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KCM 70Z7, Operation & Maintenance Manual


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©2015 KCM Corporation All rights reserved.

 FOREWORD

Read this manual

 carefully before starting and operating 

the machine for the first time to learn how to operate 
and service your machine correctly. Failure to do so could 
result in personal injury or machine damage.

This standard specification machine

 can be operated 

under the following conditions without being modified.
Atmospheric Temperature: -20 °C to 40 °C (-4 °F to 104 °F)
Altitude: 0 m to 2000 m (0 ft to 6600 ft)

In case the machine is used under conditions other than 
described above, consult your nearest Kawasaki dealer.

This manual should be considered

 a permanent part of 

your machine and should remain with the machine when 
you sell it. Replace immediately if missing, damaged or 
not readable.

This machine is of metric

 design. Measurements in this 

manual are metric. American standard measurements are 
included when appropriate. Use only metric hardware 
and tools as specified.

Right-hand and left-hand

 sides are determined by 

facing in the direction of forward travel.

Write product identification numbers

 in the Machine 

Numbers section. Accurately record all the numbers 
to help in tracing the machine should it be stolen. 
Your dealer also needs these numbers when you order 
parts. If this manual is kept on the machine, also file the 
identification numbers in a secure place off the machine. 

Use only diesel fuel with quality specified in JIS K-2204, 
EN-590 or ASTM D-975 which contents 15 ppm or lower 
sulfur.
Also use fuel that complies with solid contamination level 
of class 18/16/13 of ISO4406-1999 (solid contamination 
includes dust). If the fuel specified above is not used, 
exhaust gas that exceeds the regulation values may be 
discharged, causing serious problem on the engine. 
Consult your nearest Kawasaki dealer.

Warranty

 is provided as a part of Kawasaki’s support 

program for customers who operate and maintain their 
equipment as described in this manual. The warranty is 
explained on the warranty certificate which you should 
have received from your dealer.

This warranty provides you with the assurance that 
Kawasaki will back its products where defects appear 
within the warranty period. In some circumstances, 
Kawasaki also provides field improvements, often without 
charge to the customer, even if the product is out of 
warranty. 

Should the equipment be abused, or modified to 
change its performance beyond the original factory 
specifications, the warranty will become void and field 
improvements may be denied. 

Setting fuel delivery above specifications or otherwise 
overpowering machines will result in such action.

Only qualified, experienced operators officially licensed 
(according to local law) should be allowed to operate 
the machine. Moreover, only officially licensed personnel 
should be allowed to inspect and service the machine.

PRIOR TO OPERATING THIS MACHINE, INCLUDING 
COMMUNICATION SYSTEM, IN A COUNTRY OTHER 
THAN A COUNTRY OF ITS INTENDED USE, IT MAY 
BE NECESSARY TO MAKE MODIFICATIONS TO IT SO 
THAT IT COMPLIES WITH THE LOCAL REGULATORY 
STANDARDS (INCLUDING SAFETY STANDARDS) 
AND LEGAL REQUIREMENTS OF THAT PARTICULAR 
COUNTRY. PLEASE DO NOT EXPORT OR OPERATE 
THIS MACHINE OUTSIDE OF THE COUNTRY OF ITS 
INTENDED USE UNTIL SUCH COMPLIANCE HAS BEEN 
CONFIRMED. PLEASE CONTACT KCM CORPORATION OF 
AMERICA OR ANY OF OUR AUTHORIZED DISTRIBUTOR 
OR DEALER IF YOU HAVE ANY QUESTIONS 
CONCERNING COMPLIANCE.

All information, illustrations and specifications in this manual are based on the latest product information available at the 
time of publication. The right is reserved to make changes at any time without notice.

Summary of Contents for 70Z7

Page 1: ...an K 93108 00691 April 2015 OPERATION MAINTENANCE MANUAL WHEEL LOADER 70Z7 70TM7 Powered by CUMMINS QSB6 7 Engine Serial No 70C6 5001 and up NOTICE READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING AND...

Page 2: ...93108 00691 April 2015...

Page 3: ...charged causing serious problem on the engine Consult your nearest Kawasaki dealer Warranty is provided as a part of Kawasaki s support program for customers who operate and maintain their equipment a...

Page 4: ...PERATOR S STATION BREAK IN OPERATINGTHE ENGINE MOVINGTHE MACHINE OPERATINGTHEMACHINE TRANSPORTING MAINTENANCE MAINTENANCEUNDERSPECIALENVIRONMENTALCONDITIONS STORAGE SPECIFICATIONS OTHERATTACHMENTANDDE...

Page 5: ......

Page 6: ...High Pressure Fluids S 28 Prevent Fires S 29 Evacuating in Case of Fire S 31 Beware of Exhaust Fumes S 31 Precautions for Welding and Grinding S 31 Avoid Heating Near Pressurized Fluid Lines S 32 Avoi...

Page 7: ...ck Type 1 61 Loading Multi Function Joystick Lever Option 1 62 Auxiliary Control Lever Option 1 63 Forward Reverse Selector Switch 1 64 Operational Procedure 1 64 Loading Control Lever Lock Switch 1 6...

Page 8: ...ng 5 13 Avoid Rapid Steering Changes and or Sudden Braking 5 13 Avoid Operation with Loads on Only One Side 5 13 Excavation 5 14 Loading Accumulated Soil 5 14 Digging and Loading Level Ground 5 15 Gra...

Page 9: ...or 7 86 Check Brake Disks Service and Parking 7 86 J Tire 7 87 Check and Replace Tire Tire Pressure 7 87 Check Tire for Damage 7 87 Check Wheel Bolt Torque 7 88 K Air Conditioner 7 93 Clean Replace Ai...

Page 10: ...achine and hydraulic components These numbers are requested when inquiring any information on the machine and or components Fill these serial Nos in the blank spaces in this group to immediately make...

Page 11: ...MACHINE NUMBERS 2 MEMO...

Page 12: ...G indicates a potentially hazardous situation which if not avoided could result in death or serious injury x CAUTION indicates a potentially hazardous situation which if not avoided may result in mino...

Page 13: ...fications will void Kawasaki Warranty Policy x Never attempt to modify or disassemble the inlet exhaust parts Avoid giving shocks on the muffler by striking elements with other objects or dropping the...

Page 14: ...umbers for doctors ambulance service hospital and fire department posted near your telephone Wear Protective Clothing y Wear close fitting clothing and safety equipment appropriate to the job You may...

Page 15: ...or earplugs to protect against objectionable or uncomfortably loud noises Inspect Machine y Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal...

Page 16: ...ab Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight possibly starting a fire x Refrain from using music headphones or mobile telephones in the cab wh...

Page 17: ...y Never allow anyone to ride attachment or the load This is an extremely dangerous practice Adjust Operator s Seat y A poorly adjusted seat for either the operator or the work at hand may quickly fat...

Page 18: ...Turn the parking brake switch ON and the key switch OFF to stop the engine x Before leaving the machine close all windows doors and access covers and lock them up Fasten Your Seat Belt y If the machi...

Page 19: ...ating the machine If any faulty illumination is present immediately repair it x Ensure the cab door windows doors and covers are securely locked x Check the mirrors and the monitor in the CAB for prob...

Page 20: ...eutral x Before starting the engine confirm the safety around the machine and sound the horn to alert bystanders Jump Starting y Battery gas can explode resulting in serious injury x If the engine mus...

Page 21: ...ce ground edges and road shoulders as necessary Keep the machine well back from the edges of excavations and road shoulders x When working on an incline or on a road shoulder employ a signal person as...

Page 22: ...S and FOPS Any modification of the ROPS structure will modify its performances and its certification will be lost ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure Provide S...

Page 23: ...f the possibility of slipping and or turning over the machine when driving on a slope x When driving on level ground hold the bucket at mark A 300 mm 12 in above the ground as illustrated x Avoid trav...

Page 24: ...n serious injury or death x When driving up or down a slope keep the bucket facing the direction of travel approximately 200 to 300 mm approximately 8 to 12 in A above the ground x If the machine star...

Page 25: ...sult in personal injury and or death x Avoid rapid drive direction changes which could possibly cause personal injury and or death Drive on Snow Safely y Beware of the possibility of slipping or turni...

Page 26: ...elect level ground when possible to park machine x Do not park the machine on a grade x Lower the bucket to the ground x Put the forward reverse lever switch in neutral x Run the engine at low idle sp...

Page 27: ...ngled in the machine x Keep all personnel away from the machine by sounding the horn and or using hand signals Use extra care to be sure no one is in from the articulation area before turning the mach...

Page 28: ...NG WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT y The danger of tipping is always present when operating on...

Page 29: ...nes x If a fiber optic cable should be accidentally severed do not look into the end Doing so may result in serious eye injury x Contact your local diggers hot line if available in your area and or th...

Page 30: ...obstacle may become damaged and personal injury may result x Take care to avoid coming in contact with overhead obstacles with the bucket or arm during operation Precautions for Lightning y The machi...

Page 31: ...ever attach a sling or chain to the bucket teeth or to the attachment fork or grapple for example They may come off causing the load to fall Protect Against Flying Debris y If flying debris hit eyes o...

Page 32: ...3 minutes x Turn key switch to OFF to stop engine x Remove the key from the key switch x Turn the control lever lock switch to the lock position x Close windows roof vent and cab door x Lock all acce...

Page 33: ...lways use a ramp or deck strong enough to support the machine weight 3 Use a low speed gear 4 Never steer the machine while being on the ramp If the traveling direction must be changed while being on...

Page 34: ...le smoking or when near open flame or sparks x Always stop the engine before refueling the machine x Fill the fuel tank outdoors y All fuels most lubricants and some coolants are flammable x Store fla...

Page 35: ...witch 8 Attach a Do Not Operate tag on the control lever 9 Connect the front and rear chassis with articulation stopper 10 Allow the engine to cool x Refer to page 7 7 Preparations for Inspection and...

Page 36: ...work on the machine attach a Do Not Operate tag on the control lever This tag is available from your authorized dealer Support Machine Properly y Never attempt to work on the machine without securing...

Page 37: ...o perform the job Have it done by your authorized dealer or a qualified repair service x Always maintain the correct tire pressure DO NOT inflate tire above the recommended pressure x When inflating t...

Page 38: ...Skin contact with escaping hot water or steam can cause severe burns x Avoid possible injury from hot spraying water DO NOT remove the radiator cap until the engine is cool When opening turn the cap s...

Page 39: ...result in severe burns gangrene or otherwise serious injury or death Avoid High Pressure Fluids y Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing ser...

Page 40: ...lines x Never install bent or damaged lines pipes or hoses x Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance Check for Shorts y Short...

Page 41: ...have passed through the wire screen may cause fires Check and clean the machine every day and immediately remove accumulated flammables The temperature around the engine may tend to become higher wit...

Page 42: ...aust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area Precautions for Welding and Grinding y Welding may generate gas and or small fires x...

Page 43: ...Lines Containing Flammable Fluids x Do not weld or flame cut pipes or tubes that contain flammable fluids x Clean them thoroughly with nonflammable solvent before welding or flame cutting them Precau...

Page 44: ...sbestos and Silicon Dust and Other Contamination y Take care not to inhale dust produced in the work site Inhalation of asbestos fibers may be the cause of lung cancer Inhalation of silicon dust and o...

Page 45: ...tighten all terminals x Connect terminals to the correct electrical poles Failure to do so may cause damage to the electrical parts or fire y Battery electrolyte is poisonous If the battery should ex...

Page 46: ...on chemical products used with your machine Dispose of Waste Properly y Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with Kawasaki equipment i...

Page 47: ...rminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices Inquire the device manufacturer for electrical wave disturbance upon using an elect...

Page 48: ...tting electrical waves Specific Absorption Rate SAR measured by 10 g per unit of communication terminal equipment Model A Model B E GSM900 0 573 W Kg 914 8 MHz 0 12 W Kg 897 6 MHz DCS 1800 0 130 W Kg...

Page 49: ...rtation To lock 1 Align the front and rear chassis straight ahead 2 Remove the clip pin and pin from the end of the Articulation Stopper on the rear chassis 3 Turn the link and fix the end to the brac...

Page 50: ...g them to ensure safe machine operation Always keep the safety labels clean In case a safety sign is lost or no longer readable immediately obtain a new replacement and affix it again in position on t...

Page 51: ...SAFETY LABELS S 40 6 10 4 1 3 9 6 5 SS 3461...

Page 52: ...ure WARNING Oil injection hazard y Nitrogen accumulator contains compressed gas and fluid which could result in death or serious injury Release the oil pressure from all brake circuits before removing...

Page 53: ...such as the engine muffler etc immediately after operation of the machine Severe burns may result 4 Use no starting fluid WARNING Explosion Hazard y Do not use ether This engine is equipped with elect...

Page 54: ...oil if the oil inlet is uncapped during or right after operation Read manual for safe and proper handing 6 Top of Hydraulic Oil Tank and Radiator WARNING Burn Hazard y Pressurized system spray of hot...

Page 55: ...d y The articulation area becomes a pinch point when steering the machine Keep all personnel away from the articulation area during operation of the machine 9 Top of Right Rear Frame Lock Bar WARNING...

Page 56: ...zard of rotating parts such as belt Turn off before inspection and maintenance 12 Bottoms at Both Right and Left Side Covers of Rear Frame WARNING Runover Hazard y Machine movement if engine starts in...

Page 57: ...Inside Battery Box WARNING Explosion Hazard y Sign indicates an explosion hazard Keep fire and open flames away from this area 15 Inside Battery Box CAUTION Chemical Burn Hazard y Skin contact with el...

Page 58: ...ight WARNING Explosion Hazard y Do not cause electrical arcing from jumper cables or accidental placement of metal objects on the battery terminals Read and understand the operator s manual 18 Both Si...

Page 59: ...e top WARNING y Prior to operation maintenance disassembling and transportation of the machine be sure to read and understand the Operator s Manual 21 Cab Inside Right Front Column 2nd safety sign fro...

Page 60: ...brake to parking position lower the front attachment to the ground lock the control levers and remove the key from the key switch 23 Cab Inside Right Front Column 4th safety sign from the top WARNING...

Page 61: ...SAFETY LABELS S 50 25 Cab Inside Right Front Column CAUTION Steering Hazard y Unlock articulation stopper before operating machine YA00015796 KC...

Page 62: ...Rear Fender 10 Front Fender 11 Lift Arm Cylinder 12 Lift Arm 13 Exhaust Pipe 14 Hydraulic Oil Tank 15 Articulation Lock Bar 16 Rear Work Light 17 Battery One each on both the right and left sides 18 R...

Page 63: ...nt Fender 11 Lift Arm Cylinder 12 Lift Arm 13 Exhaust Pipe 14 Hydraulic Oil Tank 15 Articulation Lock Bar 16 Rear Work Light 17 Battery One each on both the right and left sides 18 Rear Combination Li...

Page 64: ...it is very dangerous WARNING y Never attach a wire on the foot holds 1 or handrails 2 to lift the cab or main body or while transporting the machine on a truck or trailer as it is dangerous y The doo...

Page 65: ...1 4 Cab Features 1 Front Defroster 2 Front Console 3 Operator s Seat 4 Right Console 5 Document Holder 6 Hot Cool Box 7 Rear Defroster 8 Glove Compartment 9 Cup Holder 10 Floor Mat MNEC 01 035 1 1 2...

Page 66: ...ont Rear Window Wiper Switch 12 Forward Reverse Lever Shift Switch 13 Steering Column Tilt Pedal 14 Tilt Telescopic Lever 15 Turn Signal Lever Light Switch High Low Beam Switch 16 Key Switch 17 Travel...

Page 67: ...witch 10 Fan Reverse Rotation Switch 11 Auxiliary 12 Auxiliary Quick Coupler Switch 70TM7 13 Secondary Steering Operation Check Switch Option 14 Lift Arm Auto Leveler Height Kickout Switch 15 Lift Arm...

Page 68: ...10 Forward Reverse Selector Switch 11 Fan Reverse Rotation Switch 12 Auxiliary 13 Auxiliary Quick Coupler Switch 70TM7 14 Secondary Steering Operation Check Switch Option 15 Lift Arm Auto Leveler Heig...

Page 69: ...Mode Indicator 21 Monitor Mode Selector 22 Not Used 23 Monitor Display Selector Up 24 Preheat Indicator 25 Monitor Display Selector Down 26 Forward Reverse Selector Switch Indicator 27 Monitor Displa...

Page 70: ...ge decreases or becomes excessively high x If the air cleaner is restricted x If the hydraulic oil temperature becomes higher than the specification x If any abnormality is found in engine operation x...

Page 71: ...vice indicator will light and the alarm buzzer will sound Immediately move the machine to a safe area set the machine in the park position and stop the engine Inspect the brake system for any abnormal...

Page 72: ...Transmission Warning Indicator Red If any serious abnormality occurs in the transmission and or transmission related parts the red indicator will light If the transmission warning indicator and the s...

Page 73: ...engine at slow idle speed to lower the coolant temperature When required let engine cool check coolant level and add coolant if needed Engine Oil Low Pressure Indicator Red WARNING If the engine is k...

Page 74: ...ted as long as the preheat indicator stays ON When the preheat indicator goes OFF engine preheating is completed Low Steering Oil Pressure Indicator Optional IMPORTANT The secondary steering system sh...

Page 75: ...ult your nearest Kawasaki dealer NOTE After the engine is started the emergency steering system emits a operating sound for around 2 seconds to automatically check the system function If any abnormali...

Page 76: ...pt higher than the specification for a short period of time both the transmission oil temperature indicator and the service indicator come ON Immediately stop operation of the machine and run the engi...

Page 77: ...ion Fuel Gauge The fuel level is indicated by the needle Refuel before the needle reaches in the red range E When the needle reaches in the red range E the fuel level indicator lights NOTE The fuel le...

Page 78: ...the turn signal and the turn signal indicator start flashing High Beam Indicator Blue When the head lights are used at the high beam position the indicator will light Work Light Indicator Yellow When...

Page 79: ...is indicator will light Control Lever Lock Indicator Red When the control lever lock switch is in ON position the control lever lock indicator will light Power Mode Indicator Green When the power mode...

Page 80: ...rrives Items to be indicated x Hydraulic oil change x Hydraulic oil filter replacement 1 2 x Transmission oil change x Transmission oil filter replacement x Engine oil change x Engine oil filter repla...

Page 81: ...isplay Mode Selector 3 Monitor Display Selector Up 4 Monitor Display Selector Down 5 Speedometer 6 Information Display 7 Hold Indicator 8 Forward Reverse and Shift Position Indicator 9 Ride Control In...

Page 82: ...icator 1 displays the machine driving status selected FNR lever and shift positions FNR Forward Reverse Position Indicator FNR position indicator 2 displays the selected position of forward F neutral...

Page 83: ...en forward reverse lever 4 is in either the forward or reverse position shift position indicator 3 displays the actually selected shift stage x Forward 5 stages x Reverse 3 stages M4GB 01 041 M4GB 01...

Page 84: ...eter 1 indicates the present machine driving speed While information display 2 is indicating the drive distance each time monitor mode selector 3 is pressed the indicated speed unit alternates between...

Page 85: ...s when the engine runs in energy efficient condition It becomes OFF when the driving speed is 2 km h 1 24 mph or lower or under heavy driving load NOTE You may push the down shift switch when the ECO...

Page 86: ...itor display selector 2 is pressed the display on the machine information screen is shifted from the clock screen 8 to return to engine start ready screen 5 Display order of Items in the normal displa...

Page 87: ...ne operating hours up to present In case the operating hour exceeds 99999 9h the meter restarts counting the hour from 0 hour When this display is indicated press monitor display selector 2 once at a...

Page 88: ...hen the remaining hour reading becomes 0 hour maintenance indicator 4 will light While displaying screen F when monitor display selector 2 is pressed the screen is returned to time screen B When monit...

Page 89: ...of Engine oil hour meter is displayed Refer to page 1 30 for the resetting of oil change and filter replacement intervals y Engine Oil Hour Meter Screen M and time screen N indicating the remaining h...

Page 90: ...T of Axle oil hour meter is displayed Refer to page 1 30 for the resetting of oil change and filter replacement intervals y Axle Oil Hour Meter Screen T and time screen U indicating the remaining hour...

Page 91: ...completed Keep pressing switch 1 until the desired resetting time is displayed Time display is changed four seconds after pressing switch 1 While keeping switch 1 pressed press switch 3 Each time swit...

Page 92: ...pped from the factory is 1000 0 While displaying the change interval hours keep pressing switch 1 NOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired re...

Page 93: ...e factory is 2000 0 While displaying the change interval hours keep pressing switch 1 NOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time...

Page 94: ...00 0 While displaying the change interval hours keep pressing switch 1 NOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed T...

Page 95: ...he factory is 1000 0 While displaying the replacement interval hours keep pressing switch 1 NOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resettin...

Page 96: ...0 While displaying the change interval hours keep pressing switch 1 NOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time...

Page 97: ...is 500 0 While displaying the replacement interval hours keep pressing switch 1 NOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is di...

Page 98: ...tory is 500 0 While displaying the replacement interval hours keep pressing switch 1 NOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time...

Page 99: ...While displaying the change interval hours keep pressing switch 1 NOTE When switch 1 is released time resetting is completed Keep pressing switch 1 until the desired resetting time is displayed Time...

Page 100: ...ng screen 2 Month Setting Press monitor display selector 2 or 3 to increase or decrease the figure displayed on the screen respectively After displaying the desired month determine the displayed year...

Page 101: ...Pedal 11 Front Rear Window Wiper Switch 12 Forward Reverse Lever Shift Switch 13 Steering Column Tilt Pedal 14 Tilt Telescopic Lever 15 Turn Signal Lever Light Switch High Low Beam Switch 16 Key Switc...

Page 102: ...d When a machine failure occurs use this switch to inform other vehicles that the machine is in an emergency situation When the on hazard switch 1 is pressed front and rear turn signals hazard light 2...

Page 103: ...ition to turn front work lights 2 ON Rear work lights 3 stay OFF When the side with mark on switch 1 is pressed both front work lights 2 and rear work lights 3 are turned ON CAUTION Do not turn the wo...

Page 104: ...brake is applied parking brake indicator 2 will light Press the OFF side of parking brake switch 1 to release the parking brake Check that parking brake indicator 2 goes OFF by pressing the switch fir...

Page 105: ...ral lever lock 1 in the LOCK position Pull UNLOCK Push LOCK Steering Wheel WARNING CRUSH HAZARD Keep personnel out of area of articulation joint IMPORTANT When steering wheel 5 is fully turned the fro...

Page 106: ...the descriptions in the OPERATING ENGINE section for the detail information WARNING Never turn key switch 9 OFF while moving the machine Failure to do so will result in inoperable steering wheel and...

Page 107: ...ange direction to persons and or other vehicles by operating turn signal lever 7 Return turn signal lever 7 to neutral manually L Left Turn R Right Turn NOTE The lever does not return automatically wh...

Page 108: ...Signal Hazard Light 5 Brake Light Tail Light Light Switch Position Headlight Clearance Light Tail Light Monitor Panel Light OFF NOTE The light switch position keeps lit even if the key switch is turn...

Page 109: ...in the low beam position when other vehicles are present in the vicinity By bringing down the signal lever 7 with the headlight ON the headlight beam turns upward and the high beam indicator 8 comes...

Page 110: ...ly y Keep the areas around the brake pedals clean to prevent dust and or grit from accumulating The brake may not be fully released and become inoperable Left and right brake pedals 1 2 can function a...

Page 111: ...uation Also it may cause damage to the transmission NOTE The engine will not be started unless the forward reverse switch 3 and forward reverse lever 1 are in the neutral position For safety turn the...

Page 112: ...ze type washer fluid in freezing weather y Squirt windshield washer fluid on the dry windshield before operating the wiper Besides continuous operation of the wiper with windshield at semiarid conditi...

Page 113: ...asher solvent that will not freeze The front windshield wiper operates at fast speed The front windshield wiper operates at slow speed INT The front windshield wiper intermittently operates OFF The fr...

Page 114: ...to the desired position Push lever 1 until it contacts the stopper ensuring the steering column is locked x By depressing steering column tilt pedal 2 the steering column moves forward and the distan...

Page 115: ...he gear shifts according to the shift switch AUTO 1 Mode Starts out traveling at 2nd speed When traveling load increases it automatically shifts from 2nd to 1st speed Auto DSS function This mode is su...

Page 116: ...ghtly depressing the left brake pedal Suitable for loading work on a level surface Declutch ON while deeply depressing the left brake pedal Suitable for work on a slope x Declutch OFF When depressing...

Page 117: ...during the countdown period the shutdown timer is canceled and the engine will not stop 30 seconds before the engine stop the indicator 2 starts flashing The buzzer also sounds The buzzer sounds once...

Page 118: ...witch When shift change delay mode switch 2 is set in ON while shift switch 1 is in 3rd or 4th speed position the shift up timing in 2nd speed J 3rd speed is delayed Loading work can be easily done in...

Page 119: ...Reverse Rotation Switch 11 Auxiliary 12 Auxiliary Quick Coupler Switch 70TM7 13 Secondary Steering Operation Check Switch Optional 14 Lift Arm Auto Leveler Height Kickout Switch 15 Lift Arm Auto Leve...

Page 120: ...bucket is tilted back also this is the transportation position G Detent When the bucket control lever is moved from the bucket dump position to the bucket tilt or roll back position the bucket control...

Page 121: ...eld in that position When the lift arm moves to the preset position the lift arm control lever automatically moves to Neutral N position NOTE When operating the machine in the Float C position lower t...

Page 122: ...d Reverse Selector Switch 11 Fan Reverse Rotation Switch 12 Auxiliary 13 Auxiliary Quick Coupler Switch 70TM7 14 Secondary Steering Operation Check Switch Option 15 Lift Arm Auto Leveler Height Kickou...

Page 123: ...ed and held in that position A Lift Arm Raise F Detent The lift arm is held in the raise position G Detent When the multi function joystick lever is moved from the bucket dump position to the bucket t...

Page 124: ...TION 1 63 Auxiliary Control Lever Option An optional control lever 1 can be installed to control the attachment Refer to the operator s manual for the attachment how to use this lever 1 1 70MNDB 01 05...

Page 125: ...e be sure to depress the brake pedal to ensure safety 2 When forward reverse selector switch 2 is turned ON while both forward reverse lever 3 and forward reverse switch 1 are in the neutral N positio...

Page 126: ...ition before transporting the machine or leaving the machine at the end of the shift Refer to page 5 4 for details Control lever lock switch 1 is provided to prevent unexpected machine operation if th...

Page 127: ...reverse lever 2 in the neutral N position before operating 1st speed fixed switch 1 1st Speed Fixed ON Set shift switch 3 to 2nd speed Push the ON side of 1st speed fixed switch 1 The transmission gea...

Page 128: ...ing work effectiveness Under auto shifting mode the gear is shifted in regular engine RPM s min 1 and shift mapping Power mode OFF When the power mode is turned OFF the machine operates putting more e...

Page 129: ...rn to the normal direction Normal rotation J Reverse rotation J Normal rotation J The fan rotates in the normal direction for 10 minutes for the first time After that it keeps normal rotation for 30 m...

Page 130: ...indicator 2 is flashing y Always operate the switch while parked with the parking brake When the parking brake is released the fan reverse condition is automatically canceled after 1 minute In case a...

Page 131: ...itch to check if the secondary steering pump is operable While the ON side of switch 1 is being pressed secondary steering pump operates Secondary steering indicator 2 lights ON while the pump is oper...

Page 132: ...OPERATOR S STATION 1 71 Ride Control Switch Option WARNING y To ensure safety operate the ride control switch only after parking the machine with the bucket lowered to the ground...

Page 133: ...inoperable When ride control switch 1 is turned to AUTO mode the ride control indicator 2 lights ON OFF When ride control switch 1 is turned OFF ride control indicator 2 on the monitor display goes OF...

Page 134: ...tor 2 is displayed and the machine holds the speed gear range that is currently displayed on the monitor Operate one of the following to release the hold function Press the hold switch again Change th...

Page 135: ...OR S STATION 1 74 Horn Switch The horn switch is provided on the control lever to improve operator comfort Fingertip Control Type MNEC 01 042 Horn Switch Horn Switch Multi Function Joystick Type MNEC...

Page 136: ...ET 4 and 8 Sets the lift arm stop position at the current arm height Press and slide to release lock switch 3 ON 5 and 9 Stops the raising or lowering lift arm at the specified height OFF 6 and 10 Dea...

Page 137: ...on a slope When operating under low load or the forward reverse lever is in Neutral N position the mode will not change to power mode even if quick power mode switch is pressed The switch selection i...

Page 138: ...switch 3 is set to reverse R the gear returns to 2nd speed Press DSS 2 when ECO indicator 5 turns OFF while operating on a slope or during snow removal In this case the gear temporarily shifts down t...

Page 139: ...Bolt Adjust the position of the right console as follows 1 Loosen three bolts M10 3 4 and adjust the position of the right console by sliding it back or forth Holding and moving armrest 1 maybe easier...

Page 140: ...ert the cigar lighter into the panel until the knob is seated in the original position and not pressed in Using 24 VDC Electrical Power Supply CAUTION Do not connect accessories that use power other t...

Page 141: ...g can be obtained by pressing the top side mark on temperature control switch 32 C 90 F or the bottom side mark 18 C 64 F respectively y Preheating During preheating the cab in winter with the foot ve...

Page 142: ...Switch 10 Mode Switch 11 AUTO Switch 12 Air Conditioner Switch 13 Circulation Fresh Air Switch 14 Defroster Switch NOTE Except for the foot vent 4 and defroster vent 5 all vents are provided with lou...

Page 143: ...side mark on blower switch 7 is pressed the blower speed is decreased by one increment NOTE In the AUTO mode operation the fan speed will be automatically controlled with the fan speed indicator flas...

Page 144: ...e set temperature is increased by 0 5 C 0 9 F increments x Decreasing Temperature Each time the bottom side mark on temperature control switch 9 is pressed the set temperature is decreased by 0 5 C 0...

Page 145: ...ode Each time mode switch 3 is pressed the vent location can be changed in 6 stages as illustrated below AUTOJ J J J J Press defroster switch 4 to change defroster vent mode x AUTO mode The air vent l...

Page 146: ...ation mode is selected Air temperature blower speed vent mode and ventilation mode can be selected as desired x Air Conditioner Switch 12 The air conditioner will turn on and the air conditioner indic...

Page 147: ...ate mode switch 10 to change foot defroster mode Cool Head Warm Feet Operation Cool and warm air is simultaneously supplied to the head vents and feet vents respectively 1 Press blower switch 7 to adj...

Page 148: ...e windows become clouded during rainy weather or on humid days operate the air conditioner to aid in keeping the windows clear When the atmosphere is very damp and if the air conditioner has run exces...

Page 149: ...p and parallel with backrest when not in use 2 Turn adjustment knob 2 for desired lumbar support 3 Lift handle 3 and allow the back cushion to angle forward or lean backward into the cushion Release t...

Page 150: ...electric power can be utilized Never connect accessories that use power other than 12 V Damage to the batteries and accessories may result Do not supply power to accessories for a long time without r...

Page 151: ...tion as a safety valve to prevent excess current from flowing through and to protect the electrical system The fuse capacity varies depending on its corresponding circuit Be sure to replace the blown...

Page 152: ...10 A 13 SEAT HEATER Opt 20 A 2 HEAD LAMP RH 5 A 12 OPTION 20 A 1 AUTO SHUT DOWN 5 A 11 RADIO 10 A Fuse Box B 10 ECU 30 A 20 SECONDARY STEERING Opt 5 A 9 TCU 10 A 19 HI BEAM 10 A 8 CONTROLLER 10 A 18 W...

Page 153: ...hot cool box x If the A C is on cool air is sent into the box x If the heater is on warm air is sent into the box Tray and Drink Holder IMPORTANT Tray 2 is not waterproof type Be careful not to spill...

Page 154: ...OPERATOR S STATION 1 93 ROPS Cab ROPS cab 1 is standard equipment 1 ROPS Cab 2 Speakers 3 Front Interior Light 4 Sun Visor MNEC 01 049 MNEC 01 050 MNEC 01 051 1 2 3 M4GF 01 010 4...

Page 155: ...OPERATOR S STATION 1 94 5 Radio 6 Cab Switch Panel Optional 7 Inside Rear View Mirror 8 Rear Interior Light 9 Emergency Exit Hammer 10 Coat Hat Hook M4GB 01 116 M4GB 01 117 5 7 8 9 6 MNEC 01 053 10...

Page 156: ...ion positions x ON The light 2 comes and stays ON x Neutral When the cab door is opened the light 2 comes ON When closed the light 2 goes OFF x OFF The light 2 goes OFF Rear Interior Light Switch 3 ON...

Page 157: ...the cab top down to a desired place Emergency Exit Hammer In case the cab door becomes difficult or impossible to open if an emergency situation occurs exit machine by breaking the windowpane using th...

Page 158: ...y Light Switch 2 Auxiliary 3 Auxiliary 4 Auxiliary 5 Auxiliary Rotary Light Switch Optional Press either upper part or lower part of the switch to turn the rotary light ON Press middle part of the swi...

Page 159: ...mirrors so that persons standing on left and right back end of the machine or object with height of 1 m and 30 cm in diameter can be recognized from the operator s seat Always keep the mirrors clean N...

Page 160: ...lifting door lock knob 5 pull lever 6 to disengage the door lock Window Open Close Levers When window open close levers 7 on both sides are simultaneously pressed the window is unlocked allowing the...

Page 161: ...tch may loose possibly causing an accident Push the door toward the outside of the cab to fully open the door 175 Cab Door Release Lever CAUTION When keeping the door open open the door until latch 10...

Page 162: ...e to turn the key switch OFF and wait 1 minute or more after the engine stops before turning battery disconnect switch Because controllers communicate with each other and record information after the...

Page 163: ...When operating the machine with battery disconnect switch 2 ON close the battery box cover 2 When turning lever 1 90 counterclockwise the lever is lateral to the ground battery disconnect switch 2 tur...

Page 164: ...operating the machine be sure to disengage lock bar 1 from front chassis 4 and fasten the lock bar to rear chassis with pin 2 and form lock clip 3 Articulation lock bar 1 locks the front and rear chas...

Page 165: ...of tires avoid towing operation requiring more than the available towing force Tractive capacity 158 0 kN 16120 kgf 35539 lbf Towing pin 4 is located on the rear end of the machine It is used for tow...

Page 166: ...e care not to pinch fingers when opening closing side cover 1 y As the side cover flips up by itself care should be taken not to be hit with the cover when opening it y Before checking around the engi...

Page 167: ...machine always check that the rear grille is well latched Push rear grille 2 open close button 1 to allow the rear grille to open upward so that refilling the fuel tank or cleaning of the cooling fan...

Page 168: ...the steps are provided on both sides of the machine only use the steps on the left side for cab entry The control levers are located on the right side obstructing easy access Right side steps are for...

Page 169: ...ATOR S STATION 1 108 Vandal Resistant Devices Locks can be installed to transmission inlet cap 1 tool box 2 battery covers 3 and radiator inlet cover 4 optional M4GB 01 147 1 2 3 MNDB 01 028 MNDB 01 0...

Page 170: ...TATION 1 109 Vandal Resistant Devices continue from previous page Fuel tank cap 5 side covers 6 and air conditioner fresh air filter 7 can be locked with the starter key 7 MNEC 01 055 5 6 MNDB 01 026...

Page 171: ...OPERATOR S STATION 1 110 MEMO...

Page 172: ...rakes during operation and burning friction material y Running hydraulic system pressure over relief setting pressures too often and heating the oil excessively y Tractively twisting the boom arms or...

Page 173: ...BREAK IN 2 2 MEMO...

Page 174: ...reign material found 3 Wheel Disk Mounting condition of the wheel disk is correct 4 Lights and Turn Signals They light up or flash normally with clear view and no lens damage 5 Outside Rear View Mirro...

Page 175: ...e and abnormal noise of chassis parts 7 Washer fluid level 10 Loader 1 Oil leaks and damage to cylinders pipe lines and hoses 2 Loose worn and missing cutting edges 3 Wear and damage to the bucket 4 L...

Page 176: ...tion If your machine is not equipped with forward reverse switch 4 set only forward reverse lever 2 in the neutral N position NOTE Unless forward reverse lever 2 and forward reverse switch are in neut...

Page 177: ...7 While seated on the operator s seat with your back in contact with the backrest adjust each function of the seat so that the brake pedal can be fully applied 8 Fasten seat belt 10 along your body wi...

Page 178: ...d discharge warning indicator 5 will continue to stay ON and it will go OFF only after the engine is started and circuits are filled Preheating will automatically start with the key switch ON The preh...

Page 179: ...s kept at low idle for maximum 35 seconds when the coolant transmission oil or hydraulic oil temperature is low or for 3 seconds if these temperatures are in the acceptable operation range After this...

Page 180: ...turn to the ON position Run the engine at low idle without applying accelerator pedal 3 IMPORTANT At starting the engine the engine RPM min 1 is kept at low idle for maximum 35 seconds to warm up the...

Page 181: ...evel 3 Check that engine coolant temperature gauge 3 is in the range 4 NOTE To check indicator bulbs and the buzzer function when the key switch is turned ON monitor indicators come ON and continue to...

Page 182: ...el is lower than specified Explosion of the battery may result y Park the machine and a machine with the booster batteries on a dry or concrete surface not on steel plates If the machine is parked on...

Page 183: ...s possible from the bracket 1 4 After securely connecting the booster cables start the engine on the booster battery mounted machine 1 5 Start the engine on the machine 1 6 After the engine starts lea...

Page 184: ...Be sure to perform warm up not only to protect the hydraulic components from being damaged but also to ensure safe operation If the machine is operated with the hydraulic oil temperature below 20 C 6...

Page 185: ...ly increases from slow idle to 1000 min 1 rpm and enters warm up mode when hydraulic oil temperature is 0 C 32 F or lower Further when either hydraulic oil temperature reaches 30 C 86 F or higher or e...

Page 186: ...down at low rpm s the lubricant on the turbocharger bearing and seal surfaces may be dissipated due to the intense heat inside the turbocharger possibly damaging the turbocharger 2 Run the engine at s...

Page 187: ...OPERATING THE ENGINE 3 14 MEMO...

Page 188: ...Conduct correct start up procedure 2 After raising the lift arm set the lift arms and bucket in the operating position 3 Before driving on public roads set the machine to the driving position as illu...

Page 189: ...t Avoid turning ride control switch 4 to ON position while moving the machine Failure to do so may automatically move the lift arm up or down Refer to page 1 71 for detailed information of ride contro...

Page 190: ...king brake Check that at this time parking brake indicator 1 goes OFF NOTE When starting to ascend a slope turn declutch switch 9 OFF clutch engaged and depress the brake pedal 6 Gradually release the...

Page 191: ...h 11 to F or R Select the most appropriate transmission range position according to the operating conditions Select the most appropriate travel pattern by operating travel mode selector 13 AUTO 1 Mode...

Page 192: ...Q 3rd Speed 5th Speed 1st Speed Q 2nd Speed Q 3rd Speed Q 4th Speed Q 5th Speed 1st Speed Q 2nd Speed Q 3rd Speed AUTO 2 2nd Speed Only 2nd speed Only 2nd speed 3rd Speed 2nd Speed Q 3rd Speed 2nd Sp...

Page 193: ...r mode indicator 2 lights ON The power mode is suited for heavy digging work prioritizing work effectiveness Under auto shifting mode the gear is shifted in regular RPM s min 1 and shift mapping NOTE...

Page 194: ...2nd range position Shift Up Delay Forward movement The gear shifts up when moving the machine at high speed in 2nd range for 4 seconds or longer The gear will not shift while the lift arm is raising...

Page 195: ...stopping the machine on level ground NOTE While running the engine when the parking brake is applied with forward reverse selector switch lever 3 in neutral parking brake indicator 2 comes ON 2 While...

Page 196: ...ator pedal Changing Forward Reverse Drive Direction WARNING y Before changing the forward reverse drive direction confirm that the direction of drive is clear y To ensure operator s safety and ensure...

Page 197: ...is extremely dangerous and may cause the machine to turn over IMPORTANT When the steering wheel is fully turned the front and the rear frames come in contact with the stoppers so that the steering wh...

Page 198: ...s damage to the system may result Even though the machine is equipped with the secondary steering system if the steering function becomes inoperable while moving machine press secondary steering check...

Page 199: ...achine for a long period of time return the forward reverse lever to neutral N turn the parking brake switch ON and apply the parking brake to ensure safety 4 During long load and carry applications t...

Page 200: ...running the engine at high RPM s min 1 under no load x If any abnormal condition such as an abnormal noise vibration or smell is noticed while operating immediately stop the engine and inspect the ma...

Page 201: ...sion or front and rear propeller shafts in water or mud Avoid operating in water as much as possible x If operating in water or mud is unavoidable do not allow the machine to be submerged deeper than...

Page 202: ...imum travel speed Failure to do so may damage the machine and or a serious accident may result When steering on a slope lower the loader front to increase the machine stability Do not steer on a steep...

Page 203: ...s disabled by one or more of the following methods x Use disabled machine triangles x Turn the hazard lights ON x Use an emergency signal instrument emergency signal light or reflective triangles WARN...

Page 204: ...rol lever 6 and lift arm control lever 7 5 Press LOCK side of control lever lock switch 8 IMPORTANT This machine is equipped with a turbocharged engine Therefore if the engine is stopped without first...

Page 205: ...s may discharge the batteries Be sure to turn key switch to OFF position before leaving the machine 7 Turn key switch 9 to OFF position to stop the engine Remove the key from the switch 8 Before leavi...

Page 206: ...cooling down at low RPM s the lubricant on the turbocharger bearing and seal surfaces may be dissipated due to the intense heat present inside turbocharger possibly damaging the turbocharger 3 Run the...

Page 207: ...ake pedal The brake oil pressure will be quickly reduced so that the brakes become inoperable If the machine does not stop even if the brake pedal is applied press the parking brake switch ON side to...

Page 208: ...A Lift Arm Raise F Detent The lift arm is held in the raise position with the detent Bucket Control Lever 2 Lever Position Bucket Operation E Bucket Dump The bucket is tilted forward to dump the bucke...

Page 209: ...n the bucket reaches the preset position bucket control lever 2 automatically moves to the Neutral N position 3 When pushing down lift arm control lever 1 to the Float position C the lift arm moves to...

Page 210: ...in that position A Lift Arm Raise F Detent The lift arm is held in the raise position with the detent G Detent When the multi function joystick lever is moved from the bucket dump position to the buck...

Page 211: ...cted machine operation if the operator were to mistakenly come in contact with the bucket and or lift arm control lever when getting on or off the machine When control lever lock switch 1 is placed in...

Page 212: ...train Declutch ON when lightly depressing the left pedal 3 Suited to loading work on a level surface or on a gentle slope Declutch ON when firmly applying the left pedal 3 Suited to operate on a steep...

Page 213: ...not work NOTE The proximity switch is adjusted so that the arm stops before reaching the highest raising position To adjust the position of this switch consult your nearest authorized dealer Adjustme...

Page 214: ...ction can not be done when the lift arm is above the horizontal position of the lift arms Also height setting of raising direction can not be done when the lift arm is below the horizontal position of...

Page 215: ...he bucket is stopped with the bucket bottom parallel with the road surface For example after discharging material into a truck or a hopper when bucket control lever 4 is placed to detent position G th...

Page 216: ...olts 1 2 used move the bracket and then tighten the nuts 4 After adjustment start the engine Check that the bucket can be stopped at the desired angle position 70TM7 1 After moving the bucket to the d...

Page 217: ...g condition on the next page 30 seconds before the engine stop the buzzer sounds The buzzer sounds once at 30 seconds before intermittently sounds from 15 seconds and then stops after 15 seconds The a...

Page 218: ...raulic oil and transmission temperature are not high IMPORTANT y When the engine stops because of the auto idling stop function turn the key switch to ACC or OFF once and then turn it to START to rest...

Page 219: ...d with FOPS and ROPS if the machine is to be operated in the areas where the possibility of rollover or falling stones exists y If operation on excessively soft ground is required operate the machine...

Page 220: ...t or attachment to receive loads at only one side Damage to the machine may result Avoid Rapid Steering Changes and or Sudden Braking WARNING Always maintain a flat work site surface Avoid rapid steer...

Page 221: ...in a straight ahead position when entering the material 2 Lower the bucket parallel to the ground Drive the bucket straight into the material NOTE Use approximately 1 2 full engine speed 3 Raise the l...

Page 222: ...described below Always take care not to apply loads to only to one side of the bucket 1 Position the bucket teeth slightly downward dump forward 10 degrees or less 2 While moving the machine forward i...

Page 223: ...med by moving the machine forward severe loads are applied to the front attachment possibly creating cracks or damage to the front attachment 1 After filling the bucket dump the bucket gradually to sp...

Page 224: ...nd dump truck method Select either method depending on the work site conditions while taking the cost and safety into account Load and Carrying Method WARNING y Be sure to provide a tire stopper 1 in...

Page 225: ...t a right angle Then travel forward to carry material onto the dump truck 2 Position the wheel loader so that the material can be loaded around the center of the dump body In case the dump body is lon...

Page 226: ...ally in neutral and the lift arm rises faster 3 Return the lift arm control lever to the Hold position when the bucket reaches the enough height to clear the truck or hopper sideboards If the lift arm...

Page 227: ...s to the working tools Keep bucket or attachment bottom parallel to ground Dozing with a wheel loader means a working method performed by a wheel loader using the wheel loader bucket in place of a bul...

Page 228: ...steering of the machine y Use tire chains on all four wheels y Pay attention to the presence of the utility facilities such fire hydrants manholes curbs roadside drains etc The facilities or the mach...

Page 229: ...CHINE chapter 2 Refill the fuel tank CAUTION Wash the machine when needed In areas of exposed metal spray a light coat of rust preventive oil to protect the machine from rusting If the machine continu...

Page 230: ...connectors Most lights such as the headlights work lights and turn signal lights are water resistant 4 1 Clean the machine thoroughly Clean each cylinder rod plated areas and the radiator with extra...

Page 231: ...OPERATING THE MACHINE 5 24 MEMO...

Page 232: ...eight limits and traffic regulations Take any detours that may be needed into account In some cases getting approval from the authority concerned disassembling the machine to bring it within dimension...

Page 233: ...and flatbed Dirty ramps loading docks and flatbeds with oil mud or ice on them are slippery and dangerous 2 Chock 1 the truck and trailer wheels while using a ramp or loading dock 3 Ramps must be the...

Page 234: ...shifting Loading 1 Load the machine so that the centerline of the machine aligns with the centerline of the trailer flatbed 2 Slowly move the machine on the ramp 3 Lower the bucket onto the trailer d...

Page 235: ...the parking brake Slowly rest the bucket on the trailer deck or load carrying platform 2 Place blocks 1 in front of and behind the tires to prevent the machine from moving 3 Securely fasten the machin...

Page 236: ...l loader by driving on roads x Observe the rules and regulations associated to this wheel loader and travel carefully x Recommended tire pressures and traveling speeds may vary depending on the type o...

Page 237: ...and brake system are operable Release the parking brake y If the engine is inoperable Removing the propeller shafts x When the parking brake cannot be released manually release the parking brake Refe...

Page 238: ...king brake be sure to chock tires with wheel stoppers CAUTION y As soon as towing is complete connect the parking brake y Towing only when moving the machine to a place where the machine is inspected...

Page 239: ...e cap 1 counterclockwise and remove cap 1 2 Rotate lock nut 2 counterclockwise by using tool 3 and remove lock nut 2 Wrench Size 24 mm 0 08 in 3 Rotate set bolt 4 counterclockwise with allen wrench 5...

Page 240: ...rs between the front axle and wire cables to prevent damage to wire cables y Towing from the rear end of the machine When using wire ropes be sure to attach wire cables to the drawbar pin Always use t...

Page 241: ...in machine damage and or injury of personnel y Do not lift the machine quickly Excessive load will be applied to the wire cables and or lifting tools and may cause them to break y Do not allow anyone...

Page 242: ...or death and or machine breakdown y Failure to use recommended fuel lubricants and genuine Kawasaki parts will result in loss of Kawasaki product warranty y Never adjust engine governor Never adjust h...

Page 243: ...g x Inquire on the proper way to recycle or dispose of oil fuel coolant filters batteries and other waste from your local environmental or recycling center or from your authorized dealer Check the Hou...

Page 244: ...oler and Other Cooling System 11 Work Light 12 Rear Combination Light 13 Batteries 14 Fuel Tank 15 Engine 16 Rear Axle 17 Rear Propeller Shaft 18 Transmission 19 Center Propeller Shaft 20 Steering Cyl...

Page 245: ...and Other Cooling System 11 Work Light 12 Rear Combination Lamp 13 Batteries 14 Fuel Tank 15 Engine 16 Rear Axle 17 Rear Propeller Shaft 18 Transmission 19 Center Propeller Shaft 20 Steering Cylinder...

Page 246: ...gularly y Symbols The following symbols are used in the maintenance guide table Grease Front Joint Pin Cylinder Pin Propeller Shaft Hydraulic Oil Engine Oil Hydraulic Oil Filters Pilot Filter Hydrauli...

Page 247: ...7 37 4 Hydraulic Oil Filter Suction 7 45 14 Transmission Oil 7 34 5 Hydraulic Oil Filter Main 7 48 15 Engine Oil Filter 7 28 6 Air Breather Element 7 50 16 Hydraulic Oil Filter Pilot 7 46 7 Hydraulic...

Page 248: ...ntrol switch 3 OFF 4 Place forward reverse lever 4 and forward reverse switch to neutral and place neutral lever lock 6 to lock position 5 Apply the parking brake Turn parking brake 5 ON 6 Chock the t...

Page 249: ...dable pay special attention to ensure that hands feet and clothing do not become entangled y If parts or tools are dropped or inserted into the fan or the belt they may fly off or be cut off Do not dr...

Page 250: ...movement of the machine 1 Align the front and rear chassis centers with each other 2 Remove form pin 5 to remove set pin 1 from the rear frame hole 3 Pull out and rotate articulation lock bar 2 to al...

Page 251: ...opened the cover may move suddenly Be careful not to come in contact with the cover y Before inspecting around the engine be sure to secure side cover 1 with holding rod 4 y In case the machine is eq...

Page 252: ...grille 2 is not open y Rear grille 2 may spring open Take care not to be hit by the rear grille Opening the rear grille Push open close button 1 laterally to open rear grille 2 upward This provides ac...

Page 253: ...l hose Fuel tank to injection pump Oil filter hose Engine to oil filter Heater hose Heater to engine Brakes Brake valve seals Rubber parts Every 1 years Wet type brake D ring for piston Every 4 years...

Page 254: ...Check Fuel Level 7 59 Check Drive Belt 7 72 Check Fuel Hoses 7 66 Check Crankcase Breather Tube 7 30 Dust Ejection Valve 7 68 Check Air Inlet System 7 69 Check Drive Belt Tension 7 72 Change Engine O...

Page 255: ...ort Mounting Bolts U 7 106 Greasing Front Propeller Shaft 7 23 Greasing Center Propeller Shaft 7 24 Greasing Rear Propeller Shaft 7 25 Steering system Check Play Amount in Steering Wheel Movement 7 10...

Page 256: ...ting Bolts 7 100 Check and Replace Seat Belt and Lower Tether Every 3 years 7 100 Clean Engine Compartment and Hood 7 104 Check Steps and Handrails for Damage and Looseness 7 103 Check Windshield Wash...

Page 257: ...months 7 97 Check Refrigerant Every 6 months 7 98 Check Air Conditioner Condenser Every 6 months 7 97 Check Air Conditioner Every 6 months 7 96 Check Air Conditioner Piping Every 6 months 7 96 Check C...

Page 258: ...No 2 grease is suitable for most temperatures Use NLGI No 1 or No 0 grease for extremely low temperature The machine shipped from factory is filled with lubricants marked with Recommended Engine Oil...

Page 259: ...oil classification API CF 10W or Multi purpose Automatic Transmission Fluid x The machine shipped from the factory is filled with lubricants marked with x When the atmospheric temperature is below 20...

Page 260: ...h the atmospheric temperature The machine shipped from the factory is filled with oil marked When the atmospheric temperature is between 40 C and 20 C Use the proper hydraulic oil having high and low...

Page 261: ...hours 250 hours at first time only 2 Bucket link pin every 500 hours 250 hours at first time only 70Z7 One point each to bucket link pins 2 and 3 70TM7 Bucket link pins 2 One point each to right and l...

Page 262: ...rs at first time only 7 One point each to right and left lift arm cylinder rod pins 11 every 500 hours 250 hours at first time only One point each to right and left lift cylinder pins 12 every 500 hou...

Page 263: ...point each to front right and left steering cylinder pins 14 and 15 every 250 hours Cylinder left front 14 Cylinder right front 15 10 One point each to right and left steering cylinder rod pins 16 an...

Page 264: ...t each to front and rear axle support pins 16 and 17 every 10 hours Front 16 Rear 17 13 One point to front propeller shaft universal 18 every 12000 hours NOTE When the machine is continuously operated...

Page 265: ...50 hours 15 One point to center propeller shaft universal front 20 every 12000 hours One point to center propeller shaft universal rear 22 every 12000 hours 16 One point to center propeller shaft spli...

Page 266: ...er shaft universal 23 every 12000 hours 18 One point to rear propeller shaft splines 24 every 2000 hours 19 Two points to brake pedal 25 every 1000 hours 20 One point to brake pedal linkage 26 every 1...

Page 267: ...again The oil level should be between the upper and lower marks on oil level gauge 1 If oil level is below the lower limit mark add the recommended engine oil via oil filler 2 If oil level exceeds th...

Page 268: ...waste oil in accordance with the local regulation and or law Be sure to replace the engine oil filter when changing the engine oil at the same time 1 Park the machine following the same procedures as...

Page 269: ...fied amount of approved engine oil Refer to Recommended Engine Oil on page 7 17 25 liters 6 6 gallons 10 Check that the oil level is between the maximum and minimum level scales on oil level gauge 1 T...

Page 270: ...IMPORTANT y Take care not to allow foreign matter such as dirt to enter the oil filter y Be careful not to damage the filter body when removing or installing the filter y Never reuse a cartridge type...

Page 271: ...g any maintenance work Failure to do so may cause severe burns 1 Park the machine following the same procedure as described on page 7 7 for preparation of inspection maintenance work 2 Check tube 1 fo...

Page 272: ...reather cover 3 NOTE Make a note of bolt 2 position for reference at assembling work 4 Remove crankcase air breather cover 3 5 Remove air breather element 4 from rocker lever cover 5 Do not remove gas...

Page 273: ...ver 5 NOTE Install gasket 6 in the order from A to E shown in the right illustration Softly push gasket 6 when installing it Gasket 6 will not fit inside the groove if it is pushed hard with the finge...

Page 274: ...ng the same procedure as described on page 7 7 for preparation of inspection maintenance work 2 Check damper 1 on the fan end of the engine crankshaft 3 If any cracks dents or deformation is found con...

Page 275: ...smission may result Before starting the engine check the transmission oil level with oil level gauge 2 When the oil level is within range the float in the oil level gauge shall be in the center with t...

Page 276: ...oil filter to prevent oil from adhering to the parking brake disk If oil adhered clean the parking brake disk by using cleaning liquid to completely remove oil Failure to do so may cause the parking b...

Page 277: ...Turn the key switch OFF to stop the engine Leave the machine untouched for 10 minutes 5 Prepare a container of more than 50 L 13 gal capacity to receive the oil NOTE Drain plug 5 is magnetized If exc...

Page 278: ...e 11 At this time tighten the cartridge filter an additional 3 4 turn with a filter wrench Take care not to tighten the filter cartridge excessively Be careful not to damage filter cartridge by overti...

Page 279: ...work 2 Install articulation lock bar 4 to the front and rear of the chassis by following the procedures described on page 7 9 3 Clean the vicinity around drain plug 1 and the oil drain plug hole 4 Ar...

Page 280: ...rear of the chassis by following the procedures described on page 7 9 3 Clean the vicinity of oil level plug 2 4 Remove oil level plug 2 Clean the tip of dipstick 3 connected to oil level plug 2 with...

Page 281: ...ving the air breathers Open the machine front cover Front axle air breather 1 is located at the right side Remove the cover 2 Put a cover on the air breather port to prevent foreign matter from enteri...

Page 282: ...nents hydraulic oil and lubricants are completely cooled and after releasing residual circuit pressures 2 1Release internal pressure 2 2Be sure to relieve the air pressure from the hydraulic oil tank...

Page 283: ...to twist when connecting them The life of twisted hoses will be shortened considerably y Carefully tighten low pressure hose clamps Do not overtighten them y When adding hydraulic oil always use comp...

Page 284: ...he level gauge drain oil down to the appropriate level using a pump 1 Park the machine following the same procedures as described on page 7 7 for preparation of inspection maintenance work 2 Check oil...

Page 285: ...es described on page 7 9 3 Before changing the hydraulic oil be sure to relieve the air pressure from the hydraulic oil tank 3 by pressing air bleed valve 2 IMPORTANT When changing hydraulic oil take...

Page 286: ...m and tilt the bucket forward and backward Stop the engine Check for any oil leakage Check the oil level using level gauge 6 Bleed Air from the Hydraulic System After changing hydraulic oil or replaci...

Page 287: ...out Failure to do so will allow trapped dust to fall into tank 2 Clean the suction filter and the hydraulic oil tank inside with cleaning solvent Swab out cleaning oil with a lint free cloth 3 Fill th...

Page 288: ...the chassis by following the procedures described on page 7 9 3 Before replacing the filter element be sure to relieve the air pressure from the hydraulic oil tank by pressing air bleed valve 1 4 Rem...

Page 289: ...lter bleed air from the hydraulic pump and check the oil level in the hydraulic oil tank Refer to the descriptions for Bleed air from the hydraulic system in item 2 If the machine is operated without...

Page 290: ...owing the procedures described on page 7 9 3 Clean the vicinity around cover plate 1 4 Get a container and workshop towels to hold the spilled oil and the element Relieve the air pressure from the hyd...

Page 291: ...er to the descriptions for Bleed air from the hydraulic system in item 2 If the machine is operated without bleeding the air mixed in the hydraulic circuit damage to the hydraulic pump may result NOTE...

Page 292: ...3 Rotate cover 3 clockwise approx 1 4 turns Remove cap 2 by rotating it counterclockwise 4 Rotate cover 3 counterclockwise and remove it Remove element 4 5 Install new element 4 Tighten cover 3 clock...

Page 293: ...Raise the lift arm at the maximum height and then set the lift arm control lever in the Neutral N position 3 Turn the key switch OFF to stop the engine 4 Turn the key switch to ON position Do not star...

Page 294: ...e machine s vertical vibration during travel Travel the machine at the speed faster than Ride Control Drive Speed Setting displayed on the multi monitor If the machine s vertical vibration is not damp...

Page 295: ...y Park the machine on a solid level surface Lower the bucket to the ground Stop the engine Remove key from the key switch Push the control lever lock switch to the lock position y Check for missing o...

Page 296: ...overs Exposed reinforcement 6 Replace Hose covers Blister 7 Replace Hose Bend 8 Replace Use proper bend radius Hose Collapse 9 Replace Use proper bend radius Hose ends and fittings Deformation or Corr...

Page 297: ...Welded surfaces on flange joints Leak 12 Replace Every 250 hours Flange joint neck Crack 13 Replace Welded surfaces on flange joints Crack 12 Replace Clamps Missing Replace Deformation Replace Loose R...

Page 298: ...it in place 4 Tighten fitting 2 by hand pressing the fitting joint together to ensure O ring 1 remains in place and is not damaged 5 Tighten fitting 2 or nut 4 to the torque values shown Do not allow...

Page 299: ...1 Tighten fitting 7 by hand 2 Tighten fitting 7 or nut 8 to the torque values shown Do not allow hose 5 to twist when tightening fittings Width across flats mm 17 0 67 in 19 0 75 in 22 0 87 in 27 1 06...

Page 300: ...ed Recommended Fuel Use only super high quality or high quality DIESEL FUEL JIS K 2204 D 975 Kerosene must NOT be used Use of poor quality fuel tank cleaning solvents unapproved fuel additives gasolin...

Page 301: ...before fueling Do not smoke while you fill the fuel tank or work on fuel system 2 Check fuel gauge 1 on the monitor panel Add fuel if necessary IMPORTANT Keep all dirt dust water and other foreign mat...

Page 302: ...erate the machine remove plug 2 from the tip of drain valve 1 on the fuel tank bottom and open drain valve 1 to drain water and or sediment from the fuel tank Plug 2 is installed to protect drain valv...

Page 303: ...hard to start or make it run rough or not run at all After running the fuel tank dry draining water from fuel filter or fuel pre filter 1 or replacing the fuel filter be sure to bleed the air from th...

Page 304: ...a filter wrench Arrange a container to receive fuel for safety and to prevent ground from contamination 2 Apply a thin film of clean fuel to the gasket of new cartridge filter 2 3 Turn cartridge filt...

Page 305: ...el tank Procedures 1 Remove cartridge filter 1 by using a filter wrench Arrange a container to receive fuel for safety and to prevent ground from contamination 2 Apply a thin film of clean fuel to the...

Page 306: ...r 1 first Then securely tighten cover 1 to pump 5 using a wrench NOTE Wrench size 17 mm 0 7 inch IMPORTANT y Only clean and replace the strainer as well as gaskets 2 and 4 while servicing the fuel pum...

Page 307: ...install bent or damaged hoses According to the check points shown below check hoses for oil leaks and damage If any problem is found replace or retighten as instructed in the table Hose Interval hours...

Page 308: ...low foreign matter such as dirt to enter the engine when cleaning or replacing elements 2 Remove clip band 3 and remove cover 2 3 Hold the outer element release knob 6 Pull out outer element 4 from th...

Page 309: ...e valve from both sides by using your fingers until the end of dust ejection valve 1 opens If dust is difficult to be removed loosen the clip at the root of dust ejection valve 1 to remove dust ejecti...

Page 310: ...tem daily Check pipes and hoses of the air inlet system for wear damage or loose connections and clamps Replace damaged pipes and hoses Retighten loose clamps Tightening torque 8 N m 0 8 kg m 6 lbf ft...

Page 311: ...o Coolant Capacity 28 0 liter 7 4 gallons LLC liter gallon Soft Water liter gallon 15 5 0 33 9 2 2 4 18 8 5 0 20 4 0 38 10 6 2 8 17 4 4 6 25 13 43 12 0 3 2 16 0 4 2 30 22 48 13 4 3 6 14 6 3 8 WARNING...

Page 312: ...een the top and bottom of sight glass 3 or the coolant level is invisible which is below the bottom of sight glass 3 fill coolant until the coolant level exceeds the top of sight glass 3 In case no co...

Page 313: ...y 10 hours daily Check the drive belt for any trouble If any cracks are found replace the belt with a new one Check and Adjust Drive Belt Tension every 250 hours or whenever the slack is found An auto...

Page 314: ...pection maintenance work 2 Install articulation lock bar to the front and rear of the chassis by following the procedures described on page 7 9 3 Remove radiator cap 1 Open radiator drain cock 2 and t...

Page 315: ...rs 6 and 7 to clean radiator 4 oil cooler 5 and intercooler 1 from the hydraulic driven fan side Over the Rear Grille Open the rear grill to check and clean torque converter cooler 3 and air condenser...

Page 316: ...ation of such components is required contact your authorized dealer Batteries WARNING Battery gas can explode Keep sparks and flames away from batteries Check batteries only when cool Use a flashlight...

Page 317: ...teries IMPORTANT If the battery is used with the electrolyte solution level lower than the specified level the battery performance may deteriorate quickly IMPORTANT Do not refill electrolyte solution...

Page 318: ...and a mirror to do this It is difficult to accurately judge the electrolyte solution level in this case Therefore when the electrolyte solution level is flush with the U L the level is correct Referr...

Page 319: ...es If you spill acid on yourself call 911 then 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 If splashed in eyes flush with water for 10 to 15 minutes Get medi...

Page 320: ...ttery with a new maintenance free battery Different types of batteries may have different rates of charge This difference could overload one of the batteries and cause it to fail Check Monitor Functio...

Page 321: ...apply the parking brake and clear the machine area of other personnel The horn switch button is located at the steering wheel center and bucket control lever In case the machine is equipped with a mul...

Page 322: ...mark or a burning odor is noticed at a harness consult your nearest authorized dealer Replace Fuse 1 If any electrical equipment becomes inoperable first check the fuses in the fuse boxes A B located...

Page 323: ...A 13 SEAT HEATER Opt 20 A 2 HEAD LAMP RH 5 A 12 OPTION 20 A 1 AUTO SHUT DOWN 5 A 11 RADIO 10 A Fuse Box B 10 ECU 30 A 20 SECONDARY STEERING Opt 5 A 9 TCU 10 A 19 HI BEAM 10 A 8 CONTROLLER 10 A 18 WIPE...

Page 324: ...and or soil accumulates in vicinity 3 of the brake pedal remove the accumulated dust and or soil Check Brake Performance The machine must be stopped within 5 m range after the brake is applied while d...

Page 325: ...ion Keep bystanders away from the machine Use the steepest available slope on the worksite Park the machine with no load applied on a 15 inclining dry surface slope The machine must not move with the...

Page 326: ...rm function is deactivated Start the engine Run the engine at 1 200 RPM min 1 to pressurize the accumulator Check that when the pressure builds in the accumulator the alarm buzzer stops sounding and t...

Page 327: ...ations achieved possibly creating very hazardous situations Ask your nearest authorized dealer for checking NOTE Check the accumulator for the ride control equipped machine in the same manner Check Br...

Page 328: ...pressure y Even if only one tread pattern has worn out replace the tire with new one Tires must be evenly sized Before operating the machine check the tires for damage y When replacing one tire use a...

Page 329: ...lowing the same procedures as described on page 7 7 for preparation of inspection maintenance work 2 Install the articulation lock bar to the front and rear of the chassis by following the procedures...

Page 330: ...mode the machine is engaged in Consult your nearest authorized dealer or tire manufacturer for more detailed information Driving on Public Roads Standard Pressure x Loading excavation on normal groun...

Page 331: ...A may become narrower interference can occur between the tire and the machine parts When size and tread pattern of tires are changed install the correct oscillation stopper 1 by referring the list bel...

Page 332: ...positions x Align the tire rotation direction with the tire tread design pattern Tread design pattern direction optional will affect not only economy of tire but also safety of operation How to Check...

Page 333: ...When one axle is raised off the ground block the tires at the axle that is still in contact with the ground x After the machine is raised off ground be sure to block the machine using rigid supports...

Page 334: ...eep the nozzle more than 500 mm 20 in away from the core surface 2 Clean fresh filter 4 using compressed air or by washing with water Washing procedure with water is as follows 2 1 Use tap water 2 2 S...

Page 335: ...high damage to the filter fins may result Always use compressed air at the lower pressure than 0 2 MPa 2kgf cm2 Keep the nozzle more than 500 mm away from the core surface 2 Clean double filter 7 Clea...

Page 336: ...using a vacuum clean or lightly tapping to dust the filter IMPORTANT Inappropriate installation of the filter may cause dust to enter into the air conditioner causing malfunction or breakdown of the a...

Page 337: ...ooling mode once a week to prevent lack of lubrication CAUTION Avoid steam cleaning Do not clean the compressor and receiver tank with steam The high temperature will cause the refrigerant gas pressur...

Page 338: ...sh which may damage the fins Check Air Conditioner Compressor Belt every 6 months Check the belt for abnormal deflection and damage Check HVAC belt tension by depressing the midpoint shown with L mark...

Page 339: ...by the specified quantity In case any abnormality is found in the air conditioner consult your nearest authorized dealer Type Refrigerant No Quantity kg HFC R134a 0 90 0 05 IMPORTANT Do not release r...

Page 340: ...t hard wood support blocks under the bucket to support it Stop the engine 2 Loosen bolts 1 and nuts 2 Remove bucket teeth 3 or cutting edge 4 3 Install new teeth 3 or cutting edge 4 If the reverse sid...

Page 341: ...seat belt and lower tether every 3 years regardless of appearance Check ROPS cab Resin Cab Roof and Roof Mounting Bolts every 10 hours daily Check the appearance of ROPS cab 3 and resin cab roof 4 for...

Page 342: ...er when the steering wheel is fully turned and that the steering cylinders operate normally 1 Start the engine Turn the parking brake switch ON 2 Slightly lift the bucket above the ground Place the co...

Page 343: ...and Noise DANGER Exhaust inhalation hazard Ventilate the shop with fresh air when carrying out warming up warm up operation indoor Failure to do so may cause asphyxiation from exhaust gas resulting i...

Page 344: ...f needed Check Steps and Handrails for Damage and Looseness every 10 hours Check steps 3 and handrails 4 for damage looseness and contamination If oil grease or mud are on the steps and or handrails 4...

Page 345: ...the accumulated dust and debris and or dust from the engine areas Check Sound Absorbing Mat Around Engine every 10 hours Daily CAUTION If the sound absorbing mat in the engine compartment loosens the...

Page 346: ...y during first time 50 operating hours Check front and rear axle support mounting bolts for looseness Tightening torque values of the front axle and rear axle support mounting bolts Front Axle Mountin...

Page 347: ...17 143 15 105 5 Propeller shaft support bearing mounting bolt 20 2 30 206 21 152 6 Transmission mounting bolt Bracket 20 4 30 401 41 296 7 Transmission mounting bolt Cushion rubber 18 2 27 315 32 230...

Page 348: ...converter cooler mounting bolt 10 4 17 36 2 4 27 21 Air conditioner condenser mounting bolt 8 4 12 12 5 1 9 22 Air conditioner compressor mounting bolt 8 4 12 24 5 to 29 4 2 5 to 3 18 to 22 23 Cab cu...

Page 349: ...400 40 295 170 17 125 30 1 18 27 1 06 17 0 67 22 0 87 750 75 553 550 55 406 220 22 162 32 1 26 24 0 94 950 95 700 700 70 516 280 28 207 36 1 42 32 1 26 19 0 75 27 1 06 1400 140 1033 1050 105 774 400 4...

Page 350: ...axle mounting bolt Bolt dia mm in 24 0 9 Quantity 8 2 Rear axle support mounting bolt Bolt dia mm in 24 0 9 Quantity 8 3 Wheel rim mounting bolt Bolt dia mm in 24 0 9 Quantity 60 M4GB 07 124 M4GB 07 1...

Page 351: ...ply LOCTITE 262 or equivalent 5 Propeller shaft support bearing mounting bolt Bolt dia mm in 20 0 8 Quantity 2 NOTE Apply LOCTITE 262 or equivalent 6 Transmission mounting bolt Bracket Bolt dia mm in...

Page 352: ...tity 2 NOTE Apply LOCTITE 262 or equivalent 8 Engine mounting bolt Bracket Bolt dia mm in 12 0 5 Quantity 6 NOTE Apply LOCTITE 262 or equivalent 9 Engine mounting bolt Cushion rubber Bolt dia mm in 18...

Page 353: ...uffler mounting bolt Bolt dia mm in 10 0 4 Quantity 8 11 Counterweight mounting bolt Bolt dia mm in 30 1 2 Quantity 4 12 Top center pin upper flange lock Bolt dia mm in 16 0 6 Quantity 7 MNEC 07 068 M...

Page 354: ...3 Bottom center pin lock Bolt dia mm in 16 0 6 Quantity 1 14 Loader front pin lock 70Z7 70TM7 Bolt dia mm in 16 0 6 12 0 5 16 0 6 12 0 5 Quantity 9 4 14 22 70Z7 70Z7 70TM7 M4GB 07 180 MNEC 07 058 M4GB...

Page 355: ...ity 4 16 Radiator frame mounting bolt Bolt dia mm in 16 0 6 Quantity 6 NOTE Apply LOCTITE 262 or equivalent 17 Radiator mounting bolt Bolt dia mm in 8 0 3 Quantity 2 18 Intercooler mounting bolt Bolt...

Page 356: ...mounting bolt Bolt dia mm in 10 0 4 Quantity 2 20 Torque converter cooler mounting bolt Bolt dia mm in 10 0 4 Quantity 4 21 Air conditioner condenser mounting bolt Bolt dia mm in 8 0 3 Quantity 4 MNEC...

Page 357: ...ting bolt Bolt dia mm in 8 0 3 Quantity 4 23 Cab cushion rubber mounting bolt Bolt dia mm in 16 0 6 Quantity 4 NOTE Apply LOCTITE 262 or equivalent 24 Bucket tooth mounting bolt Optional Bolt dia in 1...

Page 358: ...MAINTENANCE 7 117 25 Cutting edge mounting bolt Bolt dia in 1 Quantity 12 26 Wear plate mounting bolt Bolt dia in 1 Quantity 4 M4GB 07 116 M4GB 07 150...

Page 359: ...MAINTENANCE 7 118 MEMO...

Page 360: ...itable for low temperature Check the fuel tank breather pipe freezing Lubricant Use high quality low viscosity hydraulic oil and engine oil Engine Coolant Be sure to use antifreeze Battery Fully charg...

Page 361: ...ine oil in the engine crankcase to cold weather type oil 4 Use fuel 1 diesel fuel To prevent condensation on the inside wall in the fuel tank fully refill the fuel tank with 1 diesel fuel after each s...

Page 362: ...oke 9 Road surfaces covered with snow especially when snow has been compacted will be frozen Use tire chains on all four wheels 10 Take anti freeze measures after completing operation x Spray keyholes...

Page 363: ...MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9 4 MEMO...

Page 364: ...ash the radiator by water and then dry it Prevention of Dust and Moisture Store the machine in a dry garage and cover it Tools Inspect and repair then store Periodic Operation Operate the machine at l...

Page 365: ...eration Failure to do so may cause damage to the engine hydraulic equipment transmission axle etc due to insufficient lubrication or coolant y If lubrication running is not performed for more than thr...

Page 366: ...disconnect switch ON 7 Start the engine Run the engine at less than 1 000 RPM s for several minutes before full load operation 8 Repeat the process several times 9 Stop the engine Check each device f...

Page 367: ...STORAGE 10 4 MEMO...

Page 368: ...ngine Auxiliaries Problem Cause Solution Batteries will not charge Broken battery separator Replace Faulty regulator Adjust and replace Faulty ground line Repair Faulty alternator Repair and replace B...

Page 369: ...of fuel Change fuel Refill tank with good quality fuel Faulty intake air heater Replace air heater Air mixed in the fuel supply line Bleed air Faulty injection pump or nozzle Repair or replace Reduced...

Page 370: ...hydraulic pump noise level increases Faulty hydraulic pump Repair Replace Lack of hydraulic oil Refill Broken suction pipe and or hose Repair Replace All actuators have no power Malfunction due to wor...

Page 371: ...bles in area of brake pedals Remove clean area Service brake fluid loss hydraulic oil Oil leak from brake line and or hose connector Retighten or repair Oil leak due to brake piston seal inside axle R...

Page 372: ...ng Clearance 45 mm in 2730 107 5 I Dumping Reach 45 mm in 1140 45 R1 Minimum Rotation Radius mm in 5300 209 R2 Minimum Rotation Radius mm in 6230 245 Travel Speed Forward Reverse km h mph 38 5 26 5 23...

Page 373: ...n 3100 122 E Tread mm in 2050 80 7 F Ground Clearance mm in 460 18 1 G Bucket Hinge Height mm in 4110 162 H Dumping Clearance 45 mm in 2780 109 2840 112 I Dumping Reach 45 mm in 1360 53 5 1270 50 0 R1...

Page 374: ...D Improperly locked attachment could release and cause serious injury or death Coupling to Attachment IMPORTANT Make sure that hydraulic coupler switch 1 is placed to unlock position 2 1 In front of t...

Page 375: ...o your side Hold the bucket control lever in the Roll Back position until the coupler plungers are fully extended 7 Visually confirm engagement of plungers by lifting coupler into view WARNING Do not...

Page 376: ...power is shut off Serious injury could occur 1 Press hydraulic coupler switch 1 down to unlock position 2 2 Hold the bucket control lever in Rollback position until locking plungers have fully retrac...

Page 377: ...pler OTHER ATTACHMENTS AND DEVICE General Maintenance Daily x Inspect the locking mechanism x Inspect hoses for leaks x Apply grease to zerk fittings Every 1000 hours x Inspect rollback dump stoppers...

Page 378: ...t or Attachment Over Anyone S 17 Avoid Power Lines S 19 Avoid Rapid Steering Changes and or Sudden Braking 5 13 Avoid Tipping S 17 Axle Housing Air Breather Clean 7 40 Axle Oil 7 18 Axle Oil Change 7...

Page 379: ...lters 7 93 Clearance Light Indicator Green 1 18 Clock Setting Mode 1 39 Clouded Windows A C 1 87 Coat Hat Hook 1 96 Cold Weather Season Precautions for Maintenance 9 2 Cold Weather Warm Up 3 12 Cold W...

Page 380: ...ter Element Replace 7 64 Fuel Pump Strainer Clean 7 65 Fuel System Maintenance 7 59 Fuel Tank Drain Water and Sediment 7 61 Fuse Box 1 90 Fuse Box A 1 91 7 82 Fuse Box B 1 91 7 82 Fuses Check 7 81 G G...

Page 381: ...Truck Loading Safely S 18 Periodic Replacement of Parts 7 12 Pilot Circuit Accumulator Check 7 52 Pilot Circuit Accumulator Replace 7 53 Pilot Oil Filter Replace 7 47 Power Mode Indicator Green 1 18 P...

Page 382: ...40 1 44 4 10 Steering Wheel Movement Check Play Amount 7 101 Steps 1 107 Steps Check 7 103 Stock Piling 5 20 Stop the Machine 4 17 Stopping Engine 3 13 STORAGE 10 1 Store Attachments Safely S 21 Stor...

Page 383: ...INDEX 14 6 Window Open Close Levers 1 99 Windshield Washer Fluid Level Check 7 100 Wiper Operation 1 51 Wiper Switch 1 51 Work Light Indicator Yellow 1 17 Work Light Switch 1 42 Work Lights Check 7 80...

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