Kawasaki 115 z7 wheel loader service repair manual

©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

( アメリカ用 )
93216-00580
May 2013
SHOP MANUAL
WHEEL LOADER
115Z7
Operational Performance Test
Troubleshooting
OperationalPerformanceTest
115Z7SHOPMANUAL93216-00580
Troubleshooting

( アメリカ用 )
93216-00590
March2014
SHOP MANUAL
WHEEL LOADER
115Z7
Disassembly & Reassembly
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).
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
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
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
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

Kawasaki 115 z7 wheel loader service repair manual

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