Torquing the cylinder head on a 6WG1 takes six steps. The M18 bolts go to 177 N·m, then 245 N·m, then 60 to 90 degrees of angle, finishing at 324 N·m. This Kawasaki 95Z7 / 115Z7 engine shop manual gives that sequence and the bolt order.
It combines two books in the July 2012 edition. Book 93215-00620 covers general information and troubleshooting: blink-count DTCs, common rail, EGR, DPD regeneration and the engine control wiring diagram. Book 93215-00630 covers removal, disassembly, inspection and reassembly of the Interim Tier 4 6WG1. It applies to Serial No. 97J1-5001 and up and 11J1-5001 and up.
Valve clearance is 0.4 mm on intake and exhaust, set cold with a feeler gauge between the rocker arm and camshaft. That lets you close up the head and valve train to the book's own numbers.
What's Inside This Kawasaki 95Z7, 115Z7 Isuzu 6WG1 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 1-7 | Safety Information for Repair Work, Engine Stand Use, Electrical System Precautions |
| Service Information Guide | 8-27 | How to Use the Manual, Standard Bolt and Nut Tightening Torques, Thread Locking Agents |
| Maintenance Information | 28-93 | Primary Specifications, Engine Control System, Fuel, Cooling, Lubrication, EGR, Preheat QOS, DPD, Functional Checks |
| Functional Inspection | 94-111 | OBD System Check, Diagnostic Light, Engine Control Checks |
| Symptom | 112-127 | Start Failure, Stalling, Rough Idle, White and Black Smoke, Noise, Fuel and Oil Consumption, Low Output, DPD Regeneration |
| DTC Information | 128-237 | Diagnostic Trouble Codes with Flash Codes, Detection Conditions and Diagnostic Procedures |
| Engine Control | 238-361 | ECM, Sensors, Injectors, Common Rail, Circuit Checks |
| Wiring Diagram | 362-396 | Engine Control Wiring Diagram, Connector Location, Connector List, Terminal Names |
| Mechanical | 397-761 | Removal, Installation, Disassembly, Reassembly and Inspection: Cylinder Head, Valves, Pistons, Crankshaft, Timing Gears |
| Fuel System | 762-821 | Fuel Pipes, Common Rail, Supply Pump, Injectors, Fuel Filter |
| Cooling | 822-853 | Water Pump, Thermostat, Coolant Pipes |
| Lubrication | 854-901 | Oil Pump, Oil Cooler, Oil Filter, Oil Thermo Valve |
| Induction | 902-919 | Turbocharger, Intake Ducts |
| Exhaust | 920-933 | Exhaust Manifold and Pipes, Exhaust Sensors |
| Aux. Emission Control Devices | 934-955 | EGR Cooler, EGR Valve, Emission Control Parts |
| Electrical | 956-993 | Starter, Generator, Glow Plugs, Tightening Torque Views |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine type | Diesel/4-cycle/water-cooled, inline 6-cylinder OHC | p. 32 |
| Cylinder bore x stroke | 147 mm {5.78 in} x 154 mm {6.06 in} | p. 32 |
| Displacement | 15.681 L {956.85 cu·in} | p. 32 |
| Compression ratio | 16.5 | p. 32 |
| Compression pressure | 2940 kPa { 30 kgf/cm2 } /200 r/min | p. 32 |
| Rated output | 397 kW { 540 ps } /1800 r/min | p. 32 |
| Maximum torque | 2250 N · m { 229 kgf · m } /1500 r/min | p. 32 |
| Dry weight | 1150 kg { 2535 lb } | p. 32 |
| Fuel injection order | 1, 5, 3, 6, 2, 4 | p. 32 |
| Valve clearance (intake and exhaust, cold) | 0.4 mm { 0.0157 in } While cool | p. 32 |
| Injection pump type | Electronic control common rail type | p. 32 |
| Turbocharger type | RHG8V {IHI} | p. 32 |
| Engine oil level | 42 to 57 L { 11 to 15 US gal / 9 to 13 Imp.gal } Reference value | p. 32 |
| Oil pan capacity | 37 to 52 L { 10 to 14 US gal / 8 to 11 Imp.gal } | p. 32 |
| Volume of coolant in engine | 36.0 L { 10 US gal / 8 Imp.gal } | p. 32 |
| Thermostat opening temperature | 76.5 °C { 170 °F } | p. 33 |
| Thermostat full-open temperature / lift | 90 °C { 194 °F } /11 mm (0.43 in) | p. 33 |
| Generator nominal output | 24 V - 50 A | p. 33 |
| Starter output | 24 V /7.0 kW | p. 33 |
| Oil pump discharge pressure | 0.54 MPa { 6 kgf/cm2 / 78 psi } | p. 34 |
Kawasaki 95Z7, 115Z7 Isuzu 6WG1 Common Problems This Manual Covers
Hard start after a fuel filter change
Maintenance Information gives the fuel filter air removal steps. Loosen the plug and work the priming pump 20 times or more until fuel spills out. Then retighten the plug. The DTC check expects a warm restart to crank in 5 seconds or less, so you can confirm the fix there.
Manual Section: Maintenance Information p. 58Excessive black smoke
The Symptom section's black smoke diagnosis starts with a preliminary inspection before anything comes apart. Do those checks in order. Then move to Engine Control for injector and common rail circuits, and to Induction for the IHI RHG8V turbocharger and intake ducts.
Manual Section: Symptom / Induction p. 119Valve train noise or clearance out after head work
The Mechanical section sets valve clearance at 0.4 mm on intake and exhaust while cool. Measure it with a feeler gauge between the rocker arm and camshaft. If the head was off, follow the six-step tightening order first, finishing at 324 N·m. The fuel injection order 1, 5, 3, 6, 2, 4 is in the primary specifications.
Manual Section: Mechanical p. 475Frequently Asked Questions
Can I read engine fault codes on a Kawasaki 95Z7 or 115Z7 6WG1 without a scan tool?
Yes. You read the codes by counting the blinks of the diagnostic light. The DTC Information section lists each flash code with its detection condition and diagnostic procedure. The DTC check covers clearing old codes, warming up and checking idle. A warm restart should crank in 5 seconds or less. p. 89
I replaced an injector on the 95Z7 / 115Z7 6WG1. Do I have to program anything?
Yes. The injector ID code has to be programmed after you replace an injector, the ECM or the engine. The manual flags this in its maintenance information, so it gets done before the loader goes back to work. p. 31
What causes excessive white smoke on the 6WG1 in a 95Z7 or 115Z7?
The Symptom section lists the causes it checks: insufficient compression, piston problems, turbocharger failure, and an oil level that is raised or sucked down. Each one has its own check. You can rule causes out in order instead of guessing at the turbo first. p. 118
Why is DPD regeneration taking so long on my 115Z7 or 95Z7?
The Symptom section has a chart for slow DPD regeneration. It sends you to the water pump, a clogged radiator, the coolant level and the air intake system. The engine holds 36.0 L of coolant, so a low level is worth checking first. p. 127
Does this 95Z7 / 115Z7 6WG1 manual cover the loader hydraulics or only the engine?
It covers only the engine. It is the Isuzu 6WG1 engine shop manual for the 95Z7 and 115Z7 wheel loaders. Topics include mechanical, fuel, cooling, lubrication, induction, exhaust, emission control, electrical and engine control. Loader valve and lift arm work belong in the machine manual. p. 2
