural drift excessively

Bucket / Attachment floating or drifting

Leakage from control valve plunger Damaged cylinder piston or piston packing Leakage in pilot relief valve Over load relief pressure too low Control valve failure Natural drift of cylinder / packing

144

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

139

TROUBLESHOOTING

BRAKE PROBLEM

POSSIBLE CAUSES

SOLUTIONS

PAGE

Adjust or replace lining

126

Parking brake does not work properly

Worn brake lining Insufficient oil pressure (will not release) Failure of switch or solenoid valve Poor wiring or ground to switch or solenoid valve

Remove or clean

Brake dragging

Dirt, debris under base of brake pedal Warped brake discs Air in brake oil circuit Auto-adjuster valve failureValve failure

Air in brake oil circuit Braking power too low Auto-adjuster valve failure Brake piston seal leakage Brake pressure drops rapidly

Cracked or leaking brake line Brake valve failure Parking brake cylinder leakage Defective brake accumulator

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

Ｋａｗａｓａｋ ｉ

TORQUE CONVERTER & TRANSMISSION PROBLEM

POSSIBLE CAUSES Excessively cold oil / Wrong oil type

Engine is running but machine does not move

Parking brake is applied Transmission oil level too low Transmission suction strainer clogging Clutch oil pressure too low Transmission clutch failure Transmission controller failure Defective electrical circuit

145

SOLUTIONS

PAGE

Warm oil / Replace oil with proper viscosity for temperature Release parking brake Add oil / Repair leak Clean strainer

139

Ｋａｗａｓａｋ ｉ

65 122

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSES

SOLUTIONS

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

Inspect and correct Refill oil / Repair leak Clean or replace strainer

Oil leakage from transmission

Air breather clogged Seal damage (between engine and torque converter housing)

Clean and refill with oil

Torque converter overheat

Oil level too low Dozing, continuous pushing application Operating in too high a speed range Long downhill driving Radiator clogged: coolant temp also high Defective alarm switch (gauge is in green) Torque converter / Transmission failure Oil pressure too low

Add oil / Repair leak Reduce load Use lower gear Change application Clean radiator fins

Low power

PAGE 65 122

Ｋａｗａｓａｋ ｉ

123

Ｋａｗａｓａｋ ｉ

65 70 98

Ｋａｗａｓａｋ ｉ

AIR CONDITIONER (option) PROBLEM

POSSIBLE CAUSES

Hot water continues to flow through heater core A/C not set for maximum cooling Low cooling when A/C Condensor fins plugged "ON" A/C filters plugged A/C compressor belts slipping/broken A/C refrigerant charge low

Low heater out put

Engine not warmed up No hot water flow to heater core Air conditioner running Heater vents not adjusted properly Defective heater motor or switch

146

SOLUTIONS

PAGE

Shut off valve in heater hose line at block Adjust controls/vents Clean Clean or replace Adjust/Replace

50 99 118 117

Ｋａｗａｓａｋ ｉ

Warm up engine Open shut off valve on block Turn A/C off Adjust controls/vents Ｋａｗａｓａｋ ｉ

50

SPECIFICATIONS

SPECIFICATIONS (For Europe Specification)

Specifications shown are for a machine equipped with standard features. Some options or special attachment will change the specifications shown. Specifications subject to change without notice.

Bucket General Purpose Bucket with cutting edge

General Purpose Bucket with teeth

Bucket capacity (m3)

5.0

4.8

4.3

Dumping height (mm)

3,220

3,105

3,320

Dumping reach (mm)

1,350

1,420

1,295

Rock Bucket no teeth

Kind of bucket

V-edged Rock Bucket no teeth

Rock Bucket with teeth

V-edged Rock Bucket with teeth

Kind of bucket

Bucket capacity (m2)

4.3

4.5

4.5

Dumping height (mm)

3,100

3,165

2,970

Dumping reach (mm)

1,425

1,450

1,550

Operating Load

7,800kg

Operating Weight

29,660kg (with ROPS canopy, cabin and General purpose bucket with teeth)

Engine Model Type

CUMMINS N14 Diesel 4 cycle, Water Cooled, Turbo charged, after cooled and direct injection 14,010cm3 235kW / 2,100min-1

Displacement Net Flywheel Horsepower Tire (standard)

29.5 R25 ☆

Max. Running Speed (forward/reverse)

1st : 7.7 / 8.1km/h 2nd : 14.5 / 15.3km/h 3rd : 22.7 / 23.5km/h 4th : 35.0 / - km/h

147

SPECIFICATIONS

Sound Level 75dB (A) Continuous A-Weighted sound pressure level at workstation.

Measurement is obtained in accordance with ISO 6394.

Airborne sound power level 111dB (A) Measurement is obtained in accordance with 86 / 662 / EEC. Hand-arm vibration Less than 2.5m/s2 The weighted root mean square acceleration value to which the hands/arms are subjected.

Measurements are obtained in accordance with ISO 5349.

Whole-body vibration Less than 0.5m/s2 The weighted root mean square acceleration value to which the body is subjected.

Measurements are obtained in accordance with ISO 2631.

148

PERIODICAL REPLACEMENT PARTS LIST

PERIODICAL REPLACEMENT PARTS LIST Section

Part Name Oil filter

Part Number

Q'ty

Remarks

YE3318853

1

Every 250 hrs

DCA4 Coolant filter YEWF2073

1

Every 250 hrs

DCA4 Liquid

YEDCA60L YEDCA65L

1 2

Every 2000 hrs

Fuel filter

YE3315847

2

Every 250 hrs

Ether cylinder

YE259370

1

When required

Fan belt

YE3040385

2

When required

Water pump belt

YE217638

1

When required

Alternator belt

YE3040303

2

When required

Air cleaner element

30981-70440-7 30981-70430-7

1 1

After six cleanings or once a year

Transmission & Oil filter Torque Converter

30981-70340-7

1

Every 500 hrs

Hydraulic tank

Return filter

30981-20060

1

Every 1000 hrs

O-ring

47131-73540

1

Every 1000 hrs

Pilot pump control Backup ring line filter

47194-70800

1

Every 1000 hrs

Filter element

30981-70570

1

Every 2000 hrs

Filter element

40330-60270 40330-70370

1 5

Every 2000 hrs

Compressor belt

78023-11280

1

When required

Engine

Air Conditioner (option)

149

95ZIV-3 OPERATION & MAINTENANCE MANUAL AAA-M97C3E01-996 AAA-M97C3E01-99Z AAA-M97C3E01-006

① 1999.6.30 ③ 1999.12.1 ⑤ 2000.9.10

K

② 1999.7.30 ④ 2000.6.25 ⑥ 2001.3.15

KAWASAKI HEAVY INDUSTRIES, LTD. CONSTRUCTION MACHINERY DIV. 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 650-0044

Banshu Works

2680 Oka Inami-cho Kako-gun, Hyogo 675-1113

All rights reserved. No copy allowed without written consent.