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AAA-S11C3V14-012 (93216-00091)

WHEEL LOADER SHOP MANUAL

115Z Powered by CUMMINS QSK19-C Engine. SERIAL NUMBERS 11C3-5501 and up.

Disassembly & Reassembly Service Standard

FOREWORD To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual. To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual. Disassembly & Reassembly Service Standard Note: ① For Genaral Information and Functions and Structure, refer to the 115ZⅣ -2 Shop Manual AAA-S11C3V00-012 (93215-00071) ② For Troubleshooting and Measurement for Performance Check, refer to the 115ZⅣ -2 Shop Manual AAA-S11C3V01-012 (93215-00081). ③ For the engine, refer to the engine Shop Manual provided by the engine manufacturer. The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service. This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.

（1）

Safety Precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below.

・ This manual is intended for properly trained and equipped service technicians. ・ Any work on the machine must be performed by the trained personnel only. ・ Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine. ・ Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles. ・ Place the machine on a level and solid ground, and place chocks against the wheels to prevent movement. ・ Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the steering wheel. ・ Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe. ・ Be sure to apply the articulation stopper before starting work. ・ While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks. ・ When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping. ・ Do not start to work in an enclosed area if adequate ventilation is not provided. ・ To remove a heavy unit (20kg (40 lbs) or more), be sure to use a crane or other lifting tool. ・ Just after stopping operation, be careful not to directly touch a hot component. You may get burned. ・ Contact tire manufacturer's local dealer for tire servicing and changing. ・ Always store the tools in good condition, and use them properly. ・ Keep the work area clean. Clean up spills immediately. ・ Avoid the use of flammable solvents and cleaners. ・ When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud. ・ Use safe work platforms to reach higher areas of the machine.

（2）

Safety Symbols An accident may occur if you disregard safety rules. In this manual, several expressions are used according to levels of danger for inspection and repair work as shown below. Read the work procedures and cautions described in this manual, and take preventive measures against possible problems before starting service work.

DANGER This danger symbol identifies special warnings or procedures which, if not strictly observed, will result in death or serious injury.

WARNING This warning symbol identifies special warnings or procedures which, if not strictly observed, could result in death or serious injury.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, may result in minor or moderate injury.

IMPORTANT This important symbol identifies special instructions or procedures which, if not correctly followed, may result in serious machine damage.

We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing service work.

（3）

Symbols For safe and effective service work, the following symbols are used for notes and useful information in this manual. Symbol

Item Reference

Description Shows the condition or procedure that will be useful or efficient in doing service work. Shows the weight of a part or unit. The weight

Weight

should be considered in selecting wire rope or cable for slinging work or determining the working posture.

Shows the tightening torque of a section that Tightening should be carefully tightened during assembly torque work.

Coating

Oil or water supply

Drainage

Shows the type of coating or adhesive and the coating section.

Shows the oil or water supply port and the refill amount.

Shows the oil or water drain port and the drain amount.

IMPORTANT If the specified conditions are not satisfied or the specified procedure is not observed, there is a strong possibility that the product will be damaged or the performance of the product will be reduced. The message shows the preventive measures.

（4）

Hexagon Bolt Tightening Torque (0) Bolt type: 6 1 0 0 1 - 1 2 0 3 0 (1) Thread type: Metric thread=0 (0) (1) ( 2 ) ( 3 ) (4) (5) Unified thread=2 (2) Bolt strength: 4〜11 T (3) Thread pitch: Metric thread: Coarse pitch thread (C), fine pitch thread (F) Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF) (4) Diameter: 12 → 12mm Metric ; 12 → 12/16 → 3/4 inch Unified (5) Length: 030=30mm (Length is always given in mm for metric or unified bolts.) Bolt size Type

Nominal dimension

Nominal dia.

Pitch

M10 M12 M14 M16

Metric thread

Unified thread

10 12 14 16

M18

M20

M22

M24

M27

M30

M33

5/16

(N-m)

Bolt strength 4.6 (4T)

8.8 (8T)

10.9T (11T)

(F) 1.25

132

(F) 1.25

142

206

(F) 1.5

152

221

216

314

(F) 1.5

226

330

103

299

436

(F) 1.5

113

324

476

147

417

608

(F) 1.5

162

451

662

196

559

814

(F) 1.5

211

598

878

255

721

1,030

(F) 2.0

270

770

1,128

373

1,030

1,520

(F) 2.0

397

1,128

1,618

510

1,422

2,109

(F) 2.0

549

1,569

2,256

686

1,912

2,844

(F) 2.0

736

2,059

3,040

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

127

358

525

7/8

9 UNC

196

554

809

16 UNC

309

868

1,275

★ :Tighten the bolts according to the above list, unless otherwise specified.

（5）

(kgf-m) Bolt size Type

Nominal dia.

Pitch

4.6 (4T)

8.8 (8T)

10.9T (11T)

0.9

2.7

3.9

M10

1.9

5.4

7.8

(F) 1.25

2.0

5.6

8.2

M12

3.3

9.2

13.5

(F) 1.25

3.5

9.8

14.5

M14

5.2

14.5

21.0

(F) 1.5

5.5

15.5

22.5

M16

7.8

22.0

32.0

(F) 1.5

8.2

23.0

33.7

10.5

30.5

44.5

(F) 1.5

11.5

33.0

48.5

15.0

42.5

62.0

(F) 1.5

16.5

46.0

67.5

20.0

57.0

83.0

(F) 1.5

21.5

61.0

89.5

26.0

73.5

105.0

(F) 2.0

27.5

78.5

115.0

38.0

105.0

155.0

(F) 2.0

40.5

115.0

165.0

52.0

145.0

215.0

(F) 2.0

56.0

160.0

230.0

70.0

195.0

290.0

(F) 2.0

75.0

210.0

310.0

M18 Metric thread

M20 M22 M24

Unified thread

Bolt strength

Nominal dimension

18 20 22 24

M27

M30

M33

5/16

18 UNC

0.9

2.5

3.6

3/8

16 UNC

1.6

4.5

6.6

7/16

14 UNC

2.6

7.2

10.5

1/2

13 UNC

3.7

10.5

15.0

9/16

12 UNC

5.3

15.0

22.0

5/8

11 UNC

7.3

20.5

30.0

3/4

10 UNC

13.0

36.5

53.5

7/8

9 UNC

20.0

56.5

82.5

16 UNC

31.5

88.5

130.0

★ :Tighten the bolts according to the above list, unless otherwise specified.

（6）

(lb-ft.) Bolt size Type

Nominal dia.

Pitch

4.6 (4T)

8.8 (8T)

10.9T (11T)

6.5

19.5

M10

13.7

(F) 1.25

14.5

M12

(F) 1.25

105

M14

105

150

(F) 1.5

110

160

M16

160

230

(F) 1.5

165

245

220

320

(F) 1.5

235

350

105

305

450

(F) 1.5

120

330

490

145

410

600

(F) 1.5

155

440

650

190

530

760

(F) 2.0

200

565

830

275

760

1120

(F) 2.0

295

830

1190

375

1050

1550

(F) 2.0

405

1160

1660

505

1410

2100

(F) 2.0

540

1520

2240

M18 Metric thread

M20 M22 M24

Unified thread

Bolt strength

Nominal dimension

18 20 22 24

M27

M30

M33

5/16

18 UNC

6.5

18.0

3/8

16 UNC

11.5

7/16

14 UNC

18.8

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

145

410

595

16 UNC

225

640

940

★ :Tighten the bolts according to the above list, unless otherwise specified.

（7）

Flanged Hexagon Bolt Tightening Torque 1.Bolt Type

Metric thread

2.Bolt strength

4〜8T

3.Thread pitch

Coarse pitch thread(C)

(N-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

0.8

1.25

M10

1.5

M12

1.75

M16

−

231

M20

2.5

−

441

M24

−

765

4.8 (4T)

8.8 (8T)

(kgf-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

0.8

0.4

0.7

1.2

1.25

1.5

2.9

M10

1.5

2.9

5.4

M12

1.75

5.1

9.6

M16

2 2.5

− −

23.5

M20 M24

−

78.0

45.0

(lb-ft) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

0.8

2.9

5.0

8.6

1.25

10.8

20.9

M10

1.5

20.9

38.9

M12

1.75

36.7

69.1

M16

−

169.2

M20

2.5

−

324.0

M24

−

561.6

（8）

Hose Band Tightening Torque Low pressure hose (heat resisting hose)

Hose band

Tightening torque

(N-m)

(kgf-cm)

(lb-ft)

1.6

1.2

2.9

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

1.6

1.2

2.9

Inner dia.(mm) Outer dia.(mm) 6.3

16.5

HH022W

7.9

18.5

HH022W

9.5

20.5

HH022W

12.7

24.5

HH027W

15.9

29.9

HH031W

19.0

30.0

HH031W

25.4

38.0

HH044W

31.8

45.8

HH052W

38.1

52.1

HH057W

50.8

67.8

HH071W

60.5

76.0

HH082W

75.5

93.0

HH095W

Low pressure hose Inner dia.(mm) Outer dia.(mm)

Hose band

16.5

HH022W

18.5

HH022W

20.5

HH022W

22.0

HH023W

24.5

HH027W

26.0

HH027W

29.0

HH031W

30.5

HH031W

32.0

HH038W

34.0

HH038W

39.5

HH044W

41.5

HH044W

46.0

HH052W

48.0

HH052W

54.0

HH057W

70.5

HH076W

73.0

HH076W

To connect the hose to the pipe, tighten the hose band at the following position: Hose

Hose band Center of pipe protrusion 10〜20mm

（9）

Pipe

Liquid Gasket and Screw Lock Agent To reassemble the disassembled parts, be sure to use the specified liquid gasket or screw lock agent of the equivalent according to the following lists:

Liquid Gasket Code

Manufacturer

Product name

ＡＡ０１

Loctite

Plastic Gasket 568

ＡＡ０２

Loctite

Hydraulic sealant

ＡＡ０３

Three Bond

Three Bond 1215

Code

Manufacturer

Product name

ＡＢ０１

Loctite

Loctite 262

ＡＢ０２

Three Bond

Three Bond 1327

ＡＢ０３

Three Bond

Three Bond 1374

Screw Lock Agent

・ Cautions regarding parts removal

・ Cautions regarding reassembly

If a screw or shaft to be removed has been locked by one of the above agents, remove the screw or shaft using a general tool, such as a wrench or puller. If it is difficult to remove the screw or shaft, heat the bolt to soften the agent (200 to 250 ℃ ) using a soldering iron or gas torch. Caution: If there is a seal near the screw or shaft to be removed, carefully use the heating method for removal, to avoid damage to the seal. If heat has been used to remove the bolt a new bolt should be used during reassembly.

To reassembly a screw: Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw. Note:A piece of hardened lock agent may be peeled off and remain in the component. The remaining piece may cause malfunction during operation.

To bond a plane or to fit a shaft: Remove the hardened lock agent using a wire brush or the like, and polish the surface using sand paper. Use of a loctite primer like Locquic ® Primer T cleans threads and speeds curing time.

Antiseize Agent Code

Manufacturer

ＡＣ０１

Loctite

Product name Loctite 767 (Paste or spray)

（ 10 ）

Cautions Regarding Welding Repair Service If welding is needed to repair the chassis, observe the following precautions to protect the hydraulic cylinders, hydraulic units, gear sets, and electrical units from possible damage.

Cautions: 1)Remove the ground terminal from the battery. 2) The controller circuit breaker should be turned "OFF" . 3)Ground the welder near the section to be welded. 4) To ground the welder, check that the electric current will not flow through the cylinders. Cylinder head covers for some models have a low-conductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod. Example 1:

Section to be welded Do not ground this section. Electric current may flow through the cylinders. Ground this section. (correct grounding)

Example 2:

Do not ground this section. Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

（ 11 ）

5) The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes.

Be sure to mask these units and parts before welding.

a)Plated section Cover the plated sections with heat-resistant cloth, such as glass wool or canvas . Note: The weld spattered on the plated sections causes corrosion.

Hydraulic cylinder

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

b)Cover the hydraulic units, electrical units, harnesses, hydraulic hoses, nylon tubes, etc. with heat-resistant cloth (glass wool or canvas) or scrap material to protect them from spatter. 1m or more

Scrap material, etc.

Section to be welded

1m or more

c) Hydraulic hoses, nylon tubes, or harnesses are easily damaged by the heat during welding. To protect them from the heat, remove them from the section to be welded to make enough clearance.

Section to be welded Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

（ 12 ）

Weight of Main Components

Part name

Approx. Weight (kg)

Approx. Weight (lb)

Bucket

4,940

10,900

Boom

3,200

7,040

" Z " -Lever

425/pc

940/pc

1pc

Link (Bucket to Lever)

76/pc

167/pc

1pc

Engine room assembly

520

1,150

Including air cleaner and condenser

Hydraulic tank

370

820

Excluding oil

Fuel tank

314

690

Excluding fuel

110

242

Left

194

Right

Cab

350

770

Floor board

340

750

Rops

850

1,870

Front chassis

3,800

8,360

Rear chassis

3,650

8,030

Counterweight

2,450

5,390

Engine

2,000

4,400

Excluding oil

Radiator

650

1,430

Excluding water and oil

Torque converter

280

620

Excluding oil

Transmission

1,030

2,270

Excluding oil

First propeller shaft

Second propeller shaft

128

Third propeller shaft

Air cleaner

42/pc

92/pc

Exhaust silencer (Muffler)

Front axle assembly

2,815

6,200

Excluding tires and oil

Rear axle assembly

3,085

6,790

Excluding tires and oil (Including axle support)

557

1,225

Front

562

1,236

Rear

Multiple control valve

100

220

Steering valve

110

Hydraulic

Gear pump

100

system

Boom cylinder

525/pc

1,160/pc

Bucket cylinder

245/pc

540/pc

Steering cylinder

80/pc

180/pc

Tire

1,480/pc

3,260/pc

Battery

60/pc

130/pc

Item Unit name

Chassis

Remarks

RVT bucket

Deck

Power line

Differential

Other

With handrail

（ 13 ）

Including air conditioner unit and seat

Double pump

With rim (35/65-33-24PR); No Hydro Inflation

Applying and Storing Articulation Stopper 1.Applying articulation stopper WARNING Unexpected movement of the machine could cause serious injury or death. There is a possibility that a service man may be crushed in the articulation area if the machine unexpectedly turns during repair work. To prevent such an accident, be sure to apply the articulation stopper before starting work.

1) Park the machine so that the frame is straight ahead. Remove the bolt (1).from the articulation stopper on the rear chassis.

2)Turn the rod (2) (articulation stopper) to the front and then align the pin hole. Insert the pin (3) into the rod to lock the front chassis to the rear chassis.

2 3

WARNING To align the pin with the pin hole, start the engine and slightly turn the steering wheel. Be careful! Your body or finger may be crushed in the machine when the machine turns. Stay out of the articulation area while aligning the holes. When inspecting or servicing machine in articulation area, do not start the engine without applying the articulation stopper and place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel.

LOCKED POSITION

3 2

2.Storing articulation stopper Store the rod (2) and pin (3) as shown.

STORED POSITION

（ 14 ）

Chassis Group ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-1 Power Group ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-1 Torque Converter & Transmission Group ・・・・・・・・・・・・・・・ 34-1 Hydraulic Group ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-1 Brake Group ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-1 Electrical Group ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 64-1

CHASSIS GROUP 14 Disassembly and Reassembly Removing and Reinstalling Deck ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-2 Removing and Reinstalling Fuel Tank ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-3 Removing and Reinstalling Hydraulic Tank ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-4 Removing and Reinstalling Engine Room ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-5 Removing and Reinstalling ROPS ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-8 Removing and Reinstalling Cab ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-9 Removing and Reinstalling Floor Board ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-12 Removing and Reinstalling Boom ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-14 Removing and Reinstalling Center Pin ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 14-17

14-1

Removing and Reinstalling Deck

115Z Ⅳー 2

CHASSIS 14

Removing and Reinstalling Deck 1.Removing deck WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting deck removal: ・ Position the machine on level ground, and apply the parking brake. ・ Lower the bucket onto the ground, and block the tires with chocks, etc. to prevent them from moving. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

Note : The illustration shows the parts on the left side. On the right side, the parts are located at the same points. 1)Remove the step (1). Torque for assembly: : Bolt : 53N-m (5.4kgf-m) (39 lb-ft)

115K14001

2)Sling a hand rail (2)(3) and remove the bolts (4)(5)(6). Remove the deck (together with the handrail). : Bolt: (4)(5)(6) : 93N-m (9.55kgf-m) (69 lb-ft) : Deck (with handrail) : 110kg (242 lbs) left 88kg (194 lbs) right

3 5 115K14002

2.Reinstalling deck For reinstallation, follow the above procedure in the reversed direction.

14-2

Removing and Reinstalling Fuel Tank

115Z Ⅳー 2

CHASSIS 14

Removing and Reinstalling Fuel Tank 1.Removing fuel tank WARNING 1

Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting fuel tank removal: ・ Position the machine on level ground, and apply the parking brake. ・ Lower the bucket onto the ground, and block the tires with chocks, etc. to prevent them from moving. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

Before starting work: a)Drain fuel from the fuel tank. (Fuel tank capacity: 620 l (164 Gal.)) b)Remove the deck by referring to page 14-02.

1)Disconnect the level sensor electrical line coupler (1). Temporarily sling the fuel tank (2). Remove the retainer bolt (3). : Fuel tank : 314kg (690 lbs)(empty) Torque for assembly: : Retainer bolt (3) : 765N-m (78.0kgf-m) (564 lb-ft)

97K14003

2)Slightly pull out the fuel tank (2) to disconnect the suction hose (4) and return hose (5). 5

115V14009

2.Reinstalling fuel tank For reinstallation, follow the above procedure in the reversed direction. Note : After reinstallation, be sure to completely bleed air in the fuel line.

14-3

Removing and Reinstalling Hydraulic Tank

115Z Ⅳー 2

CHASSIS 14

Removing and Reinstalling Hydraulic Tank 1.Removing hydraulic tank WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting hydraulic tank removal: ・ Position the machine on level ground, and apply the parking brake. ・ Lower the bucket onto the ground, and block the tires with chocks, etc. to prevent them from moving. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

Before starting work: a)Drain hydraulic oil from the hydraulic tank. (Hydraulic tank capacity. : 225 l (60 Gal.)) b)Remove the deck by referring to page 14-02. c) Put matching marks for the hydraulic hoses and pipes located on the hydraulic tank, and then remove them. d)Disconnect the suction hose and return hose.

1) Temporarily sling the hydraulic tank (1) and remove the bolts (2). : Hydraulic tank : 370kg (820lbs)(Empty) Torque for assembly: : Retainer bolt : 721N-m (73.5kgf-m) (532 lb-ft)

2.Reinstalling hydraulic tank For reinstallation, follow the above procedure in the reversed direction. Note : After reinstallation, be sure to check the pipes for leakage, and also check the oil level of the hydraulic tank.

14-4

115V14001

Removing and Reinstalling Engine Room

115Z Ⅳー 2

CHASSIS 14

Removing and Reinstalling Engine Room 1.Removing engine room WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting engine room removal: ・ Position the machine on level ground, and apply the parking brake. ・ Lower the bucket onto the ground, and block the tires with chocks, etc. to prevent them from moving. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

Before starting work: a)Recover/recycle freon refrigerant on machine with optional air conditioner, if required. Note : If the quick coupler is attached, no recovery/recycling will be needed. b)Remove the right and left decks together with the handrail .

115K14004

1)Remove the cover (1) from both the right and left sides.

2)Remove the band (2) of the brake oil tank. Temporarily clamp the brake oil tank to the rear chassis.

115V14010

3)Remove the side cover (3) and round bar (4). Sling the side cover and remove the bolt (5) for the side cover hinge. Remove the side cover.

14-5

115K14006

Removing and Reinstalling Engine Room

115Z Ⅳー 2

CHASSIS 14

4)Remove the nut (7) for the roof cushion and lift the roof (6). : Roof : 95kg (210 lbs) Torque for assembly: : Nut (7) : 32N-m (3.25kgf-m) (23.5 lb-ft)

115K14007

5)Remove the wiring of the inside screen board. Remove the hoses (10)(11) of the receiver tank (9) and condenser (8).

8 9 11

115V14011

6)Remove the hose band (13) for the air cleaner rubber hose (12), and then remove the hose.

12 13

115V14012

7)Disconnect the screen board retainer bolt (14) and lift the screen board. Note : Slowly lift the screen board while checking that there are no obstacles. : Screen board (with condenser and air cleaner) :260kg (572 lbs) Torque for assembly: : Bolt (14) : 216N-m (22.0kgf-m) (159 lb-ft)

115K14010

14-6

Removing and Reinstalling Engine Room

115Z Ⅳー 2

CHASSIS 14

8)Remove the cover (15) (right and left) for the radiator guard. Remove the bolt (16) for radiator guard. Temporarily sling the radiator guard. Note : Slowly lift the radiator guard while checking that there are no obstacles. : Radiator guard (with grill) : 250kg (550 lbs) Torque for assembly: : Bolt (16) : 216N-m (22.0kgf-m) (159 lb-ft) 16

115K14011

2.Reinstalling engine room For reinstallation, follow the above procedure in the reversed direction. Note : After reinstallation, be sure to check the air conditioner for refrigerant leakage. Also check that the air cleaner rubber hose connection band is properly positioned and tightened with proper torque.

14-7

Removing and Reinstalling ROPS

115Z Ⅳー 2

CHASSIS 14

Removing and Reinstalling ROPS 1.Removing ROPS WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket onto the ground, and apply the parking brake. ・ Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

1) Temporarily sling the hook A attached on the ROPS (1). Remove twenty retainer bolts (2) (right and left) and lift the ROPS. : ROPS : 850kg (1870 lbs) Torque for assembly: : Bolt (2) : 2,108N-m (215kgf-m) (1556 lb-ft)

1 A

2.Reinstalling ROPS For reinstallation, follow the above procedure in the reversed direction.

115V14013

14-8

Removing and Reinstalling Cab

115Z Ⅳー 2

CHASSIS 14

Removing and Reinstalling Cab 1.Removing cab WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket onto the ground, and apply the parking brake. ・ Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

Before starting work: ・ Remove the ROPS . ・ Remove the deck both right and left side.

1) The cover (1) for the outer filter is located at the right rear side of the cab. Turn the rings counterclockwise and then remove the cover (1). Remove the outer filter (2) from the cab. Note : When installing the outer filter into the cab, be sure to align the air flow arrow on the outer filter to point toward the cab.

2)Remove the cover (3).

65K14051

3)Disconnect the vinyl tube (4) for window washer liquid. 4

65K14052

14-9

115Z Ⅳー 2

CHASSIS 14

4)Disconnect the electrical line coupler (5) and the ground cable (6). 5

65K14053

5)Remove the nut (7) and the lever (8). Then remove the cover (9).

Torque for assembly: : Nut (7) : 34N-m (3.5kgf-m)(25 lb-ft)

9 65K14054

6)Remove the pin (11) for the arm (10). Tilt the steering shaft (12) backward.

12 10

65K14014

7)Remove the bolt (13). Front Right/Left 2pcs each Rear Right/Left 2pcs each Torque for assembly : : Bolt : 721N-m (73.5kgf-m)(532 lb-ft)

Cab

Floor board 13

14-10

65V14002

115Z Ⅳー 2

8)Remove the bolts (14) and the seal washer (15). Install the eye bolt (M16 × 2.0) on the cab. Lift the cab slowly. : Cab : 350kg (770 lbs)

CHASSIS 14

Cab

14 15

65V14003

2.Reinstalling cab For reinstallation, follow the above procedure in the reversed direction.

3.Cautions regarding reassembly 1)Check the movement of the wiper and adjust the moving angle if necessary. 2)Tune the clock and the radio.

14-11

Removing and Reinstalling Floor Board

115Z Ⅳー 2

CHASSIS 14

Removing and Reinstalling Floor Board 1.Removing floor board WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket onto the ground, and release the residual pressure from the hydraulic oil tank and lines. ・ Drain the air in the air tank. ・ Disconnect the (-)side of the battery. ・ Disconnect the (+)side of the battery.

Before starting work: a)Remove the deck from both the right and left sides of the machine. b)Remove the cab. c) Disconnect the hose and the electrical coupler between the floor board and the chassis. d)Disconnect the pipes from the air conditioner lines at the self seal couplings. Note : Before disconnecting the electrical coupler, hoses and pipes, put match mark on them. Prepare a can for the oil, Cover the disconnected hoses and pipes with vinly to protect them from dust and dirt. 1)Remove the floor board (3) retaining nut (4). Install the eye bolt (M16 × 2.0) to the floor board at 4 places. Attach sling then gradually lift the floor board while checking that there are no obstacles and that all the pipes, cables, pins, etc. are disconnected.

3 4

: Including ope. board, 340kg (750 lbs) air conditioner, seat, etc. Torque for assembly: : Nut (4) : 230N-m (23.5kgf-m)(170 lb-ft) 97K14018

14-12

Removing and Reinstalling Floor Board

115Z Ⅳー 2

2.Reinstalling floor board For reinstallation, follow the above procedure in the reversed direction. Note : After reinstallation, start the engine, and then check the refrigerant, and oil lines for leakage. Also check operation of the electrical equipment.

14-13

CHASSIS 14

Removing and Reinstalling Boom

115Z Ⅳー 2

CHASSIS 14

Removing and Reinstalling Boom 1.Removing boom WARNING

WARNING

Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer could cause a breakage resulting in injury or death. ・ Keep persons away from working area. ・ Use a support plate in case a steel hammer is used. ・ Use a copper-hammer or a plastic hammer. ・ Always wear protection goggles.

Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket onto the ground, and release the residual pressure from the hydraulic oil tank and lines. ・ Apply the parking brake and remove the starter key.

Note : The illustration shows the parts on the right side. On the left side, the parts are located at the same points. 2

1)Remove the pin (3) connecting the bucket (1) and the link (2). : Bucket : 4,940kg (10,900 lbs) Note : There are shims in the pin sections. Carefully store the removed shims, and correctly reinsert the shims when reinstalling the bucket.

115V14002

2)Remove the connection pin (15) from the boom (4) and bucket (1). Note : There are shims in the pin sections. Carefully store the removed shims, and correctly reinsert the shims when reinstalling the bucket.

1 115V14003

3) Temporarily sling the link (2), and then remove the connection pin (6) from the lever (5). : Link (for 1 pc) : 76kg (167 lbs)

6 90K14008

14-14

Removing and Reinstalling Boom

115Z Ⅳー 2

CHASSIS 14

The illustrations show the parts on the right side. On the left side, the parts are located at the same points. 4)Remove the grease pipe (7) from the lever (5).

CAUTION

You have to work at a high position to remove the grease pipe. Always use a stepladder for this work.

90K14009

5) Temporarily sling the bucket cylinder (8), and then remove the connection pin (9) from the lever (5) and bucket cylinder (8). 9

: Bucket cylinder : 245kg (540 lbs)

5 90K14010

6)Start the engine and shorten the bucket cylinder rod (10). Lower the bucket cylinder rod (10) on the machine.

90K14011

7) Temporarily sling the lever (5), and then remove the lever pin (11) and lever (5). 11

: Lever (for 1 pc) : 425kg (940 lbs)

90K14012

14-15

Removing and Reinstalling Boom

115Z Ⅳー 2

CHASSIS 14

The illustrations show the parts on the right side. On the left side, the parts are located at the same points.

13 12

8)Remove the grease hose (13) from the pin (12). Insert the wooden block between the boom the cylinder (14) and the piping (15), and then remove the pins (12) from the cylinder rod on both the right and left sides of the boom. Note : Wooden block helps to install the pin insertion easily when reinstallation.

9) Temporarily sling the cross pipe of the boom (4), and then remove the pins (16) from the boom on both the right and left side of the boom.

Wooden block

115V14004

: Boom : 3,200kg (7,040 lbs)

CAUTION

Loss of control of the boom structure during removal or installation could result in injury or machine damage. When you sling the boom, be sure to check that the boom is horizontal. If the boom is inclined, it may unexpectedly tilt the end of the boom resulting in loss of control.

90K14014

2.Reinstalling boom For reinstallation, follow the above procedure in the reversed direction. Note : After reinstallation, grease the boom, and then operate it. During operation, check the boom for abnormal noise.

14-16

115Z Ⅳー 2

Removing and Reinstalling Center Pin

CHASSIS 14

Removing and Reinstalling Center Pin Upper

Bearing cover Shim adjustment

Front chassis Rear chassis T1

115ZA1206

T1: 421N-m (43.0kgf-m) (311 lb-ft) T2: 662N-m (67.5kgf-m) (488 lb-ft) Shim adjustment: Adjust the clearance to 0.1±0.05mm (0.0039±0.0020 in.) using the shim. After that, tighten the T1 bolt.

Split shim

115ZA1404

Lower T3

Front chassis Rear chassis

115V14005

T3: 417N-m (42.5kgf-m) (307 lb-ft)

115K14014

14-17

Removing and Reinstalling Center Pin

115Z Ⅳー 2

CHASSIS 14

1.Removing center pin WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting center pin removal: ・ Place the machine on a level and paved ground. ・ Lower the bucket onto the ground, and block the front tires with chocks, etc to prevent them from moving. ・ Apply the stopper to the rear wheel oscillation section to prevent the machine from oscillation. ・ Release the residual pressure from the hydraulic line, and also release the internal pressure from the hydraulic tank. ・ Cover the steering cylinder rod to prevent it from being scratched.

Transmission

1)Remove the second propeller shaft assembly (1). Torque for assembly: : Bolts : 221N-m (22.5kgf-m) (163 lb-ft) : Screw lock agent application (Three bond 1327)

115V14006

2)Remove the right and left steering cylinder retainer pins (2) and the shims (3).

Steering Cylinder 115V14007

3)Disconnect the brake hose and high pressure hose , and disconnect the electrical line from the coupler. : Hydraulic oil : Approx. 3 l (0.8 Gal.) :Brake oil : Approx. 3 l (0.8 Gal.) Note : Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

4)Remove the retainer bolt (4) and then remove the plate (5). Torque for assembly: : Bolt (4) : 662N-m (67.5kgf-m) (488 lb-ft) (with lubricating oil)

4 115V14008

14-18

Removing and Reinstalling Center Pin

115Z Ⅳー 2

CHASSIS 14

5)Before disconnecting the front chassis (6) from the rear chassis, be sure to support the front chassis using the jack and blocks so that the front chassis will not fall backward. Before disconnecting the front chassis from the rear chassis, be sure to sling the rear chassis using a crane (apply the rope to the hook (8)) so that the rear chassis will not fall backward.

7 6 Jack

WARNING 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 a sling before using and do not use improper sling. ・Use signals as agreed upon before starting work. ・Stay out of the working area while using a crane.

95V14018

97K14028

6)Push the upper center pin out using a jack.

Jack

95V14019

7)Support the bottom of the fuel tank (9) using a garage jack. Push the lower center pin (10) out using another jack to remove the pin.

Jack

WARNING 9 Chassis separation is dangerous work. To ensure your safety, be careful in doing this work Garage jack

95V14020

14-19

115Z Ⅳー 2

Removing and Reinstalling Center Pin

CHASSIS 14

8)Slowly turn the rear tires both the right and the left sides using a bar to separate the rear chassis. Note : While turning the rear tires, check that the garage jack under the fuel tank shifts backward together with the rear chassis. In addition, adjust the height using the rear crane whenever the height adjustment is necessary. Bar 95V14021

9)Remove the ring (11) and remove the bolts (13) from the bearing cover (12). When reinstalling, install the bearing cover so that the direction of the grease nipple is positioned as illustrated. Torque for assembly: : Bolts (13) : 417N-m (42.5kgf-m) (307 lb-ft)

Rear chassis

Front chassis

115K14009

Front

Grease nipple Installation direction 45 ° 115V15001

10)Remove the shim (14). Note : If the taper roller bearing (15) is replaced, be sure to adjust the clearance using the shim. Thickness of shim(mm):0.1,0.2,0.3,0.5, and 1.0

14-20

14 97K14032

Removing and Reinstalling Center Pin

115Z Ⅳー 2

11)Check the dust seals in upper center pin (16) and lower center pin (17). If a seal is damaged replace it with new one. Note :Direction of dust seal (Top)

CHASSIS 14

(Bottom)

97K14033

12)When the spherical bearing (18) is replaced, install the bearing outer ring so that the split is perpendicular to the front - rear line of the machine. 18

97K14034

2.Reinstalling center pin For reinstallation, follow the above procedure in the reversed direciton.

3.Cautions regarding reassembly ①After reinstallation, grease the center pins, and operate them. During operation, check the pins for abnormal noise and looseness. ②Be sure to completely bleed the brake of air. For air bleeding procedure, refer to the Section 24. ③ Check each section for oil leakage.

WARNING Insufficient air bleeding in brake oil line could cause an accident resulting in injury or death be sure to completely bleed the brake of air.

14-21

CHASSIS GROUP 15 Service standard Linkage ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 15-2 Linkage Pin Standard Clearance Values ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 15-3 Center Pin ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 15-4 Bucket ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 15-5 Bucket Positioner and Boom Kick-Out ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 15-6

15-1

115Z Ⅳ -2

Linkage

CHASSIS 15

Linkage 2. Boom-Lever

1. Bucket-Boom

3. Boom-Boom cylinder

φ１２０ φ１００

4. Front chassis-Boom

φ１２０

5. Bucket-Rod

6. Lever-Rod

φ９０

φ１２０ φ９０

9. Boom cylinderFront chassis

8. Bucket cylinderFront chassis

7. Lever-Bucket cylinder

φ１２０

φ１００

10. Front chassisSteering cylinder

11. Steering cylinderRear chassis

１１５ＺＡ１２０２

φ７０

9 115ZA1203

15-2

Linkage Pin Standard Clearance Values

115Z Ⅳ -2

CHASSIS 15

Linkage Pin Standard Clearance Values Unit : mm (in.) Judgment standard No.

Item

Pin standard dimension -0.120

Joint section between bucket and boom

Joint section between boom and lever

Joint section between boom and boom cylinder

Joint section between front chassis and boom

Joint section between bucket and link

Joint section between lever and link

Joint section between lever and bucket cylinder

φ 100

( φ 3.9370)

( φ 3.9370) φ 120

( φ 4.7244)

( φ 4.7244) φ 120

( φ 4.7244)

( φ 4.7244) φ 120

( φ 4.7244)

( φ 4.7244) φ 90

( φ 3.5433)

( φ 3.5433) φ 90

( φ 3.5433)

( φ 3.5433) + 0.140 0

φ 100 -0.155

φ 100

( φ 3.9370)

-0.120

+ 0.140 0

φ 90 -0.155

-0.120

※

+ 0.140 0

φ 90 -0.155

-0.120

+ 0.160 0

φ 120 -0.185

-0.120

※

+ 0.160 0

φ 120 -0.185

-0.145

+ 0.160 0

φ 120 -0.185

-0.145

+ 0.140 0

φ 100 -0.155

-0.145

※

Bushing standard dimension

Joint section between bucket cylinder and front φ 100 -0.155

φ 100

+ 0.140 0

chassis

( φ 3.9370)

Joint section between boom cylinder and

φ 120 -0.185

φ 120

front chassis

( φ 4.7244)

Joint section between front chassis and

φ 70 -0.130

φ 70

steering cylinder

( φ 2.7559)

Joint section between steering cylinder and

φ 70 -0.130

φ 70

rear chassis

( φ 2.7559)

-0.145

-0.100

( φ 3.9370) + 0.160 0

+ 0.120 0

Standard clearance

Solution Tolerance

0.295〜0.120

1.0

(0.0116〜0.0047)

(0.0393)

0.345〜0.145

1.0

(0.0135〜0.0057)

(0.0393)

0.345〜0.145

1.0

(0.0135〜0.0057)

(0.0393)

0.345〜0.145

1.0

(0.0135〜0.0057)

(0.0393)

0.295〜0.120

1.0

(0.0116〜0.0047)

(0.0393)

0.295〜0.120

1.0

(0.0116〜0.0047)

(0.0393)

0.295〜0.120

1.0

(0.0116〜0.0047)

(0.0393)

0.295〜0.120

1.0

(0.0116〜0.0047)

(0.0393)

0.345〜0.145

1.0

(0.0135〜0.0057)

(0.0393)

0.250〜0.100

1.0

(0.0098〜0.0039)

(0.0393)

0.250〜0.100

1.0

(0.0098〜0.0039)

(0.0393)

Liner clearance adjustment ※

※ Adjustment procedure (for adjustment of liner clearance marked with asterisk): Adjust the liner clearance (marked with " ※ ") between the bosses to 1.2mm or less using liner of 1mm thickness. For the steering cylinder, adjust the liner clearance on the rear chassis side first, and then adjust the liner clearance on the front chassis side while checking that the cylinder is not inclined. Liners should be placed on both sides of the linkage as much as possible. Wear then occurs on the liners and reduces wear on the chassis. Excessive vertical free play in the steering cylinders can result in loud knocking noises when the steering wheel is turned.

15-3

Replacement

Center Pin

115Z Ⅳ -2

CHASSIS 15

Center Pin Adjusting Shim(#5)

〔Upper section〕

The clearance between the front chassis and bearing cover (#3) is 0.75±0.5mm before shim adjustment. Add shims so that the clearance is 0.1 ± 0.05mm.

5 Front chassis

#8・・・662N-m (67.5 kgf-m)(488 lb-ft) (with lubricating oil) #9・・・421N-m (43.0kgf-m) (311 lb-ft)

Rear chassis

115ZA1206

Installing bearing cover(#3) Install the bearing cover so that the grease pipe mounting hole is positioned at the specified angle as shown in the right figure.

Rear chassis

Front chassis

Front

Grease pipe direction 45 ° 115V15001

Installing bearing outer ring(#3)

〔Lower section〕

Install the bearing outer ring so that the split is perpendicular to the front-rear line of the machine.

3 Front chassis Rear chassis

115ZA1207

Front

Rear 3

Grease pipe installation direction

Split of outer bearing 26° 90ZA13-004-4

15-4

115Z Ⅳ -2

Bucket

CHASSIS 15

Bucket (Wear plate mounting section)

19.1

Wear plate

１１５ＺＡ１５０１

１１５ＺＡ１５０２

Judgment standard No.

Item

Wear plate wearing

Wear plate mounting bolt tightening torque

Standard dimension

Allowable limit

Wear limit

45 mm

19.1 mm

25.9 mm

834N-m (85.0kgf-m) (615 lb-ft)

Solution Replacement Tightening

Tooth welding procedure (Tooth)

(Corner tooth)

Straight edge

Straight edge V-shape edge

V-shape edge

※1

(10 × 15) 15 (10 × 15) 15

※2

(10 × 15) １１５ＺＡ１５０５

１１５ＺＡ１５０３

Tooth should be contacted to this surface.

(10 × 15) 15 Tooth should be contacted to this surface.

Cutting edge Cutting edge (10 × 15) 15

１１５ＺＡ１５０４

Item

Straight edge

Welding portion

１１５ＺＡ１５０６

V-shape edge Weld on

part

Welding rod

Low hydrogen welding rod equivalent to ASTM E 7016

Pre-heat

150 ℃ (Both edge and tooth) ※1

Welding prohibition area

※2

17 mm 17 mm

※3

15 mm

Note) In the case the tooth contacts to the cutting edge, there may be max. 4mm clearance between the tooth and the bottom face of the cutting edge. Extend the welding leg length as much as the clearance. 15-5

115Z Ⅳ -2

Bucket Positioner and Boom Kick-Out

CHASSIS 15

Bucket Positioner and Boom Kick-Out (Optional)

Boom kick-out

Bucket positioner

９７ＺＡ１５０６

Bucket positioner

Adjusting plate

Direction of indicator lamp Proximity switch

Indicator lamp

Connector

4 1

９７ＺＡ１５０７

15-6

Bucket Positioner and Boom Kick-Out

115ZIV-2

CHASSIS 15

Boom kick-out

Adjusting plate

3 Position of the adjusting plate when the kick-out adjustable angle is zero.

Connector

Proximity switch Direction of indicator lamp

９７ＺＡ１５０８

Unit : mm No.

Item

Judgment standard

Solution

Clearance of bucket positioner switch

5 ± 2 (0.196±0.078 in.)

Adjustment

Clearance of boom kick-out switch

5 ± 2 (0.196±0.078 in.)

Adjustment

Adjusting plate mounting bolt tightening torque

Switch mounting nut tightening torque

5 6

Positioner

90N-m (9.2kgf-m) (67lb-ft)

Kick-out

53N-m (5.4kgf-m) (39lb-ft)

Tightening

20N-m (2.0kgf-m) (14lb-ft)

Tightening

Bucket positioner adjustable angle

-7 ° 〜 +7 °

Adjustment

Boom kick-out adjustable angle

0〜41.2 °

Adjustment

15-7

Bucket Positioner and Boom Kick-Out

115Z Ⅳ -2

CHASSIS 15

Bucket positioner adjustable angle

-7° 7°

Boom kick-out adjustable angle

９５ＺⅣ１４０３

15-8

POWER GROUP 24 Disassembly and Reassembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-2 Power Line Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-3 Radiator Mount Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-4 Removing and Reinstalling Radiator ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-6 Removing and Reinstalling Engine ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-8 Removing and Reinstalling Propeller Shaft ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-10 Removing and Reinstalling Air Cleaner ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-11 Removing and Reinstalling Muffler ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-12 Removing and Reinstalling Fan ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-13 Front Axle Assembly Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-15 Removing and Reinstalling Front Axle Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-17 Disassembling and Reassembling Front Axle ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-24 Floating Seal ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-27 Disassembling and Reassembling Internal Gear Hub ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-30 Disassembling and Reassembling Spider Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-32 Special Jigs for Disassembling Axle ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-38 Rear Axle Assembly Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-40 Axle Support Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-41 Removing and Reinstalling Rear Axle Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-45 Axle Support Bushing Installation Procedure ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-46 Removing and Reinstalling Differential ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-48 Front Differential Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-49 Rear Differential Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 24-50 Disassembling and Reassembling Differential Assembly ・

24-1

115Z Ⅳ -2

Power Line Tightening Torque

POWER 24

Power Line Tightening Torque L1 T8 T7 T6 1st propeller shaft

L4 T1

Engine

T8 L1

L1 T6

T6 T2 L4

T1 0 T9 L2

Torque converter

T3 L3 Rear differential ass'y

T9 L 2 L4 T4 Front differential ass'y

T8 L1

T5 T5

T8 L1

2nd propeller shaft

Transmission

3rd propeller shaft

Parking brake group

１１５Ｖ２４００１

:Bolt tightening torque T1 :44N-m (4.5kgf-m) (33 lb-ft) T2 :71N-m (7.2kgf-m) (52 lb-ft) T3 :196N-m (20.0kgf-m) (145 lb-ft) T4 :72N-m (73.5kgf-m) (532 lb-ft) T5 :221N-m (22.5kgf-m) (163 lb-ft) T6 :216N-m (22.0kgf-m) (159 lb-ft) T7 :294N-m (30.0kgf-m) (217 lb-ft) T8 :417N-m (42.5kgf-m) (307 lb-ft) T9 :142N-m (14.5kgf-m) (105 lb-ft) T1 0:49N-m (5.0kgf-m) (36 lb-ft)

L 1 :Screw lock agent application (Loctite 262) L 2 :Screw lock agent application (Three Bond 1327 or equivalent) L 3 :Screw lock agent application (Three Bond 1374 or equivalent) L 4 :With lubrication oil (Engine oil or gear oil) Note: Always replace drive shaft bolts with new bolts-Never reuse.

24-2

Radiator Mount Tightening Torque

115Z Ⅳ -2

POWER 24

Radiator Mount Tightening Torque Radiator

T1 Engine

T2 L1

Rear chassis

:Bolt tightening torque T1 :51N-m (5.2kgf-m) (38 lb-ft) T2 :216N-m (22.0kgf-m) (159 lb-ft) T3 :93N-m (9.5kgf-m) (69 lb-ft)

L 1 :Withliquidadhesive(Loctite262orequivalent)

24-3

Removing and Reinstalling Radiator

115Z Ⅳ -2

POWER 24

Removing and Reinstalling Radiator 1.Removing radiator

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Lower the bucket onto the ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

Before starting work: a)Remove the engine room. (Refer to Section 14.) b)Remove the radiator guard. 1)Remove the under cover and then remove the drain plug (1) to drain the coolant. :Under cover : Front 45kg (99 Ibs) Center 40kg (88 Ibs) Rear 37kg (81 Ibs) :Coolant : 76 l (20 gal) Capacity for coolant in system : 128 l(33.8 gal.) 2)Open the coolant drain cock (2) (3) at the engine side to drain the coolant from the engine.

１９７Ｋ２４００３

２３

１１５Ｋ２４０３７

3)Disconnect the coolant hose (4), torque converter oil cooler hose (5) and hydraulic oil cooler hose (6). Note: Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt. ５

６

24-4

４

１１５Ｖ２４００３

Removing and Reinstalling Radiator

115Z Ⅳ -2

POWER 24

4)Disconnect the hoses (7) (8) (9) from the radiator. Also disconnect the electrical coupler (10) for the water level sensor. Note: Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

９

１０

８

７１１５Ｖ２４００４

5)Remove the fan guard (11), retainer bolts (12) and stay (13). :Retainer bolt : 216N-m (22.0kgf-m) (159 lb-ft) :Screw lock agent (Loctite 262) application

１６

１１

１３

１２１５

6)Temporarily sling the radiator. Remove the bolts (14) (15) both the right and left sides. Torque for assembly: :Retainer bolt (14) (15) : 51N-m (5.2kgf-m) (38 lb-ft) :Screw lock agent (Loctite 262) application

１４

１１５Ｖ２４００５

7)Lift the radiator (16) to remove it. :Radiator : 650kg (1,430 lbs)

Clearances

９５Ｖ２４００３

2.Reinstalling radiator For reinstallation, follow the above procedure in the reversed direction. Note: Reinstall the radiator while checking that the right and left clearances between the fan and the radiator guard are equal to each other.

24-5

Removing and Reinstalling Engine

115Z Ⅳ -2

Removing and Reinstalling Engine 1.Removing engine

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

Before starting work: a)Remove the engine room. (Refer to Section 14.) b)Refer to "Removing radiator". c)Remove the torque converter. (Refer to Section 34.) d)Drain the engine oil from the engine oil pan. 1)Disconnect the negative side of the battery cable. Then remove the positive cable. 2)Disconnect the each sensor, alternator, starter motor and air conditioner etc. 3)Disconnect the fuel hose, ether hose, heater hose, cooler hose and drain hose etc. 4)Disconnect the accelerator controller cable.

24-6

POWER 24

115Z Ⅳ -2

Removing and Reinstalling Engine

5)Temporarily sling the engine assembly and then remove the engine retainer bolt (1) (2). Slowly lift the engine while checking that there are no obstacles. Note: When lifting the engine, always use the engine lifting (3) stored in the right hand side battery box and the sling tool (A) together. Do not lift the engine with the engine lifting (3) alone. Torque for assembly: :Engine assy : 2,000kg (4,400 Ibs) (1) : 417N-m (42.5kgf-m) (307 lb-ft) (2) : 294N-m (30.0kgf-m) (217 lb-ft) :Screw lock agent application (Loctite 262)

２００

Engine

１１１５Ｖ２４００６

Ａ

Ｒ１５

２５

３０

２５

φ １８Ｄｒｉｌｌ

５０

２５

φ １８Ｄｒｉｌｌ

２

３

３２０

１００

３２０

４０１５

Sling tool A

POWER 24

２５

２５４２０

４２０１１５ＺＫ２４００６

８４０

２４−００８−１

2.Reinstalling engine For reinstallation, follow the above procedure in the reversed direction.

Cautions regarding engine reinstallation ① There is an O-ring in the housing between the engine and torque converter. Be sure to replace the O-ring with a new one. ② Refill the engine with the proper quantity and type engine oil. ③ Refill the radiator with premixed coolant. ④ After reinstalling the engine, completely bleed the fuel line of air. ⑤ Set the starter key to ON, and then check the monitor lamps of electrical equipment. ⑥ Operate the engine at the idling speed for 5 minutes. After that, check the amount of the coolant. ⑦ While gradually increasing the engine speed, check operation of the electrical equipment.

24-7

Removing and Reinstalling Prop. Shaft

115Z Ⅳ -2

POWER 24

Removing and Reinstalling Propeller Shaft WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Lower the bucket onto the ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

1.Removing first propeller shaft Remove the bolts (2) (3) for the first propeller shaft (1). Torque for assembly: :Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft) :Screw lock agent (Three Bond 1327) application :First propeller shaft : 14kg (30 lbs)

２

１

３

Torque converter

９

８７１１５Ｖ２４００７

2.Removing second propeller shaft Remove the bolts (5) (6) for second propeller shaft (4). Torque for assembly: :Retainer bolt : 221N-m (22.5kgf-m) (163 lb-ft) :Screw lock agent (Three Bond 1327) application :Second propeller shaft : 58kg (128 lbs) Note: If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner. Keep the flame away from the seals of the coupling. Do not reuse the bolts, always replace with new ones.

3.Removing third propeller shaft Remove the bolts (8) (9) for third propeller shaft (7). Torque for assembly: :Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft) :Screw lock agent (Three Bond 1327) application :Third propeller shaft : 28kg (60 lbs) 24-8

５ Front differential

６４

Parking brake group １１５Ｖ２４００８

115Z Ⅳ -2

POWER 24

4.Reinstalling propeller shaft

２４．６１

８２．５５

４６．０５

３５．７２

５８．７３

Transmission

３５．７２

８４．１４

８２．５５

For reinstallation, follow the above procedure in the reversed direction. Note: During reinstallation, align the direction of the flange yokes as illustrated. 〔 Difference in the yoke phase (direction)will cause the propeller shaft damage.〕

５８．７３

First propeller shaft installation

８４．１４

Removing and Reinstalling Propeller Shaft

Second propeller shaft installation

Third propeller shaft installation １１５Ｖ２４０１５

24-9

Removing and Reinstalling Air Cleaner

115Z Ⅳ -2

POWER 24

Removing and Reinstalling Air Cleaner 1.Removing air cleaner

1)Remove the wing nut (1), and then remove the cover (2). Remove the wing nut (3), and then remove the outer element (4). Remove the wing nut (5), and then remove the inner element (6). Note: Removing inside elements reduces the weight and facilitates air cleaner case removal work.

１５３

６

４

２

７０Ｋ２４００７

2)Remove the bolt (7) and remove the plate (8). ８７

１１５Ｋ２４００７

3)Disconnect the air duct (9) and remove the bolt (10). After that, remove the air cleaner. Torque for assembly : :Retainer bolt : 53N-m (5.4kgf-m) (39 lb-ft) :Air cleaner : 42kg /pc (90 lb/pc)

１０

2.Reinstalling air cleaner For reinstallation, follow the above procedure in the reversed direction.

９１１５Ｋ２４０１０

24-10

Removing and Reinstalling Muffler

115Z Ⅳ -2

POWER 24

Removing and Reinstalling Muffler 1.Removing muffler

WARNING

CAUTION You may get burned if you remove the muffler before the engine is cool enough. To prevent such an incident, be sure to stop the engine, and open the side covers. Start the muffler removal work when the engine is cool enough.

Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Lower the bucket onto the ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

1)Remove the U-bolt and the exhaust pipe (2).

１

2)Remove the bolt (3) and then lift the muffler (1). :Muffler : 30kg (66 lbs) Torque for assembly: :Bolt : 93N-m (9.55kgf-m) (69 lb-ft) With lubricating oil Note: After disconnection, cover the pipe at the turbocharger side with vinyl, plugs or the like to protect the turbocharger from dust and dirt.

３

２９７Ｋ２４０１３

2. Reinstalling muffler For reinstallation, follow the above procedure in the reversed direction. Note: After reinstallation, check all the joints for gas leakage and vibration.

24-11

Removing and Reinstalling Fan

115Z Ⅳ -2

POWER 24

Removing and Reinstalling Fan 1.Removing fan

WARNING If a person starts the engine without informing the service man who is repairing the machine, an accident resulting in injury or death could occur. To prevent such an accident: ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

1)Remove the fan guard (1). Torque for assembly: :Retainer bolt : 93N-m (9.55kgf-m) (69 lb-ft)

１

１１５Ｋ２４０１３

2)Remove the bolt (2) for the fan, and then take the fan (3) and spacer (4) out to the right side. Note: Carefully remove the fan while checking that the fan will not damage the radiator fins. Inspect the fan for any signs damage or cracks. Replace the fan if there are any signs of damage or cracks. Fan blade breakage can cause extensive damage. Torque for assembly: :Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft)

３４

２１１５Ｋ２４０１４

2.Reinstalling fan For reinstallation, follow the above procedure in the reversed direction.

24-12

115Z Ⅳ -2

Front Axle Assembly Tightening Torque

POWER 24

Front Axle Assembly Tightening Torque (S/N 11C3-5501〜5524)

T9 L 2

(B)

L3 T8 L 1 Front differential ass'y

T7 T1 0 T1 0 T6 L1 T1 0 T1 1

(A) T4 L1

T1 0 T3

L1 T1

T2 １１５Ｖ２４００９

:Bolt tightening torque T1 :892N-m (91.0kgf-m) (658 lb-ft) T2 :834N-m (85.0kgf-m) (615 lb-ft) T3 :90N-m (9.2kgf-m) (67 lb-ft) T4 :721N-m (73.5kgf-m) (532 lb-ft) T5 :86N-m (8.8kgf-m) (64 lb-ft) T6 :53N-m (5.4kgf-m) (39 lb-ft) T7 :33N-m (3.4kgf-m) (25 lb-ft) T8 :314N-m (32.0kgf-m) (232 lb-ft) T9 :686N-m (70.0kgf-m) (506 lb-ft) T1 0:78N-m (8.0kgf-m) (58 lb-ft) T1 1:15N-m (1.5kgf-m) (11 lb-ft)

L 1 :Screw lock agent (Three Bond 1327) application L 2 :With lubrication oil (Engine oil or gear oil) L 3 :Liquid gasket (Three Bond 1215)

Note:Tighten (A) while measuring the preload applied to section (B) . Preload of section (B) : 353〜392N (36〜40kgf) (79〜88 Ibs) This is "breakaway" force. The force required to start the wheel turning.

24-13

115Z Ⅳ -2

Front Axle Assembly Tightening Torque

POWER 24

Front Axle Assembly Tightening Torque (S/N 11C3-5525〜)

T9 L2 L3

(B)

T8 L 1 T7

Front differential ass'y

T1 0 T1 0

T1 0 T1 1

(A) T4 L1

T1 0

L 1 :Screw lock agent (Three Bond 1327) application L 2 :With lubrication oil (Engine oil or gear oil) L 3 :Liquid gasket (Three Bond 1215)

Note: Tighten (A) while measuring the preload applied to section (B). Preload of section (B) : 353〜392N (36〜40kgf)(79〜88lbs) This is "breakaway" force. The force required to start the wheel turning.

24-14

Removing and Reinstalling Front Axle

115Z Ⅳ -2

POWER 24

Removing and Reinstalling Front Axle Assembly 1.Removing front axle assembly

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. Apply the parking brake and the articulation stopper. ・ Lift the boom, and place a stand under the boom to support it or install a boom cylinder lock collar.

Before starting work ・ Lift the front wheel using the bucket, and then place a stand under the front chassis to support the chassis. Block the rear wheels with chocks. ・ To drain the oil from the axle. :Drain oil : 180 l(48 gal.)

Stand Stand

1)Remove the right and left wheel and tire assemblies (1). １

:1 Tire : 1,480kg (3,260 lbs) Torque for assembly: :Retainer bolt : 892N-m (91.0kgf-m) (658 lb-ft) without lubrication oil Retainer nut : 834N-m (85.0kgf-m) (615 Ib-ft)

９７Ｋ２４０２８

2)Remove the second propeller shaft retainer bolt (2). Remove the cover (3) and the brake pipe (4). Disconnect the air breather tube (5) from the upper part of the axle. Reassembly : Clean the nylon breather tube before reinstalling. Torque for assembly: :Retainer bolt : 221N-m (22.5kgf-m) (163 lb-ft) :Screw lock agent (Three Bond 1327) application :Brake oil : Approx. 0.3 l (0.1gal.)

５２４

３

９７Ｋ２４０２９

24-15

Removing and Reinstalling Front Axle

115Z Ⅳ -2

POWER 24

3)Temporarily sling the axle assembly (6), and then remove the retainer bolts (7). Place the axle assembly (6) on a carrier to smoothly pull out. :Axle assembly : 2,815kg (6,200 lbs) Torque for assembly: :Retainer bolt : 686N-m (70.0kgf-m) (506 lb-ft) Note: During reassembly b e s u r e b o t h mating surfaces are clean and free of paint.

７

６１１５Ｖ２４０１６

2.Reinstalling front axle assembly For reinstallation, follow the above procedure in the reversed direction. After reinstallation, completely bleed air in the auto adjuster valve first and then the service brake.

CAUTION Before air bleeding in the brake oil line, be sure that the wheel and tire assemblies are installed on the wheel hub. If fail to do, the bolts (4 pcs) temporarily tighten the spider and the wheel hub may be broken by the brake piston. Finally the spider and the cover may fall off.

ＳｏｃｋｅｔｂｏｌｔＳｐｉｄｅｒ

９５Ｖ２４０１１

Reference Air bleeding procedure Connect a vinyl tube to the air bleeder nipple, and place an oil can to receive the oil. Fill the brake oil tank (S/N 11C3 - 5501〜5600). Slightly loosen the air bleeder nipple, and then press the brake pedal several times. When the oil flows from the air bleeder nipple, close the nipple. After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple. Repeat this until there is no air in the oil. When the oil level in the reservoir lowers, add oil to the tank. Completely bleed each wheel of air.

24-16

Disassembling and Reassembling Axle

115Z Ⅳ -2

POWER 24

Disassembling and Reassembling Front Axle 1.Disassembling front axle

WARNING Unexpected movement of the machine or components could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the rear wheels with chocks or the like to prevent the wheels from moving.

Before starting work: a)Lower the bucket onto the ground. Lift the front wheels while supporting the machine with the bucket. Place a stand (A) under the front chassis to support it. Check that the tires are off the ground. b)Lift the boom until it is horizontal, and place a stand (B) under the boom to support it or install a boom cylinder lock collar.

Stand (B)

Stand (A) １１５Ｖ２４０１７

1)Remove the wheel and tire assembly (1) from the side to be disassemblied (example: left side). １

:Tire of 1 wheel :1,480kg (3,260 lbs) (without hydroinflation) Torque for assembly: :Retainer bolt : 892N-m (91.0kgf-m) (658 Ib-ft) Retainer nut : 834N-m (85.0kgf-m) (615 lb-ft) without lubrication oil

９７Ｋ２４０２８

2)Remove the drain plug (2) from the differential section to drain oil. :Gear oil : Approx. 110 l(29 gal.)

２９７Ｋ２４０４４

24-17

Disassembling and Reassembling Axle

115Z Ⅳ -2

POWER 24

3)Turn the drain plug (4) to the bottom of the wheel hub (3) to drain oil. :Gear oil : 70 l(18.5 gal.) Note: To replace the oil, refer to the oil amount described below. :Wheel hub section : 35 l(9.3 gal.) l for left side, 35 l(9.3 gal.) for right side Differential section : 110 l(29 gal.) Total oil amount for front axle : 180 l(48 gal.)

３

４９７Ｋ２４０４５

4)Remove the cover (5). Torque for assembly: :Retainer bolt : 90N-m (9.2kgf-m) (67 lb-ft) :Screw lock agent (Three Bond 1327) application ５

９７Ｋ２４０４６

5)Remove the snap ring (6), and then remove the sun gear (7).

７

６

6)Temporarily sling the spider using the hoisting tool (A). Remove four spider retainer bolts (8) to remove the spider assembly (9). Torque for assembly: :Retainer bolt : 86N-m (8.8kgf-m) (64 lb-ft) :Spider assembly : 200kg (440 lbs)

１１５Ｖ２４０１８

Ａ

９

８

９７Ｋ２４０４８

24-18

Disassembling and Reassembling Axle

115Z Ⅳ -2

7)Remove the friction plate (10) and the steel plate (11). (Each 3 pcs of the friction plate and steel plate are installed.) Note: Clean the brake plates, and then check the plates for distortion, discoloration and wear. Refer to Section 55 for additional information.

POWER 24

１０

９７Ｋ２４０４９

１１９７Ｋ２４０５０

8)Turn the wheel hub (3) until the drain plug is positioned on the top. Connect the turnbuckle to the eye bolt (A) to lock the wheel hub. Note: Be sure to lock the wheel hub, or the hub will drop when the axle nut is removed and the internal gear hub is removed.

Ｔｕｒｎｂｕｃｋｌｅ

Ａ

３９５Ｖ２４０１２

9)Remove the axle shaft (12), disc gear (13) and wear ring (behind disc gear (13)).

１３１２

９５Ｖ２４０１３

24-19

Disassembling and Reassembling Axle

115Z Ⅳ -2

10)Remove the bolt (14), lock plate (15) and then remove the axle nut (16). Note: Axle nut width across flat:180mm

POWER 24

１５

:Retainer bolt : 53N-m (5.4kgf-m) (39 lb-ft) :Screw lock agent (Three Bond 1327) application

１６

１４

１１５Ｖ２４０１９

11)Pull out the internal gear hub (17) to the extension end face using the internal gear hub puller (C).

１７Ｃ

１１５Ｖ２４０１０

12)Sling the internal gear hub (17) using the internal gear hub hoisting tool (D). Remove the internal gear hub (17).

１７

Ｄ

:Internal gear hub : 180kg (396 lbs)

13)Sling the wheel hub (3) using the wheel hub hoisting tool (E). Remove the turnbuckle, and then remove the wheel hub (3).

Ｅ３

:Wheel hub : 260kg (570 lbs)

９７Ｋ２４０５５

24-20

Disassembling and Reassembling Axle

115Z Ⅳ -2

14)Remove the oil seal (18). Also remove the sleeve from the axle. (S/N 11C3 - 5501〜5524) Note: Disassemble the other wheels as described above.

POWER 24

１８

９７Ｋ２４０５６

2.Reassembling front axle To reassemble the front axle, follow the above procedure in the reversed direction.

IMPORTANT ・ Replace all the O-rings and seals with new ones. ・ Clean and check all the parts. If a part is damaged, replace it.

3.Cautions regarding reassembly 1)To insert the oil seal into the wheel hub, use the wheel hub oil seal press-in jig (F). 2)Pack grease into the clearance between the oil seal and sleeve. Note: Refer to "Floating Seal" for the machines S/N 11C3 - 5525 and up.

Oil seal Packed grease

Sleeve

No oil on this surface

3)Install the jig (E) to the wheel hub (3). Sling the wheel hub (3) and temporarily install it to the axle housing.

(S/N 11C3 - 5501〜5524)

９５ＺⅣ２４０２

Ｅ３

９７Ｋ２４０５５

24-21

Disassembling and Reassembling Axle

115Z Ⅳ -2

POWER 24

4)Install the bearing of the wheel hub (3) using the jig (G).

３

Remove the jig (G) and install the jig (H). Tighten the axle nut until the bearing contacts to the axle housing.

Ｇ３ Bearing should be contacted to axle housing.

Axle nut

Ｈ

１１５Ｖ２４０２０

5)Reinstall the internal gear hub assembly (17). Note: Before reinstallation, align the brake oil hole of the axle housing extension with that of the internal gear hub assembly. Spring pin

Internal gear hub

１７

１１５Ｖ２４０２１

Example LF

The spring pins should be at the upper position. １６

6)Tighten the axle nut (16) using the jig (B) so that the preload of the tire mounting hole section is 353 〜 392N (36〜40kgf)(79〜88 lbs). Note: Measure the minimum pulling force to rotate the wheel hub using spring scale. : Use the bolt for the jig (A).

９７Ｋ２４０５９

7)Disconnect the brake pipe (19) and elbow (20). Attach the jig (I) for brake oil leakage test.

２０

１９９７Ｋ２４０６０

24-22

Disassembling and Reassembling Axle

115Z Ⅳ -2

POWER 24

8)Apply 588kPa (6kgf/cm )(85psi) air pressure for approximately 1 minute. Shut off the valve. Check that the pressure does not fall. Note: 1.Use the jig (J) to hold the brake piston not to come out.

Jig (I)

Air supply PT 3/8 Air pressure gauge (6kg/cm2) (PF3/8 with the adapter)

Ｊ

１１５Ｖ２４０２２

2.If the pressure falls, air is leaking from the brake piston O-rings or internal gear hub O-rings. Disassemble the internal gear hub again to repair the leakage.

Spring pin

Friction plate

Cooling holes

9)Make sure to reassemble the steel plates and friction plates as follows. ① Install the steel plate with 4-teeth section first. The 4-teeth section of the steel plate is located between the spring pins installed on the internal gear. ② Install the friction plate. ③ Install the steel plate with two 1-tooth sections so that the spring pins are positioned outside of the both 1-tooth section. ④ Install the friction plate. Note: Align the cooling holes of three friction plates with each other.

Steel plate

２４−０２０−

Spring pins

Internal gear

10)Check that the wheel hub drain plug is diagonal to the spider top mark. Fill the oil to the specified level. ２４−０２０−

11)After reinstalling the brake, be sure to completely bleed the brake of air. Note: After reinstalling tires, check that manual rotation of the tires is possible. Also check the wheels for oil leakage.

Wheel hub Spider TOP mark

Drain plug (at bottom)

24-23

115Z Ⅳ -2

Floating Seal

POWER 24

Floating Seal (S/N 11C3-5525〜) Construction Floating seal location

Assembling procedure Ｆｌｏａｔｉｎｇｓｅａｌ

ＷｈｅｅｌｈｕｂＡｘｌｅｈｏｕｓｉｎｇ

1.Checking before seal installation (1)Checking seal ・Check the seal ring for distortion and scratches. ・Check the O-ring for scratches. (2)Check the wheel hub and the ring for bur. If any remove it by sand paper etc. (3)Clean the seal installation part on the wheel hub and the seal ring, and remove oil on them.

ＲｉｎｇＲｉｎｇ

Ｒｅｍｏｖｅｏｉｌ

Ｓｅａｌｃｒｏｓｓｓｅｃｔｉｏｎ

Ｐｕｔｔｈｉｎｇｅａｒｏｉｌ（Ｄｏｎｏｔｕｓｅｇｒｅａｓｅ）

Ｏ ‐ ｒｉｎｇ

ＳｅａｌＲｉｎｇ

Note : The rotating ring and the fixing ring are exactly the same. They can be used both ways.

24-24

Ｄｏｎｏｔｔｏｕｃｈｂｙｈａｎｄ（Ｉｔｍａｙｃａｕｓｅｒｕｓｔｉｎｇ）

115Z Ⅳ -2

Floating Seal

2.Assembling procedure (1)In case no jig is used ・Install the O-ring on the seal ring. ・Put thin gear oil on the O-ring. ・Insert the floating seal into the ring and the wheel h u b pushing the O-ring by fingers. (Make sub-assembly) ・Check if the seal ring is correctly positioned or the O-ring is not twisted. ・Clean the surface and put thin gear oil on it. ・Install the ring and the wheel hub to the axle housing.

POWER 24

・Install the guide jig to the wheel hub and / or the ring. ・Put thin gear oil on the O-ring. ・Insert the floating seal into the guide jig.

Ｇｕｉｄｅｊｉｇ

(2)In case jig is used

１

２

Ｂｅｆｏｒｅｉｎｓｔａｌｌａｔｉｏｎ

３

・Fix the installation jig to the floating seal, and push it until it reaches to the guide jig. (Make sub assembly) ・Remove the guide jig and the installation jig from the floating seal. ・Clean the surface and put thin gear oil on it. ・Install the ring and the wheel hub to the axle housing.

４

1.Wheel hub 2.Guide jig 3.Installation jig 4.Floating seal

Ｇｕｉｄｅｊｉｇ

Ｉｎｓｔａｌｌａｔｉｏｎ

Ａｆｔｅｒｉｎｓｔａｌｌａｔｉｏｎ

24-25

Floating Seal

115Z Ⅳ -2

3.Caution before operation ・After assembling, turn the wheel hub 2〜 3 turns by hands. ・Check if it turns lightly by hands. If it is tight to turn the wheel hub, the O-ring may be twisted. In this case it may be necessary to disassemble the floating seal.

24-26

POWER 24

Internal Gear Hub

115Z Ⅳ -2

POWER 24

Disassembling and Reassembling Internal Gear Hub 1.Disassembling internal gear hub 1)Turn up the internal gear hub (1), and then remove the two O-rings (2). １

２

2)Remove sixteen bolts (4) from the brake piston (3) and then remove the return spring (5). Torque for assembly: :Locknut : 33N-m (3.4kgf-m) (25 lb-ft)

４

３

５４

3)Insert two remover bolts (4) into the brake piston (3), then tighten the bolts (6) to remove the piston (3). Note: Use the brake piston removal/installation jig (J).

６

４

Ｊ

24-27

３

Internal Gear Hub

115Z Ⅳ -2

POWER 24

4)Remove the brake piston O-rings (8) (9). ９

８

5)There is a snap ring that connects the internal gear (10) to the internal gear hub (1). Shift the snap ring to the inside using a round bar or the like.

１０

１

6)Sling the internal gear (10) to remove it.

１０

１

2.Reassembling internal gear hub To reassemble the internal gear hub, follow the procedure described in the reversed direction.

24-28

115Z Ⅳ -2

Internal Gear Hub

POWER 24

3.Cautions regarding reassembly IMPORTANT ・ Replace the O-rings with new ones. ・ Clean and check all the parts. If a part is damaged, replace it with a new one.

1)When reinstalling the brake piston (3) to the internal gear hub using the bolts (11), align the oil groove (A) of the internal gear hub with the oil groove (B) of the brake piston. Note that the direction of the brake oil holes for the right hand side is different from the one for the left hand side.

B Oil groove

１１

１

2)When reassembling the internal gear (10) to the internal gear hub (1), place the oil groove (B) of the brake piston (3) to be between the spring pins (12). (Reason) To reinstall the internal gear hub on the axle, the brake oil path should be aligned to these oil grooves. In addition, the oil grooves are used for alignment of the spring pin. Moreover, the aligned grooves are used for external measurment of brake disc wear. Note: Check that the snap ring is properly inserted into the groove of the internal gear.

A Oil groove ３１１５Ｖ２４０１０

１２

3)Before reinstallation of the taper roller bearing, be F) to 150 ℃ sure to heat the bearing to 120 ℃ (248 ° F) in oil. (302 °

３

4)Apply grease to the O-rings. １０

１１１５Ｖ２４０１１

24-29

Spider Assembly

115Z Ⅳ -2

POWER 24

Disassembling and Reassembling Spider Assembly 1.Disassembling spider assembly 1)Remove the lock bolts (2) for the planetary pin (1), and then remove the plate (3). Torque for assembly: :Lock bolts : 721N-m (73.5kgf-m) (532 lb-ft) :Screw lock agent (Three Bond 1327) application ３２１

2)Insert a lock bolt (2) into the planetary pin (1), and remove the pin. Remove the planetary gear (4) with the wear rings and the bearings as a unit.

２１

４

3)Remove the wear rings and the bearings (5) from the planetary gear (4). Note: Machines S/N 11C3 - 5501 〜 5806 use three bearings(5) as shown. Machines S/N 11C3 - 5807 and up use two larger bearings.

５

４ Wear rings １１５Ｖ２４０１２

4)Turn the spider (6) upside down. Using a plastic hammer, tap the brake retainer (7) off the spider. Remove the spring pin (8).

７

８

６１１５Ｖ２４０２３

24-30

Spider Assembly

115Z Ⅳ -2

2.Reassembling spider assembly Before starting work: ・ Clean all the parts. ・ Check the brake retainer, pins, bearings, planetary gears, wear rings for distortion and wear. ・ Replace the O-ring and defective parts with new ones. ・ Inspect the internal bores of the spider for wear.

3.Cautions regarding reassembly ・ To reinstall the brake retainer, check that there is no clearance between the spider and the brake retainer. ・ The brake retainer may only be installed as it was removed. It may not be flipped over due to the roll pin hole design. ・ To insert the planetary pin, align the core holes of the planetary gear with that of the wear ring. ・ The lock bolt hole of the planetary pin is shifted from the center. Check that the bolt hole is shifted to the inside. ・ Manually turn the planetary gear to check that the gear smoothly rotates.

24-31

POWER 24

115Z Ⅳ -2

Special Jigs for Disassembling Axle

POWER 24

Special Jigs for Disassembling Axle (A) Spider hoisting tool

(Material: SS41) φ12 Round bar

82.5

t 9

6 13

37.5

110

117

75 ２４−０２６−Ａ

M24 × 2

Bolt

Cut the threaded area off the M10 eye bolt before use. 40

(Material SCM21 Hardening HS70 〜 80)

(B)Axle nut tightening jig φ 80 □38

Hexagon(Width across flat 180mm)

φ229

24-32

２４−０２６−Ｂ

115Z Ⅳ -2

Special Jigs for Disassembling Axle

POWER 24

(C)Internal gear hub puller

(Material: SS41) 2-12 Drill

t12

248 280 ２４−０２７−Ｃ

(D)Internal gear hub hoisting tool

(Material: SS41) 2-22 Drill 23

285

t15

30 30 240

285

195

110

625

220

3.2

185

340

385

5 5

A-A

24-33

２４−０２７−Ｄ

115Z Ⅳ -2

Special Jigs for Disassembling Axle

POWER 24

(E)Wheel hub hoisting tool

(Material: SS41) φ13

82.5

13 t5 t5

37.5

t5 13

t3.2 Pipe

M24 l 60 20

t 5 ２４−０２８−Ｅ

(F)Wheel hub oil seal press-in jig

(Material: SS41)

21.5

φ 200

φ 288 φ298 φ 336 φ342

24-34

２４−０２８−Ｆ

115Z Ⅳ -2

Special Jigs for Disassembling Axle

POWER 24

(G)Wheel hub installation jig

(Material: SS41)

8 divisions into equal parts

110

140

φ260 φ20 2

φ190 φ2 30

Knurling 120 22

228 250 ２４−０２９−Ｇ

(H)Bearing insertion jig

(Material: SS41)

φ189 φ230

φ355 φ308 φ280 φ220

44 ２４−０２９−Ｈ

24-35

115Z Ⅳ -2

Special Jigs for Disassembling Axle

POWER 24

(J) Brake piston holding jig

(Material SS41 T12)

4- φ 12

M16 × 2

208

124 248 416 445

100

M16×2(Totally threaded)

24-36

115Z Ⅳ -2

Special Jigs for Disassembling Axle

POWER 24

(K)Floating seal jig For wheel hub １６．５

２０１２±０．２

Φ３７０

Φ４２０

Φ３７０

Φ４３０

Φ４１００ Φ３９３．７ −０．１ Φ３８７．５±０． Φ３８２±０．１

Φ４４０

＋０．１０

３

Φ３９４．７＋０．０５

＋０．３０

Φ３８８．５±０．

Φ４３０

Φ４０３＋０．２５

３

１２±０．１

５

１１．５±０．３

Ｒ０．

Ｃ

Ｒ０．２〜Ｒ０．５

For ring １３

13.5+0.2 -

３

２０３

１．５

Φ４１００ Φ３９３．７ −０．１ Φ３８７．５±０． Φ３８２±０．１

Φ４５０

＋０．１０

Φ３９４．７＋０．０５

Φ３８８．５±０．

Φ４０５−−００．．３２０５

Ｃ３

１２±０．１

１１．５±０．３

Ｃ

Ｒ０．３

Ｒ０．２〜Ｒ０．５

24-37

115Z Ⅳ -2

Rear Axle Assembly Tightening Torque

POWER 24

Rear Axle Assembly Tightening Torque (S/N 11C3-5501〜5524)

(B) T8 L1 T7

Rear differential

T6 L 1

(A) T4 L 1

T5 L1

T3 T1

T2 １１５ＺＡ２４０８

Note: Tighten (A) while measuring the preload applied to section (B) . Preload of section (B) : 353〜392N(36〜40kgf) (79〜88 Ibs) This is "breakaway" force. The force required to start the wheel turning.

L 1 :Screw lock agent (Three Bond 1327) application

24-38

115Z Ⅳ -2

Rear Axle Assembly Tightening Torque

POWER 24

Rear Axle Assembly Tightening Torque (S/N 11C3-5525〜)

(B) T8 L 1 T7

Rear differential

T6 L 1

(A) T4 L 1

T5 L1

T3 T1

Note: Tighten (A) while measuring the preload applied to section (B) . Preload of section (B) : 353〜392N(36〜40kgf) (79〜88 Ibs) This is "breakaway" force. The force required to start the wheel turning.

L 1 :Screw lock agent (Three Bond 1327) application

24-39

115Z Ⅳ -2

Axle Support Tightening Torque

POWER 24

Axle Support Tightening Torque Rear axle Grease piping

T2 L2

T1 L 1

Grease piping

Front

T1 L 1 T2 L2

T1 L1

１１５Ｖ２４０１３

:Bolt tightening torque T1 :1,030N-m (105kgf-m) (760 lb-ft) T2 :686N-m (70.0kgf-m) (506 lb-ft)

L1 :Screw lock agent (Three Bond 1327) application L2 :With lubrication oil (Engine oil or gear oil)

24-40

Removing and Reinstalling Rear Axle Assy

115Z Ⅳ -2

POWER 24

Removing and Reinstalling Rear Axle Assembly 1.Removing rear axle assembly

Before starting work: 1)Lower the bucket onto the ground. Lift the front wheels while supporting the machine with the bucket. Place a stand (A) under the rear chassis (behind the center pin) to support the chassis.

Ａ

９７Ｋ２４０３２

2)Lift the boom, and then roll the bucket back to level. Check that the rear wheels are off the ground. Place a stand (B) under the counter weight to support it. Ｂ

９７Ｋ２４０３３

3)Remove the under cover (1). :Under cover : 45kg (99 lbs)

１９７Ｋ２４０３４

24-41

Removing and Reinstalling Rear Axle Assy

115Z Ⅳ -2

POWER 24

4)Insert wooden blocks into the swing stopper section to prevent the axle from swinging . Wooden block

WARNING The axle will not be balanced when a tire is removed. If stoppers are not inserted, your fingers or body may be caught in the machine.

９５Ｖ２４０１７

5)Remove the right and left wheel and tire assemblies. Torque for assembly: :Retainer bolt : 892N-m (91.0kgf-m) (658 lb-ft) Retainer nut : 834N-m (85.0kgf-m) (615 lb-ft) :Tire of 1 wheel: 1,480kg (3,260 lb-ft)

２

９７Ｋ２４０３５

6)Remove the third propeller shaft retainer bolts (4) to remove the propeller shaft (3). Torque for assembly: :Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft) :Screw lock agent (Three Bond 1327) application :Third propeller shaft : 23kg (50 lbs) ３

４

９７Ｋ２４０３６

7)Disconnect the air breather tube (5). ５

Rear axle ９５Ｖ２４０１８

24-42

Removing and Reinstalling Rear Axle Assy

115Z Ⅳ -2

POWER 24

8)Disconnect the front and rear grease pipes and then remove the brake hose (6) and the brake pipe (7). :Brake oil : approx. 4 l(1.06 gal.) Note: Cover and plug the hose and fittings on the auto adjuster valve to prevent dirt entry. ６

WARNING When removing the rear axle assembly, the axle support may rotate resulting in injury. Before removing the axle support retainer bolts, fix the axle support by wire not to rotate.

７６

７１１５Ｋ２４０２７

８

9)Temporarily sling the rear axle , and remove the right and left retainer bolts (8) from the rear axle front support. Remove the right and left retainer bolts (8) from the rear axle rear support. Torque for assembly: :Retainer bolt : 686N-m (70.0kgf-m) (506 lb-ft) With lubricating oil (Engine oil or gear oil) :Rear axle : 3,085kg (6,790 lbs) Note: Be careful not to bend or damage the brake oil pipes.

Knock pin

８

Front support

Rear support １１５ＺＡ２４１０

10)Lower the rear axle (9) on the carrier. Note: The rear support is locked by not only the bolts but also dowel pins. Carefully remove or reinstall the support while checking the dowel pins.

９１１５Ｖ２４０２４

11) Pull out the rear axle on the carrier.

CAUTION The axle assembly could fall off the carrier causing injury. Before pulling out the rear axle, carefully position the axle onto the carrier using a strap so that the axle will not fall from the carrier.

24-43

Removing and Reinstalling Rear Axle Assy

115Z Ⅳ -2

POWER 24

12) Remove the snap ring (10), sling the front axle support (11) and remove it. :Axle support : Approx. 81kg (178 Ibs)

１５

１６

13) Remove the packing (12) and O-ring (13). 14) Remove the bushing (14), O-ring (15) and the packing (16). 15) Temporarily sling the rear axle support (17) and remove the retainer bolt (18). Remove the plate (19) and the wearing (20). Torpue for assembly :Bolt (18) : 1,030N-m (105kgf-m) (760 lb-ft) :Screw lock agent (Three Bond 1327) application 16) Remove the retainer bolt (21). Remove the plate (22), wearing (23), and then remove the axle support. Torque for assembly :Bolt (21) : 1,030N-m (105kgf-m) (760 lb-ft) :Screw lock agent (Three Bond 1327) application :Axle support : Approx. 114kg (250 lbs)

１０

１２

１３１１

１４９７Ｋ２４０４０

２０２３１７

2.Reinstalling rear axle assembly For reinstallation, follow the above procedure in the reversed direction. After reinstallation, completely bleed air in the auto adjuster valve first and then the service brake.

24-44

１８１９２２２１

２４

17) Remove the snap ring (24), packing (25) , bushing (26) from the axle support.

２６

２５９７Ｋ２４０４１

Axle Support Bushing Installation

115Z Ⅳ -2

POWER 24

Axle Support Bushing Installation Procedure 1.Front support

Front support ４

３

1) Install the packing (1) and O-ring (2) on the swing shaft. 2) Put the bushing into hot water to heat the bushing to 80 ℃ . Install the bushing onto the swing shaft as shown in the illustration.

Swing shaft

１

２

５ Axle support

３１

3)After installing the axle support onto the swing shaft, install the O-ring (3), packing (4) and the snap ring (5).

９０

１１５Ｖ２４０２５

CAUTION When installing the bushing onto the swing shaft, make sure no oil left on the inner surface of the bushing or the swing shaft surface. If oil is left on them, the bushing may turn alone causing the bushing wear.

2.Rear support 1) Before installing put the bushing (6) into dry ice then install it on to the rear axle support. Rear support 2) Install the packing (7) on to the axle support and install the snap ring (8).

８

Swing shaft

７

６

3) Install the axle support on to the swing shaft not to damage the packing lip. Axle support

Note:When installing the axle support fill enough grease between the packing and the axle support as shown in the illustration.

24-45

End １１５Ｖ２４０２６

Removing and Reinstalling Differential

115Z Ⅳ -2

POWER 24

Removing and Reinstalling Differential 1.Removing differential

Before starting work: a)Lower the bucket onto the ground. Lift the front wheels while supporting the machine with the bucket. Place a stand (A) under the rear chassis (behind the center pin) to support the chassis. b)Lift the boom until it is horizontal, and place a stand (B) under the boom to support it or install a boom cylinder lock collar. c)Remove the drain plug from the differential section to drain oil. d)Turn both tires until the drain port is at the bottom to drain oil.

Stand B Stand A

Note: To replace the oil, refer to the oil amount described below. l :Wheel hub section : 35 l(9.3 gal.) for left side 35 l(9.3 gal.) for right side Differential section : 110 l(29 gal.) Total oil amount for front axle : 180 l(48 gal.)

１１５Ｖ２４０２７

1)Remove the bolts (1), and then remove the cover (2). Torque for assembly: :Retainer bolt : 90N-m (9.2kgf-m) (67 lb-ft) :Screw lock agent (Three Bond 1327) application １２

１１５Ｋ２４０３３

24-46

115Z Ⅳ -2

Removing and Reinstalling Differential

POWER 24

2)Pull only the axle shaft (4) out about 300mm (1ft.) both the right and left sides. Note: Do not pull the axle shaft (4)out with the sun gear (3) . If the sun gear (3) and the axle shaft (4) are pulled out together, the wear ring (6) behind the disc gear (5) may come out with the disc gear.

３

６４５３

１１５Ｋ２４０３４

４１１５ＺＡ２４１５

７

3)Remove the bolts (7), and then remove the retainer bolts except the one (8) on each side. Torque for assembly: :Differential retainer bolts : 314N-m (32.0kgf-m)(232 lb-ft) :Screw lock agent (Three Bond 1327) application

８

１１５Ｋ２４０３５

4)Using the bolt holes for the bolts (7), install the jack (A) to the differential by the bolts (9). Remove the remaining two bolts (8). Slowly pull out the differential (10) from the axle housing. ９

:Bolts (7) : M24 × 3 １０８

Ａ

１１５Ｋ２４０３６

2.Reinstalling differential ・For reinstallation, follow the above procedure in the reversed direction.

3.Removing and reinstalling rear differential ・Remove the rear axle assembly from the machine before removing the rear differential. Refer to "Removing and reinstalling rear axle assembly".

24-47

115Z Ⅳ -2

Front Differential Tightening Torque

POWER 24

Front Differential Tightening Torque (D) Shim T=0.10〜1.00

(A)

T6 L 2

(E) T1 L1

T2 L2

(B) Spacer

T2 L 2

T=29.20〜29.48

T5 L 2

(E) １１５Ｖ２４０１４

Note: 1)To tighten ◯ T1, measure the preload of section (A) . Preload of section (A) : 39 to 49N (4 to 5kgf) (9 to 11 lbs) Use spacer (B) to adjust the preload. 2)Use shim (D) to adjust the tooth contact of spiral bevel gears (C) . Use nut (E) to adjust the backlash.

:Bolt tightening torque T1 :1,030N-m (105kgf-m) (760 lb-ft) T2 :314N-m (32.0kgf-m) (232 lb-ft) T3 :1,128N-m (115kgf-m) (832 lb-ft) T4 :912N-m (93.0kgf-m) (673 lb-ft) T5 :53N-m (5.4kgf-m) (39 lb-ft) T6 :314N-m (32.0kgf-m) (232 lb-ft)

L 1 :Liquid gasket (Three Bond 1215) L 2 :Screw lock agent (Three Bond 1327) application

24-48

115Z Ⅳ -2

Rear Differential Tightening Torque

POWER 24

Rear Differential Tightening Torque (E)

T3 L2

T5 L2 T4

T5 L 2

(D) Shim T=0.10〜1.00 T2 L2

(A) (B) Spacer

T6 L 2

T1 L 1

(E)

T=29.20〜29.48

T2 L 2 １１５ＺＡ２４１７

L 1 :Liquid gasket (Three Bond 1215) L 2 :Screw lock agent (Three Bond 1327) application

24-49

Differential Assembly

115Z Ⅳ -2

POWER 24

Disassembling and Reassembling Differential Assembly 1.Disassembling differential assembly

Adjustment nut

Before starting work: a)Fix the differential assembly onto the disassembly workbench. b)Insert a straight-end screwdriver or the like into the clearance between the piston and the bevel gear to prevent the gear from rotation. Loosen the nut. Torque for assembly: :Nut : 1,030N-m (105.0kgf-m) (760 lb-ft)

Shim Nut Bevel gear

Pinion

Adjustment nut

１１５ＺＡ２４１８

1)Remove the right and left lock plates (2) from the adjustment nuts (1). Torque for assembly: :Retainer bolt : 53N-m (5.4kgf-m) (39 lb-ft) :Screw lock agent (Three Bond 1327) application

2)Remove the right and left nuts (3), bearing cap (4), and adjustment nut (1). Torque for assembly: :Retainer nut : 912N-m (93.0kgf-m) (673 lb-ft)

4 1

3)Lift the differential cage assembly (5) to remove it. 5

24-50

Differential Assembly

115Z Ⅳ -2

POWER 24

4)Put a matchmark on the alignment point of the differential cage (1). Remove the bolts (2), and then separate the differential cage. Torque for assembly: :Retainer bolt : 314N-m (32.0kgf-m) (232 lb-ft) :Screw lock agent (Three Bond 1327) application １

２

Matchmark

5)Remove the bushing (3) and the side gear (4).

４３

6)Remove the spider (5) with the pinion gears (6) and the thrust washers (7) as a unit.

６７５

7)Remove the side gear (8).

８

24-51

Differential Assembly

115Z Ⅳ -2

POWER 24

8)Remove the bushing (1).

１

9)Turn the differential upside down. Remove the bolts (3) from the bevel gear (2) to separate the gear. Torque for assembly: :Retainer bolt : 1,128N-m (115kgf-m) (832 lb-ft) :Screw lock agent (Three Bond 1327) application

３

２

10)Remove the bolts (4) to remove the pinion (5). At the same time, remove the shim. Torque for assembly: :Retainer bolt : 314N-m (32.0kgf-m) (232 lb-ft) :Screw lock agent (Three Bond 1327) application

５

５４

11)Remove the nut (6) and the O-ring (7). Nut width across flat : 65mm (2.559 in.) Torque for assembly: :Nut : 1,030N-m (105kgf-m) (760 lb-ft) :Liquid gasket (Three Bond 1215)

６

７９５ＺⅣ２４０５

24-52

Differential Assembly

115Z Ⅳ -2

POWER 24

12)Remove the flange yoke (1) and the oil seal retainer (2), and then remove the oil seals (3) and the O-ring (4) from the oil seal retainer (2). Pinion

13)Remove the taper roller bearings (7) and the spacer (8). 14)Remove the snap ring (9) and the roller bearing (10) from the pinion.

５１０９

６７

１２３４８

24-53

７

９５ＺⅣ２４０６

115Z Ⅳ -2

Differential Assembly

POWER 24

2.Reassembling differential assembly To reassemble the differential assembly, follow the above procedure in the reversed direction.

IMPORTANT ・ Clean and check all the parts. If a part is worn or damaged, replace it. ・ Be sure to replace O-rings and seals with new ones.

3.Cautions regarding reassembly 1)Check the preload of the pinion section by following the procedure below: ①Install the new roller bearing (2) and snap ring (9) on the pinion (1) if replacement is needed. Note: After attachment, stake the bearing at three points as shown in the right figure. ②Install the new tapered roller bearing (3) and the spacer (4) on the pinion (1) if replacement is needed. ③Install the cage (5) and the tapered roller bearing (6). ④Put the yoke (7) and nut (8) on the pinion (1). Note: Do not install the oil seal and O-ring of the nut. : Nut : 1,030N-m (105kgf-m) (760 lb-ft) ⑤Measure the preload at section (A) (bolt hole).

５

４

８

９２

１

６

３Ａ

１１５ＺＡ２４２８

Pinion

Bearing

Pinion Stake at 3 points ９５Ｚ４２４５９‐５５

:Standard preload * : 39 to 49N (4 to 5kgf) (9 to 11 lbs) If the preload is out of the above range, replace the spacer (4) to adjust the preload to the specified range. * Preload is the force required to start the cage moving-breakaway force. Note: There are 15 types of spacers from 29.20mm (1.149 in.)to 29.48mm(1.160 in.) in increments of 0.02mm(0.0007 in.). Thicker spacers reduce preload; thinner spacers increase preload. ⑥Remove the nut (8) and the flange yoke (7).

24-54

７

115Z Ⅳ -2

Differential Assembly

POWER 24

2)Before installing the oil seal, be sure to apply grease to the lip and liquid gasket at the outside of the seal. 5mm

3mm

Check the direction of the lips

Grease nipple

Apply liquid gasket (AA03) to this surface Apply grease

Oil seal installation (front diff.)

１１５ＺＡ２４３０

Shim ６

3)Install the O-ring (4) and the shim to the cage. Install the cage to the differential case (5) and tighten the bolts (6) temporarily. After adjusting tooth contact, tighten the bolts (6) with the specified tightening torque.

５

:Bolt : 314N-m (32.0kgf-m) (232 lb-ft) :Screw lock agent (Three Bond 1327) application Note: Shims should be selected to adjust the tooth contact. For adjusting tooth contact, refer to "Adjusting tooth contact". 4)Adjust the backlash as follows: ①Tighten the adjustment nut (3) on the bevel gear side until the backlash is "0". Then back off the adjustment nut 2 to 3 notches. ②Tighten the right adjustment nut (8). After you feel that the nut is tight, turn it one more notch. ③Attach the dial gauge stand to the carrier. Attach the dial gauge (A) to a tooth of the bevel gear (7). Read the backlash value indicated on the dial gauge. ④Adjust the backlash. Standard backlash : 0.36 to 0.46mm (0.0141 to 0.0181 in.) ・ Tighten the adjustment nut (3) on the bevel gear side or loosen the adjustment nut (8) on the opposite side to reduce the backlash. ・ Loosen the adjustment nut (3) on the bevel gear side or tighten the adjustment nut (8) on the opposite side to increase the backlash.

24-55

４１１５ＺＡ２４３２

８

Ａ

７３

１１５ＺＡ２４３５

Differential Assembly

115Z Ⅳ -2

5)After reassembling differential assembly, apply grease to the grease nipple until the grease comes out from the bleeder.

POWER 24

Flange yoke

Direction of grease nipple (Straight for front diff.) 5mm

3mm

Bleeder

Flange yoke Grease

A Detail Grease nipple

24-56

１１５ＺＡ２４３７

115Z Ⅳ -2

Differential Assy

POWER 24

Adjusting tooth contact After adjusting the backlash to the standard value, check that manual rotation of the gear is possible. After that, paint blue or red on the tooth surface of ring gear, and check the tooth contact. To adjust the tooth contact, adjust the thickness of the shim between the pinion and cage, and turn the adjustment nut.

Tooth contact

Adjusting method

Correct

Loosen the bearing adjuster on the rear side of 2

ring gear, and tighten the adjuster of tooth side at B

the same quantity as loosening, so that the ring gear is far apart from the drive pinion. Check again the backlash and tooth contact.

Do the reverse adjusting as B.

Decrease the thickness of shim at the part of D

bearing cage being installed and makes drive pinion approach the ring gear. Check again the backlash and tooth contact. 1

Increase the thickness of shim reverse as D, and makes drive pinion apart from the ring gear. 1

24-57

115Z Ⅳ -2

Differential Assembly

POWER 24

Three types of tooth contact shown below are acceptable as best tooth contact.

Tooth contact position and length(rate) 10 1

Pattern A

HEEL 4〜5

Pitch line TOE

BOTTOM 10 2

Pattern B

5 TOP

4 TOP

Pitch line

HEEL 4〜5

TOE

3 Pattern C

BOTTOM 10 4 3 TOP

TOE Pitch line

HEEL 4〜5

BOTTOM

Service parts: After adjusting the tooth contact and backlash in our factory, we will wrap the ring gear and drive pinion as a set. Therefore, replace the ring gear and drive pinion as a set.

24-58

Note: Individual sale of the ring gear or the drive pinion is not possible.

POWER GROUP 25 Service standard Propeller Shaft Service Standard ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 25-2 Axle Service Standard ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 25-3 Differential Service Standard ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 25-4

25-1

115Z Ⅳ -2

Propeller Shaft Service Standard

POWER 25

Propeller Shaft Service Standard

2 Measurement of circumferential play

Second propeller shaft

→ Parking brake side

3 Measurement of transverse play 1 1

First propeller shaft

Third propeller shaft

115ZA2438

No.

Item

Tolerance mm (inch)

Solution

Spider bearing play

1st, 2nd, 3rd propeller shaft

0.25 (0.0098)

Replacement

Spline circumferential play

Second propeller shaft

0.8 (0.0315)

Replacement

Spline transverse play

Second propeller shaft

1.0 (0.0394)

Replacement

25-2

115Z Ⅳ -2

Axle Service Standard

POWER 25

Axle Service Standard Axle group

2,4 3

1,4

115ZA2439

mm (inch) Judgment standard No.

Item

Solution Standard dimension

Tolerance

Backlash between sun gear and planetary gear

0.15〜0.73 (0.0059〜0.0287)

←

Replacement

Backlash between planetary gear and internal gear

0.17〜0.89 (0.0067〜0.0350)

←

Replacement

Clearance between spider pin and pin hole

0.036〜0.075 (0.0014〜0.0029)

←

Replacement

Tooth contact of gear

No abnormality

Replacement

Bushing and wear ring wear

No oil groove

Replacement

Axle support wear

Dia.: 1.0 / Radius: 0.5 (stepped) (0.0393) (0.0197)

Replacement

25-3

115Z Ⅳ -2

Differential Service Standards

POWER 25

Differential Service Standards Differential

4 1

mm (inch) Judgment standard No.

Item

Solution Standard valve

Tolerance

Backlash between ring gear and drive pinion

0.36〜0.46 (0.0141〜0.0181)

←

Adjustment

Backlash between side gear and pinion gear

0.30〜0.56 (0.0118〜0.0220)

←

Adjustment

Clearance between pinion gear and spider

0.075〜0.100 (0.0029〜0.0039)

←

Replacement

Runout of ring gear rear surface (when assembled)

0.075 (0.0029)

←

Adjustment or replacement

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

Tooth contact

No abnormality

Replacement

25-4

TORQUE CONVERTER & TRANSMISSION GROUP 34 Disassembly and Reassembly Power Line Bolt Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-2 Removing and Reinstalling Torque Converter Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-3 Torque Converter Bolt Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-5 Disassembling and Reassembling Torque Converter ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-6 Removing and Reinstalling Transmission Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-15 Bolt Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-18 Disassembling and Reassembling Transmission Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-20 Disassembling and Reassembling Clutch Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-34 Disassembling and Reassembling Low and 3rd Clutch Spider ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-49 Disassembling and Reassembling 1st and 2nd Clutch Spider ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-51 Disassembling and Reassembling Reverse Clutch Spider ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-53 Disassembling and Reassembling 1st Clutch Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-55 Disassembling and Reassembling High Clutch Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-59 Removing and Reinstalling Modulator Valve Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-63 Removing and Reinstalling Control Valve Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 34-65

34-1

115Z Ⅳ -2

Power Line Bolt Tightening Torque

TORQUE CONVERTER & TRANSMISSION 34

Power Line Bolt Tightening Torque L 1 T8 T7 L 1 T

1st propeller shaft

L4 L1

Engine

L1 T6

L3 T6 T2 L 4

T10 T9 L 2

Torque converter

L1 Rear differential

L4 T4 Front differential

T8 L1

L2 T5 2nd propeller shaft

Transmission 3rd propeller shaft

Parking brake group

115V34001

: Bolt tightening torque T1 : 44N-m (4.5kgf-m) (33 lb-ft) T2 : 71N-m (7.2kgf-m) (52 lb-ft) T3 : 196N-m (20.0kgf-m) (145 lb-ft) T4 : 721N-m (73.5kgf-m) (532 lb-ft) T5 : 221N-m (22.5kgf-m) (163 lb-ft) T6 : 216N-m (22.0kgf-m) (159 lb-ft) T7 : 294N-m (30.0kgf-m) (217 lb-ft) T8 : 417N-m (42.5kgf-m) (307 lb-ft) T9 : 142N-m (14.5kgf-m) (105 lb-ft) T10:49N-m (5.0kgf-m) (36 lb-ft)

L1 : Screw lock agent application (Loctite 262) L2 : Screw lock agent application (Three Bond 1327 or 1215) L3 : Screw lock agent application (Three Bond 1374) L4 : With lubricating oil (Engine oil or gear oil)

34-2

Removing and Reinstalling T / C Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

Removing and Reinstalling Torque Converter Assembly 1.Removing torque converter assembly WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. Lower the bucket onto the ground, and then block the tires with chocks to prevent wheels from moving. ・ Disconnect the ground cable from the negative side of the battery.

Before starting work: a)Remove the engine room by referring to Section 14. b)Consider the type of failure and if the torque converter oil cooler must also be removed for cleaning or replacement. ・If a small amount of contamination is found in the transmission strainer and filter the cooler does not need removal. ・If a large amount of contamination is found the cooler must be removed - Refer to Section 24. 1)Remove the 1st propeller shaft (1). Note : If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner. Keep the flame away from the seals of the coupling. Do not reuse the bolt once heated. Tightening torque for assembly : Bolt : 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327) 2)Remove the pipe (2) and the hose (3).

115K34101

3)Remove the drain hose (4).

4)Remove the cooler inlet hose (5) and then disconnect the connector (8) of the engine tacho-sensor.

115K34102

5)Disconnect the hose (6) and the connector (7) of the oil temperature sensor.

34-3

115K34103

Removing and Reinstalling T / C Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

6) Lift the torque converter temporarily and remove twelve bolts (9). Tightening torque for assembly : Bolt : 71N-m (7.2kgf-m) (52 lb-ft) : Torque converter assembly : 280kg (620 lbs)

9 115K34104

7)Slide the torque converter assembly toward the front of the machine until the torque converter and the ring gear on the engine side have disengaged, and then lift the assembly up and out.

2.Reinstalling torque converter assembly To reinstall the torque converter assembly, follow the above removal procedure in the reverse direction.

3.Cautions for installation ① Be sure to replace the O-ring at the connecting part between engine and transmission, with new one. ② Apply liquid gasket (Three Bond 1215) to the mating faces of the torque converter housing and the engine flywheel housing.

34-4

115Z Ⅳ -2

Torque Converter Bolt Tightening Torque

TORQUE CONVERTER & TRANSMISSION 34

Torque Converter Bolt Tightening Torque

T7 T5 T1 T4 T2 T1

115ZA32002

: Tightening torque T1 : 25N-m (2.6kgf-m) (19 lb-ft) T2 : 193N-m (19.7kgf-m) (143 lb-ft) T3 : 58N-m (5.9kgf-m) (43 lb-ft) T4 : 102N-m (10.4kgf-m) (75 lb-ft) T5 : 80N-m (8.2kgf-m) (59 lb-ft) T6 : 45N-m (4.6kgf-m) (33 lb-ft) T7 : 36N-m (3.7kgf-m) (27 lb-ft)

34-5

115Z Ⅳ -2

Torque Converter

TORQUE CONVERTER & TRANSMISSION 34

Disassembling and Reassembling Torque Converter 1.Disassembling torque converter Before starting work: ・Clean the transmission assembly. ・Drain oil from the transmission.

Drain plug

115ZA3402

1)Remove the oil pipes (1) (2) and the tacho-sensor.

1 2

115ZA3403

2)Remove the bolt (4) to remove the pilot boss (5). 5

3)Remove the bolt (6) and the washer (7). 115V34002

5 4

6 6 7 115V34003

34-6

Torque Converter

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

4) Install the torque converter on the block. : Torque converter : 280kg (620 lbs)

Block 115ZA3405

5)Remove the torque converter pump (8).

115V34004

6)Raise the calked part of the bolt (9) and remove the bolt (9) and the plate (10), and then remove the O-ring (11) and the flange yoke (12). 7)Remove the bolt (13) and the seal retainer (14).

14 14 13

9 12 10

34-7

115V34005

Torque Converter

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

8)Pull out the turbine shaft (15).

115V34006

9)Remove the bolts (17) to remove the torque converter case (16). 17

16 115V34007

10)Lift and remove the torque converter case (16).

11)Remove the bolts (19) and then separate the assembly into the pump impeller assembly (18) and the drive cover by using jack bolt holes to separate. 19

Drive cover 115V34008

34-8

Torque Converter

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

12)Remove the snap ring (22) for positioning the stator carrier (20) and the stator (21). 13)Remove the stator (21). 22

115K34112

14)Remove the spacer (23) and the stator carrier (20).

115K34113

15)Turn over the pump cover, and remove all the bolts (25) of drive gear (24) except a pair of diametrically opposed bolts.

Pump cover 24

34-9

115V34008

Torque Converter

115Z Ⅳ -2

16)Put the pump impeller assembly (18) on wooden blocks, and remove the bolt (25) and impeller hub (27).

TORQUE CONVERTER & TRANSMISSION 34

25 Wooden block

115ZA3406

17)Remove the drive gear (24).

24 25

115K34115

18)Remove the turbine impeller (29) from the drive cover (28).

28 29

34-10

115V34010

115Z Ⅳ -2

Torque Converter

TORQUE CONVERTER & TRANSMISSION 34

2.Reassembling torque converter assembly Note :・Clean and check all the parts. If a part is damaged, replace it with a new one. Refer to Section 35 for wear limits. ・When assembling, apply transmission oil to the parts. ・Replace all the seals and packings with new ones. ・Replace the bearing with new one if necessary, manually turn the bearing to check that the bearing rotates properly.

28 29

1) Install the turbine impeller (29) into the drive cover (28).

115V34011

2) Install the drive gear (24) and impeller hub (27) into the pump impeller (26). 3) Temporarily tighten two bolts (25).

Wooden block 115ZA3406

4) Turn over the pump impeller assembly (18) and put it on the wooden blocks. 5) Tighten the bolts (25). : Bolt : 102N-m (10.4kgf-m) (75 lb-ft) 18 25

6) Install the stator carrier (20) into the pump impeller assembly (18). Note : Take care not to damage the seal ring when inserting the carrier.

Pump impeller assembly

Seal ring

Stator carrier

20 8

１１５ＺＡ３４０７

34-11

Torque Converter

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

7) Install the spacer (23). 8) Install the stator (20), then install the snap ring (21). Install the nut (31).

9) Install the O-ring (30) onto the pump impeller (26). 23

21 20

30 26

115V34012

10)Install the pump impeller assembly (18) to the drive cover (on the turbine side). 11)Tighten the bolts (19). : Bolt : 80N-m (8.2kgf-m) (59 lb-ft) 18 19

12)Install the torque converter case (16). Note : Align the stator carrier knock pins with the knock pin holes in the torque converter case (3 locations). 16

34-12

115Z Ⅳ -2

Torque Converter

TORQUE CONVERTER & TRANSMISSION 34

13)Tighten the stator carrier mounting bolts (17) with the torque converter case (16). : Bolt : 58N-m (5.9kgf-m) (43 lb-ft)

14)Install the turbine shaft (15). Note : Take care not to damage the oil seal ring when inserting the shaft.

Seal ring

15)Install the seal retainer (14) and tightening the bolts (13). : Bolt : 25N-m (2.6kgf-m) (19 lb-ft)

14 13

16)Install the flange yoke (11) and the O-ring (12). 17)Install the plate (10) and lock plate (13), and tighten the bolt (9). : Bolt : 193N-m (19.7kgf-m) (143 lb-ft) Note : Be sure to rise the bolt lock plate. 9

13 Seal retainer

12 115ZA3408

34-13

115Z Ⅳ -2

Torque Converter

TORQUE CONVERTER & TRANSMISSION 34

18)Tighten the bolts (A) to install the torque converter pump (8). : Bolt (A) : 36N-m (3.7kgf-m) (27 lb-ft)

A 8

115V34013

19)Install the washer (7) and the knock pin, then tighten the bolt (6). : Bolt : 193N-m (19.7kgf-m) (143 lb-ft)

7 4

Knock pin 115ZA3409

115V34014

20) Install the pilot boss (5) with the bolts (4). : Bolt : 25N-m (2.6kgf-m) (19 lb-ft)

21)Install the oil pipes (1) (2), and the engine tachosensor.

1 2

115V34015

34-14

Removing and Reinstalling T / M Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

Removing and Reinstalling Transmission Assembly 1.Removing transmission assembly

1 2

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. Lower the bucket onto the ground, and then block the tires with chocks to prevent wheels from moving. ・ Disconnect the ground cable from the negative side of the battery.

Before starting work: a)Remove the cab and the floor board by referring to Section 14. b)Consider the type of failure and if the torque converter oil cooler must also be removed for cleaning or replacement. ・If a small amount of contamination is found in the transmission strainer and filter the cooler does not need removal. ・If a large amount of contamination is found the cooler must be removed - Refer to Section 24. 1)Remove the bolts (2) from the 1st propeller shaft (1). Note : If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner. Keep the flame away from the seals of the coupling. Do not reuse the bolts, always replace with new ones. Tightening torque for assembly : Bolt : 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327) 2)Remove the drain plug (3) to drain the transmission oil. : Transmission oil : 60 l (15.8 gal.) 3)Remove the retainer bolt of the 3rd propeller shaft (4) on the transmission side only. Tightening torque for assembly : Bolt : 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327) 4)Remove the bolt (9) from the 2nd propeller shaft (8) on the transmission side only. Tightening torque for assembly : Bolt : 221N-m (22.5kgf-m) (163 lb-ft) : Screw lock agent application (Three Bond 1327) 5)Disconnect the electrical wire for the torque converter temperature switch sensor (5), speed sensor connector (6) and then remove the oil level gauge hose (7).

115K34119

4 9 115V34016

115V34017

7 115V34018

34-15

Removing and Reinstalling T / M Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

6)Remove the unloader valve hoses (10). Note : After removing the hoses, cover the hoses with vinyl to protect from dust and dirt.

7)Remove the hydro-master hoses (11) (12) and the reducing valve hoses (13). Note : After removing the hoses, cover the hoses with vinyl to protect from dust and dirt. 11 13

8)Remove the hydro-master (14) with the bracket (15). Note : After removing the hoses, cover the hoses with vinyl to protect from dust and dirt.

9)Remove the reducing valve (16) with the block. Note : After removing the hoses, cover the hoses with vinyl to protect from dust and dirt.

34-16

14 15

Removing and Reinstalling T / M Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

10)Remove the modulation valve hoses (17) (18) and the steering valve hose (19). Note : After removing the hoses, cover the hoses with vinyl to protect from dust and dirt.

18 17

11)Lift the transmission assembly temporarily, remove the bolts (20) (right / left). Tightening torque for assembly : Bolt : 90N-m (9.2kgf-m) (67 lb-ft) : Screw lock agent application (Three Bond 1327) : Transmission assembly : 1,030kg (2,270 lbs) 20

12)Remove the bolts (21) (right / left). Tightening torque for assembly : Bolt : 417N-m (42.5kgf-m) (307 lb-ft) : Screw lock agent application (Three Bond 1374)

13)Lift and remove the transmission assembly. Note : In this case, lift the transmission assembly slowly, while avoiding contact with other parts.

Transmission assembly

34-17

115Z Ⅳ -2

Bolt Tightening Torque

TORQUE CONVERTER & TRANSMISSION 34

Bolt Tightening Torque T6

T5 T2

T1」

T3 L 1 T4

115V34019

: Bolt tightening torque T1 : 53N-m (5.4kgf-m)(39 lb-ft)

T5 : 132N-m (13.5kgf-m)(98 lb-ft)

T2 : 86N-m (8.8kgf-m)(64 lb-ft)

T6 : 31N-m (3.2kgf-m)(23 lb-ft)

T3 : 94N-m (9.6kgf-m)(69 lb-ft) T4 : 883N-m (90.0kgf-m)(651 lb-ft)

T7 : 176N-m (18.0kgf-m)(130 lb-ft) T8 : 157N-m (16.0kgf-m)(116 lb-ft) 34-18

L1 : With lubricating oil

115Z Ⅳ -2

Bolt Tightening Torque

T10 T11

TORQUE CONVERTER & TRANSMISSION 34

T12 115ZA3410

: Bolt tightening torque T9 : 92N-m (9.4kgf-m) (68 lb-ft) T10 : 59N-m (6.0kgf-m) (43 lb-ft) (for valve body) T11 : 10N-m (1.0kgf-m) (7 lb-ft) (for coil nut) T12 : 26N-m (2.7kgf-m) (20 lb-ft)

34-19

115Z Ⅳ -2

Transmission

TORQUE CONVERTER & TRANSMISSION 34

Disassembling and Reassembling Transmission Assembly 1.Disassembling transmission assembly

Before starting work: a)Clean the transmission assembly. b)Drain oil from the transmission. c) Remove the flange yoke. d)Remove the modulator valve unit and the solenoid valve unit.

5 6

1)Remove the plugs (1) and the O-rings (2). 2)Remove the bolts (3) and then remove the cover (4), gasket (5) and the piston ring inside of the cover.

115K34124

5 4

115ZA3411

3)Remove eight hex. socket head bolts (7). 7 115K34125

4)Remove the bolts (8) and the seal retainer (9) and then remove the O-ring (10) and the oil seals (11) (12) from the seal retainer (9).

5)Remove the retainer (13) and the O-ring (14). 12 13

8 12

9 115K34126

115ZA3412

34-20

115Z Ⅳ -2

Transmission

TORQUE CONVERTER & TRANSMISSION 34

6)Raise the calked part of the bolt (15) and remove the bolt (15), and then remove the plate (16) and the sleeve (17). Note : No need to remove the pin (18). 16 17 15

15 16 18

115ZA3413

115K34127

7)Remove the seal retainer (21) , O-ring (22) with the ball bearing (19) and the piston ring (20).

22 19

115K34128

8)Remove the input case (23).

115K34129

9)Remove the high clutch assembly (24). 24

34-21

Transmission

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

10)Remove the bolts (25) and then remove the clutch assembly (26) by lifting it. 26

11)Remove the flange (28) and the cover (31). 12)Remove the snap ring (35) and pull out the bearing (34).

28 31

13)Remove the rings (36) (37).

14)Remove the idler cover (38).

115V34020

115V34021

34-22

Transmission

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

15)Remove the idler gear (42).

16)Remove the snap ring (44) and remove the bearing inner race (43).

115V34022

17)Remove the bearing outer race (43) for the idle gear. 18)Remove the nut (48) of the output flange and then remove the flange yoke (46).

34-23

46 115V34023

Transmission

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

19)Remove the housing (51). 20)Remove the sleeve (53).

51 115V34023

21)Turn over the transmission and remove the flange yoke (55). 22)Remove the seal retainer (58) from the transmission case.

58 115V34024

34-24

Transmission

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

23)Pull out the output shaft (63) and remove the bearing.

24)Remove the output gear (67). 67

34-25

115Z Ⅳ -2

Transmission

TORQUE CONVERTER & TRANSMISSION 34

2.Reassembling transmission assembly Note :・Clean and check all the parts. If a part is damaged, replace it with a new one.Refer to Section 35 for wear limits. ・When assembling, apply transmission oil to the parts. ・Replace all the seals and packings with new ones. ・Replace the bearing with new one if necessary, manually turn the bearing to check that the bearing rotates properly.

Cautions for assembling ・Apply lithium base grease in side of the seal lip part and apply a coat of liquid gasket (Three Bond 1215) to the outer surface of the oil seal. ・Apply a coat of lithium base grease to the O-ring.

IMPORTANT Turn the each shaft to check that it is installed properly. If it is installed properly, the shaft will turn lightly. If the shaft could not be turned, disassemble it again for check.

1) Install the output gear (67) in the transmission case.

IMPORTANT Install the output gear so that the chamfered side is faced to the front side.

2) Turn over the transmission case so that the output gear side is faced to the bottom side. And then install the spacer (64), bearing (65) and the snap ring (66) to the output shaft (63).

66 63

34-26

115Z Ⅳ -2

Transmission

TORQUE CONVERTER & TRANSMISSION 34

3)Align the spline of the output shaft (63) with that of the output gear (67) and then install the output shaft (63) in the transmission by hitting with a plastic hammer.

4) Install the oil seal (60), grease seal (61) and the O-ring (62) to the seal retainer (58). Note : Be sure to insert the oil seal (60) with its lip faces inward. Apply grease to the seal lip.

60 61 58

58 58

5) Install the seal retainer (58) with the bolts (59). 59

: Bolt : 53N-m (5.4kgf-m) (39 lb-ft)

6) Install the flange yoke (55) and attach the O-ring and the plate (56), and then install the snap ring (57) to lock them.

57 56

34-27

115Z Ⅳ -2

Transmission

TORQUE CONVERTER & TRANSMISSION 34

7) Turn over the transmission case and install the bearing (54) to the transmission case. 52

46 50

47 48

51 53 49

115V34025

8) Install the sleeve (53) to output shaft.

9) Install the oil seal (49) and the O-ring (50) to the housing (51) and then install the housing (51) to the transmission case with the bolts (52). Note : The oil seal should be installed as the following fig. Apply a coat of grease to the oil seal lip. 50 51

10)Install the flange yoke (46) and the O-ring (47) and then tighten the nut (48). : Nut (48) : 883N-m (90.0kgf-m) (651 lb-ft)

34-28

Transmission

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

11)Install the bearing outer race (45) for the idle gear.

12)Install the bearing inner races to the both sides of the idle gear (42), and fix it with the snap ring (44).

13)Install the idle gear.

14)Install the O-ring (40) and the bearing (41) to the idler cover (38).

34-29

41 115ZA3414

Transmission

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

15)Install the idler cover (38) and tighten the bolts (39). 39

: Bolt (39) : 94N-m (9.6kgf-m) (69 lb-ft)

16)Install the rings (36) (37).

17)Install the bearing (34) and then install the snap ring (35).

18)Install the flange (33) with the O-ring (32). 33

19)Install the flange (28) with the bolts (27) and then install the packing (29) and the plate (31) with the bolts (30).

31 27 30

: Bolt (27) (30) : 94N-m (9.6kgf-m) (69 lb-ft) 28

34-30

115Z Ⅳ -2

Transmission

TORQUE CONVERTER & TRANSMISSION 34

20)Install the clutch pack assembly (26) to the transmission case.

IMPORTANT Be sure to align the bolt holes of the clutch pack assembly with that of (7) of the step 31, and to align the oil holes of the clutch pack assembly with that of (1) (2) of the step 33.

21)Tighten the bolts (25). Staking

: Bolt (25) : 94N-m (9.6kgf-m) (69 lb-ft) 22)Stake the clutch pack body at two points around the knock pin (2 pcs) as shown in the illustration.

23)Install the high clutch assembly (24). 24

24)Install the input casing (23). 23

: Bolt : 94N-m (9.6kgf-m) (69 lb-ft)

34-31

115Z Ⅳ -2

Transmission

TORQUE CONVERTER & TRANSMISSION 34

25)Install the O-ring (22). 22

26)Install the ball bearing (19) to the seal retainer (21) and then install the seal retainer (21) with the bearing to the shaft.

27)Install two piston rings (20) to the seal retainer. 19

28)Insert the sleeve (17), and insert the plate (16) with the pin (18) and then tighten the bolt (15). : Bolt (15) : 157N-m (16.0kgf-m) (116 lb-ft)

IMPORTANT After tightening the bolt (15), calk the collar of the bolt against the grooves (2 points) of the plate (16).

16 17 15

115ZA3413

29)Attach the O-ring (14) to the retainer (13) and install the retainer (13) with the O-ring (14) to the seal retainer (21). Oil port A

14 8 12

15 115ZA3412

Note : Install the retainer (13) so that the oil port (A) faces to the top. 34-32

115Z Ⅳ -2

Transmission

TORQUE CONVERTER & TRANSMISSION 34

30)Attach the O-ring (10) and install the oil seals (11) (12) to the seal retainer (9) and then install the seal retainer (9) with the bolts (8). 12

: Bolt (8) : 53N-m (5.4kgf-m) (39 lb-ft)

8 11 10

9 115V34026

31)Turn over the transmission and then tighten the hex. socket bolts (8 pcs). : Bolt (7) : 86N-m (8.8kgf-m) (64 lb-ft)

115V34027

32)Install the piston ring (6) in the cover (4) and then install the cover (4) with the gasket (5) to the housing with the bolts (3). : Bolt (3) : 53N-m (5.4kgf-m) (39 lb-ft) 5 4

115ZA3411

33)Install the plug (1) and the O-ring (2). 2 2

115V34028

34-33

115Z Ⅳ -2

Clutch Assembly

TORQUE CONVERTER & TRANSMISSION 34

Disassembling and Reassembling Clutch Assembly 1.Disassembling clutch assembly 1

Before starting work: ・Remove the clutch assembly from the transmission housing, and set it on the work bench. 1)Remove the lock nut (1). Note : Be sure to raise the calked (staked) nut parts (4 points). Calking (Staking) (Point marked with ・)

2 Collar 97ZA3422

2) Lift and remove the 1st clutch assembly (2).

3)Remove the ring (3) and eleven housing connecting bolts (4).

3 4

4)Put matchmarks to each housing and the piston prior to disassembling.

Matchmark

34-34

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

5)Remove twelve springs (6), two steel plates (7) and one friction (8).

7, 8 6

6)Pull out the ring gear (9) and then remove the remaining friction and steel plates and six pins (10).

7)Remove the 3rd and 2nd clutch housing (11).

8)Remove twelve springs (12) and then remove the friction plate (13), the steel plate (14) and the pin (15).

13, 14

34-35

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

9)Remove the 2nd spider assembly (16).

10)Remove the sun gear shaft assembly (17). 17

11)Loosen two bolts (18) and remove the housing (19).

12)Remove six springs (20) and then remove two steel plates (21) and one friction plate (22).

21, 22

34-36

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

13)Remove the ring gear (23).

14)Remove seven remaining friction plates (22), six steel plates (21) and six pins (24).

22, 21

15)Remove the snap ring (25) and then remove the spacer (26). 25, 26

16)Remove low and 3rd spider assembly (27). 27

34-37

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

17)Remove the low clutch housing (28).

18)Remove the O-ring (29) of low clutch housing oil port.

19)Remove twelve springs (30), eight steel plates (31), eight friction plates (32) and six pins (33).

31, 32

30 33

20)Remove the snap ring (34), the sun gear (35) and then pull out the main shaft (36).

34 35

34-38

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

21)Remove the snap ring (37) at the lower side of the spider and then remove the clutch gear (38).

22)Remove the reverse spider assembly (39) from the reverse housing (40). 39

34-39

115Z Ⅳ -2

Clutch Assembly

2.Reassembling clutch assembly Before starting work: ・Clean and check each part, and replace part with a new one if necessary. (Refer to section 35 for the limit.) ・Be sure to apply transmission oil to each necessary point when reassembling the clutch assembly. ・Measure each piston stroke of 2nd, 3rd, low and reverse. ・Replace the packing and the seals with new ones.

〔Measurement of piston stroke〕 ①Assemble the desired clutch piston to each clutch housing, and measure the dimension with pressing the piston down as shown in the illustration. (This is dimension A.) ②Set the necessary quantity of friction plates and steel plates referring to the following table and measure the total thickness. (This is dimension B.) Friction plate

Steel plate

2nd

3 pcs

3rd

4 pcs

Low

8 pcs

Reverse

8 pcs

③The dimension A-B is the piston stroke and the piston stroke should be within the range shown in the following table. Piston stroke

mm (in.)

2nd

2.0 ± 0.5 (0.0787±0.0196)

3rd

3.0 ± 0.5 (0.1181±0.0196)

Low

5.5 ± 0.5 (0.2165±0.0196)

Reverse

5.5 ± 0.5 (0.2165±0.0196)

34-40

TORQUE CONVERTER & TRANSMISSION 34

115Z Ⅳ -2

Clutch Assembly

TORQUE CONVERTER & TRANSMISSION 34

1) Install each piston of 2nd, 3rd, low and reverse into housing at first.

IMPORTANT Be sure to insert piston seal ring with its lip directed as the following figure.

Lip Piston

９７ＺＡ３４２３

Note :・Apply sufficient coat of transmission oil to the seal ring. ・Install the clutch piston proportionally. ・When assembling the low clutch piston into the housing in advance, be careful not to mistake assembling position. (Check matchmarks marked at time of disassembling. See right-hand illustration.) 40

115V34029

2)Set the reverse housing (40) with the piston on the work bench. 39

3) Install the reverse spider assembly (39) into the reverse housing (40).

4) Install the clutch gear (38) with the snap ring (37). 38

34-41

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

5) Install the sun gear (35) to the main shaft (36) with the snap rings (on both sides of the sun gear), and then install the main shaft (36) to the spider assembly.

34 35

6) Install six knock pins, and eight friction plates (32) and eight steel plates (31) alternately. Note : Start installing from friction plate. Apply a coat of transmission oil to the contact surface between the friction plates and the steel plates.

33 31

7) Install twelve springs (30).

Oil hole

8) Install the O-ring (29) in the low clutch housing (28). 28

34-42

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

9) Install the low clutch housing (28) so that the oil holes shown at the step (7) are aligned with the oil holes (29) shown at the step (8).

Oil hole

10)Turn the spring with hands to check that it is fitted properly in upper/lower spring holes. (If it is fitted properly in the hole, the spring will turn lightly.)

11)Install the low and 3rd spider assembly (27). 27

12)Install the spacer (26) and the snap ring (25).

25,26

34-43

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

13)Install six pins (24), and then install seven friction plates (22) and six steel plates (21) alternately. Note : Start installing from friction plate. Apply a coat of transmission oil to the contact surface between the friction plates and the steel plates. 21 24

14)Install the ring gear (23).

15)Install two remaining steel plates and one friction plate and six springs (20). Note : Be sure that the plates installed at the step (15) contact with the plates installed at the step (13). If not, the ring gear (23) is not installed properly. So, correct the installation of the gear. Apply a coat of transmission oil to the contact surface between the friction plates and the steel plates.

16)After putting the housing (19) temporarily, turn the spring (20) with hands to check that it is fitted properly in upper/lower spring holes, and then tighten two bolts (18).

: Bolt : 31N-m (3.2kgf-m) (23 lb-ft)

34-44

115Z Ⅳ -2

Clutch Assembly

TORQUE CONVERTER & TRANSMISSION 34

17)Apply the air pressure of 6kg/cm (85.3 psi) through the oil hole to check for piston operation and air leakage.

18)Install the sun gear shaft assembly (17). 17

19)Install the 2nd spider assembly (16).

20)Install the pin (15) and then install four steel plates (14) and four friction plates (13) alternately. Note : Be sure to start installing from steel plate. Apply a coat of transmission oil to the contact surface between the friction plates and the steel plates.

34-45

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

21)Install twelve springs (12).

22)Install 3rd and 2nd clutch housing (11). Note : Check the matchmarks and align oil hole position.

11 Oil hole

23)Install six pins (10), and then install two friction plates (8) and one steel plate (7) alternately. Note : Apply a coat of transmission oil to the contact surface between the friction plates and the steel plates.

24)Install the ring gear (9).

34-46

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

25)Install one remaining friction plate and two steel plates alternately. Note : Be sure that the plates installed at the step (23) contact with the plates installed at the step (25). If not, the ring gear (9) is not installed properly. So, correct the installation of the gear. 26)Install twelve springs (6). 6

27)After putting the housing (5) temporarily turn the spring with hands to check that it is fitted properly in upper/lower spring holes.

28)Install eleven housing connecting bolts (4).

: Bolt : 132N-m (13.5kgf-m) (98 lb-ft)

29)Apply the air pressure of 6kg/cm2 (85.3 psi) through the oil hole to check for piston operation and air leakage.

30)Install the ring (3).

Clutch gear

Spider

115ZA3415

34-47

Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

31)Install the 1st clutch assembly (2). 2

32)Tighten the lock nut (1). Width across flats : 80mm (3.15 in.) : Lock nut : 176N-m (18.0kgf-m) (130 lb-ft)

33)After tightening the lock nut, calk (stake) the collar of nut against the spline groove. (4 equally divided portion on circumference)

Calking (Staking) (4 points)

Collar 95Z Ⅳ 3405

Collar

Spline groove

1.5 or more

Calking (Staking)

95Z Ⅳ 3404

34-48

115Z Ⅳ -2

Clutch Spider Assembly

TORQUE CONVERTER & TRANSMISSION 34

Disassembling and Reassembling Low and 3rd Clutch Spider 1.Disassembling low and 3rd clutch spider 1)Remove the snap ring (1), and separate the spider assembly (2) and the internal gear (3). Then, remove the snap ring (4) and the ring plate (5).

2 3 1 4 5

2)Drive the spring pin (7) that locks the pin (6) all the way into the pin to unlock it, and then pull out the pin (6). Note : Once the pin has been removed, take the spring pin out of the pin.

7 6

97ZA3425

34-49

115W34002

Clutch Spider Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

3)Remove the planetary gears (8), the needle bearings (9), and the washers (10).

10 10

2.Reassembling low and 3rd clutch spider To reassemble low and 3rd clutch spider, follow the above disassembly procedure in the reverse direction. Before starting work: ・Clean and inspect each part, replace if necessary. For inspection and wear standards, refer to Section 35. ・Replace the bearing with new one if necessary, manually turn the bearing to check that the bearing rotates properly.

IMPORTANT When inserting each pin, make sure the oil hole position faces outward. 6 Oil hole

34-50

10 115W34003

115Z Ⅳ -2

Clutch Spider Assembly

TORQUE CONVERTER & TRANSMISSION 34

Disassembling and Reassembling 1st and 2nd Clutch Spider 1.Disassembling 1st and 2nd clutch spider 1) Force the snap ring (1) inward using a round bar to separate the spider (2) and the ring gear (3).

2 97ZA3429

2)Remove the snap ring (4), then remove the plate (5).

4 5 115K34143

3)Drive the planetary pin (6) positioning spring pin (7) with a round bar until the spring pin is inserted completely into the planetary pin (3 locations).

7 6

97ZA3425

4)Pull out the planetary pin (6), and then remove the planetary gear (7), wearings (8), and needle bearing (9). Note : Once the planetary pin has been removed, take the spring pin out.

8 7 9 8 6

97ZA3430

34-51

115Z Ⅳ -2

Clutch Spider Assembly

TORQUE CONVERTER & TRANSMISSION 34

5) Force the snap ring (10) inward with a round bar to separate the spider (2) and the 1st speed clutch gear (11).

11 10 2

97ZA3431

2.Reassembling 1st and 2nd clutch spider To reassemble 1st and 2nd clutch spider, follow the above disassembly procedure in the reverse direction. Before starting work: ・Clean and inspect each part, replace if necessary. For inspection and wear standards, refer to Section 35. ・Replace the bearing with new one if necessary, manually turn the bearing to check that the bearing rotates properly.

IMPORTANT Insert the planetary pin so that the oil hole in it faces outward.

Planetary pin

Clutch gear

34-52

Oil hole

Clutch Spider Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

Disassembling and Reassembling Reverse Clutch Spider 1.Disassembling reverse clutch spider 1)Remove the snap ring (1) to separate the spider (2) and the clutch drum (3). 2

97ZA3434

2)Drive the spring pin (5) that locks the pin (4) all the way into the pin, then remove the pin (4), washers (6), planetary gear (7), and needle bearing (8).

8 6 6

115ZA3425

5 4

34-53

Disassembling and Reassembling Reverse Clutch Spider 115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

2.Reassembling reverse clutch spider To reassemble reverse clutch spider, follow the above disassembly procedure in the reverse direction. Before starting work: ・Clean and inspect each part, replace if necessary. For inspection and wear standards, refer to Section 35. ・Replace the bearing with new one if necessary, manually turn the bearing to check that the bearing rotates properly.

IMPORTANT Insert the planetary pin so that the oil hole in it faces outward.

Planetary pin

Oil hole

34-54

115Z Ⅳ -2

Disassembling & Reassembling 1st Clutch

TORQUE CONVERTER & TRANSMISSION 34

Disassembling and Reassembling 1st Clutch Assembly 1.Disassembling 1st clutch assembly 1)Raise the calked (staked) part of the bearing nut (1) with a punch, then remove the nut. 1

Keyway

95Z Ⅳ 3401

Collar

Raise the calked (staked) part.

2)Remove the retainer (2), bearings (3) (4), and two seal rings (5) from the clutch hub (6). Remove the two O-rings (7) from the retainer.

5 4 2 7 3

6 97ZA3438

3)Disassembling the clutch assembly: Remove the snap ring (8), then remove the pressure plate (9), and the alternate layers of nine friction plates (10) and eight steel plates (11).

11 10

97ZA3439

34-55

Disassembling & Reassembling 1st Clutch

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

4)Remove the snap ring (14) by pushing down the ring plate (12) with a press (13), then take out the ring plate, springs (15) and piston (16). Remove the seal rings (17) (18) from the piston.

12 16

18 17

97ZA3440

5)Remove all the bolts (19), then remove the drop gear (20). Remove the snap ring (21) to separate the clutch drum (22) and clutch hub (23).

23 20

19 115V34033

34-56

115Z Ⅳ -2

Disassembling & Reassembling 1st Clutch

TORQUE CONVERTER & TRANSMISSION 34

2.Reassembling 1st clutch assembly Before starting work: ・Clean and inspect each part, replace if necessary. For inspection and wear standards, refer to Section 35. ・Replace the bearing with new one if necessary, manually turn the bearing to check that the bearing rotates properly.

1)Assemble the clutch drum (22) and clutch hub (23) with the snap ring (21). 97ZA3442

2) Install the drop gear (20) to the clutch hub (23) with the bolts (19). : Bolt (19) : 132N-m (13.5kgf-m) (98 lb-ft)

19 20 115K34144

3) Install the seal rings (17) (18) on the piston (16). 16 18

Direction of the seal lip

97ZA3443

97ZA3444

4) Install the piston (16), springs (15), and ring plate (12), in that order, on the clutch drum (22). Then, push down the ring plate with a press (13), and assemble the plate with the snap ring (14). 16

12 22

97ZA3445

34-57

Disassembling & Reassembling 1st Clutch

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

5)After installing the piston, reassemble the alternate layers of plates, starting with friction plate (10), steel plate (11), then friction plate (10) in the clutch drum (22). Then install the pressure plate (9), and assemble it with the snap ring (8). Standard piston stroke : 6.0±0.5mm (0.2362±0.0197 ″)

115V34034

6) Install the two seal rings (5) in the clutch hub (6), and install the bearing (4). Install the bearing retainer (2) after putting the two O-rings on it, and then install the bearing (3) and bearing nut (1) in turn. Note : Apply grease to the seal rings, and bend them inward as much as possible. : Bearing nut (1) Tighten the nut so as to the pre-load at the point A is between 98 and 118N (10 〜12kgf) (22〜26 lbs).

115V34035

7)After confirming the pre-load of the bearing (3) (4), calk (stake) the nut to lock it.

97ZA3437

Calked (Staked)

34-58

High Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

Disassembling and Reassembling High Clutch Assembly 1.Disassembling high clutch assembly 1)Remove the snap ring (1), then remove the pressure plate (2).

4 3 2 1 3 4

115K34145

2)Remove the friction plates (3) and steel plates (4) from the clutch drum. Friction plates : 4 pcs Steel plates : 3 pcs

115ZA3418

3)Push down the spring retainer (5) with a press, and remove the snap ring (6).

4)After removing the snap ring, remove the spring retainer (5). 5 6

5)Remove the springs (7) and the piston (8). 8 7

115K34154

34-59

High Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

6) Turn over the clutch drum assembly. 9

7) Force the snap ring (9) inward with a round bar to separate the clutch drum (10) and clutch hub (11). 10

2.Reassembling high clutch assembly

115ZA3419

Before starting work: ・Clean and inspect each part, replace if necessary. For inspection and wear standards, refer to Section 35. ・Replace the bearing with new one if necessary, manually turn the bearing to check that the bearing rotates properly.

1) Install the clutch hub (11) to the clutch drum (10) with the snap ring (9). 9

2) Turn over the clutch drum assembly. 115ZA3419

3)Measure piston stroke: 1. Temporarily install the piston (8), friction plates (3), steel plates (4), pressure plate (2), and snap ring (1). 2.Measure dimension (A) shown at the right (piston stroke). Piston stroke : 3.0±0.5mm (0.12±0.02 ″) 3. If stroke is not within the above range, replace the piston, friction plates and steel plates with new ones. Note : Do not install the seal rings into the piston at this stage.

1 A 2

4 3

8 115ZA3420

34-60

115Z Ⅳ -2

High Clutch Assembly

TORQUE CONVERTER & TRANSMISSION 34

4) Install the seal rings (12) (13) to the piston. Piston

2 1

115ZA3421

5) Install the piston (8) and springs (7) in the clutch drum assembly (10).

8 115V34031

6) Install the spring retainer (5) and then push down the spring retainer (5) with a press. 7) Install the snap ring (6).

6 115ZA3422

8) Install the friction plates (3) and steel plates (4) alternately. Friction plates : 4 pcs Steel plates : 3 pcs

4 3

115ZA3423

34-61

High Clutch Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

9) Install the pressure plate (2), and then install the snap ring (1). 2 1

115V34032

34-62

Modulator Valve Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

Removing and Reinstalling Modulator Valve Assembly 1.Removing modulator valve assembly 1)Open the cover (1). 1

115K34148

2)Disconnect all the wire harness coupler (2) (3). Note : Put match marks on them to avoid mis-wiring when reassembling. 3)Remove the hoses (4) (5). Note : Cover the disconnected hoses with vinyl, plugs, or caps to protect them from dust, water, and dirt.

3 2

115K34149

4)Remove ten retainer bolts (6) and then remove the modulator valve unit. Tightening torque for assembly : Bolt (5) : 26N-m (2.7kgf-m) (20 lb-ft)

115K34150

115K34151

34-63

Modulator Valve Assembly

115Z Ⅳ -2

2.Reinstalling modulator valve assembly To reinstall the modulator valve, follow the above removal procedure in the reverse direction.

Cautions for installation 1)Be sure to replace all the O-rings and gaskets with new ones. 2)Sequentially tighten the bolts in the order from the center to the outside. Apply equal (specified) torque to all the bolts. 3)Align the match marks of the electric wire couplers, and then connect the couplers while checking that the electric wires are not tangled with each other. 4) Install the cover while checking that the emergency operation bolts are positioned over the center of the solenoid valves. 5)During installation, be careful not to damage the gasket.

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, be sure to stop the engine, and block the tires with chocks before you start service work under the machine. During the service work under the machine, closely contact with the person in the cab using signals preliminarily determined.

6)At the completion of installation, start the engine, and check that the shift lever properly functions at all the positions. 7)Check oil leakage. 8)Adjust the transmission oil level to the specified point with the dipstick.

34-64

TORQUE CONVERTER & TRANSMISSION 34

Control Valve Assembly

115Z Ⅳ -2

TORQUE CONVERTER & TRANSMISSION 34

Removing and Reinstalling Control Valve Assembly 1.Removing control valve assembly 1)Open the cover (1). 1

115K34148

2)Disconnect all the wire harness coupler (2). Note : Put match marks on them to avoid mis-wiring when reassembling. 2

3)Remove four bolts (3) and then remove the cover (4). 4)Remove nine bolts (5) and then remove the block. Tightening torque for assembly : Bolt : 92N-m (9.4kgf-m) (68 lb-ft)

115K34155

2.Removing solenoid valve assembly

5 4

1)Remove the nut (6) and then remove the solenoid (7). Tightening torque for assembly : Nut : 10N-m (1.0kgf-m) (7 lb-ft)

2)Remove the valve (8). Tightening torque for assembly : Valve : 59N-m (6.0kgf-m) (43 lb-ft) 115K34152

3.Reinstalling control valve and solenoid valve

To reinstall the control valve and the solenoid valve, follow the above removal procedure in the reverse direction.

7 6 7

Cautions for installation ①Tighten the valve with the specified torque. Tightening with over torque causes improper valve operation.

115K34153

34-65

TORQUE CONVERTER & TRANSMISSION GROUP 35 Service standard Torque Converter Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 35-2 Transmission Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 35-3 Gear Pump ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 35-5 Clutch Specifications ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 35-6 Clutch Oil Pressure ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 35-7

35-1

115Z Ⅳ -2

Torque Converter Assembly

TORQUE CONVERTER & TRANSMISSION 35

Torque Converter Assembly

Pump drive

1 A

Seal ring Stator carrier

6 Output coupling

Turbine shaft

Seal ring

B C

115V35001

mm (in.) Judgement criteria REF.

ITEM

Solution Standard value

3 H

3.7

H=4

3.6

h=0

0.15

T = 4.1

4.3

t = 2.4

2.1

H = 2.8

2.4

h=0

0.15

T = 2.5

2.8

h=0

h = 0.1

Replace

t=4

Replace

Limit

6 115ZA3502

35-2

Replace

115Z Ⅳ -2

Transmission Assembly

TORQUE CONVERTER & TRANSMISSION 35

Transmission Assembly

6 8

1 9 9

3 4 9 5

115ZA32-02

35-3

115Z Ⅳ -2

Transmission Assembly

TORQUE CONVERTER & TRANSMISSION 35

mm (in.), kg (lbs) Judgement criteria REF.

ITEM

High clutch piston return spring

Reverse clutch pistion return spring

Low clutch pistion return spring

3rd clutch pistion return spring

2nd clutch pistion return spring

1st clutch pistion return spring

Standard value

Allowable limit

Free length

Installed length

Installed load

Free length

Installed load

23.41

±0.48

±1.4

(1.1023)

(0.9449)

(51.50)

( ±0.0189)

( ±3.08)

26.82

±1.64

±2.2

(3.2283)

(2.8346)

(59.00)

( ±0.0646)

( ±4.84)

26.82

±1.64

±2.2

(3.2283)

(2.8346)

(59.00)

( ±0.0646)

( ±4.84)

49.5

27.36

±0.99

±1.6

(1.9488)

(1.6142)

(60.20)

( ±0.0389)

( ±3.52)

49.5

27.36

±0.99

±1.6

(1.9488)

(1.6142)

(60.20)

( ±0.0389)

( ±3.52)

49.5

27.36

±0.99

±1.6

(1.9488)

(1.6142)

(60.20)

( ±0.0389)

( ±3.52)

Standard value

Standard clearance

Seal width

3.8 (0.1496)

Seal thickness

4.0 (0.1575)

Seal width

4.3 (0.1693)

Seal thickness

5.0 (0.1968)

0 -0.1 ( -0.0039) 0 -0.1 ( -0.0039) 0 -0.1 ( -0.0039) 0 -0.1 ( -0.0039)

Seal width

2.8 (0.1496)

± 0.1 (±0.0039)

-0.15 (-0.0059)

Seal thickness

4.55 (0.1791)

± 0.1 (±0.0039)

-0.15 (-0.0059)

Seal width Seal thickness

35-4

Solution

Replace

Allowable limit -0.15 (-0.0059) Replace -0.15 (-0.0059) -0.15 (-0.0059) Replace -0.15 (-0.0059)

Replace

115Z Ⅳ -2

Gear Pump

TORQUE CONVERTER & TRANSMISSION 35

Gear Pump

１１５ＺＡ３２−０５

Gear pump specifications Theoretical discharge

72.6 cc/rev

Maximum operation pressure

3.4MPa (35kgf/cm2) (498 psi)

Maximum operation speed

3000min-1

Actual discharge

Approx. 50 l /min Conditions: Pump speed 900min-1 Oil temp. 80 ° C (176 ° F) Oil viscosity 10CST(SAE10W) Discharge pressure 3.4MPa (35kgf/cm1) (498 psi)

35-5

115Z Ⅳ -2

Clutch specifications

TORQUE CONVERTER & TRANSMISSION 35

Clutch specifications mm (in.) Friction plate

Name of

Piston stroke

clutch

mm (in.)

Low clutch

5.5 ± 0.5 (0.2165 ± 0.0196)

Reverse clutch

5.5 ± 0.5 (0.2165 ± 0.0196)

High clutch

3.0 ± 0.5 (0.1181 ± 0.0196)

1st speed clutch

6.0 ± 0.5 (0.2362 ± 0.0196)

2nd speed clutch

2.0 ± 0.5 (0.0787 ± 0.0196)

3rd speed clutch

3.0 ± 0.5 (0.1181 ± 0.0196)

Number of plate

Steel plate

Number of Outer Inner Thickness mm (in.) Number Outer Inner Thickness mm (in.) return spring dia. dia. dia. dia. of plate mm (in.) mm (in.) New/Wear limit mm (in.) mm (in.) New/Wear limit 360φ 279φ (14.1732) (10.9842)

236φ (9.2913)

159φ (6.2598)

360φ 279φ (14.1732) (10.9842)

4 ± 0.13/3.5 (0.1575 ± 0.0051 /0.1378) (Sintered)

4 ± 0.1/3.4 (0.1575 ± 0.0039 /0.1339) (Sintered)

4 ± 0.13/3.8 (0.1575 ± 0.0051 /0.1496) (Paper)

Limit for distortion (flatness)

426φ 298φ (16.7716) (11.7323)

252φ (9.9212)

173φ (6.8110)

426φ 298φ (16.7716) (11.7323)

less than 0.25 (〜0.0098)

35-6

3.5 ± 0.1/3.3 (0.1378 ± 0.0039 /0.1299)

3.2 ± 0.1/3.0 (0.1260 ± 0.0039 /0.1181)

3.5 ± 0.1/3.3 (0.1378 ± 0.0039 /0.1299)

6 12 12 12 12 12

115Z Ⅳ -2

Clutch Oil Pressure

TORQUE CONVERTER & TRANSMISSION 35

Clutch Oil Pressure

Measurement port size

Oil pressure (Approx.) MPa (kgf/cm2) (psi)

Shift lever position

Main clutch oil pressure

PF 3/8

3.3 (34)(483)

at any position

Low clutch oil pressure

PF 3/8

3.3 (34)(483)

F-1〜3

High clutch oil pressure

PF 3/8

3.3 (34)(483)

F-4

Reverse clutch oil pressure

PF 3/8

3.3 (34)(483)

1st clutch oil pressure

PF 3/8

2.5 (25)(356)

1st speed

2nd clutch oil pressure

PF 3/8

3.3 (34)(483)

2nd speed

3rd clutch oil pressure

PF 3/8

3.3 (34)(483)

3rd speed

Measuring port location

Main clutch oil pressure measurement port : PF3/8

・ Torque converter oil temperature: 50 to 80 ℃ (120〜180 ° F) ・ Engine revolution: at all speed range

1st speed clutch oil pressure measurement port : PF3/8

Low clutch oil pressure measurement port : PF3/8

2nd speed clutch oil pressure measurement port : PF3/8

High clutch oil pressure measurement port : PF3/8

Reverse clutch oil pressure measurement port : PF3/8

3rd speed clutch oil pressure measurement port : PF3/8

Clutch oil pressure measuring port

35-7

HYDRAULIC GROUP 44 Disassembly and Reassembly Hydraulic Pump ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-3 Removing and Reinstalling Gear Pump Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-5 Steering Pilot Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-7 Removing and Reinstalling Steering Pilot Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-8 Disassembling and Reassembling Steering Pilot Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-10 Steering Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-18 Removing and Reinstalling Steering Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-19 Disassembling and Reassembling Steering Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-21 Stop Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-26 Removing and Reinstalling Stop Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-27 Disassembling and Reassembling Stop Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-29 Multiple Control Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-30 Removing and Reinstalling Multiple Control Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-31 Disassembling and Reassembling Multiple Control Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-34 Boom Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-37 Removing and Reinstalling Boom Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-38 Bucket Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-40 Removing and Reinstalling Bucket Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-41 Steering Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-44 Removing and Reinstalling Steering Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-45 Hydraulic Cylinder Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-48 Disassembling and Reassembling Hydraulic Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-49 Pilot Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-54 Pilot Valve Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-55

44-1

Removing and Reinstalling Pilot Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-56 Disassembling and Reassembling Pilot Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-58 Pilot Relief Valve Unit ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 44-62

44-2

115Z Ⅳ -2

Hydraulic Pump

HYDRAULIC 44

Hydraulic Pump

115V42005

Pump specifications KAWASAKI PART NUMBER

JSB PART NUMBER

44093-61220 2104874

DISPLACEMENT in3/REV (mL/REV)

JOHN S. BARNES MODEL NUMBER

F3-G3030W-4FJ28CJ28CJ-12861L

Measurement conditions : Oil temperature 50 ℃〜80 ℃ Hydraulic oil ISO VG46

44-3

FRONT PUMP

REAR PUMP

5.51 (91)

MIN. RATED RATED SPEED PRESS SPEED AT RATED P.S.I. (min-1) PRESSURE (bar) (min-1) 2750

4000 (276)

600

115Z Ⅳ -2

Hydraulic Pump

HYDRAULIC 44

115V42006

Pump specifications

KAWASAKI MACHINE

115ZⅣ -2

KAWASAKI PART NUMBER

44093-61230

JSB PART NUMBER

2104946

JOHN S. BARNES MODEL NUMBER

F3-G3020W-4FJ25CJ138M-12861L

44-4

DISPLACEMENT in3/REV (mL/REV) FRONT PUMP

REAR PUMP

4.91 (80)

2.60 (43)

MIN. RATED SPEED RATED PRESS AT RATED SPEED P.S.I. PRESSURE (min-1) (bar) (min-1) 3000

4000 (276)

600

Removing and Reinstalling Gear Pump Assy

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Gear Pump Assembly 1.Removing gear pump assembly WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Disconnect the negative side of the cable from the battery. ・ Release the residual pressure from the hydraulic line.

Before starting work: a)Remove the screen board by referring to Section 14. b)Clean the area around the hydraulic pump. 5

1)Disconnect the outlet hose (3) (4) and the suction pipe (5) from the pump (1) (2). Remove the pump retainer bolts (6) (7). Torque for assembly: : Bolt : 94N-m (9.6kgf-m) (69 lb-ft)

2)Sling the gear pump (1) (2) and remove them from the torque converter. : Pump (1) Pump (2)

28kg (62 lb-ft) 35kg (77 lb-ft)

115K44002

4 4 1

44-5

115K44003

Removing and Reinstalling Gear Pump Assy

115Z Ⅳ -2

2.Reinstalling gear pump assembly To reinstall the gear pump, follow the above removal procedure in the reversed direction. Replace all gaskets, O-rings, and seals during reinstallation.

Cautions regarding reinstallation IMPORTANT 1) Be sure to remove all caps, plugs, tape, etc. from the pump and pour new oil from the outlet and inlet ports into the pump to form an oil film inside the pump. 2)While reinstalling the gear pump, take care not to allow dust, dirt, or foreign material into the case. 3) Check the oil level of the hydraulic tank. 4) Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe. Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 l ). 5)Operate the engine at low-idling speed for 5 minutes or more. Do not operate any hydraulic functions during this period. Note : If the engine speed is set to high-idling just after starting, the pump may be seized. 6)Move each cylinder almost full stroke 5-6 times. Do not fully extend or retract any cylinder during this period. 7) Confirm that there is no abnormal heat, noise, or abnormal operation of the system during this break-in period. 8) Inspect the hydraulic oil sight gauge and confirm that there are no bubbles in the hydraulic oil. Bubbles may indicate a suction side air leak that must be corrected to prevent premature pump failure.

44-6

HYDRAULIC 44

115Z Ⅳ -2

Steering Pilot Valve

HYDRAULIC 44

Steering Pilot Valve Tightening torque

15 14

16 14 15

Spool

7 8 7 5

Sleeve

4 3 2

19 17

115K44035

1. Dust seal 2. Retainer ring 3. Seal retainer 4. O-ring 5. Quadring seal 6. Bearing kit 7. Race 8. Needle bearing

9. Ball 10. Adapter 11. Pin 12. Case assembly 13. Spring 14. Spring 15.O-ring 16. Plate

Tightening torque T1 : 28N-m (2.9kgf-m) (21 lb-ft)

17.Shaft 18.Rotor assembly 19.O-ring 20.Spacer 21.End plate 22.Screw 23.Screw

:7.0kg (15 lbs)

44-7

Removing and Reinstalling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Steering Pilot Valve 1.Removing steering pilot valve WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Apply the articulation stopper. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel. ・ Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right. ・ Relieve the internal pressure from the hydraulic tank.

1)Remove the lock lever (1) and the cover (2).

90K44006

2)Remove the plate (3). 3)Remove the sound suppression sheet (4).

4 90K44007

44-8

Removing and Reinstalling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

4)Put matchmarks on the hoses (6), and then disconnect them from the steering pilot valve (5).

6 5

5)Remove the bolt (7), and then remove the steering pilot valve. Torque for assembly: : Bolt : 29N-m (3.0kgf-m) (22 lb-ft) : Steering pilot valve : 7kg (15 lbs) Note : One person should support the steering pilot valve under the machine. The person in the cab should remove the retainer bolt.This work should be done by two persons.

2.Reinstalling steering pilot valve To reinstall the steering pilot valve, follow the above removal procedure in the reversed direction. At the completion of reinstallation, check operation of the steering pilot valve by following the procedure below:

WARNING Entering the articulation area while engine is running may cause serious injury or death. So, when entering the area, stop the engine and place "DO NOT START " or "DO NOT OPERATE" tag on steering wheel.

1)Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise. 2)Check around the valve for oil leakage.

44-9

Disassembling&Reassembling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Steering Pilot Valve 1.Disassembling steering pilot valve Before starting work: a)Clean the steering pilot valve. b)Clamp the steering pilot valve in a vise. Copper

(Disassembling rotor) 1)Remove the bolt (1), end plate (2) and O-ring (3).

2 3 90K44010

2)Remove the rotor assembly (4), spacer (5) and O-ring (6). Note : Keep the star (7)in the rotor assembly (4).

7 6

90K44011

3)Remove the drive shaft (8), plate (9) and O-ring (10).

9 10

90K44012

44-10

Disassembling&Reassembling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

(Disassembling valve) Take care not to damage the finished surface. 4)Remove the retainer ring (11) by a screw driver.

11 90ZA44-018-2

5)Remove the seal retainer (12) by pressing the spool and sleeve from behind with your fingers. 12

90ZA44-018-3

6)Remove the X-ring seal (13) and dust seal (14) from the seal retainer (12). 14

90ZA44-018-4

7)Remove the races (15) and needle bearing (16) from the spool (17) and sleeve (18). 15 16 15

18 90ZA44-019-1

44-11

115Z Ⅳ -2

Disassembling&Reassembling Steering P/V

HYDRAULIC 44

8)Pull the spool and sleeve assembly (18) out slowly, turning it clockwise and counter-clockwise from the housing (19). Note : Take care so that the spool and sleeve do not damage the housing.

18 19 90ZA44-019-2

9)Pull the pin (20) from the spool and sleeve assembly.

90ZA44-019-3

10)Push the spool slightly out of the sleeve, and remove the centering springs (21). Pull the spool from the sleeve while slowly turning the spool clockwise and counter-clockwise.

Push out

Sleeve Spool

９０ＺⅣ４４１０

90ZA44-019-4

44-12

Disassembling&Reassembling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

11)Remove the O-ring (22) from the housing. 22

O-ring I.D 9.3φ

24 O-ring I.D 7.6φ

(Disassembling emergency check valve) Note : Liquid adhesive is applied to the set screw.

90ZA44-020-1

10φ

12)Remove the set screw (23) from the housing. 10φ 30

13)Pull out the check valve (24) with the puller (B). 50

14)Tap gently on the housing to take out the ball (25) and the retainer (26).

Thread 10-24UNC

4.8φ

44-13

90ZA44-020-2

Disassembling&Reassembling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

2.Reassembling steering pilot valve Before starting work: a)Clean and inspect each part. If necessary replace it with new one. b)Apply grease to the O-rings. (There is no need to grease the X-ring seal.) Note : Make sure that the end of the check valve with the hole in it is facing downward when inserting the valve into the housing.

1) Insert the retainer (26) and ball (25), put O-rings on the check valve (24), and then press the check valve into the housing. Apply Loctite 262 or equivalent to the screw (23), and then tighten the screw. : Screw : 12N-m (1.2kgf-m) (9 lb-ft) : With liquid adhesive (Loctite 262 or equivalent) Note : Confirm that the screw is tightened to the extent that the screw head is slightly below the edge of the housing.

23 O-ring I.D 9.3φ O-ring I.D 7.6φ

24 25 26

90ZA44-021-1

2)Assemble the spool (17) and sleeve (18) so that the spring grooves in them are lined up. Note : Align the match - marks on the spool and sleeve.

Spring groove

Match mark

90ZA44-021-2

3) Install the springs (21) through the spring grooves in the sleeve and spool (18) using a spring insertion jig. Note : Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

Spring insertion jig

18 90ZA44-021-3

44-14

Disassembling&Reassembling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

4) Insert the pin (20) in the holes in the spool (17) and sleeve (18) until the end of the pin is flush with the surface of the sleeve.

5) Insert the spool and sleeve assembly (18) from the back of the housing (19). Note : ① Take care not to tilt the assembly and cause damage during insertion. ② Insert the assembly until the back end of the assembly is flush with the back end of the housing. ③ Confirm that the assembly can be turned easily in the housing.

18 19 90ZA44-022-2

6) Install the O-ring (22), races (15) and needle bearing (16).

16 15

90ZA44-022-3

7) Insert the dust seal (13) and the X-ring seal (14) in the seal retainer (12). 13

44-15

Disassembling&Reassembling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

8) Insert the seal retainer (12) onto the spool, and then tap it gently into position with a plastic-faced hammer. Then install the retainer ring (11).

90ZA44-023-1

Note : Be sure the position and direction of the seals. Dust seal

Screw driver

Retainer ring Seal retainer X-ring seal O-ring

90ZA44-023-2

9)Put on the O-ring (10), then align the bolt holes in the plate (9) with those in the housing.

90ZA44-023-3

10)Insert the drive shaft (8) to mate its yoke with the pin (20). Port face

8 Pin parallel with port face

20 90ZA44-023-4

44-16

Disassembling&Reassembling Steering P/V

115Z Ⅳ -2

HYDRAULIC 44

11)Put the O-ring (6) in the rotor assembly (4).

90ZA44-024-1

12)Holding the rotor assembly with the O-ring side facing the plate, install the assembly so that the grooves in the star-shaped bore mesh with the drive shaft. Note : ① Align the bolt holes in the rotor assembly with those in the housing without disengaging the drive shaft from the rotor assembly's star - shaped bore. ② Confirm that lines A, B, C and D are all parallel.

Grooves in rotor bore

A B

Drive shaft

13)Install the spacer (5), O-ring (6) and end cap (2).

Port face

6 5

90ZA44-024-2

: Provisional tightening torque : 15N-m (1.5kgf-m) (11 lb-ft) Tightening torque : 28N-m (2.9kgf-m) (21 lb-ft) Note : Provisionally tighten the bolt (1), then tighten them securely in the order shown at the right.

90ZA44-024-3

90ZA44-024-4

44-17

115Z Ⅳ -2

Steering Valve

HYDRAULIC 44

Steering Valve T6 3 T3 T7 T5

4 T1

T1 8

7 5

T7 T4 L 1

T3 T4 L 1 T2 1

5 T5

7 9 97ZA4404

: Tightening torque T1 : 98N-m (10.0kgf-m) (72 lb-ft) T2 : 9N-m (0.9kgf-m) (6.5 lb-ft) T3 : 176N-m (18.0kgf-m) (130 lb-ft) T4 : 10N-m (1.0kgf-m) (7 lb-ft) T5 : 44N-m (4.5kgf-m) (33 lb-ft) T6 : 78N-m (8.0kgf-m) (58 lb-ft) T7 : 88N-m (9.0kgf-m) (65 lb-ft) L1 : With liquid adhesive (Loctite 262 or equivalent)

1. Steering plunger 2. Flow control plunger 3.Main relief valve 4. Overload relief valve 5. Cap 6. Poppet 7. Stopper 8. Plug 9. Spring seat 10.Valve body

: 48kg (110 lbs)

44-18

Removing and Reinstalling Steering Valve

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Steering Valve 1.Removing steering valve 2

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Relieve the internal pressure from the hydraulic tank. ・ Oil spilled on the parking brake shoe section may cause malfunction. To prevent such a problem, cover the shoe section with vinyl before valve removal.

115K44004

Before starting work: a)Remove the deck on the left side.

8 7

1)Disconnect the block (1) and hoses (2) (3).

6 4

2)Disconnect the hoses (4) (5) (6) (7) (8). : Hydraulic oil : Approx. 1 l (0.3 gal.)

11 115K44005

3)Disconnect the hose (9).

9 115K44006

4)Remove the bolt (11) and then remove the steering valve (10). Torque for assembly: : Bolt : 88N-m (9.0kgf-m) (65 lb-ft) : Steering valve : 48kg (110 lbs) Note : Cover the disconnected hoses and the valve with vinyl, plugs or caps to protect them from dust and dirt.

115K44007

44-19

Removing and Reinstalling Steering Valve

115Z Ⅳ -2

2.Reinstalling steering valve To reinstall the steering valve, follow the above removal procedure in the reversed direction. At the completion of reinstallation, check operation of the steering valve by following the procedure below:

1)Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise. 2)Check around the valve for oil leakage. 3)Measure various values for performance check. Measure the time required for full steering. Measure the relief valve setting pressure. (Refer to the Section 03 - Measurement for Performance Check).

44-20

HYDRAULIC 44

Disassembling and Reassembling STV

115Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Steering Valve 1.Disassembling steering valve Before starting work: a)Clean the valve body.

1)Remove the right and left overload relief valves (1). : Torque for assembly : 88N-m (9.0kgf-m) (65 lb-ft)

2)Remove the main relief valve (2). Torque for assembly: : Main relief valve : 78N-m (8.0kgf-m) (58 lb-ft) Note : The orifice is behind the main relief valve.Do not loose the orifice during the service work.

3)Remove the retainer bolt (5) from the cap (4). Torque for assembly: : Retainer bolt : 44N-m (4.5kgf-m) (32 lb-ft)

4)Remove the cap (4). Also remove the O-ring from the cap.

44-21

Disassembling and Reassembling STV

115Z Ⅳ -2

HYDRAULIC 44

5)Remove the spring (6). 6

6)Remove the spring seat (7). Note : To disassemble other side of the cap part, follow the above removal procedure.

7)Pull out the steering plunger (8) slowly. Note : Carefully pull out the plunger so that it is not forced out or distorted. Handle the plunger with extreme care, even a small nick, dent, or scratch can ruin the plunger which requires replacement of the entire valve.

8)Remove the plug (9). Torque for assembly: : Plug : 176N-m (18.0kgf-m) (130 lb-ft)

44-22

Disassembling and Reassembling STV

115Z Ⅳ -2

HYDRAULIC 44

9)Remove the filter (10) at the bottom of the plug to prevent it from being lost, and remove the spring (11).

10)Remove the plug (12). Torque for assembly: : Plug : 176N-m (18.0kgf-m) (130 lb-ft)

11)Slowly pull out the flow control plunger (13). Note : Carefully pull out the plunger so that it is not forced out or distorted. Handle the plunger with extreme care.

44-23

115Z Ⅳ -2

Disassembling and Reassembling STV

HYDRAULIC 44

12)Disassemble the steering plunger Clamp the steering plunger in a vise using the block for clamping plunger, and remove the cap screw (14)(both sides). Torque for assembly: : Cap screw : 10N-m (1.0kgf-m) (7 lb-ft) : With liquid adhesive (Loctite 262 or equivalent)

30〜40

2〜4

Block for clamping plunger (Hard wood)

70〜100

φ25

10〜20

φ20

With hex. socket or hex. head

5 4.7 -0.30

For disassembling/assembling cap screw

９０ＺＡ４４−０３１

13)Remove the poppet (15) and the spring (16) from the plunger (both sides).

14)Main relief valve disassembly Loosen the lock nut (17) and remove the adjuster (18), spring (19), poppet (20), O-ring (21) and back up ring (22). Note : Replace O-ring and back-up ring with new ones. Do not disassemble the pilot seat (23) crimped to the plug (9).

17 21

21 19

23 22 21

90ZA44-032

44-24

115Z Ⅳ -2

Disassembling and Reassembling STV

2.Reassembling steering valve To reassemble the steering valve, follow the above disassembly procedure in the reversed direction. Cautions regarding reassembly: Before starting work: a)Clean and check all the parts. Replace all O-rings and seals. b)Before reassembly, apply a coating of hydraulic oil to all the parts. c) Be sure to apply the specified torque to tighten each part. d) Install the filter and the orifice for the main relief valve as shown below. Main relief valve

Filter

Install so that concave face of orifice faces filter. ９５ＺⅣ４４０１

44-25

HYDRAULIC 44

115Z Ⅳ -2

Stop Valve

HYDRAULIC 44

Stop Valve 16 15 14

11 10 9

5 3

1. Bolt 2. Boot 3. Flange 4. Bolt 5.Wiper 6. Spacer

90K44051

13. Plug 14. Spring 15. O-ring 16. Plug

7. U-packing 8. Spool 9. Poppet 10. Spring 11. O-ring 12.Washer

44-26

Removing and Reinstalling Stop Valve

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Stop Valve 1.Removing stop valve WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

(The illustration shows the machine left hand side.) 1)Disconnect the hose (1) and the oil pipe (2). Note : Cover the disconnected hose and pipe with vinyl, cap or plug to protect them from dust, water and dirt.

2)Remove the bolt (3) and then remove the stop valve (4). 4 115K44008

2.Reinstalling stop valve For reinstallation, follow the above procedure in the reversed procedure.

44-27

115Z Ⅳ -2

Removing and Reinstalling Stop Valve

HYDRAULIC 44

3.Cautions regarding reinstalling: Adjust the stop valve as shown below before installing it.

WARNING Be careful ! Your body or finger could be crushed in the machine when the machine turns. Be sure to observe the following items before starting the steering stopper adjustment. ・ When adjusting the steering stopper, do not start the engine and place "DO NOT START" or "DO NOT OPERATE" tag on the steering wheel. ・ After adjusting the steering stopper, stay out of the articulation area when confirming the function of the stop valve.

1)Confirm the proper position of the stop valve assembly (on each side). 28〜32mm (1.10〜1.25 in.)

Stop valve (installed on rear chassis)

Plate (installed on front chassis)

3mm (0.12 in.)

Stop valve actuation position 90Z Ⅳ 4304

2)When the chassis stopper clearance is 25 〜 39mm (1.0 〜 1.5 in.), confirm that the stop valve is forced in 3mm (0.12 in.) when the stopper bolt length is 28 〜32mm (1.10〜1.25 in.) as shown. 3)Check each section for oil leakage.

44-28

Disassembling & Reassembling Stop Valve

115Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Stop Valve 1.Disassembling stop valve Before starting work: a)Clean the stop valve assembly. 1)Remove the boot (1).

90K44053

2) Loosen the adapter (2).

WARNING The inner spring could spring out causing injury. Do not point the spring toward your face. 2

3)Remove the spring (3). 3

4)Remove the spool assembly (4). 4 90K44054

5)Clamp the spool assembly (4) at the bottom side in a vise and remove the screw (5) using a screw driver. 6)Remove the washer (6), spring (7), O-ring (9) and poppet (8) from the spool assembly (4).

7 5

4 9

Two flats

90K44055

2.Reassembling stop valve To reassemble the stop valve, follow the above procedure in the reversed direction.

44-29

115Z Ⅳ -2

Multiple Control Valve

HYDRAULIC 44

Multiple Control Valve T5 T3

Overload relief valve with make -up function

T4 T8 L 1

T10 Make-up valve

T9 T6

T11

Boom spool

Bucket spool

Main relief valve

T6 T1 97ZA4409

: Tightening torque T1 : 196N-m (20.0kgf-m) (145 lb-ft) T2 : 284N-m (29.0kgf-m) (210 lb-ft) T3 : 226N-m (23.0kgf-m) (166 lb-ft) T4 : 39N-m (4.0kgf-m) (29 lb-ft) T5 : 245N-m (25.0kgf-m) (181 lb-ft) T6 : 54N-m (5.5kgf-m) (40 lb-ft) T7 : 74N-m (7.5kgf-m) (54 lb-ft) T8 : 39N-m (4.0kgf-m) (29 lb-ft) T9 : 128N-m (13.0kgf-m) (94 lb-ft) T10 : 10N-m (1.0kgf-m) (7 lb-ft) T11 : 29N-m (3.0kgf-m) (22 lb-ft)

: 100kg (220 lbs)

L1 : Screw lock agent application (Three Bond 1327)

44-30

Removing and Reinstalling MCV

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Multiple Control Valve 1.Removing multiple control valve WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Lift the boom until it is horizontal, and then place a stand (A) to support the bottom of the boom.

Stand (A)

85K44038

1)Remove the cover (1).

115K44009

2)Remove the pipe (2) (3). Note : Cover the disconnected hoses with vinyl, cap or plug to protect them from dust, water and dirt.

5 4

Control valve

3)Remove the pipe (4) (5). Put matchmarks on the pilot line hoses (6) and then disconnect them. Note : Cover the disconnected hoses with vinyl, cap or plug to protect them from dust, water and dirt.

115K44010

115K44011

44-31

Removing and Reinstalling MCV

115Z Ⅳ -2

HYDRAULIC 44

4)Remove the pipe (7) and the hose (8). Note : Cover the disconnected hoses with vinyl, cap or plug to protect them from dust, water and dirt. 8 7

Control valve

115V44001

5)Remove the bolts (10) for the control valve (9). Use a hoist to remove the control valve. Torque for assembly: : Bolt : 98N-m (10.0kgf-m) (72 lb-ft) : Multiple control valve : 100kg (220 lbs) 9

115K44013

44-32

Removing and Reinstalling MCV

115Z Ⅳ -2

2.Reinstalling multiple control valve To reinstall the multiple control valve, follow the above removal procedure in the reversed direction. Cautions regarding reinstallation: a)Replace all the O-rings with new ones. b)Wash the multiple control valve mounting area.

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, be sure to stop the engine before you start working under the machine. In addition, block the tires with chocks to prevent the wheels from moving. While working under the machine, carefully keep contact with the person in the cab by giving signals to each other.

c) Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the Section 03. d)Operate the bucket and the boom, and check that they operate correctly. e)Check each section for oil leakage. f ) Add hydraulic oil to the tank until the oil level rises to the specified point.

44-33

HYDRAULIC 44

Disassembling and Reassembling MCV

115Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Multiple Control Valve 1.Disassembling multiple control valve IMPORTANT ・ Place the removed parts, in order, on a clean paper or cloth. ・ Do not disassemble any section unless disassembly is absolutely necessary for repair or adjustment. ・ As a rule, the main relief valve or overload relief valve once disassembled should be replaced as an assembly. Therefore, do not disassemble these valves, unless absolutely necessary.

a)Clean the valve body 1)Bucket spool disassembling Remove the socket head bolt (1) and the cover (2). Hexagon hole width across flat: 8mm (5/16 in.) Torque for assembly: : Bolt : 54N-m (5.5kgf-m) (40 lb-ft)

2 1

2)Pull out the spool assembly from the bucket side. Note : Carefully pull out the spool so that it is not forced out or distorted. Handle the spool with extreme care, even a small nick, dent, or scratch can ruin the spool which requires replacement of the entire valve.

3)Clamp the spool (3) in a vise using copper plates and then loosen the bolt (4). Hexagon hole width across flat: 12mm (1/2 in.) Torque for assembly: : Bolt : 4.0kg-m (29 lb-ft) : Screw lock agent application (Three Bond 1327)

44-34

Disassembling and Reassembling MCV

115Z Ⅳ -2

HYDRAULIC 44

4)Remove the bolt (4), spring retainer (5), outer spring (6), inner spring (7), stopper (8) and spring retainer (9).

6 4

5 9 8

5)Boom spool disassembling To disassemble the boom spool, follow the bucket spool disassembling procedure.

6)Remove the overload relief valves (10). Hexagon width across flat: 34mm (1 11/32 in.) Torque for assembly: : Overload relief valve : 74N-m (7.5kgf-m) (54 lb-ft) Note : The overload relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary.

7)Remove the main relief valve (11). Hexagon width across flat: 41mm (1 5/8 in.) Torque for assembly: : Main relief valve : 128N-m (13.0kgf-m) (94 lb-ft) Note : The main relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary.

44-35

Disassembling and Reassembling MCV

115Z Ⅳ -2

HYDRAULIC 44

8)Remove the plug (12), and then remove the spring (13) and the poppet (14). Hexagon hole width across flat: 14mm (9/16 in.) Torque for assembly: : Plug : 226N-m (23.0kgf-m) (166 lb-ft)

14 12

9)Remove the make up valve (15) from the body. Hexagon width across flat: 34mm (1 11/32 in.) Torque for assembly: : Make up valve : 128N-m (13.0kgf-m) (94 lb-ft)

2.Reassembling multiple control valve To reassemble the multiple control valve, follow the above removal procedure in the reversed direction. Cautions regarding reassembling: ・ Clean and check all the parts. If a part is defective, replace or repair it. ・ Replace all the O-rings with new ones. ・ Apply a thin coat of hydraulic oil or grease to each part before reassembly. ・ Apply the specified torque to tighten each main part.

44-36

115Z Ⅳ -2

Boom Cylinder

HYDRAULIC 44

Boom Cylinder 11

2 12

15 16

17 22 5

20 18 19

22 1

4 9

115K44014

1.Cylinder tube 2.Rod 3.Piston 4.Rod cover 5.Bushing 6.Bushing 7.Piston nut (Width across flat 120mm) 8.Stop ring 9.Bolt 11.Wear ring 12.Seal set 15.O-ring 16.O-ring

17.Back-up ring 18.U-packing 19.Back-up ring 20.Buffer ring 21.Dust seal 22.Dust seal 23.Screw 24.Grease nipple 25.Wear ring

: 525kg (1,160 lbs) For torque values refer to "Hydraulic cylinder tightening torque".

44-37

Removing and Reinstalling Boom Cylinder

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Boom Cylinder 1.Removing boom cylinder (The illustration shows the left side of the machine.)

WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Raise the boom until it is horizontal, and then place a stand (A) under the boom to support it. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Use a stepladder or work platform, and do not stand on the machine.

a)Clean the area around the cylinder and piping. Note : Relieving residual pressure from pipe 1. Raise the boom. When the boom is approximately 30cm (1 foot) above stand (A), stop the engine. 2. Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. 3. Open the cap of the hydraulic tank to relieve the residual pressure.

Stand (A)

85K44038

2 3 1

1)Remove the pipe connection bolt (1) (4 pcs). Note : Cover the disconnected pipe with vinyl, plugs, or caps to protect them from dust, water and dirt. 2)Remove the pipe connection bolt (2) (3) (8 pcs). : Drain oil : Approx. 15 l (4 gal.) Note : Cover the disconnected pipe with vinyl, plugs, or caps to protect them from dust, water and dirt.

115V44002

3) Temporarily sling the boom cylinder. : Boom cylinder : 525kg (1,160 lbs) Note : Cover the disconnected pipe with vinyl, plugs, or caps to protect them from dust, water and dirt.

115K44016

44-38

Removing and Reinstalling Boom Cylinder

115Z Ⅳ -2

HYDRAULIC 44

4)Disconnect the grease hose (4) from the pin (6). Remove the bolt (5) to remove the pin (6).

WARNING When the pin is removed, the cylinder comes down resulting injury or death. To prevent such an accident, before removing the pin, make sure that the cylinder is supported by a sling.

6 5

115K44017

5) Temporarily sling the bottom side of the cylinder. Remove the lock bolt (7) for the pin (8). Remove the pin (8) using jack bolts. 7

5 6

115K44018

6) Lift the boom cylinder slowly, and lower it onto the ground.

2.Reinstalling boom cylinder To reinstall the boom cylinder, follow the above removal procedure in the reversed direction. Note : Be sure the pins accept grease after installation. 115K44019

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100mm (4.0 in.) before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-39

115Z Ⅳ -2

Bucket Cylinder

HYDRAULIC 44

Bucket Cylinder

14 13 12 24 15

22 6

18 19 6

6 RH ONLY

5 23

26 25

21 T1 7

10 9 T2

115Z Ⅳ 4403

1.Cylinder tube 2.Rod 3.Piston 4.Rod cover 5.Bushing 6.Bushing 7.Piston nut 8.Stop ring 9.Bolt 10.Spring washer 11.Wear ring 12.Back-up ring 13.Back ring

14.Slipper ring 15.O-ring 16.O-ring 17.Back-up ring 18.U-packing 19.Back-up ring 20.Buffer ring 21.Scraper ring 22.Dust seal 23.Stop ring 24.Wear ring 25.O-ring 26.Plug : Bucket cylinder : 245kg (540 lbs) For torque values refer to "Hydraulic cylinder tightening torque".

44-40

Removing and Reinstalling Bucket Cyl.

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Bucket Cylinder 1.Removing bucket cylinder WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Place the boom and bucket on the ground. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Use a step, and do not stand on the machine.

a)Clean the area around the cylinder and piping. Note : Relieving residual pressure from pipe 1. Lower the boom and bucket to the ground. 2. Stop the engine and move the bucket and boom levers back and forth. 3. Open the cap of the hydraulic tank to relieve the residual pressure. 2

1, 3

1)Disconnect the bucket positioner coupler (1) and then remove the rod (2) and the positioner switch (3).

115K44020

2)Disconnect the hoses (4). : Drain oil : Approx. 1 l (0.26 gal.) Note : Cover the disconnected hose and the cylinder with vinyl, cap or plugs to protect them from dust, water and dirt. 5

3)Disconnect the grease pipe (5). 4 115K44021

4) Temporarily sling the bucket cylinder (6). After that, remove the bolt (7) to remove the pin (8). : Bucket cylinder : 245kg (540 lbs)

115K44022

44-41

Removing and Reinstalling Bucket Cyl.

115Z Ⅳ -2

HYDRAULIC 44

5)Remove the grease pipe (9). Remove the lock bolt (10) for the pin (11) at the bottom side of the cylinder, and then remove the pin (11).

115K44023

6) Lift the bucket cylinder (5) slowly, and lower it onto the ground. 5

115V44003

44-42

Removing and Reinstalling Bucket Cyl.

115Z Ⅳ -2

HYDRAULIC 44

2.Reinstalling bucket cylinder To reinstall the bucket cylinder, follow the above removal procedure in the reversed direction. Note : Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation WARNING During service work, do not stand on the machine. Standing on tire, boom or linkage could cause accidents and serious injury or death. Use a step, ladder, or work platform and do not stand on the machine.

①Bleed the cylinder of air.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100mm before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

※5±2

１１５ＺＡ４４−０４７−４

②Adjust the bucket positioner so that the clearance between the switch and the rod is 5±2mm (0.12 〜 0.27 in.).

44-43

115Z Ⅳ -2

Steering Cylinder

HYDRAULIC 44

Steering Cylinder 13

14 15

16 17

18 24 3

19 20

23 6

23 11 22 1 23 4 9 8

115K44025

1.Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 8. Piston nut 9. Stop ring 10.Stop ring 11. Set screw 13.Wear ring

14. Square ring 15. Slipper ring 16.O-ring 17.O-ring 18. Back-up ring 19.U-packing 20. Back-up ring 22. Scraper ring 23.Dust seal 24. Buffer ring

: Steering cylinder : 80kg (180 lbs) For torque values refer to "Hydraulic cylinder tightening torque".

44-44

Removing and Reinstalling Steering Cyl.

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Steering Cylinder 1.Removing steering cylinder (The illustration shows the machine left hand side.)

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Place the boom and bucket on the ground. ・ Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line. ・ Open the cap of the hydraulic tank to relieve the internal pressure from the tank. ・ Place a "DO NOT START!" tag on the steering wheel.

5 6

a)Clean the area around the cylinder to be removed.

1 7

1)Remove the bolts (1) (4 pcs). : Drain : Approx. 2 l (0.5 gal.) Note : Cover the disconnected hose with vinyl, caps, or plugs to protect them from dust, water, and dirt.

115K44026

2)Remove the bolt (2) for the hose (3), the bolt (4) for the hose (5) at the bottom of the cylinder.

: Drain : Approx. 1 l (0.26 gal.) Note : Cover the disconnected hose and the cylinder with vinyl, cap or plugs to protect them from dust, water, and dirt. 3)Remove the bolt (6), and then remove the pipe (7).

115K44027

4)Remove the bolt (8), and then remove the pin (9). 5) Temporarily sling the cylinder. Remove the cylinder rod (10) from the pin section. Note : There are shims in the pin sections. Carefully store the removed shims, and correctly reinsert the shims when reinstalling the cylinder.

: Steering cylinder : 80kg (180 lbs)

115K44028

44-45

Removing and Reinstalling Steering Cyl.

115Z Ⅳ -2

HYDRAULIC 44

6)Push the rod (10) into the cylinder to shorten the length of the cylinder. : Oil will be drained from the oil port of the cylinder. Place a container at the oil port to catch the drained oil. Approx. 4 l (1 gal.)

115K44029

7)Remove the grease pipe (11) and the bolt (12) to remove the pin (13). Remove the pin (13).

11 Grease pipe

12 13

8)Remove the cylinder (14) from the pin section. Note : There are shims in the pin sections. Carefully store the removed shims, and correctly reinsert the shims when reinstalling the cylinder.

9) Lift the steering cylinder (14) slowly, and lower it onto the ground. 115K44030

44-46

Removing and Reinstalling Steering Cyl.

115Z Ⅳ -2

2.Reinstalling steering cylinder To reinstall the steering cylinder, follow the above removal procedure in the reversed direction. Note : Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation ①When reinstall the pins

IMPORTANT Insert shims so that the clearance between the chassis and the cylinder is 1.2mm or less. Place approximately the same number of shims under the cylinder as on top of the cylinder.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area could cause injury or death. When turning the steering wheel while engine is running, do not enter the articulation area of the machine. If a person is in the articulation area, do not start the engine.

②Bleed the cylinder of air

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or backup ring may be seized. Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100mm (4.0 in.) before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

44-47

HYDRAULIC 44

115Z Ⅳ -2

Hydraulic Cylinder Tightening Torque

HYDRAULIC 44

Hydraulic Cylinder Tightening Torque (S/N 11C3-5701〜) Boom cylinder 23 ・ 20

15 14 12, 13 21 1 22 16

11 ・ 8 7 10 6 5

１１５Ｋ４２０２０−１

: Tightening torque #16 ・・・・・ 9807N-m(1000kgf-m)(7235Ib-ft) #18 ・・・・・ 843N-m(86kgf-m)(622Ib-ft)

Bucket cylinder 23 ・ 20

22 16 15 14 12 13 14 21 1 3

8 14・19 7 6 4 9 17 5

20・23

25・26

27・28 Gauge port PF1/4(Right side)

６５Ａ４２０３４

: Tightening torque #16 ・・・・・ 5394〜5884N-m(550〜600kgf-m) (3979〜4340Ib-ft) #25 ・・・・・ 735 〜 883N-m(75 〜 90kgf-m)(543 〜 651Ib-ft)

Steering cylinder 23 ・ 20

16 22 15

14 13 12

11 17 5 6 4 9・ 10 24

23 ・ 20

１１５Ｋ４２０２０−２

: Tightening torque #4 ・・・・・・ 2354〜2550N-m(240〜260kgf-m) (1740〜1880Ib-ft) #16 ・・・・・ 1177〜1373N-m(120〜140kgf-m) (868〜1010Ib-ft) 44-48

1. Piston 2. Piston rod 3. Cylinder tube 4. Rod cover 5. Dust seal 6. Backup ring 7. U-packing 8. Buffer ring 9. Bushing 10. Backup ring 11. O-ring 12. Slipper ring 13. Square ring 14. O-ring 15. Wear ring 16. Piston nut 17. Stop ring 18. Bolt 19. Backup ring 20. Dust seal 21. Wear ring 22. Stop ring 23. Bushing 24. Set screw 25. Bolt 26. Washer 27. O-ring 28. Plug

Disassembling and Reassembling Hyd. Cyl.

115Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Hydraulic Cylinder 1.Disassembling hydraulic cylinder Note : The bucket cylinder disassembling procedure is described below. For other cylinders, follow the same procedure. 1) Install the bottom side of the cylinder to the repair stand.

Repair stand

2)Put the matchmarks on the rod cover (1) and the cylinder tube (2). Remove the rod cover bolt (3).

Matchmark

: Bolt : 883N-m (90.0kgf-m) (651 lb-ft) (Bucket cylinder)

2 1

3)Remove the piston rod assembly (4) from the cylinder tube. 4

: Hydraulic oil will be drained, so place a container to receive the drain oil.

90Z Ⅳ 4408

4)Remove the cylinder tube from the repair stand and install the rod assembly (4) to the repair stand and support the rod as shown in the figure.

Repair stand

Wooden block

44-49

Disassembling and Reassembling Hyd. Cyl.

115Z Ⅳ -2

HYDRAULIC 44

5)Remove the stop ring (5) and put matchmarks on the rod and the piston nut for alignment with the stop ring holes.

Matchmark

6)Use a hydraulic jack or hydraulic cylinder to loosen the piston nut (6). Tightening torque Bucket cylinder : 5,884N-m (600kgf-m) (4,341 lb-ft)

6 C

Hydraulic jack

Hydraulic cylinder

7)Remove the piston nut (6), and then remove the piston (7) from the piston rod (4). 6

8)Remove the wear ring (8), the back-up ring (20), the square ring (back ring) (9), the slipper ring (10), the O-ring (11) and the wear ring (12). (There is no wear ring (12) for steering cylinder.)

20 10 20 12

11 (Boom cylinder) (Bucket cylinder)

44-50

11 (Steering cylinder)

Disassembling and Reassembling Hyd. Cyl.

115Z Ⅳ -2

HYDRAULIC 44

9)Remove the rod cover (1) from the piston rod (4). 1

10)Remove the scraper ring (13), back-up ring (14), U-packing (15), buffer ring (18), back-up ring (16) and the O-ring (17) from the rod cover (1).

For boom and bucket cylinder

2.Reassembling hydraulic cylinder To reassemble the hydraulic cylinders, follow the above removal procedure in the reversed direction. Note : Refer to page 44-52 for the cautions when reinstalling.

44-51

Disassembling and Reassembling Hyd. Cyl.

115Z Ⅳ -2

HYDRAULIC 44

3.Cautions regarding reassembling Before starting work: a)Be sure to replace all the seals and packings. b)Clean and check all the parts. If a part is damaged, replace it. c) Before reassembling the parts, apply a coat of hydraulic oil to the parts.

CAUTION Hot oil can cause injury or burns. Avoid contact with hot oil.

Note : Put the slipper ring (10) into hot oil to heat the ring to 120 to 150 ℃ . (This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston. Therefore, heat the slipper ring to expand its inner diameter for easy attachment.) : Attach the slipper ring while taking care not to extremely expand it. : After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

Note : Caulk the scraper ring (13) at four points to prevent the seal from coming out. Note : Before installing the back-up ring (2) and the O-ring (3), heat the back-up ring. (This is because the inner diameter of the back-up ring is smaller than the outer diameter of the rod cover. To easily attach the back-up ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.) Be careful not to extremely expand the back-up ring. After installation, wait until the back-up ring is cooled, and then insert the rod cover into the cylinder tube. Note : Reinstall the rod cover of the steering cylinder, screw the rod cover using a spanner wrench. Screw in and tighten the set screw. Caulk the set screw. : 2,550N-m (260kgf-m) (1,881 lb-ft)

44-52

Disassembling and Reassembling Hyd. Cyl.

115Z Ⅳ -2

HYDRAULIC 44

Note : Caulk the rod cover (1) at 4 points to prevent the scraper ring (13) coming out.

Caulking

13 65K44067

Caulking 70V44005

44-53

115Z Ⅳ -2

Pilot Valve

HYDRAULIC 44

Pilot Valve For bucket control

Neutral

1 Dump

Roll back

For bucket control

For boom control

8 2

To tank port

4 5 6

From pump port

85W4211

To MCV oil packs

８５Ｗ４２１８

View from the rear

For boom control

Raise

Neutral

Down

1. Lever 2. Disc 3. Push rod 4. Spring seat 5. Spring for secondary pressure 6. Return spring 7. Spool 8. Detent magnet solenoid

Float

To tank port ８５Ｗ４２１９

44-54

115Z Ⅳ -2

Pilot Valve Tightening Torque

HYDRAULIC 44

Pilot Valve Tightening Torque : Tightening torque T1 : 29N-m (3.0kgf-m) (22 lb-ft) T2 : 36N-m (3.7kgf-m) (27 lb-ft) T3 : 17N-m (1.7kgf-m) (12 lb-ft) T4 : 29N-m (3.0kgf-m) (22 lb-ft) T5 : 29N-m (3.0kgf-m) (22 lb-ft) T6 : 17N-m (1.7kgf-m) (12 lb-ft) T7 : 42N-m (4.3kgf-m) (31 lb-ft) T8 : 12N-m (1.2kgf-m) (9 lb-ft)

For boom control Front

For bucket control

: Pilot valve 9.5kg (21 lbs) : L1 : Screw lock agent (Three Bond1327)

T5 T6 L1

T6 L1

T4 T4 T4

90K44090

44-55

application

Removing and Reinstalling Pilot Valve

115Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Pilot Valve 1.Removing pilot valve WARNING

Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. In addition, apply the parking brake. ・ Lower the bucket onto the ground, and then relieve the internal pressure from the line. ・ Relieve the internal pressure from the hydraulic tank. 85K44032

1)Open the cab door (right). Remove the control cover (1). 2

2)Disconnect the electrical line (2) of QUAD (PUS) switch. 3)Disconnect the electrical line (3) of pilot valve. 3

85K44033

4)Remove the knobs (4), and then separate QUAD (PUS) switch (5). Note : Switch design may vary slightly.

5 85K44034

5)Remove the retainer bolts (6) from the cover (5), and then shift the cover to the front. Remove the boot (6) and cover (7) (8) (9) (10).

10 8 9 6

7 85K44035

44-56

Removing and Reinstalling Pilot Valve

115Z Ⅳ -2

HYDRAULIC 44

6)Disconnect the electric line coupler from the pilot valve, and disconnect all the hoses (11). : Drain oil : Approx. 1 l (0.3 gal.) Note : Before disconnecting the electric coupler and hoses, be sure to put match marks on them. After disconnection, cover the disconnected hoses with vinyl, caps, or plugs to protect them from dust and dirt.

11 11

: Bolt : 34N-m (3.5kgf-m) (25 lb-ft)

85K44036

7)Disconnect the arm (12) and rod (13) located on the upper part at the ball joint. 8)Disconnect the rod (13) and lever (14) at the ball joint.

12 13

9)Remove the pilot valve retainer bolt (15), and then remove the pilot valve assembly (16). 14

: Pilot valve : 9.5kg (21 lbs)

14 15 16 85K44037

2.Reinstalling pilot valve To reinstall the pilot valve, follow the removal procedure in the reversed direction. Note : After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage. If the oil level is too low, add hydraulic oil to the tank.

44-57

Disassembling and Reassembling P / V

115Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Pilot Valve 1.Disassembling pilot valve Note :・Put plug on each port then clean the outer surface of the vlave. ・Place the removed parts, in order, on a clean paper or cloth. ・Carefully disassemble the pilot valve so that the parts are not scratched.

1)Clamp the pilot valve in a vise. Pull up the boot (1) to remove it from the cover (2).

For boom control Front For bucket control

70K44045

2) Loosen the lock nut for the solenoid (3) and then remove the solenoid from the cover (2). Torque for assembly : : Solenoid : 42N-m (4.3kgf-m) (31 lb-ft) Note : Before removing the solenoid (3), measure the distance "A". A

Lock nut

3 4

70K44046

７０ＺⅣ４２０７

Carefully store the ball (4).

44-58

Disassembling and Reassembling P / V

115Z Ⅳ -2

HYDRAULIC 44

3)Remove the socket bolt (5). Torque for assembly: : Bolt : 29N-m (3.0kgf-m) (22 lb-ft)

5 6 7

4)Remove the lever (6) from the disc (7).

70K44047

5) Loosen the socket bolt (8).

Torque for assembly: : Retainer bolt : 17N-m (1.7kgf-m) (12 lb-ft) : Screw lock agent (Three Bont 1327) application 6)Remove the cam shaft (9). Note :・Temporarily install the socket bolt (5) into the disc. ・Pull the cam shaft to the direction shown.

9 70K44048

7)Pull up the socket bolt (5) with the disc (7) and remove it. 8)Put match mark on the cover (2) and the case assembly. Remove the socket bolt (10).

70K44049

9)Remove the cover (2) from the case assembly. 2

70K44050

44-59

Disassembling and Reassembling P / V

115Z Ⅳ -2

10)Remove the plug (11) together with the push rod (12). Note :・Carefully store the spring and spring seat in the push rod. ・Carefully remove the plug so that the parts are not scratched. ・In case the plug(11)does not come out, use the screw driver to remove it.

HYDRAULIC 44

11 12 13 14

CAUTION Be careful! The spring inside the case assembly may spring out and hit your face. Do not point the plug assembly toward your face.

70K44051

11)Remove the springs (15) (16) from the case assembly (14).

70K44052

Note : When installing, carefully install the spool assembly so that the end of the spool does not hit the hole corner in the case assembly. Carefully install into the case

70ZA4409

12)Clamp the case assembly (14) in the vise up side down. Remove the socket bolt (17), then remove the plate (18) from the case assembly. Torque for assembly: : Bolt : 29N-m (3.0kgf-m) (22 lb-ft)

17 18

14 70K44053

44-60

Disassembling and Reassembling P / V

115Z Ⅳ -2

HYDRAULIC 44

13)Remove the spring (19) and the spring seat (20) from the push rod (12). Note : The spring (19) and the spring seat (20) are used in the following position. Boom down/Float 70Z Ⅳ〜115Z Ⅳ Boom raise 70Z Ⅳ〜85Z Ⅳ Roll back 70Z Ⅳ〜85Z Ⅳ Dump 70Z Ⅳ〜85Z Ⅳ

14)Remove the push rod (12) from the plug (11).

20 70K44054

15)Push down the spring seat (23), and then remove the plane washer (24). Note :・Carefully remove the plane washer so that the spool is not scratched. ・Do not push the spring seat (23) down more than 4mm.

24 23

25 26

16)Remove the spring seat (23), spring (25), plane washer (24) and the shim from the spool (22). Note : Shim for adjusting secondary pressure. Some spool need shim, but others may not need it.

2.Reassembling pilot valve To reassemble the pilot valve, follow the above disassembly procedure in the reversed direction. Note :・Clean and check all the parts. If a part is defective, replace or repair the part. ・Replace all the O-rings and seals with new ones. ・Apply the specified torque to tighten each main parts. ・Apply a thin coat of hydraulic oil or grease to each part before reassembly. ・Measure the resistance of each coil magnet assembly. The resistance should be 238Ω ±10 at normal room temperature (20 ° C). If measured in extremely low temperatures the resistance will be less. At operating temperature the resistance will be higher. Cautions regarding reassembling : Install the plane washer (24) so that the plane washer sharp edge side comes to the top position. Note : Do not push the spring seat (23) down more than 4mm.

44-61

22 70K44055

Sharp edge side

70ZA4408

115Z Ⅳ -2

Pilot Relief Valve Unit

HYDRAULIC 44

Pilot Relief Valve Unit 1.Removing pilot relief valve unit WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Relief the internal pressure from the hydraulic tank. ・ Place a "DO NOT START!" tag on the steering wheel.

1)Open the cover (1) behind the cab. 1

115K44036

2)Put matchmarks on the hoses (2), then disconnect them. Remove the bolt (3) and the relief valve. : Cover the disconnected hoses with vinyl, caps, or plugs to protect them from dust, water, and dirt.

2 To Pilot valve To Multiple control valve

2.Reinstalling pilot relief valve unit To reinstall the pilot relief valve unit, follow the above removal procedure in the reversed direction.

Caution regarding reinstallation: ①When reassembling the pilot relief valve unit, after the completion of reinstallation, be sure to check the pressure. Refer to Section 03 for the pressure check procedure. Refer to Section 03 for the standard measurement valve. ②Start the engine and check that the boom properly works. ③Check for oil leakage. 44-62

To Unloader valve

To Steering valve 115K44034

HYDRAULIC GROUP 45 Service standard Steering Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 45-2 Hydraulic Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 45-3 Pilot Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 45-4

45-1

115Z Ⅳ -2

Steering Valve

HYDRAULIC 45

Steering Valve

Steering valve

１１５ＺＡ４５０１

Tightening torque No. 1

Unit : N-m (kgf-m) (lb-ft) Item

Steering valve retainer bolt

45-2

Standard value

Remedy

216 (22.0) (159)

Tightening

115Z Ⅳ -2

Hydraulic Cylinder

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder (Note) The cylinder showin in the above figure is the boom cylinder.

3 115K42020-1

Steering cylinder

(Note) The cylinder showin in the above figure is the steering cylinder.

3 115K42020-2

1. Clearance between rod and bushing

Unit : mm (in.) Judgment standard

No.

Standard dimension of rod dia.

Item

0.096 (0.0037)

-0.090 (-0.0035)

+0.060 (+0.0023)

0.290 (0.0114)

-0.036 (-0.0014)

+0.195 (+0.0076)

0.096 (0.0037)

-0.090 (-0.0035) -0.030 (-0.0011)

+0.060 (+0.0023) +0.110 (+0.0043)

0.285 (0.0112) 0.030 (0.0011)

-0.076 (-0.0030)

0 (0)

0.186 (0.0073)

〜

+0.200 (+0.0078)

〜〜

〜

φ 70 ( φ 2.7559)

Steering cylinder

-0.036 (-0.0014)

〜

Bucket cylinder

clearance

〜

φ 100 ( φ 3.9370)

Bushing

〜

Boom cylinder

Limit

Standard

Rod

〜

φ 120 ( φ 4.7244)

Standard value

Solution

Bushing

Clearance

+0.300 (+0.0118)

0.390 (0.0153)

Replacement

+0.295 (+0.0116)

0.385 (0.0151)

Replacement

+0.210 (+0.0082)

0.286 (0.0112)

Replacement

2. Tightening torque No.

Item Piston nut tightening torque

N-m (kgf-m) (lb-ft) Piston nut width across flat mm (in.)

Rod cover bolt tightening torque N-m (kgf-m) (lb-ft)

Boom cylinder

Bucket cylinder

Steering cylinder

M85 × 2 8,826 (900) (6,512)

M76 × 2 5,884 (600) (4,341)

M42 × 1.5 1,373 (140) (1,013)

120 (4.72)

110 (4.33)

65 (2.56)

843 (86) (622)

883 (90) (651)

(Rod cover) 2,550 (260) (1,881)

45-3

115Z Ⅳ -2

Pilot Valve

HYDRAULIC 45

Pilot Valve

212-1

70V45002

Judgement standard No.

Item Wear 1mm

212-1

Push rod

Solution

(φ7)

45-4

Standard value

Allowable limit

36mm

35mm

Replacement

BRAKE GROUP 54 Disassembly and Reassembly Brake Valve Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-3 Brake Valve Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-4 Removing and Reinstalling Brake Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-5 Disassembling and Reassembling Brake Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-8 Hydro-master ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-10 Hydro-master Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-11 Removing and Reinstalling Hydro-master ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-12 Disassembling and Reassembling Hydro-master ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-14 Accumulator ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-17 Accumulator Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-17 Removing and Reinstalling Accumulator ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-18 Disassembling and Reassembling Accumulator ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-19 Jigs ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-23 Procedure for Charging Nitrogen Gas ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-25 Unloader Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-27 Unloader Valve Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-28 Removing and Reinstalling Unloader Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-29 Disassembling and Reassembling Unloader Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-30 Auto-Adjuster Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-32 Auto-Adjuster Valve Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-33 Removing and Reinstalling Auto-Adjuster Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-34 Disassembling and Reassembling Auto-Adjuster Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-35 Removing and Reinstalling Service Brake ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-36 Oil Cylinder for Parking ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-37

54-1

Oil Cylinder Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-37 Removing and Reinstalling Oil Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-38 Disassembling and Reassembling Oil Cylinder ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-41 Parking Brake Assembly ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-43 Parking Brake Assembly Tightening Torque ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-44 Removing and Reinstalling Parking Brake ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-45 Disassembling and Reassembling Parking Brake ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 54-47

54-2

115Z Ⅳ -2

Brake Valve Assembly

BRAKE 54

Brake Valve Assembly Accumulator port

Accumulator port

ｋｇｍ

Hydro-master port

Hydro-master port 97ZA5206

Tank port 23 22

30 24

20 19 18

21 14

26 32

25 31

28 29 33

4 5 6 7

15 1

97ZA5207

1. Body

12. Bolt

23. Spring

2. Spool

13. Cover

24. Bolt

3. Plunger

14. O-ring

25. Spring washer

4. Bolt

15. O-ring

26. Retainer

5. Spring seat

16. Cover Assembly

27. Case

6. Spring

17. Bolt

28. Oil seal

7. Spool

18. Spring

29. Ring

8. Plunger

19. Stop ring

30. Input spool

9. Spring seat

20. Plate

31. Dust cover

10. Stop ring

21. Spring seat

32 Push rod

11. Spring

22. Spring

33. Stop ring

54-3

10 11

115Z Ⅳ -2

Brake Valve Tightening Torque

BRAKE 54

Brake Valve Tightening Torque

T1 L1 T2 T4

97ZA5401

:Tightening torque T1 : 9N-m (0.9kgf-m) (6.5 lb-ft) width across flats : 10mm (0.393 in.) T2 : 25N-m (2.6kgf-m) (19 lb-ft)

width across flats : 6mm (0.236 in.)

T3 : 34N-m (3.5kgf-m) (25 lb-ft)

width across flats : 14mm (0.551 in.)

T4 : 49N-m (5.0kgf-m) (36 lb-ft)

width across flats : 8mm (0.315 in.)

L1 : Screw lock agent application (Three Bond 1327)

54-4

Removing and Reinstalling Brake Valve

115Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Brake Valve 1.Removing brake valve WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

Before starting work: ・ Stop the engine. Depress the brake pedal many times until there is no brake pressure. ・ Remove the cover under the left deck. ・ Prepare a container to catch drained oil.

1)Disconnect the rod (1) at the ball joint (2) part and remove the return spring (3).

Brake valve

1 2

2)Remove the seat and the seat stand and then disconnect the hoses (4) (5) (6).

115K54001

4 5 6

10 Brake valve

7 115K54002

Valve unit

3)After disconnecting the hoses (7) (8), remove the bolts (9) and then remove the brake valve (10). Note : Cover the disconnected pipes and the hoses with clean vinyl to protect them from dust and dirt.

9 115K54003

54-5

Removing and Reinstalling Brake Valve

115Z Ⅳ -2

2.Reinstalling brake valve To reinstall the brake valve, follow the above removal procedure in the reversed direction. After reinstallation: a)Check all the pipe joints for oil leakage. b)Adjust the brake pedal linkage. c) Completely bleed the brake line of air following the procedure of Section 53. d)Check the brake performance following the procedure of Section 53.

54-6

BRAKE 54

Removing and Reinstalling Brake Valve

3.Adjustment linkage

procedure

brake

115Z Ⅳ -2

BRAKE 54

pedal (Standard released condition) Pedal depressed condition

WARNING Improper adjustment of the linkage could cause serious injury or death. Adjust the linkage properly as follows.

R. H. pedal

Reference fig.

1)Adjustment of right brake pedal linkage. ① Adjust the adjusting rod (12) so that the stroke play of the adjusting (12) is between 0 and 1.0mm (0.039 in.) under the standard released condition. ② Adjust the bolt (A) so that the valve stroke is 20mm (0.787 in.) under the pedal depressed condition. 2)Adjustment of left brake pedal linkage. ① After adjusting the right brake pedal, adjust the adjusting bolt (13) so that the stroke play of the rod (12) is 0 and 1.0mm (0.039 in.). 〔Adjust the bolt (13) so that the bolt head contacts to the link (14).〕 ② Adjust the bolt (B) so that the valve stroke is 20mm (0.787 in.) under the pedal depressed condition.

Valve stroke

97ZA5402

(Standard released condition)

L. H. pedal

4 13 14 97ZA5403

3)After adjusting the right and left brake pedal linkage, install the return spring (4).

Reference fig. : 244mm

Standard length of engagement

Standard length of engagement : 17mm Min. 11mm

12 3 97ZA5406

54-7

115Z Ⅳ -2

Brake Valve

Disassembling and Reassembling Brake Valve 1.Disassembling brake valve IMPORTANT ・ Clean the outer surface of the brake valve. ・ Put match marks on the parts before disassembly. ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

Refer to the drawing of the brake valve assy when disassembling. 1)Remove the dust cover (31) and the push rod (32). 2)Remove the bolts (17) and then remove the cover (16) and the O-ring (15). Torque for assembly : Bolt (17) 49N-m (5.0kgf-m) (36 lb-ft) width across flats: 8mm (0.315 in.) 3)Remove the stop ring (19), the plate (20), the spring seat (21), the spring (18) and (23). 4)Clamp the flats of the input spool (30) in a vise or the like, then remove the bolt (24) and the case (27). Slowly pull out the input spool (30). Torque for assembly : Bolt (24) 34N-m (3.5kgf-m) (25 lb-ft) width across flats: 14mm (0.551 in.) : Screw lock agent application (Three bond 1327) 5)Remove the retainer (26) and the spring (22) from the case (27). 6)Remove the stop ring (33) and then remove the ring (29) and the oil seal (28). 7)Remove the bolt (12) and then remove the cover (13), the spring (11) and the O-ring (14). Torque for assembly : Bolt (12) 25N-m (2.6kgf-m) (19 lb-ft) width across flats: 6mm (0.238 in.) 8)Slowly pull out the spool (7) and the spool (2) then remove the plunger (8) and the plunger (3) from each spool. 54-8

BRAKE 54

115Z Ⅳ -2

Brake Valve

9)Remove the bolt (4) from the spool (7) and then remove the spring (5), the spring (6) and the stop ring (10) on the other side of the spool. Torque for assembly : Bolt (4) 9N-m (0.9kgf-m) (6.5 lb-ft) width across flats: 10mm (0.394 in.)

2.Reassembling brake valve To reassemble the brake valve, follow the above disassembly procedure in the reversed direction.

3.Cautions regarding reassembly Notes : ・Clean the metal parts using approved brake cleaning solvent, and then blow the compressed air to dry them. ・After cleaning, check the parts for damage and wear. If a part is defective, replace it with a new one. ・Replace all the O-rings and seals with new ones. Refer to the brake valve assy drawing and the tightening torque value when reassembling. Notes : ・Take measures to prevent the entry of foreign matter during reassembly. ・Apply a thin coating of hydraulic oil to all the sliding surfaces of the body such as plunger, spool, etc.. ・Slide the spool 2 or 3 times to confirm that it moves smoothly. ・Confirm that the spring is in proper contact with the spring seat when assembling the spring. Driving jig for oil seal (28) φ40 (1.575 in.)

φ22.4 (0.882 in.)

９７ＺＡ５４０５

54-9

BRAKE 54

115Z Ⅳ -2

Hydro-master

BRAKE 54

Hydro-master 27

ｋｇｍ

25 24 23 Primary chamber port from brake valve

97ZA5208

13 6

21 22

From brake oil tank

Secondary chamber port from brake cylinder port 28

20 2

1 3

5 8

15 16

97ZA5209

1. Body

11. Snap ring

21. O-ring

2. Piston

12. Spring seat

22. Piston

3. U-packing

13. Spring

23.Washer

4. O-ring

14. Spring

24. Spring

5. O-ring

15. Collar

25. O-ring

6. Valve seat

16. O-ring

26. Plug

7. Ball

17. Spring seat

27. Bolt

8. Spring seat

18. Bleed screw

28. Plug

9. Spring

19. Switch assembly

29. Orifice

20. Cover

30. Plug

10. Spring seat

54-10

Hydro-master Tightening Torque

115Z Ⅳ -2

BRAKE 54

Hydro-master Tightening Torque T6 T5

T2 T3 L 1

T1 L 1

115ZA5403

:Tightening torque T1 : 167N-m (17.0kgf-m) (122 lb-ft)

width across flats : 14mm (0.551 in.)

T2 : 15N-m (1.5kgf-m) (11 lb-ft)

width across flats : 5mm (0.197 in.)

T3 : 59N-m (6.0kgf-m) (43 lb-ft)

width across flats : 8mm (0.315 in.)

T4 : 83N-m (8.5kgf-m) (61 lb-ft)

width across flats : 10mm (0.394 in.)

T5 : 11N-m (1.1kgf-m) (8 lb-ft)

width across flats : 28.6mm (1.126 in.)

T6 : 49N-m (5.0kgf-m) (36 lb-ft)

width across flats : 8mm (0.315 in.)

T7 : 12N-m (1.2kgf-m) (9 lb-ft)

width across flats : 10mm (0.394 in.)

L1 : Screw lock agent application (Three bond 1327)

54-11

Removing and Reinstalling Hydro-master

115Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Hydro-master 1.Removing hydro-master WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. ・ Use a stepladder or the like to reach a high position of the machine. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

Before starting work: ・ Stop the engine. Depress the brake pedal many times until there is no brake pressure. ・ Prepare a container to catch drained oil. 3

1)Remove two bolts (2) of the plate (1) and four bolts (4) of the deck (3). 1

115K54007

2)Open the plate (1) and disconnect the hose bands (5) (2 places) and then remove the deck (3).

115K54008

3)Remove the hoses (6), (7), (8), wiring harness of the pressure diff. indicator (9), wiring harness of the pressure switch (10) and remove the bolts (11) and then remove the hydro-master. Note : Cover the disconnected hose and the pipe with clean vinyl to protect them from dust and dirt.

7 6 10

115K54009

54-12

Removing and Reinstalling Hydro-master

115Z Ⅳ -2

2.Reinstalling hydro-master To reinstall the hydro-master, follow the above removal procedure in the reversed direction. After reinstallation: a)Check all the pipe joints for oil leakage. b)Completely bleed the brake line of air following the procedure of Section 53. c) Check the brake performance following the procedure of Section 53.

54-13

BRAKE 54

115Z Ⅳ -2

Hydro-master

Disassembling and Reassembling Hydro-master 1.Disassembling hydro-master IMPORTANT ・ Clean the outer surface of the hydro-master. ・ Put match marks on the parts before disassembly. ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

Refer to the drawing of the hydro-master when disassembling.

WARNING The inner spring could spring out causing injury. To prevent this, press and hold the cover (20) and while holding the cover (20), remove the bolts (27) slowly.

1)Remove the bolts (27) while holding the cover (20) and remove the cover (20) slowly. Torque for assembly : Bolt (27) 49N-m (5.0kgf-m) (36 lb-ft) width across flats: 8mm (0.315 in.) 2)Remove the switch assembly (19). Torque for assembly : Switch assembly 11N-m (1.1kgf-m) (8 lb-ft) width across flats: 28.6mm (1.126 in.) 3)Remove the plug (26), the spring (24), the washer (23) and the piston (22), and then remove the O-ring (25) of the plug (26) and the O-ring (21) of the piston (22). Torque for assembly : Plug 83N-m (8.5kgf-m) (61 lb-ft) width across flats: 10mm (0.394 in.) 4)Remove the plug (30) of the cover (20) and then remove the orifice (29). Torque for assembly : Plug 59N-m (6.0kgf-m) (43 lb-ft) width across flats: 8mm (0.315 in.) Orifice 15N-m (1.5kgf-m) (11 lb-ft) width across flats: 5mm (0.197 in.) : Screw lock agent application (Three bond 1327) 5)Remove the springs (13), (14), the collar (15), the O-ring (16) and the spring seat (12).

54-14

BRAKE 54

115Z Ⅳ -2

Hydro-master

6)Remove the piston (2). Note : Apply air pressure of 49 〜 98kPa(0.5 〜 2 1.0kgf/cm ) (7〜14 psi) through the brake valve port to remove the piston.

WARNING The piston could pushing out with high air pressure causing injury. To prevent this, do not apply air pressure higher than 98kPa (1.0kgf/cm 2) (14 psi) to remove the piston.

7)Remove the stop ring (11), the spring seat (10), the spring (9), the spring seat (8), the steel ball (7) and the valve seat (6). 8)Remove the U-packing (3) and the O-ring (4). 9)Remove the bleed screw (18) and the plug (28). Torque for assembly : Bleed screw 12N-m (1.2kgf-m) (9 lb-ft) width across flats: 10mm (0.394 in.) Plug 167N-m (17.0kgf-m) (122 lb-ft) width across flats: 14mm (0.551 in.) : Screw lock agent application (Three bond 1327)

54-15

BRAKE 54

Hydro-master

115Z Ⅳ -2

2.Reassembling hydro-master To reassemble the hydro-master, follow the above disassembly procedure in the reversed direction. Notes : ・Clean the metal parts using approved brake cleaning solvent, and then blow the compressed air to dry them. ・After cleaning, check the parts for damage and wear. If a part is defective, replace it with a new one. ・Replace all the O-rings and seals with new ones and apply a coat of hydraulic oil to them before reassembling. ・While reassembling the hydro-master, take care not to allow dust, dirt, or foreign material into the body. Refer to the hydro-master drawing and the tightening torque value when disassembling.

54-16

BRAKE 54

115Z Ⅳ -2

Accumulator

BRAKE 54

Accumulator 11 10 9

12 4

8 6

5 6

97K52003

1.Cylinder 2.Top cover 3.Oil port 4.Nut

5.Piston 6.O-ring 7.Back-up ring 8.Seal

9.Core 10. Seal washer 11. Cap 12. Spring pin

Accumulator Tightening Torque

T3 T2 T1 T3

:Tightening torque T1 : 15N-m (1.5kgf-m) (11 lb-ft) T2 : 0.5N-m (0.05kgf-m) (0.4 lb-ft) T3 : 206N-m (21.0kgf-m) (152 lb-ft) 115K54010

54-17

115Z Ⅳ -2

Removing and Reinstalling Accumulator

BRAKE 54

Removing and Reinstalling Accumulator 1.Removing accumulator Refer to Section accumulator.

for

the

location

the

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. ・ Use a stepladder or the like to reach a high position of the machine.

Before starting work: ・ Stop the engine. Depress the brake pedal many times until there is no brake pressure. ・ Prepare a container to catch drained oil.

3 4

1)Remove the hose (1). 5

2)Remove the nut (2), bands (3), the rubber sheet (4) and then remove the accumulator (5). : 16kg (35 lbs)

2 1

2.Reinstalling accumulator To reinstall the accumulator, follow the above removal procedure in the reversed direction. Note : After reinstallation, check all the pipe- joints for oil leakage.

54-18

115K54011

115Z Ⅳ -2

Accumulator

BRAKE 54

Disassembling and Reassembling Accumulator 1.Disassembling accumulator WARNING Improper gas pressure could cause serious injury or death. To prevent such an accident, observe the following item : ・ Before measuring the gas pressure or charging the gas, stop the engine and release the oil pressure in the line by depressing the brake pedal until there is no brake pressure.

IMPORTANT ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

Before starting work: ・ Clean the outer surface of the accumulator.

1)Remove the cap (11) of the gas valve (9) and install the charging valve to the gas valve (9), then bleed the gas completely from the accumulator. 2) Insert the core tool to the core and turn counterclockwise. And then remove the core (9). (Refer to the page 54-23 for the core tool) Torque for assembly : Core 0.5N-m (0.05kgf-m) (0.36 lb-ft) Note : Do not reused the core once used, always use a new one.

54-19

11 10 9

12 4 2 6 1

7 8 6 7 5 6 3

97K54016

115Z Ⅳ -2

Accumulator

BRAKE 54

3)Remove the spring pin (12) and then remove the nut (4), oil port (3) by using the jig (A).

3 or 4

Accumulator

Jig (A) 97K54017

4)Remove the top cover (2) by using the jig (B).

Jig (B)

2 95K54018

5)Remove the piston (5) by using the rod, and then remove the seal from the top cover (2), oil port (3) and piston (5).

IMPORTANT ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

Rod

5 97K54019

54-20

Accumulator

115Z Ⅳ -2

BRAKE 54

2.Reassembling accumulator Before starting work: ・ Clean the parts. 1. Install the seal to the piston (5). 5

1)Apply grease in the seal groove of the piston (5).

× : apply grease

97K54020

2)Before installing, heat the back up ring (7) up to 80〜100 ° C. Install the back up ring (7) as illustrated.

97K54021

3)Apply grease a bit on the O-ring (6) and install it.

6 97K54022

4)Before installing, heat the slider seal (8) up to 80 〜100 ° C. Install the slider seal (8).

97K54023

5)Apply grease on the seal.

97K54024

54-21

Accumulator

115Z Ⅳ -2

BRAKE 54

2. Apply grease a bit in the inner surface of piston guide. Install the piston guide to the cylinder (1).

Piston guide

97K54025

3. Insert the piston (5) to the piston guide, and then press in the hydraulic cylinder.

Hydraulic cylinder

97K54026

4. Apply grease a bit on the O-ring (6). Install them to the top cover (2) and the oil port (3).

5. Install the top cover (2), nut (4) and the oil port (3) into the cylinder (1). Torque for assembly : ♯ 3,4・・・206N-m (21.0kgf-m) (152 lb-ft)

6. Make a hole (φ4 and 8mm deep) on the cylinder 12mm from the edge of the cylinder. Install the spring pin (12).

12mm 8mm

7. Apply grease a bit in the seal of core. Turn it clock wise by using the core tool, and tighten. Torque for assembly : ♯ 9・・・・0.5N-m (0.05kgf-m) (0.4 lb-ft)

54-22

97K54027

115Z Ⅳ -2

Jigs

BRAKE 54

8. Charge nitrogen gas after reassembly. Refer to "Procedure for charging Nitrogen Gas".

9. Install the seal washer (10) and cap (11). Torque for assembly : ♯ 11・・15N-m (1.5kgf-m) (11 lb-ft)

Jigs 1.Core tool 5V1 Repair thread(core thread)

Section A-A

2.2

4.5

φ 21

51 ± 0.5

97K54028

Thread size 5V1・・φ 5.2 × 0.705 (For auto mobile tire valve)

54-23

115Z Ⅳ -2

Jigs

BRAKE 54

φ 14

2.Jig (A) : For nut and oil port removal and reinstallation

φ6

φ 40 φ 90

300 97K54029

3.For top cover removal 180

5/8-18UNF

97K54030

85 36

φ 114.3

φ 100

φ 110

No bur

φ 102

4.Piston guide

φ 14

φ 28

97K54031

54-24

Procedure for Charging Nitrogen Gas

115Z Ⅳ -2

BRAKE 54

Procedure for Charging Nitrogen Gas 1

・ Nitrogen gas charging tools :

1. Charging valve assembly 1-1 Handle (for adjusting screw) 1-2 Handle (for bleeder plug) 1-3 Valve body 2 2. Pressure gauge (50kg/cm (710 psi)) 3. Hose assembly 4. Nitrogen (N2) gas cylinder

1-1

1-3

1-2

Accumulator M9 Ⅱ ILLUST D

Charging valve installation

1.Charging nitrogen gas WARNING Improper gas pressure can cause serious injury or death. To prevent such an accident, observe the following item : ・ Before measuring the gas pressure or charging the gas, stop the engine and release the oil pressure in the line by depressing the brake pedal until there is no brake pressure.

1) Turn the handle (1-1) counterclockwise until it stops turning. 2) Turn the handle (1-2) counterclockwise to open. 3)Remove the core (gas valve) cap and then install the charging valve assembly (1) to the gas valve.

Accumulator

4) Install the pressure gauge (2) to the charging valve assembly and connect the hose (3) to the nitrogen gas cylinder. 5)Slightly open the valve of the nitrogen gas cylinder. Turn the handle (1-2) clockwise to close after confirming the gas comes out from the handle (1-2) part. 6)Slowly turn the handle (1-1) clockwise to open the piston of the gas valve. 7)Open the valve of the nitrogen gas cylinder more and put a charge into the accumulator. Note : Close the valve of the nitrogen gas cylinder when checking the gas pressure on the gauge to read the gauge needle at the stable condition.

54-25

97K54034

Procedure for Charging Nitrogen Gas

115Z Ⅳ -2

〔Charging pressure : 2.9MPa (30kgf/cm2) (427 psi) at 20 ℃ (68F ° )〕 Note : Gas pressure is variable with temperature. Use the following formula for the correct nitrogen charging pressure. If the pressure on the gauge is too high, slowly turn the handle (1-2) counter-clockwise. 2 PX=30(kg/cm ) × {273+ t ( ℃ )} / {273+20( ℃ )} PX : Charging gas pressure t : Ambient temperature 30 : Standard gas pressure 8) Turn the handle (1-1) counterclockwise to return the piston of the gas valve (6). Then turn the handle (1-2) counterclockwise to bleed the gas from the charging assembly and the hose. 9)After removing the pressure gauge (2), remove the charging assembly from the accumulator. Notes : ・Apply soapy water to the gas valve (6) to check for gas leakage. ・Recheck the gas pressure once within a week after the charging. ・Check the gas pressure at every 2000 operation hours. ・A little gas is lost each time of the checking, so add the gas to compensate for the loss.

54-26

BRAKE 54

115Z Ⅳ -2

Unloader Valve

BRAKE 54

Unloader Valve

Pilot port

Drain port

Pump port

B A

2 1

3 Orifice B

Orifice A

Accumulator port 97ZA5203

1. Body 2.Spool 3.Spring 4.Pressure governor

5.Low pressure indicator 6.Check valve 7. Pilot poppet 8.Plunger

54-27

115Z Ⅳ -2

Unloader Valve Tightening Torque

BRAKE 54

Unloader Valve Tightening Torque

T3 T4

6 T2 3

2 8 T1

1 5 4 6

10 11

12 13 T1

8 T1

:Tightening torque T1 : 49N-m (5.0kgf-m) (36 lb-ft)

width across flats : 8mm (0.315 in.)

T2 : 15N-m (1.5kgf-m) (11 lb-ft)

width across flats : 5mm (0.197 in.)

T3 : 11N-m (1.1kgf-m) (8 lb-ft)

width across flats : 28.6mm (1.126 in.)

T4 : 9N-m (10.0kgf-m) (72 lb-ft)

width across flats : 30mm (1.181 in.)

54-28

97ZA5413

Removing and Reinstalling Unloader Valve

115Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Unloader Valve 1.Removing unloader valve Refer to Section 52-004 for the location of the unloader valve.

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

Before starting work: ・ Stop the engine. Depress the brake pedal many times until there is no brake pressure. ・ Prepare a container to catch drained oil.

1)Remove the hose (1), the pipe (2), the coupler (3), the bolts (4) and then remove the unloader valve (5). Note : Cover the disconnected hoses with clean vinyl to protect them from dust and dirt.

4 1

1 3

2.Reinstalling unloader valve To reinstall the unloader valve, follow the above removal procedure in the reversed direction. Note : After reinstallation, check all the pipe- joints for oil leakage.

54-29

5 115K54012

115Z Ⅳ -2

Unloader Valve

Disassembling and Reassembling Unloader Valve 1.Disassembling unloader valve IMPORTANT ・ Clean the outer surface of the unloader valve. ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

Refer to the drawing of the unloader valve when disassembling. 1)Remove the bolts (8), then remove the pressure governor assembly (7) and the pressure switch assembly (9) from the body (1). Torque for assembly : Bolt 49N-m (5.0kgf-m) (36 lb-ft) width across flats: 8mm (0.315 in.) 2)Remove the O-rings (5), (6). 3)Pull out the spool (2) and the spring (4), and then remove the orifice (3) from the spool (2). Torque for assembly : Orifice 15N-m (1.5kgf-m) (11 lb-ft) width across flats: 5mm (0.197 in.) 4)Remove the bolts (13), and then remove the cover (12), the check valve (10), the spring (11), and the O-ring (14). Torque for assembly : Bolt 49N-m (5.0kgf-m) (36 lb-ft) width across flats: 8mm (0.315 in.) Note : Do not disassemble the pressure governor assembly (7) and the pressure switch assembly(9) unless it is necessary. Because, readjustment of the pressure and the shim are required. Torque for assembly : Switch assembly 11N-m (1.1kgf-m) (8 lb-ft) width across flats: 28.6mm (1.126 in.)

54-30

BRAKE 54

Unloader Valve

115Z Ⅳ -2

2.Reassembling unloader valve To reassemble the unloader valve, follow the above disassembly procedure in the reversed direction. Notes : ・Clean the metal parts using approved brake cleaning solvent, and then blow the compressed air to dry them. ・After cleaning, check the parts for damage and wear. If a part is defective, replace it with a new one. ・Replace all the O-rings and seals with new ones. Refer to the unloader valve drawing and the tightening torque value when reassembling. Notes : ・While reassembling the unloader valve, take care not to allow dust, dirt or foreign material into the body. ・Apply a coat of hydraulic oil to the sliding surface of the spool and etc.. ・Be sure to insert the spool in the proper direction. After installing the spool, move it back and forth a few times to confirm smooth movement. ・Confirm that the spring(4)is resting on the spring seats in the pressure governor assembly (7) and the body (1).

54-31

BRAKE 54

Auto-Adjuster Valve

115Z Ⅳ -2

BRAKE 54

Auto-Adjuster Valve 8

Brake piston port

3 9

Hydro-master port

12 10 14 13

1.Cylinder 2.Piston 3.O-ring 4.Valve body 5.Valve 6.Spring 7.O-ring 8.Body 9.O-ring 10.Spring washer

11.Bolt 12.Plain washer 13.Plate 14.Bolt 15.Air bleeder screw 16.Cap 17.Washer 18.Screw 19.O-ring

54-32

115Z Ⅳ -2

Auto-Adjuster Valve Tightening Torque

BRAKE 54

Auto-Adjuster Valve Tightening Torque 11 10 T4

4 7 5

6 3

14 T2

2 T3 18

15 T3

19 12

:Tightening torque T1 : 39N-m (4.0kgf-m) (29 lb-ft) T2 : 54N-m (5.5kgf-m) (40 lb-ft) T3 : 10N-m (1.0kgf-m) (7 lb-ft) T4 : 15N-m (1.5kgf-m) (11 lb-ft)

54-33

Removing and Reinstalling Auto-Adjuster Valve

115Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Auto-Adjuster Valve 1.Removing auto-adjuster valve (The illustration shows the front wheels).

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

Before starting work: ・ Relieve the residual pressure in the line by loosening the left and the right air bleeder nipples. 1)Remove the hose (1), pipe (2) and the bolts (3) and then remove the auto-adjuster valve (4). Oil will be drained from the hose. Place a container to catch the drained oil. : Brake oil 0.5 l (0.13 gal.)

2 2

3 115K540014

2.Reinstalling auto-adjuster valve To reinstall the auto-adjuster valve, follow the above removal procedure in the reversed direction. Note : After reinstallation, completely bleed the brake line of air. For the detailed procedure of air bleeding, refer to Section 53.

54-34

Disassembling and Reassembling Autovalve

115Z Ⅳ -2

BRAKE 54

Disassembling and Reassembling Auto-Adjuster Valve 1.Disassembling auto-adjuster valve (The disassembly procedure described below is for the left-side of the valve. )

IMPORTANT ・ Clean the outer surface of the auto-adjuster . ・ Put match marks on the parts before disassembly. ・ Place the removed parts according to the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

1)Remove the bolts (1). Torque for assembly : Bolt 54N-m (5.5kgf-m) (39 lb-ft)

2)Separate the cylinder into two sections (2). 8

3)Pull out the piston (3) from the cylinder (2).

4)Gently clamp the two opposite flats of the piston (3) using a vice. Loosen the valve body (4), and then remove the valve (5), the spring (6), the washer (7), the O-ring (8), and air bleeder screw (9). 5)Disassebled the opposite side the same as the above.

2.Reassembling auto-adjuster valve To reassemble the auto-adjuster valve, follow the above disassembly procedure in the reversed direction. Note : Be sure to replace all the O-rings with new ones, and apply a coat of brake oil to them before reassembly. Inspect the parts for scoring or other damage. Replace as necessary.

54-35

4 6 5 3 115K54015

Removing and Reinstalling Service Brake

115Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Service Brake Follow the steps in the Section 24 (Power Group) for removing and reinstalling service brake.

Note : After reinstalling tires, check that manual rotation of the tires is possible. Also ckeck the wheels for oil leakage.

Bolt

Spider

70K54004

Reference Air bleeding procedure Connect a vinyl tube to the air bleeder nipple, and place an oil can to receive the oil. Fill the brake oil tank. Slightly loosen the air bleeder nipple, and then press the brake pedal several times. When the oil flows from the air bleeder nipple, close the nipple. After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple. Repeat this until there is no air in the oil. When the oil level in the reservoir lowers, add oil to the tank. Completely bleed each wheel of air.

54-36

115Z Ⅳ -2

Oil Cylinder for Parking

BRAKE 54

Oil Cylinder for Parking 13

14 15 7

1 10 11

Stroke 65mm

18 8

23 (φ10mm) Hole C for rod cover tightening (loosening) 24

Width across flats : 24mm

115ZA5208

1. Cylinder tube

9. Rod cover

17. Wear ring

2. Piston rod

10. Plane washer

18.O-ring

3. Piston

11. Bolt

19. Set screw

4. Cover

12. Filter

20.U-nut

5. Spring retainer A

13. Stud bolt

21.O-ring

6. Spring retainer B

14.U-packing

22. Set screw

7. Coil spring

15.Wear ring

23. Bolt

8. Head cover

16.Wear ring

24. Plane washer

Oil Cylinder Tightening Torque 1117kg 763kg

140mm

230mm 65mm Stroke 295mm(Installedlength) 435mm(Freelength) Spring force

T1 : 1,275N-m (130kgf-m) (941 lb-ft) T2 : 314N-m (32kgf-m) (232 lb-ft)

115ZA5409

54-37

115Z Ⅳ -2

Removing and Reinstalling Oil Cylinder

BRAKE 54

Removing and Reinstalling Oil Cylinder 1.Removing oil cylinder WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ When removing the oil cylinder, the machine may move. To prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

1) If there is an oil pressure source, release the parking brake, and then remove the split pin (1) and the pin (2). Note : If there is no oil pressure source; Remove the two bolts (4) from the cover (3) and screw in the two bolts to the holes to overcome the spring force and then remove the pin (2).

115K54016

Bolt (5) size : M12 × 1.75

3 2-M12 × 1.75

130

115ZA5410

Oil port PF 1/4(O-ring)

54-38

4 115ZA5411

Removing and Reinstalling Oil Cylinder

115Z Ⅳ -2

BRAKE 54

2)Disconnect the hose (6). Note : Cover the disconnected hose with clean vinyl to protect it from dust and dirt. 6

115K54018

3) Install the eye bolt and temporarily sling the cylinder (7).

Eye bolt fitting hole 2-M12 × 1.75

: Oil cylinder 68kg (150 lbs) Note : Thread size for eye bolt:M12 × 1.75

Oil port PF 1/4(O-ring)

115K54020

4)Remove the nut (8) and remove the oil cylinder (7). 8

115K54021

2.Reinstalling oil cylinder To reinstall the oil cylinder, follow the above removal procedure in the reversed direction.

54-39

Removing and Reinstalling Oil Cylinder

115Z Ⅳ -2

BRAKE 54

3.Adjusting procedure of parking brake 1)Adjust the parking brake before connecting the joint yoke (2) and the arm (4). Oil cylinder

Adjusting clearance 1. Turn the parking brake switch to OFF position. 2. Turn the adjust bolt clockwise to expand the brake shoes until the linings come in contact with the brake drum. 3. After that, turn the adjust bolt 3 notches counterclockwise. The clearance will be adjusted to 0.3 ± 0.1mm (0.0118 ± 0.0039 ″)

Adjusting bolt

Joint yoke 2

1 Pin 3 Arm 4

115ZA5205

2)Adjust the joint yoke (2) so that the dimension (A) is 17.5mm (0.6890 in.) and then install the pin (3) to connect the joint yoke (2) and the arm (4). Lock nut Joint yoke

115ZA5413

54-40

115Z Ⅳ -2

Oil Cylinder

BRAKE 54

Disassembling and Reassembling Oil Cylinder 1.Disassembling oil cylinder IMPORTANT ・ Clean the outer surface of the oil cylinder. ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

Refer to the disassembling.

drawing

Page

54-37

when

1)Remove the set screws (19), (22). 2)Clamp the cover (4) in a vise. Note : Do not over clamp the cover (4) to avoid distortion of the cover (4). 3)Remove the bolt (11) and then remove the head cover (8). Torque for assembly : Bolt (11) 314N-m (32.0kgf-m) (232 lb-ft) 4)Pull out the piston rod (2) with the piston (3) from the cylinder tube (1). 5) Loosen the rod cover (9) one turn using the hole (C). This results the rod cover (9) with the spring retainer B (6) moved approx. 3mm by the spring force. 6)Remove the oil cylinder from the vise. 7)Set the cylinder on a press with the rod cover (9) side directed upward.

Jig A

8)Set the jig (A) on the spring retainer B (6) and press the jig (A) 1 〜 2mm (0.0394 〜 0.0787 in.) to make clearance between the rod cover (9) and the spring retainer B (6). This results the rod cover (9) can be removed easily. JIG dimension: φ75 ×φ40 × 60mm ( φ2.95 ×φ1.57 × 2.36 in.)

115ZA5414

54-41

115Z Ⅳ -2

Oil Cylinder

IMPORTANT Do not push the spring retainer B more than 2mm or the spring retainer B may be damaged.

Note : The necessary capacity of a press: Openings:420mm (16.54 in.) and more Stroke:175mm (6.90 in.) and more Press capacity:1,500kg (3,300 lbs) and more 9)Remove the rod cover (9) using the hole (C). 10)Slowly reduce the press until the spring loses the spring force. 11)Remove jig (A), rod cover (9), spring retainer B (6) and the coil spring (7). 12)Remove the spring retainer A (5). 13)Clamp the cover (4) in a vise and remove the cylinder tube (1) using the bolt holes. 14)Clamp the area of the two chamfered flats of the piston rod (2) and remove the U-nut (20) and the piston (3). Torque for assembly : U-nut 1,275N-m (130kgf-m) (941 lb-ft)

2.Reassembling oil cylinder To reassemble the oil cylinder, follow the above disassembly procedure in the reversed direction. Note : After cleaning, check the parts for damage and wear. If a part is defective, replace it with a new one. Refer to Page 54-37 for the drawing and the tightening torque value when reassembling. Note : Apply a coat of hydraulic oil to the seals.

54-42

BRAKE 54

115Z Ⅳ -2

Parking Brake Assembly

BRAKE 54

Parking Brake Assembly 4

Front

1. Parking brake 2. Brake drum 3. Pillow unit 4.Oil cylinder 5. Propeller shaft 5

115ZA5415

Parking brake 2

3 5

4 7

Thickness of lining (A)…16±0.5mm (0.6300±0.0197 in.) Wearing limit……………11.0mm (0.4330 in.)

6 115ZA5206

115ZA5207

1. Adjuster

4.Brake shoe

7.Camshaft

2. Bracket

5.Spring

8. Lever

3. Brake cover

6.Anchor pin 54-43

115Z Ⅳ -2

Parking Brake Assembly Tightening Torque

BRAKE 54

Parking Brake Assembly Tightening Torque T1

Oil cylinder

T3 2nd propeller shaft Parking brake

:Tightening torque

T2 L 1

T1 : 206N-m (21.0kgf-m) (152 lb-ft) (With lub. oil) T2 : 76N-m (7.8kgf-m) (56 lb-ft) T3 : 1,030N-m (105.0kgf-m) (760 lb-ft) T4 : 721N-m (73.5kgf-m) (532 lb-ft) (With lub. oil) T5 L 1 T5 : 221N-m (22.5kgf-m) (163 lb-ft) Differential gear

L1 : Screw lock agent application (Three bond 1327)

115ZA5416

Parking brake tightening torque 50

13 12

23 22

15 16

T2 1

:Tightening torque T1 : 34N-m (3.5kgf-m) (25 lb-ft) T2 : 157N-m (16.0kgf-m)

115ZA5417

(116 lb-ft) T3 : 34N-m (3.5kgf-m) (25 lb-ft)

54-44

Removing and Reinstalling Parking Brake

115Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Parking Brake 1.Removing parking brake WARNING Unexpected movement of the machine could cause injury or death. To prevent such and accident, observe the following items: ・ When removing the parking brake, the machine may move. So, to prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

Before starting work: ・ Remove 2nd propeller shaft. (Refer to the Section 24) 1)Disconnect the hose (1). Note : Cover the disconnected hoses with clean vinyl to protect them from dust and dirt.

115K54025

2) Install eye bolts (2) on the oil cylinder and temporarily sling the oil cylinder with the parking brake. Note : Eye bolt size:M12 × 1.75

Eye bolt fitting hole 2-M12 × 1.75

: Parking brake assembly: Approx. 300kg (660 lbs)

115V54001

3)Remove the retainer bolts (3) of the propeller shaft. Torque for assembly : Bolt 221N-m (22.5kgf-m) (163 lb-ft) : Screw lock agent application (Three bond 1327)

115V54002

54-45

Removing and Reinstalling Parking Brake

115Z Ⅳ -2

4)Remove the grease pipe (4) and remove the bolts (5). Torque for assembly : Bolt 721N-m (73.5kgf-m) (532 lb-ft) (with lub. oil)

BRAKE 54

115K54028

5)Slowly place the parking brake assembly on a carrier to smoothly pull out the assembly to the front side.

2.Reinstalling parking brake To reinstall the parking brake, follow the above removal procedure in the reversed direction. Note : To adjust the parking brake, refer to Section 53. To check performance of the parking brake, refer to Section 53.

54-46

115Z Ⅳ -2

Parking Brake

BRAKE 54

Disassembling and Reassembling Parking Brake 1.Disassembling Parking brake assembly IMPORTANT ・ Clean the outer surface of the parking brake assembly. ・ Place the removed parts according to the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

Refer to the disassembling.

drawing

Page

54-44

when

1)Remove the dust cover (50). Torque for assembly : Bolt (31) 34N-m (3.5kgf-m) (25 lb-ft) 2)Remove the return spring (23). 3)Remove the bolt (8) and the lock plate (6). Torque for assembly : Bolt (8) 34N-m (3.5kgf-m) (25 lb-ft) 4)Remove the anchor pin (5). Notes : ・Use an anchor pin puller using the thread of the anchor pin for ease removing. Anchor thread size:M16 × 1.5 ・Apply a coat of grease to the anchor pin when reassembly.

Anchor pin puller

5 115ZA5418

5)Remove the cam roller (24) from the brake shoes (21), (22). Note : Apply a coat of multipurpose-type EP/Moly grease to the inner surface of the cam roller. 18

6)Remove the snap ring (19) and then remove the stopper plate (18), spacer (32) and the adjuster assembly (17). Align the matchmarks of the camshaft (16) and the stopper plate (18) and then fix them with the stop ring (19) when reassembly. 7)Pull out the camshaft (16). Note : When assembly of the camshaft, insert the shaft so that the end face of the shaft upward.

16 115ZA5419

Matchmarks

115ZA5420

54-47

Parking Brake

115Z Ⅳ -2

BRAKE 54

8)Remove the bolt (14) and then remove the bracket (9). Torque for assembly : Bolt 157N-m (16.0kgf-m) (116 lb-ft)

2.Reassembling parking brake assembly To reassemble the parking brake, follow the above disassembly procedure in the reversed direction. Notes : ・Clean and check the disassembled parts. If a part is defective, replace it. Refer to the drawing and the tightening torque values when reassembling.

Notes : ・When reassembling, take care not to allow dust, dirt, or foreign material into the parking brake. ・After installing the camshaft (16) and the bracket (9), lubricate until grease is seen at the port A. ・After installing the brake drum, adjust the brake shoe clearance.

A Grease nipple

115ZA5421

54-48

BRAKE GROUP 55 Service standard Brake Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 55-2 Hydro-master ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 55-3 Auto-Adjuster Valve ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 55-4 Service Brake ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 55-5 Parking Brake ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 55-6

55-1

115Z Ⅳ -2

Brake Valve

BRAKE 55

Brake Valve Tank port

7 6

１

９７ＺＡ５２０７

Unit : mm (in.) Judgment standard No.

Item

Tolerance

Standard dimension

Shaft

Hole

Standard clearance

Allowable clearance

Solution

Clearance between cylinder and piston

φ 18 (0.7087)

+0.011(+0.0004) 0 (0)

0.006(0.0002)〜 0.014(0.0005)

0.016 (0.0006)

Replacement

Clearance between spool and plunger

φ 12 (0.4724)

-0.010(-0.0004) -0.015(-0.0006)

+0.018(+0.0007) 0 (0)

0.010(0.0004)〜 0.033(0.0013)

0.037 (0.0015)

Replacement

Clearance between cover and spool input

φ 22.4 (0.8819)

-0.020(-0.0008) -0.053(-0.0021)

+0.033(+0.0013) 0 (0)

0.020(0.0008)〜 0.086(0.0034)

0.098 (0.0039)

Replacement

Standard dimension No.

Item

Allowable load

Free length mm (in.)

Installation length mm (in.)

Installation load kg (lbs)

Solution

Spring

27.3 (1.0748)

20 (0.7874)

8 (17.6)

8 ± 0.8 (17.6 ± 1.76)

Replacement

Spring

39.5 (1.5551)

27 (1.0630)

6 (13.2)

6 ± 0.6 (13.2 ± 1.32)

Replacement

Spring

31 (1.2205)

at 27.5mm(1.0827 in.) in height 20.4 ± 2 (44.9 ± 4.4)

Replacement

Spring

53.3 (2.0984)

47.5 (1.8701)

8 (17.6)

8 ± 0.8 (17.6 ± 1.76)

Replacement

Spring

19.5 (0.7677)

at 17.5mm(0.6890 in.) in height 7.8 ± 0.8 (17.2 ± 1.76)

Replacement

55-2

115Z Ⅳ -2

Hydro-master

BRAKE 55

Hydro-master

９７ＺＡ５２０８

1 5

９７ＺＡ５２０９

Unit : mm (in.) Judgment standard No.

Item

Tolerance

Standard dimension

Shaft

Hole

Standard clearance

Allowable clearance

Solution

Clearance between body and piston

φ 63 (2.4803)

-0.100(-0.0040) -0.146(-0.0057)

+0.046(+0.0018) 0 (0)

0.100(0.0040)〜 0.192(0.0076)

0.220 (0.0087)

Replacement

Clearance between cover and piston

φ 12 (0.4724)

-0.032(-0.0013) -0.059(-0.0023)

+0.043(+0.0017) 0 (0)

0.032(0.0013)〜 0.102(0.0040)

0.117 (0.0046)

Replacement

Standard dimension No.

Item

Allowable load

Free length mm (in.)

Installation length mm (in.)

Installation load kg (lbs)

Solution

Spring

11.4 (0.4488)

7.4 (0.2913)

0.1 (0.22)

0.1 ± 0.015 (0.22 ± 0.033)

Replacement

Spring

211.4 (8.3228)

148 (5.8270)

22.9 (50.4)

22.9 ± 2.3 (50.4 ± 5.06)

Replacement

Spring

236.1 (9.2953)

148 (5.8270)

14.2 (31.2)

14.2 ± 1.4 (31.2 ± 3.08)

Replacement

Spring

41.6 (1.6378)

28 (1.1024)

11 (24.2)

11 ± 1 (24.2 ± 2.2)

Replacement

55-3

115Z Ⅳ -2

Auto-Adjuster Valve

BRAKE 55

Auto-Adjuster Valve

5 4

7 1

Wet brake piston port

6 Hydro-master port

Unit : mm (in.) Judgment standard No.

Item

Tolerance

Standard

Allowable

Solution

dimension

Shaft

Hole

clearance

cylinder and piston

φ 55 (2.1653)

-0.100 (-0.0039) 〜 -0.146 (-0.0057)

+ 0.08 (+0.0031) 〜 0 (0)

0.100 (0.0039) 〜 0.226 (0.0089)

0.264 (0.0104)

Replacement

Clearance between check valve and body

φ 14 (0.5511)

-0.032 (-0.0012) +0.043 (+0.0017) 〜〜 -0.059 (-0.0023) 0 (0)

0.032 (0.0012) 〜 0.102 (0.0040)

0.110 (0.0043)

Replacement

Clearance between

Standard dimension Item

Allowable load

Free length

Installation length

Installation load (kg)

23.5 (0.9252)

20 (0.7874)

9.2 (20 lbs)

9.2 ± 1.3 (20 ± 2.8 lbs)

Spring

Retainer bolt tightening torque

54N-m (5.5kgf-m) (40 lb-ft)

Air bleeder screw tightening torque

10N-m (1.0kgf-m) (7 lb-ft)

Remedy

Replacement

Tightening 6

Valve body tightening torque

39N-m (4.0kgf-m) (29 lb-ft)

Plug tightening torque

15N-m (1.5kgf-m) (11 lb-ft)

55-4

115Z Ⅳ -2

Service Brake

BRAKE 55

Service Brake 7

2, 6

1, 6

９７ＺＡ５２１９

Unit : mm (in.) Judgment standard No.

Item

Solution

Standard dimension

Tolerance

Wear limit

Thickness of steel plate

5.0 (0.1968)

+0 (+0) 〜 -0.2 (-0.0078)

4.4 (0.1732)

Thickness of friction plate

7.0 (0.2756)

±0.1 (±0.0118)

5.7 (0.2244)

Thickness of brake disc when measured by calipers (with brake applied)

41.0 (1.6142)

+0.3 (+0.0118) 〜 -0.5 (-0.0196)

35.2 (1.3858)

Piston seal contact face

(Work dimension) 375 (14.7638)

-0.210 (-0.0082) 〜 -0.299 (-0.0117)

Piston seal contact face

(Work dimension) 305 (12.0079)

+0 (+0) 〜 +0.081(+0.0319)

Distortion of steel and friction plate

0.30 (0.0118)

Free length

Installation length

Installation load (kg)

54 (2.1260)

49 (1.9291)

29.3 (64 lbs)

Return spring

55-5

Replacement

115Z Ⅳ -2

Parking Brake

BRAKE 55

Parking Brake

8 4 7

１１５ＺＡ５２０８

Clearance

Spring (4) released

5,6

１１５ＺＡ５２０６

Unit : mm (in.) Judgment standard No.

Item

Solution Standard dimension

Wear limit (limit)

11.0 (0.4331)

0.5 (0.0197)

Wear of lining

Deflection of drum

0.4 (0.0157) or more

Replacement

Lining inspection

Grease or oil on the lining

Replacement

Expansion of return spring

There is a clearance between the spring and the coil when the spring is released.

Replacement

Anchor pin

30.0 (1.1811)

29.85 (1.1752)

Replacement

Bushing

30.15 (1.1870)

Replacement

Cam roller

40.3 (1.5866)

40.1 (1.5787)

Replacement

1.0 (0.0394)

Replacement

Camshaft

0.05〜0.11 (0.0020〜0.0043)

0.6 (0.0236)

Replacement

Deflection Clearance to the bushing

55-6

Replacement

ELECTRICAL GROUP 64 Disassembly and Reassembly Removing and Reinstalling Wiper Motor ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 64-2 Removing and Reinstalling Controller ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 64-4 Removing and Reinstalling Fuse ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 64-6

64-1

Removing and Reinstalling Wiper Motor

115Z Ⅳ -2

ELECTRICAL 64

Removing and Reinstalling Wiper Motor (Not for North American machine.) 1.Removing wiper motor 1)Remove the cover (1).

65K64007

2)Remove the nut (2), and then remove the wiper arm (3).

65K64008

3)Remove the nut (4) and the bolt (5). After that, remove the wiper arm (3).

5 3

65K64009

4)Remove the cover (6) and the cover (7). 6, 7

65K64010

64-2

Removing and Reinstalling Wiper Motor

115Z Ⅳ -2

5)Remove the defroster hose (8).

ELECTRICAL 64

6)Disconnect the electric line coupler (9) from the wiper motor.

65K64011

7)Remove the wiper motor retainer bolt (10). 8)Remove the ground line (11).

9)Disconnect the coupler (12) of the wiper motor relay.

11 10

10)Remove the wiper motor (13).

12 65K64012

2.Reinstalling wiper motor To reinstall the wiper motor, follow the above removal procedure in the reversed direction. Note : When reinstalling the wiper arm, adjust the operation angle by the nut(2)shown page 64-2.

64-3

Removing and Reinstalling Controller

115Z Ⅳ -2

ELECTRICAL 64

Removing and Reinstalling Controller WARNING Before removing the controller, be sure to stop the engine, and remove the starter key. In addition, hang a "DO NOT START THE ENGINE!" tag on the instrument panel.

1 2

1.Removing controller (for transmission) 1)Remove the top cover (1) (2).

115K64005

2)Disconnect the controller coupler (3 places) (3).

3 115K64006

3)Remove the controller bolt (4) and then pull it (5) up.

4 5

115K64007

2.Removing controller (for monitor) 1)Remove the cover (1).

115K64008

64-4

Removing and Reinstalling Controller

115Z Ⅳ -2

ELECTRICAL 64

2)Disconnect the couplers (2) and remove the bolts (3) (4 pcs) to remove the controller.

3 Retainer bolt

2 115K64009

3.Reinstalling controller To reinstall the controller, follow the above removal procedure in the reversed direction. Note : After reinstallation, set the starter key to the ON position, and check the function of the LED indicator.In addition, run the machine, and check operation of the machine. Note : The following items may have caused the controller to fail. Test and correct any problems before installing a new controller, using procedures on Section 63. ① Short in the output circuit. ② Defective diode allowing voltage surges.

64-5

Removing and Reinstalling Fuse

115Z Ⅳ -2

ELECTRICAL 64

Removing and Reinstalling Fuse 1.Removing fuse from inside of control box. CAUTION Before removing a fuse, be sure to turn off the starter key. 1 2

1)Remove the cover (1) (2).

115K64010

2)Remove the bolt (3).

Fuse inside the control box 5A

SPARE

R. WORK LIGHT

F. WORK LIGHT

10A 10A 10A

BACK LAMP STOP LAMP TURN SIGNAL

SPARE

COLD STARTER

F. WIPER SPARE

FUEL VALVE

NEUTRAL RELAY

BATTERY RELAY

AIRCON (OPTION)

RADIO

20A 20A 20A

AIRCON (OPTION)

15A 15A 15A 15A 15A

SPARE

4 WAY FLASHER HORN ROOM LAMP

SPARE

10A 10A

R. WORK LIGHT (CAB)

PARKING BRAKE CONTROLLER BUZZER MONITOR

SPARE SPARE

3 115K64011

BOOM KICKOUT BUCKET POSITIONER

R. WIPER

Fuse box

20A 10A 10A 15A 10A

SPARE

LIGHTING HEAD LIGHT

64-6

Removing and Reinstalling Fuse

115Z Ⅳ -2

ELECTRICAL 64

2.(A) Removing fuse from cab 1)Remove the cover (5). 3A

10A

15A

Radio

Clock

Fog lamp

10A

20A

Unused (spare) Unused (spare) Unused .(spare)

Unused (spare)

Air conditioner

10A

Rotary lamp

Air conditioner

20A

Work lamp Room lamp

15A

(B) Removing fuse from cab (For North American machine) 1)Remove screw to remove cover. ・Replace fuse only with same type and rating. ・All cab fuses are 10 Amp.

64-7

F wiper

R wiper

F work lamp

R work lamp

P light, fan

Option

115Z Ⅳ -2 Disassembly & Reassembly, Service Standard AAA-S11C3V14-979 AAA-S11C3V14-012

① 1997.9

② 2001.2

KAWASAKI HEAVY INDUSTRIES, LTD. Rolling Stock, Construction Machinery & Crushing Plant Company Construction Machinery Division Tokyo Head Office

W.T.C. Bldg., 2-4-1 Hamamatsu-cho Minato-ku, Tokyo 105-6116

Kobe Head Office

Kobe Crystal Tower, 1-1-3 Higashi Kawasaki-cho Chuo-ku, Kobe, Hyogo 650-0044

Banshu Works

2680 Oka Inami-cho Kako-gun, Hyogo 675-1113