Factory relief settings, gear clearances and circuit logic for the Kawasaki KSS70, KSS80Z Super Shovel live in one place: this 242-page shop manual PDF, Kawasaki publication S0701-5. Wiring diagrams trace the starter, charging and regulator circuits through every key position, including the KSS70 AC circuit, while hydraulic schematics follow oil from the gear pump through the control valve, relief valves and the bucket and dump positioners. Teardown work takes the largest share of the book: torque converter, transmission, differential, steering gear, and the brake line from air master to disc brake, plus troubleshooting tables for power, axle, hydraulic, steering and positioner faults. Set your control valve main relief at 175 kg/cm², and replace parts if differential gear to spider clearance runs past 0.105 mm. Some days it's just you, a stalled shovel, and nobody to call. Print the sections you need and let them get greasy at the bench; the bookmarked, text-searchable original stays clean on your drive.
What's Inside This Kawasaki KSS70, KSS80Z Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 3-14 | Detailed Specifications, Water and Oil Capacity Table, Construction, KSS70 Out-Side View, KSS80Z Out-Side View |
| Service Data | 15-20 | Service Data Table, Measurement Procedures, Tightening Torque, Common Bolts |
| Chassis | 29-34 | Bucket Cutting Edge Replacement (Welding Rods Available, Preheating, After Welding), Center Pin (Construction and Inspection), Lever 1 (Construction and Removal) |
| Electrical System | 35-58 | Electrical (Circuit Connection, When the Starter Key Is Shifted to "Off" Position, When the Engine Is Started) |
| Power System | 59-108 | Torque Converter & Transmission Line (General, When the Control Valve Is in Neutral Position, When the Control Valve Is in Forward and Low-Speed Position) |
| Axle System | 109-130 | Axle (Construction, Disassembly and Assembly), Differential Gear (Construction, Removal and Remounting, Special Tool, Disassembly, Inspection, Assembly) |
| Hydraulic System | 131-164 | Hydraulic Line (Construction and Operation) |
| Steering Line | 165-184 | Steering Valve, Steering Gear |
| Brake Line | 185-242 | Brake Valve, Air Master, Disc Brake, Governor, Auto Drain Valve |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Steering relief valve Main relief valve | 160 kg/cm² | p. 17 |
| Steering relief valve Over load relief valve | 210 kg/cm² | p. 17 |
| Boom or bucket is gone down under the control valve is in neutral (Bucket cylinder) | 4 mm/min | p. 17 |
| Free play between axle shaft and side gear | 0.2 mm | p. 118 |
| Clearance between diff. gear and spider | 0.04-0.105 mm | p. 118 |
| O-ring & back up ring clearance | 1mm | p. 148 |
| KSS70 | ||
| Total weight | 27,560 lbs. (12,500 kg) | p. 3 |
| Engine Output | 143 HP (145 PS) | p. 3 |
| Max. tractive effort | 26,400 lbs. (12,000 kg) | p. 4 |
| KSS80Z | ||
| Total weight | 32,410 lbs. (14,700 kg) | p. 3 |
| Engine Output | 158 HP (160 PS) | p. 3 |
| Max. tractive effort | 28,880 lbs. (13,100 kg) | p. 4 |
Kawasaki KSS70, KSS80Z Common Problems This Manual Covers
Kawasaki KSS70 KSS80Z multiple control valve hydraulic oil pressure does not rise or rises excessively
Check the main relief valve at the multiple control valve with a pressure gauge before pulling any cylinders. Compare the reading against the 175 kg/cm² main relief set pressure on page 17, and check the overload relief against 210 kg/cm². Then work through the hydraulic troubleshooting steps for pressure that will not rise or climbs too high.
Manual Section: Service Data p. 17Boom or bucket cylinder drifts down while parked with the control valve held in neutral
Measure bucket cylinder drift with the control valve in neutral and the bucket raised off the ground. Time it with a tape and a stopwatch, then compare it against the 4 mm/min drift spec on page 17. Work through the boom and bucket lowering checks in the hydraulic troubleshooting steps before you tear down a cylinder.
Manual Section: Service Data p. 17Steering handle stiff, slow to respond, or steering oil pressure does not rise
Check steering relief pressure before you blame the steering gear. Compare the reading against the 160 kg/cm² steering relief setting on page 169. If pressure checks good, inspect the steering valve and steering gear following the Steering Line section starting on page 165.
Manual Section: Steering Line p. 169Transmission clutch oil pressure abnormal with time lag on engagement or considerable shock when shifting
Check clutch oil pressure and oil temperature, then work through the power system troubleshooting steps for time lag and shift shock. Inspect torque converter and transmission control valve operation in the neutral and forward low speed positions, following the Power System section starting on page 59, before you split anything.
Manual Section: Power System TroubleshootingBrake system air pressure drops with large air consumption or brakes dragging
Check how fast air pressure builds with the engine running and how fast it bleeds down after shutdown. Check governor and auto drain valve operation, then inspect the brake valve, air master and disc brake for dragging, following the Brake Line section starting on page 185. Check the pads for heavy wear while you are at the disc brake.
Manual Section: Brake Line p. 185Front or rear axle differential making abnormal noise while traveling under load
Remove and disassemble the differential following the Axle System section starting on page 109. Measure clearance between the diff gear and spider against 0.04 to 0.105 mm, and check free play between the axle shaft and side gear against 0.2 mm, both on page 118. Replace any worn diff gear or spider before you reassemble.
Manual Section: Axle System p. 118Frequently Asked Questions
What are the torque specifications for the wheel pin to wheel hub bolts on the KSS70 and KSS80Z?
The tightening torque for the wheel pin to wheel hub bolts on both the KSS70 and KSS80Z models is 40 to 50 kgm. p. 19
What is the standard oil consumption for the KSS70 and KSS80Z engines?
The standard oil consumption for the KSS70 is 0.074 to 0.172 liters per hour, and for the KSS80Z, it is 0.097 to 0.226 liters per hour. p. 3
What is the stall torque ratio for the torque converter on the KSS70 and KSS80Z?
The stall torque ratio for the torque converter on both the KSS70 and KSS80Z is 3.7:1. p. 3
What is the set pressure for the multiple control valve on the KSS70 and KSS80Z?
The set pressure for the multiple control valve on both models is 2,490 PSI (175 kg/cm²). p. 9
What is the tightening torque for the main pump on the KSS70 and KSS80Z?
The tightening torque for the main pump is 24 kgm. p. 149
Do I get instant access to this Kawasaki KSS70 Shop Manual?
This is a 242-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Is printing allowed for this Kawasaki KSS70 Shop Manual?
Yes. Print the sections you need to take out to the shop for your own use. Standard letter or A4 paper works.
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