KCM 90Z7/92Z7 Wheel Loader HINO E13C-VV Engine OPERATION & MAINTENANCE Manual PDF

Language : English
Pages : 413
Downloadable : Yes
File Type : PDF

MACHINE NUMBERS 1
SAFETYS-1
Recognize Safety InformationS-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 Attachment S-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 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 MachineS-12
Drive Safely S-12
Drive Machine Safely (Work Site)S-13
Drive Safely with Bucket LoadedS-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 SafelyS-18
Avoid Power Lines S-19
Precautions for Operation S-19
Precautions for Lightning S-19
Object Handling S-20
Protect Against Flying DebrisS-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 ProperlyS-25
Stay Clear of Moving PartsS-26
Support Maintenance ProperlyS-26
Prevent Parts from Flying S-27
Prevent Burns S-27
Replace Rubber Hoses Periodically S-28
Avoid High-Pressure Fluids S-28
Prevent FiresS-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 LinesS-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 FilterS-36
Precautions for Communication Terminal S-36
Precaution for Communication Terminal Equipment
(Option)S-37
Articulation Stopper (Lock Bar)S-38
Joystick Steering System ON/OFF (Option) S-39
SAFETY LABELSS-40
COMPONENTS NAME 1-1
Components Name 1-1
OPERATOR’S STATION1-3
Exhaust Filter1-3
Diesel Particulate Filter (DPF, Exhaust Filter)1-4
Description of DPF functions 1-4
Automatic regeneration 1-5
Repeated inhibiting of exhaust filter cleaning 1-6
Cab Features 1-7
Front Console 1-8
Joystick Steering (Option) 1-9
Right Console 1-10
Fingertip Control Type1-10
Multi-Function Joystick Type1-11
Monitor Panel 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 (Option) (Red) 1-14
Transmission Warning Indicator (Red)1-14
Communication Error Indicator (Yellow) 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
Air Filter Restriction Indicator (Red) 1-16
Preheat Indicator (Yellow) 1-16
Coolant Temperature Gauge1-17
Fuel Gauge 1-17
Turn Signal Indicator (Green) 1-18
High Beam Indicator (Blue)1-18
CONTENTS
Work Light Indicator (Yellow) 1-18
Clearance Light Indicator (Green) 1-18
Control lever lock indicator (Red)1-18
Multi Function Monitor 1-19
Default Setting 1-20
Basic Screen 1-21
How to Use Screens 1-22
Displaying Basic Screen 1-22
Monitor Operation 1-26
Alarm Occurrence Screen1-27
Remedy 1-29
Exhaust Filter Regeneration 1-32
Exhaust Filter Status Display 1-32
Automatic regeneration (Auto-regeneration) 1-32
Manual Regeneration 1-34
Service Regeneration 1-34
Main Menu 1-35
Ride Control Drive Speed Setting (Option)1-36
Dual Lift Arm Auto-Leveler1-37
Height Kickout ON/OFF, Stop Height Setting 1-38
Lower Kickout ON/OFF, Stop Height Setting1-39
Brightness Adjustment 1-40
Mail (Option)1-42
Setting Menu 1-44
Date and Time 1-45
Time adjustment 1-45
Date Adjustment 1-47
Display Mode Setting 1-49
Auto Idling Stop1-51
Auto idling stop: ON/OFF 1-51
Acting Time Setting 1-52
Rear View Camera Monitor1-53
Exhaust Filter Regeneration Inhibited1-55
Setting Procedure1-55
Transmission Setting1-57
Shift Change Delay Mode Setting 1-57
Parallel/Tandem Switching Height Setting1-59
Warm Up Operation 1-61
Display Item Selection1-63
Main Menu Display Order Change 1-65
Information Menu 1-67
Operation Condition1-68
Fuel Consumption 1-68
Maintenance1-70
Maintenance Notice 1-70
Time Remains and Maintenance Interval 1-72
Troubleshooting 1-74
Monitoring 1-76
Front Console Switches, Pedals, Steering Wheel, and
Joystick Steering (Option)1-78
Hazard Switch 1-79
Work Light Switch 1-80
Parking Brake Switch1-81
Neutral Lever Lock (for the Forward/Reverse Lever)1-82
Steering Wheel 1-82
Horn Switch 1-82
Key Switch 1-83
Joystick Steering (Option) 1-84
Turn Signal Lever 1-85
Turn Signal Switch (Option) 1-85
Light Switch 1-86
High-Low Beam Switch 1-87
Accelerator Pedal 1-87
Brake Pedal1-88
Service Brake1-88
Declutch Brake1-88
Forward/Reverse Lever/ Shift Switch 1-89
Forward/Reverse Lever 1-89
Shift Switch1-89
Tilt, Telescopic Lever/Steering Column Tilt Pedal1-90
Wiper Switch1-90
Wiper Operation1-90
Front/Rear Wiper Switch1-91
Right Console / Switches 1-92
Fingertip Control Type1-92
Loading Control Levers 1-93
Right Console / Switches 1-95
Multi-Function Joystick Type1-95
Loading Multi-Function Joystick Lever (Option) 1-96
Auxiliary Control Lever (Option) 1-97
Forward/Reverse Selector Switch1-98
Operational Procedure1-98
Loading Control Lever Lock Switch 1-99
Declutch Position Switch 1-99
Travel Mode Selector Switch 1-100
Power Mode Selector Switch1-100
Fan Reverse Rotation Switch 1-102
OFF 1-102
AUTO1-102
Manual Operation1-103
Hydraulic Coupler Switch (Option) 1-103
Secondary Steering Operation Check Switch
(Option) 1-104
Exhaust Filter Switch 1-104
Ride Control Switch (Option)1-105
AUTO1-106
OFF 1-106
Hold Switch1-107
Right Console Slide Lever 1-107
Quick Power Switch1-108
DSS (Down Shift Switch)1-109
Horn Switch 1-109
Cigar Lighter (24 V DC Electrical Outlet)1-110
Using Cigar Lighter 1-110
Ash Tray 1-110
Auto Air Conditioner 1-111
Feature 1-111
Components Name 1-112
Controller Part Name and Function1-113
Cab Heater Operation 1-115
Cooling Operation1-116
Defroster Operation1-117
CONTENTS
Cool Head/Warm Feet Operation 1-117
Tips for Optimal Air Conditioner Usage 1-118
For Rapid Cooling 1-118
When Windows Become Fogged 1-118
Off-Season Air Conditioner Maintenance 1-118
Adjusting Operator’s Seat (Air Suspension Type
Seat)1-119
Components Name 1-119
Rear Tray1-120
Electric Power Output (Option) 1-120
Fuse Box 1-121
Fuse Box A1-122
Fuse Box B 1-122
Hot/Cool Box 1-123
Tray and Drink Holder 1-123
ROPS Cab 1-124
Front Interior Light 1-126
Rear Interior Light1-126
Sun Visor1-127
Emergency Exit Hammer 1-127
Coat/Hat Hook 1-127
Upper Switch Panel (Option) 1-128
Rotary Light Switch (Option) 1-128
Outside Rear View Mirror 1-129
Inside Rear View Mirror 1-129
Cab Door1-129
Door Lock Knob 1-130
Door Open/Close Lever 1-130
Window Open/Close Levers 1-130
When Fully Opening the Door 1-131
Cab Door Release Lever 1-131
Battery Disconnect Switch 1-132
Switch Operation 1-133
Articulation Stopper (Lock Bar) 1-134
Towing Pin 1-135
Inspection/Maintenance Side Access Cover 1-136
Rear Grille 1-137
Steps1-138
Tool Box 1-138
Vandal-Resistant Devices1-139
BREAK-IN2-1
Break-in Period for New Machine2-1
Work Mode for Break-in2-1
OPERATING THE ENGINE 3-1
Inspect Machine Daily Before Starting 3-1
Check Before Starting 3-3
Starting Engine 3-6
Starting in Cold Weather3-8
Preheating 3-8
Check After Starting 3-9
Using Booster Batteries 3-10
Warm Up 3-12
Cold Weather Warm Up 3-13
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
Shift Range of Auto Transmission4-5
Power Mode Selector 4-6
Shift Change Delay Mode4-6
Parking Brake Switch4-7
Drive Speed Change 4-8
Changing Forward/Reverse Drive Direction 4-8
Steering 4-9
Joystick Steering (Option) 4-10
Secondary Steering (Option) 4-11
Emergency Stop and Restart of Operation4-11
Precautions for traveling 4-12
Operating in Water or on Soft Ground4-13
Precautions for Driving on Slopes 4-14
Precautions to be Taken if Machine Failure Occurs4-15
Stop 4-16
Parking 4-18
Emergency Stopping 4-19
OPERATING THE MACHINE 5-1
Loading Control Levers 5-1
Fingertip Control Type5-1
Loading Multi-Function Joystick Lever (Option) 5-3
Control Lever Lock 5-4
Declutch Position Switch 5-5
Adjustment of Bucket Auto Leveler 5-6
Adjustment of Dual Lift Arm Auto Leveler 5-8
Auto Idling Stop5-9
Auto Idling Stop Operating condition5-10
Exhaust Filter Manual Regeneration5-11
Manual Regeneration Procedure 5-11
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
Braking5-14
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 Method5-18
Loader and Dump Truck Combination Method 5-19
V-Shape Loading 5-19
I-Shape Loading5-19
Dumping into Truck or Hopper 5-20
Dozing5-21
Stock Piling5-21
Removing Snow5-22
Lifting Wheel Loader5-22
Precautions for After Operation5-23
CONTENTS
TRANSPORTING 6-1
Transporting by Road 6-1
Selecting a Trailer6-1
Loading / Unloading on Trailer 6-2
Fastening Machine for Transporting6-4
Transporting Wheel Loader (Urgent Situation) 6-5
Precautions for Driving On Roads6-5
Precautions for Towing 6-6
Releasing Parking Brake6-7
Towing Method 6-9
Lifting Machine 6-10
MAINTENANCE7-1
Correct Maintenance and Inspection Procedures 7-1
Check the Hour Meter Regularly 7-3
Layout 7-4
Lubrication Guide7-5
Preparations for Inspection and Maintenance 7-7
Articulation Lock7-9
Inspection/ Maintenance Side Access Cover 7-10
Rear Grille7-11
Inspection and Maintenance Table7-13
Kind of Oils 7-17
Recommended Grease 7-17
Recommended Engine Oil 7-17
Recommended Transmission Oil 7-18
Recommended Axle Oil 7-18
Recommended Hydraulic Oil 7-19
Recommended Coolant7-19
AGreasing 7-20
BEngine 7-25
Check Engine Oil Level 7-25
Change Engine Oil 7-26
Replace Engine Oil Filter7-28
CPower Train 7-29
Check Transmission Oil Level7-29
Change Transmission Oil 7-30
Change Transmission Oil Filter7-30
Clean Transmission Strainer 7-30
Clean Torque Converter Air Breather7-33
Check Axle Oil Level 7-34
Change Axle Oil 7-36
Check Surroundings Around Axle and Covers for
Oil Leaks 7-38
Clean Axle Housing Air Breather 7-39
DHydraulic System 7-40
Check Hydraulic Oil Level7-42
Change Hydraulic Oil7-43
Clean Suction Filter7-45
Clean Pilot Oil Filter7-46
Line Filter in Brake Circuit 7-46
Line Filter in Steering Circuit 7-47
Replace Hydraulic Oil Return Filter 7-48
Replace Air Breather Element 7-49
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage 7-50
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage (Option) 7-51
Check Gas Pressure in Ride Control Accumulator
(Option) 7-51
Check Gas Pressure in Steering Accumulator 7-51
Check Hoses and Lines 7-52
EFuel System 7-57
Check Fuel Level7-57
Drain Water and Sediment from Fuel Tank 7-59
Drain Fuel Filter 7-60
Draining Procedures (Main Filter) 7-60
Draining Procedures (Pre-Filter) 7-61
Bleed Air from the Fuel System7-62
Replace Fuel Main Filter Element 7-64
Replace Fuel Pre-Filter Element 7-65
Clean Fuel Pump Strainer 7-66
Check Fuel Hoses 7-67
Check Water Separator (Option)7-68
FAir Cleaner 7-70
Clean and Replace Air Cleaner Element7-70
GCooling System 7-71
Check Coolant Level 7-72
Check Drive Belt7-73
Change Coolant 7-74
Clean Radiator/Oil Cooler Cores and Other Cooling
System 7-75
HElectrical System7-76
Batteries7-76
Electrolyte Level Check7-78
Check Electrolyte Specific Gravity7-79
Replace Batteries 7-80
Check Monitor Functions and All Other Instrument
Operation 7-80
Check Work Lights 7-81
Check Horn and Backup Alarm 7-81
Check Electrical Harnesses and Fuses 7-82
Fuse Box A 7-83
Fuse Box B7-83
IBrake System7-84
Check Right and Left Brake Interlocking
Performance 7-84
Check Parking Brake Force 7-85
Check Accumulator Function, Gas Leakage,
Looseness, and Damage7-86
Check Gas Pressure in Accumulator 7-87
Check Brake Disks (Service and Parking) 7-87
JTire 7-88
Check and Replace Tire (Tire Pressure)7-88
Check Tire for Damage7-89
Check Wheel Bolt Torque 7-89
KAir Conditioner7-93
Clean/Replace Air Conditioner Circulation/Fresh
Air Filters7-93
Check Air Conditioner 7-96
Check Air Conditioner Piping 7-96
Check Air Conditioner Condenser 7-97
CONTENTS
Check Air Conditioner Fan Belt 7-97
Check Refrigerant7-98
Check Compressor and Pulley 7-98
Replace Air Conditioner Receiver Dryer7-98
LExhaust Filter 7-99
Check and Clean Filter Element of Exhaust Filter 7-99
Check and Clean Exhaust Filter 7-99
MMiscellaneous 7-100
Check Bucket Teeth and Cutting Edge 7-100
Check and Replace Seat Belt and Lower Tether 7-101
Check ROPS cab, Resin Cab Roof, and Roof
Mounting Bolts 7-101
Check Windshield Washer Fluid Level 7-102
Check Play Amount in Steering Wheel Movement 7-102
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise7-103
Check Rearview Mirror and Inside Rearview
Mirror 7-104
Check Steps and Handrails for Damage and
Looseness 7-104
Clean Engine Compartment and Hood 7-105
Check Sound Absorbing Mat Around Engine 7-105
Check Engine Manifold7-105
Check and Adjust Valve Clearance7-105
Check Engine Compression Pressure7-106
Check and Clean Starter and Alternator 7-106
Check Turbocharger Bearing 7-106
Retighten Front Axle and Rear Axle Support
Mounting Bolts 7-106
Check Tightening Torque of Nuts and Bolts7-107
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS9-1
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
Specifications 12-1
INDEX 14-1