KCM 70Z7 - General Maintenance

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13-4

Quick Coupler

OTHER ATTACHMENTS AND DEVICE

General Maintenance

Daily

x Inspect the locking mechanism

x Inspect hoses for leaks

x Apply grease to zerk fittings

Every 1000 hours

x Inspect rollback & dump stoppers, if applicable.

Main Page

Table of Contents6
Machine Numbers10
Safety12
Recognize Safety Information12
Understand Signal Words12
Follow Safety Instructions13
Prepare for Emergencies14
Wear Protective Clothing14
Protect against Noise15
Inspect Machine15
General Precautions for Cab16
Use Handrails and Steps17
Never Ride Attachment17
Adjust Operator's Seat17
Ensure Safety before Rising from or Leaving Operator's Seat18
Fasten Your Seat Belt18
Move and Operate Machine Safely19
Handle Starting Aids Safely19
Operate Only from Operator's Seat20
Jump Starting20
Investigate Job Site Beforehand21
Equipment of Head Guard, ROPS, FOPS22
Provide Signals for Jobs Involving Multiple Machines22
Keep Riders off Machine23
Drive Safely23
Drive Machine Safely (Work Site24
Drive Safely with Bucket Loaded25
Drive on Snow Safely25
Travel on Public Roads Safely26
Avoid Injury from Rollaway Accidents26
Avoid Accidents from Backing up and Turning27
Avoid Positioning Bucket or Attachment over Anyone28
Avoid Tipping28
Never Undercut a High Bank29
Dig with Caution29
Perform Truck Loading Safely29
Avoid Power Lines30
Precautions for Operation30
Precautions for Lightning30
Object Handling31
Protect against Flying Debris31
Park Machine Safely32
Store Attachments Safely32
Transport Safely33
Handle Fluids Safely−Avoid Fires34
Practice Safe Maintenance35
Warn Others of Service Work36
Support Machine Properly36
Stay Clear of Moving Parts37
Support Maintenance Properly37
Prevent Parts from Flying38
Prevent Burns38
Replace Rubber Hoses Periodically39
Avoid High-Pressure Fluids39
Prevent Fires40
Evacuating in Case of Fire42
Beware of Exhaust Fumes42
Precautions for Welding and Grinding42
Avoid Heating Near Pressurized Fluid Lines43
Avoid Applying Heat to Lines Containing Flammable Fluids43
Precautions for Handling Accumulator and Gas Damper43
Remove Paint before Welding or Heating44
Beware of Asbestos and Silicon Dust and Other Contamination44
Prevent Battery Explosions45
Service Air Conditioning System Safely45
Handle Chemical Products Safely46
Dispose of Waste Properly46
Precautions for Communication Terminal47
Precaution for Communication Terminal Equipment48
Articulation Stopper (Lock Bar49
Safety Labels50
Components Name62
Getting On/Off the Machine64
Operator's Station65
Cab Features65
Front Console66
Right Console67
Fingertip Control Type67
Multi-Function Joystick Type68
Monitor Panel69
Service Indicator70
Parking Brake Indicator (Red)71
Brake Oil Low Pressure Indicator (Red)71
Hydraulic Oil Level Indicator (Red)71
Low Steering Oil Pressure Indicator (Red) (Option)72
Transmission Warning Indicator (Red)72
Discharge Warning Indicator (Red)72
Engine Warning Indicator (Red)73
Overheat Indicator (Red)73
Engine Oil Low Pressure Indicator (Red)73
Air Filter Restriction Indicator (Red)74
Preheat Indicator (Yellow)74
Secondary Steering Indicator (Yellow)75
Seat Belt Indicator (Red)75
Water Separator Indicator (Red)75
Hydraulic Oil Temperature Indicator (Red)76
Transmission Oil Temperature Indicator (Red)76
Axle Oil Temperature Indicator (Red)76
Coolant Temperature Gauge77
Fuel Gauge77
Transmission Oil Temperature Gauge77
Turn Signal Indicator (Green)78
High Beam Indicator (Blue)78
Work Light Indicator (Yellow)78
Clearance Light Indicator (Green)79
Control Lever Lock Indicator (Red)79
Power Mode Indicator (Green)79
Maintenance Indicator80
Forward/Reverse Selector Switch Indicator (Green)80
Fan Reverse Rotation Indicator (Green)80
Monitor Display81
Forward/Reverse and Shift Position Indicator82
FNR (Forward/Reverse) Position Indicator82
Hold Indicator83
Shift Position Indicator83
Speedometer84
Ride Control Indicator85
ECO Indicator85
Machine Information Display86
Shifting Item to be Indicated on Machine Information Display87
Resetting of Oil Change and Filter Replacement Intervals91
Clock Setting Mode100
Switches, Steering Wheel and Pedals101
Hazard Switch102
Work Light Switch103
Parking Brake Switch104
Neutral Lever Lock (for the Forward/Reverse Lever)105
Steering Wheel105
Key Switch106
Turn Signal Lever107
Light Switch108
High-Low Beam Switch109
Accelerator Pedal110
Brake Pedal110
Service Brake110
Declutch Brake110
Forward/Reverse Lever/ Shift Switch111
Forward/Reverse Lever111
Shift Switch111
Wiper Switch112
Wiper Operation112
Front/Rear Wiper Switch113
Tilt, Telescopic Lever/Steering Column Tilt Pedal114
Travel Mode Selector115
Declutch Position Switch116
Auto Idling Stop Switch117
Shift Change Delay Mode Switch118
Right Console / Switches119
Fingertip Control Type119
Loading Control Levers120
Right Console / Switches122
Multi-Function Joystick Type122
Loading Multi-Function Joystick Lever (Option)123
Auxiliary Control Lever (Option)124
Forward/Reverse Selector Switch125
Operational Procedure125
Loading Control Lever Lock Switch126
1St Speed Fixed Switch127
Power Mode Selector128
Fan Reverse Rotation Switch129
Off129
Auto129
Manual Operation130
Secondary Steering Operation Check Switch (Option)131
Ride Control Switch (Option)132
Auto133
Off133
Hold Switch134
Horn Switch135
Dual Lift Arm Auto Leveler Switch136
Lower Kickout Setting/Height Kickout Setting136
Quick Power Switch137
DSS (down Shift Switch)138
Armrest Adjust Handle139
Cigar Lighter (24 VDC Electrical Outlet)140
Using Cigar Lighter140
Using 24 VDC Electrical Power Supply140
Ash Tray140
Auto Air Conditioner141
Feature141
Auto Air Conditioner142
Components Name142
Controller Part Name and Function143
Defroster Operation147
Cool Head/Warm Feet Operation147
Tips for Optimal Air Conditioner Usage148
For Rapid Cooling148
When Windows Become Clouded148
Off-Season Air Conditioner Maintenance148
Adjusting Operator's Seat (Air Suspension Type Seat)149
Components Name149
Rear Tray150
Electric Power Output (Optional)150
Fuse Box151
Fuse Box a152
Fuse Box B152
Hot/Cool Box153
Tray and Drink Holder153
ROPS Cab154
Front Interior Light156
Rear Interior Light156
Sun Visor157
Emergency Exit Hammer157
Coat/Hat Hook157
Upper Switch Panel (Optional)158
Rotary Light Switch (Optional)158
Outside Rear View Mirror159
Inside Rear View Mirror159
Cab Door159
Door Lock Knob160
Door Open/Close Lever160
Window Open/Close Levers160
When Fully Opening the Door161
Cab Door Release Lever161
Battery Disconnect Switch162
Switch Operation163
Articulation Lock Bar164
Towing Pin165
Inspection/Maintenance Side Access Cover166
Rear Grille167
Steps168
Tool Box168
Vandal-Resistant Devices169
Break-In172
Break-In Period for New Machine172
Use ECO Mode for Break-In172
Operating the Engine174
Inspect Machine Daily before Starting174
Check before Starting176
Starting Engine178
Starting in Cold Weather180
Check after Starting181
Using Booster Batteries182
Warm up184
Cold Weather Warm up185
Stopping Engine186
Moving the Machine188
Driving the Machine188
Starting to Move189
Parking Brake Switch195
Drive Speed Change196
Changing Forward/Reverse Drive Direction196
Steering Wheel197
Secondary Steering (Optional)198
Emergency Stop and Restart of Operation199
Precautions for Driving on Slopes202
Precautions to be Taken if Machine Failure Occurs203
Stop the Machine204
Parking206
Emergency Evacuation207
Operating the Machine208
Loading Control Levers208
Control Lever Lock211
Declutch Position Switch212
Lift Arm Height Kickout213
Adjustment of Loader Front213
Adjustment of Dual Lift Arm Auto Leveler214
Adjustment of Bucket Auto Leveler215
Auto Idling Stop217
Before Operation219
Precautions for Operation219
Ensure Safety When Operating on Road Shoulders219
Avoid Overloading220
Avoid Rapid Steering Changes And/Or Sudden Braking220
Avoid Operation with Loads on Only One Side220
Excavation221
Loading Accumulated Soil221
Digging and Loading Level Ground222
Grading223
Loading224
Load and Carrying Method224
Loader and Dump Truck Combination Method225
V-Shape Loading225
I-Shape Loading225
Dumping into Truck or Hopper226
Dozing227
Stock Piling227
Removing Snow228
Lifting Wheel Loader228
Precautions for after Operation229
Transporting232
Transporting by Road232
Selecting a Trailer232
Loading / Unloading on Trailer233
Fastening Machine for Transporting235
Transporting Wheel Loader (Urgent Situation)236
Towing Method240
Lifting Machine241
Maintenance242
Correct Maintenance and Inspection Procedures242
Check the Hour Meter Regularly243
Layout244
Preparations for Inspection and Maintenance248
Articulation Lock250
Inspection/ Maintenance Access Side Cover251
Rear Grille252
Periodic Replacement of Parts253
Inspection and Maintenance Table254
Kind of Oils258
Greasing261
Engine267
Check Engine Oil Level267
Change Engine Oil268
Replace Engine Oil Filter270
Check Crankcase Breather Tube271
Replace Crankcase Air Breather Element272
Check Vibration Damper274
Power Train275
Check Transmission Oil Level275
Change Transmission Oil and Transmission Oil Filter276
Change Axle Oil279
Check Surroundings Around Axle and Covers for Oil Leaks281
Clean Axle Housing Air Breather281
Hydraulic System282
Check Hydraulic Oil Level284
Change Hydraulic Oil285
Clean Suction Filter287
Replace Pilot Oil Filter288
Replace Hydraulic Tank Oil Filter290
Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage293
Replace Pilot Circuit Accumulator294
Check Ride Control Accumulator Function, Gas Leakage, Looseness, and Damage294
Check Gas Pressure in Ride Control Accumulator294
Check Hoses and Lines295
Fuel System300
Check Fuel Level300
Drain Water and Sediment from Fuel Tank302
Drain Fuel Filter303
Replace Fuel Main Filter Element304
Replace Fuel Pre-Filter Element305
Clean Fuel Pump Strainer306
Check Fuel Hoses307
Air Cleaner308
Clean and Replace Air Cleaner Element308
Dust Ejection Valve309
Check Air Inlet System310
Cooling System311
Check Coolant Level312
Check Drive Belt313
Check and Adjust Drive Belt Tension313
Change Coolant314
Clean Radiator/Oil Cooler Cores and Other Cooling System315
Electrical System316
Batteries316
Replace Batteries320
Check Monitor Functions and All Other Instrument Operation320
Check Work Lights321
Check Horn and Reverse Buzzer321
Check Electrical Harnesses and Fuses322
Fuse Box a323
Fuse Box B323
Brake System324
Check Right and Left Brake Interlocking Performance324
Check Parking Brake Force325
Check Accumulator Function, Gas Leakage, Looseness, and Damage326
Check Gas Pressure in Accumulator327
Check Brake Disks (Service and Parking)327
Tire328
Check and Replace Tire (Tire Pressure)328
Check Tire for Damage328
Check Wheel Bolt Torque329
Air Conditioner334
Clean/Replace Air Conditioner Circulation/Fresh Air Filters334
Check Air Conditioner337
Check Air Conditioner Piping337
Check Air Conditioner Condenser338
Check Air Conditioner Compressor Belt338
Check Refrigerant339
Check Compressor and Pulley339
Miscellaneous340
Check Bucket Teeth and Cutting Edge340
Check and Replace Seat Belt and Lower Tether341
Check ROPS Cab, Resin Cab Roof, and Roof Mounting Bolts341
Check Windshield Washer Fluid Level341
Check Play Amount in Steering Wheel Movement342
Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise343
Check Rearview Mirror and Inside Rearview Mirror344
Check Steps and Handrails for Damage and Looseness344
Clean Engine Compartment and Hood345
Check Sound Absorbing Mat Around Engine345
Check and Adjust Valve Clearance345
Retighten Front Axle and Rear Axle Support Mounting Bolts346
Tightening and Retightening Torque of Nuts and Bolts347
Maintenance under Special Environmental Conditions360
Maintenance under Special Environmental Conditions361
Precautions for Maintenance During Cold Weather Season361
Storage364
Storing the Machine364
Troubleshooting368
Specifications372
Other Attachments and Device374
Quick Coupler374
How to Use Hydraulic Loader Coupler374
General Maintenance377
Index378

KCM 70Z7 - General Maintenance

Table of Contents