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Kawasaki 115 z7 wheel loader service repair manual

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The document provides instructions to remove and install the cab assembly on a wheel loader. Key steps include: - Disconnecting electrical and hydraulic connections and removing mounting bolts and nuts. - Using slings and an overhead crane to lift the cab assembly, which weighs 1000 kg, off the rear chassis and place it on wood blocks. - Reversing the removal steps to install the cab assembly, reconnecting all electrical and hydraulic components and tightening mounting hardware to the specified torques. Proper precautions like releasing pressure and applying lubricant to seals are emphasized.

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©2013 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 ) 93216-00570 May 2013 SHOP MANUAL WHEEL LOADER 115Z7 General Information Function & Structure Powered by ISUZU 6WG1 ENGINE Serial No. 11J1-5001 and up GeneralInformation 115Z7SHOPMANUAL93216-00570 Function&Structure
©2013 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 ) 93216-00580 May 2013 SHOP MANUAL WHEEL LOADER 115Z7 Operational Performance Test Troubleshooting Powered by ISUZU 6WG1 ENGINE Serial No. 11J1-5001 and up OperationalPerformanceTest 115Z7SHOPMANUAL93216-00580 Troubleshooting
©2014 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 ) 93216-00590 March2014 SHOP MANUAL WHEEL LOADER 115Z7 Disassembly & Reassembly Powered by ISUZU 6WG1 ENGINE Serial No. 11J1-5001 and up 115Z7SHOPMANUALDisassembly&Reassembly93216-00590
93216-00570 SHOP MANUAL (Function & Structure) INTRODUCTION........................................................................................................................... IN-01~02 SECTION 1 GENERAL Group 1 Specifications .............................................................................................................T1-1 Group 2 Component Layout.....................................................................................................T1-2 Group 3 Component Specifications .........................................................................................T1-3 SECTION 2 SYSTEM Group 1 Controller....................................................................................................................T2-1 Group 2 Control System...........................................................................................................T2-2 Group 3 ECM System ..............................................................................................................T2-3 Group 4 Hydraulic System .......................................................................................................T2-4 Group 5 Electrical System........................................................................................................T2-5 SECTION 3 COMPONENT OPERATION Group 1 Pump Device..............................................................................................................T3-1 Group 2 Control Valve..............................................................................................................T3-2 Group 3 Cooling Fan................................................................................................................T3-3 Group 4 Steering Pilot Valve ....................................................................................................T3-4 Group 5 Steering Valve ............................................................................................................T3-5 Group 6 Pilot Valve...................................................................................................................T3-6 Group 7 Charging Circuit .........................................................................................................T3-7 Group 8 Drive Unit....................................................................................................................T3-8 Group 9 Axle ............................................................................................................................T3-9 Group 10 Brake Valve ..............................................................................................................T3-10 Group 11 Others....................................................................................................................... T3-11 INDEX ATTACHMENT Hydraulic Circuit Diagram & Brake Circuit Diagram Electrical Connection Diagram Electrical Wiring Diagram - Front Chassis Electrical Wiring Diagram - Rear Chassis Electrical Wiring Diagram - Floor (Rear & Side Console) Electrical Wiring Diagram - Floor (Front Console) Electrical Wiring Diagram - CAB 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.
93216-00580 May 2013 115Z7 SHOP MANUAL (Operational Performance Test & Troubleshooting) INTRODUCTION........................................................................................................................... IN-01~02 Symbol and Abbreviation...............................................................................................................SY-1~2 SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction .............................................................................................................T4-1-1 Group 2 Standard..................................................................................................................T4-2-1 Group 3 Engine Test..............................................................................................................T4-3-1 Group 4 Machine Performance Test .....................................................................................T4-4-1 Group 5 Component Test......................................................................................................T4-5-1 SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure ............................................................................................T5-1-1 Group 2 Monitor ....................................................................................................................T5-2-1 Group 4 Component Layout..................................................................................................T5-4-1 Group 5 Troubleshooting A ...................................................................................................T5-5-1 Group 6 Troubleshooting B...................................................................................................T5-6-1 Group 7 Air Conditioner ........................................................................................................T5-7-1 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.
93216-00590 June 2014 115Z7 D&R WORK SHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling.......................................................W1-1 Group 2 Tightening..................................................................................................................W1-2 Group 3 Painting .....................................................................................................................W1-3 Group 4 Bleeding Air...............................................................................................................W1-4 Group 5 Pressure Release Procedure....................................................................................W1-5 Group 6 Preparation................................................................................................................W1-6 SECTION 2 MAINTENANCE STANDARD Group 1 Body ..........................................................................................................................W2-1 Group 2 Front Attachment.......................................................................................................W2-2 SECTION 3 BODY Group 1 Cab............................................................................................................................W3-1 Group 2 Counterweight...........................................................................................................W3-2 Group 3 Center Hinge.............................................................................................................W3-3 Group 4 Engine .......................................................................................................................W3-4 Group 5 Radiator Assembly ....................................................................................................W3-5 Group 6 Hydraulic Oil Tank .....................................................................................................W3-6 Group 7 Fuel Tank...................................................................................................................W3-7 Group 8 Pump Device.............................................................................................................W3-8 Group 9 Control Valve.............................................................................................................W3-9 Group 10 Pilot Valve................................................................................................................W3-10 Group 11 Unloader Valve........................................................................................................W3-11 Group 12 Combination Valve ..................................................................................................W3-12 Group 14 Flow Regulator Valve ..............................................................................................W3-14 Group 15 Cooling Fan System................................................................................................W3-15 Group 16 Exhaust Filter ..........................................................................................................W3-16 Group 17 Ride Control Valve and Accumulator ......................................................................W3-17 Group 18 Battery.....................................................................................................................W3-18
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. Wait until oil cools before starting any work. Do not turn the cap of hydraulic oil tank (1) quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) dCAUTION: Bleed air from hydraulic oil tank. (Refer to W1-4-1.) 2. Open the cover at battery box (1). 3. Turn battery disconnect switch (2) to OFF position. Disconnect the ground cable. 115WNEC-03-01-02115WNEC-03-01-01 2 ON OFF 1 1
Group 1 Cab SECTION 3 BODY W3-1-1-2 4. Remove following parts at right and left sides. (Refer to W3-4-2.) Rear Fender (Front) (1) Rear Fender (Rear) (2) Deck (3) 5. Temporarily attach slings to hooks (A) on ROPS (4) and remove bolts (5) (22 used) and washers (6) (22 used). j : 46 mm (1.81 in) dCAUTION: ROPS weight: 948 kg (2090 lb) 6. Carefully lift ROPS (4) to remove from the floor board. 115WNEC-03-01-13115WNEC-03-01-03 1 6 23 4 A A 3 5
Group 1 Cab SECTION 3 BODY W3-1-1-3 7. Remove bolts (2) (4 used). Remove cover (1). j : 14 mm (0.55 in) 8. Remove bolts (4) (4 used) and washers (5) (2 used). Remove covers (3) (2 used). j : 14 mm (0.55 in) 9. Remove bolts (7) (3 used) and washer (8). Remove cover (1). j : 14 mm (0.55 in) 10. Remove bolts (6) (6 used). Remove cover (5). j : 14 mm (0.55 in) 115WNEC-03-01-04 2 3 4 6 5 7 8 5 1 53 4 9
Group 1 Cab SECTION 3 BODY W3-1-1-4 11. Disconnect connectors (5) (3 used). 12. Disconnect connectors (4) (2 used). 13. Disconnect connector (3). 14. Disconnect connector (2). 15. Disconnect connector (1). 16. Place a container under steering pilot valve (OrbitrolTM ) (a). Put matchmarks and disconnect hoses (6, 7, 8, 9). j : 22 mm (0.87 in) 2 1 5 115WNEC-03-01-05 115WNEC-03-01-09 a- Steering Pilot Valve (Orbitrol) 4 3 9 7 8 6 a
Group 1 Cab SECTION 3 BODY W3-1-1-5 a- Brake Valve 17. Place a container under brake valve (a). Put matchmarks and disconnect hoses (1, 2, 3, 4, 5). j : 27 mm (1.06 in) j : 36 mm (1.42 in) 18. Disconnect grounding cable (6). j : 17 mm (0.67 in) 115WNEC-03-01-06 6 a 2 5 1 34
Group 1 Cab SECTION 3 BODY W3-1-1-6 19. Place a container under flow control valve (a). Put matchmarks and disconnect hoses (1, 2, 3, 4). j : 22 mm (0.87 in) 20. Disconnect hoses (5, 6). 21. Disconnect connectors (7, 8) and the clamps. 22. Disconnect hose (9). j : 22 mm (0.87 in) 115WNEC-03-01-07 a- Flow Control Valve 8 7 9 5 6 1, 2, 3, 4 a
Group 1 Cab SECTION 3 BODY W3-1-1-7 23. Disconnect hose (1) from the washer tank. 24. Remove pipe (2) and O-ring (3). j : 27 mm (1.06 in) 25. Remove pipe (4) and O-ring (5). j : 19 mm (0.75 in) 26. Disconnect couplers (6) (2 used). 115WNEC-03-01-08 1 2, 3 4, 5 6
Group 1 Cab SECTION 3 BODY W3-1-1-8 dCAUTION: Cab assembly weight: 1000 kg (2205 lb) 27. To install eyebolts, remove 4 each of cap at 4 positions (a) on the top of cab (2). 28. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a). Attach nylon slings to the eyebolts, hoist and hold cab assembly (2). a- Eyebolt Mounting Hole 115WNEC-03-01-10 1 2 a a
Group 1 Cab SECTION 3 BODY W3-1-1-9 115WNEC-03-01-11 29. Remove nuts (2) (4 used). j : 22 mm (0.87 in) 30. Gradually lift the cab (1) assembly while checking that all pipes, hoses, cables, etc. are disconnected. fNOTE: Move down cab (1) onto the rear chassis when disconnecting hoses, cables, etc. if any found. 31. Remove cab (1) assembly and place it on wooden blocks. a- Rubber Cushion b- Rear Chassis 1 A B 115WNEC-03-01-12 2 2 b a a Detail A Detail B 1
Group 1 Cab SECTION 3 BODY W3-1-1-10 Installation dCAUTION: Cab (2) assembly weight: 1000 kg (2205 lb) 1. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a) (4 places) of cab assembly (2). Attach nylon slings to the eyebolts (4 places). Hoist cab assembly (2). fNOTE: Install caps (1) after mounting cab (2) assembly on the rear chassis. a- Eyebolt Mounting Hole 115WNEC-03-01-10 1 2 a a
Group 1 Cab SECTION 3 BODY W3-1-1-11 IMPORTANT: Do not contact the front chassis and hydraulic oil tank when removing and installing the cab (1) assembly from the machine. 2. Install nuts (2) (4 used). j : 22 mm (0.87 in) m : 230 N·m (23.5 kgf·m, 170 lbf·ft) 115WNEC-03-01-11 a- Rubber Cushion b- Rear Chassis 1 A B 115WNEC-03-01-12 2 2 b a a Detail A Detail B 1
Group 1 Cab SECTION 3 BODY W3-1-1-12 3. Install couplers (6) (2 used). 4. Install O-ring (5) and pipe (4). fNOTE: Apply ND-OIL8 onto the O-ring at hose (8) mounting part. j : 19 mm (0.75 in) m : 14.7 N·m (1.5 kgf·m, 10.8 lbf·ft) 5. Install O-ring (3) and pipe (2). fNOTE: Apply ND-OIL8 onto the O-ring at hose (7) mounting part. j : 27 mm (1.06 in) m : 34.3 N·m (3.5 kgf·m, 25.3 lbf·ft) 6. Connect hose (1) to the washer tank. 7. Supply coolant. fNOTE: Coolant amount: 85 L (22.5 gal) 115WNEC-03-01-08 1 2, 3 4, 5 6
Group 1 Cab SECTION 3 BODY W3-1-1-13 8. Connect hose (9). j : 22 mm (0.87 in) m : 40 N·m (4 kgf·m, 30 lbf·ft) 9. Connect connectors (7, 8). 10. Connect hoses (5, 6). 11. Connect hoses (4, 3, 2, 1) to flow control valve (a). j : 22 mm (0.87 in) m : 40 N·m (4 kgf·m, 30 lbf·ft) fNOTE: Refer to the matchmarks when connecting hoses. 115WNEC-03-01-07 a- Flow Control Valve 8 7 9 5 6 1, 2, 3, 4 a
Group 1 Cab SECTION 3 BODY W3-1-1-14 12. Install grounding cable (6). j : 17 mm (0.67 in) m : 94 N·m (9.6 kgf·m, 69 lbf·ft) 13. Connect hoses (5, 4, 3, 2, 1) to brake valve (a). j : 27 mm (1.06 in) m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 36 mm (1.42 in) m : 180 N·m (18 kgf·m, 133 lbf·ft) a- Brake Valve 115WNEC-03-01-06 6 a 2 5 1 34
Group 1 Cab SECTION 3 BODY W3-1-1-15 14. Connect hoses (9, 8, 7, 6) to OrbitrolTM (a). j : 22 mm (0.87 in) m : 40 N·m (4 kgf·m, 30 lbf·ft) fNOTE: Refer to the matchmarks when connecting hoses. 15. Connect connectors (3, 2, 1) respectively. 16. Connect connector (4) (2 used). 17. Connect connector (5) (3 used). 2 1 5 115WNEC-03-01-05115WNEC-03-01-09 a- Steering Pilot Valve (Orbitrol) 4 3 9 7 8 6 a
Group 1 Cab SECTION 3 BODY W3-1-1-16 18. Install cover (5) with bolts (6) (6 used). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 19. Install cover (9) with bolts (7) (3 used) and washer (8). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 20. Install covers (3) (2 used) with bolts (4) (4 used) and washers (5) (2 used). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 21. Install cover (1) with bolts (2) (4 used). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 115WNEC-03-01-04 2 3 4 6 5 7 8 5 1 53 4 9
Group 1 Cab SECTION 3 BODY W3-1-1-17 22. Set battery switch (2) in battery box (1) to the ON position. 23. Bleed air from the hydraulic system. (Refer to W1-4- 1.) IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil and water leaks. 24. Fill refrigerant in the air conditioner. (Refer to T5-7 in the Troubleshooting S/M.) 115WNEC-03-01-02115WNEC-03-01-01 2 ON OFF 1 1
Group 1 Cab SECTION 3 BODY W3-1-1-18 dCAUTION: ROPS weight: 948 kg (2090 lb) 25. Attach slings to hooks (A) on ROPS (4) and lift ROPS (4). 26. Install bolts (5) (22 used) and washers (6) (22 used). j : 46 mm (1.81 in) m : 1421 N·m (145 kgf·m, 1050 lbf·ft) 27. Remove slings. 28. Install following parts at right and left sides. (Refer to W3-4-2.) Deck (3) Rear Fender (Rear) (2) Rear Fender (Front) (1) 115WNEC-03-01-13 115WNEC-03-01-03 1 6 23 4 A A 3 5
W3-2-1-1 SECTION 3 BODY Group 2 Counterweight Removal and Installation of Counterweight Removal 1. Set the machine for inspection and maintenance. (Refer to W1-6-1.) Removal of Battery Box (Right) (Without Battery Disconnect Switch) 2. Remove caps (3) (4 used) from counterweights (1, 2). Install the eyebolts and attach slings. Hoist both counterweights tentatively. dCAUTION: Counterweight (1, 2) weight: 1300 kg (2866 lb)/each 3. Remove bolts (4) (4 used) and washers (5) (4 used), and lift up both counterweights (1, 2) to remove them from the rear chassis. j : 36 mm (1.42 in) 115WNEC-03-02-01 2 3 5 4 1
W3-2-1-2 Group 2 Counterweight SECTION 3 BODY 4. Remove bolts (6) (2 used) and plate (7) on both sides. j : 14 mm (0.55 in) 5. Remove shim (8) and plate (9) on both sides. 1 2 6 7 8 9 115WNEC-03-02-02
W3-2-1-3 Group 2 Counterweight SECTION 3 BODY Installation dCAUTION: Counterweight (1, 2) weight: 1300 kg (2866 lb)/each 1. Sling both counterweights (1, 2). 2. Install counterweights (1, 2) and temporarily fix them on the rear chassis with bolts (4) (4 used) and washers (5) (4 used). j : 36 mm (1.42 in) 115WNEC-03-02-01 2 3 5 4 1
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W3-2-1-4 Group 2 Counterweight SECTION 3 BODY 3. Insert plate (9) into counterweights (1, 2) from the top. 4. Adjust the clearance between counterweights (1, 2) and the rear chassis 1 mm or less with shim (8). 5. Fix plate (7) with bolt (6). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 6. Tighten bolt (4). j : 36 mm (1.42 in) m : 721 N·m (73.5 kgf·m, 531 lbf·ft) 7. Install caps (3) (2 used) on both sides. 1 2 6 7 8 9 115WNEC-03-02-02
SECTION 3 BODY W3-3-1-1 Group 3 Center Hinge Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove the following devices. Front Attachment (Refer to W5-1-1.) ROPS and Cab assembly (Refer to W3-1-1.) Propeller Shaft (Refer to W4-4-1.) Steering Cylinder (Refer to W4-8-1.) Hydraulic Hoses of Front Chassis Side (Refer to W3- 3-2.) 3. Support front chassis (1) and rear chassis (2) by using stable stands (a). 4. Sling rear chassis (2) using a crane (apply rope (b) to the hook) so that rear chassis (2) will not fall backward. dCAUTION: When using a crane, insufficient signal and sling could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: Check the sling before using it and do not use improper sling. Use the signals as agreed upon before starting work. Stay out of the working area while using a crane. a- Stand b- Wire Rope 115WNEC-03-03-19 Removal and Installation of Center Hinge b b 1 a a 2
Group 3 Center Hinge SECTION 3 BODY W3-3-1-2 5. Remove bolts (1) (6 used) and washers (2) (6 used) to remove plate (3). j : 30 mm (1.18 in) 6. Remove bolt (4), spring washer (5), and washer (6). j : 27 mm (1.06 in) 7. Push out upper center hinge pin (7) and lower center hinge pin (8) respectively using a jack or “Porto-power”. Remove bush (9). [ Upper Hinge Section ] [ Lower Hinge Section ] 115WNEC-03-03-02115WNEC-03-03-01 1, 2, 3 9 3 2 1 4 5 6 7 8

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Kawasaki 115 z7 wheel loader service repair manual

  • 1. ©2013 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 ) 93216-00570 May 2013 SHOP MANUAL WHEEL LOADER 115Z7 General Information Function & Structure Powered by ISUZU 6WG1 ENGINE Serial No. 11J1-5001 and up GeneralInformation 115Z7SHOPMANUAL93216-00570 Function&Structure
  • 2. ©2013 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 ) 93216-00580 May 2013 SHOP MANUAL WHEEL LOADER 115Z7 Operational Performance Test Troubleshooting Powered by ISUZU 6WG1 ENGINE Serial No. 11J1-5001 and up OperationalPerformanceTest 115Z7SHOPMANUAL93216-00580 Troubleshooting
  • 3. ©2014 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 ) 93216-00590 March2014 SHOP MANUAL WHEEL LOADER 115Z7 Disassembly & Reassembly Powered by ISUZU 6WG1 ENGINE Serial No. 11J1-5001 and up 115Z7SHOPMANUALDisassembly&Reassembly93216-00590
  • 4. 93216-00570 SHOP MANUAL (Function & Structure) INTRODUCTION........................................................................................................................... IN-01~02 SECTION 1 GENERAL Group 1 Specifications .............................................................................................................T1-1 Group 2 Component Layout.....................................................................................................T1-2 Group 3 Component Specifications .........................................................................................T1-3 SECTION 2 SYSTEM Group 1 Controller....................................................................................................................T2-1 Group 2 Control System...........................................................................................................T2-2 Group 3 ECM System ..............................................................................................................T2-3 Group 4 Hydraulic System .......................................................................................................T2-4 Group 5 Electrical System........................................................................................................T2-5 SECTION 3 COMPONENT OPERATION Group 1 Pump Device..............................................................................................................T3-1 Group 2 Control Valve..............................................................................................................T3-2 Group 3 Cooling Fan................................................................................................................T3-3 Group 4 Steering Pilot Valve ....................................................................................................T3-4 Group 5 Steering Valve ............................................................................................................T3-5 Group 6 Pilot Valve...................................................................................................................T3-6 Group 7 Charging Circuit .........................................................................................................T3-7 Group 8 Drive Unit....................................................................................................................T3-8 Group 9 Axle ............................................................................................................................T3-9 Group 10 Brake Valve ..............................................................................................................T3-10 Group 11 Others....................................................................................................................... T3-11 INDEX ATTACHMENT Hydraulic Circuit Diagram & Brake Circuit Diagram Electrical Connection Diagram Electrical Wiring Diagram - Front Chassis Electrical Wiring Diagram - Rear Chassis Electrical Wiring Diagram - Floor (Rear & Side Console) Electrical Wiring Diagram - Floor (Front Console) Electrical Wiring Diagram - CAB 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. 93216-00580 May 2013 115Z7 SHOP MANUAL (Operational Performance Test & Troubleshooting) INTRODUCTION........................................................................................................................... IN-01~02 Symbol and Abbreviation...............................................................................................................SY-1~2 SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction .............................................................................................................T4-1-1 Group 2 Standard..................................................................................................................T4-2-1 Group 3 Engine Test..............................................................................................................T4-3-1 Group 4 Machine Performance Test .....................................................................................T4-4-1 Group 5 Component Test......................................................................................................T4-5-1 SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure ............................................................................................T5-1-1 Group 2 Monitor ....................................................................................................................T5-2-1 Group 4 Component Layout..................................................................................................T5-4-1 Group 5 Troubleshooting A ...................................................................................................T5-5-1 Group 6 Troubleshooting B...................................................................................................T5-6-1 Group 7 Air Conditioner ........................................................................................................T5-7-1 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.
  • 6. 93216-00590 June 2014 115Z7 D&R WORK SHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling.......................................................W1-1 Group 2 Tightening..................................................................................................................W1-2 Group 3 Painting .....................................................................................................................W1-3 Group 4 Bleeding Air...............................................................................................................W1-4 Group 5 Pressure Release Procedure....................................................................................W1-5 Group 6 Preparation................................................................................................................W1-6 SECTION 2 MAINTENANCE STANDARD Group 1 Body ..........................................................................................................................W2-1 Group 2 Front Attachment.......................................................................................................W2-2 SECTION 3 BODY Group 1 Cab............................................................................................................................W3-1 Group 2 Counterweight...........................................................................................................W3-2 Group 3 Center Hinge.............................................................................................................W3-3 Group 4 Engine .......................................................................................................................W3-4 Group 5 Radiator Assembly ....................................................................................................W3-5 Group 6 Hydraulic Oil Tank .....................................................................................................W3-6 Group 7 Fuel Tank...................................................................................................................W3-7 Group 8 Pump Device.............................................................................................................W3-8 Group 9 Control Valve.............................................................................................................W3-9 Group 10 Pilot Valve................................................................................................................W3-10 Group 11 Unloader Valve........................................................................................................W3-11 Group 12 Combination Valve ..................................................................................................W3-12 Group 14 Flow Regulator Valve ..............................................................................................W3-14 Group 15 Cooling Fan System................................................................................................W3-15 Group 16 Exhaust Filter ..........................................................................................................W3-16 Group 17 Ride Control Valve and Accumulator ......................................................................W3-17 Group 18 Battery.....................................................................................................................W3-18
  • 7. 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. Wait until oil cools before starting any work. Do not turn the cap of hydraulic oil tank (1) quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) dCAUTION: Bleed air from hydraulic oil tank. (Refer to W1-4-1.) 2. Open the cover at battery box (1). 3. Turn battery disconnect switch (2) to OFF position. Disconnect the ground cable. 115WNEC-03-01-02115WNEC-03-01-01 2 ON OFF 1 1
  • 8. Group 1 Cab SECTION 3 BODY W3-1-1-2 4. Remove following parts at right and left sides. (Refer to W3-4-2.) Rear Fender (Front) (1) Rear Fender (Rear) (2) Deck (3) 5. Temporarily attach slings to hooks (A) on ROPS (4) and remove bolts (5) (22 used) and washers (6) (22 used). j : 46 mm (1.81 in) dCAUTION: ROPS weight: 948 kg (2090 lb) 6. Carefully lift ROPS (4) to remove from the floor board. 115WNEC-03-01-13115WNEC-03-01-03 1 6 23 4 A A 3 5
  • 9. Group 1 Cab SECTION 3 BODY W3-1-1-3 7. Remove bolts (2) (4 used). Remove cover (1). j : 14 mm (0.55 in) 8. Remove bolts (4) (4 used) and washers (5) (2 used). Remove covers (3) (2 used). j : 14 mm (0.55 in) 9. Remove bolts (7) (3 used) and washer (8). Remove cover (1). j : 14 mm (0.55 in) 10. Remove bolts (6) (6 used). Remove cover (5). j : 14 mm (0.55 in) 115WNEC-03-01-04 2 3 4 6 5 7 8 5 1 53 4 9
  • 10. Group 1 Cab SECTION 3 BODY W3-1-1-4 11. Disconnect connectors (5) (3 used). 12. Disconnect connectors (4) (2 used). 13. Disconnect connector (3). 14. Disconnect connector (2). 15. Disconnect connector (1). 16. Place a container under steering pilot valve (OrbitrolTM ) (a). Put matchmarks and disconnect hoses (6, 7, 8, 9). j : 22 mm (0.87 in) 2 1 5 115WNEC-03-01-05 115WNEC-03-01-09 a- Steering Pilot Valve (Orbitrol) 4 3 9 7 8 6 a
  • 11. Group 1 Cab SECTION 3 BODY W3-1-1-5 a- Brake Valve 17. Place a container under brake valve (a). Put matchmarks and disconnect hoses (1, 2, 3, 4, 5). j : 27 mm (1.06 in) j : 36 mm (1.42 in) 18. Disconnect grounding cable (6). j : 17 mm (0.67 in) 115WNEC-03-01-06 6 a 2 5 1 34
  • 12. Group 1 Cab SECTION 3 BODY W3-1-1-6 19. Place a container under flow control valve (a). Put matchmarks and disconnect hoses (1, 2, 3, 4). j : 22 mm (0.87 in) 20. Disconnect hoses (5, 6). 21. Disconnect connectors (7, 8) and the clamps. 22. Disconnect hose (9). j : 22 mm (0.87 in) 115WNEC-03-01-07 a- Flow Control Valve 8 7 9 5 6 1, 2, 3, 4 a
  • 13. Group 1 Cab SECTION 3 BODY W3-1-1-7 23. Disconnect hose (1) from the washer tank. 24. Remove pipe (2) and O-ring (3). j : 27 mm (1.06 in) 25. Remove pipe (4) and O-ring (5). j : 19 mm (0.75 in) 26. Disconnect couplers (6) (2 used). 115WNEC-03-01-08 1 2, 3 4, 5 6
  • 14. Group 1 Cab SECTION 3 BODY W3-1-1-8 dCAUTION: Cab assembly weight: 1000 kg (2205 lb) 27. To install eyebolts, remove 4 each of cap at 4 positions (a) on the top of cab (2). 28. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a). Attach nylon slings to the eyebolts, hoist and hold cab assembly (2). a- Eyebolt Mounting Hole 115WNEC-03-01-10 1 2 a a
  • 15. Group 1 Cab SECTION 3 BODY W3-1-1-9 115WNEC-03-01-11 29. Remove nuts (2) (4 used). j : 22 mm (0.87 in) 30. Gradually lift the cab (1) assembly while checking that all pipes, hoses, cables, etc. are disconnected. fNOTE: Move down cab (1) onto the rear chassis when disconnecting hoses, cables, etc. if any found. 31. Remove cab (1) assembly and place it on wooden blocks. a- Rubber Cushion b- Rear Chassis 1 A B 115WNEC-03-01-12 2 2 b a a Detail A Detail B 1
  • 16. Group 1 Cab SECTION 3 BODY W3-1-1-10 Installation dCAUTION: Cab (2) assembly weight: 1000 kg (2205 lb) 1. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a) (4 places) of cab assembly (2). Attach nylon slings to the eyebolts (4 places). Hoist cab assembly (2). fNOTE: Install caps (1) after mounting cab (2) assembly on the rear chassis. a- Eyebolt Mounting Hole 115WNEC-03-01-10 1 2 a a
  • 17. Group 1 Cab SECTION 3 BODY W3-1-1-11 IMPORTANT: Do not contact the front chassis and hydraulic oil tank when removing and installing the cab (1) assembly from the machine. 2. Install nuts (2) (4 used). j : 22 mm (0.87 in) m : 230 N·m (23.5 kgf·m, 170 lbf·ft) 115WNEC-03-01-11 a- Rubber Cushion b- Rear Chassis 1 A B 115WNEC-03-01-12 2 2 b a a Detail A Detail B 1
  • 18. Group 1 Cab SECTION 3 BODY W3-1-1-12 3. Install couplers (6) (2 used). 4. Install O-ring (5) and pipe (4). fNOTE: Apply ND-OIL8 onto the O-ring at hose (8) mounting part. j : 19 mm (0.75 in) m : 14.7 N·m (1.5 kgf·m, 10.8 lbf·ft) 5. Install O-ring (3) and pipe (2). fNOTE: Apply ND-OIL8 onto the O-ring at hose (7) mounting part. j : 27 mm (1.06 in) m : 34.3 N·m (3.5 kgf·m, 25.3 lbf·ft) 6. Connect hose (1) to the washer tank. 7. Supply coolant. fNOTE: Coolant amount: 85 L (22.5 gal) 115WNEC-03-01-08 1 2, 3 4, 5 6
  • 19. Group 1 Cab SECTION 3 BODY W3-1-1-13 8. Connect hose (9). j : 22 mm (0.87 in) m : 40 N·m (4 kgf·m, 30 lbf·ft) 9. Connect connectors (7, 8). 10. Connect hoses (5, 6). 11. Connect hoses (4, 3, 2, 1) to flow control valve (a). j : 22 mm (0.87 in) m : 40 N·m (4 kgf·m, 30 lbf·ft) fNOTE: Refer to the matchmarks when connecting hoses. 115WNEC-03-01-07 a- Flow Control Valve 8 7 9 5 6 1, 2, 3, 4 a
  • 20. Group 1 Cab SECTION 3 BODY W3-1-1-14 12. Install grounding cable (6). j : 17 mm (0.67 in) m : 94 N·m (9.6 kgf·m, 69 lbf·ft) 13. Connect hoses (5, 4, 3, 2, 1) to brake valve (a). j : 27 mm (1.06 in) m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 36 mm (1.42 in) m : 180 N·m (18 kgf·m, 133 lbf·ft) a- Brake Valve 115WNEC-03-01-06 6 a 2 5 1 34
  • 21. Group 1 Cab SECTION 3 BODY W3-1-1-15 14. Connect hoses (9, 8, 7, 6) to OrbitrolTM (a). j : 22 mm (0.87 in) m : 40 N·m (4 kgf·m, 30 lbf·ft) fNOTE: Refer to the matchmarks when connecting hoses. 15. Connect connectors (3, 2, 1) respectively. 16. Connect connector (4) (2 used). 17. Connect connector (5) (3 used). 2 1 5 115WNEC-03-01-05115WNEC-03-01-09 a- Steering Pilot Valve (Orbitrol) 4 3 9 7 8 6 a
  • 22. Group 1 Cab SECTION 3 BODY W3-1-1-16 18. Install cover (5) with bolts (6) (6 used). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 19. Install cover (9) with bolts (7) (3 used) and washer (8). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 20. Install covers (3) (2 used) with bolts (4) (4 used) and washers (5) (2 used). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 21. Install cover (1) with bolts (2) (4 used). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 115WNEC-03-01-04 2 3 4 6 5 7 8 5 1 53 4 9
  • 23. Group 1 Cab SECTION 3 BODY W3-1-1-17 22. Set battery switch (2) in battery box (1) to the ON position. 23. Bleed air from the hydraulic system. (Refer to W1-4- 1.) IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil and water leaks. 24. Fill refrigerant in the air conditioner. (Refer to T5-7 in the Troubleshooting S/M.) 115WNEC-03-01-02115WNEC-03-01-01 2 ON OFF 1 1
  • 24. Group 1 Cab SECTION 3 BODY W3-1-1-18 dCAUTION: ROPS weight: 948 kg (2090 lb) 25. Attach slings to hooks (A) on ROPS (4) and lift ROPS (4). 26. Install bolts (5) (22 used) and washers (6) (22 used). j : 46 mm (1.81 in) m : 1421 N·m (145 kgf·m, 1050 lbf·ft) 27. Remove slings. 28. Install following parts at right and left sides. (Refer to W3-4-2.) Deck (3) Rear Fender (Rear) (2) Rear Fender (Front) (1) 115WNEC-03-01-13 115WNEC-03-01-03 1 6 23 4 A A 3 5
  • 25. W3-2-1-1 SECTION 3 BODY Group 2 Counterweight Removal and Installation of Counterweight Removal 1. Set the machine for inspection and maintenance. (Refer to W1-6-1.) Removal of Battery Box (Right) (Without Battery Disconnect Switch) 2. Remove caps (3) (4 used) from counterweights (1, 2). Install the eyebolts and attach slings. Hoist both counterweights tentatively. dCAUTION: Counterweight (1, 2) weight: 1300 kg (2866 lb)/each 3. Remove bolts (4) (4 used) and washers (5) (4 used), and lift up both counterweights (1, 2) to remove them from the rear chassis. j : 36 mm (1.42 in) 115WNEC-03-02-01 2 3 5 4 1
  • 26. W3-2-1-2 Group 2 Counterweight SECTION 3 BODY 4. Remove bolts (6) (2 used) and plate (7) on both sides. j : 14 mm (0.55 in) 5. Remove shim (8) and plate (9) on both sides. 1 2 6 7 8 9 115WNEC-03-02-02
  • 27. W3-2-1-3 Group 2 Counterweight SECTION 3 BODY Installation dCAUTION: Counterweight (1, 2) weight: 1300 kg (2866 lb)/each 1. Sling both counterweights (1, 2). 2. Install counterweights (1, 2) and temporarily fix them on the rear chassis with bolts (4) (4 used) and washers (5) (4 used). j : 36 mm (1.42 in) 115WNEC-03-02-01 2 3 5 4 1
  • 28. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 29. W3-2-1-4 Group 2 Counterweight SECTION 3 BODY 3. Insert plate (9) into counterweights (1, 2) from the top. 4. Adjust the clearance between counterweights (1, 2) and the rear chassis 1 mm or less with shim (8). 5. Fix plate (7) with bolt (6). j : 14 mm (0.55 in) m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 6. Tighten bolt (4). j : 36 mm (1.42 in) m : 721 N·m (73.5 kgf·m, 531 lbf·ft) 7. Install caps (3) (2 used) on both sides. 1 2 6 7 8 9 115WNEC-03-02-02
  • 30. SECTION 3 BODY W3-3-1-1 Group 3 Center Hinge Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove the following devices. Front Attachment (Refer to W5-1-1.) ROPS and Cab assembly (Refer to W3-1-1.) Propeller Shaft (Refer to W4-4-1.) Steering Cylinder (Refer to W4-8-1.) Hydraulic Hoses of Front Chassis Side (Refer to W3- 3-2.) 3. Support front chassis (1) and rear chassis (2) by using stable stands (a). 4. Sling rear chassis (2) using a crane (apply rope (b) to the hook) so that rear chassis (2) will not fall backward. dCAUTION: When using a crane, insufficient signal and sling could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: Check the sling before using it and do not use improper sling. Use the signals as agreed upon before starting work. Stay out of the working area while using a crane. a- Stand b- Wire Rope 115WNEC-03-03-19 Removal and Installation of Center Hinge b b 1 a a 2
  • 31. Group 3 Center Hinge SECTION 3 BODY W3-3-1-2 5. Remove bolts (1) (6 used) and washers (2) (6 used) to remove plate (3). j : 30 mm (1.18 in) 6. Remove bolt (4), spring washer (5), and washer (6). j : 27 mm (1.06 in) 7. Push out upper center hinge pin (7) and lower center hinge pin (8) respectively using a jack or “Porto-power”. Remove bush (9). [ Upper Hinge Section ] [ Lower Hinge Section ] 115WNEC-03-03-02115WNEC-03-03-01 1, 2, 3 9 3 2 1 4 5 6 7 8