Kawasaki 85Z7 WHEEL LOADER ISUZU 6HK1 Engine OPERATION & MAINTENANCE MANUAL PDF

Language : English
Pages : 403
Downloadable : Yes
File Type : PDF

MACHINE NUMBERS1
SAFETY S-1
Recognize Safety InformationS-1
Understand Signal WordsS-1
Follow Safety InstructionsS-2
Prepare for EmergenciesS-3
Wear Protective ClothingS-3
Protect Against NoiseS-4
Inspect MachineS-4
General Precautions for CabS-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 BeltS-7
Move and Operate Machine SafelyS-8
Handle Starting Aids SafelyS-8
Operate Only from Operator’s SeatS-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 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 S-37
Articulation Stopper S-38
SAFETY LABELS S-39
COMPONENTS NAME 1-1
Components Name1-1
OPERATOR’S STATION 1-3
Exhaust Filter1-3
Diesel Particulate Filter(DPF, Exhaust Filter)1-4
Description of DPF functions1-4
Automatic regeneration 1-5
Repeated inhibiting of exhaust filter cleaning1-6
Cab Features1-7
Front Console1-8
Right Console1-9
Fingertip Control Type1-9
Multi-Function Joystick Type1-10
Monitor Panel1-11
Parking Brake Indicator (Red)1-12
Brake Oil Low Pressure Indicator (Red)1-12
Hydraulic Oil Level Indicator (Red)1-12
Low Steering Oil Pressure Indicator (Optional) (Red)1-13
Transmission Warning Indicator (Red)1-13
Communication Error Indicator (Yellow)1-13
Discharge Warning Indicator (Red)1-13
Engine Trouble Indicator (Red)1-14
Overheat Indicator (Red)1-14
Engine Oil Low Pressure Indicator (Red)1-14
Air Filter Restriction Indicator (Red)1-15
Preheat Indicator (Yellow)1-15
Coolant Temperature Gauge1-16
Fuel Gauge1-16
Turn Signal Indicator (Green)1-17
High Beam Indicator (Blue)1-17
Work Light Indicator (Yellow)1-17
Clearance Light Indicator (Green)1-18
Control lever lock indicator (Red)1-18
Multi Function Monitor1-19
Default Setting1-20
CONTENTS
Basic Screen1-21
How to Use Screens1-22
Displaying Basic Screen1-22
Monitor Operation1-26
Alarm Occurrence Screen1-27
Remedy1-29
Exhaust Filter Regeneration1-32
Exhaust Filter Status Display1-32
Automatic regeneration (Auto-regeneration)1-32
Manual Regeneration1-34
Service Regeneration1-34
Main Menu1-35
Ride Control Drive Speed Setting (Optional)1-36
Dual Lift Arm Auto-Leveler1-37
Height Kickout ON/OFF, Stop Height Setting1-38
Lower Kickout ON/OFF, Stop Height Setting1-39
Brightness Adjustment1-40
Setting Menu1-42
Date and Time1-43
Time adjustment1-43
Date Adjustment1-45
Display Mode Setting1-47
Auto Idling Stop1-49
Auto idling stop: ON/OFF1-49
Acting Time Setting1-50
Rear View Camera Monitor1-51
Exhaust Filter Regeneration Inhibited1-53
Setting Procedure1-53
Transmission Setting1-55
Shift Change Delay Mode Setting 1-55
Parallel/Tandem Switching Height Setting1-57
Warm Up Operation1-59
Display Item Selection1-61
Main Menu Display Order Change1-63
Information Menu1-65
Operation Condition1-66
Fuel Consumption1-66
Maintenance1-68
Maintenance Notice1-68
Time Remains and Maintenance Interval1-70
Troubleshooting1-72
Monitoring1-74
Switches, Steering Wheel and Pedals1-76
Hazard Switch1-77
Work Light Switch1-78
Parking Brake Switch1-79
Neutral Lever Lock (for the Forward/Reverse Lever)1-80
Steering Wheel1-80
Horn Switch1-80
Key Switch1-81
Turn Signal Lever1-82
Light Switch1-83
High-Low Beam Switch1-84
Accelerator Pedal1-85
Brake Pedal1-85
Service Brake1-85
Declutch Brake1-85
Forward/Reverse Lever/ Shift Switch1-86
Forward/Reverse Lever1-86
Shift Switch1-86
Wiper Switch1-87
Wiper Operation1-87
Front/Rear Wiper Switch1-88
Tilt, Telescopic Lever/Steering Column Tilt Pedal 1-89
Right Console / Switches1-90
Fingertip Control Type1-90
Loading Control Levers1-91
Right Console / Switches1-93
Multi-Function Joystick Type1-93
Loading Multi-Function Joystick Lever (Optional)1-94
Auxiliary Control Lever (Option)1-95
Forward/Reverse Selector Switch1-96
Operational Procedure1-96
Loading Control Lever Lock Switch1-97
Declutch Position Switch1-97
Travel Mode Selector1-98
Power Mode Selector1-99
Fan Reverse Rotation Switch1-100
OFF1-100
AUTO 1-100
Manual Operation 1-101
Hydraulic Coupler Switch (Option)1-101
Secondary Steering Operation Check Switch
(Optional)1-102
Exhaust Filter Switch1-102
Ride Control Switch (Optional)1-103
AUTO1-104
OFF1-104
Hold Switch1-105
Right Console Slide Lever1-105
Quick Power Switch1-106
DSS (Down Shift Switch)1-107
Horn Switch 1-107
Cigar Lighter (24 V DC Electrical Outlet)1-108
Using Cigar Lighter1-108
Using 24 VDC Electrical Power Supply1-108
Ash Tray1-108
Auto Air Conditioner1-109
Feature1-109
Components Name1-110
Controller Part Name and Function1-111
Cab Heater Operation1-113
Cooling Operation1-114
Defroster Operation1-115
Cool Head/Warm Feet Operation1-115
Tips for Optimal Air Conditioner Usage1-116
For Rapid Cooling1-116
When Windows Become Fogged1-116
Off-Season Air Conditioner Maintenance1-116
Adjusting Operator’s Seat
(Air Suspension Type Seat)1-117
Components Name1-117
CONTENTS
Rear Tray1-118
Electric Power Output (Optional)1-118
Fuse Box1-119
Fuse Box A1-120
Fuse Box B1-120
Hot/Cool Box1-121
Tray and Drink Holder1-121
ROPS Cab1-122
Front Interior Light1-124
Rear Interior Light1-124
Sun Visor1-125
Emergency Exit Hammer1-125
Coat/Hat Hook1-125
Upper Switch Panel (Optional)1-126
Rotary Light Switch (Optional)1-126
Outside Rear View Mirror1-127
Inside Rear View Mirror1-127
Cab Door1-127
Door Lock Knob1-128
Door Open/Close Lever1-128
Window Open/Close Levers1-128
When Fully Opening the Door1-129
Cab Door Release Lever1-129
Battery Disconnect Switch 1-130
Switch Operation1-131
Articulation Lock Bar1-132
Towing Pin1-133
Inspection/Maintenance Side Access Cover1-134
Rear Grille1-135
Steps1-136
Tool Box 1-136
Vandal-Resistant Devices1-137
BREAK-IN 2-1
Break-in Period for New Machine2-1
Use ECO Mode for Break-in2-1
OPERATING THE ENGINE 3-1
Inspect Machine Daily Before Starting3-1
Check Before Starting3-3
Starting Engine3-5
Starting in Cold Weather3-7
Check After Starting3-8
Using Booster Batteries3-9
Warm Up3-11
Cold Weather Warm Up3-12
Stopping Engine3-14
MOVING THE MACHINE 4-1
Driving the Machine4-1
Starting to Move4-2
Parking Brake Switch4-7
Drive Speed Change4-8
Changing Forward/Reverse Drive Direction4-8
Steering Wheel4-9
Secondary Steering (Optional)4-10
Emergency Stop and Restart of Operation4-11
Precautions for Driving on Slopes4-14
Precautions to be Taken if Machine Failure Occurs4-15
Stop the Machine4-16
Parking4-18
Emergency Stopping4-19
OPERATING THE MACHINE 5-1
Loading Control Levers5-1
Control Lever Lock5-4
Declutch Position Switch5-5
Adjustment of Bucket Auto Leveler5-6
Adjustment of Dual Lift Arm Auto Leveler5-8
Auto Idling Stop5-9
Exhaust Filter Manual Regeneration5-11
Before Operation5-13
Precautions for Operation5-13
Ensure Safety When Operating on Road Shoulders5-13
Avoid Overloading5-14
Avoid Rapid Steering Changes and/or Sudden
Braking5-14
Avoid Operation with Loads on Only One Side5-14
Excavation5-15
Grading5-17
Loading5-18
Dozing5-21
Stock Piling5-21
Removing Snow5-22
Lifting Wheel Loader5-22
Precautions for After Operation5-23
TRANSPORTING 6-1
Transporting by Road6-1
Selecting a Trailer6-1
Loading / Unloading on Trailer6-2
Fastening Machine for Transporting6-4
Transporting Wheel Loader (Urgent Situation)6-5
Towing Method6-9
Lifting Machine6-10
MAINTENANCE 7-1
Correct Maintenance and Inspection Procedures7-1
Check the Hour Meter Regularly7-3
Layout7-4
Preparations for Inspection and Maintenance7-7
Articulation Lock7-9
Inspection/ Maintenance Access Side Cover7-10
Rear Grille7-11
Periodic Replacement of Parts7-12
Inspection and Maintenance Table7-13
Kind of Oils7-17
A Greasing7-20
B Engine7-25
Check Engine Oil Level 7-25
Change Engine Oil 7-26
Replace Engine Oil Filter7-28
C Power Train7-29
Check Transmission Oil Level7-29
Change Transmission Oil and
Transmission Oil Filter7-30
CONTENTS
Change Axle Oil7-33
Check Surroundings Around Axle and Covers for
Oil Leaks7-35
Clean Axle Housing Air Breather7-35
D Hydraulic System7-36
Check Hydraulic Oil Level7-38
Change Hydraulic Oil7-39
Clean Suction Filter7-42
Replace Pilot Oil Filter7-43
Replace Hydraulic Tank Oil Filter7-45
Replace Air Breather Element7-46
Check Pilot Circuit Accumulator Function,
Gas Leakage, Looseness, and Damage7-47
Replace Pilot Circuit Accumulator7-48
Check Ride Control Accumulator Function,
Gas Leakage, Looseness, and Damage7-48
Check Gas Pressure in Ride Control Accumulator7-48
Check Hoses and Lines7-49
E Fuel System7-54
Check Fuel Level7-54
Drain Water and Sediment from Fuel Tank7-56
Drain Fuel Filter/Water Separator7-57
Replace Fuel Main Filter Element7-61
Replace Fuel Pre-Filter Element7-62
Clean Fuel Pump Strainer7-63
Check Water Separator (Optional)7-64
Check Fuel Hoses7-66
F Air Cleaner7-67
Clean and Replace Air Cleaner Element7-67
G Cooling System7-68
Check Coolant Level7-69
Check Drive Belt7-70
Check Drive Belt Tension7-70
Adjust Drive Belt Tension 7-70
Change Coolant7-71
Clean Radiator/Oil Cooler Cores and Other Cooling
System7-72
H Electrical System7-73
Batteries7-73
Replace Batteries7-77
Check Monitor Functions and All Other Instrument
Operation7-77
Check Work Lights7-78
Check Horn and Backup Alarm7-78
Check Electrical Harnesses and Fuses7-79
I Brake System7-81
Check Right and Left Brake Interlocking
Performance7-81
Check Parking Brake Force7-82
Check Accumulator Function, Gas Leakage,
Looseness, and Damage7-83
Check Gas Pressure in Accumulator7-84
Check Brake Disks (Service and Parking)7-84
J Tire7-85
Check and Replace Tire (Tire Pressure)7-85
Check Tire for Damage7-85
Check Wheel Bolt Torque7-86
K Air Conditioner7-91
Clean/Replace Air Conditioner Circulation/
Fresh Air Filters7-91
Check Air Conditioner7-94
Check Air Conditioner Piping7-94
Check Air Conditioner Condenser7-95
Check Air Conditioner Fan Belt7-95
Check Refrigerant7-96
Check Compressor and Pulley7-96
L Exhaust Filter7-97
Check and Clean Filter Element of Exhaust Filter7-97
Check and Clean Exhaust Filter7-97
M Miscellaneous7-98
Check Bucket Teeth and Cutting Edge7-98
Check and Replace Seat Belt and Lower Tether7-99
Check ROPS cab, Resin Cab Roof, and Roof
Mounting Bolts7-99
Check Windshield Washer Fluid Level7-99
Check Play Amount in Steering Wheel Movement7-100
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise7-101
Check Rearview Mirror and Inside Rearview
Mirror7-102
Check Steps and Handrails for Damage and
Looseness7-102
Clean Engine Compartment and Hood7-103
Check Sound Absorbing Mat Around Engine7-103
Check Engine Cylinder Head and Manifold7-103
Check and Adjust Valve Clearance7-103
Check Engine Compression Pressure7-104
Check and Clean Starter and Alternator7-104
Check and Replace EGR Device7-104
Clean EGR Cooler7-104
Check Turbocharger7-104
Check and Clean Fuel Injector Nozzle7-104
Retighten Front Axle and Rear Axle Support
Mounting Bolts7-104
Check Tightening Torque of Nuts and Bolts7-105
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS 9-1
Maintenance Under Special Environmental Conditions9-1
Precautions for Maintenance During Cold Weather
Season9-2
STORAGE 10-1
Storing the Machine10-1
TROUBLESHOOTING 11-1
Troubleshooting11-1
SPECIFICATIONS 12-1
Specifications12-1
INDEX 14-1