93113-00571

April 1, 2009

FOREWORD
Congratulations on your purchase of the Kawasaki Wheel Loader 90ZV-2.
This manual contains safety, operation, transportation, maintenance and troubleshooting
information. Read and understand the information in this manual carefully before operating
or performing any maintenance of the machine. Failure to do so could result in personal
injury or equipment failure. The safety of yourself and others depends upon your care and
judgement in the operation and maintenance of this machine. Keep the manual with this
machine at all times.

Kawasaki pursues a policy of continuing improvement in design and performance of this

machine. The right is therefore reserved to vary specifications without prior notice or obliga-
tion.

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

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

Read and understand this manual before operating and save this manual on the machine.
If lost, damaged or unreadable, replace the manual immediately.
SAFETY NOTICE
Whenever you see the symbols shown below in this manual or on the machine, read and understand their
messages.

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

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

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

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

Always follow safe operating and maintenance practices.

Kawasaki cannot anticipate every possible circumstance, use, or misuse of the machine that might involve a
potential hazard. The warnings in this Operation & Maintenance Manual and on the machine are therefore not
all inclusive.
If an operation or maintenance procedure is not performed as specifically recommended by Kawasaki, you
must satisfy yourself that it is safe for you and others. You should also ensure that the machine will not be
damaged by the operation or maintenance procedure you choose.

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

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
effort has been made to ensure it as complete and accurate as possible.
CONTENTS
1.SAFETY ...................................................................................................................................................... 1.1
SAFETY ..................................................................................................................................................... 1.2
Safe Operation..................................................................................................................................... 1.2
Safe Maintenance.............................................................................................................................. 1.12
Safety Signs....................................................................................................................................... 1.18
Safety Devices ................................................................................................................................... 1.28
2.OPERATION ............................................................................................................................................... 2.1
COMPONENT NAME/LOCATION ............................................................................................................. 2.2
OPERATOR'S AREA ................................................................................................................................. 2.3
Pedals and Levers ............................................................................................................................... 2.3
Switches ............................................................................................................................................ 2.10
Indicators ........................................................................................................................................... 2.24
MODM ............................................................................................................................................... 2.32
Seat ................................................................................................................................................... 2.42
Electrical Protection ........................................................................................................................... 2.44
Radio - AM / FM Cassette (24Volt Type) (option) .............................................................................. 2.46
Air Conditioner ................................................................................................................................... 2.54
Ride Control (option).......................................................................................................................... 2.61
Grease Gun Holder............................................................................................................................ 2.62
Quick Coupler (option) ....................................................................................................................... 2.63
OPERATION ............................................................................................................................................ 2.66
Check before Operation..................................................................................................................... 2.66
Starting the Engine ............................................................................................................................ 2.76
Idling Management System ............................................................................................................... 2.78
Check after Starting the Engine ......................................................................................................... 2.79
Operating the Machine ...................................................................................................................... 2.84
Parking............................................................................................................................................... 2.87
Stopping the Engine........................................................................................................................... 2.88
Operating Techniques ........................................................................................................................ 2.89
 SPECIAL PROCEDURES........................................................................................................................ 2.96
Adjustments ....................................................................................................................................... 2.96
Roading / Special Applications........................................................................................................... 2.97
Booster Batteries / Jumper Cables .................................................................................................... 2.98
Towing.............................................................................................................................................. 2.100
Transportation .................................................................................................................................. 2.101
Long Term Storage........................................................................................................................... 2.103
Welding ............................................................................................................................................ 2.107
3.MAINTENANCE .......................................................................................................................................... 3.1
MAINTENANCE ......................................................................................................................................... 3.2
Serial Number Location ....................................................................................................................... 3.2
Inspection and Maintenance Table ...................................................................................................... 3.4
When Required Inspection and Maintenance ...................................................................................... 3.7
Every 10 Hours or Daily ..................................................................................................................... 3.18
Every 50 Hours or 1 Week ................................................................................................................. 3.19
Every 250 Hours or 1 Month .............................................................................................................. 3.25
Every 500 Hours or 3 Months ............................................................................................................ 3.34
Every 1000 Hours or 6 Months .......................................................................................................... 3.39
Every 2000 Hours or 1 Year............................................................................................................... 3.45
Recommended Lubricants ................................................................................................................. 3.56
Coolant Specification ......................................................................................................................... 3.58
TROUBLESHOOTING ............................................................................................................................. 3.59
SPECIFICATIONS ................................................................................................................................... 3.69
 1.1

1.SAFETY
1.2
SAFETY
Safe Operation

SAFETY

Safe Operation
Operator Safety

OM0026a

Wear safe clothing:

OM0001 - Close fitting clothing -- loose or baggy clothing

can catch on equipment or controls.

Read and understand the Operation & Mainte- - Protective clothing as required by the job or con-
nance Manual. ditions for example:

- Hard hat
- Gloves
- Steel-toe shoes
- Eye/face protection
- Antidust mask or approved respirator

OM0180

Be aware of the location and meaning of safety

signs (decals) on the machine. Report or replace
any that are missing or unreadable.
OM0002
Be alert and ready to operate the machine safely:

- Do not operate if excessively tired. - Do not wear jewelry that may catch on the
equipment, controls or may short and cause
- Do not operate if taking medication that causes burns if in contact with electrical components.
drowsiness.

- Do not operate if under the influence of alcohol

or drugs.
 1.3
SAFETY
Safe Operation

Mounting and Dismounting Safety

OM0222

OM0010
The inhalation of asbestos-laden dust involves the
risk of having an adverse health effect. At the
wrecking site and the site handling industrial waste, Face the machine when mounting or dismounting.
there is a possibility of inhaling asbestos-laden
dust. Maintain three points of contact when climbing (two
hands and one foot, or two feet and one hand).
It is requested that the following measures should
be taken at the site where there is a possibility that When mounting or dismounting, never carry tools
asbestos-laden dust flies in all directions. or other objects in your hands.

- The worker should were protective equipment Climb and step only where steps and handrails are
such as a dust-protective mask. provided.
- Sprinkle water in order to prevent asbestos from
flying in the air.
- Do not use compressed air for cleaning work.
- Do not allow any person other than workers to
come near the working site.
- Observe strictly the laws, regulations and rules
regarding the environmental standards at work-
ing sites.

Asbestos is not used both in this product and genu-

ine parts. However, as it is feared that asbestos
may be used in non-genuine parts, please be sure
to use our genuine parts for replacement.
OM0181

Use only the handrails provided to climb -- do not

use the steering wheel, shift lever, mirror brackets,
or control lever.

Use extra caution mounting and dismounting when

slippery conditions exist (oil, ice, snow, mud, or wet
conditions).

Never jump from the machine regardless if

machine is moving or stopped.

Report or replace any damaged or missing steps,

handrails, or anti-skid material.
1.4
SAFETY
Safe Operation

Before Starting Safety

OM0012

OM0006
Do not allow unauthorized personnel on the
machine.
Know the location of safety items and procedures:

- Fire extinguishers
- Fire blankets
- First aid kits
- Emergency phone numbers

Walk around the machine to be sure no one is

working or laying under the machine.

Inspect the machine for safety hazards and, if

found, have them corrected:

- Broken lights, mirrors, windows, etc.

- Fuel leaks, oil leaks, or debris build-up
- Improper tire inflation or tire damage
- Missing or unreadable safety signs (decals)

Be sure the Roll Over Protective Structure (ROPS)

is:

- in place.
- properly attached (no bolts loose or missing).
- not damaged.
- not modified.
 1.5
SAFETY
Safe Operation

Articulation Stopper
"STORED"
OM0005 90ZV0002

Perform the normal daily maintenance. - 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

Lock avoid fire.

Do not leave a lighter in the cab. The lighter may

Unlock cause explosion by high temperature in the cab.
85ZV20005b

Do not bring inflammable or explosive materials

Be sure the following safety devices work or are
such as:
positioned properly.
- spray can
- Parking Brake -- Applied
- chemical cylinder
- Control Lever Lock -- Locked
Do not attach a suction cup on the window to avoid
firing.

In case of fire during operation:

N - 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
65ZV 5089
needed at the work area.

- Transmission Shift Lever -- Neutral

1.6
SAFETY
Safe Operation

OM0007 OM0011

Adjust the seat, seat belt and steering column, mir- Do not start to work in an enclosed area if adequate
rors, etc. ventilation is not provided. Fumes could build up
during operation that could cause drowsiness,
Properly fasten the seat belt. injury, or death.

Blow the horn for a few seconds just before starting

the engine to alert bystanders.

DANGER

DO NOT
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE

OM0182

Do not start or operate the machine if a "DO NOT OM0183

START" or a "DO NOT OPERATE" tag is on the key
switch, steering wheel or controls.
Start the machine only from in the operator's seat.
Do not operate the engine where there are or can
be combustible vapors. These vapors can be - Do not reach through the window to start.
drawn through the air intake system and cause - Do not stand on the ground and start.
engine overspeeding, which can result in a fire, and - Never attempt to start by shorting across the
explosion. starter motor terminals since this can bypass the
neutral start safety device.

If jumper cables are required to start the engine,

follow the correct procedure in "Booster Batteries /
Jumper Cables" page 2.98.
 1.7
SAFETY
Safe Operation

Operational Safety The range of temperature the machine is to be

operated is between -35ºC ~ 45ºC.
Before operating the machine, refer to "SPECIFI-
CATIONS" listed on page 3.69.
When working on a grade:
Do not use the machine with excessive load than
specified, to avoid a stack of the machine and/or - Turn "OFF" the declutch switch.
any risk of injury caused by potential structural - Keep the attachment low.
damage of the machine due to the overload. - Keep the attachment facing up the grade as
Use the permitted attachments and optional parts often as possible.
provided, when needed, which are suitable for the - Drive directly up or down the grade -- never
operating conditions and job contents. across the grade.
- Stop when changing direction on a grade to
maintain stability.
SITE SAFETY: - Never coast down a grade.
- Select the same low gear to go down the grade
Consider the safety of the job site before operating as was selected to climb the grade. This pro-
the machine: vides some engine braking.

- 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.

OM0018

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.
OM0021
Check for enough clearance before entering a
building, doorway, tunnel, under wires or other
Avoid working under or near overhanging material structures.
that could fall on the machine.
Do not expose the machine to flames.
Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

Do not operate the machine at work area close to

fire or dry grass is.

Operate the machine slowly over rough ground and

on a grade.

Do not operate on any grade that may be unstable

(loose material, soft material, snow, or ice).
1.8
SAFETY
Safe Operation

SAFETY DURING NORMAL OPERATIONS: When roading the machine:

Vision to the rear on any machine is limited. Always - Travel in forward only.
use special caution when backing up. - Travel only as fast as conditions and safety
allow.
Know the machine limits and do not exceed them. - Know and follow all local laws that may require
rotating beacon, slow moving vehicle (SMV)
signs, width signs or flags, lead or chase vehi-
cles, four-way flashers, or clearance lights, etc.
- If roading long distances (over 3 km), periodi-
cally stop to allow tires, transmission, engine to
cool down. Excessive tire heat caused by road-
ing 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

OM0013 machine only when an emergency, like loss of brak-
ing occurs.
Using the machine for purposes other than speci-
Be sure there are no bystanders under the raised
fied in the Operation & Maintenance Manual may
bucket or attachment.
create hazards that are not mentioned in this man-
ual.

Do not use the machine as a crane where the

safety of the operator or other workers are involved.

Properly counterweight and ballast the machine

depending upon the bucket size and material or
attachment application. Do not exceed the recom-
mendations and limits.

Maintain stability by carrying the load as low as

possible throughout each cycle.
OM0184

Never position or move the load over the cab of a

truck or other vehicle.

approx. 40 cm
OM0016

- The normal carry position is about 40 cm above

the ground.
 1.9
SAFETY
Safe Operation

SPECIAL OPERATING CONDITIONS:

OM0020

OM0185
Never use the "Float" position to lower the boom
since it will fall rapidly.
Avoid entering water deeper than the bottom of the
Drive into a load at a medium speed. Do not run wheel rim.
into the material at high speed.
If entering water is unavoidable:
Always be alert for abnormal noises, odors, vibra-
tions, heat, etc. - Use caution that there are no hidden hazards --
(drop-offs, holes, rocks, logs, etc.).
- Check for normal braking after leaving the
water.
- Check differential gear oil for contamination.

Reduce speed and avoid rapid steering movement

when traction is poor -- mud, snow, ice, etc. Use tire
chains if necessary.

When darkness, fog, snow, dust, smoke, etc.

reduce visibility, use the following precautions:

- Use adequate lighting.

- Use flashers or beacons (if equipped).
- Reduce speed.
- Periodically stop and inspect the job site.
- Take more frequent breaks to reduce fatigue.

If towing or pulling something is required:

- Keep helpers or bystanders away from between

the machine and the towed vehicle or object.
- Use a cable of adequate capacity and in good
condition.
- Use a cable that has appropriate pull hooks.
- Use only the hitch provided on the rear of the
machine.
1.10
SAFETY
Safe Operation

80ZV0001

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

applying tension.
- Make sure to install the split pin into the hitch pin
to avoid the hitch pin coming off.
- If brakes and steering are working on the towed
vehicle, keep an operator in the operator's seat
and have him control the vehicle.
- If brakes are not working on the towed vehicle,
attach another vehicle of adequate size to the
rear to act as a braking vehicle.
- Use the machine as a tow vehicle only for short
distance.
 1.11
SAFETY
Safe Operation

Parking Safety If parking near a road, be sure and erect safety bar-
riers and lights as required.
Stop the machine on level ground with the service
brakes -- not the parking brake.

Lower the attachment to the ground and apply the

parking brake.

OM0025

If parking on level ground is not possible, follow

these precautions:

- Lower the attachment to the ground and apply

some down pressure.
- Block the tires.
- Apply the parking brake.

To prevent unauthorized use:

- Remove the key.

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

OM0186

Inspect the machine and report any needed

repairs.
1.12
SAFETY
Safe Maintenance

Safe Maintenance
Safety Preparations Before Mainte-
nance

Do not rush. Walk, do not run. Avoid shortcuts that

may cause accidents.

Perform maintenance and repairs only if trained.

Follow the Operation & Maintenance Manual or
Shop Manual.
OM0002

Air conditioner servicing and repair should be per-

formed by trained specialists since injury and/or
environmental pollution can result from improper - Do not wear jewelry that may catch on equip-
servicing. ment, controls, or may short and cause burns if
in contact with electrical components.
Allow only properly trained tire mechanics with the
proper tools to service tires and rims.

OM0026a

Wear safe clothing to perform maintenance:

- Close fitting clothing -- loose or baggy clothing

can catch on equipment or controls.
- Protective clothing as required by the job or con-
ditions -- for example:

- Hard hat
- Gloves
- Steel-toe shoes
- Eye / face protection
- Antidust mask or approved respirator
 1.13
SAFETY
Safe Maintenance

OM0025
OM0222

The inhalation of asbestos-laden dust involves the Before performing any maintenance:
risk of having an adverse health effect. At the
wrecking site and the site handling industrial waste, - Park on level ground.
there is a possibility of inhaling asbestos-laden - Block the tires securely.
dust. - Apply the parking brake.
- Lower the boom and attachment to the ground.
It is requested that the following measures should - Stop the engine (unless specified in the Opera-
be taken at the site where there is a possibility that tion & Maintenance Manual or Shop Manual).
asbestos-laden dust flies in all directions.
Use a piece of cardboard or wood to find fluid leaks
- The worker should were protective equipment under pressure but do not use your bare hand. Die-
such as a dust-protective mask. sel fuel or hydraulic fluid under pressure can pene-
- Sprinkle water in order to prevent asbestos from trate skin or eyes and cause serious injury,
flying in the air. blindness or death.
- Do not use compressed air for cleaning work.
- Do not allow any person other than workers to
come near the working site.
- Observe strictly the laws, regulations and rules
regarding the environmental standards at work-
ing sites.

Asbestos is not used both in this product and genu-

ine parts. However, as it is feared that asbestos
may be used in non-genuine parts, please be sure
to use our genuine parts for replacement.

OM0029

Never make repairs on pressurized components.

Release all trapped air and hydraulic pressure by:

- Stopping the engine after lowering the attach-

ment to the ground.
- Moving the loading control levers back and
forth.
- Turning the steering wheel right and left several
times.
- Turning the hydraulic tank cap 1/3 turn counter-
clockwise.
1.14
SAFETY
Safe Maintenance

Support bar
DANGER

DO NOT
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE

OM0182
85ZV28463

Attach a "DO NOT START" or "DO NOT OPER-

ATE" tag on the key switch or the steering wheel.

When working beneath the machine, use sturdy

and stable supports to hold it up. Do not depend on
hydraulic cylinders or attachment.

70ZV27373

It may be a possibility that your hands or fingers are

pinched with cover suddenly closed by mighty wind
etc.

OM0031 Surely support the cover by support bar when car-

rying on inspection work keeping the cover open.

If working under the raised boom or attachment, be Pay attention not to pinch your fingers when you
sure to properly block or support boom. close door.
(The illustration above is shown the model 70ZV-2
Do not stand on tires. Use safe and sturdy working engine room.)
platforms.
 1.15
SAFETY
Safe Maintenance

Explosion / Fire / Burn Prevention Clean up all spills of coolant, fuel, oil, etc. to pre-
vent fire and slipping hazards.
Before removing any coolant hoses or plugs,
relieve any trapped pressure in the cooling system. Never use flammable solvents like gasoline or die-
sel fuel for cleaning parts.
Cooling system additives and cleaners may contain
alkali that can cause caustic burns or blindness.
Avoid contact with skin or eyes.

Pour all fuel and oil into appropriate containers.

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

Hot oils or coolant and components can cause

burns. Allow components to cool to a safe tempera-
ture before servicing.

Keep flame and sparks away from flammable and OM0032

explosive materials such as:

- Fuel If overheated tire is suspected, never stand in front

- Oil of the tire. Stay away until the tire and rim cool
- Antifreeze down.
- Batteries
- Wood chips
- Straw, leaves, pine straw
- Oily rags
- Grease
- Ether starting fluid

OM0033

Tire and rim assemblies if improperly serviced can

explode with deadly force. When inflating tires;

OM0187 - Make sure wheel parts are correctly installed.

- Use a self attaching (locking) air chuck.
- Use a remotely located valve to turn air pres-
Never smoke while fueling a machine. Stop the sure on and off.
engine before fueling. - Stand behind the tread not beside the rim.
- Do not inflate tires more than the recommended
- Fill oil at well ventilated place. pressure.
- Do not leave the machine when filling oil. - Use a safety cage for a repaired tire.
- Fasten the oil filler cap tightly.
Serious injury may result from explosion of tire/rim
Remove flammable materials from hot engine com- assembly due to improper welding on the rim with-
ponent areas (i.e.; muffler, manifold, etc.). out first removing tire. Remove tire from rim when
welding rim.
1.16
SAFETY
Safe Maintenance

Do not operate the engine where there are or can Other Maintenance Safety Concerns
be combustible vapors. These vapors can be
drawn through the air intake system and cause Periodically check the ROPS bolts (if equipped) to
engine overspeeding, which can result in a fire, and be sure they are in place and tight.
explosion.

To prevent ignition, use the luminaire when check-

ing oil, cooling water, fuel and battery electrolyte
level.

Move ignitable things to a safe place when grinding

welding or gas cutting.

Charge a battery at well ventilated place and keep

fire away from it during charging.

OM0008

Never weld, drill or in any way modify the ROPS

without approval from the manufacturer.

Stop the engine before opening the engine access

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

During servicing, inspect the wiring harnesses, con-

nections and wires and replace any that may be
chafed, or tighten any that may be loose.

OM0188

Keep the area clear of bystanders and wear eye

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

Keep the area clear of bystanders and wear proper

eye protection and protective clothing when grind-
ing or welding.
 1.17
SAFETY
Safe Maintenance

Do not enter the articulation area when engine is

running.

Articulation Stopper
"LOCKED"
90ZV0001

When transporting the machine on a truck or lifting

the machine, lock the articulation stopper in the
"LOCKED" position.

Used oil may cause skin disease if allowed to

remain on the skin for extended periods. Wash skin
completely to remove used oils.

Drain and discard of used oil and coolant properly

to prevent environmental pollution.

Treat the oil and the coolant following the notes on

the MSDS (Material Safety Data Sheet).

Dispose of the waste oil and the coolant following

the law and/or local regulations.

When oil or fuel leaks from the high pressure rub-

ber hose, it may cause an accident or fire by a
wrong actuation. If something is wrong with the rub-
ber 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 dam-
aged by vibrating or scratching other parts.
- Fasten the rubber hose with designated torque
when the connection is loosen.
- Exchange the hose base when it is damaged or
deformed.
- Exchange the hose cover when it is damaged,
cut or expanded.
- Exchange the moving contact of the rubber
hose when it is twisted or bent.
1.18
SAFETY
Safety Signs

Safety Signs
All safety signs which are on the machine are
shown here. Read them and understand them thor-
oughly. 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 miss-
ing, damaged, or worn, get a replacement from
your Kawasaki dealer and install it in the correct
position.

NOTE
The sample safety signs in this section have part
numbers to help you and your dealer obtain the
correct replacement.
 1.19
SAFETY
Safety Signs

1. 16.

WARNING

DANGER
Removal, damage or alteration
of Roll Over Protctive Structure
(ROPS) will result in death or
Serious injury.
Always keep ROPS in place.
FOR THE SAFETY OF
WORK SITE PARSONNEL, Do not operate this machine if
THE BACK-UP ALARM ROPS has been removed,
MUST ALWAYS SOUND
WHEN THIS MACHINE IS
damaged, or altered.
IN REVERSE. 44841-20870

IF THERE IS NO SOUND, Inside L.H, R.H

CHECK AND REPAIR THE
BACK-UP ALARM
IMMEDIATELY.

44787-23880 44787-24020 44787-24680

L.H, R.H L.H, R.H Inside L.H

90ZV02597-0719PV

4. 5. R.H 17. 6.

44787-23950 44787-23940 44787-24040 44787-24010

1.20
SAFETY
Safety Signs

10. 8. 11.

44787-23850 44787-23870 44787-23900

Inside Inside

90ZV02597-0719TVa

11. 10. 8. Inside 9. Inside

44787-23900 44787-23850 44787-23870 44787-23860

 1.21
SAFETY
Safety Signs

2. 13. 18. 6.

STOP

44787-23910 44787-23970 44787-24000 44787-24010

L.H, R.H

90ZV02597-0719RE

3. L.H, R.H 7. L.H, R.H

IMPORTANT
Improper procedure of cleaning
air cleaner element can cause
severe engine damage.
Do not clean or replace
element while engine is
running.
Clean only outer element.
Never clean inner element.
44787-20950

STOP

44787-23920 44787-23930
1.22
SAFETY
Safety Signs

12.
Parking brake cylinder

80ZV02597-0729EE

44787-23980

Inside of Cab

B A

70ZV02597-0717BSa
B A 70ZV02597-0717BS
B-B A-A
70ZV02597-0717AS

14. 15.

DANGER
Removal, damage or alteration
of Roll Over Protctive Structure
(ROPS) will result in death or
Serious injury.
Always keep ROPS in place.
Do not operate this machine if
ROPS has been removed,
damaged, or altered.
44841-20870

44787-23960 44787-23840
 1.23
SAFETY
Safety Signs

1. 3.

STOP

44787-23880 44787-23920

DANGER WARNING

No room in this area while turning machine. Contact with moving belts or pulleys could result in
death or serious injury.
Crushing will result in death or serious injury.
Stop engine before working in this area.
Stay out of this area when machine could move or
turn.

2. 4.

STOP

44787-23910 44787-23950

WARNING DANGER

Contact with moving fan could result in death or Sudden or accidental movement of boom will result
serious injury. in death or serious injury.

Keep all guards in place. Before walking or working under raised boom:

Keep hands away from fan area. - Securely block or brace boom.

- Remove key and tag "Do Not Operate."

- Release all trapped oil pressure before opening

any piping.
1.24
SAFETY
Safety Signs

5. 7.

44787-23940 44787-23930

WARNING WARNING

Machine will not turn with articulation stopper in Machine movement could result in death or serious
locked position. injury.

Unlock articulation stopper before operating Stay out of this machine.

machine.

6. 8.

44787-24010 44787-23870

WARNING CAUTION

Nitrogen accumulator contains compressed gas When handling battery cable, you may get an elec-
and fluid which could result in death or serious tric shock.
injury.
Read, understand, and follow Operation & Mainte-
Release the oil pressure from all brake circuit (and nance Manual before servicing machine.
steering circuit for 65/70ZV-2 only) before removing
any oil lines or piping.

Do not attempt to service or repair accumulator

unless properly trained and equipped.
 1.25
SAFETY
Safety Signs

9. 10.

44787-23860 44787-23850

WARNING WARNING

Batteries produce explosive gases which could Pressurized system: spray of hot fluid could result
result in death or serious injury. in death or serious injury.

Keep flames and sparks away. Allow system to cool and vent pressure slowly
before servicing.
Vent area before servicing.

Batteries contain lead, and acid which may result in

minor or moderate injury.

Avoid contact with skin or clothing.

If lead, or acid contacts skin or clothing, immedi-

ately wash with water.

11.

44787-23900

CAUTION

You may fall from here.

Do not step on here.

1.26
SAFETY
Safety Signs

12. 14.

44787-23980 44787-23960

WARNING WARNING

Compressed spring may accidently be released Accidental movement of machine could result in
and could result in death or serious injury. death or serious injury.

Read Shop Manual before repairing this part. Before checking transmission oil:
- Park on level ground.
- Lower attachment to ground.
- Place transmission in neutral.
- Set parking brake.
- Tag "Do Not Operate."
13.

44787-23970

WARNING

Machine movement, if engine starts in gear, could

result in death or serious injury.

- Do not start engine by shorting across starter

terminals.

- Do not start engine while standing on ground.

Make sure to start engine only from operator's seat

with transmission in neutral and parking brake
applied.
 1.27
SAFETY
Safety Signs

15. 17.

44787-23840 44787-24040

WARNING WARNING

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

Read, understand, and follow Operation & Mainte- Allow system to cool and vent pressure slowly
nance Manual before operating or servicing before servicing.
machine.

Follow all safety signs and instructions in Operation

& Maintenance Manual or on machine.

16. 18.

44787-24020 44787-24000

WARNING WARNING

Pressurized system: spray of hot fluid could result Do not use ether. This engine equipped with elec-
in death or serious injury. tric heater starting aid.

Allow system to cool and vent pressure slowly Use of ether could cause explosion and could result
before servicing. in death or serious injury.
1.28
SAFETY
Safety Devices

Safety Devices Articulation Stopper

Loading Control Lever Lock WARNING

With articulation stopper in LOCKED position,
DANGER machine will not steer; which, while operating,
Accidental movement of boom or machine will could cause an accident, injury or death.
result in death or serious injury.
Do not lock Articulation Stopper during normal
When parking or leaving machine, or when per- operation.
forming maintenance on it, always lower attach-
ment to ground and lock loading control levers. Articulation stopper locks the front and rear chassis
to prevent them from sudden articulation during
inspection or transportation.

To lock:

Lock

Unlock
85ZV20005b

This device locks the loading control levers to pre- "LOCKED" position
vent accidental lowering of the attachment or boom. 90ZV0001

- To lock, set the loading control levers to "NEU-

TRAL" and pull-up the lock lever to forward. 1. Align the front and rear chassis straight ahead.

- To unlock, push down the lock lever to back- 2. Using a 14 mm wrench remove the bolt that
ward. fixes the articulation stopper to the storage
bracket on the front chassis.

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

the Articulation Stopper.

4. Turn the link and fix the end to the bracket on

the front chassis (as shown).

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

position.)
 1.29
SAFETY
Safety Devices

To unlock: Neutral Start System

The transmission has a neutral start system which

allows the engine to start only when the transmis-
sion shift lever is in NEUTRAL position.

Emergency Brake

When the service brake does not work, emergency

"STORED" position
brake can be applied manually.

90ZV0002

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 97ZVOM0038

on the bracket.

- Pull the emergency brake switch to engage the

emergency brake and disengage the transmis-
sion.
1.30
SAFETY
Safety Devices

Secondary Steering (option) ROPS (Roll Over Protective Structure)

Cab
WARNING
Operation without normal steering could cause WARNING
loss of control and injury or death. Operating with damaged or improperly mounted
ROPS Cab could serious injury or death. Be sure
If secondary steering lamp lights up, steer to observe the following.
machine IMMEDIATELY to safe location and - Whenever seated, fasten the seat belt. (If
stop it. equipped)
- Do not modify ROPS Cab, such as drilling or
Secondary steering works automatically when the welding.
steering hydraulic pressure goes down or the - Do not use ROPS Cab deformed.
engine stops while the machine is operating. - If any damage or loose bolts are found, do not
operate until repaired.
When the steering hydraulic pressure goes down - Never repair or modify ROPS Cab without
while the engine is running, the steering hydraulic manufacturer’s approval and instructions.
warning lamp lights up.

Refer to "Secondary Steering Warning Lamp (red)

(option)" page 2.30.

If the secondary 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 emer-

gency brake or lower the attachment to stop
the machine.

4. Place wheel chocks in front of and behind the

tires to prevent the machine from moving.

5. Contact your local Kawasaki dealer for neces-

sary testing and repair.
 2.1

2.OPERATION
2.2
COMPONENT NAME/LOCATION

COMPONENT NAME/LOCATION
25
4 17 24 23 22 10 9

5
3

12 11 21
90ZV2OMCOMPO-c

15 18 19 13,14 18 6 8 20 16 7

1. Bucket (Attachment) 14. Hydraulic Tank (Right hand side)

2. Boom 15. Front Axle / Differential Ass'y
3. "Z" Lever 16. Rear Axle / Differential Ass'y
4. Boom Cylinders (2) 17. Air Cleaner (Right hand side)
5. Bucket Cylinders (2) 18. Parking Brake (2)
6. Steering Cylinders (2) 19. 2nd Propeller Shaft
7. Engine 20. 3rd Propeller Shaft
8. Torque Converter & Transmission Ass'y 21. Batteries (2)
9. Radiator & Torque Converter Cooler (one each side--two 12VDC=24VDC system)
(Lower tank) 22. Cooling Fan
10. Air Cooler (for engine intake air) 23. Fan Motor (hydraulic type)
11. Hydraulic Oil Cooler 24. Exhaust Muffler
12. Fuel Cooler 25. ROPS Cab
13. Fuel Tank (Left hand side)

NOTE
When a component or an item location is given as
"Left hand side" or "Right hand side", it is according
to the operator's left side or right side when sitting
in the seat.
 2.3
OPERATOR'S AREA
Pedals and Levers

OPERATOR'S AREA

Pedals and Levers 1. Transmission Shift Lever

Transmission Shift Lever is used to control machine

11 speed and direction.
2
3 - Push the lever forward to move the machine for-
1 ward.

- When the lever is in NEUTRAL, the machine

should not move on level ground.

- Pull the lever backward to move the machine

backward.

9 10 9 8 97ZVOM0041 - The four forward and four reverse speed shifting

modes are selected by rotating the shift lever.

6 (option) 7
4

85ZV20005c
65ZV 5089

1. Transmission Shift Lever [1]: 1st speed (fixed)

2. Horn Button
3. High-Low Beam Lever / Turn Signal Lever [2]: 2nd speed (fixed)
(option)
4. Boom Control Lever [3]: 3rd speed (fixed)
5. Bucket Control Lever
6. Auxiliary Attachment Control Lever (option) [A]: 2nd, 3rd and 4th speed is automatically
7. Wrist Rest selected for the machine running condition.
8. Accelerator Pedal
9. Brake Pedals
10. Steering Column Telescopic Tilt Handle
11. Steering Wheel 2. Horn Button

Horn Button is used to blow the horn.

- Press the button in the center of the steering

wheel to blow the horn.
2.4
OPERATOR'S AREA
Pedals and Levers

3. High-Low Beam Lever / Turn Signal 4. Boom Control Lever

Lever (option)
Boom control lever is used to control the boom
movement.

Low beam position

(c) (d)
(b)
(a)

High beam position

97ZVOM0044

85ZV20005c
This lever is used to change the head lights beam
high and low. This lever also turns on the turn sig-
nals. (a) Float
- Move the lever to full forward detent position.
- The head lights are in the high beam position The boom will lower and move freely following
when the lever is pushed down (low position). the ground surface.

- The light switch can be operated regardless of - An automatic boom height positioner is provided
the lever position. which will automatically release the detent and
return the lever to the "Hold" position when a
preset boom height is reached.

(b) Lower
- Move the lever forward. The boom will lower.
When held in this position, down pressure will
be applied to the attachment.

- An automatic boom height positioner is provided

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

97ZVOM0044 (c) Hold

- Return the lever to the center position. The
boom will stop and remain in that position.
- Push the lever forward to turn on the left turn
signal. (d) Raise
- Move the lever rearward. The boom is raised.
- Pull the lever backward to turn on the right turn When pulled fully back it is held in a detented
signal. position.
- Return the lever to the center position when the - An automatic boom height positioner is provided
turn is completed. The lever does not return which will automatically release the detent and
automatically when the steering wheel is return the lever to the "Hold" position when a
returned to center. preset boom height is reached.
 2.5
OPERATOR'S AREA
Pedals and Levers

- For adjustment procedure Refer to "Kickout 5. Bucket Control Lever

Control Switch" page 2.18.
Bucket control lever is used to control the bucket or
attachment movement.
In case that the boom does not stop moving even
when the boom control lever is in the HOLD posi-
tion, turn the starter switch to the "OFF" position to
stop the engine.

(d)
IMPORTANT (b) (c)
(a)
If the engine stops by some trouble, lower the
boom and place the bucket on the ground imme-
diately.

85ZV20005c

(a) Dump
- Move the lever forward. The bucket or attach-
ment will dump.

(b) Hold
- Return the lever to the center position. The
bucket or attachment will stop and remain in that
position.

(c) Roll Back (Dual Motion)

- Move the lever rearward half way. The bucket or
attachment will roll back slowly.
- When the boom control lever is in the "Raise"
detent position, both bucket or attachment and
boom will move slowly.

(d) Roll Back (Detent)

- Move the lever rearward. The bucket or attach-
ment will roll back.
- An automatic bucket or attachment leveler is
provided which will automatically release the
detent and return the lever to the "Hold" position
when the bucket or attachment reaches to the
preset angle.
- For adjustment procedure refer to "Bucket /
Attachment Leveler Adjustment" page 2.96.

In case that the bucket does not stop moving even

when the bucket control lever is in the HOLD posi-
tion, turn the starter switch to the "OFF" position to
stop the engine.
2.6
OPERATOR'S AREA
Pedals and Levers

6. Auxiliary Attachment Control Lever 7. Wrist Rest

(option)

Auxiliary attachment control lever is used to control

the auxiliary attachment such as log clamps, multi-
purpose buckets, etc.

Unlock

(b) (c)
(a)
Lock

65ZV4705

Wrist rest is used to put on the wrist or arm while

operating the bucket/boom control levers.

85ZV20005c (High/Low)
Pull the lever out and turn, bringing back to the orig-
(a) Normally this position will close the attach- inal position, to adjust the height.
ment.
(Front/Rear)
(b) This center position will cause the attachment Loosen the screws to adjust the position.
to stop and remain in that position.

(c) Normally this position will open the attachment.

In case that the auxiliary attachment does not stop

moving even when the auxiliary attachment control
lever is in the HOLD position, turn the starter switch
to the "OFF" position to stop the engine.

NOTE
If equipped with attachments other than the stan-
dard 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.
 2.7
OPERATOR'S AREA
Pedals and Levers

8. Accelerator Pedal To avoid these troubles, the following steps

are important

1. Wait one second before turning the key from

the "ON" to the "START" position.

2. Do not step on the pedal while the engine is

starting, nor just after the engine starts.

97ZVOM0038

Accelerator pedal is used to control the engine

speed.

- Step on the pedal to increase the engine speed.

- Release the pedal to decrease the engine

speed.

WARNING
Control pedals which stick could cause loss of
control and injury or death.

- Be sure control pedals move freely before

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

In case that the accelerator pedal does not release,

step on one of the brake pedals or turn the starter
switch to the "OFF" position.

Effect on the machine

1. If the throttle pedal is applied while turning the

key switch to the start position, the engine
maximum speed will only increase to 80 % of
high idle.

2. If the throttle pedal is applied while the engine

is starting, this function will turn "ON" 1 second
after releasing the pedal and engine speed will
only increase 80 % of high idle.
2.8
OPERATOR'S AREA
Pedals and Levers

9. Brake Pedals
CAUTION
WARNING Declutch feature momentarily places transmis-
sion in neutral, which may allow machine to roll
Continuous use of brake could cause rapid or
when on a grade.
abnormal brake disc wear and / or brake circuit
malfunctions which could cause loss of control
Be sure to turn off declutch switch when operat-
and injury or death.
ing on a grade.
- Do not use brake pedals as foot rest.
- Do not ride brakes. In case the brake does not work, pull the parking
- Use brake pedals only when applying brakes. brake switch to apply the emergency brake. The
parking brake can be used as the emergency
brake.

97ZVOM0038

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 declutch

switch (See page 2.17) 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 declutch switch to

the "ON" position. When the switch is "ON", a
green indicator lamp on the dash will also be
turned on.
 2.9
OPERATOR'S AREA
Pedals and Levers

10. Steering Column Telescopic Tilt

Handle

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

- Stop machine before adjusting steering wheel

height and angle of steering column.
- Be sure to push down fully the telescopic tilt
handle lock lever before operating machine.

Steering column telescopic tilt handle is used to

adjust the steering wheel up and down, and to tilt
the steering column forward or backward for opera-
tor's comfort.

Release

Lock

97ZVOM0045

1. Pull up the telescopic tilt handle lock lever and

move the steering wheel to the desired posi-
tion.

2. Push down the telescopic tilt handle lock lever

fully to lock the steering wheel in position.
2.10
OPERATOR'S AREA
Switches

Switches

11 4
6 5
15
16

STOP

85ZV2 0001b

2 378
12 9

65ZV5089c
65ZV 5088e

10 18 17

20
19
14 13 1 85ZV2 FR SWITCH
85ZV20006b

1. Starter Switch 12. MODM

2. Parking Brake Switch 13. Declutch ON/OFF and Adjustable Preset
3. Light Switch Switch
4. Front Working Light Switch 14. Kickout Control Switch
5. Rear Working Light Switch 15. Efficient Loading System Switch
6. (FE) Fuel Efficient Mode Switch 16. Selection Switch for Shift Lever or F/R Switch
7. Front Wiper Switch (option)
8. Rear Wiper Switch 17. F/R Switch (option)
9. Cigarette Lighter 18. Reversal Fan Switch (option)
10. Downshift Button 19. Ride Control Switch (option)
11. Four-Way Flasher Switch 20. Shift Hold Switch (option)
 2.11
OPERATOR'S AREA
Switches

1. Starter Switch 2. Parking Brake Switch

WARNING
Accidental movement of machine could result in
death or serious injury.
OFF ON
PREHEAT START
Be sure to pull parking brake switch when park-
ing or leaving machine, and during maintenance
or transportation.

65ZV0074

OFF
- Key can be either inserted or pulled out.

- Engine is stopped and most electrical circuits

are turned off.

ON
- Current flows to all circuits. 97ZVOM0038

START Parking brake switch is used for parking the

- When the transmission shift lever is in NEU- machine. When the switch is pulled, the parking
TRAL, starter motor turns, starting the engine. brake is applied and the transmission is disen-
gaged. When the switch is pushed, the parking
- When released the key will automatically return brake is released.
to the "ON" position.
Should the directional shift lever be moved into the
PREHEAT forward or reverse position while the parking brake
- This position is used when it is too cold to start is applied and the engine is running, a warning
the engine. buzzer will sound.
- Intake air will be heated and the preheat lamp
comes on. When released the key will automati-
cally return to the "ON" position.
2.12
OPERATOR'S AREA
Switches

3. Light Switch 4. Front Working Light Switch

85ZV2 0002b

65ZV 5088e OFF

This is a three position switch.

OFF ON

- Width (clearance) lamps (option), tail lamps,

front head lights, and gauge lamps turn off.
switch-4

- Width (clearance) lamps (option), tail lamps, and

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

- Width (clearance) lamps (option), tail lamps, Turn off the front working lights when roading to
front head lights, and gauge lamps turn on. prevent blinding the driver in front of you.
 2.13
OPERATOR'S AREA
Switches

5. Rear Working Light Switch 6. (FE) Fuel Efficient Mode Switch

85ZV2 0002b 85ZV2 0002b

OFF OFF

ON ON

switch-4 switch-3

Rear working light switch is used for turning on and

off the rear working lights.

Turn off the rear working lights when roading to pre-

Engine Torque

vent blinding the driver behind you.

Power Mode

FE Mode

Engine Speed
90ZV2 5001

The operator can select either "Power" or "Fuel Effi-

cient" (FE) engine mode.

Power mode provides added power for extreme

applications.

Fuel efficient mode offers better fuel economy for

standard applications.

When this switch is turned "ON" the switch lamp

lights up and the engine power is reduced to pro-
vide better fuel economy.
2.14
OPERATOR'S AREA
Switches

7. Front Wiper Switch 8. Rear Wiper Switch

65ZV 5088e 65ZV 5088e

Front wiper switch is used to wipe the front wind- Rear wiper switch is used to wipe the rear wind-
shield and spray solvent. shield.

INT LOW
HIGH OFF ON
OFF

PUSH
PUSH

OM0189 OM0190

OFF : OFF :

INT : Intermittent ON : Low speed

LOW : Low speed PUSH : Spraying solvent on the windshield

HIGH : High speed

PUSH : Spraying solvent on the windshield

 2.15
OPERATOR'S AREA
Switches

9. Cigarette Lighter 10. Downshift Button

65ZV 5088e 85ZV20005c

Cigarette lighter is used to light a cigarette or cigar. Downshift button is used to quickly shift down the
transmission from 2nd gear to 1st gear without
- Push the lighter in and wait for a few seconds. moving the transmission shift lever.
The lighter will spring back to be ready for light-
ing a cigarette or cigar. - When operating the machine in 2nd speed with
the shift lever in [2] or [A] position, the transmis-
- The cigarette lighter power-outlet socket can be sion will shift down to 1st gear by pressing
used as a power source with max. 24 volts 10 downshift button.
amperes in case of emergency.
- Pressing downshift button again or moving the
transmission shift lever to the opposite direction
releases the 1st gear setting to return to 2nd
gear.
2.16
OPERATOR'S AREA
Switches

11. Four-Way Flasher Switch 12. MODM

85ZV2 0002b

65ZV5089c
OFF

The MODM has the following functions:

ON
- Information monitor

- Displays outside air temperature, machine

speed and engine speed, engine coolant tem-
switch-3
perature, transmission oil temperature, hydrau-
lic oil temperature and miles driven etc.

The two front and two rear turn signal lights will - Replacement monitor
flash when four-way flasher switch is ON.
Allows check of the replacement time for the
This is used in emergency, when parking on the parts and oil periodically replaced, allows setting
road, etc. to warn other vehicles. of the replacement interval, and displays the
replacement pop-ups.

- Error log monitor

Allows check of previous errors, and displays

active errors.

- Input/Output monitor

Displays the ON/OFF status of input and output

signals.

- Parameter setting monitor

Allows check and change of the parameter set-

ting.

- Specification setting monitor

Allows check and change of the specification

setting.

Refer to page 2.32 for the MODM operation.

 2.17
OPERATOR'S AREA
Switches

13. Declutch ON/OFF and Adjustable

Preset Switch CAUTION
Declutch feature momentarily places transmis-
sion in neutral which may allow machine to roll
when on a grade.

Do not turn declutch ON/OFF switch to "ON"

when operating on a grade.

Declutch
Declutch OFF preset
Adjustable Declutch Preset

Declutch ON

85ZV20005c

Hold
Declutch ON/OFF

Reset

OFF switch-5

Adjustable declutch preset switch is used to

change the angle of the brake pedal to disengage
ON
the transmission clutch.

With the engine running, step on the brake pedal

switch-5
up to the desired angle, and press the switch to set
the declutch pedal angle.
Declutch ON/OFF switch is used to change the
function of the brake pedals. WARNING
Accidental movement of machine could result in
Normally this switch should be "ON". death or serious injury.

OFF Be sure to stop machine and pull parking brake

- When the brake pedal is step on, the service switch before adjusting brake pedal angle.
brakes are engaged and the transmission direc-
tional clutch remains engaged. (brake only)

ON
- When the brake pedal is step on, the service
brakes are engaged and the transmission direc-
tional clutch is disengaged (brake and declutch).

Refer to "Brake Pedals" page 2.8 for the function of

the brake pedals.
2.18
OPERATOR'S AREA
Switches

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

NOTE
- Float detent is ready to be reactivated 2 sec-
onds just after the previous lower kickout opera-
tion. Use the float detent after 2 seconds or
more later the lower kickout operates.

- The bucket may hit the ground, if the boom

leaves the clearance a bit higher above the
lower kickout position.
85ZV20005c
- Preset the lower kickout position at a higher
point when it is cold due to the thicker oil.

WARNING
(Upper) (Lower)
Accidental movement of machine could result in
death or serious injury.
Hold Hold
Be sure to stop machine and pull parking brake
switch before adjusting boom position.
Reset Reset

switch-5

Kickout control switch is used to set the desired

upper and lower boom position.

- Raise the boom to desired position and press

the left side of the switch for 1 second to set the
upper kickout position.

After the buzzer sounds, the boom height is set

at that position.

When the boom control lever is placed at

"Raise" position and the boom reaches at the
preset height, the lift kickout automatically
releases the detent and returns the boom con-
trol lever to "Hold" position.

- Lower the boom to desired position and press

the right side of the switch for 1 second to set
the lower kickout position.

After the buzzer sounds, the boom height is set

at that position.

When the boom control lever is placed at "Float"

 2.19
OPERATOR'S AREA
Switches

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

This improves loading efficiency and save fuels.

85ZV2 0002b
The boom height position at which the ELS
engages is preset at the factory before delivery.
However it can be changed to engage at different
positions by doing the following steps.

To change the ELS engagement boom height, raise

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

switch-3

ELS (Efficient Loading System) increases rim-pull

power when digging while consuming less fuel.

It is useful to use the ELS for heavy duty digging

application or fuel efficient engine mode.

ELS system works under the following condition.

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

FAST

SLOW

90ZV2 5002
2.20
OPERATOR'S AREA
Switches

16. Selection Switch for Shift Lever or

F/R Switch (option)

STOP

85ZV2 0003b

OFF

ON

switch-4

Selection switch for shift lever or F/R switch is used

to switch the forward/reverse function by using from
the shift lever to the F/R switch (option).

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

Regardless of the shift lever position, while the F/R

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

Pressing selection switch again, the light goes out,

and the function of F/R switch is cancelled.

The shift lever can be used to move the machine

forward or reverse.

However for safety purposes, place the shift lever

in the neutral position before pressing selection
switch again.
 2.21
OPERATOR'S AREA
Switches

17. F/R Switch (option)

85ZV2 FR SWITCH

F/R switch is used to move the machine forward

and reverse.

Place the F/R switch in F position to move the

machine forward, and in R position to move the
machine reverse.

The machine does not move either way when the

F/R switch is in N position.

Operation Shift lever position F/R switch position Selection switch

By F/R switch Any position N ON
By shift lever N Any position OFF
2.22
OPERATOR'S AREA
Switches

18. Reversal Fan Switch (option) Functional Limitation

When either one of the following temperatures

exceeds the preset upper limit(s), the cooling fan
reverse rotation function does not work:

- Engine coolant temperature

- Torque converter oil temperature
- Hydraulic oil temperature

85ZV20006b

OFF

ON

switch-3

Engaging this switch reverses the rotation of the

cooling fan for cleaning the radiator fins.

When pushing this switch for more than 2 seconds

while the engine is running or with the starter switch
at "ON" position, the switch turns "ON", the pilot
lamp on the switch lights up and the cooling fan
turns in reverse rotation for 1 minute, after which it
returns to it's normal rotation.

The fan turns continuously in reverse direction for 1

minute at 30 minute intervals.

When the switch is pushed again for more than 2

seconds, the cooling fan reversal switch turns
"OFF" and the pilot lamp on the switch turns "OFF".
Then the cooling fan turns in the normal direction.

The cooling fan reversal switch can be operated

any time the engine is running. It is not necessary
to stop the machine to push the reversal cooling fan
switch.
 2.23
OPERATOR'S AREA
Switches

19. Ride Control Switch (option) 20. Shift Hold Switch (option)

85ZV20006b 85ZV20006b

Shift hold switch is used to fix the gear when oper-

ating the machine with the transmission shift lever
in [A] position.

OFF Pressing shift hold switch again cancels the setting

and the machine runs in [A] speed as before.

NOTE
ON Even if the gear is fixed at the 4th position, it will
automatically shift down to the 3rd gear position
when machine speed becomes 3 km/h or slower to
avoid knocking or engine stop.
switch-3

When the ride control switch is ON, the ride control

works. Refer to "Ride Control (option)" page 2.61.
2.24
OPERATOR'S AREA
Indicators

Indicators

1 21 20 5 17 19 18 9 2 23 4 10

11(28)

12

13
14
15
STOP
16

85ZV2 0004
27 25 26 24 22 6 8 7 3 2
(28)

1. Speedometer 15. Air Cleaner Warning Lamp (red)

2. Engine Coolant Temperature Gauge 16. Charge Lamp (red)
3. Torque Converter Oil Temperature Gauge 17. Turn Signal Indicator Lamp (Left) (green)
4. Fuel Gauge 18. Turn Signal Indicator Lamp (Right) (green)
5. Parking Brake Indicator Lamp (red) 19. High Beam Indicator Lamp (blue)
6. Declutch Lamp (green) 20. Auto Shift Indicator Lamp
7. Working Light Indicator Lamp (green) 21. Neutral Indicator Lamp
8. Preheat Indicator Lamp (orange) 22. Transmission Status Monitor
9. Central Warning Lamp (red) 23. Hour Meter
10. MCU (Machine Control Unit) Warning Lamp 24. Secondary Steering Warning Lamp (red)
(red) (option)
11. Brake Pressure Warning Lamp (red) 25. Engine Warning Lamps
12. Engine Oil Pressure Warning Lamp (red) 26. Reversal Fan Pilot Lamp (green)(option)
13. Engine Coolant Temperature Warning Lamp 27. F/R Switch Indicator Lamp (green)(option)
(red) 28. Hydraulic Oil Level Warning Lamp (simulta-
14. Torque Converter Oil Temperature Warning neous flashing)(red)(11. 24.)
Lamp (red)

When the starter switch is turned to "ON", all warn-

ing lamps (9) ~ (16), (24) and (25) light up for three
seconds. This is the lamp (bulb) test period (lamp
(16) lights up until engine starts).

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

Stop machine and correct problems if any red

lamps come on.
 2.25
OPERATOR'S AREA
Indicators

1. Speedometer 3. Torque Converter Oil Temperature

Gauge

20 30

10 40 C H
T/C OIL
TEMP

0 50
km/h
97ZVOM0050
70ZV0008

Indicates the temperature of oil circulating through

Indicates the machine ground speed in km/h. the torque converter and the transmission. It is nor-
mal if the indicator is in the white zone (56~125ºC)
while operating.

2. Engine Coolant Temperature Gauge - If the indicator enters the red zone while operat-
ing, slow the engine down to mid-range speed,
shift to neutral, and wait until the indicator
reaches the white zone.
C H
WATER
TEMP - If the indicator does not come back into the
white zone quickly, stop the engine and find the
cause.
97ZVOM0049

Refer to "TROUBLESHOOTING" page 3.63.

Indicates engine coolant temperature. It is normal
when the indicator stays in the white zone
(67~102ºC).
4. Fuel Gauge
- If the indicator enters the red zone while operat-
ing, slow the engine down to mid-range speed
and wait until the indicator reaches the white
E F
zone.
FUEL

- If the gauge stays in the red zone, stop the

engine and allow it to cool naturally. After cool-
ing, check the cooling system. 65ZV0005

Refer to "TROUBLESHOOTING" page 3.59. Indicates the fuel amount in the fuel tank.

- Be sure to refuel at the end of each work day to

avoid condensation in the tank.
2.26
OPERATOR'S AREA
Indicators

5. Parking Brake Indicator Lamp (red) 8. Preheat Indicator Lamp (orange)

P
OM0052 OM0176

Lights up when the parking brake is applied. Lights up when the starter switch is in the "PRE-
HEAT" position.
If the transmission shift lever is moved into "F" or
"R" position while this lamp is on, an alarm sounds
and the machine stays in neutral.
9. Central Warning Lamp (red)

6. Declutch Lamp (green)

OM0056

Flashes when any of the warning lamps come on.

OM0054

Lights up when the declutch switch is "ON".

10. MCU (Machine Control Unit) Warn-
- When lit, the service brakes are engaged and ing Lamp (red)
the transmission directional clutch is disen-
gaged by step on the brake pedals.

- When not lit, only the brakes are engaged as the

brake pedal is step on.

OM0057

7. Working Light Indicator Lamp

(green) Lights up when MCU malfunctions.

- If it lights up while operating, stop the engine

and contact your nearest Kawasaki dealer for
necessary repair.

OM0055

Lights up when working lights are on.

 2.27
OPERATOR'S AREA
Indicators

11. Brake Pressure Warning Lamp (red) 13. Engine Coolant Temperature Warn-
ing Lamp (red)
WARNING
Loss of braking force could result in death or
serious injury.

Stop machine IMMEDIATELY and correct prob-

lem if brake pressure warning lamp lights up dur- OM0060
ing operation.
Lights up when coolant temperature overheats.
Brake Pressure Warning Lamp lights up and the (Over 102ºC)
warning buzzer sounds when the brake oil pressure
is lower than 3.9 MPa. - 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
OM0058 engine and find the cause. Refer to "TROUBLE-
SHOOTING" page 3.59.
- If it lights up while operating, IMMEDIATELY
stop the machine and find the cause. CAUTION
Refer to "TROUBLESHOOTING" page 3.62. Hot coolant spray may cause burns.

Never open radiator cap when engine is hot.

12. Engine Oil Pressure Warning Lamp Stop engine and allow radiator and coolant to
cool completely before opening cap slowly to
(red) relieve pressure.

OM0059

Lights up when engine oil pressure is low. Also the

warning buzzer sounds.

- If it lights up while operating, IMMEDIATELY

stop the engine and find the cause.

Refer to "TROUBLESHOOTING" page 3.59.

2.28
OPERATOR'S AREA
Indicators

14. Torque Converter Oil Temperature 16. Charge Lamp (red)

Warning Lamp (red)

Lights up when transmission oil overheats. (Over

120±5ºC)

OM0063

Lights up when alternator charge level is low.

OM0061 - If it lights up, check the charging circuit.

- If it lights up while operating, slow the engine Refer to "TROUBLESHOOTING" page 3.61.
speed down to mid-range, shift to neutral, and
wait until the lamp goes out. Check the torque
converter oil temperature gauge before resum-
ing the operation. 17. Turn Signal Indicator Lamp (Left)
(green)
- 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 "TROUBLE-
SHOOTING" page 3.63.

OM0065
15. Air Cleaner Warning Lamp (red)
Flashes when the turn signal switch lever is moved
forward.

18. Turn Signal Indicator Lamp (Right)

OM0062
(green)
Lights up when air filter is clogged.

- If it lights up while operating, stop the engine

and clean or replace the air cleaner outer ele-
ment.
OM0066
Refer to "Clean or Replace Air Cleaner Element"
page 3.9.
Flashes when the turn signal switch lever is moved
rearward.
 2.29
OPERATOR'S AREA
Indicators

19. High Beam Indicator Lamp (blue) 22. Transmission Status Monitor

4
3
OM0067
2
Lights up when headlights are switched to high 1
beam. OM0070

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

- 2nd Gear

AUTO Lights up when the shift lever is in [2] or [A]

position and transmission is in 2nd gear.

OM0068
- 3rd Gear
Lights up when the shift lever is in [3] or [A]
Lights up when the transmission control lever is in position and transmission is in 3rd gear.
the [A] position.
- 4th Gear
Lights up when the shift lever is in [A] position
and transmission is in 4th gear.
21. Neutral Indicator Lamp

23. Hour Meter

N OM0069
1/10h

OM0071
Lights up when transmission is in neutral.
Hour meter indicates the accumulated total hours
of engine operation. Use to determine the timing of
periodic inspection and maintenance service.
2.30
OPERATOR'S AREA
Indicators

24. Secondary Steering Warning Lamp 25. Engine Warning Lamps

(red) (option)
Engine stop lamp

STOP
OM0072

OM0191
Red
Lights up when the steering hydraulic pressure is
lower than specified when the engine is running.
If a stop (red) lamp comes on while the engine is in
operation, the fault can be engine disabling. Stop
Also the warning buzzer sounds.
the engine operation in a safe manner as soon as
possible.

Engine warning lamp

OM0192
Yellow

If the yellow warning lamp illuminates, the engine

can still be operated, but it can lose some system
features that can sometimes result in a power loss.
The failure must be repaired as soon as conve-
nient.

Engine protection lamp

OM0193
Orange

If the orange warning lamp comes on while driving,

it means that a fault code has been recorded. The
light will remain on as long as the fault is occurring.

The light will begin to flash if the condition contin-

ues to get worse. The engine power and/or speed
will be gradually reduced. If the engine protection
shutdown feature is enabled, the engine will shut
down to prevent engine damage.
 2.31
OPERATOR'S AREA
Indicators

26. Reversal Fan Pilot Lamp 28. Hydraulic Oil Level Warning Lamp
(green)(option) (simultaneous flashing)(red)(11. 24.)

OM0223 OM0058

Lights up when the reversal fan switch is ON.

Refer to "Reversal Fan Switch (option)" page 2.22.

OM0072

27. F/R Switch Indicator Lamp

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

- When the lamp flashes simultaneously, IMME-

DIATELY stop the machine and check for leaks
in the hydraulic line.
OM0218
Refill the hydraulic tank with oil as needed.
Refer to "Check Hydraulic Oil Level" page 2.68.
Lights up when the selection switch for shift lever or
F/R switch is ON.

Refer to "Selection Switch for Shift Lever or F/R

Switch (option)" page 2.20.
2.32
OPERATOR'S AREA
MODM

MODM Monitor Changeover

(Machine Operation Diagnostic Module)
Replacement Error log
monitor monitor

[ ]button [ ]button
Information Input/Output
monitor monitor

Specification Parameter
setting monitor setting monitor

Display window [ (step back)] [ (step forward)]

button button

90ZV-262001 Change over the monitor using the following proce-

dure:
MODM function When the starter switch is ON, the information
monitor is first displayed on initial monitor.
The MODM has the following functions:
Press the [ (step back)] button and [ (step
- Information monitor forward)] button at the same time to change over
the monitor mode in sequence "Information monitor
- Displays outside air temperature, machine → Replacement monitor → Error log monitor →
speed and engine speed, engine coolant tem- Input/Output monitor → Parameter setting monitor
perature, transmission oil temperature, hydrau- → Specification setting monitor → Information
lic oil temperature and miles driven etc. monitor".

- Replacement monitor However the monitor mode can not be changed in

reverse such as "Information monitor → Specifica-
Allows check of the replacement time for the tion setting monitor → Parameter setting monitor
parts and oil periodically replaced, allows setting ....."
of the replacement interval, and displays the
replacement pop-ups. The display will not be changed to the next monitor
when you hold the buttons.
- Error log monitor

Allows check of previous errors, and displays

active errors.

- Input/Output monitor

- Parameter setting monitor

Allows check and change of the parameter set-

ting.

- Specification setting monitor

Allows check and change of the specification

setting.
 2.33
OPERATOR'S AREA
MODM

Information Monitor 1. Outside air temperature

Information monitor display

When the starter switch is ON, the outside air tem-

perature is displayed. 90ZV-262024

Every time the [ (step forward)] button is The monitor displays the current outside air temper-
pressed or every time the [ (step back)] button ature when the starter switch is ON.
is pressed, the displayed contents are changed
over in sequence as below. Press the [ ] button to change over the display
unit from "ºC" to "ºF". Press the [ ] button again to
Step forward Step back return the display unit from "ºF" to "ºC".

2. Machine speed and engine speed

Outside air temperature

Machine speed and engine speed 90ZV-262025

Press the [ ] button to change the display unit

Engine coolant temperature from "km/h" to "mile/h"

Press the [ ] button again to return the display unit

from "mile/h" to "km/h".
T/M oil temperature
For speed to be accurate, the correct tire size must
be entered into the main MCU via this MODM unit.
Hydraulic oil temperature

Odometer

Cycle

Cylinder oil pressure

Voltage

Hour meter

85ZV2 0008
2.34
OPERATOR'S AREA
MODM

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

90ZV-262026 90ZV-262027

The monitor displays the current engine coolant The monitor displays the current transmission oil
temperature and maximum engine coolant temper- temperature and maximum transmission oil tem-
ature recorded since the work on the day is started perature recorded since the work on the day is
(that is, since the engine starter switch is ON). started (that is, since the engine starter switch is
ON).
Even if the engine is stopped once and then started
again, if the time is before 24:00, the monitor dis- Even if the engine is stopped once and then started
plays the maximum engine coolant temperature again, if the time is before 24:00, the monitor dis-
recorded on the day. plays the maximum transmission oil temperature
recorded on the day.
The maximum engine coolant temperature is auto-
matically reset everyday at 24:00, whether the The maximum transmission oil temperature is auto-
engine starter switch is turned on or off. matically reset everyday at 24:00, whether the
engine starter switch is turned on or off.
Immediately after reset, the engine coolant temper-
ature at the time of reset is displayed as the maxi- Immediately after reset, the transmission oil tem-
mum engine coolant temperature. In other words, perature at the time of reset is displayed as the
the current engine coolant temperature is equiva- maximum transmission oil temperature. In other
lent to the maximum engine coolant temperature. words, the current transmission oil temperature is
equivalent to the maximum transmission oil temper-
Press the [ ] button to reset the maximum engine ature.
coolant temperature. Immediately after reset, the
engine coolant temperature at the time of reset is Press the [ ] button to reset the maximum trans-
displayed as the maximum engine coolant temper- mission oil temperature. Immediately after reset,
ature. the transmission oil temperature at the time of reset
is displayed as the maximum transmission oil tem-
Press the [ ] button to change over the display perature.
unit from "ºC" to "ºF". Press the [ ] button again to
return the display unit from "ºF" to "ºC". Press the [ ] button to change over the display
unit from "ºC" to "ºF". Press the [ ] button again to
return the display unit from "ºF" to "ºC".
 2.35
OPERATOR'S AREA
MODM

5. Current hydraulic oil temperature and maxi- 6. Odometer (total miles driven) and trip meter
mum hydraulic oil temperature recorded (which can be reset)
(which can be reset)

90ZV-262029

90ZV-262028

The monitor displays the total number of miles

The monitor displays the current hydraulic oil tem- driven in the upper line, and the trip meter in the
perature and maximum hydraulic oil temperature lower line.
recorded since the work on the day is started (that
is, since the engine starter switch to ON). Press the [ ] button to reset the trip meter dis-
played in the lower line.
Even if the engine is stopped once and then started
again, if the time is before 24:00, the monitor dis- Press the [ ] button to change over the display
plays the maximum hydraulic oil temperature unit from "km" to "mile". Press the [ ] button again
recorded on the day. to return the display unit from "mile" to "km".

The maximum hydraulic oil temperature is automat-

ically reset everyday at 24:00, whether the engine 7. Number of cycles and cycle time
starter switch is turned on or off.

Immediately after reset, the hydraulic oil tempera-

ture at the time of reset is displayed as the maxi-
90ZV-262030
mum hydraulic oil temperature. In other words, the
current hydraulic oil temperature is equivalent to
the maximum hydraulic oil temperature. The monitor displays the number of cycles in the
upper line and the time required for one cycle (mov-
Press the [ ] button to reset the maximum hydrau- ing forward twice and moving backward twice) in
lic oil temperature. Immediately after reset, the the lower line.
hydraulic oil temperature at the time of reset is dis-
played as the maximum hydraulic oil temperature. Press the [ ] button to reset both the number of
cycles and the cycle time.
Press the [ ] button to change over the display
unit from "ºC" to "ºF". Press the [ ] button again to After reset, the monitor displays newly the number
return the display unit from "ºF" to "ºC". of cycles in the upper line and the time required for
one cycle in the lower line.

8. Hydraulic system oil pressure

90ZV-262031a

The monitor displays the unloader pressure of the

efficient loading system (ELS).

Press the [ ] button to change over the display

unit from "MPa" to "psi". Press the [ ] button again
to return the display unit from "psi" to "MPa".
2.36
OPERATOR'S AREA
MODM

9. Voltage Unit conversion and language selection

Select the unit and language using the [ ] button.

Unit conversion (for distance, temperature and

90ZV-262032
pressure)

Press the [ ] button once to change the display

10. Hour meter (total operating hours) and trip unit. Press the [ ] button again to return to the pre-
meter (which can be reset) vious display unit.

Language selection
90ZV-262033
Press and hold the [ ] button for 3 seconds or
more to display the language selection screen.
The monitor displays the total operating hours in
the upper line, and the trip meter in the lower line. English is selected as the initial setting.
Japanese, French, German, Italian and Spanish
Press the [ ] button to reset the trip meter dis- can be selected.
played in the lower line. Press the [ (step forward)] button or [ (step
back)] button to select the language.

For returning to the information monitor after select-

ing the language, press and hold the [ ] button for
2 seconds or more.

For returning to the information monitor without

selecting the language, press the [ ] button.
 2.37
OPERATOR'S AREA
MODM

Replacement Monitor Step forward Step back

Replacement time check

Press the [ (step forward)] button and [

Engine oil filter
(step back)] button at the same time to change over
the screen from the information monitor to the
replacement monitor.
Fuel filter

90ZV-262034
Coolant filter

The display window displays the remaining time

until next replacement of the engine oil filter car-
T/C line filter
tridge to be changed.

Every time the [ (step forward)] button is

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

Engine oil

T/C and T/M oil

Axle gear oil

Hydraulic oil

85ZV2 0009
2.38
OPERATOR'S AREA
MODM

Replacement interval set (timer reset) Replacement pop-up

When the machine is shipped, the standard

replacement interval is set as the initial setting.
90ZV-262038
Press and hold the [ ] button for 2 seconds or
more on the replacement monitor screen to display
the timer reset screen. When the remaining time until the next replacement
The timer reset screen displays the standard reaches " 0 ", the replacement pop-up appears and
replacement interval. flashes on the display window.

For setting the standard replacement interval, press

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

Example: Engine oil

90ZV-262037

For setting the replacement interval other than the

standard replacement interval, follow the procedure
below:

∗∗∗∗ +50 90ZV-262039

∗∗∗∗ +100 (2 seconds or more)
∗∗∗∗ −50
∗∗∗∗ −100 (2 seconds or more) When two or more replacement pop-ups occur at
the same time, the corresponding items flash in
Every time the [ (step forward)] button is turn.
pressed, "50" is added.
After the remaining time for the next replacement
Every time the [ (step back)] button is pressed, reaches " 0 ", the corresponding pop-up appears up
"50" is subtracted. to three times when the starter switch is ON.
(The outside air temperature is displayed for 3 sec-
When the [ (step forward)] button is pressed onds, and then the replacement pop-up flashes.)
and held for 2 seconds or more, "100" is added
continuously. When the [ (step forward)] button, [ (step
back)] button, [ ] button or [ ] button is pressed,
When the [ (step back)] button is pressed and however, it returns to the previous screen again.
held for 2 seconds or more, "100" is subtracted
continuously. After replacing the corresponding filter or oil, return
to the timer reset screen and set the replacement
After setting the replacement interval, press and interval. Refer to the replacement interval set (timer
hold the [ ] button for 2 seconds or more, the reset) procedure above.
replacement interval is reset and it returns to the
replacement monitor screen again.
 2.39
OPERATOR'S AREA
MODM

Error Log Monitor Engine error log

Error log history check When two or more error codes are recorded, press
the [ (step forward)] button to display the next
Up to 100 machine errors history and up to 100 latest error code.
engine errors history are recorded in the error log. Press the [ (step back)] button to display the
The error code and the date and time at the occur- error code in chronological order.
rence (in the format "year/month/day hour/minute/
second") are recorded in the error log.
Clear error log
Error codes are displayed from the latest one.
Clear machine error log
Selection of machine error log and engine Press and hold the [ ] button for 2 seconds or
error log more to display the clear error log screen.

When the machine error log screen is displayed, Press and hold the [ ] button for 2 seconds or
press and hold the [ (step forward)] button for 2 more to clear the entire error log.
seconds or more to display the engine error log When there are two or more error codes recorded,
screen which shows the latest engine error code. all error codes recorded are cleared by performing
the clear error log operation once.
When the engine error log screen is displayed,
press and hold the [ (step back)] button for 2 Press the [ ] button not to clear the error log.
seconds or more to display the machine error log Then, the error log is not cleared, and it returns to
screen which shows the latest machine error code. the machine error log screen again.

The machine error log screen and engine error log Clear engine error log
screen can be distinguished as follows:
Press and hold the [ ] button for 2 seconds or
Displayed error code: more to display the clear error log screen.
CN∗∗∗ ..... Machine error log screen
EG∗∗∗ ..... Engine error log screen Press and hold the [ ] button for 2 seconds or
more to clear the entire error log.
Machine error log When there are two or more error codes recorded,
all error codes recorded are cleared by performing
When two or more error codes are recorded, press the clear error log operation once.
the [ (step forward)] button to display the next
latest error code. Press the [ ] button not to clear the error log.
Press the [ (step back)] button to display the Then, the error log is not cleared, and it returns to
error code in chronological order. the engine error log screen again.
2.40
OPERATOR'S AREA
MODM

Active error (error pop up) Input/Output Monitor

When an error occurs, the corresponding error
Input/Output monitor display
code is forcibly displayed on the screen.
When two or more active errors occur, up to 5 error Every time the [ (step forward)] button is
codes are displayed repeatedly. (Up to 10 error pressed and held for 2 seconds or every time the
codes for CN and EG total errors) [ (step back)] button is pressed and held for 2
seconds, the displayed contents are changed over
Press one of the [ (step forward)] button, [ in sequence as follows.
(step back)] button, [ ] button or [ ] button. The
screen displayed before the active error codes Press and hold Press and hold
appears again. Step forward Step back

Active error codes are displayed repeatedly, when-

ever the starter switch is ON, until the causes of
errors are eliminated. Input signal

Input sensor
IMPORTANT
Error log is important information for machine
maintenance. Do not clear error log before figur- Output signal
ing out cause.

Continuous machine operation, with active error

shown, may cause severe machine damage. Current output

If active error shows, please contact Kawasaki

dealer in your area. 85ZV2 0010

Refer to "TROUBLESHOOTING" page 3.66 for 1. Input signal monitor

error code.
This monitor displays the ON/OFF status of the
shift lever, setting switches, pressure switches,
etc.

2. Input sensor monitor

This monitor allows check of the input level of

the brake pedal output oil pressure, steering oil
pressure, boom angle etc.

3. Output signal monitor

This monitor displays the ON/OFF status of the

transmission forward/backward solenoid
valves, speed range solenoid valves, indicator
lamps and warning lamps on the instrument
panel, etc.

4. Current output monitor

This monitor allows check of the current output

level of the cooling fan.
 2.41
OPERATOR'S AREA
MODM

Parameter Setting Monitor

Display of parameter setting monitor

This monitor allows check of the parameters cur-

rently set.

Specification Setting Monitor

Specification setting monitor display

This monitor allows check of the specifications cur-

rently set.
2.42
OPERATOR'S AREA
Seat

Seat Combined Height and Weight Adjuster

Seat Adjustment 1. Sit on the seat.

(KAB811) 2. Turn handle (a) to adjust seat height.
Adjust the seat for comfort and so that the pedals Clockwise to raise seat.
may be pushed fully down when the operator's
back is fully back. Anti-Clockwise to lower seat.

WARNING 3. Check ride indicator (b) shows green.

Unexpected movement of seat could result in
If red, readjust seat height.
death or serious injury.
Within the green band of the ride indicator there is
Stop machine before adjusting seat position.
75 mm of height adjustment for any driver.

NOTE
The seat is designed so that it is unnecessary to
make any adjustment for the driver weight.
3
Up-Stop Height Adjustment Control
2
To adjust the up-stop height, rotate hand wheel (c)
clockwise to raise the seat unseated, rotate it
1 counter-clockwise to lower the seat unseated.
c

a b
95ZV OM EU SEAT

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 posi-

tion, release handle.

Armrests

Rotate control knob (3) to select desired angle.

Pivot up and parallel with backrest when not in use.
 2.43
OPERATOR'S AREA
Seat

Seat Belt

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

- Inspect seat belt and mounting hardware

before operating machine and replace any
defective components.

- Always fasten seat belt when operating

machine.

- Properly adjust seat belt at beginning of each

shift or when operator changes.

1 3
2

OM0007

1. Pull at seat belt (1) and fasten it along your

body without kinking or twisting it.

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

buckle (2). Be sure it locks securely.

3. For releasing the seat belt, press the "press

button" in buckle (2) and remove belt end (3)
from buckle(2).

The tether is inside the seat boot.

No adjustment necessary.
2.44
OPERATOR'S AREA
Electrical Protection

Electrical Protection
(1) Left (2) Left
LIGHTING
Fuse Boxes SPARE 5A
HEAD LIGHT
20A

SPARE 5A R. WORK LIGHT 15A

2 R. WIPER / WASHER 5A
BOOM KICKOUT
10A
1 BUCKET LEVELER

F. WIPER / WASHER 10A TURN SIGNAL 15A

PARKING BRAKE
CIGAR LIGHTER 10A 30A
MCU (MACHINE)

SPARE 15A F. WORK LIGHT 15A

AIR SUS SEAT

RADIO 3A 10A
(option)

85ZV28505 SPARE 10A SPARE 15A

SPARE 10A SPARE 15A

4 WAY FLASHER
HORN
SPARE 20A 15A
DOME LAMP
RADIO BACK UP
AIRCON 5A SPARE 10A

AIRCON 5A PREHEAT 15A

3 BUZZER
AIRCON 10A 5A
MONITOR

AIRCON 20A NEUTRAL RELAY 5A

90ZV28476
BATTERY RELAY
SPARE 20A 5A
ECM (ENGINE)
Main Fuse Boxes are located in the right hand side Right Right
console in the cab and contain thirty fuses. Addi-
tional fuse box (3) is located in the engine compart- (3) Front
ment on the right hand side of the machine. It
ECM (ENGINE) 10A
contains six fuses.
SPARE 7.5A

SPARE 7.5A

SPARE 7.5A

ECM (ENGINE) 10A

SPARE 10A
Rear
 2.45
OPERATOR'S AREA
Electrical Protection

Fusible Link
IMPORTANT
Fusible link protects the main hot wire from short
When replacing fuse, be sure to turn the starter circuits.
switch to "OFF" position.

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

Never replace fuses with higher amperage rat-

ing.

90ZV28476

1. If the fusible link is blown, the following prob-

lem occurs.

Problem (symptom)
Fuse
damaged
During engine operation During engine stop

- Engine will stop auto- - All the electrical circuit

matically. will not function.
30A - All the power for all - Engine can not be
electrical circuit will be started.
OFF.

- Horn [and opt. flasher] - The same conditions

will operate. as "During engine
- All the others will not operation!" but engine
operate and the can be started and
70A machine can not be stopped.
(1) operated.
- Engine will not stop
automatically but can
be stopped with starter
switch OFF.

- The machine can be - The same conditions

operated but the bat- as "During engine
70A teries can not be operation".
(2) charged and the batter-
ies will be discharged
soon.

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

2. To check the cause and replace the fusible

link, call your nearest Kawasaki dealer.
2.46
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option)

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

21 14 16
15 20 9 10 11
clarion
ON OFF VOL
AM SLEEP PUSH
CD
AM/FM CASSETTE COMBINATION
1
ST

SCAN
AUDIO MODE ALARM TIMER 3
1 DISP
REW FF
H M
PS
2 CD
AM
4
APC
5 6
APC AS
TAPE FM
TUNE

RadioCassetteUSA

5 3 6 7 4 17 18 19 8
13 12
 2.47
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option)

Name of Operation
Symbol Function Description Remarks
part method

Volume Turning PUSH Push this SW to turn the power on or off.

knob power on/ The SW alternately turns the power on or off every
off time you push the SW.
Sleep timer PUSH with To use the sleep timer, push this SW with the ACC
ACC turned turned off. This function causes the unit to continue
off to operate for one hour and then automatically
turns it off. At this time, "Sleep" will be shown on
the display panel.
Sound Use this adjustment knob to adjust the sound vol-
volume ume.
adjustment To increase the sound volume, turn this knob clock-
MIN MAX wise to the desired volume level.
To decrease the sound volume, turn this knob
counterclockwise to the desired volume level.
Sound bal- Selected with Use this knob to adjust the balance between the
ance audio mode left and right speakers.
adjustment button When turning the knob clockwise, with BALANCE
mode, the sound volume from the left speakers will
1 decrease, and the sound will be shifted to the right.
When turning the knob counterclockwise, the
L R sound volume from the right speakers will
decrease, and the sound will be shifted to the left.
Fader Selected with Use this knob to adjust the balance between the
adjustment audio mode front and rear speakers. When turning the knob
button clockwise, with FADER mode, the sound volume
from the rear speakers will decrease, and the
sound will be shifted to the front. When turning the
knob counterclockwise, the sound volume from the
REAR FRONT front speakers will decrease, and the sound will be
shifted to the rear.
Sound tone Selected with Use this knob to adjust bass / treble to the desired
adjustment audio mode level.
button When turning the knob clockwise, with BASS/TRE-
BLE mode, the sound will be boosted up.
When turning the knob counterclockwise, the
sound will be cut.
CUT BOOST

MODE Audio PUSH Every time you push this SW, the audio mode will
mode be changed in the following order.
Audio switching
mode but- BASS → TREBLE → FADER
ton ↑ ↓
VOLUME ← BALANCE
2
No operation for 10 sec. or longer will return the
mode to VOLUME. (Indication varies according to
the audio source.)
When each mode is selected, the corresponding
mode will be shown on the LCD display. However,
turning the VOL knob, the mode stops showing and
each level will be shown on the LCD display.
2.48
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option)

Name of Operation
Symbol Function Description Remarks
part method

Turning PUSH Every time you push this button, alarm will be
alarm ON/ switched ON or OFF. (This function works with the
OFF ACC turned on or while the sleep timer is ON.)
Alarm but- The alarm mark will be lit while the alarm is set.
ton Alarm set- When the time reaches the set time, you hear the Alarm
ting: alarm sound for 3 min. To stop the alarm sound, mark
Setting push any button.
clock on Continuing to push the button for 2 sec. or more will
3
the hour cause the mode to shift to the alarm setting mode.
Push the button in the clock set mode to set the
clock on the hour and reset the mode. If the minute
value of the current time is less than 30, the min-
utes will be rounded down and the seconds will be
reset. If the minutes value is more than 30, the min-
utes will be rounded up, one hour will be added to
the hour value, and the seconds will be reset.
Switching PUSH When the timer button is pushed, the timer mark
timer ON/ will be lit and the mode will shift to the timer setting
OFF mode. At this time "0:00" will be shown on the dis-
One-touch play. However, if the timer has been set before-
timer but- Timer set- hand, the residual time will be shown on the Timer
ton ting display. (While the timer is running, the residual mark
time decreases gradually.)
In the timer set mode, every time you push the but-
ton, indications will be changed in the following
order. (When the button is released, the indication
will be changed.)

0:15 → 0:30 → 1:00 → 2:00

↑ ↓
0:00 3:00
4 ↑ ↓
6:00 ← 5:00 ← 4:00

When pushing the button for a long period in the

timer set mode, the timer setting time increases in
5-minute steps. (Speed: 5 min./sec.)
"0:00" indicates that the timer is set to "OFF". At
this time, the timer setting mode will be canceled
unless you start to set the timer within 15 sec.
When performing operations other than timer set-
ting in the timer setting mode, the current time will
be set and the timer setting mode will be canceled.
When the residual time reaches 0, you hear the
alarm sound for 3 min.
The timer mark continues to light while the timer
works.
TAPE Cassette PUSH When the tape is loaded, push this button to play or
tape play/ stop the operation of the cassette tape.
5
TAPE but- stop In FF/REW/APC -FF/APC-REW, the mode will shift
ton to "Play".
CD CD PUSH When the CD changer is loaded, push this button
changer to play or stop the operation of the CD changer.
6
CD button play/stop The CD Changer is optional and not normally sup-
plied.
 2.49
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option)

Name of Operation
Symbol Function Description Remarks
part method

AM/FM Band PUSH While the radio is turned on, push this button to
switching change the radio frequency band. If a mode other
AM/FM Turning on than the radio is selected, push this button to turn
band radio on the radio at the last-tuned station.
7 selector Setting Push this button for less than 2 sec. to change the
button clock on radio frequency band from AM to FM or from FM to
the hour AM. If this button is pushed for 2 sec. or longer, a
beep sound will be generated and the bands 1 and
2 will be switched with each other.
PS Preset PUSH When this button is pushed for less than 2 sec-
AS scan in onds, the mode will shift to the PS mode and the
radio mode preset stations will be played sequentially for 5 sec.
PS, AS To stop the scan feature, push the button again
button and the radio will remain set to the last station. If
the radio wave of the preset station is weak, the
Preset station will be skipped.
Scan (PS) Every time the station is shifted, a beep sound will
be generated.
Auto Store If the radio cannot receive any stations, 2 times the
(AS) preset stations will be automatically cancelled.
The preset scan will work on the currently-selected
band (AM or FM).
Radio store PUSH When this button is pushed for 2 sec. or longer, the
button radio will generate a beep sound and the mode is
Auto store shifted to the AS. Then the radio will search sta-
in radio tions upward from the lower band end and auto-
mode matically store them in the preset memory. The six
stations that have the strongest wave will be stored
in frequency order.
(AS will stop at the upper band end and the stron-
8 gest station will be called up.)
Auto store (AS) will work on the currently-selected
band (AM or FM).
If 6 stations are not stored fully, the previously-
tuned stations will remain as they are.
Program PUSH Program scan will be performed in cassette tape
scan in mode. The beginning of each music track will be
cassette sequentially played for 10 sec.
tape mode When the button is pushed again in PS mode, the
PS feature will be canceled and the currently
selected music track will be played in full without
skipping to the next music.
Program PUSH Program scan will be performed in CD mode. The
scan in CD beginning of each track of the loaded CDs will be
mode sequentially played for 10 sec.
When the button is pushed again in PS mode, the
PS feature will be canceled and the currently
selected music track will be played in full without
skipping to the next music.
CD Changer is an option and is not normally
offered.
2.50
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option)

Name of Operation
Symbol Function Description Remarks
part method

Cassette PUSH Push this button to eject the cassette tape.

tape ejec- This can be performed even with ACC off.
tion
9

Eject but-
ton
DISP Display PUSH Push this button to switch the indications shown on
change the display panel. Each time you push this button,
Display the current time, alarm time, frequency (in radio
button mode), track No. and disc NO. indications (in CD
changer mode), and cassette tape EQ position indi-
cation (in cassette tape mode) will be shifted to
sequentially.
While the current time is shown on the display
10
panel, pushing the button for 2 sec. or more will
generate a beep sound. Then the indication will
blink, and the mode will be shifted to the clock set-
ting mode.
While the alarm time is shown on the display panel,
pushing the button for 2 sec. or more will generate
a beep sound and the mode will shift to the alarm
setting mode.
SCAN Radio PUSH Pushing this button will change the mode to Auto
scanning Tuning mode and will play each station for 5 sec.
11 SCAN but- To stop the scan feature and listen the currently
ton tuned station continuously, push the button again
while the station is tuned in and is being played.
 2.51
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option)

Name of Operation
Symbol Function Description Remarks
part method

Manual PUSH Push the button for less 0.5 sec. to increase the fre-
tuning in Upward quency or to decrease the frequency.
radio mode

Downward

Tuning but-
for 0.5 sec. or
ton
less
Seeking in PUSH Pushing the button for 0.5 sec. or longer will gener-
radio mode Upward ate a beep sound.
While SEEK UP, SEEK DOWN or ILLUMI OFF is
selected, the unit will seek radio stations in DX
12 Downward mode. While ILLUMI ON is selected, the unit will
seek radio stations in Local mode. (However, seek
13
functions only in AM mode.)
for 0.5 sec. or
less
In clock PUSH Push the button once for less 0.5 sec. to increase
time set- Downward the current hour value by one hour. Push the button
ting mode for 0.5 sec. or longer to increase hours continu-
ously.
"Hour" set-
ting
"Minute" PUSH Push the button once for less 0.5 sec. to increase
setting Upward the minutes value by one minute. Push the button
for 0.5 sec. or longer to increase minutes continu-
ously.

In radio PUSH Push the button for less 2 sec. to recall preset sta-
1 mode: tions. Pushing the button for 2 sec. or longer will
REW
Recalling generate a beep sound and the currently tuned sta-
Preset 1 and storing tion will be stored.
preset
REW but- memories
ton
14 In cassette PUSH Push the button to rewind the cassette tape.
tape mode:
REW
In CD PUSH Push the button to go down to the previous disc.
mode: (Recalling the previous disc.)
DISC
DOWN
2.52
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option)

Name of Operation
Symbol Function Description Remarks
part method

2 PRO In radio PUSH Push the button for less 2 sec. to recall preset sta-
mode: tions. Pushing the button for 2 sec. or longer will
Preset 2 Recalling generate a beep sound and the currently tuned sta-
and storing tion will be stored.
Program preset
button memories
15 In cassette PUSH Push the button to program the tape. (Switching
tape mode: forward or reverse modes.)
Program Pushing the button in FF, REW (APC) mode will
play the cassette tape.
In CD PUSH Push the button to go to the next disc.
mode: (Recalling the next disc.)
DISC UP
In radio PUSH Push the button for less 2 sec. to recall preset sta-
3 mode: tions. Pushing the button for 2 sec. or longer will
FF
Recalling generate a beep sound and the currently tuned sta-
Preset 3 and storing tion will be stored.
FF button preset
memories
16
In cassette PUSH Push the button to wind forward the cassette tape
tape mode: quickly.
FF
In CD PUSH Push the button to go to the next disc. (Recalling
mode: the next disc.)
DISC UP
In radio PUSH Push the button for less 2 sec. to recall preset sta-
4 mode: tions. Pushing the button for 2 sec. or longer will
APC
Recalling generate a beep sound and will store the currently
Preset 4 and storing tuned station.
APC but- preset
ton memories
In cassette PUSH Push the button to search for the beginning of the
tape mode: currently-played music track. Pushing the button
APC REW again in APC REW mode will search for the begin-
17 ning of the previous music. (Every time it is pushed
after that, the number of music tracks to search for
will be increased by 1.)
In CD PUSH Push the button for less 2 sec. to search for the No beep
mode: beginning of the currently-played track. sounds
TRACK (If the button is pushed at the beginning of the
DOWN music track, the beginning of the previous music
track will be searched for.)
REVIEW Push the button for 2 sec. or longer to rewind the
CD fast.)
 2.53
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type) (option)

Name of Operation
Symbol Function Description Remarks
part method

In radio PUSH Push the button for less 2 sec. to recall preset sta-
5 mode: tions. Pushing the button for 2 sec. or longer will
Recalling generate a beep sound and the currently tuned sta-
Preset 5 and storing tion will be stored.
Dolby but- preset
18 ton memories
In cassette PUSH Every time the button is pushed, DOLBY will be
tape mode: turned on or off alternately. Pushing the button for 2
Turning on/ sec. or longer will generate a beep sound and the
off currently tuned station will be stored.
In radio PUSH Push the button for less 2 sec. to recall preset sta-
6 mode: tions. Pushing the button for 2 sec. or longer will
APC
Recalling generate a beep sound and the currently tuned sta-
Preset 6 and storing tion will be stored.
APC but- preset
ton memories
In cassette PUSH Push the button to search for the beginning of the
tape mode: next music track. In APC FF mode, pushing the
19 APC FF button again will search for the next-alternate
music.
(Every time the button is pushed after that, the
number of music tracks to search for will be
increased by 1.)
In CD PUSH Push the button for less 2 sec. to search for the No beep
mode: next music track. sounds
TRACK UP Push the button for 2 sec. or longer to wind forward
QUE the music.
Tape Cassette Insert the cassette tape with the open side of the Auto
20 insertion tape inser- cassette tape faced rightward to play the cassette metal
slot tion slot tape.
LCD indi- indicator Displays time, frequency, etc.
21
cator
Beep tone A beep sound will be generated when functions are
(guide changed depending on the push time of the button.
tone) (Approx. 2KHz, 50ms)
2.54
OPERATOR'S AREA
Air Conditioner

Air Conditioner Switches

Ventilation Name and Location 1 2 3 4 5

(d) (d) Insolation sensor

(d) (d)

(b) (b)

97ZVOM0093

6 7 8

(c) (c) (c) (c)

1. OFF switch
(a) (a) (a)
2. Blower switches
3. Temperature setting switches
4. Vent mode selector switch
97ZVOM0092 5. AUTO switch
6. Inside/outside air selector switches
7. Liquid crystal display (LCD) unit
(a) Rear ventilation and defroster port
8. Air conditioner ON/Off switch
(b) Face ventilation port
(c) Foot ventilation port
While AUTO switch (5), inside/outside air selector
(d) Defroster port
switches (6) or air conditioner ON/OFF switch (8) is
functioning, the LED lamp above each switch is lit.
The wind direction from the ventilation ports (a) (b)
can be changed arbitrarily by manipulating the lou-
ver. OFF switch (1)

Rear ventilation ports (a) can be used as defroster This switch stops the operation of the blower and
ports for the rear window glass by manipulating the the air conditioner.
direction of the louver. When OFF switch (1) is pressed, the set tempera-
ture and the air blow quantity displayed on LCD unit
(7) as well as the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
turned "off", and operation is stopped.
 2.55
OPERATOR'S AREA
Air Conditioner

Blower switches (2) Vent mode selector switch (4)

These switches change over the air flow quantity in This switch changes over the vent mode.
six steps.
When vent mode selector switch (4) is pressed, the
The air flow quantity is displayed on the LCD unit. vent mode displayed on LCD unit (7) is changed
over, and air is blown from the displayed vent posi-
When the switch is pressed, the air flow quan- tions.
tity increases.
In the automatic mode, the vent mode is automati-
When the switch is pressed, the air flow quan- cally changed over.
tity decreases.
Display Vent positions
In the automatic mode, the air flow quantity is auto- on LCD Vent mode Remarks
matically changed over. unit (A) (B) (C) (D)
Face (blow-off to
<Display on the LCD unit and the air blow quantity> upper portion of
body mainly dur-
O O -
LCD Ventilation amount
ing cooling)
Air quantity "low" Face and foot O O O -
Air quantity "medium 1" Foot (blow-off to
feet mainly dur- O -
ing heating)
Air quantity "medium 2" This mode
is not
Foot and
Air quantity "medium 3" defroster
O O O selected in
automatic
mode.
Air quantity "medium 4"
This mode
is not
Air quantity "high" Defroster O O selected in
automatic
mode.
Temperature setting switches (3) Air is blown from the ventilation ports marked with "O".

These switches set the temperature inside the cab

AUTO switch (5)
in the range from 18.0~32.0ºC
This switch automatically changes over the air blow
When the switch is pressed, the set tempera-
quantity, the vent mode and the inside/outside air in
ture increases.
accordance with the set temperature.
When the switch is pressed, the set tempera-
When AUTO switch (5) is pressed, the indicator
ture decreases.
lamp above it lights.
Usually, set the temperature to 23.0~25.0ºC.
Usually, press this switch, set the temperature by
<Display on the LCD unit and the function> using temperature setting switches (3), and use the
air conditioner in the automatic mode.
Display on LCD
Set temperature
unit
18.0ºC Maximum cooling
When the automatic mode is changed over to the
manual mode, the indicator lamp above AUTO
Temperature inside cab is controlled so
18.5~31.5ºC switch (5) is extinguished. In the manual mode, the
that set temperature is realized.
32.0ºC Maximum heating air blow quantity, the vent mode and the inside/out-
side air can be changed over by manipulating each
switch.
2.56
OPERATOR'S AREA
Air Conditioner

Inside/outside air selector switches (6) Operating Method (Normal Use)

These switches change over inside air circulation
and outside air entry. Automatic operation

When an either switch is pressed, the indicator 3 5

lamp above it lights to indicate the selected air flow
status.

In the automatic mode, outside air introduction and

inside air circulation are automatically changed
over.
97ZVOM0093

Inside air recirculation The outside air is shut down, and the 8
air inside the cab is circulated.
Press this switch to rapidly cool or
heat the air inside the cab or when
the outside air is dirty.
1. Set AUTO switch (5) to ON. Confirm that the
set temperature and the air flow quantity are
Outside air entry
The outside air enters the cab. displayed on the LCD unit, and that the indica-
Press this switch to introduce clean
air into the cab or defog the windows.
tor lamps above AUTO switch (5) and air con-
ditioner ON/OFF switch (8) are lit.

2. Adjust temperature setting switches (3), and

Liquid crystal display (LCD) unit (7)
set arbitrary temperature.
The air conditioner automatically changes over
This LCD unit indicates the set temperature, the air
the air flow quantity, the vent mode and the
flow quantity and the vent mode during operation.
inside/outside air to realize the set tempera-
ture.
When OFF switch (1) is pressed, the set tempera-
ture and the air flow quantity are extinguished and
NOTE
the operation is stopped.
When the vent mode is set to or in
the automatic operation, if the engine water tem-
Air conditioner ON/Off switch (8) perature is low, the air flow quantity is restricted to
prevent blow-off of cold air.
This switch turns on and off the air conditioner
(cooling or dehumidification/heating).
Stopping the automatic operation
When this switch (8) is pressed, the air conditioner
is turned on and the indicator lamp above the 1
switch lights. When this switch is pressed again,
the air conditioner is turned off and the indicator
lamp is extinguished.

However, the air conditioner is turned on only while

the blower is operating (that is, while the air blow
97ZVOM0093
quantity is displayed on the LCD unit).

Press OFF switch (1). Then, the set temperature

and the air flow quantity displayed on the LCD unit
are extinguished, the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
are extinguished, and the operation is stopped.
 2.57
OPERATOR'S AREA
Air Conditioner

Manual operation Operation Method (Other Uses)

2 3 4 Head cooling, feet heating (bi-level) opera-

tion

In the bi-level operation, cool air is blown to the

face and hot air is blown to the feet.

97ZVOM0093 2 3 4 5
6 8

1. Press blower switches (2), and adjust the air

flow quantity.
Confirm that the set temperature and the air
flow quantity are displayed on the LCD unit. 97ZVOM0093

6 8
2. Set to ON air conditioner ON/OFF switch (8).
Confirm that the indicator lamp above the
switch lights. 1. Press blower switches (2), and adjust the air
flow quantity.
3. Adjust temperature setting switches (3), and Confirm that the set temperature and the air
set arbitrary temperature. flow quantity are displayed on the LCD unit.

4. Press vent mode selector switch (4), and 2. Press vent mode selector switch (4), and dis-
select arbitrary vent mode. play the vent mode on the LCD unit.

5. Press an either inside/outside air selector 3. Set to ON air conditioner ON/OFF switch (8).
switch (6) to select inside air circulation or out- Confirm that the indicator lamp above the
side air entry. switch lights.

4. Arbitrarily set blower switches (2), temperature

Stopping the manual operation setting switches (3) and inside/outside air
selector switches (6).
1
Then, the air conditioner realizes the bi-level opera-
tion in which cold air is blown to the head and hot
air is blown to the feet.

97ZVOM0093

Press OFF switch (1). Then, the set temperature

and the air flow quantity displayed on the LCD unit
are extinguished, the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
are extinguished, and the operation is stopped.
2.58
OPERATOR'S AREA
Air Conditioner

Defroster operation Other Functions

2 3 4 Self-diagnosis function

Each sensor and equipment used in the air condi-

tioner can be diagnosed for failure.

1 3
97ZVOM0093

6 8

1. Press blower switches (2), and adjust the air

flow quantity.
Confirm that the set temperature and the air 97ZVOM0093

flow quantity are displayed on the LCD unit. 6

2. Press vent mode selector switch (4), and dis-
play the vent mode or on the 1. Press OFF switch (1) to stop the operation.
LCD unit. (The set temperature and the air blow quantity
displayed on the LCD are extinguished.)
3. Set outside air introduction selector switch (6).
2. When both temperature setting switches " "
4. Press temperature setting switches (3), and and " " (3) are pressed and held together
display the set temperature "32.0" (maximum for 3 seconds or more, the failure mode is dis-
heating status) on the LCD unit. played on the LCD unit.

<Display on the LCD unit and the failure mode>

Adjust the louver at each vent position so that air
flow reaches the windows. Display Failure mode
E- No failure
When defogging the windows or dehumidifying the E11 Wire breakage in inside air sensor
air inside the cab in rainy season, set air condi- E12 Short-circuit in inside air sensor
tioner ON/OFF switch (8) to ON. E13 Wire breakage in outside air sensor
E14 Short-circuit in outside air sensor
E15 Wire breakage in water temperature sensor
E16 Short-circuit in water temperature sensor
E18 Short-circuit in insolation sensor
E21 Wire breakage in vent sensor
E22 Short-circuit in vent sensor
E43 Abnormality in vent damper
E44 Abnormality in air mixing damper
E45 Abnormality in inside/outside air
E51 Abnormality in refrigerant pressure

- If two or more failure are detected, the displayed

contents can be scrolled through by pressing
either one of temperature levels (3) " " or
" ".

- Press OFF switch (1) again to finish the self

diagnosis function and return to the normal dis-
play.
 2.59
OPERATOR'S AREA
Air Conditioner

If a failure is detected by the self-diagnosis func- For Efficient Use of the Air Conditioner
tion, ask the dealer for inspection and repair.

After completing the inspection and/or the repair, When the temperature inside the cabin
delete the failure codes memorized in the com- should be cooled down rapidly
puter.
When the machine is left under a scorching sun in
If not removed, the failure codes memorized in the the middle of summer, the temperature inside the
computer continue to display on the LCD unit cabin may be very hot.
whenever diagnosing.
In order to rapidly cool down the cabin in such a
To delete the failure codes, press and hold both case, completely close the windows and doors first,
inside/outside air selector switches (6) for 3 sec- drive hot air out of the cabin, then operate the air
onds or more. conditioner.

Refer to "TROUBLESHOOTING" page 3.59 for the Start up the engine, press AUTO switch (5), then
failure and solution. set the temperature to "18.0" by manipulating tem-
perature setting switches (3). In this status, run the
engine for 2~3 minutes with high revolution, then
Celsius-Fahrenheit selector function for the close the windows.
set temperature display
When the temperature inside the cabin is decreas-
While the blower is operating, press and hold both ing, set the arbitrary temperature.
temperature setting switches (3) " " and " "
together for 5 seconds or more to change over the
unit of the displayed value between Celsius and When the windows are misted
Fahrenheit. However, the unit type (C or F) itself is
not displayed. In the rainy season, etc., if the humidity inside the
cabin is high and the inner surfaces of the windows
Only the set value is displayed. are misted, mist can be removed by operating the
air conditioner. Or if the humidity of the outside air
Value displayed on LCD unit is high, the temperature inside the cabin may be
Celsius (ºC) 18.0~32.0 too low and the outer surfaces of the windows may
Fahrenheit (ºF) 65~90 be misted. In such a case, properly control the tem-
perature inside the cabin by controlling the set tem-
perature, stopping the air conditioner, etc.
2.60
OPERATOR'S AREA
Air Conditioner

Action to be taken when the air condi- NOTE

tioner is not used Any technician that operates a refrigerant recovery
and recycling machine must first be certified
through an EPA approved testing program.
Even if the air conditioner is not used, operate the
air conditioner with the engine low idle for several
minutes at least once a month so that the lubricat-
ing oil in each part of the compressor is not elimi-
nated (running-in of the air conditioner).

If the temperature inside the cabin is low in winter,

the air conditioner may be disabled. In such a case,
increase the temperature inside the cabin by using
the heater, then perform running-in of the air condi-
tioner.

IMPORTANT
- If the air conditioner is not operated for a long
time, the lubricating oil inside the compressor
may be eliminated, and the compressor may
be seized or damaged. Make sure to operate
the air conditioner once or twice a month even
while the air conditioner is not necessary or
while the machine is stored for a long time.
- During running - in of the air conditioner, make
sure to start it up with the engine low idle.
Never start up the air conditioner with the
engine high idle: Such start up may damage
the air conditioner.
- If water enters the control panel or the insola-
tion sensor, unexpected failure may be
caused. Pay attention so that water does not
enter. In addition, make sure to keep fire off
the control panel and the insolation sensor.
- Always keep the insolation sensor clean and
free from adhesion of dusts so that the air con-
ditioner can offer its auto function sufficiently.
Keep the area around the insolation sensor
free from objects which may hinder the sensor
function.
- Special tools and instruments are required to
fill the refrigerant (gas) and perform other ser-
vicing. Make sure to let such works be per-
formed in a service shop with required
facilities specified by our company.
 2.61
OPERATOR'S AREA
Ride Control (option)

Ride Control (option)

Roading a wheel loader over rough terrain will
cause fore and aft pitching motion to the machine.
The pitching motion is reduced when the ride con-
trol is installed.

Operation and Function

85ZV20006b

1. Before start the travelling machine, turn the

ride control switch ON.

The ride control pilot lamp comes to ON.

2. Move the machine forward.

The ride control functions automatically when

the machine travelling speed reaches more
than 7 km/h.

NOTE
When the bucket is fully tilted the ride control does
not work. Dump the bucket a bit when travelling.
2.62
OPERATOR'S AREA
Grease Gun Holder

Grease Gun Holder

90ZV5009

Grease gun holder is provided in the left side bat-

tery box. It is used for keeping the grease gun on
the machine when not in use.
 2.63
OPERATOR'S AREA
Quick Coupler (option)

Quick Coupler (option) Installation Procedure

Attachment Installation to Quick Cou-

pler

Regardless of the attachment types, the installation

procedure is all the same.

For removing an attachment, follow the installation

procedure in the reversed direction.

Component Name
ATT0031

1. In front of the attachment, lower the boom by

2 the boom control lever and move the quick
coupler to "Dump" position by the bucket con-
3 1 trol lever.

2. Move the machine forward to the hook of the

attachment.

4 3. Insert the upper pipe of the coupler frame to

the hook by operating boom control and bucket
5 control levers.
ATT0029

85ZV2 35010-6035
ATT0032

4. Roll back the quick coupler to hang up the

1. Coupler frame hook and lift the attachment.
2. Hydraulic pressure hose (for 3-way piping
spec. machine) 5. For 3-way piping spec. machine, insert the
3. Hydraulic pressure connecting unit to attach- quick coupler lock pin by operating the attach-
ment (One-touch operation type) ment control lever to fix the attachment.
4. Hook For 2-way piping spec. machine with quick
5. Lock pin support coupler, insert the quick coupler lock pin by
6. Quick coupler lock pin switch operating the quick coupler lock pin switch on
(for 2-way piping spec. machine with quick the control box, with the bucket control lever
coupler) held on the "Roll Back" position. Then fix the
attachment.
2.64
OPERATOR'S AREA
Quick Coupler (option)

For 3-way piping spec. machine For 2-way piping spec. machine with quick
coupler
Lever Location
Switch Location

(b)
(a) (c)

85ZV2 35010-6035

85ZV20005a

(a) The lock pin is fixed.

(b) In neutral position, the lock pin is held on the ( ) The lock pin is fixed.
position. ( N ) In neutral position (when the switch is kept
(c) The lock pin is disconnected. parallel.), the lock pin is held on the position.
( ) The lock pin is disconnected.
NOTE
After fixing the lock pin, confirm the indicator is at NOTE
the right position. During the operation of the switch, keep the bucket
control lever on the "Roll Back" position.
DANGER
During operation if operator accidentally move
the control lever for the quick coupler lock pin,
the lock pin moves accordingly, as a result there
will be a possibility that the attachment falls. It
causes serious injury or death.

Unless the hydraulic source to the attachment is

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

WARNING
Your body or finger could be crushed by the lock
pin when the lock pin moves.
Stay out of the lock pin area during lock pin oper-
ation.
 2.65
OPERATOR'S AREA
Quick Coupler (option)

Hydraulic Pressure Hose & Electrical

Wiring Connecting to Attachment Dust cap

When 3-way piping spec. machine installs the

attachment that needs the hydraulic pressure
source, connect the hydraulic pressure hose from
the quick coupler to the attachment side.

Regardless of the piping specifications, when the

electrical power supply is needed to the attach-
ment, connect the electrical wiring. Quick coupler
ATT0034
Regardless of the attachment types, the installation
procedure is all the same.
4. Cover the connecting hole disconnected from
the quick coupler hose with the dust cap.
Connecting Procedure

Electrical wiring connector

B

ATT0035
ATT0033

5. When the electrical power supply is needed to

1. Stop the engine. Move the control lever back
the attachment, connect the electrical wiring
and forth and bleed the residual pressure in
connector.
the hydraulic line.
When disconnecting the connector, keep the
waterproof cap.
2. Disconnect two hydraulic pressure hoses con-
nected to the quick coupler at section A (One-
touch operation type). IMPORTANT
Cover the disconnected hydraulic pressure hose,
3. Connect the disconnected hoses to section B hose connecting hole and electrical wiring con-
at the attachment side (One-touch operation nector with caps to protect them from dust and
type). water.
Connect the hose at right side of the machine
to right side of the attachment. Connect the
hose at left side of the machine to left side of
the attachment.
2.66
OPERATION
Check before Operation

OPERATION

Check before Operation

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

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

Items to Check and What to Look for:

Items to Check What to Look for

Bucket / Attachment Damage, missing bolts, leaks, and excessive wear

Bucket Control Linkage Damage, missing bolts, excessive wear, and looseness

Lights Broken bulbs, wires or lenses

Radiator Fins Trash and dirt build-up

Cooling System Leaks and trash build-up

Batteries Loose terminals, dirt build up on top of the batteries

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

Date: Model-S/N: Hours: Inspector:

You may wish to copy this page and use it as a daily check list.
 2.67
OPERATION
Check before Operation

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

CAUTION Refer to "Replace Engine Oil and Oil Filter Car-

Hot engine oil and components may cause tridge" page 3.34.
burns.
NOTE
Avoid contact with hot oil or engine components. 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.
Check

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.

Fill cap
90ZV2879

H (High)
L (Low)

OM0216

1. Check the oil level with the dipstick.

2. Keep the oil level between the "H" (high) mark

and "L" (low) mark on the dipstick.

3. If needed, add the required amount of the

same brand and viscosity oil as originally used
through the refill port.

Refer to "Recommended Lubricants" page

3.56 for the suitable viscosity of the oil accord-
ing to the ambient temperature.
2.68
OPERATION
Check before Operation

Check Hydraulic Oil Level 3.56 for the suitable viscosity of the oil accord-
ing to the ambient temperature.

CAUTION
Pressurized hydraulic tank is used for this
machine.

Pressure may throw tank cap and hot oil out of

tank causing injury or burns.

Relieve all pressure by pressing down the filler

cap.

Check
Level

90ZV5077

1. Lower the attachment to the ground.

2. Stop the engine.

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

hydraulic tank.

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

of the level gauge.

Filler cap

90ZV2890

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

Refer to "Recommended Lubricants" page

 2.69
OPERATION
Check before Operation

Check Engine Coolant Level

Radiator guard Cap
Neck pipe
CAUTION
Pressurized radiator tank is used for this
machine.

Spray of hot coolant may cause burns. Water surface

Stop engine and allow radiator and coolant to

cool completely, then open cap slowly to relieve
pressure.
OM0095

CAUTION 3. Check the coolant level.

Cooling system conditioner contains alkali that
could caustic burns or blindness. 4. Coolant level is normal if coolant is to the lower
part of neck pipe.
Avoid contact with skin and eyes to prevent
injury. 5. If needed, add the required amount of the cool-
ant.
1. Stop the engine and allow the radiator and Refer to "Coolant Specification" page 3.58 for
coolant to cool completely. the correct mixture.

6. Change the coolant if it is particularly dirty.

Refer to "Replace Coolant" page 3.14.

1 7. If the coolant contains oil, diagnose the prob-

lem and correct it.

90ZV2929

2. Slowly turn radiator cap (1) until it touches the

stopper to release inner pressure.

Pushing the cap, turn it to open.

2.70
OPERATION
Check before Operation

Drain Water and Sediment from Fuel Fil- Check Wiring Harnesses
ter
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.

90ZV2879

- Open the drain cock on the bottom of the fuel fil-

ter to allow water and sediment to drain into a
suitable container.

- Dispose of the drained water and sediment

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.
 2.71
OPERATION
Check before Operation

Articulation Stopper Check Tire for Damage, Air and Tread

Depth

90ZV0002

OM0032

- Make sure the articulation stopper is secured in

the "STORED" position as shown.
WARNING
Improper service or changing tires and rims
could cause explosion resulting in serious injury
or death.

Do not service or change tire and rims unless

properly trained and equipped.

Contact your nearest Kawasaki dealer or tire

manufacturer’s local dealer for tire servicing or
changing.

WARNING
Overheated tire could explode causing serious
injury or death.

If overheated tire is suspected, do not approach

tire to distance of less than 15 m.

Stay away until tire and rim cool down.

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

Consult your tire dealer or Kawasaki dealer.

2.72
OPERATION
Check before Operation

Tread
Low Pressure OK High Pressure

Side walls
Breakers

Carcass

Beads / Bead wire

97ZVOM0103 OM0104

Tire performance and its life depend greatly on the If the following defects are found in tires, for safety
tire air pressure. reasons the tires should be replaced with new tires.

It is important to keep the tire pressure at the rec- For the replacement contact Kawasaki dealer or a
ommended level. tire manufacturers local dealer.

Under the abnormal condition, check and adjust the - Bead wire is broken or bent, or the tire is greatly
air pressure to the standard value. deformed.

Refer to "Check Tire Air Pressure" page 3.23 for - Wear is excessive and the carcass ply (includ-
the adjusting procedure. ing breaker) is exposed for more than 1/4 of the
circumference.

- Damage to the carcass exceeds 1/3 of the tire

width.

- Tire layers are separated.

- Radial cracks reach the carcass.

- Deformation or damage which makes the tire

unsuitable for use.
 2.73
OPERATION
Check before Operation

Check Drive Belt Check Air Intake System

CAUTION CAUTION
Contact with moving belt or pulleys may cause Hot engine components may cause burns.
injuries.
Avoid contact with hot engine components.
Stop engine before opening engine access
panel.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
1. Park the machine on level ground, apply the ground, and stop the engine.
parking brake, lower the attachment to the
ground, and stop the engine. Remove the key
and tag "Do Not Operate".

2. Open the engine access panel.

3. Visually inspect the drive belt for looseness

and damage.

OK
90ZV2 04063-0075

OK
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

OM0099
contact your nearest Kawasaki dealer.

4. If the belt is too stretched to permit adjustment

IMPORTANT
or shows cuts or cracks, replace it. Severe engine damage may result from running
with unfiltered air.

Do not operate engine if any leaks or defects are

Check Crankcase Breather Tube found on air intake system.

Inspect the crankcase breather tube for sludge or

debris on or in the tube.

Inspect the tube more frequently in icy conditions.

2.74
OPERATION
Check before Operation

Check Cooling Fan Check Horn Operation

1. Push the horn button in the center of the steer-

ing wheel.

2. The horn should sound loudly.

OK

ROPS (Roll Over Protective Structure)

Cab
OK
WARNING
OM0102
Operating with damaged or improperly mounted
ROPS Cab could result in death or serious injury.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the If any damage or loose bolts are found, do not
ground, and stop the engine. Remove the key operate until repaired.
and tag "Do Not Operate".
Never repair or modify ROPS Cab without manu-
2. Open the engine rear grill. facturer’s approval and instructions.

3. Visually inspect the cooling fan for damage.

- Check the condition of the ROPS Cab and its
mounting bolts.
4. If the fan shows cracks, loose rivets, bent or
loose blades, replace it.

Adjust and Check Rear View Mirrors

- Adjust and check the condition of the rear view

mirrors.

- If there is any dirt on or damage to the rear view

mirrors, clean or fix them.

Check Parking Brake

- Make sure the parking brake switch is pulled up.

 2.75
OPERATION
Check before Operation

Check Monitor Panel Operation

1. Turn the starter switch to the "ON" position.

2. All warning lamps (red) should come on for

about three seconds. Refer to "Indicators"
page 2.24.

3. Rotate and move the transmission shift lever to

each position, pull the high-low beam lever,
and operate the rear working light switch and
declutch switch.

4. The transmission status monitor lamps (green)

and the indicator lamps (green or blue) should
come on respectively.

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

Refer to "Indicators" page 2.24.

Check Control Levers

- Make sure the boom and tilt control levers are in

the "HOLD" position.

Check Transmission Shift Lever

- Make sure the transmission shift lever is in the

neutral position.
2.76
OPERATION
Starting the Engine

Starting the Engine

WARNING OFF ON
PREHEAT START
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 starer

terminals.
- Do not start engine while standing on ground.
65ZV0075
Make sure to start engine only from operator’s
seat with transmission in neutral and parking
brake applied. 5. After the engine starts, release the key and it
will return to the "ON" position.

6. If the transmission shift lever is not in the

Normal Start "NEUTRAL" position, the engine will not crank.
(Ambient temperature above 0ºC)
NOTE
1. Do not step on the accelerator pedal. - When the starter switch key is in the "ON" posi-
tion, the engine itself will diagnose engine fail-
ure, if any, in 2 seconds.

During this time, all of the engine warning lamp

are being turned on. This checks the bulbs.
OFF ON
PREHEAT START
When the diagnosis is completed the engine
warning lamps are turned off.

Before starting the engine, make sure all of the

warning lamps are turned off. If the stop (red)
lamp remains on, do not start the engine.

65ZV0076 - Do not turn the starter switch key to the

"START" position while the engine is running.
2. Turn the starter switch key to "ON" position
- The engine oil pressure warning lamp should go
and leave it there for 3 seconds. Check the
out in less than ten seconds after the engine
indicator lamps.
starts. If it remains on, stop the engine immedi-
ately and see "TROUBLESHOOTING" page
3. Turn the starter switch key to "START" position
3.59.
to start the engine.

To protect starter and battery, do not keep the IMPORTANT

starter switch in the "START" position for more
Low engine oil pressure may cause severe
than 20 seconds.
engine damage.
4. If the engine fails to start, wait about two min-
Be sure engine oil pressure warning lamp goes
utes before trying to restart. This allows the
out quickly.
starter motor to cool which prevents starter
motor damage.
 2.77
OPERATION
Starting the Engine

Cold Start NOTE

(Ambient temperature below 0ºC) - Do not turn the starter switch key to the
"START" position while the engine is running.
1. Do not step on the accelerator pedal.
- 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 immedi-
ately and see "TROUBLESHOOTING" page
3.59.
PREHEAT OFF ON
START
IMPORTANT
Low engine oil pressure may cause engine dam-
age.

Be sure engine oil pressure warning lamp goes

out quickly.
65ZV0077

2. The turn the starter switch key to the "PRE-

HEAT" position for about fifteen seconds.

3. Turn the starter switch key to the "START"

position to start the engine. To protect starter
and battery, do not keep the starter switch in
the "START" position for more than 20 sec-
onds.

4. If the engine fails to start, wait about two min-

utes before trying to restart. This allows the
starter motor to cool which prevents starter
motor damage.

5. After the engine starts, release the key and it

will return to the "ON" position.

6. If the transmission shift lever is not in the

"NEUTRAL" position, the engine will not crank.

7. In case the engine does not start on the first

attempt, repeat the above procedures after
intervals of about one to two minutes.

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

- Do not use ether. This engine equipped with

electric heater starting aid.
2.78
OPERATION
Idling Management System

Idling Management System Hibernate Mode

Warm-up control Mode ON:

Idle-up function Decreases the engine idling speed from 800 min-1
to 725 min-1 under the following condition.
When the engine coolant temperature is 10ºC or
lower, the engine idling speed increases from 800 - When the transmission shift lever is placed in
min-1 to 1,000 min-1. "N" position, the engine coolant temperature is
higher than 60ºC, and the engine speed is held
at 950 min -1 or less for 10 seconds.

Fan low speed control

When the engine coolant temperature is 60ºC or Mode OFF:

lower and the engine speed is 1,200 min-1 or less,
the cooling fan retains its minimum speed regard- Returns to the normal engine speed under either
less of the engine speed. one of the following conditions.

- When the transmission shift lever is placed

other than in "N" position.
Engine Acceleration Control (Function)
(Turbo Protection) - When the engine speed is 950 min-1 or more

When the engine coolant temperature is 10ºC or - When the engine coolant temperature is 60ºC or
lower, the accelerator is not activated a few sec- lower
onds and delays the response for acceleration.

Forcible Mode OFF:

When the generated power by the alternator low-

ers, the mode is OFF forcibly.

In this case turn off the starter switch and start the
engine again to reset the hibernate mode.
 2.79
OPERATION
Check after Starting the Engine

Check after Starting the Engine Check Warning Lamps

- Keep the engine running at low to medium

speed and warm it up for about five minutes.

- Do not subject the engine to sudden accelera-

tion until the end of the warm-up period.

IMPORTANT
Do not idle the engine for excessively long peri-
STOP

ods of time. 85ZV2 0004

Long periods of idling (more than 10 minutes)

can damage an engine because combustion
chamber temperatures drop so low the fuel can 1. Check the warning lamps on the instrument
not burn completely. panel.

This will cause carbon to form in the injector 2. If any red lamp (except for "PARKING") is on,
spray holes and on the piston rings and can do not operate the machine.
result in stuck valves.
3. Refer to "Indicators" page 2.24 for the meaning
of each lamp and the correction.
2.80
OPERATION
Check after Starting the Engine

Check Fuel Level Check Transmission Oil Level

DANGER
There is no room in articulation are when
machine is turning.
E F
Crushing will result in serious injury or death.

FUEL When checking oil level:

- Low attachment to ground.
- Put transmission shift lever in neutral.
65ZV0005 - Apply parking brake.
- Place "DO NOT OPERATE" tag on steering
wheel.
- Make sure nobody is on machine.

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

instrument panel.

2. Add fuel to fill the tank if the gauge shows

below "F".

Refer to "Recommended Lubricants" page

3.56 for the proper fuel.

Check and
Fill Tube
90ZV2837

1. Park the machine on level ground, apply the

parking brake, and lower the attachment to the
ground.

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

In hot In cold

Specified oil level

97ZVOM0107

3. At low oil temperature, use the side of dipstick

marked "COLD". Normal oil level is within
shaded area as shown.
 2.81
OPERATION
Check after Starting the Engine

4. At high oil temperature, use the side of dipstick Check Service Brake Operation
marked "HOT". Normal oil level is within
shaded area as shown. 1. Turn "OFF" the declutch switch.

5. If the oil level is lower than the specified, add 2. Firmly step on the left hand brake pedal.
recommended oil while the engine is at idle.
Do not overfill. 3. Release the parking brake.

Refer to "Recommended Lubricants" page 4. Select the transmission shift lever 2nd and
3.56. FORWARD.

WARNING 5. Slowly accelerate the engine to full speed.

With articulation stopper in "LOCKED" position, 6. The machine should not move.
machine will not steer which, while operating,
could cause an accident result in death or seri-
ous injury. IMPORTANT
If machine moves when firmly step on right hand
Return articulation stopper to "STORED" posi- brake with transmission in 2nd and FORWARD,
tion after checking transmission oil level. there is some problem with service brake.

Do not operate until problem has been corrected.

IMPORTANT
Never mix CD engine oil and auto transmission
fluid.
Check Parking Brake Operation
Either may be used in transmission but they
must not be mixed.
1. If the service brakes work normally, test the
Determine what type of oil is in transmission and parking brake.
use only that type.
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.

2.82
OPERATION
Check after Starting the Engine

Check Steering Wheel Operation Check Exhaust Gas

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.

Check Back-up Alarm Operation

95ZVOM2926
1. Apply the service brakes.

2. Release the parking brake. 1. Check the color of the exhaust gas.

3. Move the shift lever to "REVERSE". Normal exhaust gas color is clear or light gray
when engine is warm. White, black, or blue
4. The back-up alarm should sound and be heard smoke during steady warm operation of the
in the operator's seat. engine indicates a malfunction. (It is normal for
some black smoke to occur during rapid accel-
IMPORTANT eration.)

If back-up alarm does not sound when parking 2. If abnormal exhaust gas color occurs, have the
brake is released and shift lever is in REVERSE machine checked immediately.
position, there is some problem with back-up
alarm. Refer to "TROUBLESHOOTING" page 3.60.

Do not operate until problem has been corrected.

 2.83
OPERATION
Check after Starting the Engine

General Inspection

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

When inspecting machine while engine is run-

ning:

- Make sure nobody is on machine.

- Lower attachment to ground.
- Turn parking brake switch to "ON".
- Do not enter or access hazardous areas of
machine:
- Articulation area
- Under machine
- Engine compartment, etc.

With the parking brake applied, transmission shift

lever in NEUTRAL, loading levers in NEUTRAL,
and the attachment on the ground, walk around the
machine and look for any problems, leaks, or signs
of failure.
2.84
OPERATION
Operating the Machine

Operating the Machine Starting the Machine

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

Do not stop engine while machine is moving.

WARNING approx. 40 cm
OM0016
Moving machine in congested areas could result
in death or serious injury.

Be sure area is clear of personnel and obstruc-

tions. 1. Raise the bucket to the carry position approxi-
mately 40 cm above the ground.

IMPORTANT 2. Step on the brake pedal.

Operating machine on a grade may cause lack 3. Push the parking brake switch to release the
of lubrication resulting in severe engine or com- parking brake.
ponents damage.
4. Turn the transmission shift lever to the desired
Do not operate machine on a grade over 30º. travel speed mode and then shift to the desired
direction.

30º Max.

OM0194
97ZVOM0038

5. Release the brake pedal then step on 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 step

on brake pedal before releasing parking brake.
 2.85
OPERATION
Operating the Machine

Starting the Machine on a Grade Speed and Direction Change

1. Turn "OFF" the declutch switch.

2. Step on the left brake pedal.

65ZV 5089

1. Select the proper gear shifting mode by rotat-

ing the transmission shift lever. Refer to the fol-
97ZVOM0038
lowing tables on page 2.86 for the gear
selection mode.
3. Step on the accelerator pedal while releasing
the left brake pedal to start the machine off This machine is equipped with the automatic
slowly. shifting system which selects the proper gear
automatically using a micro computer to elimi-
nate tiresome manual shifting.

65ZV 5089

2. For a direction change, decelerate the

machine then move the transmission shift lever
to forward or reverse.

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

Slow down machine and shift transmission to 1st

or 2nd gear when changing direction.
2.86
OPERATION
Operating the Machine

85ZV20005c

3. When the transmission is in the 2nd gear, it

can be quickly shifted down to the 1st gear by
pressing the downshift button.

4. Pressing the downshift button again, moving

the transmission shift lever to the neutral posi-
tion, or operating the parking brake switch
automatically returns to the 2nd gear from the
1st gear.

Refer to "Downshift Button" page 2.15.

Lever
Selected Gear Operating Condition
Position
1. Excavating or
scooping in a nar-
[1] 1st row space
2. Running downhill
on a steep slope
1. Scooping or load-
ing loose material
[2] 2nd
2. Running downhill
on a slope
[3] 3rd Carrying or roading
2nd, 3rd or 4th Scooping, loading,
[A] (automatically carrying or roading
shifted)

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

Use proper gear for each job.

 2.87
OPERATION
Parking

Parking 3. Shift the transmission shift lever to "NEU-

TRAL".

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.

OM0025

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 brak-
ing force.

Except for emergency do not apply parking

brake while machine is moving.

97ZVOM0038

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

2.88
OPERATION
Stopping the Engine

Stopping the Engine

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

Do not stop engine while machine is moving.

IMPORTANT
Failure to allow engine to cool down before stop-
ping may cause premature turbocharger failure.

Run engine at low idle speed for about five min-

utes before stopping engine.

1. Let the engine idle for about five minutes

before stopping.

OFF ON
PREHEAT START

65ZV0074

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

stop the engine.

3. After stopping the engine, remove the key and

store it in a safe place.

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

Prevent unauthorized operation.

When leaving machine for extended period of

time, remove the starter key, lock cab doors or
lock vandal cover over dashboard and right hand
console (if equipped).
 2.89
OPERATION
Operating Techniques

Operating Techniques Loading

IMPORTANT
Machine damage may result from improper load-
ing procedures.

- Do not dig or scoop with machine frame artic-

ulated.
- Do not drive machine into material at high
speed.

30º Max. NOTE

- When loading rocks or hardpacked material, the
OM0194 use of bucket teeth is recommended.

- For loose stockpile material replaceable bolt-on

IMPORTANT cutting edges should be used.
Operating machine on a grade may cause lack
of lubrication resulting in severe damage on
engine or other components.

Do not operate machine on a grade over 30º.

OM0111

1. Move the machine forward to the material.

2. Steer the machine in a straight ahead position

when entering the material.

OM0113

3. Lower the bucket parallel to the ground.

2.90
OPERATION
Operating Techniques

4. Drive the bucket straight into the material. Use

approximately 1/2 - full engine speed.

OM0112

OM0114 10. On later passes, aim the center of the bucket

at the protruding portion of the material.

5. Move the boom control lever to the "Raise"

detent position and run the machine forward
slowly in 1st or 2nd speed.

Reduce wheel slippage by slightly reducing

engine speed.

OM0115

6. Move the bucket control lever to the "Roll

Back" and the "Hold" position several times to
get more material in the bucket.

7. When the bucket is filled, move the bucket

control lever to the "Roll Back" position.

8. Release the bucket control lever to the "Hold"

position and the boom will rise.

9. Reverse the machine.

 2.91
OPERATION
Operating Techniques

Excavating Dozing

1. Move the machine forward to the material.

IMPORTANT
2. Steer the machine in a straight ahead position Dozing or pushing with dumped bucket or attach-
when entering the material. ment may cause severe damage to linkages.

It may also cause engine over-heating and

torque converter over-heating.

Keep bucket or attachment bottom parallel to

ground.

OM0119

3. Lower the bucket parallel to the ground or

dump it slightly forward.

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

OM0123

Increase engine speed as the bucket digs

deeper.

OM0120

5. When the bucket is filled, move the bucket

control lever to the "Roll Back" position.

6. Move the boom control lever to the "Raise"

position to clear the ground.
2.92
OPERATION
Operating Techniques

Ground Levelling

1. Keep the loaded bucket slightly above the

ground.

OM0123

4. To get smoother surface, put some material in

the bucket, place the bucket parallel to the
OM0121
ground, run the machine backward with the
boom control lever in the "Float" position.

2. While running the machine backward, dump IMPORTANT

the bucket little by little to evenly spread mate-
rial on the ground. Pushing material with dumped bucket may
cause severe damage to linkages.

Be sure to run machine backward when leveling

ground.

OM0122

3. Dump the bucket, allow the cutting edge to

contact the ground, and run the machine back-
ward.
 2.93
OPERATION
Operating Techniques

Carrying Dumping into Truck or Hopper

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

Do not make quick turns or abrupt braking when

boom is raised.

approx. 40 cm Keep boom low for best stability especially on

OM0016 slopes.

WARNING
1. Fully roll back the loaded bucket before carry- Machine contact with overhead wires or other
ing to prevent spillage. objects could result in death or serious injury.

2. Keep the bucket approximately 40 cm above Be sure there are no overhead wires or obstruc-
the ground when carrying. tions before raising boom to full height.

IMPORTANT Refer to "Loading" or "Excavating" page 2.89, 2.91

for the loading procedure.
When carrying material over 450 m at high
speed, tire overheating may occur.

Follow tire manufacturer's instructions for tire

inflation on this type of application.

OM0116

1. Move the boom control lever to the "Raise"

position to raise the loaded bucket while
approaching the truck or the hopper.

2. Use the declutch switch in the "ON" position if

working on a level site.

When the left brake pedal (declutch pedal) is

step on, the transmission is placed automati-
cally in neutral and the boom rises faster.
2.94
OPERATION
Operating Techniques

3. Return the boom control lever to the "Hold"

position when the bucket reaches the enough
height to clear the truck or hopper sideboards.
WARNING
Fast boom lowering motion may cause machine
If the boom is equipped with the kickout rear wheels to jump up, reducing stability and
device, the boom will automatically stop and control.
the boom control lever will return to the "Hold"
position when the bucket reaches the preset Do not lower boom using detented "Float" posi-
height. tion especially when bucket is full.

Holding the boom control lever in the "Raise"

position will continue to raise the boom if
required.

Refer to "Kickout Control Switch" page 2.18 for

adjustment of the preset height.

4. Position the machine in the center of the truck

body or hopper to dump the load.

OM0195

5. Push the bucket control lever forward to the

"Dump" position to empty the bucket.

OM0196

6. Roll back the bucket to clear the truck or hop-

per sideboards and lower the boom while
reversing the machine.
 2.95
OPERATION
Operating Techniques

Typical Truck Loading Methods T Cycle Operation

I Cycle Operation

OM0126

OM0124 This method is effective for the sites where trucks

continuously come and go.

This method is recommended where the working

area is limited.

V or L Cycle Operation

(L-cycle) (V-cycle)

OM0125

This is the most efficient operation for the shortest

cycle time.
2.96
SPECIAL PROCEDURES
Adjustments

SPECIAL PROCEDURES

Adjustments 6. To test the adjustment; start the engine, raise

the boom approximately half way, dump the
attachment, and move the bucket control lever
Bucket / Attachment Leveler Adjust-
to the "Roll Back" detent position to rollback
ment the attachment.

WARNING When the preset angle is reached, the bucket

control lever should return to the "Hold" posi-
Accidental movement of machine could result in tion. Lower the attachment to the ground and
death or serious injury. confirm the proper angle has been set.

Apply parking brake and use wheel chocks to

prevent sudden movement of machine.
4

WARNING
Standing on tire, boom or linkage could cause
accidents resulting in death or serious injury.
3
Use safe sturdy platform to reach bucket leveler
adjustment.
5±2 mm

1. Park the machine on level ground and apply OM0128

the parking brake.

2. Lower the attachment to the ground, adjust it to NOTE

the desired angle, set the bucket control lever Clearance between switch (4) and rod (3) should
to the hold position, and stop the engine. be about 5 mm.

The switch may be adjusted in or out to set this

clearance.

2
1
97ZVOM0127

3. Loosen bolts (1) with a 17 mm wrench.

4. Move bracket (2) forward to increase, or rear-

ward to decrease the attachment preset angle.

5. Tighten bolts (1).

 2.97
SPECIAL PROCEDURES
Roading / Special Applications

Roading / Special Applications

WARNING
Overheated tire could explode causing serious
injury or death.

If overheated tire is suspected during operation

or servicing, do not approach tire to distance of
less than 15 m.

Stay away until tire and rim cool down.

When the machine travels at high speed or for a

long distance, the tires or other components such
as engine and transmission / torque converter may
become extremely hot causing an explosion, early
wear, or damage. If the machine must be driven for
a long distance, take the following precautions:

- Follow the regulations related to this machine,

and drive carefully.

- The most suitable tire pressure, travel speed, or

tire type differ according to the condition of the
travel surface. Contact your nearest Kawasaki
dealer or a tire dealer for information.

- "Ton km/h" limitations must be observed. Con-

sult a tire dealer for the speed limit of the tires
involved.

- Carefully watch the engine coolant temperature

gauge and the torque converter oil temperature
gauge on the operation panel not to exceed the
white zone on them.

- After traveling a distance, stop the machine with

engine running to allow the tires and compo-
nents to cool. Check the tires and other parts for
damage.

- Do not put calcium chloride or dry ballast in the

tires when traveling.

- Whenever possible use a lead and/or follow

vehicle and all available warning devices even if
not required by regulations.
2.98
SPECIAL PROCEDURES
Booster Batteries / Jumper Cables

Booster Batteries / Jumper 1. Before connecting jumper cables:

Cables - The booster cables must be of the heavy duty
type and in good condition.
DANGER - Be sure the problem is inadequate battery
Improper procedure to start engine using jumper charge and not some other electrical problems.
cables could cause battery case explosion.
- Stop the engine of the boost machine or turn off
- Do this work by two persons. While one per- the booster supply if using an auxiliary power
son sits on the operator's seat, the other per- source.
son connects jumper cables.
- Wear eye or face protection when working on 2. Raise and lock the battery box covers.
or around batteries.
- The booster batteries should be of similar size 3. Be sure vent caps are tight and level. Place
and capacity as the batteries being boosted. damp cloth over vent caps on both batteries.
- 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. + - + -
Booster Batteries Batteries being boosted

WARNING
If the battery is being used with insufficient bat- Rear chassis close to starter motor ground being jump started
tery electrolyte level, the deterioration on the
OM0131
parts in the case could be in the advanced stage.

It could cause to shorten the battery life or to 4. Move back the protective rubber covers (red)
emit sparks from the deterioration parts in the from the positive post (+) of the battery.
case, as a result the battery case could explode.
5. Connect one end of the red jumper cable to the
Keep the battery electrolyte level in the proper positive post (+) of the discharged battery.
level.
6. Connect the other end of the red jumper cable
to the 24 volt side of the booster battery set or
WARNING power source.
Batteries contain lead, and acid which may
cause burns. 7. Connect one end of the black jumper cable to
the ground side of the booster battery set or
Avoid contact with skin or clothing and wear power source.
hand, eye, and face protection when working on
or around batteries. 8. The final connection should be the remaining
end of the black jumper cable to the rear chas-
If lead, or acid contacts skin or clothing, immedi- sis close to starter motor ground being jump
ately wash with water. started.

9. Start the booster machine's engine or turn the

NOTE auxiliary power source on.
This machine uses a 24VDC negative ground elec-
trical system. 10. Allow a few minutes to provide partial charge
to the discharged batteries.
 2.99
SPECIAL PROCEDURES
Booster Batteries / Jumper Cables

11. Start the machine being boosted as described

on "Starting the Engine" page 2.76.

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 pro-

tective covers over the battery terminals and
close the battery box covers.

14. Test the starting / charging system to deter-

mine the cause of the problem and correct it.
2.100
SPECIAL PROCEDURES
Towing

Towing If your machine must be towed, contact your near-

est Kawasaki dealer for the necessary information
or assistance.
WARNING
Improper towing could result in death or serious
injury.

Follow safety warnings found under "Safe Oper-

ation -- SPECIAL OPERATING CONDITIONS:"
page 1.9.

This machine is equipped with a hitch on the rear

end for towing a troubled machine.

1. Inspect the cable for damage. Never use a

damaged cable.

95ZVOM2917

2. Connect the cable to the drawbar. Make sure

the drawbar and split pin are in the original
position.

3. Connect the other end of the cable to the trou-

bled machine.

4. If the service brake on the towed machine

does not work;

do not allow an operator on the towed

machine, and attach another vehicle of ade-
quate size to the rear to act as a braking vehi-
cle.

5. Keep personnel away from between the towing

machine and the towed machine.

6. Tow the machine slowly with gradual and

smooth movement.

7. Use flashing lights or other warning signals

when towing.
 2.101
SPECIAL PROCEDURES
Transportation

Transportation 5. Lower the bucket and lock each control lever

using the loading control lever lock (page
1.28).
When transporting the machine, observe the vari-
ous road rules, road transportation vehicle laws 6. Apply the parking brake and set the articulation
and vehicle limit ordinances, etc. stopper in the "LOCKED" position (page 1.28).
It is a good idea to obtain a special platform for
loading and unloading the machine. 7. Tape over the exhaust stack outlet to prevent
turbo "Wind-milling" damage.
1. Park the trailer on flat firm roadbed. Keep a
fairly long distance between the road shoulder
and the machine.

65ZV0010

OM0132 8. Place blocks in front of and behind the tires to

prevent the machine from moving.

2. Properly apply the brakes of the trailer and

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

3. Fix the ramp in line with the centers of the

trailer and the machine.

OM0197

9. Fasten the machine to the trailer with chains or

cables at 4 fixing points (red painted) provided
on the machine.

65ZV0009 Additional cables or chains may be used but

do not damage brake lines or cylinder rods.

4. Determine the position of the ramp, then slowly

load the machine onto the specified part of the IMPORTANT
trailer. Brake pipe runs on axle housing.

NOTE Do not fasten axle housing.

Have someone in clear view and in a safe position
provide directions while loading.
2.102
SPECIAL PROCEDURES
Transportation

10. Determine the route for transporting the

machine by taking into account the width,
height and weight of the machine and truck.

OM0198
GRAVITY CENTER

11. In the case that it is necessary to lift the

machine, sling the machine at 4 fixing points
(red painted) provided on the machine as
shown.

Weight: 26 ton
 2.103
SPECIAL PROCEDURES
Long Term Storage

Long Term Storage 9. Securely cover the inlet and outlet ports of the
air cleaner and muffler.
Before Storage

1. Wash and clean all parts of the machine and

touch up the paint finish to avoid rusting.

2. Lubricate every greasing point described in

"Greasing" section page 3.16, 3.19, 3.25 and
3.45.

3. Be sure to refuel in the fuel tank.

4. Replace engine oil, transmission oil, differential

and planetary oil and hydraulic system oil.

5. Idle the engine for about 15 minutes so that

fuel and lubricant circulate throughout the
engine, transmission and torque converter.

6. Store the machine indoors and keep it dry.

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

The range of temperature the machine is to be

stored is between -35ºC ~ 45ºC.

OM0028

7. Disconnect the cables from the batteries or if

freezing temperatures are expected, remove
the batteries from the machine and store sepa-
rately in a heated area.

8. If freezing temperatures are expected, check

and adjust the antifreeze/water mixture.

Refer to "Coolant Specification" page 3.58 for

the mixing ratio.
2.104
SPECIAL PROCEDURES
Long Term Storage

Battery removal / reinstallation proce-

dure

WARNING 5 2 1 3
4
Batteries produce explosive gases which could
cause burns or blindness. 6

- Ventilate area to remove explosive gases.

- Wear eye or face protection when working on

or around batteries. 8 7 85ZV28463

- Keep flames and sparks away from batteries.

1. Remove bolt (1)(2) and remove the rear lamp
- Keep cable ends from touching each other or with plate (3) from the battery box.
machine to avoid sparks.
Hang the rear lamp with plate (3) temporarily
up on the rear chassis by rope.
WARNING
Batteries contain lead, and acid which may 2. Disconnect battery cables (4)(5) from the bat-
cause burns. tery.

Avoid contact with skin or clothing and wear 3. Loosen rod nuts (6)(7) and remove plate (8)
hand, eye, and face protection when working on from the battery.
or around batteries.
4. Remove the battery not to give it a tilt from the
If lead, or acid contacts skin or clothing, immedi- battery box.
ately wash with water.
If possible remove the battery from the battery
box by two persons.
IMPORTANT
For reinstallation, follow the above procedure
If a battery terminal is removed from a machine in the reversed direction.
in less than 30 seconds after the key is put into
the OFF position, it can corrupt the ECM pro- Carry on the same procedure for the other bat-
gram, which can disable the engine. Always wait tery.
1 full minute to be sure to be past this "write to
memory function" prior to removing battery termi-
nals.
 2.105
SPECIAL PROCEDURES
Long Term Storage

During Storage After Storage

Once a month remove the covers, run the engine,

and move the machine a short distance to form a
new oil film on the lubricated parts.

1. Check the following points.

Refer to "Check before Operation" page 2.66

and "Check after Starting the Engine" page
2.79.

- Coolant level
- Engine oil level
90ZV2836
- Hydraulic oil level
- Transmission oil level
- Brake function
- Steering function

2. Operate the machine as follows.

- Run just the engine for about five minutes at

low idle.

- Move all cylinders of the hydraulic system full

stroke 2~3 times.

- Run the machine about 10 m in every gear

and direction.
90ZV5077

- Move the steering full stroke each way about

2~3 times. 1. Loosen the drain cock or plug of the fuel tank
and the hydraulic tank to drain any water into a
3. Operate the air conditioner as follows. suitable container. Dispose of properly.

- Operate the air conditioner with the engine 2. Remove the covers, connect the cables to the
low idle for several minutes once a month so batteries and start the engine.
that the lubricating oil in each part of the
compressor is not eliminated. 3. Replace engine and transmission oil with new
specified oil after warming up both engine and
transmission.

Refer to "Replace Engine Oil and Oil Filter Car-

tridge" page 3.34 and "Replace Transmission
Oil" page 3.39.

4. Start the engine and check for any abnormali-

ties.

5. Warm up the machine until all gauges reach

the normal range.
2.106
SPECIAL PROCEDURES
Long Term Storage

Cautions on Battery Replacement or

Battery Cable Removal

When battery or battery cable is removed, follow PREHEAT

OFF ON
START
the procedure below to avoid miss throttle opera-
tion by ECM.

OFF ON
PREHEAT START
65ZV0074

3. Turn the starter switch key to OFF position.

4. Start the engine and check the max. engine

speed.
65ZV0075

1. Turn the starter switch key to ON position.

Step on
→ Release
(2sec.)
⇓
Step on
→ Release
(2sec.)
⇓
Step on
→ Release
(2sec.)

65ZV2 03153-0026

2. Slowly step on the accelerator pedal to the full

stroke position 3 times.
(Keep it at the full stroke position 2 seconds
and release it)

IMPORTANT
Fully step on the accelerator pedal to the full
stroke position. If the pedal is not step on fully
enough, it causes that the max. engine speed
does not reach the standard figure.
 2.107
SPECIAL PROCEDURES
Welding

Welding low-conductive metal that will cause spark if

the welding current flows. The spark may dam-
age the cylinder rod.
Cautions Regarding Welding Repair
Service 6. Calibrate throttle pedal to ECM.

Example 1: (a) Turn the starter switch to "ON".

(b) Fully step on and release the throttle pedal
three times.
Section to be welded (c) Turn the starter switch to "OFF".

Hydraulic cylinder
Ground this section. Do not ground this section.
(correct grounding) Electric current may flow
through the cylinders.
135ZV0052

Plated section (Mask this section.)

Example 2:

135ZV0054

Section to be welded
Pin section with pin
Do not ground this section. temporarily inserted
Ground this section.
Electric current may flow (correct grounding)
through the cylinders. Pin
135ZV0053

If welding is needed to repair the chassis, observe

the following precautions to protect the hydraulic
cylinders, hydraulic units, gear sets, and electrical Plated section (Mask this section.)
units from possible damage. 135ZV0055

1. Turn the starter switch OFF. 7. The weld spattered on the hydraulic cylinders
and on the plated sections of pins will damage
2. Remove the battery terminals both positive the cylinders and pins. There are other parts
and negative sides from the battery. that may be damaged by the spatter; hydraulic
units, harnesses, hydraulic hoses, and nylon
3. Disconnect the connector for MCU (machine tubes.
controller), ECM (engine controller) and air Be sure to mask these units and parts before
conditioner. welding.

4. Ground the welder near the section to be - Plated section

welded. Cover the plated sections with heat-resistant
cloth, such as glass wool or canvas.
5. To ground the welder, check that the electric
current will not flow through the cylinders.
Cylinder head covers for some models have a
2.108
SPECIAL PROCEDURES
Welding

NOTE
The weld spattered on the plated sections causes
corrosion.

Scrap material, etc.

1 m or more

Section to
be welded

1 m or more

135ZV0056

- Cover the hydraulic units, electrical units, har-

nesses, hydraulic hoses, nylon tubes, etc. with
heat-resistant cloth (glass wool or canvas) or
scrap material to protect them from spatter.

Section to
be welded

Hydraulic hose,
Nylon tube, or
Harness
Remove
and if
Chassis necessary
wrap

135ZV0057

- Hydraulic hoses, nylon tubes, or harnesses are

easily damaged by the heat during welding. To
protect them from the heat, remove them from
the section to be welded to make enough clear-
ance.
 3.1

3.MAINTENANCE
3.2
MAINTENANCE
Serial Number Location

MAINTENANCE
Before performing maintenance or repairs, read,
understand and follow "Safe Maintenance" section
page 1.12.

The maintenance or repair of the machine must be

performed by well-Trained or experienced person-
nel only.

WARNING
Do not open high pressure fuel
system with engine running. 90ZV2873
Engine operation causes high fuel
pressure.
2. Engine Serial Number
High pressure fuel spray can
cause serious injury or death.

High pressure fuel

Serial Number Location

When contacting Kawasaki dealer or the dealers of
other products for servicing or repair, refer to the
serial number found in the following locations. See MODEL
next page for general location. SERIAL NO.

For quick reference, record each serial number in

MADE IN JAPAN
the blanks below.
SN PLATE 41668-2006B

If a component, like engine or transmission, is

changed, record the new serial number here.

3. Transmission / Torque Converter Serial Num-

ber

Model
MODEL
SERIAL NO. Serial Number

Design Number
MADE IN JAPAN

SN PLATE 41668-2063B

1. Machine Serial Number

 3.3
MAINTENANCE
Serial Number Location

SERIAL NO.
-

70ZV0004

4. Cab Serial Number

Model Number

Serial Number

Cab (R.H Inside)

90ZV2OMCOMPO-c

Machine (L.H) T/M E/G (R.H)

3.4
MAINTENANCE
Inspection and Maintenance Table

Inspection and Maintenance

Table IMPORTANT
Check and/or carry out the maintenance at inter- Severe applications require more frequent main-
vals of the specified operating hours below or the tenance.
calender date, whichever comes first. Severe conditions include heavy dust, extremely
abrasive material, caustic chemicals, extremely
wet conditions or abnormally hot or cold ambient
temperatures.

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required
Check Engine Oil Level 2.67
Check Engine Coolant Level 2.69
Check Warning Lamps 2.79
Check Exhaust Gas 2.82
Drain Water and Sediment from Fuel Filter 2.70
Check Fuel Level 2.80
Check Drive Belt 2.73
Check Crankcase Breather Tube 2.73
Check Air Intake System 2.73
Check Cooling Fan 2.74
Drain Water and Sediment from Fuel Tank 3.22
Replace Fuel Filter Cartridge 3.29
Adjust Belt Tension 3.28
Engine
Replace Engine Oil and Oil Filter Cartridge 3.34
Replace DCA4 Coolant Filter Cartridge 3.37
Clean Fuel Tank 3.50
Check and Adjust Valve Lash Clearance 3.52
Check Vibration Damper 3.50
Check Water Pump 3.51
Check Turbocharger 3.52
Check Mounting Bolts 3.52
Check and Adjust Injection Timing 3.52
Clean or Replace Air Cleaner Element 3.9
Clean Radiator / Air cooler / Hydraulic oil
3.11
cooler Fins
Clean or Replace Air Cleaner Element After six cleanings or once a year 3.9
Replace Coolant Every 2 years or 3000 hours 3.14
 3.5
MAINTENANCE
Inspection and Maintenance Table

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required
Check Transmission Oil Level 2.80
Transmission Replace Transmission Oil Filter Cartridge 3.33, 3.36
& Torque
Converter Replace Transmission Oil 3.39
Clean or Replace Transmission Breather 3.40
Check Tire for Damage, Air and Tread
2.71
Depth
Check Tire Air Pressure 3.23
Greasing (Axle support) 3.21
Check Differential Gear Oil 3.26
Check Planetary Gear Oil 3.27
Greasing (Pillow block bearing unit) 3.25
Axle system
Check Tightness of Wheel Bolts 3.28
Greasing (2nd Propeller Shaft Spline) 3.45
Replace Differential Gear Oil 3.47
Replace Planetary Gear Oil 3.48
Greasing (2nd Propeller Shaft) Every 12000 hours 3.17
Greasing (3rd Propeller Shaft) Every 12000 hours 3.17
Check Steering Wheel Operation 2.82
Steering
Greasing (Steering Cylinder) 3.21
system
Clean Filter for Orbitrol® 3.33, 3.54

Check Service Brake Operation 2.81

Check Parking Brake Operation 2.81
Adjust Parking Brake Lining 3.42
Brake Inspect the Front Parking Brake Pads and
3.43
system Rotor
Check Service Brake Disk Wear 3.51
Check Brake Accumulator 3.51
Clean Filter for Brake Line 3.33, 3.53
3.6
MAINTENANCE
Inspection and Maintenance Table

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required

Check Hydraulic Oil Level 2.68

Greasing 3.19
Replace Hydraulic Oil Return Filter 3.33, 3.41
Loading
Replace Hydraulic Oil, Clean Filter 3.46
system
Replace Filter in the Hydraulic Tank Cap 3.55
Replace Bucket Teeth (option) 3.7
Replace Cutting Edge (option) 3.8
Adjust and Check Rear View Mirrors 2.74
ROPS (Roll Over Protective Structure) Cab 2.74
Greasing (Center Pin) 3.21
Chassis
Check Ride Control Accumulator (option) 3.55
Check and/or Replace Seat Belt 3.9
Check Windshield Washer Fluid 3.13
Check Monitor Panel Operation 2.75
Check Horn Operation 2.74
Electrical Check Back-up Alarm Operation 2.82
system Check Wiring Harnesses 2.70
Check Battery Electrolyte Level 3.22
Check or Replace Fuses 3.12
Check and Adjust Air Conditioner Belt 3.30
Clean Air Conditioner Filter Element 3.31
Air Check Air Conditioner Refrigerant 3.43
Conditioner Replace Air Conditioner Filter Elements 3.52
Clean Air Conditioner Condenser 3.14
Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours 3.16
Others Walk-Around Inspection 2.66
 3.7
MAINTENANCE
When Required Inspection and Maintenance

When Required Inspection and Replace Bucket Teeth (option)

Maintenance
When the bucket teeth are worn, replace them as
follows.
WARNING
1. Park the machine on level ground and apply
Improper inspection or maintenance could result the parking brake.
in death or serious injury.

Read, understand, and follow all warnings and

instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or 1
maintenance procedures.

2 Block

97ZVOM0136

2. Raise the bucket to a convenient height and

put blocks under the bucket to prevent it from
coming down.

3. Stop the engine.

4. Remove bolts and nuts (1), then remove

bucket teeth (2).

5. Install the new teeth on the bucket with new

bolts.
3.8
MAINTENANCE
When Required Inspection and Maintenance

Replace Cutting Edge (option)

1. Park the machine on level ground and apply

the parking brake.

OM0188

WARNING
Teeth and bucket edges are hardened steel 65ZV0011
which may chip when struck by steel hammer
causing injury.
2. Raise the bucket to a convenient height and
- Always wear eye protection. put blocks under the bucket to prevent it from
- Use dead blow hammer or brass drift between coming down.
hammer and tooth.
- Keep bystanders away from work area. 3. Stop the engine.

6. To prevent any clearance between the tooth 4. Remove the cutting edge. Clean all contact
and the edge of the bucket, tighten the nut par- surfaces (bottom of bucket, top of cutting
tially, then hit the top of the tooth. edge).

7. Tighten the nuts to 1,098~1,314 N-m. 5. If other side of the cutting edge is not worn,
turn it around and install it so that the new side
8. Retighten them after operating the machine for faces the front. If both sides are worn, install a
a few hours. new cutting edge.

NOTE 6. Install all bolts and tighten them to

For non-Kawasaki buckets or teeth, consult the 1,098~1,314 N-m.
manufacturer for the proper procedures.
7. Retighten them after a few hours operation.
 3.9
MAINTENANCE
When Required Inspection and Maintenance

Check and/or Replace Seat Belt Clean or Replace Air Cleaner Element

1. Inspect the condition of the seat belt and all When the warning monitor lamp lights up, clean or
mounting hardware frequently. replace the air cleaner element.

2. Replace the seat belt or any part of the mount-

ing hardware if it is damaged.
IMPORTANT
Improper procedure of cleaning air cleaner may
3. Replace the seat belt every three years regard- cause severe engine damage.
less of its condition or appearance.
- Do not clean or replace air filters while engine
is running.
- Clean only outer element. Never clean inner
element.
- Clean or replace element only when indicator
lamp comes on.
- Never clean the elements by bumping or hit-
ting them against a solid surface.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

65ZV0012

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

3. Remove the outer element.

3.10
MAINTENANCE
When Required Inspection and Maintenance

10. Be advised that the element cleaning should

be effective up to 6 times. At the 7th mainte-
nance or once a year as well as when you find
any damage, replace both of the outer and
inner elements.

OM0138

4. Clean the element using dry compressed air

(196 kPa) by applying from the inside of the
element to blow off dirt and/or dust. Apply the
air along the length of the filter to avoid the
damage to the paper element.

OM0139

5. Place a light inside the filter element. If the light

spots are seen through the element, it must
have cracks or pinholes. Replace it with a new
element.

6. Check rubber seal (3), and if you find any dam-

age, replace it with a new element.

7. Before installing the outer element, confirm

that the inner element is seated properly, and
then, reinstall the outer element.

8. Confirm that the o-ring fits properly, and secure

the cover latches.

9. If the engine exhaust gas is not clean enough

even after cleaning (still exhausting excessive
black smoke), replace the element.
 3.11
MAINTENANCE
When Required Inspection and Maintenance

Clean Radiator / Air cooler / Hydraulic

oil cooler Fins

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

90ZV MT2-233

3. Remove clean-out traps from bottom of radia-

tor shroud.

IMPORTANT
95ZVOM2917 Clean-out traps and side cover doors must be
reinstalled and closed securely, or engine perfor-
mance will be affected.

IMPORTANT
High pressure air or water may damage radiator
/ air cooler / hydraulic oil cooler fins.

- When used for cleaning purposes, the pres-

sure of compressed air should be at 196 kPa
or less.
- When using high-pressure water, keep the
nozzle a distance of at least 500 mm away
90ZV5055 from the core surface, applying the water jet
perpendicular to the core.
- Move nozzle from side to side; not up and
2. Push the knob and open the radiator grill. down.
Open covers on the radiator guard both the
right hand side and the left hand side for clean
the air cooler and hydraulic oil cooler. 4. Blow off mud, dirt, or clogging debris from the
radiator / air cooler / hydraulic oil cooler fins
with compressed air. Use a pressure washer to
remove harder debris.

Compressed air or water should be directed

from rear toward the engine.

5. Reverse the direction to flush all debris from

the radiator / air cooler / hydraulic oil cooler
fins.

6. Reinstall clean-out traps.

3.12
MAINTENANCE
When Required Inspection and Maintenance

7. Close the engine access panels and covers. Check or Replace Fuses
Be sure side cover doors are closed securely.
If the doors are not closed securely cooling air
will leak out and cooling will be reduced.

80ZV8214

90ZV28476

1. Park the machine on level ground, apply the

parking brake, and lower the attachment to the
ground.

2. Stop the engine and turn the starter switch key

to the "OFF" position.

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

fuse box and additional fuse box.

4. Check the fuses. If any blown fuses are found,

replace them with new ones.

Refer to "Fuse Boxes" page 2.44.

5. Determine the cause of the blown fuses and

repair.
 3.13
MAINTENANCE
When Required Inspection and Maintenance

Check Windshield Washer Fluid

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

Never replace fuses with higher amperage rat-

ing.

90ZV2890

1. Park the machine on level ground, apply the

parking brake, and lower the attachment to the
ground.

2. Check the fluid level.

3. Replace the fluid if it is dirty.

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

5. Use windshield washer solvent for both better

cleaning and to prevent freezing. Adjust the
mixture according to the manufacturer's
instructions.
3.14
MAINTENANCE
When Required Inspection and Maintenance

Clean Air Conditioner Condenser Replace Coolant

If mud, insects, or other debris are stuck to the air - Since the Anti-Freeze "Long Life Coolant" (LLC)
conditioner condenser, air flow through the con- is originally used for the machine shipped from
denser will be reduced causing decreased cooling the factory, it is not necessary to replace the
ability. coolant for the first two years.

- If the cooling system conditioner (from a local

supplier) is used at the time of last replacement,
follow its instructions or contact your nearest
Kawasaki dealer for the replacement interval.

CAUTION
Pressurized radiator tank is used for this
machine.

Spray of hot coolant may cause burns.

90ZV2823 Stop engine and allow radiator and coolant to

cool completely, then open cap slowly to relieve
pressure.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine. 1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
2. Inspect the condenser and replace it if any ground, and stop the engine.
damage is found.
2. Inspect all coolant hoses.
3. Clean its fins using compressed air, a pressure
washer or a soft brush. Be sure the air pres- Replace any that are cracked, swollen, or brit-
sure is below 196 kPa. If a pressure washer is tle.
used, keep the nozzle about 50 cm away from
the fins to prevent fin damage.

4. If water is used for the cleaning, cover the elec-

trical parts of the engine and the electric con-
denser fan with plastic sheets. Remove the
plastic sheets after cleaning.

IMPORTANT
An excessively high air or water discharge pres-
sure can damage the condenser fins.

- When used for cleaning purposes, the pres- 90ZV28462

sure of compressed air should be at 196 kPa
or less.
3. Loosen the drain plug and drain coolant (about
- When cleaning with water, apply the water jet
40 liters) into a suitable container.
perpendicular to the core.
 3.15
MAINTENANCE
When Required Inspection and Maintenance

11. If the water being drained is still dirty, the sys-

tem must be flushed again until the water is
clean (step 5~11).

12. Tighten the drain plug and fill the system with
the premixed coolant.

Refer to "Coolant Specification" page 3.58 for

the mixing instruction.

13. Add one part of DCA65L coolant additive at the

90ZV2929 same time.

14. Replace the DCA4 coolant filter (WF2072).

4. Slowly turn the radiator cap until it touches the
stopper to release inner pressure.
Refer to "Replace DCA4 Coolant Filter Car-
tridge" page 3.37 for the procedure.
Pushing the cap, turn it to open.
15. Idle the engine for five minutes to purge air
Follow the law and/or local regulations to prop-
mixed into the coolant. (Leave the radiator cap
erly dispose of or recycle the coolant.
off.)

CAUTION 16. Add coolant as necessary.

Cooling system conditioner contains alkali that
may cause caustic burns or blindness. 17. Reinstall the radiator cap.

Avoid contact with skin and eyes to prevent For additional cold weather servicing information,
injury. refer to "Coolant Specification" page 3.58 for
details.

5. Tighten the drain plug and fill the cooling sys-

tem with clean water.

Do not install the radiator cap.

6. Operate the engine for one hour with the cool-

ant temperature above 80ºC. Then let the
engine cool down naturally with the engine
shut "OFF".

7. Stop the engine and loosen the drain plug to

drain the cooling system.

8. Tighten the drain plug and fill the cooling sys-

tem with clean water.

Do not install the radiator cap or the new cool-

ant filter.

9. Operate the engine for five minutes with the

coolant temperature above 80ºC.

10. Stop the engine and loosen the drain plug to

drain the cooling system.
3.16
MAINTENANCE
When Required Inspection and Maintenance

Replace Air Conditioner Receiver Dryer Greasing

(Every 3 years or 6000 hours) (Every 12000 hours)

- Contact your Kawasaki dealer. 1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page

3.56 for the correct grease. Use lithium base
grease for universal joints.
 3.17
MAINTENANCE
When Required Inspection and Maintenance

85ZVOM3316 95ZVOM2901

- 3rd Propeller Shaft

(two places)

90ZV2842

95ZVOM2843

- 2nd Propeller Shaft

(three places)
3.18
MAINTENANCE
Every 10 Hours or Daily

Every 10 Hours or Daily

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

Read, understand, and follow all warnings and

instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or
maintenance procedures.

See "Check before Operation" page 2.66 and

"Check after Starting the Engine" page 2.79.
 3.19
MAINTENANCE
Every 50 Hours or 1 Week

Every 50 Hours or 1 Week Greasing

1. Park the machine on level ground, apply the

WARNING parking brake, lower the attachment to the
Improper inspection or maintenance could result ground, and stop the engine.
in death or serious injury.
2. Lubricate fittings on the following components.
Read, understand, and follow all warnings and Wipe and clean all fittings before greasing.
instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or Lubricate until fresh grease is seen at each
maintenance procedures. joint. Immediately replace or report any broken
or defective grease fittings.

Every 50 hours or 1 week, whichever comes first, Refer to "Recommended Lubricants" page
perform the following inspection and maintenance 3.56 for the correct grease.
in addition to the "Daily Inspection and Mainte-
nance".

90ZV0003

- Bucket-Boom
(two places)

90ZV0003

- Bucket-Rod
(two places)
3.20
MAINTENANCE
Every 50 Hours or 1 Week

90ZV0004 90ZV2835

- Lever-Rod - Bucket Cylinder-Front Chassis

(two places) (two places)

90ZV0005 90ZV5030

- Lever-Boom - Boom Cylinder-Boom

(two places) (two places)

90ZV0005 90ZV2835

- Bucket Cylinder-Lever - Boom Cylinder-Front Chassis

(two places) (two places)
 3.21
MAINTENANCE
Every 50 Hours or 1 Week

90ZV2838
90ZV5030

- Boom-Front Chassis
(two places)

90ZV2837

- Center Pin
90ZV2837 (two places)

- Steering Cylinder
(four places) L.H and R.H

90ZV2909

- Axle support
(two places)
3.22
MAINTENANCE
Every 50 Hours or 1 Week

Drain Water and Sediment from Fuel Check Battery Electrolyte Level
Tank
WARNING
CAUTION Batteries produce explosive gases which could
Escaping fuel is flammable and harmful to skin. cause burns or blindness.

- Do not smoke while draining moisture and - Ventilate area to remove explosive gases.
sediment from fuel tank. - Wear eye or face protection when working on
- Do not drain fuel with engine running. or around batteries.
- Do not allow fuel to remain on skin for - Keep flames and sparks away from batteries.
extended period of time. Wash thoroughly with
soap and water.
WARNING
1. Park the machine on level ground, apply the If the batteries being used have insufficient bat-
parking brake, lower the attachment to the tery electrolyte level, parts in the battery case
ground, and stop the engine. could rapidly deteriorate.

It could shorten battery life or the battery case

could explode.

Keep the battery electrolyte level at the proper

level.

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

Avoid contact with skin or clothing and wear

90ZV2836
hand, eye, and face protection when working on
or around batteries.
2. Prepare a suitable container.
If lead, or acid contacts skin or clothing, immedi-
3. Open the drain cock on the bottom of the fuel ately wash with water.
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.
 3.23
MAINTENANCE
Every 50 Hours or 1 Week

Check Tire Air Pressure

Low Pressure OK High Pressure

90ZV5009

70ZV0016
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine. Tire performance and its life depend greatly on the
tire air pressure.
2. Clean the battery surface with a clean cloth or
soft brush. - Low air pressure causes excessive deflection,
heat, and accelerated wear.

- High air pressure cause reduced traction, slip-

page, and possible blow outs.

It is important to keep the tire pressure at the rec-

ommended level.

Special applications, such as long load and carry

operations, may require different pressures. Con-
sult the tire manufacturer.
Low OK High

OM0096 WARNING
Overheated tire may explode causing serious
3. Check the battery electrolyte level in each cell. injury or death.
Electrolyte should cover the cell plates.
If overheated tire is suspected, do not approach
4. If the level is low, add distilled water until it tire to distance of less than 15 m.
reaches the bottom of the filler neck.
Stay away until tire and rim cool down.
NOTE
If a maintenance free battery is used, step 3 and 4 1. Before starting work and while the tires are still
of this inspection and maintenance is not required. cool, measure the tire air pressure with the tire
pressure gauge.
3.24
MAINTENANCE
Every 50 Hours or 1 Week

Recommended Tire Air Pressure

Radial tire

Air pressure
Size
Front Rear
26.5 R25 471~490 kPa 373~392 kPa

Bias ply tire

Air pressure
Size
OM0032 Front Rear
26.5-25-20PR 422~441 kPa 324~343 kPa
26.5-25-24PR 490~510 kPa 392~412 kPa
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 shut-
off valve.
- Stand behind tread of tire and keep all per-
sons away from side of tire.
- Do not inflate tire more than recommended
pressure.
- Use safety cage if available.

OM0033

2. Adjust air pressure according to the recom-

mended pressures below.

When inflating a tire, stand behind the tread

and use a self-attaching chuck with a remotely
located valve to turn air pressure on and off.
 3.25
MAINTENANCE
Every 250 Hours or 1 Month

Every 250 Hours or 1 Month Greasing

1. Park the machine on level ground, apply the

WARNING parking brake, lower the attachment to the
Improper inspection or maintenance could result ground, and stop the engine.
in death or serious injury.
2. Lubricate fittings on the following components.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance" Refer to "Recommended Lubricants" page
page 1.12 before performing any inspection or 3.56 for the correct grease. Use lithium base
maintenance procedures. grease for universal joints.

Every 250 hours or 1 month, whichever comes first,

perform the following inspection and maintenance
in addition to the "Daily" and "50 hours" inspections
and maintenance.

90ZV2857

- Pillow block bearing unit

(one place)
3.26
MAINTENANCE
Every 250 Hours or 1 Month

Check Differential Gear Oil 4. If there is any sign of water in the oil, drain and
replace the oil. Oil containing water looks
milky.
CAUTION
The axles are pressurized through the hydraulic Dispose of the drained oil properly.
tank.
5. Install and tighten the level plug.
When removing the oil level check plug a large
volume of hot oil could spray out. It causes seri- 6. Check the rear axle oil level following the same
ous burns. steps.

Before removing the oil level check plug, push

down on the hydraulic tank cap to release the air
pressure inside the hydraulic tank.

Do not touch the parts or oil when it is hot.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

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

70ZV OM 2514

2. Remove the oil level plug from the front axle

housing, using a 12 mm hex (Allen) wrench.

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

specified oil through the level plug hole.

Refer to "Recommended Lubricants" page

3.56.
 3.27
MAINTENANCE
Every 250 Hours or 1 Month

Check Planetary Gear Oil 7. If there is any sign of water in the oil, drain and
replace the oil. Oil containing water looks
milky.
CAUTION
The axles are pressurized through the hydraulic Dispose of the drained oil properly.
tank.
8. Install and tighten the level plug.
When removing the oil level check plug a large
volume of hot oil could spray out. It causes seri-
ous burns.

Before removing the oil level check plug, push

down on the hydraulic tank cap to release the air
pressure inside the hydraulic tank.

Do not touch the parts or oil when it is hot.

1. Check the oil level on all four wheels.

80ZVOM3340

2. Move the machine on level ground so that

"TOP" mark (1) on the planetary gear housing
comes top.

3. Turn "ON" the parking brake switch, lower the

attachment to the ground, and stop the engine.

4. Remove oil level plug (2) on the housing, using

a 12 mm hex (Allen) wrench.

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

specified oil through the level plug hole.

Refer to "Recommended Lubricants" page

3.56.

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.
3.28
MAINTENANCE
Every 250 Hours or 1 Month

Check Tightness of Wheel Bolts Adjust Belt Tension

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
CAUTION
ground, and stop the engine. Contact with moving belts or pulleys may cause
injuries.

Stop engine before opening engine access

panel.

Inspection

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine. Remove the key
and place "Do Not Operate" tag on the instru-
ment panel.
80ZVOM3340

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

m.

3. Retighten if necessary.

OM0215

2. Open the engine access 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.
 3.29
MAINTENANCE
Every 250 Hours or 1 Month

Replace Fuel Filter Cartridge

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.
OM0201

1. Park the machine on level ground, apply the

5. Apply pressure approximately 98 N to the cen- parking brake, lower the attachment to the
ter of the belt between the pulleys; deflection of ground, and with fuel tank full, stop the engine.
about 10 mm is normal.
2. Place a small drain pan (about 8 liter) under
Adjustment the fuel filter.

4 2
1

3 90ZV2817 90ZV2879

1. Loosen bolts (1)(2) and (3). 3. Remove and properly dispose of the fuel filter.

2. Turn adjusting bolt (4) to adjust the belt tension 4. Clean the filter head gasket surface.
correctly.
5. Apply a light film of clean engine oil to the gas-
3. Tighten the bolts and nuts. ket surface of the new filter.

6. Loosely install fuel filter on the fuel filter head.

7. Permit the filter to gravity fill from fuel in tank.

NOTE
This will take a few minutes.
Do not walk away and let filter overrun with fuel.
3.30
MAINTENANCE
Every 250 Hours or 1 Month

Check and Adjust Air Conditioner Belt

CAUTION
Contact with moving belts or pulleys may cause
injuries.

Stop engine before opening engine access

panel.

1. Park the machine on level ground, apply the

OM0200 parking brake, lower the attachment to the
ground, and stop the engine. Remove the key
and page "Do Not Start" tag on the instrument
8. Tighten the filter an additional one-half to panel.
three-fourths turn after the gasket contacts the
filter head surface. Follow the instructions sup- 2. Open the engine access panel.
plied with the filter.

IMPORTANT
Do not over tighten the filter.

9. Turn the starter switch key to the START posi-

tion, and turn it back to the OFF position within
15 seconds.
Do not leave the key at the START position for
longer than 20 seconds.

10. Wait about 5 seconds until the engine stops

OM0201
completely, and repeat step 9.

11. If the engine does not start after repeating step 3. Visually inspect the compressor belt on both
10 five times, wait for 2 minutes or longer to top and bottom sides for looseness and dam-
cool down the starter enough. age.
12. Repeat steps 9 through 11 until the engine 4. If the belt is too stretched to permit adjustment
starts. Make sure to have 2 minutes interval for or shows cuts or cracks, replace it and adjust
the starter cooling. the tension correctly.
13. After replacing the filter and/or oil, reset the 5. Apply pressure approximately 98 N to the cen-
interval timer for the replacement. Go to the ter of the belt between the pulleys; deflection of
timer reset screen of the MODM, and reset the about 10 mm is normal.
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.37.

 3.31
MAINTENANCE
Every 250 Hours or 1 Month

Clean Air Conditioner Filter Element

Outer filter cleaning

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
1 ground.
1
2. Turn the air conditioner "OFF" and stop the
engine.
2
90ZV28471

6. If the belt is too loose or tight, adjust the ten-

sion by loosening lock nuts (1) and turning
adjusting nut (2) on the compressor bracket.

97ZVOM0152

3. The cover for the outer filter is located at the

left rear side of the cab.

Turn the rings counterclockwise and then

remove the cover.

97ZVOM0153

4. Remove the outer filter from the cab.

5. Remove dust with compressed air. Use air

pressure below 196 kPa.

6. To remove more stubborn debris, wash the fil-

ter with clean water. Leave them for five to
seven days for dry in the shade.
3.32
MAINTENANCE
Every 250 Hours or 1 Month

7. After approximately 20 cleanings, replace the 2. Remove dust with compressed air. Use air
filter with new one. pressure below 196 kPa.

Refer to "Replace Air Conditioner Filter Ele- 3. To remove more stubborn debris, wash the fil-
ments" page 3.52. ter with clean water. Leave them for five to
seven days for dry.
8. When installing the outer filter into the cab, be
sure to align the air flow arrow on the outer fil- 4. After approximately 20 cleanings, replace the
ter to point toward the cab. filters with new ones.

Refer to "Replace Air Conditioner Filter Ele-

ments" page 3.52.

5. Install the filter, install 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.

97ZVOM0152

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

clockwise to fix the cover.

Inner filter cleaning

1
97ZVOM2473

1. The inner filter is located at behind the opera-

tor's seat.

Open unit cover (1) using screw driver.

Loosen screw (2) by fingers to remove cover

(3).

Remove the filter and clean it.

 3.33
MAINTENANCE
Every 250 Hours or 1 Month

Replace Filter

(First time replacement or cleaning only)

- Transmission Oil Filter Cartridge

Replace it first time only at 250 hours operation,

after that replace it at every 500 hours opera-
tion.

Refer to "Every 500 Hours or 3 Months" page

3.36.

After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.37.

- Hydraulic Oil Return Filter

Replace it first time only at 250 hours operation,

after that replace it at every 1000 hours opera-
tion.

Refer to "Every 1000 Hours or 6 Months" page

3.41.

After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.37.

- Brake Line Filter

Clean it first time only at 250 hours operation,

after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page

3.53.

- Orbitrol® Filter

Clean it first time only at 250 hours operation,

after that clean it at every 2000 hours operation.

Refer to "Every 2000 Hours or 1 Year" page

3.54.
3.34
MAINTENANCE
Every 500 Hours or 3 Months

Every 500 Hours or 3 Months Replace Engine Oil and Oil Filter Car-
tridge
WARNING
CAUTION
Improper inspection or maintenance could result
in death or serious injury. Hot oil and engine components may cause
burns.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance" Avoid contact with hot oil or engine components.
page 1.12 before performing any inspection or
maintenance procedures. 1. If the machine is cold operate the engine to
bring the engine coolant temperature about
Every 500 hours or 3 months, whichever comes 40ºC. When the needle of the coolant tempera-
first, perform the following inspection and mainte- ture gauge reaches the middle of the white
nance in addition to the "Daily", "50 hours", and zone, the temperature is about 40ºC.
"250 hours" inspection and maintenance.
2. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.

90ZV28462

3. Loosen the drain plug.

4. Drain oil, about 37 liters, into a suitable con-

tainer.
 3.35
MAINTENANCE
Every 500 Hours or 3 Months

Dipstick

Oil Fill
90ZV27254 90ZV2879

5. Remove the oil filter and properly dispose of it. 11. Fill the engine with clean oil to the proper level.
Make sure the O-ring is removed with the filter.
Refer to "Recommended Lubricants" page
6. Clean the oil filter head gasket surface. 3.56 for the oil specifications. Total system
capacity including the filter is 37 liters.
7. Fill the new filter with clean engine oil.
12. Idle the engine to inspect for leaks at the filter
Refer to "Recommended Lubricants" page and the drain plug.
3.56 for the oil specifications.
13. Stop the engine. Wait approximately five min-
8. Apply a light film of engine oil to the gasket sur- utes to let the oil drain back to the oil pan.
face of the new filter cartridge.
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.

17. After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.37.

OM0200

CAUTION
9. Install and tighten the filter until the gasket con-
Used engine oil may cause skin disease or irrita-
tacts filter head surface. Then tighten it by
tion.
hand an additional three-fourths to one turn.
Do not allow used engine oil to remain on skin
Refer to the instructions supplied with the filter.
for prolonged periods of time.
10. Retighten the oil drain plug, and tighten to 80
Clean skin thoroughly with soap and water.
N-m torque.
3.36
MAINTENANCE
Every 500 Hours or 3 Months

Replace Transmission Oil Filter Car-

tridge DANGER
Accidental movement of machine could result in
CAUTION death or serious injury.
Hot oil and components may cause burns.
When inspecting or servicing machine in articu-
lation area:
Avoid contact with hot oil or components.
- Lower attachment to ground.
- Put transmission shift lever in neutral.
1. If the machine is cold, operate the machine to - Apply parking brake.
bring the torque converter oil temperature - Make sure nobody is on machine.
about 30~40ºC. - Place "DO NOT OPERATE" tag on steering
wheel.
2. Park the machine on 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.

90ZV2837

9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page
2.80.
90ZV28498 Add the specified oil as necessary to bring the
oil level to the "H" (high) mark on the dipstick.
Refer to "Recommended Lubricants" page
4. Turn the filter counterclockwise to remove.
3.56 for the specified oil.
Properly dispose of the oil and filter.
10. After replacing the filter and/or oil, reset the
5. Clean the filter head gasket surface.
interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
6. Apply a light film of clean engine oil to the gas-
corresponding replacement interval.
ket surface of the new filter.
Refer to "Replacement Monitor" page 2.37.
7. Install the filter on the filter head. Turn it clock-
wise to tighten. Follow the instructions on the
filter. CAUTION
Used oil may cause skin disease.
8. Idle the engine about ten minutes and inspect
for leaks around the filter.
Do not allow used oil to remain on skin for pro-
longed periods of time.

Clean skin thoroughly with soap and water.

 3.37
MAINTENANCE
Every 500 Hours or 3 Months

Replace DCA4 Coolant Filter Cartridge

CAUTION
Pressurized radiator tank is used for this
machine.
2
Spray of hot coolant may cause burns.

Stop engine and allow radiator and coolant to

cool completely, then open cap slowly to relieve
1
pressure.
90ZV27254

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

Hot coolant and engine components can cause
4. Remove and properly dispose of coolant filter
burns.
(1).
Avoid contact with coolant or engine compo-
5. Clean the filter head gasket surface.
nents.
6. Apply a light film of clean engine oil to the gas-
NOTE ket surface of a new DCA4 coolant filter car-
The filter WF2075 is initially installed when the tridge (WF2072).
machine is shipped from the factory. This filter can
not be obtained as a spare parts.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

OM0200

7. Install the filter firmly by hand. Follow the

instructions supplied with the filter.

90ZV2929
8. Open the coolant shut-off valves and install the
radiator cap.

2. Slowly open 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.
3.38
MAINTENANCE
Every 500 Hours or 3 Months

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

Refer to "Coolant Specification" page 3.58 for

the correct mixture.

13. After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.37.

 3.39
MAINTENANCE
Every 1000 Hours or 6 Months

Every 1000 Hours or 6 Months Replace Transmission Oil

WARNING WARNING
Accidental movement of machine could result in
Improper inspection or maintenance could result
death or serious injury.
in death or serious injury.
When inspecting or servicing machine in articu-
Read, understand, and follow all warnings and
lation area:
instructions contained in "Safe Maintenance"
- Lower attachment to ground.
page 1.12 before performing any inspection or
- Put transmission shift lever in neutral.
maintenance procedures.
- Apply parking brake.
- Make sure nobody is on machine.
Every 1000 hours or 6 months, whichever comes - Place "DO NOT START" or "DO NOT OPER-
first, perform the following inspection and mainte- ATE" tag on steering wheel.
nance in addition to the "Daily", "50 hours", "250
hours", and "500 hours" inspection and mainte-
nance. 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 tem-
perature about 30~40ºC.

2. Park the machine on level ground, turn "ON"

the parking brake switch, lower the attachment
to the ground, and stop the engine.

1 3

2
95ZVOM2898

3. Remove drain plug (1) with a 36 mm wrench.

4. Drain oil into a suitable container (about 24

liters).

Properly dispose of or recycle the waste oil.

5. Loosen four bolts (2) with a 14 mm wrench.

3.40
MAINTENANCE
Every 1000 Hours or 6 Months

6. Remove flange (3) together with the pipe and Clean or Replace Transmission
suction strainer. Breather
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 dealer.

8. Reinstall the drain plug and the strainer with a

new gasket.

9. Tighten four bolts (2) to 53.0 N-m.

90ZV2620

10. Fill with the specified oil.

1. Park the machine on level ground, apply the
Refer to "Recommended Lubricants" page parking brake, lower the attachment to the
3.56. ground, and stop the engine.

11. Idle the engine and check for leaks. 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.

90ZV2837

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

Refer to "Check Transmission Oil Level" page

2.80 and "Recommended Lubricants" page
3.56.

13. After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.37.

 3.41
MAINTENANCE
Every 1000 Hours or 6 Months

Replace Hydraulic Oil Return Filter

1
2
CAUTION
Pressurized hydraulic tank is used for this 3
machine.
4
Pressurized hot oil may cause injury or burns. 5
Relieve all pressure by pressing down the filler
cap. 6
97ZVOM0166
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine. 6. Remove O-ring (3), spring (4), and bypass
valve (5) from the filter housing.
2. Open the access cover on the right deck.
7. Remove and properly dispose of filter (6) and
waste oil.
2 1 Filler cap
8. Clean the inside of the filter housing.

9. Replace O-ring (3).

10. Apply a light film of clean hydraulic oil on the

filter cover O-ring surface.

11. Install filter element (6), bypass valve (5),

spring (4), new O-ring (3) and filter cover (1).

90ZV2890 12. Close the access cover.

13. After replacing the filter and/or oil, reset the

3. Press down the filler cap to relieve the tank interval timer for the replacement. Go to the
pressure. timer reset screen of the MODM, and reset the
corresponding replacement interval.
4. Clean around the top of filter cover (1).
Refer to "Replacement Monitor" page 2.37.
5. Remove two bolts (2) with a 17 mm wrench
and open filter cover (1).

Two bolts (2) may be used as "Jacking screws"

to push up the cover. Install them into the two
threaded holes in the cover. Screw them in
equally to force the cover up evenly.
3.42
MAINTENANCE
Every 1000 Hours or 6 Months

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

WARNING 5. Place a "DO NOT OPERATE" tag on the steer-

When parking brake is released for adjusting ing wheel.
brake lining, machine could move unexpectedly
causing serious injury or death.

Make sure to lower attachment to ground, and

Adjuster wheel
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 1
access.

2. Lower the attachment to the ground and turn Special Tool

(Accessory)
"OFF" the parking brake switch.
97ZVOM0168

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

brake drum.
1
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 down-

ward. (Now the clearance is 0.23 mm)
80ZVUSA0002
9. Check parking brake operation as described
on page 2.81.

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

8º OM0167

3. Align inspection hole (1) with the adjuster

wheel by turning the hole 8º counterclockwise
from the bottom.

Do not enter the articulation area or under the

machine.
 3.43
MAINTENANCE
Every 1000 Hours or 6 Months

Inspect the Front Parking Brake Pads Check Air Conditioner Refrigerant
and Rotor

Rotor

Pad and carrier

Piston

A 95ZV0018
85ZV2829a

B
1. Apply the parking brake and lower the attach-
1. Park the machine in safe place on firm level ment to the ground.
ground, apply the parking brake and lower the
attachment to the ground. 2. Remove the cover.

2. Measure the pad thickness. 3. Press the flow control switch to set maximum
air flow.
Replace the both pads with new ones, if pad
thickness (A) reaches to about 9 mm (0.354 in) 4. Set the temperature control switch fully to the
cool position and fully open the cab doors.
3. Measure the rotor thickness.
5. Slightly accelerate the engine to about the mid-
Replace the rotor with new one, if rotor thick- dle speed range.
ness (B) reaches to about 10.5 mm (0.414 in) (compressor speed 1,500~1,800 min-1)

Contact your Kawasaki dealers for the replacement 6. Compare the flow of bubbles in the sight glass
of the pads and/or the rotor. with the drawings in the following table.

WARNING
Overfilled refrigerant may cause dangerous high
pressure and poor cooling action; and low refrig-
erant level may cause compressor damage.

Always maintain refrigerant in normal level.

3.44
MAINTENANCE
Every 1000 Hours or 6 Months

Adjust of Appearance of the

Solutions
refrigerant sight glass

Normal Almost clear.

Any bubbles dis-
appear if the
engine speed is
increased to
1,500 min-1.
High

No bubble is
seen. Contact your local
Kawasaki dealer
for inspection and
Low recharging refrig-
A flow of bubbles erant.
is visible.
 3.45
MAINTENANCE
Every 2000 Hours or 1 Year

Every 2000 Hours or 1 Year Greasing

1. Park the machine on level ground.

WARNING Lower the attachment to the lowest position
Improper inspection or maintenance could result and tilt back the bucket fully.
in death or serious injury.
2. Steer the machine fully to the right or left, and
Read, understand, and follow all warnings and stop the engine.
instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or 3. Lubricate the fitting on the sleeve yoke.
maintenance procedures.
4. To lubricate the spline enough, start the engine
and slowly turn the machine from side to side 2
Every 2000 hours or 1 year, whichever comes first, or 3 times after greasing.
perform the following inspection and maintenance
in addition to the "Daily", "50 hours", "250 hours", Refer to "Recommended Lubricants" page
"500 hours", and "1000 hours" inspections and 3.56 for the correct grease. Use lithium base
maintenance. grease for universal joints.

95ZVOM2843

- 2nd Propeller Shaft Spline

(one place)

IMPORTANT
When greased with the machine in straight,
remove the fitting on the sleeve yoke and follow
the procedure above step 4.
3.46
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Hydraulic Oil, Clean Filter

WARNING 2
Pressurized hydraulic tank is used for this
machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler

cap.

1 90ZV5077
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine. 7. Remove drain plug (1) using a 24 mm wrench
to drain oil.
2. Move the bucket and boom control levers back
and forth to relieve the pressure. 8. Dispose of the waste oil properly.

9. Remove the nuts with a 14 mm wrench to

remove inspection cover (2).

CAUTION
Compressed air may cause injury.

- Wear protective clothing and eye protection.

- Air pressure must be below 196 kPa.

10. Remove the suction strainer. Inspect and clean

them with solvent and compressed air.
90ZV2890

A few small particles in the strainer is normal.

3. Insert the key into the side of the filler cap and Large metal, rubber pieces, or a large amount
turn the key counterclockwise. of fine particles is abnormal. If found, contact
your Kawasaki dealer.
4. Press down the filler cap to relieve the tank
pressure. 11. Clean inside of the tank and magnet plug.

5. Remove the inlet cap. 12. Install the suction strainer, new gasket and
inspection cover (2), and tighten the nuts. Do
not overtighten.
CAUTION
Hydraulic oil may be hot and may cause burns. 13. Install and tighten the drain plug.

Avoid contact with hydraulic oil. 14. Add the specified hydraulic oil through the oil
inlet hole.

6. Prepare a suitable container to catch the drain- Refer to "Recommended Lubricants" page
ing oil (about 175 liters). 3.56.

15. Close the oil inlet cap.

 3.47
MAINTENANCE
Every 2000 Hours or 1 Year

16. Start the engine and allow the engine to idle for Replace Differential Gear Oil
about five minutes.

17. Operate the bucket, boom, and steering cylin- CAUTION

ders for about five minutes, then lower the The axles are pressurized through the hydraulic
attachment to the ground. tank.

18. Inspect for leaks. When removing the oil level check plug a large
volume of hot oil could spray out. It causes seri-
19. Make sure hydraulic oil is to the center of the ous burns.
oil level gauge. Add hydraulic oil if necessary.
Before removing the oil level check plug, push
20. After replacing the filter and/or oil, reset the down on the hydraulic tank cap to release the air
interval timer for the replacement. Go to the pressure inside the hydraulic tank.
timer reset screen of the MODM, and reset the
corresponding replacement interval. Do not touch the parts or oil when it is hot.

Refer to "Replacement Monitor" page 2.37.

1. If the machine is cold operate the machine for
a few minutes to bring the differential gear oil
temperature about 40ºC.

2. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

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

2 70ZV OM 2514

3. Remove level plug (1) and drain plug (2) from

the front axle housing, with a 12 mm Hex
(Allen) wrench.

Some fine metallic powder will normally stick to

the magnet plugs.

Simply wipe it off.

3.48
MAINTENANCE
Every 2000 Hours or 1 Year

4. Drain the oil (about 47 liters) into a suitable Replace Planetary Gear Oil
container.

5. Dispose of the waste oil properly. CAUTION

The axles are pressurized through the hydraulic
CAUTION tank.

Used oil may cause skin disease. When removing the oil level check plug a large
volume of hot oil could spray out. It causes seri-
Do not allow used oil to remain on skin for pro- ous burns.
longed periods of time.
Before removing the oil level check plug, push
Clean skin thoroughly with soap and water. down on the hydraulic tank cap to release the air
pressure inside the hydraulic tank.
6. Install the drain plug.
Do not touch the parts or oil when it is hot.
7. Refill the recommended oil through level plug
hole (1) until the oil comes out from the hole. 1. Replace the planetary gear oil on all four
wheels.
Refer to "Recommended Lubricants" page
3.56.
1
8. Install and tighten the level plug.

9. Replace the rear differential oil following the

same steps.
2

Required oil volume for the rear differential is

about 50 liters.

10. After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the 80ZVOM3340
corresponding replacement interval.

Refer to "Replacement Monitor" page 2.37. 2. Move the machine on level ground so that
"TOP" mark (1) on the planetary gear housing
comes to the 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.
 3.49
MAINTENANCE
Every 2000 Hours or 1 Year

Refer to "Replacement Monitor" page 2.37.

3
70ZV OM 2514

4. Remove level plug (2) and drain plug (3) from

the planetary gear housing, using a 12 mm hex
(Allen) wrench.

Some fine metallic powder will normally stick to

magnet plug (2).

Simply wipe it off.

5. Drain the oil (about 15 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 pro-

longed periods of time.

Clean skin thoroughly with soap and water.

7. Install and tighten the drain plug.

8. Refill the recommended oil through level plug

hole (2) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page

3.56.

9. Install and tighten the level plug.

10. Repeat these steps for all four planetaries.

11. After replacing the filter and/or oil, reset the

interval timer for the replacement. Go to the
timer reset screen of the MODM, and reset the
corresponding replacement interval.
3.50
MAINTENANCE
Every 2000 Hours or 1 Year

Clean Fuel Tank Check Vibration Damper

1. Park the machine on level ground, apply the

CAUTION parking brake, lower the attachment to the
Escaping fuel is flammable and harmful to skin. ground, and stop the engine.

- Do not smoke while draining moisture and

sediment from tank.
- Do not drain with engine running.
- Do not allow fuel to remain on skin for an
extended period of time. Wash thoroughly with
soap and water.

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

1. Park the machine on level ground, apply the

90ZV28520
parking brake, lower the attachment to the
ground, and stop the engine.
2. Check the damper on the fan end of the engine
crankshaft.

OK OK

1 90ZV2836

80ZVUSA0004
2. Remove drain plug (1) using a 24 mm wrench
to drain oil.
3. If dents, cracks, or any deformations are found,
3. Drain the remaining fuel into a suitable con- contact your nearest Kawasaki dealer or Cum-
tainer. mins Engine dealer for replacement.

4. Remove the nuts with a 14 mm wrench to

remove inspection cover (2).

5. Clean inside of the tank.

6. Install the inspection cover with a new gasket.

Tighten the nuts evenly. Do not overtighten.

7. Close the drain cock.

8. Fill the fuel tank.

9. Check for any leaks at the cover and plug.

 3.51
MAINTENANCE
Every 2000 Hours or 1 Year

Check Brake Accumulator

A
Test the brake accumulator for proper pre-charge of
nitrogen gas.

WARNING
Pressurized nitrogen gas in brake accumulator
could explode causing serious injury or death.

C Never service brake accumulator unless trained

B
65ZV0024
properly.

1. Park the machine on level ground, apply the

4. Check index lines (A) in vibration damper hub parking brake, and lower the attachment to the
(B) and inertia member (C). If the lines are ground.
more than 1.59 mm out of alignment, replace
the vibration damper. 2. Run the engine at low idle for five minutes to fill
the brake accumulator with oil.

3. Stop the engine.

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

5. Count the number of times you can step on the

right hand brake pedal before the brake warn-
ing light comes on.

OK 6. If the number counted is less than nine, there

is some problem with the accumulator. Contact
your nearest Kawasaki dealer.
65ZV0023

5. Inspect the rubber member for deterioration. If

pieces of rubber are missing or if the elastic Check Service Brake Disk Wear
member is more than 3.18 mm below the metal
surface, replace the damper. - Contact your Kawasaki dealer.

Also, look for forward movement on the

damper ring on the hub. Replace the vibration
damper if any movement is detected. Check Water Pump
6. If dents, cracks, or any deformations are found,
If a steady flow or drip of coolant or oil is observed
contact your nearest Kawasaki dealer or Cum-
at the weep hole, replace the water pump with a
mins Engine dealer for replacement.
new or rebuilt unit.

Contact your nearest Kawasaki dealer or Cummins

Engine dealer for replacement.
3.52
MAINTENANCE
Every 2000 Hours or 1 Year

Check Turbocharger Replace Air Conditioner Filter Elements

- Tighten the turbocharger mounting nuts.

Outer filter replacement
Torque Value : 61 N-m
1. Park the machine on level ground, apply the
- Check the turbine housing / compressor hous-
parking brake and lower the attachment to the
ing sealing surface for leaks.
ground.
If leak is found, tighten the V-band clamp nut.
2. Turn the air conditioner "OFF" and stop the
engine.

Check Mounting Bolts

Inspect the engine mounts for rubber deterioration,

age hardening, and broken or lost bolts.

Replace any broken or lost bolts and damaged rub-

ber.

Tighten the engine mounting nuts and bolts.

Torque Value : 441 N-m

97ZVOM0152

Check and Adjust Injection Timing 3. The cover for the outer filter is located at the
left rear side of the cab.
- Contact your Kawasaki dealer or local Cummins
engine dealer. Turn the rings counterclockwise and then
remove the cover.

Check and Adjust Valve Lash Clearance

- Contact your Kawasaki dealer or local Cummins

engine dealer.

97ZVOM0153

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 fil-
ter to point toward the cab.
 3.53
MAINTENANCE
Every 2000 Hours or 1 Year

Clean Filter for Brake Line

CAUTION
Hot oil and components may cause burns.

Vent all pressure by pressing hydraulic cap

down.

Avoid contact with hot oil or components.

97ZVOM0152 1. Park the machine on level ground, turn "ON"

the parking brake switch, lower the attachment
to the ground, and stop the engine.
5. Install the cover to the cab and turn the rings
clockwise to fix the cover.

Rear Axle C/L

Inner filter replacement
Front

3
Chassis L.H

90ZV2 03261-0005

1
97ZVOM2473

The inner filter is located at behind the operator's Air blow

seat. FLOW

Open unit cover (1) using screw driver.

Filter case Filter Nipple
Loosen screw (2) by fingers to remove cover (3).

Remove the filter and replace it with new one.

OM0212

2. Place a suitable container under the filter.

3. Remove the nipple with filter and properly

clean the filter.

4. Install the nipple with filter and tighten it with

60~80 N-m torque.

5. Idle the engine about ten minutes and inspect

for leaks around the filter.
3.54
MAINTENANCE
Every 2000 Hours or 1 Year

Clean Filter for Orbitrol® 6. Install the nipple with filter and tighten it with
60~80 N-m torque.

CAUTION 7. Idle the engine about ten minutes and inspect

Hot oil and components may cause burns. for leaks around the filter.

Vent all pressure by pressing hydraulic cap

down.

Avoid contact with hot oil or components.

1. Park the machine on level ground, turn "ON"

the parking brake switch, 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. Move the steering each way about 2~3 times

to relieve the pressure.

R.H

Front
Chassis C/L
90ZV03148-0551

Air blow
FLOW

Filter case Filter Nipple

OM0212

4. Place a suitable container under the filter.

5. Remove the nipple with filter and properly

clean the filter.
 3.55
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Filter in the Hydraulic Tank Cap Check Ride Control Accumulator
(option)
CAUTION
Pressurized hydraulic tank is used for this WARNING
machine. Pressurized nitrogen gas in ride control accumu-
lator could explode causing serious injury or
Pressurized hot oil may cause injury or burns. death.

Vent all pressure by pressing cap before open- Never service ride control accumulator unless
ing. trained properly.

Contact your nearest Kawasaki dealer.

1

3
2
97ZVOM0170

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.

2. Move the bucket and boom control levers back

and forth to relieve the pressure.

3. Insert the key into the side of filter cap (1) and
turn the key counterclockwise.

4. Press down filter cap (1) to relieve the tank

pressure.

5. Remove the filter cap.

6. Remove spiral snap ring (2), valve assy (3),

spring (4), filter element (5).

7. Replace element (5). (Part number 30981-

70330)

8. Install the element, spring, valve assy, and spi-

ral snap ring.
3.56
MAINTENANCE
Recommended Lubricants

Recommended Lubricants

Refill capacity Ambient Temperature (ºC) Change Interval

Kind of Oil -30 -20 -10 0 10 20 30 40
(Approximate) (Hours)

Engine oil SAE10W-30 ∗2

Engine 37 liter
(CH4 or CI4) SAE15W-40 500

Engine oil (CD) or SAE10W

Transmission 38 liter 1,000
ATF ATF

∗1 ∗3 ISO VG32
Hydraulic tank 2,000
165 liter Hydraulic oil ISO VG46

Differential & Front: 74 liter Engine oil SAE40 or SAE50

Engine oil (CD) 2,000
Planetary Rear: 80 liter
ASTM D975 No.1
Fuel tank 370 liter Diesel fuel ASTM D975 No.2 daily

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

Engine Use oil that meets engine oil classification API CH4, CI4 or CG4.
∗2. Change engine oil every 250 hours if CG4 is used.
Engine oil drain intervals need to be reduced by 50 % when fuel sulfur content
exceeds 0.5 %.

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.
∗3. In a case that fire-resistant fluid is used in the hydraulic circuit, replace hydrau-
lic pump every 6,000 hrs operation.

Differential & Use class API CD engine oil with 5 % "Antichatter" additive or friction modifier.
Planetary

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

Grease NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for a needle bearing.
 3.57
MAINTENANCE
Recommended Lubricants

Diesel Fuel Requirements for diesel fuel

Specifications
Grade No.1-D Grade No.2-D
Flash Point ºC. min. 38 52
Water and Sediment % vol. max 0.05 0.05
Distillation Temperature ºC 90 % vol. recovered max. 288 338
Kinematic Viscosity mm2 /s at 40ºC min. 1.3 1.9
max. 2.4 4.1
Ash % mass max. 0.01 0.01
Sulfur % mass max. 0.50 0.50
Cetane Number min. 40 40
Carbon residue on 10 % distillation residue % mass max. 0.15 0.35
3.58
MAINTENANCE
Coolant Specification

Coolant Specification
The machine is originally filled with Long Life Cool-
ant (non-Amin type ethylene glycol) which need not
be replaced for the first two years or 3000 hours.

Do not use Amin type Long Life Coolant in cooling

system. It may cause a corrosion against radiator
or heater core.

If standard antifreeze (not Long Life Coolant) is

used for the replacement, it should be replaced
every six months.

Recommended Mixture of Antifreeze

Expected Minimum
-35ºC -30ºC -25ºC -20ºC -15ºC
Ambient Temperature
Pure Water (liter) 18.8 20.8 22.8 24.8 26.8
Antifreeze (liter) 21.2 19.2 17.2 15.2 13.2
Mixture Ratio (%) 53 48 43 38 33

- Too much antifreeze in the coolant mixture may

cause engine overheating.

Keep 33 % antifreeze mixture (same as the mix-

ture for a minimum ambient temperature of -15
ºC) if the engine overheats in a high ambient
temperature.

- Do not use hard water or water with high levels

of calcium and magnesium ions as the coolant
water.

IMPORTANT
Do not mix different brands of antifreeze
because they each contain special additives.
Careless mixing often diminishes the effect of
these additives and causes packing damage or
water leakage.
 3.59
TROUBLESHOOTING

TROUBLESHOOTING
This troubleshooting section is not intended to
cover every condition, however many of the com-
mon possibilities are listed.
Following are example of problems and their solu-
tions.
Contact your local Kawasaki dealer for the items
marked with or your local authorized CUM-
kawasaki

MINS ENGINE dealer for the items marked with

to repair.
CUMMINS

ENGINE

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Low engine oil level Add oil 2.67
Wrong grade oil for weather conditions Change oil 3.34
Engine oil pres- Clogging oil filter element Change filter and oil 3.34
sure warning lamp Defective alarm switch
lights up, and Oil leakage from pipe or joint
buzzer sounds Clogging suction strainer kawasaki or CUMMINS

Excessive engine wear

Defective oil pump
Low engine coolant level Add coolant 2.69
Fan circuit pressure or flow too low kawasaki

Coolant temp. Clogging radiator fins Clean 3.11

warning lamp Scale or mineral build up inside radiator Flush or professionally clean 3.14
lights up Defective alarm switch (gauge is in green)
Low water pump flow kawasaki or CUMMINS

Thermostat stuck or missing

Engine does not Fuel filter element clogging Replace fuel filter 3.29
start when the Starter motor speed too low Booster Battery may be used 2.98
starter motor is Defective engine shut off solenoid
turning Fuel pump failure
(Also see ELEC- Incorrect fuel injection timing kawasaki or CUMMINS

TRICAL TROU- Compression pressure too low

BLESHOOTING) Defective injectors
Air in fuel lines Tighten fuel connections and fil- 3.29
ter
Unstable (rough)
Fuel filter element clogging Replace fuel filter 3.29
idling
Fuel pump failure
Incorrect fuel injection timing
kawasaki or CUMMINS

Air cleaner element clogging Clean or replace element 3.9

Fuel filter element clogging Replace fuel filter 3.29
Throttle pedal electrical signal incorrect kawasaki

Engine oil level too high Check dipstick and correct level 2.67
Insufficient power Incorrect valve clearance
Piston ring wear
Defective injectors kawasaki or CUMMINS

Fuel pump failure

Air cooler restricted
3.60
TROUBLESHOOTING

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Wrong type of oil Use correct type of oil 3.56
Engine oil level too low or too high Correct oil level 2.67
Defective injectors
Incorrect valve clearance
Unusual combus-
Main bearing / con-rod bearing wear
tion noise or
Crankshaft uneven wear
mechanical noise kawasaki or CUMMINS
Connecting rod bent
Timing gear wear
Water pump bearing wear
Failed turbo or muffler
Fuel being diluted with water Replace with specified fuel and 3.29
White exhaust
Wrong grade fuel replace fuel filter
smoke
Incorrect fuel injection timing
(After engine has
Compression pressure too low
reached operating kawasaki or CUMMINS
Turbo seal leakage
temp.)
Coolant ingestion
Air cleaner element clogging Clean or replace element 3.9
Turbo damage
Black exhaust
Incorrect fuel injection timing
smoke kawasaki or CUMMINS
Fuel injection pump failure
Defective injectors
 3.61
TROUBLESHOOTING

ELECTRICAL

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Broken or slipping alternator belt Adjust or replace belt 2.73
Defective battery Replace battery
Charge lamp lights
Alternator failure
up
Defective wiring kawasaki or CUMMINS

Defective wiring to ground (short)

Starter motor does Transmission not in NEUTRAL Shift to NEUTRAL 1.29
not turn when Insufficient battery charge Battery charge or booster 2.98
starter switch key Starter switch failure kawasaki

is turned to Defective wiring

"START" Starter motor failure
kawasaki or CUMMINS

Hydraulic control levers not in NEUTRAL Move levers to NEUTRAL 2.5

Insufficient battery charging Battery charge or booster 2.98
Engine oil viscosity too high (thick) Replace oil 3.34
Starter motor turns
Poor connection at batteries or ground Clean and tighten all terminals
engine slowly
Defective wiring kawasaki

Starter motor failure kawasaki

or CUMMINS

Steering valve failure kawasaki

STEERING

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Tires are under inflated Check/adjust tire pressure 3.23
Severe conditions (over loaded, deep Change operation
mud, etc.)
Oil pressure too low
Hard steering
Steering valve failure
Steering cylinder failure kawasaki

Defective Orbitrol®
Pump failure
Articulation stopper in locked position Move articulation stopper to 1.28
"STORED" position
Excessive load on steering Reduce load
Steering valve failure
Will not steer Orbitrol® failure
Pump failure kawasaki

Relief valve failure

Steering cylinder failure
Blocked screen filter Clean filter 3.54
Excessively cold oil / wrong grade oil Warm oil / Replace oil with 3.56
proper viscosity for temperature
Steering Drift
Steering control valve failure
kawasaki
Steering pilot valve failure
3.62
TROUBLESHOOTING

HYDRAULIC

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Excessively cold oil Warm oil 3.56
Wrong grade oil Replace with proper grade oil
Oil pressure too low
Boom raises too Damaged cylinder piston or piston pack-
slowly ing
kawasaki
Pump flow too low
Pilot pressure too low
Engine RPM too low
Excessively cold oil / Wrong oil type Warm oil / Replace oil with 3.56
proper viscosity for temperature
Boom natural drift Leakage from control valve plunger
excessively Damaged cylinder piston or piston pack-
kawasaki
ing
Leakage in pilot relief valve
Bucket / Attach- Over load relief pressure too low
ment floating or Control valve failure kawasaki

drifting Natural drift of cylinder / packing

BRAKE

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Worn brake lining Adjust or replace lining 3.42
Parking brake Insufficient oil pressure (will not release)
does not work Failure of switch or solenoid valve
kawasaki
properly Poor wiring or ground to switch or sole-
noid valve
Dirt, debris under base of brake pedal Remove or clean
Brake dragging Warped brake discs
kawasaki
Air in brake oil circuit
Air in brake oil circuit
Braking power too kawasaki
Brake piston seal leakage
low
Blocked screen filter Clean filter 3.53
Cracked or leaking brake line
Brake valve failure
Brake pressure
Parking brake cylinder leakage kawasaki
drops rapidly
Defective brake accumulator
Defective brake seals
 3.63
TROUBLESHOOTING

TORQUE CONVERTER & TRANSMISSION

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Excessively cold oil / Wrong oil type Warm oil / Replace oil with 3.56
proper viscosity for temperature
Parking brake is applied Release parking brake
Engine is running Transmission oil level too low Add oil / Repair leak 2.80
but machine does Transmission suction strainer clogging Clean strainer 3.39
not move Clutch oil pressure too low
Transmission clutch failure
kawasaki
MCU failure
Defective electrical circuit
Service or parking brake dragging Inspect and correct
Low oil level in transmission Refill oil / Repair leak 2.80
Suction strainer in transmission clogging Clean or replace strainer 3.39
Low power
Clutch oil pressure too low
Torque converter oil pressure too low kawasaki

Transmission clutch failure

Air breather clogged Clean and refill with oil 3.40
Oil leakage from
Seal damage (between engine and torque
transmission kawasaki
converter housing)
Oil level too low Add oil / Repair leak 2.80
Dozing, continuous pushing application Reduce load
Operating in too high a speed range Use lower gear 2.85
Torque converter Long downhill driving Change application
overheat Radiator clogged: coolant temp also high Clean radiator fins 3.11
Defective alarm switch (gauge is in green)
Torque converter / Transmission failure kawasaki

Oil pressure too low

AIR CONDITIONER

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Hot water continues to flow through Shut off valve in heater hose
heater core line at block
A/C not set for maximum cooling Adjust controls/vents 2.54
Low cooling when
Condenser fins plugged Clean 3.14
A/C "ON"
A/C filters plugged Clean or replace 3.31
A/C compressor belts slipping/broken Adjust/Replace 3.30
A/C refrigerant charge low kawasaki

Engine not warmed up Warm up engine

No hot water flow to heater core Open shut off valve on block
Low heater out put Air conditioner running Turn A/C off
Heater vents not adjusted properly Adjust controls/vents 2.54
Defective heater motor or switch kawasaki
3.64
TROUBLESHOOTING

AIR CONDITIONER FAILURE MODE

FAILURE MODE FAILURE SOLUTIONS

E11 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the inside air sensor) - Wire breakage in the inside air sensor (THI) - Replacement
E12 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
inside air sensor) - Short-circuit in the inside air sensor (THI) - Replacement
E13 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the outside air sensor) - Wire breakage in the outside air sensor (THAM) - Replacement
E14 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
outside air sensor) - Short-circuit in the outside air sensor (THAM) - Replacement
E15 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the water temperature - Wire breakage in the water temperature sensor - Replacement
sensor) (THW)
E16 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
water temperature sen- - Short-circuit in the water temperature sensor (THW) - Replacement
sor)
E18 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
insolation sensor) - Short-circuit in the insolation sensor (THI) - Replacement
E21 (Wire breakage in - Breakage in the wire harness - Checking the wiring
the ventilation sensor) - Wire breakage in the ventilation sensor (THF) - Replacement
E22 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
ventilation sensor) - Short-circuit in the ventilation sensor (THF) - Replacement
- Defective wire harness or loosen connector - Checking the wiring
E43 (Abnormality in the - Defective servo motor - Replacement
ventilation servo motor) - Stuck foreign material - Removing the
foreign material
- Defective wire harness or loosen connector - Checking the wiring
E44 (Abnormality in the
- Defective servo motor - Replacement
air mixture damper
- Stuck foreign material - Removing the
motor)
foreign material
- Defective wire harness or loosen connector - Checking the wiring
E45 (Abnormality in the
- Defective servo motor - Replacement
inside/outside air
- Stuck foreign material - Removing the
switching motor)
foreign material
 3.65
TROUBLESHOOTING

FAILURE MODE FAILURE SOLUTIONS

- High pressure switch actuation
- Outside air temperature is too high
- Insufficient cooling of condenser
- Defective fan motor - Motor replacement
- Clogging in condenser - Cleaning
- Refrigerant overfilling - Adjusting refriger-
ant quantity
- Aeration into refrigerant circuit - Circuit evacuation
E51 (Abnormality in the
& refilling
refrigerant pressure)
- Low pressure switch actuation
- Outside air temperature is too low
- Insufficient refrigerant quantity - Circuit evacuation
& refilling
- Gas leak - Repair leakage
spot
- Circuit evacuation
& refilling
3.66
TROUBLESHOOTING

MODM
Error log monitor failure code (Input side)

Code Failure Detection condition (In case of)

Shift lever F & R contact ON at the same time
CN121 Shift lever F & R switch malfunction
Failure continues for more than 3 seconds
Shift lever any of more than two 1•2•3•A contact ON at the same time
CN122 Shift lever 1•2•3•A switch malfunction (1)
Failure continues for more than 3 seconds
CN123 Shift lever 1•2•3•A switch malfunction (2) All 1•2•3•A signal OFF continues for more than 3 seconds
CN141 Shift-up switch malfunction Switch is ON for more than 10 seconds
CN142 Shift-down switch malfunction Switch is ON for more than 10 seconds
Shift-up switch & shift-down switch contact ON at the same time
CN143 Shift-up switch & shift-down switch malfunction
Failure continues for more than 3 seconds
CN145 Kick-down switch malfunction Switch is ON for more than 10 seconds
T/M oil pressure switch malfunction
CN151 Signal OFF continues for more than 10 seconds during engine running
(This applies to the model 115ZV-2 only)
T/M oil pressure sensor malfunction T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more
CN152
(This applies to the model 95ZV-2 only) than 10 seconds during engine running
CN213 Inching sensor malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
CN214 Inching sensor malfunction (2) Voltage is larger than 4.6 V for more than 3 seconds
CN161 Machine speed sensor malfunction (1) Input circuit is disconnected for more than 3 seconds
CN162 Machine speed sensor malfunction (2) Input value is over 70 km/h (44 mile/h) for more than 3 seconds
No E/G speed sensor input for more than 3 seconds when E/G speed
CN163 E/G speed sensor 1 (ECM output) malfunction (1)
sensor selection is OFF (Input circuit is disconnected)
Input value is more than 3,000 min-1 for more than 3 seconds when
CN164 E/G speed sensor 1 (ECM output) malfunction (2)
E/G speed sensor selection is OFF
E/G speed sensor 2 (Sensor output) malfunction No E/G speed sensor input for more than 3 seconds when E/G speed
CN165
(1) sensor selection is ON (Input circuit is disconnected)
E/G speed sensor 2 (Sensor output) malfunction Input value is more than 3,000 min-1 for more than 3 seconds when
CN167
(2) E/G speed sensor selection is ON
CN232 S/S potentiometer malfunction (1) Voltage is lower than 0.1 V for more than 3 seconds
CN234 S/S potentiometer malfunction (2) Voltage is larger than 4.9 V for more than 3 seconds
CN236 S/S shift switch (F & R contact) malfunction Failure continues for more than 3 seconds
CN146 Shift hold switch malfunction Switch is ON for more than 10 seconds
Secondary steering oil pressure sensor malfunc-
CN251 Voltage is lower than 0.2 V for more than 3 seconds
tion(1)
Secondary steering oil pressure sensor malfunc-
CN252 Voltage is larger than 4.6 V for more than 3 seconds
tion (2)
Oil pressure sensor detects secondary steering oil pressure below
CN254 Low secondary steering oil pressure 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine
running
CN262 Kickout potentiometer malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
CN263 Kickout potentiometer malfunction (2) Voltage is larger than 4.6 V for more than 3 seconds
Efficient loading system hydraulic oil pressure sen-
CN271 Voltage is lower than 0.2 V for more than 3 seconds
sor malfunction (1)
Efficient loading system hydraulic oil pressure sen-
CN272 Voltage is larger than 4.6 V for more than 3 seconds
sor malfunction (2)
CN312 Brake oil pressure sensor 1 malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
CN313 Brake oil pressure sensor 1 malfunction (2) Voltage is larger than 4.6 V for more than 3 seconds
CN315 Brake oil pressure sensor 2 malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
CN316 Brake oil pressure sensor 2 malfunction (2) Voltage is larger than 4.6 V for more than 3 seconds
CN321 E/G coolant temperature sensor malfunction (1) Input voltage is larger than 3.56 V for more than 3 seconds
CN323 E/G coolant temperature sensor malfunction (2) Input voltage is lower than 0.263 V for more than 3 seconds
CN341 T/M oil temperature sensor malfunction (1) Input voltage is larger than 3.56 V for more than 3 seconds
CN342 T/M oil temperature sensor malfunction (2) Input voltage is lower than 0.263 V for more than 3 seconds
 3.67
TROUBLESHOOTING

Code Failure Detection condition (In case of)

CN351 Hydraulic oil temperature sensor malfunction (1) Input voltage is larger than 3.56 V for more than 3 seconds
CN352 Hydraulic oil temperature sensor malfunction (2) Input voltage is lower than 0.263 V for more than 3 seconds
Input signal corresponds to "any other pattern" in fuel level indication
CN381 Fuel level sensor malfunction
table
CN391 Air temperature probe malfunction (1) Input voltage is larger than 4.35 V for more than 3 seconds
CN392 Air temperature probe malfunction (2) Input voltage is lower than 0.13 V for more than 3 seconds
Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6
CN412 Abnormal brake oil pressure (1)
kgf/cm2) (592 psi) for more than 1 second during engine running
Brake oil pressure sensor 2 detects pressure below 4,081 kPa for
CN413 Abnormal brake oil pressure (2)
(41.6 kgf/cm2) (592 psi) more than 1 second during engine running
Brake oil pressure difference switch is in abnormal condition for more
CN414 Abnormal brake oil pressure difference
than 1 second
Brake oil amount switch is in abnormal condition for more than 1 sec-
CN415 Abnormal brake oil amount
ond
Engine oil pressure switch is OFF for more than 2 seconds during
CN421 Abnormal engine oil pressure
engine running
CN431 Abnormal engine coolant temperature (1) Engine coolant temperature switch is ON for more than 2 seconds
Engine coolant temperature sensor is in 101 deg. C (214 deg. F) con-
CN432 Abnormal engine coolant temperature (2)
dition for more than 2 seconds
CN451 Abnormal T/M oil temperature (1) T/M oil temperature switch is ON for more than 2 seconds
T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for
CN452 Abnormal T/M oil temperature (2)
more than 2 seconds
Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condi-
CN461 Abnormal hydraulic oil temperature
tion for more than 2 seconds
30 minutes after starter switch is ON, T/M oil filter switch is ON for
CN471 Clogged T/M oil filter more than 2 seconds when T/M oil temperature sensor detects oil tem-
perature more than 60 deg. C (140 deg. F)
CN481 Clogged air cleaner element Air cleaner switch is ON for more than 2 seconds
Radiator cooling water level switch is OFF for more than 2 seconds
CN491 Abnormal cooling water level in radiator
when the engine is off.
Hydraulic oil level switch is in abnormal condition for more than 30 sec-
CN496 Abnormal hydraulic oil level
onds
CN497 Abnormal brake disc oil temperature Brake disc oil temperature switch is ON for more than 1 second
CN498 Abnormal disc wear Brake disc wear switch is ON for more than 1 second
CN912 Abnormal MCU voltage (1) Voltage is larger than 30±1 V
CN913 Abnormal MCU voltage (2) Voltage is lower than 22±0.5 V during engine running
3.68
TROUBLESHOOTING

Error log monitor failure code (Output side)

Code Failure Detection condition

CN512 F solenoid valve malfunction F solenoid valve is short-circuited or disconnected
CN514 R solenoid valve malfunction R solenoid valve is short-circuited or disconnected
CN516 1st solenoid valve malfunction 1st solenoid valve is short-circuited or disconnected
CN518 2nd solenoid valve malfunction 2nd solenoid valve is short-circuited or disconnected
CN521 3rd solenoid valve malfunction 3rd solenoid valve is short-circuited or disconnected
CN524 4th solenoid valve malfunction 4th solenoid valve is short-circuited or disconnected
CN526 D solenoid valve malfunction D solenoid valve is short-circuited or disconnected
CN528 H solenoid valve malfunction H solenoid valve is short-circuited or disconnected
CN531 LU solenoid valve malfunction LU solenoid valve is short-circuited or disconnected
CN534 Auto brake solenoid valve malfunction Auto brake solenoid valve is short-circuited or disconnected
Speed change control solenoid valve malfunction
CN536 Speed change control solenoid valve is short-circuited
(1)
Speed change control solenoid valve malfunction
CN537 Speed change control solenoid valve is disconnected
(2)
CN621 S/S solenoid valve R malfunction (1) S/S solenoid valve R is short-circuited
CN622 S/S solenoid valve R malfunction (2) S/S solenoid valve R is disconnected
CN623 S/S solenoid valve L malfunction (1) S/S solenoid valve L is short-circuited
CN624 S/S solenoid valve L malfunction (2) S/S solenoid valve L is disconnected
CN631 Pressure increase solenoid valve malfunction Pressure increase solenoid valve is short-circuited or disconnected
CN641 Ride control solenoid valve malfunction Ride control solenoid valve is short-circuited or disconnected
Efficient loading system selection solenoid valve Efficient loading system selection solenoid valve is short-circuited or
CN681
malfunction disconnected
CN712 Cooling fan solenoid valve malfunction (1) Cooling fan solenoid valve is short-circuited
CN713 Cooling fan solenoid valve malfunction (2) Cooling fan solenoid valve is disconnected
CN721 Hour meter drive malfunction Hour meter drive is short-circuited
 3.69
SPECIFICATIONS

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

Bucket Data

Hight Lift Spec. Bucket Hight Lift Spec. Bucket Hight Lift Spec. Bucket
Kind of bucket
No Cutting Edge With Teeth With Cutting Edge
Bucket capacity (m3) 3.4 3.4 3.6
Dumping clearance
3,715 3,500 3,620
(mm)
Dumping reach (mm) 1,075 1,210 1,125

General Purpose General Purpose General Purpose Loose Material Bucket

Kind of bucket Bucket No Cutting Bucket With Teeth Bucket With Cutting With Cutting Edge
Edge Edge
Bucket capacity (m3) 3.8 3.8 4.0 4.5
Dumping clearance
3,225 3,005 3,130 3,045
(mm)
Dumping reach (mm) 1,130 1,260 1,180 1,260

Rock Bucket No Teeth Rock Bucket With V-edged Rock Bucket V-edged Rock Bucket
Kind of bucket
Teeth No Teeth With Teeth
Bucket capacity (m3) 3.4 3.4 3.5 3.6
Dumping clearance
3,225 3,005 3,080 2,895
(mm)
Dumping reach (mm) 1,130 1,260 1,270 1,370

Minimum turning radius

at outside bucket
6,840 mm
at center of outside tire
5,800 mm
Full articulation angle 40º

40º
Tread
2,230 mm 1,180
4,360
Width (outside tire)
3,535
2,930 mm 3,130

Width (outside bucket)

50º
3,100 mm

515
Equipped with GSC bucket with bolt
on cutting edge
3,400

26.5 (L-3) Tire and ROPS Cab 8,600

WL OPERATING SPEC EU
3.70
SPECIFICATIONS

Bucket Selection Chart

3.4
High Lift
Boom

3.6

3.8
Bucket Capacity (m3)

4.0
Standard Boom

3.4

3.6

3.5

4.3

4.5
1200

1450

1700

1950

2200
115% 95%
Material Density (kg/m3)

Operating Weight 22,925 kg

Engine Model CUMMINS QSM11 Diesel

Type 4 cycle, Water Cooled, Direct injection, Turbo charged & air cooled
intercooler
Displacement 10.83 Liter
Rated Power 216 kW / 2,100 min-1
(Gross)

Tire (standard) 26.5 R25

Max. Running Speed 1st : 6.9 / 7.6 km/h

(forward/reverse) 2nd:12.0 / 13.1 km/h
3rd :21.4 / 23.3 km/h
4th :33.5 / 35.1 km/h

Hand-arm vibration Less than 2.5 m/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 0.5 m/s2

The weighted root mean square acceleration value to which the body is subjected.
Measurements are obtained in accordance with ISO 2631.

The weight and load figure include, enclosed ROPS cab, GSC bucket with bolt-on cutting edge, 26.5 R25
tires, full fuel tank and operator.
INDEX
(FE) Fuel Efficient Mode Switch ................................2.13 Check Differential Gear Oil .......................................3.26
Check Drive Belt .......................................................2.73
Check Engine Coolant Level .....................................2.69
A
Check Engine Oil Level .............................................2.67
Accelerator Pedal ........................................................2.7
Check Exhaust Gas ..................................................2.82
Adjust and Check Rear View Mirrors ........................2.74
Check Fuel Level ......................................................2.80
Adjust Belt Tension ...................................................3.28
Check Horn Operation ..............................................2.74
Adjust Parking Brake Lining ......................................3.42
Check Hydraulic Oil Level .........................................2.68
Adjustments ..............................................................2.96
Check Monitor Panel Operation ................................2.75
After Storage ...........................................................2.105
Check Mounting Bolts ...............................................3.52
Air Cleaner Warning Lamp (red) ...............................2.28
Check or Replace Fuses ...........................................3.12
Air Conditioner ..........................................................2.54
Check Parking Brake ................................................2.74
Action to be taken when the air conditioner is not
Check Parking Brake Operation ...............................2.81
used ......................................................................2.60
Check Planetary Gear Oil .........................................3.27
For Efficient Use of the Air Conditioner .................2.59
Check Ride Control Accumulator (option) .................3.55
Operating Method (Normal Use) ............................2.56
Check Service Brake Disk Wear ...............................3.51
Operation Method (Other Uses) ............................2.57
Check Service Brake Operation ................................2.81
Other Functions .....................................................2.58
Check Steering Wheel Operation .............................2.82
Switches ................................................................2.54
Check Tightness of Wheel Bolts ...............................3.28
Ventilation Name and Location ..............................2.54
Check Tire Air Pressure ............................................3.23
Articulation Stopper ..........................................1.28, 2.71
Check Tire for Damage, Air and Tread Depth ..........2.71
Attachment Installation to Quick Coupler ..................2.63
Check Transmission Oil Level ..................................2.80
Auto Shift Indicator Lamp ..........................................2.29
Check Transmission Shift Lever ...............................2.75
Auxiliary Attachment Control Lever (option) ................2.6
Check Turbocharger .................................................3.52
Check Vibration Damper ...........................................3.50
B Check Warning Lamps ..............................................2.79
Battery removal / reinstallation procedure ...............2.104 Check Water Pump ...................................................3.51
Before Starting Safety .................................................1.4 Check Windshield Washer Fluid ...............................3.13
Before Storage ........................................................2.103 Check Wiring Harnesses ..........................................2.70
Boom Control Lever ....................................................2.4 Cigarette Lighter .......................................................2.15
Booster Batteries / Jumper Cables ...........................2.98 Clean Air Conditioner Condenser .............................3.14
Brake Pedals ...............................................................2.8 Clean Air Conditioner Filter Element .........................3.31
Brake Pressure Warning Lamp (red) ........................2.27 Clean Filter for Brake Line ........................................3.53
Bucket / Attachment Positioner Adjustment ..............2.96 Clean Filter for Orbitrol® ............................................3.54
Bucket Control Lever ...................................................2.5 Clean Fuel Tank ........................................................3.50
Clean or Replace Air Cleaner Element .......................3.9
Clean or Replace Transmission Breather .................3.40
C Clean Radiator / Air cooler / Hydraulic oil cooler Fins
Carrying .....................................................................2.93 ...............................................................................3.11
Cautions on Battery Replacement or Cold Start ..................................................................2.77
Battery Cable Removal ........................................2.106 COMPONENT NAME/LOCATION ..............................2.2
Cautions Regarding Welding Repair Service ..........2.107 Coolant Specification ................................................3.58
Central Warning Lamp (red) ......................................2.26
Charge Lamp (red) ....................................................2.28
Check after Starting the Engine ................................2.79 D
Check Air Conditioner Refrigerant ............................3.43 Declutch Lamp (green) .............................................2.26
Check Air Intake System ...........................................2.73 Declutch ON/OFF and Adjustable Preset Switch ......2.17
Check and Adjust Air Conditioner Belt ......................3.30 Downshift Button .......................................................2.15
Check and Adjust Injection Timing ............................3.52 Dozing .......................................................................2.91
Check and Adjust Valve Lash Clearance ..................3.52 Drain Water and Sediment from Fuel Filter ..............2.70
Check and/or Replace Seat Belt .................................3.9 Drain Water and Sediment from Fuel Tank ..............3.22
Check Back-up Alarm Operation ...............................2.82 Dumping into Truck or Hopper ..................................2.93
Check Battery Electrolyte Level ................................3.22 During Storage ........................................................2.105
Check before Operation ............................................2.66
Check Brake Accumulator .........................................3.51 E
Check Control Levers ................................................2.75
Efficient Loading System Switch ...............................2.19
Check Cooling Fan ....................................................2.74
Electrical Protection ..................................................2.44
Check Crankcase Breather Tube ..............................2.73
Emergency Brake ..................................................... 1.29 Loading ..................................................................... 2.89
Engine Coolant Temperature Gauge ....................... 2.25 Loading Control Lever Lock ..................................... 1.28
Engine Coolant Temperature Warning Lamp (red) Long Term Storage ................................................ 2.103
.............................................................................. 2.27
Engine Oil Pressure Warning Lamp (red) ................. 2.27
M
Error Log Monitor ..................................................... 2.39
MAINTENANCE ......................................................... 3.2
Every 10 Hours or Daily ............................................ 3.18
MCU (Machine Control Unit) Warning Lamp (red)
Every 1000 Hours or 6 Months ................................. 3.39
.............................................................................. 2.26
Every 2000 Hours or 1 Year ..................................... 3.45
MODM ............................................................. 2.16, 2.32
Every 250 Hours or 1 Month .................................... 3.25
MODM function ........................................................ 2.32
Every 50 Hours or 1 Week ....................................... 3.19
Monitor Changeover ................................................. 2.32
Every 500 Hours or 3 Months ................................... 3.34
Mounting and Dismounting Safety ............................. 1.3
Excavating ................................................................ 2.91
Explosion / Fire / Burn Prevention ............................ 1.15
N
F Neutral Indicator Lamp ............................................. 2.29
Neutral Start System ................................................ 1.29
F/R Switch (option) ................................................... 2.21
Normal Start ............................................................. 2.76
F/R Switch Indicator Lamp (green)(option) ............... 2.31
Four-Way Flasher Switch ......................................... 2.16
Front Wiper Switch ................................................... 2.14 O
Front Working Light Switch ....................................... 2.12 Operating Techniques .............................................. 2.89
Fuel Gauge ............................................................... 2.25 Operating the Machine ............................................. 2.84
Fuse Boxes .............................................................. 2.44 OPERATION ............................................................ 2.66
Fusible Link .............................................................. 2.45 Operation and Function ............................................ 2.61
Operational Safety ...................................................... 1.7
G Operator Safety .......................................................... 1.2
OPERATOR'S AREA ................................................. 2.3
General Inspection ................................................... 2.83
Other Maintenance Safety Concerns ....................... 1.16
Grease Gun Holder .................................................. 2.62
Greasing ........................................ 3.16, 3.19, 3.25, 3.45
Ground Levelling ...................................................... 2.92 P
Parameter Setting Monitor ....................................... 2.41
H Parking ..................................................................... 2.87
Parking Brake Indicator Lamp (red) ......................... 2.26
Hibernate Mode ........................................................ 2.78
Parking Brake Switch ............................................... 2.11
High beam Indicator Lamp (blue) ............................. 2.29
Parking Safety .......................................................... 1.11
High-Low Beam Lever / Turn Signal Lever (option)
Pedals and Levers ...................................................... 2.3
................................................................................ 2.4
Preheat Indicator Lamp (orange) ............................. 2.26
Horn Button ................................................................ 2.3
Hour Meter ............................................................... 2.29
Hydraulic Oil Level Warning Lamp Q
(simultaneous flashing)(red)(11. 24.) .................... 2.31 Quick Coupler (option) ............................................. 2.63
Hydraulic Pressure Hose & Electrical Wiring
Connecting to Attachment ..................................... 2.65
R
Radio - AM / FM Cassette (24Volt Type) (option) .... 2.46
I Rear Wiper Switch .................................................... 2.14
Idling Management System ...................................... 2.78 Rear Working Light Switch ....................................... 2.13
Indicators .................................................................. 2.24 Recommended Lubricants ....................................... 3.56
Information Monitor .................................................. 2.33 Recommended Mixture of Antifreeze ....................... 3.58
Input/Output Monitor ................................................. 2.40 Replace Air Conditioner Filter Elements .................. 3.52
Inspect the Front Parking Brake Pads and Rotor Replace Air Conditioner Receiver Dryer .................. 3.16
.............................................................................. 3.43 Replace Bucket Teeth (option) ................................... 3.7
Inspection and Maintenance Table ............................ 3.4 Replace Coolant ....................................................... 3.14
Replace Cutting Edge (option) ................................... 3.8
K Replace DCA4 Coolant Filter Cartridge ................... 3.37
Replace Differential Gear Oil .................................... 3.47
Kickout Control Switch ............................................. 2.18
Replace Filter ........................................................... 3.33
Replace Filter in the Hydraulic Tank Cap ................. 3.55
L Replace Fuel Filter Cartridge ................................... 3.29
Light Switch .............................................................. 2.12 Replace Hydraulic Oil Return Filter .......................... 3.41
Replace Hydraulic Oil, Clean Filter ...........................3.46 When Required Inspection and Maintenance .............3.7
Replace Planetary Gear Oil ......................................3.48 Working Light Indicator Lamp (green) .......................2.26
Replace Transmission Oil .........................................3.39 Wrist Rest ...................................................................2.6
Replace Transmission Oil Filter Cartridge ................3.36
Replacement Monitor ................................................2.37
Reversal Fan Pilot Lamp (green)(option) ..................2.31
Reversal Fan Switch (option) ....................................2.22
Ride Control (option) .................................................2.61
Ride Control Switch (option) .....................................2.23
Roading / Special Applications ..................................2.97
ROPS (Roll Over Protective Structure) Cab
......................................................................1.30, 2.74

S
Safe Operation ............................................................1.2
SAFETY ......................................................................1.2
Safety Devices ..........................................................1.28
Safety Preparations Before Maintenance .................1.12
Safety Signs ..............................................................1.18
Seat ...........................................................................2.42
Seat Adjustment ........................................................2.42
Seat Belt ....................................................................2.43
Secondary Steering (option) .....................................1.30
Secondary Steering Warning Lamp (red) (option)
...............................................................................2.30
Selection Switch for Shift Lever or F/R Switch
(option) ...................................................................2.20
Serial Number Location ...............................................3.2
Shift Hold Switch (option) ..........................................2.23
SPECIAL PROCEDURES .........................................2.96
Specification Setting Monitor .....................................2.41
SPECIFICATIONS ....................................................3.69
Speed and Direction Change ....................................2.85
Speedometer .............................................................2.25
Starter Switch ............................................................2.11
Starting the Engine ....................................................2.76
Starting the Machine .................................................2.84
Starting the Machine on a Grade ..............................2.85
Steering Column Telescopic Tilt Handle .....................2.9
Stopping the Engine ..................................................2.88
Switches ....................................................................2.10

T
Torque Converter Oil Temperature Gauge ...............2.25
Torque Converter Oil Temperature Warning Lamp
(red) .......................................................................2.28
Towing .....................................................................2.100
Transmission Shift Lever .............................................2.3
Transmission Status Monitor .....................................2.29
Transportation .........................................................2.101
TROUBLESHOOTING ..............................................3.59
Turn Signal Indicator Lamp (Left) (green) .................2.28
Turn Signal Indicator Lamp (Right) (green) ...............2.28
Typical Truck Loading Methods ................................2.95

W
Walk-Around Inspection ............................................2.66
Warm-up control ........................................................2.78
Welding ...................................................................2.107
Maintenance Log

Date Machine hours Service performed

Date Machine hours Service performed
Date Machine hours Service performed
Date Machine hours Service performed
Notes