KCM 70Z7 Wheel Loader CUMMINS QSB6.7 Engine Operation & Maintenance Manual SN 70C6-5001 and up PN 93108-00690

MACHINE NUMBERS1
SAFETYS-1
Recognize Safety Information S-1
Understand Signal WordsS-1
Follow Safety Instructions S-2
Prepare for Emergencies S-3
Wear Protective Clothing S-3
Protect Against Noise S-4
Inspect Machine S-4
General Precautions for Cab S-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
SeatS-7
Fasten Your Seat Belt S-7
Move and Operate Machine Safely S-8
Handle Starting Aids SafelyS-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 SafelyS-14
Travel on Public Roads Safely S-15
Avoid Injury from Rollaway AccidentsS-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 SafelyS-18
Avoid Power Lines S-19
Precautions for Operation S-19
Precautions for LightningS-19
Object Handling S-20
Protect Against Flying DebrisS-20
Park Machine Safely S-21
Store Attachments SafelyS-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 FlyingS-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 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
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 Name 1-1
GETTING ON/OFF THE MACHINE 1-3
Getting ON/OFF the Machine1-3
OPERATOR’S STATION1-4
Cab Features 1-4
Front Console 1-5
Right Console 1-6
Fingertip Control Type1-6
Multi-Function Joystick Type1-7
Monitor Panel 1-8
Service Indicator 1-9
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) 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
Low Steering Oil Pressure Indicator (Optional)1-13
Secondary Steering Indicator (Yellow)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 Gauge 1-16
Fuel Gauge 1-16
Transmission Oil Temperature Gauge 1-16
Turn Signal Indicator (Green) 1-17
CONTENTS
High Beam Indicator (Blue) 1-17
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 Indicator 1-19
Forward/Reverse Selector Switch Indicator (Green) 1-19
Fan Reverse Rotation Indicator (Green)1-19
Monitor Display1-20
Forward/Reverse and Shift Position Indicator 1-21
FNR (Forward/Reverse) Position Indicator1-21
Hold Indicator 1-22
Shift Position Indicator 1-22
Speedometer 1-23
Ride Control Indicator 1-24
ECO Indicator 1-24
Machine Information Display 1-25
Shifting Item to be Indicated on Machine
Information Display1-26
Resetting of Oil Change and Filter Replacement
Intervals 1-30
Clock Setting Mode 1-39
Switches, Steering Wheel and Pedals 1-40
Hazard Switch 1-41
Work Light Switch 1-42
Parking Brake Switch 1-43
Neutral Lever Lock (for the Forward/Reverse Lever) 1-44
Steering Wheel 1-44
Key Switch 1-45
Turn Signal Lever 1-46
Light Switch 1-47
High-Low Beam Switch 1-48
Accelerator Pedal 1-49
Brake Pedal1-49
Service Brake 1-49
Declutch Brake1-49
Forward/Reverse Lever/ Shift Switch 1-50
Forward/Reverse Lever1-50
Shift Switch 1-50
Wiper Switch 1-51
Wiper Operation 1-51
Front/Rear Wiper Switch 1-52
Tilt, Telescopic Lever/Steering Column Tilt Pedal1-53
Travel Mode Selector 1-54
Declutch Position Switch 1-55
Auto Idling Stop Switch1-56
Shift Change Delay Mode Switch 1-57
Right Console / Switches 1-58
Fingertip Control Type 1-58
Loading Control Levers 1-59
Right Console / Switches 1-61
Multi-Function Joystick Type 1-61
Loading Multi-Function Joystick Lever (Optional) 1-62
Auxiliary Control Lever (Option)1-63
Forward/Reverse Selector Switch 1-64
Operational Procedure 1-64
Control Lever Lock Switch1-65
1st Speed Fixed Switch 1-66
Power Mode Selector 1-67
Fan Reverse Rotation Switch 1-68
OFF 1-68
AUTO 1-68
Manual Operation 1-69
Secondary Steering Operation Check Switch
(Optional) 1-70
Ride Control Switch (Optional) 1-71
AUTO1-72
OFF 1-72
Hold Switch 1-73
Horn Switch 1-74
Dual Lift Arm Auto Leveler Switch1-75
Lower Kickout Setting/Height Kickout Setting 1-75
Quick Power Switch1-76
DSS (Down Shift Switch) 1-77
Armrest Adjust Handle 1-78
Cigar Lighter (24 VDC Electrical Outlet) 1-79
Using Cigar Lighter1-79
Using 24 VDC Electrical Power Supply 1-79
Ash Tray 1-79
Auto Air Conditioner 1-80
Feature 1-80
Auto Air Conditioner 1-81
Components Name 1-81
Controller Part Name and Function1-82
Controller Part Name and Function1-84
Defroster Operation 1-86
Cool Head/Warm Feet Operation 1-86
Tips for Optimal Air Conditioner Usage 1-87
For Rapid Cooling 1-87
When Windows Become Clouded 1-87
Off-Season Air Conditioner Maintenance 1-87
Adjusting Operator’s Seat (Air Suspension Type Seat) 1-88
Components Name 1-88
Rear Tray 1-89
Electric Power Output (Optional) 1-89
Fuse Box 1-90
Fuse Box A1-91
Fuse Box B 1-91
Hot/Cool Box 1-92
Tray and Drink Holder1-92
ROPS Cab1-93
Front Interior Light 1-95
Rear Interior Light 1-95
Sun Visor 1-96
Emergency Exit Hammer 1-96
Coat/Hat Hook 1-96
Upper Switch Panel (Optional) 1-97
Rotary Light Switch (Optional) 1-97
Outside Rear View Mirror 1-98
Inside Rear View Mirror 1-98
Cab Door 1-98
Door Lock Knob 1-99
CONTENTS
Door Open/Close Lever 1-99
Window Open/Close Levers1-99
When Fully Opening the Door 1-100
Cab Door Release Lever 1-100
Battery Disconnect Switch1-101
Switch Operation 1-102
Articulation Lock Bar1-103
Towing Pin 1-104
Inspection/Maintenance Side Access Cover1-105
Rear Grille 1-106
Steps1-107
Tool Box1-107
Vandal-Resistant Devices 1-108
BREAK-IN 2-1
Break-in Period for New Machine 2-1
Use ECO Mode for Break-in 2-1
OPERATING THE ENGINE3-1
Inspect Machine Daily Before Starting 3-1
Check Before Starting 3-3
Starting Engine 3-5
Starting in Cold Weather 3-7
Check After Starting 3-8
Using Booster Batteries3-9
Warm Up 3-11
Cold Weather Warm Up 3-12
Stopping Engine 3-13
MOVING THE MACHINE 4-1
Driving the Machine 4-1
Starting to Move 4-2
Parking Brake Switch 4-8
Drive Speed Change 4-9
Changing Forward/Reverse Drive Direction 4-9
Steering Wheel 4-10
Secondary Steering (Optional) 4-11
Emergency Stop and Restart of Operation4-12
Precautions for Driving on Slopes 4-15
Precautions to be Taken if Machine Failure Occurs 4-16
Stop the Machine4-17
Parking4-19
Emergency Evacuation 4-20
OPERATING THE MACHINE 5-1
Loading Control Levers5-1
Control Lever Lock 5-4
Declutch Position Switch 5-5
Lift Arm Height Kickout5-6
Adjustment of Loader Front 5-6
Adjustment of Dual Lift Arm Auto Leveler5-7
Adjustment of Bucket Auto Leveler 5-8
Auto Idling Stop 5-10
Before Operation 5-12
Precautions for Operation5-12
Ensure Safety When Operating on Road Shoulders 5-12
Avoid Overloading 5-13
Avoid Rapid Steering Changes and/or Sudden
Braking 5-13
Avoid Operation with Loads on Only One Side5-13
Excavation 5-14
Grading 5-16
Loading 5-17
Dozing 5-20
Stock Piling5-20
Removing Snow 5-21
Lifting Wheel Loader 5-21
Precautions for After Operation 5-22
TRANSPORTING 6-1
Transporting by Road 6-1
Selecting a Trailer 6-1
Loading / Unloading on Trailer 6-2
Fastening Machine for Transporting 6-4
Transporting Wheel Loader (Urgent Situation) 6-5
Towing Method 6-9
Lifting Machine6-10
MAINTENANCE7-1
Correct Maintenance and Inspection Procedures 7-1
Check the Hour Meter Regularly 7-3
Layout 7-4
Preparations for Inspection and Maintenance7-7
Articulation Lock 7-9
Inspection/ Maintenance Access Side Cover 7-10
Rear Grille 7-11
Periodic Replacement of Parts7-12
Inspection and Maintenance Table 7-13
Kind of Oils 7-17
AGreasing 7-20
BEngine 7-25
Check Engine Oil Level7-25
Change Engine Oil7-26
Replace Engine Oil Filter 7-28
Check Crankcase Breather Tube 7-29
Replace Crankcase Air Breather Element 7-30
Check Vibration Dumper 7-32
CPower Train 7-33
Check Transmission Oil Level 7-33
Change Transmission Oil and Transmission Oil
Filter7-34
Change Axle Oil 7-37
Check Surroundings Around Axle and Covers for Oil
Leaks 7-39
Clean Axle Housing Air Breather 7-39
DHydraulic System7-40
Check Hydraulic Oil Level 7-42
Change Hydraulic Oil7-43
Clean Suction Filter 7-45
Replace Pilot Oil Filter7-46
Replace Hydraulic Tank Oil Filter 7-48
Replace Air Breather Element7-50
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage 7-51
CONTENTS
Replace Pilot Circuit Accumulator 7-52
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage 7-52
Check Gas Pressure in Ride Control Accumulator 7-52
Check Hoses and Lines7-53
EFuel System 7-58
Check Fuel Level 7-58
Drain Water and Sediment from Fuel Tank 7-60
Drain Fuel Filter 7-61
Replace Fuel Main Filter Element 7-62
Replace Fuel Pre-Filter Element7-63
Clean Fuel Pump Strainer7-64
Check Fuel Hoses 7-65
FAir Cleaner 7-66
Clean and Replace Air Cleaner Element7-66
Dust Ejection Valve7-67
Check Air Inlet System 7-68
GCooling System 7-69
Check Coolant Level 7-70
Check Drive Belt 7-71
Check and Adjust Drive Belt Tension 7-71
Change Coolant 7-72
Clean Radiator/Oil Cooler Cores and Other Cooling
System 7-73
HElectrical System 7-74
Batteries7-74
Replace Batteries 7-78
Check Monitor Functions and All Other Instrument
Operation7-78
Check Work Lights 7-79
Check Horn and Reverse Buzzer 7-79
Check Electrical Harnesses and Fuses7-80
Fuse Box A7-81
Fuse Box B 7-81
IBrake System 7-82
Check Right and Left Brake Interlocking
Performance 7-82
Check Parking Brake Force 7-83
Check Accumulator Function, Gas Leakage,
Looseness, and Damage7-84
Check Gas Pressure in Accumulator7-85
Check Brake Disks (Service and Parking) 7-85
JTire 7-86
Check and Replace Tire (Tire Pressure) 7-86
Check Tire for Damage 7-86
Check Wheel Bolt Torque7-87
KAir Conditioner7-92
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters 7-92
Check Air Conditioner 7-95
Check Air Conditioner Piping7-95
Check Air Conditioner Condenser 7-96
Check Air Conditioner Compressor Belt7-96
Check Refrigerant 7-97
Check Compressor and Pulley 7-97
LMiscellaneous 7-99
Check Bucket Teeth and Cutting Edge 7-99
Check and Replace Seat Belt and Lower Tether7-100
Check ROPS cab, Resin Cab Roof, and Roof
Mounting Bolts7-100
Check Windshield Washer Fluid Level 7-100
Check Play Amount in Steering Wheel Movement 7-101
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise 7-102
Check Rearview Mirror and Inside Rearview
Mirror 7-103
Check Steps and Handrails for Damage and
Looseness 7-103
Clean Engine Compartment and Hood 7-104
Check Sound Absorbing Mat Around Engine 7-104
Check and Adjust Valve Clearance 7-104
Retighten Front Axle and Rear Axle Support
Mounting Bolts7-105
Tightening and Retightening Torque of Nuts and
Bolts 7-106
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
SPECIFICATIONS 12-1
Specifications12-1
OTHER ATTACHMENTS AND DEVICE 13-1
Quick Coupler 13-1
How to Use Hydraulic Loader Coupler 13-1
General Maintenance 13-4
INDEX 14-1