KCM 115Z7 WHEEL LOADER ISUZU 6WG1 Engine OPERATION &MAINTENANCE Manual PDF

Language : English
Pages : 427
Downloadable : Yes
File Type : PDF

MACHINE NUMBERS1
SAFETY S-1
Recognize Safety InformationS-1
Understand Signal WordsS-1
Follow Safety InstructionsS-2
Prepare for EmergenciesS-3
Wear Protective ClothingS-3
Protect Against NoiseS-4
Inspect MachineS-4
General Precautions for CabS-5
Use Handrails and StepsS-6
Never Ride AttachmentS-6
Adjust Operator’s SeatS-6
Ensure Safety Before Rising from or Leaving Operator’s
SeatS-7
Fasten Your Seat BeltS-7
Move and Operate Machine SafelyS-8
Handle Starting Aids SafelyS-8
Operate Only from Operator’s SeatS-9
Jump StartingS-9
Investigate Job Site Beforehand S-10
Equipment of Head Guard, ROPS, FOPS S-11
Provide Signals for Jobs Involving Multiple 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 or Attachment 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 Lightning 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
Avoid 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
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
Notes for Exhaust Filter S-36
Precautions for Communication Terminal S-36
Precaution for Communication Terminal Equipment S-37
Articulation Stopper (Lock Bar) S-38
Joystick Steering System ON/OFF S-39
ROPS (Roll Over Protective Structure) S-40
SAFETY LABELS S-41
COMPONENTS NAME 1-1
Components Name1-1
OPERATOR’S STATION 1-3
Exhaust Filter1-3
Exhaust Filter (Diesel Particulate Filter or DPF)1-4
Description of DPF functions1-4
Automatic Regeneration 1-5
Repeated Inhibiting of Exhaust Filter Cleaning1-6
Cab Features1-7
Front Console1-8
Joystick Steering1-9
Right Console 1-10
Fingertip Control Type 1-10
Multi-Function Joystick Type 1-11
Monitor Panel1-12
Parking Brake Indicator (Red) 1-13
Brake Oil Low Pressure Indicator (Red) 1-13
Hydraulic Oil Level Indicator (Red) 1-13
Low Steering Oil Pressure Indicator (Option) (Red) 1-14
Transmission Warning Indicator (Red) 1-14
Communication Error Indicator (Yellow) 1-14
Discharge Warning Indicator (Red) 1-14
Engine Warning Indicator (Red) 1-15
Overheat Indicator (Red) 1-15
Engine Oil Low Pressure Indicator (Red) 1-15
Air Filter Restriction Indicator (Red) 1-16
Preheat Indicator (Yellow) 1-16
Coolant Temperature Gauge 1-17
Fuel Gauge1-17
Turn Signal Indicator (Green) 1-18
High Beam Indicator (Blue) 1-18
CONTENTS
115Z7 US
Work Light Indicator (Yellow) 1-18
Clearance Light Indicator (Green)1-18
Control Lever Lock Indicator (Red)1-18
Multi Function Monitor1-19
Feature 1-19
Screen Configuration 1-19
Default Setting1-20
Basic Screen1-21
How to Use Screens1-22
Displaying Basic Screen1-22
Monitor Operation1-26
Alarm Occurrence Screen1-27
Remedy1-29
Exhaust Filter Regeneration1-32
Exhaust Filter Status Display1-32
Automatic regeneration (Auto-regeneration)1-32
Manual Regeneration1-34
Service Regeneration1-34
Main Menu1-35
Ride Control Drive Speed Setting (Option)1-36
Dual Lift Arm Auto-Leveler1-37
Height Kickout ON/OFF, Stop Height Setting1-38
Lower Kickout ON/OFF, Stop Height Setting1-39
Brightness Adjustment1-40
Mail1-42
Setting Menu1-44
Date and Time 1-45
Time Adjustment 1-45
Date Adjustment 1-47
Display Mode Setting1-49
Auto Idling Stop 1-51
Auto Idling Stop: ON/OFF 1-51
Acting Time Setting 1-52
Rear View Camera Monitor 1-53
Exhaust Filter Regeneration Inhibited 1-55
Transmission Setting1-57
Shift Change Delay Mode Setting 1-57
Lockup Setting1-59
Traction Control Setting1-61
Parallel/Tandem Switching Height Setting 1-63
Warm Up Operation1-65
Display Item Selection1-67
Main Menu Display Order Change 1-69
Information Menu 1-71
Operation Condition 1-72
Fuel Consumption 1-72
Maintenance1-74
Maintenance Notice 1-74
Time Remains and Maintenance Interval 1-76
Troubleshooting1-78
Monitoring 1-80
Front Console Switches, Pedals, and Joystick Steering 1-83
Hazard Switch 1-84
Work Light Switch1-85
Parking Brake Switch 1-86
Key Switch1-87
Accelerator Pedal 1-88
Brake Pedal 1-88
Service Brake 1-88
Declutch Brake 1-88
Joystick Steering 1-89
Joystick Steering Lever 1-89
Forward/Reverse Switch 1-89
Shift Switch 1-90
Joystick Steering System Switch 1-90
Light Switch 1-91
Wiper Switch 1-92
Wiper Operation 1-92
Front/Rear Wiper Switch 1-93
Right Console / Switches 1-94
Fingertip Control Type 1-94
Loading Control Levers 1-95
Lift Arm Control Lever1-95
Bucket Control Lever1-95
Right Console / Switches 1-97
Multi-Function Joystick Type 1-97
Loading Multi-Function Joystick Lever (Option) 1-98
Auxiliary Control Lever (Option) 1-99
Turn Signal Switch1-100
Loading Control Lever Lock Switch1-101
Declutch Position Switch1-101
Travel Mode Selector Switch1-102
Power Mode Selector Switch1-103
Fan Reverse Rotation Switch1-104
OFF1-104
AUTO 1-104
Manual Operation 1-105
Hydraulic Coupler Switch (Option)1-105
Secondary Steering Operation Check Switch
(Option)1-106
Exhaust Filter Switch1-106
Ride Control Switch (Option)1-107
AUTO1-107
OFF1-107
Hold Switch1-108
Quick Power Switch1-109
Right Console Slide Lever1-109
DSS (Down Shift Switch)1-110
Horn Switch 1-111
Cigar Lighter (24 V DC Electrical Outlet)1-112
Using Cigar Lighter1-112
Ash Tray1-112
Auto Air Conditioner1-113
Feature1-113
Components Name1-114
Controller Part Name and Function1-115
Mode/Temperature Control Switch1-115
Fan/AUTO Switch1-116
Air Conditioner ON/OFF Switch1-116
Circulation/Fresh Air Switch1-116
Defroster Switch1-116
CONTENTS
115Z7 US
Cab Heater Operation1-117
Cooling Operation1-118
Defroster Operation1-119
Cool Head/Warm Feet Operation1-119
Tips for Optimal Air Conditioner Usage1-120
For Rapid Cooling1-120
When Windows Become Fogged1-120
Off-Season Air Conditioner Maintenance1-120
Adjusting Operator’s Seat (Air Suspension Type
Seat)1-121
Components Name1-121
Rear Tray1-122
Electric Power Output (Option)1-122
Fuse Box1-123
Fuse Box A1-124
Fuse Box B1-124
Hot/Cool Box1-125
Tray and Drink Holder1-125
Cab1-126
Front Interior Light1-128
Rear Interior Light1-128
Sun Visor1-129
Emergency Exit Hammer1-129
Coat/Hat Hook1-129
Upper Switch Panel (Option)1-130
Rotary Light Switch (Option)1-130
Outside Rear View Mirror1-131
Inside Rear View Mirror1-131
Cab Door1-131
Door Lock Knob1-132
Door Open/Close Lever1-132
Window Open/Close Levers1-132
Battery Disconnect Switch 1-133
Switch Operation1-134
Articulation Stopper (Lock Bar)1-135
Towing Pin1-136
Inspection/Maintenance Access Covers1-137
Rear Grille1-138
Steps1-139
Tool Box 1-139
Vandal-Resistant Devices1-140
BREAK-IN 2-1
Break-in Period for New Machine2-1
Work Mode for Break-in2-1
OPERATING THE ENGINE 3-1
Inspect Machine Daily Before Starting3-1
Check Before Starting3-3
Starting Engine3-6
Starting in Cold Weather3-8
Preheating3-8
Check After Starting3-9
Check Monitor Operation3-9
Check Engine Noise and Exhaust Gas Color3-9
Using Booster Batteries 3-10
Warm Up3-12
Cold Weather Warm Up 3-13
Stopping Engine3-15
MOVING THE MACHINE 4-1
Driving the Machine4-1
Precautions for Starting to Move4-1
Starting to Move4-2
Shift Range of Auto Transmission4-5
Power Mode Selector4-6
Shift Change Delay Mode4-6
Parking Brake Switch4-7
Drive Speed Change (Manual Shift)4-8
Changing Forward/Reverse Drive Direction4-8
Steering4-9
Secondary Steering (Option)4-10
Emergency Stop and Restart of Operation4-11
Precautions for Traveling4-12
Operating in Water or on Soft Ground4-13
Precautions for Driving on Slopes4-14
Precautions to be Taken if Machine Failure Occurs4-15
Stop4-16
Parking4-18
Emergency Stopping4-19
When the Engine has Stalled During Operation4-19
Auto Brake4-20
OPERATING THE MACHINE 5-1
Loading Control Levers5-1
Fingertip Control Type5-1
Loading Multi-Function Joystick Lever (Option)5-3
Control Lever Lock5-4
Control Lever Lock Operation5-4
Declutch Position Switch5-5
Adjustment of Bucket Auto Leveler5-6
Adjustment of Dual Lift Arm Auto Leveler5-8
Auto Idling Stop5-9
Auto Idling Stop Operating Condition5-10
Exhaust Filter Manual Regeneration5-11
Manual Regeneration Procedure5-11
Before Operation5-13
Precautions for Operation5-13
Ensure Safety When Operating on Road Shoulders5-13
Avoid Overloading5-14
Avoid Rapid Steering Changes and/or Sudden
Braking5-14
Avoid Operation with Loads on Only One Side5-14
Excavation5-15
Loading Accumulated Soil5-15
Digging and Loading Level Ground5-16
Grading5-17
Loading5-18
Load and Carrying Method5-18
Loader and Dump Truck Combination Method5-19
V-Shape Loading5-19
I-Shape Loading5-19
Dumping into Truck or Hopper5-20
CONTENTS
115Z7 US
Dozing5-21
Stock Piling5-21
Removing Snow5-22
Lifting Wheel Loader5-22
Precautions for After Operation5-23
TRANSPORTING 6-1
Transporting by Road6-1
Selecting a Trailer6-1
Loading / Unloading on Trailer6-2
Ramp/Loading Dock6-2
Loading / Unloading on Trailer6-3
Loading6-3
Fastening Machine for Transporting6-4
Transporting Wheel Loader (Urgent Situation)6-5
Precautions for Driving On Roads6-5
Precautions for Towing6-6
Releasing Parking Brake6-7
Towing Method6-9
Lifting Machine6-10
MAINTENANCE 7-1
Correct Maintenance and Inspection Procedures7-1
Check the Hour Meter Regularly7-3
Layout7-4
Lubrication Guide7-5
Preparations for Inspection and Maintenance7-6
Articulation Lock7-8
Inspection/ Maintenance Access Covers7-9
Rear Grille7-10
Inspection and Maintenance Table 7-12
Kind of Oils7-16
Recommended Grease7-16
Recommended Engine Oil7-16
Recommended Transmission Oil7-17
Recommended Axle Oil7-17
Recommended Hydraulic Oil7-18
Recommended Coolant7-18
A Greasing 7-19
B Engine7-25
Check Engine Oil Level 7-25
Change Engine Oil 7-26
Replace Engine Oil Filter7-28
C Power Train 7-30
Check Transmission Oil Level 7-30
Change Transmission Oil 7-31
Change Transmission Oil Filter 7-31
Clean Transmission and Torque Converter
Air Breathers7-34
Check Axle Oil Level 7-35
Check Differential Gear Oil Level7-35
Check Planetary Gear Oil Level7-36
Change Axle Oil 7-37
Change Differential Gear Oil7-37
Change Planetary Gear Oil7-38
Replace Axle Oil Cooler Line Filter (Option) 7-39
Clean Axle Oil Cooler Fins (Option) 7-39
D Hydraulic System 7-40
Inspection and Maintenance of Hydraulic
Equipment 7-40
Check Hydraulic Oil Level 7-41
Change Hydraulic Oil7-42
Bleed Air from the Hydraulic System7-43
Bleed Air from the Hydraulic Circuit7-43
Clean Suction Filter 7-44
Clean Pilot Oil Filter 7-45
Line Filter in Steering Circuit7-45
Line Filter in Brake Circuit7-46
Replace Hydraulic Oil Return Filter 7-47
Replace Air Breather Element 7-48
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage 7-49
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage (Option) 7-50
Check Gas Pressure in Ride Control Accumulator
(Option) 7-50
Check Gas Pressure in Steering Accumulator 7-50
Check Hoses and Lines 7-51
Service Recommendations for Hydraulic
Fittings7-54
Flat Face O-ring Seal Fitting (ORS Fitting)7-54
Metal Face Seal Fittings7-55
E Fuel System7-56
Check Fuel Level 7-56
Recommended Fuel7-56
About Biodiesel Fuel7-56
Refueling7-57
Drain Water and Sediment from Fuel Tank 7-58
Drain Fuel Filter 7-59
Draining Procedures (Main Filter)7-59
Draining Procedures (Pre-Filter)7-60
Bleed Air from the Fuel System7-61
Air Bleeding Procedure7-61
If Air Mixed After Common Rail7-62
Replace Fuel Main Filter Element 7-63
Replace Fuel Pre-Filter Element 7-64
Clean Fuel Pump Strainer 7-65
Check Fuel Hoses 7-66
Check Water Separator (Option)7-67
Drain Procedures7-67
Element Replacement Procedure7-68
F Air Cleaner7-69
Clean and Replace Air Cleaner Element 7-69
G Cooling System 7-70
Coolant7-70
Check Coolant Level 7-71
Check Drive Belt 7-72
Measurement of Deflection Amount and Vibration
Frequency7-72
Adjusting Drive Belt7-72
Replacing Drive Belt7-73
Change Coolant 7-74
CONTENTS
115Z7 US
Clean Radiator/Oil Cooler Cores and Other Cooling
System7-77
H Electrical System7-78
Batteries 7-78
Electrolyte Level Check7-80
Check Electrolyte Specific Gravity7-81
Replace Batteries 7-82
Check Monitor Functions and All Other Instrument
Operation 7-82
Check Work Lights 7-83
Check Horn and Backup Alarm 7-84
Check Electrical Harnesses and Fuses 7-85
Fuse Box A 7-86
Fuse Box B 7-86
I Brake System 7-87
Check Right and Left Brake Interlocking
Performance 7-87
Check Brake Performance7-87
Check Play in Brake Pedal Stroke7-87
Check Parking Brake Force 7-88
Check Parking Brake Gear Oil Level 7-89
Change Parking Brake Gear Oil 7-90
Check Accumulator Function, Gas Leakage,
Looseness, and Damage 7-91
Check Brake Disks (Service and Parking) 7-92
Check Gas Pressure in Accumulator 7-92
J Tire 7-93
Check and Replace Tire (Tire Pressure) 7-93
Check Air Pressure7-93
Check Tire for Damage7-94
Check Wheel Bolt Torque 7-94
Replace Tire7-94
Tire Sizes to be Used7-95
Driving on Public Roads: Standard Pressure7-95
Tire Rotation7-96
Rotation Procedure7-96
How to Check Wear Amount (Tread Design Groove
Depth)7-96
Removal and Installation of Tire7-97
Tire Wheel7-97
K Air Conditioner 7-98
Clean/Replace Air Conditioner Circulation/
Fresh Air Filters 7-98
Clean Fresh Air Filter7-98
Clean Circulation Air Filter7-100
Check Air Conditioner7-101
Check Air Conditioner Piping7-101
Check Air Conditioner Condenser7-102
Check Air Conditioner Compressor Belt7-102
Compressor Belt Tension Adjustment
Procedure7-102
Check Refrigerant7-103
Replace Air Conditioner Receiver Dryer7-103
Check Compressor and Pulley7-103
Check Compressor7-103
L Exhaust Filter7-104
Check and Clean Filter Element of Exhaust Filter7-104
Check and Clean Exhaust Filter7-104
M Miscellaneous7-105
Check Bucket Teeth7-105
Check and Replace Seat Belt and Lower Tether7-106
Check ROPS, ROPS Mounting Bolts, and Cab7-106
Check Windshield Washer Fluid Level7-107
Check Play Amount in Joystick Steering
Movement7-107
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise7-108
Exhaust Gas Color and Noise7-108
Check Rearview Mirror and
Inside Rearview Mirror7-109
Check Steps and Handrails for Damage and
Looseness7-109
Clean Engine Compartment and Hood7-110
Check Sound Absorbing Mat Around Engine7-110
Check and Adjust Valve Clearance7-110
Check Engine Compression Pressure7-110
Check and Clean Starter and Alternator7-111
Check Fuel Injector7-111
Check Turbocharger7-111
Check and Adjust Engine Controller (ECM)7-111
Check and Clean EGR Valve7-111
Check and Clean EGR Cooler7-111
Check DPF Differential Pressure7-111
Retighten Front Axle and Rear Axle Support
Mounting Bolts7-112
Check Tightening Torque of Nuts and Bolts7-113
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS 9-1
Maintenance Under Special Environmental Conditions9-1
Precautions for Maintenance During Cold Weather
Season9-2
STORAGE 10-1
Storing the Machine10-1
Removing the Machine from Storage10-2
TROUBLESHOOTING 11-1
Troubleshooting11-1
1 Engine11-1
2 Engine Auxiliaries11-1
3 Engine does not Start11-2
4 Control Lever11-3
5 Hydraulic System11-3
6 Drive Function11-4
7 Others11-5
SPECIFICATIONS 12-1
Specifications12-1
Intended Use12-1
INDEX 14-1