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Kawasaki 70Z7B WHEEL LOADER Service Repair Manual (Serial No. 70C8-5001 and up)

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Kawasaki 70Z7B WHEEL LOADER Service Repair Manual (Serial No. 70C8-5001 and up)

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  1. 93208-00850 November 2016 70Z7B S HOP MANUAL S HOP MANUAL WHEEL LOADER Func tion & S truc ture General Information 70Z7B General Information Function & Structure 93208-00850 Powered by CUMMINS QSB6.7 Engine Serial No. 70C8-5001 and up ©2016 KCM Corporation. All rights reserved. Printed in Japan (K) （アメリカ用） （アメリカ用）

  2. 93208-00860 November 2016 70Z7B SHOP MANUAL SHOP MANUAL WHEEL LOADER 70Z7B Troubleshooting Operational Performance Test Operational Performance Test Troubleshooting 93208-00860 Powered by CUMMINS QSB6.7 Engine Serial No. 70C8-5001 and up ©2016 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 アメリカ用 )

  3. 93208-00850 SECTION 1 GENERAL Group 1 Specifications Group 2 Component Layout Group 3 Component Specifications SECTION AND GROUP CONTENTS SECTION 2 SYSTEM Group 1 Controller Group 2 Control System Group 3 Engine System Group 4 Hydraulic System Group 5 Electrical System SHOP MANUAL (Function & Structure) SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Control Valve Group 3 Cooling Fan System Group 4 Steering Pilot Valve Group 5 Priority Valve Group 6 Pilot Valve Group 7 Brake Charge Valve/Manifold Valve Group 8 Drive Unit Group 9 Axle Group 10 Brake Valve Group 11 Ride Control Valve Group 12 Others 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.

  4. 93208-00860 SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Machine Performance Test Group 5 Component Test Group 6 Adjustment SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 e-Service Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Air Conditioner SECTION AND GROUP CONTENTS SHOP MANUAL (Troubleshooting) 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.

  5. SECTION 1 GENERAL CONTENTS Group 1 Specifications Specifications .......................................................................T1-1-1 Group 2 Component Layout Main Component (Overview) .........................................T1-2-1 Main Component ................................................................T1-2-3 Electrical System (Overview) ..........................................T1-2-5 Air Cleaner and Radiator Assembly ..............................T1-2-6 Battery Box ............................................................................T1-2-8 Hydraulic Tank ......................................................................T1-2-9 Fuel Tank ..............................................................................T1-2-10 Drive Unit .............................................................................T1-2-11 Front Axle .............................................................................T1-2-12 Cab .........................................................................................T1-2-13 Engine ...................................................................................T1-2-19 Aftertreatment Device ....................................................T1-2-20 Fan Valve (Option).............................................................T1-2-21 Priority Valve .......................................................................T1-2-21 Pump Device ......................................................................T1-2-22 Control Valve.......................................................................T1-2-22 Manifold Valve ....................................................................T1-2-23 Parking Brake Solenoid Valve Block ...........................T1-2-23 Brake Charge Valve (Unloader Valve) .........................T1-2-23 Ride Control Valve (Option) ...........................................T1-2-24 Secondary Steering Block (Option) ............................T1-2-25 Secondary Steering Pump (Option) ...........................T1-2-25 Flow Regulator Valve .......................................................T1-2-25 DEF Tank ...............................................................................T1-2-26 DEF Supply Module ..........................................................T1-2-26 Group 3 Component Specifications Engine .....................................................................................T1-3-1 Engine Accessories .............................................................T1-3-5 Hydraulic Component .......................................................T1-3-6 Electrical Component ......................................................T1-3-11 70Z7B F&S (US)

  6. SECTION 1 GENERAL Group 1 Specifications Specifications 45 ° I E G B C H 40 ° F D R1 A R2 MPD8-12-001 Model - 70Z7B 2.8 (3.7) 14560 (32100) 10440 (23020) CUMMINS QSB6.7 8000 (315) 2730 (107) 3280 (129) 3100 (122) 2050 (81) 395 (16) 3920 (155) 2760 (109) 1110 (44) 5580 (220) 6230 (245) 38.5 (23.9)/26.5 (16.5) (38.5 (23.9)/28.3 (17.6)) 5/3 40 20.5-25-12PR (L2) Bucket Capacity: heaped Operating Weight Tipping Load Engine A: Overall Length B: Overall Width (Bucket) C: Overall Height D: Wheel Base E: Tread (front and rear tires) F: Ground Clearance G: Bucket Hinge Height H: Dumping Clearance (45 °) I: Dumping Reach (45 °) R1: Minimum Rotation Radius R2: Minimum Rotation Radius Travel Speed Forward/Reverse (at Power mode) Transmission Speeds (F/R) Articulation Angle (Left/Right) deg Tire Size fNOTE: These specifications are subject to change without notice. m3 (Y3) kg (lbs) kg (lbs) - mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) km/h (mph) - ( ° ) - T1-1-1

  7. SECTION 1 GENERAL Group 2 Component Layout Main Component (Overview) 8 7 6 5 4 3 2 9 1 10 11 TNEK-01-02-007 1- 2- 3- 4- Bucket Bucket Link Bell Crank (Lever) Bucket Cylinder 5- Front Combination Light (Headlight, Turn Signal Light, Clearance Light, Hazard Light) (2 Used) 6- 7- 8- 9- Horn (2 Used) Front Work Light (2 Used) Cab (Refer to T1-2-13.) DEF Tank Box 10- Lift Arm Cylinder (2 Used) 11- Lift Arm T1-2-1

  8. SECTION 1 GENERAL Group 2 Component Layout 13 12 14 TNEK-01-02-008 15 12- Rear Work Light (2 Used) 13- Rain Cap/Pre-Cleaner (Option) 14- Battery Box (Refer to T1-2-8.) 15- Rear Combination Light (Turn Signal Light, Hazard Light, Tail Light, Brake Light) (2 Used) T1-2-2

  9. SECTION 1 GENERAL Group 2 Component Layout Main Component 1 2 3 4 5 6 7 8 16 15 14 17 13 12 11 10 9 TPD8-01-02-001 1- Air Cleaner and Radiator Assembly (Refer to T1-2-6.) Aftertreatment Device (Refer to T1-2-20.) Hydraulic Tank (Refer to T1- 2-9.) Parking Brake Solenoid Valve (Refer to T1-2-23.) 5- Manifold Valve (Refer to T1- 2-23.) Brake Valve Steering Pilot Valve Multiple Control Valve (Refer to T1-2-22.) Ride Control Valve (Refer to T1-2-24.) 10- Ride Control Accumulator (Option) 11- Brake Charge Valve (Unloader Valve) (Refer to T1-2-23.) 12- Pilot Filter 13- Service Brake Accumulator (2 Used) 14- Flow Regulator Valve (Refer to T1-2-25.) 15- Pilot Valve 16- Engine (Refer to T1-2-19.) 17- Priority Valve 2- 6- 7- 8- 3- 4- 9- T1-2-3

  10. SECTION 1 GENERAL Group 2 Component Layout 17 19 21 22 23 31 24 30 29 28 27 26 25 TPD8-01-02-002 17- Front Axle (Refer to T1-2-12.) 19- Steering Accumulator (2 Used) 21- Pump Device (Refer to T1-2- 22.) 22- Drive Unit (Refer to T1-2-11.) 23- Fuel Prefilter 24- Fuel Tank (Refer to T1-2-10.) 25- DEF Supply Module 26- DEF Tank 27- Torque Converter Cooler Check Valve 28- Rear Axle 29- Third (Rear) Propeller Shaft 30- Second (Front) Propeller Shaft 31- Steering Cylinder (2 Used) T1-2-4

  11. SECTION 1 GENERAL Group 2 Component Layout Electrical System (Overview) 4 3 2 1 10 9 8 5 6 7 TNEK-01-02-003 1- 2- Engine (Refer to T1-2-19.) Hydraulic Tank (Refer to T1- 2-9.) Cab (Refer to T1-2-13.) 4- 5- 6- 7- Bucket Proximity Switch Lift Arm Proximity Switch Battery Box (Refer to T1-2-8.) Fuel Tank (Refer to T1-2-10.) 8- 9- 10- DEF Supply Module (Refer to T1-2-25.) DEF Tank (Refer to T1-2-25.) Backup Alarm 3- T1-2-5

  12. SECTION 1 GENERAL Group 2 Component Layout Air Cleaner and Radiator Assembly View A 1 2 5 5 6 1 8 7 4 3 TNEK-01-02-011 TNEK-01-02-012 A 1- 2- Air Cleaner Radiator Assembly (Refer to T1-2-7.) 3- 4- Fan Valve (Refer to T1-2-21.) Intercooler Outlet Temperature Sensor 5- 6- 7- Reserve Tank Air Filter Restriction Switch TBAP Sensor 8- Coolant Level Sensor T1-2-6

  13. SECTION 1 GENERAL Group 2 Component Layout Radiator Assembly 1 View A 5 2 4 6 A a 3 a TNEK-01-02-010 TNEK-01-02-009 a- Machine Front Side 1- 2- Reserve Tank Radiator 3- 4- Oil Cooler Intercooler 5- 6- Torque Converter Cooler Fan Motor T1-2-7

  14. SECTION 1 GENERAL Group 2 Component Layout Battery Box 1 Detail A 5 6 2 A 7 4 8 3 9 10 2 11 TNEK-01-02-004 MNEK-01-015 1- 2- 3- Battery Box Battery (2 Used) Battery Disconnect Switch 4- 5- 6- Battery Relay Fusible Link (70 A) Fusible Link (140 A) 7- 8- 9- Fusible Link (65 A) Fusible Link (45 A) Fusible Link (65 A) 10- Starter Relay 11- Intake Air Heater Relay T1-2-8

  15. SECTION 1 GENERAL Group 2 Component Layout Hydraulic Tank 1 2 3 a 5 4 TNEG-01-02-014 a- Machine Front Side 1- 2- Hydraulic Tank Hydraulic Oil Level Sensor 3- Washer Fluid Tank 4- Hydraulic Oil Temperature Sensor 5- Secondary Steering Pump (Option) (Refer to T1-2-25.) T1-2-9

  16. SECTION 1 GENERAL Group 2 Component Layout Fuel Tank 5 4 1 3 a TNEK-01-02-013 2 a- Machine Front Side 1- 2- Fuel Tank Fuel Level Sensor 3- 4- Fuel Pump Water Separator Sensor 5- Fuel Prefilter T1-2-10

  17. SECTION 1 GENERAL Group 2 Component Layout Drive Unit 1 7 2 a 6 8 A 5 3 9 4 TNEK-01-02-014 TNEK-01-02-015 View A 10 15 11 14 13 12 TNEK-01-02-016 a- Machine Front Side 1- Transmission Intermediate Shaft Sensor Torque Converter Output Speed Sensor Transmission Oil Filter Machine Speed Sensor Transmission Oil Filter Restriction Switch 6- Torque Converter Input Speed Sensor Breather Torque Converter Oil Temperature Sensor Transmission Control Valve 10- Proportional Solenoid Valve Y1 (For Fast-Speed Forward Clutch) 11- Proportional Solenoid Valve Y2 (For Reverse Clutch) 12- Proportional Solenoid Valve Y3 (For 1st Speed Clutch) 13- Proportional Solenoid Valve Y4 (For 3rd Speed Clutch) 14- Proportional Solenoid Valve Y5 (For Slow-Speed Forward Clutch) 15- Proportional Solenoid Valve Y6 (For 2nd Speed Clutch) 2- 7- 8- 3- 4- 5- 9- T1-2-11

  18. SECTION 1 GENERAL Group 2 Component Layout Front Axle 1 2 TNEE-01-02-018 1- Pressure Sensor (Brake Secondary Pressure) 2- Axle Oil Temperature Sensor T1-2-12

  19. SECTION 1 GENERAL Group 2 Component Layout Cab 1 11 2 12 3 3 Detail D 9 10 a 4 e F b TNEK-01-02-017 D e View F 8 7 6 5 c TNEG-01-02-002 TNEG-01-02-041 a- Front Console (Refer to T1-2- 14.) b- Right Console (Refer to T1-2- 15.) c- Rear Console (Refer to T1-2- 16.) e- Control Unit (Refer to T1-2-17.) 1- 2- 3- 4- Radio Upper Switch Panel (Option) Speaker (2 Used) Rear Wiper Motor 5- 6- 7- 8- Accelerator Pedal Sensor Brake Angle Sensor Brake Light Switch Front Wiper Motor 9- 10- Front Wiper (2) Relay 11- GPS Antenna (Option) Front Wiper (1) Relay 12- Communication Terminal Antenna T1-2-13

  20. SECTION 1 GENERAL Group 2 Component Layout Front Console 1 2 3 4 5 6 7 8 MNEC-01-036 9 12 13 14 11 10 15 MNEC-01-037 MNEC-01-038 1- 2- 3- 4- Hazard Light Switch Work Light Switch Parking Brake Switch Neutral Lever Lock for Forward/Reverse Lever Steering Wheel 6- Monitor Panel (Refer to T1- 2-18.) Horn Accelerator Pedal Brake/ Declutch Pedal (Both at left and right are interlocked.) 10- Front/Rear Wiper Switch 11- Forward/Reverse Lever/Shift Switch 12- Turn Signal Lever/Light Switch/Dimmer Switch 13- Key Switch 14- Multi-Function Monitor/Air Conditioner Control Panel 15- Cigar Lighter 7- 8- 9- 5- T1-2-14

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  22. SECTION 1 GENERAL Group 2 Component Layout Right Console Fingertip Control Lever Type 4 19 5 6 7 8 9 3*(1) 2*(3) 10 11 12 20 1*(2) 21 18 13 14 15 1716 MNEC-01-042 MNEC-01-041 Multi-Function Joystick Lever Type 21 19 1 5 6 7 8 22 10 11 12 24 23 25 26 13 14 15 1716 MNEC-01-044 MNEC-01-043 1*- Auxiliary Control Lever (Option) 2*- Bucket Control Lever 3*- Lift Arm Control Lever 4- Forward/Reverse Switch 5- Control Lever Lock Switch 6- Declutch Position Switch 7- Travel Mode Switch 8- 9- Power Mode Switch Forward/Reverse Selector Switch 10- Fan Reversing Switch 11- Auxiliary 12- Hydraulic Coupler Switch (Option) 13- Secondary Steering Check Switch (Option) 14- Manual Regeneration Switch 15- Auxiliary 16- First Speed Fixed Switch 17- Ride Control Switch (Option) 18- Hold Switch 19- DSS (Down Shift Switch) 20- Horn Switch 21- Quick Power Switch 22- Forward/Reverse Selector Switch 23- Forward/Reverse Switch 24- Multi-Function Joystick Lever 25- Hold Switch (Under the Lever) 26- Horn Switch (Under the Lever) fNOTE: * The layout of each control lever may depend on the machine specification. T1-2-15

  23. SECTION 1 GENERAL Group 2 Component Layout Rear Console 1 2 3 35 9 8 7 6 5 4 14 13 12 11 10 19 18 17 16 15 24 23 22 21 20 36 27 29 28 26 25 37 34 33 32 31 30 38 TNEK-01-02-018 1- 2- 3- 4- 5- 6- 7- 8- 9- 10- Supply Module Relay (C-R6) 11- DEF Sensor Relay (C-R7) Fuse Box B Fuse Box A MPDr. Connector ECM Main Relay Starter Cut Relay (C-R1) Fuel Pump Relay (C-R2) DEF Heater Relay 1 (C-R3) DEF Heater Relay 2 (C-R4) DEF Heater Relay 3 (C-R5) 12- Parking Brake Light Relay (C-R8) 13- ECM Timer Relay (C-R9) 14- Not Used 15- Headlight Relay (Left) (A-R1) 16- Headlight Relay (Right) (A-R2) 17- High Beam Relay (A-R3) 18- Bucket Leveler Relay (A-R4) 19- Back Buzzer Relay (A-R5) 20- Work Light (Front) Relay (A-R6) 21- Work Light (Rear) Relay (A-R7) 22- Right Turn Signal Light Relay (A-R8) 23- Horn Relay (A-R9) 24- Secondary Steering Relay (A-R10) 25- Parking Brake Relay 1 (B-R1) 26- Parking Brake Relay 2 (B-R2) 27- Control Lever Lock Relay (B-R3) 28- Brake Light Relay (B-R4) 29- Load Dump Relay (B-R5) 30- Neutral Relay (B-R6) 31- Left Turn Signal Light Relay (B-R7) 32- Front Washer Relay (B-R8) 33- Rear Wiper Relay (B-R9) 34- Rear Washer Relay (B-R10) 35- Relay Box C 36- Relay Box A 37- Relay Box B 38- Engine Data Link Connector T1-2-16

  24. SECTION 1 GENERAL Group 2 Component Layout Control Unit b TNEG-01-02-004 1 TNED-01-02-029 3 6 4 a 2 5 TNEK-01-02-020 a TNEK-01-02-019 a- Machine Front Side b- Monitor 1- Monitor Controller 2- TCU (Transmission Control Unit) 3- 4- MC (Main Controller) GSM/GPS (Option) 5- 6- Flasher Relay Air Conditioner Controller T1-2-17

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