Kawasaki 70 z7b wheel loader service repair manual (serial no. 70c6 5001 and up)
- 1. Ā©2017 KCM Corporation. All rights reserved. Printed in Japan (K) ļ¼ć¢ć”ćŖć«ēØļ¼ 93208-00870 May 2017 SHOP MANUAL WHEEL LOADER 70Z7B Disassembly & Reassembly Powered by CUMMINS QSB6.7 ENGINE Serial No. 70C6-5001 and up Volume 1 70Z7B SHOP MANUAL Disassembly & Reassembly Vol.1 93208-00870
- 2. SECTION AND GROUP CONTENTS WORKSHOP MANUAL 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. SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Body Group 2 Front Attachment SECTION 3 BODY Group 1 Cab Group 2 Counterweight Group 3 Center Hinge Group 4 Engine Group 5 Radiator Assembly Group 6 Hydraulic Oil Tank Group 7 Fuel Tank Group 8 Pump Device Group 9 Control Valve Group 10 Pilot Valve Group 11 Brake Charge Valve Group 12 Manifold Valve Group 13 Solenoid Valve Group 14 Flow Regulator Valve Group 15 Cooling Fan System Group 16 Ride Control Device Group 17 Battery Disconnect Switch Group 18 Aftertreatment Device Group 19 DEF Tank Group 20 Coolant Control Valve Group 21 DEF Supply Module Group 22 Exterior Components 93208-00870 Volume 1
- 3. SECTION AND GROUP CONTENTS WORKSHOP MANUAL 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. SECTION 4 TRAVEL SYSTEM Group 1 Tire Group 2 Drive Unit Group 3 Axle Group 4 Propeller Shaft Group 5 Brake Valve Group 6 Steering Device Group 7 Secondary Steering Device SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder 93208-00870 Volume 2
- 4. 70Z7B D&R Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling.................................................................W1-1-1-1 Group 2 Tightening Tightening Bolts and Nuts..........................................W1-2-1-1 Piping Joint ......................................................................W1-2-1-4 Group 3 Painting Group 4 Bleeding Air Bleed Air from the Hydraulic System......................W1-4-1-1 Bleed Air from the Fuel System.................................W1-4-1-2 Bleeding Air from Brake (Axle)..................................W1-4-1-3 Group 5 Preparation Preparations for Inspection and Maintenance....W1-5-1-1 Releasing Pressure from Hydraulic Circuit............W1-5-1-6 Releasing Pressure from Ride Control Accumulator...............................................................W1-5-1-7 Releasing Pressure from Parking Brake Accumulator...............................................................W1-5-1-8 Releasing Pressure from Hydraulic Oil Tank.........W1-5-1-9 Releasing Pressure from Expansion Tank...........W1-5-1-10 SECTION 1 GENERAL CONTENTS
- 5. W1-1-1-1 Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL Precautions for Disassembling and Assembling Precautions for Disassembling ļ Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling / assembling, resulting in damage to machine components as well as decreased efficiency in service work. ļ Inspect the Machine Be sure to thoroughly understand all disassembling / assembling procedures beforehand to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. ļ The machine model, machine serial number, and hour meter reading. ļ Reason for disassembly (symptoms, failed parts, and causes). ļ Clogging of filters and oil, water, or air leaks, if any. Capacities and condition of lubricants. ļ Loose or damaged parts. ļ Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. Precautions for Disassembling and Assembling ļ Precautions for Disassembling ļ Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. ļ Before disassembling, clean the exterior of the components and place on a workbench. ļ Drain hydraulic oil and gear oil from the hydraulic components and reduction gear. ļ Be sure to provide appropriate containers for draining fluids. ļ Use matching marks for easier reassembling if necessary. ļ Be sure to use the specified special tools when instructed. ļ If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause (s), and then take the appropriate measures to remove it. ļ Orderly arrange disassembled parts. Mark and tag them if necessary. ļ Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. ļ Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. ļ Measure and record the degree of wear and clearances. ļ Precautions for Assembling ļ Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. ļ Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. ļ Apply appropriate lubricant oil to parts in order to prevent them from seizing. ļ Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been disassembled. Apply grease before installing. ļ Be sure that liquid-gasket-applied surfaces are clean and dry. ļ If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. ļ Fit the matching marks made when disassembling and assemble them. ļ Be sure to use the designated tools to assemble bearings, bushings, and oil seals. ļ Keep a record of the number of tools used for disassembly / assembly. After assembling is completed, count the number of tools so as to make sure that no forgotten tools remain in the assembled machine.
- 6. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-2 Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures: ļ Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil to sliding surface (e) of seal ring (1). ļ Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear. ļ Check the step part of seal ring (1). ļ Check O-ring (2) for tears, breaks, deformation, or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble. ļ Clean the floating seal and seal mounting bores with cleaning solvent. ļ Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air. ļ Clean seal ring (1) and O-ring (2) mounting bores. Check the bore surface for scuffing or scoring by touching the surface with finger. ļ After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1). ļ After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f) by measuring the distances between (e) and (f) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating. 1 2 a b c d a - Correct b - Incorrect c - Twist of O-Ring d - Bend of O-Ring a - Correct b - Incorrect e - Sliding Surface f - Seal Mating Surface f e 2 a A A B B b A=B Aā B W178-02-11-001 W178-02-11-002 W178-02-11-003
- 7. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-3 Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. ļ Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. ļ Lower the temperature of the lifted load to lower than 100 Ā°C (212 Ā°F). If the temperature of the lifted load is over 100 Ā°C (212 Ā°F), do not lift the load. ļ Do not lift acid or alkali chemicals. ļ Take care not to allow the sling to become wet. The load may slip. ļ When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. ļ When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. ļ Avoid using twisted, bound, connected, or hitched slings. ļ Do not place any object on twisted or bent slings. (Refer to the right illustration.) ļ When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. ļ Avoid dragging slings on the ground, throwing slings, or pushing slings with a metal object. ļ When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. ļ Store the nylon slings indoors so that they wonāt deteriorate with heat, sun light, or chemicals. a b c a - Correct Eyehole Lifting Method b - Incorrect Eyehole Lifting Method c - Bent of Sling W102-04-02-016 W105-04-01-008 W162-01-01-009
- 8. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-4 dCAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to following examples. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7 years. Damaged Appearance a a a e f b b c c g d a - Broken Sewing Thread a - Broken Sewing Thread e - Separation of Belt b - Scuffing f - Scoring b - Scuffing c - Fuzz d - Broken Sewing Thread c - Fuzz g - Broken Warp a - Broken Sewing Thread W162-01-01-002 W162-01-01-003 W162-01-01-004 W162-01-01-005 W162-01-01-006 W162-01-01-007 W162-01-01-008
- 9. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-5 Maintenance Standard Terminology āStandardā 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary. āAllowable Limitā 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is difficult after exceeding this limit. 3. Repair or adjustment is impossible after exceeding this limit. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching theāAllowable Limitā.
- 10. W3-1-1-1 Group 1 Cab SECTION 3 BODY Removal and Installation of Cab dCAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns. Allow oil to cool before starting any work. IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) dCAUTION: Operate the steering wheel in right and left several times, and release any pressure in the circuit. dCAUTION: Operate the brake pedal more than 50 times and release any pressure in the circuit. dCAUTION: Release any pressure from hydraulic oil tank (1). (Refer to W1-5-1.) 2. Remove bolts, washers (4) (6 used). Remove the cover (2) assembly and O-ring (3). j : 17 mm 3. Place a container. Drain off hydraulic oil by using an oil feed pump. fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 1 2, 3 4 WNEK50-03-06-001
- 11. Group 1 Cab SECTION 3 BODY W3-1-1-2 ļ Without battery disconnect switch 4. Open covers (2, 3). 5. Remove bolt, washer (1). Remove rubber plate (4). j : 17 mm 6. Remove bolt, washer (5) and clip (6). j : 17 mm IMPORTANT: Turn the key switch to the OFF position, wait 5 minutes or longer, and then disconnect ground (7). 7. Loosen bolt (8). Disconnect ground (7). j : 17 mm a- Battery Box WNEK50-03-01-001 Detail A 5, 6 1 2 8 7 3 A a 4 WNEK50-03-01-002
- 12. Group 1 Cab SECTION 3 BODY W3-1-1-3 ļ With battery disconnect switch 8. Open cover (1). IMPORTANT: Turn the key switch to the OFF position, wait 5 minutes or longer, and then turn battery disconnect switch (2) to the OFF position. 9. Set battery disconnect switch (2) to OFF position (b). b- OFF Position c- ON Position a- Battery Box Detail A 2 b c WNEK50-03-22-043 1 A a WNEK50-03-17-001
- 13. Group 1 Cab SECTION 3 BODY W3-1-1-4 10. Release any pressure in the the expansion tank. (Refer to W1-5-1.) 11. Open left and right side covers (front) (1). 12. Place a container under hose (2). Loosen cock (3). Drain off coolant. Close cock (3). fNOTE: Amount of coolant: 33 L (8.7 US gal) 13. Release refrigerant of the air conditioner. (Refer to T5-7 in the separated volume, Technical Manual.) WNEK50-03-19-003 1 2 3 WNEK50-03-19-010
- 14. Group 1 Cab SECTION 3 BODY W3-1-1-5 14. Remove following exterior components from left and right side. (Refer to W3-22-1.) ļ Step (3) ļ Rear Fender (Front) (5) ļ Lower Cover (6) 15. Remove the following parts. (Refer to W3-22-1.) ļ Cab Under Cover (1) ļ Deck (2) ļ Inspection Cover (4, 7, 9) ļ Battery Box (8) WPD850-03-01-003 WNEK50-03-22-003 1 2 3 4 5 6 3 5 7 6 8, 9
- 15. Group 1 Cab SECTION 3 BODY W3-1-1-6 16. Remove bolts, washers (3) (4 used). Remove rubber plate (4). j : 17 mm 17. Remove bolts, washers (1) (1 used). Remove bracket (2). j : 17 mm WPD850-03-01-001 3 4 1 2
- 16. Group 1 Cab SECTION 3 BODY W3-1-1-7 18. Disconnect hoses (1) (4 used). j : 19 mm 19. Disconnect hose (2). j : 22 mm Detail A a- Flow Regulator Valve WNEK50-03-01-005 WNEK50-03-01-004 A a 2 1
- 17. Group 1 Cab SECTION 3 BODY W3-1-1-8 20. Disconnect hose (1). j : 27 mm Detail A a- Suction Pipe b- Flow Regulator Valve WNEK50-03-01-007 A 1 a b WNEK50-03-01-006
- 18. Group 1 Cab SECTION 3 BODY W3-1-1-9 21. Remove bolt, washer (4) and clip (5). j : 17 mm 22. Disconnect connectors (1, 2) and connectors (3) (3 used). 23. Disconnect connector (8) (only the machine with the ride control device). Remove connector (8) from bracket (9). 24. Remove bolt, washer (6). Remove bracket (7). j : 17 mm 25. Disconnect connectors (10) (2 used). Remove connectors (10) (2 used) from brackets (11, 12). Detail A Detail B Detail C c- Flow Regulator Valve WNEK50-03-01-008 3 4, 5 6, 7 8, 9 WNDB-03-01-105 a a- Vehicle Front Side b- Cab A b 1 2 C B c 10 11 10 12 WNEK50-03-01-009 WNEK50-03-01-010
- 19. Group 1 Cab SECTION 3 BODY W3-1-1-10 27. Remove bolt, washer (1) and clips (2, 3). j : 17 mm 28. Disconnect hoses (4) (2 used). 29. Remove bolt, washer (5), nut (6), and clip (7). j : 17 mm 30. Remove hoses (4) (9 used) from clips (8, 2) (2 used for each). 31. Disconnect hose (10). Remove O-ring (11) from hose (10). j : 27 mm 32. Disconnect hose (12). Remove O-ring (13) from hose (12). j : 19 mm Detail A View B Detail C a- Washer Tank b- Hydraulic Oil Tank A C a B 1, 2, 3 4 4 5, 6, 7 8 9 4 10, 11 12, 13 WNEK50-03-01-012 WNEK50-03-01-013 WNEK50-03-01-014 WNEK50-03-01-011 b
- 20. Group 1 Cab SECTION 3 BODY W3-1-1-11 33. Disconnect hose (7). j : 27 mm 34. Disconnect hoses (8) (2 used). j : 27 mm 35. Disconnect hose (9). j : 19 mm Detail C Detail B WPD850-03-01-002 WPD850-04-06-007 7 9 8 WNEK50-03-01-011 B C
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- 22. Group 1 Cab SECTION 3 BODY W3-1-1-12 36. Disconnect hose (1). j : 22 mm 37. Remove bolt, washer (4), nut (5), and clip (6). j : 17 mm 38. Loosen clamps (2) (2 used). Disconnect hoses (3) (2 used). j : 7 mm Detail A View B WNEK50-03-01-017 WNEK50-03-01-018 A 1 B 4, 5 3 6 2 WNEK50-03-01-016
- 23. Group 1 Cab SECTION 3 BODY W3-1-1-13 39. Remove bolt, washer (2), nut (3), and clips (1) (2 used). j : 17 mm 40. Disconnect hoses (4) (2 used). j : 22 mm Detail A View B A B 1 B 2, 3 4 WNEK50-03-01-016 WNEK50-03-01-021 WNEK50-03-01-022
- 24. Group 1 Cab SECTION 3 BODY W3-1-1-14 41. Remove bolt, washer (2) and clip (3). j : 17 mm 42. Disconnect connector (1). 43. Disconnect hoses (6) (2 used). j : 19 mm Detail A View B A 1 B 2, 3 WNEK50-03-01-023 WPD850-03-01-005 WPD850-03-01-004