KCM 60Z7 Wheel Loader DEUTZ TCD36 Engine Parts Manual – PDF

Language : English
Pages : 350
Downloadable : Yes
File Type : PDF

MACHINE NUMBERS 1
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 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
SAFETY LABELS S-39
COMPONENTS NAME 1-1
Components Name 1-1
GETTING ON/OFF THE MACHINE 1-2
Getting ON/OFF the Machine 1-2
OPERATOR’S STATION 1-3
Cab Features 1-3
Front Console 1-4
Right Console 1-5
Monitor Panel 1-6
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 Gauge 1-12
HST Oil Temperature Gauge 1-12
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 Display 1-15
Forward/Reverse and Shift Position Indicator 1-16
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
Intervals 1-25
Hydraulic Oil Change Interval Hour Meter 1-25
Hydraulic Oil Filter 1 Replacement Interval Hour
Meter 1-26
Hydraulic Oil Filter 3 Replacement Interval Hour
Meter 1-27
Transmission Oil Change Interval Hour Meter 1-28
Transmission Oil Filter Replacement Interval Hour
Meter 1-29
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 Procedures 1-34
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 Lever 1-38
Light Switch 1-39
High-Low Beam Switch 1-40
Key Switch 1-40
Wiper Switch 1-41
Wiper Operation 1-41
Front/Rear Wiper Switch 1-42
Hazard Switch 1-43
Work Light Switch 1-44
Parking Brake Switch 1-45
Accelerator Pedal 1-46
Brake/Inching Pedal 1-46
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 Switch 1-53
Power Mode Switch 1-54
Ride Control Switch (Option) 1-55
AUTO1-55
OFF 1-55
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 Lighter 1-58
Using Cigar Lighter Port as External Power Source 1-58
Ash Tray 1-59
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 Operation 1-66
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 Holder 1-72
ROPS Cab 1-73
Front Interior Light 1-75
Rear Interior Light 1-75
Sun Visor 1-76
Emergency Exit Hammer 1-76
Coat/Hat Hook 1-76
Upper Switch Panel (Option) 1-77
Rotary Light Switch (Option) 1-77
Outside Rear View Mirror 1-78
Inside Rear View Mirror 1-78
Cab Door 1-78
Door Lock Knob 1-79
Door Open/Close Lever 1-79
Window Open/Close Levers 1-79
When Fully Opening the Door 1-80
Cab Door Release Lever 1-80
Battery Disconnect Switch 1-81
Switch Operation 1-82
Articulation Lock Bar 1-83
Towing Pin 1-84
Inspection/Maintenance Side Access Cover 1-85
Steps1-86
Rear Grille 1-86
Vandal-Resistant Devices1-87
Seat Belt 1-88
Seat Belt1-88
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 Starting 3-3
CONTENTS
Starting Engine 3-5
Starting in Cold Weather3-7
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
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 driving 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
Control Lever Lock Switch 5-2
Control Lever Lock Switch Operation 5-2
Ride Control Switch (Option) 5-3
AUTO5-4
OFF 5-4
Lift Arm Height Kick Out 5-5
Adjustment Bucket Auto Leveler 5-6
Adjustment Procedures 5-7
Before Operation 5-8
Precautions for Operation 5-8
Ensure Safety When Operating on Road Shoulders 5-8
Avoid Overloading 5-9
Avoid Rapid Steering Changes and/or Sudden Braking 5-9
Avoid Operation with Biased Loads 5-9
Excavation 5-10
Loading Accumulated Soil5-10
Digging and Loading Level Ground 5-11
Grading 5-12
Loading 5-13
Load and Carrying Method 5-14
Loader and Dump Truck Combination Method 5-15
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 Operations 5-18
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
Releasing Parking Brake 6-7
Towing Method 6-9
Lifting Machine 6-10
MAINTENANCE 7-1
Correct Maintenance and Inspection Procedures 7-1
Check the Hour Meter Regularly 7-3
Layout 7-4
Maintenance Guide Table 7-5
Preparations for Inspection and Maintenance 7-7
Articulation Lock7-9
Inspection/Maintenance Access Side Cover 7-10
Rear Grille 7-11
Periodic Replacement of Parts 7-12
Inspection and Maintenance Table 7-14
Kind of Oils 7-18
Recommended Grease 7-18
Recommended Engine Oil 7-19
Recommended Transmission Oil 7-20
Recommended Axle Oil 7-21
Recommended Hydraulic Oil 7-22
Recommended Coolant 7-22
Recommended Brake Oil 7-23
A Greasing 7-24
B Engine 7-30
Check Engine Oil Level 7-30
Change Engine Oil 7-31
Replace Engine Oil Filter 7-33
C Power Train 7-34
Check Transmission Oil Level 7-34
Change Transmission Oil 7-35
Clean Transmission Strainer 7-35
Replace Transmission Oil Filter 7-37
Change Axle Oil 7-38
Check Oil Level 7-39
Check Surroundings Around Axle and Covers for Oil
Leaks 7-40
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 Tank 7-44
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 System 7-57
Check Fuel Level 7-57
Drain Water and Sediment from Fuel Tank 7-59
Drain Fuel Pre-Filter 7-60
Bleed Air from the Fuel System 7-61
Replace Fuel Main Filter 7-62
Replace Fuel Pre-Filter 7-63
Check Fuel Hoses 7-64
F Air Cleaner 7-65
Clean and Replace Air Cleaner Element 7-65
G Cooling System 7-66
Check Coolant Level 7-67
Check Drive Belt 7-68
Replace Drive Belt 7-68
Replace Automatic Tensioner 7-68
Change Coolant 7-69
Clean Radiator/Oil Cooler and Other Cooling
System 7-71
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
Operation 7-76
Check Lights 7-77
Check Horn and Reverse Buzzer 7-77
Check Electrical Harnesses and Fuses 7-78
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 Force 7-82
Check Brake Disks (Service and Parking) 7-83
Change Brake Oil 7-83
J Tire 7-84
Check and Replace Tire (Tire Pressure) 7-84
Check Tire for Damage 7-84
Check Wheel Bolt Torque 7-85
Removal and Installation of Tire 7-88
K Air Conditioner 7-89
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters 7-89
Check Air Conditioner 7-93
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 Pulley 7-95
L Miscellaneous 7-96
Check Bucket Teeth and Cutting Edge 7-96
Check and Replace Seat Belt and Lower Tether 7-97
Check ROPS Cab Mounting Bolts 7-97
Check Windshield Washer Fluid Level 7-97
Check Play Amount in Steering Wheel Movement 7-98
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 Alternator 7-102
Retighten Front Axle and Rear Axle Support
Mounting Bolts 7-102
Check and Replace EGR Device 7-103
Clean EGR Cooler 7-103
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
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
OPTIONAL ATTACHMENTS 13-1
Hydraulic Type Quick Coupler Operation 13-1
Removal 13-1
CONTENTS
Installation 13-2
Disconnecting/connecting hydraulic hose 13-3
INDEX 14-1