KCM 62Z7/67Z7/67TM7 Wheel Loader ISUZU 4HK1 Engine Parts Manual – PDF

ENGINE EMISSION CONTROL LABEL 1
MACHINE NUMBERS 3
SAFETY S-1
Recognize Safety Information S-1
Understand Signal Words S-1
Follow Safety Instructions S-2
Prepare for Emergencies S-3
Wear Protective ClothingS-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 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 MachinesS-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
AnyoneS-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 FiresS-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 FumesS-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
(Option) S-37
SAFETY LABELS S-39
COMPONENTS NAME 1-1
Components Name 1-1
GETTING ON/OFF THE MACHINE 1-3
Getting ON/OFF the Machine 1-3
OPERATOR’S STATION 1-4
Exhaust Filter 1-4
Diesel Particulate Filter 1-5
Description of DPF functions 1-5
Automatic regeneration 1-6
Cab Features 1-7
Front Console 1-8
Right Console 1-9
Multi-Function Joystick Type 1-9
Right Console 1-10
Fingertip Control Type 1-10
Monitor Panel 1-11
Service Indicator 1-12
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 (Red) 1-14
HST Warning Indicator (Red) 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
Exhaust Filter Warning Indicator 1-16
Exhaust Filter Warning (Blinking Red) 1-16
Exhaust Filter Regeneration Request
(Blinking Yellow) 1-16
Exhaust Filter Regeneration Request
(Lighting Yellow) 1-16
CONTENTS
Exhaust Filter Regeneration Inhibited Warning
Indicator (Yellow) 1-16
Air Filter Restriction Indicator (Red) 1-17
Preheat Indicator (Yellow) 1-17
Fuel Filter Restriction Indicator (Red) 1-17
HST Oil Temperature Indicator (Red) 1-17
Secondary Steering Indicator (Yellow) (Option) 1-18
Seat Belt Indicator (Red) 1-18
Water Separator Indicator (Red) (Option) 1-18
Coolant Temperature Gauge 1-19
Fuel Gauge 1-19
HST Oil Temperature Gauge 1-19
Turn Signal Indicator (Green) 1-20
High Beam Indicator (Blue) 1-20
Work Light Indicator (Yellow) 1-20
Exhaust Filter Regeneration Inhibited Indicator
(Yellow) 1-20
Clearance Light Indicator (Green) 1-21
Control Lever Lock Indicator (Red) 1-21
Power Mode Indicator (Green) 1-21
Maintenance Indicator (Yellow) 1-22
Forward/Reverse Selector Switch Indicator (Green) 1-22
Fan Reverse Rotation Indicator (Green)1-22
Monitor Display 1-23
Forward/Reverse and Shift Position Indicator 1-24
Speedometer 1-26
Ride Control Indicator (Option) 1-27
ECO Indicator 1-27
Machine Information Display 1-28
Shifting Item to be Indicated on Machine
Information Display 1-29
Resetting of Oil Change and Filter Replacement
Intervals 1-35
Hydraulic Oil Change Interval Hour Meter 1-35
Hydraulic Oil Filter 1 Replacement Interval Hour
Meter 1-36
Hydraulic Oil Filter 2 Replacement Interval Hour
Meter 1-37
Hydraulic Oil Filter 3 Replacement Interval Hour
Meter 1-38
Transmission Oil Change Interval Hour Meter 1-39
Transmission Oil Filter Replacement Interval Hour
Meter 1-40
Engine Oil Change Interval Hour Meter 1-41
Engine Oil Filter Replacement Interval Hour Meter 1-42
Fuel Filter Replacement Interval Hour Meter 1-43
Axle Oil Change Interval Hour Meter 1-44
Exhaust Filter Replacement Interval Hour Meter 1-45
Clock Setting Mode 1-46
Clock (24H) Setting Procedures 1-46
Switches, Steering Wheel and Pedals 1-47
Forward/Reverse Lever/ Shift Switch 1-48
Forward/Reverse Lever 1-48
Shift Switch 1-48
Neutral Lever Lock (for the Forward/Reverse Lever) 1-49
Steering Wheel 1-49
Horn Switch 1-49
Turn Signal Lever 1-50
Light Switch 1-51
High-Low Beam Switch 1-52
Key Switch 1-52
Wiper Switch 1-53
Wiper Operation 1-53
Front/Rear Wiper Switch 1-54
Hazard Switch 1-55
Work Light Switch 1-56
Parking Brake Switch 1-57
Accelerator Pedal 1-58
Brake/Inching Pedal 1-58
Tilt, Telescopic Lever/Steering Column Tilt Pedal 1-59
1st Speed Select Switch 1-60
Auto Idling Stop Switch 1-61
Right Console / Switches 1-62
Multi-Function Joystick Type 1-62
Multi-Function Joystick Lever 1-63
Right Console / Switches 1-64
Fingertip Control Type 1-64
Control Lever 1-65
Control Lever Lock Switch 1-67
Armrest Adjust Handle 1-68
Creep Mode Switch 1-69
Traction Control Switch 1-70
Power Mode Switch 1-71
Exhaust Filter Regeneration Switch 1-72
Exhaust Filter Manual Regeneration 1-73
Manual Regeneration Procedure 1-74
Automatic Regeneration (Auto-Regeneration) 1-75
Exhaust Filter Regeneration Inhibited 1-76
Ride Control Switch (Option) 1-77
AUTO1-78
OFF 1-78
Fan Reverse Rotation Switch 1-79
Manual Operation 1-79
AUTO 1-80
OFF 1-80
Forward/Reverse Selector Switch 1-81
Operational Procedure 1-81
Secondary Steering Operation Check Switch (Option) 1-82
Dual Lift Arm Auto Leveler (67TM7) 1-83
Cigar Lighter (24 VDC Electrical Outlet) 1-84
Using Cigar Lighter 1-84
Using 24 VDC Electrical Power Supply 1-84
Ash Tray 1-85
Auto Air Conditioner 1-86
Feature 1-86
Components Name 1-87
Controller Part Name and Function 1-88
Mode/Temperature Control Switch 1-90
Defroster Operation 1-92
Cool Head/Warm Feet Operation 1-92
CONTENTS
Tips for Optimal Air Conditioner Usage 1-93
For Rapid Cooling 1-93
When Windows Become Clouded 1-93
Off-Season Air Conditioner Maintenance 1-93
Adjusting Operator’s Seat (Air Suspension Type Seat) 1-94
Components Name 1-94
Rear Tray 1-95
Electric Power Output (Optional) 1-95
Fuse Box 1-96
Fuse Box A 1-97
Fuse Box B 1-97
Hot/Cool Box 1-98
Tray and Drink Holder 1-98
ROPS Cab 1-99
Front Interior Light 1-101
Rear Interior Light 1-101
Sun Visor 1-102
Emergency Exit Hammer 1-102
Coat/Hat Hook 1-102
Upper Switch Panel (Option) 1-103
Rotary Light Switch (Option) 1-103
Outside Rear View Mirror 1-104
Inside Rear View Mirror 1-104
Cab Door 1-104
Door Lock Knob 1-105
Door Open/Close Lever 1-105
Window Open/Close Levers 1-105
When Fully Opening the Door 1-106
Cab Door Release Lever 1-106
Battery Disconnect Switch 1-107
Switch Operation 1-108
Articulation Lock Bar 1-109
Towing Pin 1-110
Inspection/Maintenance Side Access Cover 1-111
Steps1-112
Tool Box 1-112
Vandal-Resistant Devices1-113
Seat Belt 1-115
Seat Belt1-115
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 Starting 3-3
Starting Engine 3-5
Starting in Cold Weather3-7
Preheating 3-7
Check After Starting 3-8
Using Booster Batteries 3-9
Warm Up 3-11
Cold Weather Warm Up 3-12
Stopping Engine 3-14
MOVING THE MACHINE 4-1
Driving the Machine 4-1
Precautions for starting to move 4-1
Starting to Move 4-2
Parking Brake Switch 4-4
Drive Speed Change4-5
Changing Forward/Reverse Drive Direction 4-5
Steering Wheel 4-6
Secondary Steering (Option) 4-7
Emergency Stop and Restart of Operation 4-8
Precautions for traveling 4-9
Operating in Water or on Soft Ground 4-10
Precautions for Driving on Slopes 4-11
Precautions for Driving Speeds 4-12
Speed Control Function4-12
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
Multi-Function Joystick Lever 5-1
Fingertip Control Type 5-2
Control Lever Lock Switch 5-4
Control Lever Lock Switch Operation 5-4
Ride Control Switch (Option) 5-5
AUTO5-6
OFF 5-6
Lift Arm Height Kickout (62Z7, 67Z7) 5-7
Adjustment of Loader Front 5-7
Adjustment of Dual Lift Arm Auto Leveler (67TM7)5-8
Lower Kickout Setting/Height Kickout Setting 5-8
Adjustment of Bucket Auto Leveler 5-9
Auto Idling Stop 5-11
Auto Idling Stop Operating Condition 5-12
Before Operation 5-13
Precautions for Operation 5-13
Ensure Safety When Operating on Road Shoulders 5-13
Avoid Overloading 5-14
Avoid Rapid Steering Changes and/or Sudden
Braking 5-14
Avoid Operation with Loads on Only One Side 5-14
Excavation 5-15
Loading Accumulated Soil5-15
Digging and Loading Level Ground 5-16
Grading 5-17
Loading 5-18
Load and Carrying Method 5-19
Loader and Dump Truck Combination Method 5-20
V-Shape Loading 5-20
I-Shape Loading 5-20
Dozing 5-21
Stock Piling 5-21
Removing Snow 5-22
Lifting Wheel Loader 5-22
Precautions for After Operations 5-23
CONTENTS
TRANSPORTING 6-1
Transporting by Road 6-1
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
Hydraulic Circuit Bypass 6-7
Releasing Parking Brake 6-8
Towing Method 6-10
Lifting Machine 6-11
MAINTENANCE 7-1
Correct Maintenance and Inspection Procedures 7-1
Check the Hour Meter Regularly 7-2
Layout 7-3
Maintenance Guide Table 7-5
Preparations for Inspection and Maintenance 7-7
Articulation Lock7-9
Inspection/Maintenance Access Side Cover 7-10
Periodic Replacement of Parts 7-11
Inspection and Maintenance Table 7-13
Kind of Oils 7-17
Recommended Grease 7-17
Recommended Engine Oil 7-18
Recommended Transmission Oil 7-19
Recommended Axle Oil 7-20
Recommended Hydraulic Oil 7-21
Recommended Coolant 7-21
A Greasing 7-22
B Engine 7-28
Check Engine Oil Level 7-28
Change Engine Oil 7-29
Replace Engine Oil Filter 7-31
C Power Train 7-32
Check Transmission Oil Level 7-32
Change Transmission Oil 7-33
Clean Transmission Strainer 7-33
Replace Transmission Oil Filter 7-35
Check Axle Oil 7-36
Change Axle Oil 7-37
Check Surroundings Around Axle and Covers for
Oil Leaks 7-38
Clean Axle Housing Air Breather 7-38
D Hydraulic System 7-39
Inspection and Maintenance of Hydraulic Equipment 7-39
Check Hydraulic Oil Level 7-41
Change Hydraulic Oil/Clean Hydraulic Oil Tank 7-42
Bleed Air from the Hydraulic System 7-43
Bleed Air from the Hydraulic Circuit7-43
Clean Suction Filter 7-44
Replace Pilot Oil Filter7-45
Replace Hydraulic Tank Return Filter 7-47
Replace HST Charge Filter 7-49
Replace Air Breather Element 7-50
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage 7-51
Replace Pilot Circuit Accumulator 7-52
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage (Option) 7-52
Check Gas Pressure in Ride Control Accumulator
(Option) 7-52
Check Gas Pressure in Steering Accumulator 7-52
Check Hoses and Lines 7-53
Service Recommendations for Hydraulic Fittings 7-56
Flat Face O-ring Seal Fitting (ORS Fitting) 7-56
Metal Face Seal Fittings 7-57
E Fuel System 7-58
Check Fuel Level 7-58
Recommended Fuel 7-58
Refueling 7-59
Drain Water and Sediment from Fuel Tank 7-60
Drain Fuel Filter 7-61
Draining Procedures (Main Filter) 7-61
Draining Procedures (Pre-Filter) 7-62
Bleed Air from the Fuel System 7-63
Air Bleeding by Priming Pump 7-64
Replace Fuel Main Filter Element 7-65
Replace Fuel Pre-Filter Element 7-66
Clean Fuel Solenoid Pump Strainer 7-67
Check Water Separator (Option) 7-68
Drain Procedures 7-68
Element Replacement Procedure 7-69
Check Fuel Hoses 7-70
F Air Cleaner 7-71
Clean and Replace Air Cleaner Element 7-71
G Cooling System 7-72
Coolant 7-72
Precautions for handling antifreeze 7-72
Check Coolant Level 7-73
Check Drive Belt 7-74
Check Drive Belt Tension 7-74
Adjust Drive Belt Tension 7-74
Change Coolant 7-75
Clean Radiator/Oil Cooler and Other Cooling
System 7-77
H Electrical System 7-78
Batteries 7-78
Electrolyte Level Check 7-80
Check Electrolyte Specific Gravity 7-81
Replace Batteries 7-82
Check Monitor Functions and All Other Instrument
Operation 7-82
Check Lights 7-83
Check Horn and Reverse Buzzer 7-83
Check Electrical Harnesses and Fuses 7-84
Replace Fuse 7-84
I Brake System 7-86
Check Right and Left Brake Interlocking
Performance 7-86
CONTENTS
Check Brake Performance 7-86
Check Play in Brake Pedal Stroke 7-86
Check Parking Brake Force 7-87
Check Accumulator Function, Gas Leakage,
Looseness, and Damage 7-88
Check Gas Pressure in Accumulator 7-89
Check Brake Disks (Service and Parking) 7-89
J Tire 7-90
Check and Replace Tire (Tire Pressure) 7-90
Check Air Pressure 7-90
Check Tire for Damage 7-91
Check Wheel Bolt Torque 7-91
Replace Tire7-91
Tire Sizes to be Used 7-92
Driving on Public Roads: Standard Pressure 7-92
Tire Rotation 7-93
How to Check Wear Amount 7-93
Removal and Installation of Tire 7-94
K Air Conditioner 7-95
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters 7-95
Clean Fresh Air Filter 7-95
Clean and Replace Double Filter (Option) 7-97
Clean Circulation Air Filter 7-98
Check Air Conditioner 7-99
Check Air Conditioner Piping 7-99
Check Air Conditioner Condenser 7-100
Check Air Conditioner Fan Belt 7-100
Belt Tension Adjustment Procedure 7-100
Check Refrigerant 7-101
Check Compressor and Pulley 7-101
L Miscellaneous 7-102
Check Bucket Teeth and Cutting Edge 7-102
Check and Replace Seat Belt and Lower Tether 7-103
Check ROPS cab Mounting Bolts 7-103
Check Windshield Washer Fluid Level 7-103
Check Play Amount in Steering Wheel Stroke 7-104
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise 7-105
Exhaust Gas Color and Noise 7-105
Check Rearview Mirror and Inside Rearview
Mirror 7-106
Check Steps and Handrails for Damage and
Looseness 7-106
Clean Engine Compartment and Hood 7-107
Check Sound Absorbing Mat Around Engine 7-107
Check Engine Cylinder Head Bolts 7-108
Check and Adjust Valve Clearance 7-108
Check Engine Compression Pressure 7-108
Check and Clean Starter and Alternator 7-108
Retighten Front Axle and Rear Axle Support
Mounting Bolts 7-108
Check and Replace EGR Device 7-109
Clean EGR Cooler 7-109
Check Turbocharger 7-109
Check and Clean Injection Nozzle 7-109
Tightening and Retightening Torque of Nuts and
Bolts 7-110
Tightening Torque Chart 7-110
M Exhaust Filter 7-121
Check and Clean Filter Element of Exhaust Filter 7-121
Check and Clean Exhaust Filter 7-121
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS 9-1
Maintenance Under Special Environmental Conditions 9-1
Precautions for Maintenance During Cold Weather
Season 9-2
STORAGE 10-1
Storing the Machine 10-1
TROUBLESHOOTING 11-1
Troubleshooting 11-1
Engine 11-1
Engine Auxiliaries 11-1
Engine does not Start 11-2
Control Lever 11-2
Hydraulic System 11-3
Drive Function 11-4
Steering System 11-4
Accelerator Pedal 11-4
Parking Brake 11-4
Service Brake 11-5
Transmission 11-5
Propeller Shaft 11-5
Front Axle, Rear Axle 11-5
SPECIFICATIONS 12-1
Specifications 12-1
Sound Level Results (2000/14/EC) 12-3
Vibration Level 12-3
OPTIONAL ATTACHMENTS 13-1
Hydraulic Type Quick Coupler Operation 13-1
INDEX 14-1