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93205-00070 August 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. 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

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

(F) 1.25

132

(F) 1.25

142

206

(F) 1.5

152

221

216

314

(F) 1.5

226

330

299

436

(F) 1.5

324

476

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

M10 M12

Metric thread

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

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

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

2.7

3.9

5.4

7.8

(F) 1.25

5.6

8.2

9.2

13.5

(F) 1.25

9.8

14.5

21.0

(F) 1.5

15.5

22.5

22.0

32.0

(F) 1.5

23.0

33.7

30.5

44.5

(F) 1.5

33.0

48.5

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

M10 M12

Metric thread

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

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

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

19.5

(F) 1.25

105

150

(F) 1.5

110

160

230

(F) 1.5

165

245

220

320

(F) 1.5

235

350

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

M10 M12

Metric thread

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

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

0.8

8.8 (8T)

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 reassemble 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 Through-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 screws from the end of the thread and start threading 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) Ground the welder near the section to be welded, and route welding leads away from machine. 5) To ground the welder, check that the electric current will not flow through the cylinders, pins or dectrical parts. 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

435

960

Item Unit name

Chassis

Power line

Boom

490

1,080

120

265

Link (Bucket to Lever)

Engine room assembly

155

340

Hydraulic tank

110

Excluding oil

Fuel tank

155

Excluding fuel

Floor board

135

300

Cab

550

1,230

ROPS cab

Engine

395

870

Including oil

Radiator

135

300

Excluding water and oil

Transmission

380

840

Excluding oil

Second propeller shaft

Third propeller shaft

Front axle assembly

380

840

Excluding tires and oil

Rear axle assembly

440

970

Excluding tires and oil (Including axle support)

Differentials

105

230

Weight each (Both Front and Rear)

Steering valve (Orbitrol )

Gear pump

Other

GSN bucket

" Z " -Lever

Multiple control valve

Hydraulic system

Remarks

Boom cylinder

55/pc

120/pc

Excluding oil

Bucket cylinder

100

Excluding oil

Steering cylinder

15/pc

35/pc

Excluding oil

Tire

140/pc

310/pc

With rim (16.9-24-10PR); No Hydro Inflation

Battery

35/pc

80/pc

(13)

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 the bolt from the articulation stopper on the rear chassis.

2) Turn rod (1) (articulation stopper) until it comes in contact with pin (2). Insert the pin (2) 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.

1 "LOCKED" position

60ZV US 3652L

2. Storing articulation stopper

Store rod (1) and pin (2) as shown.

"STORED" position

(14)

60ZV US 3652

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

MEMO

CHASSIS GROUP 14 Disassembly and Reassembly Fuel Tank ....................................................................................................14-2 Engine Room ..............................................................................................14-3 Cab .............................................................................................................14-4 Floor Board .................................................................................................14-6 Boom ..........................................................................................................14-8 Center Pin .................................................................................................14-11

14-1

Fuel Tank

50ZV

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 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. Fuel tank

Before starting work: - Drain fuel from the fuel tank. (Fuel tank capacity: 131 (35 Gal.)) - Remove the engine room. - Remove the radiator.

50ZV14001

1) Put a matchmark on fuel hoses (1) and disconnect them from the fuel tank. 2) Disconnect the level sensor electrical line coupler. Fix eye bolt (M12) to the fuel tank and attach sling to fuel tank. Then remove bolt (2) and slowly lower the fuel tank. : Fuel tank: 70 kg (155 lbs) Torque for assembly: : Bolt (4): 436 N-m (44.5 kgf-m) (322 lb-ft)

Rear chassis

Eye bolt

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.

50ZV14002

14-2

Engine Room

50ZV

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 engine key, and hang a "DO NOT START ENGINE !" tag on steering wheel. Before starting work: - Remove the brake oil tank together with the hose from the engine room. Cap off parts of tank to avoid dust ingression. Cap off lines to tank for same reason. 1) Disconnect hose (1) between the air cleaner and the engine. Note: Cover the hose and port of the engine to protect the engine from dust and dirt.

50ZV14003J

2) Remove bolts (2) (3) from the engine room. Torque for assembly: : Bolt (2) (3): 94 N-m (9.6 kgf-m) (69 lb-ft) 2

2 Sleeve 60ZV14003 60ZV14004J

3) Suspend the engine room with a sling. : Engine room: 155 kg (340 lbs) Note: Slowly lift the engine room while checking that there are no obstacles.

2. Reinstalling engine room For reinstallation, follow the above procedure in the reversed direction. 14-3

Cab

50ZV

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 parking brake. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel. 4

Before starting work: - Remove the deck both right and left side. - Disconnect the electrical line coupler

1) Remove covers (1) (2). 2) Remove steps (3) (4). 3 1

60ZV14006J

3) Remove cover (5)

60ZV14007J

4) Remove cover (6) and remove bolts (7) (8). Tilt steering shaft (9) backward. 9 7 8 6

60ZV14004

14-4

Cab

50ZV

CHASSIS 14

5) Remove bolts (10) (11). Torque for assembly: : Bolt (10) (8 pcs): 721 N-m (73.5 kgf-m) (532 lb-ft) Bolt (11) (4 pcs): 231 N-m (23.5 kgf-m) (170 lb-ft)

10 11

Floor board

10 60ZV14005

6) Remove bolts (12). Install eye bolt (M16 x 2.0) on cab. Attach sling and remove cab.

11 Plug

11 Plug Floor board top view

: Cab: 550 kg (1,210 lbs)

2. Reinstalling cab For reinstallation, follow the above procedure in the reversed direction. Note: Fix the air conditioner filter with the tape so that it is not falled down.

14-5

60ZV14006

Floor Board

50ZV

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 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 matchmarks 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.

Pilot valve

2 1

3 60ZV14007

1) Disconnect hoses (1) (2) (3).

2) Disconnect the hose between the Orbitrol ® and the steering cylinder, the hose between the Orbitrol® and the cushion valve and the hose between Orbitrol® and the priority valve. : Hydraulic oil about 0.5 (1/8 Gal.) Note: Cover the disconnected hoses with plastic caps or plug to protect them from dust, water and dirt. 60ZV14012J

14-6

Floor Board

50ZV

CHASSIS 14

3) Disconnect accel. control cable (3) at the engine side.

3 50ZV14004J

4) Remove floor board (4) retaining nut (5). Install eye bolt (M16x2) to floor board at 4 places. Attach sling then gradually lift the floor board while checking that there are no obstacles and that all the pipes, cables, pins, etc. are disconnected. : Including ope. board 340 kg (750 lbs) air conditioner, seat, etc. Torque for assembly : : Nut (5): 230 N-m (23.5 kgf-m) (170 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.

60ZV14014J

14-7

Boom

50ZV

CHASSIS 14

Boom Removing and reinstalling boom

WARNING

1. Removing boom

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 pins (2) (3) for bucket (1) to remove the bucket. : Bucket: 435 kg (960 lbs) Note: There are shims in the pin sections. Carefully store removed shims, and correctly reinsert shims when reinstalling bucket. 2) Remove connection pin (6) from rod (4) and lever (5).

: Link: 22 kg (50 lbs)

3 1

6 4 2 60ZV14015J

3) Attach sling to bucket cylinder (7), and then remove connection pin (8) from lever (5) and bucket cylinder (7).

: Bucket cylinder: 45 kg (100 lbs) 5

CAUTION Before removing the connecting pin, hold the lever with a rope not to tilt the end of the lever. 60ZV14016J

14-8

Boom

50ZV

CHASSIS 14

4) Lift bucket cylinder (7) on the rod side. Apply a cable from the cab hoisting point to the bucket cylinder, and then temporarily turn up the cylinder.

CAUTION - To temporarily turn up the bucket cylinder, check that the cylinder angle is 90° or less. Further tilting may cause the cylinder to overturn onto the cab. - You have to work on the machine to turn up the bucket cylinder. Carefully check your step on the machine.

60ZV14017J

5) Attach sling to lever (5), and then remove lever pin (9). 5

: Lever : 120 kg (265 lbs)

65ZV14024J

6) Start the engine. Lift boom (10) until it is horizontal, and then place stand (A) to support the bottom of the boom. Attach sling to boom cylinders (11), and then remove pins (12) from the cylinder rods on both the right and left sides of the boom.

10 12

CAUTION Stop the engine when the boom is approximately 30 cm above the stand (A). Set the boom lever to the boom down position to lower the boom onto the stand (A). Depress the hydraulic oil tank cap and open it to release the internal pressure.

14-9

65ZV14025J

Boom

50ZV

CHASSIS 14

7) Attach sling to cross pipe of boom (10), and then remove pins (13) from the boom on both the right and left side. Note: The pin sections are adjusted (to 1.2 mm or less clearance) using liners. Do not lose the liners during the service work.

8) Slowly lift boom (10) to remove it from machine. : Boom: 490 kg (1,080 lbs)

10 13

60ZV14018J

WARNING Loss of control of the boom structure during removal or installation may 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: Be sure to adjust the clearance of the retainer pin sections using the liners. After reinstallation, grease the boom pins, and then operate boom. During operation, check the boom for abnormal noise.

14-10

Center Pin

50ZV

CHASSIS 14

Center Pin Upper center pin

Lower center pin

50ZV14003

T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 319 N-m (32.5 kgf-m) (235 lb-ft) (with lubricating oil (Engine oil or gear oil)) 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.

14-11

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

50ZV

CHASSIS 15

Linkage mm (in) 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

ø50 ø70 (1.97) (2.75)

4. Front chassis - Boom

ø55 (2.16)

5. Bucket - Rod

6. Lever - Rod

ø60 ø60 (2.36) (2.36)

ø55 (2.16)

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

ø55 (2.16)

ø50 (1.97)

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

ø35 (1.38)

50ZV12001

9 2

11 5

50ZV12006

15-2

Linkage Pin Standard Clearance Values

50ZV

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

ø50 (ø1.97)

0.167 ~ 0.211 (0.0066 ~ 0.0083)

1.0 (0.0393)

Replacement

∗

Joint section between boom and lever

ø70 (ø2.75)

0.224 ~ 0.276 (0.0088 ~ 0.0109)

1.0 (0.0393)

Replacement

Joint section between boom and boom cylinder

ø55 (ø2.16)

0.167 ~ 0.211 (0.0066 ~ 0.0083)

1.0 (0.0393)

Replacement

∗∗

Joint section between front chassis and boom

ø55 (ø2.16)

0.167 ~ 0.211 (0.0066 ~ 0.0083)

1.0 (0.0393)

Replacement

∗

Joint section between bucket and rod

ø60 (ø2.36)

0.202 ~ 0.251 (0.0080 ~ 0.0099)

1.0 (0.0393)

Replacement

∗

Joint section between lever and rod

ø60 (ø2.36)

0.202 ~ 0.251 (0.0080 ~ 0.0099)

1.0 (0.0393)

Replacement

∗

Joint section between lever and bucket cylinder

ø50 (ø1.97)

0.167 ~ 0.211 (0.0066 ~ 0.0083)

1.0 (0.0393)

Replacement

∗

Joint section between bucket cylinder and front chassis

ø50 (ø1.97)

0.167 ~ 0.211 (0.0066 ~ 0.0083)

1.0 (0.0393)

Replacement

Joint section between boom cylinder and front chassis

ø55 (ø2.16)

0.167 ~ 0.211 (0.0066 ~ 0.0083)

1.0 (0.0393)

Replacement

∗

Joint section between front chassis and steering cylinder

ø35 (ø1.38)

0.135 ~ 0.172 (0.0053 ~ 0.0068)

1.0 (0.0393)

Replacement

∗

Joint section between steering cylinder and rear chassis

ø35 (ø1.38)

0.135 ~ 0.172 (0.0053 ~ 0.0068)

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 2.8 mm, adjust using liner of 2.8 mm thickness. 70ZV15001

15-3

Center Pin

50ZV

CHASSIS 15

Center Pin Shim adjustment The clearance between the front chassis and bearing cover (#3) is 0.5±0.5 mm (0.02±0.02 in) before shim adjustment. Add shims (#5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in). After that, tighten bolt (#10). #9: 319 N-m (32.5 kgf-m) (235 lb-ft) (with lubricating oil (Engine oil or gear oil)) #10: 230 N-m (23.5 kgf-m) (170 lb-ft)

3 5

Front chassis 6 7

11 2

Rear chassis 50ZV12004

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

15-4

65ZV15001

Bucket Positioner and Boom Kick-Out

50ZV

CHASSIS 15

Bucket Positioner and Boom Kick-Out

Bucket positioner

60ZV15003

15(0.6 in.)

5±2(0.2±0.09 in.)

2.2(0.09 in.)

Bucket positioner

✽

Plate Plate

Indicator lamp direction

Proximity switch 60ZV15005

15-5

Bucket Positioner and Boom Kick-Out

50ZV

CHASSIS 15

Unit : mm Item

No.

Judgment standard

Solution

5 ± 2 (0.196 ± 0.078 in.)

Adjustment

Clearance of bucket positioner switch

Adjusting plate mounting bolt tightening torque

90 N-m (9.15 kgf-m) (66 lb-ft)

Tightening

Switch mounting nut tightening torque

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

Tightening

Bucket positioner adjustable angle

-7° ~ 7°

Adjustment

Bucket positioner adjustable angle

-7°

0°

+7° 60ZV15004J

15-6

POWER GROUP 24 Disassembly and Reassembly Power Line ..................................................................................................24-2 Radiator ......................................................................................................24-3 Engine .........................................................................................................24-6 Propeller Shaft ............................................................................................24-8 Air Cleaner ..................................................................................................24-9 Muffler .......................................................................................................24-10 Axle Assembly ..........................................................................................24-11 Front Axle Assembly .................................................................................24-12 Rear Axle Assembly .................................................................................24-26 Axle Support .............................................................................................24-30 Differential Assembly ................................................................................24-31

24-1

Power Line

50ZV

POWER 24

Power Line Tightening torque

T1 L 3

T3 L 3

T2 L 3 T3 L 3 T4 L 1

T5 L 1

T9 L 2 Rear differential T3 L 3

T4 L 1 T8 L 2 T7 L 2

Third propeller shaft T6 L 2

50ZV24001

Front differential

: Bolt tightening torque T1: 44 N-m (4.50 kgf-m) ( 33 lb-ft) T2: 53 N-m (5.40 kgf-m) ( 39 lb-ft) T3: 417 N-m (42.5 kgf-m) (307 lb-ft) T4: 94 N-m (9.55 kgf-m) ( 69 lb-ft) T5: 132 N-m (13.5 kgf-m) ( 98 lb-ft) T6: 80 N-m (8.15 kgf-m) ( 59 lb-ft) T7: 230 N-m (23.5 kgf-m) (170 lb-ft) T8: 142 N-m (14.5 kgf-m) (105 lb-ft) T9: 137 N-m (14.0 kgf-m) (101 lb-ft)

Second propeller shaft

L1: Screw lock agent (Loctite® 262) application L2: Screw lock agent (Three Bond 1327) application L3: With lubrication oil (Engine oil or gear oil) Always replace drive shaft bolts with new bolts – Never reuse.

IMPORTANT Always use appropriate locking agents on drive lines or drive line damage will result.

24-2

Radiator

50ZV

POWER 24

Radiator Tightening torque

B Fan center D

C B A

Crank center

T1 L 3

A-A

T1 L 3

B-B

C-Detail

D-Detail

50ZV24002

: Bolt tightening torque T1: 94 N-m (9.55 kgf-m) (69 lb-ft)

L3: With lubrication oil (Engine oil or gear oil)

24-3

Radiator

50ZV

POWER 24

Removing and reinstalling radiator 1. Removing radiator

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

Before starting work: - Remove the engine room (Refer to Chassis group.) 1) Remove drain plug (1) to drain the coolant. : Coolant: 8 (2.1 gal.)

2) Disconnect coolant hose (2) (3) from the radiator. Note: Cover the disconnected hose with caps to protect hoses from dust and dirt. 4

3) Remove radiator guard (4).

4) Remove plate (5). Torque for assembly: : Bolt: 94 N-m (9.55 kgf-m) (69 lb-ft) : With lubricating oil (Engine oil or gear oil) Bolt (Radiator side) 5) Attach sling to radiator (6). Remove right and left retainer bolts (7). : Radiator: 135 kg (300 lbs) Torque for assembly: : Retainer bolt (7): 94 N-m (9.55 kgf-m) (69 lb-ft) : With lubricating oil (Engine oil or gear oil)

1 50ZV24003J

24-4

Radiator

50ZV

POWER 24

6) Lift the radiator about 10 cm (4 in.) and then disconnect transmission cooler hoses (8) (9). : Engine oil (or ATF): 0.5

(0.13 Gal.)

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

9 60ZV24003

7) Remove radiator (6) from the rear chassis.

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

24-5

Engine

50ZV

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 (with the air cleaner). (Refer to Chassis Group). b) Recover the air conditioner refrigerant (option) using the proper recovery method. c) Remove the radiator. 1) Disconnect the negative side of the battery cable. 2) Disconnect the wire from all sensors, alternator and air conditioner. 3) Disconnect fuel hose, heater / cooler hose, air compressor wiring and drain hose. 4) Disconnect the accelerator control cable from the engine. 2

5) Remove cover (1) on the torque converter case. Turn the torque converter drive cover slowly, and remove bolt (2) connecting the engine flywheel and the torque converter flexible plate. Torque for assembly: : Bolt (2): 44 N-m (4.50 kgf-m) (33 lb-ft) : With lubrication oil (Engine oil or gear oil) 50ZV24004J

24-6

Engine

50ZV

POWER 24

6) Sling engine to remove engine mounting bolt (3). Slowly lift engine about 100 mm (3.9 in.) while checking that there are no obstacles.

CAUTION Because it is needed to sling engine at an angle when removing, install chain block to radiator side. : Engine assembly: Approx. 395 kg (870 lbs) Torque for assembly: : Bolt (3): 417 N-m (42.5 kgf-m) (307 lb-ft) : With lubricating oil (Engine oil or gear oil)

50ZV24005J

7) Remove bolt (4) connecting torque converter case and engine flywheel housing. Torque for assembly: : Bolt (4): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) 8) Separate engine and transmission from each other, and then lift the engine. Note: Lift engine approximately 100 mm (4 in.). Insert wooden piece of approximately 200 mm (8 in.) thickness into clearance between flywheel bottom and rear axle to separate engine and transmission. Repeat this two to three times to completely separate engine and the transmission from each other. Carefully lift engine while checking that there are no obstacles around it.

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

3. Cautions regarding engine reinstallation - Refill engine with proper quantity and type engine oil. - Refill radiator with premixed coolant (approx 50 % water / 50 % antifreeze, or according to local requirements.). - 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 amount of coolant. - While gradually increasing engine speed, check operation of electrical equipment, and check for leaks. 24-7

50ZV24006J

Propeller Shaft

50ZV

POWER 24

Propeller Shaft Removing and reinstalling propeller shaft

2 3

1. Removing second propeller shaft 1) Remove bolt (2) from transmission side of propeller shaft (1). Torque for assembly: : Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application 2) Remove bolt (3) from pillow unit bearing (4). Torque for assembly: : Bolt (3): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent (Loctite® 262) application 3) Remove bolt (6) to disconnect propeller shaft from front differential (5). Support shaft by cable or rolling floor jack. Take out the second propeller shaft to the front. Torque for assembly: : Bolt (6): 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application : Second propeller shaft: 25 kg (55 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.

1 4

60ZV24004

60ZV24005

2. Removing third propeller shaft 1) Remove bolt (7). Torque for assembly: : Bolt (7): 137 N-m (14.0 kgf-m) (101 lb-ft) : Screw lock agent (Three bond 1327) application 2) Remove the third propeller shaft. : Third propeller shaft: 5 kg (11 lbs)

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.] 24-8

60ZV24006

Air Cleaner

50ZV

POWER 24

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

1) Disconnect air hose (1). 2) While supporting air cleaner case (2) with your hand, remove band retainer bolt (3), and then lower the air cleaner case.

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.

50ZV24007J

Air duct insertion amount and hose band position Hose band Worm gear for hose band should be placed a half turns away from each 2~3 mm other. (0.08-0.12 in.) Fix hose band on convex part of air duct. Air duct ✽Engine side 30 mm (1.2 in.) or more ✽

60ZV24025

24-9

Hose ✽Air cleaner side 35 mm (1.4 in.) or more

Muffler

50ZV

POWER 24

Muffler Removing and reinstalling muffler 3

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 engine is cold enough.

1 Muffler

1) Remove bolt (1) and then remove clamp (2) and exhaust pipe (3). Torque for assembly: : Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft)

50ZV24003

2) Remove cover (4) on the engine roof.

3) Remove bolt (5) and then remove muffler (6). Torque for assembly: : Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft)

50ZV24009J

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.

50ZV24010J

24-10

Axle Assembly

50ZV

POWER 24

Axle Assembly T3 L 3

Tightening torque 1. Front axle

T1 L 1 A

Mating face L2 T2 T5 L 1

2. Rear axle

50ZV24004

Note: Unspecified tightening torque is equal to the one for front axle.

: Bolt tightening torque T1: 314 N-m (32.0 kgf-m) (232 Ib-ft)

T3 L 3

T2: 892 N-m (91.0 kgf-m) (658 Ib-ft) T3: 721 N-m (73.5 kgf-m) (532 Ib-ft) T4: 132 N-m (13.5 kgf-m) ( 98 Ib-ft) T5: 206 N-m (21.0 kgf-m) (152 Ib-ft)

T4 L 3

: L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three bond 1215) application L3: With lubrication oil (Engine oil or gear oil) Preload of section (A): 52~73 N(5.3~7.4 kgf) (11.7~16.3 lbf)

50ZV24012J

24-11

Front Axle Assembly

50ZV

POWER 24

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

Stand Stand 65ZV24018

1) Remove right and left wheel and tire assemblies (1). : 1 Tire: 140 kg (310 lbs) Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

65ZV24029J

2) Remove the retainer bolt (3) for the second propeller shaft (2). Torque for assembly: : Retainer bolt (3): 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Three Bond 1327) application

65ZV24030J

24-12

Front Axle Assembly

50ZV

POWER 24

3) Disconnect air bleeder tube (4) and brake pipes (5). Note: Install plastic caps to protect from dirt entering fittings or pipes.

50ZV24013J

60ZV24019J

4) Attach sling to axle assembly (6), and then remove eight retainer bolts (7). : Axle assembly: Approx. 380 kg (840 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 65ZV24032J

5) Place axle assembly (6) on a carrier or rolling floor jack with special adapter to smoothly pull out the assembly.

24-13

Front Axle Assembly

50ZV

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. Reference Air bleeding procedure Connect a clean vinyl tube to the air bleeder nipple, and place an oil can to receive the oil, or route the 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.

24-14

Front Axle Assembly

50ZV

POWER 24

Disassembling and reassembling front axle 1. Disassembling front axle Before starting work: a) Remove axle assembly from chassis. Refer to "Removing front axle assembly". b) Drain gear oil : Gear oil: 20 (5.3 Gal.) (front, rear each) c) Place axle assembly on work table using support (1) (2).

2 1 65ZV24044J

Sling

1) Attach sling to axle housing (4) and remove bolts (3). Separate axle housing (4) from differential assembly. Note: Striking axle housing lightly by hammer may help to separate it from differential assembly. : Axle housing: 130 kg (290 lbs) 3

WARNING

65ZV24019

Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer may 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.

2) Remove sun gear (5) and disc plate (6). 6

24-15

65ZV24046J

Front Axle Assembly

50ZV

POWER 24

3) Remove steel plate (7). 7

65ZV24047J

4) Attach sling to axle housing (4) and install jig to end.

Jig

65ZV24020

Jig ø18 bar (4 pcs) welded P.C.D. 210 (8.3 in.)

60 (2.4 in.) 220 (8.7 in.)

ø350 (13.8 in.)

100 (3.9 in.)

80 (3.1 in.)

14 (0.6 in.) P.C.D.210(8.3 in.)

Axle shaft 60ZV24021

24-16

Front Axle Assembly

50ZV

POWER 24

5) Remove retainer (8). 8

65ZV24050J

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

10 9

65ZV24051J

7) Remove internal gear (11). Note: When using puller, temporarily install bolt (9) not to damage the axle shaft thread part.

65ZV24052J

8) Attach sling to axle housing (4) and remove it together with bearing (12) from axle shaft.

4 4

Axle shaft

12 50ZV24005

24-17

65ZV24054J

Front Axle Assembly

50ZV

POWER 24

9) Remove axle shaft (13) from jig.

65ZV24055J

10) Remove bearing (14) and oil seal (15) from axle shaft.

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.

24-18

14 15 65ZV24056J

Front Axle Assembly

50ZV

POWER 24

2. Reassembling axle assembly 13

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.

14 15

1) Install jig to axle shaft (13) and insert outer race (A) of oil seal (15) to axle shaft. Note: - Put gear oil to oil seal outer race (A). - Insert race (A) to the place lower than bearing installation end.

65ZV24057J

Inner race (B)

Axle shaft

Outer race (A)

2) Put grease in lips of inner race (B) of oil seal (15). Insert oil seal inner race (B) into axle shaft and then assemble it with oil seal outer race (A).

Bearing installation end

Do not apply any oil here.

Oil seal details Grease

60ZV24010

3) Insert bearing (14) into axle shaft.

WARNING Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer may 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.

4) Assemble axle shaft (13) to axle housing (4). 4

65ZV24059J

24-19

Front Axle Assembly

50ZV

POWER 24

5) Insert oil seal inner race into axle housing.

65ZV24060J

6) Install bearing (12). 16

7) Put shim (16) on end of axle shaft. Shim: T=0.1 mm (0.0039 in), 0.2 mm (0.0079 in), 0.3 mm (0.0118 in), 0.35 mm (0.0138 in), 0.5 mm (0.0197 in), 1.0 mm (0.0394 in)

65ZV24061J

8) Install spider assembly (10) and tighten lock bolt (9).

Bolt (9)

Spider assembly (10) 9 Axle shaft (13) 10

Shim (16)

Taper roller bearing (12)

50ZV24006

9) Measure the preload at section (A) (bolt hole). Preload: 52~73 N (5.3~7.4 kgf) (12~16 lbf) In case the preload is not in correct range, shim adjustment (changing shim) necessary. Repeat step 7) and 8) to get correct preload. Disassemble and reassemble spider assembly for shim adjustment. Refer to "Disassembling and reassembling spider assembly".

65ZV24063J

Spring balance

65ZV24025

24-20

Front Axle Assembly

50ZV

POWER 24

10) When the preload is in correct range, remove lock bolt and spider assembly.

11) Insert one of knock pins (17) and then insert internal gear (11). Insert three knock pins.

11 17 65ZV24065J

12) Install spider assembly (10). Put liquid gasket to lock bolt (9) and tighten it. : 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application

10 8

13) Install retainer (8).

9 65ZV24066J

14) Install steel plate (7) to differential assembly (18).

7 65ZV24067J

15) Install disc plate (6) and sun gear (5). 6

5 65ZV24068J

24-21

Front Axle Assembly

50ZV

16) Install axle housing (4) to the differential assembly.

POWER 24

Bolt

: 206 N-m (21.0 kgf-m) (152 lb-ft) : Screw lock agent (Three Bond 1327) application Liquid gasket (Three Bond 1215) application

WARNING After installing axle housing to differential assembly, when sling is removed, axle assembly may be inclined. Loss of control of axle assembly could result in injury. Put support under axle housing.

Refill gear oil after reassembling. : Gear oil: 20 (5.3 Gal.) Note: Use antichatter oil additive. This is available from the Kawasaki Parts Dept.

24-22

Liquid gasket application

65ZV24026

Front Axle Assembly

50ZV

POWER 24

Disassembling and reassembling spider assembly

1. Disassembling spider assembly 1) Put the spider assembly (1) on wooden blocks.

65ZV24070J

2) Push spring pin (2) into planetary pin (3) using a bar. Spring pin hole dia. ø6 +– 00.12 3) Strike planetary pin (3) out from axle shaft side to differential side.

3 65ZV24071J

4) Remove spring pin from planetary pin (3).

5) Remove planetary gear (4) and thrust washer (5).

5 4 65ZV24072J

24-23

Front Axle Assembly

50ZV

POWER 24

6) Remove needle bearing (6) from planetary gear (4). 4

60ZV24022J

7) Remove washer (7) with shim.

65ZV24074J

2. Reassembling spider assembly

Clean and check all the parts. If a part is worn or damaged, replace it. 1) Apply gear oil to planetary gear (4) and needle bearing (6). Install needle bearing into planetary gear.

60ZV24022J

2) Install washer (7) with shim to spider (1). 7

65ZV24075J

24-24

Front Axle Assembly

50ZV

POWER 24

3) Apply gear oil to planetary gear (4) and thrust washer (5). Install them to spider (1).

4 65ZV24076J

4) Apply gear oil to planetary pin (3). Insert planetary pin (3) into spider to match spring pin holes on both parts.

3 Pin holes

65ZV24027

5) Insert spring pin (2). The spring pin should not jut out from spider. Use a new spring pin.

65ZV24078J

24-25

Rear Axle Assembly

50ZV

POWER 24

Rear Axle Assembly 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.

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

A 60ZV24011

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

60ZV24026

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

Wooden block

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 machine.

65ZV24028

24-26

Rear Axle Assembly

50ZV

POWER 24

4) Remove right and left wheel and tire assemblies (1). : Tire of 1 wheel: Approx. 140 kg (310 lbs) Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb)

60ZV24025J

5) Remove the third propeller shaft retainer bolts (2) to remove propeller shaft. Torque for assembly: : Retainer bolt: 137 N-m (14.0 kgf-m) (101 lb) : Screw lock agent (Three Bond 1327) application

65ZV24037J

6) Disconnect grease pipe (3) both front and rear sides.

60ZV24026J

7) Disconnect air breather tube and brake hose (4).

4 Rear differential 50ZV24007

24-27

Rear Axle Assembly

50ZV

POWER 24

8) Attach sling to rear axle (5), and remove right and left retainer bolts (6) from rear axle support. Lower rear axle (5) on carrier and pull it out.

Torque for assembly: : Retainer bolt: 721 N-m (73.5 kgf-m) (506 lb-ft)

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

65ZV24040J

9) Attach sling to front axle support (7), and remove it from rear axle. The support should slide off rear axle. : Axle support: Approx. 55 kg (120 lbs)

7 65ZV24041J

10) Attach sling to rear support (8) temporarily and remove bolts (9) from plate (10). Remove plate (10). Remove rear support (8). Torque for assembly: : Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Axle support: Approx. 80 kg (175 lbs) Remove and clean breather fitting. When fitting is reinstalled use Liquid gasket (Three Bond 1215) on threads. Place breather fitting on top position. Lubricate after reassembly to be sure grease comes out breather.

8 10

65ZV24042J

11) Remove packing (11). 11

65ZV24043J

24-28

Rear Axle Assembly

50ZV

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 rear axle assembly, refer to "Disassembling and reassembling front axle assembly".

24-29

POWER 24

Axle Support

50ZV

POWER 24

Axle Support Disassembling and reassembling axle support

Grease piping

1. Disassembling axle support (front) 1) Remove packings (2), bushing (3) and packing (4) from axle support (1). Note: To reinsert bushing (3), position large chamfer side of bushing at grease piping hole side, and position end gap of bushing at bottom. Apply enough grease to inner surface of bushing.

4 3 2 1

Front

50ZV24008

Large chamfer

Small chamfer 30°

Bushing section 65ZV24030

2. Disassembling axle support (rear)

1) Remove packings (6) and bushing (7) from axle support (5). Note: To reinsert bushing (7), position large chamfer side of bushing at grease piping hole side, and position end gap of bushing at bottom. Apply enough grease to inner surface of bushing.

7 Grease piping

Front 6

5 50ZV24009

3. Reassembling axle support To reassemble axle support, follow the above procedure in the reversed direction. Note: After reassembly, manually operate axle to check it for abnormal noise and looseness.

24-30

Differential Assembly

50ZV

POWER 24

Differential Assembly T5 L 1

Tightening torque

T1 L 3

(Front differential assembly shown)

4 T3 1

3 2

T5 L 1

T2 L 1

T5 L 1

50ZV24019J

T4 L 1

: Bolt tightening torque T1: 363 N-m (37.0 kgf-m) (268 lb-ft) T2: 206 N-m (21.0 kgf-m) (152 lb-ft) T3: 20 N-m ( 2.0 kgf-m) ( 14 lb-ft) T4: 26 N-m (2.65 kgf-m) ( 19 lb-ft) T5: 132 N-m (13.5 kgf-m) ( 98 lb-ft) : L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three Bond 1215) L3: With lubrication oil (Engine oil or gear oil)

Note: 1) To tighten T1, measure preload of section A. Preload of section A: 16~30 N (1.6~3.1 kgf) (4~7 lbf) Use spacer (1) to adjust preload. 2) Use shim (4) to adjust tooth contact of spiral bevel gears (2) (3). Adjust backlash by nut (5). 3) Press bearing (6) (the ring part to be faced to the pinion) into the pinion and stake the end of the pinion at three points. Caulking(Stake) Bearing Diff. pinion

: Front 105 kg (230 lbs) Rear 108 kg (240 lbs)

Ring part 65ZV24032

24-31

Differential Assembly

50ZV

Disassembling and reassembling differential assembly

POWER 24

1. Disassembling differential assembly Before starting work: - Support differential assembly to prevent it from tilting. 1) Fix remover bolts into brake piston (1). Feed air through brake pipe connecting port, and draw out brake piston.

Remover bolt

CAUTION If extremely high air pressure is applied instantly, piston may spring out unexpectedly. To prevent this, apply low pressure 98~196 kPa (1~2 kgf/cm2) (14~28 psi) and install stopper.

2) Remove differential carrier cover (2).

65ZV24033

50ZV24020J

3) Lift differential cage lightly by lifting tool A .

45(1.8) 12(0.5)

mm(in.)

20 (0.8) ø11 (0.4)

Width across flat 10

M10x1.5

70(2.8)

15 (0.6)

28(1.1) 320(12.6)

11(0.4)

Nut

ø13(0.5)

18(0.7) 7(0.3) 2(0.08)

ø20(0.8)

t9 (0.4)

65ZV24083J

67(2.6)

33 (1.3)

70(2.8)

140(5.5)

14 (0.6)

Material SS41

30 11 (1.2) (0.4) abt 10 °

t6(0.2) 38 (1.5) 60ZV24027

Lifting tool A 24-32

Differential Assembly

50ZV

POWER 24

4) Remove bolts (4) and bearing carrier (5) (both right and left sides). 4

5 65ZV24085J

5) Remove differential cage (6) from differential carrier (7). Refer to "Disassembling and reassembling differential cage". 6 7

65ZV24086J

6) Remove bolts (8) and then remove pinion assembly (9) from differential carrier. Refer to "Disassembling and reassembling pinion assembly".

Tap for remover bolt 8 9

60ZV24014

24-33

Differential Assembly

50ZV

POWER 24

2. Reassembling differential assembly

IMPORTANT

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

1) Install differential cage (6) into differential carrier (7).

65ZV24088J

2) Install pinion assembly (9) to differential carrier (7). Note: Match holes of differential cage, differential carrier and shims. Torque for assembly: : Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Three Bond 1327) application

8 9

60ZV24041J

3) Place differential carrier side ways.

Differential carrier 50ZV24015

4) Install O-ring (10) to differential carrier. Note: Apply gear oil to O-ring.

10 65ZV24091J

24-34

Differential Assembly

50ZV

POWER 24

5) Install bearing carrier (5) to differential carrier (7) and tighten bolts (6). Torque for assembly: : Bolt (6): 206 N-m (21.0 kgf-m) (152 lb-ft) : Screw lock agent (Three Bond 1327) application

7 5

65ZV24093J

Insert

6) Install O-ring to brake piston. Note: Apply gear oil to O-ring and install O-ring with no torsion.

O-ring

Piston

65ZV24049

7) Apply gear oil to differential carrier and brake piston (1). Install brake piston (1) to differential carrier. Note: When installing piston, take care not to cut O-ring.

65ZV24095J

24-35

Differential Assembly

50ZV

POWER 24

8) Turn over differential carrier and carry out reassembling on opposite side through the procedure mentioned in foregoing steps 4) to 7).

9) After reassembling, conduct an airtight test for brake piston (on both right and left side).

➀ Install jig B to differential carrier using axle housing installation holes. mm(in.)

65ZV24096J

t=16

40 (1.6)

ø18(0.7)

P.C.D.330(13.0) P.C.D.254(10.0)

ø210(8.3)

25(1.0) ø390(15.4)

ø290(11.4)

120° Material SS41

Jig B

60ZV24023

➁ Feed air pressure at about 588 kPa (6 kgf/cm2) (85 psi) through brake pipe connecting port C.

➂ Splash soapy water over brake piston (1) and air bleeder nipple and then check for air leak. ➃ If no air leaks from each check point, stop air feeding and loosen air bleeder nipple to discharge air. ➄ If brake piston leaks air, remove piston, replace Oring with a new one, carry out the operation in the foregoing steps 4) to 8) and then conduct an airtight test. ➅ If there' s no leak, remove jig and push in brake piston completely. Note: If brake piston is insufficiently pushed in, axle housing cannot be attached. Be careful to push it in.

24-36

C 65ZV24098J

Differential Assembly

50ZV

10) Turn differential carrier (7) with the cover attached side upward and hold the differential carrier by supports to prevent it from tilting. 11) Adjust the backlash. ➀ Remove lock plate (11). (on both the right and left sides) ➁ Tighten adjusting nut (12) on the ring gear side until the backlash is reduced down to zero, and then loosen the nut by 2 to 3 notches. ➂ Tighten adjusting nut (13) on the opposite side until you feel a touch, and then tighten the nut further by one notch. ➃ Attach the dial gauge stand to the carrier, fit the dial gauge to the tooth surface of ring gear (14), and read the value of backlash.

POWER 24

65ZV24099J

Adjusting nut 12

Ring gear

Bolt

Shim

➄ Adjust the backlash to the standard value of 0.20 to 0.28 mm. (0.007~0.011 in) - Loosening the nut on the ring gear side and tighten that on the opposite side will increase the backlash. - Tightening the nut on the ring gear side and loosening that on the opposite side will decrease the backlash.

Bolt

Lock plate 11

Adjusting nut 13

50ZV24011

12) Check for the tooth contact. ➀ If the normal tooth contact is not obtained. Adjust the thickness of shims at the pinion assembly attached part and the backlash to make it normal, referring to the item of "Adjusting tooth contact". Thickness of shims: 0.075, 0.10, 0.25, 0.50, 0.80 mm (0.0029, 0.0039, 0.0098, 0.0196, 0.0314 in) Note: When adjusting with shims, match the holes of the carrier cage, the differential carrier and the shims to each other. 13) Mount lock plate (11), and then tighten the bolts to fix the lock plate. : Retainer bolt: 26 N-m (2.7 kgf-m) (20 lb-ft) : Screw lock agent (Three Bond 1327) application

65ZV24101J

14) Install differential carrier cover (2).

65ZV24102J

24-37

Differential Assembly

50ZV

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

24-38

Differential Assembly

50ZV

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.

24-39

Differential Assembly

50ZV

POWER 24

Disassembling and reassembling differential assembly

1. Disassembling differential cage Note: Before starting work, put a matchmark on the alignment point of the differential cage. 1) Remove bolts (1) and then remove ring gear (2). Torque for assembly: : Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Three Bond 1327) application

Matchmark

1 3 65ZV24039

2) If bearing (3) is damaged, remove the bearing.

3) Remove bolts (4) and separate the cage. Torque for assembly: : Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Three Bond 1327) application

Matchmark

65ZV24040

65ZV24105J

24-40

Differential Assembly

50ZV

POWER 24

4) Remove spider (5), differential pinion (6), side gear (7) and thrust washer (8) from the differential cage.

Thrust washer

Diff. cage

6 5 7 8 8 7 60ZV24016

2. Reassembling differential cage To reassemble the differential cage, follow the above procedure in the reversed direction. Note: - Clean and check all the parts. If a part is worn or damaged, replace it with new one. - Apply gear oil to the parts before reassembling. - Warm bearing (3) in a oil bath up to 120~150 °C (248~302 F°) before installation.

24-41

Differential Assembly

50ZV

POWER 24

Disassembling and reassembling differential assembly 1. Disassembling pinion assembly

1) Remove bolts (1) from the differential carrier.

65ZV24107J

2) Install removing bolt (2) and remove the pinion assembly from the differential carrier. The pinion retainer bolt (1) can be used for removing bolt (2) (M12x1.75).

60ZV24043J

3) Install the pinion assembly to working jig A (for front diff.) and fix it with a vise. Remove nut (3), square ring (4) and flange yoke (5). t =12

80(3.1)

43 (1.7)

A ø12 (0.5)

65ZV24109J

90(3.5)

89(3.5)

40 (1.6)

160(6.3)

170(6.7) 60(2.4)

4 70(2.8)

170(6.7)

5 Material SS41

Jig A 50ZV24013

7 50ZV24024J

24-42

Differential Assembly

50ZV

POWER 24

4) Remove pinion gear (6) and pinion cage (7) together. Tap pinion gear (6) out of pinion cage (7) with a plastic hammer.

50ZV24025

5) Remove oil seal (8), spacer (9) and taper roller bearing (10) from pinion cage (7).

8 9

6) Remove spacer (11). Remove taper roller bearing (12) and roller bearing (13) from the pinion, using the bearing puller. Note: Do not remove them unless they should be replaced.

50ZV24026

12 11

65ZV24114J

24-43

Differential Assembly

50ZV

POWER 24

2. Reassembling pinion assembly 1) Warm roller bearing (13) in oil up to 120 to 150 °C (248~302 °F) and install it to the pinion. After bearing cools, stake the pinion's end at three points.

Caulking (stake)

65ZV24046

2) Install taper roller bearing (12) to the pinion and fit spacer (11) thereto.

12 11

65ZV24116J

3) Fit taper roller bearing (10) and spacer (9) orderly into the pinion cage. Note: Do not install the oil seal. The oil seal should be installed after the preload of the bearing is adjusted.

Oil seal

Pinion cage 50ZV24014

4) Install flange yoke (5) to jig and fix it with a vise.

65ZV24119J

24-44

Differential Assembly

50ZV

POWER 24

5) Install pinion cage (7) to flange yoke (5) and then install O-ring (14).

65ZV24120J

6) Install pinion gear (6) to pinion cage (7).

65ZV24121J

7) Install square ring (4) and nut (3) to the pinion gear. 4 3

65ZV24122J

8) Tighten the nut. Tightening torque: 363 N-m(37 kgf-m)(268 lb-ft)

65ZV24123J

24-45

Differential Assembly

50ZV

9) Measure the preload. Standard: 16~30 N (1.6~3.1 kgf) (4~7 lbf) If the measured preload exceeds the standard range, make an adjustment by replacing spacers. Spacer: T=14.68~15.08 (0.5780~0.5937 in) (23 pieces at 0.02 pitch) (0.0007 in) Thicker spacers reduce preload ;thinner spacers increase preload.

POWER 24

"Fish scale" tool for measuring preload.

60ZV24028

10) After adjusting the preload, remove the nut and detach the flange from the pinion cage. Install the oil seal to the pinion cage. : Liquid gasket (Three bond 1215) application

11) Install the flange yoke to the pinion cage and tighten the fixing nut. : Nut: 363 N-m (37 kgf-m) (268 lb-ft) : Liquid gasket (Three Bond 1215) application Nut width across flat: 38.1 mm (1.50 in.)

24-46

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

25-1

Propeller Shaft Service Standard

50ZV

POWER 25

Propeller Shaft Service Standard

Third propeller shaft

2 Measurement of circumferential play

3 Measurement of transverse play Second propeller shaft 60ZV25001

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

25-2

Axle and Differential Service Standard

50ZV

POWER 25

Axle and Differential Service Standard Axle assembly

50ZV25001J

Unit : mm (in.) Judgment standard Item

No.

Solution Standard dimension

Tolerance

Backlash between sun gear and planetary gear

0.112 ~ 0.488 (0.0044 ~ 0.0192)

←

Replacement

Backlash between planetary gear and internal gear

0.16 ~ 0.66 (0.0063 ~ 0.0260)

←

Replacement

Clearance between spider pin and pin hole

0.0 ~ 0.036 (0.0 ~ 0.0014)

0.1 (0.0394)

Replacement

Clearance between spider pin and needle bearing

0 ø40 -0.011 0 (ø1.6 -0.0004)

←

Replacement

Tooth contact of gear

No abnormality

25-3

Replacement

Axle and Differential Service Standard

50ZV

POWER 25

Differential 3

50ZV25002J

Unit : mm (in.) Judgment standard Item

No.

Solution Standard valve

Tolerance

Backlash between ring gear and drive pinion

0.20 ~ 0.28 (0.0079 ~ 0.0110)

←

Adjustment

Backlash between side gear and pinion gear

0.23 ~ 0.45 (0.0091 ~ 0.0177)

←

Adjustment

Clearance between pinion gear and spider

0.013 ~ 0.038 (0.0005 ~ 0.0015)

←

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 ........................................................................34-9 Transmission Assembly.............................................................................34-13 Clutch Pack................................................................................................34-19 Control Valve Assembly.............................................................................34-21

34-1

Torque Converter and Transmission Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly Tightening torque

T1 L 3

T3 L 3

T2 L 3 T3 L 3 T4 L 1

T5 L 1

T9 L 2 Rear differential T3 L 3

T4 L 1 T8 L 2 T7 L 2

Third propeller shaft T6 L 2

50ZV24001

Front differential

Second propeller shaft

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

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

34-2

Torque Converter and Transmission Assembly

50ZV

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 front plate. - 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 thoroughly cleaned or replaced. - Lines to cooler must also be replaced. 1) Remove drain plug (1) to drain the transmission oil. : Transmission oil: 20

(5.3 Gal.)

2) Disconnect hose for the transmission oil level gauge. Note: Cover the disconnected hose with plastic cap to protect the hose from dust and dirt.

60ZV34001J

Oil pump

3) Remove oil pump suction pipe (2). Note: Cover the disconnected pipe with plastic caps to protect the pipe from dust and dirt.

2 60ZV34001

34-3

Torque Converter and Transmission Assembly

50ZV

4) Remove hoses (3) (4) from hydraulic pump. Remove bolts (5) and then remove hydraulic pump assembly. Tightening torque for assembly: : Bolt: 90 N-m (9.15 kgf-m) (66 lb-ft) Note: After removing the pipes and hoses, plug or cover the disconnected parts with clean vinyl to protect from dust and dirt.

TORQUE CONVERTER AND TRANSMISSION 34

Oil pump

: Hydraulic pump assembly: 5 kg (11 lbs) Note: Be sure to replace the gasket of the hydraulic pump flange with a new one.

Priority valve

60ZV34002

5) Disconnect hose (6) between torque converter pump and the line filter. Note: Cover the disconnected hose with plastic caps to protect the hose from dust and dirt.

Boost master

6) Disconnect hoses (7) (8) between the torque converter and the oil cooler. Note: Cover the disconnected hose with plastic cap to protect the hose from dust and dirt.

7) Disconnect hose (9) between boost master and line filter and hoses (10) (11) between boost master and transmission. Note: Cover the disconnected hoses with plastic cap to protect the hoses from dust and dirt.

9 60ZV34003

34-4

Torque Converter and Transmission Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

8) Disconnect hoses (12) between boost master and brake oil tank. Brake oil tank 12

Boost master

60ZV34004

9) Disconnect electric wire coupler (13) for the solenoid valve on the control valve.

Control valve

60ZV34005

10) Remove bolts (14) from the second propeller shaft on the transmission side only. Tightening torque for assembly: : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327)

60ZV34006

11) Disconnect bolts (15) from the third propeller shaft 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 bolt once heated. : Bolt: 137 N-m (14.0 kgf-m) (101 lb-ft) : Screw lock agent application (Three Bond 1327) 34-5

3rd propeller shaft 60ZV34007

Torque Converter and Transmission Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

12) Attach sling to the transmission assembly and then loosen bolts (16). Remove the bolt (17). Tightening torque for assembly: : Bolt: 417 N-m (42.5 kgf-m) (307 lb-ft) : Transmission assembly: 400 kg (880 lbs)

60ZV34008

13) Insert wooden pieces (18) into the clearance between the bottom of the engine flywheel housing and the rear axle housing. 18

60ZV34009

14) Remove the cover (19) on the torque converter case. Remove bolts (20) connecting the torque converter flexible plate and the engine flywheel. Remove bolts (21) connecting the torque converter case and the flywheel housing. Tightening torque for assembly: : Bolt (20): 44 N-m (4.50 kgf-m) (33 lb-ft) Bolt (21): 53 N-m (5.40 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

50ZV34001

15) Pull the transmission assembly straight out approximately 100 mm (4 in.) to the front then slowly lift it.

CAUTION Slowly lift the transmission assembly while checking that there are no obstacles.

34-6

Torque Converter and Transmission Assembly

50ZV

2. Reinstalling torque converter and transmission assembly To reinstall the torque converter and transmission assembly, follow the above removal procedure in the reverse direction. After reinstallation, check operation of the transmission assembly by the following procedure.

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, be sure to stop engine, and block 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.

34-7

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly

DATE:

HOURS:

50ZV

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/cm ) (psi)

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.

34-8

Torque Converter Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter Assembly

(Kawasaki CT110J01)

Bolt tightening torque

T5 35T

L1 58~74 N-m (5.9~7.5 kgf-m) (43~54 Ib-ft)

52T

T3 L1

41T

1st

31T

27T

T5 32T

61T 46T

2nd 46T

27T

22T

49T

42T

T5 3rd

T2 42T

: Bolt tightening torque T1: 28 N-m (2.85 kgf-m) ( 21 lb-ft) T2: 53 N-m (5.40 kgf-m) ( 39 lb-ft) T3: 216 N-m (22.0 kgf-m) (159 lb-ft) T4: 34 N-m (3.50 kgf-m) ( 25 lb-ft) T5: 69 N-m (7.00 kgf-m) ( 51 lb-ft)

L1 T3

L1: Screw lock agent (Loctite® 262) application

60ZV34026

34-9

Torque Converter Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling torque converter assembly 1. Disassembling torque converter assembly Before starting work: - Clean the transmission assembly. - Drain oil from the transmission. 1) Remove bolt (1) and then remove pipe (2). Tightening torque for assembly: : Bolt: 69 N-m (7.00 kgf-m) (51 lb-ft)

2) Remove hose (3).

For jack screw For jack screw

3) Remove bolt (4) connecting torque converter housing and transmission housing. Separate torque converter housing and transmission housing by using jack screw (M10x1.5). Tightening torque for assembly: : Bolt: 69 N-m (7.00 kgf-m) (51 lb-ft)

4) Lift torque converter housing (5) slowly. : Torque converter assembly: 190 kg (420 lbs) Note: Use a transmission stand to securely mount the transmission in its place while performing repairs.

60ZV34011

60ZV34012

34-10

Torque Converter Assembly

50ZV

5) Remove bolt (6). Tightening torque for assembly : : Bolt: 58~74 N-m (5.9~7.5 kgf-m) (43~54 lb-ft) : Screw lock agent application (Loctite® 262)

TORQUE CONVERTER AND TRANSMISSION 34

8 A

6) Remove flexible plate (7) and pilot boss (8).

60ZV34015J

7) Remove snap ring (9) and washer (10). Remove shims (11) (12) (13). 9 10 11, 12, 13 B

A-Detail 60ZV34013

Note: Adjust the clearance B using shims (11) (12) (13) as to be 0~0.2 mm (0~0.008 in.) when assembling.

8) Remove impeller assembly (14) from torque converter housing.

60ZV34017J

34-11

Torque Converter Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

9) Remove bolt (15). Tightening torque for assembly: : Bolt: 28 N-m (2.85 kgf-m) (21 lb-ft)

18 19

10) Remove cover (16). 22

Note: When reassembling, replace oil seal (17) and O-ring with new ones.

21 60ZV34018J

11) Remove ring (18).

12) Tap turbine shaft (19) lightly by plastic hammer. Remove it with gear (20) and bearing (21) from torque converter case.

13) Remove ring (22).

2. Reassembling torque converter assembly To reassemble the torque converter assembly, follow the above procedure in the reversed direction. Before starting work: - Clean and check all the parts. If a part is worn or damaged, replace it with a new one. - Before reassembly, apply transmission oil to the parts. - Be sure to replace O-rings and seals with new ones. - Install new bearing if replacement is needed. After reassembling, make sure to rotate the drive cover by hand.

65ZV34005

34-12

Transmission Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly

(Kawasaki CT110J01)

Bolt tightening torque

T5 35T

L1 58~74 N-m (5.9~7.5 kgf-m) (43~54 Ib-ft)

52T

T3 L1

41T

1st

31T

27T

T5 32T

61T 46T

2nd 46T

27T

22T

49T

42T

T5 3rd

T2 42T

L1 T3

L1: Screw lock agent (Loctite® 262) application

60ZV34026

34-13

Transmission Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling transmission assembly 1. Disassembling transmission assembly Before starting work: - Clean the transmission assembly.

1) Remove bolt (1) and then remove pipe (2). Tightening torque for assembly: : Bolt: 69 N-m (7.00 kgf-m) (51 lb-ft)

Hose

For jack screw For jack screw

2) Remove hose.

1 60ZV34014

42T

49T

4) Remove snap ring (5) (6) (7) on each bearing outer race.

5) Temporarily install end cover (3) on transmission case with bolt (4) 3~4 pcs. Note: This prevents shafts and bearings fall down when transmission case is turned upside down.

34-14

27T

31T

46T

42T

3rd

2nd

22T

61T

32T

1st

3) Place transmission assembly as end cover (3) faces up side. Remove bolt (4). Remove end cover (3) by using jack screw (M10x1.5). Tightening torque for assembly: : Bolt: 69 N-m (7.00 kgf-m) (51 lb-ft)

60ZV34020J

Transmission Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

6) Place transmission assembly as illustrated. Remove bolt (8) connecting torque converter housing and transmission housing. Separate torque converter housing and transmission housing by using jack screw (M10x1.5).

Tightening torque for assembly: : Bolt: 69 N-m (7.00 kgf-m) (51 lb-ft)

7) Lift torque converter housing (9) slowly. : Torque converter assembly: 190 kg (420 lbs)

60ZV34025

8) Install eye bolt (M16x2) in R&1st clutch shaft end and lift it slowly. : R&1st clutch: 28 kg (65 lbs)

60ZV34022J

9) Lift F&2nd clutch shaft and 3rd clutch shaft at the same time using special jig.

Jig

: F&2nd and 3rd clutch: 60 kg (135 lbs)

60ZV34015

34-15

Transmission Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

10) Place transmission case as end cover (3) faces up side. 3 4

11) Remove bolt (4) and then remove end cover (3).

12) Place transmission case as illustrated.

60ZV34029J

13) Remove bolt (10).

17 12

Tightening torque for assembly : : Bolt: 216 N-m (22.0 kgf-m) (159 lb-ft) L1: Screw lock agent application (Loctite® 262)

14) Remove brake cover (11).

16 15 18

60ZV34029J

15) Remove bolt (12) and then remove brake assembly (13). Tightening torque for assembly: : Bolt: 53 N-m (5.40 kgf-m) (39 lb-ft) 16) Remove bolt (14) and then remove speedometer case (15). Tightening torque for assembly: : Bolt: 69 N-m (7.00 kgf-m) (51 lb-ft) 17) Remove speedometer drive gear (16) and ball (17) from output shaft. 18) Remove snap ring on bearing outer race and then remove bolt for shroud. Tightening torque for assembly: : Bolt: 34 N-m (3.50 kgf-m) (25 lb-ft)

19) Tap output shaft (19) lightly to rear side then remove shroud (18). 60ZV34025J

20) Tap output shaft (19) more to rear side. 34-16

Transmission Assembly

50ZV

2.Reassembling transmission assembly To reassemble the transmission assembly, follow the above procedure in the reversed direction. Before reassembling - Clean and check all the parts. If a part is worn or damaged, replace it with a new one. - Before reassembly, apply transmission oil to the parts. - Be sure to replace O-rings and seals with new ones. - Install new bearing if replacement is needed.

Cautions for installation - When installing oil seal apply lithium grease to inner lip. - When installing O-ring, apply lithium grease to O-ring. Apply grease to the shaft seal ring groove before installing seal ring.

IMPORTANT Make sure to rotate the shaft by hand during assembly and after assembly . If it is hard to rotate the shaft by hand, disassemble and check the cause.

34-17

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

Special tool Clutch shaft lifting tool (Special tool A) 124

124

ø4

32.4

–

ø60

176.04±0.05

50 57.6

150

(mm)

3 – M10x1.5

100

100 60

ø17 0 ø40 – 0.2

Jig No.1

(t =16)

Jig No.2

ø60

Hexagon socket head cap screw (2 pcs)

: 50

M16 x 2 M10 Eye bolt

ø17 0 ø40 – 0.2

Jig No.3

Clutch (F&2nd) assembly Clutch (3rd) assembly

60ZV34016

34-18

Clutch Pack

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

Clutch Pack Disassembling and reassembling clutch pack Caution 1. Reverse/1st speed clutch pack

Plate(Chamfer on inside dia. faces to the clutch disc)

Outer race press fit

Inner race press fit

Outer race press fit 1ST

Inner race press fit

Washer

60ZV34016

Groove side

2. Forward/2nd speed clutch pack Plate(Chamfer on inside dia. faces to the clutch disc)

Outer race press fit Inner race press fit

2ND

Inner race press fit

Washer Groove side 60ZV34018

34-19

Clutch Pack

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

3. 3rd speed clutch pack Plate(Chamfer on inside dia. faces to the clutch disc)

Inner race press fit Inner race press fit

3RD 60ZV34019

Clutch piston return spring snap ring remover (Special tool B) (mm) φ85

° 60

360

φ72±0.5

40 φ79±0.5

60ZV34027J

34-20

Control Valve Assembly

50ZV

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Assembly Removing and reinstalling control valve

1. Removing control valve

WARNING

Control valve

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 the 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.

60ZV34020

1) Disconnect electric wiring coupler (1) for solenoid valve on the control valve.

2) Remove bolts (2) (3) and the control valve. Tightening torque for assembly: : Bolt (2): 34 N-m (3.5 kgf-m) (25 lb-ft) Bolt (3): 16 N-m (1.6 kgf-m) (12 lb-ft) Control valve

Note: Cover the disconnected parts with vinyl to protect them from dust, water and dirt.

CAUTION When removing/reinstalling the control valve, be sure to protect the attaching face both on the transmission case and the control valve from dust and dirt. 60ZV34021

3) Remove solenoid valve nut (4).

4) Remove solenoid valve (5). Tightening torque for assembly: : Solenoid valve nut: 9.8 N-m (1.00 kgf-m) (7 lb-ft) Solenoid valve: 29 N-m (3.0 kgf-m) (22 lb-ft)

60ZV34022

34-21

Control Valve Assembly

50ZV

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

Cautions for installation 1) Be sure to replace all the O-rings and gaskets with new ones. 2) Sequentially tighten the bolts in the order from center to the outside. Apply equal (specified) torque to all the bolts.

3) During installation, be careful not to damage 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 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. 4) At the completion of installation, start the engine, and check that the shift lever properly functions at all the positions. 5) Check oil leakage. 6) Adjust the transmission oil level to the specified point with the dipstick.

34-22

TORQUE CONVERTER AND TRANSMISSION 34

TORQUE CONVERTER AND TRANSMISSION GROUP 35 Service Standard Clutch Oil Pressure .....................................................................................35-2

35-1

Clutch Oil Pressure

50ZV

TORQUE CONVERTER AND TRANSMISSION 35

Clutch Oil Pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items : - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men. - Prohibit any person from walking into dangerous areas. - Near articulation area of the machine - Under the machine - Around the engine - In front of or behind the machine 1

5 6 9 4 7 2

9 8

60ZV33001

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

Measuring port location

Measuring port size

800

2400

Torque converter inlet pressure

PT1/4

0.1 (1.3) (18) or more

0.3~0.7 (3~7) (43~100)

All speed range

Torque converter outlet pressure

↑

0.1 (1.0) (14) or more

0.15~0.5 (1.5~5) (21~71)

↑

Main oil press.

PF1/4

1.5 (15) (213) or more

1.8~2.1 (18~21) (256~299)

All speed range

PT1/4

1.5 (15) (213) or more

1.8~2.1 (18~21) (256~299)

Shift lever position

Engine revolution (min-1) (rpm)

↑

1ST

↑

2ND

↑

3RD

↑

PT1/8

0.002~0.05 (0.02~0.5) (0.3~7)

0.08~0.2 (0.8~1.7) (11~24)

All speed range

5 6

Clutch oil pressure

Lub. oil pressure

35-2

HYDRAULIC GROUP 44 Disassembly and Reassembly Warning Regarding Removing and Reinstalling ..........................................44-2 Hydraulic Parts Cautions Regarding Disassembly and Reassembly of................................44-3 Hydraulic Parts Hydraulic Pump Assembly...........................................................................44-4 Hydraulic Cylinder........................................................................................44-8 Pilot Valve..................................................................................................44-24 Multiple Control Valve................................................................................44-34 Priority Valve..............................................................................................44-39 Orbitrol® ......................................................................................................44-41 Cushion Valve............................................................................................44-52

44-1

Warning Regarding Removing and Reinstalling Hydraulic Parts

50ZV

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 may be 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 Hydraulic Parts

50ZV

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 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 as so 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 apart.

- 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 the ports so as not to allow foreign material to enter.

44-3

Hydraulic Pump Assembly

50ZV

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.

CAUTION Removing hoses and plugs without bleeding residual pressure could cause injury 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.

1) Remove covers (1) (2). 60ZV44001

2) Disconnect outlet hose (4) and suction pipe (5) from hydraulic pump (3). Note: Cover the disconnected pipe with vinyl, cap or plugs to protect from dust and dirt.

6 4

Torqueconverter

3) Remove hydraulic pump retainer bolt (6) and remove the pump. Torque for assembly: : #6......89.7 N-m (9.15 kgf-m) (66.2 lb-ft) : Hydraulic pump: Approx. 14 kg (31 lbs)

4 60ZV44002

3 5

60ZV44003

44-4

Hydraulic Pump Assembly

50ZV

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 (1 Gal)). Reinstall the plug. 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

50ZV

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 pump first. Check the whole hydraulic circuit and find it's 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 reoccurrence.

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 double and triple pumps which are able to be separated.

44-6

HYDRAULIC 44

Hydraulic Pump Assembly

50ZV

HYDRAULIC 44

1.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

95ZV44002

[Example 2]

Front cover

Drive gear shaft

Oil seal

Snap ring 95ZV44003

44-7

Hydraulic Cylinder

50ZV

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 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

60ZV44004

- 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. With the lever held in down position, lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. 3.Open the cap of the hydraulic tank to vent residual pressure. Leave hydraulic tank cap loosely on top of tank opening.

1 60ZV44003

1) Attach sling to boom cylinder (1). Remove lock bolt (2) and pin (3). Retract the cylinder to shorten piston rod (4). : Boom cylinder: 55 kg (120 lbs) 3

60ZV44113

44-8

Hydraulic Cylinder

50ZV

HYDRAULIC 44

2) Disconnect hoses (5) (6). 1

6 5

60ZV44114

3) Remove lock bolt (7) from retainer pin (8) on the bottom side. Remove pin (8) and then lift boom cylinder(1). For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

60ZV44115

2.Reinstalling boom cylinder To reinstall the boom cylinder, follow the above removal procedure in the reversed direction. Note: Be sure the pins and bushings are clean, free of surface irregularities, and 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 1)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. 2)After that, stroke the cylinder piston fully to both ends 4 to 5 times. 3)Add hydraulic oil to tank, and check cylinder and its piping for oil leakage.

44-9

Hydraulic Cylinder

50ZV

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 boom and bucket on 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. - 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.

1) Remove the coupler of bucket positioner proximity switch (1), and then remove bracket (2). 6 1 60ZV44008

2) Attach sling to bucket cylinder (3). After that, remove lock bolt (4) and pin (5). : Bucket cylinder: 45 kg (100 lbs)

5 4

3) Remove rod (6), for the bucket positioner.

60ZV44009

44-10

Hydraulic Cylinder

50ZV

HYDRAULIC 44

4) Start the engine and retract cylinder to shorten piston rod (7). Stop the engine and disconnect hose (8) (9).

8 9

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

3 7

60ZV44010

6) Disconnect the grease pipe. After that remove lock bolt (10) and pull out pin (11) to remove bucket cylinder (3) .

11 10

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

60ZV44011

44-11

Hydraulic Cylinder

50ZV

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 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 1)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. 2)After that, stroke the cylinder piston fully to both ends 4 to 5 times. 3)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

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

44-12

HYDRAULIC 44

Hydraulic Cylinder

50ZV

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 boom and bucket on ground. - Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line. - Open the cap of the hydraulic tank to relieve the internal pressure from the tank. - Place a "DO NOT START!" tag on the steering wheel or the operator's seat .

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

60ZV44012

1) Disconnect hoses (1) (2). Note: Cover the disconnected hoses with vinyl, cap, or plugs to protect them from dust, water, and dirt. 2) There is pin (5) between front chassis (3) and steering cylinder (4). Remove pin (5), and then push piston rod (6) 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. 3) Remove pin (7) and remove steering cylinder assembly (4). : Steering cylinder: 15 kg (33 lbs) For detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

44-13

Rear

5 6

Front

3 60ZV44013

Hydraulic Cylinder

50ZV

HYDRAULIC 44

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 1)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. 2)After that, stroke the cylinder piston fully to both ends 4 to 5 times. 3)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 could cause injury or death. When turning the steering wheel while engine is running, do not enter the articulation area of the machine. If a person is in the articulation area, do not start the engine.

44-14

Hydraulic Cylinder

50ZV

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

T2 50ZV44001

2) Bucket cylinder T3

T4 3) Steering cylinder T6

: N-m (kgf-m) (lb-ft) T1: 2,157 ( 220) (1,591) T2: 863 ( 88) ( 637) T3: 1,431 ( 148) (1,056) T4: 647 ( 66) ( 477) T5: 16.2 (1.65) ( 12) T6: 392 ( 40) ( 289) T7: 304 ( 31) ( 224) T8: 6.9 ( 0.7) ( 5)

50ZV44002

50ZV44003

Cylinder

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

Boom

60 (2.36) – M39 x 3

Bucket

60 (2.36) – M39 x 2

Steering

41 (1.61) – M24 x 1.5

44-15

Hydraulic Cylinder

50ZV

HYDRAULIC 44

2.Disassembling hydraulic cylinder Note:The bucket cylinder disassembling procedure is described below. For other cylinders, follow the same procedure. Before starting work: a) Remove the hydraulic cylinder from the machine. Remove oil from the cylinder. b) Hold the cylinder tightly in horizontal position. c) Prepare an oil container. d) Prepare wooden blocks. e) Prepare a wrench powered by a hydraulic jack or cylinder.

Pipe Hook wrench 1.5m

1) Loosen the rod cover (1) one or two turns with a hook wrench. 1 60ZV44017

2) Pull the piston rod (2). Note: Make sure all ports are open. : Place an oil container under the port on the rod cover side to catch oil.

Wood block

3) With the piston rod fully extended, unscrew and remove the rod cover from the cylinder tube. Note: Pull the rod horizontally on the wood blocks.

60ZV44018

4) Install the piston rod to the repair stand. Repair stand

1 2

Wood block

View A 60ZV44019

44-16

Hydraulic Cylinder

50ZV

HYDRAULIC 44

5) Loosen the screw and remove the piston nut. The piston nut (piston) is tightened to a specified torque. About 1.5 times torque is required to loosen the nut. Use a wrench powered by a hydraulic jack or cylinder.

Screw

Piston nut width across flat Boom cylinder

60 mm(2.36 in.)

Bucket cylinder

60 mm(2.36 in.)

Steering cylinder

41 mm(1.61 in.) Piston nut 60ZV44020

Bucket cyl.

Steering cyl.

Piston nut

Wrench

Hydraulic jack

Hydraulic cylinder 60ZV44021

6) Remove the piston (4), then the rod cover (1) in this order, from the piston rod. Note: Do NOT let the threads damage the rod seal when removing the rod cover from the piston rod.

Bucket cyl. 2

60ZV44023

Steering cyl.

4 1 60ZV44024

44-17

Hydraulic Cylinder

50ZV

7) Remove the slipper ring (5) and the seal ring assy (6) from the piston (4).

HYDRAULIC 44

Boom cyl.

5 4

60ZV44116

Bucket cyl.

5 4 6 5

60ZV44024

Steering cyl.

4 6 5

8) Remove the wiper ring (8) from the rod cover (1). Remove the O-ring (9), back-up ring (12), O-ring (13), Uring (11), and bushing (10), in this order, from the rod cover. Note: Unless the bushing is damaged or excessively worn, do not remove it.

60ZV44025

10 9 1 13

12 11

60ZV44026

44-18

Hydraulic Cylinder

50ZV

HYDRAULIC 44

3.Reassembling hydraulic cylinder Before starting work: a) Clean the removed parts and apply hydraulic oil to them. b) Check each part, and if necessary, replace it with a new one. c) Replace all seals and O-ring with new ones.

(Reassembling the rod cover) 1) Using a tool, press-fit the bushing (10). Note: Apply grease or hydraulic oil to the rod cover beforehand.

Push Tool

60ZV44027

2) Force the U-ring (11) into the rod cover (1) until a part of the U-ring fits in groove (B).

1 11

60ZV44028

3) Push the opposite side of the U-ring (11) with your fingers until the whole U-ring fits in groove (B). Note: ➀Use a tool (aluminum or plastic) if difficult to push with your fingers. After inserting, push the inner circumference of the ➁ U-ring outward to check the fit in the groove.

Tool

60ZV44029

44-19

Hydraulic Cylinder

50ZV

HYDRAULIC 44

4) Immerse the back-up ring (12) in hot water (30~50 °C (86~125 °F)) for two to three minutes. Install it in the rod cover while stretching it. Note: Cool down the back-up ring so that it shrinks to its original size before proceeding to the next step.

Push while stretching back-up ring

60ZV44030

5) After confirming that the back-up ring (12) has cooled, put the O-ring (13) in the rod cover. Also install the O-ring (9) into the rod cover. Back-up ring

Rod cover

O-ring Pressure side 60ZV44033

60ZV44031

6) Using a press-fit tool, press-fit the wiper ring (8) into the rod cover (1).

Press-fit-tool

60ZV44032

44-20

Hydraulic Cylinder

50ZV

7) Install the slipper ring (5) and the seal ring assy (6) on the piston (4).

HYDRAULIC 44

Boom cyl.

5 4

60ZV44116

Bucket cyl.

5 4 6 5

60ZV44024

Steering cyl.

4 6 5

44-21

60ZV44025

Hydraulic Cylinder

50ZV

8) Install the rod cover (1) and piston (4) on the piston rod (2). Note: Do NOT let the threads damage the seal when installing the rod cover on the piston rod.

HYDRAULIC 44

Bucket cyl. 2

60ZV44023

Steering cyl.

4 1 60ZV44024

9) Install the piston rod (2) to the repair stand.

Repair stand

1 2

Wood block

View A 60ZV44019

10) Tighten the piston nut (piston) to the torque specified below. Piston nut width Tightening torque across flats mm (in.) N-m (kgf-m) (lb-ft) Boom cylinder

60 (2.36)

2,157 (220) (1,591)

Bucket cylinder

60 (2.36)

1,431 (148) (1,056)

Steering cylinder

41 (1.61)

392 ( 40) ( 289)

Piston nut

Wrench

Hydraulic jack

Hydraulic cylinder 60ZV44021

44-22

Hydraulic Cylinder

50ZV

11) Insert the ball (15) and screw in the screw (16). After tightening the screw, caulk the screw (16) at 2 points to prevent the screw coming out.

HYDRAULIC 44

16 15

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

16.2 (1.65) ( 12)

Steering cylinder

6.9 ( 0.7) (5.0) Piston nut Bucket cyl.

Steering cyl. 60ZV44034

(Reinstalling the piston rod) 1) Install the piston rod (2) into the cylinder tube. Note: Do NOT let the threads on the cylinder tube damage the piston seal.

Wood block

60ZV44018

2) Tighten the rod cover (1) to the torque specified below. Tightening torque N-m(kgf-m)(lb-ft) Boom cylinder

863 ( 88) (637)

Bucket cylinder

647 ( 66) (477)

Steering cylinder

304 ( 31) (224)

Hook wrench 1 60ZV44035

44-23

Pilot Valve

50ZV

HYDRAULIC 44

Pilot Valve Removing and reinstalling pilot valve 1

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. Before starting work: - Stop the engine and lower the bucket to the ground. After that move the lever back and forth, left and right and relieve inner pressure from pilot line.

5 60ZV44036

1) Remove knob (1) from the control lever.

2 4 6

2) Remove screw (2) and pull out boot (3) and plate (4) from the control lever. 2

3) Remove covers (5) (6). 65ZV44015

4) Remove all hoses (8) from pilot valve (7).

Note: - Before disconnecting, put matchmarks on hoses. - Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

44-24

60ZV44038

Pilot Valve

50ZV

HYDRAULIC 44

5) Remove bolt (9) and then remove pilot valve (7) with plate (10). : Pilot valve: Approx. 6 kg (13 Ibs) 9

60ZV44039

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

44-25

60ZV44040

Pilot Valve

50ZV

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 T3

T2 L1

Port 4 (a2) Boom down

Port 2 (b2) Boom up

Port 3 (a1) Bucket roll back

Port 1 (b1) Bucket dump 60ZV44041

: Tightening torque T1: 32.3 N-m ( 3.3 kgf-m) (23.9 lb-ft) T2: 50.0 N-m ( 5.1 kgf-m) (36.9 lb-ft) T3: 73.5 N-m ( 7.5 kgf-m) (54.2 lb-ft) T4: 13.3 N-m (1.36 kgf-m) ( 9.8 lb-ft)

Apply grease when reassembling L1: Sliding surface L2: Top of plunger

: Approx. 5.3 kg (11.7 lbs) 44-26

Pilot Valve

50ZV

HYDRAULIC 44

2.Disassembling pilot valve 1

1) Using copper plates, fix the pilot valve in a vice and remove boot (1).

60ZV44042

2) Loosen the adjusting nut (2) and circular plate (3) with wrenches and remove adjusting nut (2) and circular plate (3).

Adjusting nut width across flat..........22 mm (7/8 in.) Circular plate width across flat..........36 mm (1 7/16 in.)

Torque for assembly: : #2, 3............73.5 N-m (7.5 kgf-m) (54.2 lb-ft)

60ZV44043

3) Using jig A B , turn joint (4) counterclockwise to remove it. Note: Refer to the next page for the detail of removing joint. Torque for assembly: : #4............50.0 N-m (5.1 kgf-m) (36.9 lb-ft)

When reassembling, apply grease to the sliding surface. 60ZV44044

60ZV44045

44-27

Pilot Valve

50ZV

HYDRAULIC 44

0.5x15°

Detail of removing joint (4)

C0.5

12 9.5

ø 26.5 23.5

6 ±0.1

R12

(Width across flat)

R5.2

C0.5

10.4 ±0.1

14.5

±0.1

Material; SCM415 N Carburizing and quenching

Material; SCM415 N 1 Carburizing and quenching

2 Material; S45C

Quantity; 2

25 17

Jig B

ø 19 ø 28

+0.2

ø 21 0 ø 25 ø 30

Section A - A +0.013 0

Fit tolerance; H6 / n6 Press 1 and 2 into.

+0.028 +0.015

Turn jig A counterclockwise

B +0.2

15 0

Jig A

B Joint B

Jig A + B installation

Section B - B 60ZV44117

4) Remove plate (5).

60ZV44047

44-28

Pilot Valve

50ZV

HYDRAULIC 44

5) Loosen bolt (6) with the hexagon (allen) wrench and remove plate (7). Hexagon wrench width across flat........5 mm (3/16 in.)

Note: At this time detent casing (8) is lifted by inner spring force. Be careful that it does not fly up and strike someone. 7

Torque for assembly: : #6............13.3 N-m (1.36 kgf-m) (9.8 lb-ft)

8 60ZV44048

6) The solenoid sub assembly in detent casing (8) might be contacted with suction board. Press push rod (9) to separate them from solenoid sub assembly in detent casing (8).

60ZV44049

7) Pull out push rod (9) and remove detent casing (8) with the solenoid sub assembly.

9 8

60ZV44050

8) Remove suction board (10) and outer spring (11). 10

60ZV44051

44-29

Pilot Valve

50ZV

HYDRAULIC 44

9) Remove spring seat (11) using pliers. 11

60ZV44042

10) Loosen bolt (12) with the hexagon (allen) wrench and remove it. Hexagon wrench width across flat........5 mm (3/16 in.)

Note: When loosing bolt (12), center plate (13), push rod (14) and plug (15) might be lifted. When pulling out the bolt, be careful that parts do not get thrown from assembly. Torque for assembly: : #12............13.3 N-m (1.36 kgf-m) (9.8 lb-ft)

60ZV44043

11) Remove plate (13).

15 16

60ZV44054

12) Put a driver into the groove of plug (15) and pull out plug (15) from casing (16). Note: - Be careful not to damage surfaces around the groove of the plug. - Carefully place all plugs, springs and reducing valve spools in the order it was removed so as to assemble them into the casing port.

Screw driver

60ZV44055

44-30

Pilot Valve

50ZV

HYDRAULIC 44

Difference in reducing valve Port No. Parts

1~3

➀ Spring

➁ Spring seat

➂ Return spring

1 pc

2 pcs

➃ Spring seat

1 pc

2 pcs

➄ Washer 2

2 4 3

5 Outside

Bucket dump (T)

Boom down

Port 4(a2)

Port 3(a1) A-A

Front

41 T P 32

60ZV44120

Rear Boom raise

(P)

Bucket roll back

Inside Oil port (Viewed from top)

60ZV44119

13) Fix casing (16) in a vice so that port board (17) can be on top. Loosen bolt (18) with the hexagon (allen) wrench. Hexagon wrench width across flat........6 mm (1/4 in.)

17 16

Torque for assembly: : #18............32.3 N-m (3.3 kgf-m) (23.9 lb-ft) 60ZV44057

14) Remove port board (17) and O-ring (19).

60ZV44058

44-31

Pilot Valve

50ZV

HYDRAULIC 44

15) Disassembling reducing valve ➀Stand the bottom of the spool straight on the working table. Push down spring seat (20) and remove washer set (1 semicircle, 2 pcs) (21) using the head of a small screw driver. Note: - Be careful not to damage the spool surface. - Do not press down spring seat (20) more than 6 mm.

21 60ZV44059

➁Disconnect spool (22), spring seat (20), spring (23)

and washer 2 (24).

23 24

Note: Only reducing valve in Port 4 has washer 2 (24).

60ZV44060

➂Pull out spring seat (25) and spring (26) from push rod (14) and then pull out push rod (14) from plug (15). Remove O-ring (27) and the seal in the bore from plug (15).

Note: Only Port 4 has spring seat (25) and spring (26).

14 60ZV44061

16) Remove solenoid sub (28) from detent casing (8). 28

Note: When removing the solenoid sub, do not pull the electrical harness.

60ZV44042

44-32

Pilot Valve

50ZV

HYDRAULIC 44

3. Reassembling pilot valve To reassemble the pilot valve, follow the above disassembly procedure in the reversed direction. Note: When reassembling seal (29) into plug (15), be careful about the direction of lip of seal (20).

Plug (15) Seal (29)

Push rod

Apply hydraulic oil

60ZV44063

44-33

Multiple Control Valve

50ZV

HYDRAULIC 44

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

Before starting work: - Release residual pressure in the pilot line, loading line and tank.

Multiple control valve 65ZV44065

1) Put matchmarks on hoses (1) of the pilot line, and then disconnect them. Note: Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

2) Disconnect pump port hose (2) to the multiple control valve and tank port hose (3). Multiple control valve

2 65ZV44065

3) Disconnect hoses (4) (5) to the bucket and boom cylinder from the multiple control valve. : Approximately 2~3 (0.5~0.8 gal.) of hydraulic oil will be drained from the disconnected hoses. Place a container to receive the drained oil. Note: Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

Multiple control valve

65ZV44066

44-34

Multiple Control Valve

50ZV

4) Remove four retainer bolts (6) from the multiple control valve, and then remove multiple control valve. Torque for assembly: : #6......93.7 N-m (9.6 kgf-m) (69.1 lb-ft) : Multiple control valve: 20 kg (44 lbs)

HYDRAULIC 44

Multiple control valve

6 60ZV44067

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

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. 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.

44-35

Multiple Control Valve

50ZV

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 Inlet section

T1 Bucket spool section

T5 T

Pa1

Pb1

Pb2

Pa2 B2

T1 T1

Boom spool section T2

A-A D-D B

Load check valve T4

T4 Pa

Pa Pb

T5 L1

T 5 L1

T4 B-B

T4 C-C 60ZV44121

: N-m (kgf-m) (lb-ft) T1: 88 ( 9.0) ( 65) T2: 65 ( 6.6) ( 48) T3: 101 (10.3) (74.5) T4: 9.8 ( 1.0) ( 7.2) T5: 7.8 ( 0.8) ( 5.8)

L1: Screw lock agent application : Approx. 21 kg (46 lbs)

44-36

(Loctite® 271)

Multiple Control Valve

50ZV

HYDRAULIC 44

2.Disassembling multiple control valve

1) Remove main relief valve (1), overload relief valve (2) and make-up valve (3). Torque for assembly: : #1, 2, 3......88 N-m (9.0 kgf-m) (65 lb-ft)

8 2

2) Remove nut (4) (5) from tie rod (6) (7) and then pull out inlet section (8), bucket spool section (9), boom spool section (10) and outlet section (11) as an assembly.

Note: The poppet, spring and O-ring of the load check valve are at mating face. Carefully pull out each assembly so that they are not damaged or distorted.

3 7 6

[Disassembling bucket section] For boom section, follow the same disassembling procedure.

60ZV44069J

3) Pull out O-ring (12), spring (13) and poppet (14) from the mating face. 4) Remove bolt (15) to remove cap (16) (17). Torque for assembly: : #15......9.8 N-m (1.0 kgf-m) (7.2 lb-ft) 12

14 60ZV44070

5) Pull out spool (19) with cap screw (18) from valve housing (20). Note: Carefully pull out the spool so that it is not scratched or damaged. Be sure to keep direction and placement of spool as it was originally.

20 16

18 19

15 60ZV44071

44-37

Multiple Control Valve

50ZV

6) Insert spool (19) between wooden blocks (21) so that the periphery of the spool is not damaged, and set it in a vise. Loosen cap screw (18) and remove spring seat (22) and spring (23). Note: Screw lock is applied to the thread of cap screw (18) and so heat the periphery of the thread to 200 to 250 °C (392~482 °F) to remove it. In case that the thread of cap screw is overheated, replace spring (23) with new one.

HYDRAULIC 44

18 23

60ZV44110

Torque for assembly: : #18......7.8 N-m (0.8 kgf-m) (5.8 lb-ft) : Screw lock agent application (Loctite® 271)

7.8

70~100

mm(in.)

3. Reassembling multiple control valve To reassemble the multiple control valve, follow the above disassembling procedure in the reversed direction. Note: When tightening each section with the tie rod, work on a flat plate or table.

44-38

60ZV44073

Priority Valve

50ZV

HYDRAULIC 44

Priority Valve Removing and reinstalling priority valve 1. Removing priority 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 the bucket to ground. - Block tires with chocks to prevent the 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.

1 4

3 60ZV44074

Before starting work: - Release residual pressure in the loading and steering lines.

1) Disconnect hose (2) from the pump, hose (3) to the multiple control valve and drain hose (4). 7

2) Disconnect hose (5) (6) to the Orbitrol®. : Approximately 1 (0.26 gal.) of hydraulic oil will be drained from the disconnected hoses. Place a container to receive the drained oil. Note: Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt. 3) Loosen bolt (7) to remove priority valve (1). : Priority valve: Approx. 6 kg (13 lbs)

2. Reinstalling priority valve To reinstall the priority valve, follow the above removal procedure in the reversed direction. 44-39

5 60ZV44075

Priority Valve

50ZV

HYDRAULIC 44

Disassembling and reassembling priority 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

: N-m (kgf-m) (lb-ft) T1: 25 (2.5) (18) T2: 54 (5.5) (40)

1 3

4 60ZV44076

2. Caution regarding disassembly and reassembly - Carefully remove plug (1) or (2). It may spring out by the spring force. Alternately loosen plug (1) (2) to reduce the spring force and remove them. - When reassembling relief valve (3), take care not to lose ball (5).

44-40

50ZV

Orbitrol®

HYDRAULIC 44

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

95ZV44060

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

95ZV44061

3) Remove sound suppression sheet (3).

3 95ZV44062

44-41

Orbitrol®

50ZV

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

HYDRAULIC 44

Orbitrol R

4 70ZV14008

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 around the Orbitrol® for oil leakage :

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.

44-42

Orbitrol®

50ZV

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 Centering springs

Push spool

O-ring

Check value

Plate O-ring

Sleeve

1 2 Make-up valve Needle bearing

Ball Housing

O-ring

Seal unit Spacer

End cap

OLRV

Drive shaft Retainer

: N-m (kgf-m) (lb-ft) ............ #1, 2 28 (2.9) (21)

44-43

Rotor assembly

60ZV44122

Orbitrol®

50ZV

2.Disassembling Orbitrol®

HYDRAULIC 44

Make matchmarks before disassembling unit.

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

Housing

Copper plate 60ZV44123

2) Remove six bolts (1), one retainer screw (2), end cap (3), O-ring (4) and spacer (5). Note: The make-up valve installed in the housing is tightened with bolts (A). When removing the bolts, take care not to drop the make-up valve.

60ZV44079

1 5 2

3 4

60ZV44080

3) Remove rotor assembly (6) and O-ring (7). Note: Keep star (8) in rotor assembly (6).

97ZV44049

44-44

Orbitrol®

50ZV

HYDRAULIC 44

4) Remove drive shaft (9), spacer plate (10) and O-ring (11).

10 9 11 60ZV44082

5) Remove the housing from the vise. Remove adapter screw (12) of the emergency check valve by a screw driver. Also remove spring (14), retainer plug (15) and ball (16) of the make-up valve.

13 12

16 15 14

60ZV44083

(Disassembling valve) 6) Remove retainer ring (7) with a screw driver. Note: Carefully remove the retainer ring so that it does not spring out.

60ZV44084

7) Place the housing horizontally on clean cloth. Rotate the spool and sleeve so that the pin can be in a horizontal position. Remove seal retainer (18) by pressing the spool and sleeve from behind with your fingers.

60ZV44085

44-45

Orbitrol®

50ZV

HYDRAULIC 44

8) Remove X-ring seal (19) and dust seal (20) from seal retainer (18). Note: Take care not to damage seal retainer (18).

60ZV44086

9) Remove races (21), needle bearing (22) and O-ring (23). 21

22 60ZV44087

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

Housing

Spool / sleeve assembly 60ZV44088

11) Pull out pin (24) from the spool and sleeve assembly. Note: Before pulling out pin (24), put matchmarks with marker pen on spool (25) and sleeve (26) for reassembly.

Spool / sleeve assembly

25 24

Matchmark 60ZV44089

44-46

Orbitrol®

50ZV

HYDRAULIC 44

12) Push spool (25) slightly out of sleeve (26), and remove centering springs (27).

27 26

60ZV44090

13) Pull the spool (25) from the sleeve (26) while slowly turning the spool clockwise and counterclockwise. 26

60ZV44091

14) Using the hexagon (allen) wrench (width across flat : 3/16 in.), remove plug (27) to remove O-ring (28) from the plug. Take out spring (29), ball holder (30) and ball (31) (2 places).

29 28 27 31 30 60ZV44092

Note: Inlet check valve (32) built in port P is connected with the housing and cannot be removed.

60ZV44093

44-47

Orbitrol®

50ZV

HYDRAULIC 44

3.Reassembling Orbitrol®

Spring groove

(Reassembling valve) 1) Assemble spool (25) and sleeve (26) so that the spring grooves in them are lined up. Use light oil for assembly of parts. Note: ➀Confirm that the spool can be turned easily in the sleeve. ➁Align the matchmarks on the spool and sleeve.

Spring groove 25

Matchmark 60ZV44094

2) Install centering springs (27) through the spring grooves in spool (25) and sleeve (26) 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.

26 60ZV44095

3) Insert pin (24) in the holes in spool (25) and sleeve (26) until the end of the pin is flush with the surface of the sleeve. 25

Matchmark 60ZV44096

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

Housing

Spool / sleeve assembly

60ZV44097

44-48

Orbitrol®

50ZV

HYDRAULIC 44

5) Install O-ring (23), races (21) and needle bearing (22). 21

60ZV44099

6) Insert dust seal (20) and the X-ring seal (19) in seal retainer (18).

60ZV44086

7) Insert seal retainer (18) onto spool (25), and then tap it gently into position with a plastic-faced hammer. Then install retainer ring (17).

18 25

60ZV44099

Note: Be sure that the position and direction of the seals are placed correctly.

Screw driver Dust seal Retainer ring Seal retainer X-ring seal O-ring

60ZV44100

44-49

Orbitrol®

50ZV

HYDRAULIC 44

8) Insert O-ring (28) in plug (27). Apply grease to ball holder (30) and install ball (31). Insert ball holder (30) and spring (29) into the housing and then insert plug (27) using the hexagon wrench (width across flat: 3/16 in.)

27 OLRV units

28 29

Housing

60ZV44124

(Reassembling rotor) 9) 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.

Housing

Plate

60ZV44102

10) Insert ball (16), retainer plug (15) and spring (14) of the make-up valve to the housing. Insert ball (13) of the emergency check valve and tighten adapter screw (12) by a screw driver. Then install O-ring (11) to the housing and put on spacer plate (10). Align the bolt holes in the plate with those in the housing.

12 13

60ZV44103

11) Insert drive shaft (9) to mate its yoke with pin (24). Rotate the spool and sleeve so that the pin (24) can be parallel with the port face.

Port face 9 Parallelize with port face

Note: Put a matchmark on the end face of the drive shaft parallel with the pin.

24 60ZV44111

44-50

Orbitrol®

50ZV

HYDRAULIC 44

12) Put O-ring (7) in rotor assembly (6).

60ZV44105

13) Holding the rotor assembly with the O-ring side facing the spacer 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.

Grooves in rotor bore

A B

Drive shaft

C D

14) Install spacer (5), O-ring (4) and end cap (3). Provisionally tighten bolt (1) and retainer screw (2).

Port face

95ZV44029

1 5

Note: Insert retainer screw (2) to the hole where the ball of the emergency check valve is inserted to. : Provisional tightening torque: 15 N-m (1.5 kgf-m) (11 lb-ft) Tightening torque: 28 N-m (2.9 kgf-m) (21 lb-ft)

3 4

60ZV44106

15) Evenly tighten the retainer screw and bolts in the order shown at the right.

2 3

7 5 60ZV44112

44-51

Cushion Valve

50ZV

HYDRAULIC 44

Cushion Valve Removing and reinstalling cushion valve 1.Removing cushion valve

1 Front

Floor board

Before starting work: - Release residual pressure in the loading and steering lines. 60ZV44107

1) Disconnect hoses (2) from cushion valve (1).

2) Remove retainer bolt (3) to remove cushion valve (1).

: Cushion valve: Approx. 4 kg (9 lbs)

60ZV44108

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

44-52

Cushion Valve

50ZV

HYDRAULIC 44

Disassembling and reassembling cushion 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 B

A A B-B

T3 L1

T 3 L1

T2 A A-A

60ZV44109

: N-m (kgf-m) (lb-ft) T1: 59 (6.0) ( 43) T2: 137 ( 14) (101) T3: 20 (2.0) ( 14) : L1: Screw lock application (Do not seal the orifice with screw lock) Wind the seal tape for plugs A .

44-53

MEMO

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

45-1

Hydraulic Cylinder

50ZV

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder

5 50ZV45001

Unit : mm (in.)

Standard valve No.

Item

Judgment standard Standard dimension

Standard clearance

Tolerance limit

Clearance between boom cylinder rod and bushing

ø55 (2.1654)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

0.5 (0.0197)

Clearance between pin and inner diameter

ø55 (2.1654)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0394)

Clearance between pin and bushing

ø55 (2.1654)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0394)

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

Solution

Replacement

863 (88) (637)

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

2,157 (220) (1,591)

Width across flat mm (in)

60 (2.36)

Piston nut

45-2

Tightening

Hydraulic Cylinder

50ZV

HYDRAULIC 45

Bucket cylinder 5

4 50ZV45002

Steering cylinder

50ZV45003

Unit : mm (in.)

Standard valve No.

Item

Judgment standard Standard dimension

Standard clearance

Tolerance limit

Clearance between bucket cylinder rod and bushing

ø50 (1.9685)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

0.5 (0.0197)

Clearance between steering cylinder rod and bushing

ø35 (1.3780)

0.080 ~ 0.205 (0.0031 ~ 0.0081)

0.5 (0.0197)

Clearance between bucket cylinder piston rod pin and bushing

ø50 (1.9685)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0394)

Clearance between steering cylinder piston rod pin and bushing

ø35 (1.3780)

0.080 ~ 0.205 (0.0031 ~ 0.0081)

1.0 (0.0394)

Clearance between bucket cylinder bottom pin and bushing

ø50 (1.9685)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0394)

Clearance between steering cylinder bottom pin and bushing

ø35 (1.3780)

0.080 ~ 0.205 (0.0031 ~ 0.0081)

1.0 (0.0394)

Solution

Replacement

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

Bucket cylinder

647 (66) (477)

Steering cylinder

304 (31) (224)

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

1,431 (146) (1,056) Bucket cylinder

Width across flat mm (in) 5

60 (2.36)

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

392 (40) (289) Steering cylinder

Width across flat mm (in)

41 (1.61)

45-3

Tightening

Pilot Valve

50ZV

HYDRAULIC 45

Pilot Valve 5

60ZV45004

Unit : mm (in.) No.

Item

Measuring condition

- Lever in neutral position ………1,200 cm3/min and more Valve assembly

3.5 MPa (36 kgf/cm2) (512 psi)

Leak quantity

2. Hydraulic oil………VG46

- Lever in operation

3. Oil temperature………60 °C

No.

Item

Solution

Judgment standard (limit)

1. Primary pressure………

replacement

……2,400 cm /min and more 3

Judgment standard Standard dimension

Wear limit

Solution

61 mm (2.4016 in.)

2 Length of push rod

1 mm (0.0394 in.) and more

Replacement

6 mm (0.2362 in.)

0.5 mm (0.0197 in.) and more

Solenoid sub assembly replacement

–

2 mm (0.0787 in.) and more

Replacement of related parts such as disc, joint etc.

36 mm (1.4173 in.)

3 4

Inner diameter of solenoid bushing

Adjusting nut wear (upper part)

45-4

BRAKE GROUP 54 Disassembly and Reassembly Hydraulic Servo Master ..............................................................................54-2 Service Brake .............................................................................................54-8 Parking Brake .............................................................................................54-9

54-1

Hydraulic Servo Master

50ZV

BRAKE 54

Hydraulic Servo Master Removing and reinstalling hydraulic servo master 1. Removing hydraulic servo master

3 1

1) Disconnect the joint between hydraulic servo master (1) and arm (2) of the brake pedal linkage from L-ball joint (3). 60ZV54001

2) Loosen locknut (4) to remove rod (5) from hydraulic servo master (1). 3) Remove brake pipings (6) to front and rear brake from hydraulic servo master (1), and remove hoses (7) from the brake oil tank.

Note: Bend and hold the end of the hose from the brake oil tank to protect oil leakage.

60ZV54002

60ZV54003

54-2

Hydraulic Servo Master

50ZV

4) Remove hose (8) from the torque converter pump, and hose (9) to the torque converter and drain hose (10) at hydraulic servo master (1) side.

BRAKE 54

9 1

10 60ZV54004

5) Remove retainer bolt (11) to remove hydraulic servo master (1). : Hydraulic servo master: Approx. 10 kg (22 Ibs) Torque for assembly: : Bolt (11): 52.9 N-m (5.4 kgf-m) (39.1 lb-ft)

11 60ZV54005

2. Reinstalling hydraulic servo master To reinstall the hydraulic servo master, 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 and hoses for oil leakage. To check or adjust the service brake linkage, refer to Section 53.

54-3

Hydraulic Servo Master

50ZV

BRAKE 54

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

1. Cross section and tightening torque

Hydraulic servo section

Master cylinder section

T4 T5

: N-m (kgf-m) (lb-ft) T1: 147 ( 15) (109) T2: 7 (0.7) ( 5.1) T3: 4 (0.4) ( 2.9) T4: 11 (1.1) ( 8) T5: 23 (2.3) ( 17)

60ZV54006

54-4

Hydraulic Servo Master

50ZV

BRAKE 54

2. Disassembling hydraulic servo master Before starting work: : Drain oil in the hydraulic servo master. Remove any mud, dust or other foreign matter from it.

Disassembling the hydraulic servo section 1) While pushing push rod (1), remove retaining ring (2). 1

2 60ZV54007

2) Remove piston (4) and boot (3) from servo piston (5). 5

60ZV54008

3) Using a screwdriver, remove the back-up ring and piston cup (6). Take care not to damage them. Remove assist piston (7) from servo piston (5).

60ZV54009

54-5

Hydraulic Servo Master

50ZV

BRAKE 54

4) Remove retaining ring (8) from plunger (9). Separate plunger (9) and servo piston (5), and then remove spring (10).

10 5 8

60ZV54010

5) Remove cap (11). Remove spring (12) and relief valve (13). Torque for assembly: : Relief valve (13): 147 N-m (15 kgf-m) (109 lb-ft)

12 13

60ZV54011

6) Remove three bolts (14). Separate master cylinder section (15) and hydraulic servo section (16). Note: These two may be separated first. Torque for assembly: : Bolts (14): 23 N-m (2.3 kgf-m) (17 lb-ft)

14 60ZV54012

7) Remove retaining ring (17) from body (16). Remove back-up plate (18) and sealing cup (19).

17 18 19

60ZV54013

54-6

Hydraulic Servo Master

50ZV

BRAKE 54

Disassembling the master cylinder section 1) Remove secondary piston stopper (21). Torque for assembly: : Stopper (21): 7 N-m (0.7 kgf-m) (5.1 lb-ft) 21

60ZV54014

2) While pushing primary piston (23), remove retaining ring (22).

22 23 60ZV54015

3) Remove primary piston (23). 4) Remove secondary piston (24). Note: Do not disassemble the primary piston and the secondary piston, which are both functionally important parts. (If necessary, replace them with their respective repair kits.)

23 22

60ZV54016

3. Reassembling hydraulic servo master For reassembling, follow the above disassembly produre in the reversed direction.

24 23

54-7

60ZV54017

Service Brake

50ZV

Service Brake Disassembling and reassembling service brake Refer to "Disassembling and Reassembling Front Axle" in Power group.

54-8

BRAKE 54

Parking Brake

50ZV

BRAKE 54

Parking Brake Removing and reinstalling / disassembling and reassembling parking brake 1. Removing and disassembling parking brake

WARNING When removing the parking brake, 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, and then block tires with chocks to prevent wheels from moving. - Apply articulation stopper. - Remove the engine key, and hang a "DO NOT START Engine!" tag on the steering wheel.

Control cable 3 1

1) Drain the transmission oil. 2 Parking brake

2) Remove nut (1) and bolt (2) to disconnect the control cable from turn buckle (3).

3) Remove bolts (5) of propeller shaft (4). Torque for assembly: : Bolt (5): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent AB02 application

60ZV54018

4) Remove bolt (6) and then remove flange yoke (7) and brake drum (8) all together. If necessary, remove bolt (9) to disconnect flange yoke (7) and brake drum (8). Torque for assembly: : Bolt (6): 216 N-m ( 22 kgf-m) (159 lb-ft) Bolt (9): 34.5 N-m (3.5 kgf-m) ( 25 lb-ft) : Bolt (6): Screw lock agent AB01 application

4 60ZV54019

42T

8 9 6

IMPORTANT During reinstallation, align the direction of the flange yokes on the second and third propeller shaft sides of the transmission. Misalignment may cause abnormal noise or pulsation.

60ZV54020

54-9

Parking Brake

50ZV

BRAKE 54

5) Remove bolt (10) to remove parking brake assembly (11).

42T

Torque for assembly: : Bolt (10): 52.9 N-m (5.4 kgf-m) (39 lb-ft)

6) Remove right and left springs (12) from parking brake assembly (11) using brake spring pliers. Remove plate (13).

60ZV54021

60ZV54022

7) Turn shoes hold-down pin (14) 90 degrees and remove it. Remove right and left brake shoes (15) all together.

60ZV54023

8) Remove spring (16), and then remove adjusting screw (17). Note: Measure the wear of the brake shoes. If the shoes are extremely worn, replace them. Refer to Section 53 or 55 inspection standards.

16 17

60ZV54024

54-10

Parking Brake

50ZV

BRAKE 54

9) Remove U-retainer (18) to remove strut (19).

18 19

60ZV54025

60ZV54026

2. Reinstalling and reassembling parking brake To reinstall and reassemble the parking brake, follow the above removal and disassembly procedure in the reversed direction.

54-11

MEMO

BRAKE GROUP 55 Service Standard Hydraulic Servo Master ..............................................................................55-2 Service Brake .............................................................................................55-3 Parking Brake .............................................................................................55-4 Brake Pedal Linkage....................................................................................55-5

55-1

Hydraulic Servo Master

50ZV

BRAKE 55

Hydraulic Servo Master 4

REF.

ITEM

Judgment criteria

Correction

Standard value

Allowable limit

119 (12.1) (27)

95 (9.7) (21)

Outside 226 (23) (51)

180 (18.4) (40)

Inside 108 (11) (24)

86 (8.8) (19)

147 (15) (33)

118 (12) (26)

Replacement

Primary side (spring height 31.2 mm (1.2283 in))

211 (21.5) (47)

169 (17.2) (38)

Replacement

Secondary side (spring height 32 mm (1.2598 in))

172 (17.5) (39)

137 (14.0) (31)

Replacement

Clearance to body (mm) (in)

—

0.2 (0.0079)

Replacement

Seat surface

—

No abnormality

Replacement

Hydraulic servo relief valve spring force (spring height 48 mm) N (kgf) (Ibf)

Hydraulic servo return spring force N (kgf) (Ibf)

Hydraulic servo extension spring force (spring height 42 mm) N (kgf) (Ibf)

Master cylinder return spring force N (kgf) (Ibf)

Hydraulic servo relief valve

Remarks

Replacement

Clearance between hydraulic servo plunger and body (mm) (in)

—

0.15 (0.0059)

Replacement • Overhaul

Clearance between hydraulic servo piston and body (mm) (in)

—

0.20 (0.0079)

Replacement • Overhaul

Clearance between hydraulic servo piston and assist pin (mm) (in)

—

0.20 (0.0079)

Replacement • Overhaul

Clearance between hydraulic servo piston and piston guide (mm) (in)

—

0.20 (0.0079)

Replacement • Overhaul

Clearance between hydraulic servo assist piston and body (mm) (in)

—

0.43 (0.0169)

Replacement • Overhaul

Clearance between master cylinder piston and cylinder (mm) (in)

0.035 ~ 0.127 (0.0013 ~ 0.005)

0.20 (0.0079)

Replacement • Overhaul

Hydraulic servo master plunger play (mm) (in)

0.5 ~ 2.0 (0.0197 ~ 0.0787)

3.00 (0.1181)

Replacement • Overhaul

55-2

60ZV55001

Height 58 mm (2.2835 in) Height 55 mm (2.1654 in)

Service Brake

50ZV

BRAKE 55

Service Brake

60ZV55002

Unit : mm (in.) No.

Item Thickness of steel plate

Standard dimension

0 0 – 0.2 – 0.0078

(

6 (0.2362)

1 Distortion of steel plate (flatness)

Judgment standard Tolerance

)

Wear limit

Solution

5.5 (0.2165)

—

0.3 (0.0118) and more

Thickness of friction plate

8.5 (0.3346)

± 0.15 (± 0.0059)

7.5 (0.2953)

Depth of lining groove

0.4 (0.0157) and more

—

Thickness of lining (both sides)

1.5 (0.0591)

0.1 (0.0039) and less

—

Thickness of brake retainer

27.5 (1.0827)

0 0 – 0.1 – 0.0039

Replacement

(

55-3

)

27.1 (1.0669)

Parking Brake

50ZV

BRAKE 55

Parking Brake

60ZV55003

Unit : mm (in.) No.

Item

Wear of lining

Lining inspection

Expansion of adjuster spring

Expansion of return spring

Judgment standard Standard dimension Wear limit 5.1 (0.2008)

1.0 (0.0394) from the rivet head

Grease or oil on the lining

Solution Replacement Replacement

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

55-4

Replacement

Brake Pedal Linkage

50ZV

BRAKE 55

Brake Pedal Linkage

3 Brake pedal assembly

48˚

218 – 50 mm (8.58 in.)

Reference dimension: 251 mm (9.88 in.)

Std. thread engagement Min:9 mm (0.35 in.)

16.5 mm (0.65 in.) 5 Std. thread engagement Min:11 mm (0.43 in.)

6 10

15 mm (0.59 in)

16 mm (0.63 in)

8 11

11 7

115 mm (4.528 in.)

55-5

60ZV53004

MEMO

Notes