93109-00573

80Z5
December 24, 2012

OPERATION &
MAINTENANCE MANUAL

WHEEL LOADER

80Z5

NOTICE
93109-00573

READ AND UNDERSTAND THIS

©2012 KCM Corporation. All rights reserved.
MANUAL BEFORE OPERATING
AND SAVE THIS MANUAL ON
Powered by HINO J08C-TI Engine THE MACHINE
Printed in Japan (K)
( 輸出一般向 ) Serial No. 80H1-0501 and up
 93109-00573
December 24, 2012

FOREWORD
Congratulations on your purchase of the Kawasaki Wheel Loader 80Z5.
This manual contains safety, operation, transportation, maintenance and troubleshooting
information. Read and understand the information in this manual carefully before operating
or performing any maintenance of the machine. Failure to do so could result in personal
injury or equipment failure. The safety of yourself and others depends upon your care and
judgement in the operation and maintenance of this machine. Keep the manual with this
machine at all times.

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

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

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

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

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

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

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

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

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

Always follow safe operating and maintenance practices.

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

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

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
effort has been made to ensure it as complete and accurate as possible.
CONTENTS
1.SAFETY ...................................................................................................................................................... 1.1
SAFETY ..................................................................................................................................................... 1.2
Safe Operation..................................................................................................................................... 1.2
Safe Maintenance.............................................................................................................................. 1.12
Safety Signs....................................................................................................................................... 1.18
Safety Devices................................................................................................................................... 1.28
2.OPERATION ............................................................................................................................................... 2.1
COMPONENT NAME/LOCATION ............................................................................................................. 2.2
OPERATOR'S AREA ................................................................................................................................. 2.3
Pedals and Levers ............................................................................................................................... 2.3
Switches .............................................................................................................................................. 2.9
Indicators ........................................................................................................................................... 2.17
Seat ................................................................................................................................................... 2.24
Electrical Protection ........................................................................................................................... 2.28
Air Conditioner ................................................................................................................................... 2.30
Ride Control (option).......................................................................................................................... 2.37
Manual Box........................................................................................................................................ 2.38
Grease Gun Holder............................................................................................................................ 2.39
Quick Coupler (option)....................................................................................................................... 2.40
OPERATION ............................................................................................................................................ 2.43
Check before Operation..................................................................................................................... 2.43
Starting the Engine ............................................................................................................................ 2.52
Check after Starting the Engine ......................................................................................................... 2.54
Operating the Machine ...................................................................................................................... 2.59
Parking............................................................................................................................................... 2.62
Stopping the Engine........................................................................................................................... 2.63
Operating Techniques........................................................................................................................ 2.64
SPECIAL PROCEDURES ....................................................................................................................... 2.72
Adjustments ....................................................................................................................................... 2.72
Roading / Special Applications .......................................................................................................... 2.75
Booster Batteries / Jumper Cables .................................................................................................... 2.76
Towing................................................................................................................................................ 2.78
Transportation.................................................................................................................................... 2.80
Long Term Storage ............................................................................................................................ 2.82
Welding .............................................................................................................................................. 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 ..................................................................................................................... 3.19
Every 50 Hours or 1 Week ................................................................................................................. 3.20
Every 250 Hours or 1 Month .............................................................................................................. 3.26
Every 500 Hours or 3 Months ............................................................................................................ 3.35
Every 1000 Hours or 6 Months .......................................................................................................... 3.39
Every 2000 Hours or 1 Year............................................................................................................... 3.45
Recommended Lubricants ................................................................................................................. 3.55
Coolant Specification ......................................................................................................................... 3.57
TROUBLESHOOTING ............................................................................................................................. 3.58
SPECIFICATIONS ................................................................................................................................... 3.65
 1.1

1.SAFETY
1.2
SAFETY
Safe Operation

SAFETY

Safe Operation
Operator Safety

OM0026a

Wear safe clothing:

OM0001 - Close fitting clothing -- loose or baggy clothing

can catch on equipment or controls.

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

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

OM0180

Be aware of the location and meaning of safety

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

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

- Do not operate if under the influence of alcohol

or drugs.
 1.3
SAFETY
Safe Operation

Mounting and Dismounting Safety

OM0222

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

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

Asbestos is not used both in this product and genu-

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

Use only the handrails provided to climb -- do not

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

Use extra caution mounting and dismounting when

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

Never jump from the machine regardless if

machine is moving or stopped.

Report or replace any damaged or missing steps,

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

Before Starting Safety

OM0012
OM0006

Do not allow unauthorized personnel on the

machine. Only the operator alone should be on the Know the location of safety items and procedures:
machine.
- Fire extinguishers
Do not carry person(s) with this machine like a pas- - Fire blankets
senger car. - First aid kits
- Emergency phone numbers
It is prohibited to raise person(s) put in bucket or
attachment. Walk around the machine to be sure no one is
working or laying under the machine.

Inspect the machine for safety hazards and, if

found, have them corrected:

- Broken lights, mirrors, windows, etc.

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

Be sure the Roll Over Protective Structure (ROPS)

is:

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

OM0005 Articulation Stopper "STORED" 85ZV0002

Perform the normal daily maintenance. - Articulation Stopper -- Locked in the "STORED"
position.
- Back-up Alarm -- Operational

Securely lock the cab door either fully open or

closed.

Secure any loose items inside the cab (lunch

boxes, tools, vacuum bottles, etc.).

After using the ashtray, close the ashtray cap to

Lock avoid fire.

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

Unlock 70ZV0009
cause explosion by high temperature in the cab.

Do not bring inflammable or explosive materials

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

In case of fire during operation:

N - Turn off the starter switch and stop the engine.

- Extinguish fire with a fire extinguisher (Depend
on the situation).
- With hand rails and steps, get off the machine
and stay away from it.

Depending on the situation, the way of evacuation

will be changed. If necessary, periodic fire drill is
65ZV 5089
needed at the work area.

- Transmission Shift Lever -- Neutral

1.6
SAFETY
Safe Operation

OM0007 OM0011

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

Blow the horn for a few seconds just before starting

the engine to alert bystanders.

DANGER

DO NOT
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE

OM0182

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

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

If jumper cables are required to start the engine,

follow the correct procedure in "Booster Batteries /
Jumper Cables" page 2.76.

Operational Safety
Follow the regulations related to this machine, and
drive carefully.
Before operating the machine, refer to "SPECIFI-
CATIONS" listed on page 3.65.
Do not use the machine with excessive load than
specified, to avoid a stack of the machine and/or
any risk of injury caused by potential structural
damage of the machine due to the overload.
Use the permitted attachments and optional parts
provided, when needed, which are suitable for the
operating conditions and job contents.
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.
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.
Do not operate the machine at work area close to
fire or dry grass is.
Do not operate the machine under circumstances
where toxic gas is generated or asbestos is flying in
all directions.
1.7
SAFETY
Safe Operation
Operate the machine slowly over rough ground and
on a grade.
Do not operate on any grade that may be unstable
(loose material, soft material, snow, or ice).
The range of temperature the machine is to be
operated is between -25ºC ~ 35ºC.
When working on a grade:
- Turn "OFF" the declutch switch.
- Keep the attachment low.
- Keep the attachment facing up the grade as
often as possible.
- Drive directly up or down the grade -- never
across the grade.
- Stop when changing direction on a grade to
maintain stability.
- Never coast down a grade.
- Select the same low gear to go down the grade
as was selected to climb the grade. This pro-
vides some engine braking.
OM0018
Before crossing a bridge, make sure that the
capacity of the bridge is greater than the weight of
the machine and any load it may be carrying.
Check for enough clearance before entering a
building, doorway, tunnel, under wires or other
structures.
Do not expose the machine to flames.
Follow all local, federal or provincial laws and regu-
lations regarding calling to locate underground haz-
ards such as buried cables and pipes prior to
digging.
1.8
SAFETY
Safe Operation

SAFETY DURING NORMAL OPERATIONS: When roading the machine:

Vision to the rear on any machine is limited. Always
use special caution when backing up.
Know the machine limits and do not exceed them.
- 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 3 km), periodi-
cally stop to allow tires, transmission, engine to
cool down. Excessive tire heat caused by road-
ing can cause blow-outs and loss of control.

Stop the machine motion immediately if any failure

occurs that causes reduced control (e.g.; engine,
pump, or brake system failures).

Lower the bucket or attachment to stop the

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

Do not use the machine as a crane where the

safety of the operator or other workers are involved.

Properly counterweight and ballast the machine

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

Maintain stability by carrying the load as low as

possible throughout each cycle.
OM0184

Never position or move the load over the cab of a

truck or other vehicle.

approx. 40 cm
OM0016

- The normal carry position is about 40 cm above

the ground.

OM0020
Never use the "Float" position to lower the boom
since it will fall rapidly.
Drive into a load at a medium speed. Do not run
into the material at high speed.
Always be alert for abnormal noises, odors, vibra-
tions, heat, etc.
1.9
SAFETY
Safe Operation
SPECIAL OPERATING CONDITIONS:
OM0185
Avoid entering water deeper than the bottom of the
wheel rim.
If entering water is unavoidable:
- Use caution that there are no hidden hazards --
(drop-offs, holes, rocks, logs, etc.).
- Check for normal braking after leaving the
water.
- Check differential gear oil for contamination.
Reduce speed and avoid rapid steering movement
when traction is poor -- mud, snow, ice, etc. Use tire
chains if necessary.
When darkness, fog, snow, dust, smoke, etc.
reduce visibility, use the following precautions:
- Use adequate lighting.
- Use flashers or beacons (if equipped).
- Reduce speed.
- Periodically stop and inspect the job site.
- Take more frequent breaks to reduce fatigue.
If towing or pulling something is required:
- Keep helpers or bystanders away from between
the machine and the towed vehicle or object.
- Use a cable of adequate capacity and in good
condition.
- Use a cable that has appropriate pull hooks.
- Use only the hitch provided on the rear of the
machine.
1.10
SAFETY
Safe Operation

80ZV0001

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

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

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

Lower the attachment to the ground and apply the

parking brake.

OM0025

If parking on level ground is not possible, follow

these precautions:

- Lower the attachment to the ground and apply

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

To prevent unauthorized use:

- Remove the key.

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

OM0186

Inspect the machine and report any needed

repairs.
1.12
SAFETY
Safe Maintenance

Safe Maintenance
Safety Preparations Before Mainte-
nance

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

may cause accidents.

The maintenance or repair of the machine must be

performed by well-Trained or experienced person-
nel only.
OM0002

Perform maintenance and repairs only if trained.

Follow the Operation & Maintenance Manual or
Shop Manual. - Do not wear jewelry that may catch on equip-
ment, controls, or may short and cause burns if
Air conditioner servicing and repair should be per- in contact with electrical components.
formed by trained specialists since injury and/or
environmental pollution can result from improper
servicing.

Allow only properly trained tire mechanics with the

proper tools to service tires and rims.

OM0222

The inhalation of asbestos-laden dust involves the

risk of having an adverse health effect. At the
wrecking site and the site handling industrial waste,
there is a possibility of inhaling asbestos-laden
OM0026a dust.

Wear safe clothing to perform maintenance:
- Close fitting clothing -- loose or baggy clothing
can catch on equipment or controls.
- Protective clothing as required by the job or con-
ditions -- for example:
- Hard hat
- Gloves
- Steel-toe shoes
- Eye / face protection
- Antidust mask or approved respirator
It is requested that the following measures should
be taken at the site where there is a possibility that
asbestos-laden dust flies in all directions.
- The worker should wear protective equipment
such as a dust-protective mask.
- Sprinkle water in order to prevent asbestos from
flying in the air.
- Do not use compressed air for cleaning work.
- Do not allow any person other than workers to
come near the working site.
- Observe strictly the laws, regulations and rules
regarding the environmental standards at work-
ing sites.
 1.13
SAFETY
Safe Maintenance

Asbestos is not used both in this product and genu-

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

OM0029

Never make repairs on pressurized components.

OM0025
Before performing any maintenance:
- Park on level ground.
- Block the tires securely.
- Apply the parking brake.
- Lower the boom and attachment to the ground.
- Stop the engine (unless specified in the Opera-
tion & Maintenance Manual or Shop Manual).
Use a piece of cardboard or wood to find fluid leaks
under pressure but do not use your bare hand. Die-
sel fuel or hydraulic fluid under pressure can pene-
trate skin or eyes and cause serious injury,
blindness or death.
Release all trapped air and hydraulic pressure by:
- Stopping the engine after lowering the attach-
ment to the ground.
- Moving the loading control levers back and
forth.
- Turning the steering wheel right and left several
times.
- Turning the hydraulic tank cap 1/3 turn counter-
clockwise.
Always ask our authorized dealer in your area to
repair or maintain on pressurized components.
1.14
SAFETY
Safe Maintenance

Support bar
DANGER

DO NOT
START
MEN
WORKING
ON
MACHINERY
SIGNED BY
DATE

OM0182
85ZV28463

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

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

When working beneath the machine, use sturdy

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

70ZV27373

It may be a possibility that your hands or fingers are

pinched with cover suddenly closed by mighty wind
etc.

OM0031 Surely support the cover by support bar when car-

rying on inspection work keeping the cover open.

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

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

Pour all fuel and oil into appropriate containers.

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

Hot oils or coolant and components can cause

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

Keep flame and sparks away from flammable and OM0032

explosive materials such as:

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

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

OM0033

Tire and rim assemblies if improperly serviced can

explode with deadly force. When inflating tires;

OM0187 - Make sure wheel parts are correctly installed.

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

Other Maintenance Safety Concerns

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

To prevent ignition, use the luminaire when check-

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

Move ignitable things to a safe place when grinding

welding or gas cutting.

Charge a battery at well ventilated place and keep

fire away from it during charging.

OM0008

Never weld, drill or in any way modify the ROPS

without approval from the manufacturer.

Stop the engine before opening the engine access

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

During servicing, inspect the wiring harnesses, con-

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

OM0188

Keep the area clear of bystanders and wear eye

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

Keep the area clear of bystanders and wear proper

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

Do not enter the articulation area when engine is

running.

Articulation Stopper "LOCKED"

85ZV0001

When transporting the machine on a truck or lifting

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

Used oil may cause skin disease if allowed to

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

Drain and discard of used oil and coolant properly

to prevent environmental pollution.

Treat the oil and the coolant following the notes on

the MSDS (Material Safety Data Sheet).

Dispose of the waste oil and the coolant following

the law and/or local regulations.

When oil or fuel leaks from the high pressure rub-

ber hose, it may cause an accident or fire by a
wrong actuation. If something is wrong with the rub-
ber hose, immediate repair is needed:

- Correct them and fasten the rubber hose when

a clamp, guard and cushion are loosen. Do not
keep them loosen, or the rubber hose is dam-
aged by vibrating or scratching other parts.
- Fasten the rubber hose with designated torque
when the connection is loosen.
- Exchange the hose base when it is damaged or
deformed.
- Exchange the hose cover when it is damaged,
cut or expanded.
- Exchange the moving contact of the rubber
hose when it is twisted or bent.
1.18
SAFETY
Safety Signs

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

It is very important that all safety signs be on the

machine in the locations shown. If any sign is miss-
ing, damaged, or worn, get a replacement from
your Kawasaki dealer and install it in the correct
position.

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

1. 16.

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

Inside L.H, R.H

44787-23880 44787-24020
L.H, R.H L.H, R.H

80Z5 02597-1235PV

4. 5. R.H 17. 6.

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

1.20
SAFETY
Safety Signs

10. 8. 11.

44787-23850 44787-23870 44787-23900

Inside Inside

80Z5 02597-1235TV

11. 10. 8. Inside 9. Inside

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

 1.21
SAFETY
Safety Signs

2. 13.

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

STOP

44787-23910 44787-23970
L.H, R.H

80Z5 02597-1235RV

3. L.H, R.H 7. L.H, R.H 6. 18.

STOP

44787-23920 44787-23930 44787-24010 44787-24000

1.22
SAFETY
Safety Signs

12.
Parking brake cylinder

80ZV02597-0729EE

44787-23980

Inside of Cab

B A

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

14. 15.

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

44787-23960 44787-23840
 1.23
SAFETY
Safety Signs

1. 3.

STOP

44787-23880 44787-23920

DANGER WARNING

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

2. 4.

STOP

44787-23910 44787-23950

WARNING DANGER

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

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

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

- Remove key and tag "Do Not Operate."

- Release all trapped oil pressure before opening

any piping.
1.24
SAFETY
Safety Signs

5. 7.

44787-23940 44787-23930

WARNING WARNING

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

Unlock articulation stopper before operating Stay out of this machine.

machine.

6. 8.

44787-24010 44787-23870

WARNING CAUTION

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

Do not attempt to service or repair accumulator

unless properly trained and equipped.
 1.25
SAFETY
Safety Signs

9. 10.

44787-23860 44787-23850

WARNING WARNING

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

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

Batteries contain lead, and acid which may result in

minor or moderate injury.

Avoid contact with skin or clothing.

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

ately wash with water.

11.

44787-23900

CAUTION

You may fall from here.

Do not step on here.

1.26
SAFETY
Safety Signs

12. 14.

44787-23980 44787-23960

WARNING WARNING

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

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

44787-23970

WARNING

Machine movement, if engine starts in gear, could

result in death or serious injury.

- Do not start engine by shorting across starter

terminals.

- Do not start engine while standing on ground.

Make sure to start engine only from operator's seat

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

15. 17.

44787-23840 44787-24040

WARNING WARNING

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

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

Follow all safety signs and instructions in Operation

& Maintenance Manual or on machine.

16. 18.

44787-24020 44787-24000

WARNING WARNING

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

Allow system to cool and vent pressure slowly Use of ether could cause explosion and could result
before servicing. in death or serious injury.
1.28
SAFETY
Safety Devices
Safety Devices
Loading Control Lever Lock
DANGER
Accidental movement of boom or machine will
result in death or serious injury.
When parking or leaving machine, or when per-
forming maintenance on it, always lower attach-
ment to ground and lock loading control levers.
Lock
Unlock 70ZV0009
This device locks the loading control levers to pre-
vent accidental lowering of the attachment or boom.
- To lock, set the loading control levers to "NEU-
TRAL" and pull-up the lock lever to forward.
- To unlock, push down the lock lever to back-
ward.
Control Lever Lock for Quick Coupler
Lock Pin [3rd spool valve specification
(option)]
DANGER
During operation if operator accidentally move
the control lever for the quick coupler lock pin,
the lock pin moves accordingly, as a result there
will be a possibility that the attachment falls. It
causes serious injury or death.
Unless the hydraulic source to the attachment is
needed on the machine equipped with the 3rd
spool valve, make sure to lock the control lever
(attachment lever) for the quick coupler lock pin.
This device prevents the attachment from falling in
the following working condition.
When the attachment with no hydraulic source
needed is installed on the 3rd spool valve specifica-
tion machine, during operation if operator moves
the control lever (attachment lever) for quick cou-
pler lock pin, as a result the attachment falls.
Unlock
Lock
70ZV0010e
Lock:
1. Place the control lever (attachment lever) for
the quick coupler lock pin in the neutral posi-
tion.
2. Loosen the screw for the lock plate.
3. Slide the lock plate to lock the control lever.
4. Tighten the screw to fix the lock plate.

Unlock:
1. Loosen the screw for the lock plate.
2. Slide the lock plate to unlock the control lever.
3. Tighten the screw to fix the lock plate.
1.29
SAFETY
Safety Devices
Articulation Stopper
WARNING
With articulation stopper in LOCKED position,
machine will not steer; which, while operating,
could cause an accident, injury or death.
Do not lock Articulation Stopper during normal
operation.
Articulation stopper locks the front and rear chassis
to prevent them from sudden articulation during
inspection or transportation.
To lock:
"LOCKED" position
85ZV0001
1. Align the front and rear chassis straight ahead.
2. Using a 14 mm wrench remove the bolt that
fixes the articulation stopper to the storage
bracket on the front chassis.
3. Remove the clip pin and pin from the end of
the Articulation Stopper.
4. Turn the link and fix the end to the bracket on
the rear chassis (as shown).
5. Insert the pin and clip pin. (This is the LOCKED
position.)
1.30
SAFETY
Safety Devices

To unlock: Neutral Start System

The transmission has a neutral start system which

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

Emergency Brake

When the service brake does not work, emergency

brake can be applied manually.

"STORED" position 85ZV0002

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

the articulation stopper on the rear chassis
bracket.

2. Turn the link to the front chassis bracket.

3. Insert the pin and clip pin. (This is the

STORED position.)

4. Tighten the bolt to fix the articulation stopper 97ZVOM0038

on the bracket.

- Pull the emergency brake switch to engage the

emergency brake and disengage the transmis-
sion.

Secondary Steering (option)
WARNING
Operation without normal steering could cause
loss of control and injury or death.
If secondary steering lamp lights up, steer
machine IMMEDIATELY to safe location and
stop it.
Secondary 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 "Secondary Steering Warning Lamp (red)
(option)" page 2.23.
If the secondary steering works:
1. Keep the starter switch in the "ON" position
even when the engine unexpectedly stops.
2. Immediately operate the steering wheel to
bring the machine to a road shoulder or safe
location.
3. Stop the machine. If necessary, use the emer-
gency brake or lower the attachment to stop
the machine.
4. Place wheel chocks in front of and behind the
tires to prevent the machine from moving.
5. Contact your local Kawasaki dealer for neces-
sary testing and repair.
1.31
SAFETY
Safety Devices
ROPS (Roll Over Protective Structure)
Cab
The ROPS Cab is equipped with a structure
(ROPS) to prevent the cab from being crushed and
protect the operator if the vehicle is overturned. Our
ROPS Cab is also equipped with the FOPS func-
tion to protect the operator from a falling object.
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.
ROPS and FOPS cannot comply with all overturn-
ing or falling-stone accidents.
In case of accidents beyond the following upper
limit conditions, the operator may not be protected.
ROPS
"A machine rolls on a solid clay ground slope tilted
by 30º at 16 km/h or less travelling speed and over-
turns by 360º around an axis in back and forth
direction." (from JIS A8910)
FOPS
"Non-cutting 295.7 kg object falls freely from a 4 m-
height point (or an equivalent potential energy
level)." (based on JIS A8920)
ROPS Cab deformed does not assure safety for
operator as a protective cab.
1.32

MEMO
 2.1

2.OPERATION
2.2
COMPONENT NAME/LOCATION

COMPONENT NAME/LOCATION

24
16 23 22 21 10 9

5 4

20
11
80Z5 COMPO

14 18 12,13 17 6 8 19 15 7

1. Bucket (Attachment) 14. Front Axle / Differential Ass'y

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

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

OPERATOR'S AREA

Pedals and Levers 1. Transmission Shift Lever

Transmission Shift Lever is used to control machine

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

- When the lever is in NEUTRAL, the machine

should not move on level ground.

- Pull the lever backward to move the machine

backward.

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

modes are selected by rotating the shift lever.

6 (option) 7
4

70ZV0010
65ZV 5089

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

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

Horn Button is used to blow the horn.

- Press the button in the center of the steering

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

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

Lever
Boom control lever is used to control the boom
movement.

Low beam position

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

High beam position

97ZVOM0044

70ZV0010
This lever is used to change the head lights beam
high and low. This lever also turns on the turn sig-
nals. (a) Float
- Move the lever to full forward detent position.
- The head lights are in the high beam position The boom will lower and move freely following
when the lever is pushed down (low position). the ground surface.

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

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

- An automatic boom height positioner is provided

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

97ZVOM0044 (c) Hold

- 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.
- Return the lever to the center position. The
boom will stop and remain in that position.
(d) Raise
- Move the lever rearward. The boom is raised.
When pulled fully back it is held in a detonated
position.
- An automatic boom height positioner is provided
which will automatically release the detent and
return the lever to the "Hold" position when a
preset boom height is reached.
 2.5
OPERATOR'S AREA
Pedals and Levers

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

out Adjustment" page 2.73.
Bucket control lever is used to control the bucket or
In case that the boom does not stop moving even
attachment movement.
when the boom control lever is in the HOLD posi-
tion, turn the starter switch to the "OFF" position to
stop the engine.

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

70ZV0010

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

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

(c) Roll Back (Dual Motion)

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

(d) Roll Back (Detent)

- Move the lever rearward. The bucket or attach-
ment will roll back.
- An automatic bucket or attachment leveler is
provided which will automatically release the
detent and return the lever to the "Hold" position
when the bucket or attachment reaches to the
preset angle.
- For adjustment procedure refer to "Bucket /
Attachment Leveler Adjustment" page 2.72.

In case that the bucket does not stop moving even

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

6. Auxiliary Attachment Control Lever 7. Wrist Rest

(option)

Auxiliary attachment control lever is used to control

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

Unlock

(b) (c)
(a)
Lock

65ZV4705

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

70ZV0010
(a) Normally this position will close the attach-
ment.
(b) This center position will cause the attachment
to stop and remain in that position.
operating the bucket/boom control levers.
(High/Low)
Pull the lever out and turn, bringing back to the orig-
inal position, to adjust the height.
(Front/Rear)
Loosen the screws to adjust the position.

(c) Normally this position will open the attachment.

In case that the auxiliary attachment does not stop

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

NOTE
If equipped with attachments other than the stan-
dard bucket, consult the attachment supplier for
specific instructions.

IMPORTANT
Kawasaki will not accept any liability for any
attachments and spare parts not approved by
Kawasaki.
 2.7
OPERATOR'S AREA
Pedals and Levers

8. Accelerator Pedal 9. Brake Pedals

WARNING
Continuous use of brake could cause rapid or
abnormal brake disc wear and / or brake circuit
malfunctions which could cause loss of control
and injury or death.

- Do not use brake pedals as foot rest.

- Do not ride brakes.
- Use brake pedals only when applying brakes.
- Do not allow dirt and debris to build up around
the pedals.
97ZVOM0038 - Be sure the brake pedals move freely before
using the machine.
Accelerator pedal is used to control the engine
speed.

- Step on the pedal to increase the engine speed.

- Release the pedal to decrease the engine

speed.

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

- Be sure control pedals move freely before 97ZVOM0038

operating.
- Do not allow dirt, mud, or debris to build up
Brake pedals are used to reduce the machine
under or around pedals.
ground speed, stop the machine, or to hold the
machine.
In case that the accelerator pedal does not release,
step on one of the brake pedals or turn the starter Left and right Brake Pedals: May be used either of
switch to the "OFF" position. two ways:

1. As a brake only pedal by turning the declutch

switch (See page 2.12) to the "OFF" position.
Use this position when working on slopes or
ramps.

2. Disengage the transmission while applying the

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

To use this feature, turn the declutch switch to

the "ON" position. When the switch is "ON", a
green indicator lamp on the dash will also be
turned on.
2.8
OPERATOR'S AREA
Pedals and Levers

10. Steering Column Telescopic Tilt

CAUTION Handle
Declutch feature momentarily places transmis-
sion in neutral, which may allow machine to roll WARNING
when on a grade.
Unexpected movement of steering column could
Be sure to turn off declutch switch when operat- cause loss of control and result in death or seri-
ing on a grade. ous injury.

- Stop machine before adjusting steering wheel

In case the brake does not work, pull the parking height and angle of steering column.
brake switch to apply the emergency brake. The - Be sure to push down fully the telescopic tilt
parking brake can be used as the emergency handle lock lever before operating machine.
brake.
Steering column telescopic tilt handle is used to
adjust the steering wheel up and down, and to tilt
the steering column forward or backward for opera-
tor's comfort.

Release

Lock

97ZVOM0045

1. Pull up the telescopic tilt handle lock lever and

move the steering wheel to the desired posi-
tion.

2. Push down the telescopic tilt handle lock lever

fully to lock the steering wheel in position.
 2.9
OPERATOR'S AREA
Switches

Switches
(80H1-0501~0700)

11 4
0 0 0 0 0 0 1/10h
AUTO
6 20 30
N
5
C H E F
40
14 10 4
3
0 50 2
13 km/h
1
12
C H

65ZV0001d

(80H1-0701~)

11 4
6 5
14
13 12

80Z5 0002a

3
2 1. Starter Switch
1 2. Parking Brake Switch
3. Light Switch
4. Front Working Light Switch
5. Rear Working Light Switch
9 6. Declutch Switch
7 8 7. Front Wiper Switch
65ZV 5088

8. Rear Wiper Switch (option)

9. Cigarette Lighter (option)
10 10. Downshift Button
11. Four-Way Flasher Switch
12. Reversal Fan Switch (option)
13. Ride Control Switch (option)
14. Light Switch (option)

70ZV0010
2.10
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

All warning lamps light up for three seconds and
automatically light off.
Preheat indicator lamp also lights up as the engine
preheating starts. It automatically lights off in some
seconds.
START
- When the transmission shift lever is in NEU-
TRAL, starter motor turns, starting the engine.
- When released the key will automatically return
to the "ON" position.
Parking brake switch is used for parking the
machine. When the switch is pulled, the parking
brake is applied and the transmission is disen-
gaged. When the switch is pushed, the parking
brake is released.
Should the directional shift lever be moved into the
forward or reverse position while the parking brake
is applied and the engine is running, a warning
buzzer will sound.
 2.11
OPERATOR'S AREA
Switches

3. Light Switch 4. Front Working Light Switch

80Z5 0005

65ZV 5088
OFF

This is a three position switch.

OFF ON
- 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.
switch-4
Front working light switch is used for turning on and
off the front working lights.
Turn off the front working lights when roading to
prevent blinding the driver in front of you.
2.12
OPERATOR'S AREA
Switches

5. Rear Working Light Switch 6. Declutch Switch

80Z5 0005 80Z5 0005

Declutch switch is used to change the function of

the brake pedals.

Normally this switch should be "ON".

OFF
OFF
- When the brake pedals are depressed, only the
service brakes are engaged keeping the trans-
ON mission directional clutch engaged. (brake only)

ON
- When the brake pedals are depressed, the ser-
switch-4 vice brakes are engaged and the transmission
directional clutch is disengaged (brake and
declutch).
Rear working light switch is used for turning on and
off the rear working lights.
Refer to "Brake Pedals" page 2.7 for the function of
both left and right brake pedals.
Turn off the rear working lights when roading to pre-
vent blinding the driver behind you.
CAUTION
Declutch feature momentarily places transmis-
sion in neutral which may allow machine to roll
when on a grade.

Do not turn declutch switch to "ON" when operat-

ing on a grade.
 2.13
OPERATOR'S AREA
Switches

7. Front Wiper Switch 8. Rear Wiper Switch (option)

65ZV 5088 65ZV 5088

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

2.14
OPERATOR'S AREA
Switches
9. Cigarette Lighter (option)
65ZV 5088
Cigarette lighter is used to light a cigarette or cigar.
- Push the lighter in and wait for a few seconds.
The lighter will spring back to be ready for light-
ing a cigarette or cigar.
- The cigarette lighter power-outlet socket can be
used as a power source with max. 24 volts 10
amperes in case of emergency.
10. Downshift Button
70ZV0010
Downshift button 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
downshift button.
- Pressing downshift button again or moving the
transmission shift lever to the opposite direction
releases the 1st gear setting to return to 2nd
gear.
 2.15
OPERATOR'S AREA
Switches

11. Four-Way Flasher Switch 12. Reversal Fan Switch (option)

80Z5 0005 80Z5 0005

OFF

ON ON/OFF

switch-3 switch-4

The two front and two rear turn signal lights will Engaging this switch reverses the rotation of the
flash when four-way flasher switch is ON. cooling fan for cleaning the radiator fins.

This is used in emergency, when parking on the
road, etc. to warn other vehicles.
When pushing this switch for more than 2 seconds
while the engine is running or with the starter switch
at "ON" position, the switch turns "ON", the pilot
lamp 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 turns "OFF". Then the
cooling fan turns in the normal direction.

The cooling fan reversal switch can be operated

any time the engine is running. It is not necessary
to stop the machine to push the reversal cooling fan
switch.
2.16
OPERATOR'S AREA
Switches

13. Ride Control Switch (option) 14. Light Switch (option)

80Z5 0005 80Z5 0005

OFF

OFF OFF
ON
HIGH BEAM LOW BEAM

switch-3 switch-5

When the ride control switch is ON, the ride control
works. Refer to "Ride Control (option)" page 2.37.
This is a three position switch.
OFF
- Width (clearance) lamps (option), tail lamps,
front head lights, and gauge lamps turn off.

(Low beam)
- Width (clearance) lamps (option), tail lamps,
front head lights, and gauge lamps turn on.

(High beam)
- Front head lights are in the high beam position.
 2.17
OPERATOR'S AREA
Indicators

Indicators
(80H1-0501~0700)

1 21 20 5 17 19 18 9 23 4
10

0 0 0 0 0 0 1/10h
11
AUTO
20 30
N
E F
12
C H
40 4
10
3 13
0 50 2
km/h
1
C H 14
15

16
65ZV5003a
25 24 22 6 8 7 3 2

(80H1-0701~)

1 22 21 17 20 19 5 9 7 18 2 4 10

11

12

13
14
15

16

80Z5 0003a

24 23 25 26 8 6 3
2.18
OPERATOR'S AREA
Indicators

1. Speedometer 1. Speedometer
2. Engine Coolant Temperature Gauge
3. Torque Converter Oil Temperature Gauge
4. Fuel Gauge
5. Parking Brake Indicator Lamp (red) 20 30
6. Declutch Lamp (green) 40
10
7. Working Light Indicator Lamp (green)
8. Preheat Indicator Lamp (yellow) 50
0
9. Central Warning Lamp (red) km/h
10. MCU (Machine Control Unit) Warning Lamp
(red) 70ZV0008

11. Brake Pressure Warning Lamp (red)

12. Engine Oil Pressure Warning Lamp (red) Indicates the machine ground speed in km/h.
13. Engine Coolant Temperature Warning Lamp
(red)
14. Torque Converter Oil Temperature Warning
Lamp (red) 2. Engine Coolant Temperature Gauge
15. Air Cleaner Warning Lamp (red)
16. Charge Lamp (red)
17. Turn Signal Indicator Lamp (Left) (green)
18. Turn Signal Indicator Lamp (Right) (green) C H

19. High Beam Indicator Lamp (blue) WATER

TEMP
20. Auto Shift Indicator Lamp (green)
21. Neutral Indicator Lamp (green)
22. Transmission Status Monitor (yellow) 97ZVOM0049

23. Hour Meter

24. Secondary Steering Warning Lamp (red)
(option)
25. Ride Control Pilot Lamp (green) (option)
26. Reversal Fan Pilot Lamp (green) (80H1-
0701~) (option)
When the starter switch is turned to "ON", all warn-
ing lamps (9) ~ (16) and (24) light up for three sec-
onds. This is the lamp (bulb) test period (lamp (16)
lights up until engine starts).
Preheat indicator lamp (8) also lights up when the
starter switch is turned to “ON”, and lights off in
some seconds when the engine preheating is fin-
ished.
Indicates engine coolant temperature. It is normal
when the indicator stays in the white zone
(67~102ºC).
- 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.
- If the gauge stays in the red zone, stop the
engine and allow it to cool naturally. After cool-
ing, check the cooling system.
Refer to "TROUBLESHOOTING" page 3.58.

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.
 2.19
OPERATOR'S AREA
Indicators

3. Torque Converter Oil Temperature 5. Parking Brake Indicator Lamp (red)

Gauge

C
T/C OIL
H
P
TEMP

OM0052

97ZVOM0050
Indicates the temperature of oil circulating through
the torque converter and the transmission. It is nor-
mal if the indicator is in the white zone (56~125ºC)
while operating.
Lights up when the parking brake is applied.
If the transmission shift lever is moved into "F" or
"R" position while this lamp is on, an alarm sounds
and the machine stays in neutral.

- If the indicator enters the red zone while operat-

ing, slow the engine down to mid-range speed,
6. Declutch Lamp (green)
shift to neutral, and wait until the indicator
reaches the white zone.

- If the indicator does not come back into the

white zone quickly, stop the engine and find the
cause.

Refer to "TROUBLESHOOTING" page 3.62. OM0054

Lights up when the declutch switch is "ON".

4. Fuel Gauge - When lit, the service brakes are engaged and
the transmission directional clutch is disen-
gaged by step on the brake pedals.
E F
- When not lit, only the brakes are engaged as the
FUEL brake pedal is step on.

65ZV0005

7. Working Light Indicator Lamp

Indicates the fuel amount in the fuel tank. (green)
- Be sure to refuel at the end of each work day to
avoid condensation in the tank.

OM0055

Lights up when working lights are on.

2.20
OPERATOR'S AREA
Indicators

8. Preheat Indicator Lamp (yellow) 11. Brake Pressure Warning Lamp (red)

WARNING
Loss of braking force could result in death or
serious injury.

OM0176 Stop machine IMMEDIATELY and correct prob-

Lights up when the starter switch is in the "ON"
position.
It automatically lights off in some seconds.
lem if brake pressure warning lamp lights up dur-
ing operation.
Brake Pressure Warning Lamp lights up and the
warning buzzer sounds when the brake oil pressure
is lower than 3.9 MPa.

9. Central Warning Lamp (red)

OM0058

OM0056 - If it lights up while operating, IMMEDIATELY

stop the machine and find the cause.
Flashes when any of the warning lamps come on.
Refer to "TROUBLESHOOTING" page 3.61.

10. MCU (Machine Control Unit) Warn-

12. Engine Oil Pressure Warning Lamp
ing Lamp (red)
(red)

OM0057
OM0059

Lights up when MCU malfunctions.

- If it lights up while operating, stop the engine
and contact your nearest Kawasaki dealer for
necessary repair.
Lights up when engine oil pressure is low. Also the
warning buzzer sounds.
- If it lights up while operating, IMMEDIATELY
stop the engine and find the cause.

Refer to "TROUBLESHOOTING" page 3.58.


13. Engine Coolant Temperature Warn-
ing Lamp (red)
OM0060
Lights up when coolant temperature overheats.
(Over 102ºC)
- If it lights up while operating, slow the engine
speed down to mid-range, shift to neutral, and
wait until the lamp goes out. Check the coolant
temperature gauge before resuming operation.
- If the light does not go out quickly or lights up
again after resuming the operation, stop the
engine and find the cause. Refer to "TROUBLE-
SHOOTING" page 3.58.
CAUTION
Hot coolant spray may cause burns.
Never open radiator cap when engine is hot.
Stop engine and allow radiator and coolant to
cool completely before opening cap slowly to
relieve pressure.
2.21
OPERATOR'S AREA
Indicators
14. Torque Converter Oil Temperature
Warning Lamp (red)
Lights up when transmission oil overheats. (Over
120±5ºC)
OM0061
- If it lights up while operating, slow the engine
speed down to mid-range, shift to neutral, and
wait until the lamp goes out. Check the torque
converter oil temperature gauge before resum-
ing the operation.
- If the light does not go out quickly or lights up
again after resuming the operation, stop the
engine and find the cause. Refer to "TROUBLE-
SHOOTING" page 3.62.
15. Air Cleaner Warning Lamp (red)
OM0062
Lights up when air filter is clogged.
- If it lights up while operating, stop the engine
and clean or replace the air cleaner outer ele-
ment.
Refer to "Clean or Replace Air Cleaner Element"
page 3.10.
2.22
OPERATOR'S AREA
Indicators

16. Charge Lamp (red) 19. High Beam Indicator Lamp (blue)

OM0063 OM0067

Lights up when alternator charge level is low. Lights up when headlights are switched to high
beam.
- If it lights up, check the charging circuit.

Refer to "TROUBLESHOOTING" page 3.60.

20. Auto Shift Indicator Lamp (green)

17. Turn Signal Indicator Lamp (Left)

(green)
AUTO
OM0068

Lights up when the transmission control lever is in

the [A] position.
OM0065

Flashes when the turn signal switch lever is moved

forward. 21. Neutral Indicator Lamp (green)

18. Turn Signal Indicator Lamp (Right)

(green)
N OM0069

Lights up when transmission is in neutral.

OM0066

Flashes when the turn signal switch lever is moved

rearward.
 2.23
OPERATOR'S AREA
Indicators

22. Transmission Status Monitor (yel- 24. Secondary Steering Warning Lamp
low) (red) (option)

4
3
2 OM0072

1 Lights up when the steering hydraulic pressure is

OM0070 lower than specified when the engine is running.

Also the warning buzzer sounds.

- 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.
25. Ride Control Pilot Lamp (green)
- 2nd Gear (option)
Lights up when the shift lever is in [2] or [A]
position and transmission is in 2nd gear.

- 3rd Gear
Lights up when the shift lever is in [3] or [A]
position and transmission is in 3rd gear.
OM0206
- 4th Gear
Lights up when the shift lever is in [A] position Lights up when the ride control switch is ON.
and transmission is in 4th gear.
Refer to "Ride Control (option)" page 2.37.

23. Hour Meter

26. Reversal Fan Pilot Lamp (green)
(80H1-0701~) (option)
1/10h

OM0071

Hour meter indicates the accumulated total hours

of engine operation. Use to determine the timing of
OM0223
periodic inspection and maintenance service.

Lights up when the reversal fan switch is ON.

Refer to "Reversal Fan Switch (option)" page 2.15.

2.24
OPERATOR'S AREA
Seat

Seat Combined Height and Weight Adjuster

Seat Adjustment 1. Sit on the seat.

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

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

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

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

a b
95ZV OM EU SEAT

Reclining

Rotate control handle (1) forward and hold, select

backrest angle, release control handle.

Forward / Backward

Lift lever (2) up and hold, slide seat to desired posi-

tion, release handle.

Armrests

Rotate control knob (3) to select desired angle.

Pivot up and parallel with backrest when not in use.
 2.25
OPERATOR'S AREA
Seat

Seat Adjustment Combined Height and Weight Adjuster

(KAB111)
1. Turn handle (a) to adjust seat height.
Adjust the seat for comfort and so that the pedals
may be pushed fully down when the operator's Clockwise to raise seat.
back is fully back.
Anti-Clockwise to lower seat.

WARNING 2. Sit on the seat and check ride indicator (b)

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

NOTE
The seat is designed so that it is unnecessary to
make any adjustment for the driver weight.

2 1

a b 3 65ZVKAB111SEAT

Reclining

Rotate control handle (1) forward and hold, select

backrest angle, release control handle.

Forward / Backward

Lift lever (2) up and hold, slide seat to desired posi-

tion, release handle.

Armrests

Rotate control knob (3) to select desired angle.

Pivot up and parallel with backrest when not in use.
2.26
OPERATOR'S AREA
Seat

Seat Adjustment Combined Height and Weight Adjuster

(KAB851)
1. Sit on the seat.
Adjust the seat for comfort and so that the pedals
may be pushed fully down when the operator's 2. Pull lever (4) up or push it down to adjust seat
back is fully back. height.

3. Check ride indicator (5) shows green.

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

NOTE
The seat is designed so that it is unnecessary to
make any adjustment for the driver weight.

Armrests
2 Rotate controller (6) under armrest to select desired
7
angle. Pivot up and parallel with backrest when not
3 in use.
1
4
Lumber support
5 6 80ZV AIR SUS.SEAT
Rotate lumber support knob (7) counterclockwise to
adjust the lumber support position.
5 adjusting positions are available.
Reclining

Pull control handle (1) upward and hold, select IMPORTANT

backrest angle, release control handle. Always adjust the seat height when seated.

Forward / Backward Adjusting the seat height should be done in 1

minute. Wait for 30 minutes for the next adjusting
Lift lever (2) up and hold, slide seat to desired posi- operation.
tion, release lever.

Up-Stop Height Adjustment Control

To adjust the up-stop height, rotate control knob (3)

clockwise to raise the seat unseated, rotate it coun-
terclockwise to lower the seat unseated.
 2.27
OPERATOR'S AREA
Seat

Seat Belt

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

- Inspect seat belt and mounting hardware

before operating machine and replace any
defective components.

- Always fasten seat belt when operating

machine.

- Properly adjust seat belt at beginning of each

shift or when operator changes.

1 3
2

OM0007

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

body without kinking or twisting it.

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

buckle (2). Be sure it locks securely.

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

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

The tether is inside the seat boot.

No adjustment necessary.
2.28
OPERATOR'S AREA
Electrical Protection

Electrical Protection
(1) (2)
EMERGENCY
Fuse Boxes SPARE 20A RELAY 5A
HEATER TIMER
(80H1-0501~0700)
AIRCON 20A NEUTRAL RELAY 5A
2 BUZZER
1 AIRCON 10A
MONITOR
5A

AIRCON 5A SPARE 15A

AIRCON 5A SPARE 10A

4 WAY FLASHER
HORN
SPARE 20A 15A
DOME LAMP
RADIO BACK UP
SPARE 10A SPARE 15A
View from top cover 80ZV8214

SPARE 10A SPARE 15A

(80H1-0701~) AIR SUSPENSION
RADIO 3A 10A
SEAT (option)
2
1 SPARE 15A F. WORK LIGHT 15A

PARKING BRAKE
CIGAR LIGHTER 10A 30A
MCU (MACHINE)
F. WIPER /
10A TURN SIGNAL 15A
WASHER
BOOM KICKOUT
R. WIPER / BUCKET LEVELER
5A 10A
WASHER RIDE CONTROL
(option)

View from top cover SPARE 5A R. WORK LIGHT 15A

80ZV8214b

LIGHTING
SPARE 5A 20A
HEAD LIGHT
Main Fuse Boxes are located in the right hand side
console in the cab and contain thirty fuses.

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

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

Never replace fuses with higher amperage rat-

ing.
 2.29
OPERATOR'S AREA
Electrical Protection

Fusible Link

Fusible link protects the main hot wire from short

circuits.

80ZV 4898

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

lem occurs.

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

- Engine will stop auto- - All the electrical circuit

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

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

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

- The machine can be - The same conditions

operated but the bat- as "During engine
50A
teries can not be operation".
(Alterna-
charged and the batter-
tor line)
ies will be discharged
soon.

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

2. To check the cause and replace the fusible

link, call your nearest Kawasaki dealer.
2.30
OPERATOR'S AREA
Air Conditioner

Air Conditioner Switches

Ventilation Name and Location 1 2 3 4 5

(d) (d) Insolation sensor

(d) (d)

(b) (b)

97ZVOM0093

6 7 8

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

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

Rear ventilation ports (a) can be used as defroster
ports for the rear window glass by manipulating the
direction of the louver.
This switch stops the operation of the blower and
the air conditioner.
When OFF switch (1) is pressed, the set tempera-
ture and the air blow quantity displayed on LCD unit
(7) as well as the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
turned "off", and operation is stopped.
 2.31
OPERATOR'S AREA
Air Conditioner

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

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

These switches set the temperature inside the cab

AUTO switch (5)
in the range from 18.0~32.0ºC.
This switch automatically changes over the air blow
When the switch is pressed, the set tempera-
quantity, the vent mode and the inside/outside air in
ture increases.
accordance with the set temperature.
When the switch is pressed, the set tempera-
When AUTO switch (5) is pressed, the indicator
ture decreases.
lamp above it lights.
Usually, set the temperature to 23.0~25.0ºC.
Usually, press this switch, set the temperature by
<Display on the LCD unit and the function> using temperature setting switches (3), and use the
air conditioner in the automatic mode.
Display on LCD
Set temperature
unit
18.0ºC Maximum cooling
When the automatic mode is changed over to the
manual mode, the indicator lamp above AUTO
Temperature inside cab is controlled so
18.5~31.5ºC switch (5) is extinguished. In the manual mode, the
that set temperature is realized.
32.0ºC Maximum heating air blow quantity, the vent mode and the inside/out-
side air can be changed over by manipulating each
switch.
2.32
OPERATOR'S AREA
Air Conditioner

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

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

When an either switch is pressed, the indicator 3 5

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

In the automatic mode, outside air introduction and

inside air circulation are automatically changed
over.
97ZVOM0093

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

2. Adjust temperature setting switches (3), and

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

However, the air conditioner is turned on only while

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

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

and the air flow quantity displayed on the LCD unit
are extinguished, the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
are extinguished, and the operation is stopped.

Manual operation
2 3 4 Head cooling, feet heating (bi-level) opera-
97ZVOM0093
6 8
1. Press blower switches (2), and adjust the air
flow quantity.
Confirm that the set temperature and the air
flow quantity are displayed on the LCD unit.
2. Set to ON air conditioner ON/OFF switch (8).
Confirm that the indicator lamp above the
switch lights.
3. Adjust temperature setting switches (3), and
set arbitrary temperature.
4. Press vent mode selector switch (4), and
select arbitrary vent mode.
5. Press an either inside/outside air selector
switch (6) to select inside air circulation or out-
side air entry.
Stopping the manual operation
1
97ZVOM0093
Press OFF switch (1). Then, the set temperature
and the air flow quantity displayed on the LCD unit
are extinguished, the indicator lamps above AUTO
switch (5) and air conditioner ON/OFF switch (8)
are extinguished, and the operation is stopped.
2.33
OPERATOR'S AREA
Air Conditioner
Operation Method (Other Uses)
tion
In the bi-level operation, cool air is blown to the
face and hot air is blown to the feet.
2 3 4 5
97ZVOM0093
6 8
1. Press blower switches (2), and adjust the air
flow quantity.
Confirm that the set temperature and the air
flow quantity are displayed on the LCD unit.
2. Press vent mode selector switch (4), and dis-
play the vent mode on the LCD unit.
3. Set to ON air conditioner ON/OFF switch (8).
Confirm that the indicator lamp above the
switch lights.
4. Arbitrarily set blower switches (2), temperature
setting switches (3) and inside/outside air
selector switches (6).
Then, the air conditioner realizes the bi-level opera-
tion in which cold air is blown to the head and hot
air is blown to the feet.
2.34
OPERATOR'S AREA
Air Conditioner

Defroster operation Other Functions

2 3 4 Self-diagnosis function

Each sensor and equipment used in the air condi-

tioner can be diagnosed for failure.

1 3
97ZVOM0093

6 8

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

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

flow quantity are displayed on the LCD unit. 6

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

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

- If two or more failure are detected, the displayed

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

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

diagnosis function and return to the normal dis-
play.

If a failure is detected by the self-diagnosis func-
tion, ask the dealer for inspection and repair.
After completing the inspection and/or the repair,
delete the failure codes memorized in the com-
puter.
If not removed, the failure codes memorized in the
computer continue to display on the LCD unit
whenever diagnosing.
To delete the failure codes, press and hold both
inside/outside air selector switches (6) for 3 sec-
onds or more.
Refer to "TROUBLESHOOTING" page 3.58 for the
failure and solution.
Celsius-Fahrenheit selector function for the
set temperature display
While the blower is operating, press and hold both
temperature setting switches (3) " " and "
together for 5 seconds or more to change over the
unit of the displayed value between Celsius and
Fahrenheit. However, the unit type (C or F) itself is
not displayed.
Only the set value is displayed.
Value displayed on LCD unit
Celsius (ºC) 18.0~32.0
Fahrenheit (ºF) 65~90
2.35
OPERATOR'S AREA
Air Conditioner
For Efficient Use of the Air Conditioner
When the temperature inside the cabin
should be cooled down rapidly
When the machine is left under a scorching sun in
the middle of summer, the temperature inside the
cabin may be very hot.
In order to rapidly cool down the cabin in such a
case, completely close the windows and doors first,
drive hot air out of the cabin, then operate the air
conditioner.
Start up the engine, press AUTO switch (5), then
set the temperature to "18.0" by manipulating tem-
perature setting switches (3). In this status, run the
engine for 2~3 minutes with high revolution, then
close the windows.
When the temperature inside the cabin is decreas-
ing, set the arbitrary temperature.
"
When the windows are misted
In the rainy season, etc., if the humidity inside the
cabin is high and the inner surfaces of the windows
are misted, mist can be removed by operating the
air conditioner. Or if the humidity of the outside air
is high, the temperature inside the cabin may be
too low and the outer surfaces of the windows may
be misted. In such a case, properly control the tem-
perature inside the cabin by controlling the set tem-
perature, stopping the air conditioner, etc.
2.36
OPERATOR'S AREA
Air Conditioner

Action to be taken when the air condi- NOTE

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

If the temperature inside the cabin is low in winter,

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

IMPORTANT
- If the air conditioner is not operated for a long
time, the lubricating oil inside the compressor
may be eliminated, and the compressor may
be seized or damaged. Make sure to operate
the air conditioner once or twice a month even
while the air conditioner is not necessary or
while the machine is stored for a long time.
- During running - in of the air conditioner, make
sure to start it up with the engine low idle.
Never start up the air conditioner with the
engine high idle: Such start up may damage
the air conditioner.
- If water enters the control panel or the insola-
tion sensor, unexpected failure may be
caused. Pay attention so that water does not
enter. In addition, make sure to keep fire off
the control panel and the insolation sensor.
- Always keep the insolation sensor clean and
free from adhesion of dusts so that the air con-
ditioner can offer its auto function sufficiently.
Keep the area around the insolation sensor
free from objects which may hinder the sensor
function.
- Special tools and instruments are required to
fill the refrigerant (gas) and perform other ser-
vicing. Make sure to let such works be per-
formed in a service shop with required
facilities specified by our company.
 2.37
OPERATOR'S AREA
Ride Control (option)

Ride Control (option)

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

Operation and Function

(80H1-0501~0700)

0 0 0 0 0 0 1/10h
AUTO
20 30
N
C H E F
40 4
10
3
0 50 2
km/h
1
C H

65ZV0001d

(80H1-0701~)

80Z5 0002a

1. Before start the travelling machine, turn the

ride control switch ON.

The ride control pilot lamp comes to ON.

2. Move the machine forward.

The ride control functions automatically when

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

NOTE
When the bucket is fully tilted the ride control does
not work. Dump the bucket a bit when travelling.
2.38
OPERATOR'S AREA
Manual Box

Manual Box

90ZV2 9690

Manual box is provided in the left rear of the driver

seat to put in the Operation & Maintenance Manual.
 2.39
OPERATOR'S AREA
Grease Gun Holder

Grease Gun Holder

90ZV5009

Grease gun holder is provided in the left side bat-

tery box. It is used for keeping the grease gun on
the machine when not in use.
2.40
OPERATOR'S AREA
Quick Coupler (option)

Quick Coupler (option) Installation Procedure

Attachment Installation to Quick Cou-

pler

Regardless of the attachment types, the installation

procedure is all the same.

For removing an attachment, follow the installation

procedure in the reversed direction.

Component Name
ATT0031

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

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

2. Move the machine forward to the hook of the

attachment.

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

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

85ZV2 35010-6035
ATT0032

4. Roll back the quick coupler to hang up the

1. Coupler frame hook and lift the attachment.
2. Hydraulic pressure hose (for 3-way piping
spec. machine) 5. For 3-way piping spec. machine, insert the
3. Hydraulic pressure connecting unit to attach- quick coupler lock pin by operating the attach-
ment (One-touch operation type) ment control lever to fix the attachment.
4. Hook For 2-way piping spec. machine with quick
5. Lock pin support coupler, insert the quick coupler lock pin by
6. Quick coupler lock pin switch operating the quick coupler lock pin switch on
(for 2-way piping spec. machine with quick the control box, with the bucket control lever
coupler) held on the "Roll Back" position. Then fix the
attachment.
 2.41
OPERATOR'S AREA
Quick Coupler (option)

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

(b)
(a) (c)

85ZV2 35010-6035

70ZV0010

(a) The lock pin is fixed.

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

Unless the hydraulic source to the attachment is

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

WARNING
Your body or finger could be crushed by the lock
pin when the lock pin moves.
Stay out of the lock pin area during lock pin oper-
ation.
2.42
OPERATOR'S AREA
Quick Coupler (option)

Hydraulic Pressure Hose & Electrical

Wiring Connecting to Attachment Dust cap

When 3-way piping spec. machine installs the

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

Regardless of the piping specifications, when the

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

Electrical wiring connector

B

ATT0035
ATT0033

5. When the electrical power supply is needed to

1. Stop the engine. Move the control lever back
the attachment, connect the electrical wiring
and forth and bleed the residual pressure in
connector.
the hydraulic line.
When disconnecting the connector, keep the
waterproof cap.
2. Disconnect two hydraulic pressure hoses con-
nected to the quick coupler at section A (One-
touch operation type). IMPORTANT
Cover the disconnected hydraulic pressure hose,
3. Connect the disconnected hoses to section B hose connecting hole and electrical wiring con-
at the attachment side (One-touch operation nector with caps to protect them from dust and
type). water.
Connect the hose at right side of the machine
to right side of the attachment. Connect the
hose at left side of the machine to left side of
the attachment.
 2.43
OPERATION
Check before Operation

OPERATION

Check before Operation

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

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

Items to Check and What to Look for:

Items to Check What to Look for

Bucket / Attachment Damage, missing bolts, leaks, and excessive wear
Bucket Control Linkage Damage, missing bolts, excessive wear, and looseness
Lights Broken bulbs, wires or lenses
Radiator Fins Trash and dirt build-up
Cooling System Leaks and trash build-up
Batteries Loose terminals, dirt build up on top of the batteries
Steps and Handrails Damage and cleanliness
Differentials (front and rear) Leaks
Hydraulic System Leaks
Final Drive (front and rear) Leaks
Covers and Guards Damage or missing
Transmission Leaks
Instrument Panel Broken gauges or indicator lights
Brake Lines Damage and leaks
Engine Compartment Leaks, debris build-up and flammable materials left
Date: Model-S/N: Hours: Inspector:
You may wish to copy this page and use it as a daily check list.
2.44
OPERATION
Check before Operation

Check Engine Oil Level 1. Check the oil level with the dipstick.

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

CAUTION and "L" (low) mark on the dipstick.
Hot engine oil and components may cause
burns. 3. If needed, add the required amount of the
same brand and viscosity oil as originally used
Avoid contact with hot oil or engine components. through the refill port.

Refer to "Recommended Lubricants" page

Dip stick 3.55 for the suitable viscosity of the oil accord-
ing to the ambient temperature.

4. If the oil is particularly dirty or contains water

(milky appearance), replace the oil.

Refer to "Replace Engine Oil and Oil Filter Car-

tridge" page 3.27.

NOTE
Wait about 30 minutes after stopping the engine to
measure the oil level. The precise oil level cannot
Fill cap 70ZV 4693 be measured immediately after stopping engine
due to residual oil in the upper parts of the engine.

IMPORTANT
Improper oil level may damage engine.

Do not operate engine with oil level below "L"

(low) mark or above "H" (high) mark.

Add or drain oil to keep proper oil level.

H
L

OM0177
 2.45
OPERATION
Check before Operation

Check Hydraulic Oil Level (S/N 0501~0510)

CAUTION Filler cap

Pressurized hydraulic tank is used for this
machine.

Pressure may throw tank cap and hot oil out of

tank causing injury or burns.

Relieve all pressure by pressing down the filler

cap or the breather valve.
80ZV27801

Check Level (S/N 0511~)

Breather valve

85ZVOM3230

80ZV27801a

1. Lower the attachment to the ground.

5. If needed, add the required amount of the oil.
2. Stop the engine.
Refer to "Recommended Lubricants" page
3. Check the oil level gauge on the side of the 3.55 for the suitable viscosity of the oil accord-
hydraulic tank. ing to the ambient temperature.

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

of the level gauge.
2.46
OPERATION
Check before Operation

Check Engine Coolant Level Drain Water and Sediment from Fuel Fil-
ter
CAUTION
Cooling system conditioner contains alkali that 1
could caustic burns or blindness.

Avoid contact with skin and eyes to prevent

injury.

FULL
85ZV 4505

LOW

When the float in the water separator is higher than

the line, drain water and sediment.

1. Park the machine on a level ground, apply the

parking brake, lower the attachment to the
80Z5 2791 ground, and stop the engine.

1. Check the coolant level in the radiator sub-
tank.
2. Coolant level is normal if it is between FULL
and LOW lines.
3. If needed, add the required amount of the cool-
ant to the radiator sub-tank.
Refer to "Coolant Specification" page 3.57 for
the correct mixture.
4. Change the coolant if it is particularly dirty.
2. Looen plug (1).
3. Looen plug (2) to drain water and sediment
into a suitable ocntainer.
4. When clean fuel comes out, tighten the plugs.
5. Bleed air from the fuel line.
Refer to "Replace Fuel Filter Cartridge-Bleed-
ing" page 3.37 for the procedure.
6. Dispose of the drained water and sediment
properly.

Refer to "Replace Coolant" page 3.15. CAUTION

5. If the coolant contains oil, diagnose the prob-
lem and correct it.
Escaping fuel is flammable and harmful to skin.
- Do not smoke while draining moisture and
sediment from filter.
- Do not drain with engine running.
- Do not allow diesel fuel to remain on skin for
an extended period of time.
 2.47
OPERATION
Check before 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.
"STORED" position 85ZV0002

- Make sure the articulation stopper is secured in

the "STORED" position as shown.
2.48
OPERATION
Check before 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 3.24 for
Do not service or change tire and rims unless
the adjusting procedure.
properly trained and equipped.

Contact your nearest Kawasaki dealer or tire

manufacturer’s local dealer for tire servicing or
changing.

WARNING
Overheated tire could explode causing serious
injury or death.

If overheated tire is suspected, do not approach

tire to distance of less than 15 m.

Stay away until tire and rim cool down.

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

Consult your tire dealer or Kawasaki dealer.

 2.49
OPERATION
Check before Operation

Tread Check Air Intake System

CAUTION
Side walls
Breakers Hot engine components may cause burns.

Carcass
Avoid contact with hot engine components.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.
Beads / Bead wire
OM0104

If the following defects are found in tires, for safety

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 85ZV 4496
circumference.

- Damage to the carcass exceeds 1/3 of the tire
width.
- Tire layers are separated.
- Radial cracks reach the carcass.
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.

- Deformation or damage which makes the tire IMPORTANT

unsuitable for use.
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.
2.50
OPERATION
Check before Operation

Check Cooling Fan Check Horn Operation

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

ing wheel.

2. The horn should sound loudly.

OK

ROPS (Roll Over Protective Structure)

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

3. Visually inspect the cooling fan for damage.

ROPS Cab deformed does not assure safety for
operator as a protective cab.
4. If the fan shows cracks, loose rivets, bent or
loose blades, replace it.
- 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.

 2.51
OPERATION
Check before Operation

Check Monitor Panel Operation

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

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

about three seconds. Refer to "Indicators"
page 2.17.

3. Rotate and move the transmission shift lever to

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

4. The transmission status monitor lamps (green)

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

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

Refer to "Indicators" page 2.17.

Check Control Levers

- Make sure the boom and tilt control levers are in

the "HOLD" position.

Check Transmission Shift Lever

- Make sure the transmission shift lever is in the

neutral position.
2.52
OPERATION
Starting the Engine

Starting the Engine Normal Start

(Ambient temperature above 0ºC)

WARNING 1. Do not step on the accelerator pedal.

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 OFF ON

terminals. START
- Do not start engine while standing on ground.

Make sure to start engine only from operator’s

seat with transmission in neutral and parking
brake applied.

97ZVOM0076

(80H1-0501~0700)

0 0 0 0 0 0 1/10h
AUTO
20 30
N
C H E F
40 4
10
3
0 50 2
km/h
1
C H

65ZV5003a

(80H1-0701~)

80Z5 0003a

2. Turn the starter switch key to "ON" position

and leave it there about 3 seconds. Check the
warning lamps.
The preheat indicator lamp also lights up as
the intake air is being heated automatically.
 2.53
OPERATION
Starting the Engine

3. After all the lamps turn off, turn the starter

switch key to "START" position to start the
engine.
Turn the starter switch to “START” position in 5
seconds after the preheat lamp turns off for
smooth engine start.
4. If the engine fails to start, wait about two min-
utes before trying to restart. This allows the
starter motor to cool which prevents starter
motor damage.
IMPORTANT
To protect starter and battery, do not keep the
starter switch in the "START" position for more
than 20 seconds.
Low engine oil pressure may cause severe
engine damage.
Do not turn the starter switch key to the "START"
position while the engine is running.

OFF ON
START

97ZVOM0075

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

will return to the "ON" position.

NOTE
- If the transmission shift lever is not in the "NEU-
TRAL" position, the engine will not crank.

- When the starter switch key is in the "ON" posi-

tion, the engine itself will diagnose engine fail-
ure, if any, in 2 seconds.

During this time, all of the engine warning lamp

are being turned on. This checks the bulbs.

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.

- The engine oil pressure warning lamp should go

out in less than ten seconds after the engine
starts. If it remains on, stop the engine immedi-
ately and see "TROUBLESHOOTING" page
3.58.
2.54
OPERATION
Check after Starting the Engine

Check after Starting the Engine Check Warning Lamps

(80H1-0501~0700)
- Keep the engine running at low to medium
speed and warm it up for about five minutes.

- Do not subject the engine to sudden accelera-

tion until the end of the warm-up period. 0 0 0 0 0 0 1/10h
AUTO
20 30
N
C H E F

WARNING 10
40 4
3
0 50 2
Do not open the engine access panel while the km/h
1
C H
engine is running.

Contact with moving fan and belts or pulleys

65ZV5003a
could result in death or serious injury.

IMPORTANT (80H1-0701~)
Do not idle the engine for excessively long peri-
ods of time.

Long periods of idling (more than 10 minutes)

can damage an engine because combustion
chamber temperatures drop so low the fuel can
not burn completely.

This will cause carbon to form in the injector

spray holes and on the piston rings and can
result in stuck valves. 80Z5 0003a

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 2.17 for the meaning

of each lamp and the correction.
 2.55
OPERATION
Check after Starting the Engine

Check Fuel Level Check Transmission Oil Level

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

FUEL When checking oil level:

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

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

instrument panel.

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

below "F".

Refer to "Recommended Lubricants" page

3.55 for the proper fuel.

Check and
Fill Tube

80ZVOM3271

1. Park the machine on level ground, apply the

parking brake, and lower the attachment to the
ground.

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

In hot In cold

Specified oil level

97ZVOM0107

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

marked "COLD". Normal oil level is within
shaded area as shown.
2.56
OPERATION
Check after Starting the Engine
4. At high oil temperature, use the side of dipstick
marked "HOT". Normal oil level is within
shaded area as shown.
5. If the oil level is lower than the specified, add
recommended oil while the engine is at idle.
Do not overfill.
Refer to "Recommended Lubricants" page
3.55.
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.
Check Service Brake Operation
1. Turn "OFF" the declutch switch.
2. Firmly step on the left hand brake pedal.
3. Release the parking brake.
4. Select the transmission shift lever 2nd and
FORWARD.
5. Slowly accelerate the engine to full speed.
6. The machine should not move.
IMPORTANT
If machine moves when firmly step on right hand
brake with transmission in 2nd and FORWARD,
there is some problem with service brake.
Do not operate until problem has been corrected.
Check Parking Brake Operation
1. If the service brakes work normally, test the
parking brake.
2. Move the machine to a safe open place on a
slope.
3. Stop the machine with the service brake.
4. Pull up the parking brake switch.
5. Release the service brakes.
6. The machine should not move.
IMPORTANT
If machine moves when parking brake switch is
pulled, there is some problem with parking
brake.
Do not operate until problem has been corrected.

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.
Check Back-up Alarm Operation
1. Apply the service brakes.
2. Release the parking brake.
3. Move the shift lever to "REVERSE".
4. The back-up alarm should sound and be heard
in the operator's seat.
IMPORTANT
If back-up alarm does not sound when parking
brake is released and shift lever is in REVERSE
position, there is some problem with back-up
alarm.
Do not operate until problem has been corrected.
2.57
OPERATION
Check after Starting the Engine
Check Exhaust Gas
95ZVOM2926
1. Check the color of the exhaust gas.
Normal exhaust gas color is clear or light gray
when engine is warm. White, black, or blue
smoke during steady warm operation of the
engine indicates a malfunction. (It is normal for
some black smoke to occur during rapid accel-
eration.)
2. If abnormal exhaust gas color occurs, have the
machine checked immediately.
Refer to "TROUBLESHOOTING" page 3.59.
2.58
OPERATION
Check after Starting the Engine

General Inspection

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

When inspecting machine while engine is run-

ning:

- Make sure nobody is on machine.

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

With the parking brake applied, transmission shift

lever in NEUTRAL, loading levers in NEUTRAL,
and the attachment on the ground, walk around the
machine and look for any problems, leaks, or signs
of failure.
 2.59
OPERATION
Operating the Machine

Operating the Machine Starting the Machine

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

Do not stop engine while machine is moving.

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

Be sure area is clear of personnel and obstruc-

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

IMPORTANT 2. Step on the brake pedal.

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

30º Max.

OM0194
97ZVOM0038

5. Release the brake pedal then step on the

accelerator pedal to drive the machine.

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

When starting machine on a grade, firmly step

on brake pedal before releasing parking brake.
2.60
OPERATION
Operating the Machine
Starting the Machine on a Grade
1. Turn "OFF" the declutch switch.
2. Step on the left brake pedal.
97ZVOM0038
3. Step on the accelerator pedal while releasing
the left brake pedal to start the machine off
slowly.
Speed and Direction Change
65ZV 5089
1. Select the proper gear shifting mode by rotat-
ing the transmission shift lever. Refer to the fol-
lowing tables on page 2.61 for the gear
selection mode.
This machine is equipped with the automatic
shifting system which selects the proper gear
automatically using a micro computer to 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.
 2.61
OPERATION
Operating the Machine

Running in Deep Mud or Water

Axle housing

70ZV0010

A=Maximum depth of water allowable during operation

OM0109
(including waves).
3. When the transmission is in the 2nd gear, it
can be quickly shifted down to the 1st gear by
pressing the downshift button. Running the machine in mud, snow, or water at or
near a level of A (even for a brief period of time) is
4. Pressing the downshift button again, moving considered a severe application.
the transmission shift lever to the neutral posi-
tion, or operating the parking brake switch 1. Immediately after encountering this condition,
automatically returns to the 2nd gear from the check both differentials for water contamina-
1st gear. tion in the oil. Water mixed with the oil will
cause a milky or foamy appearance.
Refer to "Downshift Button" page 2.14.
2. Drain and refill if water is found.
Lever Refer to "Check Differential Gear Oil" page
Selected Gear Operating Condition
Position 3.28 and "Check Planetary Gear Oil" page
1. Excavating or 3.29 or consult the nearest Kawasaki dealer
scooping in a nar- for further assistance.
[1] 1st row space
2. Running downhill
on a steep slope
1. Scooping or load-
ing loose material
[2] 2nd
2. Running downhill
on a slope
[3] 3rd Carrying or roading
2nd, 3rd or 4th Scooping, loading,
[A] (automatically carrying or roading
shifted)

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

Use proper gear for each job.

2.62
OPERATION
Parking

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

4. Pull up the parking brake switch to apply the

parking brake.

5. Lower the attachment to the ground and apply

a small amount of down pressure.

OM0025

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

Park machine in safe place on firm level ground.

If machine has to be parked on a grade, place

wheel chocks under wheels and dig attachment
into ground.

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

Except for emergency do not apply parking

brake while machine is moving.

97ZVOM0038

1. Release the accelerator pedal.

2. Apply the service brake to stop the machine.

 2.63
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).
2.64
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.

 2.65
OPERATION
Operating Techniques

4. Drive the bucket straight into the material. Use

approximately 1/2 - full engine speed.

OM0112

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

at the protruding portion of the material.

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

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

Reduce wheel slippage by slightly reducing

engine speed.

OM0115

6. Move the bucket control lever to the "Roll

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

7. When the bucket is filled, move the bucket

control lever to the "Roll Back" position.

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

position and the boom will rise.

9. Reverse the machine.

2.66
OPERATION
Operating Techniques

Excavating

1. Move the machine forward to the material.

2. Steer the machine in a straight ahead position

when entering the material.

OM0120

5. When the bucket is filled, move the bucket

control lever to the "Roll Back" position.
10 degrees or less
6. Move the boom control lever to the "Raise"
position to clear the ground.
OM0118a

3. Lower the bucket parallel to the ground or

dump it slightly forward (10 degrees or less).

OM0119

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

Increase engine speed as the bucket digs

deeper.
 2.67
OPERATION
Operating Techniques

Dozing Ground Levelling

1. Keep the loaded bucket slightly above the

IMPORTANT ground.
Dozing or pushing with dumped bucket or attach-
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.

OM0121

2. While running the machine backward, dump

the bucket little by little to evenly spread mate-
rial on the ground.

OM0123

OM0122

3. Dump the bucket, allow the cutting edge to

contact the ground, and run the machine back-
ward.
2.68
OPERATION
Operating Techniques
OM0123
4. To get smoother surface, put some material in
the bucket, place the bucket parallel to the
ground, run the machine backward with the
boom control lever in the "Float" position.
IMPORTANT
Pushing material with dumped bucket may
cause severe damage to linkages.
Be sure to run machine backward when leveling
ground.
Carrying
approx. 40 cm
OM0016
1. Fully roll back the loaded bucket before carry-
ing to prevent spillage.
2. Keep the bucket approximately 40 cm above
the ground when carrying.
IMPORTANT
When carrying material over 450 m at high
speed, tire overheating may occur.
Follow tire manufacturer's instructions for tire
inflation on this type of application.

Dumping into Truck or Hopper
WARNING
When boom is raised, machine stability is
reduced and could cause machine to tip over
causing serious injury or death.
Do not make quick turns or abrupt braking when
boom is raised.
Keep boom low for best stability especially on
slopes.
WARNING
Machine contact with overhead wires or other
objects could result in death or serious injury.
Be sure there are no overhead wires or obstruc-
tions before raising boom to full height.
Refer to "Loading" or "Excavating" page 2.64, 2.66
for the loading procedure.
OM0116
1. Move the boom control lever to the "Raise"
position to raise the loaded bucket while
approaching the truck or the hopper.
2. Use the declutch switch in the "ON" position if
working on a level site.
When the left brake pedal (declutch pedal) is
step on, the transmission is placed automati-
cally in neutral and the boom rises faster.
2.69
OPERATION
Operating Techniques
3. Return the boom control lever to the "Hold"
position when the bucket reaches the enough
height to clear the truck or hopper sideboards.
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
required.
Refer to "Boom Kickout Adjustment" page 2.73 for
adjustment of the preset height.
4. Position the machine in the center of the truck
body or hopper to dump the load.
OM0195
5. Push the bucket control lever forward to the
"Dump" position to empty the bucket.
OM0196
6. Roll back the bucket to clear the truck or hop-
per sideboards and lower the boom while
reversing the machine.
2.70
OPERATION
Operating Techniques

Typical Truck Loading Methods

WARNING
Fast boom lowering motion may cause machine I Cycle Operation
rear wheels to jump up, reducing stability and
control.

Do not lower boom using detented "Float" posi-

tion especially when bucket is full.

OM0124

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.
 2.71
OPERATION
Operating Techniques

T Cycle Operation

OM0126

This method is effective for the sites where trucks

continuously come and go.
2.72
SPECIAL PROCEDURES
Adjustments

SPECIAL PROCEDURES

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

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

WARNING When the preset angle is reached, the bucket

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

Apply parking brake and use wheel chocks to

prevent sudden movement of machine.
4

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

1. Park the machine on level ground and apply OM0128

the parking brake.

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

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

The switch may be adjusted in or out to set this

clearance.

2
1
97ZVOM0127

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

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

ward to decrease the attachment preset angle.

5. Tighten bolts (1).

 2.73
SPECIAL PROCEDURES
Adjustments

Boom Kickout Adjustment 1

2
DANGER
Sudden or accidental movement of boom will
result in death or serious injury.

Before walking or working under raised boom:

- Securely block or brace boom.
- Remove key and tag "Do Not Operate" on the
- steering wheel. 3
85ZV0003

WARNING
Standing on tire can cause accidents resulting in 5. Loosen the two bolts (1). Align the plate (2)
death or serious injury. with the switch (3).

Use safe sturdy platform to reach boom kickout
adjustment.
1. Park the machine on level ground and apply
the parking brake.
2. Raise the boom to the desired height and stop
the engine.
3. Lock the bucket and boom control levers in the
"Hold" position using the loading control lever
lock.
6. Move the plate (2) clockwise to decrease, or
counterclockwise to increase the boom lift kick-
out height.
7. Tighten the bolts (1).
8. Remove the support from the boom and link-
age.
9. To test the adjustment; start the engine, slowly
lower the boom to the ground, and move the
boom control lever to the "Raise" detent posi-
tion to raise the boom.

When the preset height is reached, the boom

control lever should return to the "Hold" posi-
tion.

2
OM0031

4. Block the boom and linkage from falling down 5 ± 2mm

using a proper support.
OM0128

NOTE
Clearance between the switch (3) and plate (2)
should be about 5mm.
2.74
SPECIAL PROCEDURES
Adjustments

The switch may be adjusted in or out to set this

clearance.
 2.75
SPECIAL PROCEDURES
Roading / Special Applications

Roading / Special Applications

WARNING
Overheated tire could explode causing serious
injury or death.

If overheated tire is suspected during operation

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

Stay away until tire and rim cool down.

When the machine travels at high speed or for a

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

- Follow the regulations related to this machine,

and drive carefully.

- The most suitable tire pressure, travel speed, or

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

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

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

- Carefully watch the engine coolant temperature

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

- After traveling a distance, stop the machine with

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

- Do not put calcium chloride or dry ballast in the

tires when traveling.

- Whenever possible use a lead and/or follow

vehicle and all available warning devices even if
not required by regulations.
2.76
SPECIAL PROCEDURES
Booster Batteries / Jumper Cables
Booster Batteries / Jumper
Cables
DANGER
Improper procedure to start engine using jumper
cables could cause battery case explosion.
- Do this work by two persons. While one per-
son sits on the operator's seat, the other per-
son connects jumper cables.
- Wear eye or face protection when working on
or around batteries.
- The booster batteries should be of similar size
and capacity as the batteries being boosted.
- Do not allow the two machines to touch. This
prevents possible sparks between or in the
machines being used.
- Keep flames and sparks away from batteries.
- Keep jumper cable ends from touching each
other or machine to avoid sparks.
- Make last connection to grounded part of
frame away from battery compartment.
WARNING
If the battery is being used with insufficient bat-
tery electrolyte level, the deterioration on the
parts in the case could be in the advanced stage.
It could cause to shorten the battery life or to
emit sparks from the deterioration parts in the
case, as a result the battery case could explode.
Keep the battery electrolyte level in the proper
level.
WARNING
Batteries contain lead, and acid which may
cause burns.
Avoid contact with skin or clothing and wear
hand, eye, and face protection when working on
or around batteries.
If lead, or acid contacts skin or clothing, immedi-
ately wash with water.
NOTE
This machine uses a 24VDC negative ground elec-
trical system.
1. Before connecting jumper cables:
- The booster cables must be of the heavy duty
type and in good condition.
- Be sure the problem is inadequate battery
charge and not some other electrical problems.
- Stop the engine of the boost machine or turn off
the booster supply if using an auxiliary power
source.
2. Raise and lock the battery box covers.
3. Be sure vent caps are tight and level. Place
damp cloth over vent caps on both batteries.
- + - +
+ - + -
Booster Batteries Batteries being boosted
Rear chassis close to starter motor ground being jump started
OM0131
4. Move back the protective rubber covers (red)
from the positive post (+) of the battery.
5. Connect one end of the red jumper cable to the
positive post (+) of the discharged battery.
6. Connect the other end of the red jumper cable
to the 24 volt side of the booster battery set or
power source.
7. Connect one end of the black jumper cable to
the ground side of the booster battery set or
power source.
8. The final connection should be the remaining
end of the black jumper cable to the rear chas-
sis close to starter motor ground being jump
started.
9. Start the booster machine's engine or turn the
auxiliary power source on.
10. Allow a few minutes to provide partial charge
to the discharged batteries.
 2.77
SPECIAL PROCEDURES
Booster Batteries / Jumper Cables

11. Start the machine being boosted as described

on "Starting the Engine" page 2.52.

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.
2.78
SPECIAL PROCEDURES
Towing

Towing
Allowable load: 55,980 N

WARNING Towing speed: Less than 10 km/h

Improper towing could result in death or serious
injury.
Follow safety warnings found under "Safe Oper-
ation -- SPECIAL OPERATING CONDITIONS:"
page 1.9.
This machine is equipped with a hitch on the rear
end for towing a troubled machine.
Distance between the pulling vehicle and the towed
vehicle: More than 5 m and the towed vehicle is
able to stop safely.
IMPORTANT
- When towing a machine be sure not to add
load over the allowable load described on the
draw hook or the sling hooks.

1. Inspect the cable for damage. Never use a - When this machine is pulled out, rescued, by
damaged cable. other machine, do not use the draw hook,
always use the sling hooks.

If your machine must be towed, contact your near-

est Kawasaki dealer for the necessary information
or assistance.

95ZVOM2917

2. Connect the cable to the drawbar. Make sure

the drawbar and split pin are in the original
position.

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

bled machine.

4. If the service brake on the towed machine

does not work;

do not allow an operator on the towed

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

5. Keep personnel away from between the towing

machine and the towed machine.

6. Tow the machine slowly with gradual and

smooth movement.

7. Use flashing lights or other warning signals

when towing.
 2.79
SPECIAL PROCEDURES
Towing

Wire hooking position and range/

stretching impossible range/tolerance

Hook tolerance

Loads which can be applied to one position of

the hook (one wire)

Model 80Z5
Front side Tolerance [N] 223,000
Rear side Tolerance [N] 223,000

Hooking position

Rear side
Front side

HOOKING POSITION

CAUTION
- Be sure to hoist the loader at 4 points and lift it
at 2 points.
- Hoisting/lifting angles are not limited in partic-
ular. (The tolerance is set to an acceptable
level even if stretching it at any angle.)
- When lifting it, a wire interferes with the bat-
tery box, etc. which may cause damage
(depending on the lifting direction).
2.80
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- 1.28).
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 1.29).
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.

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

trailer and the machine.

OM0197

9. Fasten the machine to the trailer with chains or

cables at 4 fixing points (red painted) provided
on the machine.
65ZV0009
Additional cables or chains may be used but
do not damage brake lines or cylinder rods.
4. Determine the position of the ramp, then slowly
load the machine onto the specified part of the
trailer. IMPORTANT
Brake pipe runs on axle housing.
NOTE
Have someone in clear view and in a safe position Do not fasten axle housing.
provide directions while loading.
 2.81
SPECIAL PROCEDURES
Transportation

Bucket hoisting position

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

BUCKET TSURI-1

OM0198
GRAVITY CENTER

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

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

Weight: 20 ton

BUCKET TSURI-2

BUCKET TSURI-3

Before hoisting the bucket, hook wire rope, etc.

through the hole for hoisting the bucket.
2.82
SPECIAL PROCEDURES
Long Term Storage

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

1. Wash and clean all parts of the machine and

touch up the paint finish to avoid rusting.

2. Lubricate every greasing point described in

"Greasing" section page 3.17, 3.20, 3.26 and
3.45.

3. Be sure to refuel in the fuel tank.

4. Replace engine oil, transmission oil, differential

and planetary oil and hydraulic system oil.

5. Idle the engine for about 15 minutes so that

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

6. Store the machine indoors and keep it dry.

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

The range of temperature the machine is to be

stored is between -25ºC ~ 35ºC.

OM0028

7. Disconnect the cables from the batteries or if

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

8. If freezing temperatures are expected, check

and adjust the antifreeze/water mixture.

Refer to "Coolant Specification" page 3.57 for

the mixing ratio.
 2.83
SPECIAL PROCEDURES
Long Term Storage

Battery removal / reinstallation proce-

dure

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

- Ventilate area to remove explosive gases.

- Wear eye or face protection when working on

or around batteries. 8 7 85ZV28463

- Keep flames and sparks away from batteries.

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

Avoid contact with skin or clothing and wear 3. Loosen rod nuts (6)(7) and remove plate (8)
hand, eye, and face protection when working on from the battery.
or around batteries.
4. Remove the battery not to give it a tilt from the
If lead, or acid contacts skin or clothing, immedi- battery box.
ately wash with water.
If possible remove the battery from the battery
box by two persons.
IMPORTANT
For reinstallation, follow the above procedure
If a battery terminal is removed from a machine in the reversed direction.
in less than 30 seconds after the key is put into
the OFF position, it can corrupt the ECM pro- Carry on the same procedure for the other bat-
gram, which can disable the engine. Always wait tery.
1 full minute to be sure to be past this "write to
memory function" prior to removing battery termi-
nals.
2.84
SPECIAL PROCEDURES
Long Term Storage

During Storage After Storage

Once a month remove the covers, run the engine,

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

1. Check the following points.

Refer to "Check before Operation" page 2.43

and "Check after Starting the Engine" page
2.54.

- Coolant level
- Engine oil level
- Hydraulic oil level 80ZVOM3269

- Transmission oil level

- Brake function
- Steering function

2. Operate the machine as follows.

- Run just the engine for about five minutes at

low idle.

- Move all cylinders of the hydraulic system full

stroke 2~3 times.

- Run the machine about 10 m in every gear

and direction.
85ZVOM3230

- Move the steering full stroke each way about

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

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

Refer to "Replace Engine Oil and Oil Filter Car-

tridge" page 3.27 and "Replace Transmission
Oil" page 3.39.

4. Start the engine and check for any abnormali-

ties.

5. Warm up the machine until all gauges reach

the normal range.
 2.85
SPECIAL PROCEDURES
Welding

Welding 5. To ground the welder, check that the electric

current will not flow through the cylinders.
Cylinder head covers for some models have a
Cautions Regarding Welding Repair
low-conductive metal that will cause spark if
Service the welding current flows. The spark may dam-
age the cylinder rod.
Example 1:
6. Calibrate throttle pedal to ECM.

Section to be welded (a) Turn the starter switch to "ON".

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

Ground this section. Do not ground this section.

(correct grounding) Electric current may flow
through the cylinders.
Hydraulic cylinder
135ZV0052

Example 2:

Plated section (Mask this section.)

135ZV0054

Section to be welded

Do not ground this section. Ground this section.

Electric current may flow (correct grounding)
through the cylinders.
135ZV0053 Pin section with pin
temporarily inserted

If welding is needed to repair the chassis, observe Pin

the following precautions to protect the hydraulic
cylinders, hydraulic units, gear sets, and electrical
units from possible damage.

1. Turn the starter switch OFF. Plated section (Mask this section.)
135ZV0055

2. Remove the battery terminals both positive

and negative sides from the battery.
3. Disconnect the connector for MCU (machine
controller), ECM (engine controller) and air
conditioner.
4. Ground the welder near the section to be
welded.
7. The weld spattered on the hydraulic cylinders
and on the plated sections of pins will damage
the cylinders and pins. There are other parts
that may be damaged by the spatter; hydraulic
units, harnesses, hydraulic hoses, and nylon
tubes.
Be sure to mask these units and parts before
welding.

- Plated section
Cover the plated sections with heat-resistant
cloth, such as glass wool or canvas.
2.86
SPECIAL PROCEDURES
Welding

NOTE
The weld spattered on the plated sections causes
corrosion.

Scrap material, etc.

1 m or more

Section to
be welded

1 m or more

135ZV0056

- Cover the hydraulic units, electrical units, har-

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

Section to
be welded

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

135ZV0057

- Hydraulic hoses, nylon tubes, or harnesses are

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

NOTE
You must change the welding rod grade depending
on the welding part and place. Should you have
any question regarding the welding repair service,
please contact KCM dealer in your area during
business hours.
 3.1

3.MAINTENANCE
3.2
MAINTENANCE
Serial Number Location

MAINTENANCE
Before performing maintenance or repairs, read, Serial Number Location
understand and follow "Safe Maintenance" section
page 1.12. When contacting Kawasaki dealer or the dealers of
other products for servicing or repair, refer to the
The maintenance or repair of the machine must be serial number found in the following locations. See
performed by well-Trained or experienced person- next page for general location.
nel only.
For quick reference, record each serial number in
the blanks below.
WARNING If a component, like engine or transmission, is
Do not open high pressure fuel changed, record the new serial number here.
system with engine running.
Engine operation causes high fuel
pressure.
High pressure fuel spray can
cause serious injury or death.
MODEL
High pressure fuel
SERIAL NO.

Use KCM genuine parts for replacement.

MADE IN JAPAN

SN PLATE 41668-2063B

1. Machine Serial Number

70ZV J08C-TI

2. Engine Serial Number

 3.3
MAINTENANCE
Serial Number Location

MODEL
SERIAL NO.

MADE IN JAPAN

SN PLATE 41668-2006B

3. Transmission / Torque Converter Serial Num-

ber

Model

Serial Number

Design Number

SERIAL NO.
-

70ZV0004

4. Cab Serial Number

Model Number

Serial Number
3.4
MAINTENANCE
Serial Number Location

Cab (R.H Inside)

80Z5 COMPO
Machine (L.H)
T/M E/G (R.H)
 3.5
MAINTENANCE
Inspection and Maintenance Table

Inspection and Maintenance

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

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required
Check Engine Oil Level 2.44
Check Engine Coolant Level 2.46
Check Warning Lamps 2.54
Check Exhaust Gas 2.57
Drain Water and Sediment from Fuel Filter 2.46
Check Fuel Level 2.55
Check Air Intake System 2.49
Check Cooling Fan 2.50
Drain Water and Sediment from Fuel Tank 3.23
Check and Adjust Drive Belt 3.32
Replace Engine Oil and Oil Filter Cartridge 3.27
Clean Fuel Feed Pump Strainer 3.38
Replace Fuel Filter Cartridge 3.36
Check Exhaust Pipe and Muffler 3.38
Engine Check and Clean Starter Motor and Alter-
3.44
nator
Check Turbocharger 3.44
Check and Retighten Cylinder Head Bolts 3.44
Check Fuel Injection Pump 3.44
Check and Adjust Engine 3.44
Clean Fuel Tank 3.50
Check and Adjust Valve Lash Clearance 3.50
Retighten Intake/Exhaust Manifold 3.54
Retighten Bolts of Oil Pan 3.54
Check Heater Plugs 3.54
Clean or Replace Air Cleaner Element 3.10
Clean Radiator / Air cooler / Hydraulic oil
3.12
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 3.15
3.6
MAINTENANCE
Inspection and Maintenance Table

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required
Check Transmission Oil Level 2.55
Transmission Replace Transmission Oil Filter Cartridge 3.34, 3.35
& Torque
Converter Replace Transmission Oil 3.39
Clean or Replace Transmission Breather 3.41
Check Tire for Damage, Air and Tread
2.48
Depth
Check Tire Air Pressure 3.24
Greasing (Axle support) 3.22
Check Differential Gear Oil 3.28
Check Planetary Gear Oil 3.29
Greasing (Pillow block bearing unit) 3.26
Axle system
Check Tightness of Wheel Bolts 3.30
Greasing (2nd Propeller Shaft Spline) 3.45
Replace Differential Gear Oil 3.48
Replace Planetary Gear Oil 3.49
Greasing (2nd Propeller Shaft) Every 12000 hours 3.18
Greasing (3rd Propeller Shaft) Every 12000 hours 3.18
Check Steering Wheel Operation 2.57
Steering
Greasing (Steering Cylinder) 3.22
system
Clean Filter for Orbitrol® 3.34, 3.52

Check Service Brake Operation 2.56

Check Parking Brake Operation 2.56
Brake Adjust Parking Brake Lining 3.42
system Check Service Brake Disk Wear 3.50
Check Brake Accumulator 3.50
Clean Filter for Brake Line 3.34, 3.52

Check Hydraulic Oil Level 2.45

Greasing 3.20
Replace Hydraulic Oil Return Filter 3.34, 3.41

Replace Hydraulic Oil, Clean Filter 3.46

Loading
Replace Filter in the Hydraulic Tank Cap
system 3.53
(S/N 0501~0510)
Replace Filter in the Hydraulic Tank
3.54
Breather Valve (S/N 0511~)
Replace Bucket Teeth (option) 3.8
Replace Cutting Edge 3.9
 3.7
MAINTENANCE
Inspection and Maintenance Table

: First time replacement or cleaning only

Operating hours When

Section Item for check Page
10 50 250 500 1000 2000 Required
Adjust and Check Rear View Mirrors 2.50
ROPS (Roll Over Protective Structure) Cab 2.50
Greasing (Center Pin) 3.22
Chassis
Check Ride Control Accumulator (option) 3.54
Check and/or Replace Seat Belt 3.10
Check Windshield Washer Fluid 3.14
Check Monitor Panel Operation 2.51
Check Horn Operation 2.50
Electrical Check Back-up Alarm Operation 2.57
system Check Wiring Harnesses 2.47
Check Battery Electrolyte Level 3.23
Check or Replace Fuses 3.13
Check and Adjust Air Conditioner Belt 3.31
Clean Air Conditioner Filter Element 3.33
Air Check Air Conditioner Refrigerant 3.43
Conditioner Replace Air Conditioner Filter Elements 3.51
Clean Air Conditioner Condenser 3.15
Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours 3.17
Others Walk-Around Inspection 2.43
3.8
MAINTENANCE
When Required Inspection and Maintenance

When Required Inspection and Replace Bucket Teeth (option)

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

Read, understand, and follow all warnings and

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

2 Block

97ZVOM0136

2. Raise the bucket to a convenient height and

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

3. Stop the engine.

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

bucket teeth (2).

5. Install the new teeth on the bucket with new

bolts.
 3.9
MAINTENANCE
When Required Inspection and Maintenance

Replace Cutting Edge

1. Park the machine on level ground and apply

the parking brake.

OM0188

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

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

7. Tighten the nuts to 696~834 N-m. 5. If other side of the cutting edge is not worn,
turn it around and install it so that the new side
8. Retighten them after operating the machine for faces the front. If both sides are worn, install a
a few hours. new cutting edge.

NOTE 6. Install all bolts and tighten them to 696~834 N-

For non-Kawasaki buckets or teeth, consult the m.
manufacturer for the proper procedures.
7. Retighten them after a few hours operation.
3.10
MAINTENANCE
When Required Inspection and Maintenance
Check and/or Replace Seat Belt
1. Inspect the condition of the seat belt and all
mounting hardware frequently.
2. Replace the seat belt or any part of the mount-
ing hardware if it is damaged.
3. Replace the seat belt every three years regard-
less of its condition or appearance.
Clean or Replace Air Cleaner Element
When the warning monitor lamp lights up, clean or
replace the air cleaner element.
IMPORTANT
Improper procedure of cleaning air cleaner may
cause severe engine damage.
- Do not clean or replace air filters while engine
is running.
- Clean only outer element. Never clean inner
element.
- Clean or replace element only when indicator
lamp comes on.
- Never clean the elements by bumping or hit-
ting them against a solid surface.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
85Z5 3054
2. Remove cover (2) by loosening wing nut (1).
3. Remove the outer element.
 3.11
MAINTENANCE
When Required Inspection and Maintenance

10. Be advised that the element cleaning should

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

OM0138

4. Clean the element using dry compressed air

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

OM0139

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

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

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

age, replace it with a new element.

7. Before installing the outer element, confirm

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

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

the cover latches.

9. If the engine exhaust gas is not clean enough

even after cleaning (still exhausting excessive
black smoke), replace the element.
3.12
MAINTENANCE
When Required Inspection and Maintenance
Clean Radiator / Air cooler / Hydraulic
oil cooler Fins
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
95ZVOM2917
90ZV5055
2. Push the knob and open the radiator grill.
Open covers on the radiator guard both the
right hand side and the left hand side for clean
the air cooler and hydraulic oil cooler.
85Z5 LP-HGA-233
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 196 kPa
or less.
- When using high-pressure water, keep the
nozzle a distance of at least 500 mm 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.
 3.13
MAINTENANCE
When Required Inspection and Maintenance

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

View from top cover 80ZV8214

80ZV 4898

1. Park the machine on level ground, apply the

parking brake, and lower the attachment to the
ground.

2. Stop the engine and turn the starter switch key

to the "OFF" position.

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

fuse box and additional fuse box.

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

replace them with new ones.

Refer to "Fuse Boxes" page 2.28.

5. Determine the cause of the blown fuses and

repair.
3.14
MAINTENANCE
When Required Inspection and Maintenance

Check Windshield Washer Fluid

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

Never replace fuses with higher amperage rat-

ing.

80ZV27801

1. Park the machine on level ground, apply the

parking brake, and lower the attachment to the
ground.

2. Check the fluid level.

3. Replace the fluid if it is dirty.

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

5. Use windshield washer solvent for both better

cleaning and to prevent freezing. Adjust the
mixture according to the manufacturer's
instructions.
 3.15
MAINTENANCE
When Required Inspection and Maintenance

Clean Air Conditioner Condenser Replace Coolant

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

- If the cooling system conditioner (from a local

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

CAUTION
Pressurized radiator tank is used for this
machine.

Spray of hot coolant may cause burns.

85Z5 2687 Stop engine and allow radiator and coolant to

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

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

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

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

- When used for cleaning purposes, the pres- 80Z5 2791

sure of compressed air should be at 196 kPa
or less. 3. Confirm the coolant in the radiator sub-tank is
- When cleaning with water, apply the water jet cool enough.
perpendicular to the core.
4. Remove the radiator sub-tank from the
machine and drain coolant from it.
3.16
MAINTENANCE
When Required Inspection and Maintenance
1 shut "OFF".
80Z5 2775
5. Loosen the drain plug (1) and drain coolant
(about 33 liters) into a suitable container.
2
85Z5 2691
6. Slowly turn the radiator cap (2) until it touches
the stopper to release inner pressure.
Pushing the cap, turn it to open.
Follow the law and/or local regulations to prop-
erly dispose of or recycle the coolant.
CAUTION
Cooling system conditioner contains alkali that
may cause caustic burns or blindness.
Avoid contact with skin and eyes to prevent
injury.
7. Tighten the drain plug and fill the cooling sys-
tem with clean water.
Do not install the radiator cap.
8. Operate the engine for one hour with the cool-
ant temperature above 80ºC. Then let the
engine cool down naturally with the engine
9. Stop the engine and loosen the drain plug to
drain the cooling system.
10. Tighten the drain plug and fill the cooling sys-
tem with clean water.
Do not install the radiator cap or the new cool-
ant filter.
11. Operate the engine for five minutes with the
coolant temperature above 80ºC.
12. Stop the engine and loosen 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 5~11).
14. Tighten the drain plug and fill the system with
the premixed coolant.
Refer to "Coolant Specification" page 3.57 for
the mixing instruction.
15. Idle the engine for five minutes to purge air
mixed into the coolant. (Leave the radiator cap
off.)
16. Add coolant as necessary.
17. Reinstall the radiator cap.
For additional cold weather servicing information,
refer to "Coolant Specification" page 3.57 for
details.
 3.17
MAINTENANCE
When Required Inspection and Maintenance

Replace Air Conditioner Receiver Dryer Greasing

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

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

2. Lubricate fittings on the following components.

Refer to "Recommended Lubricants" page

3.55 for the correct grease. Use lithium base
grease for universal joints.
3.18
MAINTENANCE
When Required Inspection and Maintenance

85ZVOM3316 95ZVOM2901

- 3rd Propeller Shaft

(two places)

80ZVOM3314

95ZVOM2843

- 2nd Propeller Shaft

(three places)
 3.19
MAINTENANCE
Every 10 Hours or Daily

Every 10 Hours or Daily

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

Read, understand, and follow all warnings and

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

See "Check before Operation" page 2.43 and

"Check after Starting the Engine" page 2.54.
3.20
MAINTENANCE
Every 50 Hours or 1 Week

Every 50 Hours or 1 Week Greasing

1. Park the machine on level ground, apply the

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

Every 50 hours or 1 week, whichever comes first, Refer to "Recommended Lubricants" page
perform the following inspection and maintenance 3.55 for the correct grease.
in addition to the "Daily Inspection and Mainte-
nance".

85ZVOM3357

- Bucket-Boom
(two places)

85ZVOM3357

- Bucket-Rod
(one place)
 3.21
MAINTENANCE
Every 50 Hours or 1 Week

85ZVOM3357 80ZVOM3272

- Lever-Rod - Bucket Cylinder-Front Chassis

(one place) (one place)

85ZVOM3357 85ZVOM3357

- Lever-Boom - Boom Cylinder-Boom

(one place) (two places)

85ZVOM3357 85ZVOM3353

- Bucket Cylinder-Lever - Boom Cylinder-Front Chassis

(one place) (two places)
3.22
MAINTENANCE
Every 50 Hours or 1 Week

85ZVOM3353 80ZVOM3272

- Boom-Front Chassis
(two places)

80ZVOM3271

- Center Pin
80ZVOM3271
(two places)

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

80ZV2 9728

- Axle support
(two places)

Drain Water and Sediment from Fuel
Tank
CAUTION
Escaping fuel is flammable and harmful to skin.
- Do not smoke while draining moisture and
sediment from fuel tank.
- Do not drain fuel with engine running.
- Do not allow fuel to remain on skin for
extended period of time. Wash thoroughly with
soap and water.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
80ZVOM3269
2. Prepare a suitable container.
3. Loosen the drain plug on the bottom of the fuel
tank.
4. Drain water and sediment along with fuel.
5. Retighten up the drain plug.
6. Dispose of the drained fuel and water properly.
7. Add fuel.
NOTE
To reduce water and sediment build up in the tank,
refuel the machine at the end of each shift.
3.23
MAINTENANCE
Every 50 Hours or 1 Week
Check Battery Electrolyte Level
WARNING
Batteries produce explosive gases which could
cause burns or blindness.
- Ventilate area to remove explosive gases.
- Wear eye or face protection when working on
or around batteries.
- Keep flames and sparks away from batteries.
WARNING
If the batteries being used have insufficient bat-
tery electrolyte level, parts in the battery case
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
hand, eye, and face protection when working
on or around batteries.
If lead, or acid contacts skin or clothing, immedi-
ately wash with water.
Dispose of used batteries by recycling.
Do not handle batteries with general waste. When
handling the used batteries follow the law and/or
local regulation in your country, state, or province.
3.24
MAINTENANCE
Every 50 Hours or 1 Week

Check Tire Air Pressure

Low Pressure OK High Pressure

90ZV5009

1. Park the machine on level ground, apply the 135ZV7532

parking brake, lower the attachment to the

ground, and stop the engine.
2. Clean the battery surface with a clean cloth or
soft brush.
Tire performance and its life depend greatly on the
tire air pressure.
- Low air pressure causes excessive deflection,
heat, and accelerated wear.

- High air pressure cause reduced traction, 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
3. Check the battery electrolyte level in each cell.
Electrolyte should cover the cell plates.
4. If the level is low, add distilled water until it
reaches the bottom of the filler neck.
NOTE
If a maintenance free battery is used, step 3 and 4
of this inspection and maintenance is not required.
WARNING
Overheated tire may explode causing serious
injury or death.
If overheated tire is suspected, do not approach
tire to distance of less than 15 m.
Stay away until tire and rim cool down.
1. Before starting work and while the tires are still
cool, measure the tire air pressure with the tire
pressure gauge.
 3.25
MAINTENANCE
Every 50 Hours or 1 Week

Recommended Tire Air Pressure

Bias ply tire

Air pressure
Size
Front Rear
23.5-25-16PR 392~412 kPa 294~314 kPa
23.5-25-20PR 471~490 kPa 373~392 kPa

OM0032

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

When inflating tires;

- Make sure wheel parts are correctly installed.
- Use self-attaching air chuck with remote shut-
off valve.
- Stand behind tread of tire and keep all per-
sons away from side of tire.
- Do not inflate tire more than recommended
pressure.
- Use safety cage if available.

OM0033

2. Adjust air pressure according to the recom-

mended pressures below.

When inflating a tire, stand behind the tread

and use a self-attaching chuck with a remotely
located valve to turn air pressure on and off.
3.26
MAINTENANCE
Every 250 Hours or 1 Month

Every 250 Hours or 1 Month Greasing

1. Park the machine on level ground, apply the

WARNING parking brake, lower the attachment to the
Improper inspection or maintenance could result ground, and stop the engine.
in death or serious injury.
2. Lubricate fittings on the following components.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance" Refer to "Recommended Lubricants" page
page 1.12 before performing any inspection or 3.55 for the correct grease.
maintenance procedures.

Every 250 hours or 1 month, whichever comes first,

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

80ZVOM3271

- Pillow block bearing unit

(one place)
 3.27
MAINTENANCE
Every 250 Hours or 1 Month

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 70ZV 4661
40ºC. When the needle of the coolant tempera-
ture gauge reaches the middle of the white
5. Remove the oil filter and properly dispose of it.
zone, the temperature is about 40ºC.
Make sure the O-ring is removed with the filter.
2. Park the machine on level ground, apply the
6. Clean the oil filter head gasket surface.
parking brake, lower the attachment to the
ground, and stop the engine.
7. Fill the new filter with clean engine oil.

Refer to "Recommended Lubricants" page

3.55 for the oil specifications.

8. Apply a light film of engine oil to the gasket sur-

face of the new filter cartridge.

80Z5 2775

3. Loosen the drain plug.

4. Drain oil, about 23 liters, into a suitable con-

tainer.
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.

10. Retighten the oil drain plug, and tighten to 80

N-m torque.
3.28
MAINTENANCE
Every 250 Hours or 1 Month
Dip stick
Fill cap 70ZV 4693
11. Fill the engine with clean oil to the proper level.
Refer to "Recommended Lubricants" page
3.55 for the oil specifications. Total system
capacity including the filter is 33 liters.
12. Idle the engine to inspect for leaks at the filter
and the drain plug.
13. Stop the engine. Wait approximately 30 min-
utes to let the oil drain back to the oil pan.
14. Check the oil level again.
15. Add the specified oil if necessary to bring the
oil level to the "H" (High) mark on the dipstick.
16. Properly dispose of or recycle the waste oil.
CAUTION
Used engine oil may cause skin disease or irrita-
tion.
Do not allow used engine oil to remain on skin
for prolonged periods of time.
Clean skin thoroughly with soap and water.
Check Differential Gear Oil
CAUTION
The axles are pressurized through the hydraulic
tank.
When removing the oil level check plug a large
volume of hot oil could spray out. It causes seri-
ous burns.
Before removing the oil level check plug, push
down on the hydraulic tank cap or the breather
valve to release the air pressure inside the
hydraulic tank.
Do not touch the parts or oil when it is hot.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
WARNING
If the boom is raised to ease access securely
block or brace the boom to prevent accidental
lowering.
70ZV OM 2514
2. Remove the oil level plug from the front axle
housing, using a 12 mm hex (Allen) wrench.
3. If the oil level is lower than the plug, add the
specified oil through the level plug hole.
Refer to "Recommended Lubricants" page
3.55.
 3.29
MAINTENANCE
Every 250 Hours or 1 Month

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

Before removing the oil level check plug, push

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

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

1. Check the oil level on all four wheels.

80ZVOM3340

2. Move the machine on level ground so that

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

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

attachment to the ground, and stop the engine.

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

a 12 mm hex (Allen) wrench.

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

specified oil through the level plug hole.

Refer to "Recommended Lubricants" page

3.55.
3.30
MAINTENANCE
Every 250 Hours or 1 Month

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.
Check Tightness of Wheel Bolts
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.

7. If there is any sign of water in the oil, drain and

replace the oil. Oil containing water looks
milky.

Dispose of the drained oil properly.

8. Install and tighten the level plug.

80ZVOM3340

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

m.

3. Retighten if necessary.
 3.31
MAINTENANCE
Every 250 Hours or 1 Month

Check and Adjust Air Conditioner Belt

CAUTION 1
Contact with moving belts or pulleys may cause
injuries.

Stop engine before opening engine access

panel. 3

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine. Remove the key
and page "Do Not Start" tag on the instrument
panel.
2. Open the engine access panel.
2 85ZV 4519
6. If the belt is too loose or tight, adjust the ten-
sion by loosening lock nut (1) and bolt (2), turn-
ing adjusting bolt (3) on the tension pulley
bracket.

OM0201

3. Visually inspect the compressor belt on both

top and bottom sides for looseness and dam-
age.

4. If the belt is too stretched to permit adjustment

or shows cuts or cracks, replace it and adjust
the tension correctly.

5. Measure the belt tension using a belt tension

gauge so that it is applied 353±88 N (initial ten-
sion : 559±108 N).
3.32
MAINTENANCE
Every 250 Hours or 1 Month

Check and Adjust Drive Belt Adjustment

CAUTION 2
Contact with moving belt or pulleys may cause 3
injury.

Stop engine before opening engine side panel.

Inspection

1. Park the machine on a level ground, apply the

parking brake, lower the attachment to the
ground, and stop the engine.
1
65ZV2 9579

2. Open the engine access panel.

1. Loosen bolt (1) and nut (2).
3. Visually inspect the belt on both top and bot-
tom sides for looseness and damage. 2. Turn adjusting screw (3) to adjust the belt ten-
sion correctly.

98 N 3. Tighten bolts (1) and nut (2).

Idle pulley 4. If new belts are installed, check and adjust

10~15 mm them again after one hour of operation.
Alternator
pulley

Crank pulley

OM0227

4. If the belt is too stretched to permit adjustment

or shows cuts or cracks, replace it and adjust
the tension correctly.

5. Apply pressure, approximately 98N, to the cen-

ter of the belt between the pulleys. Correctly
adjusted belt will slack 10~15 mm.

Clean Air Conditioner Filter Element
Outer filter cleaning
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground.
2. Turn the air conditioner "OFF" and stop the
engine.
97ZVOM0152
3. The cover for the outer filter is located at the
left rear side of the cab.
Turn the rings counterclockwise and then
remove the cover.
97ZVOM0153
4. Remove the outer filter from the cab.
5. Remove dust with compressed air. Use air
pressure below 196 kPa.
6. To remove more stubborn debris, wash the fil-
ter with clean water. Leave them for five to
seven days for dry in the shade.
3.33
MAINTENANCE
Every 250 Hours or 1 Month
7. After approximately 20 cleanings, replace the
filter with new one.
Refer to "Replace Air Conditioner Filter Ele-
ments" page 3.51.
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.
97ZVOM0152
9. Install the cover to the cab and turn the rings
clockwise to fix the cover.
Inner filter cleaning
1
97ZVOM2473
1. The inner filter is located at behind the opera-
tor's seat.
Open unit cover (1) using screw driver.
Loosen screw (2) by fingers to remove cover
(3).
Remove the filter and clean it.
3.34
MAINTENANCE
Every 250 Hours or 1 Month

2. Remove dust with compressed air. Use air Replace Filter

pressure below 196 kPa.
(First time replacement or cleaning only)
3. To remove more stubborn debris, wash the fil-
ter with clean water. Leave them for five to - Transmission Oil Filter Cartridge
seven days for dry.
Replace it first time only at 250 hours operation,
4. After approximately 20 cleanings, replace the after that replace it at every 500 hours opera-
filters with new ones. tion.

Refer to "Replace Air Conditioner Filter Ele- Refer to "Every 500 Hours or 3 Months" page
ments" page 3.51. 3.35.

5. Install the filter, install filter cover (3) and cover - Hydraulic Oil Return Filter
(1).
Replace it first time only at 250 hours operation,
NOTE after that replace it at every 1000 hours opera-
It is recommended to have a second set of filters to tion.
use while another set is being dried.
Refer to "Every 1000 Hours or 6 Months" page
This filter is for dust, and has no effect on chemical 3.41.
substance like gas and asbestos etc.
- 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

3.52.

- 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.

Every 500 Hours or 3 Months
WARNING
Improper inspection or maintenance could result
in death or serious injury.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or
maintenance procedures.
Every 500 hours or 3 months, whichever comes
first, perform the following inspection and mainte-
nance in addition to the "Daily", "50 hours", and
"250 hours" inspection and maintenance.
3.35
MAINTENANCE
Every 500 Hours or 3 Months
Replace Transmission Oil Filter Car-
tridge
CAUTION
Hot oil and components may cause burns.
Avoid contact with hot oil or components.
1. If the machine is cold, operate the machine to
bring the torque converter oil temperature
about 30~40ºC.
2. Park the machine on level ground, turn "ON"
the parking brake switch, lower the attachment
to the ground, and stop the engine.
3. Place a suitable container (about 4 liters)
under the transmission oil filter.
85ZVOM3226
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.
Tightening torque: 30~40 N-m
8. Idle the engine about ten minutes and inspect
for leaks around the filter.
3.36
MAINTENANCE
Every 500 Hours or 3 Months
DANGER
Accidental movement of machine could result in
death or serious injury.
When inspecting or servicing machine in articu-
lation area:
- Lower attachment to ground.
- Put transmission shift lever in neutral.
- Apply parking brake.
- Make sure nobody is on machine.
- Place "DO NOT OPERATE" tag on steering
wheel.
80ZVOM3271
9. Check transmission oil level.
Refer to "Check Transmission Oil Level" page
2.55.
Add the specified oil as necessary to bring the
oil level to the "H" (high) mark on the dipstick.
Refer to "Recommended Lubricants" page
3.55 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.
Replace Fuel Filter Cartridge
CAUTION
Escaping fuel is flammable and harmful to skin.
- Do not smoke while draining moisture and
sediment from fuel filter.
- Do not drain with engine running.
- Do not allow fuel to remain on skin for
extended period of time. Wash thoroughly with
soap and water.
1. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
2. Place a small drain pan (about 1 liter) under
the fuel filter.
70ZV 4694
3. Remove and properly dispose of the fuel filter.
4. Clean the filter head gasket surface.
5. Apply a light film of clean engine oil to the gas-
ket surface of the new filter.
6. Fill the filter with clean fuel.
7. Install the filter loosely on the filter head.
Turn it until the gasket loosely contacts the fil-
ter head surface.
8. Tighten the filter an additional two-thirds to
three-fourths turn after the gasket contacts the
filter head surface. Follow the instructions sup-
plied with the filter.
 3.37
MAINTENANCE
Every 500 Hours or 3 Months

6. Wipe off any spilled fuel.

IMPORTANT 7. Start the engine and check for leaks.
Do not over tighten the filter.
8. Properly dispose of the spilled fuel and oily
After cleaning the fuel filter cartridge, be sure to rags.
purge fuel line of air.
NOTE
If the engine will not start, is difficult to start, or does
Bleeding not run smoothly, stop the engine and bleed it
again.

70ZV 4698

1. Turn the knob (1) on the priming pump of the

injection pump counterclockwise until it comes
up.

70ZV 4694

2. Loosen the bleeder screw (2) on the fuel filter.

3. Pump the knob (1) up and down until fuel

comes out of the bleeder port without air bub-
bles.

4. Tighten the bleeder screw (2).

5. Push down and turn the priming pump knob (1)

to lock.
3.38
MAINTENANCE
Every 500 Hours or 3 Months

Clean Fuel Feed Pump Strainer Check Exhaust Pipe and Muffler

Check the exhaust pipes and muffler installation

CAUTION and joints for looseness and exhaust gas leakage
Escaping fuel is flammable and harmful to skin. from their joints.

- Do not smoke while cleaning.

- Do not allow diesel fuel to remain on skin for
an extended period of time. Wash thoroughly
with soap and water.

2 1
70ZV 4698a

1. Place a suitable container under the feed

pump and remove joint bolt (1).

2. Remove strainer (2) from joint bolt. Properly

clean the strainer and blow off dirt and/or dust.

CAUTION
Compressed air may cause injury.

- Wear protective clothing and eye protection.

- Air pressure must be below 196kPa.

3. For installation, follow the above procedure in

reverse order.

After cleaning the strainer, be sure to purge fuel line

of air. Refer to "Replace Fuel Filter Cartridge" page
3.36.
 3.39
MAINTENANCE
Every 1000 Hours or 6 Months

Every 1000 Hours or 6 Months Replace Transmission Oil

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

Avoid contact with transmission oil.

1. If the machine is cold operate the machine for

a few minutes to bring the transmission oil tem-
perature about 30~40ºC.

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

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

1 3

2
95ZVOM2898

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

4. Drain oil into a suitable container (about 38

liters).

Properly dispose of or recycle the waste oil.

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

3.40
MAINTENANCE
Every 1000 Hours or 6 Months

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

suction strainer.

Set screw

Flange
80ZVOM3271

Gasket

Strainer
97ZVOM0164
7. Remove the set screw using a 2.5 mm hex
(allen) wrench from the strainer.
8. Remove the suction strainer from the flange,
brush off any debris and clean with solvent.
13. Check the oil level with the dipstick. Add the
specified oil if necessary to maintain the proper
oil level.
Refer to "Check Transmission Oil Level" page
2.55 and "Recommended Lubricants" page
3.55.

It is normal for a few fine particles to be on the

strainer. Large pieces or a large quantity of
particles indicates a problem.

Contact a Kawasaki dealer.

9. Reinstall the drain plug and the strainer with a

new gasket.

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

11. Fill with the specified oil.

Refer to "Recommended Lubricants" page

3.55.

12. Idle the engine and check for leaks.

 3.41
MAINTENANCE
Every 1000 Hours or 6 Months

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.

Relieve all pressure by pressing down the filler

cap or the breather valve.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the
85ZVOM3250
ground, and stop the engine.

2. Open the access cover on the right deck.

1. Park the machine on level ground, apply the
parking brake, lower the attachment to the (S/N 0501~0510)
2
ground, and stop the engine.

2. Remove the breather from the transmission Filler cap

case.

3. Clean the breather in the cleaning oil tub, then

spray dry compressed air from the bottom of
the breather.

Even after cleaning, if the breather is not clean

enough, replace the breather. 1
80ZV27801

4. Install the breather onto the transmission case.

(S/N 0511~)
2

Breather valve

1
80ZV27801a

3. Press down the filler cap or the breather valve

to relieve the tank pressure.

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

3.42
MAINTENANCE
Every 1000 Hours or 6 Months

5. Remove two bolts (2) with a 17 mm wrench Adjust Parking Brake Lining
and open filter cover (1).

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

to push up the cover. Install them into the two When parking brake is released for adjusting
threaded holes in the cover. Screw them in brake lining, machine could move unexpectedly
equally to force the cover up evenly. causing serious injury or death.

Make sure to lower attachment to ground, and

1 put chocks under wheels.
2

3 1. Park the machine in a safe place on firm level

ground and steer it fully to one side for easier
4 access.

5 2. Lower the attachment to the ground and turn

"OFF" the parking brake switch.
6
97ZVOM0166

1
6. Remove O-ring (3), spring (4), and bypass
valve (5) from the filter housing.

7. Remove and properly dispose of filter (6) and

waste oil.

8. Clean the inside of the filter housing.

9. Replace O-ring (3). 85ZV 3245

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

filter cover O-ring surface.

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

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

12. Close the access cover.

8º OM0167

3. Align inspection hole (1) with the adjuster

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

Do not enter the articulation area or under the

machine.

4. Place wheel chocks in front of and behind the
tires to prevent the machine from moving.
5. Place a "DO NOT OPERATE" tag on the steer-
ing wheel.
Adjuster wheel
1
Special Tool
(Accessory)
97ZVOM0168
6. Remove a cap of inspection hole (1) on the
brake drum.
7. Turn the adjuster wheel fully upward to close
the clearance between the brake drum and the
brake lining (shoe). The adjuster wheel can be
reached through the inspection hole.
8. Return the adjuster wheel eight clicks down-
ward. (Now the clearance is 0.23 mm)
9. Check parking brake operation as described
on page 2.56.
NOTE
If the brake drum has been excessively hot (ie.
burnt paint) or the parking brake will not adjust,
contact your Kawasaki dealer.
3.43
MAINTENANCE
Every 1000 Hours or 6 Months
Check Air Conditioner Refrigerant
85Z5 2688
1. Apply the parking brake and lower the attach-
ment to the ground.
2. Remove the cover.
3. Press the flow control switch to set maximum
air flow.
4. Set the temperature control switch fully to the
cool position and fully open the cab doors.
5. Slightly accelerate the engine to about the mid-
dle speed range.
(compressor speed 1,500~1,800 min-1)
6. Compare the flow of bubbles in the sight glass
with the drawings in the following table.
WARNING
Overfilled refrigerant may cause dangerous high
pressure and poor cooling action; and low refrig-
erant level may cause compressor damage.
Always maintain refrigerant in normal level.
3.44
MAINTENANCE
Every 1000 Hours or 6 Months

Check and Clean Starter Motor and

Adjust of Appearance of the
Solutions Alternator
refrigerant sight glass

Normal Almost clear. - Contact your Kawasaki dealer.

Any bubbles dis-
appear if the
engine speed is
increased to
1,500 min-1. Check Turbocharger
High
- Contact your Kawasaki dealer.
No bubble is
seen. Contact your local
Kawasaki dealer
for inspection and
Low recharging refrig-
Check and Retighten Cylinder Head
A flow of bubbles erant. Bolts
is visible.
- Contact your Kawasaki dealer.

Check Fuel Injection Pump

- Contact your Kawasaki dealer.

Check and Adjust Engine

Contact your Kawasaki dealer or local Cummins

engine dealer for checking and adjusting the follow-
ing items:

- Engine Compression Pressure

- Injection Pressure

- Injection Timing

Every 2000 Hours or 1 Year
WARNING
Improper inspection or maintenance could result
in death or serious injury.
Read, understand, and follow all warnings and
instructions contained in "Safe Maintenance"
page 1.12 before performing any inspection or
maintenance procedures.
Every 2000 hours or 1 year, whichever comes first,
perform the following inspection and maintenance
in addition to the "Daily", "50 hours", "250 hours",
"500 hours", and "1000 hours" inspections and
maintenance.
3.45
MAINTENANCE
Every 2000 Hours or 1 Year
Greasing
1. Park the machine on level ground.
Lower the attachment to the lowest position
and tilt back the bucket fully.
2. Steer the machine fully to the right or left, and
stop the engine.
3. Lubricate the fitting on the sleeve yoke.
4. To lubricate the spline enough, start the engine
and slowly turn the machine from side to side 2
or 3 times after greasing.
Refer to "Recommended Lubricants" page
3.55 for the correct grease. Use lithium base
grease for a propeller shaft spline .
95ZVOM2843
- 2nd Propeller Shaft Spline
(one place)
IMPORTANT
When greased with the machine in straight,
remove the fitting on the sleeve yoke and follow
the procedure above step 4.
3.46
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Hydraulic Oil, Clean Filter Remove breather valve (S/N 0511~)

WARNING
Pressurized hydraulic tank is used for this
machine.

Pressurized hot oil may cause injury or burns.

Relieve all pressure by pressing down the filler

cap or the breather valve.

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the 80ZV27801a
ground, and stop the engine.

2. Move the bucket and boom control levers back 6. Push down the top of the breather valve to
and forth to relieve the pressure. relieve the tank pressure.

Remove oil inlet cap (S/N 0501~0510)

2 1

T4A breather valve2

80ZV27801 7. Remove four bolts (1) to remove breather

valve (2) and O-ring (3).
3. Insert the key into the side of the filler cap and
turn the key counterclockwise. CAUTION
4. Press down the filler cap to relieve the tank Hydraulic oil may be hot and may cause burns.
pressure.
Avoid contact with hydraulic oil.
5. Remove the inlet cap.

CAUTION
Hydraulic oil may be hot and may cause burns.

Avoid contact with hydraulic oil.


Replace hydraulic oil
8. Prepare a suitable container to catch the drain-
ing oil (about 85 liters).
4 85ZVOM3230
9. Remove drain plug (4) using a 24 mm wrench
to drain oil.
10. Dispose of the waste oil properly.
11. Remove the nuts with a 14 mm wrench to
remove inspection cover (5).
CAUTION
Compressed air may cause injury.
- Wear protective clothing and eye protection.
- Air pressure must be below 196 kPa.
3.47
MAINTENANCE
Every 2000 Hours or 1 Year
7 6
A
65DV2 02522-0436
12. Remove lock bolt (6) and suction strainer (7).
Inspect and clean them with solvent and com-
pressed 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.
13. Clean inside of the tank and magnet plug.
14. Apply lubrication oil to the threaded area (A)
and install suction strainer (7). Tighten it with
155 N-m torque, and fix with lock bolt (6).
15. Install the new gasket and inspection cover (5),
and tighten the nuts. Do not overtighten.
16. Install and tighten the drain plug.
17. Add the specified hydraulic oil through the oil
inlet hole.
Refer to "Recommended Lubricants" page
3.55.
18. Install the oil inlet cap or breather valve (2) and
new O-ring (3).
19. Start the engine and allow the engine to idle for
about five minutes.
20. Operate the bucket, boom, and steering cylin-
ders for about five minutes, then lower the
attachment to the ground.
21. Inspect for leaks.
22. Make sure hydraulic oil is to the center of the
oil level gauge. Add hydraulic oil if necessary.
3.48
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Differential Gear Oil

CAUTION
The axles are pressurized through the hydraulic
tank.
When removing the oil level check plug a large
volume of hot oil could spray out. It causes seri-
ous burns.
Before removing the oil level check plug, push
down on the hydraulic tank cap or the breather
valve to release the air pressure inside the
hydraulic tank.
Do not touch the parts or oil when it is hot.
1. If the machine is cold operate the machine for
a few minutes to bring the differential gear oil
temperature about 40ºC.
2. Park the machine on level ground, apply the
parking brake, lower the attachment to the
ground, and stop the engine.
WARNING
If the boom is raised to ease access securely
block or brace the boom to prevent accidental
lowering.
4. Drain the oil (about 30 liters) into a suitable
container.
5. Dispose of the waste oil properly.
CAUTION
Used oil may cause skin disease.
Do not allow used oil to remain on skin for pro-
longed periods of time.
Clean skin thoroughly with soap and water.
6. Install the drain plug.
7. Refill the recommended oil through level plug
hole (1) until the oil comes out from the hole.
Refer to "Recommended Lubricants" page
3.55.
8. Install and tighten the level plug.
9. Replace the rear differential oil following the
same steps.
Required oil volume for the rear differential is
about 50 liters.

2 70ZV OM 2514

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

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

Some fine metallic powder will normally stick to

the magnet plugs.

Simply wipe it off.

 3.49
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Planetary Gear Oil

CAUTION
The axles are pressurized through the hydraulic
tank.

When removing the oil level check plug a large

volume of hot oil could spray out. It causes seri-
ous burns.

Before removing the oil level check plug, push 3

down on the hydraulic tank cap or the breather
valve to release the air pressure inside the
hydraulic tank.
Do not touch the parts or oil when it is hot.
70ZV OM 2514
4. Remove level plug (2) and drain plug (3) from
the planetary gear housing, using a 12 mm hex
(Allen) wrench.

1. Replace the planetary gear oil on all four Some fine metallic powder will normally stick to
wheels. magnet plug (2).

Simply wipe it off.

1
5. Drain the oil (about 12 liters) into a suitable
container.
2
6. Dispose of the waste oil properly.

CAUTION
Used oil may cause skin disease.

Do not allow used oil to remain on skin for pro-

80ZVOM3340
longed periods of time.

Clean skin thoroughly with soap and water.

2. Move the machine on level ground so that
"TOP" mark (1) on the planetary gear housing
comes to the top. 7. Install and tighten the drain plug.

3. Turn "ON" the parking brake switch, lower the 8. Refill the recommended oil through level plug
attachment to the ground, and stop the engine. hole (2) until the oil comes out from the hole.

Refer to "Recommended Lubricants" page

WARNING 3.55.
If the boom is raised to ease access securely
block or brace the boom to prevent accidental 9. Install and tighten the level plug.
lowering.
10. Repeat these steps for all four planetaries.
3.50
MAINTENANCE
Every 2000 Hours or 1 Year

Clean Fuel Tank Check Brake Accumulator

Test the brake accumulator for proper pre-charge of

CAUTION nitrogen gas.
Escaping fuel is flammable and harmful to skin.

- Do not smoke while draining moisture and

sediment from tank.
- Do not drain with engine running.
- Do not allow fuel to remain on skin for an
extended period of time. Wash thoroughly with
soap and water.
WARNING
Pressurized nitrogen gas in brake accumulator
could explode causing serious injury or death.
Never service brake accumulator unless trained
properly.

NOTE 1. Park the machine on level ground, apply the

It is easiest to clean the fuel tank when the fuel is parking brake, and lower the attachment to the
almost empty. ground.

1. Park the machine on level ground, apply the 2. Run the engine at low idle for five minutes to fill
parking brake, lower the attachment to the the brake accumulator with oil.
ground, and stop the engine.
3. Stop the engine.

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

5. Count the number of times you can step on the

2 right hand brake pedal before the brake warn-
ing light comes on.

6. If the number counted is less than nine, there

is some problem with the accumulator. Contact
your nearest Kawasaki dealer.
1
80ZVOM3269

Check Service Brake Disk Wear

2. Remove drain plug (1) using a 24 mm wrench
to drain oil. - Contact your Kawasaki dealer.

3. Drain the remaining fuel into a suitable con-

tainer.
Check and Adjust Valve Lash Clearance
4. Remove the nuts with a 14 mm wrench to
remove inspection cover (2). - Contact your Kawasaki dealer or local Cummins
engine dealer.
5. Clean inside of the tank.

6. Install the inspection cover with a new gasket.

Tighten the nuts evenly. Do not overtighten.

7. Close the drain cock.

8. Fill the fuel tank.

9. Check for any leaks at the cover and plug.

 3.51
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Air Conditioner Filter Elements

Outer filter replacement

1. Park the machine on level ground, apply the

parking brake and lower the attachment to the
ground.

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

engine.

97ZVOM0152

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

clockwise to fix the cover.

Inner filter replacement

97ZVOM0152

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

Turn the rings counterclockwise and then

remove the cover. 1
97ZVOM2473

The inner filter is located at behind the operator's

seat.

Open unit cover (1) using screw driver.

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

Remove the filter and replace it with new one.

NOTE
97ZVOM0153 This filter is for dust, and has no effect on chemical
substance like gas and asbestos etc.
4. Remove the outer filter from the cab, and
replace it with new one.

When installing the outer filter into the cab, be

sure to align the air flow arrow on the outer fil-
ter to point toward the cab.
3.52
MAINTENANCE
Every 2000 Hours or 1 Year

Clean Filter for Brake Line Clean Filter for Orbitrol®

CAUTION CAUTION
Hot oil and components may cause burns. Hot oil and components may cause burns.

Vent all pressure by pressing hydraulic cap or Vent all pressure by pressing hydraulic cap or
the breather valve down. the breather valve down.

Avoid contact with hot oil or components. Avoid contact with hot oil or components.

1. Park the machine on level ground, turn "ON" 1. Park the machine on level ground, turn "ON"
the parking brake switch, lower the attachment the parking brake switch, lower the attachment
to the ground, and stop the engine. to the ground, and stop the engine.

2. Move the bucket and boom control levers back

and forth to relieve the pressure.

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

Front
to relieve the pressure.

Screen board

Front Cross (Upper)

80ZV03148-06300

Front

Chassis C/L

80ZV04033-02960
Air blow
FLOW

Filter case Filter Nipple

Air blow
FLOW
OM0212

2. Place a suitable container under the filter. Filter case Filter Nipple

3. Remove the nipple with filter and properly

clean the filter.
OM0212

4. Install the nipple with filter and tighten it with

60~80 N-m torque. 4. Place a suitable container under the filter.

5. Idle the engine about ten minutes and inspect 5. Remove the nipple with filter and properly
for leaks around the filter. clean the filter.
 3.53
MAINTENANCE
Every 2000 Hours or 1 Year

6. Install the nipple with filter and tighten it with Replace Filter in the Hydraulic Tank
60~80 N-m torque. Cap (S/N 0501~0510)
7. Idle the engine about ten minutes and inspect
for leaks around the filter. CAUTION
Pressurized hydraulic tank is used for this
machine.

Pressurized hot oil may cause injury or burns.

Vent all pressure by pressing cap before open-

ing.

3
2
97ZVOM0170

1. Park the machine on level ground, apply the

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

2. Move the bucket and boom control levers back

and forth to relieve the pressure.

3. Insert the key into the side of filter cap (1) and
turn the key counterclockwise.

4. Press down filter cap (1) to relieve the tank

pressure.

5. Remove the filter cap.

6. Remove spiral snap ring (2), valve assy (3),

spring (4), filter element (5).

7. Replace element (5).

8. Install the element, spring, valve assy, and spi-

ral snap ring.
3.54
MAINTENANCE
Every 2000 Hours or 1 Year

Replace Filter in the Hydraulic Tank Check Ride Control Accumulator

Breather Valve (S/N 0511~) (option)

CAUTION WARNING
Pressurized hydraulic tank is used for this Pressurized nitrogen gas in ride control accumu-
machine. lator could explode causing serious injury or
death.
Pressurized hot oil may cause injury or burns.
Never service ride control accumulator unless
Vent all pressure by pressing breather valve trained properly.
before opening.
Contact your Kawasaki dealer.

1
2
Retighten Intake/Exhaust Manifold
3
- Contact your Kawasaki dealer.

4
Retighten Bolts of Oil Pan

- Contact your Kawasaki dealer.

T4A breather valve

1. Park the machine on level ground, apply the

parking brake, lower the attachment to the Check Heater Plugs
ground, and stop the engine.
1. Turn the starter switch to “ON” position when
2. Move the bucket and boom control levers back
the engine is cooled enough.
and forth to relieve the pressure.
2. wait about five seconds and touch the heater
3. Press down cap (1) to relieve the tank pres-
plug terminal.
sure.
3. If the terminal is cool contact your Kawasaki
4. Remove cap (1), nut (2), cover (3), and filter
dealer.
element (4).

5. Replace element (4).

6. Install the element, cover, nut, and cap.

Tightening torque: Nut (2) 8~10 N-m

 3.55
MAINTENANCE
Recommended Lubricants

Recommended Lubricants

Refill capacity Ambient Temperature (ºC) Change Interval

Kind of Oil -30 -20 -10 0 10 20 30 40
(Approximate) (Hours)

SAE10W-30
Engine oil SAE15W-40
Engine 23 liter 250
(CD or CF4)
SAE30

Engine oil (CD) or SAE10W

Transmission 35 liter 1,000
ATF ATF

∗1 ∗2 ISO VG32
Hydraulic tank ISO VG46
2,000
85 liter Hydraulic oil
Differential & Front: 54 liter Engine oil SAE40 or SAE50
Engine oil (CD) 2,000
Planetary Rear: 59 liter
ASTM D975 No.1
Fuel tank 290 liter Diesel fuel ASTM D975 No.2 daily

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

Engine Use oil that meets engine oil classification API CD or CF4.

Transmission Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid).
Never mix engine oil and A.T.F.

Hydraulic System Use industrial-type hydraulic oils which are certified by suppliers having anti-wear,
anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of
the wrong viscosity of oil can cause improper operation of hydraulic functions or
premature pump failure.
∗2. In a case that fire-resistant fluid is to be used in the hydraulic circuit, some
hydraulic equipment must be replaced. Contact your Kawasaki dealer for ser-
vice.
Be sure to use ISO VG32 when the temperature is below -15ºC. When replac-
ing the hydraulic oil ISO VG46 with ISO VG32, the brakes must be bled to fully
circulate the new oil, or brake problems could occur. Contact Kawasaki dealer
for service.

Differential & Use class API CD engine oil with 5 % "Antichatter" additive or friction modifier.
Planetary

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

Grease NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for universal joints and a propeller shaft spline.
3.56
MAINTENANCE
Recommended Lubricants

Diesel Fuel Requirements for diesel fuel

Specifications
Grade No.1-D Grade No.2-D
Flash Point ºC. min. 38 52
Water and Sediment % vol. max 0.05 0.05
Distillation Temperature ºC 90% vol. recovered max. 288 338
Kinematic Viscosity mm2 /s at 40ºC min. 1.3 1.9
max. 2.4 4.1
Ash % mass max. 0.01 0.01
Sulfur % mass max. 0.50 0.50
Cetane Number min. 40 40
Carbon residue on 10% distillation residue % mass max. 0.15 0.35
 3.57
MAINTENANCE
Coolant Specification

Coolant Specification
The machine is originally filled with Long Life Cool-
ant (non-Amin type ethylene glycol) which need not
be replaced for the first two years or 3000 hours.

Do not use Amin type Long Life Coolant in cooling

system. It may cause a corrosion against radiator
or heater core.

If standard antifreeze (not Long Life Coolant) is

used for the replacement, it should be replaced
every six months.

Recommended Mixture of Antifreeze

Expected Minimum
-35ºC -30ºC -25ºC -20ºC -15ºC
Ambient Temperature
Pure Water (liter) 15.7 17.4 19.0 20.7 22.4
Antifreeze (liter) 17.7 16.0 14.4 12.7 11.0
Mixture Ratio (%) 53 48 43 38 33

- Too much antifreeze in the coolant mixture may

cause engine overheating.

Keep 33 % antifreeze mixture (same as the mix-

ture for a minimum ambient temperature of -15
ºC) if the engine overheats in a high ambient
temperature.

- Do not use hard water or water with high levels

of calcium and magnesium ions as the coolant
water.

IMPORTANT
Do not mix different brands of antifreeze
because they each contain special additives.
Careless mixing often diminishes the effect of
these additives and causes packing damage or
water leakage.
3.58
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 2.44
Wrong grade oil for weather conditions Change oil 3.27
Engine oil pres- Clogging oil filter element Change filter and oil 3.27
sure warning lamp Defective alarm switch
lights up, and Oil leakage from pipe or joint
buzzer sounds Clogging suction strainer kawasaki or CUMMINS

Excessive engine wear

Defective oil pump
Low engine coolant level Add coolant 2.46
Fan circuit pressure or flow too low kawasaki

Coolant temp. Clogging radiator fins Clean 3.12

warning lamp Scale or mineral build up inside radiator Flush or professionally clean 3.15
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 3.36
start when the Starter motor speed too low Booster Battery may be used 2.76
starter motor is Defective engine shut off solenoid
turning Fuel pump failure
(Also see ELEC- Incorrect fuel injection timing kawasaki or CUMMINS

TRICAL TROU- Compression pressure too low

BLESHOOTING) Defective injectors
Air in fuel lines Tighten fuel connections and fil- 3.36
ter
Unstable (rough)
Fuel filter element clogging Replace fuel filter 3.36
idling
Fuel pump failure
Incorrect fuel injection timing
kawasaki or CUMMINS

Air cleaner element clogging Clean or replace element 3.10

Fuel filter element clogging Replace fuel filter 3.36
Throttle pedal electrical signal incorrect kawasaki

Engine oil level too high Check dipstick and correct level 2.44
Insufficient power Incorrect valve clearance
Piston ring wear
Defective injectors kawasaki or CUMMINS

Fuel pump failure

Air cooler restricted
 3.59
TROUBLESHOOTING

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Wrong type of oil Use correct type of oil 3.55
Engine oil level too low or too high Correct oil level 2.44
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 3.36
White exhaust
Wrong grade fuel replace fuel filter
smoke
Incorrect fuel injection timing
(After engine has
Compression pressure too low
reached operating kawasaki or CUMMINS
Turbo seal leakage
temp.)
Coolant ingestion
Air cleaner element clogging Clean or replace element 3.10
Turbo damage
Black exhaust
Incorrect fuel injection timing
smoke kawasaki or CUMMINS
Fuel injection pump failure
Defective injectors
3.60
TROUBLESHOOTING

ELECTRICAL

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Broken or slipping alternator belt Adjust or replace belt 3.32
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 1.30
not turn when Insufficient battery charge Battery charge or booster 2.76
starter switch key Starter switch failure kawasaki

is turned to Defective wiring

"START" Starter motor failure
kawasaki or CUMMINS

Hydraulic control levers not in NEUTRAL Move levers to NEUTRAL 2.4

Insufficient battery charging Battery charge or booster 2.76
Engine oil viscosity too high (thick) Replace oil 3.27
Starter motor turns
Poor connection at batteries or ground Clean and tighten all terminals
engine slowly
Defective wiring kawasaki

Starter motor failure kawasaki

or CUMMINS

Steering valve failure kawasaki

STEERING

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Tires are under inflated Check/adjust tire pressure 3.24
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 1.29
"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 3.55
proper viscosity for temperature
Steering Drift
Steering control valve failure
kawasaki
Steering pilot valve failure
 3.61
TROUBLESHOOTING

HYDRAULIC

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Excessively cold oil Warm oil 3.55
Wrong grade oil Replace with proper grade oil
Oil pressure too low
Boom raises too Damaged cylinder piston or piston pack-
slowly ing
kawasaki
Pump flow too low
Pilot pressure too low
Engine RPM too low
Excessively cold oil / Wrong oil type Warm oil / Replace oil with 3.55
proper viscosity for temperature
Boom natural drift Leakage from control valve plunger
excessively Damaged cylinder piston or piston pack-
kawasaki
ing
Leakage in pilot relief valve
Bucket / Attach- Over load relief pressure too low
ment floating or Control valve failure kawasaki

drifting Natural drift of cylinder / packing

BRAKE

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Worn brake lining Adjust or replace lining 3.42
Parking brake Insufficient oil pressure (will not release)
does not work Failure of switch or solenoid valve
kawasaki
properly Poor wiring or ground to switch or sole-
noid valve
Wrong type of oil Use correct type of oil 3.55
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 3.52
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

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Excessively cold oil / Wrong oil type Warm oil / Replace oil with 3.55
proper viscosity for temperature
Parking brake is applied Release parking brake
Engine is running Transmission oil level too low Add oil / Repair leak 2.55
but machine does Transmission suction strainer clogging Clean strainer 3.39
not move Clutch oil pressure too low
Transmission clutch failure
kawasaki
MCU failure
Defective electrical circuit
Service or parking brake dragging Inspect and correct
Low oil level in transmission Refill oil / Repair leak 2.55
Suction strainer in transmission clogging Clean or replace strainer 3.39
Low power
Clutch oil pressure too low
Torque converter oil pressure too low kawasaki

Transmission clutch failure

Air breather clogged Clean and refill with oil 3.41
Oil leakage from
Seal damage (between engine and torque
transmission kawasaki
converter housing)
Oil level too low Add oil / Repair leak 2.55
Dozing, continuous pushing application Reduce load
Operating in too high a speed range Use lower gear 2.60
Torque converter Long downhill driving Change application
overheat Radiator clogged: coolant temp also high Clean radiator fins 3.12
Defective alarm switch (gauge is in green)
Torque converter / Transmission failure kawasaki

Oil pressure too low

AIR CONDITIONER

PROBLEM POSSIBLE CAUSES SOLUTIONS PAGE

Hot water continues to flow through Shut off valve in heater hose
heater core line at block
A/C not set for maximum cooling Adjust controls/vents 2.30
Low cooling when
Condenser fins plugged Clean 3.15
A/C "ON"
A/C filters plugged Clean or replace 3.33
A/C compressor belts slipping/broken Adjust/Replace 3.31
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 2.30
Defective heater motor or switch kawasaki
 3.63
TROUBLESHOOTING

AIR CONDITIONER FAILURE MODE

FAILURE MODE FAILURE SOLUTIONS

E11 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the inside air sensor) - Wire breakage in the inside air sensor (THI) - Replacement
E12 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
inside air sensor) - Short-circuit in the inside air sensor (THI) - Replacement
E13 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the outside air sensor) - Wire breakage in the outside air sensor (THAM) - Replacement
E14 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
outside air sensor) - Short-circuit in the outside air sensor (THAM) - Replacement
E15 (Wire breakage in - Breakage in the wire harness or loosen connector - Checking the wiring
the water temperature - Wire breakage in the water temperature sensor - Replacement
sensor) (THW)
E16 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
water temperature sen- - Short-circuit in the water temperature sensor (THW) - Replacement
sor)
E18 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
insolation sensor) - Short-circuit in the insolation sensor (THI) - Replacement
E21 (Wire breakage in - Breakage in the wire harness - Checking the wiring
the ventilation sensor) - Wire breakage in the ventilation sensor (THF) - Replacement
E22 (Short-circuit in the - Short-circuit in the wire harness - Checking the wiring
ventilation sensor) - Short-circuit in the ventilation sensor (THF) - Replacement
- Defective wire harness or loosen connector - Checking the wiring
E43 (Abnormality in the - Defective servo motor - Replacement
ventilation servo motor) - Stuck foreign material - Removing the
foreign material
- Defective wire harness or loosen connector - Checking the wiring
E44 (Abnormality in the
- Defective servo motor - Replacement
air mixture damper
- Stuck foreign material - Removing the
motor)
foreign material
- Defective wire harness or loosen connector - Checking the wiring
E45 (Abnormality in the
- Defective servo motor - Replacement
inside/outside air
- Stuck foreign material - Removing the
switching motor)
foreign material
3.64
TROUBLESHOOTING

FAILURE MODE FAILURE SOLUTIONS

- High pressure switch actuation
- Outside air temperature is too high
- Insufficient cooling of condenser
- Defective fan motor - Motor replacement
- Clogging in condenser - Cleaning
- Refrigerant overfilling - Adjusting refriger-
ant quantity
- Aeration into refrigerant circuit - Circuit evacuation
E51 (Abnormality in the
& refilling
refrigerant pressure)
- Low pressure switch actuation
- Outside air temperature is too low
- Insufficient refrigerant quantity - Circuit evacuation
& refilling
- Gas leak - Repair leakage
spot
- Circuit evacuation
& refilling
 3.65
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.
Intended use
This product is designed for loading, excavation,
grading, dozing and/or scooping.
Refer to "Operating Techniques" for further infor-
mation.

Do not use the machine with excessive load than

specified, to avoid getting stuck of the machine
and/or any risk of injury caused by potential struc-
tural damage of the machine due to the overload.
Use the permitted attachments and optional parts
provided, when needed, which are suitable for the
operating conditions and job contents.

Bucket Date

General Purpose General Purpose General Purpose

General Purpose
Kind of bucket Bucket With Bolt-on Bucket With Bolt-on Cut- Bucket With Teeth
Bucket With Teeth
Cutting Edge ting Edge
Bucket capacity (m3) 3.2 3.0 3.6 3.5
Dumping clearance
2,960 2,870 2,875 2,780
(mm)
Dumping reach (mm) 1,130 1,190 1,215 1,275

Rock Bucket With V-edged Rock Bucket Coal Bucket With Bolt-
Kind of bucket
Teeth With Teeth on Cutting Edge
Bucket capacity (m3) 2.6 2.7 4.5
Dumping clearance
2,860 2,765 2,680
(mm)
Dumping reach (mm) 1,195 1,355 1,415
3.66
SPECIFICATIONS

Minimum turning radius

at outside bucket
6,715 mm
at center of outside tire
5,810 mm
Full articulation angle 37º
45º
Tread
1,130
2,060 mm 4,095

Width (outside tire) 3,440

2,960
2,680 mm
Width (outside bucket) 50º
2,800 mm
465

Equipped with GSC bucket with bolt

on cutting edge 3,200

8,105
23.5 (L-3) Tire and ROPS Cab
WL OPERATING SPEC EU
 3.67
SPECIFICATIONS

Bucket Selection Chart

Standard Boom

4.5 Coal

3.6 GSC
Bucket Capacity (m3)

3.5 GST

3.2 GSC

3.0 GST

2.7 RVT

2.6 RST
1000

1200

1400

1600

1800

2000

2200
Bucket fill Material Density (kg/m3 )
115% 100% 95% 80Z5 0001

Operating Weight 17,730 kg

Tipping Load 14,635 / 12,765 kg

(Straight/Full turn)

Engine Model HINO J08C-TI

Type 4 cycle, Water Cooled, Direct injection, Turbo charged & air cooled
intercooler
Displacement 7.96 Liter
Rated Power (Net) 149 kW / 2,200 min-1

Tire 23.5 (L3)

Max. Running Speed 1st : 7.2 / 7.3 km/h

(forward/reverse) 2nd:12.0 / 12.2 km/h
3rd :21.3 / 21.6 km/h
4th :36.2 / 36.7 km/h

The weight and load figure include, enclosed ROPS cab, GSC bucket with bolt-on cutting edge, 23.5 (L3)
tires, full fuel tank and operator.

Safety regulations regarding safety of machinery including attachments: All rated capacities are determined
on a condition that machines are placed on a horizontal and solid ground. If it is necessary to operate the
machine on conditions other than above specified (for example, soft ground or irregular ground, inclined or
slippery ground), the operator must consider the above conditions.

Outer filter for the air conditioner is for dust, and has no effect on chemical substance like gas and asbestos
etc.
3.68

MEMO
INDEX
A Check Engine Coolant Level .....................................2.46
Accelerator Pedal ........................................................2.7
Adjust and Check Rear View Mirrors ........................2.50
Adjust Parking Brake Lining ......................................3.42
Adjustments ..............................................................2.72
After Storage .............................................................2.84
Air Cleaner Warning Lamp (red) ...............................2.21
Air Conditioner ..........................................................2.30
Action to be taken when the air conditioner is
not used ................................................................2.36
For Efficient Use of the Air Conditioner .................2.35
Operating Method (Normal Use) ............................2.32
Operation Method (Other Uses) ............................2.33
Other Functions .....................................................2.34
Switches ................................................................2.30
Ventilation Name and Location ..............................2.30
Articulation Stopper ..........................................1.29, 2.47
Attachment Installation to Quick Coupler ..................2.40
Auto Shift Indicator Lamp (green) .............................2.22
Auxiliary Attachment Control Lever (option) ................2.6
B Check Transmission Shift Lever ...............................2.51
Battery removal / reinstallation procedure .................2.83
Before Starting Safety .................................................1.4
Before Storage ..........................................................2.82
Boom Control Lever ....................................................2.4
Boom Kickout Adjustment .........................................2.73
Booster Batteries / Jumper Cables ...........................2.76
Brake Pedals ...............................................................2.7
Brake Pressure Warning Lamp (red) ........................2.20
Bucket / Attachment Leveler Adjustment ..................2.72
Bucket Control Lever ...................................................2.5
Bucket hoisting position ............................................2.81
C Clean or Replace Transmission Breather .................3.41
Carrying .....................................................................2.68
Cautions Regarding Welding Repair Service ............2.85
Central Warning Lamp (red) ......................................2.20
Charge Lamp (red) ....................................................2.22
Check after Starting the Engine ................................2.54
Check Air Conditioner Refrigerant ............................3.43
Check Air Intake System ...........................................2.49
Check and Adjust Air Conditioner Belt ......................3.31
Check and Adjust Drive Belt .....................................3.32
Check and Adjust Engine ..........................................3.44
Check and Adjust Valve Lash Clearance ..................3.50
Check and Clean Starter Motor and Alternator .........3.44
Check and Retighten Cylinder Head Bolts ................3.44
Check and/or Replace Seat Belt ...............................3.10
Check Back-up Alarm Operation ...............................2.57
Check Battery Electrolyte Level ................................3.23
Check before Operation ............................................2.43
Check Brake Accumulator .........................................3.50
Check Control Levers ................................................2.51
Check Cooling Fan ....................................................2.50
Check Differential Gear Oil .......................................3.28
Check Engine Oil Level .............................................2.44
Check Exhaust Gas ..................................................2.57
Check Exhaust Pipe and Muffler ...............................3.38
Check Fuel Injection Pump .......................................3.44
Check Fuel Level ......................................................2.55
Check Heater Plugs ..................................................3.54
Check Horn Operation ..............................................2.50
Check Hydraulic Oil Level .........................................2.45
Check Monitor Panel Operation ................................2.51
Check or Replace Fuses ...........................................3.13
Check Parking Brake ................................................2.50
Check Parking Brake Operation ...............................2.56
Check Planetary Gear Oil .........................................3.29
Check Ride Control Accumulator (option) .................3.54
Check Service Brake Disk Wear ...............................3.50
Check Service Brake Operation ................................2.56
Check Steering Wheel Operation .............................2.57
Check Tightness of Wheel Bolts ...............................3.30
Check Tire Air Pressure ............................................3.24
Check Tire for Damage, Air and Tread Depth ..........2.48
Check Transmission Oil Level ..................................2.55
Check Turbocharger .................................................3.44
Check Warning Lamps ..............................................2.54
Check Windshield Washer Fluid ...............................3.14
Check Wiring Harnesses ..........................................2.47
Cigarette Lighter (option) ..........................................2.14
Clean Air Conditioner Condenser .............................3.15
Clean Air Conditioner Filter Element .........................3.33
Clean Filter for Brake Line ........................................3.52
Clean Filter for Orbitrol® ............................................3.52
Clean Fuel Feed Pump Strainer ...............................3.38
Clean Fuel Tank ........................................................3.50
Clean or Replace Air Cleaner Element .....................3.10
Clean Radiator / Air cooler / Hydraulic oil
cooler Fins ............................................................3.12
COMPONENT NAME/LOCATION ..............................2.2
Control Lever Lock for Quick Coupler Lock Pin
[3rd spool valve specification (option)] .................1.28
Coolant Specification ................................................3.57
D
Declutch Lamp (green) .............................................2.19
Declutch Switch ........................................................2.12
Downshift Button .......................................................2.14
Dozing .......................................................................2.67
Drain Water and Sediment from Fuel Filter ..............2.46
Drain Water and Sediment from Fuel Tank ..............3.23
Dumping into Truck or Hopper ..................................2.69
During Storage ..........................................................2.84
E
Electrical Protection ..................................................2.28
Emergency Brake .....................................................1.30
Engine Coolant Temperature Gauge ....................... 2.18 Normal Start ............................................................. 2.52
Engine Coolant Temperature Warning Lamp (red)
.............................................................................. 2.21
O
Engine Oil Pressure Warning Lamp (red) ................. 2.20
Operating Techniques .............................................. 2.64
Every 10 Hours or Daily ............................................ 3.19
Operating the Machine ............................................. 2.59
Every 1000 Hours or 6 Months ................................. 3.39
OPERATION ............................................................ 2.43
Every 2000 Hours or 1 Year ..................................... 3.45
Operation and Function ............................................ 2.37
Every 250 Hours or 1 Month .................................... 3.26
Operational Safety ...................................................... 1.7
Every 50 Hours or 1 Week ....................................... 3.20
Operator Safety .......................................................... 1.2
Every 500 Hours or 3 Months ................................... 3.35
OPERATOR'S AREA ................................................. 2.3
Excavating ................................................................ 2.66
Other Maintenance Safety Concerns ....................... 1.16
Explosion / Fire / Burn Prevention ............................ 1.15

F P
Parking ..................................................................... 2.62
Four-Way Flasher Switch ......................................... 2.15
Parking Brake Indicator Lamp (red) ......................... 2.19
Front Wiper Switch ................................................... 2.13
Parking Brake Switch ............................................... 2.10
Front Working Light Switch ....................................... 2.11
Parking Safety .......................................................... 1.11
Fuel Gauge ............................................................... 2.19
Pedals and Levers ...................................................... 2.3
Fuse Boxes .............................................................. 2.28
Preheat Indicator Lamp (yellow) ............................... 2.20
Fusible Link .............................................................. 2.29

G Q
General Inspection ................................................... 2.58
Grease Gun Holder .................................................. 2.39
Greasing ........................................ 3.17, 3.20, 3.26, 3.45
Ground Levelling ...................................................... 2.67
H Recommended Lubricants ....................................... 3.55
High beam Indicator Lamp (blue) ............................. 2.22
High-Low Beam Lever/Turn Signal Lever ................... 2.4
Horn Button ................................................................ 2.3
Hour Meter ............................................................... 2.23
Hydraulic Pressure Hose & Electrical Wiring
Connecting to Attachment .................................... 2.42
I Replace Filter ........................................................... 3.34
Indicators .................................................................. 2.17
Inspection and Maintenance Table ............................ 3.5
L
Light Switch .............................................................. 2.11
Light Switch (option) ................................................. 2.16
Loading ..................................................................... 2.64
Loading Control Lever Lock ..................................... 1.28
Long Term Storage .................................................. 2.82
M Retighten Intake/Exhaust Manifold ........................... 3.54
MAINTENANCE ......................................................... 3.2
Manual Box .............................................................. 2.38
MCU (Machine Control Unit) Warning Lamp (red)
.............................................................................. 2.20
Mounting and Dismounting Safety ............................. 1.3
N ROPS (Roll Over Protective Structure) Cab
Neutral Indicator Lamp (green) ................................. 2.22
Neutral Start System ................................................ 1.30
Quick Coupler (option) ............................................. 2.40
R
Rear Wiper Switch (option) ...................................... 2.13
Rear Working Light Switch ....................................... 2.12
Recommended Mixture of Antifreeze ....................... 3.57
Replace Air Conditioner Filter Elements .................. 3.51
Replace Air Conditioner Receiver Dryer .................. 3.17
Replace Bucket Teeth (option) ................................... 3.8
Replace Coolant ....................................................... 3.15
Replace Cutting Edge ................................................ 3.9
Replace Differential Gear Oil .................................... 3.48
Replace Engine Oil and Oil Filter Cartridge ............. 3.27
Replace Filter in the Hydraulic Tank
Breather Valve (S/N 0511~) ................................. 3.54
Replace Filter in the Hydraulic Tank Cap
(S/N 0501~0510) ................................................. 3.53
Replace Fuel Filter Cartridge ................................... 3.36
Replace Hydraulic Oil Return Filter .......................... 3.41
Replace Hydraulic Oil, Clean Filter .......................... 3.46
Replace Planetary Gear Oil ...................................... 3.49
Replace Transmission Oil ........................................ 3.39
Replace Transmission Oil Filter Cartridge ................ 3.35
Retighten Bolts of Oil Pan ........................................ 3.54
Reversal Fan Pilot Lamp (green) (80H1-0701~)
(option) ................................................................. 2.23
Reversal Fan Switch (option) ................................... 2.15
Ride Control (option) ................................................ 2.37
Ride Control Pilot Lamp (green) (option) .................. 2.23
Ride Control Switch (option) ..................................... 2.16
Roading / Special Applications ................................. 2.75
..................................................................... 1.31, 2.50
Running in Deep Mud or Water ................................ 2.61
S
Safe Operation ............................................................1.2
SAFETY ......................................................................1.2
Safety Devices ..........................................................1.28
Safety Preparations Before Maintenance .................1.12
Safety Signs ..............................................................1.18
Seat ...........................................................................2.24
Seat Adjustment ......................................2.24, 2.25, 2.26
Seat Belt ....................................................................2.27
Secondary Steering (option) .....................................1.31
Secondary Steering Warning Lamp (red) (option)
...............................................................................2.23
Serial Number Location ...............................................3.2
SPECIAL PROCEDURES .........................................2.72
SPECIFICATIONS ....................................................3.65
Speed and Direction Change ....................................2.60
Speedometer .............................................................2.18
Starter Switch ............................................................2.10
Starting the Engine ....................................................2.52
Starting the Machine .................................................2.59
Starting the Machine on a Grade ..............................2.60
Steering Column Telescopic Tilt Handle .....................2.8
Stopping the Engine ..................................................2.63
Switches ......................................................................2.9

T
Torque Converter Oil Temperature Gauge ...............2.19
Torque Converter Oil Temperature
Warning Lamp (red) ..............................................2.21
Towing .......................................................................2.78
Transmission Shift Lever .............................................2.3
Transmission Status Monitor (yellow) .......................2.23
Transportation ...........................................................2.80
TROUBLESHOOTING ..............................................3.58
Turn Signal Indicator Lamp (Left) (green) .................2.22
Turn Signal Indicator Lamp (Right) (green) ...............2.22
Typical Truck Loading Methods ................................2.70

W
Walk-Around Inspection ............................................2.43
Welding .....................................................................2.85
When Required Inspection and Maintenance .............3.8
Wire hooking position and range/stretching
impossible range/tolerance ...................................2.79
Working Light Indicator Lamp (green) .......................2.19
Wrist Rest ....................................................................2.6
Maintenance Log

Date Machine hours Service performed

Date Machine hours Service performed
Date Machine hours Service performed
Date Machine hours Service performed
Notes
WHEEL LOADER　80Z5
OPERATION & MAINTENANCE MANUAL

Manual part number: 93109-00573

Manufacturer:
KCM Corporation
Address: 2680 Oka, Inami-cho, Kako-gun, Hyogo 675-1113 JAPAN
URL: http://www.khi.co.jp/kenki/english/