KCM 60Z7 DEUTZ TCD36 Engine Workshop Manual PDF

Description

KCM 60Z7 Wheel Loader(Disassembly & Reassembly) DEUTZ TCD36 Engine Shop Manual – PDF DOWNLOAD

FILE DETAILS:

KCM 60Z7 Wheel Loader(Disassembly & Reassembly) DEUTZ TCD36 Engine Shop Manual – PDF DOWNLOAD

Language : English
Pages : 351
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

KCM 60Z7 Wheel Loader(Disassembly & Reassembly) DEUTZ TCD36 Engine Shop Manual – PDF DOWNLOAD

MACHINE NUMBERS 1
SAFETYS-1
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 NoiseS-4
Inspect Machine S-4
General Precautions for CabS-5
Use Handrails and Steps S-6
Never Ride AttachmentS-6
Adjust 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 StartingS-9
Investigate Job Site Beforehand S-10
Equipment of Head Guard, ROPS, FOPSS-11
Provide Signals for Jobs Involving Multiple Machines S-11
Keep Riders Off Machine S-12
Drive SafelyS-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 AccidentsS-15
Avoid Accidents from Backing Up and TurningS-16
Avoid Positioning Bucket or Attachment Over
Anyone S-17
Avoid Tipping S-17
Never Undercut a High BankS-18
Dig with Caution S-18
Perform Truck Loading Safely S-18
Avoid Power Lines S-19
Precautions for Operation S-19
Precautions for LightningS-19
Object Handling S-20
Protect Against Flying Debris S-20
Park Machine Safely S-21
Store Attachments SafelyS-21
Transport SafelyS-22
Handle Fluids Safely−Avoid FiresS-23
Practice Safe MaintenanceS-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 FlyingS-27
Prevent Burns S-27
Replace Rubber Hoses PeriodicallyS-28
Avoid High-Pressure FluidsS-28
Prevent Fires S-29
Evacuating in Case of FireS-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
FluidsS-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
ContaminationS-33
Prevent Battery ExplosionsS-34
Service Air Conditioning System SafelyS-34
Handle Chemical Products SafelyS-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
SAFETY LABELS S-39
COMPONENTS NAME 1-1
Components Name 1-1
GETTING ON/OFF THE MACHINE 1-2
Getting ON/OFF the Machine1-2
OPERATOR’S STATION1-3
Cab Features1-3
Front Console 1-4
Right Console 1-5
Monitor Panel1-6
Service Indicator 1-7
Parking Brake Indicator (Red)1-8
Brake Oil Level Indicator (Red) 1-8
Low Steering Oil Pressure Indicator (Red) (Option) 1-8
HST Warning Indicator (Red) 1-9
Discharge Warning Indicator (Red) 1-9
Engine Trouble Indicator (Red) 1-9
Overheat Indicator (Red)1-10
Engine Oil Low Pressure Indicator (Red) 1-10
Preheat Indicator (Yellow) 1-11
HST Oil Temperature Indicator (Red) 1-11
Secondary Steering Indicator (Yellow) (Option) 1-11
Seat Belt Indicator (Red) 1-11
Coolant Temperature Gauge 1-12
Fuel Gauge1-12
HST Oil Temperature Gauge1-12
Turn Signal Indicator (Green) 1-13
High Beam Indicator (Blue) 1-13
Work Light Indicator (Yellow) 1-13
Clearance Light Indicator (Green) 1-14
Control Lever Lock Indicator (Red)1-14
Power Mode Indicator (Green) 1-14
Maintenance Indicator (Yellow) 1-14
Monitor Display1-15
Forward/Reverse and Shift Position Indicator1-16
Speedometer 1-18
CONTENTS
Ride Control Indicator (Option)1-19
ECO Indicator 1-19
Machine Information Display 1-20
Shifting Item to be Indicated on Machine
Information Display 1-21
Resetting of Oil Change and Filter Replacement
Intervals1-25
Hydraulic Oil Change Interval Hour Meter1-25
Hydraulic Oil Filter 1 Replacement Interval Hour
Meter1-26
Hydraulic Oil Filter 3 Replacement Interval Hour
Meter1-27
Transmission Oil Change Interval Hour Meter 1-28
Transmission Oil Filter Replacement Interval Hour
Meter1-29
Engine Oil Change Interval Hour Meter 1-30
Engine Oil Filter Replacement Interval Hour Meter 1-31
Fuel Filter Replacement Interval Hour Meter 1-32
Axle Oil Change Interval Hour Meter 1-33
Clock Setting Mode 1-34
Clock (24H) Setting Procedures1-34
Switches, Steering Wheel and Pedals 1-35
Forward/Reverse Lever/ Shift Switch 1-36
Forward/Reverse Lever 1-36
Shift Switch 1-36
Neutral Lever Lock (for the Forward/Reverse Lever) 1-37
Steering Wheel 1-37
Horn Switch 1-37
Turn Signal Lever1-38
Light Switch 1-39
High-Low Beam Switch1-40
Key Switch 1-40
Wiper Switch 1-41
Wiper Operation 1-41
Front/Rear Wiper Switch 1-42
Hazard Switch1-43
Work Light Switch 1-44
Parking Brake Switch 1-45
Accelerator Pedal1-46
Brake/Inching Pedal1-46
Tilt, Telescopic Lever/Steering Column Tilt Pedal 1-47
Slow Speed (L) Select Switch 1-48
Right Console/Switches 1-49
Control Lever 1-50
Control Lever Lock Switch 1-51
Armrest Adjust Handle 1-52
Traction Control Switch1-53
Power Mode Switch 1-54
Ride Control Switch (Option) 1-55
AUTO 1-55
OFF1-55
Secondary Steering Operation Check Switch
(Option)1-56
Reverse Buzzer Switch (Option) 1-57
Reverse Buzzer Switch (with volume control)
(Option)1-57
Cigar Lighter (24 VDC Electrical Outlet) 1-58
Using Cigar Lighter1-58
Using Cigar Lighter Port as External Power Source 1-58
Ash Tray1-59
Auto Air Conditioner 1-60
Feature 1-60
Components Name 1-61
Controller Part Name and Function 1-62
Mode/Temperature Control Switch 1-64
Defroster Operation 1-66
Cool Head/Warm Feet Operation1-66
Tips for Optimal Air Conditioner Usage 1-67
For Rapid Cooling 1-67
When Windows Become Clouded 1-67
Off-Season Air Conditioner Maintenance 1-67
Adjusting Operator’s Seat (Air Suspension Type Seat)
1-68
Rear Tray 1-69
Electric Power Output (Option)1-69
Fuse Box 1-70
Fuse Box A 1-71
Fuse Box B 1-71
Hot/Cool Box 1-72
Tray and Drink Holder1-72
ROPS Cab1-73
Front Interior Light1-75
Rear Interior Light 1-75
Sun Visor 1-76
Emergency Exit Hammer1-76
Coat/Hat Hook 1-76
Upper Switch Panel (Option) 1-77
Rotary Light Switch (Option) 1-77
Outside Rear View Mirror1-78
Inside Rear View Mirror1-78
Cab Door 1-78
Door Lock Knob 1-79
Door Open/Close Lever1-79
Window Open/Close Levers1-79
When Fully Opening the Door 1-80
Cab Door Release Lever 1-80
Battery Disconnect Switch1-81
Switch Operation1-82
Articulation Lock Bar 1-83
Towing Pin1-84
Inspection/Maintenance Side Access Cover1-85
Steps 1-86
Rear Grille 1-86
Vandal-Resistant Devices 1-87
Seat Belt 1-88
Seat Belt 1-88
BREAK-IN 2-1
Break-in Operation for New Machine 2-1
OPERATING THE ENGINE 3-1
Inspect Machine Daily Before Starting 3-1
Check Before Starting3-3
CONTENTS
Starting Engine3-5
Starting in Cold Weather3-7
Check After Starting3-8
Using Booster Batteries3-9
Warm Up 3-11
Cold Weather Warm Up3-12
Stopping Engine 3-14
MOVING THE MACHINE4-1
Driving the Machine4-1
Starting to Move 4-2
Parking Brake Switch 4-4
Drive Speed Change 4-5
Changing Forward/Reverse Drive Direction4-5
Steering Wheel 4-6
Secondary Steering (Option) 4-7
Emergency Stop and Restart of Operation 4-8
Precautions for driving 4-9
Operating in Water or on Soft Ground 4-10
Precautions for Driving on Slopes 4-11
Precautions for Driving Speeds4-12
Speed Control Function 4-12
Precautions to be Taken if Machine Failure Occurs 4-13
Stop the Machine 4-14
Parking 4-16
Emergency Stopping 4-17
OPERATING THE MACHINE 5-1
Control Lever 5-1
Control Lever Lock Switch 5-2
Control Lever Lock Switch Operation 5-2
Ride Control Switch (Option) 5-3
AUTO 5-4
OFF5-4
Lift Arm Height Kick Out 5-5
Adjustment Bucket Auto Leveler5-6
Adjustment Procedures5-7
Before Operation5-8
Precautions for Operation 5-8
Ensure Safety When Operating on Road Shoulders5-8
Avoid Overloading5-9
Avoid Rapid Steering Changes and/or Sudden Braking 5-9
Avoid Operation with Biased Loads5-9
Excavation 5-10
Loading Accumulated Soil5-10
Digging and Loading Level Ground 5-11
Grading5-12
Loading5-13
Load and Carrying Method 5-14
Loader and Dump Truck Combination Method5-15
V-Shape Loading 5-15
I-Shape Loading 5-15
Dozing 5-16
Stock Piling 5-16
Removing Snow 5-17
Lifting Wheel Loader 5-17
Precautions for After Operations5-18
TRANSPORTING6-1
Transporting by Road6-1
Selecting a Trailer 6-1
Loading / Unloading on Trailer 6-2
Loading / Unloading on Trailer 6-3
Fastening Machine for Transporting 6-4
Transporting Wheel Loader (Urgent Situation)6-5
Precautions for Self-Traveling 6-5
Precautions for Towing 6-6
Releasing Parking Brake 6-7
Towing Method6-9
Lifting Machine6-10
MAINTENANCE 7-1
Correct Maintenance and Inspection Procedures 7-1
Check the Hour Meter Regularly 7-3
Layout7-4
Maintenance Guide Table 7-5
Preparations for Inspection and Maintenance 7-7
Articulation Lock7-9
Inspection/Maintenance Access Side Cover7-10
Rear Grille 7-11
Periodic Replacement of Parts 7-12
Inspection and Maintenance Table 7-14
Kind of Oils7-18
Recommended Grease 7-18
Recommended Engine Oil 7-19
Recommended Transmission Oil 7-20
Recommended Axle Oil7-21
Recommended Hydraulic Oil 7-22
Recommended Coolant 7-22
Recommended Brake Oil7-23
A Greasing7-24
B Engine 7-30
Check Engine Oil Level 7-30
Change Engine Oil 7-31
Replace Engine Oil Filter 7-33
C Power Train7-34
Check Transmission Oil Level 7-34
Change Transmission Oil 7-35
Clean Transmission Strainer 7-35
Replace Transmission Oil Filter 7-37
Change Axle Oil7-38
Check Oil Level 7-39
Check Surroundings Around Axle and Covers for Oil
Leaks7-40
Clean Transmission Air Breather 7-40
D Hydraulic System 7-41
Inspection and Maintenance of Hydraulic Equipment 7-41
Check Hydraulic Oil Level 7-43
Change Hydraulic Oil/Clean Hydraulic Oil Tank7-44
Clean Suction Filter 7-44
Bleed Air from the Hydraulic System 7-45
Bleed Air from the Hydraulic Circuit7-45
Replace Hydraulic Tank Oil Return Filter 7-46
Replace HST Charge Filter 7-48
Replace Air Breather Element 7-49
CONTENTS
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage (Option) 7-50
Replace Pilot Circuit Accumulator 7-51
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage (Option) 7-51
Check Gas Pressure in Ride Control Accumulator
(Option) 7-51
Check Hoses and Lines 7-52
E Fuel System7-57
Check Fuel Level 7-57
Drain Water and Sediment from Fuel Tank7-59
Drain Fuel Pre-Filter 7-60
Bleed Air from the Fuel System 7-61
Replace Fuel Main Filter7-62
Replace Fuel Pre-Filter7-63
Check Fuel Hoses7-64
F Air Cleaner7-65
Clean and Replace Air Cleaner Element 7-65
G Cooling System 7-66
Check Coolant Level7-67
Check Drive Belt 7-68
Replace Drive Belt 7-68
Replace Automatic Tensioner 7-68
Change Coolant7-69
Clean Radiator/Oil Cooler and Other Cooling
System7-71
H Electrical System 7-72
Batteries 7-72
Electrolyte Level Check 7-74
Check Electrolyte Specific Gravity 7-75
Replace Batteries 7-76
Check Monitor Functions and All Other Instrument
Operation7-76
Check Lights7-77
Check Horn and Reverse Buzzer 7-77
Check Electrical Harnesses and Fuses7-78
Fuse Box A 7-79
Fuse Box B 7-79
I Brake System 7-80
Check Brake Oil Level 7-80
Check Right and Left Brake Interlocking
Performance 7-81
Check Parking Brake Force7-82
Check Brake Disks (Service and Parking) 7-83
Change Brake Oil 7-83
J Tire7-84
Check and Replace Tire (Tire Pressure) 7-84
Check Tire for Damage 7-84
Check Wheel Bolt Torque7-85
Removal and Installation of Tire 7-88
K Air Conditioner 7-89
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters7-89
Check Air Conditioner7-93
Check Air Conditioner Piping 7-93
Check Air Conditioner Condenser 7-94
Check Air Conditioner Compressor Belt 7-94
Check Refrigerant 7-95
Check Compressor and Pulley7-95
L Miscellaneous 7-96
Check Bucket Teeth and Cutting Edge 7-96
Check and Replace Seat Belt and Lower Tether7-97
Check ROPS Cab Mounting Bolts7-97
Check Windshield Washer Fluid Level7-97
Check Play Amount in Steering Wheel Movement7-98
Check Accelerator Pedal Operation, and Exhaust Gas
Color and Noise 7-99
Check Rearview Mirror and Inside Rearview Mirror 7-100
Check Steps and Handrails for Damage and
Looseness 7-100
Clean Engine Compartment and Hood 7-101
Check Sound Absorbing Mat Around Engine 7-101
Check Engine Cylinder Head Bolts 7-102
Check Engine Compression Pressure 7-102
Check and Clean Starter and Alternator7-102
Retighten Front Axle and Rear Axle Support
Mounting Bolts7-102
Check and Replace EGR Device7-103
Clean EGR Cooler7-103
Check Turbocharger 7-103
Check and Clean Injection Nozzle 7-103
Check Tightening Torque of Nuts and Bolts 7-104
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS 9-1
Maintenance Under Special Environmental Conditions 9-1
Precautions for Maintenance During Cold Weather
Season9-2
STORAGE 10-1
Storing the Machine10-1
TROUBLESHOOTING11-1
Troubleshooting 11-1
Engine11-1
Engine Auxiliaries 11-1
Engine does not Start 11-2
Control Lever 11-2
Hydraulic System11-3
Drive Function11-4
Steering System11-4
Accelerator Pedal 11-4
Parking Brake 11-4
Service Brake11-5
Transmission11-5
Propeller Shaft11-5
Front Axle, Rear Axle11-5
SPECIFICATIONS 12-1
Specifications 12-1
OPTIONAL ATTACHMENTS13-1
Hydraulic Type Quick Coupler Operation 13-1
Removal13-1
CONTENTS
Installation 13-2
Disconnecting/connecting hydraulic hose 13-3
INDEX14-1

DESCRIPTION:

KCM 60Z7 Wheel Loader(Disassembly & Reassembly) DEUTZ TCD36 Engine Shop Manual – PDF DOWNLOAD

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 45 °C (-4 °F to 113 °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.

G.B 31/01/25