Kawasaki 40ZV-2A WHEEL LOADER Operator manual 05001 and up

1. 93103-00012 30ZV-2/40ZV-2A/42ZV-2 November 2016 OPERATION & MAINTENANCE MANUAL WHEEL LOADER 30ZV-2 40ZV-2A 42ZV-2 93103-00012 NOTICE READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING AND SAVE THIS MANUAL ON THE MACHINE Powered by Kubota V2403-M-DI-EDM Engine ©2016 KCM Corporation. All rights reserved. Printed in Japan (K) （アメリカ用） （アメリカ用） Serial No. 30ZV-2A 05001 and up 40ZV-2A 05001 and up 42ZV-2A 05001 and up

2. 93103-00012 November 2016

3. 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. Warranty is provided as a part of KCM’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 standard specification machine can be operated under the following conditions without being modified. Atmospheric Temperature: -20 °C to 45 °C (-4 °F to 113 °F) Altitude: 0 m to 2000 m (0 ft to 6600 ft) This warranty provides you with the assurance that KCM will back its products where defects appear within the warranty period. In some circumstances, KCM 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. In case the machine is used under conditions other than described above, consult your nearest authorized 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. 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. Right-hand and left-hand sides are determined by facing in the direction of forward travel. 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. 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 authorized dealer. 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. ©2016 KCM Corporation All rights reserved.

4. INDEX ENGINE EMISSION CONTROL LABEL MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS STORAGE TROUBLESHOOTING SPECIFICATIONS OPTIONAL ATTACHMENTS INDEX T

5. CONTENTS ENGINE EMISSION CONTROL LABEL Avoid High-pressure Fluids .......................................................S-28 Prevent Fires ...................................................................................S-29 Evacuating in Case of Fire ..........................................................S-30 Beware of Exhaust Fumes..........................................................S-31 Precautions for Welding and Grinding .................................S-31 Avoid Heating Near Pressurized Fluid Lines .......................S-32 Avoid Applying Heat to Lines Containing Flammable Fluids ...........................................................................................S-32 Precautions for Handling Accumulator and Gas Damper .......................................................................................S-32 Remove Paint Before Welding or Heating ...........................S-33 Beware of Asbestos and Silicon Dust and Other Contamination .........................................................................S-33 Prevent Battery Explosions .......................................................S-34 Service Air Conditioning System Safely ...............................S-34 Handle Chemical Products Safely ...........................................S-35 Dispose of Waste Properly .........................................................S-35 MACHINE NUMBERS SAFETY Recognize Safety Information ....................................................S-1 Understand Signal Words .............................................................S-1 Follow Safety Instructions ............................................................S-2 Prepare for Emergencies ...............................................................S-3 Wear Protective Clothing..............................................................S-3 Protect Against Noise ....................................................................S-4 Inspect Machine ..............................................................................S-4 General Precautions for Cab ........................................................S-5 Use Handrails and Steps ...............................................................S-6 Never Ride Attachment .................................................................S-6 Adjust the Operator’s Seat ...........................................................S-6 Ensure Safety Before Rising from or Leaving Operator’s Seat .................................................................................................S-7 Fasten Your Seat Belt ......................................................................S-7 Move and Operate Machine Safely ...........................................S-8 Handle Starting Aids Safely .........................................................S-8 Operate Only from Operator’s Seat ..........................................S-9 Jump Starting ...................................................................................S-9 Investigate Job Site Beforehand .............................................S-10 Equipment of Head Guard, ROPS, FOPS ...............................S-11 Provide Signals for Jobs Involving Multiple Numbers of Machines ....................................................................................S-11 Keep Riders Off Machine ...........................................................S-12 Drive Safely .....................................................................................S-12 Drive Machine Safely (Work Site) ............................................S-13 Drive Safely with Bucket Loaded ............................................S-14 Drive on Snow Safely ..................................................................S-14 Travel on Public Roads Safely ...................................................S-15 Avoid Injury from Rollaway Accidents ..................................S-15 Avoid Accidents from Backing Up and Turning ................S-16 Avoid Positioning Bucket Over Anyone ...............................S-17 Avoid Tipping .................................................................................S-17 Never Undercut A High Bank ...................................................S-18 Dig with Caution ...........................................................................S-18 Perform Truck Loading Safely ..................................................S-18 Avoid Power Lines ........................................................................S-19 Precautions for Operation .........................................................S-19 Precautions for Lightening .......................................................S-19 Object Handling ...........................................................................S-20 Protect Against Flying Debris ..................................................S-20 Park Machine Safely .....................................................................S-21 Store Attachments Safely ..........................................................S-21 Transport Safely ............................................................................S-22 Handle Fluids Safely−Avoid Fires............................................S-23 Practice Safe Maintenance ........................................................S-24 Warn Others of Service Work ...................................................S-25 Support Machine Properly ........................................................S-25 Stay Clear of Moving Parts ........................................................S-26 Support Maintenance Properly ...............................................S-26 Prevent Parts From Flying .........................................................S-27 Prevent Burns .................................................................................S-27 Replace Rubber Hoses Periodically ........................................S-28 SAFETY SIGNS .............................................................S-36 COMPONENTS NAME .................................................... 1-1 GETTING ON/OFF THE MACHINE ................................. 1-2 OPERATOR’S STATION Features ..............................................................................................1-3 Front Console ....................................................................................1-4 Right Console ....................................................................................1-5 Monitor Panel ...................................................................................1-6 Parking Brake Indicator .................................................................1-7 Brake Oil Low Lever Indicator .....................................................1-7 Discharge Warning Indicator.......................................................1-7 Engine Oil Low Pressure Indicator .............................................1-7 Engine Coolant Temperature Gauge ........................................1-8 Fuel Gauge .........................................................................................1-8 Hour Meter .........................................................................................1-8 Preheat Indicator .............................................................................1-9 Turn Signal Indicator ......................................................................1-9 Forward/Reverse Indicator...........................................................1-9 Switches, Steering Wheel and Pedals ....................................1-10 Forward/Reverse Lever ...............................................................1-11 Neutral Lever Lock (Forward/Reverse Lever) ......................1-11 Steering ............................................................................................1-12 Horn Switch ....................................................................................1-12 Turn Signal Lever ..........................................................................1-12 Light Switch ....................................................................................1-13 Hazard Switch (Optional) ...........................................................1-14 Front Work Light Switch (Cab) .................................................1-15 Rear Work Light Switch (Cab, Optional) ...............................1-16 Parking Brake Switch ...................................................................1-17 Front Window Wiper Switch (Cab) ..........................................1-18 Rear Window Wiper Switch (Cab) ...........................................1-18 Accelerator Pedal ..........................................................................1-19 Brake/Inching Pedal ....................................................................1-19 Right Console .................................................................................1-20 Loader Control Lever ...................................................................1-21 Single-Lever Type ....................................................................1-21 Loader Control Lever Lock ........................................................1-22

6. CONTENTS Key Switch .......................................................................................1-23 Driving Mode Switch ...................................................................1-24 Heater (Optional) Operation ....................................................1-25 Heater Switch ...........................................................................1-25 Venthole .....................................................................................1-25 Air Conditioner (Optional) Operation ...................................1-26 Components Name ................................................................1-26 Control Panel Arrangement ................................................1-26 Control Panel Switch Designation and Function.........1-27 Tips for Optimal Air Conditioner Usage ...............................1-28 Adjusting Operator’s Seat (Standard Type) .........................1-29 Seat Belt ...........................................................................................1-30 Seat Pocket .....................................................................................1-30 Fuse Box ...........................................................................................1-31 ROPS/FOPS Cab (Optional) .......................................................1-33 Room Light .....................................................................................1-35 Sun Visor (Optional) .....................................................................1-35 Drink Holder ...................................................................................1-35 Coat Hook .......................................................................................1-36 Rear View Mirror ............................................................................1-36 Room Rear View Mirror ...............................................................1-36 Cab Switch Panel (Optional) .....................................................1-37 Cab Door ..........................................................................................1-38 Door Lock Knob ............................................................................1-39 Door Open/Close Lever ..............................................................1-39 Window Open/Close Lever .......................................................1-39 When Fully Opening The Door ...........................................1-40 Door Lock Disengage Lever ................................................1-40 Articulation Lock Bar ...................................................................1-41 Towing Pin ......................................................................................1-41 Engine Hood ..................................................................................1-42 Steps..................................................................................................1-42 Vandal-Proof Devices ..................................................................1-43 Precautions for Traveling .........................................................4-7 Driving in Water or on Soft Ground .....................................4-8 Precautions for Driving on Slopes .............................................4-9 Precautions to Be Taken If The Machine Failure Occurs ..4-10 Stop/Parking ..................................................................................4-11 Emergency Occasions .................................................................4-13 OPERATING THE MACHINE Loader Control Lever ......................................................................5-1 Loader Control Lever Lock ...........................................................5-2 Adjustment of Bucket Auto Leveler ..........................................5-3 Before Operation .............................................................................5-4 Precautions for Operation ............................................................5-4 Ensure Safety When Operating on Road Shoulders ...........5-4 Avoid Overloading ..........................................................................5-5 Avoid Rapid Steering Changes and/or Sudden Braking ...5-5 Excavation ..........................................................................................5-6 Digging and Loading Level Ground .........................................5-7 Grading ...............................................................................................5-8 Loading ...............................................................................................5-9 Load and Carrying Method ....................................................5-9 Loader and Dump Track Combination Method ...........5-10 V-Shape Loading .....................................................................5-10 I-Shape Loading ......................................................................5-10 Dozing ..............................................................................................5-11 Scooping .........................................................................................5-11 Removing Snow ............................................................................5-12 Lifting Wheel Loader ...................................................................5-12 Precautions for After Operations ............................................5-13 TRANSPORTING Transporting by Road ....................................................................6-1 Transporting by Trailer ..................................................................6-1 Loading/Unloading on Trailer .....................................................6-1 Ramp/Loading Dock .................................................................6-1 Loading/Unloading ...................................................................6-2 Transporting ......................................................................................6-3 Transporting Wheel Loader (Urgent Situation) ....................6-4 Precautions for Towing ............................................................6-5 Removal of Propeller Shafts ...................................................6-6 Relieving HST Hydraulic Pressure ........................................6-7 Releasing Parking Brake ..........................................................6-8 Towing Method ................................................................................6-9 Lifting Machine .............................................................................6-10 BREAK-IN Observe Engine Operation Closely ...........................................2-1 OPERATING THE ENGINE Check Before Starting ....................................................................3-1 Starting Engine ................................................................................3-3 Starting in Cold Weather .........................................................3-4 Preheating ....................................................................................3-4 Check After Starting .......................................................................3-5 Check Monitor Operation .......................................................3-5 Check Engine Noise and Exhaust Gas Color .....................3-5 Using Booster Batteries .................................................................3-6 Warming Up Operation .................................................................3-8 Warming Up Operation in Cold Weather ................................3-9 Stopping Engine ...........................................................................3-10 MAINTENANCE Correct Maintenance and Inspection Procedures ...............7-1 Check the Hour Meter Regularly ................................................7-2 Use Correct Fuels and Lubricants ..............................................7-2 Layout ..................................................................................................7-3 Maintenance Guide Table .............................................................7-4 Preparations for Inspection and Maintenance .....................7-5 Lock Frames .......................................................................................7-6 Engine Hood .....................................................................................7-7 Periodic Replacement of Parts ....................................................7-8 Maintenance Guide ........................................................................7-9 Kind of Oils ......................................................................................7-15 Grease .........................................................................................7-15 DRIVING THE MACHINE Driving Machine ..............................................................................4-1 Starting to Move ..............................................................................4-2 Parking Brake Switch ......................................................................4-4 Changing Travel Speed .................................................................4-5 Changing Forward/Reverse Drive Direction ..........................4-5 Steering ...............................................................................................4-6 Provisional Stop and Restart of Driving ..................................4-7

7. CONTENTS Engine Oil ..................................................................................7-15 Brake Oil .....................................................................................7-16 Transmission Oil ......................................................................7-16 Axle Oil ........................................................................................7-16 Hydraulic Oil .............................................................................7-17 Long-Life Coolant ...................................................................7-17 A. Greasing ......................................................................................7-18 B. Engine ..........................................................................................7-22 Check Engine Oil Level ..........................................................7-22 Change Engine Oil ..................................................................7-23 Replace Engine Oil Filter .......................................................7-24 C. Power Train ................................................................................7-25 Change Transmission Oil ......................................................7-25 Change Axle Oil .......................................................................7-26 Check Oil Level ...................................................................7-27 Clean Transmission Air Breather ........................................7-28 Check Surrounding Areas Around Axle and Covers for Oil Leaks .........................................................................7-29 Clean Axle Housing Air Breather ......................................7-29 D. Hydraulic System .....................................................................7-30 Inspection and Maintenance of Hydraulic Equipment ...........................................................................7-30 Check Hydraulic Oil Level ....................................................7-31 Change Hydraulic Oil/Clean Hydraulic Oil Tank ...........7-32 Bleed Air from the Hydraulic System..........................7-33 Clean Suction Filter ................................................................7-34 Replace HST Oil Filter Element ...........................................7-35 Replace Return Filter ..............................................................7-37 Check Hoses and Lines .........................................................7-39 Service Recommendations for Hydraulic Fittings .7-41 E. Fuel System ................................................................................7-42 Check Fuel Level ......................................................................7-42 Recommended Fuel .........................................................7-42 Refueling ..............................................................................7-42 Drain Water and Sediment from Fuel Tank ....................7-43 Check and Drain Water from Fuel Filter ..........................7-44 Fuel Filter Drain Procedures ...........................................7-44 Bleed Air from the Fuel System ....................................7-45 Replace Fuel Filter Element .................................................7-46 Check and Drain Water from Water Separator .............7-47 Water Separator Drain Procedures ..............................7-47 Clean Water Separator Screen ............................................7-48 Check Fuel Hose ......................................................................7-49 F. Air Cleaner ...................................................................................7-50 Check Air Cleaner for Clogging ..........................................7-50 Clean and Replace Air Cleaner Element .........................7-51 G. Cooling System ........................................................................7-52 Kinds of Antifreeze ............................................................7-52 Precautions for Handling Long Life Coolant (LLC).....................................................................................7-53 Check Coolant Level ..............................................................7-54 Check Fan Drive Belt ..............................................................7-55 Check Fan Belt Tension .........................................................7-55 Adjust Fan Belt Tension .........................................................7-55 Change Coolant .......................................................................7-56 Clean Radiator and Oil Cooler ...........................................7-57 H. Electrical System ......................................................................7-58 Check Monitor Function and All Other Instrument Operation .............................................................................7-58 Check Work Lights ..................................................................7-59 Check Horn, Backup Buzzer and Backup Light ............7-59 Check Electrical Harnesses, Fuses, and Battery ............7-60 Replace Fuse ........................................................................7-60 Fuse Box ................................................................................7-61 Battery ...................................................................................7-62 Precautions for Handling Batteries .............................7-62 In Case the Batteries Were Discharged ......................7-64 Method to Recharge the Removed Battery .............7-64 Method to Replace with Charged Auxiliary Batteries .............................................................................7-65 Check Electrolyte Level .........................................................7-66 Check Electrolyte Specific Gravity ....................................7-67 I. Brake System ...............................................................................7-68 Check Brake Oil Level ............................................................7-68 Check Right and Left Brake Interlocking Performance .....................................................................7-69 Check Brake Performance ..............................................7-69 Check Play in Brake Pedal Stroke .................................7-69 Check Parking Brake Force ..................................................7-70 Check Brake Disc (Service and Parking) ..........................7-70 Check Brake Oil ........................................................................7-70 J. Tire ..................................................................................................7-71 Check and Adjust Tire Pressure ..........................................7-71 Check Tire Pressure ...........................................................7-71 Check Tire for Damage ..........................................................7-72 Check Wheel Bolt Torque .....................................................7-72 Replace Tire ...............................................................................7-72 Tire Size To Be Used ................................................................7-73 Tire Rotation .............................................................................7-74 How to Check Wear Amount (Tread Design Groove Depth)....................................................................................7-74 Removal and Installation of Tire ........................................7-75 Tire Wheel ..................................................................................7-75 K. Heater/Air Conditioner ..........................................................7-76 Check Heater for Any Damage ...........................................7-76 Check Heater Piping ..............................................................7-76 Clean and Replace Air Conditioner Circulation Air Filter ....................................................................................7-77 Clean Circulation Air Filter ..............................................7-77 Check Air Conditioner Unit .................................................7-78 High Temperature Pressure Cleaning (Steam Cleaning) ............................................................7-78 Check Pipelines ........................................................................7-78 Check Air Conditioner Condenser ....................................7-79 Check Air Conditioner Drive Belt.......................................7-79 Adjusting Compressor Drive Belt Tension ................7-79 Check Refrigerant Quantity .................................................7-80 Check Compressor And Pulley ...........................................7-80 Check Switch Operation .......................................................7-80 L. Miscellaneous ............................................................................7-81 Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear .........................................................................7-81

8. CONTENTS Check and Replace Seat Belt ...............................................7-82 Check Canopy/Cab for Damage and Mounting Bolts for Tightness ........................................................................7-82 Check Windshield Washer Fluid Level (Cab Equipped Unit) ...................................................................7-82 Check Play in Steering Wheel Stroke ...............................7-83 Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise ......................................................7-84 Exhaust Gas Color and Noise ........................................7-84 Check Rearview Mirror and Inside Rearview Mirror ...7-85 Check Steps and Handrails for Damage and Tightness ..............................................................................7-85 Clean Engine Compartment and Hood ..........................7-85 Check and Adjust Valve Clearance ...................................7-86 Check Sound Absorbing Mat Around Engine ..............7-86 Check Fuel Injection Timing ................................................7-86 Check Engine Compression Pressure ..............................7-87 Check and Clean Starter and Alternator .........................7-87 Retighten Front Axle and Rear Axle Support Mounting Bolts ...................................................................7-87 Tightening and Retightening Torque of Nuts and Bolts .....................................................................................7-88 Nuts and Bolts Tightening Torque ...............................7-89 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions ...9-1 Precautions for Maintenance During Cold Weather Season ............................................................................................9-2 STORAGE Storing the Machine ....................................................................10-1 Removing the Machine from Storage ...................................10-2 TROUBLESHOOTING ...................................................11-1 Troubleshooting ...........................................................................11-1 SPECIFICATIONS .........................................................12-1 Specifications (30ZV-2/40ZV-2A) .............................................12-1 Specifications (42ZV-2) ...............................................................12-2 OPTIONAL ATTACHMENTS Operating Quick Coupler (Mechanical Type) .....................13-1 INDEX ...........................................................................14-1

9. ENGINE EMISSION CONTROL LABEL Emission Control Label: Engine Label (for EPA) Emission control label is attached on the cylinder head cover. 30ZV-2 30M4EK-00-02 40/42ZV-2 42M4EP-00-02 40M4EK-00-03

10. MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine 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 them available upon request. Machine TYPE: _______________________________ PRODUCT IDENTIFICATION NUMBER: ___________________________ Product Identification Number PRODUCT IDENTIFICATION NUMBER: ___________________________ M4EK-00-001 fNOTE: Marks to indicate the start and end of the PIN Label *HFK4EK00A00000101* PRODUCT IDENTIFICATION NUMBER (PIN) Example) 30ZV-2: *RYUNBS60A30K15001* 40ZV-2A: *RYUNBT60A40K15001* 42ZV-2: *RYUNBA60A00005070* M4EP-00-001 Engine TYPE: _______________________________ MFG. NO.: ___________________________

11. SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-2644 Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. DANGERor WARNINGsafety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.  Some safety signs do not use any of the designated signal words above after the safety alert symbol has been used on this machine.  To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. SA-1223 f NOTE indicates an additional explanation for an element of information. S-1

12. SAFETY Follow Safety Instructions  Carefully read and follow all safety signs on the machine and all safety messages in this manual.  Safety signs should be installed, maintained and replaced when necessary.  If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).  Learn how to operate the machine and its controls correctly and safely. SA-003  Allow only trained, qualified, authorized personnel to operate the machine.  Keep your machine in proper working condition.  Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.  Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void KCM Warranty Policy.  Do not use attachments and/or optional parts or equipment not authorized by KCM. Carefully read and follow all instructions for use and safety in the operator's manual for the attachment. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void KCM Warranty Policy.  The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/ or your authorized dealer before operating or performing maintenance work on the machine. S-2

13. SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly.  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.  Establish emergency procedure guidelines to cope with fires and accidents.  Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone. SA-437 Wear Protective Clothing  Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. SA-438  Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.  Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. S-3

14. SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine  Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.  In the walk-around inspection, be sure to cover all points described in the “Inspect Machine Daily Before Starting” section in the operator’s manual. SA-435 S-4

15. SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and / or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and / or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  Do not leave parts and / or tools lying around the operator’s seat. Store them in their specified locations.  Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.  Refrain from using music headphones or mobile telephones in the cab while operating the machine.  Keep all flammable objects and / or explosives away from the machine.  After using the ashtray, always cover it to extinguish the match and / or tobacco.  Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.  Use proper floor mat dedicated to the machine. If another floor mat is used, it may be displaced and contact with the accelerator or brake pedals during operation, resulting in serious injury or death. S-5

16. SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds.  Do not hold the door handle or lever as a handrail when getting on and off the machine.  Never jump on or off the machine. Never mount or dismount a moving machine.  Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.  Never get on and off the machine with tools in your hands. SA-439 Never Ride Attachment  Never allow anyone to ride attachment or the load. This is an extremely dangerous practice. Adjust Operator’s Seat  A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperations.  The seat should be adjusted whenever changing the operator for the machine.  The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.  If not, move the seat forward or backward, and check again.  Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one. SA-462 S-6

17. SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.  Before leaving the machine, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position. Turn the parking brake switch ON, and the key switch OFF to stop the engine.  Before leaving the machine, close all windows, doors, and access covers and lock them up. Fasten Your Seat Belt  If the machine should overturn, the operator may become injured and / or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.  Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.  Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.  We recommend that the seat belt be replaced every three years regardless of its apparent condition. SA-237 S-7

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19. SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Be advised that there may be blind spots with rear view camera. Confirm the location of bystanders before moving, swinging, or operating the machine by sight and mirrors as well as the rear view monitor.  Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.  Use a signal person when moving, or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.  Ensure the cab door, windows, doors and covers are securely locked.  Check the mirrors and the monitor in the CAB for problems. If there is, replace the problem part(s) or clean the mirror, camera and the monitor. Refer to Rear View Monitor section on the cleaning of the camera and the monitor. SA-4EK-001 Handle Starting Aids Safely Starting fluid:  Starting fluid is highly flammable.  Keep all sparks and flame away when using it.  Keep starting fluid well away from batteries and cables.  Remove container from machine if engine does not need starting fluid.  To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.  Do not incinerate or puncture a starting fluid container. SA-293 S-8

20. SAFETY Operate Only from Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  NEVER start the engine while standing on the tire or on ground.  Do not start engine by shorting across starter terminals.  Before starting the engine, confirm that all control levers are in neutral.  Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders. SA-4EK-002 Jump Starting  Battery gas can explode, resulting in serious injury.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING ENGINE” chapter in the operator’s manual.  The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.  Never use a frozen battery.  Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. SA-032 S-9

21. SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.  Make a work plan. Use machines appropriate to the work and job site.  Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.  When working on an incline or on a road shoulder, employ a signal person as required.  Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist.  When the footing is weak, reinforce the ground before starting work.  When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.  Beware of the possibility of fire when operating the machine near flammable objects such as dry grass. SA-4EK-003 S-10