93215-00620
6WG1 (95Z7/115Z7) SHOP MANUAL
July 2012
For Service Training
SHOP MANUAL
ISUZU DIESEL ENGINE
Troubleshooting Information
General Information
6WG1
General Information
Troubleshooting Information
93215-00620
(For Kawasaki Wheel Loader 95Z7, 115Z7)
©2012 KCM Corporation. All rights reserved. Printed in Japan (K) Serial No. 97J1-5001 and up
( アメリカ用 ) Serial No. 11J1-5001 and up
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