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93211-00160 January 2004

Foreword

To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual. To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual. Disassembly & Reassembly Service Standard For the engine, refer to the engine Shop Manual provided by the engine manufacturer. The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service. This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.

(1)

Safety Precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below. ●This manual is intended for properly trained and equipped service technicians. ●Any work on the machine must be performed by the trained personnel only. ●Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine. ●Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles. ●Place the machine on level and solid ground, and place chocks against the wheels to prevent movement. ●Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the steering wheel. ●Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe. ●Be sure to apply the articulation stopper before starting work. ●While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks. ●When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping. ●Do not start to work in an enclosed area if adequate ventilation is not provided. ●To remove a heavy unit (20kgf (40 lbs) or more), be sure to use a crane or other lifting tool. ●Just after stopping operation, be careful not to directly touch a hot component. You may get burned. ●Contact tire manufacturer's local dealer for tire servicing and changing. ●Always store the tools in good condition, and use them properly. ●Keep the work area clean. Clean up spills immediately. ●Avoid the use of flammable solvents and cleaners. ●When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud. ●Use safe work platforms to reach higher areas of the machine. (2)

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

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

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

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

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

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

(3)

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

Item

Description

Reference

Weight

Shows the condition or procedure that will be useful or efficient in doing service work. Shows the weight of a part or unit. The weight should be considered in selecting wire rope or cable for slinging work or determining the working posture.

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

Coating

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

Oil or water supply

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

Drainage

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

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

Abbreviation To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the following abbreviation list. Additional abbreviations are listed on page 62-6. E/G ………Engine T/C ………Torque converter T/M ………Transmission SOL ………Solenoid valve SW ………Switch F …………Front or Forward QUAD ……Quick up and down shift A/M ………Auto/Manual

B …………Battery R …………Rear or Reverse RH …………Right hand side LH …………Left hand side H …………High L …………Low GND ………Ground OPT ………Option Assy ………Assembly (4)

1st ………1st speed 2nd ………2nd speed 3rd ………3rd speed 4th ………4th speed DD ………Dynamic damper M/C ………Machine min-1 ………RPM

Bolt Tightening Torque Hexagon Bolt 1) Thread type: Metric thread Unified thread 2) Bolt strength: 8.8 (8T) ~ 10.9 (11T) 3) Thread pitch: Metric thread: Coarse pitch thread (C), fine pitch thread (F) Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF) (N-m) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

M10

(F) 1.25

M12

132

(F) 1.25

142

M14

142

206

(F) 1.5

152

221

M16

216

314

(F) 1.5

226

330

M18

299

436

(F) 1.5

324

476

M20

417

608

(F) 1.5

451

662

559

814

(F) 1.5

598

878

721

1,030

(F) 2.0

770

1,128

1,030

1,520

(F) 2.0

1,128

1,618

1,422

2,109

(F) 2.0

1,569

2,256

1,912

2,844

M22 M24 M27 M30

Unified thread

22 24 27 30

M33

(F) 2.0

2,059

3,040

5/16

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

358

525

7/8

9 UNC

554

809

8 UNC

868

1,275

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

(5)

(kgf-m) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

2.7

3.9

M10

5.4

7.8

(F) 1.25

5.6

8.2

M12

9.2

13.5

(F) 1.25

9.8

14.5

M14

14.5

21.0

(F) 1.5

15.5

22.5

M16

22.0

32.0

(F) 1.5

23.0

33.7

M18

30.5

44.5

(F) 1.5

33.0

48.5

M20

42.5

62.0

(F) 1.5

46.0

67.5

57.0

83.0

(F) 1.5

61.0

89.5

73.5

105.0

(F) 2.0

78.5

115.0

105.0

155.0

(F) 2.0

115.0

165.0

145.0

215.0

(F) 2.0

160.0

230.0

195.0

290.0

M22 M24 M27 M30

Unified thread

22 24 27 30

M33

(F) 2.0

210.0

310.0

5/16

18 UNC

2.5

3.6

3/8

16 UNC

4.5

6.6

7/16

14 UNC

7.2

10.5

1/2

13 UNC

10.5

15.0

9/16

12 UNC

15.0

22.0

5/8

11 UNC

20.5

30.0

3/4

10 UNC

36.5

53.5

7/8

9 UNC

56.5

82.5

8 UNC

88.5

130.0

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

(6)

(lb-ft.) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

19.5

M10

(F) 1.25

M12

(F) 1.25

105

M14

105

150

(F) 1.5

110

160

M16

160

230

(F) 1.5

165

245

M18

220

320

(F) 1.5

235

350

M20

305

450

(F) 1.5

330

490

410

600

(F) 1.5

440

650

530

760

(F) 2.0

565

830

760

1,120

(F) 2.0

830

1,190

1,050

1,550

(F) 2.0

1,160

1,660

1,410

2,100

M22 M24 M27 M30

Unified thread

22 24 27 30

M33

(F) 2.0

1,520

2,240

5/16

18 UNC

18.0

3/8

16 UNC

7/16

14 UNC

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

410

595

8 UNC

640

940

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

(7)

Flanged Hexagon Bolt 1) Bolt type: Metric thread 2) Bolt strength: 8.8 (8T) 3) Thread pitch: Coarse pitch thread (C)

(N-m) Bolt size Type

Metric thread

Bolt strength

Nominal Dimension

Pitch

8.8 (8T)

0.8

1.25

M10

1.5

M12

1.75

M16

231

M20

2.5

441

M24

765

(kgf-m) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Pitch

8.8 (8T)

0.8

0.7

1.2

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

23.5

M20

2.5

45.0

M24

78.0

(lb-ft) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Pitch

8.8 (8T)

0.8

5.0

8.6

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

(8)

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

Hose band

Tightening torque

(N-m)

(kgf-cm)

(lb-ft)

1.6

1.2

2.9

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

1.6

1.2

2.9

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

16.5

HH022W

7.9

18.5

HH022W

9.5

20.5

HH022W

12.7

24.5

HH027W

15.9

29.9

HH031W

19.0

30.0

HH031W

25.4

38.0

HH044W

31.8

45.8

HH052W

38.1

52.1

HH057W

50.8

67.8

HH071W

60.5

76.0

HH082W

75.5

93.0

HH095W

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

Hose band

16.5

HH022W

18.5

HH022W

20.5

HH022W

22.0

HH023W

24.5

HH027W

26.0

HH027W

29.0

HH031W

30.5

HH031W

32.0

HH038W

34.0

HH038W

39.5

HH044W

41.5

HH044W

46.0

HH052W

48.0

HH052W

54.0

HH057W

70.5

HH076W

73.0

HH076W

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

Pipe

Hose band

Center of pipe protrusion 10~20 mm

(9)

70ZV00003

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

Liquid Gasket

Screw Lock Agent

Code

Manufacturer

Product name

AA01

Loctite

Plastic Gasket 568

AA02

Loctite

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite ®

Loctite ® 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

Cautions regarding parts removal If a screw or shaft to be removed has been locked by one of the above agents, remove the screw or shaft using a general tool, such as a wrench or puller. If it is difficult to remove the screw or shaft, heat the bolt to soften the agent (200 to 250°C) using a soldering iron or gas torch. Caution: If there is a seal near the screw or shaft to be removed, carefully use the heating method for removal, to avoid damage to the seal. If heat has been used to remove the bolt a new bolt should be used during reassembly. Cautions regarding reassembly To reassembly a screw: Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw. Note: A piece of hardened lock agent may be peeled off and remain in the component. The remaining piece may cause malfunction during fastener installation.

Screw lock agent application procedure Throgh-hole Apply screw lock agent one or two lines on the male threads. Screw lock agent

65ZV00002

Blind hole Apply screw lock agent all-round on the female threads at 1/3 of the female thread length from the bottom.

H Abt 1/3H

65ZV00003

How to wind a seal tape To avoid a piece of seal tape left in the circuit, leave 1 or 2 screw from the end of the thread and start winding it clockwise. Seal tape

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

Leave 1~2 screw 65ZV00004

Code

Manufacturer

Product name

AC01

Loctite ®

Loctite 767 (Paste or spray)

(10)

Cautions Regarding Welding Repair Service If welding is needed to repair the chassis, observe the following precautions to protect the hydraulic cylinders, hydraulic units, gear sets, and electrical units from possible damage. Cautions: 1) Turn the starter switch OFF. 2) Remove the battery terminals both positive and negative sides from the battery. 3) Unplug the transmission controller (SCU). 4) Engines equipped with ECM: Unplug ECM and tachometer converter as per Cummins Engine Co. 5) Ground the welder near the section to be welded. 6) To ground the welder, check that the electric current will not flow through the cylinders. Cylinder head covers for some models have a lowconductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod.

Example 1: Section to be welded Do not ground this section. Electric current may flow through the cylinders. Ground this section. (correct grounding)

Example 2:

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

Section to be welded

Ground this section. (correct grounding)

(11)

35C00002

7) The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes. Be sure to mask these units and parts before welding. Hydraulic cylinder

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

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

Scrap material, etc. 1m or more

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

35C00003

Section to be welded

1m or more 35C00004

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

Section to be welded Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

(12)

35C00005

Weight of Main Components Part name

Approx. Weight (kg)

Approx. Weight (lb)

Bucket

1,775

3,915

GSC bucket Standard

Item Unit name

Boom

1,330

2,935

" Z " -Lever

395

870

Link (Bucket to Lever)

80/pc

180/pc

Screen board

100

220

Radiator guard

170

375

Hydraulic tank

150

330

Excluding oil

Fuel tank

150

330

Excluding fuel

Floor board

230

510

Including ope. board, instrument panel and control box

Cab (Rops)

500

1,100

Left side

110

With handrail

Right side

135

With handrail

Front chassis

1,720

3,795

Engine room

Chassis

Deck

Remarks

Rear chassis

1,510

3,330

Counter weight

1,270

2,800

Engine

706

1,560

Excluding oil

Radiator assembly

310

685

Excluding water and oil

Transmission

900

1,985

Excluding oil

Second propeller shaft

155

Third propeller shaft

Front axle assembly

1,180

2,600

Excluding tires and oil

Rear axle assembly

1,380

3,045

Excluding tires and oil (Including axle support)

Differential

175

385

Multiple control valve

125

Pilot valve

Steering valve

Hydraulic

Gear pump

120

system

Fan motor

Boom cylinder

190/pc

420/pc

Excluding oil

Bucket cylinder

220

485

Excluding oil

Steering cylinder

40/pc

90/pc

Excluding oil

Tire

650/pc

1,435/pc

With rim (26.5-25-20PR(L-3)); No Hydro Inflation

Battery

35/pc

77/pc

Power line

Other

(13)

Triple pump

Applying and Storing Articulation Stopper 1. Applying articulation stopper

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

1) Park the machine so that the frame is straight ahead. Using a 17 mm wrench remove bolt (1) from the articulation stopper on the front chassis. 1

2) Turn rod (2) (articulation stopper) until it comes in contact with pin (3). Insert the pin (3) into the rod to lock the front chassis to the rear chassis.

WARNING

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

LOCKED POSITION

1 2

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

STORED POSITION

(14)

CHASSIS GROUP Disassembly & Reassembly........................................14-1 Service Standard ........................................................15-1 POWER GROUP Disassembly & Reassembly........................................24-1 Service Standard ........................................................25-1 TORQUE CONVERTER & TRANSMISSION GROUP Disassembly & Reassembly........................................34-1 Service Standard ........................................................35-1 HYDRAULIC GROUP Disassembly & Reassembly........................................44-1 Service Standard ........................................................45-1 BRAKE GROUP Disassembly & Reassembly........................................54-1 Service Standard ........................................................55-1 OPERATOR STATION GROUP Disassembly & Reassembly........................................74-1 Service Standard ........................................................75-1

MEMO

CHASSIS GROUP 14 Disassembly and Reassembly Deck ............................................................................................................14-2 Fuel Tank ....................................................................................................14-3 Hydraulic Tank ............................................................................................14-4 Engine Room ..............................................................................................14-6 Cab .............................................................................................................14-9 Floor Board ...............................................................................................14-11 Boom ........................................................................................................14-12 Center Pin .................................................................................................14-15

14-1

Deck

85ZV

CHASSIS 14

Deck Removing and reinstalling deck 1. Removing deck

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting deck removal: - Position machine on level ground, and apply the parking brake. - Lower bucket to ground, and block 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: - Remove the washer tank. 1) Apply a sling to handrail (1) and deck (4), then remove bolt (2) (3). Torque for assembly: : Bolt: 90 N-m (9.2 kgf-m) (66 lb-ft) : Deck (with handrail): 50 kg (110 lbs)

Screen board

Fuel tank

85ZV14001

2) Apply a sling to handrail (5) and deck (8), then remove bolt (6) (7). Torque for assembly: : Bolt: 90 N-m (9.2 kgf-m) (66 lb-ft) : Deck (with handrail): 60 kg (135 lbs) 3) Carefully balance the assembly and, remove deck (4) (8) together with the handrail.

6 Screen board 85ZV14002

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

14-2

Fuel Tank

85ZV

CHASSIS 14

Fuel Tank Removing and reinstalling fuel tank 1. Removing fuel tank

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting fuel tank removal: - Position machine on level ground, and apply the parking brake. - Lower bucket to ground, and block 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: - Drain fuel from the fuel tank. (Fuel tank capacity: 305 (81 gal.)) - Remove the deck. 1) Remove bolt (1) and then remove the cover. 2) Disconnect level sensor electrical line coupler (2). Rear chassis

3) Attach sling to fuel tank. : Fuel tank: 150 kg (330 lbs) (empty)

4) Remove retainer bolts (3). Torque for assembly: : Retainer bolt (3): 441 N-m (45.0 kgf-m) (326 lb-ft)

3 Fuel tank

Cover 2

5) Slightly pull out fuel tank to disconnect suction/return hose (4). Plug the fuel line to prevent dirt entry. Be careful not to damage the fitting on the tank.

85ZV14003

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

Fuel tank 85ZV14004

14-3

Hydraulic Tank

85ZV

CHASSIS 14

Hydraulic Tank Removing and reinstalling hydraulic tank 1. Removing hydraulic tank

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting hydraulic tank removal: - Position machine on level ground, and apply the parking brake. - Lower bucket to ground, and block 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.

Rear chassis 1

Before starting work: - Drain hydraulic oil from hydraulic tank. (Hydraulic tank capacity.: 120 (32 gal.)) - Remove the deck. - Clean the area around the tank.

1) Disconnect hose (1) and remove transmission line filter (2) bracket bolt (3).

85ZV14005

5 6

2) Disconnect electrical line (5) and vinyl tube (4) for window washer liquid tank.

3) Disconnect hoses (6). - Plug or cover hoses and fittings to prevent leakage and dirt entry.

4) Disconnect hoses (7) (8) (9) (10) (11). - Plug or cover hoses and fittings to prevent leakage and dirt entry.

Window washer liquid tank

85ZV14006

8 9

11 Hydraulic tank

85ZV14007

14-4

Hydraulic Tank

85ZV

CHASSIS 14

5) Attach sling to hydraulic tank, and remove the bolts (12).

12 Rear chassis

: Hydraulic tank: 150 kg (330 lbs) (empty) Torque for assembly: : Bolt (12): 230 N-m (23.5 kgf-m) (170 lb-ft)

Hydraulic tank 85ZV14008

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.

14-5

Engine Room

85ZV

CHASSIS 14

Engine Room Removing and reinstalling engine room 1. Removing engine room

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting engine room removal: - Position machine on level ground, and apply the parking brake. - Lower bucket to ground, and block 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.

2 1

Before starting work: - Recover/recycle refrigerant on machine with optional air conditioner, if required.

90ZV14008

1) Remove the right and left decks (1) together with the handrail (2). 3

2) Remove the covers (3) from both the right and left sides.

90ZV14009

3) Remove the exhaust pipe (4). 4

85ZV14009

14-6

Engine Room

85ZV

4) Remove wire (5) and nut (6) for engine cover isolator mount and lift engine cover.

CHASSIS 14

: Engine cover (roof): 40 kg (88 lbs) Torque for assembly: : Nut (6): 28 N-m (2.9 kgf-m) (21 lb-ft) Rear chassis

85ZV14010

5) Remove round bar (7) of side cover (8). Attach sling to side cover, and remove bolt (9). Remove side cover (8).

Rear chassis

85ZV14011

6) Remove hose (10) between air cleaner and turbocharger at the turbocharger side.

Engine

Note: Cover hose and port of turbocharger to protect turbocharger from dust and dirt. 7) Disconnect indicator wire coupler (11).

10 85ZV14012

8) Disconnect hose (12) (13) from condenser and receiver tank.

Receiver tank 12 13

Note: Before hose disconnection, be sure to recover/ recycle the refrigerant.

Condenser

Compressor 85ZV14013

14-7

Engine Room

85ZV

CHASSIS 14

9) Disconnect the screen board retainer bolts (14) and lift the screen board. Screen board

Note: Slowly lift the screen board while checking that there are no obstacles. Rear chassis

: Screen board (with condenser and air cleaner) 100 kg (220 lbs) Torque for assembly: : Bolt: 230 N-m (23.5 kgf-m) (169 lb-ft)

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.

14-8

85ZV14014

Cab

85ZV

CHASSIS 14

Cab Removing and reinstalling cab 1. Removing cab

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. - Position machine on level ground, and block tires with chocks, etc. to prevent them from moving. - Lower bucket to 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 deck both right and left side. - Disconnect the electrical line coupler

1) Remove covers (1) and (2).

1 95ZV14013

2) Cover (3) for the filter is located at right rear side of the cab. Turn rings counterclockwise and then remove the cover (3). Remove filter from the cab.

Note: When installing the filter into the cab, be sure to align the air flow arrow on the filter to point toward the cab.

K95ZV14014

Filter K95ZV14015

14-9

Cab

85ZV

CHASSIS 14

3) Remove cover (4).

95ZV14016

4) Remove bolt (5). Tilt steering shaft (6) backward. 5

95ZV14017

5) Remove bolts (7). Front Right/Left 3pcs each Rear Right/Left 4pcs each Torque for assembly : : Bolt: 765 N-m (78.0 kgf-m) (562 lb-ft)

6) Remove the bolts (8). Install eye bolt (M16 x 2.0) on cab. Attach sling and remove cab. : Cab: 500 kg (1,100 lbs)

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

Floor board 95ZV14018

14-10

Floor Board

85ZV

CHASSIS 14

Floor Board Removing and reinstalling floor board 1. Removing floor board

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. - Position machine on level ground, and block tires with chocks, etc. to prevent them from moving. - Lower bucket to ground, and release residual pressure from the hydraulic oil tank and lines. - Disconnect the side of the battery. - Disconnect the side of the battery. Before starting work: - Remove deck from both the right and left sides of machine. - Remove the cab. - Disconnect hose and electrical couplers between the floor board and chassis. - Recover air conditioner refrigerant (option) using the proper recovery method. Note: Before disconnecting electrical couplers, hoses and pipes, put match marks on them to help with reassembly. Prepare a drain pan for the oil. Cover the disconnected hoses and pipes with vinyl to protect them from dust and dirt.

1) Remove floor board retaining nut (1). Attach sling then gradually lift the floor board while checking that there are no obstacles and that all pipes, cables, pins, etc. are disconnected. : Including ope. board 550 kg (1,210 lbs) air conditioner, seat, etc. Torque for assembly : : Nut (1): 441 N-m (45.0 kgf-m) (324 lb-ft)

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. 14-11

95ZV14019

Boom

85ZV

CHASSIS 14

Boom Removing and reinstalling boom 1. Removing boom

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.

1) Remove pin (3) connecting bucket (1) and the link (2). 2

Note: There are shims in the pin sections. Carefully store removed shims, and correctly reinsert shims when reinstalling the bucket.

2) Remove connection pin (5) from boom (4) and bucket (1) to remove bucket.

: Bucket: 1,775 kg (3,915 lbs)

85ZV14015

3) Attach sling to link (2), and then remove connection pin (6) from lever (7) and link (2). 7

: Link: 80 kg (180 lbs) 6

2 85ZV14016

14-12

Boom

85ZV

CHASSIS 14

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

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

4) Attach sling to bucket cylinder (8), and then remove connection pin (9) from lever (7) and bucket cylinder (8). : Bucket cylinder: 220 kg (485 lbs) 8

IMPORTANT Never rest cylinder rods on surfaces that may damage them. This may cause cylinder seal to leak.

7 85ZV14017

5) Start engine and shorten bucket cylinder rod (10). Stop engine. Lower bucket cylinder rod (10) on machine.

85ZV14018

6) Attach sling to lever (7), and then remove lever pin (11). 7) Remove lever (7). : Lever: 395 kg (870 lbs)

11 85ZV14019

14-13

Boom

85ZV

CHASSIS 14

8) Attach sling to boom cylinders (12), and then remove pins (13) from cylinder rods on both the right and left sides of boom. 12 13

85ZV14020

9) Start the engine and shorten boom cylinder rod (14), after that stop the engine. Lower boom cylinder rod (14) on the machine. 14

Boom cylinder

85ZV14021

10) Attach sling to torque tube of boom (4), and then remove pins (15) from boom on both the right and left side of boom.

11) Slowly lift boom (4) to remove it from machine. : Boom: 1,330 kg (2,935 lbs) 15

WARNING Loss of control of the boom structure during removal or installation could result in injury or death. 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. Stay clear of boom.

2. Reinstalling boom For reinstallation, follow the above procedure in the reversed direction. Note: After reinstallation, grease the boom pins, and then operate boom. During operation, check boom for abnormal noise. 14-14

85ZV14022

Center Pin

85ZV

CHASSIS 14

Center Pin Upper center pin T1

Shim adjustment

Front chassis

Rear chassis

85ZV14023

T1: 216 N-m (22 kgf-m) (159 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubricating oil (Engine oil or gear oil))

Shim

Shim adjustment: Adjust the clearance to 0.1 ± 0.05 mm (0.0039 ± 0.0020 in.) using the appropriate shim. After that, tighten the T1 bolt. T3

T2 85ZV14025

Lower center pin

Front chassis Rear chassis 85ZV14024

T3: 441 N-m (45.0 kgf-m) (324 lb-ft)

85ZV14026

14-15

Center Pin

85ZV

CHASSIS 14

Removing and reinstalling center pin 1. Removing center pin

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

Transmission

1) Remove bolts (1) and disconnect the second propeller shaft (2). Torque for assembly: : Bolts: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three bond 1327)

1 85ZV14027

2) Remove right and left steering cylinder retainer pins (3) and shims (4). Note: Wrap the steering cylinder rods to prevent accidental damage to the chrome rods.

4 Rear chassis

3 Front chassis Steering cylinder

85ZV14028

3) Disconnect the hose. Disconnect the electrical line from the coupler. Note: Cover disconnected hoses with vinyl to protect hoses from dust and dirt. 4) Remove upper center pin retainer bolt (5). Torque for assembly: : Retainer bolt: 422 N-m (43.0 kgf-m) (311 lb-ft)

85ZV14029

14-16

Center Pin

85ZV

CHASSIS 14

5) Screw the M12 (Pitch 1.75) bolt of approximately 70 mm length into the center of the bushing (6) to push out bushing. This bolt is used as a jack screw.

Jack screw: M12 (Pitch 1.75), totally threaded M12 x 1.75 Jack screw 70 90ZV14028

85ZV14030

6) Before disconnecting front chassis (7) from rear chassis, be sure to support front chassis using a jack and blocks so that front chassis will not be fall backward.

Jack

7) Before disconnecting front chassis from rear chassis, be sure to sling rear chassis using a crane (apply sling to the pin (8)) so that rear chassis will not fall backward.

90ZV14030

WARNING When using a crane, incorrect signals and in sufficient sling capacity could cause an accident resulting in injury or death. To prevent such an accident, observe the following items : - Check sling capacity 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.

90ZV14031

8) Push upper center pin (9) out using a jack. 9

By jack

14-17

85ZV14031

Center Pin

85ZV

CHASSIS 14

9) While supporting the bottom of fuel tank using a rolling floor jack, remove lock bolt from the lower center pin (10), and then push the lower center pin (10) out using another jack to remove pin.

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

By jack

10) Slowly turn rear tires to both right and left sides using a bar to separate the rear chassis.

85ZV14033

Note: While turning rear tires, check that the rolling floor jack under fuel tank rolls backward together with the rear chassis. In addition, adjust the height using rear crane whenever height adjustment is necessary. 11) Remove ring (11). Bar

12) Remove bolts (12) from bearing cover (13). Torque for assembly: : Retainer bolt: 216 N-m (22.0 kgf-m) (159 lb-ft)

90W14014

Front

11 Grease nipple installation direction

22.5°

85ZV14032

WARNING When the chassis is separated, unless support for the chassis is sufficient, it could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Make sure blocks, support and jack are placed in the right position to properly support the chassis. 14-18

14 85ZV14034

Center Pin

85ZV

CHASSIS 14

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

14) Replace dust seals in upper center pin and lower center pin with new ones. Bearing outer ring

Note: Direction of dust seal Front

(Top)

Rear

(Bottom)

Split of outer bearing 20° 90ZV14036

90ZV14037

Grease nipple installation direction

15) When spherical bearing for lower center pin is replaced, install bearing outer ring so that the split is perpendicular to the front - rear line of machine.

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

3. Cautions regarding reassembly

WARNING

1) After reinstallation, grease center pins, and operate them. During operation, check the pins for abnormal noise and looseness. 2) Be sure to completely bleed the brakes of air. For air bleeding procedure, refer to the Section 24. 3) Check each section for oil leakage. 4) No oil leakage should be found in any part.

14-19

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.

MEMO

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

15-1

Linkage

85ZV

CHASSIS 15

Linkage mm (in) 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

ø130 (5.11) ø70 (2.76)

4. Front chassis - Boom

ø90 (3.54)

5. Bucket - Rod

6. Lever - Rod

ø90 ø90 (3.54) (3.54)

ø100 (3.94)

8. Bucket cylinder Front chassis

7. Lever - Bucket cylinder

ø100 (3.94)

ø90 (3.54)

ø100 (3.94)

10. Front chassis Steering cylinder

9. Boom cylinder Front chassis

11. Steering cylinder Rear chassis

85ZV12002

ø50 (1.97)

8 4

5 10

6 85ZVE12004

15-2

Linkage Pin Standard Clearance Values

85ZV

CHASSIS 15

Linkage Pin Standard Clearance Values Unit : mm (in.) Judgment standard Item

No.

Solution

Pin standard dimension

Standard clearance

Tolerance

∗

Joint section between bucket and boom

ø70 (ø2.7559)

0.104 ~ 0.213 (0.0041 ~ 0.0083)

1.0 (0.0393)

Replacement

∗

Joint section between boom and lever

ø130 (ø5.1181)

0.153 ~ 0.293 (0.0060 ~ 0.0115)

1.0 (0.0393)

Replacement

Joint section between boom and boom cylinder

ø90 (ø3.5433)

0.117 ~ 0.237 (0.0046 ~ 0.0093)

1.0 (0.0393)

Replacement

∗∗

Joint section between front chassis and boom

ø100 (ø3.9370)

0.117 ~ 0.242 (0.0046 ~ 0.0095)

1.0 (0.0393)

Replacement

∗

Joint section between bucket and link

ø90 (ø3.5433)

0.117 ~ 0.237 (0.0046 ~ 0.0093)

1.0 (0.0393)

Replacement

∗

Joint section between lever and link

ø90 (ø3.5433)

0.117 ~ 0.237 (0.0046 ~ 0.0093)

1.0 (0.0393)

Replacement

∗

Joint section between lever and bucket cylinder

ø100 (ø3.9370)

0.117 ~ 0.242 (0.0046 ~ 0.0095)

1.0 (0.0393)

Replacement

∗

Joint section between bucket cylinder and front chassis

ø100 (ø3.9370)

0.117 ~ 0.242 (0.0046 ~ 0.0095)

1.0 (0.0393)

Replacement

Joint section between boom cylinder and front chassis

ø90 (ø3.5433)

0.117 ~ 0.237 (0.0046 ~ 0.0093)

1.0 (0.0393)

Replacement

∗

Joint section between front chassis and steering cylinder

ø50 (ø1.9685)

0.085 ~ 0.178 (0.0033 ~ 0.0070)

1.0 (0.0393)

Replacement

∗

Joint section between steering cylinder and rear chassis

ø50 (ø1.9685)

0.085 ~ 0.178 (0.0033 ~ 0.0070)

1.0 (0.0393)

Replacement

Liner clearance adjustment ∗

∗∗ Adjustment procedure (for adjustment of liner clearance marked with asterisk):

∗ Adjust the liner clearance between the bosses to 1.2 mm or less using liner of 1 mm 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.

∗∗ Only in case the clearance at the machine center side is more than 4.5 mm, adjust using liner of 4.5 mm thickness. 70ZV15001

15-3

Center Pin

85ZV

CHASSIS 15

Center Pin Shim adjustment

The clearance between the front chassis and bearing cover is 0.75 ± 0.5 mm (0.0295 ± 0.0197 in.) before shim adjustment. Add shims so that the clearance is 0.1 ± 0.05 mm (0.0039 ± 0.0020 in.). : Bolts T1: 216 N-m (22.0 kgf-m) (159 lb-ft)

Bearing cover Shim adjustment Front chassis

Rear chassis

T2: 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubricating oil (Engine oil or gear oil))

85ZV15001

Installing bearing cover Install the bearing cover so that the grease nipple mounting hole is positioned at the specified angle as shown in the right figure.

Front

Grease nipple installation direction

22.5°

85ZV15002

Installing lower center pin bearing outer ring Install the bearing outer ring so that the split is perpendicular to the front-rear line of the machine. Front chassis

Bearing outer ring Rear chassis 85ZV15003

Bearing outer ring Front

Rear

Split of outer bearing 20° 90ZV14037

15-4

Grease nipple installation direction

Bucket Positioner and Boom Kick-Out

85ZV

CHASSIS 15

Bucket Positioner and Boom Kick-Out

Bucket positioner

Boom kick-out

85ZV15004

Bucket positioner

∗ Adjusting plate 5

Direction of indicator lamp

Indicator lamp 3

5±2

2.5

Proximity switch

4 1

85ZV15005

15-5

Bucket Positioner and Boom Kick-Out

85ZV

CHASSIS 15

Boom kick-out

Ma Ad x hoi st ad justi an jus ng g tab pla le t le are e a

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

36°

46°

15°

7°

Direction of indicator lamp Proximity switch 2 Hoist arm 85ZV15010

Unit : mm Item

No.

Judgment standard

Solution

Clearance of bucket positioner switch

5 ± 2 (0.196 ± 0.078 in.)

Adjustment

Clearance of boom kick-out switch

5 ± 1 (0.196 ± 0.039 in.)

Adjustment

Adjusting plate mounting bolt tightening torque

Switch mounting nut tightening torque

Positioner

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

Kick-out

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

Tightening

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

Tightening

Bucket positioner adjustable angle

-7° ~ +12°

Adjustment

Boom kick-out adjustable angle

0 ~ 36°

Adjustment

15-6

Bucket Positioner and Boom Kick-Out

85ZV

CHASSIS 15

Bucket positioner adjustable angle

-7° Adjusting length: 6 mm (0.236 in.)

+12°

0° 57 mm (2.244 in.)

129 mm (5.079 in.) 85ZV15007

Boom kick-out hoist angle

Plate installation angle

7° ~ 43°

Kick-out adjustable angle

0° ~ 36°

Hoist angle

10° ~ 46°

85ZV15008

Note: This feature may be adjusted to match boom height to truck applications for truck fleets that have same side board clearances.

15-7

MEMO

POWER GROUP 24 Disassembly and Reassembly Power Line...................................................................................................24-2 Radiator .......................................................................................................24-3 Engine..........................................................................................................24-7 Propeller Shaft ...........................................................................................24-10 Air Cleaner.................................................................................................24-12 Muffler........................................................................................................24-14 Front Axle Assembly..................................................................................24-15 Internal Gear Hub ......................................................................................24-27 Spider Assembly........................................................................................24-30 Special Tool ...............................................................................................24-32 Rear Axle Assembly ..................................................................................24-36 Axle Support ..............................................................................................24-40 Differential Assembly .................................................................................24-46

24-1

Power Line

85ZV

POWER 24

Power Line Tightening torque T1 L1

T2 L 1

T1 L1 T3 L 3 T4 L 3

T6 L 1

T1 L1

T5 L 2

85ZV24001

: Bolt tightening torque T1: 417 N-m (42.5 kgf-m) (307 lb-ft)

Always replace drive shaft bolts with new bolts – Never reuse.

T2: 230 N-m (23.5 kgf-m) (170 lb-ft) T3: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T4: 67 N-m ( 6.8 kgf-m) ( 49 lb-ft) T5: 142 N-m (14.5 kgf-m) (105 lb-ft) T6: 441 N-m (45.0 kgf-m) (325 lb-ft)

L1: Screw lock agent (Loctite® 262) application L2: Screw lock agent (Three Bond 1327) application L3: With lubrication oil (Engine oil or gear oil) 24-2

Radiator

85ZV

POWER 24

Radiator Tightening torque

T2 L 3 Corrosion resister

T3 L 3 T1 L1 Radiator T5 L 3

T4 L 3

T3 L 3

Rear chassis

85ZV24002

: Bolt tightening torque T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 49 N-m ( 5.0 kgf-m) ( 36 lb-ft) T3: 94 N-m ( 9.6 kgf-m) ( 69 lb-ft) T4: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T5: 355 N-m ( 36 kgf-m) (260 lb-ft)

L1: Screw lock agent (Loctite® 262) application L3: With lubrication oil (Engine oil or gear oil)

24-3

Radiator

85ZV

POWER 24

Removing and reinstalling radiator 1. Removing radiator

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply articulation stopper. - Block front wheels with chocks to prevent 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: - Remove the engine roof (Refer to Section 14). - Remove the fan motor (Refer to Section 44).

1 Rear chassis

1) Remove the bolt (1). Torque for assembly: : Bolt 230 N-m (23.5 kgf-m) (170 lb-ft)

85ZV24003

∗Oil/air coolers are not shown

2) Attach sling to radiator guard (2), and remove. : Radiator guard: 170 kg (375 lbs)

Radiator 3

3) Drain coolant from radiator. : Coolant 42 (11.1 gal.)

Engine

6 Drain line

85ZV24004

4) Disconnect coolant hose (3) (4) (5) (6) (7) (8) from radiator. Note: Cover disconnected hoses with caps to protect hoses from dust and dirt.

Air cooler

5) Disconnect air cooler hose (9) (10) from air cooler. Note: Cover disconnected hoses with caps to protect hoses from dust and dirt.

Engine 85ZV24005

24-4

Radiator

85ZV

POWER 24

6) Remove hose (11) (12) from hydraulic oil cooler. : Hydraulic oil 2 (0.53 gal.)

Radiator

Note: Cover disconnected hoses with plastic caps to protect hoses from dust and dirt.

Oil cooler

12 90ZV24006

7) Disconnect hose (13) (14) from torque converter oil cooler. : Torque converter oil 2 (0.53 gal.)

Radiator

Transmission

Note: Cover disconnected hoses with plastic caps to protect hoses from dust and dirt.

85ZV24006

8) Remove bolts (15) and remove thermo sensing valve (16). Torque for assembly: : Bolt 53 N-m (5.4 kgf-m) (3.9 lb-ft)

Radiator

15 90ZV24009

9) Attach sling to the radiator (17). Remove right and left retainer bolts (18) (19), and lift radiator. : Radiator: 310 kg (685 lbs) Torque for assembly: : Retainer bolt (18): 49 N-m (5.0 kgf-m) (36 lb-ft) : With lubricating oil (Engine oil or gear oil) : Retainer bolt (19): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent (Loctite® 262) application

Rear chassis 17

85ZV24007

24-5

Radiator

85ZV

POWER 24

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.

Clearance

90ZV24010

24-6

Engine

85ZV

POWER 24

Engine Removing and reinstalling engine 1. Removing engine

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply articulation stopper. - Block front wheels with chocks to prevent 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. - Select correct tooling to remove engine and transmission. Before starting work: a) Remove the engine room (Refer to Section 14). b) Remove the floor board with the cab (Refer to Section 14). c) Remove the fan guard and the fan (Refer to Section 44). d) Collect the air conditioner refrigerant (option) using the proper recovery method. e) Drain engine oil : Engine oil: Approx. 27 (7.1 gal.)

+ Battery 90ZV24014

1) Disconnect the negative side of the battery cable (1). Then remove the positive cable. 2) Remove wires from alternator, starter motor air cleaner, T/C oil sensor, T/C oil temp. switch, air intake preheater, T/M solenoids, A/C compressor clutch(opt), A/C condenser, water temp. switch, and oil pressure switch. Remove connector for engine pressure switch, tachometer and coolant temperature gauge. Disconnect heater hose and fuel hose also disconnect air conditioner lines from compressor. 3) Remove engine oil drain hose. 4) Attach sling to the engine and transmission assembly. : Engine and transmission assembly: 1,610 kg (3,549 lb) 85ZV24032

24-7

Engine

85ZV

5) Remove engine assembly mounting bolts (2). Torque for assembly: : Retainer bolt: 441 N-m (45 kgf-m) (325 lb-ft) : Screw lock agent (Loctite® 262) application

POWER 24

Engine

2 85ZV24008

6) Remove two block mounting bolts (3) (both sides). Torque for assembly: : Retainer bolt: 417 N-m (42.5 kgf-m) (307 lb-ft) : Screw lock agent (Loctite® 262) application

7) Disconnect the 2nd propeller shaft and the 3rd propeller shaft from transmission assembly. 8) Carefully lift the engine and transmission assembly while checking that there are no obstacles around them. : Engine and transmission assembly: 1,610 kg (3,549 lb)

85ZV24009

9) Remove the engine and transmission assembly from rear chassis. Place them on a stand. 10) Attach sling to the engine assembly and remove bolts (4) from housing between engine flywheel and transmission. Torque for assembly: : Retainer bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : Engine assembly: 706 kg (1,560 lb)

11) Move engine assembly back side to disengage flywheel ring gear. 12) After confirming that ring gear has been disengaged, remove engine assembly by lifting it slowly.

24-8

85ZV24010

Engine

85ZV

POWER 24

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

3. Cautions regarding engine reinstallation

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

24-9

85ZV24011

Propeller Shaft

85ZV

POWER 24

Propeller Shaft Removing and reinstalling propeller shaft 1. Removing second propeller shaft

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply articulation stopper. - Block front wheels with chocks to prevent wheels from moving. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery. 1) Remove bolt (2) from the transmission side of propeller shaft (1). Torque for assembly: : Retainer bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application

4 3

85ZV24012

2) Disconnect the grease pipe, and remove the bolt (4) from pillow unit bearing (5). Torque for assembly: : Retainer bolt: 417 N-m (42.5 kgf-m) (307 lb-ft) : Screw lock agent (Loctite® 262) application 3) Remove bolt (3) to disconnect propeller shaft from front differential. Support shaft by cable or rolling floor jack. Take out the second propeller shaft to the front. Torque for assembly: : Retainer bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application : Second propeller shaft: 70 kg (155 lbs) Note: If retainer bolt is too tight due to screw lock agent, heat the bolt head to about 235 °C (450 °F) using low flame of a gas torch. Keep the flame away from seals of coupling. Do not reuse the bolts, always replace with new ones.

24-10

Propeller Shaft

85ZV

POWER 24

2. Removing third propeller shaft 1) Remove bolt (6). Torque for assembly: : Retainer bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application : Third propeller shaft: 15 kg (35 lbs)

6 85ZV24013

3. Reinstalling propeller shaft For reinstallation, follow the above procedure in the reversed direction. Note: During reinstallation, align the direction of the flange yokes on the second and third propeller shaft sides of the transmission. (Refer to Section 22) [Difference in the yoke phase (direction) will cause the propeller shaft damage.]

24-11

Air Cleaner

85ZV

POWER 24

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

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply articulation stopper. - Block front wheels with chocks to prevent wheels from moving. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery. 1) Remove cap nut (1), and then remove cover (2). Note: Removing inside elements reduces the weight and facilitates air cleaner case removal work.

5 1 6 3 4 2

2) Remove wing nut (3), and then remove outer element (4). 3) Remove wing nut (5), and then remove inner element (6).

90ZV24022

8 Engine

4) Disconnect air duct (7). Disconnect indicator wire coupler (8).

85ZV24014

5) Remove cover (10) from the top of screen board (9).

Screen board 9 90ZV24024

24-12

Air Cleaner

85ZV

POWER 24

6) While supporting air cleaner case (11) with your hand, remove band retainer bolts (12), and then lower the air cleaner case.

Screen board

85ZV24015

7) Take out air cleaner case (13) from the opening. 13

90ZV24026

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.

24-13

Muffler

85ZV

POWER 24

Muffler Removing and reinstalling muffler 1. Removing muffler

CAUTION You may get burned if you remove muffler before engine is cold enough. To prevent such an incident, be sure to stop the engine, and open side covers. Start the muffler removal work when the engine is cold enough. 1) Remove bolt (1) and then remove exhaust pipe (2).

2) Remove the engine room by referring to Section 14. : Engine room: 270 kg (595 lbs)

85ZV24016

3) Remove four bolts (5) and U-clamp (4), and then remove muffler (3). : Muffler: 23 kg (50 lbs)

5 4

85ZV24017

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.

24-14

Front Axle Assembly

85ZV

POWER 24

Front Axle Assembly Tightening torque T3 L 1

T8 L 3

Floating seal Front differential T9 T2 T9 T9

B A

T5 L 1

T1 L1

T9 T7

T4 90ZV24029

T L 6

Note: 1. Axle nut tightening procedure 1) Tighten axle nut (A) with 1,765 N-m (180 kgf-m)(1,300 Ib-ft) tightening torque to install the taper roller bearing. 2) Loosen axle nut (A). 3) Tighten axle nut (A) again with 1,765 N-m (180 kgf-m)(1,300 Ib-ft) tightening torque. 4) Turn the wheel hub 2~3 turns back and forth, and measure the preload applied to section (B). Preload of section (B): 226~265 N (23~27 kgf) (50~59 Ibs)∗ ∗ This is "breakaway" force. The force required to start the wheel turning. 2. Use jig to install the floating seal to the axle assembly.

: Bolt tightening torque T1: 216 N-m ( 22 kgf-m) (159 Ib-ft) T2: 33 N-m ( 3.4 kgf-m) ( 25 Ib-ft) T3: 132 N-m (13.5 kgf-m) ( 98 Ib-ft) T4: 86 N-m ( 8.8 kgf-m) ( 64 Ib-ft) T5: 53 N-m ( 5.4 kgf-m) ( 39 Ib-ft) T6: 90 N-m ( 9.2 kgf-m) ( 67 Ib-ft) T7: 892 N-m (91.0 kgf-m) (658 Ib-ft) T8: 721 N-m (73.5 kgf-m) (532 Ib-ft) T9: 78 N-m ( 8.0 kgf-m) ( 58 Ib-ft) : L1: Screw lock agent (Three Bond 1327) application L3: With lubricating oil (Engine oil or gear oil)

24-15

Front Axle Assembly

85ZV

POWER 24

Removing and reinstalling front axle assembly 1. Removing front axle assembly

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply the parking brake and articulation stopper. - Block front wheels with chocks to prevent wheels from moving. - Stands must be able to support weight of front chassis, boom, and bucket.

Stand Stand 85ZV24018

1) Lift the front wheel using the bucket, and then place a stand under the front chassis to support the chassis. Front axle

2) Lift the boom, and place a stand under the boom to support it or install a boom cylinder lock collar. 90ZV24031

3) Disconnect the air breather tube (1) from the upper part of the axle housing. Install plastic caps on hose and fitting. 4) Remove the second propeller shaft retainer bolt (2). Torque for assembly: : Retainer bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application

85ZV24019

5) Remove right and left wheel and tire assemblies (3). : 1 Tire: 650 kg (1,435 lbs) Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

90ZV24033

24-16

Front Axle Assembly

85ZV

POWER 24

6) Disconnect brake pipes (4). Note: Install plastic caps to protect from dirt entering fittings or pipes. 4

Front axle

85ZV24020

7) Attach sling to axle assembly (5), and then remove eight retainer bolts (6). : Axle assembly: 1,180 kg (2,600 lbs) Torque for assembly: : Retainer bolt: 721 N-m (73.5 kgf-m)(532 lb-ft) Note: During reassembly be sure both mating surfaces are clean and free of paint.

6 90ZV24035

8) Place axle assembly (5) on a carrier or rolling floor jack with special adapter to smoothly pull out the assembly.

24-17

Front Axle Assembly

85ZV

POWER 24

2. Reinstalling front axle assembly For reinstallation, follow the above procedure in the reversed direction. After reinstallation, completely bleed air in the service brake line.

CAUTION Before air bleeding in the brake oil line, be sure that wheel and tire assemblies are installed on wheel hub. If fail to do, the bolts (4 pcs) temporarily tighten the spider and wheel hub may be broken by brake piston. Finally the spider and cover may fall off. Spider Socket bolt 90ZV24036

Reference Air bleeding procedure Start and run engine to build brake accumulator pressure. Shut "off" engine. Rebuild brake accumulator pressure as often as is needed. Connect a clean vinyl tube to the air bleeder nipple, and place an oil can to receive the oil, or route to hydraulic 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. Completely bleed each wheel of air.

24-18

Front Axle Assembly

85ZV

POWER 24

Disassembling and reassembling front axle 1. Disassembling front axle

WARNING Unexpected movement of machine or components could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and then apply the parking brake. - Apply articulation stopper. - Block rear wheels with chocks to prevent wheels from moving. - Stands must be able to support weight of front chassis, boom, and bucket. Note: Refer to page 24-32~24-35 1) Lower bucket to ground. Lift the front wheels while supporting the machine with the bucket. Place a stand under the front chassis to support it. Check that the tires are off the ground.

2) Lift the boom until it is horizontal. Place a stand under the boom to support it.

Stand Stand 85ZV24018

3) Remove wheel and tire assembly (1) from the side to be disassembled (example: left side). : Tire of 1 wheel: 650 kg (1,435 lbs) Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

90ZV24052

4) Remove drain plug (2) from the differential section to drain oil. : Gear oil: Approx. 42 (11.1 gal.)

Differential section 90ZV24053

24-19

Front Axle Assembly

85ZV

5) Turn drain plug (4) to the bottom of wheel hub (3) to drain oil. : Gear oil: Approx. 32 (8.4 gal.) Note: To replace the oil, refer to the oil amount described below. Wheel hub section: 16 (4.2 gal.) for left side, 16 (4.2 gal.) for right side Differential section: 42 (11.1 gal.) [48 (12.7 gal.) for rear] Total oil amount for front axle: 74 (19.5 gal.) Total oil amount for rear axle: 80 (21.1 gal.)

POWER 24

3 4 90ZV24054

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

TOP

90ZV24055

7) Attach sling to spider using hoisting tool (A). Remove four spider retainer bolts (6) to remove spider assembly (7). Torque for assembly:

A 7 6

TOP

: Retainer bolt: 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 100 kg (220 lbs)

90ZV24056

8) Remove snap ring (8), and then remove sun gear (9). 9

9) Remove friction plates (10).

10 90ZV24057

24-20

Front Axle Assembly

85ZV

POWER 24

10) Remove steel plate (11) and disc gear (12). Note: Clean the brake plates, and then check the plates for distortion, discoloration and wear. Refer to the section 52 and 55 (Brake Group) for additional information.

90ZV24058

11) Remove axle shaft (13) and wear ring (14). Remove retainer bolts (15) and then remove lock plate (16). Note: When reassembling axle shaft (13) into the axle housing, "work" the shaft (13) to align splines and insert axle shaft (13) into the differential.

13 16

12) Turn wheel hub (3) until the drain plug is positioned on the top. Connect the turnbuckle to eye bolt (E) to lock the wheel hub and then place a wooden block under the wheel hub to support it.

90ZV24059

Turnbuckle E

Note: Be sure to secure the wheel hub, or the hub will drop when the axle nut is removed and the internal gear hub is removed. 3 90ZV24060

13) Remove axle nut (17). Torque for assembly: : Nut: 1,765 N-m (180 kgf-m) (1,300 lb-ft) Note: Axle nut width across flat: 120 mm (4.72 in.)

90ZV24061

24-21

Front Axle Assembly

85ZV

POWER 24

14) Pull out the internal gear hub (18) to the extension end face using the internal gear hub puller (B).

Extension

Jig (B)

18 Wooden block

15) Attach sling to internal gear hub (18) using internal gear hub hoisting tool (C). And remove hub (18).

K90ZV24062

Wooden block

16) Install wheel hub hoisting tool (D) and (E) and remove the turn buckle. Then remove wheel hub (3).

17) Remove taper roller bearing (19). Removal method: For easy removal, heat the inner race using a gas burner with low flame.

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

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

24-22

K90ZV24063

D, E 3

Wooden block

K90ZV24064

Front Axle Assembly

85ZV

POWER 24

Bearing

3. Cautions regarding reassembly

O-ring

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

Wheel hub

O-ring Axle housing

(2) Check the wheel hub and the ring for burs. If there are any remove by using sand paper etc. (3) Clean the O-ring installation part on the wheel hub and the seal ring, and remove oil on them. Seal ring

Ring 90ZV24065

2) Assemble the floating seal as follows. (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 O-ring and seal ring into the ring and the wheel hub pushing the O-ring with fingers. (Make sub-assembly) - Check if the seal ring is correctly positioned and that the O-ring is not twisted. - Clean the surface and put thin gear oil on it. - Install the ring, bearing and the wheel hub to the axle housing.

Ring

Remove oil

Put thin gear oil (Do not use grease)

Do not touch (It may cause rusting) 90ZV24066

24-23

Front Axle Assembly

85ZV

POWER 24

(2) In case jig is used

2 3

70ZV24095J

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

Guide jig

- 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. - 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.

Before installation 90ZV24068

Guide jig

Installation jig

(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.

After installation 85ZV24027

24-24

Front Axle Assembly

85ZV

3) Reinstall internal gear hub assembly (18). Note: Before reinstallation, align the brake oil hole of the axle housing extension with that of the internal gear hub assembly. Note that the spring pin is positioned at the top when the brake holes are properly aligned.

POWER 24

Spring pin

Internal gear

Brake oil holes

Brake oil holes at 2 locations

90ZV24070

90ZV24072

Axle housing extension

Example LF

4) Tighten axle nut (17) with 1,765 N-m (180 kgf-m) (1,300 lb-ft) tightening torque to install the taper roller bearing, after that loosen that axle nut (17). 17 90ZV24073

5) Tighten axle nut (17) so that the preload of the tire mounting hole section is 226 to 265 N (23 to 27 kgf) (50 to 59 lbs). Note: This is the force to start the wheel hub moving or "breakaway" force.

6) Attach jig (G) to the brake oil inlet port on the axle housing. Jig (G)

Brake oil inlet port

Shut off valve

90ZV24074

Air supply PT 1/4

Air pressure gauge

90ZV24071

24-25

Front Axle Assembly

85ZV

POWER 24

7) Install 4 bolts to hold the brake piston not to come out. Apply 588 kPa (6 kgf/cm 2) (85 psi) air pressure for approximately 1 minute. Shut off the valve. Check that the pressure does not fall. Note: 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. Bolt

Bolt 90ZV24075

8) To reassemble the steel plates and friction plates, observe the following items. Note that the plates should be assembled to make possible the plate wear measurement after reassembling.

Spring pin Friction plate

➀ Insert the steel plate having 4-teeth sections first. Then install a friction plate. ➁ Insert the steel plate having two 2-teeth sections so that the spring pin is positioned at the midpoint between the 2-teeth sections. ➂ Align the cooling holes of two friction plates with each other.

Align the black teeth with each other

Cooling holes Steel plate 90ZV24076

9) Check that the wheel hub drain plug is at the bottom when the spider "TOP" mark is at top.

Wheel hub Spider "TOP" mark (at top)

Brake oil line

Drain plug (at bottom) 90ZV24077

10) 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.

24-26

Internal Gear Hub

85ZV

POWER 24

Internal Gear Hub Disassembling and reassembling internal gear hub 1

1. Disassembling internal gear hub 1) Turn up internal gear hub (1), and then remove two Orings (2). 2

90ZV24092

2) Remove taper roller bearing (3). Removal method: For easy removal, heat the inner race using a gas torch with low flame. 3

90ZV24093

3) Remove eight bolts (5) and return spring (6) from brake piston (4). Remove socket bolt (7), bushing (8), sleeve (9) and then remove spring (10) from brake piston (4).

6 5

Lock nut

7 8

Torque for assembly: : Locknut: 33 N-m (3.4 kgf-m) (25 lb-ft) : Socket bolt: 50 N-m (5.1 kgf-m) (37 lb-ft) Use Loctite® 262 and primer when reassembling.

10 9

4 90ZV24094

4) Insert two jack screw (11) into brake piston (4) to remove the piston. 4

Example LF 90ZV24095

24-27

Internal Gear Hub

85ZV

POWER 24

5) Remove brake piston O-rings (12) (13). 12

13 90ZV24096

6) There a snap ring (15) that connects internal gear (14) to internal gear hub (1). Shift the snap ring to the inside using a round bar or the like.

90ZV24097

7) Attach slings to internal gear (14) to remove it. 14

15 90ZV24098

24-28

Internal Gear Hub

85ZV

POWER 24

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

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 reassembling internal gear (14) and brake piston (4) to the internal gear hub, align the oil plug holes of the internal gear hub with that of the brake piston oil groove and spring pin (16). (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 measurement of brake disc wear.

Be certain these plugs are tight.

Oil holes Oil groove

Example LF

Hub

4 90ZV24099

2) Before reinstallation of the taper roller bearing (3), be sure to heat the bearing to 90 °C (194 °F) to 120 °C (248 °F) in oil. 3

3) Apply grease to the O-rings.

4) Check that the snap ring is properly inserted into the groove of the internal gear.

5) When reassembling the piston, temporarily install the piston and then tighten the bolt evenly. Confirm that the piston is fully retracted. (Refer to section 54-18)

90ZV24100

Bolt

85ZV24025

24-29

Example LF

Spider Assembly

85ZV

POWER 24

Spider Assembly Disassembling and reassembling spider assembly 1. Disassembling spider assembly 1) Remove lock bolts (1) and then plate (2). Torque for assembly: : Lock bolts: 216 N-m (22.0 kgf-m) (159 lb-ft) : Screw lock agent (Three bond 1327) application

1 90ZV24136

2) Insert lock bolt (1) into planetary pin (3), and remove the pin. Remove planetary gear (4) with the wear rings and the bearings as a unit.

1 3

90ZV24137

3) Remove wear rings (6) and bearing (5) from planetary gear (4).

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

90ZV24138

8 90ZV24139

24-30

Spider Assembly

85ZV

2. Reassembling spider assembly Before starting work: - Clean all the parts. - Check the brake retainer, pins, bearings, planetary gears, wear ring, 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. - When refilling axle and planetaries with lubricant, use friction modjien (anti-chatter) additive.

24-31

POWER 24

Special Tool

85ZV

POWER 24

Special Tool Special tool for axle (A) Spider hoisting tool mm (in.)

(Material: SS41)

(1.

4(0.2) C2(0.08)

3(0.1)

75(3.0)

R 8(

12 (0.5)

R (0 10 .4 )

10 (0.4)

46(1.8)

φ 6-mm (0.2-in.) dia. round steel

65(2.6)

t6(0.2)

(0.2)

C2 (0.08)

m rill 5-m .)d φ 2 .0-in (1

22(0.9)

46(1.8)

105(4.1)

10 (0.4)

3(0.1)

C 2(0.08)

65(2.6) 90ZV24085

(B) Internal gear hub puller mm (in.)

(Material: SS41)

30(1.2)

t12(0.5)

30(1.2)

2× φ12(0.5)

90(3.5)

180(7.1)

C 5(0.2)

206(8.1)

90ZV24086

24-32

Special Tool

85ZV

POWER 24

(Material: SS41)

75(3.0) ø13-mm(0.5-in.) drilled 35(1.4)

t12(0.5)

R 15

20 R .8) (0

107(4.2)

235(9.3) 345(14)

0 R2 .8) (0

13 35

5 R1 .6) (0

270(10.6)

215(8.5)

10 (0.4)

.4)

7 (0.3)

0(2

(0.4)

5 R1 .6) (0

0 R1 .4) (0

15 (0.6) 25 (1.0)

56(2.2) 3 15 (0.1) (0.6)

t9(0.4)

35 (1.4)

(0.6)

292(11.5)

0 R2 .8) (0

434(17)

35 (1.4)

155(6.1) (1.4) (0.5)

25 (1.0)

)

27.5 (1.1)

35(1.4) 90(3.5)

27.5 (1.1)

A-A

90ZV24087

24-33

Special Tool

85ZV

POWER 24

(D) Wheel hub hoisting tool

(Material: SS41)

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

50 (2)

15 (0.6)

65 (2.6)

12 (0.5)

80 (3.2)

20 (0.8)

15 (0.6)

6 (1/4)

35 (1.4)

ø (1 31 .2 )

25 (1)

10(0.4)

12(0.5)

75 (3)

(E) Eye bolt M30 x 2

Cut the threaded area off the M10 eye bolt before use. 40 (1.6)

85ZV24028

24-34

5(0.2)

10±0.3 (0.4±0.01) R0.3 (0.01)

For wheel hub

20(0.8) 3(0.1)

12±0.3 (0.5±0.004)

10±0.3 (0.4±0.01)

R0.3 (0.01)

R0.2~R0.5 (0.008~0.02)

24-35 +0

φ224.8(8.9)

13(0.5)

R0.2~R0.5 (0.008~0.02) C

1. 13(0.5)

3C 3(0.1)

(

3(0.1)

2. (

φ230(9.1)

φ190(7.5)

φ14.6 +0 –0.1 (8.4 –0.004 ) +0.1 φ209.6 +0 (8.2±0.004) φ201.1±0.1(7.9±0.004)

85ZV

φ260(10.2)

3(0.1) 7±0.2 (0.28±0.008)

) 10±0.3 (0.4±0.01)

φ220(8.7)

15(0.6)

( 3C

2. 3(0.1)

φ258(10.2)

20(0.8)

–0.012 φ214.8 –0.1 –0.05 (8.9 –0.014 ) φ270(10.6)

For wheel hub

φ246 +0 –0.1 (9.7 –0.004 ) φ242±0.1(9.5±0.004) φ235±0.1(9.3±0.004)

1. )

+0.004 φ247.2 ++0.1 0.05 (9.7 +0.002 ) φ260(10.2)

C 10±0.3 (0.4±0.01) –0.012 φ226 –0.30 –0.35 (8.9 –0.014 ) φ209.4±0.1(8.2±0.004)

8±0.2 (0.31±0.008)

–0.010 φ256 –0.26 –0.3 (10.1 –0.012 ) φ241±0.1(9.5±0.004)

15(0.6)

(

φ230(9.1)

φ260(10.2)

3(0.1)

φ190(7.5)

φ214.6 +0 –0.1 (8.4 –0.004 ) +0.1 φ209.6 +0 (8.2±0.004) φ201.1±0.1(7.9±0.004)

φ224.8(8.9)

φ240(9.5)

φ235(9.3)

+0.004

φ214 +0.1 +0.05 (8.4 +0.002 )

φ220(8.7)

+0.010

φ223 +0.25 +0.3 (8.8 +0.012 ) φ209.4±0.1(8.2±0.004)

10±0.3 (0.4±0.01)

φ24.6 +0 –0.1(9.7 –0.004 ) φ242±0.1(9.5±0.004) φ235±0.1(9.3±0.004)

φ258(10.2)

φ270(10.6)

5(0.2)

φ265(10.4)

+0.004

φ247.2 +0.1 +0.05 (9.7 +0.002 )

φ241.8±0.1(9.5±0.004)

+0.010

φ253 +0.25 +0.3 (10.8 +0.012 )

Special Tool POWER 24

(F) Floating seal jig mm (in.) (1) 70ZV~80ZV

For ring )

20(0.8) 11±0.2 (0.43±0.008)

3(0.1) 3(0.1)

10.4±0.3 (0.41±0.01) R0.3 (0.01) R0.2~R0.5 (0.008~0.02)

90ZV24090

(2) 85ZV~90ZV

For ring 20(0.8)

)

10.9±0.2 (0.43±0.008)

3(0.1) 3(0.1)

12±0.1 (0.5±0.004)

R0.3 (0.01)

R0.2~R0.5 (0.008~0.02)

90ZV24091

Rear Axle Assembly

85ZV

POWER 24

Rear Axle Assembly Tightening torque

S/N - 9004~

T4 T6 T4

S/N - 9004~ T3 L 1 B

T5 L 1

S/N ~ 9003 T2 L1

T8 L1

85ZVE24015

: Bolt tightening torque

Note: 1. Axle nut tightening procedure 1) Tighten axle nut (A) with 1,765 N-m (180 kgf-m) (1,300 Ib-ft) tightening torque to install the taper roller bearing. 2) Loosen axle nut (A). 3) Tighten axle nut (A) again with 1,765 N-m (180 kgf-m)(1,300 Ib-ft) tightening torque. 4) Turn the wheel hub 2~3 turns back and forth, and measure the preload applied to section (B). Preload of section (B): 226~265 N (23~27 kgf) (50~59 Ibs)∗ ∗ This is "breakaway" force. The force required to start the wheel turning. 2. Use jig to install the floating seal to the axle assembly.

T1: 892 N-m (91.0 kgf-m) (658 lb-ft) T2: 216 N-m (22.0 kgf-m) (159 lb-ft) T3: 314 N-m (32.0 kgf-m) (232 lb-ft) T4: 78 N-m ( 8.0 kgf-m) ( 58 lb-ft) T5: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T6: 33 N-m ( 3.4 kgf-m) ( 25 lb-ft) T7: 86 N-m ( 8.8 kgf-m) ( 64 lb-ft) T8: 90 N-m ( 9.2 kgf-m) ( 67 lb-ft) : L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three Bond 1215) L3: With lubricating oil (Engine oil or gear oil)

24-36

Rear Axle Assembly

85ZV

POWER 24

Removing and reinstalling rear axle assembly 1. Removing rear axle assembly

WARNING Unexpected movement of machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply articulation stopper. - Block front wheels with chocks to prevent wheels from moving. 1) Lower bucket to ground. Lift the front wheels while supporting the machine with the bucket. Place stand (A) under the rear chassis (behind the center pin) to support the chassis. A

90ZV24039

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

90ZV24040

3) Insert wooden blocks into the swing stopper section to prevent the axle from swinging.

Wooden blocks

WARNING The axle will not be balanced when a tire is removed. If wooden blocks are not inserted, your fingers or body may be caught in the machine. : Lower cover: 23 kg (50 lbs) 90ZV24041

24-37

Rear Axle Assembly

85ZV

4) Remove right and left wheel and tire assemblies (1). : Tire of 1 wheel: 650 kg (1,435 lbs) (without hydro-inflation) Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

POWER 24

90ZV24042

5) Remove the third propeller shaft retainer bolts (3) to remove propeller shaft (2). Torque for assembly: : Retainer bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application : Third propeller shaft: 15 kg (35 lbs)

6) Disconnect air breather tube (4). Note: Remove and clean tube (4) before reinstalling. Install plastic cap on breather fitting.

85ZV24021

Breather fitting

Rear axle

90ZV24044

7) Disconnect the front and rear grease pipes.

8) Disconnect the hose (5) from the brake oil inlet side. Note: Cover and plug the hose and fittings to prevent dirt entry.

Rear axle

24-38

90ZV24045

Rear Axle Assembly

85ZV

POWER 24

9) Attach sling to rear axle (6), and remove right and left retainer bolts (7) from the rear axle support. Lower rear axle (6) on the carrier and then pull out the rear axle 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.

CAUTION Axle assembly could fall off the carrier causing injury. Before pulling out the axle, carefully position axle onto carrier using a strap so that axle will not fall from carrier. Torque for assembly: : Retainer bolt: 721 N-m (73.5 kgf-m) (532 lb-ft) : Rear axle: 1,380 kg (3,045 lbs) Note: Be careful not to bend or damage oil pipes.

2. Reinstalling rear axle assembly For reinstallation, follow the above procedure in the reversed direction. Refer to "Reinstalling front axle assembly" for air bleeding in the service brake.

3. For disassembling and reassembling the rear axle assembly, refer to "Disassembling and reassembling front axle".

24-39

6 90ZV24046

Axle Support

85ZV

POWER 24

Axle Support (S/N 85C4-9001~9003) Tightening torque

T1 L2

T2 L1

90ZV24038

: Bolt tightening torque T1: 721 N-m (73.5 kgf-m) (532 lb-ft) T2: 441 N-m (45.0 kgf-m) (326 lb-ft) : L1: Screw lock agent (Three Bond 1327) application L2: With lubricating oil (Engine oil or gear oil)

24-40

Axle Support

85ZV

POWER 24

Disassembling and reassembling axle support 1. Disassembling axle support Before starting work - Remove the rear axle assembly from the rear chassis.

1) Remove snap ring (1), packing (2), O-ring (3). Remove the front support from the rear axle assembly. : Axle support: 88.0 kg (194 lbs)

Front support

2) Remove bushing (4), O-ring (5), packing (6) from the rear axle assembly.

3 2 6

1 5

Rear axle assembly 4 85ZVE24002

Rear support

3) Remove the bolt (7), plate (8), wear ring (9), packing (10), O-ring(11). Torque for assembly: : Retainer bolt: 441 N-m (45.0 kgf-m) (326 lb-ft) : Screw lock agent (Three Bond 1327) application

11 7

4) Remove the rear support from the rear axle assembly. : Axle support: 110 kg (243 lbs)

13 Rear axle assembly

5) Remove bushing (12), O-ring (13), ring (14), packing(15) and wear ring (16) from the rear axle assembly.

24-41

Axle Support

85ZV

POWER 24

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

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

3. Cautions regarding reassembly Bushing Before installing put the bushing into hot water to heat bushing (4)(12) to 80 °C (175 °F). Install bushing (4)(12) onto the swing shaft as shown in the illustration.

Front support

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 causing bushing wear.

Swing shaft 85ZVE24004

Rear support Note: When installing the axle support fill enough grease between the packing and the axle support as shown in the illustration. 12

Swing shaft 85ZVE24005

24-42

Axle Support

85ZV

POWER 24

Axle Support (S/N 85C4-9004~) Tightening torque T1 L2

T3 L1

T2 L1

85ZVE24006

: Bolt tightening torque T1: 721 N-m (73.5 kgf-m) (532 lb-ft) T2: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T3: 608 N-m (62.0 kgf-m) (449 lb-ft) : L1: Screw lock agent (Three Bond 1327) application L2: With lubricating oil (Engine oil or gear oil)

24-43

Axle Support

85ZV

POWER 24

Disassembling and reassembling axle support 1. Disassembling axle support Before starting work - Remove the rear axle assembly from the rear chassis.

1) Remove bolt (1). Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (40 lb-ft)

Front support

2) Remove ring (2), packing (3) and front support from the rear axle assembly. : Axle support: 87 kg (192 lbs)

3 2 Rear axle assembly

3) Remove packing (4) and bushing (5) from the front support.

5 1

4) Remove bolt (6). Torque for assembly: : Bolt: 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application 5) Remove plate (7) and wear ring (8).

85ZVE24007

8 Rear support

10 6

12 9

6) Remove bolt (9). Remove plate (10) and wear ring (11). Torque for assembly: : Bolt: 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application 7) Remove the rear support from the rear axle assembly. : Axle support: 110 kg (243 lbs) 8) Remove packing (12) and bushing (13) front the rear support.

24-44

Rear axle assembly 85ZVE24008

Axle Support

85ZV

POWER 24

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

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

3. Cautions regarding reassembly Bushing Before installing put bushing (5)(13) into dry ice then install it on to the axle support.

Front support

CAUTION 5

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 causing bushing wear.

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

Swing shaft

85ZVE24009

Rear support

Swing shaft 85ZVE24010

24-45

Differential Assembly

85ZV

POWER 24

Differential Assembly Removing and reinstalling differential 1. Removing differential Before starting work: a) Drain oil from the axle assembly. b) Remove the axle from the machine. c) Place the axle assembly on workbenches. d) For the rear axle, remove the axle supports. For axle support removal, refer to the steps of "Removing and Reinstalling Rear Axle Assembly". : Axle assembly Front: 1,180 kg (2,600 lbs) Rear: 1,380 kg (3,045 lbs)

90ZV24078

A 2

cover bolts

TOP

1) Attach sling to the spider using hoisting tool (A). Remove bolts and cover (1). Remove retainer bolts (2) to remove spider assembly. Torque for assembly: : Retainer bolt: 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 100 kg (220 lbs)

Spider assembly

1 90ZV24079

2) Pull out right and left axle shafts (3) 30 cm (12 in.).

30cm (1 foot)

90ZV24080

3) Remove bolts (5) from differential (4). Torque for assembly: : Front differential retainer bolts: 132 N-m (13.5 kgf-m) (98 lb-ft) : Rear differential retainer bolts: 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application

5 90ZV24081

24-46

Differential Assembly

85ZV

POWER 24

Note: Spacers are inserted in eight "•" mark sections of the front differential. Spacers in " " mark sections

90ZV24082

4) Attach sling to differential (4), and insert bolts into the remover tap (Jack Screw) holes (6) to slightly lift the differential. : Differential: 175 kg (385 lbs) Note: Be careful to sling the differential so that it is balanced and is lifted straight up.

6 90ZV24083

5) Lift the differential using the sling, and then remove Oring (7).

90ZV24084

2. Reinstalling differential For reinstallation, follow the above procedure in the reversed direction. Note: After reinstallation, refill with the specified oil until the oil level rises to the level check plug. Also refill each planetary assy. Manually turn the flange yoke of the differential to check that the right and left wheel hubs turn smoothly. Also check the differential for oil leakage. 24-47

IMPORTANT When refilling axle and planetaries with lubricant, use friction modifier (antichatter) additive.

Differential Assembly

85ZV

POWER 24

Disassembling and reassembling differential assembly 1. Front differential tightening torque T5 L1

T6 L1

T2 L1

F D T6 L1

T7 L1 T3 L 1 F E A

Shim (T=0.07)

(T=0.50)

T4 L1

T1 L2

(T=16.70) (T=16.98)

90ZV24101

Note: 1) To tighten T1 , measure the preload of section A . Preload of section A : 57 to 66 N (5.8 to 6.7 kgf) (13 to 15 lbs) Use spacer B to adjust the preload. 2) Use shim E to adjust the tooth contact of spiral bevel gears C D . Adjust the backlash by nut F .

: Bolt tightening torque T1: 883 N-m (90.0 kgf-m) (651 lb-ft) T2: 515 N-m (52.5 kgf-m) (380 lb-ft) T3: 330 N-m (33.7 kgf-m) (244 lb-ft) T4: 314 N-m (32.0 kgf-m) (232 lb-ft) T5: 235 N-m (24.0 kgf-m) (174 lb-ft) T6: 53 N-m (5.35 kgf-m) ( 39 lb-ft) T7: 132 N-m (13.5 kgf-m) ( 98 lb-ft) : L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three Bond 1215) 24-48

Differential Assembly

85ZV

POWER 24

2. Rear differential tightening torque T2 L1

T3 L 1 D

F T6 L1

T5 L1 C

T7 L1

A T1 L2

Shim (T=0.07) (T=0.50)

S/N - 9004~

T4 L1

(T=16.70) (T=16.98)

85ZVE24011

Note: 1) To tighten T1 , measure the preload of section A . Preload of section: 57 to 66 N (5.8 to 6.7 kgf) (13 to 15 lbs) Use spacer B to adjust the preload. 2) Use shim E to adjust the tooth contact of spiral bevel gears C D . Use nut F to adjust the backlash.

: Bolt tightening torque T1: 883 N-m (90.0 kgf-m) (651 lb-ft) T2: 515 N-m (52.5 kgf-m) (380 lb-ft) T3: 331 N-m (33.7 kgf-m) (244 lb-ft) T4: 314 N-m (32.0 kgf-m) (232 lb-ft) T5: 235 N-m (24.0 kgf-m) (174 lb-ft) T6: 53 N-m (5.35 kgf-m) ( 39 lb-ft) T7: 314 N-m (32.0 kgf-m) (232 lb-ft) : L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three Bond 1215)

24-49

Differential Assembly

85ZV

POWER 24

Adjust nut

3. Disassembling differential assembly 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 pinion and the bevel gear to prevent the gear from rotating. Loosen pinion nut A . Torque for assembly: : Nut A : 883 N-m (90 kgf-m) (651 lb-ft) Note: Nut width across flat: 57.1 mm (2.25 in.)

Shim

Nut A Bevel gear

Pinion

Adjust nut

1) Since the trunnion is installed on the rear differential assembly from S/N-9004~, remove the trunnion first before disassembling the differential assembly.

90ZV24103

Trunnion

85ZVE24012

2) Remove right and left lock plates (2), bolts (3), bearing cap (4) and adjustment nut (1). 3

2 85ZVE24013

3) Remove bearing outer race (5). Lift differential cage assembly (6) to remove it.

90ZV24150

24-50

Differential Assembly

85ZV

POWER 24

4) Put a matchmark on the alignment point of differential cage (7). Remove bolts (8), and then separate the differential cage.

Matchmark 90ZV24107

5) Remove thrust washer (9) and side gear (10).

10 9 90ZV24108

6) Remove spider (11) with pinion gears (12) and thrust washers (13) as a unit.

13 11 90ZV24109

7) Remove side gear (14).

90ZV24110

24-51

Differential Assembly

85ZV

POWER 24

8) Remove thrust washer (15). 15

90ZV2411

9) Turn the differential upside down. Remove bolts (17) from bevel gear (16) to separate the gear.

16 90ZV24112

10) Remove bolts (18) to remove pinion (19). At the same time, remove the shim. Note: Refer to step (1) bolts for disassembling the rear differential assembly from S/N-9004~.

18 90ZV24113

11) Remove nut (20) and O-ring (21). Note: Nut width across flat: 57.1 mm (2.25 in.). 20

90ZV24114

24-52

Differential Assembly

85ZV

POWER 24

12) Remove flange yoke (22).

90ZV24115

13) Remove pinion (23) from cage (24). 23

90ZV24116

14) Remove taper roller bearing (25).

25 90ZV24117

15) Remove spacer (26). 26

90ZV24118

24-53

Differential Assembly

85ZV

POWER 24

4. 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. 1) Check the preload of the pinion section by following the procedure below: ➀ Install new roller bearing (27) on pinion (23) if replacement is needed. Note: After attachment, stake the bearing at three points as shown in the right figure.

➁ Install new tapered roller bearing (28) and spacer (26) on pinion (23) if replacement is needed. ➂ Install cage (24) and tapered roller bearing (25). ➃ Put yoke (22) and install nut (20) on pinion (23). Note: Do not install the oil seal and O-ring of the nut. : Nut: 883 N-m (90 kgf-m) (651 lb-ft) ➄ Secure yoke in a vise. Measure the preload at section (A) (bolt hole).

20 25 27

A 22 90ZV24120

Pinion

Bearing

0 Pinion

90ZV24119

: Standard preload ∗: 57 to 66 N (5.8 to 6.7 kgf) (13~15 lbs) If the preload is out of the above range, replace spacer (26) to adjust the preload to the specified range. ∗ Preload is the force required to start the cage movingbreakaway force.(Not rolling force.) Note: There are 15 types of spacers from 16.70 to 16.98 mm in increments of 0.02 mm. Thicker spacers reduce preload; thinner spacers increase preload. Remove nut (20) and flange yoke (22). ➅ 2) Install oil seal (29) to cage (24). : Before installing oil seal, be sure to apply grease to the lip and liquid gasket the outside of the seal. 24-54

Stake at 3 points

90ZV24121

Check direction of the lips Apply liquid gasket (AA03) to these surfaces 29 24 90ZV24122

Differential Assembly

85ZV

POWER 24

3) Install flange yoke (22), and then O-ring (21). Apply liquid gasket to nut (20), and then tighten the nut. (Nut width across flat: 57.1 mm)

: Nut: 883 N-m (90 kgf-m) (651 lb-ft) : Liquid gasket (Three Bond 1215) application 20

21 90ZV24123

4) Install O-ring (30) and the shims (the one(s) removed during disassembly) to the cage. Insert the cage into differential case (31), and tighten the retainer bolt (18). Note: Install the trunnion to the rear differential assembly for S/N-9004 and up. : Bolt: 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application

Front

Rear (S/N - 9004~) Shim

Shim

Trunnion 85ZVE24014

5) Install thrust washer (15) and side gear (14) to differential cage (32).

90ZV24144

6) Attach spider (11) with side gears (12) and thrust washers (13) as a unit.

90ZV24145

24-55

Differential Assembly

85ZV

POWER 24

7) Install side gear (10) and thrust washer (9). 9

90ZV24146

8) Align differential cage (7) with the matchmark, and then tighten bolts (8).

: Retainer bolt: 235 N-m (24.0 kgf-m) (174 lb-ft) : Screw lock agent (Three Bond 1327) application Matchmark

90ZV24147

9) Tighten bolts (17) in bevel gear (16).

16 17

: Retainer bolt: 330 N-m (33.7 kgf-m) (244 lb-ft) : Screw lock agent (Three Bond 1327) application

90ZV24148

10) Install differential cage assembly (6) in the carrier assembly.

90ZV24149

24-56

Differential Assembly

85ZV

POWER 24

11) Reinstall bearing cap (4), and then temporarily tighten bolts (3). Reinstall the adjustment nut. (For both the right and left sides)

Adjust nut 90ZV24131

12) Adjust the backlash as follows: ➀ Tighten adjustment nut (33) on the bevel gear side until the backlash is "0". Then back off the adjustment nut 2 to 3 notches.

➁ Tighten opposite side adjustment nut (1). After you feel that the nut is tight, turn it one more notch. ➂ Attach the dial gauge stand to the carrier. Attach dial gauge (A) to a tooth of bevel gear (16). Read the backlash value indicated on the dial gauge. ➃ Adjust the backlash. Standard backlash: 0.26 to 0.38 mm (0.0102~0.0149 ″) - Tighten adjustment nut (33) on the bevel gear side or loosen adjustment nut (1) on the opposite side to reduce the backlash. - Loosen adjustment nut (33) on the bevel gear side or tighten adjustment nut (1) on the opposite side to increase the backlash.

90ZV24132

34 3 2

90ZV24133

13) Tighten bolts (3) of bearing cap (4). : Retainer bolt: 515 N-m (52.5 kgf-m) (380 lb-ft) : Screw lock agent (Three Bond 1327) application

14) Mount lock plate (2), and then tighten bolts (34) to fix the lock plate. : Retainer bolts: 53 N-m (5.35 kgf-m) (39 lb-ft) : Screw lock agent (Three Bond 1327) application

24-57

Differential Assembly

85ZV

POWER 24

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

Possible cause

Adjusting method

Correct

Ring gear is too close to the drive pinion

Loosen bearing adjuster on rear side of ring gear, and tighten adjuster of tooth side at the same quantity as loosening, so that ring gear is far apart from drive pinion. Check again backlash and tooth contact.

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

Increase thickness of shim at the part of bearing cage being installed and makes drive pinion apart from ring gear. Check again the backlash and tooth contact.

Drive pinion is too far from the ring gear.

Decrease thickness of shim reverse as D, and makes drive pinion approach ring gear. Check again backlash and tooth contact.

90ZV24134

24-58

Differential Assembly

85ZV

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

HEEL 4~5

Pitch line TOE

BOTTOM 10 2

Pattern B

4 TOP

Pitch line

HEEL 4~5

TOE BOTTOM 10 3 Pattern C

4 TOP

TOE Pitch line

HEEL 4~5

BOTTOM

10 90ZV24135

Service parts: After adjusting the tooth contact and backlash in our factory, we will wrap the bevel gear and drive pinion as a unit. Therefore, replace the bevel gear and drive pinion as a unit. Note: Single sale of the bevel gear or the drive pinion is not possible.

24-59

MEMO

POWER GROUP 25 Service Standard Propeller Shaft Service Standard ...............................................................25-2 Axle and Differential Service Standard .......................................................25-3

25-1

Propeller Shaft Service Standard

85ZV

POWER 25

Propeller Shaft Service Standard

Third propeller shaft 1

a 2 Measurement of circumferential play

3 Measurement of transverse play

Second propeller shaft 85ZV25001

Unit : mm (in.) Item

No.

Tolerance

Solution

Spider bearing play

Second, third propeller shaft

0.25 (0.0098)

Replacement

Spline circumferential play

Second propeller shaft

0.8 (0.0315)

Replacement

Spline transverse play

Second propeller shaft

1.0 (0.0394)

Replacement

Note: Bolt tightening torque a: 77 N-m ( 7.9 kgf-m) ( 57 lb-ft) b: 162 N-m (16.5 kgf-m) (119 lb-ft)

25-2

Axle and Differential Service Standard

85ZV

POWER 25

Axle and Differential Service Standard Axle group

6 (S/N - 9004~) 5 4

2, 3

1, 3

4 5 85ZVE25001

7 (S/N - 9004~)

Unit : mm (in.) Judgment standard No.

Item

Solution Standard dimension

Tolerance

Backlash between sun gear and planetary gear

0.12 ~ 0.60 (0.0047 ~ 0.0236)

←

Replacement

Backlash between planetary gear and internal gear

0.14 ~ 0.73 (0.0055 ~ 0.0287)

←

Replacement

Tooth contact of gear

No abnormality

Replacement

Axle support wear

Dia.: 1.0 (0.0393) / Radius: 0.5 (0.0196) (stepped)

Replacement

Bushing and wear ring wear

No oil groove

Replacement

Trunnion wear

Dia.: 1.0 (0.0393) / Radius: 0.5 (0.0196) (stepped)

Replacement

Sleeve wear

Dia.: 1.0 (0.0393) / Radius: 0.5 (0.0196) (stepped)

Replacement

25-3

Axle and Differential Service Standard

85ZV

POWER 25

Differential

2 3

90ZV25003

Unit : mm (in.) Judgment standard Item

No.

Solution Standard valve

Tolerance

Backlash between ring gear and drive pinion

0.26 ~ 0.38 (0.0102 ~ 0.0149)

←

Adjustment

Backlash between side gear and pinion gear

0.23 ~ 0.58 (0.0090 ~ 0.0228)

←

Adjustment

Clearance between pinion gear and spider

0.098 ~ 0.126 (0.0038 ~ 0.0049)

←

Replacement

Runout of ring gear rear surface (when assembled)

0.076 (0.0029)

←

Adjustment or replacement

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

Tooth contact

No abnormality

Replacement

25-4

TORQUE CONVERTER AND TRANSMISSION GROUP 34 Disassembly and Reassembly Torque Converter and Transmission Assembly...........................................34-2 Torque Converter Assembly ......................................................................34-10 Transmission Assembly.............................................................................34-18 Forward/Reverse Clutch Pack ...................................................................34-32 1st/3rd Speed Clutch Pack ........................................................................34-35 2nd Speed Clutch Pack .............................................................................34-38 4th Speed Clutch Pack ..............................................................................34-40 Control Valve Assembly.............................................................................34-43

34-1

Torque Converter and Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly Tightening torque T1 L1

T2 L 1

T1 L1 T3 L 3 T4 L 3

T6 L 1

T1 L1

T5 L 2

85ZV24001

: Bolt tightening torque T1: 417 N-m (42.5 kgf-m) (307 lb-ft) T2: 230 N-m (23.5 kgf-m) (170 lb-ft) T3: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T4: 67 N-m ( 6.8 kgf-m) ( 49 lb-ft) T5: 142 N-m (14.5 kgf-m) (105 lb-ft) T6: 441 N-m (45.0 kgf-m) (325 lb-ft)

Always replace drive shaft bolts with new bolts – Never reuse.

L1: Screw lock agent (Loctite® 262) application L2: Screw lock agent (Three Bond 1327) application L3: With lubrication oil (Engine oil or gear oil)

34-2

Torque Converter and Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Removing and reinstalling torque converter and transmission assembly 1. Removing torque converter and transmission assembly

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. Lower bucket to ground, and then block tires with chocks to prevent wheels from moving. - Disconnect the ground cable from the negative side of the battery. Before starting work: - Remove the cab and the floor board (Refer to Section 14). - Remove the engine room (Refer to Section 14). - Consider the type of failure and if the T/C 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 and throughly cleaned or replaced. - Lines to cooler must also be replaced. 1) Remove drain plug (1) to drain the transmission oil. : Transmission oil: 38 (10 gal.) 2) Disconnect bolts (3) from third propeller shaft (2) on the transmission side. 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 (3): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327) 3) Remove bolt (5) from second propeller shaft (4) on the transmission side only. Disconnect electric wire (6) from the speed meter sensor and speed sensor. Tightening torque for assembly : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327) 34-3

90ZV34001

5 90ZV34002

90ZV34003

Torque Converter and Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

IMPORTANT When the transmission is lifted, the parking brake actuator will come in contact with the chassis. To prevent this, remove the parking brake actuator before lifting the transmission.

4) Release the parking brake and disconnect the link of the actuator. If the machine has low accumulator oil pressure, feed oil into hose (7) from an external source. Note: If there is no oil source, apply a rope or cable to the link, and then pull it down using a bar to compress the spring of the actuator. After that, remove the pin.

Solenoid valve 85ZV34001

5) Remove split pin (8), and then remove pin (9). 10 11

6) Remove bolts (11) from the actuator mounting bracket (10). Disconnect the oil source, and then remove actuator (12).

90ZV34005

7) Disconnect hose (13) from the transmission level gauge. Note: After removing the hose, plug or cover the disconnected part with clean vinyl to protect from dust and dirt.

IMPORTANT

When the transmission is lifted, it will come in contact with the steering valve. To prevent this, remove the steering valve before lifting the transmission. 8) Disconnect all the hoses and the pipes from the steering valve and remove the steering valve with the bracket. Install plastic caps or plugs to prevent dirt entry into valve and hoses.

85ZV34002

Steering valve

85ZV34003

34-4

Torque Converter and Transmission Assembly

85ZV

9) Disconnect hoses and pipes (14) (15) (16) from the oil pump. Note: After removing the hoses, cover the hoses with plastic caps, and cover the pump ports with caps to protect them from dust and dirt.

TORQUE CONVERTER AND TRANSMISSION 34

Oil pump

Transmission

16 14

10) Remove suction hoses (17) (18), and then remove pump assembly (19). Note: After removing the hoses, cover the hoses with plastic caps, and cover the pump ports with the caps to protect them from dust and dirt. Refer to the Section 44 "Hydraulic Group" for the reinstallation. Tightening torque for assembly : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Gear pump: 55 kg (120 lbs)

90ZV34007

Transmission

19 17

90ZV34008

11) Disconnect the electrical wire for torque converter temperature switch sensor (20).

85ZV34004

12) There are two hoses (21) between torque converter and the cooler. There are two hoses (22) between the line filter and the transmission. Disconnect hoses (21) (22). Note: After removing the hose, cover the fitting section with plastic caps or plugs to protect the fitting section from dust and dirt.

21 22

85ZV34005

34-5

Torque Converter and Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

13) Remove all electric wire couplers (24) from control valve (23). Note: Before disconnecting the couplers, be sure to put matchmarks on the couplers. For reassembly refer to the connection illustration "Reinstalling control valve".

85ZV34006

14) Attach sling to transmission assembly (25), and then remove 12 bolts (26) from the engine flywheel housing. Tightening torque for assembly : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) : Transmission assembly: 880 kg (1,940 lbs)

85ZV34007

15) Remove bolts (27) (both sides). Tightening torque for assembly : Bolt (27): 417 N-m (42.5 kgf-m) (307 lb-ft) : Screw lock agent (Loctite® 262) application 27

Note: The joint section between the engine and the transmission consists of the pilot boss and the gear coupling as shown in the figure. The pilot boss is inserted for centering, and the gear coupling is used for power transmission. To separate the transmission from the engine, remove the bolts from the engine flywheel housing, and then pull the transmission straight out to the front.

85ZV34008

Engine flywheel housing

Flywheel

Pull to separate transmission

Pilot boss

Ring Ring gear

Transmission

85ZV34009

34-6

Engine-transmission joint section

Torque Converter and Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

16) Separate the transmission assembly from the engine, and then put the engine on the rear axle housing. Note: Lift the transmission approximately 100 mm (4 in.), and then insert a wooden piece of 200 mm (8 in.) into the clearance between the bottom of the engine flywheel housing and the rear axle housing. Lower the transmission to make a slight clearance between the engine and the transmission. Repeat the above procedure 2 to 3 times while pulling the transmission away from the engine to separate them.

Wooden piece 85ZV34010

Wooden block

85K34016

17) Slowly lift transmission assembly (28) while avoiding contact with other parts. 28

85ZV34011

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

34-7

Torque Converter and Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

3. Cautions for installation - Be sure to replace the O-ring (1) with new one. - Be sure pilot boss bushing (ring) is installed. Transmission side

Engine side Flywheel

Ring gear 90ZV34017

Ring

- Rotate the engine flywheel to align the ring gear. - After reinstallation, check operation of the transmission assembly by the following procedure.

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, be sure to stop the engine, and block to the tires with chocks before you start service work. During the service work clearly communicate with the person in the operator seat using signals as agreed upon before hand.

1) At the completion of reinstallation, start the engine, and check that the shift lever properly functions at all the positions. 2) Check each section for oil leakage. 3) Adjust the transmission oil level to the specified point with the level gauge. 4) Perform the start-up tests as shown on the attached sheet.

34-8

85K34019

Torque Converter and Transmission Assembly

DATE:

HOURS:

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

MACHINE MODEL & SERIAL NO.:

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO.:

AMBIENT TEMP: COMPONENT SERIAL NO.:

CHECKLIST TO BE COMPLETED BEFORE START-UP TRANSMISSION COOLER CLEANED

TRANSMISSION PIPING CLEANED

IN-LINE PRESSURE FILTER REPLACED

TRANSMISSION LINKAGE CHECKED

ALL DATA TO BE RECORDED AT OPERATING TEMPERATURE. IF INITIAL TEST DATA IS INCORRECT, THEN CORRECT AND RETEST.

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

HIGH IDLE RPM LOW IDLE RPM T/C STALL RPM HYDRAULIC STALL RPM FULL STALL RPM CREEP WITH BRAKE (F1) RPM CREEP WITH BRAKE (R2) RPM

CLUTCH PRESSURE AT LOW IDLE F1

MPa (kgf/cm2) (psi)

CLUTCH PRESSURE AT HIGH IDLE F1

MPa (kgf/cm2) (psi)

COMMENTS:

Serviceman's Signature

KAWASAKI HEAVY INDUSTRIES, LTD. CONSTRUCTION MACHINERY DIVISION Copy as required. Make attachments if needed.

34-9

Torque Converter Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter Assembly T6 L 3

Bolt tightening torque T2 L 3

T7 L 3

T6 L 3

T5 L 1

T3 L 1

90ZV34018

T2 L 3

T4 T2 L 3

T1: 29 N-m ( 3 kgf-m) ( 22 lb-ft) T5: 94 N-m (9.6 kgf-m) (69 lb-ft) T2: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T6: 59 N-m ( 6 kgf-m) (43 lb-ft) T3: 216 N-m (22.0 kgf-m) (159 lb-ft) T7: 86 N-m (8.8 kgf-m) (64 lb-ft) T4: 392 N-m ( 40 kgf-m) (289 lb-ft) (Molybdenum disulfide grease / MOS2 application) L1: Screw lock agent application (Loctite® 262) L3: With lubrication oil (Engine oil or gear oil) 34-10

T1 L 3

Torque Converter Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling torque converter assembly 2

1. Disassembling torque converter assembly

Hose

Before starting work: - Clean the transmission assembly. - Drain oil from the transmission. 1) Remove bolts (1), cover (2) and then remove the hose. 1 90ZV34019

2) Removing the front cover from the pump impeller. Remove bolts (3). (Number of bolts: 24)

3 85K34021

3) Remove front cover (4). After removing the front cover, remove the ball bearing (5). Note: If a shim is attached, remove the shim from the bearing and store it for reassembly.

Shim

90ZV34020

4) Remove turbine impeller assembly (8).

90ZV34021

34-11

Torque Converter Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) Remove thrust washers (9), thrust bearing (10), and ring (11).

9 11

90ZV34022

6) Remove snap ring (12) and stator (13). 13

90ZV34023

7) Remove collar (14), thrust washer (15), thrust bearing (16) and ring (17). 15 17

14 16

90ZV34024

8) Remove pump impeller assembly (18). 18

90ZV34025

34-12

Torque Converter Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

9) Remove seal ring (19), bolts (20), and then stator shaft (21).

20 21 90ZV34026

10) Remove seal ring (22). 11) Attach sling to torque converter housing. Separate torque converter housing from transmission housing.

22 25

23 24

12) Turn the torque converter housing over. 13) Remove snap ring (23) and turbine shaft bearing (24). Torque converter housing 90ZV34027

14) Remove turbine shaft (25). 29

15) Remove nut (26) from bolt (27).

16) Remove bolt (27) from the torque converter housing. 28

17) Remove spring (28) and washer (29) from bolt (27).

Torque converter housing 90ZV34115

34-13

Torque Converter Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

2. Reassembling torque converter assembly

IMPORTANT - Clean and check all the parts. If a part is damaged, replace it with a new one. - Before reassembly, apply transmission oil to the parts.

1) Turn the torque converter housing over. 2) Install spring (28) and washer (29) to bolt (27).

29 26

3) Install the bolt (27) to the housing.

IMPORTANT

Adjust the clearance between torque converter housing and bolt (27) to 35.2 mm.

Torque converter housing 90ZV34115

35.2 85ZV34019

4) Install washer (29) and nut (26) onto bolt (27). Tightening torque for assembly : Nut: 50 N-m (5.1 kgf-m) (37 lb-ft) : Screw lock agent application (Loctite® 262)

34-14

Torque Converter Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) Install turbine shaft bearing (24). 21

6) Install turbine shaft (25) and snap ring (23).

8) Attach seal ring (22). : Apply grease to the seal ring, and then insert into the groove. 9) Tighten bolts (20) to fix stator shaft (21), and then install the seal ring (19). : Bolt: 59 N-m (6 kgf-m) (43 lb-ft) : With lubrication oil (Engine oil or gear oil)

7) Connect the torque converter housing to the transmission housing.

90ZV34031

IMPORTANT Adjusting thrust clearance ➀ Temporarily assemble pump impeller (18) on the PTO drive gear, stator, bearing washers etc. and turbine impeller (8). ➁ Measure the distance from ball bearing (5) to the mounting face of the pump impeller assembly. Regard the obtained distance as dimension A. ➂ Measure the distance from the mounting face of the front cover (4) to the end face of the bearing receiver. Regard the obtained distance as dimension B. ➃ Adjust the difference between distance B and distance A (thrust clearance) to 0.2 to 0.4 mm using a shim as shown in the figure below. ➄ After shim adjustment, remove the ball bearing (step (2) above), and then sequentially attach the shim and then the ball bearing to the front cover.

90ZV34116

90ZV34117

B – A = 0.2 ~ 0.4 mm B Front cover

Ball bearing 90ZV34032

Adjusting shim

34-15

90ZV34033

Torque Converter Assembly

85ZV

10) Install pump impeller assembly (18), and then attach ring (17), thrust bearing (16), thrust washer (15), and collar (14). : Bolt: 59 N-m (6 kgf-m) (43 lb-ft) : With lubrication oil (Engine oil or gear oil)

TORQUE CONVERTER AND TRANSMISSION 34

90ZV34034

11) Install stator (13), and attach snap ring (12). 13

IMPORTANT If the stator is installed upside down, the stator will not function properly. Correctly install stator (13).

90ZV34023

12) Attach ring (11), thrust washer (9), and thrust bearing (10).

9 11

90ZV34022

13) Install turbine impeller assembly (8).

90ZV34021

34-16

Torque Converter Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

14) Install the front cover, and then tighten bolts (3) to connect the front cover to the pump impeller assembly. Number of bolts: 24 : Bolt: 29 N-m (3 kgf-m) (22 lb-ft) : With lubrication oil (Engine oil or gear oil)

3 85K34021

15) Install cover (2), and then tighten bolts (1). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) Note: At the completion of reassembly, manually turn the front cover to check that it rotates smoothly.

Hose

1 90ZV34019

16) Install the torque converter housing on to the transmission housing. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

Torque converter housing Transmission housing 90ZV34035

17) Connect the hose between the torque converter housing and transmission housing. Hose

90ZV34036

34-17

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly T6 L 3

Bolt tightening torque

T2 L 3

T7 L 3

T6 L 3

T5 L 1

T3 L 1

90ZV34018

T2 L 3

T4 T2 L 3

T1 L 3

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling transmission assembly 1. Disassembling transmission assembly

Hose

Before starting work: - Clean the transmission assembly. - Remove the coupling yoke, the sleeve and the snap ring of ball bearing for the third propeller shaft. Unless removed, they will fall off. - Place the transmission assembly so that the parking brake side is up. - For disassembling and reassembling for the parking brake, refer to "Brake Group 54".

90ZV34037

1) Disconnect hose. 2) Remove the bolts (1). Lift the control valve assy (2), and remove it. : Control valve assembly: 20 kg (44 lb) Note: Refer to "Removing and reinstalling control valve" to remove control valve assy (2).

1 90ZV34038

3) Remove bolt (3), and remove the brake drum (4). 4

90ZV34039

4) Remove nut (5), then remove flange yoke (6). 6

90ZV34040

34-19

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) Remove bolt (7), and then remove brake assembly (8).

7 90ZV34041

6) Remove bolt (9) and then remove drive cover assembly (10). 9

9 90ZV34042

7) Hit in output shaft (11) (approx 71 mm (2.8 in)) after that remove output shaft (11) with the ball bearing.

Ball bearing

71mm

4 3

90ZV34043

8) Remove the bolts (12), cover (13). 12

1 4 3

85ZV34013

34-20

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

9) Remove gear (14). 14

1 4 3

85ZV34014

10) Remove bolt (15).

15 85ZV34015

11) Remove bearing (16), after that remove the 4th speed clutch pack assembly (17).

90ZV34044

12) Remove the 1st speed clutch pack assembly (18). Note: Pull out the 1st speed clutch pack assembly. It is tight due to the ball bearing between the housing and the shaft.

Ball bearing

90ZV34045

34-21

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

13) Remove bolt (19). 19

90ZV34119

14) Lift transmission housing (20) slowly. 20

90ZV34120

15) Remove the 3rd and the forward speed clutch pack assembly (21).

90ZV34121

16) Remove the 2nd and the reverse speed clutch pack assembly (22). Note: Pull out the 2nd and the reverse speed clutch pack assembly. It is tight due to the ball bearing between the housing and the shaft.

90ZV34122

34-22

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

17) Remove bolt (23), plate (24), snap ring (25), bearing (26) and gear (27). 23 24 25 26 27

90ZV34123

18) Remove bolt (28) and then remove shaft (29). 28 29

90ZV34124

19) Remove bolt (30) and then remove charge pump assembly (31).

34-23

90ZV34125

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

2. Reassembling transmission assembly Note: - For clutch pack disassembly and reassembly refer to "Disassembly and reassembling clutch pack". - Clean and check all the parts. If a part is damaged, replace it with a new one. Refer to "service standard" for wear limits. - When assembling, apply transmission oil to the parts. - Replace all the seals and packings with new ones. - When installing each clutch pack assembly, manually turn the gears to check that the gears are engaged properly.

30 90ZV34126

1) Install torque converter gear pump (31) with bolt (30). Note: - Check the thrust clearance (0.5 to 0.9 mm) at pump shaft (32) (PTO shaft). Tap the shaft with a soft hammer to check the thrust clearance, if necessary. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

28 29

2) Install shaft (29) with bolt (28). : Bolt: 59 N-m (6 kgf-m) (43 lb-ft)

3) Install gear (27), bearing (26) and snap ring (25) onto shaft (29). Install the plate (24) and tighten bolt (23). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

90ZV34124

23 24 25 26 27

90ZV34123

34-24

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

4) Install the 2nd and the reverse speed clutch pack assembly (22).

90ZV34127

5) Install bearing (33) into the housing.

90ZV34128

6) Install the 3rd and the forward speed clutch assembly (21).

90ZV34129

7) Install transmission housing (20) on to the T/C housing. 20

90ZV34130

34-25

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

8) Tighten bolt (19). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) 19

90ZV34119

9) Install the 1st speed clutch pack assembly (18) and 4th speed clutch pack assembly (17).

90ZV34132

10) Install bearing (16) on to the 1st speed clutch pack assembly (18).

90ZV34133

11) Install small end bearing (34) on output shaft (11) and install the snap ring.

90ZV34134

34-26

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

12) Install the output shaft (11) into the housing (20). Note: Support output shaft (11) from the bottom side to avoid it fell down. 11

90ZV34135

13) Tighten bolt (15). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

15 85ZV34015

14) Install gear (14) onto output shaft (11).

90ZV34137

15) Measure and record the clearance between the 1st speed clutch pack gear (18) and the 4th speed clutch pack gear (17). Note: The clearance between them should be no less than 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.).

18 90ZV34138

34-27

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

16) Measure the distance from the bearing of the 4th speed clutch pack (17) to the mounting face (including gasket) of the housing. Regard the obtained distance as dimension A.

90ZV34139

17) Measure the distance from the bearing of the 1st speed clutch pack (18) to the mounting face (including gasket) of the housing. Regard the obtained distance as dimension A'.

18 90ZV34140

18) Measure the distance from the mounting face of cover (13) to the end face of the bearing receiver for the 4th speed clutch pack. Regard the obtained distance as dimension B.

90ZV34141

19) Measure the distance from the mounting face of cover (13) to the end face of the bearing receiver for the 1st speed clutch pack. Regard the obtained distance as dimension B'.

90ZV34142

34-28

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

20) Adjust the difference between the distance B and the distance A (thrust clearance) to 0.5 ~ 1.0 mm using shim (35). B – A = 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.)

35 85W34032

21) Adjust the difference between the distance B' and the distance A' (thrust clearance) to 0.5 ~ 1.0 mm using shim (36). B' – A' = 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.)

85W34033

Note: Insert the shim into the section C so that the difference between the distance A (A') and the distance B (B') is adjusted to a clearance of 0.5 to 1.0 mm (0.02 to 0.04 in.).

90ZV34056

22) Install cover (13) onto the transmission housing. 13

85ZV34016

34-29

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

23) Install ball bearing (37) and gear (38) onto the output shaft. 37

38 38

90ZV34057

85W34035

24) Install drive cover assembly (10) and tighten bolt (9). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

9 90ZV34143

25) Tighten bolts (12). Install brake assembly (8) and tighten bolt (7). : Bolt (12): 53 N-m (5.4 kgf-m) ( 39 lb-ft) : With lubrication oil (Engine oil or gear oil) : Bolt (7): 216 N-m ( 22 kgf-m) (159 lb-ft) : Screw lock agent application (Loctite® 262)

90ZV34144

26) Install brake drum (4) and tighten bolt (3). : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Screw lock agent application (Loctite® 262) Install flange yoke (6) and tighten nut (5). : Nut: 392 N-m (40 kgf-m) (289 lb-ft) (Molybdenum disulfide grease / MOS 2 application)

4 3

85W34038

34-30

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

27) Install control valve assembly (2) and tighten bolts (1). Note: Refer to "Removing and reinstalling control valve" to reinstall control valve assy (2).

85W34039

90ZV34118

34-31

Forward/Reverse Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Forward/Reverse Clutch Pack Disassembling and reassembling forward/reverse clutch pack

1. Disassembling forward/reverse clutch pack (The disassembling procedure for the reverse clutch pack is described below.) Note: - The structure of the forward clutch pack is the same as to that of the reverse clutch pack. Therefore, to disassemble or reassemble the forward clutch pack, follow the reverse clutch pack procedure.

90ZV34058

1) Remove snap ring (1). 2) Attach the bearing puller to gear (2), and then remove the gear with bearing (3) as a unit. There is thrust washer (4) between gear (2) and the ball bearing. Remove the thrust washer. Note: To disassemble the forward clutch pack, remove the roller bearing inner race. For inspection and wear standard refer to "Service standard".

3 2 90ZV34059

90ZV34060

3) Remove two needle bearings (5) and thrust washer (6). After that remove snap ring (7) and backing plate (8). Note: When reassembling install the thrust washers (4) (6) so that the notch faces the gear (2).

5 6 7 8 85ZV34033J

34-32

Forward/Reverse Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

4) Alternately remove friction plates (9) and steel plates (10). Note: - Number of friction plates: 7 Number of steel plates: 6 - After reinstalling the piston (14), be sure to insert the friction plate (9) first.

85ZV34034J

5) Slightly depress ring (12). Remove snap ring (11) and ring (12).

11 12

85ZV34035J

6) Remove 20 springs (13), and then turn clutch over and tap shaft on a wooden block to remove piston (14). 7) Remove ring (16) from piston (14). 15 13

8) Remove piston ring (17) (18) from the shaft assy. 14 16 18

Shaft assembly 85ZV34018

34-33

Forward/Reverse Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

2. Reassembling forward/reverse clutch pack For reassembling follow the above procedure in the reversed direction. Note: - Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings. - To assemble the forward/reverse clutch pack, be sure to apply transmission oil. - Be sure the residual pressure prevention orifices are not plugged. Pass a small wire through the orifices.

3. Cautions regarding reassembly 1) After assembling clutch pack. - Using a straight edge and depth micrometer apply pressure (approx. 0.6 MPa [6 kgf/cm2 ] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Depth micrometer Straight edge

Piston stroke Forward

3.3 ± 0.5 mm (0.13 ± 0.02 in.)

Reverse

3.3 ± 0.5 mm (0.13 ± 0.02 in.)

Air line

Note: If the piston stroke value is beyond the above range, replace the parts, or check that the parts are not warped and are correctly reassembled.

34-34

Backing plate 85W34041

1st/3rd Speed Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

1st/3rd Speed Clutch Pack Disassembling and reassembling 1st/3rd speed clutch pack 1. Disassembling 1st/3rd speed clutch pack Note: This disassembling and reassembling procedures for the 1st and 3rd clutch packs are basically the same. The different points are described for each procedure.

1) Remove the ball bearing (1) using a puller. Note: Use a spacer over the shaft to protect the shaft and inner bearing from damage.

Spacer

1 85K34099

2) [3rd speed]

a) Remove thrust washer (2), and then remove rear gear (3). b) Using internal or blind hole puller remove needle bearings (4) and thrust washer (5). Note: When reassembling install thrust washers (2) (5) so that the notch faces gear (3). [1st speed] a) Remove thrust washers (6) and thrust bearing (7). b) Using internal or blind hole puller remove needle bearings (8), thrust washers (9), and thrust bearing (10).

3rd speed

1st speed

5 10

9 90ZV34071

3) Remove snap ring (11) and backing plate (12).

12 11

Shaft assembly

90ZV34072

34-35

1st/3rd Speed Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

4) Alternately remove friction plates (13) and steel plate (14). Note: After reinstalling the piston (18), be sure to insert the friction plate (13) first. Friction plates

Steel plates

1st speed

3rd speed

5) Remove snap ring (15) and ring (16). 16 15

90ZV34073

6) Remove 20 springs (17), and then turn clutch over and tap shaft on a wooden block to remove piston (18). 19

7) Remove U-ring (19) from piston (18).

8) Remove piston ring (20) from the shaft assembly.

Shaft assembly

90ZV34074

34-36

1st/3rd Speed Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

2. Reassembling 1st/3rd speed clutch pack For reassembling follow the above procedure in the reversed direction. Note: - Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings. - To assemble the 1st/3rd speed clutch pack, be sure to apply transmission oil. - Be sure the residual pressure prevention orifices are not plugged. Pass a small wire through the orifices.

3.5 ± 0.5 mm (0.14 ± 0.02 in.)

3rd speed

2.1 ± 0.5 mm (0.08 ± 0.02 in.)

Note: If the piston stroke value is beyond the above range, replace the parts, or check that the parts are not warped and are correctly reassembled.

34-37

85K34107

2nd Speed Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

2nd Speed Clutch Pack Disassembling and reassembling 2nd speed clutch pack

4 3

1. Disassembling 2nd speed clutch pack 1) Remove spacer (1) and gear (2). After that, remove snap ring (3) and backing plate (4).

90ZV34082

2) Remove friction plates (5) and steel plates (6). Note: - Number of friction plates: 5 Number of steel plates: 4 - After reinstalling the piston (13), be sure to insert the friction plate (5) first.

90ZV34083

3) Remove thrust washer (7), thrust bearing (9) and thrust washer (8). Store the thrust washers for possible reuse.

8 7

90ZV34084

4) Depress plate (11) and remove snap ring (10), and plate (11). 5) Remove 20 springs (12). 12 11 10

90ZV34085

34-38

2nd Speed Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

6) Turn clutch over and tap shaft on a wooden block to remove the piston (13). 14

7) Remove U-ring (14) from piston (13).

8) Remove piston ring (15) from shaft assembly. Shaft assembly 90ZV34086

2. Reassembling 2nd speed clutch pack For reassembling follow the above procedure in the reversed direction. Note: - Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings. - To reassemble the 2nd speed clutch pack, be sure to apply transmission oil.

2.1 ± 0.5 mm (0.08 ± 0.02 in.)

Note: If the piston stroke value is beyond the above range, replace the parts, or check that the parts are not warped and are correctly reassembled. 85K34107

34-39

4th Speed Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

4th Speed Clutch Pack Disassembling and reassembling 4th speed clutch pack 1. Disassembling 4th speed clutch pack 1) Using a puller remove the ball bearing (1). 1

90ZV34091

2) Remove thrust washer (2) and gear (3). Use an internal or blind hole puller to remove needle bearing (4) from inside the gear. Remove needle bearing (4) and thrust washer (5). Note: When reassembling install the thrust washers (2) (5) so that the notch faces gear (3).

5 4 2 3

90ZV34092

3) Remove snap ring (6) and backing plate (7). 7 6

90ZV34093

4) Remove friction plates (8) and steel plates (9). Note: - Number of friction plates: 5 Number of steel plate: 4 - After reinstalling the piston (13), be sure to insert the friction plate (8) first.

90ZV34094

34-40

4th Speed Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) Depress ring (11) and remove snap ring (10), and ring (11).

11 10

90ZV34095

6) Remove 20 springs (12), and then turn clutch over and tap shaft on a wooden block to remove piston (13).

7) Remove U-ring (14) from piston (13).

13 12

8) Remove piston ring (15) (16) from the shaft assembly.

Shaft assembly

90ZV34096

2. Reassembling 4th speed clutch pack For reassembling follow the above procedure in the reversed direction. Note: - Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings. - To reassemble the 4th speed clutch pack, be sure to apply transmission oil.

34-41

4th Speed Clutch Pack

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

3. Cautions regarding reassembly 1) When installing the gear to the shaft, follow the procedure below. - Assemble the gear onto the clutch drum with the bolts. - Heat them up to 190 °C. - Insert the shaft into the clutch drum and gear. : Bolt: 86 N-m (8.8 kgf-m) (64 lb-ft) : With lubrication oil (Engine oil or gear oil)

Shaft Gear

Clutch drum 90ZV34114

2) After assembling clutch pack. - Using a straight edge and depth micrometer apply pressure (approx. 0.6 MPa [6 kgf/cm2 ] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke. Piston stroke 4th speed

Depth micrometer Straight edge

Air line

2.1 ± 0.5 mm (0.08 ± 0.02 in.)

Note: If the piston stroke value is beyond the above range, replace the parts, or check that the parts are not warped and are correctly reassembled.

Backing plate 85W34041

34-42

Control Valve Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Assembly Tightening torque

T3.

90ZV34104

T1: 20 N-m (2.0 kgf-m) (14 lb-ft) T2: 39 N-m (4.0 kgf-m) (29 lb-ft) T3: 10 N-m (1.0 kgf-m) ( 7 lb-ft) (Solenoid valve nut) T4: 34 N-m (3.5 kgf-m) (24 lb-ft) (Solenoid valve body)

34-43

Control Valve Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Removing and reinstalling control valve 1. Removing control valve

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and then lower bucket to ground. - Apply the parking brake, and block tires with chocks to prevent wheels from moving. - Remove the starter key, and hang a "DO NOT START !" tag on the steering wheel.

1) Disconnect all electric wire couplers (1) and bracket (2) also disconnect adapter (3) for checking the clutch pressure. Note: Put matchmarks on the electric wire couplers.

1 3

2 85ZV34012

2) Attach sling to control valve (4), and then remove valve bolts (5). Note: Do not remove two trimmer bolts (6). Tightening torque for assembly : Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft) : With lubrication oil (Engine oil or gear oil)

90ZV34106

3) Lower the control valve to remove it. Be sure to replace the gasket.

IMPORTANT After removing or while reinstalling the control valve, take care not to allow foreign material into the main body or the control valve. Carefully remove or reinstall the control valve and gasket.

: Control valve: 20 kg (44 lbs) 34-44

Control Valve Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

2. Reinstalling control valve Cautions for installation 1) Be sure to replace all the O-rings and gaskets with new ones.

LP 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 matchmarks of the electric wire couplers, and then connect the couplers while checking that the electric wires are not tangled with each other.

Control valve

LW 4

LR LY

1 R

LG 3

LBr 4) Install the cover while checking that the emergency operation bolts are positioned over the center of the solenoid valves.

LO 90ZV34107

5) During installation, be careful not to damage the gasket.

WARNING Unexpected movement of machine could 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. During the service work, clearly communicate with the person in the cab using signals as agreed upon before hand.

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.

34-45

Control Valve Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling control valve 1. Disassembling control valve Note: Clean the control valve. 1) Remove nut (1) using special tool (A). Note: Nut width across flat: 30 mm Special tool (A) is described on the next page. For other valves, follow the same procedure. Tightening torque for assembly : Bolt: 10 N-m (1.0 kgf-m) (7 lb-ft)

85K34129

2) Remove O-ring (2), and then remove the coil (3). Note: For other solenoid valves, follow the same procedure.

85K34130

3) Remove valve (4) using a 17 mm wrench. Tightening torque for assembly : Valve: 34 N-m (3.5 kgf-m) (24 lb-ft)

90ZV34108

4) Remove plugs (5) (6), and then remove the parts from the inside. Note: Do not remove trimmer body (7) unless absolutely necessary.

5 7 6

90ZV34109

34-46

Control Valve Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) Remove regulator valve (8), trimmer plug (9), springs (10), spring retainer (11), and plug (12). 12 8

11 10 9

2. Special tool (A)

90ZV34110

Material: SS41 North American dealer tool number: KL03-102-1 75(3.0) 65(2.6) 60(2.4) 15 (0.6)

04 .0 8 -0 .00 -0

.1 -0 .2 0

(0.2)

ø7(0.3) Drill

ø30(1.2)

ø23(0.9)

ø40(1.6)

+0.008 +0.2

30 +0.1 1.2 +0.004

90ZV34111

3. Reassembling control valve To reassemble the control valve, follow the disassembling procedure in the reversed direction. Cautions for assembly 1) Before you insert the regulator valve, apply transmission oil to the valve. After insertion, check that the valve operates smoothly. 2) Placing shims under the springs to increase pressure or change modulation is not recommended. Check free lengths and if necessary replace them. 3) Check the operation of the solenoid valves. (Also check movement by pressing the manual plunger. The plunger should move freely and smoothly in both directions (spring return).) 4) Replace all seals, O-rings and gaskets. 5) Check coil resistance. Resistance: Approx. 27 Ω 34-47

MEMO

TORQUE CONVERTER AND TRANSMISSION GROUP 35 Service Standard Transmission Assembly ..............................................................................35-2 Control Valve ..............................................................................................35-3 Gear Pump .................................................................................................35-5 Clutch Plate Thickness / Piston Stroke .......................................................35-6 Clutch Oil Pressure .....................................................................................35-7

35-1

Transmission Assembly

85ZV

TORQUE CONVERTER AND TRANSMISSION 35

Transmission Assembly 13 12

4 5

14 4

3 F

2 R

14 18 5 15

Note: Numbers correspond to page 35-4.

11 90ZV35001

35-2

Control Valve

85ZV

TORQUE CONVERTER AND TRANSMISSION 35

Control Valve

2 90ZV35002

Note: Numbers correspond to page 35-4.

35-3

Control Valve

85ZV

TORQUE CONVERTER AND TRANSMISSION 35

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

REF.

Clearance

Solution Standard clearance

Allowable limit

Control valve regulator valve ~ valve body

0.030 ~ 0.061 (0.0011 ~ 0.0024)

0.09 (0.0035)

Replacement

Control valve regulator valve ~ seal retainer

0.016 ~ 0.045 (0.0006 ~ 0.0017)

0.07 (0.0027)

Replacement

Control valve trimmer plug ~ valve body

0.025 ~ 0.066 (0.0010 ~ 0.0026)

0.09 (0.0035)

Replacement

Standard value

Allowable limit

ITEM 4

T/C inlet valve spring

Free length 44.6 (1.7559)

Clutch return spring (The same spring for all clutches) T/C

24.4 (0.9606)

21 (0.8267)

Control valve regulator spring

89 (3.5039) 81.4 (3.2047)

89 (3.5039) 69 (2.7165)

Spring 6

Control valve trimmer spring

Installed length 35.2 (1.3853)

Installed load 10.2 (23)

Free length Installed load 43.6 (1.7165)

9.2 (20)

Replacement

3.3 (7)

23.7 (0.9330)

3.0 (6)

Replacement

87.5 (3.4448) 80 (3.1496)

Replacement

4.5 (10)

Replacement

5 (11)

Judgement criteria ITEM Charge pump shaft dia.

Rear yoke shaft dia.

9 10

Oil seal

Front yoke shaft dia. Speedometer driven gear shaft dia.

Standard value

Allowable limit

41.93 ~ 42.0 (1.6507 ~ 1.6535) 79.92 ~ 80.0 (3.1464 ~ 3.1496) 79.92 ~ 80.0 (3.1464 ~ 3.1496) 11.95 ~ 12.0 (0.4704 ~ 0.4724)

41.8 (1.6456) 79.8 (3.1417) 79.8 (3.1417) 11.8 (0.4645)

Replacement Replacement

4.9 +0.015 (0.1929 +0.0006 ) 0 0

Thrust washer thickness

2.9 ~ 3.1 (0.1141 ~ 0.1220)

2.7 (0.1063)

Replacement

Gear backlash

0.2 ~ 0.3 (0.0078 ~ 0.0118)

0.5 (0.0196)

Replacement

0 3.05 – 0.1 (0.1200 –00.0039)

2.9 ± 0.1 (0.1142 ± 0.0039)

0 0 3.99 – 0.1 (0.1570 – 0.0039 )

4.6 ± 0.1 (0.1811 ± 0.0039)

Clutch shaft

0 0 3.89 – 0.1 (0.1532 – 0.0039 )

(The same for all clutches)

Piston outer dia. (F, R)

Piston outer dia. (1 ~ 4 speed)

Piston inner dia.

Torque converter inlet

Seal ring

14 H

Replacement

2.85 (0.1122) 2.7 (0.1063) 3.79 (0.1492) 4.4 (0.1732) 3.69 (0.1453) 4.15 (0.1639) 4.55 (0.1791) 4.55 (0.1791) 4.7 (0.1850)

Replacement Replace oil seal when disassembling and reassembling

Torque converter outlet

4.35 ± 0.1 (0.1713 ± 0.0039) 4.75 ± 0.1 (0.1870 ± 0.0039) 4.75 ± 0.1 (0.1870 ± 0.0039)

35-4

Replacement

Replacement Replacement Replacement Replacement

Gear Pump

85ZV

TORQUE CONVERTER AND TRANSMISSION 35

Gear Pump 1 4

Gear pump specifications

Theoretical discharge

64.5 cm3/rev (3.9 in3/rev)

Maximum operation pressure

2 MPa (20 kgf/cm2) (284 psi)

Maximum operation speed (pump speed)

2,400 min-1 (rpm)

Actual discharge

Approx. 120 / min (31.7 gpm) Conditions: Pump speed 2,200 min-1 (rpm) Oil temp. 80 to 100 °C (176 ~ 212 °F) Oil viscosity 40CST (SAE10W) Discharge pressure 1.4 to 1.6 MPa (14 to 16 kgf/cm2) (199 to 228 psi)

90ZV35003

Unit: mm (in.) No.

Item

Standard value

Solution

Top clearance between gear and housing

0.08 ~ 0.11 (0.003 ~ 0.004)

Replacement

Side clearance between gear and housing

0.03 ~ 0.073 (0.001 ~ 0.003)

Replacement

Backlash between gears

0.2 ~ 0.3 (0.008 ~ 0.012)

Replacement

Tightening torque for pump fixing bolt

59 N-m (6.0 kgf-m) (43 lb-ft)

Tightening

Note: To measure the side clearance of item 2 above, with the gasket removed.

35-5

Clutch Plate Thickness / Piston Stroke

85ZV

TORQUE CONVERTER AND TRANSMISSION 35

Clutch Plate Thickness / Piston Stroke Clutch plate Number of clutch plates. Note: All the friction plates, steel plates, and return springs are interchangeable for each clutch. Name of clutch

Friction plate

Steel plate

Forward clutch

Return spring 20

Reverse clutch

1st speed clutch

2nd speed clutch

Outer dia.

ø192 (7.55 in.)

ø203.2 (7.99 in.)

Inner dia.

ø123.8 (4.87 in.)

ø133.5 (5.25 in.)

Dimension

4th speed clutch

(mm) (in.)

Thickness

3rd speed clutch

T6 L 3

T2 L 3

T7 L 3

When new 3.3±0.1 (0.13±0.004 in.) 2.6±0.1 (0.10±0.004 in.) Wear limit

3.1 (0.12 in.)

2.4 (0.09 in.)

T7 L 3

T3 L 1

T6 L 3

T1 L 3

T5 L 1

90ZV35004

T2 L 3 T4

T L 2

: Bolt tightening torque T1: 29 N-m ( 3.0 kgf-m) ( 22 lb-ft) T2: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T3: 216 N-m (22.0 kgf-m) (159 lb-ft) T4: 392 N-m (40.0 kgf-m) (289 lb-ft) (Molydenum disulfide grease/MOS2 application) T5: 94 N-m ( 9.6 kgf-m) ( 69 lb-ft) T6: 59 N-m ( 6 kgf-m) ( 43 lb-ft) T7: 86 N-m ( 8.8 kgf-m) ( 64 lb-ft) L1: Screw lock agent application (Loctite® 262) L3: With lubrication oil (Engine oil or gear oil)

Piston stroke mm (in.) Judgement criteria Clutch

35-6

Standard value

Allowable limit

Solution

Forward clutch

3.3±0.5 (0.13±0.02)

5.0 (0.2)

Replacement

Reverse clutch

3.3±0.5 (0.13±0.02)

5.0 (0.2)

Replacement

1st speed clutch

3.5±0.5 (0.14±0.02)

5.0 (0.2)

Replacement

2nd speed clutch

2.1±0.5 (0.08±0.02)

5.0 (0.2)

Replacement

3rd speed clutch

2.1±0.5 (0.08±0.02)

5.0 (0.2)

Replacement

4th speed clutch

2.1±0.5 (0.08±0.02)

5.0 (0.2)

Replacement

Clutch Oil Pressure

85ZV

TORQUE CONVERTER AND TRANSMISSION 35

Clutch Oil Pressure

1 7

4 9

90ZV35005

Standard Value

(Oil temperature 50 ~ 80 °C (120 ~ 180 °F))

Oil pressure MPa (kgf/cm2) (psi) No.

Measuring port location

Measuring port size

Engine revolution (rpm) 800 (Low idle)

2,350 (High idle)

Shift lever position

Torque converter inlet

PT3/4

0.03 ~ 0.5 (0.3 ~ 5.5) (4.3 ~ 78)

0.2 ~ 0.5 (2.0 ~ 5.5) (28 ~ 78)

All speed range

Main oil pressure

PT1/8

1.3 ± 0.2 (13 ± 2) (185 ± 28)

1.5 ± 0.2 (15 ± 2) (213 ± 28)

All speed range

PF1/4

1.3 ± 0.2 (13 ± 2) (185 ± 28)

1.5 ± 0.2 (15 ± 2) (213 ± 28)

Forward

PF1/4

1.3 ± 0.2 (13 ± 2) (185 ± 28)

1.5 ± 0.2 (15 ± 2) (213 ± 28)

Reverse

PF1/4

1.3 ± 0.2 (13 ± 2) (185 ± 28)

1.5 ± 0.2 (15 ± 2) (213 ± 28)

1st speed

PF1/4

1.3 ± 0.2 (13 ± 2) (185 ± 28)

1.5 ± 0.2 (15 ± 2) (213 ± 28)

2nd speed

PF1/4

1.3 ± 0.2 (13 ± 2) (185 ± 28)

1.5 ± 0.2 (15 ± 2) (213 ± 28)

3rd speed

PF1/4

1.3 ± 0.2 (13 ± 2) (185 ± 28)

1.5 ± 0.2 (15 ± 2) (213 ± 28)

4th speed

PT1/2

0.01 ~ 0.1 (0.1 ~ 1.0) (1.4 ~ 14)

0.05 ~ 0.2 (0.5 ~ 2.5) (7 ~ 36)

All speed range

4 5 6 7 8 9

Forward clutch oil pressure Reverse clutch oil pressure 1st speed clutch oil pressure 2nd speed clutch oil pressure 3rd speed clutch oil pressure 4th speed clutch oil pressure Transmission lubrication oil pressure

Clutch oil pressure

35-7

MEMO

HYDRAULIC GROUP 44 Disassembly and Reassembly Warning Regarding Removing and Reinstalling Hydraulic Parts .......................................................................................44-2 Cautions Regarding Disassembly and Reassembly of Hydraulic Parts .......................................................................................44-3 Hydraulic Pump Assembly...........................................................................44-4 Hydraulic Cylinder........................................................................................44-9 Pilot Valve..................................................................................................44-22 Multiple Control Valve................................................................................44-29 Orbitrol® ......................................................................................................44-35 Steering Valve ...........................................................................................44-45 Stop Valve .................................................................................................44-50 Fan Motor ..................................................................................................44-54

44-1

Warning Regarding Removing & Reinstalling Hydraulic Parts

85ZV

HYDRAULIC 44

Warning Regarding Removing and Reinstalling Hydraulic Parts Disassembly and reassembly work of hydraulic parts greatly depends on the working area and working condition (soon after operation or not). Understand the following items well and work safely.

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level and solid ground. - Apply the parking brake and block tires with chocks to prevent wheels from moving. - Be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat. - Relieve the internal pressure from the hydraulic line and hydraulic tank. - Use signals as agreed upon before starting work. - Do not enter the hazardous area. - When removing a heavy load over 20 kg(44 lbs), use a crane or a lift device. - Stay out of the working area while using a crane. - While working with the boom raised, put safety blocks or supports to prevent it from dropping suddenly. - The temperature at each part maybe high soon after the engine is stopped. Be careful not to get burned. - When removing pipes, place a container to catch the drained oil.

IMPORTANT - Cover disconnected hoses and pipes with plastic caps or plugs to protect them from dust, water and dirt. - Apply the specified torque to tighten each part.

44-2

Cautions Regarding Disassembly & Reassembly of Hyd. Parts

85ZV

HYDRAULIC 44

Cautions Regarding Disassembly and Reassembly of Hydraulic Parts Hydraulic parts may be delicate. When disassembling or reassembling, handle with care. Understand the following well to perform disassembly and reassembly work.

Cautions regarding disassembly

Cautions regarding reassembly

- Completely drain the hydraulic oil from parts. Clean unit before disassembly. Plug each open ports. - Work in a well ventilated area. - Before disassembling, put a matchmark on each alignment point. - When clamping the part in a vice, use a copper plate so as not to damage it. - Because hydraulic parts may be delicate, do not drop or scratch them. - When disassembling, do not hit or pry the parts by force. The parts may get burred and scored which may cause oil leakage or poor performance. - Do not disassemble adjusting screws unless needed. - When work is stopped, protect removed parts from dirt and debris. - Preserve disassembled parts with oil. After cleaning, do not dry with compressed air. It may cause rust due to condensation. - Carefully place removed parts in the order it was removed so as to see how they came a part.

- Check the surface and inside of the parts for burrs, scores, dirt, or rust. - Replace O-rings and seals with new ones. - Before reassembly, apply a thin coat of hydraulic oil or grease to the O-rings and seals. - Apply the specified torque to tighten parts. - After reassembly, plug all the ports so as not to allow foreign material to enter.

44-3

Hydraulic Pump Assembly

85ZV

HYDRAULIC 44

Hydraulic Pump Assembly Removing and reinstalling hydraulic pump assembly 1.Removing hydraulic pump assembly

DANGER 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. Transmission

CAUTION Removing hoses and plugs without bleeding residual pressure could cause injuries or burns from hot oil under pressure. Before removing hoses and plugs, relieve residual pressure. Relieve internal pressure from hydraulic tank to prevent oil from spraying.

3 1

Before starting work: a) Remove the cab and the floor board by referring to Section 14. b) Clean the area around the hydraulic pump. 1) Disconnect outlet hose (2) and suction hose (3) from hydraulic pump (1). Note: Cover the hoses with plastic, plugs or caps to protect from dust and dirt. 2) Remove the hydraulic pump retainer bolts. Torque for assembly: : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) 3) Remove hydraulic pump (1). : Hydraulic pump: 55 kg (120 lbs)

44-4

85ZV44001

Hydraulic Pump Assembly

85ZV

HYDRAULIC 44

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

3.Cautions regarding reinstallation When replacing hydraulic pumps or when draining hydraulic oil for extended periods, it is important to prime the hydraulic system properly. Air will be in the lines that go to and come from the pump. After a pump has been installed, or when the hydraulic oil has been drained for extended time periods, air will not purge easily from the lines, and this could lead to pump damage.

WARNING Oil injection hazard! Hydraulic oil can penetrate skin. When performing this procedure: - Release all trapped circuit pressure prior to starting any procedure involving hydraulic oil. - Wear protective gloves. - Wear eye and face protection. - Stay clear of areas where air may be purged. - Route oil into a receiving canister [such as a 5 gallon bucket] by use of an additional hose. - Rotate pump at a low RPM.

44-5

IMPORTANT 1)Fill the inlet port of the hydraulic pump with clean hydraulic oil and rotate the pump shaft by hand prior to installing the pump. It should rotate smoothly. Prior to installing pump and plumbing to pump, remove all caps, plugs, and covers from pump and piping. 2)While reinstalling the hydraulic 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 ). 5)Run 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)Actuate cylinders 5 to10 times to almost full stroke, but do not fully extend or retract any of the cylinders at this time. 7)Confirm that there is no abnormal noise or operation, and be sure that there is no excessive heat. Inspect the hydraulic oil at the sight gauge to be sure that there are no bubbles which may indicate air being drawn in at the suction side of the pump. If there are any bubbles, correct the cause prior to using the machine, as this may contribute to premature pump failure.

Hydraulic Pump Assembly

85ZV

Disassembling and reassembling hydraulic pump assembly IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

IMPORTANT - Handle pumps carefully. - In case hydraulic system breaks down, do not disassemble the pump first. Check the whole hydraulic circuit and find its cause. Confirm the cause, then repair. - When the pump is broken down, not only fix or replace it but also inspect the failure cause to prevent recurrence.

If a pump must be repaired, be sure no pieces of damaged pump material has scattered through hydraulic system. New parts must be "broken in" and performance must be checked. Do not disassemble the pump except when necessary to replace oil seals and O-rings between the double and triple pumps which are able to be separated.

44-6

HYDRAULIC 44

Hydraulic Pump Assembly

85ZV

HYDRAULIC 44

1.Cross section and tightening torque

85ZV44006J

: N-m (kgf-m) (lb-ft) T1: 177 (18) (130) T2: 275 (28) (203)

44-7

Hydraulic Pump Assembly

85ZV

HYDRAULIC 44

2.Oil seal replacement procedure There are two kinds of the pump drive gear shaft unit. One has only an oil seal, and another has an additional dust seal or oil seal outside.

[Example 1] Oil seal

In case of example 2 1) After removing the outer oil seal, remove the snap ring and the inner oil seal. 2) When removing the oil seals, remove any scores, on the front cover and drive gear shaft. 3) Cover the drive gear shaft with vinyl electrical tape to protect splines. 4) Apply a thin coat of grease to the periphery of the oil seal and lip unit. 5) Install seal straight.

Snap ring

Drive gear shaft

Front cover

90ZV44048

[Example 2]

Front cover

Drive gear shaft

Oil seal

Snap ring 90ZV44049

44-8

Hydraulic Cylinder

85ZV

HYDRAULIC 44

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

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Raise the boom until it is horizontal, and then place 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.

Stand

85ZV44003

85ZV44004

a)Clean the area around the cylinder and piping. Note: Relieving residual pressure from pipe 1.Raise the boom. When the boom is approximately 30 cm (1 foot) above stand, 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.First press down on the hydraulic tank cap to vent residual pressure, then open the cap of the hydraulic tank. Leave hydraulic tank cap loosely on top of tank opening.

1) Attach sling to boom cylinder (1). Disconnect hoses (2)(3). : Boom cylinder: 210 kg (465 lbs) 5

2) Remove lock bolt (4) and pin (5). : Bolt: 265 N-m (27.0 kgf-m) (195 lb-ft) 85ZV44006

44-9

85ZV44005

Hydraulic Cylinder

85ZV

HYDRAULIC 44

3) Place a container to receive oil from the oil port on the bottom side of the cylinder. After that, push in rod (6).

85ZV44014

4) Remove the lock bolts from the retainer pins on the bottom side, and then attach remover bolt (8) to pins (7) to remove them. : Removal bolts: M16P2 : Lock bolt: 265 N-m (27.0 kgf-m) (195 lb-ft)

5) Sling boom cylinder (1), and lower it onto the ground. After that, remove pipe (9) from the cylinder. For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

8 85ZV44015

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.

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

85ZV44016

a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100 mm (4.0 in.) before stroking fully. b)After that, stroke the cylinder piston fully to both ends 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage. 44-10

Hydraulic Cylinder

85ZV

HYDRAULIC 44

Removing and reinstalling bucket cylinder 1.Removing bucket cylinder

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block 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.

Bucket cylinder

1) Remove the coupler of bucket positioner switch (1), and then remove bracket (2).

2 3 85ZV44007

2) Remove rod (3).

3) Attach sling to bucket cylinder. After that, remove the lock bolt (4) and pin (5). : Bucket cylinder: 220 kg (485 lbs) : Tightening torque: 265 N-m (27.0 kgf-m) (195 lb-ft)

5 4 Bucket cylinder

85ZV44008

44-11

Hydraulic Cylinder

85ZV

4) Start the engine and shorten the cylinder rod. Stop the engine and disconnect hose (6)(7).

HYDRAULIC 44

Bucket cylinder

Note: Cover the disconnected hose and the cylinder with plastic, caps or plugs to protect them from dust, water and dirt. 6

Cylinder rod

5) Disconnect the grease pipe. After that remove lock bolt (8) and pin (9). : Tightening torque: 265 N-m (27.0 kgf-m) (195 lb-ft)

85ZV44009

9 Bucket cylinder

6) Slowly lift up the bucket cylinder. Lower the bucket cylinder onto the ground.

For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

44-12

Grease pipe 85ZV44010

Hydraulic Cylinder

85ZV

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 may cause accidents and serious injury or death. Use a stepladder, ladder, or work platform, and do not stand on the machine.

➀Bleed 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 100 mm (3.9 in.) before stroking fully. b)After that, stroke the cylinder piston fully to both ends 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

➁Adjust the bucket positioner so that the clearance between the switch and the rod is 5±2 mm (0.196±0.078 in.).

44-13

HYDRAULIC 44

Hydraulic Cylinder

85ZV

HYDRAULIC 44

Removing and reinstalling steering cylinder 1.Removing steering cylinder

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block 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. - Press cap downward to vent, then 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 or the operator's seat .

Before starting work: a)Clean the area around the cylinder to be removed.

1) Disconnect the hoses (1) (2). Note: Cover the disconnected hoses with plastic, caps, or plugs to protect them from dust, water, and dirt.

Steering cylinder 85ZV44011

2) There is pin (6) at the between front chassis (3) and steering cylinder (4). Remove lock bolt (5) and the pin (6), and then push the rod 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. 4 85ZV44012

44-14

Hydraulic Cylinder

85ZV

HYDRAULIC 44

3) Disconnect grease pipe (7).

7 10

4) Remove three pin lock bolts (8) and one pin lock plate (9). 5) Tap pin (10) from the bottom side to remove it from the top side. 6) Remove steering cylinder assembly (4). Note that two persons are needed to remove and lift the assembly. : Steering cylinder: 40 kg (90 lbs)

9 8 85ZV44013

For detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

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

➀When reinstalling the pins

➁Bleed the cylinder of air

IMPORTANT

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

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 100 mm (4.0 in.) before stroking fully. b)After that, stroke the cylinder piston fully to both ends 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area can 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.

44-15

Hydraulic Cylinder

90ZV

HYDRAULIC 44

Disassembling and reassembling hydraulic cylinder IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Cross section and tightening torque 1) Boom cylinder

85ZV44002J

2) Bucket cylinder

85ZV44003J

T4 3) Steering cylinder

85ZV44004J

: N-m (kgf-m) (lb-ft) T1: 4,756 (485) (3,509)

Cylinder

Piston nut width across flats mm (in) – Thread size

T2: 843 ( 86) ( 622) T3: 5,884 (600) (4,341) T4: 883 ( 90) ( 651) T5: 1,275 (130) ( 941) T6: 1,765 (180) (1,302)

Boom

90 (3.54) – M62 x 2

Bucket

110 (4.33) – M76 x 2

Steering

55 (2.17) – M36 x 1.5

44-16

Hydraulic Cylinder

85ZV

HYDRAULIC 44

2.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 95ZV44004

Matchmark

2) Put the matchmarks on rod cover (1) and cylinder tube (2). Remove rod cover bolt (3). : Bolt: 843 N-m (86.0 kgf-m) (622 lb-ft) (Boom cylinder) 883 N-m (90.0 kgf-m) (651 lb-ft) (Bucket cylinder) Rod cover: 1,765 N-m (180.0 kgf-m) (1,302 lb-ft) (Steering cylinder)

2 1 95ZV44005

3) Remove piston rod assembly (4) from the cylinder tube. : Hydraulic oil will be drained, so place a container to receive the drain oil.

95ZV44006

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

Repair stand

Wooden block 95ZV44007

44-17

Hydraulic Cylinder

85ZV

HYDRAULIC 44

5) Remove stop ring (5) and put matchmarks on rod (4) and piston nut (6) for alignment with the stop ring holes.

Matchmark

95ZV44008

6) Use a hydraulic jack or hydraulic cylinder to loosen piston nut (6). C Piston nut width across flats mm (in)

Tightening torque N-m (kgf-m) (lb-ft)

Boom cylinder

90 (3.54)

4,750 (485) (3,509)

Bucket cylinder

110 (4.33)

5,884 (600) (4,341)

Steering cylinder

55 (2.17)

1,275 (130) ( 941)

Hydraulic jack

Hydraulic cylinder 95ZV44009

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

95ZV44010

8) Remove wear ring (8), back-up ring (21), square ring (9), slipper ring (10), O-ring (11) and wear ring (12). (There is no wear ring (12) for steering cylinder.) 8

8 21 8

10 21 12

11 (Bucket cylinder) 11 (Boom cylinder)

85ZV44029

44-18

11 (Steering cylinder) 85ZV44030

Hydraulic Cylinder

85ZV

HYDRAULIC 44

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

95ZV44013

10) Remove dust seal (13), stop ring (14), scraper ring (15), back-up ring (16), U-packing (17), buffer ring (18), back-up ring (19) and O-ring (20) from rod cover (1).

20 16 17 18

To reassembling the hydraulic cylinders, follow the above removal procedure in the reversed direction. Note: Refer to page 44-20 for the cautions when reassembling.

44-19

20 16 17 13

(Bucket cylinder) (Steering cylinder)

3.Reassembling hydraulic cylinder

(Boom cylinder) 90ZV44051

Hydraulic Cylinder

85ZV

HYDRAULIC 44

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

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

Note: Put slipper ring (10) into hot oil to heat the ring to 120 to 150 °C. (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 damage by over expansion. : After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size. Note: Before installing back-up ring (2) and 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 over the back-up ring. After installation, wait until the back-up ring is cooled, and then insert the rod cover into the cylinder tube.

95ZV44016

3 95ZV44017

Note: Reinstall the rod cover of the steering cylinder, screw the rod cover using a spanner wrench. Screw in and tighten the set screw. Stake the set screw. Torque for assembly: : 1,765 N-m (180 kgf-m) (1,302 lb-ft)

95ZV44018

44-20

Hydraulic Cylinder

85ZV

HYDRAULIC 44

Note: Stake the rod cover (1) at 4 points to prevent dust seal (13) coming out for bucket cylinder and steering cylinder.

Stake

13 95ZV44019

Stake 95ZV44020

44-21

Pilot Valve

85ZV

HYDRAULIC 44

Pilot Valve Removing and reinstalling pilot valve 1.Removing pilot valve

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

Control box

1) Open the cab door (the right hand side). Remove cover (1) from the control box.

Cover mount 90ZV44022

2) Disconnect electrical line (2) of QUAD switch. Pilot valve

3) Disconnect electrical line coupler (3) from the pilot valve.

90ZV44023

4) Remove the knob (4) and then separate QUAD switch (5).

Pilot valve 4 A

44-22

90ZV44024

Pilot Valve

85ZV

HYDRAULIC 44

5) Remove boot (6) and covers (7)(8)(9)(10). 10 6 8 9

7 90ZV44025

Pilot valve

6) Disconnect hoses (11) from the pilot valve. : Drain oil: Approx. 1 (0.3 gal.) Note: Before disconnecting the electrical coupler and hoses, be sure to put matchmarks on them. After disconnection, cover the disconnected hoses with plastic, caps, or plugs to protect them from dust and dirt.

95ZV44052

7) Disconnect arm (12) and rod (13) at the ball joint part.

Pilot valve

Adapter

8) Disconnect rod (13) and lever (14) at the ball joint part. 15 13

9) Remove bolt (15) (4 pcs) and pull up the pilot valve to remove it. Adapter

Torque for assembly: : Adapter: 36 N-m (3.7 kgf-m) (27 lb-ft)

95ZV44049

: Pilot valve: 10 kg (22 lbs)

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.

44-23

Pilot Valve

85ZV

HYDRAULIC 44

Disassembling and reassembling pilot valve IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts"

1.Cross section and tightening torque For boom Front For bucket Bucket side

Boom side

T3 T1

T1 T3 L1

T3 L1 T5

: N-m (kgf-m) (lb-ft) T1: 29 (3.0) ( 22) T2: 36 (3.7) ( 27) T3: 17 (1.7) ( 12) T4: 42 (4.3) ( 31) T5: 12 (1.2) (8.7) : Pilot valve

10 kg (22 lbs) T2

L1: Screw lock agent application (Three Bond 1327)

K70V44001

44-24

Pilot Valve

85ZV

HYDRAULIC 44

2.Disassembling pilot valve (Illustrated on the bucket side. Disassemble the boom side alike.)

1) Clamp the pilot valve in a vise. Pull up boot (1) to remove it from cover (2). Loosen the lock nut for solenoid (3) and then remove the solenoid from cover (2). Torque for assembly: : Solenoid: 42 N-m (4.3 kgf-m) (31 lb-ft) Note: Before removing solenoid (3), measure the distance between solenoid (3) and cover (2). Adjustment procedure is in the Function and Structure section of shop manual.

97ZV44023

Lock nut

95ZV44076

Carefully store ball (4).

5 6

2) Loosen socket bolt (5). Remove lever (6) from disc (7). Torque for assembly: : Bolt: 29 N-m (3.0 kgf-m) (22 lb-ft) Note: Put matchmark on lever (6) and disc (7).

3) Loosen socket bolt (8). Remove cam shaft (9). Torque for assembly: : Retainer bolt: 17 N-m (1.7 kgf-m) (12 lb-ft) : Screw lock agent (Three Bond 1327) application Note: - Three Bond 1327 is applied, and more torque is needed to loosen. - Temporarily tighten socket bolt (5) to remove disc (7). - In case the cam shaft does not pull out, use the hexagon wrench to push it out. 44-25

97ZV44024

97ZV44025

Pilot Valve

85ZV

4) Pull up socket bolt (5) with disc (7) and remove it. Loosen socket bolt (10). Torque for assembly: : Bolt (10): 12 N-m (1.2 kgf-m) (8.7 lb-ft) Note: - Put matchmark on disc (7) and cover (2). - In case the spring force for the return spring is strong, alternately loosen the socket bolts so that cover (2) can be level.

HYDRAULIC 44

97ZV44026

5) Remove cover (2) from case assembly. Note: - Put matchmark on cover (2) and the case assembly.

K70V44002

6) Remove plug (11) together with push rod (12). Remove reducing valve assembly (13) from case assembly (14).

11 12 13

Note: - Put matchmark on plug (11), push rod (12) and case assembly (14). - Carefully store the spring and spring seat in the push rod. - Carefully remove the plug so that the parts are not scratched. - In case plug (11) does not come out, use the screw driver to remove it. - Carefully remove plug (11). It may spring out by the spring force. - Put matchmark on reducing valve assembly (13) and case assembly (14).

44-26

K70V44003

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.

Pilot Valve

85ZV

7) Remove return springs (15) (16) from case assembly (14). Note: - Put matchmark on return springs (15) (16) and case assembly (14). - When installing, carefully install the spool assembly so that the end of the spool does not hit the hole corner in the case assembly.

HYDRAULIC 44

14 15

K70V44004

Carefully install into the case

95ZV44022

8) Clamp case assembly (14) in the vise up side down. Loosen socket bolt (17), then remove plate (18) from the case assembly. Torque for assembly:

: Bolt: 29 N-m (3.0 kgf-m) (22 lb-ft) Note: Put matchmark on plate (18) and case assembly (14). 14 97ZV44031

9) Disassemble the plug assembly removed on paragraph 7). Remove spring (19) and spring seat (20) from push rod (12). Remove push rod (12) from plug (11).

19 20 97ZV44032

44-27

Pilot Valve

85ZV

HYDRAULIC 44

10) Disassemble the reducing valve assembly removed on paragraph 7). Push down spring seat (23), and then remove plane washer (24). Remove spring (25) and shim (26) from spool (22). Note: - Carefully remove the plane washer so that the spool is not scratched. - Do not push spring seat (23) down more than 4 mm(5/32 in.). - Shim for adjusting secondary pressure. Some spools may need shims, but others may not.

24 23

25 26

22 97ZV44033

3.Reassembling pilot valve To reassemble the pilot valve, follow the above disassembly procedure in the reversed direction. Note: - Clean and check all the parts. If a part is defective, replace or repair the part. - Replace all the O-rings and seals with new ones. - Apply the specified torque to tighten each main parts. - Apply a thin coat of hydraulic oil or grease to each part before reassembly. - Measure the resistance of each coil magnet assembly. The resistance should be 138 Ω at normal room temperature [(20 °C(70 °F)]). If measured in extremely low temperatures the resistance will be less. At operating temperature the resistance will be higher.

4.Cautions regarding reassembling Install plane washer (24) so that the plane washer sharp edge side comes to the top position. Note: Do not push spring seat (23) down more than 4 mm(5/32 in.). 44-28

Sharp edge side

22 97ZV44023

Multiple Control Valve

85ZV

HYDRAULIC 44

Multiple Control Valve Removing and reinstalling multiple control Valve 1.Removing multiple control valve

Stand

85ZV44003

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 stand (A) to support the bottom of the boom.

85ZV44017

1) Remove cover (1). Note: If possible carefully clean the area around the multiple control valve, dirt or water entering the hydraulic system can cause many future problems.

Multiple control valve

85ZV44018

2) Put matchmarks on hoses (2) of the pilot line, and then disconnect all of them. 3

3) Disconnect all pipes (3)(4) from the multiple control valve.

4 Multiple control valve 85ZV44019

44-29

Multiple Control Valve

85ZV

4) Disconnect inlet hose (5) and return hose (6). Remove pipe (7)(8) from the multiple control valve. Note: Cover the disconnected hoses with plastic, caps or plugs to protect them from dust, water and dirt. 5) Remove bolts (9) from the pipe brackets of the right and left bucket cylinders. 6) Remove bolts and nuts (10) from the pipe brackets of the right and left boom cylinders Note: This allows the piping over the valve to be moved away from the valve. 7) Remove retainer bolts (11) from the multiple control valve, and then remove the multiple control valve. Torque for assembly: : Bolt: 90 N-m (9.2 kgf-m) (67 lb-ft) : Multiple control valve: 55 kg (125 lbs)

HYDRAULIC 44

5 9

8 7

Multiple control valve 6 85ZV44020

2.Reinstalling multiple control valve To reinstall the multiple control valve, follow the above removal procedure in the reversed direction. Multiple control valve 85ZV44021

3.Cautions regarding reinstallation a)Replace all the O-rings with new ones. b)Wash the multiple control valve mounting area.

WARNING Unexpected movement of machine may cause serious injury or death. To prevent such an accident, be sure to stop the engine before you start working . In addition, block tires with chocks to prevent wheels from moving. While working, 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. 44-30

Multiple Control Valve

85ZV

HYDRAULIC 44

Disassembling and reassembling multiple control valve IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Cross section and tightening torque T3

T7 T8

T3 Main relief valve

T2 T6 T1

T3 Bucket spool

T3 Make-up valve

T6 Overload relief valve with make-up function

T4 L1

: N-m(kgf-m)(lb-ft) T1: 180(18.4)(133) T2: 39( 4.0)( 29) T3: 78( 8.0)( 58) T4: 18( 1.8)( 13) T5: 34( 3.5)( 25) T6: 410(41.8)(302) T7: 260(26.5)(192) T8: 65( 6.6)( 48)

Boom spool

: 55 kg (120 lbs)

85ZV44022

L1: Screw lock agent application (Three Bond 1327) 44-31

Multiple Control Valve

85ZV

HYDRAULIC 44

2.Disassembling multiple control valve 1) Remove main relief valve (1). Hexagon width across flat: 30 mm (1 3/16 in.) Torque for assembly: : #1: 78 N-m (8.0 kgf-m) (58 lb-ft)

70ZV44009J

2) Remove right and left overload relief valve (2). Hexagon width across flat: 32 mm (1 17/64 in.) Torque for assembly: : #2: 78 N-m (8.0 kgf-m) (58 lb-ft) 2

70ZV44010J

3) Remove make-up valve (3). Hexagon width across flat: 32 mm (1 17/64 in.) Torque for assembly: : #3: 78 N-m (8.0 kgf-m) (58 lb-ft) 3

70ZV44011J

4) Remove socket head bolt (4), (5) from the bucket and boom side of the cap. Then remove cap (6), (7). Hexagon hole width across flat: 6 mm (15/64 in.) Torque for assembly: : #4, 5: 34 N-m (3.5 kgf-m) (25 lb-ft)

4 6

44-32

70ZV44012J

Multiple Control Valve

85ZV

HYDRAULIC 44

5) Slowly pull out spool (8) from the bucket side and spool (9) from the boom side as an assembly. Note: Carefully pull out the spool so that it is not forced out or distorted.

9 70ZV44013J

6) Remove socket head bolt (10), (11) to remove cap (12), (13). Also remove the O-ring of the flange from the cap. Hexagon hole width across flat: 6 mm (15/64 in.) Torque for assembly: : #10, 11: 34 N-m (3.5 kgf-m) (25 lb-ft)

11 13

12 10

7) Remove four socket head bolts (14), and then remove cover (15). Also remove the O-ring from the mating face. Hexagon hole width across flat: 12 mm (15/32 in.) Torque for assembly:

70ZV44014J

O-ring

: #14: 180 N-m (18.4 kgf-m)(133 lb-ft) 14

85ZV44023

8) Remove plug (16) from the bucket side to remove spring (17) and poppet (18). Also remove plug (19) from the boom side. Remove the O-ring from the plug. Hexagon hole width across flat: 12 mm (15/32 in.) Torque for assembly: : 16, 19: 260 N-m (26.5 kgf-m) (192 lb-ft)

16 19 17 18

70ZV44016J

44-33

Multiple Control Valve

85ZV

HYDRAULIC 44

9) Remove the hexagon bolts and remove cap kit (20). Hexagon bolt width across flat: 8 mm (5/16 in.) Torque for assembly: : Bolt: 65 N-m (6.6 kgf-m) (48 lb-ft)

70ZV44017J

10) Remove plug assembly (21) and remove the O-ring. Hexagon hole width across flat: 17 mm (43/64 in) Torque for assembly : #21: 410 N-m (41.8 kgf-m) (302 lb-ft)

11) Set the spool assembly in a rise and then loosen bolt (22) to remove. Hexagon width across flat: 10 mm (25/64 in) Torque for assembly : #22: 18 N-m (1.8 kgf-m) (13 lb-ft) : Screw lock agent AB01 application

70ZV44018J

12) Remove spring seat (23), spring (24), stopper (25) from each spool (there are two spools).

24 25 23

Note: Cover the spool to protect it from being scratched. Spool

3. Reassembling multiple control valve To reassemble the multiple control valve, follow the above removal procedure in the reversed direction.

4. 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

85ZV44024

85ZV

Orbitrol®

HYDRAULIC 44

Orbitrol® Removing and reinstalling Orbitrol® 1. Removing Orbitrol®

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and lower bucket to ground. - Block tires with chocks to prevent wheels from moving. - Apply articulation stopper. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat. - 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.

95ZV44060

1) Remove cover (1). 2) Remove plate (2).

95ZV44061

3) Remove sound suppression sheet (3).

3 95ZV44062

44-35

Orbitrol®

85ZV

HYDRAULIC 44

4) Put matchmarks on hoses (4), and then disconnect them from Orbitrol® (5). 4 5

95ZV44063

5) Remove bolt (7), and then remove the Orbitrol®. Torque for assembly: : Bolt: 29 N-m (3.0 kgf-m) (22 lb-ft) : Orbitrol®: 7kg (15 lbs)

Note: One person should support the Orbitrol® under the machine. The person in the cab should remove the retainer bolt. This work should be done by two persons. 95ZV44064

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

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

44-36

85ZV

Orbitrol®

HYDRAULIC 44

Disassembling and reassembling Orbitrol® IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Cross section and tightening torque

85ZV44031

: N-m (kgf-m) (lb-ft) T1: 23 (2.3) (17) : 7 kg (15 lbs)

44-37

Orbitrol®

85ZV

HYDRAULIC 44

2.Disassembling Orbitrol® (Disassembling rotor) 1) Set the Orbitrol® in a vise so that the rotor side comes to the top position. Use a copper plates on a vise and do not tighten the vise strongly.

Copper plate

95ZV44025

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

2 3

97ZV44047

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

7 6

97ZV44048

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

9 10

97ZV44049

44-38

Orbitrol®

85ZV

HYDRAULIC 44

(Disassembling valve) 5) Remove the housing from the vise and put it on a clean cloth not to damage the finished surface. Remove retainer ring (11) by a screw driver.

11 97ZV44050

6) Rotate the spool and sleeve so that the pin can be in a horizontal position. Remove seal retainer (12) by pressing the spool and sleeve from behind with your fingers. 12

97ZV44051

7) Remove X-ring seal (14) and dust seal (15) from seal retainer (13). Note: Take care not to damage seal retainer (13).

97ZV44052

8) Remove races (16) and needle bearing (17) from spool (18) and sleeve (19). 16 17 16

18 19 97ZV44053

44-39

Orbitrol®

85ZV

HYDRAULIC 44

9) Pull spool and sleeve assembly (19) out slowly, turning it clockwise and counterclockwise from housing (20). Note: Take care so that the spool and sleeve do not damage the housing.

19 20 97ZV44054

10) Pull out pin (21) from the spool and sleeve assembly (19). 19

97ZV44055

11) Push spool (23) slightly out of sleeve (22), and remove centering springs (24). Pull the spool from the sleeve while slowly turning the spool clockwise and counterclockwise.

22 23 23

97ZV44056

12) Remove O-ring (25) from the housing. 13) Remove adapter (26) to take out ball (27). Note: Do not disassemble, unless absolutely necessary.

26 27

25 97ZV44057

44-40

Orbitrol®

85ZV

HYDRAULIC 44

3.Reassembling Orbitrol® 1) Assemble ball (27) and adapter (26) in the housing (20). 26 27

20 25 97ZV44058

2) Assemble spool (23) and sleeve (22) so that the spring grooves in them are lined up. Note: Align the matchmarks on the spool and sleeve. Spring groove 22 Spring groove 23

Matchmark

95ZV44026

3) Install springs (24) through the spring grooves in the sleeve and spool (19) 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.

19 97ZV44060

4) Insert pin (21) in the holes in spool (23) and sleeve (22) until the end of the pin is flush with the surface of the sleeve.

97ZV44061

44-41

Orbitrol®

85ZV

HYDRAULIC 44

5) Insert spool and sleeve assembly (19) from the back of housing (20). Note: ➀Take care not to tilt the assembly and cause damage during insertion. ➁Insert the assembly until the back end of the assembly is flush with the back end of the housing. ➂Confirm that the assembly can be turned easily in the housing.

19 20

97ZV44062

6) Install O-ring (25), races (16) and needle bearing (17). 17 16

97ZV44063

7) Insert dust seal (15) and X-ring seal (14) in seal retainer (13). 13

97ZV44052

8) Insert seal retainer (13) onto spool (23), and then tap it gently into position with a plastic-faced hammer. Then install retainer ring (11).

23 97ZV44064

44-42

Orbitrol®

85ZV

HYDRAULIC 44

Note: Be sure the position and direction of the seals. Screw driver Dust seal Retainer ring Seal retainer X-ring seal O-ring

95ZV44027

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

97ZV44066

10) Insert drive shaft (8) to mate its yoke with pin (21).

Port face 8 Pin parallel with port face

21 95ZV44028

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

97ZV44068

44-43

Orbitrol®

85ZV

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: ➀Align 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. ➁Confirm that lines A, B, C and D are all parallel.

HYDRAULIC 44

Grooves in rotor bore

B Drive shaft

C D

13) Install spacer (5), O-ring (3) and end cap (2). : Provisional tightening torque: 15 N-m (1.5 kgf-m) (11 lb-ft) Tightening torque: 23 N-m (2.3 kgf-m) (17 lb-ft)

Port face

95ZV44029

1 2

Note: Provisionally tighten bolt (1), then tighten them securely in the order shown at the right.

97ZV44070

Tightening order

95ZV44030

44-44

Steering Valve

85ZV

HYDRAULIC 44

Steering Valve Removing and reinstalling steering valve 1.Removing steering valve

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and lower bucket to ground. - Block tires with chocks to prevent 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 plastic before valve removal.

Steering valve

1 3

Before starting work: a)Remove the seat and seat bracket in the cab.

90ZV44037

1) Disconnect hoses (1)(2)(3)(4) from the steering valve.

10 6 9 7 8

2) Remove hoses (5)(6)(7)(8)(9)(10). Steering valve 5

90ZV44038

3) Remove bolt (11) and then remove the steering valve . Torque for assembly: : Bolt: 49 N-m (5.0 kgf-m) (36 lb-ft) : Steering valve: 25 kg (55 lbs) Note: Cover the disconnected hoses and the valve with plastic, plugs or caps to protect them from dust and dirt.

Steering valve

85ZV44025

44-45

Steering Valve

85ZV

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 or the operator's seat. 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).

44-46

HYDRAULIC 44

Steering Valve

85ZV

HYDRAULIC 44

Disassembling and reassembling steering valve IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Cross section and tightening torque T3 T2

Flow control spool T2

Steering spool T7

: N-m (kgf-m) (lb-ft) T1: 255 (26.0) (188) T2: 79 ( 8.0) ( 58) T3: 62 ( 6.3) ( 46) T4: 60 ( 6.1) ( 44) T5: 353 ( 36) (260) T6: 127 ( 13) ( 94) T7: 108 ( 11) ( 80) 44-47

90ZV44040

Steering Valve

85ZV

HYDRAULIC 44

2.Disassembling steering valve 1

1) Remove right and left overload relief valves (1). Width across flat: 32 mm (1.26 in) : Torque for assembly: 79 N-m (8.0 kgf-m) (59 lb-ft)

90ZV44007J

2) Remove bolt (2). Remove end cover (3). Hexagon hole width across flat: 8 mm (0.315 in) : Torque for assembly: 62 N-m (6.3 kgf-m) (46 lb-ft)

90ZV44008J

3) Remove spring (4) and spring seat (5) to pull out steering spool (6). Note: Carefully pull out the steering spool so that it is not damaged. Put matchmark to make sure the direction of the steering spool. 6 5 4 90ZV44009J

4) Slightly loosen plug (7). Note: Carefully loosen plug (7). It may spring out by the spring force. Width across flat: 14 mm (0.551 in) : Torque for assembly: 353 N-m (36 kgf-m) (260 lb-ft)

90ZV44010J

44-48

Steering Valve

85ZV

HYDRAULIC 44

5) Remove relief valve (8) and plug (9). Pull out spring (10) and flow control spool (11) from the casing. Note: - Carefully remove plug (9). It may spring out by the spring force. - Carefully pull out flow control spool (11) so that the casing and flow control spool are not scratched.

11 9

Width across flat: #8: 19 mm (0.748 in) #9: 41 mm (1.614 in) Torque for assembly: : #8, 9: 108 N-m (11 kgf-m) (80 lb-ft)

90ZV44011J

6) Remove plug (7) loosened on paragraph 4).

3.Reassembling steering valve To reassemble the steering valve, follow the above disassembly procedure in the reversed direction.

44-49

Stop Valve

85ZV

HYDRAULIC 44

Stop Valve Removing and reinstalling stop valve 1.Removing stop valve

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel. (The illustration shows the machine right hand side.) 1) Remove hoses (1)(2)(3)(4) from the stop valve.

2) Remove bolt (5) and then remove stop valve (6). 5 2 4 1

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

85ZV44026

44-50

Stop Valve

85ZV

HYDRAULIC 44

3.Cautions regarding reinstalling The stop valve works when the spool is pushed in 3 mm (0.118 in). Adjust the stopper bolt by using the following procedure. - Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension “9.7 to 19.3 mm (0.38~0.76 in)” shown in the table below.

Front chassis Reference dimension 33.9~38.4 mm (1.33~1.51 in)

Reference dimension Articulation angle ( °)

Stop valve (rear chassis) (L.H, R.H)

Stopper (bolt)

Stopper (bolt) length 37

K85ZVE43002

Clearance between machine body and stopper (mm)(in)

9.7 14.5 19.3 (0.38) (0.57) (0.76)

Stopper (bolt) length (mm) (in)

33.9 36.2 38.4 (1.33) (1.42) (1.51)

Front chassis

35°~

- After adjustment, turn the steering wheel slowly at a rate of 5 sec or more per turn, and confirm the clearance between the machine body and the stopper. - When adjustment is completed, tighten the lock nut of the stopper (bolt). : N-m (kgf-m) (lb-ft) 90 (9.2) (67)

37°

✽ The target value should be the articulation angle “36°”.

Rear chassis Reference dimension 9.7~19.3 mm (0.38~0.76 in) Clearance between machine body and stopper K85ZVE43003

44-51

Stop Valve

85ZV

HYDRAULIC 44

Disassembling and reassembling stop valve IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Cross section and tightening torque

T4 T3

97ZV44078

: N-m (kgf-m) (lb-ft) T1: 21 ( 2.1) (15.2) T2: 5 ( 0.5) ( 3.6) T3: 0.4 (0.04) ( 0.3) T4: 26.5 ( 2.7) (19.5)

44-52

Stop Valve

85ZV

HYDRAULIC 44

2.Disassembling stop valve 1) Remove boot (1) and plug (2). 2

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

A B

Torque for assembly: : #2: 21 N-m (2.1 kgf-m) (15.2 lb-ft)

97ZV44079

2) Remove spring (3) and pull out spool assembly (4). 6

3) Clamp spool assembly (4) at the bottom side in a vise and remove plug (5) using a screw driver. Remove washer (6), spring (7) and check valve (8) from the spool.

7 3 4

Torque for assembly: : #5: 5 N-m (0.5 kgf-m) (3.6 lb-ft)

Two flats 95ZV44032

4) Remove screw (9) to remove flange (10), dust seal (11), spacer (12) and U-packing (13). Torque for assembly: : #9: 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)

12 10

9 97ZV44081

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

44-53

Fan Motor

85ZV

HYDRAULIC 44

Fan Motor Removing and reinstalling fan motor

1 Fan motor

1. Removing fan motor 2

3 90ZV44043

Radiator assembly

1) Remove the hoses (1) (2) (3) from the fan motor. Use a drain pan to catch all escaping oil. 85ZV44027

2) Remove the fan guard (4) from the radiator assembly.

Fan

Fan motor

3) Attach sling to the fan. Remove the nut (5) from the fan. Torque for assembly: : nut (5): 355 N-m (36 kgf-m) (260 lb-ft) : With lubrication oil (Engine oil or gear oil) : Fan: 17 kg (38 lbs)

Rear chassis

85ZV44028

4) Attach sling to the fan motor. Remove the bolt (6), and then remove fan motor. Torque for assembly: : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) : Fan motor: 25 kg (55 lbs)

Fan motor 6

90ZV44046

44-54

Fan Motor

85ZV

HYDRAULIC 44

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

Clearance

90ZV24010

Disassembling and reassembling fan motor Follow the same procedure for the hydraulic pump disassembling / reassembling.

44-55

MEMO

HYDRAULIC GROUP 45 Service Standard Steering Valve ............................................................................................45-2 Hydraulic Cylinder .......................................................................................45-3 Pilot Valve ...................................................................................................45-4

45-1

Steering Valve

85ZV

HYDRAULIC 45

Steering Valve

90ZV45001J

Tightening torque

Unit : N-m (kgf-m) (lb-ft) Item

No. 1

Steering valve retainer bolt

Steering valve bracket retainer bolt

Standard value

Solution

94 (9.6) (69) Tightening 230 (23.5) (170)

45-2

Hydraulic Cylinder

85ZV

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder

85ZV45002J

Steering cylinder

1 85ZV45003J

Unit : mm (in.) Judgment standard No

Standard dimension of rod dia.

Item

Piston nut tightening torque N-m (kgf-m) (lb-ft) Piston nut width across flat mm (in.)

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

– 0.036 (– 0.0014)

+ 0.195 (+ 0.0076)

0.096 (0.0037)

– 0.090 (– 0.0035)

+ 0.060 (+ 0.0023)

0.285 (0.0112)

– 0.025 (– 0.0010)

+ 0.110 (+ 0.0043)

0.025 (0.0010)

– 0.064 (– 0.0025)

0 (0)

0.174 (0.0068)

0.271 (0.0106)

Item

+ 0.060 (+ 0.0023)

No.

– 0.076 (– 0.0030)

Steering cylinder

0.090 (0.0035)

ø 50 (ø 1.9685)

+ 0.195 (+ 0.0076)

Bucket cylinder

– 0.030 (– 0.0011)

ø100 (ø 3.9370)

Bushing

Boom cylinder

Rod

Standard clearance

ø 80 (ø 3.1496)

Standard value

Limit

Solution

Bushing

Clearance

+0.295 (+ 0.0116)

0.371 (0.0146)

Replacement

+0.295 (+ 0.0116)

0.385 (0.0151)

Replacement

+0.210 (+ 0.0082)

0.274 (0.0108)

Replacement

Boom cylinder

Bucket cylinder

Steering cylinder

M62 x 2 4,756 (485) (3,509)

M76 x 2 5,884 (600) (4,341)

M36 x 1.5 1,275 (130) (941)

90 (3.54)

110 (4.33)

55 (2.17)

M24 843 (86) (622)

M24 883 (90) (651)

(Rod cover) 1,765 (180) (1,302)

45-3

Pilot Valve

85ZV

HYDRAULIC 45

Pilot Valve

212-1

97ZV45002

Judgment standard No.

212-1

Item

Push rod ø 7(0.276 in)

Solution

Wear 1 mm(0.0394 in)

45-4

Standard value

Allowable limit

36 mm (1.417 in)

35 mm (1.378 in)

Replacement

BRAKE GROUP 54 Disassembly and Reassembly Unloader Valve ............................................................................................54-2 Manifold Valve Assembly.............................................................................54-5 Accumulator.................................................................................................54-7 Brake Valve ...............................................................................................54-12 Service Brake ............................................................................................54-18 Park Brake Actuator...................................................................................54-19 Parking Brake ............................................................................................54-24

54-1

Unloader Valve

85ZV

BRAKE 54

Unloader Valve Removing and reinstalling unloader valve 1.Removing unloader valve

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Block front wheels with chocks to prevent 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 the operator's seat, 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. - Press the hydraulic oil tank cap, and relieve the internal pressure from the hydraulic oil tank. - Prepare a container to catch drained oil.

1 85ZV54001

Unloader valve

1) Remove hoses (1) (2) (3) from the unloader valve. 5

2) Remove hoses (4) (5) from the unloader valve. 4

3) Remove bolts (6) and then remove the unloader valve. Torque for assembly: : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) : Unloader valve: 4 kg (8.8 lbs)

Unloader valve 85ZV54002

2.Reinstalling unloader valve To reinstall the unloader valve, follow the above removal procedure in the reversed direction. Replace all O-rings and seals during reinstallation. Note: After reinstallation, completely bleed the brake line of air, and check performance of the unloader valve. To bleed the brake line of air, refer to Section 24. To check performance of the unloader valve, refer to Section 53. 54-2

Unloader valve 85ZV54003

Rear chassis

Unloader Valve

85ZV

BRAKE 54

Disassembling and reassembling unloader valve IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts." T1

1.Cross section and tightening torque

T8 T7 T6

T2 L1

T5 : N-m (kgf-m) (lb-ft) T1: 137 ( 14) (101) T2: 14.7 (1.5) ( 11) T3: 14.7 (1.5) ( 11) T4: 58.8 ( 6) ( 43) T5: 98.1 ( 10) ( 72) T6: 118 ( 12) ( 87) T7: 16.7 (1.7) ( 12) T8: 78.5 ( 8) ( 58)

Width across flats Width across flats Width across flats Width across flats Width across flats Width across flats Width across flats Width across flats

17 mm (0.669 in) 5 mm (0.197 in) 5 mm (0.197 in) 8 mm (0.315 in) 30 mm (1.181 in) 36 mm (1.417 in) 12 mm (0.472 in) 24 mm (0.945 in)

L1: Screw lock agent application (Loctite® 262) 54-3

97ZV54002

Unloader Valve

85ZV

BRAKE 54

2.Disassembling unloader valve

1) Remove plug (1), then pull out spool (2) and spring (3). Note: Carefully remove plug (1). It may spring out by the spring force.

3 2

Torque for assembly: : 137 N-m (14 kgf-m) (101 lb-ft) Note: Do not disassemble the pressure governor assembly and the pressure switch assembly unless it is necessary. Because, readjustment of accumulator pressure and setting of shims are required.

Pressure governor assembly

95ZV54001

3.Reassembling unloader valve To reassemble the unloader valve, follow the above disassembly procedure in the reversed direction.

54-4

Manifold Valve Assembly

85ZV

BRAKE 54

Manifold Valve Assembly 2

Removing and reinstalling valve assembly

3 4

1.Removing valve assembly

WARNING

Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Block front wheels with chocks to prevent 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 the operator's seat, or disconnect the negative side of the battery.

6 Valve assembly

85ZV54004

Valve assembly

7 Rear chassis 85ZV54005

1) Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line.

Valve assembly

2) Remove the hoses (1) (2) (3) (4) (5) (6) from the valve assembly.

Rear chassis

3) Remove the hose (7) (8) (9) from valve assembly. 85ZV54006

4) Remove the bolt (10) and then remove the valve assembly. Torque for assembly: : Bolt (10): 53 N-m (5.4 kgf-m) (39 lb-ft) : Valve assembly: 10 kg (22 lbs)

2.Reinstalling valve assembly To reinstall the valve assembly, follow the above removal procedure in the reversed direction. Replace all O-rings and seals during reinstallation. Note: After reinstallation, completely bleed the brake line of air, and check performance of the valve assembly. To bleed the brake line of air, refer to Section 24. To check performance of the valve assembly, refer to Section 53.

54-5

Manifold Valve Assembly

85ZV

BRAKE 54

Disassembling and reassembling valve assembly IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Cross section and tightening torque T5 T1

T1 T1

(T)

(P)

T4 (TA)

(PI)

(PARKING) (ACCR)

(ACCF)

ACF (PA) (Z1)

(Z)

(Z2)

(PPI)

High pressure test ports

70ZV54012

: N-m (kgf-m) (lb-ft) T1:

50 (5.1) ( 37) T2: 23.5 (2.4) ( 17) T3: 38 (3.9) ( 28) T4: 11 (1.1) ( 8) 8 (0.8) (5.8) T5:

CAUTION High pressure test ports contain accumulator pressure [11.8 MPa (1,706 psi)] that can escape from these 2 plugs. Completely depress brake pedal 80~100 times to relieve all pressure before removing plugs. 54-6

Accumulator

85ZV

BRAKE 54

Accumulator Removing and reinstalling accumulator 1.Removing accumulator

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Block front wheels with chocks to prevent 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 the operator's seat, or disconnect the negative side of the battery.

Accumulator

1 4 2

85ZV54007

1) Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line. 2) Remove hoses (1) (2) (3) (4) from the accumulator. 3) Remove bolts (5), nut (6) and then remove the accumulator. Torque for assembly: : Bolt (5): 94 N-m (9.6 kgf-m) (69 lb-ft) : Accumulator: 19 kg (42 lbs)/pc

Bracket

2.Reinstalling accumulator To reinstall the accumulator, follow the above removal procedure in the reversed direction. Replace all O-rings and seals during reinstallation. Note: After reinstallation, completely bleed the brake line of air, and check performance of the accumulator. To bleed the brake line of air, refer to Section 24. To check performance of the accumulator, refer to Section 53. 54-7

Rear chassis 85ZV54008

Accumulator

85ZV

BRAKE 54

Disassembling and reassembling accumulator IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Disassembling accumulator

WARNING Disassembly without breathing the inner gas could cause serious injury or death by explosion. To prevent such an accident, observe the following item: - Carefully handle the accumulator that has the high pressure. - Before disassembly, completely reduce the gas pressure lower to the atmospheric pressure. - Do not drill and weld the body. - Do not use over the specified pressure. - Use Nitrogen gas for charge.

7 2

IMPORTANT

- Take care not to scratch the cylinder to prevent gas leak. - Carefully remove each part so that it is not scratched or dented.

12 11

1) Loosen bolt (13) to remove gas valve guard (12).

5,6

2) Remove the cap of gas valve (10) and install the charging valve to gas valve (10), then bleed the gas completely from the accumulator.

8,9

97ZV54007

Gas cap

3) Insert three pins into gas cap (3). Remove the gas cap by using a long bar. Pin hole : ø 11.4 (0.4 in)

95ZV54002

54-8

Accumulator

85ZV

4) Insert three bolts into hydraulic cap (2) and remove it by using a long bar.

BRAKE 54

7 2

3 13

Screw size: 1/2-20UNF-2B

5) Push out piston (4) toward the hydraulic end by using a bar.

5,6

2.Reassembling accumulator To reassemble the accumulator, follow the above disassembly procedure in the reversed direction. After reassembly, carry out the gas charging.

8,9

97ZV54007

Hydraulic cap

95ZV54003

54-9

Accumulator

85ZV

BRAKE 54

Procedure for charging nitrogen gas - Nitrogen gas charging tools:

1 2

1.Charging valve assembly 1-1 Handle (for adjusting screw) 1-2 Handle (for bleeder plug) 1-3 Valve body 2.Pressure gauge (4,903 kPa (50 kgf/cm2) (1,000 psi)) 3.Hose assembly 4.Nitrogen (N2) gas cylinder

1-1

1-3

1-2 3

Accumulator

Charging valve installation 95ZV54004

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 handle (1-1) counterclockwise until it stops turning. 2) Turn handle (1-2) counterclockwise to open. 3) Remove the gas valve guard cap and then install charging valve assembly (1) to the gas valve. 4) Install pressure gauge (2) to the charging valve assembly and connect the hose (3) to nitrogen gas cylinder (4). 5) Slightly open the valve of the nitrogen gas cylinder. Turn handle (1-2) clockwise to close after confirming the gas comes out from handle (1-2) part. 6) Slowly turn 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.

54-10

Accumulator

95ZV54005

Accumulator

85ZV

[Charging pressure: 2.9 MPa (30 kgf/cm 2) (427 psi) at 20 °C (68 °F)] 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) counterclockwise. PX = 30 (kgf/cm2) x {273 + t (°C)} / {273 + 20 (°C)} PX : Charging gas pressure t : Ambient temperature 30 : Standard gas pressure 8) Turn handle (1-1) counterclockwise to return the piston of the gas valve. Then turn handle (1-2) counterclockwise to bleed the gas from the charging assembly and the hose. 9) After removing pressure gauge (2), remove the charging assembly from the accumulator. Notes: - Apply soapy water to the gas valve on the accumulator 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.

54-11

BRAKE 54

Brake Valve

85ZV

BRAKE 54

Brake Valve Removing and reinstalling brake valve Cover

1.Removing brake valve

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Block front wheels with chocks to prevent 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 the operator's seat, or disconnect the negative side of the battery.

Cover 95ZV54006

Brake valve

90ZV54018

Brake valve

1) Remove all hoses and pipes shown on the illustration. 2) Remove all adapters and fittings shown on the illustration. 3) Remove bolt (1) and then remove the brake valve. Tightening torque : Bolt: 28 N-m (2.9 kgf-m) (21 lb-ft) 90ZV54010

2.Reinstalling brake valve To reinstall the brake valve, follow the above removal procedure in the reversed direction. Note: After reinstallation, completely bleed the brake line of air, and check all the pipe-joints for oil leakage. To check or adjust the brake valve, refer to Section 53. 95ZV54011

54-12

Brake Valve

85ZV

BRAKE 54

Disassembling and reassembling brake valve IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Cross section and tightening torque (Main valve)

A A-A

T1 L 1 A

: N-m (kgf-m) (lb-ft) T1:

9.8 (1.0) ( 7.2) T2: 176.4 ( 18) (130) T3: 73.5 (7.5) ( 54)

70ZV54011

L1: Screw lock agent 1303N application 54-13

Brake Valve

85ZV

BRAKE 54

Pedal

2.Disassembling brake valve Use a copper plate in vise and do not tighten the brake valve in vise strongly. [Main valve] 1) Pull out the snap pin to remove the pedal, seat, boot and pedal stopper. Note: At this step, the pin (L-Shaped) is dropped. Take care not to lose it.

Pin Seat Pedal stopper Boot

Snap pin Pin(L-shaped) 95ZV54010

2) Loosen four bolts and disconnect the bracket from the valve assembly.

Bolt (4 pcs)

Bracket

Valve assembly

95ZV54011

3) Turn the valve upside down. Loosen four bolts and separate the valve assembly into the S cylinder assembly, P cylinder assembly and T flange assembly. Note: Carefully separate the valve assembly. It may spring out by the spring force.

Bolt (4 pcs) S cylinder assembly

4) Remove the spring sub assembly from the T flange assembly. Remove the return spring and retainer all together.

P cylinder assembly

Spring sub assembly Return spring + retainer T flange assembly

95ZV54012

54-14

Brake Valve

85ZV

BRAKE 54

[Pilot Valve] Follow the same disassembling procedure for main valve. Disassembly step diagram [Main valve]

[Pilot valve]

S cylinder assembly

Spool return spring Return spring P cylinder assembly Spring sub assembly

Spring sub assembly

S flange assembly

Return spring + retainer

T flange assembly 95ZV54021

95ZV54020

54-15

Brake Valve

85ZV

3.Reassembling brake valve

BRAKE 54

S cylinder assembly

1) Install the return spring and retainer to the T flange assembly all together. Install the spring sub assembly to the T flange assembly. Note: Confirm that the rod of the spring sub assembly is at the center. Be sure to install them in the proper direction.

Spool return spring

P cylinder assembly

2) Install the P cylinder assembly to the T flange assembly. Spring sub assembly

3) Install the spool return spring to the spool of the P cylinder assembly.

4) Install the S cylinder assembly to the P cylinder assembly.

Return spring + retainer

T flange assembly

95ZV54020

5) Tighten four bolts. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft) Bolt (4 pcs) S cylinder assembly

P cylinder assembly

95ZV54022

54-16

Brake Valve

85ZV

6) Tighten four bolts to install the bracket. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft)

BRAKE 54

Bolt (4 pcs)

Bracket

Valve assembly 95ZV54011

Pedal

7) Install the boot, stopper and the seat to the valve assembly.

8) Install the pedal to the bracket. Turn the stopper bolt until the clearance between the seat and the roller is zero, then tighten the stopper lock nut to fix the stopper bolt.

Lock nut

Seat Pedal stopper Boot

Snap pin Pin(L-shaped)

: Lock nut: 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) 95ZV54023

Stopper bolt: Screw lock agent 1303N application

9) Fix the pin (L) into the pin, then insert into the bracket so that pin (L) is in the hole of the pedal.

10) Making sure of the direction, install the snap pin to the pin.

54-17

Stopper bolt

Service Brake

85ZV

BRAKE 54

Service Brake Disassembling and reassembling service brake Refer to "Disassembling and Reassembling Front Axle" in Power group.

WARNING 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 and it could cause serious injury or death.

Socket bolt Spider

95ZV54024

Upper side

Cautions on installing brake discs CAUTION When only the friction plates or the steel plates are to be replaced, if the brake piston and brake stroke adjusting mechanism are installed as they are, the brake may drag and the brake discs may seize. Push back the brake piston and brake stroke adjusting mechanism by using the following procedure.

For pushing down brake piston

1) Loosen the axle housing air bleeder nipple. 2) Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly. Bolt size for pushing brake piston back (4 required) M10 x 1.5 - 45 to 50 (1.8 to 1.97 in.) (Fully threaded)

90ZV54012

A B Wheel hub

3) After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face. A ... 134.25 to 135.75 mm (5.29 to 5.34 in.) Note: Piston stroke B 1.45 to 4.05 mm (0.057 to 0.159 in.)

Brake piston

90ZV54013

4) After finishing the installation work, bleed air completely from the brake line. 54-18

Park Brake Actuator

85ZV

BRAKE 54

Park Brake Actuator Removing and reinstalling park brake actuator 1.Removing park brake actuator

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - When removing the park brake actuator, 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 source, release the parking brake, and then remove split pin (1) and pin (2). Note: If there is no oil source, apply a cable to the link, and then pull it down using a bar to overcome the spring force, and then remove the pin.

Transmission

5 1

2) Release the residual air pressure in hydraulic tank. Disconnect oil hose (3). 3) Loosen locknut (4) to remove joint (5). Remove retainer bolts (6) to remove park brake actuator (7). : Retainer bolts: 53 N-m (5.4 kgf-m) (39 lb-ft) : Park brake actuator: 8 kg (18 lbs)

Brake assembly

90ZV54014

2.Reinstalling park brake actuator To reinstall the park brake actuator, follow the above removal procedure in the reversed direction. Note: To insert the connection pin to connect the park brake actuator to the parking brake, observe the following items: ➀Start the engine to build oil pressure in the accumulator. ➁Release the parking brake. ➂Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the park brake actuator and the parking brake. After that, insert the connection pin into the joint hole. To check performance of the parking brake, refer to Section 53.

54-19

Park Brake Actuator

85ZV

BRAKE 54

Adjusting park brake actuator 1.Adjustment procedure of park brake actuator linkage

WARNING When remove the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park machine on level ground. - Lower bucket to ground. - Apply articulation stopper.

1) Release parking brake (OFF).

2) Measure dimension "A" if it is 85 mm (3 11/32 in.). 2

3) If not, remove pin (5), split pin (6), and washer (7) and loosen lock nut (2). And adjust the linkage length by turning link (3) so that dimension "A" is 85 mm (3 11/32 in.).

4) Tighten lock nut (2) and reinstall pin (5), split pin (6) and washer (7).

2 3 5,6,7

5) Confirm the parking brake performance. (Refer to Function & Structure)

90ZV54015

Parking brake "OFF" position 1. Park brake actuator 2. Lock nut 3. Link 4. Bracket 5. Pin 6. Split pin 7. Washer

54-20

Park Brake Actuator

85ZV

BRAKE 54

Disassembling and reassembling park brake actuator IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Cautions regarding disassembly and reassembly of hydraulic parts."

1.Cross section and tightening torque

90ZV54019

No specified torque When disassembling, put matchmarks on the rod cover cap and piston. During reassembling, align the matchmarks and install the set screw.

54-21

Park Brake Actuator

85ZV

BRAKE 54

1.Disassembling park brake actuator

WARNING The inner spring could spring out causing serious injury. To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the rod cap. When reducing the pressure of the press, be sure to slowly reduce it.

Matchmark

90ZV54016

1) Removal of the set screw of rod cap Note: Since the set screw is locked by punching, cut off the punched area with 15 to 20 mm dia. drill. Since it is necessary to install the set screw at the same position during reassembly, mark the positioning matchmark on the rod cap and cylinder tube. 2) Initial loosening of rod cap Using the threaded hole of the rod cap, unscrew the rod cap approx. 1/8 turn alone.

90ZV54006J

3) Removal of rod cap Using the press, press down the rod cover with the pipe (outer dia.: 50 mm or less, inner dia.: 30 mm or more, length: 80 mm), and it will be allowed to loosen the rod cap with hand. So, remove the rod cap. 4) Slowly pull up the press until the spring loses the spring force.

5) Pull out rod cover (1), spring (2), piston rod (3) and piston (4) from the cylinder tube.

90ZV54007J

3 4

1 2

54-22

90ZV54008J

Park Brake Actuator

85ZV

6) Put matchmarks on piston (4) and rod. Remove set screw (5) to pull out piston (4). Note: - Since the set screw is locked by punching, cut off the punched area with 15 to 20 mm dia. drill. - During reassembling, align the matchmarks and install the set screw at the same position.

BRAKE 54

3 5 4

Matchmark 90ZV54017

7) Remove dust seal (6) and bushing (7) from rod cover (1). Remove wear ring (8), U-packing (9) and O-ring (10) from piston (4).

8 4 9 10

90ZV54010J

3.Reassembling park brake actuator To reassemble the park brake actuator, follow the disassembly procedure in the reversed direction.

CAUTION When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined. Tighten the rod cap to the position where the matchmark was marked before disassembly, screw in the screw, and punch it for locking.

54-23

90ZV54011J

Parking Brake

85ZV

BRAKE 54

Parking Brake Removing and reinstalling / Disassembling and reassembling parking brake 1.Removing and disassembling parking brake

WARNING When removing the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park machine on level ground. - Lower bucket to ground. - Apply articulation stopper.

1) Drain the transmission oil. 1

2) Release the parking brake, and then remove pin (3) to disconnect link (1) and lever (2).

90ZV54012J

3) Remove bolts (5) of propeller shaft (4). : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three bond 1327) 4

5 90ZV54013J

4) Remove bolt (6) of brake adjustment hole and then remove brake drum (7). Remove nut (8) and flange yoke (9). : Bolt (6): 94 N-m (9.6 kgf-m) ( 69 lb-ft) Nut (8): 392 N-m ( 40 kgf-m) (2,891 lb-ft) : Bolt (6): Screw lock agent (Three bond 1327) Nut (8): Molydenum disulfide grease/MOS 2 application

54-24

97ZV54024

Parking Brake

85ZV

BRAKE 54

5) Remove right and left springs (10) using pliers. Remove plate (11).

6) Pull out the upper guides to the front to open brake shoes (12), and then remove shoes (12) from the side guides. - If it is necessary to remove the back plate (13), remove bolt (14). Torque for assembly: : #14: 216 N-m (22 kgf-m) (159 lb-ft) : #14: Screw lock agent application (Loctite® 262)

Upper guide

Side guide

12 14

95ZV54029

7) Remove spring (15), and then remove adjusting screw (16). Note: Measure the wear of the brake shoes. If the shoes are extremely worn, replace them. Refer to Section 53 or 55 inspection standards.

2.Reinstalling and reassembling parking brake To reinstall and reassemble the parking brake, follow the above removal and disassembly 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.

54-25

97K54012

97ZV54026

MEMO

BRAKE GROUP 55 Service Standard Brake Valve ................................................................................................55-2 Service Brake .............................................................................................55-4 Parking Brake .............................................................................................55-5

55-1

Brake Valve

85ZV

BRAKE 55

Brake Valve 2 1 3 9 12

6 4 7 5 8 10 8 11 97ZV55001

Unit : mm (in.) Judgment standard No.

Item

Standard dimension

Tolerance Shaft

Hole

Solution

Standard clearance Allowable clearance

Clearance between pedal installation hole and bracket hole

ø 10 (0.3937)

-0.025~-0.075 (-0.0010~-0.0030)

+0.1 (0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Clearance between roller and pin

ø 10 (0.3937)

-0.025~-0.075 (-0.0010~-0.0030)

+0.1 (0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Outer diameter of roller

ø 30 (1.1811)

Replacement

0 -0.5 (-0.0197) Judgment standard

No.

Item

Standard dimension

Tolerance limit

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lb)

Free length mm (in)

Control spring

59.0 (2.3228)

49.7 (1.9567)

64 (6.5) (14.3)

57.5 (2.2638)

Control spring

27.2 (1.0709)

56.2 (2.2126)

Return spring

68.2 (2.6850)

58.0 (2.2835)

75 (7.6) (16.8)

61.3 (2.4134)

Balance spring

17.0 (0.6693)

15.0 (0.5906)

70 (7.1) (15.7)

16.2 (0.6378)

Spool return spring

31.5 (1.2402)

19.5 (0.7677)

17 (1.7) (3.7)

28.0 (1.1024)

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Bracket installation bolt tightening torque Cylinder installation bolt tightening torque

Plug tightening torque

176.4 N-m (18 kgf-m) (130 lb-ft)

Stopper bolt lock nut tightening torque

Solution

Installation load N (kgf) (lb)

Replacement

73.5 N-m (7.5 kgf-m) (54 lb-ft) Tightening 9.8 N-m (1.0 kgf-m) (7.2 lb-ft)

55-2

Brake Valve

85ZV

BRAKE 55

6 4 5

7 10

97ZV55002

Unit : mm (in.) Judgment standard No.

Item

Standard dimension

Solution

Tolerance Shaft

Hole

Standard clearance Allowable clearance

Clearance between pedal installation hole and bracket hole

ø 10 (0.3937)

+0.1 (0.0039) -0.025~-0.075 (-0.0010~-0.0030) 0

0.175~0.025 (0.0069~0.0010)

0.25(0.010)

Clearance between roller and pin

ø 10 (0.3937)

+0.1 (0.0039) -0.025~-0.075 (-0.0010~-0.0030) 0

0.175~0.025 (0.0069~0.0010)

0.25(0.010)

Outer diameter of roller

ø 30 (1.1811)

0 -0.5 (-0.0197)

Replacement

0.8(0.032)

Judgment standard No.

Item

Standard dimension

Tolerance limit

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lb)

Free length mm (in)

Control spring

65.1 (2.5630)

49.7 (1.9567)

104 (10.6) (23.4)

63.4 (2.4961)

Control spring

27.2 (1.0709)

56.2 (2.2126)

Return spring

86.2 (3.3937)

58.0 (2.2835)

61 (6.2) (13.7)

78.0 (0.3071)

Spool return spring

31.5 (1.2402)

19.5 (0.7677)

17 (1.7) (3.7)

28.0 (1.1024)

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Bracket installation bolt tightening torque Cylinder installation bolt tightening torque

Plug tightening torque

176.4 N-m (18 kgf-m) (130 lb-ft)

Stopper bolt lock nut tightening torque

Solution

Installation load N (kgf) (lb)

Replacement

73.5 N-m (7.5 kgf-m) (54 lb-ft) Tightening 9.8 N-m (1.0 kgf-m) (7.2 lb-ft)

55-3

Service Brake

85ZV

BRAKE 55

Service Brake

Air bleeder nipple

1, 5

Slide caliper

1, 5

Retainer

Steel plate

2, 5

Friction plate

95ZV55001

Unit : mm (in.) Judgment standard No.

Solution

Item Standard dimension

Tolerance

Wear limit

Thickness of steel plate

4.9 (0.1929)

± 0.1 (± 0.0039)

4.4 (0.1732)

Thickness of friction plate

7.0 (0.2756)

± 0.1 (± 0.0039)

5.7 (0.2244)

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

28.8 (1.1339)

± 0.3 (± 0.0118)~ – 0.5 (– 0.0196)

25.1 (0.9881)

Outer dia. (Manufacturing dimension) 355 (13.9763)

– 0.210 (– 0.0082)~ – 0.299 (– 0.0117)

–

Inner dia. (Manufacturing dimension) 310 (12.2047)

+ 0 (+ 0)~ + 0.081 (+ 0.0032)

–

0.30 (0.0118) or less

–

0.30 (0.0118) and more

Free length

Installation length

Installation load (kgf)

54 (2.1260)

49 (1.9291)

29.3 (64 lbs)

Piston seal contact face

Distortion of steel and friction plate

Return spring

55-4

Replacement

–

Replacement

Parking Brake

85ZV

BRAKE 55

Parking Brake

1 3

Clearance

Spring (4) released 4

95ZV55002

Unit : mm (in.) No. 1

Judgment standard

Item

Standard dimension

Wear limit

6.15 (0.2421)

2.95 (0.1161)

Wear of lining

Solution Replacement

Deflection of drum

0.38 (0.0149) or more

Replacement

Lining inspection

Grease or oil on the lining

Replacement

Expansion of adjuster spring

There is clearance between the spring and the coil

Expansion of return spring

when the spring is released.

55-5

Replacement

MEMO

OPERATOR STATION GROUP 74 Disassembly and Reassembly Air Conditioner ............................................................................................74-2

74-1

Air Conditioner

85ZV

OPERATOR STATION 74

Air Conditioner Removing and reinstalling air conditioner 1.Removing the air conditioner Before starting work: a)Remover the seat in the cab. b)Collect the air conditioner refrigerant using the proper recovery method. c)Remove the floor mat in the cab. 1

2 1 4 2 3

View from operator's seat

95ZVE74001

1) Remove the box (1) (2). 2) Remove the cover (3) and the plate (4). 3) Remove the cover (5) (6) (7) from the cab. 4) Remove the duct (8).

Cab

74-2

95ZVE74002

Air Conditioner

85ZV

OPERATOR STATION 74

5) Disconnect the refrigerant piping (9) and the heater hose (10). Air conditioner unit

95ZVE74003

Air conditioner unit

10 95ZVE74004

6) Remove the air conditioner mounting bolts (11). Then, remove the air conditioner (12) from the floor board. 12

95ZVE74005

2.Reinstalling the air conditioner 1) To reinstall the air conditioner, follow the above removal procedure in the reversed direction. Reference After rainstalling the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-3

Air Conditioner

85ZV

OPERATOR STATION 74

Disassembling and reassembling air conditioner Tightening torque 1) Cooling unit

T2 T6 T4

T4 T5

T6 T4

T2 T1 T5

97ZV74002

: N-m (kgf-m) T1: 5.4 (0.55) T2: 1.9 (0.19) T3: 1.0 ( 0.1) T4: 0.8 (0.08) T5: 1.9 (0.19) T6: 2.5 (0.25) 74-4

Air Conditioner

85ZV

OPERATOR STATION 74

2) Heater and accessories

T1: T2: T3: T4:

: N-m (kgf-m) 4.0 ( 0.4) 0.8 (0.08) 1.0 ( 0.1) 5.4 (0.55)

T3 T2 T2

T4 T1

97ZV74003

3) Air distributor (hood & defroster selection box)

: N-m (kgf-m) T1: 3.7 (0.38) T2: 1.0 ( 0.1) T3: 0.8 (0.08)

97ZV74004

74-5

Air Conditioner

85ZV

OPERATOR STATION 74

4) Air compressor (with magnetic clutch) T1

T2 97ZV74005

: N-m (kgf-m) T1: 4.9 (0.5) T2: 18 (1.8)

5) Condenser unit T1

T1 T2 T1

97ZV74006

T1 : N-m (kgf-m) T1: 12 ( 1.2) T2: 5.4 (0.55)

74-6

OPERATOR STATION GROUP 75 Service Standard Air Conditioner ............................................................................................75-2

75-1

Air Conditioner

85ZV

OPERATOR STATION 75

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

Criteria

Solution

Refrigerant

Charge quantity

Air bubbles should not be seen through sight glass.

Inspection/ adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Clean

Compressor

Operating status

Belt tension pulley

Operating status

Magnetic clutch should operate. Abnormal sounds should not be detected. Abnormal sounds and backlash should not be detected.

Inspection/ adjustment/ replacement Inspection/ replacement

V belt

Damage and tension

Damages should not be detected.

Replacement

Abnormal sounds or vibration should not be Inspection/ detected. replacement Each part should operate in accordance with switch Inspection/ Control mechanism Operating status operations. replacement Air quantity should not be so small as to hinder air Cleaning/ Air filter for inside/outside air Clogging conditioning. replacement Each mounting area and Looseness,gas leak and Looseness,gas leak and damages should not be Tightening/charge piping damages detected. Blower motor and fan

Operating status

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

Nut type

Pipe size or bolt size

Tightening torque N-m

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

(kgf-m)

Condenserexpansion valve

ø8 piping

Compressorcondenser

D1/2 piping

25 (2.50)

Evaporatorcompressor

D5/8 piping

34 (3.50)

Receiver

M6 bolt inreceiver (4T)

7 (0.70)

Any M6 bolt(6T) other than above

12 (1.20)

(kgf-m)

15 (1.50)

Head bolt of magnetic clutch

Mounting bolt for servo motor for inside/outside air selection (Tapping screw)

Block joint Evaporatorcompressor

Bolt size

Tightening torque N-m

75-2

18 (1.8) 0.8 (0.08)

Fixing nut of blower motor and condenser fan

5.4 (0.55)

Fixing bolt of blower motor and condenser motor

4 (0.4)

Notes