3. SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
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.
93213-00750
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Pressure Release Procedure
Group 6 Preparation
SECTION 2 MAINTENANCE STANDARD
Group 1 Body
Group 2 Front Attachment
SECTION 3 BODY
Group 1 Cab
Group 2 Counterweight
Group 3 Center Hinge
Group 4 Engine
Group 5 Radiator Assembly
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Pilot Valve
Group 11 Unloader Valve
Group 12 Combination Valve
Group 13 DEF/AdBlue Tank
Group 14 Flow Regulator Valve
Group 15 Cooling Fan System
Group 16 Aftertreatment Device
Group 17 Ride Control Valve
Group 18 Battery Disconnect Switch
4. SECTION AND GROUP
CONTENTS
SHOP MANUAL
(Troubleshooting)
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.
SECTION 4 OPERATIONAL
PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner
93213-00741
5. SECTION AND GROUP
CONTENTS
WORKSHOP MANUAL
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.
SECTION 4 TRAVEL SYSTEM
Group 1 Tire
Group 2 Drive Unit
Group 3 Axle
Group 4 Propeller Shaft
Group 5 Brake Valve
Group 6 Steering Pilot Valve
Group 7 Steering Valve
Group 8 Steering Cylinder
Group 9 Secondary Steering Device
Group 10 Reducing Valve
Group 11 Stop Valve
Group 12 Main Pressure Block
Group 13 Axle Oil Cooler
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
6. 90Z7B DR
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling..................................................................W1-1-1-1
Precautions for Using Floating Seal....................W1-1-1-2
Precautions for Using Nylon Sling.......................W1-1-1-3
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Specified Tightening Torque Chart.....................W1-2-1-1
Precautions for Spilt Flange...................................W1-2-1-3
Nut and Bolt Locking...............................................W1-2-1-3
Piping Joint.......................................................................W1-2-1-4
Quick Coupling..........................................................W1-2-1-6
Screw-In Connection................................................W1-2-1-7
Seal Tape Application...............................................W1-2-1-7
Low-Pressure-Hose Clamp Tightening..............W1-2-1-7
Connecting Hose.......................................................W1-2-1-8
Group 3 Painting
Painting..............................................................................W1-3-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1
Bleeding Air from Hydraulic System........................W1-4-1-2
Bleeding Air from Fuel System...................................W1-4-1-3
Bleeding Air from Radiator..........................................W1-4-1-5
Bleeding Air from Brake (Axle)...................................W1-4-1-6
Group 5 Pressure Release Procedure
Front Attachment Hydraulic Circuit Pressure
Release Procedure.....................................................W1-5-1-1
Ride Control Accumulator Pressure Release
Procedure.....................................................................W1-5-1-2
Parking Brake Accumulator Pressure Release
Procedure.....................................................................W1-5-1-3
Group 6 Preparation
Preparation before Inspection and
Maintenance..........................................................W1-6-1-1
Articulation Lock........................................................W1-6-1-2
Machine Position for Inspection and
Maintenance (lift arm raise)...............................W1-6-1-3
SECTION 1
GENERAL
CONTENTS
7. W1-1-1-1
Group 1 Precautions for Disassembling and Assembling
SECTION 1 GENERAL
Precautions for Disassembling and
Assembling
Precautions for Disassembling
Clean the Machine
Thoroughly wash the machine before bringing it
into the shop. Bringing a dirty machine into the shop
may cause machine components to be contaminated
during disassembling / assembling, resulting in
damage to machine components, as well as decreased
efficiency in service work.
Inspect the Machine
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
incorrect disassembling of components as well as
personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
The machine model, machine serial number, and
hour meter reading.
Reason for disassembly (symptoms, failed parts, and
causes).
Clogging of filters and oil, water or air leaks, if any.
Capacities and condition of lubricants.
Loose or damaged parts.
Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the area for
disassembling work.
Precautions for Disassembling and Assembling
Precautions for Disassembling
Cap the open ends in case the hoses and pipes
have been disconnected. In addition, attach an
identification tag onto the connectors, hoses, and
pipes for assembling.
Before disassembling, clean the exterior of the
components and place on a workbench.
Drain hydraulic oil and gear oil from the hydraulic
components and reduction gear.
Be sure to provide appropriate containers for
draining fluids.
Use matching marks for easier reassembling if
necessary.
Be sure to use the specified special tools when
instructed.
If a part or component cannot be removed after
removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), then take the
appropriate measures to remove it.
Orderly arrange disassembled parts. Mark and tag
them if necessary.
Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking, or
other damage.
Measure and record the degree of wear and
clearances.
Precautions for Assembling
Be sure to clean all parts and inspect them for any
damage. If any damage is found, repair or replace
part.
Dirt or debris on the contact or sliding surfaces may
shorten the service life of the machine. Take care not
to contaminate any contact or sliding surfaces.
Apply appropriate lubricant oil onto parts in order to
prevent them from seizing.
Be sure to replace O-rings, backup rings, oil seals, and
floating seals with new ones once they have been
disassembled. Apply grease before installing
Be sure that liquid-gasket-applied surfaces are clean
and dry.
If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to remove
the agent.
Fit the matching marks made when disassembling
and assemble them.
Be sure to use the designated tools to assemble
bearings, bushings, and oil seals.
Keep a record of the number of tools used for
disassembly / assembly. After assembling is
completed, count the number of tools so as to make
sure that no forgotten tools remain in the assembled
machine.
8. Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-8
Connecting Hose
dCAUTION: When replacing the hoses, use only
genuine Kawasaki service parts. Using hoses
other than genuine Kawasaki hoses may cause
oil leaks, hose rupture or separation of fitting,
possibly resulting in a fire on the machine. Do
not install hoses kinked. Application of high oil
pressure, vibration, or an impact to a kinked hose
may result in oil leaks, hose rupture or separation
of fitting. Utilize the print marks on hoses when
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub
against each other, wear to the hoses may result
and lead to hose rupture. Take care so that the
hoses do not come into contact with the moving
parts or sharp objects.
a
a - Rubbing Against Each Other
a - Rubbing Against Each Other b - Clamp
a - Rubbing Against Each Other b - Clamp
b b
a
a
b
Incorrect
Incorrect
Incorrect
Incorrect
Correct
Correct
Correct
Correct
W105-01-01-011
W105-01-01-012
W105-01-01-013
W105-01-01-014
9. SECTION 1 GENERAL
W1-3-1-1
Group 3 Painting
Painting
Surfaces to Be Painted Painting Color
1 Pipe (Lift Cylinder) High Grade Black
2 Pipe High Grade Black
3 Cab (Outside) High Grade Black
4 Plate Shining Silver
5 Rear Console (Inner) High Grade Black
6 Seat Bracket High Grade Black
7 Cockpit Skirt High Grade Black
8 Cockpit High Grade Black
9 Side Console (Inner) High Grade Black
10 Cab (Inner) High Grade Black
Paint the painted surface except the above listed in YA (Marigold Yellow).
1
2
3
10
9
8
4
5
6
7
90WNEC-01-03-02
WNEC-01-03-003
10. Group 3 Painting
SECTION 1 GENERAL
W1-3-1-2
Surfaces to Be Painted Painting Color
1 Light Bracket High Grade Black
2 Roof Panel Heat-Resistant Black
3 Exhaust Pipe Heat-Resistant Black
4 Pipe (Rain Cap) High Grade Black
5 Grill High Grade Black
6 Cover High Grade Black
7 Bracket (Combination Light) High Grade Black
8 Rear Cover (Side) High Grade Black
9 Front Cover High Grade Black
10 Pipe High Grade Black
11 Articulate Lock Bar Scarlet Red
Paint the painted surface except the above listed in YA (Marigold Yellow).
1
2
3
4
5
6
7
8
9
10
11
90Z7BW01-03-01
11. Group 3 Painting
SECTION 1 GENERAL
W1-3-1-3
Surfaces to Be Painted Painting Color
1 Handrail (Front) High Grade Black
2 Rear Fender High Grade Black
3 Handrail (Rear) High Grade Black
4 Fender Cover (Rear) Do not paint it.
5 Full Fender Do not paint it.
6 Bracket (Mud Guard) High Grade Black
7 Deck Plate High Grade Black
8 Step High Grade Black
9 Fender Cover (Front) Do not paint it.
Paint the painted surface except the above listed in YA (Marigold Yellow).
2
1
3
5
6
6
9 7
8
8
8
4
90Z7BW01-03-02
12. Group 3 Painting
SECTION 1 GENERAL
W1-3-1-4
Surfaces to Be Painted Painting Color
1 Rear Axle Refer to W1-3-1-5
2 Front Axle Refer to W1-3-1-6
3 Guard High Grade Black
Paint the painted surface except the above listed in YA (Marigold Yellow).
2
1
3
90Z7BW01-03-03
13. Group 3 Painting
SECTION 1 GENERAL
W1-3-1-5
Rear Axle (1)
Surfaces to Be Painted Painting Color
1 Rear Axle YA (Marigold Yellow)
2 Rim (Wheel) Mounting Part Do not paint it.
3 End of Axle and Rim (Wheel) YA (Marigold Yellow)
4 Boss Part Do not paint it.
5 Boss Part Do not paint it.
6 Guard Mounting Part (Thread Part ) Do not paint it.
7 Flange Part Do not paint it.
8 Name Plate Do not paint it.
9 End of Boss Part Do not paint it.
10 Guard Mounting Part (Thread Part ) Do not paint it.
WNEC-01-03-007
WNEC-01-03-008
WNEC-01-03-009
WNEC-01-03-010
View A View C
View B
8 10
9
B
4
5
6
C
A
7
1 2 3 2
14. Group 3 Painting
SECTION 1 GENERAL
W1-3-1-6
Front Axle (2)
Surfaces to Be Painted Painting Color
1 Rim (Wheel) Mounting Part Do not paint it.
2 End of Axle and Rim (Wheel) YA (Marigold Yellow)
3 Front Axle YA (Marigold Yellow)
4 Axle Mounting Part Do not paint it.
5 Flange Part Do not paint it.
6 Guard Mounting Part (Thread Part ) Do not paint it.
7 Name Plate Do not paint it.
8 Nut Surface Do not paint it.
9 Guard Mounting Part (Thread Part ) Do not paint it.
View A
WNEC-01-03-011
WNEC-01-03-012
8 9
7 6 5 A
1 2 1 3 4
15. SECTION 1 GENERAL
W1-4-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank
dCAUTION: Escaping fluid under pressure may
penetrate the skin and eyes, and cause serious
injury. Release the pressure before disconnecting
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation
may spout out and cause severe burns. Wait until
oil cools before starting any work. Do not turn cap
(2) of hydraulic oil tank (3) quickly. Cap (2) may fly
off by internal pressure. Release any remaining
pressure before removing cap (2).
Preparation
1. Park the machine on a solid and level surface.
Set the front attachment in position for checking
hydraulic oil level.
2. Stop the engine. Push air bleed button (1) of
hydraulic oil tank (3) and bleed air from hydraulic oil
tank (3).
3. Remove socket bolt (4)(4 used). Remove cap (2) and
O-ring (5) of hydraulic oil tank (3).
l : 6 mm
m : 20 N·m (2 kgf·m, 14.8 lbf·ft)
1 2, 5 3
4
W1R7-01-04-001
16. Group 4 Bleeding Air
SECTION 1 GENERAL
W1-4-1-2
Bleeding Air from Hydraulic System
Bleed air from the hydraulic system as follows when
hydraulic oil has been drawn, the suction filter and
suction pipe have been replaced, or the pump device and
cylinders have been removed/installed.
IMPORTANT: If air is accumulated inside of the pump
and if the engine starts in lacking of hydraulic oil,
the pump may be damaged.
Bleeding Air from Pump
Remove the air bleed plug on top of the pump. Add
hydraulic oil to the pump.
After the pump is filled with hydraulic oil, temporarily
tighten the plug. Then, start the engine and run it at
slow idle speed.
Slightly loosen the plug and bleed air from the pump
until hydraulic oil comes out from the gap.
After bleeding all air, securely tighten the plug.
IMPORTANT: If air is accumulated inside of the
cylinder and if the cylinder is operated suddenly
in lacking of hydraulic oil, the seal may be
damaged or the cylinder may seize.
Bleeding Air from Hydraulic Circuit
After refilling hydraulic oil, start the engine. While
operating each cylinder several times evenly. Slowly
start the operation. At this time, never fully stroke
the cylinders during initial operation stage.
As the pilot circuit has an air bleed device, air in the
pilot circuit will be bled while performing the above
operation.
Reset the front attachment in position for checking
hydraulic oil level.
Stop the engine. Check hydraulic oil level. Replenish
hydraulic oil if necessary.
17. Group 4 Bleeding Air
SECTION 1 GENERAL
W1-4-1-3
Bleed Air from the Fuel System
Air in the fuel system may make the engine hard to
start or make it run rough or not run at all.
After draining water and sediment from the fuel
filter, replacing the fuel filter, cleaning the fuel pump
strainer or running the fuel tank dry, be sure to bleed
the air from the fuel system according to the following
procedure.
Air Bleeding Procedure
This machine is equipped with a fuel priming solenoid
pump.
dCAUTION: Fuel leaks may lead to fires.
1. Turn the key switch to ON position. The fuel lift
pump operates to help prime the fuel system.
IMPORTANT: DO NOT start the engine.
2. The engine control module (ECM) operates the fuel
lift pump through a priming cycle which lasts at
least 30 seconds. Cycle the lift pump several times
by keying OFF, waiting 10 seconds, and keying ON
again.
3. Keep the key switch at ON position for at least 30
seconds after filling the main fuel filter.
4. Once the engine is started, slowly increase the
engine speed while air is purged from the fuel line.
5. Check the fuel supply system for fuel leaks.
IMPORTANT: Even if air is not thoroughly bled, do
not hold the key switch in the ON position for
more than 5 minutes.
In case air is not thoroughly bled, first return the
key switch to the OFF position. Then, after waiting
for more than 30 seconds, turn the key switch ON
again. Failure to do so may cause damage to the
electrical pump and/or discharging the batteries.
18. Group 4 Bleeding Air
SECTION 1 GENERAL
W1-4-1-4
If Air Mixed After Common Rail
dWARNING: INJECTION HAZARD
Fuel under high pressure
High pressure common rail, high pressure lines
fuel lines and high pressure fuel injection lines
contain high pressure fuel.
High pressure fuel injection into skin can cause
injury or death.
Keep hands away from injection lines while
turning engine with starter or while running
engine.
In case air mixed in the fuel system due to lack of
fuel and the engine is difficult to start, release air by
following the procedure given below.
1. Bleed air until the engine supply pump entrance
enough according to the above-mentioned
procedures.
2. Operate starter motor for long cranking within 20
seconds. If engine fails to start, return key switch to
OFF. Wait more than about 60 seconds, and then try
again.
19. Group 4 Bleeding Air
SECTION 1 GENERAL
W1-4-1-5
Bleeding Air from Radiator
dCAUTION: Do not loosen the radiator cap until
the system has cooled. Hot steam may spout out
and cause severe burns. Wait until coolant cools
and loosen the cap slowly. Release all pressure
and remove the cap.
Preparation
1. Park the machine on a solid and level surface.
Lower the attachment, level, all the way to the
ground or floor surface.
2. Stop the engine, and when cool, remove the
radiator cap.
3. Be sure that the radiator and surge tank, if so
equipped, is full of the correct coolant.
4. Install the radiator cap.
5. Run the engine and check for leaks.
20. Group 4 Bleeding Air
SECTION 1 GENERAL
W1-4-1-6
Bleeding Air from Brake (Axle)
dCAUTION: If air is mixed in the brake system,
the brake function is reduced and serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines and
replacing hydraulic oil.
In addition, bleed air from the brake system until
hydraulic oil (about 0.5 liters (0.13 gal)) is drawn
from each wheel (4 places) after bubbles stop.
fNOTE: Perform this work on all wheels (4 places) by two
or more persons. Air bleed plug (1) is located around the
center on front and rear axles.
1. Set the parking brake switch of front console to the
ON position, start the engine, and increases service
brake oil pressure.
2. Attach clear vinyl tube (2) onto one end of air bleed
plug (1). Insert other of clear vinyl tube (2) into clear
container (3) filled with hydraulic oil.
3. Depress brake pedal (4) several times. Then, depress
and hold brake pedal (4) to the stroke end.
4. Loosen air bleed plug (1) under condition in step 3
and drain hydraulic oil and air for several seconds.
5. Tighten air bleed plug (1).
6. Drain hydraulic oil after bubbles stop in steps 3 to 5
repeatedly.
fNOTE: When bubbles do not stop after hydraulic oil
(about 0.5 liters (0.13 gal)) is drawn, repeat step 3 to step
5.
7. Bleed air at other 3 places in the same way as step 3
to step 5.
IMPORTANT: After air bleeding work is completed at
4 places, bleed air at 4 places again.
Bleed air in the same way as step 3 to step 5 twice
and check that no air is remained inside.
1
1
1
2
3
90T4GB-05-04-04a
T4GB-05-04-005
T4GB-05-04-006
4
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22. SECTION 1 GENERAL
W1-5-1-1
Group 5 Pressure Release Procedure
Front Attachment Hydraulic Circuit Pressure
Release Procedure
Release any remaining pressure as follows before
removing/installing the front attachment.
1. Run the engine at slow idle speed without load for
five minutes.
2. Set the key switch to the OFF position. Stop the
engine.
3. Set the key switch to the ON position again. Set
front control lever lock switch (1) to the UNLOCK (b)
position.
4. With the key switch set in the ON position, operate
the control lever in order to release any pressure in
the hydraulic circuit 4 to 5 times.
5. Return front control lever lock switch (1) to the
LOCK (a) position.
6. Turn the key switch OFF.
MNEC-07-001
a- LOCK b- UNLOCK
MNEC-01-015
1
a
b
23. Group 5 Pressure Release Procedure
SECTION 1 GENERAL
W1-5-1-2
90TNED-03-02-07
Ride Control Accumulator Pressure Release
Procedure
Release any remaining pressure as follows before
removing and installing the ride control accumulator.
1. Set the machine position (lift arm raise) for
inspection and maintenance. (Refer to W1-6-1.)
2. Release any pressure in the front attachment
hydraulic circuit.
3. Bleed air from the hydraulic oil tank. (Refer to W1-4-
1.)
4. Remove nuts (2) (7 used) and washers (3) (7 used).
Remove cover (1).
j : 17 mm
5. Loosen lock nut (5) of control valve (4).
j : 13 mm
6. Loosen needle valve (6) with a wrench and release
any remaining pressure. Tighten needle valve (6).
7. Tighten lock nut (5).
j : 13 mm
m : 8 N·m (0.8 kgf·m, 5.9 lbf·ft)
1
2
3
4
6 5
90WNEC-04-08-03
24. Group 5 Pressure Release Procedure
SECTION 1 GENERAL
W1-5-1-3
Parking Brake Accumulator Pressure Release
Procedure
Release any remaining pressure as follows before
removing/installing the parking brake accumulator.
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Run the engine at slow idle speed without load for
five minutes.
4. Set key switch (2) to the OFF position. Stop the
engine.
5. Depress brake pedal (3) at least 50 times in order
to decrease the accumulated pressure left in the
service brake circuit.
6. Set key switch (2) to the ON position again. Turn
parking brake switch (1) ON or OFF at least 50 times
in order to decrease the accumulated pressure left
in the parking brake circuit.
7. Set parking brake switch (1) to ON position (b). Turn
key switch (2) OFF.
fNOTE: The service brake primary pressure and parking
brake pressure can be monitored by using the service
menu of monitor (4). (Refer to TROUBLESHOOTING /
Monitor in the separated volume, T/M.)
1 4 2
3
1
a b
a- OFF b- ON
MNEC-01-036
MNEC-01-058
