KCM 95Z7B Wheel Loader ISUZU 6WG1 Engine OPERATION & MAINTENANCE MANUAL PDF

Language : English
Pages : 443
Downloadable : Yes
File Type : PDF

MACHINE NUMBERS1
SAFETYS-1
Recognize Safety Information S-1
Understand Signal WordsS-1
Follow Safety Instructions S-2
Prepare for EmergenciesS-3
Wear Protective ClothingS-3
Protect Against Noise S-4
Inspect Machine S-4
General Precautions for Cab S-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 Belt S-7
Move and Operate Machine SafelyS-8
Handle Starting Aids SafelyS-8
Operate Only from Operator’s Seat S-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 LoadedS-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 TurningS-16
Avoid Positioning Bucket or Attachment Over Anyone
S-17
Avoid Tipping S-17
Never Undercut a High BankS-18
Dig with Caution S-18
Perform Truck Loading SafelyS-18
Avoid Power LinesS-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 SafelyS-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 Properly S-26
Prevent Parts from FlyingS-27
Prevent Burns S-27
Replace Rubber Hoses PeriodicallyS-28
Avoid High-Pressure Fluids S-28
Prevent Fires S-29
Evacuating in Case of FireS-30
Beware of Exhaust Fumes S-31
Precautions for Welding and Grinding S-31
Avoid Heating Near Pressurized Fluid Lines S-31
Avoid Applying Heat to Lines Containing Flammable
Fluids S-32
Precautions for Handling Accumulator and Gas
Damper S-32
Precautions for Diesel Exhaust Fluid (DEF)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 Aftertreatment DeviceS-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 LABELS S-40
COMPONENTS NAME1-1
Components Name 1-1
OPERATOR’S STATION1-3
Aftertreatment Device1-3
Automatic regeneration 1-5
Repeated inhibiting of aftertreatment device cleaning
1-6
Cab Features 1-7
Front Console 1-8
Joystick Steering (Option) 1-9
Right Console1-10
Fingertip Control Type 1-10
Multi-Function Joystick Type 1-11
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 Gauge 1-17
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) 1-19
Control Lever Lock Indicator (Red)1-19
Multi Function Monitor 1-20
Default Setting 1-21
Basic Screen 1-22
How to Use Screens1-23
Displaying Basic Screen 1-23
Monitor Operation1-27
Alarm Occurrence Screen 1-28
Remedy 1-30
DEF/SCR System Alarm1-33
DEF/AdBlue® Level Alarm 1-33
Urea SCR System Malfunction 1-34
Aftertreatment Device Regeneration1-35
Aftertreatment Device Regeneration
Status Display1-35
Automatic regeneration (Auto-regeneration) 1-36
Manual Regeneration 1-37
Main Menu 1-38
Ride Control Drive Speed Setting (Option)1-39
Dual Lift Arm Auto-Leveler1-40
Height/Lower Kickout ON/OFF, Stop Height Setting
1-41
Brightness Adjustment1-42
Mail (Option) 1-44
Setting Menu1-46
Date and Time1-47
Time adjustment1-47
Date Adjustment1-49
Display Mode Setting 1-51
Auto Idling Stop 1-53
Auto idling stop: ON/OFF1-53
Acting Time Setting1-54
Rear View Camera Monitor1-55
Aftertreatment Device Regeneration Inhibited 1-57
Setting Procedure1-57
Transmission Setting1-59
Shift Change Delay Mode Setting 1-59
Lockup Setting1-61
Traction Control Setting1-63
Parallel/Tandem Switching Height Setting1-65
Warm Up Operation 1-67
Display Item Selection 1-69
Main Menu Display Order Change1-71
Information Menu 1-73
Operation Condition1-74
Fuel Consumption 1-74
Maintenance 1-76
Maintenance Notice1-76
Time Remains and Maintenance Interval1-78
Troubleshooting1-80
Monitoring 1-82
Front Console Switches, Pedals, Steering Wheel and
Joystick Steering (Option) 1-85
Hazard Switch 1-86
Work Light Switch 1-87
Parking Brake Switch1-88
Neutral Lever Lock (for the Forward/Reverse Lever)1-89
Horn Switch 1-89
Key Switch1-90
Steering Wheel 1-90
Joystick Steering (Option)1-91
Joystick Steering Lever1-91
Forward/Reverse Switch1-91
Joystick Steering System Switch1-91
Turn Signal Lever 1-92
Light Switch 1-94
High-Low Beam Switch 1-95
Accelerator Pedal 1-95
Brake Pedal1-95
Service Brake 1-95
Declutch Brake1-95
Forward/Reverse Lever and Shift Switch1-96
Forward/Reverse Lever1-96
Shift Switch1-96
Tilt, Telescopic Lever/Steering Column Tilt Pedal 1-97
Wiper Switch 1-97
Wiper Operation 1-97
Front/Rear Wiper Switch1-98
Right Console / Switches1-99
Fingertip Control Type 1-99
Loading Control Levers 1-100
Right Console / Switches1-102
Multi-Function Joystick Type 1-102
Loading Multi-Function Joystick Lever (Option)1-103
Auxiliary Control Lever (Option)1-104
Forward/Reverse Selector Switch1-105
Operational Procedure 1-105
Loading Control Lever Lock Switch1-106
Declutch Position Switch1-106
Travel Mode Selector Switch 1-107
Power Mode Selector Switch1-108
Fan Reverse Rotation Switch 1-109
OFF1-109
AUTO 1-109
Manual Operation 1-110
Hydraulic Coupler Switch (Option) 1-110
Secondary Steering Operation Check Switch
(Option) 1-111
Aftertreatment Device Regeneration Switch1-111
Ride Control Switch (Option)1-112
AUTO1-112
OFF1-112
Hold Switch 1-114
Right Console Slide Lever 1-114
Horn Switch1-114
Quick Power Switch1-115
DSS (Down Shift Switch) 1-116
Cigar Lighter (24 V DC Electrical Outlet) 1-117
Using Cigar Lighter1-117
Ash Tray 1-117
CONTENTS
Auto Air Conditioner1-118
Feature 1-118
Components Name 1-119
Controller Part Name and Function1-120
Cab Heater Operation1-122
Cooling Operation 1-123
Defroster Operation1-124
Cool Head/Warm Feet Operation 1-124
Tips for Optimal Air Conditioner Usage1-125
For Rapid Cooling1-125
When Windows Become Fogged 1-125
Off-Season Air Conditioner Maintenance 1-125
Adjusting Operator’s Seat (Air Suspension Type Seat)
1-126
Components Name 1-126
Rear Tray 1-127
Electric Power Output (Option)1-127
Fuse Box1-128
Fuse Box A1-129
Fuse Box B 1-129
Hot/Cool Box 1-130
Tray and Drink Holder1-130
ROPS Cab1-131
Front Interior Light1-133
Rear Interior Light 1-133
Sun Visor 1-134
Emergency Exit Hammer1-134
Coat/Hat Hook1-134
Upper Switch Panel (Option) 1-135
Rotary Light Switch (Option) 1-135
Outside Rear View Mirror1-136
Inside Rear View Mirror 1-136
Cab Door 1-136
Door Lock Knob 1-137
Door Open/Close Lever 1-137
Window Open/Close Levers1-137
Battery Disconnect Switch1-138
Switch Operation 1-139
Articulation Stopper (Lock Bar)1-140
Towing Pin 1-141
Inspection/Maintenance Side Access Cover1-142
Rear Grille 1-143
Steps1-144
Tool Box1-144
Vandal-Resistant Devices 1-145
BREAK-IN 2-1
Break-in Period for New Machine 2-1
Work Mode for Break-in 2-1
OPERATING THE ENGINE3-1
Inspect Machine Daily Before Starting 3-1
Check Before Starting 3-3
Starting Engine 3-6
Starting in Cold Weather 3-8
Check After Starting3-9
Using Booster Batteries 3-10
Warm Up 3-12
Cold Weather Warm Up 3-13
Stopping Engine3-15
MOVING THE MACHINE4-1
Driving the Machine4-1
Starting to Move 4-2
Shift Range of Auto Transmission 4-5
Power Mode Selector4-6
Shift Change Delay Mode4-6
Parking Brake Switch 4-7
Drive Speed Change 4-8
Changing Forward/Reverse Drive Direction 4-8
Steering Wheel4-9
Joystick Steering (Option)4-10
Secondary Steering (Option)4-11
Emergency Stop and Restart of Operation4-11
Precautions for Traveling4-12
Operating in Water or on Soft Ground4-13
Precautions for Driving on Slopes 4-14
Precautions to be Taken if Machine Failure Occurs 4-15
Stop4-16
Parking4-18
Emergency Stopping 4-19
Auto Brake4-20
OPERATING THE MACHINE 5-1
Loading Control Levers5-1
Control Lever Lock 5-4
Declutch Position Switch 5-5
Adjustment of Bucket Auto Leveler 5-6
Adjustment of Bucket Angle Switch5-8
Adjustment of Dual Lift Arm Auto Leveler 5-10
Auto Idling Stop 5-11
Auto Idling Stop Operating Condition 5-12
Aftertreatment Device Manual Regeneration5-13
Before Operation 5-16
Precautions for Operation5-16
Ensure Safety When Operating on Road Shoulders 5-16
Avoid Overloading5-17
Avoid Rapid Steering Changes and/or Sudden
Braking 5-17
Avoid Operation with Loads on Only One Side5-17
Excavation5-18
Loading Accumulated Soil 5-18
Digging and Loading Level Ground5-19
Grading 5-20
Loading 5-21
Load and Carrying Method5-21
Loader and Dump Truck Combination Method5-22
V-Shape Loading5-22
I-Shape Loading 5-22
Dumping into Truck or Hopper 5-23
Dozing 5-24
Stock Piling5-24
Removing Snow 5-25
Lifting Wheel Loader5-25
CONTENTS
Precautions for After Operation5-26
TRANSPORTING6-1
Transporting by Road 6-1
Selecting a Trailer 6-1
Loading / Unloading on Trailer6-2
Fastening Machine for Transporting 6-4
Transporting Wheel Loader (Urgent Situation) 6-5
Precautions for Driving On Roads 6-5
Precautions for Towing 6-5
Releasing Parking Brake 6-7
Towing Method 6-9
Lifting Machine6-10
MAINTENANCE7-1
Correct Maintenance and Inspection Procedures7-1
Check the Hour Meter Regularly 7-3
Layout 7-4
Lubrication Guide 7-5
Preparations for Inspection and Maintenance7-6
Articulation Lock7-8
Inspection/Maintenance Side Access Cover 7-9
Rear Grille 7-10
Inspection and Maintenance Table7-11
Kind of Oils 7-15
Recommended Grease7-15
Recommended Engine Oil7-15
Recommended Transmission Oil7-16
Recommended Axle Oil 7-16
Recommended Hydraulic Oil7-17
Recommended Coolant7-17
AGreasing7-18
BEngine 7-24
Check Engine Oil Level 7-24
Change Engine Oil7-25
Replace Engine Oil Filter7-27
CPower Train7-29
Check Transmission Oil Level7-29
Change Transmission Oil7-30
Change Transmission Oil Filter 7-30
Clean Torque Converter Air Breather 7-33
Check Axle Oil Level 7-34
Change Axle Oil 7-36
Replace Axle Oil Cooler Line Filter (Option) 7-38
Clean Axle Oil Cooler Fins (Option) 7-38
DHydraulic System 7-39
Inspection and Maintenance of Hydraulic
Equipment7-39
Check Hydraulic Oil Level7-40
Change Hydraulic Oil7-41
Clean Suction Filter7-43
Clean Pilot Oil Filter7-44
Line Filter in Steering Circuit 7-44
Line Filter in Brake Circuit7-45
Line Filter in Joystic Steering Circuit (Option)7-46
Replace Hydraulic Oil Return Filter 7-47
Replace Air Breather Element 7-48
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage7-49
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage (Option)7-50
Check Gas Pressure in Ride Control Accumulator
(Option) 7-50
Check Gas Pressure in Steering Accumulator 7-50
Check Hoses and Lines 7-51
EFuel System 7-56
Check Fuel Level7-56
Recommended Fuel7-56
About Biodiesel Fuel 7-56
Refueling 7-57
Drain Water and Sediment from Fuel Tank7-58
Drain Fuel Filter7-59
Draining Procedures (Pre-Filter)7-59
Bleed Air from the Fuel System7-60
Replace Fuel Main Filter Element7-62
Replace Fuel Pre-Filter Element 7-64
Clean Fuel Supply Pump Strainer 7-65
Clean Fuel Priming Solenoid Pump Strainer 7-66
Check Fuel Hoses7-67
Check Water Separator (Option) 7-68
FAir Cleaner 7-70
Clean and Replace Air Cleaner Element 7-70
GCooling System7-71
Check Coolant Level7-72
Check Drive Belt7-73
Change Coolant 7-75
Clean Radiator/Oil Cooler Cores and Other Cooling
System7-78
HElectrical System 7-79
Batteries 7-79
Electrolyte Level Check 7-81
Check Electrolyte Specific Gravity7-82
Replace Batteries 7-83
Check Monitor Functions and All Other Instrument
Operation 7-83
Check Work Lights7-84
Check Horn and Backup Alarm7-85
Check Electrical Harnesses and Fuses 7-86
Fuse Box A 7-87
Fuse Box B7-87
IBrake System 7-88
Check Right and Left Brake Interlocking
Performance7-88
Check Parking Brake Force7-89
Check Parking Brake Gear Oil Level7-90
Change Parking Brake Gear Oil7-91
Check Accumulator Function, Gas Leakage, Looseness,
and Damage7-92
Check Gas Pressure in Accumulator 7-93
Check Brake Disks (Service and Parking)7-93
JTire7-94
Check and Replace Tire (Tire Pressure)7-94
Check Tire for Damage 7-95
CONTENTS
Check Wheel Bolt Torque7-95
KAir Conditioner7-99
Clean/Replace Air Conditioner Circulation/Fresh Air
Filters 7-99
Check Air Conditioner7-101
Check Air Conditioner Piping7-101
Check Air Conditioner Condenser 7-103
Check Air Conditioner Compressor Belt7-103
Check Refrigerant7-104
Replace Air Conditioner Receiver Dryer7-104
Check Compressor and Pulley 7-104
LAftertreatment Device7-105
Check and Clean Aftertreatment Device 7-105
MUrea SCR System7-106
Specified DEF/AdBlue®7-106
Check DEF Level 7-107
Refill DEF 7-107
DEF Exchange procedure7-109
Replace DEF Supply Module Main Filter7-110
Check Dosing Module7-111
NMiscellaneous7-112
Check Bucket Teeth and Cutting Edge 7-112
Check and Replace Seat Belt and Lower Tether7-113
Check ROPS Cab, Resin Cab Roof, and Roof
Mounting Bolts7-113
Check Windshield Washer Fluid Level7-113
Check Play Amount in Steering Wheel Movement7-114
Check Play Amount in Joystick Steering Movement
(Option)7-115
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise7-116
Check Rearview Mirror and Inside Rearview
Mirror7-117
Check Steps and Handrails for Damage and
Looseness7-117
Clean Engine Compartment and Hood 7-118
Check Sound Absorbing Mat Around Engine 7-118
Check and Adjust Valve Clearance 7-118
Check Engine Compression Pressure 7-118
Check and Clean Starter and Alternator7-119
Check Fuel Injector7-119
Check Turbocharger7-119
Check and Adjust Engine Controller (ECM)7-119
Check and Clean EGR Valve7-119
Check and Clean EGR Cooler 7-119
Replace DEF/AdBlue® Supply Module Filter
Element 7-119
Check Urea SCR System 7-119
Check Dosing Module7-120
Retighten Front Axle and Rear Axle Support
Mounting Bolts7-120
Check Tightening Torque of Nuts and Bolts 7-121
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS 9-1
Maintenance Under Special Environmental Conditions9-1
Precautions for Maintenance During Cold Weather
Season 9-2
STORAGE 10-1
Storing the Machine 10-1
TROUBLESHOOTING 11-1
Troubleshooting11-1
1Engine11-1
2Engine Auxiliaries11-1
3Engine does not Start11-2
4Control Lever 11-3
5Hydraulic System 11-3
6Drive Function11-4
7Others11-5
SPECIFICATIONS 12-1
Specifications12-1
Intended Use 12-1
INDEX 14-1