DOWNLOAD PDF : Kawasaki 115ZIV-3 WHEEL LOADER SHOP MANUAL AAA-S11M1E14-00Z

AAA-S11M1E14-00Z (93216-00122)

WHEEL LOADER SHOP MANUAL

115ZIV-3 Powered by MITSUBISHI S6A3 Engine.

SERIAL NUMBERS 11M1-9001 and up.

Disassembly & Reassembly Service Standard

CHASSIS GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-1 CHASSIS GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15-1 POWER GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-1 POWER GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 25-1 TORQUE CONVERTER & TRANSMISSION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-1 TORQUE CONVERTER & TRANSMISSION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 35-1 HYDRAULIC GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-1 HYDRAULIC GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-1 BRAKE GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-1 BRAKE GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-1 ELECTRICAL GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-1 OPERATOR STATION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 74-1 OPERATOR STATION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 75-1

CHASSIS GROUP 14 Deck ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-3 Fuel Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-4 Hydraulic Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-5 Engine Room ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-8 ROPS ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-9 Cab ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-12 Floor Board ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-13 Boom ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-16 Center Pin ・

14-1

Removing and Reinstalling Deck

115ZIV ー 3

CHASSIS 14

Deck 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)

1

115K14001

2)Sling a handrail (2)(3) and remove the bolts (4)(5)(6). Remove the deck (together with the handrail). : Bolt: (4)(5)(6) : 94N-m (9.55kgf-m) : Deck (with handrail) : 110kg left 88kg right

6

2

4

3 5 115K14002

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

14-2

Removing and Reinstalling Fuel Tank

115ZIV ー 3

CHASSIS 14

Fuel Tank 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. capacity: 620 l ) b) Remove the deck.

3

2

(Fuel tank

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

3

97K14003

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

5

Ｆｕｅｌ ｔａｎｋ

4

115M14001

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

Ｅｎｇｉｎｅ

Removing and Reinstalling Hydraulic Tank

115ZIV ー 3

CHASSIS 14

Hydraulic Tank 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 ) b) Remove the deck. 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.

2

1 115V14001

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

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

Removing and Reinstalling Engine Room

115ZIV ー 3

CHASSIS 14

Engine Room 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 .

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

1

115K14004

2)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.

5

4

14-5

3

115K14006

Removing and Reinstalling Engine Room

115ZIV ー 3

CHASSIS 14

3)Remove the nut (7) for the roof cushion and lift the roof (6). : Roof : 95kg Torque for assembly: : Nut (7) : 32N-m (3.25kgf-m)

6

7

7

115K14007

4)Remove the wiring of the inside screen board.

Remove the hoses (10)(11) of the receiver tank (9) and condenser (8).

10

8 9 11

115V14011

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

12

13 Engine

115W14003

6)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 Torque for assembly: : Bolt (14) : 216N-m (22.0kgf-m)

14

115M14002

14-6

Removing and Reinstalling Engine Room

115ZIV ー 3

CHASSIS 14

7)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 Torque for assembly: : Bolt (16) : 216N-m (22.0kgf-m) １６

１５

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

115ZIV ー 3

CHASSIS 14

ROPS 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 Torque for assembly: : Bolt (2) : 2,109N-m (215kgf-m)

１ Ａ

２

2.Reinstalling ROPS 1)For reinstallation, follow the above procedure in the reversed direction.

１１５Ｖ１４０１３

14-8

Removing and Reinstalling Cab

115ZIV ー 3

CHASSIS 14

Cab 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.

１

２

2)Remove the cover (3).

３

６５Ｋ１４０５１

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

６５Ｋ１４０５２

14-9

115ZIV ー 3

CHASSIS 14

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

６

６５Ｋ１４０５３

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

７

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

８

９ ６５Ｋ１４０５４

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

１２ １０

１１

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)

Ｃａｂ

Ｆ ｌ ｏｏｒ ｂｏａ ｒ ｄ １３

14-10

６５Ｖ１４００２

115ZIV ー 3

CHASSIS 14

Ｃａｂ

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

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

115ZIV ー 3

Removing and Reinstalling Floor Board

CHASSIS 14

Floor Board 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. side of the battery. ・ Disconnect the side of the battery. ・ Disconnect the

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.

３ ４

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. : Including ope. board, air conditioner, seat, etc.

340kg ９７Ｋ１４０１８

Torque for assembly: : Nut (4) : 230N-m (23.5kgf-m)

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.

14-12

Removing and Reinstalling Boom

115ZIV ー 3

CHASSIS 14

Boom Removing and Reinstalling Boom 1.Removing boom

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. ・ Apply the parking brake and remove the starter key.

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.

Note: The illustration shows the parts on the right side.

On the left side, the parts are located at the same points.

２

１

1)Remove the pin (3) connecting the bucket (1) and the link (2). : Bucket : 4,940kg Note: There are shims in the pin sections.

Carefully store the removed shims, and correctly reinsert the shims when reinstalling the bucket.

３ 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.

１５

４

１ １１５Ｖ１４００３

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

５

２

６ ９０Ｋ１４００８

14-13

Removing and Reinstalling Boom

115ZIV ー 3

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). ７

CAUTION You have to work at a high position to remove the grease pipe.

Always use a stepladder for this work.

５

９０Ｋ１４００９

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

８

９

: Bucket cylinder : 245kg

５ ９０Ｋ１４０１０

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

Lower the bucket cylinder rod (10) on the machine.

１０

９０Ｋ１４０１１

５

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

: Lever (for 1 pc) : 425kg

９０Ｋ１４０１２

14-14

Removing and Reinstalling Boom

115ZIV ー 3

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

CHASSIS 14

１３ １２ １５

8)Remove the grease hose (13) from the pin (12).

Insert the wooden block between the boom 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.

１４

Wooden block

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.

１１５Ｖ１４００４

４

: Boom : 3,200kg １６

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.

14-15

115ZIV ー 3

Removing and Reinstalling Center Pin

CHASSIS 14

Center Pin Removing and Reinstalling Center Pin Upper

T1

Bearing cover Shim adjustment

Front chassis Rear chassis

T2

T1

１１５ＺＡ１２０６

T1 : 422N-m (43.0kgf-m) T2 : 662N-m (67.5kgf-m) Shim adjustment: Adjust the clearance to 0.1± 0.05mm using the shim. After that, tighten the T1 bolt.

Split shim

T2

１１５ＺＡ１４０４

Lower T3

Front chassis Rear chassis

１１５Ｖ１４００５

T3 : 417N-m (42.5kgf-m)

１１５Ｋ１４０１４

14-16

Removing and Reinstalling Center Pin

115ZIV ー 3

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 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

1)Remove the second propeller shaft assembly (1).

Torque for assembly: : Bolts : 221N-m (22.5kgf-m) : Screw lock agent application (Three bond 1327)

１１５Ｖ１４００６

２

３

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 : Brake oil : Approx. 3 l 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) (with lubricating oil)

５

４ １１５Ｖ１４００８

14-17

Removing and Reinstalling Center Pin

115ZIV ー 3

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

８

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.

１０

Jack

WARNING

９

Chassis separation is dangerous work. To ensure your safety, be careful in doing this work Garage jack ９５Ｖ１４０２０

14-18

115ZIV ー 3

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)

１３

１１

I

１２

Rear chassis

Front chassis

１１５Ｋ１４００９

Front

１５

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 ９７Ｋ１４０３２

14-19

Removing and Reinstalling Center Pin

115ZIV ー 3

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

１６

(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 １７

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.

14-20

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

15-1

Linkage

115ZIV-3

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

φ１００

10. Front chassisSteering cylinder

11. Steering cylinderRear chassis

１１５ＺＡ１２０２

φ７０

φ７０

2

7

3

8

4

10

11

5

1

6

9 115ZA1203

15-2

Linkage Pin Standard Clearance Values

115ZIV-3

CHASSIS 15

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

Item

Pin standard dimension

Bushing standard dimension

-0.120

1

Joint section between bucket and boom

φ 100 -0.155

2

Joint section between boom and lever

φ 120

3

Joint section between boom and boom cylinder φ 120

4

Joint section between front chassis and boom

φ 120

5

Joint section between bucket and link

φ 90 -0.155

6

Joint section between lever and link

φ 90

7

Joint section between lever and bucket cylinder φ 100

-0.145 -0.185

-0.145 -0.185

-0.145 -0.185

φ 100

φ 120

φ 120

φ 120

-0.120

※

8

9

※

10

※

11

Joint section between bucket cylinder and front chassis Joint section between boom cylinder and front chassis Joint section between front chassis and steering cylinder Joint section between steering cylinder and rear chassis

-0.120 -0.155

φ 100

-0.120 -0.155

-0.120 -0.155

φ 70

φ 70

-0.100 -0.130

-0.100 -0.130

φ 100

φ 100

φ 120

φ 70

+ 0.160 0

+ 0.160 0

+ 0.140 0

φ 90

φ 70

+ 0.160 0

+ 0.140 0

φ 90

-0.145

φ 120 -0.185

+ 0.140 0

+ 0.140 0

+ 0.140 0

+ 0.160 0

+ 0.120 0

+ 0.120 0

Solution

Standard clearance

Tolerance

0.295〜0.120

1.0

Replacement

0.345〜0.145

1.0

Replacement

0.345〜0.145

1.0

Replacement

0.345〜0.145

1.0

Replacement

0.295〜0.120

1.0

Replacement

0.295〜0.120

1.0

Replacement

0.295〜0.120

1.0

Replacement

0.295〜0.120

1.0

Replacement

0.345〜0.145

1.0

Replacement

0.250〜0.100

1.0

Replacement

0.250〜0.100

1.0

Replacement

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

Center Pin

115ZIV-3

CHASSIS 15

Center Pin Adjusting Shim(#5) 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.

〔Upper section〕

9

3 5 Front chassis

(with lubricating oil) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・662N-m (67.5 kgf-m) #8・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・422N-m (43.0 kgf-m) #9・

Rear chassis

8

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

6

〔Lower section〕

3 Front chassis Rear chassis

115ZA1207

Front

Rear 3

Grease pipe installation direction

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

15-4

Bucket

115ZIV-3

CHASSIS 15

Bucket (Wear plate mounting section)

45

19.1

2

Wear plate

１１５ＺＡ１５０１

１１５ＺＡ１５０２

Judgment standard No.

Item

1

Wear plate wearing

2

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 )

Solution Replacement Tightening

Tooth welding procedure (Tooth)

(Corner tooth)

Straight edge

Straight edge V-shape edge

V-shape edge

※1

※1

(10 × 15) 15 (10 × 15) 15

※2

※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

Bucket Positioner and Boom Kick-out

115ZIV-3

CHASSIS 15

Bucket Positioner and Boom Kick-Out (Optional)

Boom kick-out

Bucket positioner

９７ＺＡ１５０６

Bucket positioner

Adjusting plate

5

Direction of indicator lamp Proximity switch

Indicator lamp

Connector

3

4 1

９７ＺＡ１５０７

15-6

Bucket Positioner and Boom Kick-out

115ZIV-3

CHASSIS 15

Boom kick-out

Adjusting plate

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

4

Connector

Proximity switch Direction of indicator lamp

2

９７ＺＡ１５０８

Unit : mm No.

Item

Judgment standard

Solution

1

Clearance of bucket positioner switch

5±2

Adjustment

2

Clearance of boom kick-out switch

5±2

Adjustment

3

Adjusting plate mounting bolt tightening torque

4

Switch mounting nut tightening torque

5 6

Positioner

90N-m (9.2 kgf-m )

Kick-out

53N-m (5.4 kgf-m )

Tightening

20N-m (2.0 kgf-m )

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 (Optional)

115ZIV-3

CHASSIS 15

Bucket positioner adjustable angle

-7° 7°

Boom kick-out adjustable angle

９５ＺⅣ１４０３

15-8

POWER GROUP 24 Power Line ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-3 Radiator ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-6 Engine ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-8 Propeller Shaft ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-10 Air Cleaner ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-12 Muffler ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-13 Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-42 Differential Assembly ・

24-1

Power Line

115ZIV-3

POWER 24

Power Line Tightening Torque

Engine

T4 L 1

T6 L 4 1st propeller shaft

T8 L 2 T1 L1 Torque converter

T2 L 1 T3

Front differential assy

T7 L 1 Rear differential assy

T10 L 4 T1 T9 L 2

T1 L1 T9 L 2

L1

T8 L 1

Transmission

2nd propeller shaft

T8 L 2 3rd propeller shaft

Parking brake １１５Ｍ２４００１

: Bolt tightening torque T1 : 441N-m (45.0kgf-m) T2 : 216N-m (22.0kgf-m) T3 : 49N-m (5.0kgf-m) T4 : 299N-m (30.5kgf-m) T5 : 71N-m (7.15kgf-m) T6 :44N-m (4.5kgf-m) T7 : 196N-m (20.0kgf-m) T8 : 142N-m (14.5kgf-m) T9 : 221N-m (22.5kgf-m) T10: 721N-m (73.5kgf-m)

L1 : With liquid adhesive (Loctite 262) L2 : With liquid adhesive (Three Bond 1327) L3 : With liquid adhesive (Three bond 1374) L4 : With lubricating oil (Engine oil or gear oil)

24-2

Radiator

115ZIV-3

POWER 24

Radiator Tightening Torque Radiator

T1 L 1 Engine

T2 L 1

T3 L 1

Rear chassis １１５Ｍ２４００２

: Bolt tightening torque T1 : 51N-m (5.2kgf-m) T2 : 216N-m (22.0kgf-m) T3 : 94N-m (9.6kgf-m)

L1 : With liquid adhesive (Loctite 262)

24-3

Radiator

115ZIV-3

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) and radiator guard.

1)Remove the under cover and then remove the drain plug (1) to drain the coolant. : Under cover : Front 45kg Center 58kg Rear 37kg : Coolant : 76 l Capacity for coolant in system 137 l

１ １１５Ｊ２４００３

２ ５

2)Open the coolant drain cock at the side to drain the coolant from the engine.

４ ３

６

3)Disconnect the coolant hose (2)(3) from the radiator.

Also disconnect the pipe (4)(5) and the hose (6)(7).

１１５Ｊ２４００４

７

Note: Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

T/C oil cooler

１１５Ｍ２４００３

24-4

Radiator

115ZIV-3

4)Disconnect the electrical coupler (8) from the water level sensor.

POWER 24

Ｒａｄ ｉ ａ ｔ ｏ ｒ

８

5)Remove the radiator fan guard (9).

１１５Ｍ２４００４

6)Temporarily sling the radiator. Remove the bolts (10)(11) and the plate (13).

Ｒａｄ ｉ ａ ｔ ｏ ｒ ｄｕｃ ｔ

7)Remove the bolt (12).

8)Remove the bolt (14)(15) and the plate (17)(18). ９

9)After removing the bolt (16), lift the radiator and remove it from the chassis.

１１５Ｍ２４００５

Ｒａｄ ｉ ａ ｔ ｏ ｒ

: Tightening torque ・ ・216N-m (22.0kgf-m) Bolt (#10, 11)・ ・ ・51N-m (5.2kgf-m) Bolt (#12, 16)・ ・ ・94N-m (9.6kgf-m) Bolt (#14, 15)・ : With liquid adhesive (Loctite 262) Bolt (#10) 〜Bolt (#16)

１２ １０

１６ １８ １７

１３ １１

: Radiator assy : 560kg Ｒａｄ ｉ ａ ｔ ｏ ｒ ｄｕｃ ｔ １１５Ｍ２４００６

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

１５ １４

Ｒｅａｒ ｃｈａｓｓ ｉ ｓ

Engine

115ZIV-3

POWER 24

Engine 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)Refer to Section 14. "Removing engine room". b)Refer to "Removing radiator".

Note:After removing the cooling fan, the engine may be removed without removing radiator. c) Collect the air conditioner refrigerant (option) using the proper recovery method.

1. Disconnect the negative side of the battery cable.

Then remove the positive cable.

2. Remove the wires from the alternator, starter motor and the oil pressure switch.

3. Disconnect the heater hose and the fuel hose also disconnect the air lines from the compressor.

4. Disconnect the accelerator controller cable.

5. Temporarily sling the engine, remove the retainer bolt (1)(2).

Carefully lift the engine while checking that there are no obstacles around it. : Engine assy : Approx. 2000kg Torque for assembly ・ ・ ・ ・ ・ ・ ・ ・417N-m (42.5kgf-m) : Bolt (#1)・ ・ ・ ・ ・ ・ ・ ・ ・299N-m (30.5kgf-m) Bolt (#2)・ : With liquid adhesive (Loctite 262)

Ｅｎｇｉｎｅ

１

２

１１５Ｍ２４００７

24-6

Ｔｏｒｑｕｅ ｃｏｎｖｅｒ ｔ ｅ ｒ

Engine

115ZIV-3

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

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

After that, check the amount of the coolant. ⑦While gradually increasing the engine speed, check operation of the electrical equipment.

24-7

POWER 24

Propeller Shaft

115ZIV-3

POWER 24

Propeller Shaft 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. ２

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) : Screw lock agent (Three Bond 1327) application : First propeller shaft : 14kg

１

Torque converter

３

９

８ ７ １１５Ｖ２４００７

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) : Screw lock agent (Three Bond 1327) application : Second propeller shaft : 58kg 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) : Screw lock agent (Three Bond 1327) application : Third propeller shaft : 28kg 24-8

５ Front differential

６ ４

Parking brake group １１５Ｖ２４００８

115ZIV-3

4.Reinstalling propeller shaft

POWER 24

２４． ６１

２４． ６１

８２． ５５

４６． ０５

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

Propeller Shaft

Second propeller shaft installation

Third propeller shaft installation

１１５Ｖ２４０１５

24-9

Air Cleaner

115ZIV-3

POWER 24

Air Cleaner Removing and Reinstalling Air Cleaner 1.Removing air cleaner

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 ５

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.

３

６

４

２

７０Ｋ２４００７

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

１１５Ｊ２４０１０

3)Disconnect the air duct (9) from the air cleaner.

Remove the bolt (10) and take the air cleaner out from the opening. : Air cleaner 42kg/1pc Torque for assembly ・ ・ ・ ・ ・ ・ ・53N-m(5.4kgf-m) : Bolt (#10)・

９

１０

１０

９

１１５Ｊ２４０１１

24-10

Air Cleaner

115ZIV-3

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

Note:If the bands of the air duct are not properly positioned or tightened, the duct will draw in dust that will cause an engine problem.

Carefully reinstall the air duct.

24-11

POWER 24

Muffler

115ZIV-3

POWER 24

Muffler Removing and Reinstalling Muffler 1.Removing muffler

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.

４

１

1)Remove the U-bolt (2) and the drain pipe (3).

2)Remove the retainer bolt (4) and lift the muffler (1) for removing. : Muffler 30kg Torque for assembly ・ ・ ・ ・ ・ ・ ・ ・94N-m(9.55kgf-m) : Bolt (#4)・ 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.

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.

24-12

２

３

１１５Ｊ２４０１２

Axle Assembly

115ZIV-3

POWER 24

Axle Assembly Tightening Torque Front Axle

T9 L 2 L3 T8 L 1 T7

Front differential ass'y

T10 T10 T6 L 1 T10 T11

T4 L 1

T5

T10 T3

L1 T1

T2

: Bolt tightening torque T1 : 892N-m (91.0kgf-m) T2 : 834N-m (85.0kgf-m) T3 : 90N-m (9.2kgf-m) T4 : 721N-m (73.5kgf-m) T5 : 86N-m (8.8kgf-m) T6 : 53N-m (5.4kgf-m) T7 : 33N-m (3.4kgf-m) T8 : 319N-m (32.0kgf-m) T9 : 686N-m (70.0kgf-m) T10:78N-m (8.0kgf-m) T11:15N-m (1.5kgf-m)

１１５Ｅ２４００１

L1 : Screw lock agent (Three Bond 1327) application L2 : With lubrication oil (Engine oil or gear oil) L3 : Liquid gasket (Three Bond 1215)

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

24-13

Axle Assembly

115ZIV-3

POWER 24

Tightening Torque Rear Axle

T8 L 1 T7

Rear differential

T6 L 1

T4 L 1

T5

L1

T3 T1

T2 １１５Ｅ２４００４

: Bolt tightening torque T1 : 892N-m (91.0kgf-m) T2 : 834N-m (85.0kgf-m) T3 : 90N-m (9.2kgf-m) T4 : 721N-m (73.5kgf-m) T5 : 86N-m (8.8kgf-m) T6 : 53N-m (5.4kgf-m) T7 : 33N-m (3.4kgf-m) T8 : 834N-m (85.0kgf-m)

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

L1 : Screw lock agent (Three Bond 1327) application

24-14

Axle Assembly

115ZIV-3

POWER 24

Tightening Torque Axle Support Rear axle Grease piping

T2 L 2

T1 L 1

Grease piping

Front

T2 L 2

T1 L 1

T1 L 1

１１５Ｖ２４０１３

: Bolt tightening torque T1 : 1,030N-m (105.0kgf-m) T2 : 686N-m (70.0kgf-m)

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

24-15

Axle Assembly

115ZIV-3

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

Stand Stand

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

: 1 Tire : 1,480kg Torque for assembly: : Retainer bolt : 892N-m (91.0kgf-m) without lubrication oil Retainer nut : 834N-m (85.0kgf-m)

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) : Screw lock agent (Three Bond 1327) application

５ ２ ４

３

９７Ｋ２４０２９

24-16

Axle Assembly

115ZIV-3

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 Torque for assembly: : Retainer bolt : 686N-m (70.0kgf-m) Note:During reassembly be sure both mating surfaces are clean and free of paint.

７

６ １１５Ｖ２４０１６

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.

Ｓｏｃｋｅ ｔ ｂｏ ｌ ｔ Ｓｐ ｉ ｄｅ ｒ

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. 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.

24-17

Axle Assembly

115ZIV-3

POWER 24

Removing and Reinstalling Rear Axle Assembly 1.Removing rear 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 articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving.

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

１ ９７Ｋ２４０３４

24-18

Axle Assembly

115ZIV-3

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) Retainer nut : 834N-m (85.0kgf-m) : Tire of 1 wheel : 1,480kg

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) : Screw lock agent (Three Bond 1327) application : Third propeller shaft : 28kg ３

４

９７Ｋ２４０３６

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

Rear axle ９５Ｖ２４０１８

24-19

Axle Assembly

115ZIV-3

POWER 24

8)Disconnect the front and rear grease pipes and then remove the brake hose (6) and the brake pipe (7).

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.

７ ６

７ １１５Ｋ２４０２７

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) With lubricating oil (Engine oil or gear oil) : Rear axle : 3,085kg 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.

９ １１５Ｖ２４０２４

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.

24-20

Axle Assembly

115ZIV-3

POWER 24

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

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) : 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) : Screw lock agent (Three Bond 1327) application : Axle support : Approx. 114kg

１２

１３

１０

１１

１４ ９７Ｋ２４０４０

２０ ２３ １７

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.

24-21

１８ １９ ２２ ２１

２４

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

２６

２５ ９７Ｋ２４０４１

Axle Assembly

115ZIV-3

POWER 24

Axle Support Bushing Installation procedure 1.Front support 1) Install the packing (1) and O-ring (2) on the swing shaft.

Front support ４

３

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.

１

２

５

Axle support

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

３１

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

Rear support

1) Before installing put the bushing (6) into dry ice then install it on to the rear axle support.

８

Swing shaft

７

６

2) Install the packing (7) on to the axle support and install the snap ring (8).

Axle support

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

CAUTION

End

１１５Ｖ２４０２６

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.

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

24-22

Axle Assembly

115ZIV-3

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 (without hydroinflation) Torque for assembly: : Retainer bolt : 892N-m (91.0kgf-m) Retainer nut : 834N-m (85.0kgf-m) without lubrication oil

９７Ｋ２４０２８

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

２

９７Ｋ２４０４４

24-23

Axle Assembly

115ZIV-3

POWER 24

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

３

４ ９７Ｋ２４０４５

4)Remove the cover (5).

Torque for assembly: : Retainer bolt : 90N-m (9.2kgf-m) : 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) : Spider assembly : 200kg

１１５Ｖ２４０１８

Ａ

９

８

９７Ｋ２４０４８

24-24

Axle Assembly

115ZIV-3

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

１１ ９７Ｋ２４０５０

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.

Ｔｕｒｎ ｂｕｃｋ ｌ ｅ

Ａ

３

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

９５Ｖ２４０１２

１３ １２

９５Ｖ２４０１３

24-25

115ZIV-3

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) : 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).

１７ Ｃ

１１５Ｖ２４０１０

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

Ｄ １７

: Internal gear hub : 180kg

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

Ｅ ３

: Wheel hub : 260kg

９７Ｋ２４０５５

24-26

115ZIV-3

POWER 24

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

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

3.Cautions regarding floating seal 1. Checking before seal installation (1)Checking seal ・ Check the seal ring for distortion and scratches. ・ Check the O-ring for scratches.

Ｆ ｌ ｏａｔ ｉ ｎｇ ｓｅａ ｌ Ｗｈｅｅ ｌ ｈｕｂ Ａｘ ｌ ｅ ｈｏｕｓ ｉ ｎｇ

(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.

Ｒｉ ｎｇ

Ｒ ｉ ｎｇ

Ｒｅｍｏｖｅ ｏ ｉ ｌ

Ｓｅａ ｌ ｃｒｏｓｓ ｓｅｃｔ ｉ ｏｎ

Ｐｕ ｔｔ ｈ ｉ ｎ ｇｅａｒ ｏ ｉ ｌ （Ｄｏ ｎｏ ｔ ｕｓｅ ｇｒｅａｓｅ）

Ｏ‐ ｒ ｉ ｎｇ

Ｓｅａ ｌＲ ｉ ｎｇ

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

Ｄｏ ｎｏｔ ｔｏｕｃｈ ｂｙ ｈａｎｄ （Ｉ ｔ ｍａｙ ｃａｕｓｅ ｒｕｓｔ ｉ ｎｇ）

24-27

115ZIV-3

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 hub 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.

Ｇｕ ｉ ｄｅ ｊ ｉ ｇ

(2)In case jig is used

１

２ ３

Ｂｅ ｆ ｏ ｒ ｅｉ ｎｓ ｔ ａ ｌ ｌ ａ ｔ ｉ ｏｎ ・ 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

Ｇｕ ｉ ｄｅ ｊ ｉ ｇ

Ｉ ｎ ｓ ｔ ａ ｌ ｌ ａ ｔ ｉ ｏｎ

Ａｆ ｔ ｅ ｒｉ ｎｓ ｔ ａ ｌ ｌ ａ ｔ ｉ ｏｎ

24-28

115ZIV-3

POWER 24

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.

4.Cautions regarding reassembly

Ｅ

1) Install the jig (E) to the wheel hub (3).

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

３

９７Ｋ２４０５５

2) 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 ring.

3)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.

Ｇ ３ Bearing should be contacted to ring.

Axle nut

Ｈ

１１５Ｖ２４０２０

Spring pin

１７

Example LF

The spring pins should be at the upper position. １１５Ｖ２４０２１

24-29

115ZIV-3

POWER 24

4)Tighten the axle nut (16) using the jig (B) so that the preload of the tire mounting hole section is 352 〜 392N (36〜40kgf).

Note:Measure the minimum pulling force to rotate the wheel hub using spring scale. :Use the bolt for the jig (A).

１６

９７Ｋ２４０５９

5)Disconnect the brake pipe (19) and elbow (20).

Attach the jig (I) for brake oil leakage test.

２０

１９ ９７Ｋ２４０６０

6)Apply 588kPa (6kgf/cm2) 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.

Friction plate

Spring pin

Cooling holes Steel plate

２４−０２０−

24-30

115ZIV-3

7)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.

8)Check that the wheel hub drain plug is diagonal to the spider top mark. Fill the oil to the specified level.

9)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.

24-31

POWER 24

Spring pins

Internal gear

２４−０２０−

Wheel hub Spider TOP mark

Drain plug (at bottom)

115ZIV-3

POWER 24

Special Jigs for Disassembling Axle (A) Spider hoisting too

(Material: SS41) φ12 Round bar

80

t9

24

82.5

15

t9

6

37

6 13

24

37.5

37.5

28

110

10

20

117

13

75

(Material SCM21 Hardening HS70 〜80)

(B) Axle nut tightening jigl Bolt

M24 × 2

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

40

24-32

２４−０２６−Ａ

115ZIV-3

POWER 24

(C) Internal gear hub puller

(Material: SS41) φ80 □38

5R

5C

34

40

30

5C

5C

Hexagon(Width across flat 180mm)

２４−０２６−Ｂ

φ229

(D) Internal gear hub hoisting too

(Material: SS41)

2-12 Drill

15

15

t12

248 280 ２４−０２７−Ｃ

24-33

115ZIV-3

POWER 24

(E)Wheel hub hoisting tool

(Material: SS41) 2-22 Drill 23

285

22

t 15

30 30 240

285

195

45

45

110

625

45

20

40

220

35

3.2

185

35

340

385

5 5

A-A

A

20

35

A

35

45

２４−０２７−Ｄ

24-34

115ZIV-3

POWER 24

(G)Wheel hub installation jig

(Material: SS41)

φ13

40

82.5

18

15

20

62

39

13 t5 20

t5

37.5

37.5

23

80

33

t5 13

75

25

40

t 3.2 Pipe

M24 60 20

t5 ２４−０２８−Ｅ

8 divisions into equal parts

110

140

55

55

φ260 φ202

φ190 φ230

12

Knurling 120 22

228 250 ２４−０２９−Ｇ

24-35

115ZIV-3

POWER 24

(H) Bearing insertion jig

(Material: SS41)

50

21

φ230

φ189

φ355 φ308 φ280 φ220

50

44 ２４−０２９−Ｈ

(J) Brake piston holding jig

(Material SS41 T12)

4- φ 12

30

30

M16 × 2

208

124 248 416 445

100

M16×2(Totally threaded)

24-36

115ZIV-3

POWER 24

(K) Floating seal jig For wheel hub

１１５Ｅ２４００２

For ring

１１５Ｅ２４００３

24-37

115ZIV-3

POWER 24

Disassembling and Reassembling Internal Gear Hub

１

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

４

３

５ ４

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

24-38

３

115ZIV-3

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.

24-39

115ZIV-3

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 ３ １１５Ｖ２４０１０

１２

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

３

4)Apply grease to the O-rings. １０

１ １１５Ｖ２４０１１

24-40

115ZIV-3

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) : Screw lock agent (Three Bond 1327) application

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.

３ ２ １

２ １

４

５

3)Remove the wear rings and the bearings (5) from the planetary gear (4).

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

６ １１５Ｖ２４０２３

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115ZIV-3

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.

24-42

POWER 24

Differential Assembly

115ZIV-3

POWER 24

Differential Assembly Tightening Torque Front differential assy

Shim T=0.10〜1.00 T6 L 2 L2

T1 L 1

T2 L 2 T2 L 2

Spacer T=29.20〜29.48

T3 L 2 T5 L 2

T4

T5 L 2

１１５Ｖ２４０１４

: Bolt tightening torque T1 : 1,030N-m (105kgf-m) T2 : 319N-m (32.0kgf-m) T3 : 1,128N-m (115kgf-m) T4 : 912N-m (93.0kgf-m) T5 : 53N-m (5.4kgf-m) T6 : 319N-m (32.0kgf-m)

Note:1) To tighten T1 , measure the preload of section .

Preload of section : 39 〜49N (4 to 5kgf) Use spacer to adjust the preload.

2) Use shim to adjust the tooth contact of spiral bevel gears .

Use nut to adjust the backlash.

L1 : Liquid gasket (Three Bond 1215) L2 : Screw lock agent (Three Bond 1327) application

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Differential Assembly

115ZIV-3

POWER 24

Rear differential assy

T3 L 2

T5 L 2 T4

T5 L 2

L2

L2

Shim T=0.10〜1.00 T2 L 2

Spacer T=29.20〜29.48

T6 L 2

T1 L 1

T2 L 2 １１５ＺＡ２４１７

: Bolt tightening torque T1 : 1,030N-m (105kgf-m) T2 : 319N-m (32.0kgf-m) T3 : 1,128N-m (115kgf-m) T4 : 912N-m (93.0kgf-m) T5 : 53N-m (5.4kgf-m) T6 : 834N-m (85.0kgf-m)

Note:1) To tighten T1 , measure the preload of section .

Preload of section : 39 〜49N (4 to 5kgf) Use spacer to adjust the preload.

2) Use shim to adjust the tooth contact of spiral bevel gears .

Use nut to adjust the backlash.

L1 : Liquid gasket (Three Bond 1215) L2 : Screw lock agent (Three Bond 1327) application

24-44

Differential Assembly

115ZIV-3

POWER 24

Removing and Reinstalling Differential 1.Removing front differential

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: 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 １１５Ｖ２４０２７

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

1)Remove the bolts (1), and then remove the cover (2).

Torque for assembly: : Retainer bolt : 90N-m (9.2kgf-m) : Screw lock agent (Three Bond 1327) application

１ ２

１１５Ｋ２４０３３

24-45

Differential Assembly

115ZIV-3

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

４

６

１１５Ｋ２４０３４

５ ３

４ １１５ＺＡ２４１５

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 : 319N-m (32.0kgf-m) : Screw lock agent (Three Bond 1327) application

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.

８

１１５Ｋ２４０３５

９ １０

: Bolts (7) : M24 × 3 ８

Ａ

１１５Ｋ２４０３６

2.Reinstalling front 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". : Differential retainer bolts : 834N-m (85.0kgf-m) : Screw lock agent (Three Bond 1327) application

24-46

Differential Assembly

115ZIV-3

POWER 24

Adjustment nut

Disassembling and Reassembling Differential Assembly

Shim Nut

1.Disassembling differential assembly

Bevel gear

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)

1)Remove the right and left lock plates (2) from the adjustment nuts (1).

Torque for assembly: : Retainer bolt : 53N-m (5.4kgf-m) : Screw lock agent (Three Bond 1327) application

Pinion

１１５ＺＡ２４１８

Adjustment nut

2

1

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)

3

4 1

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

5

24-47

Differential Assembly

115ZIV-3

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 : 319N-m (32.0kgf-m) : Screw lock agent (Three Bond 1327) application １

２

Matchmark

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

４ ３

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

６ ７ ５

7)Remove the side gear (8).

８

24-48

Differential Assembly

115ZIV-3

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) : 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 : 319N-m (32.0kgf-m) : Screw lock agent (Three Bond 1327) application

５

５ ４

11)Remove the nut (6) and the O-ring (7).

Nut width across flat : 65mm Torque for assembly: : Nut : 1,030N-m (105kgf-m) : Liquid gasket (Three Bond 1215)

６

７ ９５ＺⅣ２４０５

24-49

Differential Assembly

115ZIV-3

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.

５ １０ ９

６ １

７ ２ ３ ４ ８

24-50

７

９５ＺⅣ２４０６

Differential Assembly

115ZIV-3

POWER 24

2.Reassembling differential assembly 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.

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

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) ⑤Measure the preload at section (A) (bolt hole).

５

４

８

９ ２

１

６

３ Ａ

１１５ＺＡ２４２８

Pinion

Bearing

Pinion Stake at 3 points ９５Ｚ４２４５９‐ ５５

: Standard preload * : 39〜49N (4 to 5kgf) 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 to 29.48mm in increments of 0.02mm Thicker spacers reduce preload; thinner spacers increase preload. ⑥Remove the nut (8) and the flange yoke (7).

24-51

７

Differential Assembly

115ZIV-3

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 : 319N-m (32.0kgf-m) : Screw lock agent (Three Bond 1327) application Note:Shims should be selected to adjust the tooth contact.

４ １１５ＺＡ２４３２

８

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 : 0.30 to 0.41mm ・ 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.

24-52

Ａ

７ ３

１１５ＺＡ２４３５

Differential Assembly

115ZIV-3

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

Detail Grease nipple

24-53

１１５ＺＡ２４３７

Differential Assembly

115ZIV-3

After adjusting the backlash to the standard value, paint blue or red on the tooth surface of ring gear, and check the tooth contact. To adjust the tooth

Tooth contact

A

POWER 24

contact, adjust the thickness of the shim between the pinion and cage, and turn the adjusting nut.

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.

2

C

Do the reverse adjusting as B.

Decrease the thickness of shim at the part of D

2

bearing cage being installed and makes drive pinion approach the ring gear.

Check again the backlash and tooth contact.

1

E

2

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

1

24-54

Differential Assembly

115ZIV-3

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

5 TOP

4

HEEL 4〜5

Pitch line TOE

10

BOTTOM 10 2

Pattern B

4 TOP

4

Pitch line

HEEL 4〜5

10

TOE BOTTOM 10 3 Pattern C

4 TOP

TOE Pitch line

3 HEEL 4〜5

10

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.

24-55

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

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

25-1

Propeller Shaft Service Standard

115ZIV-3

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

1

Third propeller shaft

１１５ＺＡ２４３８

No.

Item

Tolerance mm

Solution

1

Spider bearing play

1st, 2nd, 3rd propeller shaft

0.25

Replacement

2

Spline circumferential play

Second propeller shaft

0.8

Replacement

3

Spline transverse play

Second propeller shaft

1.0

Replacement

25-2

Axle Service Standard

115ZIV-3

POWER 25

Axle Service Standard Axle group

2,4 3

1,4

１１５Ｊ２５００１

5

5

6

１１５Ｍ２５００１

mm Judgement standard No.

Item

Solution Standard dimension

Tolerance

1

Backlash between sun gear and planetary gear

0.15〜0.73

←

Replacement

2

Backlash between planetary gear and internal gear

0.17〜0.89

←

Replacement

3

Clearance between spider pin and pin hole

0.036〜0.075

←

Replacement

4

Tooth contact of gear

No abnormality

Replacement

5

Bushing and wear ring wear

No oil groove

Replacement

6

Axle support wear

Dia.: 1.0 / Radius: 0.5 (stepped)

Replacement

25-3

Differential Service Standard

115ZIV-3

POWER 25

Differential Service Standard Differential

２

３

４ １

mm Judgement standard No.

Item

Solution Standard valve

Tolerance

1

Backlash between ring gear and drive pinion

0.30〜0.41

←

Adjustment

2

Backlash between side gear and pinion gear

0.30〜0.56

←

Adjustment

3

Clearance between pinion gear and spider

0.075〜0.100

←

Replacement

4

Runout of ring gear rear surface (when assembled)

0.075

←

Adjustment or replacement

5

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

6

Tooth contact

No abnormality

Replacement

25-4

TORQUE CONVERTER & TRANSMISSION GROUP 34 Power Line ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-3 Torque Converter Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-5 Torque Converter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-15 Transmission Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-33 Clutch Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-48 Low and 3rd Clutch Spider ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-50 1st and 2nd Clutch Spider ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-52 Reverse Clutch Spider ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-54 1st Clutch Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-58 High Clutch Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-62 Modulator Valve Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-64 Control Valve Assembly ・

34-1

Power Line

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Power Line Bolt Tightening Torque

1st propeller shaft

L4 L

T1

L1 T6

T8 1

L3 T2 L4

T10 T L2 9

Torque converter Rear differential

T9

L2

L4 T4 Front differential

L2

T8 L1

T5

T8 L1

L2 T5 2nd propeller shaft

Transmission 3rd propeller shaft

Parking brake group

１１５Ｅ３４００１

: Bolt tightening torque T1 : 44N-m (4.5kgf-m) T2 : 71N-m (7.2kgf-m) T4 : 721N-m (73.5kgf-m) T5 : 221N-m (22.5kgf-m) T6 : 216N-m (22.0kgf-m) T8 : 417N-m (42.5kgf-m) T9 : 142N-m (14.5kgf-m) T10: 49N-m (5.0kgf-m)

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

Torque Converter Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Torque Converter Assembly 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) : Screw lock agent application (Three Bond 1327)

１

１１５Ｋ３４１０１

３ ５ ６

４

２

１１５Ｋ３４１０２

2)Remove the pipe (2) and the hose (3). ８

3)Remove the drain hose (4).

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

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

34-3

１１５Ｋ３４１０３

Torque Converter Assembly

115ZIV-3

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) : Torque converter assembly : 280kg

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

Torque Converter

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Torque Converter Bolt Tightening Torque

T6

T3

T7 T5 T1 T4 T2 T1

T2

１１５ＺＡ３２００２

: Tightening torque T1 : 25N-m (2.6kgf-m) T2 : 193N-m (19.7kgf-m) T3 : 58N-m (5.9kgf-m) T4 : 102N-m (10.4kgf-m) T5 : 80N-m (8.2kgf-m) T6 : 45N-m (4.6kgf-m) T7 : 36N-m (3.7kgf-m)

34-5

Torque Converter

115ZIV-3

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

４

１１５Ｖ３４００２

2)Remove the bolt (6) and the washer (7).

７

５ ４

６

６ ７

１１５Ｖ３４００３

34-6

Torque Converter

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

3) Install the torque converter on the block. : Torque converter : 280kg

Block １１５ＺＡ３４０５

4)Remove the torque converter pump (8).

８

１１５Ｖ３４００４

5)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).

6)Remove the bolt (13) and the seal retainer (14).

１４ １４ １３

９ １２ １０

１１

１１５Ｖ３４００５

7)Pull out the turbine shaft (15).

１５

１１５Ｖ３４００６

34-7

Torque Converter

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

１６ １１５Ｖ３４００７

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

１６

10)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

１８

Drive cover １１５Ｖ３４００８

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

12)Remove the stator (21). ２２

２０

34-8

２１

１１５Ｋ３４１１２

Torque Converter

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

２０

１１５Ｋ３４１１３

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

２５

Pump cover ２４

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

１１５Ｖ３４００８

１８

２７

２５

Wooden block

２４

１１５ＺＡ３４０６

１７

16)Remove the drive gear (24). ２４ ２５

２６

１１５Ｋ３４１１５

34-9

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

２８ ２９

34-10

１１５Ｖ３４０１０

115ZIV-3

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).

２６

１１５Ｖ３４０１１

２７

2) Install the drive gear (24) and impeller hub (27) into the pump impeller (26).

3)Temporarily tighten two bolts (25).

２４

２５

Ｗｏｏｄｅｎ ｂ ｌ ｏｃｋ 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) 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.

１８

Pump impeller assembly

Seal ring

Stator carrier

２０

１１５ＺＡ３４０７

34-11

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

7) Install the spacer (23).

8) Install the stator (20), then install the snap ring (21).

Install the nut (31).

３１ ２１２０ ２３

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

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) 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

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

１６

１７

34-12

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

14)Install the turbine shaft (15).

Note: Take care not to damage the oil seal ring when inserting the shaft.

Seal ring

１５

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

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) Note: Be sure to rise the bolt lock plate. １１

9

９ １０

１１

13 Seal retainer

10

１２

12 １１５ＺＡ３４０８

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

A ８

34-13

１１５Ｖ３４０１３

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

19)Install the washer (7) and the knock pin, then tighten the bolt (6). ７

: Bolt : 193N-m (19.7kgf-m) ５

６ ７

４

６

Knock pin １１５Ｖ３４０１４ １１５ＺＡ３４０９

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

34-14

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Transmission Assembly １

Removing and Reinstalling Transmission Assembly

２

1.Removing transmission assembly

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) : Screw lock agent application (Three Bond 1327) 2)Remove the drain plug (3) to drain the transmission oil. : Transmission oil : 60 l 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) : 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) : Screw lock agent application (Three Bond 1327) 34-15

３

１１５Ｋ３４１１９

８

４ ９ １１５Ｖ３４０１６

６

５

１１５Ｖ３４０１７

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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).

７ １１５Ｖ３４０１８

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 reducing valve hoses. Remove the reducing valve (16) with the block.

Note: After removing the hoses, cover the hoses with vinyl to protect from dust and dirt.

１０

１６

8)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

１９

34-16

Transmission Assembly

115ZIV-3

9)Lift the transmission assembly temporarily, remove the bolts (20) (right / left).

Tightening torque for assembly : Bolt : 90N-m (9.2kgf-m) : Screw lock agent application (Three Bond 1327) : Transmission assembly : 1,030kg

10)Remove the bolts (21) (right / left).

Tightening torque for assembly : Bolt : 417N-m (42.5kgf-m) : Screw lock agent application (Three Bond 1374)

TORQUE CONVERTER & TRANSMISSION 34

２０

２１

11)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

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Bolt Tightening Torque T6

T3

L1

T5 T2

L1

T8

T7

T5

T1

T3

T1」

T3

L1

T3 L1 T4

T3

T1

: Bolt tightening torque T1 : 53N-m (5.4kgf-m) T2 : 86N-m (8.8kgf-m) T3 : 94N-m (9.6kgf-m) T4 : 883N-m (90.0kgf-m)

１１５Ｖ３４０１９

T5 : 132N-m (13.5kgf-m) T6 : 31N-m (3.2kgf-m) T7 : 177N-m (18.0kgf-m) T8 : 157N-m (16.0kgf-m) 34-18

L1 : With lubricating oil

Transmission Assembly

115ZIV-3

T9

T10 T11

TORQUE CONVERTER & TRANSMISSION 34

T12 １１５ＺＡ３４１０

: Bolt tightening torque T9 : 92N-m (9.4kgf-m) T10 : 59N-m (6.0kgf-m) T11 : 10N-m (1.0kgf-m) T12 : 26N-m (2.7kgf-m)

34-19

Transmission Assembly

115ZIV-3

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.

1)Remove the plugs (1) and the O-rings (2).

２

２

１

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

５ ６

６

３

３

４

１１５Ｋ３４１２４

１１５ＺＡ３４１１

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

７ １１５Ｋ３４１２５

１１

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).

８

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

１０

１２ １０

９

１１

１４

１４

１３

８ １２

９ １１５Ｋ３４１２６

１１５ＺＡ３４１２

34-20

Transmission Assembly

115ZIV-3

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

１８

１７

１１５ＺＡ３４１３

１５ １６ １８ １１５Ｋ３４１２７

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

２０ ２１

１９

２２ １１５Ｋ３４１２８

8)Remove the input case (23).

２３

１１５Ｋ３４１２９

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

34-21

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

２５

11)Remove the flange (28) and the cover (31).

12)Remove the snap ring (35) and pull out the bearing (34).

３５

３４

２８ ３１

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

３８

14)Remove the idler cover (38).

３６

１１５Ｖ３４０２０

３７

１１５Ｖ３４０２１

15)Remove the idler gear (42).

４２

34-22

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

４３

４４

４２

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).

４６

４８

１１５Ｖ３４０２３

19)Remove the housing (51).

20)Remove the sleeve (53).

５１ １１５Ｖ３４０２３

５３

21)Turn over the transmission and remove the flange yoke (55).

22)Remove the seal transmission case.

retainer

(58)

from

the

５５

５８ １１５Ｖ３４０２４

34-23

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

６３

24)Remove the output gear (67). ６７

34-24

Transmission Assembly

115ZIV-3

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.

６７

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

６５

６４

34-25

Transmission Assembly

115ZIV-3

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.

６３

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. ６１

６０ ６１ ５８

６０ ６２ ６２

５８

５８

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

５９

: Bolt : 53N-m (5.4kgf-m)

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.

５５

５７ ５６

34-26

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

8) Install the sleeve (53) to output shaft. ５４ ５０

４６ ４７

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

４９

４６

４７

４８

５２

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

34-27

４８

５３ ４９

５１

１１５Ｖ３４０２５

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

４５

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

４４

４３

４２

13)Install the idle gear.

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

３８

３９

34-28

４０

４１ １１５ＺＡ３４１４

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

３９ ３８

: Bolt (39) : 94N-m (9.6kgf-m) 16)Install the rings (36) (37). ３７

３６

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

３４

３５

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

３２

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) ２８

２９

34-29

Transmission Assembly

115ZIV-3

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.

２６

21)Tighten the bolts (25).

Staking

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

２５

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

24)Install the input casing (23). ２３

: Bolt : 94N-m (9.6kgf-m)

34-30

Transmission Assembly

115ZIV-3

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.

２１

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)

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

２０

１６ １７ １５

１８

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

１３

１１

１０

１３

１４ ８ １２ ９

１５ １１５ＺＡ３４１２

１６

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

34-31

１７

Transmission Assembly

115ZIV-3

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)

８ １１ ９ １０ １１５Ｖ３４０２６

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

７

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) ５ ４ ３

６

１１５ＺＡ３４１１

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

２ ２

１

１１５Ｖ３４０２８

34-32

Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Clutch Assembly Disassembling and Reassembling

１

Clutch Assembly 1.Disassembling clutch assembly 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 nut parts (4 points).

Calking (Point marked with ・)

２

１

Collar ９７ＺＡ３４２２

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

3)Remove the ring connecting bolts (4).

(3)

and

eleven

housing

３ ４

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

５

Matchmark

34-33

Clutch Assembly

115ZIV-3

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).

９

１０

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

１１

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

１３，１４

１５

34-34

１２

Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

１６

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

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

１８

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

２１，２２

34-35

２０

Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

13)Remove the ring gear (23).

２３

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

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

34-36

Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

17)Remove the low clutch housing (28).

２８

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

２９

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).

３６

３４ ３５

34-37

Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

３８

３７

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

４０

34-38

Clutch Assembly

115ZIV-3

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

3 pcs

3rd

4 pcs

4 pcs

Low

8 pcs

8 pcs

Reverse

8 pcs

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 2nd

2.0 ± 0.5

3rd

3.0 ± 0.5

Low

5.5 ± 0.5

Reverse

5.5 ± 0.5

34-39

TORQUE CONVERTER & TRANSMISSION 34

Clutch Assembly

115ZIV-3

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).

４０

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

３７

34-40

Clutch Assembly

115ZIV-3

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.

３６

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

３２

7) Install twelve springs (30).

Oil hole

３０

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

２８

２９

34-41

Clutch Assembly

115ZIV-3

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).

２８

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

34-42

Clutch Assembly

115ZIV-3

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. ２４

２１

２２

14)Install the ring gear (23).

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.

２０

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).

１９

: Bolt : 31N-m (3.2kgf-m)

１８

34-43

Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

17)Apply the air pressure of 0.59MPa (6kgf/cm2) 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).

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.

１３

１５

１４

34-44

Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

21)Install twelve springs (12).

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.

８

７

１０

24)Install the ring gear (9).

９

34-45

Clutch Assembly

115ZIV-3

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. ６

26)Install twelve springs (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.

５

28)Install eleven housing connecting bolts (4).

３

: Bolt : 132N-m (13.5kgf-m)

４

29)Apply the air pressure of 0.59MPa (6kgf/cm2) through the oil hole to check for piston operation and air leakage.

３

30)Install the ring (3).

Clutch gear

Spider

１１５ＺＡ３４１５

34-46

Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

32)Tighten the lock nut (1).

Width across flats : 80mm : Lock nut : 177N-m (18.0kgf-m)

１

33)After tightening the lock nut, calk the collar of nut against the spline groove.

(4 equally divided portion on circumference)

Calking (4 points)

Collar ９５ＺⅣ３４０５

Collar

Spline groove

1.5 or more

Calking

９５ＺⅣ３４０４

34-47

Low and 3rd Clutch Spider

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Low and 3rd Clutch Spider Disassembling and Reassembling ２

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).

３ １ ４ ５ ９７ＺＡ３４２４

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

２

６

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

１０ ９ １０

34-48

８

９１０

８

９

１０

９７ＺＡ３４２６

Low and 3rd Clutch Spider

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

2.Reassembling low and 3rd clutch spider To reassemble low and 3rd clutch spider, follow the above disassembling 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 punched marks (indicating oil hole position) face outward.

Punched mark

９７ＺＡ３４２７

Pin

34-49

６ Oil hole

1st and 2nd Clutch Spider

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

1st and 2nd Clutch Spider 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).

３

１

２ ９７ＺＡ３４２９

４

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

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

34-50

1st and 2nd Clutch Spider

115ZIV-3

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 disassembling 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 punched marks (indicating oil hole position) face outward.

Planetary pin

Punched mark

Pin

Clutch gear

９７ＺＡ３４３６

34-51

Oil hole

Reverse Clutch Spider

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Reverse Clutch Spider Disassembling and Reassembling Reverse Clutch Spider

２

３

１

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

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).

４

５

８６ ６

８

７ １１５ＺＡ３４２５

５ ４

34-52

Reverse Clutch Spider

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

2.Reassembling reverse clutch spider To reassemble reverse clutch spider, follow the above disassembling 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 punched marks (indicating oil hole position) face outward.

Planetary pin

Punched mark

Pin

Oil hole

９５Ｖ３４０４０

34-53

1st Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

1st Clutch Assembly Disassembling and Reassembling 1st Clutch Assembly

１

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

Keyway

５ ４ ９５ＺⅣ３４０１

Collar

２

Raise the calked part.

７

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.

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

９

８

１１ １０

９７ＺＡ３４３９

34-54

1st Clutch Assembly

115ZIV-3

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.

１３

１４

１２

１２ １４ １６

１５

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 ２１

２２

１９ １１５Ｖ３４０３３

34-55

1st Clutch Assembly

115ZIV-3

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.

２１

２３

２２

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)

２３

１９ ２０ １１５Ｋ３４１４４

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

１７

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

１５ １２ １４

１３

１２ ２２

９７ＺＡ３４４５

34-56

1st Clutch Assembly

115ZIV-3

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

２２

１０

１１

１１

１０

９

８

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 10 and 12kg.

１

３

２

７

４

５

６

Ａ １１５Ｖ３４０３５

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

Calked ９７ＺＡ３４３７

34-57

High Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

High Clutch Assembly Disassembling and Reassembling High Clutch Assembly

４ ３ ２

1.Disassembling high clutch assembly 1)Remove the snap ring (1), then remove the pressure plate (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

３

４

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 ６

１１５Ｋ３４１５４

34-58

High Clutch Assembly

115ZIV-3

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

１１ １１５ＺＡ３４１９

2.Reassembling high 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) Install the clutch hub (11) to the clutch drum (10) with the snap ring (9).

９

１０

１１ １１５ＺＡ３４１９

2)Turn over the clutch drum assembly.

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 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.

34-59

１ Ａ ２

４ ３

８ １１５ＺＡ３４２０

High Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

4) Install the seal rings (12) (13) to the piston. Ｐ ｉ ｓ ｔ ｏｎ

２ １

１１５ＺＡ３４２１

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

１０

６

５

７

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).

５

６ １１５ＺＡ３４２２

8) Install the friction plates (3) and steel plates (4) alternately.

Friction plates : 4 pcs Steel plates : 3 pcs

４ ３

１１５ＺＡ３４２３

34-60

High Clutch Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

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

１１５Ｖ３４０３２

34-61

Modulator Valve Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Modulator Valve Assembly Removing and Reinstalling Modulator Valve Assembly

１

1.Removing modulator valve assembly 1)Open the cover (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)

５

４

１１５Ｋ３４１５０

６

１１５Ｋ３４１５１

34-62

Modulator Valve Assembly

115ZIV-3

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

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.

34-63

TORQUE CONVERTER & TRANSMISSION 34

Control Valve Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 34

Control Valve Assembly Removing and Reinstalling Control Valve Assembly

１

1.Removing control valve assembly 1)Open the cover (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) １１５Ｋ３４１５５

2.Removing solenoid valve assembly

５

1)Remove the nut (6) and then remove the solenoid (7).

Tightening torque for assembly : Nut : 10N-m (1.0kgf-m)

４

３

2)Remove the valve (8).

Tightening torque for assembly : Valve : 59N-m (6.0kgf-m)

１１５Ｋ３４１５２

3.Reinstalling control valve and solenoid valve

６

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

７ ６ ７

①Tighten the valve with the specified torque.

Tightening with over torque causes improper valve operation.

８

１１５Ｋ３４１５３

34-64

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

35-1

Torque Converter Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 35

Torque Converter Assembly

３

Ｐｕｍｐ ｄｒ ｉ ｖｅ

１ Ａ

２

Ｓｅａ ｌｒ ｉ ｎｇ Ｓ ｔ ａ ｔ ｏ ｒ ｃａｒ ｒ ｉ ｅ ｒ ６ Output coupling

５

Ｔｕｒｂ ｉ ｎｅ

４

Ｓｅａ ｌｒ ｉ ｎｇ

Ｂ Ｃ

１１５Ｖ３５００１

mm Judgement criteria REF.

ITEM

Correction Standard value

3 H

A

t

1

h

H

B

T

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

t=4

Replace 2

T

5

C

h

Limit

2

h

6 １１５ＺＡ３５０２

35-2

Replace

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 35

Transmission Assembly

６ ８

７

９

７ ９

１ ９ ９

２

３ ４ ９ ５

１１５ＺＡ３２−０２

35-3

Transmission Assembly

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 35

mm Judgement criteria REF.

ITEM

Standard value Free length

Installed length

1

High clutch piston return spring

28

24

2

Reverse clutch pistion return spring

82

72

3

Low clutch pistion return spring

82

72

4

3rd clutch pistion return spring

49.5

41

5

2nd clutch pistion return spring

49.5

41

6

1st clutch pistion return spring

49.5

41

Standard value

Allowable limit Installed load

Free length

229.6N (23.41kgf) 263N (26.82kgf) 263N (26.82kgf) 268.3N (27.36kgf) 268.3N (27.36kgf) 268.3N (27.36kgf) Standard clearance 0 -0.1 0 -0.1 0 -0.1 0 -0.1

±0.48

±1.64

±1.64

±0.99

±0.99

±0.99

Installed load

±13.7N

( ±1.4kgf) ±21.6N

( ±2.2kgf) ±21.6N

( ±2.2kgf) ±15.7N

( ±1.6kgf) ±15.7N

( ±1.6kgf) ±15.7N

( ±1.6kgf)

3.8

Seal thickness

4.0

Seal width

4.3

Seal thickness

5.0

Seal width

2.8

± 0.1

-0.15

Seal thickness

4.55

± 0.1

-0.15

8

Replace

Replace

Replace

Replace

Replace

Replace

Allowable limit

Seal width 7

Correction

-0.15 Replace -0.15 -0.15 Replace -0.15

9

Replace

Seal width Seal thickness

m3 m3 ・・・ ・

35-4

Gear Pump

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 35

Gear Pump

１１５ＺＡ３２−０５

Theoretical discharge

72.6 cm3/rev

Maximum operation pressure

3.4MPa (35kgf/cm2)

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/cm2)

35-5

Clutch specifications

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 35

Clutch specifications mm Friction plate

Name of

Piston stroke

clutch

mm

Number of plate

Low clutch

5.5 ± 0.5

8

Reverse clutch

5.5 ± 0.5

8

High clutch

3.0 ± 0.5

4

Outer dia. mm

Inner dia. mm

360φ

279φ

6.0 ± 0.5

9

2nd speed clutch

2.0 ± 0.5

3

3rd speed clutch

3.0 ± 0.5

Thickness mm (in.) Number New/Wear limit of plate

Number of

Outer dia. mm

Inner dia. mm

Thickness mm New/Wear limit

426φ

298φ

3.5 ± 0.1/3.3

8 4 ± 0.13/3.5 (Sintered)

12

3 159φ

4 ± 0.1/3.4 (Sintered)

12 252φ

173φ

3.2 ± 0.1/3.0

8

12

3 360φ

279φ

4 ± 0.13/3.8 (Paper)

4

12 426φ

4

Limit for distortion (flatness)

less than 0.25

35-6

return spring

6

8

236φ

1st speed clutch

Steel plate

298φ

3.5 ± 0.1/3.3

12

Clutch Oil Pressure

115ZIV-3

TORQUE CONVERTER & TRANSMISSION 35

Clutch Oil Pressure

Measuring port location

Measurement port size

Oil pressure (Approx.)

Shift lever position

Main clutch oil pressure

PT 3/8

2.5〜2.6MPa (25〜26kgf/cm2)

at any position

Low clutch oil pressure

PT 3/8

2.5〜2.6MPa (25〜26kgf/cm2)

F-1〜3

High clutch oil pressure

PT 3/8

2.5〜2.6MPa (25〜26kgf/cm2)

F-4

Reverse clutch oil pressure

PT 3/8

2.5〜2.6MPa (25〜26kgf/cm2)

R

1st clutch oil pressure

PF 1/4

2.2〜2.3MPa (22〜23kgf/cm2)

1st speed

2nd clutch oil pressure

PT 3/8

2.5〜2.6MPa 2nd speed (25〜26kgf/cm2)

3rd clutch oil pressure

PT 3/8

2.5〜2.6MPa 3rd speed (25〜26kgf/cm2)

１１５Ｍ３５００１

Main clutch oil pressure measurement port : PT3/8

・ Torque converter oil temperature: 50 to 80 ℃ ・ Engine revolution: at low idle 1st speed clutch oil pressure measurement port : PF1/4 １１５Ｍ３５００２

Low clutch oil pressure measurement port : PT3/8

2nd speed clutch oil pressure measurement port : PT3/8

High clutch oil pressure measurement port : PT3/8 3rd speed clutch oil pressure measurement port : PT3/8 Reverse clutch oil pressure measurement port : PT3/8

Clutch oil pressure measuring port

35-7

１１５Ｍ３５００３

HYDRAULIC GROUP 44 Hydraulic Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-6 Steering Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-16 Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-24 Stop Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-28 Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-35 Boom Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-38 Bucket Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-42 Steering Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-46 Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-51 Pilot Valve ・

44-1

Hydraulic Pump

115ZIV-3

HYDRAULIC 44

Hydraulic Pump Tightening torque

T2

T1

１１５Ｋ４４００１

: Tightening torque T1 : 196N-m (20.0kgf-m) T2 : 72N-m (7.4kgf-m)

44-2

Hydraulic Pump

115ZIV-3

HYDRAULIC 44

Removing and Reinstalling Hyd. Pump Assembly 1.Removing hyd. 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)

1

2

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

5

115K44002

28kg 35kg 3

4 4 1

6

3

2

44-3

7

115K44003

Hydraulic Pump

115ZIV-3

2.Reinstalling hydraulic pump assembly To reinstall the hydraulic pump, follow the above removal procedure in the reversed direction.

Replace all gaskets, O-rings, and seals during 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.

44-4

HYDRAULIC 44

Hydraulic Pump

115ZIV-3

HYDRAULIC 44

Disassembling and Reassembling

Front pump

2

Hydraulic Pump 1.Disassembling double pump

Rear pump

1)Clean the pump and put matchmark on the connecting section of the pump.

2)Clamp the pump at the front side in a vise.

Remove the bolt (1) connecting the front pump and the rear pump.

O-ring

1 T1 65K44070

Double pump 2

3)Separate the front pump and the rear pump.

4)Remove the coupling (2).

2

2.Disassembling triple pump 1)Follow the same procedure as double pump disassembling.

T1 1

1 T2

Triple pump

3.Reassembling double pump Before reassembling clean all the parts. Replace all the O-rings and seals with new ones.

Apply hydraulic oil to the gears and plates.

1)Clamp the front pump in a vice.

2) Install the coupling (2) to the front pump.

3) Install the O-ring onto the rear pump bracket.

4) Install the rear pump onto the front pump.

5)Tighten the bolt (1). : Torque for assembly : 196N-m (20.0kgf-m)

4.Reassembling triple pump 1. Follow the same procedure as double pump reassembling.

44-5

65K44071

Steering Pilot Valve

115ZIV-3

HYDRAULIC 44

Steering Pilot Valve Tightening torque

１５ １４ １３ １４

１６ １５

１２

Spool

２３

１１

６

２２

７ ８ ７ ５

９

Sleeve

１０

４ ３ ２

２０

１

２１

T1

１９ １７

１８

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)

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

: 7.0kg

44-6

Steering Pilot Valve

115ZIV-3

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).

１

９０Ｋ４４００６

2)Remove the plate (3).

3)Remove the sound suppression sheet (4).

２

２

３

４ ９０Ｋ４４００７

44-7

Steering Pilot Valve

115ZIV-3

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) : Steering pilot valve : 7kg

７

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.

44-8

115ZIV-3

HYDRAULIC 44

Disassembling and Reassembling Steering Pilot Valve Copper

1.Disassembling steering pilot valve Before starting work: a)Clean the steering pilot valve. b)Clamp the steering pilot valve in a vise.

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

１

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).

４

５

７ ６

９０Ｋ４４０１１

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

８

９ １０

９０Ｋ４４０１２

44-9

115ZIV-3

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

12

13

９０ＺＡ４４−０１８−４

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

15 16 15

17

18 ９０ＺＡ４４−０１９−１

44-10

115ZIV-3

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.

２０

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.

２１

Push out

Sleeve Spool

２１

９０ＺⅣ４４１０ ９０ＺＡ４４−０１９−４

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

12)Remove the adapter (23) from the housing. ２３

13)Pull out the ball (24).

２４

２２

44-11

９０Ｗ４４０１１

Disassembling&Reassembling Steering P/V

115ZIV-3

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)Assemble the spool (1) and sleeve (2) so that the spring grooves in them are lined up.

Note: Align the match - marks on the spool and sleeve.

２

Spring groove

Spring groove

Match mark

１

９０Ｗ４４０１２

2) Install the springs (3) through the spring grooves in the sleeve and spool (4) 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

３

４ ９０Ｗ４４０１３

3) Insert the pin (5) in the holes in the spool (1) and sleeve (2) until the end of the pin is flush with the surface of the sleeve.

１

２

５

９０Ｗ４４０１４

44-12

Disassembling&Reassembling Steering P/V

115ZIV-3

HYDRAULIC 44

4) Insert the spool and sleeve assembly (2) from the back of the housing (6).

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.

２ ６ ９０Ｗ４４０１５

5) Install the O-ring (7), races (8) and needle bearing (9).

９ ８

７

９０Ｗ４４０１６

6) Insert the dust seal (10) and the X-ring seal (11) in the seal retainer (12). １０

１２

１１

９０Ｗ４４０１７

7) 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 (13).

１３ １２

９０Ｗ４４０１８

44-13

Disassembring&Reassembring Steering P/V

115ZIV-3

HYDRAULIC 44

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

１５

8)Put on the O-ring (14), then align the bolt holes in the plate (15) with those in the housing.

１４

９０Ｗ４４０１９

9) Insert the drive shaft (16) to mate its yoke with the pin (17).

Port face

１６ Pin parallel with port face

１７ ９０Ｗ４４０２０

10)Put the O-ring (18) in the rotor assembly (19). １９

１８

９０Ｗ４４０２１

44-14

Disassembling&Reassembling Steering P/V

115ZIV-3

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.

HYDRAULIC 44

Grooves in rotor bore

A B

Drive shaft

C

Pin

13)Install the spacer (20), O-ring (21) and end cap (22).

D

Port face

９０ＺＡ４４−０２４−２

２０

: Provisional tightening torque : 15N-m (1.5kgf-m) Tightening torque : 28N-m (2.9kgf-m) ２３

Note: Provisionally tighten the bolt (23), then tighten them securely in the order shown at the right.

２２ ２１ １１５Ｗ４４００７

8

９０Ｋ４４０３２

44-15

Steering Valve

115ZIV-3

HYDRAULIC 44

Steering Valve T6 3 T3 T7 T5

4 T1

2

9

T1 8

7 5

6

10

T7 T4 L 1

4

T2

T3 T4 L 1 T2 1

5 T5

7 9 ９７ＺＡ４４０４

: Tightening torque T1 : 98N-m (10.0kgf-m) T2 : 9N-m (0.9kgf-m) T3 : 176N-m (18.0kgf-m) T4 : 10N-m (1.0kgf-m) T5 : 44N-m (4.5kgf-m) T6 : 78N-m (8.0kgf-m) T7 : 89N-m (9.0kgf-m) 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

44-16

Steering Valve

115ZIV-3

Removing and Reinstalling Steering Valve

HYDRAULIC 44

２

1.Removing steering 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. ・ 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.

３

１

１１５Ｋ４４００４

５ ８ ７

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

６ ４

1)Disconnect the block (1) and hoses (2) (3). １１ １１５Ｋ４４００５

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

3)Disconnect the hose (9).

９ １１５Ｋ４４００６

4)Remove the bolt (11) and then remove the steering valve (10).

Torque for assembly: : Bolt : 89N-m (9.0kgf-m) : Steering valve : 48kg Note: Cover the disconnected hoses and the valve with vinyl, plugs or caps to protect them from dust and dirt.

１０

１１５Ｋ４４００７

44-17

Steering Valve

115ZIV-3

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:

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.

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).

44-18

HYDRAULIC 44

Steering Valve

115ZIV-3

HYDRAULIC 44

Disassembling and Reassembling Steering Valve

１

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 : 89N-m (9.0kgf-m)

2)Remove the main relief valve (2).

Torque for assembly: : Main relief valve : 78N-m (8.0kgf-m) Note: The orifice is behind the main relief valve.Do not loose the orifice during the service work. ３

２

４

3)Remove the retainer bolt (5) from the cap (4).

Torque for assembly: : Retainer bolt : 44N-m (4.5kgf-m)

５

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

４

44-19

Steering Valve

115ZIV-3

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

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

8)Remove the plug (9).

Torque for assembly: : Plug : 176N-m (18.0kgf-m)

９

44-20

Steering Valve

115ZIV-3

HYDRAULIC 44

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

１１

９

１０

10)Remove the plug (12).

Torque for assembly: : Plug : 176N-m (18.0kgf-m)

１２

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.

１３

44-21

Steering Valve

115ZIV-3

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) : With liquid adhesive (Loctite 262 or equivalent)

30〜40

１４

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).

１６

１５

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).

１８

１７２１

９

２１１９

２０

２３２２２１

９０ＺＡ４４−０３２

44-22

Steering Valve

115ZIV-3

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

44-23

HYDRAULIC 44

Stop Valve

115ZIV-3

HYDRAULIC 44

Stop Valve １６ １５ １４

１２

１３

１１ ９

６

７

１０

８

５ ３

２

１

1.

2.

3.

4.

5.

6.

９０Ｋ４４０５１

４

Bolt Boot Flange Bolt Wiper Spacer

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

44-24

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

Stop Valve

115ZIV-3

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.

２

１

(The illustration shows the machine left hand side.)

２

３

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.

４ １１５Ｋ４４００８

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

2.Reinstalling stop valve To reinstall the stop valve, follow the above procedure in the reversed procedure.

44-25

Stop Valve

115ZIV-3

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

Stop valve (installed on rear chassis)

Plate (installed on front chassis)

3mm Stop valve actuation position ９０ＺⅣ

2)When the chassis stopper clearance is 25 〜 39mm, confirm that the stop valve is forced in 3mm when the stopper bolt length is 28 〜 32mm as shown.

3)Check each section for oil leakage.

44-26

Stop Valve

115ZIV-3

HYDRAULIC 44

Disassembling and Reassembling Stop Valve

２

１

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.

８

７ ５

４

6)Remove the washer (6), spring (7), O-ring (9) and poppet (8) from the spool assembly (4).

９ ６

Two flats

９０Ｋ４４０５５

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

44-27

Multiple Control Valve

115ZIV-3

HYDRAULIC 44

Multiple Control Valve T5 T3

Overload relief valve with make -up function

T4 T8 L 1

T7

T2

T7

T6

T1

T10 Make-up valve

T9 T6

T7

T11

Boom spool

T9

Bucket spool

Main relief valve

T6

T6 T1 ９７ＺＡ４４０９

: Tightening torque T1 : 196N-m (20.0kgf-m) T2 : 284N-m (29.0kgf-m) T3 : 226N-m (23.0kgf-m) T4 : 39N-m (4.0kgf-m) T5 : 245N-m (25.0kgf-m) T6 : 54N-m (5.5kgf-m) T7 : 74N-m (7.5kgf-m) T8 : 39N-m (4.0kgf-m) T9 : 127N-m (13.0kgf-m) T10 : 10N-m (1.0kgf-m) T11 : 29N-m (3.0kgf-m)

: 100kg

L1 : Screw lock agent application (Three Bond 1327)

44-28

Multiple Control Valve

115ZIV-3

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

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.

３

５ ４

２

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

６

６

１１５Ｋ４４０１１

44-29

Multiple Control Valve

115ZIV-3

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) : Multiple control valve : 100kg ９

１０

１１５Ｋ４４０１３

44-30

Multiple Control Valve

115ZIV-3

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.

44-31

HYDRAULIC 44

Multiple Control Valve

115ZIV-3

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 Torque for assembly: : Bolt : 54N-m (5.5kgf-m)

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 Torque for assembly: : Bolt : 39N-m (4.0kgf-m) : Screw lock agent application (Three Bond 1327)

４

３

44-32

Multiple Control Valve

115ZIV-3

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

７

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 Torque for assembly: : Overload relief valve : 74N-m (7.5kgf-m) Note: The overload relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary. １０

7)Remove the main relief valve (11).

Hexagon width across flat: 41mm Torque for assembly: : Main relief valve : 127N-m (13.0kgf-m) Note: The main relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary.

１１

44-33

Multiple Control Valve

115ZIV-3

HYDRAULIC 44

8)Remove the plug (12), and then remove the spring (13) and the poppet (14).

Hexagon hole width across flat: 14mm Torque for assembly: : Plug : 226N-m (23.0kgf-m)

１４ １２

１３

9)Remove the make up valve (15) from the body.

Hexagon width across flat: 34mm Torque for assembly: : Make up valve : 127N-m (13.0kgf-m)

１５

2.Reassembling multiple control valve To reassemble the multiple control valve, follow the above disassembling 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.

44-34

Boom Cylinder

115ZIV-3

HYDRAULIC 44

Boom Cylinder １１

２

１２

２５ １５

３

１６ １７ ２２ ５

６

２３

２４ ２０ １８ ６

１９ ２１

２２ １

４ ９Ｔ２

Ｔ１ ７

１１５Ｍ４４００１

1. Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 7. Piston nut (Width across flat 120mm) 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

: 508kg Tightening torque T1 : 9,807N-m (1,000kgf-m) T2 : 843N-m (86kgf-m)

44-35

Boom Cylinder

115ZIV-3

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 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. １１５Ｖ４４００２

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

3)Temporarily sling the boom cylinder. : Boom cylinder : 508kg Note: Cover the disconnected pipe with vinyl, plugs, or caps to protect them from dust, water and dirt

１１５Ｋ４４０１６

44-36

Boom Cylinder

115ZIV-3

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.

４

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

８

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 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.

44-37

Bucket Cylinder

115ZIV-3

HYDRAULIC 44

Bucket Cylinder

11

2

12 14 13 24

12

15

22

3

16

22

17

6

6

20 18 19 6

22

4

6 RH ONLY

22

1

26

5

25

21 23 T1 7

25 26

8

RH ONLY S/N 11M1-9101〜

10 T2

9

１１５Ｍ４４００２

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 (S/N 11M1-9101 〜) 26. Plug (S/N 11M1-9101〜) : Bucket cylinder : 245kg Tightening torque T1 : 5,884N-m (600kgf-m) T2 : 883N-m (90kgf-m)

44-38

Bucket Cylinder

115ZIV-3

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 １１５Ｋ４４０２０

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

Bucket Cylinder

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

５

４ １１５Ｍ４４００３

3)Disconnect the grease pipe (5).

4)Temporarily sling the bucket cylinder (6).

After that, remove the bolt (7) to remove the pin (8).

８

: Bucket cylinder : 245kg

６

１１５Ｋ４４０２２

44-39

７

Bucket Cylinder

115ZIV-3

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).

９

１１

１０

１１５Ｋ４４０２３

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

１１５Ｖ４４００３

44-40

Bucket Cylinder

115ZIV-3

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.

1)Bleed 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

１１５ＺＡ ４４−０４７−４

2)Adjust the bucket positioner so that the clearance between the switch and the rod is 5±2mm.

44-41

Steering Cylinder

115ZIV-3

HYDRAULIC 44

Steering Cylinder １３

14 ２

２３

１５ １６ １７

６

１８ ２１

３

２４

２３

１９ ２０

６

２３

２２ １

５ １０

４

２３

T2 ９

T1 ８

１１５Ｍ４４００４

1. Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 8. Piston nut 9. Stop ring 10. Stop ring 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 21. O-ring 22. Scraper ring 23. Dust seal 24. Buffer ring

: Steering cylinder : 37kg Tightening torque T1 : 1,373N-m (140kgf-m) T2 : 2,550N-m (260kgf-m)

44-42

Steering Cylinder

115ZIV-3

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.

６

５

４

２

３

１ ７

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

1)Remove the bolts (1) (4 pcs). １１５Ｋ４４０２６

: Drain : Approx. 2 l Note: Cover the disconnected hose with vinyl, caps, or plugs to protect them from dust, water, and dirt.

８

９

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 Note: Cover the disconnected hose and the cylinder with vinyl, cap or plugs to protect them from dust, water, and dirt. １１５Ｋ４４０２７

3)Remove the bolt (6), and then remove the pipe (7).

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.

１０

１１５Ｋ４４０２８

: Steering cylinder : 37kg 44-43

Steering Cylinder

115ZIV-3

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

１０

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.

１４

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

１１５Ｋ４４０３０

44-44

Steering Cylinder

115ZIV-3

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 1)When 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.

2)Bleed 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 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.

44-45

HYDRAULIC 44

Hydraulic Cylinder

115ZIV-3

HYDRAULIC 44

Hydraulic Cylinder 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

３

: Bolt : 843N-m (86.0kgf-m) (Boom cylinder) 883N-m (90.0kgf-m)(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.

９０ＺⅣ４４０８

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

４

Wooden block

44-46

Hydraulic Cylinder

115ZIV-3

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.

５

４

Matchmark

６

6)Use a hydraulic jack or hydraulic cylinder to loosen the piston nut (6).

Tightening torque Boom cylinder : 9,807N-m (1,000kgf-m) Bucket cylinder : 5,884N-m (600kgf-m) Steering cylinder : 1,373N-m (140kgf-m)

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.)

８

７

２０ １０２０ １２ ９

８

１１

１１

(Boom cylinder) (Bucket cylinder)

44-47

４

１０ ９

(Steering cylinder)

Hydraulic Cylinder

115ZIV-3

HYDRAULIC 44

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

４

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).

１

１７ １６

１８

１５

１４

１３

For boom and bucket cylinder

１１５Ｅ４４００３

１

１６

１７

１５

１４

2.Reinstalling cylinder To reinstall the cylinders, follow the above removal procedure in the reversed direction.

44-48

１３

Hydraulic Cylinder

115ZIV-3

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.

１０

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.

１３

Note: Caulk the scraper ring (13) at four points to prevent the seal from coming out.

２

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.

３

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)

44-49

Hydraulic Cylinder

115ZIV-3

HYDRAULIC 44

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

１

Caulking

１３ ６５Ｋ４４０６７

１

１３

Caulking

44-50

７０Ｖ４４００５

Pilot Valve

115ZIV-3

HYDRAULIC 44

Pilot Valve For bucket control

Neutral

1 Dump

Roll back

For bucket control

For boom control

8 2

3

T

To tank port

4 5 6

From pump port

7

P

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

44-51

Pilot Valve

115ZIV-3

HYDRAULIC 44

Tightening Torque : Tightening torque T1 : 29N-m (3.0kgf-m) T2 : 36N-m (3.7kgf-m) T3 : 17N-m (1.7kgf-m) T4 : 29N-m (3.0kgf-m) T5 : 29N-m (3.0kgf-m) T6 : 17N-m (1.7kgf-m) T7 : 42N-m (4.3kgf-m) T8 : 12N-m (1.2kgf-m)

For boom control Front

For bucket control

T3

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

T3

T5

T5 T6 L1

T6 L1

T7

T8

T7

T8

T7

T7

T4

T4 T4 T4

T2

９０Ｋ４４０９０

T1

T1

44-52

Pilot Valve

115ZIV-3

HYDRAULIC 44

Removing and Reinstalling Pilot Valve

１

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

２

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

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

３

3)Disconnect the electrical line (3) of pilot valve. ８５Ｋ４４０３３

4)Remove the knobs (4), and then separate QUAD (PUS) switch (5).

Note: Switch design may vary slightly.

４

４

５ ８５Ｋ４４０３４

5)Remove the retainer bolts 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

44-53

Pilot Valve

115ZIV-3

HYDRAULIC 44

6)Disconnect the electric line coupler from the pilot valve, and disconnect all the hoses (11). : Drain oil : Approx. 1 l Note: Before disconnecting the electric coupler and hoses, be sure to put match marks on them.

After disconnection, cover the discon- nected hoses with vinyl, caps, or plugs to protect them from dust and dirt.

１１ １１

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

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.

44-54

Pilot Valve

115ZIV-3

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.

For boom control

1)Clamp the pilot valve in a vise.

Pull up the boot (1) to remove it from the cover (2).

Front For bucket control

７０Ｋ４４０４５

１

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) Note: Before removing the solenoid (3), measure the distance "A".

A

３ ４

２ Lock nut

７０Ｋ４４０４６

７０ＺⅣ４２０７

Carefully store the ball (4).

44-55

Pilot Valve

115ZIV-3

HYDRAULIC 44

3)Remove the socket bolt (5).

Torque for assembly: : Bolt : 29N-m (3.0kgf-m)

５ ６ ７

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

７０Ｋ４４０４７

5)Loosen the socket bolt (8).

８

Torque for assembly: : Retainer bolt : 17N-m (1.7kgf-m) : Screw lock agent (Three Bont 1327) application 6)Remove the cam shaft (9).

Temporarily install the socket bolt (5) into Note: 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. １０

７

8)Put match mark on the cover (2) and the case assembly.

Remove the socket bolt (10).

２

７０Ｋ４４０４９

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

７０Ｋ４４０５０

44-56

Pilot Valve

115ZIV-3

10)Remove the plug (11) together with the push rod (12).

Carefully store the spring and spring seat in Note: 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).

１６

１４

１５

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)

１７ １８

１４ ７０Ｋ４４０５３

44-57

Pilot Valve

115ZIV-3

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 70ZIV〜115ZIV Boom raise 70ZIV〜85ZIV Roll back 70ZIV〜85ZIV Dump 70ZIV〜85ZIV

１１

１２

１９

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).

Carefully remove the plane washer so that Note: 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.

２２ ７０Ｋ４４０５５

2.Reassembling pilot valve

２４

To reassemble the pilot valve, follow the above disassemble procedure in the reversed direction.

Clean and check all the parts. If a part is Note: 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 C). If measured in temperature (20 ° extremely low temperatures the resistance will be less. At operating temperature the resistance will be higher.

２３

Sharp edge side

７０ＺＡ４４０８

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.

44-58

HYDRAULIC GROUP 45 Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-3 Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-4 Pilot Valve ・

45-1

Steering Valve

115ZIV-3

HYDRAULIC 45

Steering Valve

Steering valve

1

１１５ＺＡ４５０１

Tightening torque No. 1

Unit : N-m(kgf-m) Item

Steering valve retainer bolt

45-2

Standard value

Solution

216N-m (22.0kgf-m)

Tightening

Hydraulic Cylinder

115ZIV-3

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder

(Note) The cylinder showin in the above figure is the boom cylinder.

２

１

３ １１５Ｋ４２０２０−１

Steering cylinder

(Note) The cylinder showin in the above figure is the steering cylinder.

２

１

３ １１５Ｋ４２０２０−２

1. Clearance between rod and bushing

Unit : mm Judgement standard

No.

Standard dimension of rod dia.

Item

+0.200

0.096

-0.090

+0.060

0.290

-0.036

+0.195

0.096

-0.090

+0.060

0.285

-0.030

+0.110

0.030

-0.076

0

0.186

〜

-0.036

〜

〜

〜

〜

〜

φ 70

Steering cylinder

clearance

〜

φ 100

Bucket cylinder

Bushing

〜

1

Limit

Standard

Rod

〜

φ 120

Boom cylinder

Standard value

Solution

Bushing

Clearance

+0.300

0.390

Replacement

+0.295

0.385

Replacement

+0.210

0.286

Replacement

2. Tightening torque No.

Item Piston nut tightening torque N-m (kgf-m)

2 Piston nut width across flat mm 3

Rod cover bolt tightening torque N-m (kgf-m)

Boom cylinder

Bucket cylinder

Steering cylinder

M85 × 2 9,807 (1,000)

M76 × 2 5,884 (600)

M42 × 1.5 1,373 (140)

120

110

65

843 (86)

883 (90)

(Rod cover) 2,550 (260)

45-3

Pilot Valve

115ZIV-3

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 Brake Valve Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-13 Accumulator ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-23 Unloader Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-32 Auto-adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-36 Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-37 Oil Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-43 Parking Brake Assembly ・

54-1

Brake Valve Assembly

115ZIV-3

BRAKE 54

Brake Valve Assembly (S/N 11M1-9001〜9100) Accumulator port

Auto adjuster valve

Accumulator port

Auto adjuster valve １１５Ｊ５４００１

Tank port

３０

３２

３１ ２９

２３２２２１２０ ２７

１９ １８

２６ ３３ ２２ ２８ ２４ １６１７

３ ４ ７ １４

１３ １２ ９

８ １０

１１

１５ ２

５ ６ ３４

３５

１１５Ｗ５４００１

1. Body

13. Cover

25. Spring washer

2. Spool

14. O-ring

26. Retainer

3. Plunger

15. O-ring

27. Case

4. Bolt

16. Cover Assembly

28. Oil seal

5. Spring seat

17. Bolt

29. Ring

6. Spring

18. Spring

30. Input spool

7. Spool

19. Snap ring

31. Dust cover

8. Plunger

20. Plate

32. Push rod

9. Spring seat

21. Spring seat

33. Snap ring

10. Snap ring

22. Spring

34. Pressure difference piston

11. Spring

23. Spring

35. Switch assy

12. Bolt

24. Bolt 54-2

Brake Valve Assembly

115ZIV-3

BRAKE 54

Tightening Torque (S/N 11M1-9001〜9100)

T3

T2

T4

T1 L1 １１５Ｊ５４００３

:Tightening torque T1 : 9N-m (0.9kgf-m) width across flats : 10mm T2 : 26N-m (2.6kgf-m)

width across flats : 6mm

T3 : 34N-m (3.5kgf-m)

width across flats : 14mm

T4 : 49N-m (5.0kgf-m)

width across flats : 8mm

L1 : Screw lock agent application (Three Bond 1327)

54-3

Brake Valve Assembly

115ZIV-3

BRAKE 54

Brake Valve Assembly (S/N 11M1-9101〜)

Brake Valve (Main Valve) (This is located in the left side of the operator's room) Ａ−Ａ ３６

３５

４０ ４１ ３８ ３７ ２９

３９

４４ Ａ

３４

３２

４３

３３ ２５

４２

２６

２８ Ａ

３０ ３１ ２４ １４ １５ １７

５１ ２３

Tank port

Pilot port

２７ １９ ２２

１６

２１

１８

２０

４

１３ ５ １

３

Ｂｒａｋｅ ｐｏｒ ｔ

４７ ４６

２

Accumulator port

１０ ６

1. Body 2. Spool 3. Spring 4. Spring seat 5. E-ring 6. Spring seat 7. Stop ring 8. Plunger 9. Spring 10. O-ring

７

９ ４５

11. Cover 12. Bolt 13. Spool 14. Input spool 15. Spring seat 16. Sleeve 17. Case 18. Spring 19. Spring 20. Case

１１ ６５Ａ５２００３ １２

８

21. Stop ring 22. Spring 23. Cover 24. Oil seal 25. Stopper 26. C-ring 27. O-ring 28. Mounting plate 29. Bushing 30. Bolt

54-4

31. Washer 32. Seat 34. Pedal 35. Roller 36. Pedal cover 37. Pedal pin 38. L pin 39. Pedal collar 40. Washer

41. Pin 42. Screw 43. Nut 44. Pedal cover 45. Orifice 46. Plug 47. O-ring 51. Orifice

Brake Valve Assembly

115ZIV-3

BRAKE 54

Tightening Torque (S/N 11M1-9101〜)

T1

T3 T2 T2 T4

T3

:Tightening torque T1 : 7.85 〜 11.8N-m (0.8 〜 1.2kgf-m)

width across flats : 12mm

T2 : 9.81 〜 14.7N-m (1 〜1.5kgf-m)

width across flats : 5mm

T3 : 19.6 〜 25.5N-m (2 〜2.6kgf-m)

width across flats : 6mm

T4 : 29.4 〜 39.2N-m (3 〜4kgf-m)

width across flats : 6mm

54-5

Brake Valve Assembly

115ZIV-3

BRAKE 54

Removing and Reinstalling Brake Valve (S/N 11M1-9001〜9100) 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.

３

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.

Brake valve

1)Disconnect the rod (1) at the ball joint (2) part and remove the return spring (3).

１ ２

１１５Ｋ５４００１

2)Remove the seat and the seat stand and then disconnect the hoses (4).

４

８

１０Brake valve

７ １１５Ｅ５４００２

７

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.

８

１０

９ １１５Ｋ５４００３

54-6

Brake Valve Assembly

115ZIV-3

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.

54-7

BRAKE 54

Brake Valve Assembly

115ZIV-3

BRAKE 54

3.Adjustment procedure of brake pedal linkage

(Standard released condition) Pedal depressed condition

WARNING Ａ

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 under the standard released condition. ② Adjust the bolt (A) so that the valve stroke is 20mm under the pedal depressed condition.

Valve stroke

１２

９７ＺＡ５４０２

(Standard released 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. 〔 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 under the pedal depressed condition.

L. H. pedal

Ｂ

４

3)After adjusting the right and left brake pedal linkage, install the return spring (4).

１３ １４ ９７ＺＡ５４０３

Reference fig. : 244mm

Standard length of engagement

Standard length of engagement : 17mm Min. 11mm

１２ ３

※２４

９７ＺＡ５４０６

１１５Ｊ５４００５

Note: The inching timing can be adjustable by the ＊mark dimension.

Smaller＊dimension : Shorter inching timing Larger＊dimension : Longer inching timing 54-8

Brake Valve Assembly

115ZIV-3

BRAKE 54

Removing and Reinstalling Brake Valve (S/N 11M1-9101〜) 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.

BRAKE VALVE GROUP

9

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.

4 6 8

5

1)Disconnect the hoses (1) (2) (3) (4) (5) (6) (7) (8) (9).

1 2 3 7

Note: Cover the disconnected pipes and the hoses with clean vinyl to protect them from dust and dirt.

BRAKE VALVE 10 BRAKE VALVE 10

2)Remove the retainer bolts (10) and then remove the brake valve assembly.

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)Completely bleed the brake line of air following the procedure of Section 53. c) Check the brake performance following the procedure of Section 53.

１１５Ｍ５４００６

54-9

115ZIV-3

Disassembling and Reassembling Brake Valve (S/N 11M1-9001〜9100) 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 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) width across flats: 8mm 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) width across flats: 14mm : 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) width across flats: 6mm

54-10

BRAKE 54

115ZIV-3

8)Slowly pull out the spool (7) and the spool (2) then remove the plunger (8) and the plunger (3) from each spool 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) width across flats: 10mm

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 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

φ22.4 ９７ＺＡ５４０５

54-11

BRAKE 54

115ZIV-3

BRAKE 54

Disassembling and Reassembling Brake Valve (S/N 11M1-9101〜) 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.

1)Remove the bolt (1).

Torque for assembly : Bolt 19.6〜25.5N-m (2〜2.6kgf-m)

2 3 4

2)Remove the spring seat case (4), spring (5), the case (7).

5

Spool

6 7

3)Remove the bolt (8).

Torque for assembly : Bolt 19.6〜25.5N-m (2〜2.6kgf-m)

1

9

10

4)Remove the spring (10), and the spool.

8

１１５Ｍ５４００７

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.

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.

54-12

Accumulator

115ZIV-3

BRAKE 54

Accumulator １２ ４ ２ ６ １

１１１０ ９

１２

７ ８ ６ ７ ５ ６ ３

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 ６

３ ６ ２ ７ ９ ４

１１

１２

８

１０ ７

T3 T2

６

T1 １

T3 ７ ８ ６ ７ １１５Ｍ５４００８

:Tightening torque T1 : 15N-m (1.5kgf-m) T2 : 0.5N-m (0.05kgf-m) T3 : 206N-m (21.0kgf-m)

５

54-13

Accumulator

115ZIV-3

BRAKE 54

Removing and Reinstalling Accumulator 1.Removing Accumulator Refer to Section 52 for the location of the accumulator.

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.

３

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.

４

５

1)Remove the hose (1).

2)Remove the nut (2), bands (3), the rubber sheet (4) and then remove the accumulator (5).

２ １

: 16kg

５

４

２

３

１１５Ｋ５４０１１

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.

54-14

Accumulator

115ZIV-3

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.

１１１０９

１２４ ２ ６ １

７ ８ ６ ７５ ６ ３ １２

2) Insert the core tool to the core and turn counterclockwise. And then remove the core (9).

Torque for assembly : Core 0.5N-m (0.05kgf-m) Note: Do not reused the core once used, always use a new one. ９７Ｋ５４０１６

54-15

Accumulator

115ZIV-3

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

54-16

Accumulator

115ZIV-3

BRAKE 54

2.Reassembling accumulator Before starting work: ・ Clean the parts.

1. Install the seal to the piston (5).

1) Apply grease in the seal groove of the piston (5). ５ × : apply grease

９７Ｋ５４０２０

2) Before installing, heat the back up ring (7) up to C. 80〜100 ° Install the back up ring (7) as illustrated.

７

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).

８

９７Ｋ５４０２３

5) Apply grease on the seal.

９７Ｋ５４０２４

54-17

Accumulator

115ZIV-3

BRAKE 54

2. Apply grease a bit in the inner surface of piston guide.

Install the piston guide to the cylinder (1).

Piston guide

５

１

９７Ｋ５４０２５

3. Insert the piston (5) to the piston guide, and then press in the hydraulic cylinder.

１

Hydraulic cylinder

５

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)

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 ・ ・ ・0.5N-m (0.05kgf-m) : ♯ 9・

９７Ｋ５４０２７

54-18

Accumulator

115ZIV-3

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 ・15N-m (1.5kgf-m) : ♯ 11・

Disassembly & Reassembly Jig 1.Core tool 5V1 Repair thread(core thread)

Section A-A

２． ２

４． ５

Ａ

Ａ

φ２１

６

５１±０． ５

９７Ｋ５４０２８

Thread size ・φ 5.2 × 0.705 5V1・ (For auto mobile tire valve)

54-19

Accumulator

115ZIV-3

BRAKE 54

φ１４

８

３０

2.Jig (A) : For nut and oil port removal and reinstallation

φ６

φ４０ φ９０

３００ ９７Ｋ５４０２９

3.For top cover removal １８０

５／８−１８ＵＮＦ

６０

φ１４

φ２８

９７Ｋ５４０３０

4.Piston guide ８５ ３６

φ１１４． ３

φ１１０

φ１００

φ１０２

No bur

９７Ｋ５４０３１

54-20

Accumulator

115ZIV-3

Procedure for Charging Nitrogen Gas ・ 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. Pressure gauge (4903kPa (50kgf/cm2)) 3. Hose assembly 4. Nitrogen (N2) gas cylinder

BRAKE 54

1 2

1-1

1-3

1-2

3

4

Accumulator Ｍ９Ⅱ 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.

９７Ｋ５４０３４

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.

54-21

Accumulator

115ZIV-3

〔Charging pressure : 2942kPa (30kgf/cm2) 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.

PX=2942kPa(30kgf/cm2)×{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.

54-22

BRAKE 54

Unloader Valve

115ZIV-3

BRAKE 54

Unloader Valve (S/N 11M1-9001〜9100)

４ Drain port

Pilot port

Pump port

５

Ｂ Ａ

７ ８

３ ２

Orifice B

６

Orifice A

１

Accumulator port

１１５Ｍ５４００１

1. Body 2. Spool 3. Spring 4. Pressure governor

5. Low pressure indicator 6. Check valve 7. Pilot poppet 8. Plunger

54-23

Unloader Valve

115ZIV-3

BRAKE 54

Tightening Torque (S/N 11M1-9001〜9100) T3 T4

９

６ ２

T2 ３

１

８ T1

５ ６

４

５ １０ １１

７ ５

１４ １２

T1 ８

:Tightening torque T1 : 49N-m (5.0kgf-m)

width across flats : 8mm

T2 : 15N-m (1.5kgf-m)

width across flats : 5mm

T3 : 11N-m (1.1kgf-m)

width across flats : 28.6mm

T4 : 98N-m (10.0kgf-m)

width across flats : 30mm

54-24

１１５Ｊ５４００８

Unloader Valve

115ZIV-3

BRAKE 54

Unloader Valve (S/N 11M1-9101〜) Ｂ−Ｂ

Accumulator port

６

Tank port

２４

Ａ−Ａ ７

２１

２２ Second port

２３

１０

２０ ８

１９ １８

１

９

Pilot port (Accumulator port)

１７

３

１６

５

１５ ４ １１

１２

１４

２

Pump port

１３

1.

2.

3.

4.

5.

6.

7.

8.

9.

Body Spring Spool O-ring Plug Orifice Orifice O-ring Plug

10. Plug (Gauge port) 11. Plunger governor 12. Spring 13. O-ring 14. Plug 15. Pilot poppet 16. Spring seat 17. Spring 18. Spring

54-25

19. O-ring 20. Plug 21. Adjusting screw 22. Lock nut 23. Packing 24. Cap nut

１１５Ｍ５２００２

Unloader Valve

115ZIV-3

BRAKE 54

Tightening Torque (S/N 11M1-9101〜)

T3

T1

44 43

T5

42

T2

T2

25

40 39

29

41

28 27

37 38

26

24

30 23 22

36 35

T4 31

32 33 34

:Tightening torque T1 : 118 〜 137N-m (12 〜 14kgf-m)

width across flats : 12mm

T2 : 9.81 〜 14.7N-m (1 〜1.5kgf-m)

width across flats : 5mm

T3 : 98.1 〜 118N-m (10 〜 12kgf-m)

width across flats : 36mm

T4 : 78.5 〜 98.1N-m (8 〜10kgf-m)

width across flats : 30mm

T5 : 29.4 〜 39.2N-m (3 〜4kgf-m)

width across flats : 6mm

54-26

Unloader Valve

115ZIV-3

BRAKE 54

Removing and Reinstalling Unloader Valve (S/N 11M1-9001〜9100) 1.Removing unloader valve Refer to Section 52 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 hoses (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.

１

４

１ ３

５ ２

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.

１１５Ｍ５２００３

54-27

Unloader Valve

115ZIV-3

BRAKE 54

Removing and Reinstalling Unloader Valve (S/N 11M1-9101〜) 1.Removing unloader valve Refer to Section 52 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 hoses (1), the pipe (2), 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.

１ ２ ４

１

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.

５

54-28

１１５Ｍ５２００４

Unloader Valve

115ZIV-3

Disassembling and Reassembling Unloader Valve (S/N 11M1ー 9001〜9100) 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 "Tightening Torque" 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) width across flats: 8mm 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) width across flats: 5mm 4)Remove the plug (12), and then remove the O-ring (14), the spring (11), and the ball (10).

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) width across flats: 28.6mm

54-29

BRAKE 54

Unloader Valve

115ZIV-3

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 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)installed properly in the position

54-30

BRAKE 54

Unloader Valve

115ZIV-3

BRAKE 54

Disassembling and Reassembling Unloader Valve (S/N 11M1-9101〜 ) 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.

1 3

2

1)Remove the plug (1) and then remove the spool (2) and spring (3).

Torque for assembly : Plug 118〜 137N-m (12 〜14kgf-m) Note: Do not disassemble the pressure governor unless it is necessary.

１１５Ｍ５４００９

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.

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.

54-31

Auto-Adjuster Valve

115ZIV-3

BRAKE 54

Auto-Adjuster Valve Construction

１２

１３ ８

３

１１

１０

Brake piston port

Brake valve port

１

1. Cylinder 2. Piston 3. O-ring 4. Valve body 5. Valve 6. Spring 7. O-ring

１１５Ｗ５４００５

２

６ ５

７

４

8. Body 9. O-ring 10. Bolt 11. Air bleeder screw 12. Cap 13. Screw

54-32

９

Auto-Adjuster Valve

115ZIV-3

BRAKE 54

Tightening Torque T2 T2

T1

１１５Ｊ５４０１０

:Tightening torque T1 : 49N-m(5.0kgf-m) T2 : 12N-m(1.2kgf-m)

54-33

Auto-Adjuster Valve

115ZIV-3

BRAKE 54

Removing and Reinstalling Auto-Adjuster Valve 1.Removing auto-adjuster 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.

4

6

6 5

Before starting work: Note: Loosen the air bleeder nipple (Left and Right) and then bleed off the remain pressure of circuit.

3 2

1

1)Disconnect the pipes (1) (2) and the hoses (3) (4) (5).

Remove four retainer bolts and the auto-adjuster valve (6).

Oil will be drained from the hose. Place a container to catch the drained oil.

１１５Ｍ５２００５

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 52.

54-34

Auto-Adjuster Valve

115ZIV-3

BRAKE 54

Disassembling and Reassembling Auto-Adjuster Valve 1.Disassembling auto-adjuster 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 49N-m (5.0kgf-m)

9

2

2)Separate the cylinder into two sections (2).

3

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).

6

7

8

5 1

4

１１５Ｍ５４０１０

5)Disassembled 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

Service Brake

115ZIV-3

BRAKE 54

Service Brake Removing and Reinstalling Service Brake Follow the steps in the Section 24 (Power Group) for removing and reinstalling 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.

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

Oil Cylinder

115ZIV-3

BRAKE 54

Oil Cylinder １３

１７

９ ６

２２

２

１２

１６

１２

４

３ １４ １５ ７

５

２０ １９

１ １０ １１

Stroke 65mm

１８ ８

２１ ２３

(φ10mm) Hole 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. pring 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

T1

140mm

230mm 65mm Stroke 295mm(Installedlength) 435mm(Freelength) Spring force

T1 : 1,275N-m (130kgf-m) T2 : 314N-m (32kgf-m)

T2 １１５ＺＡ５４０９

54-37

Oil Cylinder

115ZIV-3

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).

１

２

１１５Ｋ５４０１６

３ 2-M12 × 1.75

Bolt (5) size : M12 × 1.75

Oil port 130

PF 1/4(O-ring) １１５ＺＡ５４１０

54-38

４ １１５ＺＡ５４１１

Oil Cylinder

115ZIV-3

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 Note: Thread size for eye bolt:M12 × 1.75

７

Oil port PF 1/4(O-ring)

4)Remove the nut (8) and remove the oil cylinder (7).

８

１１５Ｋ５４０２０

７

１１５Ｋ５４０２１

2.Reinstalling oil cylinder To reinstall the oil cylinder, follow the above removal procedure in the reversed direction.

54-39

Oil Cylinder

115ZIV-3

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 Adjusting bolt

１

Joint yoke ２ Pin ３ Arm ４

１１５ＺＡ５２０５

2)Adjust the joint yoke (2) so that the dimension (A) is 17.5mm and then install the pin (3) to connect the joint yoke (2) and the arm (4).

Lock nut Joint yoke

Ａ

２

１１５ＺＡ５４１３

54-40

Oil Cylinder

115ZIV-3

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 drawing when disassembling.

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) 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 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

９

６

１１５ＺＡ５４１４

54-41

Oil Cylinder

115ZIV-3

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 and more Stroke:175mm and more Press capacity:1,500kg 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)

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 the drawing and the tightening torque value when reassembling.

Note: Apply a coat of hydraulic oil to the seals.

54-42

BRAKE 54

Parking Brake Assembly

115ZIV-3

BRAKE 54

Parking Brake Assembly 4

1

3

2

Front

1. Parking brake 2. Brake drum 3. Pillow unit 4. Oil cylinder 5. Propeller shaft 5 １１５ＺＡ５４１５

2

3 5

8

4 7

A

1

Thickness of lining (A)…16±0.5mm Wearing limit……………11.0mm

6 １１５ＺＡ５２０６

１１５ＺＡ５２０７

Parking brake 1. Adjuster

4. Brake shoe

7. Camshaft

2. Bracket

5. Spring

8. Lever

3. Brake cover

6. Anchor pin 54-43

Parking Brake Assembly

115ZIV-3

BRAKE 54

Tightening Torque T1

Oil cylinder

T3 2nd propeller shaft Parking brake

T4

:Tightening torque

T2 L 1

T1 : 206N-m (21.0kgf-m) (With lub. oil) T2 : 77N-m (7.8kgf-m) T3 : 1,030N-m (105.0kgf-m) T4 : 721N-m (73.5kgf-m) (With lub. oil) T5 : 220.7N-m (22.5kgf-m) T5 L 1 Differential gear

L1 : Screw lock agent application (Three bond 1327)

１１５ＺＡ５４１６

Parking brake tightening torque 50

30

13 12

23 22

17

19

18

32

11

27

21

31

9

T

14

5

24

1

15 16

T2 1

4

33

6

7

8

T3

:Tightening torque T1 : 34N-m (3.5kgf-m) T2 : 157N-m (16.0kgf-m)

１１５ＺＡ５４１７

54-44

T3 : 34N-m (3.5kgf-m)

Parking Brake Assembly

115ZIV-3

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

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

２

: Parking brake assembly: Approx. 300kg

１１５Ｖ５４００１

3)Remove the retainer bolts (3) of the propeller shaft.

Torque for assembly : Bolt 221N-m (22.5kgf-m) : Screw lock agent application (Three bond 1327)

３

１１５Ｖ５４００２

54-45

Parking Brake Assembly

115ZIV-3

4)Remove the grease pipe (4) and remove the bolts (5).

Torque for assembly : Bolt 721N-m (73.5kgf-m) (with lub. oil)

BRAKE 54

４

５

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

Parking Brake Assembly

115ZIV-3

BRAKE 54

Disassembling and Reassembling Parking Brake 1.Disassembling Parking brake 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 drawing when disassembling.

1)Remove the dust cover (50).

Torque for assembly : Bolt (31) 34N-m (3.5kgf-m) 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) 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

１８

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.

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.

１６ １１５ＺＡ５４１９

Matchmarks

7)Pull out the camshaft (16).

Note: When assembly of the camshaft, insert the shaft so that the end face of the shaft upward.

１１５ＺＡ５４２０

54-47

Parking Brake

115ZIV-3

BRAKE 54

8)Remove the bolt (14) and then remove the bracket (9).

Torque for assembly : Bolt 156.9N-m (16.0kgf-m)

2.Reassembling parking brake 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.

１６

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.

Refer to Page 54-28 for the adjusting procedure.

９

Ａ Grease nipple

１１５ＺＡ５４２１

54-48

BRAKE GROUP 55 Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-3 Auto-adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-4 Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-5 Parking Brake ・

55-1

Brake Valve

115ZIV-3

BRAKE 55

Brake Valve (S/N 11M1-9001〜9100) Tank port

６

３

７

５

８ １

２

４

１１５Ｗ５５００１

Unit : mm Judgement standard No.

Item

Tolerance

Standard dimension

Shaft

Hole

Standard clearance

Allowable clearance

Solution

1

Clearance between body and spool

φ 18

-

+0.011 0

0.006〜 0.014

0.016

Replacement

2

Clearance between spool and plunger

φ 12

-0.010 -0.015

+0.018 0

0.010〜 0.033

0.037

Replacement

3

Clearance between cover and spool input

φ 22.4

-0.020 -0.053

+0.033 0

0.020〜 0.086

0.098

Replacement

Standard dimension No.

Item

Allowable load

Free length mm

Installation length mm

Installation load N (kgf)

Installation load N (kgf)

Solution

4

Spring

27.3

20

78 (8)

78 ± 7.8 (8 ± 0.8)

Replacement

5

Spring

39.5

27

58.8 (6)

58.8 ± 5.9 (6 ± 0.6)

Replacement

6

Spring

31

31

0

at 27.5mm in height 200 ± 20 (20.4 ± 2)

Replacement

7

Spring

53.3

47.5

78 (8)

78 ± 7.8 (8 ± 0.8)

Replacement

8

Spring

19.5

19.5

0

at 17.5mm in height 76.5 ± 7.8 (7.8 ± 0.8)

Replacement

55-2

Auto-adjuster Valve

115ZIV-3

BRAKE 55

Auto-adjuster Valve ５ ４ ６

３

１

Brake piston port

Brake valve port

２

１１５Ｗ５５００２

Unit : mm Judgement standard No.

Item

Tolerance

Standard dimension

Shaft

Hole

Standard clearance

Allowable clearance

Solution

1

Clearance between cylinder and piston

φ 55

-0.100 -0.146

+0.080 0

0.100〜 0.226

0.264

Replacement

2

Clearance between valve check and body

φ 14

-0.032 -0.059

+0.043 0

0.032〜 0.102

0.110

Replacement

Standard dimension No.

Item

Allowable load

Free length mm

Installation length mm

Installation load N (kgf)

Installation load N (kgf)

23.5

20

90 (9.2)

90 ± 13 (9.2 ± 1.3)

3

Spring

4

Bolt tightening torque

49N-m (5.0kgf-m)

5

Air bleeder screw, screw tightening torque

12N-m (1.2kgf-m)

Solution

Replacement

Tighten if necessary 6

39N-m (4.0kgf-m)

Valve body tightening torque

55-3

Service Brake

115ZIV-3

BRAKE 55

Service Brake 7

4

5

3 2, 6

1, 6

９７ＺＡ５２１９

Unit : mm Judgement standard No.

Item

Solution

Standard dimension

Tolerance

Wear limit

1

Thickness of steel plate

5.0

+0〜 -0.2

4.4

2

Thickness of friction plate

7.0

±0.1

5.7

3

Thickness of brake disc when measured by calipers (with brake applied)

41.0

+0.3〜 -0.5

35.2

4

Piston seal contact face

(Work dimension) 375

-0.210〜 -0.299

-

5

Piston seal contact face

(Work dimension) 305

+0 〜 +0.081

-

6

Distortion of steel and friction plate

-

-

0.30

Free length

Installation length

Installation load N (kgf)

54

49

287.3 (29.3)

7

Return spring

55-4

Replacement

-

Replacement

Parking Brake

115ZIV-3

BRAKE 55

Parking Brake

8 4 7

2

1

3

3

１１５ＺＡ５２０８

Clearance

Spring (4) released

5,6

１１５ＺＡ５２０６

Unit : mm Judgement standard No.

Item

Solution Standard dimension

Wear limit (limit)

11.0

0.5

1

Wear of lining

2

Deflection of drum

0.4 or more

Replacement

3

Lining inspection

Grease or oil on the lining

Replacement

4

Expansion of return spring

There is a clearance between the spring and the coil when the spring is released.

Replacement

5

Anchor pin

30.0

29.85

Replacement

6

Bushing

-

30.15

Replacement

7

Cam roller

40.3

40.1

Replacement

-

1.0

Replacement

8

Camshaft 0.05〜0.11

0.6

Replacement

Deflection Clearance to the bushing

55-5

Replacement

ELECTRICAL GROUP 64 Wiper Motor ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-4 Controller ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-6 Fuse ・

64-1

Removing and Reinstalling Wiper Motor

115ZIV-3

ELECTRICAL 64

Wiper Motor Removing and Reinstalling Wiper Motor 1.Removing wiper motor 1)Remove the cover (1). １

６５Ｋ６４００７

2)Remove the nut (2), and then remove the wiper arm (3).

２

３

3)Remove the nut (4) and the bolt (5). After that, remove the wiper arm (3).

６５Ｋ６４００８

４

５ ３

６５Ｋ６４００９

4)Remove the cover (6) and the cover (7). ６， ７

６５Ｋ６４０１０

64-2

Removing and Reinstalling Wiper Motor

115ZIV-3

5)Remove the defroster hose (8).

ELECTRICAL 64

９

6)Disconnect the electric line coupler (9) from the wiper motor.

８

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.

１３

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).

64-3

Removing and Reinstalling Controller

115ZIV-3

ELECTRICAL 64

Controller Removing and Reinstalling Controller １ ２

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.

１１５Ｋ６４００５

1.Removing controller (for transmission) 1)Remove the top cover (1) (2).

2)Disconnect the controller coupler (3 places) (3). ５

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). １

１１５Ｋ６４００８

64-4

Removing and Reinstalling Controller

115ZIV-3

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

115ZIV-3

ELECTRICAL 64

Fuse Removing and Reinstalling Fuse 1.Removing fuse from inside of control box.

CAUTION

１ ２

Before removing a fuse, be sure to turn off the starter key.

1)Remove the cover (1) (2).

１１５Ｋ６４０１０

2)Remove the bolt (3).

Fuse box

Fuse inside the control box 5A

LIGHTING HEAD LIGHT

SPARE

5A

R. WORK LIGHT

F. WORK LIGHT

10A 10A 10A

BACK LAMP STOP LAMP TURN SIGNAL

SPARE

3A

COLD STARTER

F. WIPER SPARE

FUEL VALVE

5A

NEUTRAL RELAY

5A

BATTERY RELAY

5A

AIRCON (OPTION)

5A

AIRCON (OPTION)

RADIO

20A 20A 20A

AIRCON (OPTION)

15A 15A 15A 15A 15A

SPARE

SPARE

5A

SPARE

4 WAY FLASHER HORN ROOM LAMP

5A

SPARE

5A

SPARE

10A 10A

R. WORK LIGHT (CAB)

PARKING BRAKE CONTROLLER BUZZER MONITOR

SPARE SPARE

３ １１５Ｋ６４０１１

5A

5A

BOOM KICKOUT BUCKET POSITIONER

R. WIPER

20A 10A 10A 15A 10A

SPARE

64-6

OPERATOR STATION GROUP 74

Air Conditioner .............................................................................................74-2

74-1

115ZIV _ 3

Air conditioner

OPERATOR STATION 74

Air Conditioner Air conditioner mount

Cover unit

Air damper unit

Air conditioner unit

Seat stand

Floor board

74-2

115ZIV _ 3

Air conditioner

OPERATOR STATION 74

Removing and installing of air conditioner Removing the air conditioner

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on level ground, and apply the parking brake.

• Lower the bucket to the ground, and block the tires.

• Pull out the engine key, and attach a tag indicating that startup is prohibited.

Before starting the work, •Recover the gas using a gas recovery unit.

•Remove the seat and the seat stand.

•Disconnect the air conditioner piping at the self-sealing coupling.

2 3 1

1) Remove the covers (1) to (5).

4

5

2) Disconnect the wiring (7) of the air conditioner (6) and the wiring (9) of the air damper (8) at each coupler.

9

8 6

7

74-3

Air conditioner

115ZIV _ 3

OPERATOR STATION 74

3) Disconnect the refrigerant piping (10) and the heater hose (11).

10

11

4) Remove the air conditioner mounting bolts (12) and the air damper mounting bolts (13). Then, remove the air conditioner (6) and the air damper (8).

8

6

13

12

Installing the air conditioner 1) Install the air conditioner in the reverse order of the removing procedure.

Reference After installing the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-4

115ZIV _ 3

Air conditioner

OPERATOR STATION 74

Condenser mount Receiver dryer

Condenser unit

Engine room Bracket

Condenser unit 1. Core 2. Fan shroud 3. Bracket 4. Bracket 5. Fan 6. Motor 7. Bolt 8. Resistor 9. Cable

7 6

2

8

5 1

9

4

74-5

3

115ZIV _ 3

Air conditioner

OPERATOR STATION 74

Removing and installing of condensers Removing the condensers

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on level ground, and apply the parking brake.

• Lower the bucket to the ground, and block the tires.

• Pull out the engine key, and attach a tag indicating that startup is prohibited.

1

Before starting the work, •Recover the gas using a gas recovery unit.

•Remove the air cleaner, etc. which may hinder removal.

1) Disconnect the condenser hose (1).

2) Disconnect the condenser wiring at the coupler (2).

Remove the condenser mounting nut (3), and remove the condensers.

2

3

Installing the condensers 1) Install the condensers in the reverse order of the removal procedure.

Reference After installing the condensers, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-6

115ZIV _ 3

Air conditioner

OPERATOR STATION 74

Compressor mount

3

T1 4

2 1 7 6 T2

5 Engine

T3

T2

115J74003

1. Compressor 2. Bracket 3. V belt 4. Compressor mounting bolt 5. Bracket mounting nut 6. Lock nut 7. Adjustment bolt

: Tightening torque T1 : 28N·m (2.9kg·m) T2 : 55N·m (5.6kg·m) T3 : 53N·m (5.4kg·m)

74-7

115ZIV _ 3

Air conditioner

OPERATOR STATION 74

Removing and installing of compressor Removing the compressor

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on a level ground, and lower the bucket, etc. to the ground • Block the tires, and apply the parking brake.

• In the starter key area, put up an indication that startup is prohibited.

5 4

6

Before starting the work, •Recover the gas using a gas recovery unit.

7

1) Loosen the bracket mounting bolt (1) and the lock nut (2). Turn the adjustment bolt (3) to make the V belt (4) slack, then remove the V belt from the compressor.

Tightening torque during assembly : Bolt (1) and nut (2) ....................53N·m (5.4kg·m) 2) Disconnect the compressor wiring and the cooler piping (5). Remove the compressor mounting bolt (6), and remove the compressor (7).

Tightening torque during assembly : Bolt (3)..........12N·m (1.2kg·m) : Bolt (6)..........28N·m (2.9kg·m)

Installing the compressor 1) Install the compressor in the reverse order of the removing procedure.

Reference •After installing the compressor, adjust the tension of the V belt. (Criteria: 8 to 10 mm/10 kg) •Charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leak.

•The quantity of the compressor lubricating oil (NDO1L2) is 180 cm3. Never use or mix any other oil.

74-8

2 3 1

Engine

115J74004

OPERATOR STATION GROUP 75

Air Conditioner .............................................................................................75-2

75-1

115ZIV _ 3

Air conditioner

OPERATION 75

Air Conditioner 1. Periodical Inspection/Servicing Inspection/maintenance item

Criteria

Action

Refrigerant

Charge quantity

Inspection/ Air bubbles should not be seen through sight glass. adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Compressor

Operating status

Belt tension pulley

Operating status

V belt

Damage and tension

Magnetic clutch should operate. Abnormal sounds Inspection/ adjustment/ should not be detected. replacement Abnormal sounds and backlash should not be Inspection/ detected. replacement Damages should not be detected.

Adjustment/ Tension should be proper. replacement

Blower motor and fan

Operating status

Abnormal sounds or vibration should not be detected.

Control mechanism

Operating status

Inspection/ replacement Each part should operate in accordance with switch Inspection/ operations. replacement Air quantity should not be so small as to hinder air Cleaning/ conditioning. replacement

Air filter for inside/outside air Blockage Each mounting area and piping

Clean

Looseness, gas leak and Looseness, gas leak and damage should not be damages detected.

Tightening/charge

2. Tightening Torque 1) Tightening torque for hose and pipes Connection type

Nut type

Connection area

Pipe size or bolt size

Tightening torque N·m (kgf·m)

Condenserexpansion valve

ø8 piping

15 (1.50)

Compressorcondenser

D1/2 piping

25 (2.50)

Evaporatorcompressor

D5/8 piping

34 (3.50)

Receiver

M6 bolt in receiver (4T) Any M6 bolt (6T) other than above

Special control region

Bolt size

Tightening torque N·m (kgf·m)

Head bolt of magnetic clutch

M6

13 (1.35)

Mounting bolt for servo motor for inside/outside air selection

M5

0.5 (0.05)

Fixing nut of blower motor and condenser fan

M6

5 (0.55)

Fixing bolt of blower motor and condenser motor

M5

3 (0.30)

7 (0.70)

Block joint Evaporatorcompressor

2) Tightening torque for screws and bolts in special control regions

12 (1.20)

75-2