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Kawasaki 92 z7 wheel loader operation and maintenance manual
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- 2. ©2018 KCM CorporationAll rights reserved. FOREWORD Read this manual carefully before starting and operating the machine for the first time to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage. This standard specification machine can be operated under the following conditions without being modified. Atmospheric Temperature: -20 °C to 45 °C (-4 °F to 113 °F) Altitude: 0 m to 2000 m (0 ft to 6600 ft) In case the machine is used under conditions other than described above, consult your nearest authorized dealer. This manual should be considered a permanent part of your machine and should remain with the machine when you sell it. Replace immediately if missing, damaged or not readable. This machine is of metric design. Measurements in this manual are metric. American standard measurements are included when appropriate. Use only metric hardware and tools as specified. Right-hand and left-hand sides are determined by facing in the direction of forward travel. Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. If this manual is kept on the machine, also file the identification numbers in a secure place off the machine. Use only diesel fuel with quality specified in JIS K-2204, EN-590 or ASTM D-975 which contents 15 ppm or lower sulfur. Also use fuel that complies with solid contamination level of class 18/16/13 of ISO4406-1999 (solid contamination includes dust). If the fuel specified above is not used, exhaust gas that exceeds the regulation values may be discharged, causing serious problem on the engine. Consult your nearest authorized dealer. Warranty is provided as a part of KCM’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer. This warranty provides you with the assurance that KCM will back its products where defects appear within the warranty period. In some circumstances, KCM also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action. Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine. PRIOR TO OPERATING THIS MACHINE, INCLUDING COMMUNICATION SYSTEM, IN A COUNTRY OTHER THAN A COUNTRY OF ITS INTENDED USE, IT MAY BE NECESSARY TO MAKE MODIFICATIONS TO IT SO THAT IT COMPLIES WITH THE LOCAL REGULATORY STANDARDS (INCLUDING SAFETY STANDARDS) AND LEGAL REQUIREMENTS OF THAT PARTICULAR COUNTRY. PLEASE DO NOT EXPORT OR OPERATE THIS MACHINE OUTSIDE OF THE COUNTRY OF ITS INTENDED USE UNTIL SUCH COMPLIANCE HAS BEEN CONFIRMED. PLEASE CONTACT KCM CORPORATION OF AMERICA OR ANY OF OUR AUTHORIZED DISTRIBUTOR OR DEALER IF YOU HAVE ANY QUESTIONS CONCERNING COMPLIANCE. All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.
- 3. T MACHINE NUMBERS SAFETY SAFETY LABELS COMPONENTSNAME OPERATOR’S STATION BREAK-IN OPERATINGTHE ENGINE MOVINGTHE MACHINE OPERATINGTHEMACHINE TRANSPORTING MAINTENANCE MAINTENANCEUNDERSPECIALENVIRONMENTALCONDITIONS STORAGE SPECIFICATIONS INDEX INDEX TROUBLESHOOTING
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- 5. CONTENTS MACHINE NUMBERS.........................................................1 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 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 Seat...................................................................S-6 Ensure Safety Before Rising from or Leaving Operator’s Seat .................................................................................................S-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 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 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-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 Notes for Exhaust Filter ..............................................................S-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 NAME.................................................... 1-1 Components Name ........................................................................1-1 OPERATOR’S STATION .................................................. 1-3 Exhaust Filter.....................................................................................1-3 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 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
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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 Screen..........................................................1-27 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-Leveler.......................................................1-37 Height Kickout ON/OFF, Stop Height Setting...............1-38 Lower Kickout ON/OFF, Stop Height Setting................1-39 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 Stop............................................................................1-51 Auto idling stop: ON/OFF.....................................................1-51 Acting Time Setting................................................................1-52 Rear View Camera Monitor .......................................................1-53 Exhaust Filter Regeneration Inhibited..................................1-55 Setting Procedure...................................................................1-55 Transmission Setting...................................................................1-57 Shift Change Delay Mode Setting ...................................1-57 Parallel/Tandem Switching Height Setting.........................1-59 Warm Up Operation ....................................................................1-61 Display Item Selection................................................................1-63 Main Menu Display Order Change.........................................1-65 Information Menu........................................................................1-67 Operation Condition...................................................................1-68 Fuel Consumption..................................................................1-68 Maintenance ..................................................................................1-70 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 Switch...................................................................1-81 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 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 Tilt, Telescopic Lever/Steering Column Tilt Pedal.............1-90 Wiper Switch..................................................................................1-90 Wiper Operation......................................................................1-90 Front/Rear Wiper Switch.......................................................1-91 Right Console / Switches...........................................................1-92 Fingertip Control Type..........................................................1-92 Loading Control Levers..............................................................1-93 Right Console / Switches...........................................................1-95 Multi-Function Joystick Type..............................................1-95 Loading Multi-Function Joystick Lever (Option)...............1-96 Auxiliary Control Lever (Option).............................................1-97 Forward/Reverse Selector Switch...........................................1-98 Operational Procedure..........................................................1-98 Loading Control Lever Lock Switch .......................................1-99 Declutch Position Switch...........................................................1-99 Travel Mode Selector Switch..................................................1-100 Power Mode Selector Switch .................................................1-100 Fan Reverse Rotation Switch..................................................1-102 OFF.............................................................................................1-102 AUTO ........................................................................................1-102 Manual Operation ................................................................1-103 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 AUTO..........................................................................................1-106 OFF.............................................................................................1-106 Hold Switch ..................................................................................1-107 Right Console Slide Lever........................................................1-107 Quick Power Switch...................................................................1-108 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 Function...............................1-113 Cab Heater Operation .........................................................1-115 Cooling Operation................................................................1-116 Defroster Operation.............................................................1-117
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CONTENTS Cool Head/Warm FeetOperation....................................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 Tray ........................................................................................1-120 Electric Power Output (Option).............................................1-120 Fuse Box.........................................................................................1-121 Fuse Box A ...............................................................................1-122 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 Light ......................................................................1-126 Sun Visor........................................................................................1-127 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 Door........................................................................................1-129 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 Steps................................................................................................1-138 Tool Box .........................................................................................1-138 Vandal-Resistant Devices.........................................................1-139 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 Starting....................................................................3-3 Starting Engine ................................................................................3-6 Starting in Cold Weather...............................................................3-8 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 Transmission........................................4-5 Power Mode Selector ...............................................................4-6 Shift Change Delay Mode.......................................................4-6 Parking Brake Switch......................................................................4-7 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 Operation.........................4-11 Precautions for traveling......................................................4-12 Operating in Water or on Soft Ground............................4-13 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 Levers.................................................................5-1 Fingertip Control Type.............................................................5-1 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 Stop...............................................................................5-9 Auto Idling Stop Operating condition ............................5-10 Exhaust Filter Manual Regeneration .....................................5-11 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 Braking........................................................................................5-14 Avoid Operation with Loads on Only One Side.................5-14 Excavation.......................................................................................5-15 Loading Accumulated Soil...................................................5-15 Digging and Loading Level Ground.................................5-16 Grading ............................................................................................5-17 Loading............................................................................................5-18 Load and Carrying Method.................................................5-18 Loader and Dump Truck Combination Method...........5-19 V-Shape Loading.....................................................................5-19 I-Shape Loading ......................................................................5-19 Dumping into Truck or Hopper..........................................5-20 Dozing..............................................................................................5-21 Stock Piling.....................................................................................5-21 Removing Snow............................................................................5-22 Lifting Wheel Loader...................................................................5-22 Precautions for After Operation..............................................5-23
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CONTENTS TRANSPORTING............................................................ 6-1 Transporting byRoad ....................................................................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 Precautions for Driving On Roads........................................6-5 Precautions for Towing ............................................................6-6 Releasing Parking Brake..........................................................6-7 Towing Method................................................................................6-9 Lifting Machine.............................................................................6-10 MAINTENANCE.............................................................. 7-1 Correct Maintenance and Inspection Procedures...............7-1 Check the Hour Meter Regularly................................................7-3 Layout..................................................................................................7-4 Lubrication Guide......................................................................7-5 Preparations for Inspection and Maintenance.....................7-7 Articulation Lock..............................................................................7-9 Inspection/ Maintenance Side Access Cover......................7-10 Rear Grille........................................................................................7-11 Inspection and Maintenance Table........................................7-13 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 Coolant .......................................................7-19 A. Greasing......................................................................................7-20 B. Engine..........................................................................................7-25 Check Engine Oil Level .........................................................7-25 Change Engine Oil .................................................................7-26 Replace Engine Oil Filter.......................................................7-28 C. Power Train ................................................................................7-29 Check Transmission Oil Level..............................................7-29 Change Transmission Oil......................................................7-30 Change Transmission Oil Filter...........................................7-30 Clean Transmission Strainer................................................7-30 Clean Torque Converter Air Breather...............................7-33 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 D. Hydraulic System.....................................................................7-40 Check Hydraulic Oil Level ....................................................7-42 Change Hydraulic Oil.............................................................7-43 Clean Suction Filter................................................................7-45 Clean Pilot Oil Filter................................................................7-46 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 E. Fuel System................................................................................7-57 Check Fuel Level......................................................................7-57 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 System.....................................7-62 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 F. Air Cleaner...................................................................................7-70 Clean and Replace Air Cleaner Element .........................7-70 G. Cooling System........................................................................7-71 Check Coolant Level ..............................................................7-72 Check Drive Belt......................................................................7-73 Change Coolant.......................................................................7-74 Clean Radiator/Oil Cooler Cores and Other Cooling System...................................................................................7-75 H. Electrical System......................................................................7-76 Batteries .....................................................................................7-76 Electrolyte Level Check....................................................7-78 Check Electrolyte Specific Gravity ...............................7-79 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 B..................................................................................7-83 I. Brake System...............................................................................7-84 Check Right and Left Brake Interlocking Performance........................................................................7-84 Check Parking Brake Force ..................................................7-85 Check Accumulator Function, Gas Leakage, Looseness, and Damage.................................................7-86 Check Gas Pressure in Accumulator.................................7-87 Check Brake Disks (Service and Parking)........................7-87 J. Tire..................................................................................................7-88 Check and Replace Tire (Tire Pressure)............................7-88 Check Tire for Damage..........................................................7-89 Check Wheel Bolt Torque.....................................................7-89 K. Air Conditioner.........................................................................7-93 Clean/Replace Air Conditioner Circulation/Fresh Air Filters...............................................................................7-93 Check Air Conditioner...........................................................7-96 Check Air Conditioner Piping.............................................7-96 Check Air Conditioner Condenser....................................7-97
- 9. CONTENTS Check Air ConditionerFan Belt..........................................7-97 Check Refrigerant...................................................................7-98 Check Compressor and Pulley............................................7-98 Replace Air Conditioner Receiver Dryer .........................7-98 L. Exhaust Filter .............................................................................7-99 Check and Clean Filter Element of Exhaust Filter........7-99 Check and Clean Exhaust Filter..........................................7-99 M. Miscellaneous........................................................................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 Noise .......................................................7-103 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 Manifold.......................................................7-105 Check and Adjust Valve Clearance..................................7-105 Check Engine Compression Pressure ............................7-106 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 Bolts................7-107 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 Specifications.................................................................................12-1 INDEX........................................................................... 14-1
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- 11. 1 The manufacturing Nos.explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request. Machine TYPE : MACHINE SERIAL NUMBER: Engine TYPE : MFG. NO. : MACHINE NUMBERS 90Z7 SNplate E13C_plate
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- 13. S-1 SAFETY Recognize Safety Information These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. Understand Signal Words On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. Some safety signs do not use any of the designated signal words above after the safety alert symbol has been used on this machine. To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. fNOTE indicates an additional explanation for an element of information. SA-688 SA-1223
- 14. S-2 SAFETY Follow Safety Instructions Carefully read and follow all safety signs on the machine and all safety messages in this manual. Safety signs should be installed, maintained and replaced when necessary. If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). Learn how to operate the machine and its controls correctly and safely. Allow only trained, qualified, authorized personnel to operate the machine. Keep your machine in proper working condition. Unauthorized modifications of the machine may impair its function and/or safety and affect machine life. Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void KCM Warranty Policy. Never attempt to modify or disassemble the inlet/exhaust parts and the exhaust filter. Avoid giving shocks on the exhaust filter by striking elements with other objects or dropping the elements. Failure to do so may affect the exhaust gas purifying device, possibly damaging it or lowering its performance. Do not use attachments and/or optional parts or equipment not authorized by KCM. Carefully read and follow all instructions for use and safety in the operator's manual for the attachment. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void KCM Warranty Policy. The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/ or your authorized dealer before operating or performing maintenance work on the machine. SA-003
- 15. S-3 SAFETY Prepare for Emergencies Be prepared if a fire starts or if an accident occurs. Keep a first aid kit and fire extinguisher on hand. Thoroughly read and understand the label attached on the fire extinguisher to use it properly. To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual. Establish emergency procedure guidelines to cope with fires and accidents. Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone. Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. SA-438 SA-437
- 16. S-4 SAFETY Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. Inspect Machine Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. In the walk-around inspection, be sure to cover all points described in the“Inspect Machine Daily Before Starting” section in the operator’s manual. SA-435 SA-434
- 17. S-5 SAFETY General Precautions forCab Before entering the cab, thoroughly remove all dirt and / or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and / or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. Do not leave parts and / or tools lying around the operator’s seat. Store them in their specified locations. Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. Refrain from using music headphones or mobile telephones in the cab while operating the machine. Keep all flammable objects and / or explosives away from the machine. After using the ashtray, always cover it to extinguish the match and / or tobacco. Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. Use proper floor mat dedicated to the machine. If another floor mat is used, it may be displaced and contact with the accelerator or brake pedals during operation, resulting in serious injury or death.
- 18. S-6 SAFETY Use Handrails andSteps Falling is one of the major causes of personal injury. When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. Do not use any controls as handholds. Never jump on or off the machine. Never mount or dismount a moving machine. Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. Never get on and off the machine with tools in your hands. Never Ride Attachment Never allow anyone to ride attachment or the load. This is an extremely dangerous practice. Adjust Operator’s Seat A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperations. The seat should be adjusted whenever changing the operator for the machine. The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. If not, move the seat forward or backward, and check again. Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one. SA-439 SA-462
- 19. S-7 SAFETY Ensure Safety BeforeRising from or Leaving Operator’s Seat Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death. Before leaving the machine, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position. Turn the parking brake switch ON, and the key switch OFF to stop the engine. Before leaving the machine, close all windows, doors, and access covers and lock them up. Fasten Your Seat Belt If the machine should overturn, the operator may become injured and / or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. We recommend that the seat belt be replaced every three years regardless of its apparent condition. SA-237
- 20. S-8 SAFETY Move and OperateMachine Safely Bystanders can be run over. Take extra care not to run over bystanders. Be advised that there may be blind spots with rear view camera. Confirm the location of bystanders before moving, swinging, or operating the machine by sight and mirrors as well as the rear view monitor. Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. Use a signal person when moving, or operating the machine in congested areas. Coordinate hand signals before starting the machine. Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it. Ensure the cab door, windows, doors and covers are securely locked. Check the mirrors and the monitor in the CAB for problems. If there is, replace the problem part(s) or clean the mirror, camera and the monitor. Refer to Rear View Monitor section on the cleaning of the camera and the monitor. Handle Starting Aids Safely Starting fluid: Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep starting fluid well away from batteries and cables. Remove container from machine if engine does not need starting fluid. To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location. Do not incinerate or puncture a starting fluid container. SA-293 SA-398
- 21. S-9 SAFETY Operate Only fromOperator’s Seat Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only when seated in the operator's seat. NEVER start the engine while standing on the tire or on ground. Do not start engine by shorting across starter terminals. Before starting the engine, confirm that all control levers are in neutral. Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders. Jump Starting Battery gas can explode, resulting in serious injury. If the engine must be jump started, be sure to follow the instructions shown in the“OPERATING ENGINE”chapter in the operator’s manual. The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. Never use a frozen battery. Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. SA-032 SA-431
- 22. S-10 SAFETY Investigate Job SiteBeforehand When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing. Make a work plan. Use machines appropriate to the work and job site. Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders. When working on an incline or on a road shoulder, employ a signal person as required. Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist. When the footing is weak, reinforce the ground before starting work. When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery. Beware of the possibility of fire when operating the machine near flammable objects such as dry grass. SA-447
- 23. S-11 SAFETY Equipment of HeadGuard, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performances and its certification will be lost. ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure Provide Signals for Jobs Involving Multiple Machines For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions. SA-521 SA-481
- 24. S-12 SAFETY Keep Riders OffMachine Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. Only the operator should be on the machine. Keep riders off. Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. Drive Safely Beware of the possibility of slipping and / or turning over the machine when driving on a slope. When driving on level ground, hold the bucket at mark (A) 500 mm (20 in) above the ground as illustrated. Avoid traveling over any obstacles. Drive the machine slowly when driving on rough terrain. Avoid quick direction changes. Failure to do so may cause the machine to turn over. If the engine stops while driving, the steering function becomes inoperative. Immediately stop the machine by applying the brake to prevent personal accident. SA-427 SA-448
- 25. S-13 SAFETY Drive Machine Safely(Work Site) Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive. Be sure to detour around any obstructions. Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. When driving up or down a slope, keep the bucket facing the direction of travel, approximately 500 mm (20 in) (A) above the ground. If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop. Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation. WRONG SA-449 SA-450 SA-451
- 26. S-14 SAFETY Drive Safely withBucket Loaded If the machine is operated incorrectly while driving with the bucket loaded, the machine may turn over. Be sure to follow all of the instructions indicated below. When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility. Do not exceed the rated load capacity. Always operate the machine within the rated load capacity. Avoid fast starts, stops, and quick turns. Failure to do so may result in personal injury and / or death. Avoid rapid drive direction changes which could possibly cause personal injury and / or death. Drive on Snow Safely Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces. The machine may slip more easily than expected on frozen snow surfaces even if the incline is small. Reduce speed when driving. Avoid fast starts, stops and quick turns. Road shoulder and / or set-up utilities covered with snow are difficult to locate. Be sure where they are before removing snow. Be sure to use tire chains when driving on snow. Avoid applying the brake for quick stops on snow. If a quick stop is required, lower the bucket to the ground. SA-452 SA-400
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- 28. S-15 SAFETY Travel on PublicRoads Safely This machine is not allowed to drive on public roads with the bucket loaded. Be sure to empty the bucket. Hold the bucket at mark (A) 500 mm (20 in) above the road surface as illustrated. Avoid Injury from Rollaway Accidents Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: Select level ground when possible to park machine. Do not park the machine on a grade. Lower the bucket to the ground. Put the forward / reverse lever (switch) in neutral. Run the engine at low idle speed without load for 5 minutes to cool down the engine. Turn the control lever lock switch to the lock ( ) position. Turn the parking brake switch ON. Stop the engine and remove the key from the key switch. Block both tires and lower the bucket to the ground. Position the machine to prevent rolling. Park at a reasonable distance from other machines. SA-457 SA-458 SA-453
- 29. S-16 SAFETY Avoid Accidents fromBacking Up and Turning Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and / or death by being run over or entangled in the machine. Keep all personnel away from the machine by sounding the horn and / or using hand signals. Use extra care to be sure no one is in from the articulation area before turning the machine. Keep windows, mirrors, and lights in good condition. Reduce travel speed when dust, heavy rain, fog, etc., reducing the visibility. In case good visibility is not obtained, use a signal person to guide you. SA-383 SA-312
- 30. S-17 SAFETY Avoid Positioning Bucketor Attachment Over Anyone Never allow the bucket or attachment to pass over co- workers and / or the dump truck operator’s cab. Falling material from the bucket or contact with bucket or attachment may cause serious personal accidents and / or damage to the machine. Avoid carrying the bucket or attachment over the co- workers to ensure safe operation. Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: Be extra careful before operating on a grade. Prepare machine operating area flat. Keep the bucket low to the ground and close to the machine. Reduce operating speeds to avoid tipping or slipping. Avoid changing direction when traveling on grades. NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable. Reduce speed as necessary when swinging loads. Be careful when working on frozen ground. Temperature increases will cause the ground to become soft and make ground travel unstable. SA-518 SA-463