KCM 70Z7 Wheel Loader CUMMINS QSB6.7 Engine OPERATION & MAINTENANCE Manual 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-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
Precautions for Communication Terminal S-36
Precaution for Communication Terminal Equipment S-37
Articulation Stopper (Lock Bar) S-38
SAFETY LABELS S-39
COMPONENTS NAME 1-1
Components Name1-1
GETTING ON/OFF THE MACHINE 1-3
Getting ON/OFF the Machine1-3
OPERATOR’S STATION 1-4
Cab Features1-4
Front Console1-5
Right Console1-6
Fingertip Control Type1-6
Multi-Function Joystick Type1-7
Monitor Panel1-8
Service Indicator1-9
Parking Brake Indicator (Red)1-10
Brake Oil Low Pressure Indicator (Red)1-10
Hydraulic Oil Level Indicator (Red)1-10
Low Steering Oil Pressure Indicator (Red) (Option)1-11
Transmission Warning Indicator (Red)1-11
Discharge Warning Indicator (Red)1-11
Engine Warning Indicator (Red)1-12
Overheat Indicator (Red)1-12
Engine Oil Low Pressure Indicator (Red)1-12
Air Filter Restriction Indicator (Red)1-13
Preheat Indicator (Yellow)1-13
Secondary Steering Indicator (Yellow) (Option)1-14
Seat Belt Indicator (Red)1-14
Water Separator Indicator (Red)1-14
Hydraulic Oil Temperature Indicator (Red)1-15
Transmission Warning Indicator1-15
Transmission Oil Temperature Indicator (Red)1-15
Axle Oil Temperature Indicator (Red)1-15
Coolant Temperature Gauge1-16
Fuel Gauge1-16
Transmission Oil Temperature Gauge1-16
Turn Signal Indicator (Green)1-17
High Beam Indicator (Blue)1-17
CONTENTS
Work Light Indicator (Yellow)1-17
Clearance Light Indicator (Green)1-18
Control lever lock indicator (Red)1-18
Power Mode Indicator (Green)1-18
Maintenance Indicator1-19
Forward/Reverse Selector Switch Indicator (Green)
(Option)1-19
Fan Reverse Rotation Indicator (Green)1-19
Monitor Display1-20
Forward/Reverse and Shift Position Indicator1-21
FNR (Forward/Reverse) Position Indicator1-21
Hold Indicator1-22
Shift Position Indicator1-22
Speedometer1-23
Ride Control Indicator (Option)1-24
ECO Indicator1-24
Machine Information Display1-25
Shifting Item to be Indicated on Machine
Information Display 1-26
Resetting of Oil Change and Filter Replacement
Intervals1-30
Clock Setting Mode1-39
Switches, Steering Wheel and Pedals1-40
Hazard Switch1-41
Work Light Switch1-42
Parking Brake Switch1-43
Neutral Lever Lock (for the Forward/Reverse Lever)1-44
Steering Wheel1-44
Key Switch1-45
Turn Signal Lever1-46
Light Switch1-47
High-Low Beam Switch1-48
Accelerator Pedal1-49
Brake Pedal1-49
Service Brake1-49
Declutch Brake1-49
Forward/Reverse Lever/ Shift Switch1-50
Forward/Reverse Lever1-50
Shift Switch1-50
Wiper Switch1-51
Wiper Operation1-51
Front/Rear Wiper Switch1-52
Tilt, Telescopic Lever/Steering Column Tilt Pedal1-53
Travel Mode Selector1-54
Declutch Position Switch1-55
Shift Change Delay Mode Switch1-56
Right Console / Switches1-57
Fingertip Control Type1-57
Loading Control Levers1-58
Right Console / Switches1-60
Multi-Function Joystick Type1-60
Loading Multi-Function Joystick Lever (Option)1-61
Auxiliary Control Lever (Option)1-62
Forward/Reverse Selector Switch (Option)1-63
Operational Procedure1-63
Control Lever Lock Switch1-64
1st Speed Fixed Switch1-65
Power Mode Selector1-66
Fan Reverse Rotation Switch1-67
OFF1-67
AUTO 1-67
Manual Operation 1-68
Secondary Steering Operation Check Switch
(Option)1-69
Ride Control Switch (Option)1-70
AUTO1-71
OFF1-71
Hold Switch1-72
Horn Switch 1-73
Dual Lift Arm Auto Leveler Switch (Option)1-74
Lower Kickout Setting/Height Kickout Setting1-74
Quick Power Switch1-75
DSS (Down Shift Switch)1-76
Armrest Adjust Handle1-77
Cigar Lighter (24 VDC Electrical Outlet)1-78
Using Cigar Lighter1-78
Using 24 VDC Electrical Power Supply1-78
Ash Tray1-78
Auto Air Conditioner1-79
Feature1-79
Auto Air Conditioner 1-80
Components Name1-80
Controller Part Name and Function1-81
Controller Part Name and Function1-83
Defroster Operation1-85
Cool Head/Warm Feet Operation1-85
Tips for Optimal Air Conditioner Usage1-86
For Rapid Cooling1-86
When Windows Become Clouded1-86
Off-Season Air Conditioner Maintenance1-86
Adjusting Operator’s Seat (Air Suspension Type Seat)1-87
Components Name1-87
Rear Tray1-92
Electric Power Output (Option)1-92
Fuse Box1-93
Fuse Box A1-94
Fuse Box B1-94
Hot/Cool Box1-95
Tray and Drink Holder1-95
ROPS Cab1-96
Front Interior Light1-98
Rear Interior Light1-98
Sun Visor1-99
Emergency Exit Hammer1-99
Coat/Hat Hook1-99
Upper Switch Panel (Option)1-100
Rotary Light Switch (Option)1-100
Rear View Mirror Heater Switch (Option)1-100
AM/FM Radio Operation1-101
Digital Clock Setting Procedure1-103
Audio Input1-104
Outside Rear View Mirror1-105
CONTENTS
Inside Rear View Mirror1-105
Cab Door1-105
Door Lock Knob1-106
Door Open/Close Lever1-106
Window Open/Close Levers1-106
When Fully Opening the Door1-107
Cab Door Release Lever1-107
Battery Disconnect Switch (Option) 1-108
Switch Operation1-109
Articulation Lock Bar1-110
Towing Pin1-111
Inspection/Maintenance Side Access Cover1-112
Rear Grille1-113
Steps1-114
Tool Box 1-114
Vandal-Resistant Devices (Option)1-115
BREAK-IN 2-1
Break-in Period for New Machine2-1
Use ECO Mode for Break-in2-1
OPERATING THE ENGINE 3-1
Inspect Machine Daily Before Starting3-1
Check Before Starting3-3
Starting Engine3-5
Starting in Cold Weather3-7
Check After Starting3-8
Using Booster Batteries3-9
Warm Up3-11
Cold Weather Warm Up3-12
Stopping Engine3-13
MOVING THE MACHINE 4-1
Driving the Machine4-1
Starting to Move4-2
Parking Brake Switch4-8
Drive Speed Change4-9
Changing Forward/Reverse Drive Direction4-9
Steering Wheel4-10
Secondary Steering (Option)4-11
Emergency Stop and Restart of Operation4-12
Precautions for Driving on Slopes4-15
Precautions to be Taken if Machine Failure Occurs4-16
Stop the Machine4-17
Parking4-19
Emergency Evacuation4-20
OPERATING THE MACHINE 5-1
Loading Control Levers5-1
Control Lever Lock5-4
Declutch Position Switch5-5
Lift Arm Height Kickout5-6
Adjustment of Loader Front5-6
Adjustment of Dual Lift Arm Auto Leveler (Option)5-7
Adjustment of Bucket Auto Leveler5-8
Before Operation5-10
Precautions for Operation5-10
Ensure Safety When Operating on Road Shoulders5-10
Avoid Overloading5-11
Avoid Rapid Steering Changes and/or Sudden
Braking5-11
Avoid Operation with Loads on Only One Side5-11
Excavation5-12
Grading5-14
Loading5-15
Dozing5-18
Stock Piling5-18
Removing Snow5-19
Lifting Wheel Loader5-19
Precautions for After Operation5-20
TRANSPORTING 6-1
Transporting by Road6-1
Selecting a Trailer6-1
Loading / Unloading on Trailer6-2
Fastening Machine for Transporting6-4
Transporting Wheel Loader (Urgent Situation)6-5
Towing Method6-9
Lifting Machine6-10
MAINTENANCE 7-1
Correct Maintenance and Inspection Procedures7-1
Check the Hour Meter Regularly7-3
Layout7-4
Preparations for Inspection and Maintenance7-7
Articulation Lock7-9
Inspection/ Maintenance Side Access Cover7-10
Rear Grille7-11
Periodic Replacement of Parts7-12
Inspection and Maintenance Table7-13
Kind of Oils7-17
A Greasing7-20
B Engine7-25
Check Engine Oil Level 7-25
Change Engine Oil 7-26
Replace Engine Oil Filter7-28
Check Crankcase Breather Tube7-29
Replace Crankcase Air Breather Element 7-30
Check Vibration Damper7-32
C Power Train7-33
Check Transmission Oil Level7-33
Change Transmission Oil and Transmission Oil
Filter7-34
Change Axle Oil7-37
Check Surroundings Around Axle and Covers for Oil
Leaks7-39
Clean Axle Housing Air Breather7-39
D Hydraulic System7-40
Check Hydraulic Oil Level7-42
Change Hydraulic Oil7-43
Clean Suction Filter7-45
Replace Pilot Oil Filter7-46
Replace Hydraulic Tank Oil Filter7-48
Replace Air Breather Element7-50
CONTENTS
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage7-51
Replace Pilot Circuit Accumulator7-52
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage (Option)7-52
Check Gas Pressure in Ride Control Accumulator
(Option)7-52
Check Hoses and Lines7-53
E Fuel System7-58
Check Fuel Level7-58
Drain Water and Sediment from Fuel Tank7-60
Drain Fuel Filter7-61
Replace Fuel Main Filter Element7-62
Replace Fuel Pre-Filter Element7-63
Clean Fuel Pump Strainer7-64
Check Fuel Hoses7-65
F Air Cleaner7-66
Clean and Replace Air Cleaner Element7-66
Dust Ejection Valve7-67
Check Air Inlet System7-68
G Cooling System7-69
Check Coolant Level7-70
Check Drive Belt7-71
Check and Adjust Drive Belt Tension 7-71
Change Coolant7-72
Clean Radiator/Oil Cooler Cores and Other Cooling
System7-73
H Electrical System7-74
Batteries7-74
Replace Batteries7-78
Check Monitor Functions and All Other Instrument
Operation7-78
Check Work Lights7-79
Check Horn and Reverse Buzzer7-79
Check Electrical Harnesses and Fuses7-80
Fuse Box A7-81
Fuse Box B7-81
I Brake System7-82
Check Right and Left Brake Interlocking
Performance7-82
Check Parking Brake Force7-83
Check Accumulator Function, Gas Leakage,
Looseness, and Damage7-84
Check Gas Pressure in Accumulator7-85
Check Brake Disks (Service and Parking)7-85
J Tire7-86
Check and Replace Tire (Tire Pressure)7-86
Check Tire for Damage7-86
Check Wheel Bolt Torque7-87
K Air Conditioner7-92
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters7-92
Check Air Conditioner7-95
Check Air Conditioner Piping7-95
Check Air Conditioner Condenser7-96
Check Air Conditioner Compressor Belt7-96
Check Refrigerant7-97
Check Compressor and Pulley7-97
L Miscellaneous7-99
Check Bucket Teeth and Cutting Edge7-99
Check and Replace Seat Belt and Lower Tether7-100
Check ROPS cab, Resin Cab Roof, and Roof
Mounting Bolts7-100
Check Windshield Washer Fluid Level7-100
Check Play Amount in Steering Wheel Movement7-101
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise7-102
Check Rearview Mirror and Inside Rearview
Mirror7-103
Check Steps and Handrails for Damage and
Looseness7-103
Clean Engine Compartment and Hood7-104
Check Sound Absorbing Mat Around Engine7-104
Check and Adjust Valve Clearance7-104
Retighten Front Axle and Rear Axle Support
Mounting Bolts7-105
Tightening and Retightening Torque of Nuts and
Bolts7-106
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
TROUBLESHOOTING 11-1
Troubleshooting11-1
SPECIFICATIONS 12-1
Specifications12-1
OTHER ATTACHMENTS AND DEVICE 13-1
Quick Coupler13-1
How to Use Hydraulic Loader Coupler13-1
General Maintenance13-4
INDEX 14-1