95ZV Cargador Frontal Kawazaki

93115-00264
95ZV
October 25, 2005
OPERATION &
MAINTENANCE MANUAL
WHEEL LOADER
95ZV
93115-00264
NOTICE
READ AND UNDERSTAND THIS
MANUAL BEFORE OPERATING
Powered by CUMMINS QSX15 Engine
©2005 Kawasaki Heavy Industries, Ltd. All rights reserved. Printed in Japan (i) AND SAVE THIS MANUAL ON
( アメリカ用 ) Serial No. 97C4-5141 and up THE MACHINE
WARNING
CALIFORNIA PROPOSITION 65
BATTERY WARNING
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm.
WASH HANDS AFTER HANDLING !
CALIFORNIA
Proposition 65 warning
Diesel engine exhaust and some of its constituents are known to the
State of California to cause cancer, birth defects, and other reproductive harm.
93115-00264
October 25, 2005
FOREWORD
Congratulations on your purchase of the Kawasaki Wheel Loader 95ZV.
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.
For additional details, for safe and efficient operation and maintenance of your Cummins
engine, please refer to your Cummins operation & maintenance manual.
There may be an optional supplemental operation & maintenance manual, and this also
should be referred to when operating machines that are equipped with special packages.
This manual is compiled for persons who understand English. If an operator or mainte-
nance person does not understand English, please translate what said in this manual into
his mother language.
SAFETY NOTICE
Whenever you see the symbols shown below in this manual or on the machine, read and understand their
messages.
DANGER
This danger symbol identifies special warnings or
procedures which, if not strictly observed, will result
in death or serious injury.
WARNING
This warning symbol identifies special warnings or
procedures which, if not strictly observed, could result
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...............................................................................................................................1.11
Safety Signs....................................................................................................................................... 1.16
Safety Devices................................................................................................................................... 1.21
2.OPERATION ............................................................................................................................................... 2.1
COMPONENT NAME/LOCATION ............................................................................................................. 2.2
OPERATOR'S AREA ................................................................................................................................. 2.3
Pedals and Levers ............................................................................................................................... 2.3
Switches ............................................................................................................................................ 2.10
Indicators ........................................................................................................................................... 2.21
Seat ................................................................................................................................................... 2.29
Electrical Protection ........................................................................................................................... 2.31
Radio - AM / FM Cassette (24Volt Type) ........................................................................................... 2.33
Heater or Air Conditioner ................................................................................................................... 2.41
Ride Control System (option)............................................................................................................. 2.45
OPERATION ............................................................................................................................................ 2.46
Check before Operation..................................................................................................................... 2.46
Starting the Engine ............................................................................................................................ 2.57
Check after Starting the Engine ......................................................................................................... 2.59
Operating the Machine ...................................................................................................................... 2.64
Parking............................................................................................................................................... 2.68
Stopping the Engine........................................................................................................................... 2.69
Operating Techniques........................................................................................................................ 2.70
SPECIAL PROCEDURES ....................................................................................................................... 2.77
Adjustments ....................................................................................................................................... 2.77
Roading / Special Applications .......................................................................................................... 2.79
Booster Batteries / Jumper Cables .................................................................................................... 2.80
Towing................................................................................................................................................ 2.82
Transportation.................................................................................................................................... 2.83
Long Term Storage ............................................................................................................................ 2.85
3.MAINTENANCE .......................................................................................................................................... 3.1
MAINTENANCE ......................................................................................................................................... 3.2
Serial Number Location ....................................................................................................................... 3.2
Inspection and Maintenance Table ...................................................................................................... 3.5
When Required Inspection and Maintenance ...................................................................................... 3.8
Every 10 Hours or Daily ..................................................................................................................... 3.18
Every 50 Hours or 1 Week................................................................................................................. 3.19
Every 250 Hours or 1 Month .............................................................................................................. 3.25
Every 500 Hours or 3 Months ............................................................................................................ 3.32
Every 1000 Hours or 6 Months .......................................................................................................... 3.34
Every 1500 Hours or 1 Year............................................................................................................... 3.42
Every 2000 Hours or 1 Year............................................................................................................... 3.44
Recommended Lubricants ................................................................................................................. 3.56
Coolant Specification ......................................................................................................................... 3.57
TROUBLESHOOTING............................................................................................................................. 3.58
SPECIFICATIONS ................................................................................................................................... 3.63
1.1
1.SAFETY
1.2
SAFETY
Safe Operation
SAFETY
Safe Operation
Operator Safety
OM0026
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
- Do not wear jewelry that may catch on the

equipment, controls or may short and cause
burns if in contact with electrical components.
OM0180
Be aware of the location and meaning of safety

signs (decals) on the machine. Report or replace
any that are missing or unreadable.
Be alert and ready to operate the machine safely:
- Do not operate if excessively tired.
- Do not operate if taking medication that causes

drowsiness.
- Do not operate if under the influence of alcohol

or drugs.
1.3
SAFETY
Safe Operation
Mounting and Dismounting Safety
OM0012
OM0010
Do not allow unauthorized personnel on the
machine. Only the operator alone should be on the
Face the machine when mounting or dismounting. machine.
Maintain three points of contact when climbing (two

hands and one foot, or two feet and one hand).
When mounting or dismounting, never carry tools

or other objects in your hands.
Climb and step only where steps and handrails are

provided.
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
OM0005
OM0006
Perform the normal daily maintenance.
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.
Lock
Inspect the machine for safety hazards and, if
found, have them corrected: Unlock
70ZV0010a
- Broken lights, mirrors, windows, etc.

- Fuel leaks, oil leaks, or debris build-up Be sure the following safety devices work or are
- Improper tire inflation or tire damage positioned properly.
- Missing or unreadable safety signs (decals)
- Parking Brake -- Applied (See page 2.11)
Be sure the Roll Over Protective Structure (ROPS) - Control Lever Lock -- Locked (See page 2.8)
is:
- in place.
- properly attached (no bolts loose or missing).
- not damaged.
- not modified.
N
65ZV 5089
- Transmission Shift Lever -- Neutral

1.5
SAFETY
Safe Operation
In case of fire during operation:
- Turn off the starter switch and stop the engine.

- Extinguish fire with a fire extinguisher (Depend
N
R
on the situation).
F
- With hand rails and steps, get off the machine
and stay away from it.
Depending on the situation, the way of evacuation

will be changed. If necessary, periodic fire drill is
needed at the work area.
95ZV0013
OM0007
Articulation Stopper 97ZVOM0004

"STORED" Adjust the seat, seat belt and steering column, mir-
rors, etc.
- Articulation Stopper -- Locked in the "STORED"
Properly fasten the seat belt.
position.
- Back-up Alarm -- Operational
Securely lock the cab door either fully open or

closed.
DANGER
Secure any loose items inside the cab (lunch
boxes, tools, vacuum bottles, etc.). DO NOT
START
MEN
After using the ashtray, close the ashtray cap to WORKING
avoid fire. ON
MACHINERY
Do not leave a lighter in the cab. The lighter may SIGNED BY

DATE
cause explosion by high temperature in the cab. OM0182
Do not bring inflammable or explosive materials

such as: Do not start or operate the machine if a "DO NOT
START" or a "DO NOT OPERATE" tag is on the key
- spray can switch, steering wheel or controls.
- chemical cylinder
Do not operate the engine where there are or can
Do not attach a suction cup on the window to avoid be combustible vapors. These vapors can be
a fire hazard due to intense light magnification. drawn through the air intake system and cause
engine overspeeding, which can result in a fire, and
explosion.
1.6
SAFETY
Safe Operation
Operational Safety
SITE SAFETY:
Consider the safety of the job site before operating

the machine:
- Be aware of and avoid cliffs, ditches, trenches,

overhead or underground wires, underground
pipes, other equipment, and workers in the area.
- If required, be aware of hand signals that may
be used by ground guides.
OM0011
Do not start to work in an enclosed area if adequate

ventilation is not provided. Fumes could build up
during operation that could cause drowsiness,
injury, or death.
Blow the horn for a few seconds just before starting

the engine to alert bystanders.
OM0021
Avoid working under or near overhanging material

that could fall on the machine.
Keep bystanders out of the work area.
Keep the work site as clean and flat as possible.
OM0183 Do not operate the machine at work area close to

fire or dry grass is.
Start the machine only from in the operator's seat. Operate the machine slowly over rough ground and
on a grade.
- Do not reach through the window to start.
- Do not stand on the ground and start. Do not operate on any grade that may be unstable
- Never attempt to start by shorting across the (loose material, soft material, snow, or ice).
starter motor terminals since this can bypass the
neutral start safety device. The range of temperature the machine is to be
operated is between -35ºC ~ 45ºC (-31ºF ~ 113ºF).
If jumper cables are required to start the engine,
follow the correct procedure in "Booster Batteries /
Jumper Cables" page 2.80.
1.7
SAFETY
Safe Operation
When working on a grade: SAFETY DURING NORMAL OPERATIONS:
- Turn "OFF" the transmission cut-off selector Vision to the rear on any machine is limited. Always
switch. use special caution when backing up.
- Keep the attachment low.
- Keep the attachment facing up the grade as Know the machine limits and do not exceed them.
often as possible.
- Drive directly up or down the grade -- never
across the grade.
- Stop when changing direction on a grade to
maintain stability.
- Never coast down a grade.
- Select the same low gear to go down the grade
as was selected to climb the grade. This pro-
vides some engine braking.
OM0013
Using the machine for purposes other than speci-

fied in the Operation & Maintenance Manual may
create hazards that are not mentioned in this man-
ual.
Do not use the machine as a crane where the

OM0018 safety of the operator or other workers are involved.
Properly counterweight and ballast the machine

Before crossing a bridge, make sure that the depending upon the bucket size and material or
capacity of the bridge is greater than the weight of attachment application. Do not exceed the recom-
the machine and any load it may be carrying. mendations and limits.
Check for enough clearance before entering a Maintain stability by carrying the load as low as
building, doorway, tunnel, under wires or other possible throughout each cycle.
structures.
Do not expose the machine to flames.
approx. 40cm (16in.)

OM0016
- The normal carry position is about 40cm (16in.)

above the ground.
1.8
SAFETY
Safe Operation
When roading the machine:
- Travel in forward only.

- Travel only as fast as conditions and safety
allow.
- Know and follow all local laws that may require
rotating beacon, slow moving vehicle (SMV)
signs, width signs or flags, lead or chase vehi-
cles, four-way flashers, or clearance lights, etc.
- If roading long distances (over 3km (2miles)),
periodically stop to allow tires, transmission,
engine to cool down. Excessive tire heat caused
OM0020
by roading can cause blow-outs and loss of con-
trol.
Never use the "Float" position to lower the boom
Stop the machine motion immediately if any failure
since it will fall rapidly.
occurs that causes reduced control (e.g.; engine,
pump, or brake system failures).
Drive into a load at a medium speed. Do not run
into the material at high speed.
Lower the bucket or attachment to stop the
machine only when an emergency, like loss of brak-
Always be alert for abnormal noises, odors, vibra-
ing occurs.
tions, heat, etc.
Be sure there are no bystanders under the raised
bucket or attachment.
OM0184
Never position or move the load over the cab of a

truck or other vehicle.
1.9
SAFETY
Safe Operation
SPECIAL OPERATING CONDITIONS:
Drawbar
80ZV0001
OM0185
- Be sure the drawbar is fully in its bore before
applying tension.
Avoid entering water deeper than the bottom of the - If brakes and steering are working on the towed
wheel rim. vehicle, keep an operator in the operator's seat
and have him control the vehicle.
If entering water is unavoidable: - If brakes are not working on the towed vehicle,
attach another vehicle of adequate size to the
- Use caution that there are no hidden hazards -- rear to act as a braking vehicle.
(drop-offs, holes, rocks, logs, etc.). - Use the machine as a tow vehicle only for short
- Check for normal braking after leaving the distance.
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
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.
1.11
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.
OM0025
OM0026
Before performing any maintenance:
Wear safe clothing to perform maintenance: - Park on level ground.

- Block the tires securely.
- Close fitting clothing -- loose or baggy clothing - Apply the parking brake.
can catch on equipment or controls. - Lower the boom and attachment to the ground.
- Protective clothing as required by the job or con- - Stop the engine (unless specified in the Opera-
ditions -- for example: tion & Maintenance Manual or Shop Manual).
- Hard hat Use a piece of cardboard or wood to find fluid leaks

- Gloves under pressure but do not use your bare hand. Die-
- Steel-toe shoes sel fuel or hydraulic fluid under pressure can pene-
- Eye / face protection trate skin or eyes and cause serious injury,
- Approved respirator blindness or death.
1.12
SAFETY
Safe Maintenance
OM0029 OM0031
Never make repairs on pressurized components. If working under the raised boom or attachment, be
Release all trapped air and hydraulic pressure by: sure to properly block or support boom.
- Stopping the engine after lowering the attach- Do not stand on tires. Use safe and sturdy working
ment to the ground. platforms.
- Moving the loading control levers back and
forth.
- Turning the steering wheel right and left several
times.
- Turning the hydraulic oil tank cap 1/3 turn coun-
terclockwise.
DANGER
DO NOT
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE
OM0182
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.
1.13
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.
Remove flammable materials from hot engine com-

ponent areas (i.e.; muffler, manifold, etc.).
1.14
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 side

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.
1.15
SAFETY
Safe Maintenance
Do not enter the articulation area when engine is

running.
Articulation Stopper 97ZVOM0003

"LOCKED"
When transporting the machine on a truck or lifting

the machine, lock the articulation stopper in the
"LOCKED" position.
Used oil may cause skin disease if allowed to

remain on the skin for extended periods. Wash skin
completely to remove used oils.
Drain and discard of used oil and coolant properly

to prevent environmental pollution.
When oil or fuel leaks from the high pressure 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 loose.
- Exchange the hose base when it is damaged or
deformed.
- Exchange the hose cover when it is damaged,
cut or expanded.
1.16
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.
1.17
SAFETY
Safety Signs
DANGER WARNING WARNING WARNING
Nitrogen accumulator contains

compressed gas and fluid
which could result in death or
No room in this area when turning. Pressurized system: spray of hot serious injury.
Crushing will result in death or fluid could result in death or serious Release all brake circuit oil Contact with moving fan could result
serious injury. injury. pressure before removing any in death or serious injury.
Stay out of this area when machine Allow system to cool and vent oil lines or piping. Keep hands away from fan area.
could move or turn. pressure slowly before Do not attempt to service or repair Stop engine before opening door or
servicing. accumulator unless properly trained rear grille.
and equipped. 44841-21100
44841-20600 44841-20950 44841-20750
R.H L.H, R.H Inside
L.H, R.H L.H, R.H L.H, R.H
95ZV0002a
DANGER WARNING Inside

L.H, R.H
CAUTION DANGER
Removal, damage or alteration
of Roll Over Protctive Structure
(ROPS) will result in death or
Sudden or accidental movement of Serious injury.
boom will result in death or serious Always keep ROPS in place.
injury. Do not operate this machine if
Before walking or working under Machine will not turn with articulation
raised boom. stopper in locked position. Pressurized system: spray of hot ROPS has been removed,
Securely block orbrace boom. Unlock articulation stopper before fluid could result in death or serious damaged, or altered.
Remove key and tag "Do Not operating machine. injury. 44841-20870
Operate". 44841-20640 Allow system to cool and vent
Relieve all trapped oil pressure pressure slowly before
before opening any piping. servicing.
44841-20880 44841-20720
1.18
SAFETY
Safety Signs
WARNING CAUTION
WARNING
Accidental movement of machine could
result in death or serious injury.
Before checking transmission oil:
Park on level ground.
Lower bucket to ground.
Place transmission in neutral. Batteries contain lead, and acid
Set parking brake. which may result in minor or
Tag "Do Not Operate". Batteries produce explosive gases moderate injury.
44841-20630 which could result in death or serious Avoid contact with skin or clothing.
injury. If lead, or acid contacts skin or
Keep flames and sparks away. clothing, immediately wash with
Vent area before servicing. water.
44841-20690
44841-20680
Inside Inside
95ZV0003
Inside Inside
WARNING WARNING
Pressurized system: spray of hot

Contact with moving belts or pullies
fluid could result in death or serious
could result in death or serious
injury.
injury.
Allow system to cool and vent
Stop engine before warking in this
pressure slowly before
area.
servicing.
44841-20700
44841-20720
1.19
SAFETY
Safety Signs
WARNING
CAUTION
FLAMMABLE
PART NAME : ETHER CYLINDER
PART NO : 50401-03550
INGREDIENTS : ETHYL ETHER,
CARBONIC ACIDGAS
Machine movement, if engine starts
in gear, could result in death or CAUTIONS
serious injury. 1.DON’T APPLY TO THE HUMAN BODY
Do not start engine by 2.DON’T USE NEAR FIRE
shorting across starter 3.DON’T STORE IN HOT PLACE OVER 40
terminals.
Do noto start engine while 4.DON’T THROW EVEN EMPTY
standing on ground. CYLINDER INTO FIRE
Make sure to start engine only from
operator’s seat with transmission in 44770-49180
neutral and parkingu brake applied.
Inside
44841-20660
95ZV0004
WARNING
Contact with moving fan could result

Keep hands away from fan area.
Stop engine before opening door or
rear grille.
44841-21100
95ZV0005
1.20
SAFETY
Safety Signs
WARNING
95ZV0006a
Compressed spring may
accidently be released and could
Parking brake cylinder result in death or serious injury.
Read Shop Manual before
repairing this part.
44841-20740
Inside of Cab
A
70ZV02597-0689BS
A
A-A
70ZV02597-0717AS
WARNING
DANGER
Removal, damage or alteration
of Roll Over Protctive Structure
(ROPS) will result in death or
Serious injury.
Improper operation or maintenance
Always keep ROPS in place.
could result in death or serious injury.
Do not operate this machine if Read, understand, and follow
ROPS has been removed, Operation & Maintenance Manual
damaged, or altered. before operating or servicing
44841-20870 machine.
Follow all safety signs in Operation
& Maintenance Manual or on
machine.
44841-20610
1.21
SAFETY
Safety Devices
Safety Devices K-Lever Steering System On / Off

(option)
Loading Control Lever Lock
Raised position
DANGER
Accidental movement of boom or machine will Operating
result in death or serious injury. position
When parking or leaving machine, or when per-

forming maintenance on it, always lower attach-
ment to ground and lock loading control levers.
95ZV0007
- Lift the arm rest to the fully raised position

before getting off or on the machine.
- When the arm rest is fully raised the K-Lever

system is turned off automatically. Then the
green display lamp goes out.
Lock
- Next, even when the K-Lever arm rest is low-

Unlock
70ZV0010a ered back to the operating position, the K-Lever
system still remains off.
To operate the K-Lever system again, refer to
This device locks the loading control levers to pre-
"K-Lever Switch (option)" page 2.17.
vent accidental lowering of the attachment or boom.
- To lock, set the loading control levers to "NEU- WARNING

TRAL" and pull-up the lock lever to forward.
Accidental movement of the stick while getting
on or off the machine may cause unexpected
- To unlock, push down the lock lever to back-
movement of the machine resulting in an acci-
ward.
dent, injury, or death.
Always stop, and properly park the machine and

turn off the K-Lever system while getting on or off
the machine.
The K-Lever system will be turned off by fully

raising the arm rest or turning off the key switch.
CAUTION
If the arm rest is raised while the machine is
being operated it might drop down accidentally
striking the operator.
Always keep the arm rest in the lowered position

while operating even if the K-Lever system is not
being used.
1.22
SAFETY
Safety Devices
Articulation Stopper To unlock:
WARNING
With articulation stopper in LOCKED position,
machine will not steer; which, while operating,
could cause an accident, injury or death.
Do not lock Articulation Stopper during normal

operation.
Articulation stopper locks the front and rear chassis

to prevent them from sudden articulation during "STORED" position 97ZVOM0004
inspection or transportation.
To lock:
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.)
"LOCKED" position 97ZVOM0003
1. Align the front and rear chassis straight ahead.
2. Remove the spring pin and pin to remove the

articulation stopper from the storage bracket
under the hydraulic oil tank.
3. Turn the link and fix the end to the bracket on

the front chassis (as shown).
4. Insert the pin and clip pin. (This is the LOCKED

position.)
1.23
SAFETY
Safety Devices
Neutral Start System Emergency Steering (option)
The transmission has a neutral start system which

allows the engine to start only when the transmis-
WARNING
sion shift lever is in NEUTRAL position. Operation without normal steering could cause
loss of control and injury or death.
If emergency steering lamp lights up, steer

Emergency Brake machine IMMEDIATELY to safe location and
stop it.
When the service brake does not work, emergency
brake can be applied manually. Emergency steering works automatically when the
steering hydraulic pressure goes down or the
engine stops while the machine is operating.
When the steering hydraulic pressure goes down

while the engine is running, the steering hydraulic
warning lamp lights up.
Refer to "Emergency Steering Warning Lamp (red)

(option)" page 2.27.
If the emergency steering works:
97ZVOM0038 1. Keep the starter switch in the "ON" position

even when the engine unexpectedly stops.
- Pull the emergency brake switch to engage the
emergency brake and disengage the transmis- 2. Immediately operate the steering wheel to
sion. 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.
1.24
SAFETY
Safety Devices
ROPS (Roll Over Protective Structure)

Cab
WARNING
Operating with damaged or improperly mounted
ROPS Cab could serious injury or death. Be sure
to observe the following.
- Whenever seated, fasten the seat belt. (If
equipped)
- Do not modify ROPS Cab, such as drilling or
welding.
- Do not use ROPS Cab deformed.
- If any damage or loose bolts are found, do not
operate until repaired.
- Never repair or modify ROPS Cab without
manufacturer’s approval and instructions.
2.1
2.OPERATION
2.2
COMPONENT NAME/LOCATION
COMPONENT NAME/LOCATION
25
4 24 22 10
9
17
5 7
3 16
23 95ZV0008
19
21
11
12,13
14 18 6 8 20 15
1. Bucket (Attachment) 14. Front Axle / Differential Ass'y

2. Boom 15. Rear Axle / Differential Ass'y
3. "Z" Lever (2) 16. Air Cleaner (Right hand side)
4. Boom Cylinders (2) 17. Precleaner (2)
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), & Hydraulic Oil Cooler 22. Cooling Fan
10. Air Cooler (for engine intake air) 23. Fan Motor (hydraulic type)
11. Fuel Cooler 24. Exhaust Muffler
12. Fuel Tank (Right hand side) 25. ROPS Cab
13. Hydraulic Oil 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

2. Horn Button
3. Boom Control Lever
4. Bucket Control Lever
2 5. Auxiliary Attachment Control Lever (option)
6. Wrist Rest (adjustable)
1 7. Accelerator Pedal
8. Brake Pedals
9. Steering Column Telescopic Tilt Handle
10. Loading Control Lever Lock
11. K-Lever (option)
8 9 8 7 97ZVOM0041
5 (option) 6
2
[for K-Lever (option)]
10 70ZV0010a
11
6 R
N
F
95ZV0013
2.4
OPERATOR'S AREA
Pedals and Levers
1. Transmission Shift Lever 3. Boom Control Lever
Transmission Shift Lever is used to control machine Boom control lever is used to control the boom
speed and direction. movement.
- Push the lever forward to move the machine for-

ward.
(c) (d)
(b)
- When the lever is in NEUTRAL, the machine
should not move on level ground.
(a)
- Pull the lever backward to move the machine

backward.
- The four forward and three reverse speed shift-

ing modes are selected by rotating the shift
lever.
Lever lock released 70ZV0010a
(a) Float
- Move the lever to full forward detent position.
- The boom will lower and move freely following
the ground surface.
(b) Lower
- Move the lever forward. The boom will lower.
- When held in this position, down pressure will
be applied to the attachment.
(c) Hold
65ZV 5089
- Return the lever to the center position. The
boom will stop and remain in that position.
[1]: 1st speed (fixed)
(d) Raise
[2]: 2nd speed (fixed) - Move the lever rearward. The boom is raised.
- A boom kickout is provided which will automati-
[3]: 3rd speed (fixed) cally release the detent and return the lever to
the "Hold" position when a preset boom height
[A]: 2nd, 3rd and 4th speed is automatically is reached.
selected for the machine running condition. - For adjustment procedure refer to "Boom Kick-
out Adjustment" page 2.78.
In case that the boom does not stop moving even

2. Horn Button when the boom control lever is in the HOLD posi-
tion, turn the starter switch to the "OFF" position to
Horn Button is used to blow the horn. stop the engine.
- Press the button in the center of the steering IMPORTANT

wheel to blow the horn.
If the engine stops by some trouble, lower the
boom and place the bucket on the ground imme-
diately.
2.5
OPERATOR'S AREA
Pedals and Levers
4. Bucket Control Lever 5. Auxiliary Attachment Control Lever

(option)
Bucket control lever is used to control the bucket or
attachment movement. Auxiliary attachment control lever is used to control
the auxiliary attachment such as log clamps, multi-
purpose buckets, etc.
(d) (a) (b) (c)

(b) (c)
(a)
70ZV0010a
(a) Dump 70ZV0010a
- Move the lever forward. The bucket or attach-

ment will dump. (a) Normally this position will close the attach-
ment.
(b) Hold
- Return the lever to the center position. The (b) This center position will cause the attachment
bucket or attachment will stop and remain in that to stop and remain in that position.
position.
(c) Normally this position will open the attachment.
(c) Roll Back (Dual Motion)
- Move the lever rearward half way. The bucket or In case that the auxiliary attachment does not stop
attachment will roll back slowly. moving even when the auxiliary attachment control
- When the boom control lever is in the "Raise" lever is in the HOLD position, turn the starter switch
detent position, both bucket or attachment and to the "OFF" position to stop the engine.
boom will move slowly.
NOTE
(d) Roll Back (Detent) If equipped with attachments other than the stan-
- Move the lever rearward. The bucket or attach- dard bucket, consult the attachment supplier for
ment will roll back. specific instructions.
- An automatic bucket or attachment leveler is
provided which will automatically release the
detent and return the lever to the "Hold" position IMPORTANT
when the bucket or attachment reaches to the Kawasaki will not accept any liability for any
preset angle. attachments and spare parts not approved by
- For adjustment procedure refer to "Bucket / Kawasaki.
Attachment Positioner Adjustment" page 2.77.
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. Wrist Rest (adjustable) 7. Accelerator Pedal
Unlock
Lock
65ZV4705 97ZVOM0038
Wrist rest is used to put on the wrist or arm while Accelerator pedal is used to control the engine
operating the bucket/boom control levers. speed.
(High/Low) - Depress the pedal to increase the engine

Pull the lever out and turn, bringing back to the orig- speed.
inal position, to adjust the height.
- Release the pedal to decrease the engine
(Front/Rear) speed.
Loosen the screws to adjust the position.
WARNING
Control pedals which stick could cause loss of
control and injury or death.
- Be sure control pedals move freely before

operating.
- Do not allow dirt, mud, or debris to build up
under or around pedals.
In case that the accelerator pedal does not release,

depress one of the brake pedals or turn the starter
switch to the "OFF" position.
2.7
OPERATOR'S AREA
Pedals and Levers
8. Brake Pedals
CAUTION
WARNING Transmission cut-off feature momentarily places
transmission in neutral, which may allow
Continuous use of brake could cause rapid or
machine to roll when on a grade.
abnormal brake disc wear and / or brake circuit
malfunctions which could cause loss of control
Be sure to turn off transmission cut-off (Declutch)
and injury or death.
switch when operating 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
- Do not allow dirt and debris to build up around parking brake can be used as the emergency
the pedals. brake.
- Be sure the brake pedals move freely before
using the machine.
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 transmis-

sion cut-off (Declutch) switch (See page 2.14)
to the "OFF" position. Use this position when
working on slopes or ramps.
2. Disengage the transmission while applying the

brakes. This is normally used when loading
trucks. It allows higher engine speed to provide
faster hydraulic operations.
To use this feature, turn the transmission cut-

off (Declutch) switch to the "ON" position.
When the switch is "ON", a green indicator
lamp on the dash will also be turned on.
2.8
OPERATOR'S AREA
Pedals and Levers
9. Steering Column Telescopic Tilt 10. Loading Control Lever Lock

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
Lock
handle lock lever before operating machine.
Unlock 70ZV0010a
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- This device locks the loading control levers to pre-
tor's comfort. vent accidental lowering of the attachment or boom.
- To lock, set the loading control levers to "NEU-

TRAL" and pull-up the lock lever forward.
- To unlock, push down the lock lever backward.

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.
2.9
OPERATOR'S AREA
Pedals and Levers
11. K-Lever (option)
L R
95ZV0010
- When the K-Lever is moved from the neutral

(centered) position to the right, the machine
articulates (steers) to the right.
- When the K-Lever is returned to the neutral

position the machine stops articulating.
- When the K-Lever is moved to the left the

machine articulates to the left.
- The further the K-Lever is moved to the side the

faster the machine articulates (proportional
steering).
IMPORTANT
Excessive force will damage the K-Lever. Do not
jam, slap or force the K-Lever beyond its normal
range.
Avoid putting excessive force down on the arm

rest. Never sit on the arm rest.
This type of damage is not covered by warranty

policy.
2.10
OPERATOR'S AREA
Switches
Switches
12 4
0 0 0 0 0 0 1/10h
AUTO
7 10
20
N P
5
C H F
8 4
3
14
E
0 30 2
13 x100r/min
1 17
C H
STOP
95ZV0011
1 9
11
10
2 3, 6 18
70ZV0013a 70ZV0010a
16
R
15 N
F
19
(option) 95ZV K-LEVER56387 REVERSAL FAN SW
1. Starter Switch 10. Rear Wiper Switch

2. Parking Brake Switch 11. QUAD (Quick Up And Downshift) Switch
3. Light Switch 12. Four-way Flasher Switch (option)
4. Front Working Light Switch 13. Ride Control Switch (option)
5. Rear Working Light Switch 14. K-Lever Switch (option)
6. High-Low Beam Lever / Turn Signal Lever 15. Forward / Reverse Changeover Switch for K-
(option) Lever (option)
7. Transmission Cut-Off (Declutch) Switch 16. QUAD (Quick Up And Downshift) Switch on K-
8. Cold Start (ether injection) Switch Lever (option)
9. Front Wiper Switch 17. Economy Switch
18. 12 Volt Power-outlet Socket (S/N 5207~)
19. Reversal Fan 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
START
Be sure to pull parking brake switch when park-
ing or leaving machine, and during maintenance
or transportation.
97ZVOM0074
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
forward or reverse position while the parking brake
is applied and the engine is running, a warning
buzzer will sound.
If the electrical wiring in the line fuse / parking

switch / solenoid valve malfunctions, the parking
brake is applied automatically.
Call local Kawasaki dealer for repair.

2.12
OPERATOR'S AREA
Switches
3. Light Switch 4. Front Working Light Switch
95ZV0012
Front working light switch is used for turning on and

off the front working lights.
70ZV0013a Turn off the front working lights when roading to

prevent blinding the driver in front of you.
This is a three position switch.
OFF
- Width (clearance) lamps (option), tail lamps,
front head lights, and gauge lamps turn off.
- Width (clearance) lamps (option), tail lamps, and

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

front head lights, and gauge lamps turn on.
2.13
OPERATOR'S AREA
Switches
5. Rear Working Light Switch 6. High-Low Beam Lever / Turn Signal

Lever (option)
Low beam position
95ZV0012
Rear working light switch is used for turning on and

off the rear working lights.
High beam position
Turn off the rear working lights when roading to pre-
vent blinding the driver behind you. 70ZV0013a
This lever is used to change the head lights beam

high and low. This lever also turns on the turn sig-
nals.
- The head lights are in the high beam position

when the lever is pushed down (low position).
- The light switch can be operated regardless of

the lever position.
70ZV0013a
- Push the lever forward to turn on the left turn

signal.
- Pull the lever backward to turn on the right turn

signal.
- Return the lever to the center position when the

turn is completed. The lever does not return
automatically when the steering wheel is
returned to center.
2.14
OPERATOR'S AREA
Switches
7. Transmission Cut-Off (Declutch) 8. Cold Start (ether injection) Switch

Switch
95ZV0012
95ZV0012
Cold Start Switch is used for easy engine starting in

Transmission cut-off (Declutch) switch is used to cold weather. Ether is injected into the engine after
change the function of the brake pedals. turning this switch to "ON" and "OFF".
Normally this switch should be "ON". Refer to "Cold Start" page 2.58 for proper use.
OFF
- When the brake pedals are depressed, only the
service brakes are engaged keeping the trans-
mission directional clutch engaged. (brake only)
ON
- When the brake pedals are depressed, the ser-
vice brakes are engaged and the transmission
directional clutch is disengaged (brake and
declutch).
Refer to "Brake Pedals" page 2.7 for the function of

both left and right brake pedals.
CAUTION
Transmission cut-off feature momentarily places
transmission in neutral which may allow machine
to roll when on a grade.
Do not turn transmission cut-off (Declutch)

switch to "ON" when operating on a grade.
2.15
OPERATOR'S AREA
Switches
9. Front Wiper Switch 10. Rear Wiper Switch
70ZV0013a 70ZV0013a
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

2.16
OPERATOR'S AREA
Switches
11. QUAD (Quick Up And Downshift) 12. Four-way Flasher Switch (option)
Switch
95ZV0012
The two front and two rear turn signal lights will
flash when Four-way Flasher Switch is ON.
This is used in emergency, when parking on the

70ZV0010a road, etc. to warn other vehicles.
QUAD switch is used to quickly shift down the

transmission from 2nd gear to 1st gear without
moving the transmission shift lever.
- When operating the machine in 2nd speed with

the shift lever in [2] or [A] position, the transmis-
sion will shift down to 1st gear by pressing
QUAD switch.
- Pressing QUAD switch again, moving the trans-

mission shift lever to the neutral position, or
operating the parking brake switch releases the
1st gear setting to return the transmission to 2nd
gear.
2.17
OPERATOR'S AREA
Switches
13. Ride Control Switch (option) 14. K-Lever Switch (option)
95ZV0012 95ZV0012
When the ride control switch is ON, the ride control - Perform the following steps before turning the
system works. Refer to "Ride Control System switch to "ON".
(option)" page 2.45
- Turn the engine starter switch to the "ON"
Position.
- Set the transmission shift lever to the "NEU-

TRAL" position. Select the desired speed
range.
- Lower the K-Lever arm rest to the operating

position.
Note that the K-Lever system will not turn on

unless the above steps have been com-
pleted.
0 0 0 0 0 0 1/10h
AUTO
20
10 N
C H F
4
3 E
0 30 2
x100r/min
1
C H
97ZVOM0039
- The K-Lever system is turned on when this

switch is pressed. When pressed again the sys-
tem turns off. A dash light will indicate the sys-
tem is on.
2.18
OPERATOR'S AREA
Switches
15. Forward / Reverse Changeover 16. QUAD (Quick Up And Downshift)

Switch for K-Lever (option) Switch on K-Lever (option)
R R
N N
F F
95ZV K-LEVER56387 95ZV K-LEVER56387
Forward / reverse changeover switch is used to QUAD switch is used to quickly shift down the
change direction. transmission from 2nd gear to 1st gear without
moving the transmission shift lever.
R (Reverse)
Pull the upper part of the trigger switch - When operating the machine in 2nd speed with
the shift lever in [2] or [A] position, the transmis-
N (Neutral) sion will shift down to 1st gear by pressing
Keep the trigger switch parallel QUAD switch.
F (Forward) - Pressing QUAD switch again releases the 1st

Pull the lower part of the trigger switch gear setting to return the transmission to 2nd
gear.
2.19
OPERATOR'S AREA
Switches
17. Economy Switch 18. 12 Volt Power-outlet Socket

(S/N 5207~)
95ZV0012
The economy switch is used to improve the fuel

12V
consumption. PUSH PUSH
65ZV03126-0219
This is a power-outlet for 12 volt. When using open

the socket cap and insert a plug into the socket.
2.20
OPERATOR'S AREA
Switches
19. Reversal Fan Switch (option)

IMPORTANT
Do not leave the fan continuously running in the
reverse direction, as this can affect engine per-
formance due to hot air blowing through the air-
to-air cooler.
REVERSAL FAN SW
Engaging this switch reverses the rotation of the-

cooling fan for cleaning the radiator fins.
When pushing this switch for more than 2 seconds

with the engine running, 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.
If it is necessary to turn the cooling fan continu-

ously(only for brief periods) in reverse rotation, fol-
low steps below.
1. Push the switch for more than 2 seconds.

("ON")
The cooling fan turns in reverse rotation.
2. 1 minute later, push the switch 2 times for more

than 2 seconds. ("OFF"→"ON")
3. Repeat the step 2.

2.21
OPERATOR'S AREA
Indicators
Indicators
22 21 5 18 20 19 9 24 4
10
1
11
0 0 0 0 0 0 1/10h 12
AUTO
20
10 N
C H F
13
4
3 E
14
0 30 2
x100r/min
1
15
C H
16
17
97ZVOM0039a
26
29 27 28 25 23 6 8 7 3 2
1. Tachometer 15. Air Cleaner Warning Lamp (red)

2. Engine Coolant Temperature Gauge 16. Charge Lamp (red)
3. Torque Converter Oil Temperature Gauge 17. Transmission Oil Filter Warning Lamp (red)
4. Fuel Gauge 18. Turn Signal Indicator Lamp (Left) (green)
5. Parking Brake Indicator Lamp (red) 19. Turn Signal Indicator Lamp (Right) (green)
6. Auto Brake Indicator Lamp (red) 20. High Beam Indicator Lamp (blue)
7. Transmission Cut-Off (Declutch) Lamp (green) 21. Auto Shift Indicator Lamp
8. Working Light Indicator Lamp (green) 22. Neutral Indicator Lamp
9. Central Warning Lamp (red) 23. Transmission Status Monitor
10. Transmission Control Warning Lamp (red) 24. Hour Meter
11. Brake Pressure Warning Lamp (red) 25. Emergency Steering Warning Lamp (red)
12. Engine Oil Pressure Warning Lamp (red) (option)
13. Engine Coolant Temperature Warning Lamp 26. Coolant Level Warning Lamp
(red) 27. Engine Warning Lamps
14. Torque Converter Oil Temperature Warning 28. Ride Control Indicator Lamp (green) (option)
Lamp (red) 29. K-Lever Indicator Lamp (option)
When the starter switch is turned to "ON", all warn-

ing lamps (9) ~ (16), (25) and (26) light up for three
seconds. This is the lamp (bulb) test period (lamp
(16) lights up until engine starts).
IMPORTANT
Operating machine while any of red lamps are
ON may cause injury or damage to machine.
Stop machine and correct problems if any red

lamps come on.
2.22
OPERATOR'S AREA
Indicators
1. Tachometer 3. Torque Converter Oil Temperature

Gauge
10 20
C H
T/C OIL
TEMP
0 30
x100min -1
97ZVOM0050
97ZVOM0048
Indicates the temperature of oil circulating through

Indicates the engine revolutions per minutes. the torque converter and the transmission. It is nor-
mal if the indicator is in the white zone (50 ~ 120ºC
(122 ~ 250ºF)) 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 3.62.

Indicates engine coolant temperature. It is normal
when the indicator stays in the white zone (70 ~
95ºC (158 ~ 203ºF)).
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
zone. F
- If the gauge stays in the red zone, stop the

engine and allow it to cool naturally. After cool- E
FUEL
ing, check the cooling system. 97ZVOM0051
Refer to "TROUBLESHOOTING" page 3.58. 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.
2.23
OPERATOR'S AREA
Indicators
5. Parking Brake Indicator Lamp (red) 8. Working Light Indicator Lamp

(green)
P
OM0052
OM0055
Lights up when the parking brake is applied.

Lights up when working lights are on.
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. Auto Brake Indicator Lamp (red)
OM0056
Flashes when any of the warning lamps come on.

OM0053
Lights up when the auto brake works.

10. Transmission Control Warning
Refer to "Auto Brake" page 2.67 for the detail.
Lamp (red)
7. Transmission Cut-Off (Declutch)

Lamp (green)
OM0057
Lights up when transmission controls malfunction.
- If it lights up while operating, stop the engine

OM0054
and contact your nearest Kawasaki dealer for
necessary repair.
Lights up when the transmission cut-off (Declutch)
switch is "ON".
- When lit, the service brakes are engaged and

the transmission directional clutch is disen-
gaged by depressing the brake pedals.
- When not lit, only the brakes are engaged as the

left brake pedal is depressed.
2.24
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 (215ºF))
warning buzzer sounds when the brake oil pressure
is lower than 3.9MPa (570psi). - 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 3.58.
- If it lights up while operating, IMMEDIATELY
stop the machine and find the cause. CAUTION
Refer to "TROUBLESHOOTING" page 3.61. 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.

2.25
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 (248 ± 9ºF))
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 3.60.
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. Transmission Oil Filter Warning
Lamp (red)
- 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 3.62.
OM0064
15. Air Cleaner Warning Lamp (red)
Lights up when the transmission oil filter clogs.
- When lit, replace the transmission oil filter car-

tridge.
Refer to "Replace Transmission Oil Filter Cartridge"

OM0062
page 3.32.
Lights up when air filter is clogged. (25"hg)
- If it lights up while operating, stop the engine 18. Turn Signal Indicator Lamp (Left)
and clean or replace the air cleaner outer ele- (green)
ment.
Refer to "Clean or Replace Air Cleaner Element"

page 3.10.
OM0065
Flashes when the turn signal switch lever is moved

forward.
2.26
OPERATOR'S AREA
Indicators
19. Turn Signal Indicator Lamp (Right) 22. Neutral Indicator Lamp
(green)
N OM0069
OM0066
Lights up when transmission is in neutral.

Flashes when the turn signal switch lever is moved
rearward.
23. Transmission Status Monitor
20. High Beam Indicator Lamp (blue)

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

beam. - 1st Gear
Lights up when the shift lever is in [1] position
and transmission is in 1st gear. Machine stays
in this gear until manually shifted.
21. Auto Shift Indicator Lamp
- 2nd Gear
Lights up when the shift lever is in [2] or [A]
position and transmission is in 2nd gear.
AUTO - 3rd Gear

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

the [A] position. Lights up when the shift lever is in [A] position
and transmission is in 4th gear.
2.27
OPERATOR'S AREA
Indicators
24. Hour Meter 27. Engine Warning Lamps
Engine stop lamp

0 0 0 0 0 0 1/10h
OM0205
STOP
Hour meter indicates the accumulated total hours
of engine operation. Use to determine the timing of
OM0191
periodic inspection and maintenance service. Red
If a stop (red) lamp comes on while the engine is in

operation, the fault can be engine disabling. Stop
25. Emergency Steering Warning Lamp the engine operation in a safe manner as soon as
(red) (option) possible.
Engine warning lamp
OM0072
OM0192
Lights up when the steering hydraulic pressure is Yellow
lower than specified when the engine is running.
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.
26. Coolant Level Warning Lamp The failure must be repaired as soon as conve-
nient.
Engine protection lamp
OM0073
Lights up when engine coolant level is lower than

specified. Orange OM0193
- The coolant level is checked only with the If the orange warning lamp comes on while driving,
starter switch is in the "ON" position-engine off. it means that a fault code has been recorded. The
light will remain on as long as the fault is occurring.
- Once the engine is started this level check func-
tion is turned off. 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.
2.28
OPERATOR'S AREA
Indicators
28. Ride Control Indicator Lamp (green)

(option)
OM0206
Lights up when the ride control switch is ON.
Refer to "Ride Control System (option)" page 2.45
29. K-Lever Indicator Lamp (option)
OM0218
- The green indicator lamp comes on when the K-

Lever system is turned "ON". It goes out when
the system is turned "OFF".
- The following chart shows how the different sys-

tems work with the K-Lever system ON or OFF.
K-Lever system
System or Component
OFF ON
Steering using steering wheel OK OK
F/R using shift lever OK NO
Speed change using shift
OK OK
lever
Steering using the K-Lever
NO OK
control
F/R using the buttons on the
NO OK
K-Lever control
QUAD Switch on boom con-
OK OK
trol lever
Horn Button in steering wheel OK OK
Horn Button on top of bucket
OK OK
control lever
2.29
OPERATOR'S AREA
Seat
Seat Mechanical Suspension (If so equipped)
Seat Adjustment - With seat pushed back half-way for easier

access to 5, extend the crank lever from knob
(5) and rotate Minus(-) direction for less support
Adjust the seat for comfort and so that the pedals
or Plus(+) for more support. Use indicator for
may be pushed fully down when the operator's
approximate weight setting. Release crank
back is fully against the seat back.
lever.
1 Air Suspension (If so equipped)

2
- With the key turned "ON" push the knob (same
location as 5) to increase the air pressure. This
Seat Belt will raise the seat and make a firmer ride. Pull
the knob to reduce the air pressure (air will be
6 vented). This will lower the seat and make a
softer ride.
5 Tether
- When properly adjusted the seat will not "bottom
out" over rough terrain.
4 3 70ZV0017
Forward / Backward
Armrests
- Lift the handle (6) and move the seat forward or
backward.
- Rotate control knob (1) to select desired angle.
The armrests will pivot up and parallel with
- Release the handle (6) at one of the several
backrest when not in use.
positions.
Lumbar Support
- Turn adjustment knob (2) for desired lumbar

support.
Reclining
- Lift the handle (3) and allow the back cushion to

angle forward, or lean backward into the cush-
ion. Release the handle at desired position.
Seat Height
- Remove your weight from seat while lifting the

handle (4) to the stop position. While holding the
handle (4) up, raise or push down on seat.
Release handle (4) at one of three positions.
2.30
OPERATOR'S AREA
Seat
Seat Belt
WARNING
Improper use or maintenance of seat belt could
- Inspect seat belt and mounting hardware

before operating machine and replace any
defective components.
- Always fasten seat belt when operating
machine.
- Replace the seat belt and tether every three
years regardless of appearance. Dirt can cut
the fibers weakening the belt. The belt has a
manufacture date to help decide when it
should be replaced.
- Adjust tether so it is snug without the operator
in the seat.
OM0007
1. Fasten seat belt along your body without kink-

ing or twisting it. The seat belt buckle should
firmly "snap" when coupled.
Keep buckle free of dirt and debris.
2. For releasing the seat belt, push the red button

where the belt attaches.
2.31
OPERATOR'S AREA
Electrical Protection
(1) Left (2) Front
Fuse Boxes LIGHTING

20A SPARE 5A
HEAD LIGHT
R. WORK LIGHT 15A SPARE 5A

2
BOOM KICKOUT
1 BUCKET POSITIONER
10A R. WIPER / WASHER 5A
BACK LAMP
STOP LAMP 15A F. WIPER / WASHER 10A
TURN SIGNAL
PARKING BRAKE
CONTROLLER 10A SPARE 10A
(MACHINE)
F. WORK LIGHT 15A SPARE 15A
97ZVOM0086 AIR SUS SEAT (OPTION) 10A SPARE 3A

View from top cover
SPARE 15A SPARE 10A

(97C4-5321~) 2
SPARE 15A SPARE 10A
1
4 WAY FLASHER
HORN
15A AIRCON (OPTION) 20A
DOME LAMP
RADIO BACK UP
SPARE 10A SPARE 5A
COLD STARTER 15A SPARE 5A
BUZZER
MONITOR 5A SPARE 10A
View from top cover 97ZV8210 (CONTROLLER)
NEUTRAL RELAY 5A AIRCON (OPTION) 20A
BATTERY RELAY
5A SPARE 20A
ECM (ENGINE)
Right Rear
3
(3) Front
ECM (ENGINE) 10A
SPARE 7.5A
97ZVOM0087 SPARE 7.5A
SPARE 7.5A
Main Fuse Boxes are located in the right hand side
console in the cab and contain thirty fuses. The
ECM (ENGINE) 10A
additional fuse box (3) is located in the engine com-
partment on the right hand side of the machine. It
SPARE 10A
contains six fuses.
Rear
2.32
OPERATOR'S AREA
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.
97ZVOM0087
1. If the fusible link is blown, the following prob-

lem occurs.
Problem (symptom)
Fuse During engine opera-
During engine stop
damaged tion
-Engine will be -All the electrical cir-
stopped. cuit will not func-
30A -All the power for all tion.
electrical circuit will -(Engine can not be
be OFF. started.)
-Engine can be -The same condi-
stopped. tions as "During
-Horn will operate. engine operation"
70A
-All the others will but engine can be
(A)
not operate and the started and
machine can not be stopped.
operated.
-The machine can -The same condi-
be operated but the tions as "During
70A batteries can not be engine operation".
(B) charged and the
batteries will be dis-
charged 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.
Replacing the blown fusible link without cor-
recting the problem may damage components
or cause a fire.
2.33
OPERATOR'S AREA
Radio - AM / FM Cassette (24Volt Type)
Radio - AM / FM Cassette
(24Volt Type)
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
2.34
OPERATOR'S AREA
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 left
ance audio mode 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.
2.35
OPERATOR'S AREA
Name of Operation
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.
2.36
OPERATOR'S AREA
Name of Operation
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 and
button the radio will remain set to the last station. If the
radio wave of the preset station is weak, the station
Preset 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.
2.37
OPERATOR'S AREA
Name of Operation
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.
2.38
OPERATOR'S AREA
Name of Operation
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
2.39
OPERATOR'S AREA
Name of Operation
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
FF
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
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.)
2.40
OPERATOR'S AREA
Name of Operation
part method
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.
APC
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)
2.41
OPERATOR'S AREA
Heater or Air Conditioner
Heater or Air Conditioner Switches

(~October, 2005)
Both the heater and the air conditioner (option) are
controlled by the same Touch Pad Control Panel as
Ventilation Location and Mode shown below.
3 1 2 8 (A) 7
3 3 3
1 1 ON/
FAN
ONLY
OFF
2 2
4 4 4 4 70ZV0015
(B) 4 3 5 6
70ZV0014 1. ON/OFF Switch

2. FAN ONLY Switch
3. TEMP UP/DOWN Switches (A) Temperature
VENT ○ : Open Display
1 2 3 4 4. FAN UP/DOWN Switches (B) Fan Speed Dis-
MODE ―: Close
play
○ ― ― ○ 5. UPPER Mode Switch
6. LOWER Mode Switch
― ○ ― ○ 7. DEFROST Mode Switch
8. FAN ONLY Indicator LED
○ ― ○ ○
2.42
OPERATOR'S AREA
Operation of the Automatic Tempera- To display the current cab temperature, press the
ture Control unit FAN UP and the TEMP DOWN keys simulta-
neously.
The ATC (automatic temperature control) front
panel allows the operator to adjust the setpoint to a
temperature between 60 and 90 degrees F (15ºC
and 32ºC). Once this temperature is set, the sys-
tem automatically maintains that temperature. This
setpoint will be maintained in memory and recalled
each time the system is powered up. Switching to
the Fan Only mode will disable the ATC mode and
the temperature display will be blank, which dis-
ables the heating and cooling systems. Setting the
temperature setting to 55 (13ºC) (max cooling) or
95 (35ºC) (max heating) will also disable the ATC
mode.
Front Panel Controls
1. ON/OFF Switch
Turns the unit on and off.
2. FAN ONLY Switch

Switches the unit to the fan only mode and dis-
ables the Automatic Temperature Control.
3. TEMP UP/DOWN Switches

Allows the operator to adjust the temperature
setpoint.
4. FAN UP/DOWN Switches

Allows the operator to adjust fan speed. The
"FAN ONLY" Indicator LED (8) will be turned
on.
5. UPPER Mode Switch

Switches the unit into the upper air mode.
6. LOWER Mode Switch

Switches the unit into the lower air mode.
7. DEFROST Mode Switch

Switches the unit into the defog mode and
routes the air to the defrost vents.
NOTE
Below about 32 degrees F (0ºC) the A/C is
turned off.
To change the display between degrees F and C,

press the FAN DOWN and the TEMP UP keys
simultaneously.
2.43
OPERATOR'S AREA
(November, 2005~) Switches
Ventilation Location and Mode

Manual Heater Control
3 3
3 3
1
1
1 3 4
2 2 BERGSTROM H
4 4 4
Manual Combo Control
135ZV0035
VENT ○ : Open
1 2 3 4
MODE ―: Close
○ ― ― ○
○ ○ ― ○
― ○ ― ○ 1 2 3 4
BERGSTROM AC
― ○ ○ ○
― ― ○ ○ 1. Mode Control
2. Heat/AC Control
3. Temperature Control
4. Blower Control
2.44
OPERATOR'S AREA
Front Panel Controls
Blower Control
Turn the control fully counter clockwise to turn off

the blower, or adjust the blower to the desired
speed.
Temperature Control
Adjusts the output temperature. This output is used

to control the position of the water valve.
Heat/AC Control
On the Combo control it enables/disables the AC

function.
Air conditioner on
Air conditioner off
Mode Control
Provides the signal to Adjust the mode doors to

direct the air flow.
Panel Mode
Provides air flow through door 1.
Bi-Level Mode
Provides air flow through door 1 and 2.
Floor Mode
Mix Mode
Provides air flow through door 2 and 3.
Defrost Mode
2.45
OPERATOR'S AREA
Ride Control System (option)
Ride Control System (option)

Roading a wheel loader over rough terrain will
cause fore and aft pitching motion to the machine.
The pitching motion is reduced when the ride con-
trol system is installed.
Operation and Function
0 0 0 0 0 0 1/10h
AUTO
20
10 N P
C H F
4
3 E
0 30 2
x100r/min
1
C H
STOP
95ZV0011
1 2
1. Before travelling, turn the ride control system

switch (1) ON.
The ride control system pilot lamp (2) turns

ON.
2. Move the machine forward.
The ride control system functions automatically

when the machine travelling speed reaches
more than 7km/h (4.3mph). The system auto-
matically disengages below 5km/h (3.1mph).
The indicator lamp (2) will remain on regard-
less of the machine speed if the switch (1) is
ON.
NOTE
When the bucket is fully tilted the ride control sys-
tem does not work. Dump the bucket a bit when
travelling.
2.46
OPERATION
Check before Operation
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.
2.47
OPERATION
Greasing Check Engine Oil Level
1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
CAUTION
ground, and stop the engine. Hot engine oil and components may cause
burns.
2. Lubricate fittings on the following components.
Wipe and clean all fittings before greasing. Avoid contact with hot oil or engine components.
Lubricate until fresh grease is seen at each

joint. Immediately replace or report any broken
or defective grease fittings or grease lines.
Refer to "Recommended Lubricants" page Check

3.56 for the correct grease.
Fill cap
97ZVOM0087
97ZVOM0156
- Axle support
(two places)
H (High)
IMPORTANT L (Low)
Grease axle supports daily to avoid axle support OM0216

wear.
Be sure to fully lubricate the trunnion-two fittings.
When fully lubricated grease will escape from the 1. Check the oil level with the dipstick.
breather on the rear plate and from the top of the
front support.
2.48
OPERATION
2. Keep the oil level between the "H" (high) mark Check Hydraulic Oil Level
and "L" (low) mark on the dipstick.
3. If needed, add the required amount of the CAUTION

same brand and viscosity oil as originally used Pressurized hydraulic tank is used for this
through the refill port. machine.
Refer to "Recommended Lubricants" page Pressure may throw tank cap and hot oil out of
3.56 for the suitable viscosity of the oil accord- tank causing injury or burns.
ing to the ambient temperature.
Relieve all pressure by pressing down the filler
4. If the oil is particularly dirty or contains water cap.
(milky appearance), replace the oil immedi-
ately. If oil contains coolant, diagnose the prob-
lem and correct it immediately.
Check Level
Refer to "Replace Engine Oil and Oil Filter Car-
tridge" page 3.26.
NOTE
Wait about five minutes after stopping the engine to
measure the oil level. The precise oil level cannot
be measured immediately after stopping engine
due to residual oil in the upper parts of the engine.
IMPORTANT 97ZVOM0097
Improper oil level may damage engine.

1. Lower the attachment to the ground.
Do not operate engine with oil level below “L”
(low) mark or above “H” (high) mark. 2. Stop the engine.
Add or drain oil to keep proper oil level. 3. Check the oil level gauge on the side of the
hydraulic oil tank.
4. The oil level is OK if the oil reaches the middle

of the level gauge.
2.49
OPERATION
Check Engine Coolant Level
CAUTION
Pressurized radiator tank is used for this
machine.
Spray of hot coolant may cause burns.
Stop engine and allow radiator and coolant to

cool completely, then open cap slowly to relieve
Filler cap pressure.
97ZVOM0105
5. If needed, add the required amount of the oil. CAUTION

Cooling system conditioner contains alkali that
Refer to "Recommended Lubricants" page could caustic burns or blindness.
3.56 for the suitable viscosity of the oil accord-
ing to the ambient temperature and oil type. Avoid contact with skin and eyes to prevent
injury.
1. Stop the engine and allow the radiator and

coolant to cool completely.
97ZVOM0143
2. Lift the lever (1) on the cap (2) of the radiator

tank to vent pressure and slowly open the cap
(2).
2.50
OPERATION
Drain Water and Sediment from Fuel Fil-

Radiator guard Cap ter
Neck pipe
Water surface
OM0095
3. Check the coolant level.

97ZVOM0087
4. Coolant level is normal if coolant is to the lower

part of neck pipe.
Following must be done with engine "OFF".
5. If needed, add the required amount of the cool-
- Open the drain cock on the bottom of the fuel fil-
ant.
ter to allow water and sediment to drain into a
suitable container.
Refer to "Coolant Specification" page 3.57 for
the correct mixture.
- Dispose of the drained water and sediment
properly.
6. Change the coolant if it is particularly dirty.
Refer to "Replace Coolant" page 3.14. CAUTION

Escaping fuel is flammable and harmful to skin.
7. If the coolant contains oil, diagnose the prob-
lem and correct it immediately.
- 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.
2.51
OPERATION
Check Wiring Harnesses Articulation Stopper
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.
97ZVOM0004
- Make sure the articulation stopper is secured in

the "STORED" position as shown.
2.52
OPERATION
Check Tire for Damage , Air and Tread

Low Pressure OK High Pressure
Depth
97ZVOM0103
Tire performance and its life depend greatly on the

OM0032 tire air pressure.
It is important to keep the tire pressure at the rec-

WARNING ommended level.
Improper service or changing tires and rims
Under the abnormal condition, check and adjust the
could cause explosion resulting in serious injury
air pressure to the standard value.
or death.
Refer to "Check Tire Air Pressure" page 3.23 for
Do not service or change tire and rims unless
the adjusting procedure.
properly trained and equipped.
Contact your nearest Kawasaki loader dealer or

tire manufacturer’s local dealer for tire servicing
or changing.
WARNING
Overheated tire could explode causing serious
injury or death.
If overheated tire is suspected, do not approach

tire to distance of less than 15m (50ft).
Stay away until tire and rim cool down.

2.53
OPERATION
Tread Check Drive Belt
CAUTION
Side walls
Breakers Contact with moving belt or pulleys may cause
injuries
Carcass
Stop engine before opening engine side panel.

Beads / Bead wire ground, and stop the engine. Remove the key
OM0104
and tag "Do Not Operate".
If the following defects are found in tires, for safety 2. Open the engine side panel.
reasons the tires should be replaced with new tires.
For the replacement contact Kawasaki dealer or a

tire manufacturers local dealer.
- Bead wire is broken or bent, or the tire is greatly

deformed.
- Wear is excessive and the carcass ply (includ-

ing breaker) is exposed for more than 1/4 of the
circumference.
- Damage to the carcass exceeds 1/3 of the tire

width. 97ZVOM0098
- Tire layers are separated.

3. Visually inspect the drive belt for looseness
- Radial cracks reach the carcass. and damage.
- Deformation or damage which makes the tire

unsuitable for use.
OK
OK
OM0099
4. If the belt is too stretched to permit adjustment

or shows cuts or cracks, replace it.
2.54
OPERATION
Check Crankcase Breather Tube Check Air Intake System
CAUTION
Hot engine components may cause burns.
Avoid contact with hot engine components.

OK parking brake, lower the attachment to the
ground, and stop the engine.
Cooler IN (Left)
97ZVOM0100 Cooler OUT (Right)
Inspect the crankcase breather tube for sludge or

debris on or in the tube.
97ZVOM0101
2. Check the engine intake hose, intake pipes,

pipe clamps and hose bands for damage and
tightness.
3. If damaged or loose, replace or retighten or

contact your nearest Kawasaki dealer.
IMPORTANT
Severe engine damage may result from running
with unfiltered air.
Do not operate engine if any leaks or defects are

found on air intake system.
2.55
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

Cab
OK
WARNING
OM0102
Operating with damaged or improperly mounted
ROPS could result in death or serious injury. Be
1. Park the machine on level ground, apply the sure to observe the following.
ground, and stop the engine. Remove the key - Whenever seated, fasten the seat belt.
and tag "Do Not Operate". - Do not modify ROPS, such as drilling or weld-
ing.
2. Open the engine rear grill. - Do not use ROPS if it is deformed.
- If any damage or loose bolts are found, do not
3. Visually inspect the cooling fan for damage. operate until repaired.
- Never repair or modify ROPS without manu-
4. If the fan shows cracks, loose rivets, bent or facturer's approval and instructions.
loose blades, replace it. - Inspect the ROPS and the ROPS Cab mount-
ing bolts.
- Check the condition of the ROPS Cab and its

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

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

mirrors, clean or fix them.
Check Parking Brake
- Make sure the parking brake switch is pulled up.

2.56
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 2.21.
3. Rotate and move the transmission shift lever to

each position, pull the high-low beam lever,
and operate the rear working light switch and
transmission cut-off (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 2.21.
Check Control Levers
- Make sure the boom and tilt control levers are in

the "HOLD" position. The levers should return to
the "NEUTRAL" or "HOLD" position smoothly
and naturally.
Check Transmission Shift Lever or

Switch [for K-Lever (option)]
- Make sure the transmission shift lever or switch

is in the neutral position.
2.57
OPERATION
Starting the Engine
Starting the Engine
WARNING OFF ON
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.
97ZVOM0075
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 (32ºF))
NOTE
1. Do not depress 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

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

warning lamps are turned off.
Before starting the engine, make sure all of the

warning lamps are turned off. If the stop (red)
lamp remains on, do not start the engine.
97ZVOM0076
- 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
and leave it there for 3 seconds. Check the
- The engine oil pressure warning lamp should go
indicator lamps.
out in less than ten seconds after the engine
starts. If it remains on, stop the engine immedi-
3. The turn the starter switch key to "START"
ately and see "TROUBLESHOOTING" page
position to start the engine.
3.58.
To protect starter and battery, do not keep the
starter switch in the "START" position for more IMPORTANT
than 20 seconds.
Low engine oil pressure may cause severe
engine damage.
4. If the engine fails to start, wait about two min-
utes before trying to restart. This allows the
Be sure engine oil pressure warning lamp goes
starter motor to cool which prevents starter
out quickly.
motor damage.
2.58
OPERATION
Starting the Engine
Cold Start
(Ambient temperature below 0ºC (32ºF)) IMPORTANT
1. Do not depress the accelerator pedal. Ether may cause serious engine damage.
Never attempt to inject ether into warm engine.
Use ether only as specified in this manual.
NOTE
- Do not turn the starter switch key to the
95ZV0012 "START" position while the engine is running.
- The engine oil pressure warning lamp should go

2. Turn the starter switch key to the "ON" position out in less than ten seconds after the engine
and press the cold start switch for two sec- starts. If it remains on, stop the engine immedi-
onds. (Here the ether is filled into a metering ately and see "TROUBLESHOOTING" page
valve and measured.) 3.58.
3. Turn the starter switch key to the "START"

position to start the engine and release the IMPORTANT
cold start switch. To protect starter and battery, Low engine oil pressure may cause engine dam-
do not keep the starter switch in the "START" age.
position for more than 20 seconds.
Be sure engine oil pressure warning lamp goes
4. If the engine fails to start, wait about two min- out quickly.
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
Ether is very flammable and could cause serious
injury or death.
- Avoid heat, electric sparks and flames near

ether cylinder.
- Do not store ether cylinders at temperature
above 40ºC (100ºF).
- Store ether cylinders out of children's reach.
- When winter season is over (outside tempera-
ture is above 5ºC (40ºF)), remove ether cylin-
der from machine and store it safely according
to above instructions.
2.59
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- 0 0 0 0 0 0 1/10h

AUTO
tion until the end of the warm-up period. 10
20
N
C H F
4
3 E
0 30 2
x100r/min
1
C H
97ZVOM0039
1. Check the warning lamps on the instrument

panel.
2. If any red lamp (except for "PARKING") is on,

do not operate the machine.
3. Refer to "Indicators" page 2.21 for the meaning

of each lamp and the correction.
2.60
OPERATION
Check Fuel Level Check Transmission Oil Level
DANGER
There is no room in articulation are when
machine is turning.
Crushing will result in serious injury or death.
F
When checking oil level:

- Low attachment to ground.
E
FUEL - Put transmission shift lever in neutral.
97ZVOM0051
- 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

Check and Fill Tube
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.
97ZVOM0106

parking brake, and lower the attachment to the
ground. Verify that oil is up on the dipstick prior
to starting.
"LOCKED" position 97ZVOM0003
2. Set the articulation stopper in the "LOCKED"

position.
Refer to "Articulation Stopper" page 1.22

2.61
OPERATION
3. Check the oil level with engine at low idle. Check Service Brake Operation
Before testing be sure the area behind the loader is

clear.
In hot In cold
1. Turn "OFF" the clutch cut-off (Declutch) switch.
2. Firmly depress the right hand brake pedal.

Specified oil level
3. Release the parking brake.
4. Select the transmission shift lever 2nd and

REVERSE.
97ZVOM0107
5. Slowly accelerate the engine to full speed.
4. At low oil temperature, use the side of dipstick 6. The machine should not move.
marked "COLD". Normal oil level is within
shaded area as shown. IMPORTANT
5. At high oil temperature, use the side of dipstick If machine moves when firmly depressing right
marked "HOT". Normal oil level is within hand brake with transmission in 2nd and
shaded area as shown. REVERSE there is some problem with service
brake.
6. If the oil level is lower than the specified, add
recommended oil while the engine is at idle. Do not operate until problem has been corrected.
Do not overfill.

3.56.
WARNING
With articulation stopper in "LOCKED" position,
machine will not steer which, while operating,
could cause an accident result in death or seri-
ous injury.
Return articulation stopper to "STORED" posi-

tion after checking transmission oil level.
IMPORTANT
Never mix CD engine oil and auto transmission
fluid.
Either may be used in transmission but they
must not be mixed.
Determine what type of oil is in transmission and

use only that type.
2.62
OPERATION
Check Parking Brake Operation Check Back-up Alarm Operation
1. If the service brakes work normally, test the 1. Apply the service brakes.
parking brake.
2. Release the parking brake.
2. Move the machine to a safe open place on a
slope. 3. Move the shift lever to "REVERSE" or pull the
upper part of the trigger switch [for K-Lever
3. Stop the machine with the service brake. (option)] to "REVERSE".
4. Pull up the parking brake switch. 4. The back-up alarm should sound and be heard
in the operator's seat.
5. Release the service brakes.
6. The machine should not move.

IMPORTANT
If back-up alarm does not sound when parking
brake is released and shift lever is in REVERSE
IMPORTANT position, there is some problem with back-up
If machine moves when parking brake switch is alarm.
pulled, there is some problem with parking
brake. Do not operate until problem has been corrected.
Do not operate until problem has been corrected.
Check Steering Wheel Operation
1. Be sure the area is clear of bystanders.
2. Release the brakes.
3. Steer fully right and then left.
4. Steering should be smooth in both directions.

2.63
OPERATION
Check Exhaust Gas General Inspection
WARNING
When inspecting machine while engine is run-

ning:

- Lower attachment to ground.
- Turn parking brake switch to "ON".
- Do not enter or access hazardous areas of
97ZVOM0108 machine:
- Articulation area
- Under machine
1. Check the color of the exhaust gas.
- Engine compartment, etc.
Normal exhaust gas color is clear or light gray
when engine is warm. White, black, or blue With the parking brake applied, transmission shift
smoke during steady warm operation of the lever in NEUTRAL, loading levers in NEUTRAL,
engine indicates a malfunction. (It is normal for and the attachment on the ground, walk around the
some black smoke to occur during rapid accel- machine and look for any problems, leaks, or signs
eration.) of failure.
2. If abnormal exhaust gas color occurs, have the

machine checked immediately.

2.64
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. 40cm (16in.)

OM0016
Moving machine in congested areas could result
Be sure area is clear of personnel and obstruc-

tions. 1. Raise the bucket to the carry position approxi-
mately 40cm (16in.) above the ground.
IMPORTANT 2. Depress 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 depress the

accelerator pedal to drive the machine.
WARNING
When parking brake is released, machine could
roll on a grade unexpectedly causing injury or
death.
When starting machine on a grade, firmly

depress brake pedal before releasing parking
brake.
2.65
OPERATION
Starting the Machine on a Grade Speed and Direction Change
1. Turn "OFF" the clutch cut-off (Declutch) switch. [For Std. machine]
2. Depress the left brake pedal.
65ZV 5089
97ZVOM0038
1. Select the proper gear shifting mode by rotat-
ing the transmission shift lever. Refer to the fol-
3. Depress the accelerator pedal while releasing lowing tables on page 2.67 for the gear
the left brake pedal to start the machine off selection mode.
slowly.
This machine is equipped with the automatic
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.
2.66
OPERATION
[For machine with K-Lever (option)]
1. For speed change, set the transmission shift

lever to the "NEUTRAL" position. Select the
proper gear shifting mode by rotating the trans- N
R
F
mission shift lever.
R Backward
N
F
95ZV0013
Neutral
Forward
95ZV0013
2. For a direction change, decelerate the

machine then setting forward / reverse
changeover switch to forward or reverse.
IMPORTANT 70ZV0010a
Changing direction with transmission in 3rd or

4th gear may cause serious transmission dam-
3. When the transmission is in the 2nd gear, it
age.
can be quickly shifted down to the 1st gear by
pressing the Quick Up And Downshift (QUAD)
Slow down machine and shift transmission to 1st
switch.
or 2nd gear when changing direction.
4. Pressing the QUAD switch again, moving the
transmission shift lever to the neutral position,
or operating the parking brake switch releases
the 1st gear setting to return the transmission
to the 2nd gear.
Refer to "QUAD (Quick Up And Downshift)

Switch" page 2.16.
2.67
OPERATION
Auto Brake
Lever Selected Gear Operating Condition
Position
[1] 1st 1. Excavating or AUTO

0 0 0 0 0 0 1/10h
scooping in a 10
20
N
C H F
narrow space 4
3 E
2. Running down- 0
x100r/min
30 2
1
hill on a steep
C H
slope
[2] 2nd 1. Scooping or 97ZVOM0039
loading loose
material
2. Running down- Auto Brake feature protects the transmission from
hill on a slope excessive speed. It applies the service brakes and
turns on the warning buzzer. The Auto Brake moni-
[3] 3rd Carrying or roading tor lamp also turns on.
[A] 2nd, 3rd or 4th Scooping, loading, Auto Brake works under the following conditions:
(automatically carrying or roading
shifted) 1. If the machine runs above the following speeds
forward or reverse;
[1] : 15km/h (9.3mph)
IMPORTANT [2] : 22km/h (13.7mph)
Using too high gear for job may cause torque [3] or [A] : 36km/h (22.4mph)
converter overheating.
2. When the direction is changed while running
Use proper gear for each job. over 12km/h (7.5mph).
CAUTION
When auto brake applies, machine may slow
down suddenly.
Be prepared. Wear seat belt.

2.68
OPERATION
Parking
Parking
97ZVOM0038
OM0025 1. Release the accelerator pedal.
2. Apply the service brake to stop the machine.

WARNING
3. Shift the transmission shift lever to "NEU-
Unexpected movement of machine could result TRAL".
4. Pull up the parking brake switch to apply the
Park machine in safe place on firm level ground. parking brake.
If machine has to be parked on a grade, place 5. Lower the attachment to the ground and apply
wheel chocks under wheels and dig attachment a small amount of down pressure.
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.
2.69
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
START
97ZVOM0074
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).
2.70
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.

2.71
OPERATION
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.

2.72
OPERATION
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.

position to clear the ground.
2.73
OPERATION
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.
2.74
OPERATION
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. 40cm (16in.) 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 40cm (16in.) Be sure there are no overhead wires or obstruc-
above the ground when carrying. tions before raising boom to full height.
IMPORTANT Refer to "Loading" or "Excavating" page 2.70, 2.72

for the loading procedure.
When carrying material over 450m (500yd) at
high speed, tire overheating may occur.
Follow tire manufacturer's instructions for tire

inflation on this type of application.
OM0116

position to raise the loaded bucket while
approaching the truck or the hopper.
2. Use the transmission cut-off (Declutch) switch

in the "ON" position if working on a level site.
When the left brake pedal (declutch pedal) is

depressed, the transmission is placed auto-
matically in neutral and the boom rises faster.
2.75
OPERATION
3. Return the boom control lever to the "Hold"

position when the bucket reaches the enough
height to clear the truck or hopper sideboards.
If the boom is equipped with the kickout

device, the boom will automatically stop and
the boom control lever will return to the "Hold"
position when the bucket reaches the preset
height.
Holding the boom control lever in the "Raise"

position will continue to raise the boom if
OM0196
required.
Refer to "Boom Kickout Adjustment" page 2.78 for

6. Roll back the bucket to clear the truck or hop-
adjustment of the preset height.
per sideboards and lower the boom while
reversing the machine.
4. Position the machine in the center of the truck
body or hopper to dump the load.
WARNING
Fast boom lowering motion may cause machine
rear wheels to jump up, reducing stability and
control.
Do not lower boom using detented "Float" posi-

tion especially when bucket is full.
OM0195
5. Push the bucket control lever forward to the

"Dump" position to empty the bucket.
2.76
OPERATION
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.
2.77
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 Positioner 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 posi-
tioner adjustment.
5 ± 2mm (1/8 ~ 1/4in)
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 the switch (4) and rod (3)
to the hold position, and stop the engine. should be about 5mm (0.2in).
The switch may be adjusted in or out to set this

clearance.
2
1
97ZVOM0127
3. Loosen the bolts (1) with a 17mm wrench.
4. Move the bracket (2) forward to increase, or

rearward to decrease the attachment preset
angle.
5. Tighten the bolts (1).

2.78
SPECIAL PROCEDURES
Adjustments
Boom Kickout Adjustment 1

2
DANGER
Sudden or accidental movement of boom will
Before walking or working under raised boom:

- Securely block or brace boom.
- Remove key and tag "Do Not Operate" on the
steering wheel. 3
85ZV0003
WARNING
Standing on tire can cause accidents resulting in 7. Tighten the bolts (1).
8. Remove the support from the boom and link-
Use safe sturdy platform to reach boom kickout age.
adjustment.
9. To test the adjustment; start the engine, slowly
lower the boom to the ground, and move the
1. Park the machine on level ground and apply boom control lever to the "Raise" detent posi-
the parking brake. tion to raise the boom.
2. Raise the boom to the desired height and stop When the preset height is reached, the boom
the engine. control lever should return to the "Hold" posi-
tion.
3. Lock the bucket and boom control levers in the
"Hold" position using the loading control lever
lock.
3
5 ± 2mm (1/8 ~ 1/4in)
OM0128
OM0031 NOTE
Clearance between the switch (3) and plate (2)
should be about 5mm (0.2in).
4. Block the boom and linkage from falling down
using a proper support. The switch may be adjusted in or out to set this
clearance.
5. Loosen the two bolts (1). Align the plate (2)
with the switch (3).
6. Move the plate (2) clockwise to decrease, or

counterclockwise to increase the boom lift kick-
out height.
2.79
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 15m (50ft).
When the machine travels at high speed or for a

long distance, the tires or other components may
become extremely hot causing an explosion or
early wear. If the machine must be driven for a long
distance, take the following precautions:
- Follow the regulations related to this machine,

and drive carefully.
- The most suitable tire pressure, travel speed, or

tire type differ according to the condition of the
travel surface. Contact your nearest Kawasaki
dealer or a tire dealer for information.
- "Ton km/h" (Ton MPH) limitations must be

observed. Consult a tire dealer for the speed
limit of the tires involved.
- After traveling for 30 minutes, stop the machine

with engine running to allow the tires and com-
ponents 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.
2.80
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, parts in the battery case
OM0131
could rapidly deteriorate.
It could shorten battery life or the battery could 4. Move back the protective rubber covers (red)
explode. from the positive post (+) of the battery.
Keep the battery electrolyte level in the proper 5. Connect one end of the red jumper cable to the
level. positive post (+) of the discharged battery.
6. Connect the other end of the red jumper cable

WARNING to the 24 volt side of the booster battery set or
Batteries contain lead, and acid which may power source.
cause burns.
7. Connect one end of the black jumper cable to
Avoid contact with skin or clothing and wear the ground side of the booster battery set or
hand, eye, and face protection when working on power source.
If lead, or acid contacts skin or clothing, immedi- 8. The final connection should be the remaining
ately wash with water. end of the black jumper cable to the rear chas-
sis close to starter motor ground being jump
started.
NOTE
This machine uses a 24VDC negative ground elec- 9. Start the booster machine's engine or turn the
trical system. auxiliary power source on.
10. Allow a few minutes to provide partial charge

to the discharged batteries.
2.81
SPECIAL PROCEDURES
Booster Batteries / Jumper Cables
11. Start the machine being boosted as described

on "Starting the Engine" page 2.57.
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.
2.82
SPECIAL PROCEDURES
Towing
Towing 6. Tow the machine slowly with gradual and

smooth movement. (Towing speed: Max.
10km/h) (6MPH)
The following is for emergency case only to move a
troubled machine to a short convenient location for 7. Use flashing lights or other warning signals
repair. when towing.
WARNING If your machine must be towed, contact your near-

est Kawasaki dealer for the necessary information
Improper towing could result in death or serious or assistance.
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.
Drawbar 97ZVOM0135
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.
2.83
SPECIAL PROCEDURES
Transportation
Transportation 5. Lower the bucket and lock each control lever

using the loading control lever lock (page
When transporting the machine, observe the vari- 1.21).
ous road rules, road transportation vehicle laws
and vehicle limit ordinances, etc. 6. Apply the parking brake and set the articulation
It is a good idea to obtain a special platform for stopper in the "LOCKED" position (page 1.22).
loading and unloading the machine.
7. Tape over the exhaust stack outlet to prevent
1. Park the trailer on flat firm roadbed. Keep a turbo "Wind-milling" damage.
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. Cables or Chains
3. Fix the ramp in line with the centers of the

trailer and the machine.
Front Rear
OM0207
9. Fasten the machine to the trailer with chains or

cables at lower part of the rear chassis.
65ZV0009 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.
2.84
SPECIAL PROCEDURES
Transportation
10. Determine the route for transporting the

machine by taking into account the width,
height and weight of the machine and truck.
2.85
SPECIAL PROCEDURES
Long Term Storage
Long Term Storage During Storage
Before Storage Once a month remove the covers, run the engine,
and move the machine a short distance to form a
1. Wash and clean all parts of the machine. new oil film on the lubricated parts.
2. Lubricate every greasing point described in WARNING

"Greasing" section page 3.19, 3.25 and 3.44.
Batteries contain lead, and acid which may
3. Replace engine oil, transmission oil, differential cause burns.
and planetary oil and hydraulic system oil.
Avoid contact with skin or clothing and wear
4. Idle the engine for about 15 minutes so that hand, eye, and face protection when working on
fuel and lubricant circulate throughout the or around batteries.
engine, transmission and torque converter.
If lead, or acid contacts skin or clothing, immedi-
5. Store the machine indoors and keep it dry. ately wash with water.
Never leave it outdoors. If forced to leave it
outdoors, choose a flat place, place the 1. Check the following points.
machine on wooden blocks and securely cover
it with a canvas or plastic cover, etc. Refer to "Check before Operation" page 2.46
and "Check after Starting the Engine" page
2.59.
- Coolant level
- Engine oil level
- Hydraulic oil level
- Transmission oil level
- Brake function
- Steering function
2. Operate the machine as follows.
- Run just the engine for about five minutes at

OM0028 low idle.
6. Disconnect the cables from the batteries or if - Move all cylinders of the hydraulic system
freezing temperatures are expected, remove full stroke 2 to 3 times.
the batteries from the machine and store sepa-
rately in a heated area. - Run the machine about 10m (30ft) in every
gear and direction.
7. If freezing temperatures are expected, check
and adjust the antifreeze/water mixture. - Move the steering full stroke each way
about 2~3 times.
the mixing ratio. 3. Operate the air conditioner as follows.
8. Securely cover the inlet and outlet ports of the - Operate the air conditioner with the engine
air cleaner and muffler. low idle for several minutes once a month so
that the lubricating oil in each part of the
compressor is not eliminated.
2.86
SPECIAL PROCEDURES
Long Term Storage
After Storage Cautions on Battery Replacement or

Battery Cable Removal
When battery or battery cable is removed, follow

the procedure below to avoid miss throttle opera-
tion by ECM.
OFF ON
START
97ZVOM0145
97ZVOM0075
1. Turn the starter switch key to ON position.
Depress
Release
(2sec.)
Depress
97ZVOM0097 Release
(2sec.)
1. Loosen the drain cock or plug of the fuel tank Depress

Release
and the hydraulic oil tank to drain any water (2sec.)
into a suitable container. Dispose of properly.
2. Remove the covers, connect the cables to the

97ZV0002a
batteries and start the engine.
3. Replace engine and transmission oil with new 2. Slowly depress the accelerator pedal to the full
specified oil after warming up both engine and stroke position 3 times.
transmission. (Keep it at the full stroke position 2 seconds
and release it)
Refer to "Replace Engine Oil and Oil Filter Car-
tridge" page 3.26 and "Replace Transmission
Oil" page 3.35. IMPORTANT
Fully depress the accelerator pedal to the full
4. Start the engine and check for any abnormali- stroke position. If the pedal is not depressed fully
ties. enough, it causes that the max. engine speed
does not reach the standard figure.
5. Warm up the machine until all gauges reach
the normal range.
2.87
SPECIAL PROCEDURES
Long Term Storage
OFF ON
START
97ZVOM0074
3. Turn the starter switch key to OFF position.
4. Start the engine and check the max. engine

speed.
2.88
MEMO
3.1
3.MAINTENANCE
3.2
MAINTENANCE
Serial Number Location
MAINTENANCE
Before performing maintenance or repairs, read,
understand and follow "Safe Maintenance" section
page 1.11.
The maintenance or repair of the machine must be

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

When contacting Kawasaki dealer or the dealers of
other products for servicing or repair, refer to the 97ZVOM0175
serial number found in the following locations. See

next page for general location.
2. Engine Serial Number
For quick reference, record each serial number in
the blanks below.
If a component, like engine or transmission, is

changed, record the new serial number here.
TRANSMISSION
MODEL
SERIAL NO
SERIAL NO.
ASSEMBLED IN THE U.S.A.

KAWASAKI
OF U.S. AND JAPANESE COMPONENT BY
KAWASAKI CONSTRUCTION MACHINERY
CORP. OF AMERICA OM0211
3. Transmission / Torque Converter Serial Num-

OM0208
ber
Model
1. Machine Serial Number
Serial Number
Design Number
3.3
MAINTENANCE
MODEL
SER. NO.
PATEN NO.
ROCKLAND
ROCKLAND MFG. CO., BEDFORD, PA. USA
80ZVUSA0001 BERGSTROM
4. Bucket or Attachment Serial Number 6. Air Conditioner and Heater Serial Number
(Appearance of serial number plate differs
depending on the manufacturer.)
SERIAL NO.
-
70ZV0004
70ZV0017
7. Cab Serial Number
5. Seat Serial Number Model Number
Serial Number
3.4
MAINTENANCE
Heat & A/C ROPS Cab
Seat
Bucket
95ZV0008
Machine T/M E/G

3.5
MAINTENANCE
Inspection and Maintenance Table
Inspection and Maintenance

Table
△ : First time replacement or cleaning only
Operating hours When

Section Item for check Page
10 50 250 500 1000 1500 2000 Required
Check Engine Oil Level ○ 2.47

Check Engine Coolant Level ○ 2.49
Check Warning Lamps ○ 2.59
Check Exhaust Gas ○ 2.63
Drain Water and Sediment from Fuel Filter ○ 2.50
Check Fuel Level ○ 2.60
Check Drive Belt ○ 2.53
Check Crankcase Breather Tube ○ 2.54
Check Air Intake System ○ 2.54
Check Cooling Fan ○ 2.55
Drain Water and Sediment from Fuel Tank ○ 3.22
Replace Engine Oil and Oil Filter Cartridge ○ 3.26
Add DCA4 Coolant Additive ○ 3.41
Inspect Automatic Belt Tension ○ 3.41
Engine
Replace Fuel Filter Cartridge ○ 3.42
Replace DCA4 Coolant Filter Cartridge ○ 3.54
Clean Fuel Tank ○ 3.49
Check and Adjust Valve Lash Clearance ○ 3.50
Check Vibration Damper ○ 3.49
Check Engine Compression Pressure ○ 3.50
Check Injection Pressure ○ 3.50
Check and Adjust Injection Timing ○ 3.50
Clean Crankcase Breather Tube ○ 3.53
Replace Ether Cylinder ○ 3.16
Clean or Replace Air Cleaner Element ○ 3.10
Clean Radiator / Air cooler / Hydraulic oil
○ 3.11
cooler Fins
Clean or Replace Air Cleaner Element After six cleanings or once a year ○ 3.10
Replace Coolant Every 2 years or 3000 hours ○ 3.14
Check Transmission Oil Level ○ 2.60
Transmission
& Replace Transmission Oil Filter Cartridge △ ○ 3.31, 3.32
Torque Replace Transmission Oil ○ 3.35

Converter
Clean or Replace Transmission Breather ○ 3.37
3.6
MAINTENANCE

10 50 250 500 1000 1500 2000 Required
Check Tire for Damage , Air and Tread

○ 2.52
Depth
Check Tire Air Pressure ○ 3.23
Greasing (Axle support) ○ 2.47
Check Differential Gear Oil ○ 3.27
Check Planetary Gear Oil ○ 3.28
Greasing (Pillow block bearing unit) ○ 3.25
Axle system
Check Tightness of Wheel Bolts ○ 3.29
Greasing (Differential seals) ○ 3.34
Greasing (2nd Propeller Shaft) ○ 3.44
Greasing (3rd Propeller Shaft) ○ 3.45
Replace Differential Gear Oil ○ 3.47
Replace Planetary Gear Oil ○ 3.48
Check Steering Wheel Operation ○ 2.62
Steering
Greasing (Steering Cylinder) ○ 3.21
system
Clean Filter for Orbitrol® △ ○ 3.31, 3.52
Check Service Brake Operation ○ 2.61

Check Parking Brake Operation ○ 2.62
Adjust Parking Brake Lining ○ 3.38
Brake Inspect the Front Parking Brake Pads and
○ 3.39
system Rotor
Check Service Brake Disk Wear ○ 3.50
Check Brake Accumulators ○ 3.50
Clean Filter for Brake Line △ ○ 3.31, 3.51
Check Hydraulic Oil Level ○ 2.48

Greasing ○ 3.19
Replace Hydraulic Oil Return Filter △ ○ 3.31, 3.37
Loading
Replace Hydraulic Oil, Clean Filter ○ 3.45
system
Replace Filter in the Oil Tank Cap ○ 3.51
Replace Bucket Teeth (option) ○ 3.8
Replace Cutting Edge (option) ○ 3.9
3.7
MAINTENANCE

10 50 250 500 1000 1500 2000 Required
Adjust and Check Rear View Mirrors ○ 2.55

○ 2.55
Cab
Greasing (Center Pin) ○ 3.21
Chassis
Check Ride Control Accumulator (option) ○ 3.53
Check and/or Replace Seat Belt ○ 3.10
Check Windshield Washer Fluid ○ 3.13
Check Monitor Panel Operation ○ 2.56
Check Horn Operation ○ 2.55
Electrical Check Back-up Alarm Operation ○ 2.62

system Check Wiring Harnesses ○ 2.51
Check Battery Electrolyte Level ○ 3.22
Check or Replace Fuses ○ 3.13
Check Drive Belt ○ 2.53
Clean Air Conditioner and Heater Filter
○ 3.30
Element
Air Check Air Conditioner Refrigerant ○ 3.40
Conditioner
Replace Air Conditioner Filter Elements ○ 3.16
Clean Air Conditioner Condenser ○ 3.14
Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours ○ 3.17
Others Walk-Around Inspection ○ 2.46
3.8
MAINTENANCE
When Required Inspection and Maintenance
When Required Inspection and Replace Bucket Teeth (option)

Maintenance
CAUTION
WARNING Teeth and bucket edges are hardened steel
which may chip when struck by steel hammer
Improper inspection or maintenance could result causing injury.
- Always wear eye protection.
Read, understand, and follow all warnings and - Use deadblow hammer or brass drift between
instructions contained in "Safe Maintenance" hammer and tooth.
page 1.11 before performing any inspection or - Keep bystanders away from work area.
maintenance procedures.
When the bucket teeth are worn, replace them as

follows.
1. Park the machine on level ground and apply

the parking brake.
Driving tool
Tooth
Pin
95ZV0014
2. Raise the bucket to a convenient height and

put blocks under the bucket to prevent it from
coming down.
3. Stop the engine.
4. Remove the pin and tooth using a tool.

3.9
MAINTENANCE
Replace Cutting Edge (option)
1. Park the machine on level ground and apply

the parking brake.
Tooth adapter
95ZV0015
5. Install the tooth onto the tooth adapter.
65ZV0011
2. Raise the bucket to a convenient height and

Guide rib put blocks under the bucket to prevent it from
facing coming down.
back
3. Stop the engine.
4. Remove the cutting edge. Clean all contact

surfaces (bottom of bucket, top of cutting
95ZV0016
edge).
5. If other side of the cutting edge is not worn,

6. Install the pin with the guide rib facing back. turn it around and install it so that the new side
faces the front. If both sides are worn, install a
new cutting edge.
2 to 4-poundhammer 6. Install all bolts and tighten them to 696 ~ 834N-

m (514 ~ 615ft-lb).
7. Retighten them after a few hours operation.
95ZV0017
7. Tap the pin in flush ear using 2 to 4 pound

hammer. (1 ~ 2kg)
NOTE
For non-Kawasaki buckets or teeth, consult the
manufacturer for the proper procedures.
3.10
MAINTENANCE
Check and/or Replace Seat Belt Clean or Replace Air Cleaner Element
When the warning monitor lamp lights up, clean or

replace the air cleaner element.
IMPORTANT
Seat Belt
Improper procedure of cleaning air cleaner may
cause severe engine damage.
- Do not clean or replace air filters while engine

is running.
Tether
- Clean only outer element. Never clean inner
element.
70ZV0017 - Clean or replace element only when indicator
lamp comes on.
1. Inspect the condition of the seat belt and all
mounting hardware frequently. 1. Park the machine on level ground, apply the
2. Replace the seat belt or any part of the mount- ground, and stop the engine.
ing hardware if it is damaged.
3. Replace the seat belt every three years regard- 1

less of its condition or appearance.
97ZVOM0137
2. Remove the cover (2) by loosening wing nut

(1).
3. Remove the outer element.

3.11
MAINTENANCE
Clean Radiator / Air cooler / Hydraulic

oil cooler Fins

OM0138
4. If the element is clogged by dirt or dust, spray

dry compressed air (196kPa (30psi)) along the
inside of the element up and down to blow off
dust. Do not breathe the dust. If necessary
wear a protective mask. 97ZVOM0135
OM0139
97ZVOM0140
5. Insert a lamp inside of the element for check-

ing a damaged element.
2. Push the knob and open the radiator grill.
Open covers on the radiator guard both the
6. If bright light spots are seen through the ele-
right hand side and the left hand side for clean
ment, there are cracks or pinholes in the ele-
the air cooler and hydraulic oil cooler.
ment. Replace it with a new element.
7. Inspect the rubber seal (3). If there is any dam- WARNING

age to the seal, replace the element.
Contact with moving fan could result in death or
serious injury.
8. Confirm that the wing nut is tight and the inner
element is properly seated, then reinstall the
Always close and lock the covers on the radiator
outer element, cover (2) and wing nut (1).
guard unless carrying out maintenance work.
9. Even after cleaning, if the engine exhaust gas
Stop engine before opening the covers.
is not clean enough (excessive black smoke),
replace the element.
10. After six cleanings or once a year replace the

outer element together with the inner element.
3.12
MAINTENANCE
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.
97ZVOM2444
3. Remove clean-out traps from bottom of radia-

tor shroud.
IMPORTANT
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 196kPa
(30psi) or less.
- When using high-pressure water, keep the
nozzle a distance of at least 500mm (20in)
away from the core surface, applying the
water jet perpendicular to the core.
- Move nozzle from side to side; not up and
down.
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.
7. Close the engine side panels and covers.

3.13
MAINTENANCE
Check or Replace Fuses Check Windshield Washer Fluid
97ZVOM0086 97ZVOM0105

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
97ZVOM0087
mixture according to the manufacturer's
instructions.
ground.
2. Stop the engine and turn the starter switch key

to the "OFF" position.
3. Open the covers of the main fuse box and cab

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

replace them with new ones.
Refer to "Fuse Boxes" page 2.31.
5. Determine the cause of the blown fuses and

repair.
IMPORTANT
Using wrong capacity fuse or bypassing fuse
may cause electrical system damage.
Never replace fuses with higher amperage rat-

ing.
3.14
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
machine.
95ZVOM054f Stop engine and allow radiator and coolant to

pressure.
ground, and stop the engine. 1. Park the machine on level ground, apply 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 196kPa (30psi). If a pressure tle.
washer is used, keep the nozzle about 50cm
(20in) away from the fins to prevent fin dam-
age.
1
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.
2
IMPORTANT
An excessively high air or water discharge pres-
sure can damage the condenser fins.
97ZVOM0143
- When used for cleaning purposes, the pres-

sure of compressed air should be at 196kPa
3. Lift the lever (1) to release any remaining pres-
(30psi) or less.
sure.
- When cleaning with water, apply the water jet
perpendicular to the core.
4. Remove the cap (2) slowly.
3.15
MAINTENANCE
12. Stop the engine and remove the drain plug to

drain the cooling system.
13. If the water being drained is still dirty, the sys-

tem must be flushed again until the water is
clean (step 7 ~ 13).
14. Close the drain cock and fill the system with
the premixed coolant.

the mixing instruction.
3
95ZVDOM4104
1000hrs 2years
5. Open the drain plug (3) and drain coolant 25units 50units
about 96liters (25.4gal.) into a suitable con-
tainer. 15. Add two bottles of DCA65L and two bottles of
DCA60L coolant additive at the same time.
Do not remove the coolant filter.
16. Idle the engine for five minutes to purge air
6. Follow local regulations to properly dispose of mixed into the coolant. (Leave the radiator cap
or recycle the coolant. off.)
17. Add coolant as necessary.

CAUTION
Cooling system conditioner contains alkali that 18. Reinstall the radiator cap.
may cause caustic burns or blindness.
For additional cold weather servicing information,
Avoid contact with skin and eyes to prevent refer to "Coolant Specification" page 3.57 for
injury. details.
7. Close the drain cock and fill the cooling system

with clean water and cooling system cleaner.
Follow the manufacturer's instructions.
Do not install the radiator cap.
8. Operate the engine for one hour with the cool-

ant temperature above 80ºC (180ºF). Then let
the engine cool down naturally with the engine
shut "OFF".
9. Stop the engine and remove the drain plug to

drain the cooling system.
10. Close the drain cock and fill the cooling system
with clean water.
Do not install the radiator cap or the new cool-

ant filter.
11. Operate the engine for five minutes with the

coolant temperature above 80ºC (180ºF).
3.16
MAINTENANCE
Replace Ether Cylinder Replace Air Conditioner Filter Elements
WARNING Outer filter replacement

Ether is very flammable and can could serious
injury or death if exploded.
parking brake and lower the attachment to the
ground.
Do not store new or used ether cylinder in opera-
tors area or at temperatures above 40ºC (105ºF).
2. Turn the air conditioner "OFF" and stop the
engine.
Store new or used ether cylinder in cool place
and out of children's reach.
Never dispose of cylinder by burning, crusing, or
puncturing.
70ZV0018
3. The cover for the outer filter is located at the

97ZVOM0142
left rear side of the cab.
Turn the rings counterclockwise and then

1. Remove the cover. remove the cover.
2. Loosen the clamp.
3. Remove (turn counterclockwise) the cylinder.
4. Install (turn clockwise) a new ether cylinder.
5. Tighten the clamp.
70ZV0019
4. Remove the outer filter from the cab, and

replace it with new one. (Part number 40330-
60270)
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.
3.17
MAINTENANCE
Replace Air Conditioner Receiver Dryer
(Every 3 years or 6000 hours)
- Contact your Kawasaki dealer.
70ZV0018
5. Install the cover to the cab and turn the rings

clockwise to fix the cover.
Inner filter replacement
Inner filter
Filter cover
70ZV0020
1. The inner filter is located at the right behind the

operator's seat.
Unscrew the turn knob to remove the filter

cover.
Remove the filter and clean or replace with a

new one.
(Part number BER525777)
Filter may be washed with mild detergent.

Refer to "Clean Air Conditioner and Heater Fil-
ter Element" page 3.30
3.18
MAINTENANCE
Every 10 Hours or Daily
Every 10 Hours or Daily
WARNING
Improper inspection or maintenance could result
Read, understand, and follow all warnings and

instructions contained in "Safe Maintenance"
page 1.11 before performing any inspection or
See "Check before Operation" page 2.46 and

"Check after Starting the Engine" page 2.59.
3.19
MAINTENANCE
Every 50 Hours or 1 Week
Every 50 Hours or 1 Week Greasing

WARNING parking brake, lower the attachment to the
Improper inspection or maintenance could result ground, and stop the engine.
Read, understand, and follow all warnings and Wipe and clean all fittings before greasing.
page 1.11 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
90ZV0004 97ZVOM0149
- Lever-Rod - Bucket Cylinder-Front Chassis

(two places) (two places)
90ZV0005 97ZVOM0150
- Lever-Boom - Boom Cylinder-Boom

90ZV0005 97ZVOM0151
- Bucket Cylinder-Lever - Boom Cylinder-Front Chassis

3.21
MAINTENANCE
97ZVOM0154
97ZVOM0150
- Boom-Front Chassis
(two places)
97ZVOM0154
- Center Pin
97ZVOM0155
(two places)
- Steering Cylinder
(four places) L.H. and R.H.
3.22
MAINTENANCE
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

97ZVOM0145 hand, eye, and face protection when working on
2. Prepare a suitable container.
If lead, or acid contacts skin or clothing, immedi-
3. Loosen the plug on the bottom of the fuel tank. ately wash with water.
4. Drain water and sediment along with fuel. Dispose of used batteries by recycling.
5. Close the plug.
6. Properly dispose of the drained fuel and water.
7. Add fuel.
NOTE
To reduce water and sediment build up in the tank,
refuel the machine at the end of each shift.
3.23
MAINTENANCE
Check Tire Air Pressure
Low Pressure OK High Pressure
97ZVOM0094
1. Park the machine on level ground, apply the 97ZVOM0103

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 15m (50ft).
reaches the bottom of the filler neck.
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
Recommended Tire Air Pressure (Bias ply tire)
Air pressure
Size Pattern
kPa (psi)
392~412
26.5-25-24PR L-3
(57~60)
324~343
29.5-25-22PR L-3
(47~50)
324~343
29.5-25-28PR L-3
(47~50)
OM0032
Same pressure for all four tires.
For radial tires, tires with other patterns, or special

WARNING operating conditions consult the tire manufacturer.
Explosive separation of tire and rim parts could
result in death or serious injury. For liquid tire ballast consult your Kawasaki dealer
or the tire dealer.
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

instructions contained in "Safe Maintenance" Refer to "Recommended Lubricants" page
page 1.11 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.
97ZVOM0149
- Pillow block bearing unit

(one place)
3.26
MAINTENANCE
Replace Engine Oil and Oil Filter Car-

tridge
CAUTION
Hot oil and engine components may cause
burns.
Avoid contact with hot oil or engine components.
1. If the machine is cold operate the engine to

bring the engine coolant temperature about 97ZVOM0158
40ºC (105ºF). When the needle of the coolant

temperature gauge reaches the middle of the
5. Remove the oil filter and properly dispose of it.
white zone, the temperature is about 40ºC
Make sure the O-ring is removed with the filter.
(105ºF).
6. Clean the oil filter head gasket surface.
7. Fill the new filter with clean engine oil.
3.56 for the oil specifications.
8. Apply a light film of engine oil to the gasket sur-

face of the new filter cartridge.
97ZVOM0157
3. Loosen the drain plug.
4. Drain oil, about 46liters (12gal), into a suitable

container. OM0200
9. Install and tighten the filter until the gasket con-

tacts filter head surface. Then tighten it by
hand an additional three-fourths to one turn.
Refer to the instructions supplied with the filter.
IMPORTANT
Do not over tighten the filter.
10. Close the oil drain plug, and tighten to 78.5N-m

(57ft-lb) torque.
3.27
MAINTENANCE
Check Differential Gear Oil

(two places)
Oil Fill
CAUTION
The axles are pressurized through the hydraulic
oil tank.
When removing the oil level check plug a large
volume of hot oil could spray out. It causes seri-
Dipstick ous burns.
Before removing the oil level check plug, push

97ZVOM0087
down on the hydraulic oil tank cap to release the
air pressure inside the hydraulic oil tank.
11. Fill the engine with clean oil to the proper level.
Do not touch the parts or oil when it is hot.
3.56 for the oil specifications. Total system 1. Park the machine on level ground, apply the
capacity including the filter is 45.4liters (12gal). parking brake, lower the attachment to the
12. Idle the engine to inspect for leaks at the filter
and the drain plug.
WARNING
13. Stop the engine. Wait approximately five min- If the boom is raised to ease access securely
utes to let the oil drain back to the oil pan. block or brace the boom to prevent accidental
lowering.
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

and filter.
CAUTION
Used engine oil may cause skin disease or irrita-
tion.
Do not allow used engine oil to remain on skin

97ZVOM0159
for prolonged periods of time.
Clean skin thoroughly with soap and water. 2. Remove the oil level plug from the front axle
housing, using a 12mm hex (Allen) wrench.
3. If the oil level is lower than the plug, add the

specified oil through the level plug hole.

3.56.
3.28
MAINTENANCE
4. If there is any sign of water in the oil, drain and Check Planetary Gear Oil
replace the oil. Oil containing water looks (four places)
milky.
Dispose of the drained oil properly. CAUTION

5. Install and tighten the level plug. oil tank.
6. Check the rear axle oil level following the same volume of hot oil could spray out. It causes seri-
steps. ous burns.

the hydraulic oil tank cap to release the air pres-
sure inside the hydraulic oil tank.
1. Check the oil level on all four wheels.
2 1
TOP
97ZVOM0160
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 the oil level plug (2) on the housing,

using a 12mm hex (Allen) wrench.
5. If the oil level is lower than the plug, add the

specified oil through the level plug hole.

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.
3.29
MAINTENANCE
7. If there is any sign of water in the oil, drain and Check Tightness of Wheel Bolts
replace the oil. Oil containing water looks
milky. 1. Park the machine on level ground, apply the
Dispose of the drained oil properly. ground, and stop the engine.
8. Install and tighten the level plug.
TOP
97ZVOM0160
2. Check the wheel bolts are tightened to 892N-m

(658ft-lb).
3. Retighten if necessary.
3.30
MAINTENANCE
Clean Air Conditioner and Heater Filter 6. To remove more stubborn debris, wash the fil-
Element ter with clean water. Leave them for five to
seven days to dry out of direct sunlight.
Outer filter cleaning 7. After approximately 8 ~ 10 cleanings, replace

the filter with new one. (Part number 40330-
1. Park the machine on level ground, apply the 60270)
ground. Refer to "Replace Air Conditioner Filter Ele-
ments" page 3.16.
2. Turn the air conditioner "OFF" and stop the
engine. 8. 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.
70ZV0018
70ZV0018
3. The cover for the outer filter is located at the
left rear side of the cab.
9. Install the cover to the cab and turn the rings
Turn the rings counterclockwise and then clockwise to fix the cover.
remove the cover.
Inner filter cleaning
Inner filter
Filter cover
70ZV0019
70ZV0020
4. Remove the outer filter from the cab.

1. The inner filter is located at the right behind the
5. Remove dust with compressed air. Use air
operator's seat.
pressure below 196kPa (28psi).
Unscrew the turn knob to remove the filter
cover.
Remove the filter and clean.
3.31
MAINTENANCE
2. Remove dust with compressed air. Use air Replace Filter

pressure below 196kPa (28psi). (First time replacement or cleaning only)
3. After approximately 8 ~ 10 cleanings, replace - Transmission Oil Filter Cartridge
the filters with new one. (Part number
BER525777) Replace it first time only at 250 hours operation,
after that replace it at every 500 hours opera-
Refer to "Replace Air Conditioner Filter Ele- tion.
ments" page 3.16.
Refer to "Every 500 Hours or 3 Months" page
4. Install the filter elements, install the filter cover. 3.32.
NOTE - Hydraulic Oil Return Filter
It is recommended to have a second set of filters to
use while another set is drying. 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

3.37.
- 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

3.51.
- 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

3.52.
3.32
MAINTENANCE
Every 500 Hours or 3 Months
Every 500 Hours or 3 Months Replace Transmission Oil Filter Car-

tridge
WARNING
CAUTION
Improper inspection or maintenance could result
in death or serious injury. Hot oil and components may cause burns.
Read, understand, and follow all warnings and Avoid contact with hot oil or components.
page 1.11 before performing any inspection or 1. If the machine is cold, operate the machine to
maintenance procedures. bring the torque converter oil temperature
about 30 to 40ºC (85 to 105ºF).
Every 500 hours or 3 months, whichever comes
first, perform the following inspection and mainte- 2. Park the machine on level ground, turn "ON"
nance in addition to the "Daily", "50 hours", and the parking brake switch, lower the attachment
"250 hours" inspection and maintenance. to the ground, and stop the engine.
3. Place a suitable container (about 4liters

(1gal.)) under the transmission oil filter.
97ZVOM0106
4. Turn the filter counterclockwise to remove.

Properly dispose of the oil and filter.
5. Clean the filter head gasket surface.
6. Apply a light film of clean engine oil to the gas-

ket surface of the new filter.
7. Install the filter on the filter head. Turn it clock-

wise to tighten. Follow the instructions on the
filter.
8. Idle the engine about ten minutes and inspect

for leaks around the filter.
3.33
MAINTENANCE
DANGER
When inspecting or servicing machine in articu-

lation area:
- Put transmission shift lever in neutral.
- Place "DO NOT OPERATE" tag on steering
wheel.
97ZVOM0106
9. Check transmission oil level.

Refer to "Check Transmission Oil Level" page
2.60.
Add the specified oil as necessary to bring the
oil level to the "H" (high) mark on the dipstick.
3.56 for the specified oil.
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.

3.34
MAINTENANCE
Every 1000 Hours or 6 Months Greasing

instructions contained in "Safe Maintenance" Before lubricating the seal with grease, remove
page 1.11 before performing any inspection or the breather nipple (A).
Lubricate until the grease comes out from the
breather installation hole.
Every 1000 hours or 6 months, whichever comes
first, perform the following inspection and mainte- After that, wipe it and install the breather nipple
nance in addition to the "Daily", "50 hours", "250 back again.
hours", and "500 hours" inspection and mainte-
nance. Refer to "Recommended Lubricants" page
3.56 for the correct grease. Use lithium base
grease for universal joints.
97ZVOM0161
97ZVOM0162
- Differential seals
(two places)
3.35
MAINTENANCE
Replace Transmission Oil

IMPORTANT
Before lubricating the seal with grease, make WARNING
sure to remove the breather nipple. Accidental movement of machine could result in
If fail to do this, it may cause the oil seal damage. death or serious injury.
When inspecting or servicing machine in articu-

lation area:
- Put transmission shift lever in neutral.
- Place "DO NOT START" or "DO NOT OPER-
ATE" tag on steering wheel.
CAUTION
Transmission oil may be hot and may cause
burns.
Avoid contact with transmission oil.
1. If the machine is cold operate the machine for

a few minutes to bring the transmission oil tem-
perature about 30 to 40ºC (85 to 105ºF).
2. Park the machine on level ground, turn "ON"

the parking brake switch, lower the attachment
to the ground, and stop the engine.
1 2 97ZVOM0163
3. Remove the drain plug (1) with a 24mm

wrench.
4. Drain oil into a suitable container (about

55liters (14.5gal)).
Properly dispose of or recycle the waste oil.

3.36
MAINTENANCE
5. Loosen the four bolts (2) with a 14mm wrench.
6. Remove the flange (3) together with the pipe

and suction strainer.
Set screw
97ZVOM0106
Flange
13. Check the oil level with the dipstick. Add the
Gasket
specified oil if necessary to maintain the proper
Strainer oil level.
97ZVOM0164
Refer to "Check Transmission Oil Level" page

7. Remove the set screw using a 2.5mm hex 2.60 and "Recommended Lubricants" page
(allen) wrench from the strainer. 3.56.
8. 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.
Reassemble the strainer and flange assembly.
Contact a Kawasaki dealer if you find exces-

sive debris.
9. Reinstall the drain plug and the strainer with a

new gasket.
10. Tighten the four bolts (2) to 53N-m (39ft-lb).
11. Fill with the specified oil.

3.56.
12. Idle the engine and check for leaks.

3.37
MAINTENANCE
Clean or Replace Transmission Replace Hydraulic Oil Return Filter

Breather
CAUTION
Pressurized hydraulic tank is used for this
machine.
Pressurized hot oil may cause injury or burns.

cap.

97ZVOM0165
2. Open the access cover on the left deck.

Filler cap
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.
2
Even after cleaning, if the breather is not clean
enough, replace the breather.
1 97ZVOM0105
4. Install the breather onto the transmission case.

3. Press down the filler cap to relieve the tank
pressure.
4. Clean around the top of the filter cover (1).
5. Remove two bolts (2) with a 17mm wrench and

open the filter cover (1).
The 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.
3.38
MAINTENANCE
Adjust Parking Brake Lining

1
2
WARNING
3 When parking brake is released for adjusting
brake lining, machine could move unexpectedly
4 causing serious injury or death.
5
Make sure to lower attachment to ground, and
put chocks under wheels.
6
97ZVOM0166 1. Park the machine in a safe place on firm level
ground and steer it fully to one side for easier
access.
6. Remove the O-ring (3), spring (4), and bypass
valve (5) from the filter housing. 2. Lower the attachment to the ground and turn
"OFF" the parking brake switch.
7. Remove and properly dispose of the filter (6)
and waste oil.
8. Clean the inside of the filter housing.
9. Replace the O-ring (3). 1
10. Apply a light film of clean hydraulic oil on the

filter cover O-ring surface.
11. Install the filter element (6), bypass valve (5),

spring (4), new O-ring (3) and filter cover (1).
12. Close the access cover. 80ZVUSA0002
8º OM0167
3. Align the 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.
3.39
MAINTENANCE
4. Place wheel chocks in front of and behind the Inspect the Front Parking Brake Pads
tires to prevent the machine from moving. and Rotor
5. Place a "DO NOT OPERATE" tag on the steer-
ing wheel.
Rotor
Pad and carrier
Adjuster wheel Piston
A 95ZV0018
Special Tool B
(Accessory)
97ZVOM0168 1. Park the machine in safe place on firm level

ground, apply the parking brake and lower the
attachment to the ground.
6. Remove a cap of the inspection hole (1) on the
brake drum.
2. Measure the pad thickness.
7. Turn the adjuster wheel fully upward to close
Replace the both pads with new ones, if the
the clearance between the brake drum and the
pad thickness (A) reaches to about 9mm
brake lining (shoe). The adjuster wheel can be
(0.354in.)
reached through the inspection hole.
3. Measure the rotor thickness.
8. Return the adjuster wheel eight clicks down-
ward. (Now the clearance is 0.23mm
Replace the rotor with new one, if the rotor
(0.009in.))
thickness (B) reaches to about 10.5mm
(0.414in.)
9. Check parking brake operation as described
on page 2.62.
Contact your Kawasaki dealers for the replacement
of the pads and/or the rotor.
NOTE
If the brake drum has been excessively hot (ie.
burnt paint) or the parking brake will not adjust,
contact your Kawasaki dealer.
3.40
MAINTENANCE
Check Air Conditioner Refrigerant

Adjust
Appearance of the
of refrig- Solutions
sight glass
erant
Almost clear.
Normal
Any bubbles dis-
appear if the
engine speed is
increased to
1,500min-1.
High
No bubble is
Contact your
seen.
local Kawasaki
95ZVOMMvc-051f loader dealer for
Low inspection and
recharging
1. Apply the parking brake and lower the attach- A flow of bub-
refrigerant.
ment to the ground. bles is visible.
2. Remove the cover.
3. Press the “UP Arrow Switch” to set maximum

air flow.
4. Set the temperature control switch fully to the

cool position and fully open the cab doors.
5. Slightly accelerate the engine to about the mid-

dle speed range.
(compressor speed 1500 ~ 1800min-1 (RPM))
6. Compare the flow of bubbles in the sight glass

of the receiver drier with the drawings in the
following table.
The new receiver drier also has moisture sen-

sor window with color code to indicate moisture
in the system.
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.

3.41
MAINTENANCE
Inspect Automatic Belt Tension Add DCA4 Coolant Additive

2. Lift the lever on the radiator tank cap to release

any remaining pressure, and remove the cap
slowly.
1000hrs 2years
25units 50units
3. Add DCA60L coolant from the coolant filling

97ZVOM0098
port.
DCA60L (5units) 5pcs
parking brake, lower the attachment to the or DCA60L (5units) 1pc
ground, and stop the engine. Remove the key DCA65L (20units) 1pc
and tag "Do Not Start".
4. Idle the engine for five minutes to purge air
2. Open the engine side panel. mixed into the coolant. (Leave the radiator cap
off.)
3. Visually inspect the tensioner pulley and body
for cracks. If any cracks are noticed, the ten- 5. Reinstall the radiator cap.
sioner must be replaced.
4. Check the tensioner for dirt buildup. If this con-

dition exists, the tensioner must be removed
and steam-cleaned.
3.42
MAINTENANCE
Every 1500 Hours or 1 Year
Every 1500 Hours or 1 Year Replace Fuel Filter Cartridge
WARNING CAUTION
Improper inspection or maintenance could result Escaping fuel is flammable and harmful to skin.
Do not smoke while draining moisture and sedi-
Read, understand, and follow all warnings and ment from fuel filter.
instructions contained in "Safe Maintenance" Do not drain with engine running.
page 1.11 before performing any inspection or Do not allow fuel to remain on skin for extended
maintenance procedures. period of time. Wash thoroughly with soap and
water.
Every 1500 hours or 1 year, whichever comes first,

in addition to the "Daily", "50 hours", "250 hours",
and "500 hours" inspection and maintenance.
2. Place a small drain pan (about 1liter (1qt.))
under the fuel filters.
97ZVOM0087
3. Remove and properly dispose of the fuel filters.

ket surface of the new filters.
6. Fill the filter with clean fuel.
7. Install the filter on the filter head.
Turn it until the gasket contacts the filter head

surface.
3.43
MAINTENANCE
OM0200
8. Tighten the filter an additional one-half to

three-fourths turn after the gasket contacts the
filter head surface. Follow the instructions sup-
plied with the filter.
IMPORTANT
Do not over tighten the filter.
3.44
MAINTENANCE
Every 2000 Hours or 1 Year Greasing

instructions contained in "Safe Maintenance" Refer to "Recommended Lubricants" page
page 1.11 before performing any inspection or 3.56 for the correct grease. Use lithium base
maintenance procedures. grease for universal joints.
Every 2000 hours or 1 year, whichever comes first,

in addition to the "Daily", "50 hours", "250 hours",
"500 hours", and "1000 hours" inspections and
maintenance.
97ZVOM0161
97ZVOM0169
- 2nd Propeller Shaft

(four places)
3.45
MAINTENANCE
Replace Hydraulic Oil, Clean Filter
WARNING
Pressurized hydraulic tank is used for this
machine.
Pressurized hot oil may cause injury or burns.

cap.
97ZVOM0162
- 3rd Propeller Shaft ground, and stop the engine.
(two places)
2. Move the bucket and boom control levers back
and forth to relieve the pressure.
97ZVOM0105
3. Insert the key into the side of the filler cap and
turn the key counterclockwise.
4. Press down the filler cap to relieve the tank

pressure.
5. Remove the inlet cap.
CAUTION
Hydraulic oil may be hot and may cause burns.
Avoid contact with hydraulic oil.
6. Prepare a suitable container to catch the drain-

ing oil (about 150liters (39.6gal)).
3.46
MAINTENANCE
15. Close the oil inlet cap.
2 16. Start the engine and allow the engine to idle for
about five minutes.
17. Operate the bucket, boom, and steering cylin-

ders for about five minutes, then lower the
attachment to the ground.
18. Inspect for leaks.
19. Make sure hydraulic oil is to the center of the

1 97ZVOM0097 oil level gauge. Add hydraulic oil if necessary.
7. Remove the drain plug (1) with a 12mm Hex

(Allen) wrench to drain oil.
8. Dispose of the waste oil properly.
9. Remove the nuts with a 14mm wrench to

remove the inspection cover (2).
CAUTION
Compressed air may cause injury.
- Wear protective clothing and eye protection.

- Air pressure must be below 196kPa (30psi).
10. Remove the set bolt in the large suction

strainer (No screw in the small suction strainer)
using a 8mm wrench. Remove the suction
strainers. Inspect and clean them with solvent
and compressed air.
A few small particles in the strainer is normal.

Large metal, rubber pieces, or a large amount
of fine particles is abnormal. If found, contact
your Kawasaki dealer.
11. Clean inside of the tank and magnet plug.
12. Install the suction strainers, new gasket (Part

number 31990-20030) and inspection cover
(2), and tighten the nuts. Do not overtighten.
13. Install and tighten the drain plug.
14. Add the specified hydraulic oil through the oil

inlet hole.

3.56.
3.47
MAINTENANCE
Replace Differential Gear Oil 4. Drain the oil (about 60liters (16gal)) into a suit-
able container.
CAUTION 5. Dispose of the waste oil properly.

oil tank. CAUTION
When removing the oil level check plug a large Used oil may cause skin disease.
ous burns. Do not allow used oil to remain on skin for pro-
down on the hydraulic oil tank cap to release the Clean skin thoroughly with soap and water.
6. Install the drain plug.
7. Refill the recommended oil through the level
1. If the machine is cold operate the machine for plug hole (1) until the oil comes out from the
a few minutes to bring the differential gear oil hole.
temperature about 40ºC (105ºF).
2. Park the machine on level ground, apply the 3.56.
ground, and stop the engine. 8. Install and tighten the level plug.
9. Replace the rear differential oil following the

WARNING same steps.
If the boom is raised to ease access securely
block or brace the boom to prevent accidental Required oil volume for the rear differential is
lowering. about 60liters (16gal).
2
97ZVOM0159
3. Remove the level plug (1) and drain plug (2)

from the front axle housing, with a 12mm Hex
(Allen) wrench.
Some fine metallic powder will normally stick to

the magnet plug.
Simply wipe it off.

3.48
MAINTENANCE
Replace Planetary Gear Oil
CAUTION
oil tank.
ous burns.

down on the hydraulic oil tank cap to release the 2
97ZVOM0159
Do not touch the parts or oil when it is hot. 4. Remove the level plug (2) and drain plug (3)
from the planetary gear housing, using a
1. Replace the planetary gear oil on all four 12mm hex (Allen) wrench.
wheels.
Some fine metallic powder will normally stick to
the magnet plug (2).
1
2 Simply wipe it off.
TOP
5. Drain the oil (about 20liters (5.3gal)) into a suit-
able container.
6. Dispose of the waste oil properly.
CAUTION
Used oil may cause skin disease.
97ZVOM0160
Do not allow used oil to remain on skin for pro-
2. Move the machine on level ground so that
"TOP" mark (1) on the planetary gear housing Clean skin thoroughly with soap and water.
comes to the top.
3. Turn "ON" the parking brake switch, lower the 7. Install and tighten the drain plug.
attachment to the ground, and stop the engine.
8. Refill the recommended oil through the level
plug hole (2) until the oil comes out from the
WARNING hole.
If the boom is raised to ease access securely
block or brace the boom to prevent accidental Refer to "Recommended Lubricants" page
lowering. 3.56.
9. Install and tighten the level plug.
10. Repeat these steps for all four planetaries.

3.49
MAINTENANCE
Clean Fuel Tank Check Vibration Damper

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 sedi-

ment 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. OK
1. Park the machine on level ground, apply the 97ZVOM0174

2. Check the damper on the fan end of the engine
crankshaft.
3. If dents, cracks, mounting bolt looseness, or

any deformations are found, contact your near-
est Kawasaki dealer or Cummins Engine
2 dealer for replacement.
1 97ZVOM0145
2. Open the drain cock or remove the plug (1) on

the bottom of the fuel tank.
3. Drain the remaining fuel into a suitable con-

tainer.
4. Remove the nuts with a 14mm wrench to

remove the inspection cover (2) and clean
inside of the tank.
5. Install the inspection cover with a new gasket.

(Part number 31990-20020) Tighten the nuts
evenly. Do not overtighten.
6. Close the drain cock and fill the fuel tank.
7. Check for any leaks at the cover and plug.

3.50
MAINTENANCE
Check Brake Accumulators Check Injection Pressure
Test the brake accumulators for proper pre-charge - Contact your Kawasaki dealer or local Cummins
of nitrogen gas. engine dealer.
WARNING
Pressurized nitrogen gas in brake accumulator Check and Adjust Valve Lash Clearance
could explode causing serious injury or death.
- Contact your Kawasaki dealer or local Cummins
Never service brake accumulator unless trained engine dealer.
properly.

ground.
2. Run the engine at low idle for five minutes to fill

the brake accumulator with oil.
3. Stop the engine.
4. Turn the key switch to the "ON" position.
5. Count the number of times you can depress

the right hand brake pedal before the brake
warning light comes on.
6. If the number counted is less than nine, there

is some problem with the accumulator. Contact
your nearest Kawasaki dealer.
Check Service Brake Disk Wear
- Contact your Kawasaki dealer.
Check Engine Compression Pressure

engine dealer.
Check and Adjust Injection Timing

engine dealer.
3.51
MAINTENANCE
Replace Filter in the Oil Tank Cap Clean Filter for Brake Line
CAUTION CAUTION
Pressurized hydraulic tank is used for this Hot oil and components may cause burns.
machine.
Vent all pressure by pressing hydraulic cap
Pressurized hot oil may cause injury or burns. down.
Vent all pressure by pressing cap before open- Avoid contact with hot oil or components.
ing.
1 to the ground, and stop the engine.
Center Pin C/L

4
3
Front
2
L.H
97ZVOM0170
97ZVOM0172

Air
3. Insert the key into the side of the filter cap (1) blow
and turn the key counterclockwise. FLOW
4. Press down the filter cap (1) to relieve the tank

pressure.
Filter case Filter Nipple
5. Remove the filter cap.
6. Remove spiral snap ring (2), valve assy (3), OM0212
spring (4), filter element (5).

2. Place a suitable container under the filter.
7. Replace element (5). (Part number 30981-
70330)
3. Remove the nipple with filter and properly
clean the filter.
8. Install the element, spring, valve assy, and spi-
ral snap ring.
4. Install the nipple with filter and tighten it with 60
~ 80N-m (44 ~ 59ft-lb) torque.
5. Idle the engine about ten minutes and inspect

for leaks around the filter.
3.52
MAINTENANCE
Clean Filter for Orbitrol® 6. Install the nipple with filter and tighten it with 60
~ 80N-m (44 ~ 59ft-lb) 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.

to the ground, and stop the engine.

3. Move the steering each way about 2 ~ 3 times

to relieve the pressure.
R.H
Center Pin C/L
Front
97ZVOM0171
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.
3.53
MAINTENANCE
Check Ride Control Accumulator Clean Crankcase Breather Tube

(option)
Clean and check the crankcase breather tube.
WARNING
CAUTION
Pressurized nitrogen gas in ride control accumu-
lator could explode causing serious injury or Wear protective goggles and mask to keep from
death. breathing debris.
Never service ride control accumulator unless

trained properly.
Contact your nearest Kawasaki dealer.
OK
97ZVOM0100
1. Remove the crankcase breather tube from the

breather vent tube.
OK
OM0173
2. Use solvent to clean the inside of the crank-

case breather tube, and dry with compressed
air.
3. Use air pressure to blow through the vent tube.

Replace the vent tube if it is clogged.
3.54
MAINTENANCE
Replace DCA4 Coolant Filter Cartridge
CAUTION
machine.

1
Stop engine and allow radiator and coolant to 2
pressure.
97ZVOM0158
CAUTION 3. Turn the coolant shut-off valves (2).

Hot coolant and engine components can cause
4. Remove and properly dispose of the coolant fil-
burns.
ter (1).
Avoid contact with coolant or engine compo-
nents.
NOTE ket surface of a new DCA4 coolant filter car-
The filter WF2126 is initially installed when the tridge (WF2127).
machine is shipped from the factory. This filter can
not be obtained as a spare parts.

OM0200
7. Install the filter firmly by hand. Follow the

instructions supplied with the filter.
8. Open the coolant shut-off valves and install the

97ZVOM0143
radiator cap.
2. Lift the lever on the radiator tank cap to release 9. Run the engine and check for coolant leaks.
any remaining pressure, and remove the cap
slowly. 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.
3.55
MAINTENANCE
12. If needed, add required amount of the coolant.

the correct mixture.
3.56
MAINTENANCE
Recommended Lubricants
Recommended Lubricants
Ambient Temperature
Refill capacity -22ºF -4 14 32 50 68 86 104 Change Interval
Kind of Oil
(Approximate) -30ºC -20 -10 0 10 20 30 40 (Hours)
SAE10W
Engine oil ∗2
Engine 47liter (12.4gal.) SAE10W-30
(CH4) 500
SAE15W-40
Multi-Purpose ATF
ATF
Engine oil (CD) SAE10W
Transmission 55liter (14.5gal.) 1,000
Mobil TRANS HD-10 Mobil TRANS HD-10
Valvoline DT10
Valvoline DT10
∗1 ISO VG32
Hydraulic tank Hydraulic oil 2,000
150liter (39.6gal.) ISO VG46
Front:
Differential & 100liter (26.4gal.) Mobil TRANS HD-50
Mobil TRANS HD-50
2,000
Planetary Rear: Valvoline DT50 Valvoline DT50
100liter (26.4gal.)
ASTM D975 No.1
Fuel tank 425liter (112.3gal.) Diesel fuel daily
ASTM D975 No.2
Note: ∗1 shows "Hydraulic tank oil capacity at level gauge center."
Engine Use oil that meets engine oil classification API CH4 or CG4.
∗2. Change engine oil every 250 hours unless CH4 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".

Use Mobil TRANS HD-10, Valvoline DT10 or equivalent.
Multi-purpose Automatic Transmission Fluid.
Never mix engine oil, Mobil TRANS HD-10, Valvoline DT10 and/or ATF.
TO-4 SAE30W or SAE15W-40 engine oil can be used for the machines operating
in high ambient temperatures.
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.
Differential & Use Mobil TRANS HD-50, Valvoline DT50 or equivalent with 5% "Antichatter"
Planetary additive or friction modifier.
Lubricating Grease Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for a needle bearing.
3.57
MAINTENANCE
Coolant Specification
Coolant Specification
The machine is originally filled with Long Life Cool-
ant which need not be replaced for the first two
years or 3000 hours.
If Long Life Coolant (permanent type) is not used

for the replacement, it should be replaced every six
months.
Recommended Mixture of Antifreeze
Expected Minimum -35ºC -30ºC -25ºC -20ºC -15ºC

Ambient Temperature (-31ºF) (-22ºF) (-13ºF) (-4ºF) (5ºF)
liter 45.0 50.0 55.0 59.5 64.0
Pure Water
(gal) (11.9) (13.4) (14.4) (15.8) (16.9)
liter 51.0 46.0 41.0 36.5 32.0
Antifreeze
(gal) (13.5) (12.0) (11.0) (9.6) (8.5)
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 (5ºF)) if the engine overheats in a high ambi-
ent 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.
3.58
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 2.47
Wrong grade oil for weather conditions Change oil 3.26
Engine oil pressure Clogging oil filter element Change filter and oil 3.26
warning lamp lights Defective alarm switch
up, and buzzer Oil leakage from pipe or joint
sounds Clogging suction strainer kawasaki or CUMMINS
Excessive engine wear

Defective oil pump
Low engine coolant level Add coolant 2.49
Fan circuit pressure or flow too low kawasaki
Clogging radiator fins Clean 3.11

Coolant temp. warn-
Scale or mineral build up inside radiator Flush or professionally clean 3.14
ing lamp 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 3.42
start when the Starter motor speed too low Booster Battery may be used 2.80
starter motor is turn- Defective engine shut off solenoid
ing Fuel pump failure
(Also see ELECTRI- Incorrect fuel injection timing kawasaki or CUMMINS
CAL TROUBLE- Compression pressure too low

SHOOTING) Defective injectors
Air in fuel lines Tighten fuel connections and filter 3.42
Unstable (rough) Fuel filter element clogging Replace fuel filter 3.42
idling Fuel pump failure kawasaki or CUMMINS
Incorrect fuel injection timing
3.59
TROUBLESHOOTING

Air cleaner element clogging Clean or replace element 3.10
Fuel filter element clogging Replace fuel filter 3.42
Throttle pedal electrical signal incorrect kawasaki
Engine oil level too high Check dipstick and correct level 2.47
Insufficient power Incorrect valve clearance
Piston ring wear
Defective injectors kawasaki or CUMMINS
Fuel pump failure

Air cooler restricted
Wrong type of oil Use correct type of oil 3.56
Engine oil level too low or too high Correct oil level 2.47
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 3.42
White exhaust
Wrong grade fuel replace fuel filter
smoke
(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 3.10
Turbo damage
Black exhaust
smoke kawasaki or CUMMINS
Fuel injection pump failure
Defective injectors
3.60
TROUBLESHOOTING
ELECTRICAL

Broken or slipping alternator belt Adjust or replace belt 2.53
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 1.23
not turn when Insufficient battery charge Battery charge or booster 2.80
starter switch key is Starter switch failure kawasaki
turned to Defective wiring

kawasaki or CUMMINS
"START" Starter motor failure
Hydraulic control levers not in NEUTRAL Move levers to NEUTRAL 2.5
Insufficient battery charging Battery charge or booster 2.80
Engine oil viscosity too high (thick) Replace oil 3.26
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

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 1.22
"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 3.52
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
3.61
TROUBLESHOOTING
HYDRAULIC

Excessively cold oil Warm oil 3.56
Wrong grade oil Replace with proper grade oil
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
Boom natural drift
Leakage from control valve plunger
excessively
Damaged cylinder piston or piston packing kawasaki
Leakage in pilot relief valve

Over load relief pressure too low
Bucket / Attachment
Control valve failure kawasaki
floating or drifting
Natural drift of cylinder / packing
BRAKE

Worn brake lining Adjust or replace lining 3.38
Insufficient oil pressure (will not release)
Parking brake does
Failure of switch or solenoid valve
not work properly kawasaki
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 3.51
Cracked or leaking brake line
Brake valve failure
Brake pressure
Parking brake cylinder leakage kawasaki
drops rapidly
Defective brake accumulator
Defective brake seals
3.62
TROUBLESHOOTING
TORQUE CONVERTER & TRANSMISSION

Excessively cold oil / Wrong oil type Warm oil / Replace oil with 3.56
Parking brake is applied Release parking brake
Engine is running Transmission oil level too low Add oil / Repair leak 2.60
but machine does Transmission suction strainer clogging Clean strainer 3.35
not move Clutch oil pressure too low
Transmission clutch failure
kawasaki
Transmission controller failure
Defective electrical circuit
Service or parking brake dragging Inspect and correct
Low oil level in transmission Refill oil / Repair leak 2.60
Suction strainer in transmission clogging Clean or replace strainer 3.35
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 3.37
Oil leakage from
Seal damage (between engine and torque
transmission kawasaki
converter housing)
Oil level too low Add oil / Repair leak 2.60
Dozing, continuous pushing application Reduce load
Operating in too high a speed range Use lower gear 2.65
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
AIR CONDITIONER

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 2.41
Low cooling when
Condenser fins plugged Clean 3.14
A/C "ON"
A/C filters plugged Clean or replace 3.30
A/C compressor belts slipping/broken Adjust/Replace 2.53
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 2.41
Defective heater motor or switch kawasaki
3.63
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.

3.64
SPECIFICATIONS
Standard or General 7.0yd3 (5.4m3) (Heaped) With Bolt on Cutting Edge (GSC)
Purpose Bucket Capacity 5.8yd3 (4.4m3) (Struck)
Operating Weight 66,330lb (30,080kg)
Engine Model CUMMINS QSX15

Type 4 cycle, Water Cooled, Direct injection, Turbo charged & air cooled inter-
cooler
Displacement 15,032in3 (917cm3)

Rated Power (Gross) 283kW / 2,100min-1 (380HP / 2,100rpm)
Max. Torque (Gross) 1,574N-m / 1,400min-1 (1,160ft-lb / 1,400min-1)
Tire (standard) 29.5-25-22PR(L3)
Max. Running Speed 1st : 4.8MPH ( 7.8km/h) / 5.1MPH ( 8.2km/h)

(forward/reverse) 2nd : 8.9MPH (14.3km/h) / 9.3MPH (15.0km/h)
3rd :14.3MPH (23.0km/h) / 15.0MPH (24.1km/h)
4th :22.3MPH (35.9km/h) /
The weight and load figure includes optional counterweight, enclosed ROPS cab, air conditioner, GSC bucket
with bolt-on cutting edge, 29.5-25-22PR (L-3) tires, full fuel tank and operator.
INDEX
12 Volt Power-outlet Socket (S/N 5207~) ................2.19 Check Monitor Panel Operation ..............................2.56
Check or Replace Fuses .........................................3.13
Check Parking Brake ...............................................2.55
A
Check Parking Brake Operation ..............................2.62
Accelerator Pedal ......................................................2.6
Check Planetary Gear Oil ........................................3.28
Add DCA4 Coolant Additive .....................................3.41
Check Ride Control Accumulator (option) ...............3.53
Adjust and Check Rear View Mirrors .......................2.55
Check Service Brake Disk Wear .............................3.50
Adjust Parking Brake Lining .....................................3.38
Check Service Brake Operation ..............................2.61
Adjustments .............................................................2.77
Check Steering Wheel Operation ............................2.62
After Storage ............................................................2.86
Check Tightness of Wheel Bolts ..............................3.29
Air Cleaner Warning Lamp (red) ..............................2.25
Check Tire Air Pressure ..........................................3.23
Articulation Stopper .....................................1.22, 2.51
Check Tire for Damage , Air and Tread Depth ........2.52
Auto Brake ...............................................................2.67
Check Transmission Oil Level .................................2.60
Auto Brake Indicator Lamp (red) ..............................2.23
Check Vibration Damper .........................................3.49
Auto Shift Indicator Lamp ........................................2.26
Check Warning Lamps ............................................2.59
Auxiliary Attachment Control Lever (option) ..............2.5
Check Windshield Washer Fluid ..............................3.13
Check Wiring Harnesses .........................................2.51
B Clean Air Conditioner and Heater Filter Element ....3.30
Before Starting Safety ................................................1.4 Clean Air Conditioner Condenser ............................3.14
Before Storage .........................................................2.85 Clean Crankcase Breather Tube .............................3.53
Boom Control Lever ...................................................2.4 Clean Filter for Brake Line .......................................3.51
Boom Kickout Adjustment ........................................2.78 Clean Filter for Orbitrol® ..........................................3.52
Booster Batteries / Jumper Cables ..........................2.80 Clean Fuel Tank ......................................................3.49
Brake Pedals .............................................................2.7 Clean or Replace Air Cleaner Element ....................3.10
Brake Pressure Warning Lamp (red) .......................2.24 Clean or Replace Transmission Breather ................3.37
Bucket / Attachment Positioner Adjustment .............2.77 Clean Radiator / Air cooler / Hydraulic oil cooler Fins
Bucket Control Lever .................................................2.5 .............................................................................3.11
Cold Start .................................................................2.58
Cold Start (ether injection) Switch ...........................2.14
C COMPONENT NAME/LOCATION ............................2.2
Carrying ...................................................................2.74 Coolant Level Warning Lamp ..................................2.27
Cautions on Battery Replacement or Battery Cable Coolant Specification ...............................................3.57
Removal ...............................................................2.86
Central Warning Lamp (red) ....................................2.23
Charge Lamp (red) ..................................................2.25 D
Check after Starting the Engine ...............................2.59 Dozing .....................................................................2.72
Check Air Conditioner Refrigerant ...........................3.40 Drain Water and Sediment from Fuel Filter .............2.50
Check Air Intake System .........................................2.54 Drain Water and Sediment from Fuel Tank .............3.22
Check and Adjust Injection Timing ..........................3.50 Dumping into Truck or Hopper ................................2.74
Check and Adjust Valve Lash Clearance ................3.50 During Storage ........................................................2.85
Check and/or Replace Seat Belt ..............................3.10
Check Back-up Alarm Operation .............................2.62 E
Check Battery Electrolyte Level ...............................3.22
Economy Switch ......................................................2.19
Check before Operation ...........................................2.46
Electrical Protection .................................................2.31
Check Brake Accumulators .....................................3.50
Emergency Brake ....................................................1.23
Check Control Levers ..............................................2.56
Emergency Steering (option) ...................................1.23
Check Cooling Fan ..................................................2.55
Emergency Steering Warning Lamp (red) (option)
Check Crankcase Breather Tube ............................2.54
.............................................................................2.27
Check Differential Gear Oil ......................................3.27
Engine Coolant Temperature Gauge .......................2.22
Check Drive Belt ......................................................2.53
Engine Coolant Temperature Warning Lamp (red)
Check Engine Compression Pressure .....................3.50
.............................................................................2.24
Check Engine Coolant Level ...................................2.49
Engine Oil Pressure Warning Lamp (red) ................2.24
Check Engine Oil Level ...........................................2.47
Engine Warning Lamps ...........................................2.27
Check Exhaust Gas .................................................2.63
Every 10 Hours or Daily ...........................................3.18
Check Fuel Level .....................................................2.60
Every 1000 Hours or 6 Months ................................3.34
Check Horn Operation .............................................2.55
Every 1500 Hours or 1 Year ....................................3.42
Check Hydraulic Oil Level ........................................2.48
Every 2000 Hours or 1 Year ....................................3.44
Check Injection Pressure .........................................3.50
Every 250 Hours or 1 Month ................................... 3.25 Neutral Start System ............................................... 1.23
Every 50 Hours or 1 Week ...................................... 3.19 Normal Start ............................................................ 2.57
Every 500 Hours or 3 Months .................................. 3.32
Excavating ............................................................... 2.72
Explosion / Fire / Burn Prevention ........................... 1.13
O
Operating Techniques ............................................. 2.70
Operating the Machine ............................................ 2.64
F OPERATION ........................................................... 2.46
Check Transmission Shift Lever or Switch .............. 2.56 Operation of the Automatic Temperature Control unit
Forward / Reverse Changeover Switch for K-Lever ............................................................................. 2.42
(option) ................................................................. 2.18 Operational Safety ..................................................... 1.6
Four-way Flasher Switch (option) ............................ 2.16 Operator Safety ......................................................... 1.2
Front Wiper Switch .................................................. 2.15 OPERATOR'S AREA ................................................ 2.3
Front Working Light Switch ..................................... 2.12 Other Maintenance Safety Concerns ...................... 1.14
Fuel Gauge .............................................................. 2.22
Fuse Boxes ............................................................. 2.31
P
Fusible Link ............................................................. 2.32
Parking .................................................................... 2.68
Parking Brake Indicator Lamp (red) ........................ 2.23
G Parking Brake Switch .............................................. 2.11
General Inspection .................................................. 2.63 Parking Safety ......................................................... 1.10
Greasing ...................2.47, 3.19, 3.25, 3.34, 3.44 Pedals and Levers ..................................................... 2.3
Ground Levelling ..................................................... 2.73
Q
H QUAD (Quick Up And Downshift) Switch ................ 2.16
Heater or Air Conditioner ......................................... 2.41 QUAD (Quick Up And Downshift) Switch on K-Lever
Switches ................................................... 2.41, 2.43 (option) ................................................................. 2.18
Ventilation Location and Mode ................. 2.41, 2.43
High Beam Indicator Lamp (blue) ............................ 2.26
R
High-Low Beam Lever / Turn Signal Lever (option)
Radio - AM / FM Cassette (24Volt Type) ................ 2.33
............................................................................. 2.13
Rear Wiper Switch ................................................... 2.15
Horn Button ............................................................... 2.4
Rear Working Light Switch ...................................... 2.13
Hour Meter .............................................................. 2.27
Recommended Lubricants ...................................... 3.56
Recommended Mixture of Antifreeze ...................... 3.57
I Replace Air Conditioner Filter Elements ................. 3.16
Indicators ................................................................. 2.21 Replace Air Conditioner Receiver Dryer ................. 3.17
Inspect Automatic Belt Tension ............................... 3.41 Replace Bucket Teeth (option) .................................. 3.8
Inspect the Front Parking Brake Pads and Rotor .... 3.39 Replace Coolant ...................................................... 3.14
Inspection and Maintenance Table ........................... 3.5 Replace Cutting Edge (option) .................................. 3.9
Replace DCA4 Coolant Filter Cartridge .................. 3.54
Replace Differential Gear Oil ................................... 3.47
K
Replace Engine Oil and Oil Filter Cartridge ............ 3.26
K-Lever (option) ......................................................... 2.9
Replace Ether Cylinder ........................................... 3.16
K-Lever Indicator Lamp (option) .............................. 2.28
Replace Filter .......................................................... 3.31
K-Lever Steering System On / Off (option) .............. 1.21
Replace Filter in the Oil Tank Cap .......................... 3.51
K-Lever Switch (option) ........................................... 2.17
Replace Fuel Filter Cartridge .................................. 3.42
Replace Hydraulic Oil Return Filter ......................... 3.37
L Replace Hydraulic Oil, Clean Filter ......................... 3.45
Light Switch ............................................................. 2.12 Replace Planetary Gear Oil ..................................... 3.48
Loading .................................................................... 2.70 Replace Transmission Oil ....................................... 3.35
Loading Control Lever Lock .......................... 1.21, 2.8 Replace Transmission Oil Filter Cartridge ............... 3.32
Long Term Storage ................................................. 2.85 Reversal Fan Switch (option) .................................. 2.20
Ride Control Indicator Lamp (green) (option) .......... 2.28
Ride Control Switch (option) .................................... 2.17
M Ride Control System (option) .................................. 2.45
MAINTENANCE ........................................................ 3.2 Roading / Special Applications ................................ 2.79
Mounting and Dismounting Safety ............................ 1.3 ROPS (Roll Over Protective Structure) Cab
................................................................. 1.24, 2.55
N
Neutral Indicator Lamp ............................................ 2.26
S
Safe Operation ...........................................................1.2
SAFETY .....................................................................1.2
Safety Devices .........................................................1.21
Safety Preparations Before Maintenance ................1.11
Safety Signs .............................................................1.16
Seat .........................................................................2.29
Seat Adjustment ......................................................2.29
Seat Belt ..................................................................2.30
Serial Number Location .............................................3.2
SPECIAL PROCEDURES .......................................2.77
SPECIFICATIONS ...................................................3.63
Speed and Direction Change ...................................2.65
Starter Switch ..........................................................2.11
Starting the Engine ..................................................2.57
Starting the Machine ................................................2.64
Starting the Machine on a Grade .............................2.65
Steering Column Telescopic Tilt Handle ....................2.8
Stopping the Engine ................................................2.69
Switches ..................................................................2.10
T
Tachometer ..............................................................2.22
Torque Converter Oil Temperature Gauge ..............2.22
Torque Converter Oil Temperature Warning Lamp
(red) ......................................................................2.25
Towing .....................................................................2.82
Transmission Control Warning Lamp (red) ..............2.23
Transmission Cut-Off (Declutch) Lamp (green) .......2.23
Transmission Cut-Off (Declutch) Switch ..................2.14
Transmission Oil Filter Warning Lamp (red) ............2.25
Transmission Shift Lever ...........................................2.4
Transmission Status Monitor ...................................2.26
Transportation ..........................................................2.83
TROUBLESHOOTING .............................................3.58
Turn Signal Indicator Lamp (Left) (green) ................2.25
Turn Signal Indicator Lamp (Right) (green) .............2.26
Typical Truck Loading Methods ...............................2.76
W
Walk-Around Inspection ...........................................2.46
When Required Inspection and Maintenance ............3.8
Working Light Indicator Lamp (green) .....................2.23
Wrist Rest (adjustable) ..............................................2.6
Maintenance Log
Date Machine hours Service performed

Notes

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93115-00264

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

Always follow safe operating and maintenance practices.

Wear safe clothing:

OM0001 - Close fitting clothing -- loose or baggy clothing

- Do not wear jewelry that may catch on the

Be aware of the location and meaning of safety

Be alert and ready to operate the machine safely:

- Do not operate if excessively tired.

- Do not operate if taking medication that causes

- Do not operate if under the influence of alcohol

Mounting and Dismounting Safety

Maintain three points of contact when climbing (two

When mounting or dismounting, never carry tools

Climb and step only where steps and handrails are

Use only the handrails provided to climb -- do not

Use extra caution mounting and dismounting when

Never jump from the machine regardless if

Report or replace any damaged or missing steps,

Before Starting Safety

Know the location of safety items and procedures:

Walk around the machine to be sure no one is

- Broken lights, mirrors, windows, etc.

- Transmission Shift Lever -- Neutral

In case of fire during operation:

- Turn off the starter switch and stop the engine.

Depending on the situation, the way of evacuation

Articulation Stopper 97ZVOM0004

Securely lock the cab door either fully open or

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

cause explosion by high temperature in the cab. OM0182

Do not bring inflammable or explosive materials

Consider the safety of the job site before operating

- Be aware of and avoid cliffs, ditches, trenches,

Do not start to work in an enclosed area if adequate

Blow the horn for a few seconds just before starting

Avoid working under or near overhanging material

Keep bystanders out of the work area.

Keep the work site as clean and flat as possible.

OM0183 Do not operate the machine at work area close to

When working on a grade: SAFETY DURING NORMAL OPERATIONS:

Using the machine for purposes other than speci-

Do not use the machine as a crane where the

Properly counterweight and ballast the machine

Do not expose the machine to flames.

approx. 40cm (16in.)

- The normal carry position is about 40cm (16in.)

When roading the machine:

- Travel in forward only.

Never position or move the load over the cab of a

SPECIAL OPERATING CONDITIONS:

Reduce speed and avoid rapid steering movement

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

- Use adequate lighting.

If towing or pulling something is required:

- Keep helpers or bystanders away from between

Lower the attachment to the ground and apply the

If parking on level ground is not possible, follow

- Lower the attachment to the ground and apply

To prevent unauthorized use:

- Remove the key.

Inspect the machine and report any needed

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