KCM 80Z7B WHEEL LOADER CUMMINS QSB6.7 Engine OPERATION & MAINTENANCE MANUAL – PDF

Language : English
Pages : 425
Downloadable : Yes
File Type : PDF

MACHINE NUMBERS 1
Aftertreatment Device2
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 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 SeatS-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 BeforehandS-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 SafelyS-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 TippingS-17
Never Undercut a High Bank S-18
Dig with CautionS-18
Perform Truck Loading Safely S-18
Avoid Power LinesS-19
Precautions for OperationS-19
Precautions for Lightning S-19
Object HandlingS-20
Protect Against Flying Debris S-20
Park Machine SafelyS-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 WorkS-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 BurnsS-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 FumesS-31
Precautions for Welding and GrindingS-31
Avoid Heating Near Pressurized Fluid Lines S-31
Avoid Applying Heat to Lines Containing Flammable
FluidsS-32
Precautions for Handling Accumulator and Gas Damper
S-32
Precautions for Diesel Exhaust Fluid (DEF) S-32
Remove Paint Before Welding or HeatingS-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 ProperlyS-35
Notes for Aftertreatment Device S-36
Precautions for Communication TerminalS-36
Precaution for Communication Terminal Equipment
(Option) S-37
Articulation Stopper (Lock Bar) S-38
SAFETY LABELS S-39
COMPONENTS NAME 1-1
Components Name 1-1
OPERATOR’S STATION 1-3
Aftertreatment Device 1-3
Automatic regeneration 1-5
Repeated inhibiting of aftertreatment device
cleaning1-6
Cab Features1-7
Front Console 1-8
Right Console 1-9
Fingertip Control Type 1-9
Multi-Function Joystick Type 1-10
Monitor Panel1-11
Parking Brake Indicator (Red)1-12
Brake Oil Low Pressure Indicator (Red) 1-12
Hydraulic Oil Level Indicator (Red)1-12
Low Steering Oil Pressure Indicator (Red) (Option) 1-13
Transmission Warning Indicator (Red) 1-13
Communication Error Indicator (Yellow)1-13
Discharge Warning Indicator (Red) 1-13
Engine Warning Indicator (Red) 1-14
Overheat Indicator (Red)1-14
Engine Oil Low Pressure Indicator (Red) 1-14
Air Filter Restriction Indicator (Red) 1-15
Preheat Indicator (Yellow) 1-15
Coolant Temperature Gauge 1-16
Fuel Gauge1-16
Turn Signal Indicator (Green) 1-17
High Beam Indicator (Blue) 1-17
Work Light Indicator (Yellow) 1-17
Clearance Light Indicator (Green) 1-18
CONTENTS
Control lever lock indicator (Red) 1-18
Multi Function Monitor1-19
Default Setting 1-20
Basic Screen 1-21
How to Use Screens 1-22
Displaying Basic Screen1-22
Monitor Operation1-26
Alarm Occurrence Screen 1-27
Remedy1-29
DEF/SCR System Alarm 1-31
DEF/AdBlue® Level Alarm 1-31
Urea SCR System Malfunction1-32
Aftertreatment Device Regeneration1-33
Aftertreatment Device Regeneration Status Display
1-33
Automatic regeneration (Auto-regeneration)1-34
Manual Regeneration 1-35
Main Menu1-36
Ride Control Drive Speed Setting (Option) 1-37
Dual Lift Arm Auto-Leveler 1-38
Height Kickout ON/OFF, Stop Height Setting 1-39
Lower Kickout ON/OFF, Stop Height Setting 1-40
Brightness Adjustment 1-41
Mail (Option) 1-43
Setting Menu 1-45
Date and Time 1-46
Time adjustment 1-46
Date Adjustment 1-48
Display Mode Setting 1-50
Auto Idling Stop 1-52
Auto idling stop: ON/OFF1-52
Acting Time Setting 1-53
Rear View Camera Monitor 1-54
Aftertreatment Device Regeneration Inhibit 1-56
Setting Procedure 1-56
Transmission Setting 1-58
Shift Change Delay Mode Setting 1-58
Parallel/Tandem Switching Height Setting 1-60
Warm Up Operation1-62
Display Item Selection 1-64
Main Menu Display Order Change1-66
Information Menu 1-68
Operation Condition 1-69
Fuel Consumption 1-69
Maintenance 1-71
Maintenance Notice 1-71
Time Remains and Maintenance Interval1-73
Troubleshooting 1-75
Monitoring1-77
Switches, Steering Wheel and Pedals 1-79
Hazard Switch1-80
Work Light Switch 1-81
Parking Brake Switch 1-82
Neutral Lever Lock (for the Forward/Reverse Lever) 1-83
Steering Wheel 1-83
Horn Switch 1-83
Key Switch 1-84
Turn Signal Lever1-85
Light Switch 1-86
High-Low Beam Switch1-87
Accelerator Pedal1-88
Brake Pedal 1-88
Service Brake 1-88
Declutch Brake 1-88
Forward/Reverse Lever/ Shift Switch 1-89
Forward/Reverse Lever 1-89
Shift Switch 1-89
Wiper Switch 1-90
Wiper Operation 1-90
Front/Rear Wiper Switch 1-91
Tilt, Telescopic Lever/Steering Column Tilt Pedal 1-92
Right Console / Switches1-93
Fingertip Control Type 1-93
Loading Control Levers1-94
Right Console / Switches1-96
Multi-Function Joystick Type 1-96
Loading Multi-Function Joystick Lever (Option) 1-97
Auxiliary Control Lever (Option) 1-98
Armrest Adjust Handle 1-98
Forward/Reverse Selector Switch 1-99
Operational Procedure 1-99
Loading Control Lever Lock Switch 1-100
Declutch Position Switch 1-100
Travel Mode Selector Switch1-101
Power Mode Selector Switch 1-102
Fan Reverse Rotation Switch1-103
OFF 1-103
AUTO 1-103
Manual Operation1-104
Hydraulic Coupler Switch (Option)1-104
Secondary Steering Operation Check Switch (Option)
1-105
Aftertreatment Device Regeneration Switch 1-105
1st Speed Fixed Switch 1-106
Ride Control Switch (Option) 1-107
AUTO1-107
OFF 1-107
Hold Switch 1-108
Right Console Slide Lever1-108
Quick Power Switch 1-109
DSS (Down Shift Switch) 1-110
Horn Switch 1-110
Cigar Lighter (24 V DC Electrical Outlet) 1-111
Using Cigar Lighter 1-111
Ash Tray 1-111
Auto Air Conditioner1-112
Feature1-112
Components Name1-113
Controller Part Name and Function 1-114
Cab Heater Operation 1-116
Cooling Operation 1-117
Defroster Operation 1-118
Cool Head/Warm Feet Operation 1-118
CONTENTS
Tips for Optimal Air Conditioner Usage1-119
For Rapid Cooling1-119
When Windows Become Fogged 1-119
Off-Season Air Conditioner Maintenance1-119
Adjusting Operator’s Seat (Air Suspension Type Seat)
1-120
Components Name1-120
Rear Tray 1-121
Electric Power Output (12 VDC Electrical Outlet)1-121
Fuse Box1-122
Fuse Box A 1-123
Fuse Box B1-123
Hot/Cool Box1-124
Tray and Drink Holder 1-124
ROPS Cab 1-125
Front Interior Light 1-127
Rear Interior Light 1-127
Sun Visor 1-128
Emergency Exit Hammer 1-128
Coat/Hat Hook1-128
Upper Switch Panel (Option)1-129
Rotary Light Switch (Option)1-129
Outside Rear View Mirror 1-130
Inside Rear View Mirror 1-130
Cab Door 1-130
Door Lock Knob1-131
Door Open/Close Lever 1-131
Window Open/Close Levers 1-131
When Fully Opening the Door1-132
Cab Door Release Lever1-132
Battery Disconnect Switch 1-133
Switch Operation 1-134
Articulation Stopper (Lock Bar) 1-135
Towing Pin 1-136
Inspection/Maintenance Side Access Cover 1-137
Rear Grille1-138
Steps1-139
Tool Box 1-139
Vandal-Resistant Devices1-140
Seat Belt1-142
Seat Pocket1-142
BREAK-IN 2-1
Break-in Period for New Machine 2-1
Work Mode for Break-in 2-1
OPERATING THE ENGINE 3-1
Inspect Machine Daily Before Starting 3-1
Check Before Starting3-3
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 4-7
Drive Speed Change 4-8
Changing Forward/Reverse Drive Direction4-8
Steering Wheel 4-9
Secondary Steering (Option) 4-10
Emergency Stop and Restart of Operation 4-11
Precautions for Driving on Slopes 4-14
Precautions to be Taken if Machine Failure Occurs 4-15
Stop 4-16
Parking 4-18
Emergency Stopping 4-19
OPERATING THE MACHINE 5-1
Loading Control Levers5-1
Control Lever Lock5-4
Declutch Position Switch5-5
Adjustment of Bucket Auto Leveler 5-6
Adjustment of Dual Lift Arm Auto Leveler5-8
Auto Idling Stop 5-9
Aftertreatment Device Manual Regeneration 5-11
Before Operation5-14
Precautions for Operation 5-14
Ensure Safety When Operating on Road Shoulders5-14
Avoid Overloading5-14
Avoid Rapid Steering Changes and/or Sudden Braking
5-14
Avoid Operation with Loads on Only One Side5-14
Excavation 5-15
Grading5-17
Loading5-18
Dozing 5-21
Stock Piling 5-21
Removing Snow 5-22
Lifting Wheel Loader 5-22
Precautions for After Operation 5-23
TRANSPORTING6-1
Transporting by Road6-1
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 Method6-9
Lifting Machine6-10
MAINTENANCE 7-1
Correct Maintenance and Inspection Procedures 7-1
Check the Hour Meter Regularly 7-3
Layout7-4
Preparations for Inspection and Maintenance 7-8
Articulation Lock7-10
Inspection/Maintenance Access Side Cover7-11
Rear Grille 7-12
Inspection and Maintenance Table 7-13
Kind of Oils7-17
CONTENTS
List of Consumable Parts7-21
AGreasing7-23
BEngine 7-31
Check Engine Oil Level 7-31
Change Engine Oil 7-32
Replace Engine Oil Filter 7-34
Check Crankcase Breather Tube7-35
Replace Crankcase Air Breather Element7-36
Check Vibration Damper 7-38
CPower Train7-39
Check Transmission Oil Level 7-39
Change Transmission Oil and Transmission Oil Filter
7-40
Change Axle Oil7-43
Check Oil Level 7-43
Check Surroundings Around Axle and Covers for Oil
Leaks7-45
Clean Axle Housing Air Breather 7-45
DHydraulic System 7-46
Inspection and Maintenance of Hydraulic Equipment
7-46
Check Hydraulic Oil Level 7-48
Change Hydraulic Oil/Clean Hydraulic Oil Tank7-49
Clean Suction Filter 7-51
Replace Pilot Oil Filter7-52
Replace Hydraulic Tank Oil Filter 7-54
Replace Air Breather Element 7-56
Check Pilot Circuit Accumulator Function, Gas Leakage,
Looseness, and Damage 7-57
Replace Pilot Circuit Accumulator 7-58
Check Ride Control Accumulator Function, Gas Leakage,
Looseness, and Damage 7-58
Check Gas Pressure in Ride Control Accumulator 7-58
Check Gas Pressure in Steering Accumulator 7-58
Check Hoses and Lines 7-59
EFuel System7-64
Check Fuel Level 7-64
About Biodiesel Fuel7-64
Refueling 7-65
Drain Water and Sediment from Fuel Tank7-66
Drain Fuel Filter 7-67
Bleed Air from the Fuel System 7-67
Replace Fuel Main Filter Element7-68
Replace Fuel Pre-Filter Element7-69
Clean Fuel Solenoid Pump Strainer 7-70
Check Fuel Hoses7-72
FAir Cleaner7-73
Replace Air Cleaner Element 7-73
Check Air Inlet System7-74
GCooling System 7-75
Check Coolant Level7-76
Check Drive Belt 7-77
Check Drive Belt Tensioner7-78
Change Coolant7-79
Clean Radiator/Oil Cooler and Other Cooling System
7-80
HElectrical System 7-81
Batteries 7-81
If you spill acid on yourself, call 911, then:7-82
If acid is swallowed, call 911, then:7-82
Check Monitor Functions and All Other Instrument
Operation7-85
Check Work Lights 7-86
Check Horn and Backup Alarm 7-86
Check Electrical Harnesses and Fuses7-87
Fuse Box A 7-88
Fuse Box B 7-88
IBrake System 7-89
Check Right and Left Brake Interlocking Performance
7-89
Check Parking Brake Force7-90
Check Accumulator Function, Gas Leakage, Looseness,
and Damage 7-91
Check Gas Pressure in Accumulator 7-92
Check Brake Disks (Service and Parking) 7-92
JTire7-93
Check and Replace Tire (Tire Pressure) 7-93
Check Tire for Damage 7-93
Check Wheel Bolt Torque7-94
KAir Conditioner 7-99
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters7-99
Check Air Conditioner 7-103
Check Air Conditioner Piping 7-103
Check Air Conditioner Condenser 7-104
Check Air Conditioner Drive Belt 7-104
Check Refrigerant7-105
Replace Air Conditioner Receiver Dryer7-105
Check Compressor and Pulley 7-105
LMiscellaneous7-106
Check Bucket Teeth and Cutting Edge7-106
Check and Replace Seat and Seat Belt7-107
Check ROPS cab, Resin Cab Roof, and Roof Mounting
Bolts7-107
Check Windshield Washer Fluid Level 7-107
Check Play Amount in Steering Wheel Movement
7-108
Check Accelerator Pedal Operation, and Exhaust Gas
Color and Noise 7-109
Check Rearview Mirror and Inside Rearview Mirror
7-110
Check Steps and Handrails for Damage and
Looseness 7-110
Clean Engine Compartment and Hood 7-111
Check Sound Absorbing Mat Around Engine 7-111
Cleaning of Rear View Camera Lens 7-111
Check and Adjust Valve Clearance 7-112
Retighten Front Axle and Rear Axle Support Mounting
Bolts7-112
Tightening and Retightening Torque of Nuts and
Bolts7-113
MAftertreatment Device7-124
Check and Clean Aftertreatment Device 7-124
CONTENTS
NUrea SCR System7-125
Check DEF/AdBlue®7-127
Refill DEF/AdBlue® 7-127
Change DEF/AdBlue® 7-129
Replace DEF/AdBlue® Supply Module Main Filter 7-130
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS 9-1
Maintenance Under Special Environmental Conditions
9-1
Precautions for Maintenance During Cold Weather
Season9-2
STORAGE10-1
Storing the Machine10-1
PRECAUTION ITEMS FOR LONG-TIME STORAGE 10-1
TROUBLESHOOTING11-1
Troubleshooting 11-1
SPECIFICATIONS12-1
Specifications 12-1
Intended Use 12-1
INDEX14-1