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95ZV

93215-00242

SHOP MANUAL Disassembly & Reassembly Service Standard

Printed in Japan (K) ( ヨーロッパ・輸出一般用 )

93215-00242

June 2011

SHOP MANUAL WHEEL LOADER

95ZV Disassembly & Reassembly Service Standard

93215-00242 June 2011

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.

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.

- 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.

- 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 (20 kg (40 lbs) or more), be sure to use a crane or other lifting device. - 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.

- 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. - Any technician that operates a refrigerant recovery and recycling machine must first be certified through and EPA approved testing program.

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.

MEMO

CONTENTS 95ZV General Information ..................................................................................................................................... 00-1 Symbols ............................................................................................................................................................ 00-2 Weight of Main Components ............................................................................................................................. 00-3 Bolt Tightening Torque ...................................................................................................................................... 00-4 Hose Band Tightening Torque ........................................................................................................................... 00-8 Liquid Gasket and Screw Lock Agent ............................................................................................................... 00-9 Cautions regarding parts removal ............................................................................................................... 00-9 Cautions regarding reassembly .................................................................................................................. 00-9 Screw lock agent application procedure ................................................................................................... 00-10 How to wind a seal tape ............................................................................................................................ 00-10 Cautions Regarding Welding Repair Service ...................................................................................................00-11 Cautions Regarding Handling of Bearing ........................................................................................................ 00-13 Bearing installation cautions ..................................................................................................................... 00-13 Interference fits for a bearing .................................................................................................................... 00-13 Bearing removal cautions ......................................................................................................................... 00-14 Applying and Storing Articulation Stopper ....................................................................................................... 00-15 Applying articulation stopper ..................................................................................................................... 00-15 Storing articulation stopper ....................................................................................................................... 00-16 95ZV Disassembly & Reassembly Chassis Group ............................................................................................... 14-1 Deck .................................................................................................................................................................. 14-2 Deck removing and installing ...................................................................................................................... 14-2 Fuel Tank .......................................................................................................................................................... 14-3 Fuel tank removing and installing ............................................................................................................... 14-3 Hydraulic Tank .................................................................................................................................................. 14-5 Hydraulic tank removing and installing ....................................................................................................... 14-5 Engine Room .................................................................................................................................................... 14-7 Engine room removing and installing .......................................................................................................... 14-7 Cab ................................................................................................................................................................... 14-9 Cab removing and installing ........................................................................................................................ 14-9 Floor Board ......................................................................................................................................................14-11 Floor board removing and installing ...........................................................................................................14-11 Boom ............................................................................................................................................................... 14-13 Boom removing and installing ................................................................................................................... 14-13

Center Pin ....................................................................................................................................................... 14-16 Upper center pin ........................................................................................................................................ 14-16 Lower center pin ........................................................................................................................................ 14-17 Center pin removing and installing ............................................................................................................ 14-18 95ZV Service Standard Chassis Group ................................................................................................................ 15-1 Linkage .............................................................................................................................................................. 15-2 Linkage Pin Standard Clearance Values ........................................................................................................... 15-3 Liner clearance adjustment ......................................................................................................................... 15-3 Center Pin ......................................................................................................................................................... 15-4 Center pin shim adjustment ........................................................................................................................ 15-4 Bearing cover installing ............................................................................................................................... 15-4 Lower center pin bearing outer ring installing ............................................................................................. 15-5 Bucket Positioner and Boom Kick-Out .............................................................................................................. 15-6 Bucket positioner ......................................................................................................................................... 15-7 Boom kick-out ............................................................................................................................................. 15-8 95ZV Disassembly & Reassembly Power Group .................................................................................................. 24-1 Power Line ........................................................................................................................................................ 24-2 Power line tightening torque ........................................................................................................................ 24-2 Radiator ............................................................................................................................................................. 24-3 Radiator tightening torque ........................................................................................................................... 24-3 Radiator removing and installing ................................................................................................................. 24-4 Engine ............................................................................................................................................................... 24-7 Engine removing and installing ................................................................................................................... 24-7 Propeller Shaft ................................................................................................................................................ 24-10 Propeller shaft removing and installing ..................................................................................................... 24-10 Air Cleaner ...................................................................................................................................................... 24-12 Air cleaner removing and installing ........................................................................................................... 24-12 Muffler ............................................................................................................................................................. 24-14 Muffler removing and installing ................................................................................................................. 24-14 Fan .................................................................................................................................................................. 24-15 Fan removing and installing ...................................................................................................................... 24-15 Front Axle Assembly ....................................................................................................................................... 24-16 Front axle assembly tightening torque ...................................................................................................... 24-16 Front axle assembly removing and installing ............................................................................................ 24-18 Front axle disassembling and assembling ................................................................................................ 24-21

Floating Seal ................................................................................................................................................... 24-31 Internal Gear Hub ........................................................................................................................................... 24-33 Internal gear hub disassembling and assembling ..................................................................................... 24-33 Internal gear hub assembly cautions ........................................................................................................ 24-35 Spider Assembly ............................................................................................................................................. 24-37 Spider assembly disassembling and assembling ...................................................................................... 24-37 Special Tool ..................................................................................................................................................... 24-39 Special tool for axle ................................................................................................................................... 24-39 Rear Axle Assembly ........................................................................................................................................ 24-45 Rear axle assembly tightening torque ....................................................................................................... 24-45 Rear axle assembly removing and installing ............................................................................................. 24-47 Rear axle disassembling and assembling ................................................................................................. 24-49 Axle Support ................................................................................................................................................... 24-50 Axle support tightening torque .................................................................................................................. 24-50 Axle support disassembling and assembling ............................................................................................ 24-52 Differential Assembly ...................................................................................................................................... 24-57 Differential assembly removing and installing ........................................................................................... 24-57 Differential assembly disassembling and assembling ............................................................................... 24-59 95ZV Service Standard Power Group ................................................................................................................... 25-1 Propeller Shaft Service Standard ...................................................................................................................... 25-2 Axle and Differential Service Standard .............................................................................................................. 25-3 Axle group ................................................................................................................................................... 25-3 Differential ................................................................................................................................................... 25-4 95ZV Disassembly & Reassembly Torque Converter and Transmission Group .................................................. 34-1 Torque Converter and Transmission Assembly ................................................................................................ 34-2 Torque converter and transmission assembly tightening torque ................................................................. 34-2 Torque converter and transmission assembly removing and installing ....................................................... 34-3 Torque Converter Assembly ............................................................................................................................ 34-10 Torque converter assembly bolt tightening torque .................................................................................... 34-10 Torque converter assembly disassembling and assembling ......................................................................34-11 Transmission Assembly .................................................................................................................................. 34-16 Transmission assembly bolt tightening torque .......................................................................................... 34-16 Transmission assembly disassembling and assembling .......................................................................... 34-17 Clutch Assembly ............................................................................................................................................. 34-24 Clutch assembly disassembling and assembling ...................................................................................... 34-24

Clutch Spider Assembly .................................................................................................................................. 34-37 Low and 3rd clutch spider disassembling and assembling ....................................................................... 34-37 2nd clutch spider disassembling and assembling ..................................................................................... 34-38 Reverse Clutch Spider .................................................................................................................................... 34-39 Reverse clutch spider disassembling and assembling .............................................................................. 34-39 1st Clutch Assembly ........................................................................................................................................ 34-40 1st clutch assembly disassembling and assembling ................................................................................. 34-40 High Clutch Assembly ..................................................................................................................................... 34-44 High clutch assembly disassembling and assembling .............................................................................. 34-44 Control Valve Assembly .................................................................................................................................. 34-49 Control valve assembly removing and installing ....................................................................................... 34-49 95ZV Service Standard Torque Converter and Transmission Group .................................................................... 35-1 Transmission Assembly .................................................................................................................................... 35-2 Torque Converter Gear Pump ........................................................................................................................... 35-4 Gear pump specifications ............................................................................................................................ 35-4 Gear Train and Number of Teeth ....................................................................................................................... 35-5 Clutch specifications ................................................................................................................................... 35-5 Clutch Oil Pressure ........................................................................................................................................... 35-6 95ZV Disassembly & Reassembly Hydraulic Group ............................................................................................. 44-1 Hydraulic Parts Removal and Installation Warning ........................................................................................... 44-2 Hydraulic Parts Disassembly and Assembly Cautions ...................................................................................... 44-3 Hydraulic parts disassembly cautions ......................................................................................................... 44-3 Hydraulic parts assembly cautions .............................................................................................................. 44-3 Hydraulic Pump Assembly ................................................................................................................................ 44-4 Hydraulic pump assembly removing and installing ..................................................................................... 44-4 Hydraulic pump assembly disassembling and assembling ......................................................................... 44-7 Hydraulic Cylinder ........................................................................................................................................... 44-10 Boom cylinder removing and installing ...................................................................................................... 44-10 Bucket cylinder removing and installing .................................................................................................... 44-13 Hydraulic cylinder disassembling and assembling .................................................................................... 44-15 Pilot Valve ....................................................................................................................................................... 44-22 Pilot valve removing and installing ............................................................................................................ 44-22 Pilot valve disassembling and assembling (S/N ~0290, ~9080) ............................................................... 44-26 Pilot valve disassembling and assembling (S/N 0291~0410, 9081~) ....................................................... 44-31 Pilot valve disassembling and assembling (S/N 0411~) ........................................................................... 44-42

Multiple Control Valve ..................................................................................................................................... 44-50 Multiple control valve removing and installing ........................................................................................... 44-50 Multiple control valve disassembling and assembling .............................................................................. 44-53 Orbitrol® .......................................................................................................................................................... 44-57 Orbitrol® removing and installing ............................................................................................................... 44-57 Orbitrol® disassembling and assembling .................................................................................................. 44-59 Steering Valve ................................................................................................................................................. 44-67 Steering valve removing and installing ...................................................................................................... 44-67 Steering valve disassembling and assembling ......................................................................................... 44-69 Stop Valve ....................................................................................................................................................... 44-73 Stop valve removing and installing ............................................................................................................ 44-73 Stop valve disassembling and assembling ............................................................................................... 44-75 Fan Motor ........................................................................................................................................................ 44-78 Fan motor removing and installing ............................................................................................................ 44-78 95ZV Service Standard Hydraulic Group .............................................................................................................. 45-1 Hydraulic Cylinder ............................................................................................................................................. 45-2 Pilot Valve ......................................................................................................................................................... 45-4 Steering Valve ................................................................................................................................................... 45-6 95ZV Disassembly & Reassembly Brake Group ................................................................................................... 54-1 Unloader Valve .................................................................................................................................................. 54-2 Unloader valve removing and installing ...................................................................................................... 54-2 Unloader valve disassembling and assembling .......................................................................................... 54-4 Manifold Valve Assembly .................................................................................................................................. 54-8 Valve assembly removing and installing ..................................................................................................... 54-8 Valve assembly disassembling and assembling ....................................................................................... 54-10 Accumulator .....................................................................................................................................................54-11 Accumulator removing and installing .........................................................................................................54-11 Accumulator disassembling and assembling ............................................................................................ 54-12 Nitrogen gas charging ............................................................................................................................... 54-14 Brake Valve ..................................................................................................................................................... 54-16 Brake valve removing and installing ......................................................................................................... 54-16 Brake valve disassembling and assembling ............................................................................................. 54-18 Service Brake .................................................................................................................................................. 54-23 Service brake disassembling and assembling .......................................................................................... 54-23

Parking Brake (Rear) ...................................................................................................................................... 54-25 Parking brake (rear) disassembling and assembling ................................................................................ 54-25 Parking Brake Actuator ................................................................................................................................... 54-27 Parking brake actuator removing and reinstalling ..................................................................................... 54-27 Parking brake actuator disassembling and assembling ............................................................................ 54-28 Parking Brake (Front) (for Europe only) .......................................................................................................... 54-31 Parking brake (front) removing and reinstalling ........................................................................................ 54-31 Parking brake (front) disassembling and assembling ............................................................................... 54-34 95ZV Service Standard Brake Group .................................................................................................................... 55-1 Brake Valve ....................................................................................................................................................... 55-2 Service Brake .................................................................................................................................................... 55-6 Parking Brake .................................................................................................................................................... 55-7 95ZV Disassembly & Reassembly Operator Station Group .................................................................................. 74-1 Air Conditioner .................................................................................................................................................. 74-2 Air conditioner removing and installing ....................................................................................................... 74-2 Air conditioner disassembling and assembling ........................................................................................... 74-4 Compressor V-belt .................................................................................................................................... 74-12 95ZV Service Standard Operator Station Group ................................................................................................... 75-1 Air Conditioner .................................................................................................................................................. 75-2 Periodical Inspection/Servicing ................................................................................................................... 75-2 Tightening Torque ....................................................................................................................................... 75-2

00-1 95ZV General Information

95ZV General Information Symbols .................................................................. 00-2 Weight of Main Components ................................... 00-3 Bolt Tightening Torque ............................................ 00-4 Hose Band Tightening Torque................................. 00-8 Liquid Gasket and Screw Lock Agent ..................... 00-9 Cautions Regarding Welding Repair Service .......... 00-11 Cautions Regarding Handling of Bearing ................ 00-13 Applying and Storing Articulation Stopper ............... 00-15

00-2 95ZV General Information Symbols

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

Item

Description

Reference

Shows the condition or procedure that will be useful or efficient in doing service work.

Weight

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.

Tightening Shows the tightening torque of a section that should torque be carefully tightened during assembly 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 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 1st ........... 1st speed 2nd ........... 2nd speed

3rd ............3rd speed 4th ............4th speed M/C ............Machine min-1 ............RPM QUAD .........Quick up and down shift

00-3 95ZV General Information Weight of Main Components

Weight of Main Components Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

2,850

6,280

GSC bucket Standard

Item Unit name

Boom

2,150

4,740

“Z” -Lever

290/pc

640/pc

Link (Bucket to Lever)

60/pc

130/pc

Engine room

Chassis

Screen board

180

400

Roof

150

Radiator guard

200

440

Side cover

35/pc

Hydraulic tank

280

620

Excluding oil

Fuel tank

240

530

Excluding fuel

Floor board

250

550

Including ope. board, instrument panel and control box

Cab (ROPS)

620

1,370

Deck

Left side

180

With handrail

Right side

130

With handrail

2,410

5,310

Front chassis

Power line

Rear chassis

2,520

5,560

Counter weight

1,920

4,230

Engine

1,700

3,750

Excluding oil

Radiator assembly

650

1,430

Excluding water and oil

Transmission

1,310

2,890

Excluding oil

Second propeller shaft

100

220

Third propeller shaft

Front axle assembly

1,970

4,340

Excluding tires and oil

Rear axle assembly

2,130

4,700

Excluding tires and oil (Including axle support)

Front

350

770

Rear (S/N ~0290)

360

790

Rear (S/N 0291~)

370

820

100

220

Differential

Multiple control valve

Hydraulic system

Other

Remarks

Pilot valve

Steering valve

110

Gear pump

Double pump

Single pump

Fan motor

Boom cylinder

360/pc

790/pc

Excluding oil

Bucket cylinder

180/pc

400/pc

Excluding oil

Steering cylinder

40/pc

Excluding oil

Tire

790/pc

1,740

With rim (29.5-25-22PR(L-3)); No Hydro Inflation

Battery

60/pc

130/pc

00-4 95ZV General Information Bolt Tightening Torque

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 size Type

Nominal diameter

Pitch

(F) 1.25

132

M10

M12

M14

Metric thread

Unified thread

Bolt strength

Nominal dimension

M16

M18

M20

M22

M24

M27

M30

M33

5/16

8.8 (8T)

10.9 (11T)

(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

(F) 2.0

2,059

3,040

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

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.

00-5 95ZV General Information Bolt Tightening Torque

(kgf-m) Bolt size Type

Metric thread

Nominal diameter

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

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

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

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.

00-6 95ZV General Information Bolt Tightening Torque

(lb-ft) Bolt size Type

Metric thread

Nominal diameter

Pitch

8.8 (8T)

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

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

M33

5/16

10.9 (11T)

(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

(F) 2.0

1,520

2,240

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.

00-7 95ZV General Information Bolt Tightening Torque

Flanged hexagon bolt 1. Bolt type: Metric thread 2. Bolt strength: 8.8 (8T) 3. Thread pitch: Coarse pitch thread (C) (N-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

0.8

1.25

M10

1.5

M12

1.75

M16

231

M20

2.5

441

M24

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

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 size Type

Metric thread

Bolt strength

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

00-8 95ZV General Information Hose Band Tightening Torque

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

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

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

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

Low pressure hose Inner dia. (mm) Outer dia. (mm) 6

16.5

18.5

20.5

22.0

24.5

26.0

29.0

30.5

32.0

34.0

39.5

41.5

46.0

48.0

54.0

70.5

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

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

70ZV00003

00-9 95ZV General Information Liquid Gasket and Screw Lock Agent

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: Code AA01 Liquid gasket

Screw lock agent

Manufacturer

Product name

Plastic Gasket 568

Loctite

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 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.

To bond a plane or to fit a shaft

Cautions regarding parts removal

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 prepares metal surface of the threads and speeds curing time.

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.

Antiseize Agent

If it is difficult to remove the screw or shaft, heat the bolt to soften the agent (200~250°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.

Code

Manufacturer

AC01

Loctite®

Product name Loctite® 767 (Paste or spray)

00-10 95ZV General Information Liquid Gasket and Screw Lock Agent

Screw lock agent application procedure

How to wind a seal tape

Through-hole Apply screw lock agent one or two lines on the male threads.

Seal tape

Leave 1~2 screw Screw lock agent 65ZV00004

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. 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 About 1/3H

65ZV00003

00-11 95ZV General Information Cautions Regarding Welding Repair Service

Cautions 1. Turn the starter switch OFF.

4. Ground the welder near the section to be welded.

2. Remove the battery terminals both positive and negative sides from the battery.

5. To ground the welder, check that the electric current will not flow through the cylinders. Cylinder head covers for some models have a low conductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod.

6. Calibrate throttle pedal to ECM. (a) Turn the starter switch to "ON". (b) Fully depress and release the throttle pedal three times. (c) Turn the starter switch to "OFF".

Example 1

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

35C00002

Example 2

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

Section to be welded

Ground this section. (correct grounding)

35C00006

00-12 95ZV General Information Cautions Regarding Welding Repair Service 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

Heat-resistant cloth Section to be welded

Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

35A00005

Plated section (Mask this section.)

(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.

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.) 35C00003

(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.

1m or more

Scrap material, etc.

Section to be welded

1m or more 35C00004

(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.

00-13 95ZV General Information Cautions Regarding Handling of Bearing

Cautions Regarding Handling of Bearing Bearing installation cautions

Force

IMPORTANT Unwrap a new bearing just before installing it. Metal pad

K65V2J00002

K65V2J00004

When installing a bearing to a shaft or a housing, it is important to insert the bearing by equally applying pressure on the bearing ring circumference. Do not partially apply pressure on the bearing ring, as it may cause unstable and entangled bearing operation. Do not apply pressure from the side, as it will apply load via the rolling element, making indentations on the bearing ring. Do not hit the bearing directly with a hammer, etc. to prevent indentation and crack.

If the interference is rather small, put an appropriate tool on the bearing inner ring and press the tool, not directly the bearing, with a pressing machine or a hammer to fit the bearing on the shaft, while applying equal pressure onto the inner race circumference. When installing the bearing on a shaft and also in a housing at the same time, put an appropriate metal pad both on the inner and outer rings as shown in the above figure (right), and press the bearing using the tool so that equal pressure is applied onto the inner and outer races.

CAUTION Be sure to hold the bearing straight up before and while pressing it.

Interference fits for a bearing

Heating to remove the interference

To assemble a bearing on a shaft, for example, it is usually assembling an oversize shaft into an undersized hole. The method is called “interference fit” or “press fit”.

If the interference is large enough, heat the bearing before installation. The bearing expands when heated, thus the interference can be temporarily removed, which makes interference fitting easier.

Note “Interference” here means the difference between the bearing inner ring bore and the shaft outer diameter.

There are two basic methods for assembly, sometimes used in combination: Force, and changing the size of the parts by heating.

To heat the bearing, put it in heated clean oil below 120ºC (248ºF). (This method is not applicable to bearings including grease.)

00-14 95ZV General Information Cautions Regarding Handling of Bearing

Bearing operation test after installation Manually turn the shaft or housing after installing a bearing. Verify that there is no abnormal noise, chattering, vibration, or unusual load. If any abnormality is observed, stop rotating and check the bearing.

Bearing removal cautions Pressing machine

Bearing puller

Bearing removal tool K65V2J00003

When removing bearing unit, use an appropriate tools as shown above. Make sure to apply load only to the bearing ring to pull out the bearing, and DO NOT apply any load to the rolling element. If any load is applied when removing the bearing unit because of its installation conditions, the bearing must not be reused.

00-15 95ZV General Information Applying and Storing Articulation Stopper

Applying and Storing Articulation Stopper Applying articulation stopper 2 1

Locked position IL14-2(95ZV-D&R)

IL14-1(90ZV-D&R)

2. Turn rod (2) (articulation stopper) to the front and then align the pin hole. Insert pin (1) into the rod to lock the front chassis to the rear chassis.

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.

IL14-1(95ZV-D&R)

1. Park the machine so that the frame is straight ahead. Remove pin (1) from the articulation stopper on the hydraulic tank.

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.

00-16 95ZV General Information Applying and Storing Articulation Stopper

Storing articulation stopper

Stored position

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

IL14-3(95ZV-D&R)

14-1 95ZV Disassembly & Reassembly Chassis Group

95ZV Disassembly & Reassembly Chassis Group Deck ........................................................................ 14-2 Fuel Tank................................................................. 14-3 Hydraulic Tank......................................................... 14-5 Engine Room .......................................................... 14-7 Cab.......................................................................... 14-9 Floor Board ............................................................. 14-11 Boom ....................................................................... 14-13 Center Pin ............................................................... 14-16

14-2 95ZV Disassembly & Reassembly Chassis Group Deck

Deck Deck removing and installing Deck removing

1 4

1. Remove bolt (1). : Bolt (1): 94 N-m (9.6 kgf-m) (69 lb-ft) 2. Attach sling to handrails and remove bolts (2)(3). Lift deck (4) with the handrails. : Bolt (2)(3): 94 N-m (9.6 kgf-m) (69 lb-ft) : Deck (4) (with handrails): : 80 kg (180 lbs) (LH) : 60 kg (130 lbs) (RH)

95ZV14001

Deck installing For reinstallation, follow the above procedure in reverse order.

14-3 95ZV Disassembly & Reassembly Chassis Group Fuel Tank

Fuel Tank Fuel tank removing and installing

(S/N 0263~) (S/N 9065~)

Fuel tank removing 1

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

Before starting work: - Drain fuel from the fuel tank. (Fuel tank capacity: 425 L (112 gal)) - Remove the deck and the ladder. 3 (S/N ~0262) (S/N ~9064)

95ZV14001a

1. Disconnect level sensor electrical line coupler (1). 1

2. Attach sling to fuel tank (2). 3

: Fuel tank: 240 kg (530 lbs) (when empty) 3. Remove retainer bolt (3). : Bolt (3): 765 N-m (78.0 kgf-m) (562 lb-ft)

3 95ZV14002

14-4 95ZV Disassembly & Reassembly Chassis Group Fuel Tank

95ZV14003

4. Slightly pull out fuel tank (2) to disconnect suction hose (4), return hose (5). Plug the fuel line to prevent dirt entry.

Fuel tank installing For reinstallation, follow the above procedure in reverse order.

Fuel tank installation cautions After reinstallation, be sure to completely bleed air from the fuel line.

14-5 95ZV Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic Tank Hydraulic tank removing and installing Hydraulic tank removing

2 3

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting hydraulic tank removal: - Position the machine on level ground, and apply the parking brake. - Lower the attachment onto the ground, and block the tires with chocks, etc. to prevent them from moving. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel. Before starting work: - Drain hydraulic oil from the hydraulic tank. (Hydraulic tank capacity: 150 L (40 gal)) - Remove the deck and the ladder. - Clean the area around the tank.

(S/N 0101~0450) (S/N 9001~)

95ZV14004

1. Remove hose band (1) and bolt (2). Remove hose (3) from hydraulic tank (4). Note Cover the disconnected hose with vinyl to protect them from dust and dirt.

(S/N 0451~)

Breather valve

Filter

95ZV14004a

Note The breather valve on the hydraulic tank has been changed as shown.

95ZV14005

2. Remove bolts (5) and disconnect pipes (6) (7) from the hydraulic tank. Note Cover the disconnected pipes with vinyl to protect them from dust and dirt.

14-6 95ZV Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic tank installing

For reinstallation, follow the above procedure in reverse order.

4 8

Hydraulic tank installation cautions

95ZV14006

3. Attach sling to hydraulic tank (4) and remove bolts (8). : Bolt (8): 765 N-m (78.0 kgf-m) (562 lb-ft) : Hydraulic tank: 280 kg (620 lbs) (When empty)

After reinstallation, be sure to check the pipes for leakage, and also check the oil level of the hydraulic tank. Run the engine idle for five minutes to allow the pumps to become fully lubricated.

14-7 95ZV Disassembly & Reassembly Chassis Group Engine Room

Engine Room Engine room removing and installing

Engine room removing

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

5 2

Before starting work: - Recover/recycle refrigerant on the machine with an optional air conditioner, if required. - Remove the right and left decks together with the handrail. 95ZV14008

4 1

95ZV14007

95ZV14009

1. Remove covers (1) on both right and left sides of the screen board.

2. Remove round bar (2) and wires (3) inside engine side cover (4). Temporarily attach sling to the side cover, and remove bolt (5) to remove the cover. 3. Remove nut (6) for the roof cushion and lift the roof. : Nut (6): 94 N-m (9.6 kgf-m) (69 lb-ft) : Engine roof: 70 kg (150 lbs)

14-8 95ZV Disassembly & Reassembly Chassis Group Engine Room

10 7

13 8

95ZV14010

95ZV14012

4. Remove hoses (7) (8) for receiver tank (9) and for condenser (10) respectively.

6. Disconnect screen board retainer bolt (13) and lift the screen board.

Note - Before hose disconnection, be sure to recover/recycle the refrigerant. - The receiver tank should be replaced with a new one before the system is recharged. - Cover the disconnected hoses with vinyl to protect them from dust and dirt.

: Bolt (13): 230 N-m (23.5 kgf-m) (169 lb-ft) : Screen board (with condenser and air cleaner) 250 kg (550 lbs) Note Slowly lift the screen board while checking that there are no obstacles.

Screen board

Engine room installing For reinstallation, follow the above procedure in reverse order.

12 Air cleaner

Engine room installation cautions 11 95ZV14011

5. Remove hose band (11) for air cleaner rubber hose (12), and then remove hose (12). Note Cover the disconnected hoses with vinyl to protect them from dust and dirt.

After reinstallation, be sure to check the air conditioner for refrigerant leakage. Also check that the air cleaner rubber hose connection band is properly positioned and tightened with proper torque.

14-9 95ZV Disassembly & Reassembly Chassis Group Cab

Cab Cab removing and installing Cab removing 3

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. - Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. - Lower the attachment onto the ground, and apply the parking brake. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel. Before starting work: - Remove the decks on both right and left side. - Disconnect the electrical line couplers.

65ZV14013J

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

Filter 65ZV14014J

1 95ZV14013a

1. Remove covers (1) (2).

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

14-10 95ZV Disassembly & Reassembly Chassis Group Cab

95ZV14016

4. Remove cover (4).

Floor board

95ZV14018

6. Remove bolts (7). 95ZV14017

: Bolt (7): 765 N-m (78.0 kgf-m) (562 lb-ft) 5. Remove bolt (5). Tilt steering shaft (6) backward.

7. Remove bolt (8) and install the eye bolt (M16 x 2.0) on the cab instead. Attach sling and remove the cab. : ROPS cab: 620 kg (1,370 lbs) Note When tightening bolt (8) with the washer (added on S/N 0301~, 9096~) make sure that the rubber-coated side of the washer faces down to the cab.

Cab installing For reinstallation, follow the above procedure in reverse order.

14-11 95ZV Disassembly & Reassembly Chassis Group Floor Board

Floor Board Floor board removing and installing Floor board removing

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

1. Disconnect hose and electrical couplers between the floor board and chassis such as - air duct hose under the floor board - pilot hydraulic line hoses from Orbitrol®, pilot valve, multiple control valve - hoses from the air conditioner unit - brake line hoses from the brake valve - hoses for the window washer liquid tank Note - Before disconnecting the electrical couplers, hoses and pipes between the floor board and the chassis, put matchmarks on them to help during reassembly. - Recover the air conditioner refrigerant using the proper recovery method. - Prepare a drain pan for the oil. - Cover the disconnected hoses and pipes with vinyl to protect them from dust and dirt.

14-12 95ZV Disassembly & Reassembly Chassis Group Floor Board

Floor board installing For reinstallation, follow the above procedure in reverse order.

Floor board installation cautions After reinstallation, start the engine, and then check the refrigerant, and oil lines for leakage. Also check operation of the electrical equipment.

Rubber cushion

Rear chassis

95ZV14019a

1. Remove elastic plug and floor board retaining nut (1). 2. Temporarily sling then gradually lift the floor board while checking that there are no obstacles and that all pipes, cables, pins, etc. are disconnected. : Nut (1): 441 N-m (45.0 kgf-m) (324 lb-ft) : Floor board assy including ope. stand, control box, etc.: 550 kg (1,210 lbs) Reference : Rubber cushion mounting bolt: 89.7 N-m (9.15 kgf-m) (66 lb-ft)

14-13 95ZV Disassembly & Reassembly Chassis Group Boom

Boom Boom removing and installing

Boom removing

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. - Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. - Lower the attachment onto the ground, and release the residual pressure from the hydraulic oil tank and lines. - Apply the parking brake, remove starter key, and hang a "DO NOT START ENGINE!" tag on steering wheel.

WARNING Hitting the hardened parts such as a bearing, shaft, pin or 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.

95V2E14022

1. Remove pin (3) connecting bucket (1) and link (2). Note There are shims in the pin sections. Carefully store the removed shims, and correctly reinsert the shims when reinstalling the bucket. 2. Remove connection pin (5) from bucket (1) and boom (4) to remove the bucket. : Bucket: 2,850 kg (6,280 lbs)

Note - The attachment shown is a bucket. Special procedures maybe required for forks or other attachments. - The parts viewed from the right side are shown. The same parts are located on the left side in the same way.

7 2 95V14004

3. Temporarily sling link (2), and then remove connection pin (7) from lever (6) and link (2). : Link: 60 kg (130 lbs)

14-14 95ZV Disassembly & Reassembly Chassis Group Boom

9 6 11

95ZV14020

4. Disconnect grease pipe (8) for lever (6).

CAUTION

95ZV14021

7. Temporarily sling lever (6), and then remove lever pin (11). 8. Remove lever (6).

You have to work at a high position to remove the grease pipe. Always use a stepladder for this work. 5. Temporarily sling bucket cylinder (9), and remove connection pin (10) from lever (6) and bucket cylinder (9).

: Lever: 290 kg (640 lbs)

12 13

: Bucket cylinder: 180 kg (400 lbs)

IMPORTANT Never rest cylinder rods on surfaces that may damage them. This may cause cylinder seal to leak. 95ZV14022

6. Start the engine and shorten the bucket cylinder rod. Stop the engine.

9. Remove grease hose (13) from pin (12). Insert a wooden block between the boom cylinders and the hydraulic piping. Remove pins (12) from the cylinder rods on both the right and left sides of the boom. Note Placing a wooden support piece between the boom cylinder and the hydraulic pipe helps to reinstall the pin to the boom easily.

14-15 95ZV Disassembly & Reassembly Chassis Group Boom

Boom installing

For reinstallation, follow the above procedure in reverse order.

Boom installation cautions

95ZV14023

10. Temporarily sling the torque tube of boom (4), and then remove pins (14) from the boom on both the right and left sides of the boom. 11. Slowly lift boom (4) to remove it from the machine. : Boom: 2,150 kg (4,740 lbs)

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

After reinstallation, grease the boom pins, and then operate boom. During operation, check the boom for abnormal noise. Shim the pins so that there is no more than 1 mm (0.040 in) clearance side to side. If the clearance is too much, add shims. Place about 1/2 of the shims on each side. Refer to the illustrations and instructions in the following section 15 for proper shim procedure.

14-16 95ZV Disassembly & Reassembly Chassis Group Center Pin

Center Pin Upper center pin

: T1: 441 N-m (45.0 kgf-m) (324 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) T1

L1: Lubricating oil (Engine oil or gear oil) Bearing cover Front chassis Shim adjustment

Rear chassis

T2 L1

95V2E14023

Split shim

T2 L1 95V2E14024

Center pin shim adjustment Adjust the clearance to 0.1 ± 0.05 mm (0.0039 ± 0.0020 in) using the shim. After that, tighten bolt (T1).

14-17 95ZV Disassembly & Reassembly Chassis Group Center Pin

Lower center pin

Front chassis

Rear chassis

95V2E14025

95V2E14026

14-18 95ZV Disassembly & Reassembly Chassis Group Center Pin

Center pin removing and installing Center pin removing

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting center pin removal: - Place the machine on level and paved ground. - Lower the attachment onto the ground, and block the front tires with chocks, etc. to prevent them from moving. - Apply a stopper to the rear axle oscillation section to prevent the machine from oscillation. - Release the residual pressure from the hydraulic line, and also release the internal pressure from the hydraulic tank. Release the brake accumulator pressure by slowly and fully depressing and releasing the brake pedal at least 40 times. - Cover the steering cylinder rod to prevent it from being scratched.

2 3 Steering cylinder 95ZV14029

2. Remove right and left steering cylinder retainer pins (2) and shims (3). Inspect them for wear or damage, and replace if necessary. Note Wrap the steering cylinder rods to prevent accidental damage to the chrome rods. 3. Disconnect the brake hose, multiple control valve pilot hoses, and return hose. Disconnect the electrical line from the coupler. : Hydraulic oil: Approx. 3 L (0.8 gal)

Transmission

Note Cover the disconnected hoses with plugs, caps or vinyl to protect hoses from dust and dirt.

1 Front differential 95ZV14028

1. Remove bolts and disconnect second propeller shaft (1) from the transmission. : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327) 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 to about 235ºC (450ºF). Keep the flame away from the seals of the coupling. Do not reuse the bolts, and always replace with new ones.

4 95ZV14030

4. Remove upper center pin retainer bolt (4). : Bolt (4): 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubricating oil)

14-19 95ZV Disassembly & Reassembly Chassis Group Center Pin

Jack screw

95ZV14039

97K14028

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

Jack screw: M18 (Pitch 1.5), totally threaded M18 x 1.5

WARNING 70

65ZV14011

5. Screw the M18 (Pitch 1.5) bolt of approximately 70 mm (2.76 in) length into the center of bushing (5) to push out the bushing. This bolt is used as a jack screw.

When using a crane, incorrect signals and insufficient sling capacity could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Check a sling before using and do not use damaged or frayed sling. - Use signals as agreed upon before starting work. - Stay out of the working area while using a crane. - Be sure the crane has adequate capacity.

7 By Jack

95ZV14031

Jack 95V2E14028

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

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

14-20 95ZV Disassembly & Reassembly Chassis Group Center Pin

12 By Jack

95ZV14032

9. Support the bottom of the fuel tank or rear chassis using a garage jack with wheels. Push out lower center pin (10) using another jack to remove pin.

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

95ZV14034

11. Remove ring (11) and remove bolt (12) from bearing cover (13). : Bolt (12): 441 N-m (45.0 kgf-m) (324 lb-ft)

Front

Bar 95V14021

Grease nipple installation direction

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

95ZV14033

Note When reinstalling, install the bearing cover so that the direction of the grease nipple is as illustrated above. 12. Remove shim (14).

14-21 95ZV Disassembly & Reassembly Chassis Group Center Pin

Front

Rear

16 Split of outer bearing

14 97K14032

95ZV14036

Note If taper roller bearing (15) is replaced, be sure to adjust the clearance using shims (refer to Section15). Thickness of shim: 0.1, 0.2, 0.3, 0.5, and 1.0 mm (0.004, 0.008, 0.012, 0.020 and 0.040 in)

14. When spherical bearing (16) for the lower center pin is replaced, install the bearing outer ring so that the split is perpendicular to the front - rear line of the machine.

13. Replace the dust seals in upper center pin and lower center pin with new ones.

Center pin installing For reinstallation, follow the above procedure in reverse order.

Center pin assembly cautions Center pin

95ZV14038

Note Take care of the correct direction of dust seals as shown above.

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

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

14-22 95ZV Disassembly & Reassembly Chassis Group

MEMO

15-1 95ZV Service Standard Chassis Group

95ZV Service Standard Chassis Group Linkage.................................................................... 15-2 Linkage Pin Standard Clearance Values ................. 15-3 Center Pin ............................................................... 15-4 Bucket Positioner and Boom Kick-Out .................... 15-6

15-2 95ZV Service Standard Chassis Group Linkage

Linkage 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

4. Front chassis - Boom

5. Bucket - Rod

6. Lever - Rod

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

mm (in)

5 10

K95ZV12003

15-3 95ZV Service Standard Chassis Group Linkage Pin Standard Clearance Values

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

Item

Solution

Pin standard dimension

Bushing standard dimension

Standard clearance

Tolerance

Joint section between attachment and boom

ø90-0.120 -0.155

ø90+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between boom and lever

ø110-0.120 -0.155

ø110+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between boom and boom cylinder

ø100-0.120 -0.155

ø100+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between front chassis and boom

ø110-0.120 -0.155

ø110+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between attachment and link

ø80-0.120 -0.155

ø80+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between lever and link

ø80-0.120 -0.155

ø80+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between lever and bucket cylinder

ø90-0.120 -0.155

ø90+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between bucket cylinder and front chassis

ø90-0.120 -0.155

ø90+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between boom cylinder and front chassis

ø100-0.120 -0.155

ø100+0.140 0

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

Joint section between front chassis and steering cylinder

ø50-0.100 -0.130

ø50+0.120 0

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

Joint section between steering cylinder and rear chassis

ø50-0.100 -0.130

ø50+0.120 0

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

Adjustment procedure

Liner clearance adjustment

(for the liner clearance marked with asterisk)

70ZV15001

∗ : Adjust the liner clearance between the bosses to 1.2 mm (0.0472 in) or less using liner of 1 mm (0.0393 in) thickness. For the steering cylinder, adjust the liner clearance on the rear chassis side first, and then adjust the liner clearance on the front chassis side while checking that the cylinder is not inclined. Liners should be placed on both sides of the linkage as much as possible. Wear then occurs on the liners and reduces wear on the chassis. Excessive vertical free play in the steering cylinders can result in loud knocking noises when the steering wheel is turned. ∗∗ : Only in case the clearance at the machine center side is more than 4.5 mm (0.1772 in), adjust using liner of 4.5 mm (0.1772 in) thickness.

15-4 95ZV Service Standard Chassis Group Center Pin

Center Pin Center pin shim adjustment

Bearing cover installing

T1 Bearing cover

Front

Grease nipple installation direction

Front chassis Shim adjustment

Rear chassis

T2 L1

[Upper]

[Lower]

95V2E14023

97ZV13002

The clearance between the front chassis and bearing cover is 0.75 ± 0.5 mm (0.0295 ± 0.0197 in) before shim adjustment. Add shims so that the clearance is 0.1 ± 0.05 mm (0.0039 ± 0.0020 in).

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

: T1: 441 N-m (45.0 kgf-m) (324 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) L1: Lubricating oil (Engine oil or gear oil)

15-5 95ZV Service Standard Chassis Group Center Pin

Lower center pin bearing outer ring installing Bearing outer ring

Front chassis

Rear chassis 95ZV15001

Front

Rear

Bearing outer ring

Split of outer bearing 95ZV15002

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

15-6 95ZV Service Standard Chassis Group Bucket Positioner and Boom Kick-Out

Bucket Positioner and Boom Kick-Out

Bucket positioner

Boom kick-out

90ZV15005

15-7 95ZV Service Standard Chassis Group Bucket Positioner and Boom Kick-Out

Bucket positioner

Adjusting plate

Note The illustration shows on the right side tilt cylinder

Direction of indicator lamp

5 Indicator lamp Proximity switch

5 2

2.5

4 1 95ZV15003

Bucket positioner adjustable angle

-7º Adjusting distance (5): 6 mm (0.236 in)

0 57 mm (2.244 in)

+7º 154 mm (6.063 in) K90ZV15001

No.

Item

Judgment standard

Solution

Clearance of bucket positioner switch

5±2 mm (0.196±0.078 in)

Adjustment

Adjusting plate mounting bolt tightening torque

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

Tightening

Switch mounting nut tightening torque

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

Tightening

Bucket positioner adjustable angle (distance (5))

-7º ~ +7º (6 ~ 154 mm)

Adjustment

15-8 95ZV Service Standard Chassis Group Bucket Positioner and Boom Kick-Out

Boom kick-out

dj u s 43. table 6º an g

ut a k-o Kic

A dj

ust

i ng

pla

te a 43. djusta 6º ble

are

Adjusting plate

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

Direction of indicator lamp

Proximity switch

95ZV15004

.6 º

Boom kick-out hoist angle

95ZV15005

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

15-9 95ZV Service Standard Chassis Group Bucket Positioner and Boom Kick-Out

No.

Item

Judgment standard

Solution

Clearance of boom kick-out switch

7 ± 1 mm (0.276 ± 0.078 in)

Adjustment

Adjusting plate mounting bolt tightening torque

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

Tightening

Switch mounting nut tightening torque

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

Tightening

Boom kick-out adjustable angle

0 ~ 43.6º

Adjustment

15-10 95ZV Service Standard Chassis Group

MEMO

24-1 95ZV Disassembly & Reassembly Power Group

95ZV Disassembly & Reassembly Power Group Power Line .............................................................. 24-2 Radiator................................................................... 24-3 Engine ..................................................................... 24-7 Propeller Shaft......................................................... 24-10 Air Cleaner .............................................................. 24-12 Muffler ..................................................................... 24-14 Fan .......................................................................... 24-15 Front Axle Assembly ............................................... 24-16 Floating Seal ........................................................... 24-31 Internal Gear Hub.................................................... 24-33 Spider Assembly ..................................................... 24-37 Special Tool ............................................................. 24-39 Rear Axle Assembly ................................................ 24-45 Axle Support............................................................ 24-50 Differential Assembly............................................... 24-57

24-2 95ZV Disassembly & Reassembly Power Group Power Line

Power Line Power line tightening torque Engine

T1 L 3 T2 L 1

T3 L 1 (S/N 0150~, 9001~)

T4 L 3

T5 L 3

Transmission

T1 L3 (S/N 0150~, 9001~)

(S/N 0413~)

T1 L1

T7 L1

T6 L 2

Rear differential

2nd propeller shaft

T6 L 2 3rd propeller shaft Front differential 95ZV24001a

: T1: 441 N-m (45.0 kgf-m) (325 lb-ft) T2: 230 N-m (23.5 kgf-m) (170 lb-ft) T3: 201 N-m (20.5 kgf-m) (148 lb-ft) T4: 67 N-m (6.85 kgf-m) (50 lb-ft) T5: 157 N-m (16.0 kgf-m) (116 lb-ft) T6: 142 N-m (14.5 kgf-m) (105 lb-ft) T7: 417 N-m (42.5 kgf-m) (307 lb-ft)

L1: With liquid adhesive (Loctite® 262) L2: With liquid adhesive (Three Bond 1327) L3: With lubricating oil (Engine oil or gear oil) Note Always replace drive shaft bolts with new ones - never reuse them.

24-3 95ZV Disassembly & Reassembly Power Group Radiator

Radiator Radiator tightening torque

T2 L3 T3

T6 T6

T3 L3 (S/N 0131~) (S/N 9004~)

T5 L3

T3 T4 L3

T4 L3 T1 L1

(S/N ~0242) (S/N ~9018)

T3 L3 T3 L3

T7 L3

Rear chassis

95ZV24002a

: T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 49 N-m (5.0 kgf-m) (36 lb-ft) T3: 94 N-m (9.6 kgf-m) (69 lb-ft) T4: 142 N-m (14.5 kgf-m) (105 lb-ft) T5: 474 N-m (48.5 kgf-m) (349 lb-ft) T6: 53 N-m (5.4 kgf-m) (39 lb-ft) T7: 90 N-m (9.15 kgf-m) (66 lb-ft)

L1: With liquid adhesive (Loctite® 262) L3: With lubrication oil (Engine oil or gear oil)

24-4 95ZV Disassembly & Reassembly Power Group Radiator

Radiator removing and installing Radiator removing

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

1 95ZV24003

1. Remove bolt (1). : Bolt: 230 N-m (23.5 kgf-m) (170 lb-ft) 2. Sling radiator guard (2), and then remove it.

: Radiator guard: 200 kg (440 lbs) 3. Drain the coolant from the radiator. : Coolant: 61.5 L (16 gal)

95ZV24004

4. Disconnect coolant hoses (3)~(5) from the radiator. Note Cover the disconnected hoses with caps, plugs, or vinyl to protect them from dust and dirt.

24-5 95ZV Disassembly & Reassembly Power Group Radiator

Air cooler

(S/N ~0262) (S/N ~9064)

Fuel cooler

11 7

Fuel tank 95ZV24005

5. Disconnect air cooler hoses (6) (7) from the air cooler

95ZV24007

(S/N 0263~) (S/N 9065~)

: Hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft) Note - Cover the disconnected hoses and air cooler openings with caps, plugs, or vinyl to protect them from dust and dirt. - During reassembly, carefully inspect and clean the hoses and air cooler of any contaminates. Anything left in the lines or air cooler will go directly into the engine causing extensive engine damage.

Fuel cooler

Fuel tank 95ZV24007a

7. Disconnect fuel hoses (10) (11) from the fuel cooler. 9

: fuel: 2 L (0.6 gal) Radiator

Note Cover the disconnected hoses with caps, plugs, or vinyl to protect hoses from dust and dirt.

Hydraulic cooler

8 95ZV24006

6. Remove hoses (8) (9) from the hydraulic cooler. : Hydraulic oil: 8.2 L (2.2 gal) Note Cover the disconnected hoses with caps, plugs, or vinyl to protect the hoses from dust and dirt.

24-6 95ZV Disassembly & Reassembly Power Group Radiator

Radiator installing For reinstallation, follow the above procedure in reverse order.

13 15

95ZV24008

8. Remove retainer bolts (12) and remove plate (13). : Bolt (12): 230 N-m (23.5 kgf-m) (170 lb-ft) 9. Temporarily sling radiator (14). Remove retainer bolts (15), and lift the radiator assembly. : Bolt (15): 49 N-m (5.0 kgf-m) (36 lb-ft) : Radiator assembly: 650 kg (1,430 lbs)

24-7 95ZV Disassembly & Reassembly Power Group Engine

Engine Engine removing and installing Engine removing

1. Disconnect the negative side of battery cable. Then remove the positive cable.

IMPORTANT WARNING

Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground. - Apply the articulation stopper. - Block front wheels with chocks or the like to prevent the wheels from moving. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel. - Select correct tooling to remove the engine or the transmission. Before starting work: - Remove the engine room (refer to Section 14). - Remove the fan guard and the fan (refer to "Fan" pages in this section). - Remove the hydraulic pumps (refer to Section 44). - Collect the air conditioner refrigerant (option) using the proper recovery method.

If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the “OFF” position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this “write to memory function” prior to removing battery terminals. 2. Remove the wires from the alternator, starter motor and the oil pressure switch. 3. Disconnect the heater hose and the fuel hose also disconnect the air conditioner lines from the compressor. Note Cover the disconnected hoses and pipes with vinyl to protect them from dust and dirt. 4. Support the bottom of the transmission using a garage jack. Temporarily sling the engine assembled with the transmission. : Engine and transmission: approx. 3,000 kg (6,640 lbs) Note Be sure the crane and lifting cables, chains or straps are not damaged and are safely capable to support the assembly. 5. Disconnect the second and the third propeller shafts from the transmission. : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : With liquid adhesive (Loctite® 262)

24-8 95ZV Disassembly & Reassembly Power Group Engine

Engine

95ZV24009

Engine

K95ZV24001

6. Remove engine mounting bolt (1) both on the right and left sides. : Bolt (1): 201 N-m (20.5 kgf-m) (148 lb-ft) : With liquid adhesive (Loctite® 262)

K95ZV24002

7. Remove retainer bolt (2) both on the right and left sides. : Bolt (2): 441 N-m (45.0 kgf-m) (325 lb-ft) : With lubricating oil (engine oil or gear oil)

24-9 95ZV Disassembly & Reassembly Power Group Engine

Engine installing 4 Transmission

For reinstallation, follow the above procedure in reverse order.

Engine installation cautions 3

K95ZV24003

8. Remove transmission mounting bolts (3) (4) both on the right and left sides. : Bolt (3)(4): 230 N-m (23.5 kgf-m) (170 lb-ft) : With lubricating oil (engine oil or gear oil) 9. Slightly pull up the engine at fan side and insert a hard wooden piece in the clearance between the flywheel bottom and the rear axle in order to support the torque converter.

O-ring

K95ZV24004

- There is an O-ring in the housing between engine and torque converter. Be sure to replace the O-ring with a new one, and apply liquid gasket. : Liquid gasket (Three Bond 1215) application - After reinstalling the engine, completely bleed the fuel line of air.

Engine

T/C T/M K95ZV24004

10. Remove retainer bolts (5) connecting the engine flywheel housing and the transmission. : Bolt (5): 67 N-m (6.85 kgf-m) (50 lb-ft) : With lubricating oil (engine oil or gear oil) 11. Separate the engine and the transmission from each other, and then lift the engine. Note Carefully lift the engine while checking that there are no obstacles around it. : Engine assy: approx. 1,700 kg (3,750 lbs)

- Calibrate throttle pedal to ECM. - Turn the starter switch to "ON". - Fully depress and release the throttle pedal three times. - Turn the starter switch to "OFF". - Set the starter key to ON, and then check the monitor lamps of electrical equipment. - Run the engine at the idling speed for 5 minutes. After that, recheck the amount of the coolant. - While gradually increasing the engine speed, check operation of the electrical equipment. - After the engine has reached operating temperature, inspect for leaks. - Stop the engine. Allow it to cool and make a final check of engine oil level and coolant level.

24-10 95ZV Disassembly & Reassembly Power Group Propeller Shaft

Propeller Shaft Propeller shaft removing and installing

Transmission

Second propeller shaft removing

Rear differential

2 4 Front differential

5 1

2nd propeller shaft

5 3rd propeller shaft 95ZV24010a

1. Disconnect the grease pipe, and remove bolt (2) from pillow unit bearing (1). : Bolt (2) (S/N ~0412): 441 N-m (45.0 kgf-m) (325 lb-ft) : Bolt (2) (S/N 0413~, with washer): 417 N-m (42.5 kgf-m) (310 lb-ft) : Screw lock agent (Loctite® 262) 2. Support the second propeller shaft by cable or garage jack. Remove bolt (3) at the transmission side. Remove bolt (4) to disconnect the second propeller shaft from the front differential. : Bolt (3)(4): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) 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 to about 235ºC (450ºF). Keep the flame away from the seals of the coupling. Do not reuse the bolts, and always replace with new ones. 3. Take out the second propeller shaft to the front. : Second propeller shaft: 100 kg (220 lbs)

24-11 95ZV Disassembly & Reassembly Power Group Propeller Shaft

Third propeller shaft removing

Propeller shaft installation cautions Transmission

Transmission

Rear differential

3 2 4

5 1

Front differential

2nd propeller shaft

5 3rd propeller shaft 95ZV24010a

Remove bolt (5). : Bolt (5): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application 1. Remove the third propeller shaft. : Third propeller shaft: 25 kg (55 lbs)

Propeller shaft installing For reinstallation, follow the above procedure in the reverse direction.

2nd propeller shaft

3rd propeller shaft K95ZV24005

During reinstallation, align the direction of the flange yokes on the second and third propeller shaft sides of the transmission. (Refer to 95ZV Shop Manual, Function & Structure, Section 22) [Difference in the yoke phase (direction) will cause the propeller shaft damage and "knocking" during a turn.]

24-12 95ZV Disassembly & Reassembly Power Group Air Cleaner

Air Cleaner Air cleaner removing and installing

5 1 6

Air cleaner removing 3

4 2

90ZV24022

1. Release wing nut (1), and then remove cover (2). 2. Release wing nut (3), and then remove outer element (4). 3. Release wing nut (5), and then remove inner element (6). 4. Remove the rubber valve on the bottom of the air cleaner case, and inspect it for any damage. Replace it if necessary. Note Removing inside elements reduces the weight and makes air cleaner case removal work easier.

K97V2J24019

5. Remove cover (6) installed on the screen board.

24-13 95ZV Disassembly & Reassembly Power Group Air Cleaner

Air cleaner installing

Screen board

For reinstallation, follow the above procedure in reverse order. 7

Air cleaner installation cautions 9 8

Air pipe

- Be sure the inside of air cleaner housings (9) are wiped clean.

K97V2J24020

6. Disconnect air duct (7) and disconnect indicator wire coupler (8). Inspect air ducts (7) for damage or wear. Replace if there is any damage or wear.

2~3 mm (1/8 in) 5 mm (1/4 in) or less Fix the bands avoiding the beading

10 Air duct (7) Air pipe insertion amount: 45~50 mm (1.8~2 in) K85V2U24005

2~3 mm (1/8 in)

Fix the bands avoiding the beading

K95V2U24012

7. While supporting air cleaner case (9) with your hand, remove bolts (10), and then lower the air cleaner case. 8. Take out air cleaner case (9) from the opening. 9. Cover the open pipes with caps, plugs or vinyl.

Air duct (7)

Air cleaner insertion amount: 25~32 mm (1~1.26 in) Engine insertion amount: 25~35 mm (1~1.38 in) K95ZV24006

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

24-14 95ZV Disassembly & Reassembly Power Group Muffler

Muffler Muffler removing and installing Muffler removing

4. Remove retainer bolt (5) for muffler (4) and lift it for removing. : Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft) : Muffler: 30 kg (66 lbs)

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

Note After disconnection, cover the pipe at the turbocharger side with vinyl, caps, plugs or the like to protect the turbocharger from dust and dirt.

Muffler installing 2

For reinstallation, follow the above procedure in reverse order.

4 5

Muffler installation cautions A

After reinstallation, check all the joints for gas leakage and vibration.

A 6 3

95ZV24013a

1. Remove retainer bolt (1) then remove exhaust pipe (2). : Bolt (1): 29.4 N-m (3.0 kgf-m) (22 lb-ft) 2. Remove U-clamp and exhaust pipe (3) between turbocharger and muffler (4). 3. Disconnect drain pipe (6).

24-15 95ZV Disassembly & Reassembly Power Group Fan

Fan Fan removing and installing 1

Fan motor

Fan removing

WARNING

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

95ZV24015

1. Remove retainer bolts (2) for fan (1).

: Bolt (2): 94 N-m (9.6 kgf-m) (69 lb-ft) : With lubrication oil (engine oil or gear oil) 2. Sling fan (1) and take it out. : Fan: 32.5 kg (70 lbs) Note Carefully remove the fan while checking that the fan will not damage the radiator fins. Inspect the fan and replace it if there are any signs of damage or cracks. Fan blade breakage can cause extensive damage.

Fan installing

Radiator grill

For reinstallation, follow the above procedure in reverse order. Note Refer to "Fan Motor" page 44-78 to remove and/or disassemble the fan motor.

See the enlarged drawing below.

95ZV24014

24-16 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Front Axle Assembly Front axle assembly tightening torque (S/N 9001~)

T8 L1

Front differential

T1 L 3

R. H

T8 L1

(S/N 0188~, 9004~) (S/N ~0187, ~9003)

T7 T5 T5 T5 B T6 L 1

T10 (S/N ~0311, ~9095)

A C

T3 L 1

(S/N ~0311, ~9095)

T9 L 1

L. H T2 T4 95ZV24016a

: T1: 1,420 N-m (145.0 kgf-m) (1,049 lb-ft) T2: 892 N-m (91.0 kgf-m) (658 lb-ft) T3: 417 N-m (42.5 kgf-m) (307 lb-ft) T4: 86 N-m (8.8 kgf-m) (64 lb-ft) T5: 78 N-m (8.0 kgf-m) (58 lb-ft) T6: 53 N-m (5.4 kgf-m) (39 lb-ft) T7: 33 N-m (3.4 kgf-m) (25 lb-ft) T8: 314 N-m (32.0 kgf-m) (98 lb-ft) T9: 90 N-m (9.15 kgf-m) (66 lb-ft) T10: 50 N-m (5.1 kgf-m) (37 lb-ft)

L1: Screw lock agent (Three Bond 1327) L3: With lubrication oil (Engine oil or gear oil) T10: Screw lock agent (Loctite® 648)

24-17 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Axle nut tightening procedure 1. Tighten axle nut (A) with 2,746 N-m (280 kgf-m) (2,026 lb-ft) tightening torque to install the taper roller bearing. 2. Loosen axle nut (A). 3. Tighten axle nut (A) again with the same tightening torque as above 1. 4. Turn the wheel hub 2~3 turns back and forth, and measure the preload applied to the bolt screw hole in housing (B). Preload at housing (B): 324~363 N (33~37 kgf) (73~81 lbf) Note This is "breakaway" force. The force required to start the wheel turning.

Floating seal installing Use jig to install the floating seal to the axle assembly. Refer to "Floating Seal" page 24-31 for details.

24-18 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly removing and installing Front axle assembly removing

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

1 95ZV24085

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

Before starting work: - Drain the oil from axle. (100 L) (26 gal)

: Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) without lubrication oil : Tire: 790 kg/pc (1,740 lbs/pc)

2 4

Stand Stand 95ZV24017

- Lift the front wheel using the attachment, and then place a stand under the front chassis to support the chassis. - Block the rear wheels with chocks.

1. Press the hydraulic tank breather valve cap to release the trapped tank pressure. To release the accumulator pressure, slowly and fully depress and release the brake pedal at least 40 times.

95ZV24018

3. Remove second propeller shaft retainer bolts (2). Remove cover (3) and brake pipe (4). Disconnect air breather hose from the hydraulic tank. : Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application : Hydraulic oil: Approx. 0.3 L (0.1 gal) Note - Never reuse the retainer bolts. Always replace with new ones. - Cover the disconnected hoses and pipes with vinyl to protect them from dust and dirt. - Clean air breather hose before installing.

24-19 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly installing 7

For reinstallation, follow the above procedure in reverse order.

Front axle assembly installation cautions After reinstallation, completely bleed air in the service brake.

6 95V24026

4. Temporarily sling axle assembly (6), and then remove twelve retainer bolts (7). Place axle assembly (6) on a carrier to smoothly pull out. : Bolt (6): 1,420 N-m (145 kgf-m) (1,049 lb-ft) : Axle assembly: 1,970 kg (4,340 lbs) Note During reassembly be sure both mating surfaces are clean and free of paint. Never reuse retainer bolts. Replace with new bolts.

Socket bolt (4 pcs)

Spider 95V2E24064

CAUTION Before air bleeding in the brake oil line, be sure that the wheel and tire assemblies are installed on the wheel hub. If the wheel is not installed, the socket bolts (4 pcs) used to temporarily tighten the spider and the wheel hub may be broken by the brake piston. Then the spider and the cover may fall off.

24-20 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Service brake air bleeding procedure

IMPORTANT Before bleeding the service brakes, it is important to remove all air from the brake valve manifold block, and all related valves. These include the reducing valve and park brake valve. Failure to do this correctly will result in unsatisfactory brake modulation. 1. Start and run the engine to build brake accumulator pressure. Shut "OFF" the engine. Rebuild brake accumulator pressure as often as needed.

Air bleeder nipple

Vinyl tube 70ZV52019

2. Connect a clean vinyl tube to the air bleeder nipple, and place an oil can to receive the oil, or route to hydraulic tank. 3. 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. 4. After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple. 5. Repeat this until there is no air in the oil. Completely bleed each wheel of air.

24-21 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Front axle disassembling and assembling Front axle disassembling

WARNING Unexpected movement of the machine or components could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and then apply the parking brake. - Apply the articulation stopper. - Block the rear wheels with chocks or the like to prevent the wheels from moving. - The stands must be capable of supporting the total weight of the front chassis, boom, and attachment.

1 95ZV24085

1. Remove wheel and tire assembly (1) from the side to be disassembled (example: left side). : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) without lubrication oil : Tire: 790 kg/pc (1,740 lbs/pc)

Boom cylinder lock collar

Stand Stand 95V2E24063

Note Refer to the "Special Tool" pages within this section for tooling and jigs. Before starting work: - Lower the attachment onto the ground. Lift the front wheels while supporting the machine with the attachment. Place a stand under the front chassis to support it. Check that the tires are off the ground. - Lift the boom until it is horizontal, and place a stand under the boom to support it or install a boom cylinder lock collar.

97K24044

2. Remove drain plug (2) from the differential section to drain oil. : Gear oil: Approx. 60 L (16 gal)

24-22 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

6 97K24045

95ZV24020

3. Turn drain plug (4) to the bottom of wheel hub (3) to drain oil.

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

: Gear oil: Approx. 20 L (5.3 gal) C

Note To replace the oil, refer to the oil amount described below. 9

: Wheel hub section: 20 L (5.3 gal) for left side, 20 L (5.3 gal) for right side Differential section: 60 L (15.9 gal) Total oil amount for front axle: 100 L (26.4 gal) 95V2E24072

6. Temporarily sling the spider using hoisting tool (C). Remove four spider retainer bolts (8) to remove spider assembly (9). : Retainer bolt: 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 125 kg (275 lbs)

Note The brake backing plate is fixed behind the spider assembly. Do not forget the brake retainer when reinstalling the spider assembly. 97K24046

4. Remove cover (5). : Retainer bolt: 90 N-m (9.15 kgf-m) (66 lb-ft) : Screw lock agent (Three Bond 1327)

24-23 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

17 12 11 18

10 15a 15

95V2E24065

95ZV24024

7. Remove friction plate (10). Remove steel plate (11). Remove friction plate (12) and remove steel plate (13).

9. Remove retainer bolts (16), lock plate (17) and then remove axle nut (18).

Note Clean the brake plates, and then check the plates for distortion, discoloration and wear. Refer to the sections 55 for additional information.

Note Axle nut width across flat: 160 mm : Retainer bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : Screw lock agent (Three Bond 1327) Initial tightening torque for assembly: : Nut: 2,746 N-m (280 kgf-m) (2,026 lb-ft)

Note When reassembling, measure the minimum pulling force to rotate the wheel hub using a spring scale after re-tightening nut (18).

19 A 95ZV24023

8. Remove axle shaft (14), disc gear (15) and wear ring (15a) (behind disc gear (15)).

95ZV24025

10. Pull out internal gear hub (19) to the extension end face using internal gear hub puller (A). Refer to the "Special Tool" page within this section for puller dimensions.

24-24 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembling B 19

To reassemble the front axle, follow the above procedure in reverse order.

95ZV24026

11. Sling internal gear hub assembly (19) using internal gear hub hoisting tool (B). Remove internal gear hub assembly (19). : Internal gear hub assembly: 120 kg (265 lbs) Refer to the "Special Tool" page within this section for tool dimensions. Note Be sure to support the wheel hub, or the wheel hub will drop when the internal gear hub assembly is removed.

97ZV24016

12. Sling wheel hub (3) using wheel hub hoisting tool (D), and then remove wheel hub (3). : Wheel hub: 140 kg (310 lbs) Refer to the "Special Tool" page within this section for tool dimensions.

24-25 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly cautions

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

Wheel hub installation 97ZV24019

4. Install wheel hub (4) to the axle housing extension. Note Be sure to support the wheel hub, or the wheel hub will drop.

Axle housing extension

1 2 95ZV24028

1. Install O-ring (1) to ring (2). 2. Install ring (2) to the axle housing extension. Refer to "Floating Seal" page 24-31 for additional information.

Axle housing extension 95ZV24029

3. Install wheel hub bearing (3) to the axle housing extension using jig (E). Refer to the "Special Tool" page within this section for jig dimensions.

24-26 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Internal gear hub installation

Top Spring pin

Internal gear

Spring pin

6 95V2E24067

95ZV24032

For brake oil air bleeder

Top Match these holes.

Internal gear hub

Brake oil inlet Axle housing extension 95V2E24066

Note Before reinstallation, align the brake oil hole of the axle housing extension with that of internal gear hub assembly (6).

WARNING Brake oil holes must be properly aligned on all four wheels for proper brake operation. - Improper alignment will cause reduced braking force. - Improper alignment will cause slow brake release, dragging, and rapid brake wear.

Note The spring pins should be at the top position.

24-27 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Axle nut tightening

Brake adjustment

Jig (H)

95ZV24034

97ZV24027

1. Tighten axle nut (7) using jig (F). After that, once loosen axle nut (7). This is to push in the taper roller bearing.

1. Use jig (H) to hold the brake piston not to come out.

: Nut (7): 2,746 N-m (280 kgf-m) (2,026 lb-ft) Brake oil inlet port

2. Again tighten axle nut (7) using jig (F) so that the preload of the tire mounting hole section is 324 ~ 363 N (33 kg ~ 37kgf) (73 ~ 81 lbf). Note Measure the minimum pulling force to rotate the wheel hub using a spring scale. 95ZV24035

[ Air leak testing tool ]

Shut off valve

Air supply

Brake PT 3/8

Air pressure gauge

95ZV24036

2. Check the brake oil leakage. Attach air leak testing tool as shown above to the brake oil inlet port on the axle housing.

24-28 95ZV Disassembly & Reassembly Power Group Front Axle Assembly 3. Apply 588 kPa (6 kgf/cm2) (85 psi) air pressure for approximately 1 minute. Shut off the valve. Check that the pressure does not fall.

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

Wheel hub

4. Loosen the axle housing air bleeder nipple. Brake piston Top

95ZV24038

Brake piston

6. After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face. Note Dimension A should be equal at the top and bottom sides. A: 162.45 ~ 163.85 mm (6.4 ~ 6.45 in)

For pushing down brake piston

7. After confirming that the piston is fully retracted (that Dimension A is correct) remove all four bolts. 95V2E24068

5. Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly.

Bolt size for pushing brake piston back: M10 x 1.5 - 45~50 mm (1.8~2.0 in) (Fully threaded) (4 each required)

Wheel hub

Separation disc Brake piston 95ZV24038a

Note On the machine S/N 0312~ or S/N 9096~ without the piston stroke adjuster, dimension B should be adjusted in the following range using shims. B: 1.20 ~ 1.90 mm (0.047 ~ 0.075 in)

24-29 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Top Spring pin

Spring pin

Internal gear

{

6-teeth

95V2E24069

8. Install steel plate with 6-teeth section (8) first. Note Be sure to install the thrust washer, axle shaft, and disc gear first.

95ZV24042

11. Install friction plate (11). Spring pins Friction plate

Cooling holes

Steel plate

95ZV24043

95ZV24040

9. Install friction plate (9). Top Spring pin

{

Spring pin

2 x 2-teeth

10 95V2E24070

10. Install steel plate with two 2-teeth sections (10).

Note Align the cooling holes of two friction plates with each other.

24-30 95ZV Disassembly & Reassembly Power Group Front Axle Assembly

Spider TOP mark

Wheel hub Bleeder screw

Drain plug (at bottom) 95ZV24044

12. The spider TOP mark should be placed as shown. Install the planetary assembly. 13. Fill the oil to the specified level. : Wheel hub (right and left): 20 L (5 gal) : Differential: 60 L (16 gal) 14. After reinstalling the tires, be sure to completely bleed the brake from air. Note After reinstalling tires, check that manual rotation of the tires is possible. Also check the wheels for oil leakage.

24-31 95ZV Disassembly & Reassembly Power Group Floating Seal

Floating Seal Floating seal location Ring Floating seal Wheel hub Axle housing Remove oil

Put thin gear oil (Do not use grease)

Ring

95ZV24045

Assembling procedure Do not touch (It may cause rusting)

Seal cross section

90ZV24066

O-ring

Seal ring

95ZV24046

1. Checking before seal installation (a) Checking seal - Check the seal ring for distortion and scratches. - Check the O-ring for scratches. Note The rotating ring and the fixing ring are exactly the same. They can be used on either side. (b) Check the wheel hub and the ring for burr. If any remove it by sand paper etc.

24-32 95ZV Disassembly & Reassembly Power Group Floating Seal 2. Assembling procedure (a) In case jig (G) is not used

Guide jig

- Install the O-ring on the seal ring. - Put thin gear oil on the O-ring. - Insert the floating seal into the ring and the wheel hub pushing the O-ring with fingers. (Make subassembly) - Check if the seal ring is correctly positioned and that the O-ring is not twisted. - Clean the surface and put thin gear oil on it. - Install the ring and the wheel hub to the axle housing. (b) In case jig (G) is used

Before installation 95ZVE24011

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

Guide jig

Installation jig

2 3

After installation 95ZVE24010

3. Caution before operation

70ZV24095J

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

- After assembling, turn the wheel hub 2~3 turns by hands. - Check if it turns lightly by hand. If it is tight and hard to turn the wheel hub, the O-ring may be twisted. In this case it is necessary to disassemble the floating seal.

24-33 95ZV Disassembly & Reassembly Power Group Internal Gear Hub

Internal Gear Hub Internal gear hub disassembling and assembling 5

Internal gear hub disassembling

4 95ZV24091

3. Remove twelve bolts (5) from brake piston (4). : Locknut: 33 N-m (3.4 kgf-m) (25 lb-ft) 95ZV24090

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

6 5 Lock nut

3 K95V2U24014

4. Remove return spring (6). 95ZV24052

2. Remove taper roller bearing (3). Removal method Unless the taper roller bearing is removed, the return spring for the brake piston and the brake stroke adjusting mechanism will not come out. For easy removal, heat the inner race using a gas torch with slow flame.

24-34 95ZV Disassembly & Reassembly Power Group Internal Gear Hub (S/N 0101~0311, 9001~9095 only)

5. Remove socket bolts (7). : Bolt (7): 50 N-m (5.1 kgf-m) (37 lb-ft) 8

6. Remove bushing (8) and sleeve (9). 7. Remove tolerance ring (10) from bushing (8). 7

Note When installing, attach the tolerance ring to the boss (bushing) and press-fit the shaft (sleeve).

Piston

10 95ZV24055

Boss (bushing)

Tolerance ring

Shaft (sleeve)

95V2E24071

Upper side Brake piston

For removing brake piston

14 95ZV24092

8. Insert bolts into two holes for removing the brake piston, then tighten two bolts evenly. The piston should come out evenly. Bolt size for removing piston: M10 x 1.5 - 45 ~ 50 mm (1.8 ~ 2.0 in) (Fully threaded) (2 each required)

95ZV24057

9. Remove brake piston O-rings (13)(14).

24-35 95ZV Disassembly & Reassembly Power Group Internal Gear Hub

Internal gear hub assembly cautions

IMPORTANT - Replace all the O-rings with new ones. - Clean and check all the parts. If a part is damaged, replace it with a new one. 1 4

95ZV24058

Oil groove

Oil hole

16 3

95V2E24029

95ZV24059

10. There is snap ring (15) that fixes internal gear (16) to internal gear hub (1). Shift the snap ring to the inside using a round bar or the like. 11. Sling internal gear (16) to remove it. : Internal gear: 60 kg (132 lbs)

Internal gear hub assembling To reassemble the internal gear hub, follow the procedure described in reverse order.

- When reassembling internal gear (3) and brake piston (2) to internal gear hub (1), align the oil plug groove of the internal gear hub with that of the brake piston and spring pin (4). Note To reinstall the internal gear hub on the axle, the brake oil path should be aligned to these oil grooves. In addition, the oil grooves are used for alignment of the spring pin. Also, the aligned grooves are used for external measurement of brake disc wear. - Check that the snap ring is properly inserted into the groove of the internal gear.

24-36 95ZV Disassembly & Reassembly Power Group Internal Gear Hub (S/N 0101~0311, 9001~9095 only)

Top Brake piston

1.2 mm (0.05 in) For pushing down brake piston

95V2E24068

Piston

- Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly.

95ZVE24025

- Install socket bolt (5). : Bolt (5): 50 N-m (5.1 kgf-m) (37 lb-ft)

Bolts size for pushing brake piston back M10 x 1.5 - 45 ~ 50 mm (1.77 ~ 1.97 in) (Fully threaded) (4 each required)

Note There is a clearance of approx. 1.2 mm (0.05 in) between the sleeve and the socket bolt (5).

95V2E24039

- Before reinstallation of taper roller bearing (6), be sure to heat the bearing to 90ºC (194ºF) to 120ºC (248ºF) in oil. Handle carefully to avoid injury or bearing damage. - Apply grease to the O-rings.

Sleeve

24-37 95ZV Disassembly & Reassembly Power Group Spider Assembly

Spider Assembly Spider assembly disassembling and assembling

Spider assembly disassembling

97ZA2422

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

1 95ZV24061

1. Remove lock bolts (1) and plate (2). : Lock bolt (1): 417 N-m (42.5 kgf-m) (307 lb-ft) : Screw lock agent (Three Bond 1327) application 7 1

95ZV24063

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

Spider assembly assembling 95ZV24062

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

To reassemble the spider assembly, follow described procedure in reverse order.

the

Before starting work: - Clean all the parts. - Check the brake backing plate, pins, bearings, planetary gears for distortion and wear. - Replace the wear rings and defective parts with new ones. - Inspect the internal bores of the spider for wear.

24-38 95ZV Disassembly & Reassembly Power Group Spider Assembly

Spider assy assembly cautions - To reinstall the brake backing plate, check that there is no clearance between the spider and the brake retainer. - The brake retainer may only be installed as it was removed. It may not be flipped over due to the roll pin hole design. - To insert the planetary pin, align the core holes of the planetary gear with that of the wear ring.

1 3

95ZV24062

- The lock bolt (1) hole of planetary pin (3) is shifted from the center. Check that the bolt hole is shifted to the inside. - Manually turn planetary gear (4) to check that the gear smoothly rotates. - When refilling axle and planetary gears with lubricant, use friction modifier (anti-chatter) additive.

24-39 95ZV Disassembly & Reassembly Power Group Special Tool

Special Tool Special tool for axle (A) Internal gear hub puller mm (in)

(Material: SS41) t 16 (0.63)

30 (1.2)

2 x Ø12 (0.5) drill

C5 (0.2) 204 (8.0) 230 (9.1)

K95V2U24008

30 (1.2)

(Material: SS41) 30 (1.2)

30 (1.2)

t 15 (0.6) 20 (0.8)

45 (1.8)

(B) Internal gear hub hoisting tool mm (in)

40 (1.6)

45 (1.8) 90 (3.5)

45 (1.8)

200 (7.9)

240 (9.4)

X-X

20 (0.8)

25 (1.0)

135 (5.3)

300 (11.8)

t 2.3 (0.1)

45 (1.8)

Y-Y 45 (1.8) K95V2U24009

24-40 95ZV Disassembly & Reassembly Power Group Special Tool (C) Spider hoisting tool mm (in)

25 (1.0)

(Material: SS41)

R30 (1.2) 25 (1.0)

18 (0.7)

40 (1.6)

R10 (0.4) 120 (4.7)

28 (1.1)

10 (0.4)

6 (0.2)

12 (0.5)

30 (1.2)

110 (4.3)

12 (0.5)

25 (1.0) 9

75 (3.0) K95V2U24023

24-41 95ZV Disassembly & Reassembly Power Group Special Tool (D) Wheel hub hoisting tool mm (in)

(Material: SS41) Cut the threaded area off the M10 eye bolt before use.

50 (2.0)

15 (0.6)

65 (2.6)

R10 (0.4)

6 (0.2)

12 (0.5)

80 (3.1)

20 (0.8)

15 (0.6)

25 (1.0)

10 (0.4)

35 (1.4)

31 (1.2)

12 (0.5)

75 (3.0)

M30 (1.2) x 2

Cut the threaded area off M10 eye bolt before use.

40 (1.6) K95V2U24024

24-42 95ZV Disassembly & Reassembly Power Group Special Tool (E) Bearing insertion jig mm (in)

(Material: SS41)

C3 (0.12)

C2 (0.08) 160 (6.3)

80 (3.1)

180 (7.1)

164 (6.5)

C2 (0.08)

280 (11.0)

K95V2U24025

(F) Axle nut tightening jig mm (in)

(Material: SS41) 80 (3.1) 38 (1.5)

R5 (0.2) C5 (0.2)

40 (1.6)

46 (1.8)

30 (1.2)

C5 (0.2)

Hexagon (Width across flat 160 mm (6.3 in))

229 (9.0)

C5 (0.2)

K95V2U24026

24-43 95ZV Disassembly & Reassembly Power Group Special Tool (G) Floating seal jig 1. For wheel hub

mm (in)

[ P/N for tool set: 99202-02090 ] (0.40±0.008)

(0.12)

(

(0.20)

(0.12)

)

(11.0)

(12.4) (12.0) (11.7) (11.5)

(13.4) (12.1) (11.7)

(11.9) (13.8)

(0.79)

(12.8)

(0.67)

(0.41 ±0.004)

(0.47 ±0.012)

(0.012)

(0.008~0.020)

95ZV24070

2. For ring

mm (in) (0.51)

[ P/N for tool set: 99202-02060 ]

(0.12) (0.12)

(0.79)

(

)

(0.44±0.008)

(0.12)

(13.0)

(11.0)

(12.6) (12.0) (11.7) (11.5)

(11.9) (14.0)

(11.7)

(12.2)

(0.04)

(0.41 ±0.004)

(0.47 ±0.012)

(0.012)

(0.008~0.020)

95ZV24071

24-44 95ZV Disassembly & Reassembly Power Group Special Tool (H) Brake piston removal / installation jig mm (in)

(Material: SS41)

t16 (0.63)

30 (1.2)

2 x Ø12 (0.5) drill

M16 (0.6) x 2

131.5 (5.2)

102 (4.0)

204 (8.0) 263 (10.4) 330 (13.0)

100 (3.9)

M16 x 2 (Totally threaded)

95ZV24066

24-45 95ZV Disassembly & Reassembly Power Group Rear Axle Assembly

Rear Axle Assembly Rear axle assembly tightening torque R. H (S/N ~0187, ~9003) Rear differential

(S/N 0188~, 9004~)

T2 L 1 T5

(S/N ~0290, ~9080)

T7 T5 B T6 L1 T9 (S/N ~0311, ~9095)

T3 L1

T8 L 1

L. H

(S/N ~0311, ~9095)

T1 T4

95ZV24072a

: T1: 892 N-m (91.0 kgf-m) (658 lb-ft) T2: 608 N-m (62.0 kgf-m) (449 lb-ft) T3: 417 N-m (42.5 kgf-m) (307 lb-ft) T4: 86 N-m (8.8 kgf-m) (64 lb-ft) T5: 78 N-m (8.0 kgf-m) (58 lb-ft) T6: 53 N-m (5.4 kgf-m) (39 lb-ft) T7: 33 N-m (3.4 kgf-m) (25 lb-ft) T8: 90 N-m (9.15 kgf-m) (66 lb-ft) T9: 50 N-m (5.1 kgf-m) (37 lb-ft)

L1: Screw lock agent (Three Bond 1327) T9: Screw lock agent (Loctite® 648)

24-46 95ZV Disassembly & Reassembly Power Group Rear Axle Assembly

Axle nut tightening procedure

Floating seal installing

1. Tighten axle nut (A) with 2,746 N-m (280 kgf-m) (2,026 lb-ft) tightening torque to install the taper roller bearing.

Use jig to install the floating seal to the axle assembly.

2. Loosen axle nut (A). 3. Tighten axle nut (A) again with the same tightening torque as above 1. 4. Turn the wheel hub 2~3 turns back and forth, and measure the preload applied to the bolt screw hole in the housing (B). Preload at housing (B): 324~363 N (33~37 kgf) (73~81 lbf) Note This is "breakaway" force, which is required to start the wheel turning.

Refer to Front axle assembly, "Floating Seal" page 2431 for details.

24-47 95ZV Disassembly & Reassembly Power Group Rear Axle Assembly

Rear axle assembly removing and installing Rear axle assembly removing

(S/N 0101~)

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground. - Apply the articulation stopper. - Block the front wheels with chocks or the like to prevent the wheels from moving. 1

95ZV24073

(S/N 9001~)

1A 1B A

97K24032 95ZV24073a

1. Lower the attachment onto the ground. Lift the front wheels while supporting the machine with the attachment. Place stand (A) under the rear chassis (behind the center pin but not under the tanks) to support the chassis.

B 95V2E24021

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

3. Remove the under cover(s). : Cover (1): 30 kg (66 lbs) Cover (1A): 30 kg (66 lbs) Cover (1B): 25 kg (55 lbs)

24-48 95ZV Disassembly & Reassembly Power Group Rear Axle Assembly

Transmission

Wooden blocks

Rear differential

3 3rd propeller shaft

95V24017

4. Insert wooden blocks into the swing stopper section to prevent the axle from swinging. Block both sides.

WARNING Accidental movement of the axle assembly may cause injury or death. The axle will not be balanced when a tire is removed. If wooden blocks are not inserted, your fingers or body may be caught in the machine.

95ZV24074a

6. Remove third propeller shaft retainer bolts (3) to remove the propeller shaft. : Bolt (3): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) : Third propeller shaft: 23 kg (55 lbs) Note - Always replace retainer bolts (3) with new ones. - Never reuse the propeller shaft retainer bolts. - Clean all threads with a thread lock primer to assure a fast strong bond. 7. Press the breather valve cap on the hydraulic tank to vent tank pressure.

Fitting

4 97K24035

5. Remove the right and left wheel and tire assemblies (2).

Rear axle 95ZV24075

: Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) : Standard tire: 790 kg/pc (1,740 lbs/pc)

8. Disconnect air breather hose (4) to the hydraulic tank. Clean hose (4) before reattaching it. 9. Discharge the brake accumulator by slowly and fully depressing and releasing the brake pedal at least 40 times.

24-49 95ZV Disassembly & Reassembly Power Group Rear Axle Assembly

Rear axle assembly installing

For reinstallation, follow the above procedure in reverse order. Refer to "Service brake air bleeding procedure" page 24-20 for air bleeding in the service brake.

Rear axle disassembling and assembling

5 95ZV24076

10. Disconnect the front and rear grease pipes and then remove brake hose (5) and brake pipe (6). Plug all open brake lines to avoid contamination. : Hydraulic oil: Approx. 4 L (1 gal)

7 8

95ZV24077

11. Temporarily sling rear axle (7), and remove front (R&L, 2 pieces) and rear (R&L, 4 pieces) retainer bolts (8) from the rear axle support. Lower the rear axle evenly on the carrier. Note The rear support is locked by not only the bolts but also dowel pins. Carefully remove or reinstall the support while checking the dowel pins. : Retainer bolt: 721 N-m (73.5 kgf-m) (532 lb-ft) : Rear axle and axle support: 2,750 kg (6,050 lbs) : With lubricating oil (Engine oil or gear oil) Note Be careful not to bend or damage the brake oil pipes. Never reuse the retainer bolts. Replace with new ones.

For disassembling and reassembling the rear axle assembly, refer to "Front axle disassembling and assembling" page 24-21.

24-50 95ZV Disassembly & Reassembly Power Group Axle Support

Axle Support Axle support tightening torque (S/N 0101~0290, 9001~9080) (S/N 0142~, 9004~)

T1 L2

Snap ring (S/N ~0141, ~9003)

T3 L1

T2 L1

FRONT

T2 L1

Rear axle

T2 L1

95ZV24078a

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

24-51 95ZV Disassembly & Reassembly Power Group Axle Support (S/N 0291~, 9081~) T2 L1

Rear axle

T1 L2 (S/N 0321~) (S/N ~0320, 9081~)

(S/N ~0320, 9081~)

T3 L1

(S/N 0321~)

T2 L1 FRONT

T1 L2

T2 L1

K95ZV24007

24-52 95ZV Disassembly & Reassembly Power Group Axle Support

Axle support disassembling and assembling Axle support disassembling (S/N 0101~0290, 9001~9080) 7

Before starting work - Remove the rear axle assembly from the rear chassis.

9 8

(S/N 0101~0141) (S/N 9001~9003)

Rear axle

5 6

95ZV24080a

Snap ring

4. Remove O-ring (7) and packing (8). Remove ring (9) (S/N 0142~, 9004~ only)

FRONT

16 K95ZV24008

11 (S/N 0142~0290) (S/N 9004~9080)

2 6

13 95ZV24081

5. Remove bolt (10). FRONT

95ZV24079a

1. (S/N 0101~0141, 9001~9003) Remove snap ring. (S/N 0142~0290, 9004~9080) Remove bolt (1), plate (2) and ring (3). : Bolt (1): 53 N-m (5.4 kgf-m) (40 lb-ft) 2. Remove packing (4) and O-ring (5). 3. Remove front axle support (6) from the rear axle assembly. : Axle support (6): 90 kg (200 lbs)

: Bolt (10): 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application 6. Remove plate (11) and wear ring (12). 7. Remove bolt (13). Remove plate (14) and wear ring (15) from rear axle support (16). : Bolt (13): 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application

24-53 95ZV Disassembly & Reassembly Power Group Axle Support

Axle support disassembling (S/N 0291~, 9081~)

Before starting work - Remove the rear axle assembly from the rear chassis.

4 17 18

3 95ZV24082

2 1

8. Remove rear axle support (16) from the rear axle assembly. : Axle support (16): 120 kg (265 lbs) 9. Remove packing (17) and snap ring (18).

FRONT

K97V2J24021

1. Remove bolt (1). : Bolt (1): 53 N-m (5.4 kgf-m) (40 lb-ft) 2. Remove plate (2) and packing (3).

Rear axle

K97V2J24029

3. Remove axle support (5) from the rear axle assembly. : Axle support (5): 90 kg (200 lbs) 4. Remove packing (6).

24-54 95ZV Disassembly & Reassembly Power Group Axle Support

Axle support assembling 9

To reassemble the axle support, follow the above procedure in reverse order.

10 12 15

Axle support assembly cautions

IMPORTANT

13 14 K95ZV24009

5. Remove bolt (8). : Bolt (8): 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application 6. Remove plate (9) and wear ring (10). 7. Remove bolt (11). Remove plate (12) and wear ring (13) from axle support (15). : Bolt (11): 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application

18 19

17 95V2E24034

8. Remove axle support (15) from the rear axle assembly. : Axle support (15): 120 kg (265 lbs) 9. Remove packing (16) and snap ring (17). 10. Remove bolt (18) and remove shaft (19). : Bolt (18): 608 N-m (62.0 kgf-m) (449 lb-ft)

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

24-55 95ZV Disassembly & Reassembly Power Group Axle Support

Bushing installing Front Support (S/N 0291~, 9081~)

Front Support (S/N ~0290, ~9080)

(S/N 0291~, 9081~)

(Diff. swing shaft)

1 (Diff. swing shaft)

Front

Stopper

(Axle support)

5 95ZV24083

1. Before installing, put bushing (4) into hot water to heat the bushing to 80ºC (175ºF).

95V2E24035

1. Before installing, put bushing (2) into dry ice. 2. Install lip seal packing (1) on the axle support.

2. Install ring (1), packing (2) and O-ring (3) on the swing shaft. 3. Install heated bushing (4) onto the swing shaft as shown in the illustration. 4. Carefully install the axle support onto the swing shaft. Avoid damage to lip seal packings (2)(6). 5. After installing the axle support, install O-ring (5), packing (6) and ring (7).

3. Install cooled bushing (2) to the front axle support as shown in the illustration. After installing, be sure to press bushing (2) until stopped by the stopper of the axle support.

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

4. Carefully install the axle support onto the swing shaft. Avoid damage to lip seal packings (1)(4). 5. Install ring (3) and lip seal packing (4). 6. Tighten bolts (5).

6. Install plate (8) and tighten bolts (9). : Bolt: 53 N-m (5.4 kgf-m) (40 lb-ft) : Screw lock agent (Three Bond 1327) application

: Bolt: 53 N-m (5.4 kgf-m) (40 lb-ft) : Screw lock agent (Three Bond 1327) application

24-56 95ZV Disassembly & Reassembly Power Group Axle Support Rear Support

Swing shaft Front

12 Stopper (Axle support)

95ZV24084

1. Before installing, put bushing (10) into dry ice. 2. Install cooled bushing (10) to the rear axle support as shown in the illustration. After installing, be sure to press bushing (10) until stopped by the stopper of the axle support. Note The side with a groove on bushing (10) should come to the rear side. 3. Install lip seal packing (11) onto the axle support and install snap ring (12). 4. Carefully install the axle support onto the swing shaft. Avoid damage to packing (11).

IMPORTANT When installing the bushing onto the axle support, make sure no oil is left on the outer surface of the bushing or the axle support surface. If oil is left on them, the bushing may turn alone causing the bushing wear. Note When installing the axle support, fill enough grease between the packing and the axle support as shown in the illustration (shaded area).

24-57 95ZV Disassembly & Reassembly Power Group Differential Assembly

Differential Assembly Differential assembly removing and installing

2 1

Differential assembly removing [ Front axle assembly ]

95ZV25006

1. Remove retainer bolts (1) to remove cover (2). : Bolt (1): 90 N-m (9.15 kgf-m) (66 lb-ft) : Screw lock agent (Three Bond 1327) application

95ZV25005

Before starting work: - Drain oil from the axle assembly. - Remove the axle from the machine. - Place the axle assembly on work benches. - On the rear axle, remove the axle supports.

2. Remove retainer bolts (3) to remove the spider assembly. : Bolt (3): 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 125 kg (275 lbs) 3. Pull out the right and left axle shafts with sun gears by 30 cm (1 ft).

5 4 95ZV25007

4. Remove bolts (4) from differential (5). : Front differential retainer bolts: 314 N-m (32.0 kgf-m) (98 lb-ft) : Rear differential retainer bolts: 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application

24-58 95ZV Disassembly & Reassembly Power Group Differential Assembly

Differential assembly installing For reinstallation, follow the above procedure in reverse order.

Spacers in ∗ mark sections

95ZV25008

Note Spacers are inserted in eight asterisk "∗" mark sections of the front differential.

Differential assembly installation cautions - After reinstallation, refill with the specified oil until the oil level reaches the level check plug. Also refill the oil in each planetary assy. - Manually turn the flange yoke of the differential to check that the right and left wheel hubs turn smoothly. - Check the differential for oil leakage.

IMPORTANT When refilling the axle and planetary gears with lubricant, use friction modifier (anti-chatter) additive.

6 95ZV25009

5. Temporarily sling differential (5), and insert bolts into remover tap (jack screw) holes (6) to slightly lift the differential. : Differential (Front): 350 kg (770 lbs) (Rear): 360 kg (790 lbs) Note Be careful to sling the differential so that it is balanced and is lifted straight up. 6. Lift the differential using the sling, and then remove O-ring (7).

24-59 95ZV Disassembly & Reassembly Power Group Differential Assembly

Differential assembly disassembling and assembling Front differential tightening torque T3 L2 (S/N 9001~)

(T=22.20) ~

(T=22.48)

T2 L 1

For jacking

A F

E (T=0.1~1.0) C

T1 L1

(S/N 0322~)

T4 L1

D T6

T5 L1

F 95ZV25004a

: T1: 216 N-m (22.0 kgf-m) (159 lb-ft) T2: 314 N-m (32.0 kgf-m) (232 lb-ft) T3: 883 N-m (90.0 kgf-m) (651 lb-ft) T4: 873 N-m (89.0 kgf-m) (644 lb-ft) T5: 55 N-m (5.6 kgf-m) (41 lb-ft) T6: 441 N-m (45.0 kgf-m) (326 lb-ft) L1: Screw lock agent (Three Bond 1327) L2: Liquid gasket (Three Bond 1215)

Note - Use a shim (E) to adjust the tooth contact of spiral bevel gears (C) and (D). - Use nut (F) to adjust the backlash. - To tighten nut (T3), measure the preload at the bolt screw hold in housing (A): 36~45 N (3.7~4.6 kgf) (8~10 lbf) Use spacer ring (B) to adjust the preload.

24-60 95ZV Disassembly & Reassembly Power Group Differential Assembly

Rear differential tightening torque

F T6

T4 L1

T5 L1

T1 L1 L1

(S/N 0322~)

E (T=0.1~1.0) For jacking

A T2 L1

B (T=22.10~22.48) Oil seal retainer (S/N ~0290)

T3 L2 Trunnion (S/N 0291~)

K95ZV24010

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

24-61 95ZV Disassembly & Reassembly Power Group Differential Assembly

Differential assembly disassembling Note The rear differential has the trunnion on S/N 0291 and thereafter. The disassembling/assembling procedures for the front and rear differentials are basically the same except the related parts to this functional addition. Note the differences in the following procedures when described. 1

Shim 95ZV25012

A Bevel gear

1. Remove right and left lock plates (2) from adjustment nut (1). : Retainer bolt: 55 N-m (5.6 kgf-m) (41 lb-ft) : Screw lock agent (Three Bond 1327) Pinion

Adjusting nut

95ZV25031

Before starting work: - Fix the differential assembly onto the disassembly workbench. - Insert a straight-end screwdriver or the like into the clearance between the pinion and the bevel gear to prevent the gear from rotation. Loosen nut (A).

: Nut (A): 883 N-m (90 kgf-m) (651 lb-ft) 95ZV25013

2. Remove right and left nuts (3), bearing cap (4), and adjustment nut (1). : Retainer nut: 441 N-m (45.0 kgf-m) (326 lb-ft) : Screw lock agent (Three Bond 1327)

24-62 95ZV Disassembly & Reassembly Power Group Differential Assembly

11 5

95ZV25014

97ZV24086

6. Remove spider (10) with pinion gears (11) and thrust washers (12) as a unit.

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

Matchmark 97ZV24084

4. Put a matchmark on the alignment point of differential cage (6). Remove bolts (7), and then separate the differential cage. : Bolt (7): 216 N-m (22.0 kgf-m) (159 lb-ft) : Screw lock agent (Three Bond 1327)

9 8 97ZV24085

5. Remove bushing (8) and side gear (9).

7. Remove side gear (13).

97ZV24087

24-63 95ZV Disassembly & Reassembly Power Group Differential Assembly

(Front diff.) (Rear diff. S/N ~0290) (Rear diff. S/N 9001~)

17 97ZV24088

95ZV25021a

(Rear diff. S/N 0291~)

8. Remove bushing (14).

Trunnion

18 17 K97V2J24049

15 97ZV24089

9. Turn the differential upside down. Remove bolts (16) from bevel gear (15) to separate the gear.

10. Remove bolts (17) to remove pinion (18). At the same time, remove the shim. : Bolt (17): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327)

: Bolt (16): 873 N-m (89.0 kgf-m) (644 lb-ft) : Screw lock agent (Three Bond 1327) 19

K95ZV24096

11. Remove nut (19) and O-ring (20). Nut width across flat: 65 mm (2.559 in) : Nut (19): 883 N-m (90.0 kgf-m) (651 lb-ft) : Liquid gasket (Three Bond 1215)

24-64 95ZV Disassembly & Reassembly Power Group Differential Assembly 12. Remove flange yoke (20).

(S/N 9001~) (Front diff. only)

20 20

13. Remove oil seal retainer (21), or trunnion (21)(S/N 0291~, rear differential only). 14. Remove oil seals (22) and O-ring (23).

15. Remove taper roller bearing (26) and spacer ring (27).

23 26 24

16. Remove snap ring (32) and roller bearing (31) from the pinion.

Differential assembly assembling To reassemble the differential assembly, follow the above procedure in reverse order.

Pinion

28 26

95ZV25023a

[ Rear differential ] (S/N 0291~)

29 28

Pinion

25 24 27 26 26 23 22 21 Trunnion 20 K95ZV24011

24-65 95ZV Disassembly & Reassembly Power Group Differential Assembly

Differential assy assembly cautions

[ Rear differential ]

IMPORTANT - Clean and check all the parts. If a part is worn or damaged, replace it. - Be sure to replace O-rings and seals with new ones. 1. Check the preload of the pinion section by following the procedure below: K95V2U24021

4 6

5 7

2 9

(e) Secure yoke in a vise. Measure the preload at the section shown above.

: Standard preload∗: 36~45 N (3.7~4.6 kgf) (8~10 lbf) ∗Preload here is the force required to start the cage moving-breakaway force (not a rolling force). (f)

95ZV25024

(a) Install new roller bearing (2) and snap ring (9) on pinion (1) if replacement is needed. Note The bearing ring part should face to the pinion. (b) Install new taper roller bearing (3) and spacer (4) on pinion (1) if replacement is needed. (c) Install cage (5) and taper roller bearing (6). (d) Put yoke (7) and nut (8) on pinion (1). Note Do not install the oil seal and O-ring of the nut. : Nut: 883 N-m (90.0 kgf-m) (651 lb-ft)

If the preload is out of the above range, replace spacer ring (4) to adjust the preload to the specified range.

Note There are 20 types of spacer rings from 22.10 mm (0.870 in) to 22.48 mm (0.885 in) in increments of 0.02 mm (0.0007 in). Thicker spacers reduce preload; thinner spacers increase preload. (g) Remove nut (8) and flange yoke (7).

24-66 95ZV Disassembly & Reassembly Power Group Differential Assembly

Shim

Grease nipple

Apply grease.

10 95ZV25025

Check the direction of the lips.

95ZV24087

3. Install O-ring (10) and the shim to the cage. Install the cage to differential case (11) and tighten bolts (12) temporarily. After adjusting tooth contact, tighten bolts (12) with the specified tightening torque. : Bolt (12): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327)

Apply liquid gasket (AA03) onto these surface.

95ZV25026

2. Before installing the oil seal, be sure to apply grease to the lip and liquid gasket on the outside of the seal.

Note Shims should be selected to adjust the tooth contact. For adjusting tooth contact, refer to "Adjusting tooth contact".

24-67 95ZV Disassembly & Reassembly Power Group Differential Assembly

95ZV24088

4. Adjust the backlash as follows: (a) Tighten adjustment nut (13) on the bevel gear side until the backlash is "0". Then back off the adjustment nut 2 to 3 notches. (b) Tighten opposite adjustment nut (14). After you feel that the nut is tight, turn it one more notch. (c) Attach the dial gauge stand to the carrier. Attach dial gauge (A) to a tooth of bevel gear (15). Read the backlash value indicated on the dial gauge. (d) Adjust the backlash. Standard backlash: 0.30~0.41 mm (0.0118~0.0161 in) - Tighten adjustment nut (13) on the bevel gear side or loosen adjustment nut (14) on the opposite side to reduce the backlash. - Loosen adjustment nut (13) on the bevel gear side or tighten adjustment nut (14) on the opposite side to increase the backlash.

24-68 95ZV Disassembly & Reassembly Power Group Differential Assembly

[Front differential]

[Rear differential]

TOP

Bleeder

Grease nipple

3mm (0.118 in)

5mm (0.197 in)

Oil lip seal Double lips

Single lip (Flange yoke)

Oil lip seal Double lips

Grease

Single lip (Flange yoke)

Grease

K95ZV23004

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

24-69 95ZV Disassembly & Reassembly Power Group Differential Assembly

Adjusting tooth contact: Tooth contact

Possible cause

Adjusting method

Correct

Ring gear is too close to the drive pinion

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

Drive pinion is too far from the ring gear.

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

After adjusting the backlash to the 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.

24-70 95ZV Disassembly & Reassembly Power Group Differential Assembly Three types of tooth contact shown below are acceptable as the 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

4 HEEL

Pitch line

4~5

TOE BOTTOM

10 3 Pattern C

4 TOP

TOE

3 HEEL

4~5

Pitch line BOTTOM

Service parts After adjusting the tooth contact and backlash in our factory, we wrap the ring gear and the drive pinion as a set. Therefore, replace the ring gear and the drive pinion as a set in the field. Note Individual sale of the ring gear or the drive pinion is not available.

25-1 95ZV Service Standard Power Group

95ZV Service Standard Power Group Propeller Shaft Service Standard ............................ 25-2 Axle and Differential Service Standard.................... 25-3

25-2 95ZV Service Standard Power Group Propeller Shaft Service Standard

Propeller Shaft Service Standard 1

Third propeller shaft 95ZV25032

1 4

5 2 Circumference

3 Transverse

Second propeller shaft 95ZV25033

Unit: mm (in) No.

Item

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

Bolt tightening torque

162N-m (16.5 kgf-m) (119 lb-ft)

Tightening

Bolt tightening torque

162N-m (16.5 kgf-m) (119 lb-ft)

Tightening

Clearance

Standard 76.0±3 (3±0.1)

—

25-3 95ZV Service Standard Power Group Axle and Differential Service Standard

Axle and Differential Service Standard Axle group

2,3

1,3 4

5 K95ZV25001

Unit: mm (in) Judgment standard No.

Item

Solution Standard dimension

Tolerance

Backlash between sun gear and planetary gear

0.188~0.662 (0.0074~0.0260)

←

Replacement

Backlash between planetary gear and internal gear

0.17~0.89 (0.0067~0.0350)

←

Replacement

Tooth contact of gear

Front

(+0.0035 ) ø373.5 (14.7047) +0.089 0

Rear

(+0.0028) ø211 (8.3071) +0.072 0

Axle support wear

Bushing and wear ring wear

Replacement

No abnormality

Oil groove 1.0 (0.0393)

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

Replacement

No oil groove

Replacement

25-4 95ZV Service Standard Power Group Axle and Differential Service Standard

Differential 1

5, 6 5, 6

95ZV25003

Unit: mm (in) Judgment standard No.

Item

Solution Standard valve

Tolerance

Backlash between ring gear and drive pinion

0.30~0.41 (0.0118~0.0161)

←

Adjustment

Backlash between side gear and pinion gear

0.25~0.66 (0.0098~0.0260)

←

Adjustment

Clearance between pinion gear and spider

0.10~0.17 (0.0039~0.0067)

←

Replacement

Runout of ring gear rear surface (when assembled)

0.075 (0.0029)

←

Adjustment or replacement

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

Tooth contact

No abnormality

Replacement

34-1 95ZV Disassembly & Reassembly Torque Converter and Transmission Group

95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly....... 34-2 Torque Converter Assembly .................................... 34-10 Transmission Assembly .......................................... 34-16 Clutch Assembly...................................................... 34-24 Clutch Spider Assembly .......................................... 34-37 Reverse Clutch Spider ............................................ 34-39 1st Clutch Assembly................................................ 34-40 High Clutch Assembly ............................................. 34-44 Control Valve Assembly .......................................... 34-49

34-2 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque Converter and Transmission Assembly Torque converter and transmission assembly tightening torque Engine

T1 L 3 T2 L 1

T3 L 1 (S/N 0150~, 9001~)

T4 L 3

T5 L 3

Transmission

T1 L3 (S/N 0150~, 9001~)

(S/N 0413~)

T1 L1

T7 L1

T6 L 2

Rear differential

2nd propeller shaft

T6 L 2 3rd propeller shaft Front differential 95ZV24001a

34-3 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque converter and transmission assembly removing and installing Torque converter and transmission assembly removing

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

97K34001a

1. Remove drain plug (1) to drain the transmission oil.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the “OFF” position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this “write to memory function” prior to removing battery terminals. Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure. - Press the breather valve cap on the hydraulic tank to release tank pressure. - Remove the cab and the floor board (Refer to Section 14). - Remove the engine room (Refer to Section 14). - Before ordering parts, record and use the model and serial number on the serial number plate. - Consider the type of failure and if the T/C oil cooler must be also 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 be also replaced.

: Transmission oil: 55 L (14.5 gal)

Rear differential Transmission

3rd propeller shaft

2nd propeller shaft K95ZV34001

2. Disconnect bolts (2) and remove the third propellershaft. : Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) : Third propeller shaft: 25 kg (60 lbs) Note If the retainer bolts are too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner. Keep the flame away from the seals of the coupling. Do not reuse the bolts, always replace with new ones.

34-4 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Rear differential Parking brake cylinder

Transmission

3rd propeller shaft

5 6 2nd propeller shaft K95ZV34001

3. Remove bolts (3) from the second propeller shaft on the transmission side only. : Bolt (3): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) : Second propeller shaft: 100 kg (220 lbs)

95ZV34003

5. Remove split pin (5) and remove pin (6). 6. Remove bolts (7) from the actuator mounting bracket. Disconnect the oil source, and then remove the actuator.

8 Valve unit Oil cylinder

95ZV34002

4. Release the parking brake ad disconnect the link of the actuator. If the machine has low accumulator oil pressure, feed oil into hose (4) from an external source.

IMPORTANT When the transmission is lifted, the parking brake actuator will come in contact with the chassis. To prevent this, remove the parking brake actuator before lifting the transmission. Note If there is no oil pressure source, apply a rope or cable to the link, and then pull it down using a bar to compress the spring of the actuator. After that, remove the pin.

Bracket

95ZV34004

7. Disconnect all the hoses and the pipes from steering valve (8) and remove the valve with the bracket. : Bolt: 231 N-m (23.5 kgf-m) (169 lb-ft) : Steering valve (with bracket): 65 kg (145 lbs)

IMPORTANT When the transmission is lifted, it will come in contact with the steering valve. To prevent this, remove the steering valve before lifting the transmission. Note After removing hoses and pipes, plug or cover the disconnected ports with plastic caps to protect them from dust and dirt.

34-5 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque converter

Bracket

10 95ZV34005

95ZV34006

8. Remove all the connected hoses from accumulators (9). Remove the accumulators with the bracket.

9. Remove all the connected hoses from gear pumps (10)(11), and then remove the pump assembly.

: Accumulator assy (with bracket): 55 kg (122 lbs)

IMPORTANT When the transmission is lifted, it will come in contact with the accumulators. To prevent this, remove the accumulators before lifting the transmission. Note After removing hoses, plug or cover the disconnected ports with plastic caps to protect them from dust and dirt.

: Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Gear pump (double): 40 kg (88 lbs) : Gear pump (single): 30 kg (66 lbs) Note After removing hoses, cover the hoses with plastic caps, and cover pump ports with the caps to protect them from dust and dirt. Refer to the Section 44 "Hydraulic Group" for the reinstallation.

95ZV34007

10. Disconnect the electrical wires for torque converter temperature switch and sensor (12), speed sensor (13), and then remove oil level gauge pipe (14).

34-6 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque converter

17 Line filter 95ZV34008

95ZV34010

11. Remove hoses (15) between the torque converter and the line filter.

13. Remove hose (17) between the flywheel housing and the transmission.

Note After removing hoses, cover the hoses and fitting section with clean vinyl or plugs to protect them from dust and dirt.

Note After removing hoses, cover the hoses with plastic caps to protect them from dust and dirt. (S/N ~0230) (S/N ~9010)

T/C oil cooler

95ZV34011a 95ZV34009

12. Remove hoses (16) between the torque converter and the T/C oil cooler. Note After removing hoses, cover the hoses and fitting section with clean vinyl or plugs to protect them from dust and dirt.

14. Disconnect all the connectors (18) of the control valve solenoid. Note Put matchmarks on them to avoid incorrect wiring.

34-7 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

20 21

95ZV34153

95ZV34013

15. Lift the transmission assembly temporarily and insert support (A) to the underside of engine flywheel housing. Remove retainer bolts (19).

18. Remove retainer bolt (22) (right and left side) between the torque converter and the flywheel housing.

: Bolt (19): 230 N-m (23.5 kgf-m) (170 lb-ft)

: Bolt (22): 67 N-m (6.85 kgf-m) (50 lb-ft) : With lubricating oil (Engine oil or gear oil)

Note Be sure to lift the transmission assembly through chain block (B) at front side.

19. Move the transmission assembly to the front chassis side to disengage the ring gear connection with flywheel.

16. Remove retainer bolts (20) (both sides).

20. Lift and remove the transmission assembly.

: Bolt (20): 201 N-m (20.5 kgf-m) (148 lb-ft) : Screw lock agent (Loctite® 262) 17. Remove retainer bolts (21) (both sides). : Bolt (21): 441 N-m (45.0 kgf-m) (325 lb-ft) : With lubricating oil (Engine oil or gear oil)

: Transmission assembly: 1,310 kg (2,890 lbs) Note In this case, lift the transmission assembly slowly, while avoiding contact with other parts.

Torque converter and transmission assembly installing To reinstall the torque converter and transmission assembly, follow the above removal procedures in reverse order.

34-8 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Transmission assembly installation cautions - Be sure to replace the O-ring at the connecting part between the engine and the transmission with new one. - After reinstallation, check operation of the transmission assembly by the following procedure.

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, be sure to stop the engine, and block to the tires with chocks before you start service work. During the service work clearly communicate with the person in the operator seat using signals as agreed upon before hand. 1. At the completion of reinstallation, start the engine, and check that the shift lever properly functions at all the positions. 2. Check each section for oil leakage. 3. Adjust the transmission oil level to the specified point with the level gauge. 4. Perform the start-up tests as shown on the attached sheet.

34-9 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

DATE:

HOURS:

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 2

MPa (kgf/cm ) (psi)

MPa (kgf/cm2) (psi)

MPa (kgf/cm2) (psi) CLUTCH PRESSURE AT HIGH IDLE 2

MPa (kgf/cm ) (psi)

MPa (kgf/cm2) (psi)

COMMENTS:

Serviceman’s Signature

KCM Corporation Copy as required. Make attachments if needed.

34-10 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque Converter Assembly Torque converter assembly bolt tightening torque T2 L2

Check the torque on the nut side.

T12 L2

T2 L2

T8 T8 L2

T3 L2

T4 L2

T2 L2

T9 L2

T13

T8 L2

T7 L2

Check dowel pin depth T8 L2 Apply liquid gasket to the flange.

T10 L1 T8 L2

T11 L1 T2 L2 T1 L2

T2 L2 95ZV34014a

: T1: 882 N-m (90.0 kgf-m) (651 lb-ft) T2: 53 N-m (5.40 kgf-m) (39 lb-ft) T3: 132 N-m (13.5 kgf-m) (98 lb-ft) T4: 76 N-m (7.80 kgf-m) (56 lb-ft) T5: 28 N-m (2.85 kgf-m) (21 lb-ft) (T/M S/N ~0501) T5: 38 N-m (3.90 kgf-m) (28 lb-ft) (T/M S/N 0502~) T6: 55 N-m (5.60 kgf-m) (41 lb-ft) T7: 52.5 N-m (5.35 kgf-m) (39 lb-ft) T8: 94 N-m (9.55 kgf-m) (69 lb-ft) T9: 177 N-m (18.0 kgf-m) (130 lb-ft)

T10: 132 N-m (13.5 kgf-m) (98 lb-ft) T11: 230 N-m (23.5 kgf-m) (170 lb-ft) T12: 90 N-m (9.15 kgf-m) (66 lb-ft) T13: 16.7 N-m (1.70 kgf-m) (12 lb-ft) L1: Screw lock agent (Loctite® 262) L2: With lubrication oil (Engine oil or gear oil)

34-11 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque converter assembly disassembling and assembling

Torque converter assembly disassembling Before starting work: - Clean the transmission assembly. - Drain oil from the transmission drain port and also from the torque converter drain port.

View from machine right side 95ZV34157

Nut

Spring

Plunger

95ZV34162

1. Remove pipe (1) and hoses (2)(3). Remove nut, spring and the plunger for T/C outlet relief valve (A).

95ZV34016

2. Remove control valve (4) to install the transmission assembly to the work bench or roll-over stand. : Socket bolt (M8): 50 N-m (5.10 kgf-m) (37 lb-ft)

34-12 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

95ZV34018

4. Remove 12 each of bolt (5) and gear (6). : Bolt: 94 N-m (9.55 kgf-m) (69 lb-ft)

95ZV34017

9 11

95ZV34019

5. Remove snap ring (7) and washer (8). 6. Remove 30 each of bolt (9) connecting drive cover (10) and pump impeller (11) to remove drive cover (10). Plug

95ZV34156

3. Install the transmission assembly to the work bench or roll-over stand as shown. Remove the plugs (3 each). Note When reinstalling, apply Teflon tape to plugs for sealant. Do not use Loctite® or other thread lock compounds.

: Bolt (9): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

34-13 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

95ZV34020

7. Raise the calked (staked) collar part of nut (12). Loosen nut (12) and remove stator (13). : Nut (12): 245 N-m (25.0 kgf-m) (181 lb-ft)

95ZV34022

8. Remove collar (14). 9. Separate pump impeller assembly (11) and the stator shaft.

(mm)

15 10

1.5 or more

Stake

2 Spline

2.75

Nut collar

Stake

95ZV34021

95ZV34023

Note When assembling, calk (stake) the collar of the nut against the spline.

10. Separate the assembly into drive cover (10) and turbine impeller (15).

95ZV34024

11. Remove 5 each of bolt (16). : Bolt (16): 94 N-m (9.55 kgf-m) (69 lb-ft) : Screw lock agent (Loctite® 262)

34-14 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

17,18

22 19

23 Torque converter housing

Block

17 21

95ZV34025

95ZV34159

12. Remove 12 each of bolt (17) connecting the torque converter housing and the transmission.

14. Turn the torque converter housing up side down and place it on the block as shown above.

: Bolt: 94 N-m (9.55 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil)

15. Remove snap ring (17) and washer (18).

18 Torque converter housing

Clearance (0~0.2mm) (0~0.008 in) Shim (T0.1/0.2/0.3 mm) (T0.004/0.008/0.012 in)

95ZV34158 95ZV34026

13. Separate the torque converter housing from the transmission.

Note Shim adjustment is necessary when assembling. 16. Remove socket bolt (19).

: Torque converter housing 250 kg (550 lbs) : Socket bolt: 90 N-m (9.15 kgf-m) (66 lb-ft) 17. Support turbine shaft (20) from the bottom side. 18. Remove turbine shaft (20) with stator shaft (21) from the torque converter case. 19. At the same time, separate gear (22) from turbine shaft (20). Do not forget washer (23) to be installed behind gear (22).

34-15 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque converter assembly assembling Gear

For reassembling, follow the above procedure in reverse order.

Shaft Bearing

Torque converter assy assembly cautions

IMPORTANT Gear

Bearing

Shaft Bearing

Bearing

95ZV34163

20. Remove the PTO gears, shafts and bearings in order.

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

34-16 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission Assembly Transmission assembly bolt tightening torque T2 L2

Check the torque on the nut side.

T12 L2

T2 L2

T8 T8 L2

T3 L2

T4 L2

T2 L2

T9 L2

T13

T8 L2

T7 L2

Check dowel pin depth T8 L2 Apply liquid gasket to the flange.

T10 L1 T8 L2

T11 L1 T2 L2 T1 L2

T2 L2 95ZV34014a

34-17 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission assembly disassembling and assembling Transmission assembly disassembling

Torque converter housing

2 95ZV34029

95ZV34026

Before starting work: - Separate the torque converter housing from the transmission.

2 1 95ZV34030

1. Remove cover (1) 2. Remove bolt (2). : Bolt (2): 94 N-m (9.55 kgf/cm2) (69 lb-ft) : With lubrication oil (Engine oil or gear oil)

95ZV34031

3. Remove four sleeves (3).

34-18 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Output flange Parking brake drum

4 5 95ZV34032

95ZV34034

4. Remove 12 each of bolt (4) of the clutch pack assembly.

6. Remove bolt (5), and then remove the parking brake drum.

: Bolt (4): 94 N-m (9.55 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil)

: Bolt (5): 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) 7. Remove nut (6), and then remove the output flange. : Nut (6): 882 N-m (90.0 kgf-m) (651 lb-ft) (Nut width across flats: 60 mm (2.36 in)) 8

9 95ZV34033

5. Lift and remove the clutch pack assembly.

Parking brake

: Clutch pack assembly: 390 kg (860 lbs) 7 95ZV34035a

8. Remove bolts (7) and then remove the parking brake. : Bolt (7): 230 N-m (23.5 kgf-m) (39 lb-ft) : Screw lock agent (Loctite® 262) 9. Remove bolts (8) and then remove housing (9). : Bolt (7): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

34-19 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Output flange

10 95ZV34037a

10. Remove the output flange from the output shaft. Remove bolts (10) and then remove retainer (11).

95ZV34039

12. Remove gear (13) from the transmission case. : Gear: 40 kg (90 lbs)

: Bolt (10): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

Transmission assembly assembling 12

For reassembling, follow the above procedure in the reversed direction.

95ZV34038

11. Remove output shaft (12) from the transmission rear side. : Output shaft: 26 kg (60 lbs)

34-20 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission assy assembly cautions 7 6

- Clean and check all the parts. If a part is damaged, replace it with a new one. Refer to Section 35 for wear limits. - When assembling, apply transmission oil to the parts. - Replace all the seals and packings with new ones. - When installing each clutch pack assembly, manually turn the gears to check that the gears are engaged properly.

Apply grease

8 95ZV34042

2. Install oil seals (6)(7) and O-ring (8) to housing (9) and then install housing (9) to the transmission housing with bolts (10). : Bolt (10): 53 N-m (5.4 kgf-m) (39 lb-ft) 5 95ZV34041

4 3

Note Apply grease to the oil seal before installing them to the housing.

IMPORTANT

2 Apply grease

Be careful of the direction of the oil seal lip.

5 11

1 2

95ZV34040

1. Install oil seal (1), grease seal (2) and O-ring (3) to seal retainer (4), and then install seal retainer (4) to the housing with bolts (5). : Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft) 95ZV34043

IMPORTANT Be careful, not to mistake the direction of the oil seal and the grease seal.

3. Adjust output flanges (11)(12) to the same direction (phase).

34-21 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Clutch pack assy

1st clutch pack

Guide rod O-rings

13 95V34026

95ZV34045

5. Tighten clutch pack retainer bolts (13). : Bolt (13): 94 N-m (9.55 kgf-m) (69 lb-ft)

O-ring

95ZV34044

4. Lift the clutch pack assembly, install two O-rings to the 1st clutch pack and install the guide rod to the bearing retainer, and then install the clutch pack assembly to the transmission housing. : Clutch pack assembly: 390 kg (860 lbs)

Oil hole

95V34028

IMPORTANT Be sure to align the oil holes of the clutch pack assembly with that of the transmission housing.

95ZV34046

6. Calk (stake) the clutch pack body at two points around the knock pin (4 pcs) as shown in the illustration.

34-22 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Piston ring

Knock pin O-ring

95ZV34048

95V34031

8. Install two piston rings to the shaft of the clutch pack assembly.

14 15

9. Attach the O-ring to the connection of the torque converter housing and install the torque converter housing to the transmission assembly.

14 15

Check knock pin depth 95ZV34047

7. Attach O-rings (15) to each of four sleeves (14), and install each sleeve into the oil hole of the transmission housing.

95V2E34130

Ø12+0.05 0 (0.47)

(0.24)

6 Drill

mm (in)

16 17

95ZV34049

8 (0.31)

Tighten bolt (16), and then install cover (17). 95ZV34050

: Bolt (16):94 N-m (9.55 kgf-m) (69 lb-ft) : With lubricating oil (Engine oil or gear oil)

Note Before installing the torque converter housing to the transmission assembly, check the knock pin depth.

34-23 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Guide rod

95ZV34053

Sleeve

Knock pin

Guide rod Guide rod

95ZV34052

Note Insert the two guide rods in the positions of the transmission side high clutch sleeve as shown above. Be advised that the knock pin of the transmission side high clutch sleeve should position far side, facing to the clutch pack when installed.

34-24 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

Clutch Assembly Clutch assembly disassembling and assembling

Clutch assembly disassembling

95ZV34056

2. Lift and remove high clutch assembly (2).

95ZV34054

Before starting work: - Remove the clutch assembly from the transmission housing, and set it on the work bench. 3

95ZV34057

3. Remove snap ring (3). 4. Fix the clutch assembly on the work bench up side down. 1 4

95ZV34055

1. Remove snap ring (1).

95ZV34059

5. Remove lock nut (4).

34-25 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

Calking (Staking) (Point marked with )

Matchmark Collar 95ZV34058

95V34034

Note Be sure to raise the calked (staked) nut parts (4 points).

8. Put a matchmark to each housing prior to disassembling. Remove housing (8).

10, 11 9 95ZV34060

97K34062

9. Remove 12 each of spring (9), 2 each of friction plate (11) and steel plate (10).

6. Lift and remove 1st clutch assembly (5).

95ZV34061

7. Remove 11 each of housing connecting bolt (7) and ring (6).

97K34063

10. Remove ring gear (12) and one remaining friction plate. Remove 6 each of anchor pin (13).

34-26 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

20 19

97K34064

11. Remove 2nd clutch housing (14) and 3rd clutch housing.

95ZV34064

14. Remove two bolts (19) and remove housing (20).

16, 17 15

22, 23

21 95ZV34065

95ZV34062

12. Remove 12 each of spring (15), and then remove friction plate (16) and steel plate (17).

15. Remove 6 each of spring (21), and then remove one friction plate (22) and steel plate (23).

18 24

25, 26 95ZV34066 95ZV34063

16. Remove ring gear (24). 13. Remove 2nd spider assembly (18). 17. Remove five remaining friction plates (25) and four steel plates (26).

34-27 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

33 27

32 34, 35 95ZV34067

95ZV34071

18. Remove low and reverse clutch housing (27).

33 34 35

95ZV34070

28, 29 31 95ZV34068

19. Remove 6 each of friction plate (28) and 5 each of steel plate (29), and 6 each of anchor pin (30) and 12 each of spring (31).

21. Remove snap ring (34) and spacer (35) from main shaft (33). Push main shaft (33) to remove it from low and 3rd spider assembly (32).

95ZV34072

95ZV34069

20. Remove low and 3rd spider assembly (32) with main shaft (33).

22. Remove snap ring (36) and sun gear (37) from main shaft (33).

34-28 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

Measurement of piston stroke 38 39

(Dimension A)

40 95ZV34073

95ZV34074

23. Turn over the reverse housing. Remove snap ring (38) then pull out clutch gear (39). 24. Remove reverse housing (41) from reverse spider assembly (40).

(a) Assemble the desired clutch piston to each clutch housing, and measure the dimension as shown in the illustration. (This is dimension A.)

Clutch assembly assembling Before starting work: - Clean and check each part, and replace part with a new one if necessary. (Refer to Section 35 for the limit.)

(Dimension A)

- Be sure to apply transmission oil to each necessary point when reassembling the clutch assembly. 95ZV34075

- Replace the packing and the seals with new ones. - Check each steel plate for flatness. If there is any warpage, replace the plate. - Measure each piston stroke of 2nd, 3rd, low and reverse. Refer to the following procedure.

(b) Set the necessary quantity of friction plates and steel plates referring to the following table and measure the total thickness. (This is dimension B.) (c) The dimension A-B is the piston stroke and the piston stroke should be within the range shown in the following table. Friction plate

Steel plate

Piston stroke, mm (in)

2nd

3 pcs

2 pcs

2.0±0.5 (0.0787±0.0196)

3rd

3 pcs

2.5±0.5 (0.0984±0.0196)

Low

6 pcs

5 pcs

3.5±0.5 (0.1378±0.0196)

Reverse

6 pcs

5 pcs

3.5±0.5 (0.1378±0.0196)

(d) Replace the related parts or check the assembly condition if the piston stroke is out of the above range.

34-29 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

2 95ZV34076

95ZV34077

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

2. Install bearing (1) and snap ring (2) to the reverse housing.

Note - Apply sufficient coat of transmission oil to the seal ring. - Install the clutch piston proportionally. - When assembling the low clutch piston into the housing in advance, be careful not to mistake assembling position. (Check the matchmarks put while disassembling.)

6 5

4 95ZV34078

Lip Piston

3. Install reverse housing (3) onto reverse spider assembly (4). 4. Install clutch gear (5) with snap ring (6).

95V34029

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

3 95ZV34079

5. Fix reverse housing (3) on the work bench up side down.

34-30 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

7 10

3 9

95ZV34080

95ZV34083

6. Install sun gear (7) and snap ring (8) to main shaft (9).

8. Install low and 3rd spider assembly (10) onto reverse housing assembly (3).

10 15, 16 11, 12 95ZV34082

14 95ZV34084

9. Install 6 each of anchor pin (13), 12 each of spring (14), 6 each of friction plate (15) and 5 each of steel plate (16) alternately.

9 12 11

Note Start installing with the friction plate. Apply transmission oil between the friction plate and the steel plate.

95ZV34081

7. Install main shaft (9) to low and 3rd spider assembly (10). After that install spacer (11) and snap ring (12) to main shaft (9).

34-31 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

18 17

19 97K34087

10. Install low and reverse clutch housing (17).

95ZV34086

12. Install 11 each of damper spring (18) to the low and reverse clutch housing bolt hole. Install 5 each of friction plate (19) and 4 each of steel plate (20) alternately. Note Start installing from friction plate. Apply transmission oil between the friction plate and the steel plate.

95ZV34085

11. Turn the spring by hand to check that it fits properly in the upper/lower spring holes. (If it fits properly in the hole, the spring will turn easily.)

95ZV34087

13. Install ring gear (21) with addendum notch up.

34-32 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

22 95ZV34088

95ZV34090

14. Install one remaining friction plate and one steel plate. After that, install 6 each of spring (22).

16. Apply air pressure of 0.6 MPa (6 kgf/cm2) (85 psi) through the oil hole to check for piston operation and air leakage.

Sun gear shaft assembly

24 95ZV34089

95ZV34091

15. After putting housing (23) temporarily, turn spring with hands and check that it fits properly in upper/ lower spring holes. Tighten two housing connecting bolts (24) located at diagonal position.

17. Install the sun gear shaft assembly into the 2nd carrier.

: Bolt (24): 90 N-m (9.15 kgf-m) (66 lb-ft) : With lubricating oil (Engine oil or gear oil)

34-33 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

26, 27 28 95ZV34092

18. Install 2nd spider assembly (25). Install the sun gear with the 2nd carrier onto the main shaft. Install the needle bearing assembly, sleeve, snap ring, and bushing.

95ZV34094

20. Install 12 each of spring (28).

27 29 Oil hole

95ZV34095

21. Assemble 2nd and 3rd clutch housing (29). 26

95ZV34093

19. Install 3 each of steel plate (26) and 3 each of friction plate (27) alternately. Note Start installing from steel plate. Apply transmission oil between the friction plate and the steel plate.

Note - Check the matchmark and align oil hole position. - After assembling, turn spring with hands to check that it fits properly in the upper/lower spring holes.

34-34 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

34 95ZV34096

95ZV34098

22. Install 6 each of pin (30). Install one friction plate (31) and one steel plate (32).

24. Install two remaining friction plates and one steel plate. 25. Install 12 each of spring (34).

Note - Apply transmission oil between the friction plate and the steel plate. 35

33 95ZV34099

95ZV34097

26. After putting housing (35) temporarily turn the spring with hands to check that it fits properly in the upper/lower spring holes.

23. Install ring gear (33). Note When installing the housing, be careful for two alignment dowel pins.

34-35 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

38 36

95ZV34100

27. Install 11 each of housing connecting bolt (36).

95ZV34102

30. Install 1st clutch assembly (38).

: Bolt (36): 132 N-m (13.5 kgf-m) (98 lb-ft) (Measure at the nut side) : With lubricating oil (Engine oil or gear oil) 28. Apply air pressure of 0.6 MPa (6 kgf/cm2) (85 psi) through the oil hole to check for piston operation and air leakage.

Clutch gear

Preload 95ZV34103

Spider

31. Attach and tighten lock nut (39). : Lock nut: 176 N-m (18.0 kgf-m) (130 lb-ft) : With lubricating oil (Engine oil or gear oil)

95ZV34101

29. Install ring (37).

34-36 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Assembly

mm (in)

Calking (Staking) (4 Points)

43 B

80 (3.15) Collar

95ZV34104

mm (in) Calking (Staking)

2 (0.0 8) Spline groove

35. Install bearing (42) and sleeve (43) on hub (44). Attach and tighten lock nut (45). Note Preload at B: 78.5 ~ 88.3 N (8 ~ 9 kgf) (18 ~ 20 lbs)

2.75 (0.11 )

1.5 or more (0.06)

Collar

95ZV34106

95ZIV3404

32. After tightening the lock nut, calk (stake) the collar of the nut against the spline groove. (4 equally divided portion on circumference) 95ZV34107

33. Fix the clutch pack assembly on the work bench up side down. 36. Install high clutch assembly (46).

41 47 95ZV34105 95ZV34108

34. Install snap ring (41). 37. Install snap ring (47).

34-37 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Spider Assembly

Clutch Spider Assembly Low and 3rd clutch spider disassembling and assembling

Low and 3rd clutch spider disassembling 9 1

10 9

2 10

8 95ZV34111

4 5

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

3 95ZV34109

Note Washer (10) has grooves on its surface on T/M S/N 857 and thereafter.

1. Remove snap ring (1), and separate spider assembly (2) and internal gear (3). Then remove snap ring (4) and ring plate (5).

Low and 3rd clutch spider assembling To reassemble the low and 3rd spider, follow the procedure described above in reverse order. 7

Before starting work: - Clean and inspect each part, replace, if necessary. For inspection and wear standard, refer to Section 35. - Replace the bearing with new one, if necessary, manually turn the bearing to check that the bearing rotates properly. 95ZV34110

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

34-38 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Clutch Spider Assembly

2nd clutch spider disassembling and assembling

2nd clutch spider disassembling 6 4 5

9 10

2 8 9 1

95V2E34086

4. Pull out planetary pin (6), and remove planetary gear (8), washer (9), and needle bearing (10).

95ZV34113

1. Force snap ring (1) inward using a round bar to separate spider (2) and ring gear (3).

Note - Once the planetary pin has been removed, take the spring pin out. - Washer (9) has grooves on its surface on T/M S/N 857 and thereafter.

2. Remove snap ring (4), then remove plate (5). 12 13 11 7 6

95ZV34116

95ZV34114

3. Drive spring pin (7) that locks pin (6) all the way into the pin to unlock it (3 positions).

5. Force snap ring (11) inward with a round bar to separate spider (12) and the 1st speed clutch gear (13).

2nd clutch spider assembling To reassemble the 2nd clutch spider, follow the procedure described above in reverse order. Before starting work: - Clean and inspect each part, replace if necessary. For inspection and wear standard, refer to Section 35. - Replace the bearing with new one, if necessary, manually turn the bearing to check that the bearing rotates properly.

34-39 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Reverse Clutch Spider

Reverse Clutch Spider Reverse clutch spider disassembling and assembling

Reverse clutch spider disassembling

8 8

3. Remove pin (4), washers (6), planetary gear (7) and needle bearing (8).

95ZV34120

95ZV34118

Reverse clutch spider assembling 1. Remove snap ring (1) to separate spider (2) and clutch drum (3).

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

5 4

95ZV34119

2. Drive spring pin (5) that locks pin (4) all the way into the pin.

34-40 95ZV Disassembly & Reassembly Torque Converter and Transmission Group 1st Clutch Assembly

1st Clutch Assembly 1st clutch assembly disassembling and assembling 5

1st clutch assembly disassembling

3 6 1 95ZV34123

2. Remove retainer (2), bearings (3)(4), and two seal rings (5) from clutch hub (6). 11

95ZV34121

11 10

Raise the calked part

8 9 10

95ZV34124

95ZV34122

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

3. Remove snap ring (8), then remove pressure plate (9), and alternate layers of 7 each of friction plate (10) and 6 each of steel plate (11).

34-41 95ZV Disassembly & Reassembly Torque Converter and Transmission Group 1st Clutch Assembly

1st clutch assembly assembling 13

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

97K34111

17 1 14 18 2

95ZV34127

1. Assemble clutch drum (1) and clutch hub (2) with snap ring (3). 95ZV34125

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

2 20

95ZV34128

22 19

2. Install drop gear (4) to clutch hub (2) with bolts (5).

: 76 N-m (7.8 kgf-m) (56 lb-ft) 95ZV34126

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

34-42 95ZV Disassembly & Reassembly Torque Converter and Transmission Group 1st Clutch Assembly

6 6

7 8

95ZV34129

95ZV34130

Direction of the seal lip

12 1

97ZA3444

3. Install seal rings (7)(8) on piston (6).

95ZV34131

4. Install piston (6), springs (9), and ring plate (10), in this order, on clutch drum (1). Then push down ring plate (10) with a press (11), and assemble plate (10) with snap ring (12).

34-43 95ZV Disassembly & Reassembly Torque Converter and Transmission Group 1st Clutch Assembly

14 14

1 19 16 15

22 2

95ZV34132

5. Install friction plate (13) and steel plate (14) alternately after the piston, starting with a friction plate (13). Then install pressure plate (15), and assemble it with snap ring (16). Note Be sure that the friction plate comes after piston. Standard piston stroke: 4.5 ± 0.5 mm (0.18 ± 0.02 in)

95ZV34133

6. Install two seal rings (17) in clutch hub (2), and install bearing (18). Install bearing retainer (21) after putting two Orings on it, and then install bearing (19) and bearing nut (22) in turn. : Bearing nut (22) Tighten nut so as to the pre-load at the point A is between 98 and 118 N (10~12 kgf) (22~26 lbf). Note Apply grease to the seal rings, and bend them inward as much as possible. 7. After confirming the pre-load of bearing (18)(19), calk (stake) nut (22) to lock it.

34-44 95ZV Disassembly & Reassembly Torque Converter and Transmission Group High Clutch Assembly

High Clutch Assembly High clutch assembly disassembling and assembling High clutch assembly disassembling

1 2 95ZV34136

2. Remove sleeve (2).

95ZV34135

4 3

1. Remove lock nut (1).

5 95ZV34137

3. Turn clutch assembly (3) up side down. Raise the calked (staked) part

4. Remove snap ring (4), and then pressure plate (5). 95ZV34134

Note Raise the calking (staking) of the nut collar at the key groove.

95ZV34138

5. Remove three friction plates (6) and two steel plates (7).

34-45 95ZV Disassembly & Reassembly Torque Converter and Transmission Group High Clutch Assembly

9 12

8 13 95ZV34139

95ZV34142

6. Push down spring retainer (8) by using the press, and remove snap ring (9).

10. Remove 16 each of bolt (12), and remove drop gear (13).

7. Remove the press, and remove spring retainer (8).

15 16

95ZV34143

95ZV34140

8. Remove 12 each of spring (10).

95ZV34141

9. Remove piston (11).

11. Remove snap ring (14) to separate the assembly into clutch hub (15) and clutch drum (16).

34-46 95ZV Disassembly & Reassembly Torque Converter and Transmission Group High Clutch Assembly

High clutch assembly assembling

6 7

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

1 95ZV34146

3. Install seal rings (7)(8) to piston (6).

Piston

Lip 95ZV34144

1. Install clutch hub (1) to clutch drum (2) with snap ring (3).

95ZV34155

IMPORTANT Make sure to insert piston seal ring with its lip directed as the figure above. 5

4 6 95ZV34145

2. Install drop gear (4) to clutch hub (1) with 16 each of bolt (5). : Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft)

97K34122

4. Install piston (6) to clutch drum (2).

34-47 95ZV Disassembly & Reassembly Torque Converter and Transmission Group High Clutch Assembly

15 9

14 97K34123

97K34126

8. Install pressure plates (14), and then install snap ring (15).

5. Install spring (9).

9. Measure the piston stroke. Standard piston stroke: 2.5 ± 0.5 mm (0.0984 ± 0.0196 in) 11 17 16

97K34124

6. Attach spring retainer (10), and push down spring retainer by press to assemble snap ring (11). 95V34045

10. Invert clutch assembly (16) and install sleeve (17).

97K34125

7. Install three friction plates (12) and two steel plates (13) alternately after the piston. Note Be sure that the friction plate comes after piston.

34-48 95ZV Disassembly & Reassembly Torque Converter and Transmission Group

97K34128

11. Install bearing nut (18). : Tighten the bearing nut so as to the pre-load at the point A is 78.5 ~ 88.3 N (8 ~ 9 kgf) (18 ~ 20 lbf).

Calk (stake)

95ZV34147

12. After confirming the pre-load, stake bearing nut (18) to lock it.

34-49 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control Valve Assembly Control valve assembly removing and installing

6 4

Control valve assembly removing

1 95ZV34150

3. Remove cover (4). 4. Remove 10 each of retainer bolt (5) and modulator valve unit. 95ZV34148

1. Clean the area carefully. Remove hoses (1)(2). Note Cover disconnected hoses with vinyl, plugs, or caps to protect them from dust, water, and dirt.

: Bolt (5): 25.5 N-m (2.6 kgf-m) (19 lb-ft) : With lubricating oil (Engine oil or gear oil) 5. Remove 9 each of retainer bolt (6) of the solenoid valve block and then remove the block. : Bolt (6): 50 N-m (5.1 kgf-m) (37 lb-ft) : With lubricating oil (Engine oil or gear oil)

95ZV34149

2. Disconnect all wire harness couplers (3). Note Put matchmarks on them to avoid incorrect wiring connection when reassembling.

95ZV34151

Note - Cover the disconnected valve unit, block and the connecting surface of the transmission side with vinyl to protect them from dust, water and dirt. - Be careful to prevent the O-rings from falling out during repair work.

34-50 95ZV Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve assembly installing 7 8

For reinstallation, follow the above procedure in reverse order.

Control valve assembly installation cautions

WARNING 95ZV34152

6. Remove solenoid coil nut (7) and remove solenoid (8). : Nut (7): 10 N-m (1.0 kgf-m) (7.2 lb-ft) : With lubrication oil (Engine oil)

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

7. Remove valve holder (9). : Spool: 39 N-m (40 kgf-m) (29 lb-ft) : With lubrication oil (Engine oil)

- Be sure to replace all the O-rings and gaskets with new ones. - Sequentially tighten the bolts in the order from the center to the outside. Apply equal (specified) torque to all the bolts. - Align the matchmarks of the electric wire couplers, and then connect couplers while checking that the electric wires are not tangled with each other. - Install the cover while checking that the emergency operation bolts, if equipped, are positioned over the center of the solenoid valves. - During installation, be careful not to damage the gasket. - At the completion of installation, start engine, and check that the shift lever properly functions at all positions. - Check oil leakage. - Adjust the transmission oil level to the specified point with the dipstick.

35-1 95ZV Service Standard Torque Converter and Transmission Group

95ZV Service Standard Torque Converter and Transmission Group Transmission Assembly .......................................... 35-2 Torque Converter Gear Pump ................................. 35-4 Gear Train and Number of Teeth............................. 35-5 Clutch Oil Pressure ................................................. 35-6

35-2 95ZV Service Standard Torque Converter and Transmission Group Transmission Assembly

Transmission Assembly

2, 3

12 12 11

10 12 12

4 12 12 5 12 6

7 12 8

Note Numbers correspond to the REF. numbers on page 35-3. 95ZV35001

35-3 95ZV Service Standard Torque Converter and Transmission Group Transmission Assembly

mm (in) Judgement criteria REF.

ITEM

Clearance (Pump impeller ~ Turbine impeller)

Standard clearance

Allowable limit

Solution

Standard value 4.5 (0.1772)

—

Repair

Standard value

Allowable limit

Free length

Installed length

Installed load kgf (lbf)

Free length

Installed load kgf (lbf)

ITEM

Transmission oil regulator spring

95 (3.7402)

85 (3.3165)

3.48 (7.6721)

—

Replacement

Transmission oil regulator spring

97 (3.8189)

85 (3.3165)

10.0 (22.0462)

—

Replacement

High clutch piston return spring

37 (1.4567)

30 (1.1811)

32.19 (70.9668)

±0.74 (±0.02913)

±1.7 (±3.7478)

Replacement

Reverse clutch piston return spring

60 (2.3622)

55 (2.1654)

26.84 (59.1721)

±1.2 (±0.04724)

±3.2 (±7.0548)

Replacement

Low clutch piston return spring

60 (2.3622)

55 (2.1654)

26.84 (59.1721)

±1.2 (±0.04724)

±3.2 (±7.0548)

Replacement

3rd clutch piston return spring

37 (1.4567)

30 (1.1811)

32.19 (70.9668)

±0.74 (±0.02913)

±1.7 (±3.7478)

Replacement

2nd clutch piston return spring

37 (1.4567)

30 (1.1811)

32.19 (70.9668)

±0.74 (±0.02913)

±1.7 (±3.7478)

Replacement

1st clutch piston return spring

37 (1.4567)

30 (1.1811)

32.19 (70.9668)

±0.74 (±0.02913)

±1.7 (±3.7478)

Replacement

Spring

Judgement criteria ITEM

Seal width

Seal thickness

Standard value

Standard clearance

Allowable limit

Seal width

3.8 (0.1496)

0 -0.1 (-0.0039)

-0.15 (-0.0059)

Seal thickness

4.0 (0.1575)

0 -0.1 (-0.0039)

-0.15 (-0.0059)

Seal width

4.3 (0.1693)

0 -0.1 (-0.0039)

-0.15 (-0.0059)

Seal thickness

5.0 (0.1968)

0 -0.1 (-0.0039)

-0.15 (-0.0059)

Seal width

2.8 (0.1102)

±0.1 (±0.0039)

-0.15 (-0.0059)

Seal thickness

4.55 (0.1791)

±0.1 (±0.0039)

-0.15 (-0.0059)

12 95ZV35002

Replacement

35-4 95ZV Service Standard Torque Converter and Transmission Group Torque Converter Gear Pump

Torque Converter Gear Pump A 6

001A

9 3 Outlet

Hydraulic pump side

5 11, 12 Section A-A Inlet

A 95V2E35004

7. Bearing retainer 8. Bearing retainer 9. Snap ring 10. Dowel pin 11. Bolt 12. Washer

1. Pump body 2. Pump cover 3. Drive gear 4. Driven gear 5. Needle bearing 6. Needle bearing

Gear pump specifications Theoretical discharge

73.6 cm3/rev (4.49 in3/rev)

Maximum operation pressure

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

Maximum operation speed

2,600 min-1 (rpm)

Actual discharge

Approx. 40 L/min (10.5 gpm) Conditions: Pump speed 830 min-1 (rpm) Oil temp. 80~100°C (176~212°F) Oil viscosity 10CST (SAE10W) Discharge pressure 3.4 MPa (35 kgf/cm2) (498 psi)

35-5 95ZV Service Standard Torque Converter and Transmission Group Gear Train and Number of Teeth

Gear Train and Number of Teeth

T/C

L 82

E/G

63 65

61 89

2nd propeller shaft

3rd propeller shaft

95ZV32004

L: Low range clutch H: High range clutch R: Reverse clutch

1: 1st speed clutch 2: 2nd speed clutch 3: 3rd speed clutch

Clutch specifications mm (in) Friction plate

Name of clutch

Piston stroke

Low range clutch

3.5±0.5 (0.1378±0.0196)

Reverse clutch

3.5±0.5 (0.1378±0.0196)

High range 2.5±0.5 clutch (0.0984±0.0196)

1st speed clutch

4.5±0.5 (0.1772±0.0196)

2nd speed clutch

2.0±0.5 (0.0787±0.0196)

3rd speed clutch

2.5±0.5 (0.0984±0.0196)

Limit for distortion (flatness)

Number of plate

Outer diameter

Inner diameter

Steel plate Thickness New/ Number Wear limit of plate

4±0.13/3.5 ø360 ø279 (0.1575±0.0051 (14.1732) (10.9842) /0.1378) (Sintered) ø236 (9.2913)

ø159 (6.2598)

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

4±0.13/3.8 ø360 ø279 (0.1575±0.0051 (14.1732) (10.9842) /0.1496) (Paper)

5 5 2 6 2 3

Outer diameter

Inner diameter

Thickness New/ Wear limit

3.5±0.1/3.3 ø426 ø298 (0.1378±0.0039 (16.7716) (11.7323) /0.1299)

ø252 (9.9212)

ø173 (6.8110)

3.2±0.1/3.0 (0.1260±0.0039 /0.1181)

3.5±0.1/3.3 ø426 ø298 (0.1378±0.0039 (16.7716) (11.7323) /0.1299)

~0.25 (~0.0098)

Number of return spring 6 12 12 12 12 12

35-6 95ZV Service Standard Torque Converter and Transmission Group Clutch Oil Pressure

Clutch Oil Pressure (Torque converter oil temperature 50~80ºC (120~180ºF)) Measuring port location

Measurement port size

Oil pressure (Approx.) MPa (kgf/cm2) (psi) Engine revolution: at high idle

Clutch position

Main clutch oil pressure

PF3/8

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

at any position

Low clutch oil pressure

PF1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

F-1~3

High clutch oil pressure

PF1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

F-4

Reverse clutch oil pressure

PF1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

1st clutch oil pressure

PF3/8

2.5 ~ 2.8 (26 ~ 29) (370 ~ 412)

1st speed

2nd clutch oil pressure

PF1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

2nd speed

3rd clutch oil pressure

PF1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

3rd speed

Clutch oil pressure measuring port

1st speed clutch: PF3/8 Main clutch: PF3/8

2nd speed clutch: PF1/4 95ZV35003

L clutch: PF1/4

3rd speed clutch: PF1/4 R clutch: PF1/4

95ZV35004

95ZV35005

44-1 95ZV Disassembly & Reassembly Hydraulic Group

95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning ............................................................................. 44-2 Hydraulic Parts Disassembly and Assembly Cautions ............................................................................. 44-3 Hydraulic Pump Assembly ...................................... 44-4 Hydraulic Cylinder ................................................... 44-10 Pilot Valve................................................................ 44-22 Multiple Control Valve.............................................. 44-50 Orbitrol® ................................................................... 44-57 Steering Valve ......................................................... 44-67 Stop Valve ............................................................... 44-73 Fan Motor ................................................................ 44-78

44-2 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning

Hydraulic Parts Removal and Installation Warning 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.

44-3 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Parts Disassembly and Assembly Cautions

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

Hydraulic parts disassembly cautions - 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 so as not to damage it. - Because hydraulic parts may be delicate, do not drop or scratch them. - When disassembling, do not hit or pry the parts by force. The parts may be 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.

Hydraulic parts assembly cautions - 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.

44-4 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic Pump Assembly Hydraulic pump assembly removing and installing

(S/N 0101~0258) (S/N 9001~9065) 8

Hydraulic pump assembly removing

WARNING

1 95ZV44034

(S/N 0259~) (S/N 9066~)

5 4

2 1 95ZV44034a

1. Disconnect outlet hoses (2)(3) from hydraulic pump (1) and outlet hoses (5) from hydraulic pump (4). Before starting work: - Remove the cab and the floor board by referring to Section 14. - Clean the area around the hydraulic pump assembly.

Note Cover the hoses with plastic, plugs or caps to protect from dust and dirt.

44-5 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly 2. Disconnect suction side pipe (6) for hydraulic pump (1), and disconnect pipe (7) for hydraulic pump (4).

Note Cover the pipes with plastic, plugs or caps to protect from dust and dirt. 1 Transmission

7 6

(Double pump shown)

95V2U44007

3. Sling hydraulic pump (4). Remove retainer bolt (8) and remove the pump. (S/N 0101~0258) (S/N 9001~9065)

Hydraulic tank

95ZV44035

: Bolt (8): 94 N-m (9.6 kgf-m) (69 lb-ft) : Pump (4): 30 kg (70 lbs) 4. Sling hydraulic pump (1). Remove retainer bolt (9) and remove the pump.

: Bolt (9): 94 N-m (9.6 kgf-m) (69 lb-ft) : Pump (1): 40 kg (90 lbs) 1

Hydraulic pump assembly installing 7 Transmission

(S/N 0259~) (S/N 9066~)

Hydraulic tank

95ZV44035

- To reinstall the hydraulic pump assembly, follow the above removal procedure in reverse order. - Replace all gaskets and O-rings during reinstallation.

44-6 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic pump installation cautions When replacing the 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.

IMPORTANT - 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. - While reinstalling the hydraulic pump, take care not to allow dust, dirt, or foreign material into the case. - Check the oil level of the hydraulic tank. - Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe. Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 L (1 gal)). - 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. - Actuate cylinders 5 to10 times to almost full stroke, but do not fully extend or retract any of the cylinders at this time. - 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.

44-7 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic pump assembly disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

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

WARNING Do not attempt to disassemble the pump assembly unless otherwise required, as it should significantly affect the pump performance or may cause secondary problems.

44-8 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic pump assembly cross section and tightening torque Loading and pilot and brake pump (double pump)

95V2E44030

Steering pump (single pump) T2

: T1: 177 N-m (18 kgf-m) (130 lb-ft) T2: 81 N-m (8.3 kgf-m) (60 lb-ft) T3: 210 N-m (21.5 kgf-m) (155 lb-ft)

95ZVE44002

44-9 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Oil seal replacement procedure

[Example 2]

There are two kinds of the pump drive gear shaft unit. One has one oil seal only, and the other has an additional dust seal or oil seal outside. Front cover [Example 1] Oil seal

Snap ring

Drive gear shaft

Drive gear shaft Oil seal

Oil seal

Snap ring 90ZV44049

Front cover

In case of Example 2 1. After removing the outer oil seal, remove the snap ring and the inner oil seal.

90ZV44048

2. When removing the oil seals, remove any scores on the front cover and the drive gear shaft. 3. Cover the drive gear shaft with vinyl electrical tape to protect the splines. 4. Apply a thin coat of grease to the oil seal and the lip unit. 5. Install the seal straight.

44-10 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder removing and installing Boom

Boom cylinder removing

(The illustration shows the left side of the machine.)

95V2E44003

3 2

Before starting work: - Clean the area around the cylinder and piping.

95V2E44004

1. Attach sling to boom cylinder (4). Disconnect grease hose (1) from pin (3). Remove bolt (2) to remove pin (3). : Boom cylinder: 360 kg (790 lbs)

Stand

90ZV44028

Relieving residual pressure from pipe (a) Raise the boom. When the boom is approximately 30 cm (1 foot) above stand, stop the engine. (b) Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. (c) First press down on the hydraulic tank cap to vent residual pressure, then open the cap of the hydraulic tank. Leave hydraulic tank cap loosely on top of tank opening.

44-11 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

5 95V2E44005

95ZV44040

5. Insert jack bolt (8) to pin (7), and then remove pin (7).

2. Disconnect hose (5). : Drain oil: Approx. 13 L (3.4 gal) Note Cover the disconnected hoses with plastic vinyl, plugs, or caps to protect them from dust, water and dirt. 3. Push cylinder rod into the cylinder to shorten the length of the cylinder.

95ZV44041

7 6

For a detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-15.

4 95V2E44006

4. Remove lock bolt (6) for pin (7).

6. Sling boom cylinder (4), and lower it onto the ground.

44-12 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Boom cylinder installing To reinstall the boom cylinder, follow the above removal procedure in reverse order.

Boom cylinder installation cautions Be sure the pins accept grease after installation.

Cylinder air bleeding procedure

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

44-13 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder removing and installing

Sling

Bucket cylinder removing

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 the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent the wheels from moving. - Place the boom and the attachment onto the ground. - Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Use a step, and do not stand on the machine.

4 95ZV44043

2. Attach sling to the bucket cylinder. After that, remove bolt (4) to remove pin (5). : 441 N-m (45.0 kgf-m) (324 lb-ft) : Bucket cylinder: 135 kg (300 lbs)

Before starting work: - Clean the area around the cylinder and piping. - Disconnect the grease pipe from the pin.

Bucket cylinder

Relieving residual pressure from pipe

(a) Lower the boom and the attachment onto the ground. (b) Stop the engine and move the attachment and boom levers back and forth. (c) Press the cap of the breather valve on the hydraulic tank to relieve the residual pressure.

95V2E44008

3. Start the engine and shorten cylinder rod (6). 2

4. Stop the engine and disconnect hoses (7) (8). : Drain: Approx. 1 L (0.26 gal)

Bucket cylinder

95V2E44007

1. Remove clamp (1) and coupler of bucket positioner switch (2). Remove rod (3) from the cylinder.

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

44-14 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder installing 10

To reinstall the bucket cylinder, follow the above removal procedure in reverse order.

Bucket cylinder installation cautions - Be sure the pins accept grease after installation. 95V2E44009

5. Remove bolt (9) to remove pin (10).

- Adjust the bucket leveler so that the clearance between the switch and the rod is 5 ± 2 mm (0.196 ± 0.078 in). Refer to "Bucket positioner" page 15-7.

: Bolt (9): 441 N-m (45.0 kgf-m) (324 lb-ft) 6. Slowly lift up the bucket cylinder. Lower the bucket cylinder onto the ground. For the detailed description of cylinder assembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-15.

WARNING During service work, do not stand on the machine. Standing on tire, boom or linkage may cause accidents and serious injury or death. Use a stepladder, ladder, or work platform, and do not stand on the machine.

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.

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

44-15 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling and assembling Hydraulic cylinder cross section and tightening torque

IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Boom cylinder

T2 97ZV44007

: T1: 6,669 N-m (680 kgf-m) (4,920 lb-ft) Piston nut width across flats: 110 mm (4.33 in) Thread size: M76 x 2 T2: 843 N-m (86 kgf-m) (622 lb-ft)

Steering cylinder

97ZV44009

: T5: 1,275 N-m (130 kgf-m) (941 lb-ft) Piston nut width across flats: 55 mm (2.17 in) Thread size: M36 x 1.5 T6: 1,765 N-m (180 kgf-m) (1,302 lb-ft)

44-16 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder (S/N 0101~0272, 9001~9065)

97ZV44008

: T3: 4,217 N-m (430 kgf-m) (3,111 lb-ft) Piston nut width across flats: 90 mm (3.54 in) Thread size: M60 x 2 T4: 883 N-m (90 kgf-m) (651 lb-ft)

Bucket cylinder (S/N 0273~, 9066~)

95V2E44011

(S/N 0273~0450, 9066~)

(S/N 0451~)

: T3: 5,900 N-m (602 kgf-m) (4,353 lb-ft) Piston nut width across flats: 90 mm (3.54 in) Thread size: M60 x 2 T4: 880 N-m (89.7 kgf-m) (649 lb-ft) (S/N 0273~0450, 9066~) T4: 550 N-m (56 kgf-m) (406 lb-ft) (S/N 0451~) 880 ± 90 N-m (90 ± 9 kgf-m)

550 ± 65 N-m (56 ± 6.6 kgf-m) K70V2J42023

44-17 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling Note The bucket cylinder disassembling procedure is described below. For other cylinders, follow the same procedure.

95ZV44006

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

Repair stand 95ZV44004

1. Install the bottom side of the cylinder to the repair stand.

Repair stand

4 Matchmark

Wooden block 95ZV44007

2 1 95ZV44005

2. Put the matchmarks on rod cover (1) and cylinder tube (2). Remove rod cover bolt (3). : Bolt (Boom cylinder): 843 N-m (86.0 kgf-m) (622 lb-ft) : Bolt (Bucket cylinder) (S/N ~0272, ~9065) 883 N-m (90 kgf-m) (651 lb-ft) (S/N 0271~0450, 9066~) 880 N-m (90 kgf-m) (649 lb-ft) (S/N 0451~) 550 N-m (56 kgf-m) (406 lb-ft) : Rod cover (Steering cylinder): 1,765 N-m (180.0 kgf-m) (1,302 lb-ft)

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

44-18 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Matchmark

95ZV44008

95ZV44010

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

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

6 C

Hydraulic jack

Hydraulic cylinder 95ZV44009

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

Boom cylinder

Bucket cylinder

Steering cylinder

Piston nut width across flats mm (in)

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

110 (4.33)

6,669 (680) (4,920)

90 (3.54)

(S/N ~0272) (S/N ~9065)

4,217 (430) (3,111)

(S/N 0273~) (S/N 9066~)

5,900 (602) (4,353)

55 (2.17)

1,275 (130) (941)

44-19 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

(Boom cylinder)

(Steering cylinder)

9 10

12 11

K95ZV44001

(Bucket cylinder) (S/N ~0272, ~9065)

K95ZV44002

(Bucket cylinder) (S/N 0273~, 9066~)

10 11

15 11

K95ZV44003

8. Remove the parts from piston (7). - wear ring (8) - square ring (9) - slipper ring (10) - O-ring (11) - wear ring (12) - seal set (13) - packing (14) - buck up ring (15)

95ZV44013

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

44-20 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

(Boom cylinder)

(Steering cylinder)

19 17

1 1

K95ZV44004

(Bucket cylinder) (S/N ~0272, ~9065)

21 20 18

K95ZV44005

(Bucket cylinder) (S/N 0273~, 9066~)

20 1

17 1

19 18 17

K95ZV44006

10. Remove the parts from rod cover assy (1). - scraper ring (16) - back-up ring (17) - U-packing (18) - buffer ring (19) - back-up ring (20) - O-ring (21) - dust seal (22)

Hydraulic cylinder assembling To reassembling the hydraulic cylinders, follow the above removal procedure in reverse order.

Hydraulic cylinder assembly cautions Before starting work: - Be sure to replace all the seals and packings. - Clean and check all the parts. If a part is damaged, replace it. - Before reassembling the parts, apply a coat of hydraulic oil to the parts.

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

44-21 95ZV Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

95ZV44016

K65V2E44013

Put slipper ring (10) into hot oil to heat the ring to 120~150ºC.

Reinstall the rod cover of the steering cylinder, and screw the rod cover using a spanner wrench. Screw in and tighten the set screw. Stake the set screw.

Note This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston. Therefore, heat the slipper ring to expand its inner diameter for easy attachment.

: 1,765 N-m (180 kgf-m) (1,302 lb-ft)

Attach the slipper ring while taking care not to damage the ring by over expansion. After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

Stake

2 13 95ZV44019

1 3 95ZV44017

Before installing back-up ring (2) and O-ring (3), heat the back-up ring. Note This is because the inner diameter of the back-up ring is smaller than the outer diameter of the rod cover. To easily attach the back-up ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded. Be careful not to over expand the back-up ring. After installation, wait until the back-up ring is cooled, and then insert the rod cover into the cylinder tube.

Stake 95ZV44020

Stake rod cover (1) at 4 points to prevent scraper ring (13) from coming out.

44-22 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot Valve Pilot valve removing and installing Control box

Pilot valve removing (S/N ~0290, ~9080)

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

Cover mount 90ZV44022

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

90ZV44023

2. Disconnect electrical line (2) of the QUAD switch. 3. Disconnect electrical line coupler (3) from the pilot valve. Note Before disconnecting the electrical couplers, be sure to put matchmarks on them.

44-23 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve

4 11

11 5

90ZV44024

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

90ZV44026

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

10 6 8 9

Adapter

12 12 7 15 13

90ZV44025

5. Remove boot (6) and covers (7)~(10). Adapter

90ZV44027

7. Disconnect arm (12) and rod (13) at the ball joint part. 8. Disconnect rod (13) and lever (14) at the ball joint part. 9. Remove bolt (15) (4 pcs) and pull up the pilot valve to remove it. : Adapter: 36 N-m (3.7 kgf-m) (27 lb-ft) : Pilot valve: 10 kg (14.3 lbs)

44-24 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve removing (S/N 0291~, 9081~)

Downshift button

Pilot valve

WARNING 2

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

95ZVE44039

2. Disconnect electrical line (2) of the QUAD (downshift) button. 3. Disconnect electrical line coupler (3) from the pilot valve.

Control box

Note Before disconnecting the electrical couplers, be sure to put matchmarks on them.

4 Cover mount

95ZVE44038

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

Pilot valve 95ZVE44040

4. Remove knob (4), and then separate Downshift button (5).

44-25 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

9 6

Adapter 2

13 14

Adapter 1

14 7 15 95ZVE44041

95ZVE44042

7. Loosen nut (14) and disconnect vinyl tube (12) and rod (13).

5. Remove boot (6) and covers (7)~(10).

8. Remove nut (15) (4 pcs) and pull up the pilot valve to remove it.

Pilot valve

: Adapter 1: 29.4 N-m (3.0 kgf-m) (21.7 lb-ft) Adapter 2: 49.0 N-m (5.0 kgf-m) (38.0 lb-ft) : Pilot valve: 6.5 kg (14.3 lbs)

11 11

Pilot valve installing 95ZVE44043a

6. Disconnect hoses (11) from the pilot valve.

To reinstall the pilot valve, follow the removal procedure in reverse order.

: Drain oil: Approx. 1 L (0.3 gal) Note Before disconnecting the hoses, be sure to put matchmarks on them. Cover the disconnected hoses with plastic, caps, or plugs to protect them from dust and dirt.

Pilot valve installation cautions 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.

44-26 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling and assembling (S/N ~0290, ~9080) IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve tightening torque For boom FRONT

Bucket side

Boom side

For bucket

T1 T3 L1

T3 L1

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

L1: Screw lock agent (Three Bond 1327) : Pilot valve: 6.5 kg (14.5 lbs)

95ZV44021

44-27 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling (Illustrated on the boom side. Disassemble the bucket side in the same manner.)

5 6 7

97ZV44024

4. Loosen socket bolt (5). Put a matchmark on lever (6) and disc (7) and remove lever (6) from disc (7). 97ZV44023

: Bolt (5): 29 N-m (3.0 kgf-m) (22 lb-ft) 1. Clamp the pilot valve in a vise. Pull up boot (1) to remove it from cover (2).

2. Measure the distance between solenoid (3) and cover (2).

Lock nut

9 97ZV44025

5. Loosen socket bolt (8). Remove cam shaft (9). 95ZV44076

Note Refer to 95ZV Shop Manual Function & Structure for the adjustment procedure. 3. Loosen lock nut for solenoid (3), and then remove solenoid from cover (2). : Solenoid: 42 N-m (4.3 kgf-m) (31 lb-ft)

: Bolt (8): 17 N-m (1.7 kgf-m) (12 lb-ft) Note In case the cam shaft cannot be pulled out, use the hexagon wrench to push it out.

44-28 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

11 12 7

10 13 14

97ZV44026

97ZV44028

6. Temporarily tighten socket bolt (5). Put matchmark on disc (7) and cover (2). Pull up socket bolt (5) with disc (7) to remove it.

9. Put matchmark on plug (11), push rod (12) and case assembly (14). Remove plug (11) together with push rod (12).

7. Loosen socket bolt (10).

Note - Carefully store the spring and spring seat in the push rod. - Carefully remove plug (11) as it may spring out by the spring force. Be careful so that the parts are not damaged. - In case plug (11) does not come out, use a screwdriver to remove it.

: Bolt (10): 12 N-m (1.2 kgf-m) (8.7 lb-ft) Note In case the spring force for the return spring is strong, alternately loosen the socket bolts so that cover (2) can be level.

10. Put matchmark on reducing valve assembly and case assembly. Remove reducing valve assembly (13) from case assembly (14).

12 97ZV44027

8. Put matchmark on cover (2) and the case assembly. Remove cover (2) from the case assembly.

20 97ZV44032

11. Disassemble plug (11). - Remove spring (19) and spring seat (20) from push rod (12), when mounted. - Remove push rod (12) from plug (11). Note Keep the disassembled parts per each port.

44-29 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Carefully install the spool into the case.

19 20 97ZV44032

95ZV44022

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

12. Disassemble reducing valve (13). - Push down spring seat (23). - Remove plain washer (24). - Remove spring (25) and shim (26), if any, from spool (22).

Note - Carefully remove plain washer so that the spool is not damaged. - Do not push down spring seat (23) 4 mm (5/32 in) or more. - Shim is for the secondary pressure adjustment.

97ZV44031

14. Clamp case assembly (14) in a vise up side down. Put matchmark on plate (18) and case assembly (14). Loosen socket bolt (17) and remove plate (18) from the case assembly.

: Bolt (17): 29 N-m (3.0 kgf-m) (22 lb-ft) 97ZV44029

13. Put matchmark on return springs (15)(16) and case assembly (14). Remove return springs (15)(16) from case assembly (14).

44-30 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve assembling

Pilot valve assembly cautions

To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

- Clean and check all the parts. If any part is defective, replace or repair it. - Replace all the O-rings and seals with new ones. - Apply the specified torque to tighten each main part. - Apply a thin coat of hydraulic oil or grease to each part before reassembly. - Measure the resistance of each coil magnet assembly. The resistance should be 138 Ω at normal room temperature [(20ºC) (70ºF)]. If measured in extremely low temperatures the resistance will be less, and at operating temperature the resistance will be higher.

Sharp edge side

22 95ZV44023

- Install plain washer (24) so that the plain washer sharp edge side comes to the top. - Do not push spring seat (23) 4 mm (5/32 in) or more.

44-31 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling and assembling (S/N 0291~0410, 9081~) IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve cross section and tightening torque

T7 L1

T7 L1 T4

T port:

T8 L1

P port:

T3 Port 1

Port 2

Cross section A-A

T2 A

Port 3

Port 4

Port 1, 2

B Port 3, 4

Cross section B-B 95ZVE44037

: T1: 49.0 N-m (5.0 kgf-m) (36.0 lb-ft) T2: 29.5 N-m (3.0 kgf-m) (22.0 lb-ft) T3: 20.5 N-m (2.1 kgf-m) (15.2 lb-ft) T4: 17.0 N-m (1.7 kgf-m) (12.3 lb-ft) T5: 14.5 N-m (1.5 kgf-m) (10.7 lb-ft) T6: 9.0 N-m (0.9 kgf-m) (6.5 lb-ft) T7: 7.0 N-m (0.7 kgf-m) (5.1 lb-ft) T8: 1.5 N-m (0.15 kgf-m) (1.1 lb-ft)

L1: Screw lock agent (Loctite® 241) application : Pilot valve: 6.5 kg (14.5 lbs)

44-32 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling 2

(Illustrated on the bucket side. Disassemble the boom side in the same manner.) 1

4. Put match-marks on cover assembly (2) and case assembly (5). Then remove the cover from the case assembly.

2 [Cross section view]

95ZVE44005

95ZVE44007

7 6

1. Plug all ports of the pilot valve and rinse it with illuminating kerosene.

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

95ZVE44004

7 4 3

95ZVE44006

3. Loosen socket bolts (3), which look deeper, with a hexagon (Allen) wrench.

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft) 95ZVE44003

Note Do not loosen bolt (4) here, which is later loosened in step 18.

5. Remove plug (6) by carefully pushing it up with a screwdriver while pressing push rod (7) with a cloth. Note Carefully remove plug (6) as plug (6) and push rod (7) may spring out by the force of return spring inside.

44-33 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

8 6

11 5

95ZVE44011

95ZVE44010

6. Remove push rod (7), plug (6), reducing valve parts as an assembly, and return spring (8) from case assembly (5).

8. Remove spool (11), secondary pressure spring (10) and plain washer (12) if assembled.

Note Put a match-mark on plug (6) and case assembly (5).

Note Plain washer (12) is used for the preset adjustment of spring (10), and may be of a different thickness or not used depending on the spool assembly. Make sure to keep the disassembled parts per each port.

Slide

9 95ZVE44009

7. To disassemble the reducing valve assembly, push spring seat (9) to compress secondary pressure spring (10), and slide spring seat (9) so that spool (11) is released from the bigger hole of the spring seat. Note - Do not damage the spool surface. - Do not push spring seat (9) 6 mm (0.24 in) or more.

7 95ZVE44008

9. Pull out spring (13) and spring seat (14) from push rod (7). (S/N 0291~0408 only) Note Only the port 1 and port 3 have spring (13) and spring seat (14). Make sure to keep the disassembled parts per each port. Refer to page 44-31 for the port location.

44-34 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Port 1&2

Port 3&4

95ZVE44013

95ZVE44015

10. Remove push rod (7) from plug (6). Remove O-ring (15) from plug (6).

12. Put match-marks on case assembly (5) and plate (20). Remove socket bolt (17) and nut (18) using the hexagon (Allen) wrench, and separate case assembly (5) and plate (20).

: Socket bolt (17): 20.5 N-m (2.10 kgf-m) (15.2 lb-ft)

19 6 95ZVE44014

11. Remove seal (16) from plug (6) using a small screwdriver. Note Take care not to damage the internal surface of plug (6).

20 95ZVE44012

13. Remove O-ring (19) from plate (20). Note Take care not to damage O-ring (19).

44-35 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

24 21

95ZVE44019

95ZVE44017

14. Remove O-rings (21) from case assembly (5).

17. Remove O-ring (24) from case assembly (5).

Note Take care not to damage O-ring (21).

Note Take care not to damage O-ring (24).

22 26 26

25 22 5

95ZVE44018

95ZVE44016

15. Clamp case assembly (5) in a vise. Loosen and remove socket bolts (22) on port plate (23).

18. Clamp center plate (25) in a vise. Remove socket bolts (26) in the shallow pits with a hexagon (Allen) wrench.

: Socket bolt (20): 20.5 N-m (2.10 kgf-m) (15.2 lb-ft) 16. Remove port plate (23) from case assembly (5).

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft)

44-36 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

28 25

27 95ZVE44023

19. Remove cover (2) and detent casing (27) from center plate (25). Be advised that fixing discs (29) on outer springs (28) may be stuck to detent casing (27) with grease, and could be dropped.

95ZVE44021

21. Remove detent casing (27) from cover (2). Note The push rod may be fall off the detent bush without the steel ball.

29 27

30 95ZVE44022

95ZVE44020

20. Remove outer springs (28) and fixing discs (29) on center plate (25).

22. Remove solenoid coil (30) from detent casing (27). Note While removing solenoid coil (30), do not pull the electrical harness.

44-37 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

32 31 31

95ZVE44028

23. Remove lever (31) by loosening socket bolt (32) with a hexagon (Allen) wrench.

95ZVE44026

26. Clamp lever (31) in a vise, and remove nuts (34). : Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)

: Socket bolt (32): 6.9 N-m (0.7 kgf-m) (5.1 lb-ft) Note Loctite® 241 is applied requiring bigger torque to loosen the bolt.

24. Remove cam shaft (33). 25. Take out lever (31) from cover (2).

95ZVE44027

44-38 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

35 (with pre-detent) 2 37

35 (without pre-detent)

2 F95ZVE44025

95ZVE44032

28. Remove O-rings (36) from cover (2). Note Take care not to damage O-rings (36).

Tool

95ZVE44024

27. Remove assembled detent bush (35), push rod (37), etc. from cover (2) using the tool. 37 95ZVE44031

[Tool]

(Material: SS400)

29. [For the port without pre-detent] Remove push rod (37) from detent bush (35). Put a match-mark on them beforehand.

Center hole (ø2 or less)

30 35

45 115V2E44021

44-39 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

35 95ZVE44030

30. [For the port with pre-detent] Hold detent ring (38) and press to compress spring (39), and then take out balls (40). Note Be sure to keep balls (40) (4 pcs.).

95ZVE44033

33. Remove scraper (41) from detent bush (35). Note Be sure not to damage scraper (41) or the internal surface of detent bush (35).

31. Pull out push rod (37).

Pilot valve assembling To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

39 35

95ZVE44029

32. Remove detent ring (38) and spring (39) from detent bush (35).

44-40 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve assembly cautions - Clean and check all the parts. If any part is defective, replace or repair it. - Replace all the O-rings and seals with new ones. - Apply the specified torque to tighten each main part. - Apply a thin coat of hydraulic oil or grease to each part before reassembly. - Measure the resistance of each coil magnet assembly. The resistance should be 62 Ω at normal room temperature [(20ºC) (70ºF)]. If measured in extremely low temperatures the resistance will be less, and at operating temperature the resistance will be higher. - Be aware that the assembled parts, such as the push rod, spring, etc. are different depending on the ports. Use the correct parts.

Push rod (37)

Detent bush (35)

Scraper (41)

Detail of A 95ZVE44035

- Insert scraper (41) in correct direction. - Do not push push rod (37) too much with the set screw while adjusting the position of the lever (31). It may cause bumping at Neutral position, resulting in unexpected movement at starting the engine.

44-41 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Push rod (7)

Plug (6) Seal (16) 95ZVE44034

- Install seal (16) in plug (6) in correct direction. - Do not push down the spring seat 6 mm (0.24 in) or more.

44-42 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling and assembling (S/N 0411~) IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve cross section and tightening torque

T5 L1 T3 T3

T5 L1

T1 T P T

Port 1

Port 2

Cross section A-A

Port 3

Port 4

Cross section B-B

B T2

Port 1, 2

Port 3, 4 K90Z544002

: T1: 49.0 N-m (5.0 kgf-m) (36.0 lb-ft) T2: 29.5 N-m (3.0 kgf-m) (22.0 lb-ft) T3: 17.0 N-m (1.7 kgf-m) (12.3 lb-ft) T4: 9.0 N-m (0.9 kgf-m) (6.5 lb-ft) T5: 7.0 N-m (0.7 kgf-m) (5.1 lb-ft) : Port 1~4 (adapter) 29.5 N-m (3.0 kgf-m) (22.0 lb-ft)

L1: Screw lock agent (Loctite® 241) application : Pilot valve: 6.5 kg (14.5 lbs)

44-43 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling 2

(Illustrated on the boom side. Disassemble the bucket side in the same manner.) 1

4 5

K90Z544010

4. Put match-marks on cover assembly (2) and case assembly (5). Then, remove the cover from the case assembly.

2 [Cross section view]

95ZVE44007

1. Plug all ports of the pilot valve and rinse it with illuminating kerosene.

7 6 5

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

K90Z544011

7 4 3

95ZVE44006

3. Loosen socket bolts (3), which look deeper, with a hexagon (Allen) wrench. 6

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft) K90Z544012

Note Do not loosen bolt (4) here, which is later loosened in step 18.

44-44 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

6 7

5 8

K90Z544013

95ZVE44010

6. Remove push rod (7), plug (6), reducing valve parts as an assembly, and return spring (8) from case assembly (5).

8. Remove spool (11), secondary pressure spring (10) and plane washer (12) if assembled.

Note Put a match-mark on plug (6) and case assembly (5).

Note Plane washer (12) is used for the preset adjustment of spring (10), and may be of a different thickness or not used depending on the spool assembly. Make sure to keep the disassembled parts per each port.

Slide

9 95ZVE44009

7 95ZVE44008

9. Pull out spring (13) and spring seat (14) from push rod (7). Note Only the port 1 and port 3 have spring (13) and spring seat (14). Make sure to keep the disassembled parts per each port. Refer to page 44-42 for the port location.

44-45 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

26 26

95ZVE44013

95ZVE44016

10. Remove push rod (7) from plug (6). Remove O-ring (15) from plug (6).

12. Clamp center plate (25) in a vise. Remove socket bolts (26) in the shallow pits with a hexagon (Allen) wrench. : Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft)

28 25

6 95ZVE44014

11. Remove seal (16) from plug (6) using a small screwdriver. 95ZVE44023

Note Take care not to damage the internal surface of plug (6). Note Item numbers (17) through (24) are intentionally omitted in the following steps.

13. Remove cover (2) and detent casing (27) from center plate (25). Be advised that fixing discs (29) on outer springs (28) may be stuck to detent casing (27) with grease, and could be dropped.

44-46 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

29 27

30 95ZVE44022

95ZVE44020

14. Remove outer springs (28) and fixing discs (29) on center plate (25).

16. Remove solenoid coil (30) from detent casing (27). Note While removing solenoid coil (30), do not pull the electrical harness.

31 27 95ZVE44021

15. Remove detent casing (27) from cover (2). 95ZVE44028

Note The push rod may be fall off the detent bush without the steel ball.

17. Remove lever (31) by loosening socket bolt (32) with a hexagon (Allen) wrench. : Socket bolt (32): 6.9 N-m (0.7 kgf-m) (5.1 lb-ft) Note Loctite® 241 is applied requiring bigger torque to loosen the bolt.

44-47 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

35 (with pre-detent) 31 37

35 (without pre-detent)

2 2

95ZVE44027

F95ZVE44025

18. Remove cam shaft (33). 19. Take out lever (31) from cover (2).

31 Tool

95ZVE44024

21. Remove assembled detent bush (35), push rod (37), etc. from cover (2) using the tool. 95ZVE44026

20. Clamp lever (31) in a vise, and remove nuts (34). : Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)

[Tool]

(Material: SS400) Center hole (ø2 or less)

30 35

45 115V2E44021

44-48 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

36 95ZVE44032

95ZVE44030

24. [For the port with pre-detent] Hold detent ring (38) and press to compress spring (39), and then take out balls (40).

22. Remove O-rings (36) from cover (2). Note Take care not to damage O-rings (36).

Note Be sure to keep balls (40) (4 pcs.). 25. Pull out push rod (37). 35 39 35

37 95ZVE44031

23. [For the port without pre-detent] Remove push rod (37) from detent bush (35). Put a match-mark on them beforehand.

95ZVE44029

26. Remove detent ring (38) and spring (39) from detent bush (35).

44-49 95ZV Disassembly & Reassembly Hydraulic Group Pilot Valve

Push rod (37)

Detent bush (35)

Scraper (41) Scraper (41)

Detail of A 95ZVE44033

95ZVE44035

27. Remove scraper (41) from detent bush (35).

- Insert scraper (41) in correct direction.

Note Be sure not to damage scraper (41) or the internal surface of detent bush (35).

- Do not push push rod (37) too much with the set screw while adjusting the position of the lever (31). It may cause bumping at Neutral position, resulting in unexpected movement at starting the engine.

Pilot valve assembling To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

Push rod (7)

Plug (6) Seal (16) 95ZVE44034

- Install seal (16) in plug (6) in correct direction.

44-50 95ZV Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple Control Valve Multiple control valve removing and installing Multiple control valve removing

95V2E44014

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

Stand

90ZV44028

95V2E44015

2. Loosen nuts (2) for U-bolts. (The illustration shows the machine left hand side.)

44-51 95ZV Disassembly & Reassembly Hydraulic Group Multiple Control Valve

5 10 4

95V2E44016

3. Remove bolts (3)~(7) for the oil pipe flange.

95ZV44057

5. Put matchmarks on pilot line hoses (10)(11), and then disconnect them.

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

Note Cover the disconnected hoses with plastic, caps to protect them from dust, water and dirt.

8 13 9 12

95ZV44056 95ZV44058

4. Slide boom cylinder oil pipes (8)(9) to the right. 6. Remove pipe (12) and hose (13), and then clamp them on the front chassis. : Hydraulic oil: Approx. 8 L (2.1 gal) Note Cover disconnected pipe and hose with plastic, caps or plugs to protect them from dust, water and dirt.

44-52 95ZV Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve installing To reinstall the multiple control valve, follow the above removal procedure in reverse order. 14

Multiple control valve installation cautions 15

1. Replace all the O-rings with new ones. 95ZV44059

7. Remove bolts (15) for control valve (14). Use a hoist to remove the control valve. : Bolt (15): 94 N-m (9.6 kgf-m) (69 lb-ft) : Multiple control valve: 100 kg (220 lbs)

2. Wash the multiple control valve mounting area.

WARNING Unexpected movement of the 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 the tires with chocks to prevent the wheels from moving. While working, carefully keep contact with the person in the cab by giving signals to each other. 3. Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the Section 03. 4. Operate the attachment and the boom, and check that they operate correctly. 5. Check each section for oil leakage. 6. Add hydraulic oil to the tank until the oil level rises to the specified point.

44-53 95ZV Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Multiple control valve cross section and tightening torque T3 T2 Overload relief valve with make-up function

T3 L1

T5 T1

Make-up valve

T6 Boom spool

T7 T5 Overload relief valve with makeup function

T4 T4

T6 Main relief valve

Bucket spool

95ZV44024

: T1: 196 N-m (20.0 kgf-m) (145 lb-ft) T2: 226 N-m (23.0 kgf-m) (166 lb-ft) T3: 39 N-m (4.0 kgf-m) (29 lb-ft) T4: 54 N-m (5.5 kgf-m) (40 lb-ft) T5: 74 N-m (7.5 kgf-m) (54 lb-ft) T6: 127 N-m (13.0 kgf-m) (94 lb-ft) T7: 29 N-m (3.0 kgf-m) (22 lb-ft)

L1: Screw lock agent application (Three Bond 1327) : 90 kg (200 lbs)

44-54 95ZV Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling

3 97ZV44038

2 1 97ZV44036

3. Set spool (3) in a vise using copper plates and then loosen bolt (4).

1. Bucket spool disassembling Remove two socket head bolts (1) and cover (2).

: Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft) Hole width across flat: 12 mm (0.47 in) : Screw lock agent (Three Bond 1327)

: Bolt (1): 54 N-m (5.5 kgf-m) (40 lb-ft) Hole width across flat: 8 mm (0.31 in)

6 4

5 9 8

97ZV44039

97ZV44037

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

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

44-55 95ZV Disassembly & Reassembly Hydraulic Group Multiple Control Valve

97ZV44040

5. Disassemble the boom spool by following the bucket spool disassembling procedure.

97ZV44042

7. Remove main relief valve (11). : Main relief valve: 127 N-m (13.0 kgf-m) (94 lb-ft) Head width across flat: 41 mm (1.61 in) Note The main relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary.

97ZV44041

6. Remove two overload relief valves (10). : Overload relief valve: 74 N-m (7.5 kgf-m) (54 lb-ft) Valve width across flat: 34 mm (1.34 in)

13 12

Note The overload relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary.

97ZV44043

8. Remove plug (12), and then remove spring (13) and poppet (14). : Plug (12): 226 N-m (23.0 kgf-m) (166 lb-ft) Hole width across flat: 14 mm (0.55 in)

44-56 95ZV Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve assembling To reassemble the multiple control valve, follow the above removal procedure in reverse order. 15

Multiple control valve assembly cautions - Clean and check all the parts. If a part is defective, replace or repair it. 90ZV44052

9. Remove make up valve (15) from the body. : Make up valve: 127 N-m (13.0 kgf-m) (94 lb-ft) Valve width across flat: 34 mm (1.34 in)

- Replace all the O-rings with new ones. - Apply a thin coat of hydraulic oil or grease to each part before reassembly. - Apply the specified torque to tighten each main part.

44-57 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® Orbitrol® removing and installing Orbitrol® removing

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

95ZV44061

2. Remove plate (2).

3 95ZV44062

3. Remove sound suppression sheet (3). 1

95ZV44060

1. Remove cover (1).

44-58 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® installing To reinstall the Orbitrol®, follow the above removal procedure in reverse order.

4 5

Orbitrol® installation cautions At the completion of reinstallation, check operation of the Orbitrol® by following the procedure below: 95ZV44063

WARNING 4. Put matchmarks on hoses (4), and then disconnect them from Orbitrol® (5). Note Cover the disconnected hoses with vinyl to protect them from dust and dirt.

Entering the articulation area while engine is running may cause serious injury or death. So, when entering the area, stop the engine and place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel or the operator's seat. 1. Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise. 2. Check around the Orbitrol® for oil leakage.

95ZV44064a

5. Remove bolt (6), and then remove the Orbitrol®. : Bolt (6): 29 N-m (3.0 kgf-m) (22 lb-ft) : Orbitrol®: 7 kg (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.

44-59 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Orbitrol® cross section and tightening torque

97ZV44010J

: T1: 23 N-m (2.3 kgf-m) (17 lb-ft)

: 6 kg (13 lbs)

44-60 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® disassembling 4

[Disassembling rotor] 5

7 6 Copper plate 97ZV44048

3. Remove rotor assembly (4), spacer (5) and O-ring (6). 95ZV44025

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

Note Keep rotor (7) in rotor assembly (4).

9 10 2 97ZV44049

4. Remove drive shaft (8), plate (9) and O-ring (10). 97ZV44047

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

44-61 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol® [Disassembling valve]

13 15

97ZV44052

97ZV44050

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

7. Remove seal (14) and dust seal (15) from seal retainer (13). Note - Seal (14) (S/N ~0251/~9038): X-ring seal Seal (14) (S/N 0252~/9039~): Y-packing seal - Take care not to damage seal retainer (13).

12 16 17 16

97ZV44051

18 19

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

97ZV44053

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

44-62 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

22 23

20 97ZV44054

97ZV44056

9. Pull spool and sleeve assembly (19) out slowly, turning it clockwise and counterclockwise from housing (20).

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

Note Take care so that the spool and sleeve do not damage the housing. 26 27 19

21 25 97ZV44057

12. Remove O-ring (25) from the housing. 97ZV44055

13. Remove adapter (26) to take out ball (27). 10. Pull out pin (21) from the spool and sleeve assembly (19).

Note Do not disassemble, unless absolutely necessary.

44-63 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® assembling

26 27

19 20 97ZV44060

25 97ZV44058

1. Assemble ball (27) and adapter (26) in housing (20).

3. Install springs (24) through the spring grooves in the sleeve and spool (19) using a spring insertion jig. Note Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

Spring groove

22 Spring groove

22 23 23 Matchmark

95ZV44026

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

97ZV44061

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

44-64 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

19 20

97ZV44062

97ZV44052

5. Insert spool and sleeve assembly (19) from the back of housing (20).

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

Note - Take care not to tilt the assembly and cause damage during insertion. - Insert the assembly until the back end of the assembly is flush with the back end of the housing. - Confirm that the assembly can be turned easily in the housing.

Note - Seal (14) (S/N ~0251/~9038): X-ring seal Seal (14) (S/N 0252~/9039~): Y-packing seal

13 17 16

23 97ZV44064

97ZV44063

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

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

44-65 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

Screw driver Dust seal Retainer ring

Seal retainer Seal A O-ring

90V2E44019

Note - Be sure the position and direction of the seals. - Seal (A) (S/N ~0251/~9038): X-ring seal Seal (A) (S/N 0252~/9039~): Y-packing seal (X-ring seal is shown in the above figure)

97ZV44068

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

Grooves in rotor bore

A B

Drive shaft

10 Pin

97ZV44066

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

Port face

8 Pin parallel with port face

21 95ZV44028

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

Port face

95ZV44029

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

44-66 95ZV Disassembly & Reassembly Hydraulic Group Orbitrol®

1 2 3

97ZV44070

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

Tightening order

95ZV44030

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

44-67 95ZV Disassembly & Reassembly Hydraulic Group Steering Valve

Steering Valve Steering valve removing and installing Steering valve removing

WARNING

Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and lower the attachment onto the ground. - Block the tires with chocks to prevent the wheels from moving. - Relieve the internal pressure from the hydraulic tank. - The oil spilled on the parking brake shoe section may cause malfunction. To prevent such a problem, cover the shoe section with plastic before valve removal. Before starting work: - Remove the seat and seat bracket in the cab.

95ZV44066a

2. Disconnect pipe (7). Note Cover the disconnected pipe with vinyl to protect them from dust and dirt.

2 4 1

5 95ZV44067

3. Disconnect hoses (8)(9). 95ZV44065a

1. Disconnect hoses (1)~(4) and pipes (5)~(6). : Hydraulic oil: Approx. 1 L (0.3 gal) Note Cover the disconnected hoses with vinyl to protect them from dust and dirt.

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

44-68 95ZV Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve installing

(S/N ~0230)

To reinstall the steering valve, follow the above removal procedure in reverse order. 11

Steering valve installation cautions At the completion of reinstallation, check operation of the steering valve by following the procedure below:

12 95ZV44068

WARNING

(S/N 0231~)

1. Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise. 12 95ZV44066a

4. Remove hoses (10)~(12). Note - Cover the disconnected hoses with vinyl to protect them from dust and dirt. - Hose (11) is for S/N 0101~ only.

13 14

95ZV44069

5. Remove bolt (13), and then remove steering valve (14). : Bolt: 231 N-m (23.5 kgf-m) (169 lb-ft) : Steering valve: 50 kg (110 lbs)

2. Check around the valve for oil leakage. 3. Measure various values for performance check. Measure the time required for full steering. Measure the relief valve setting pressure. (Refer to the Section 03 - Measurement for Performance Check).

44-69 95ZV Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Steering valve cross section and tightening torque (S/N ~0185, ~9003)

T7 T8

Main relief valve

Flow control spool Overload relief valve T5 T7 T2 T3

T1 T2

Steering spool

T4 T6

Overload relief valve

T5 95ZV44031

: T1: 39 N-m (4 kgf-m) (29 lb-ft) T2: 412 N-m (42 kgf-m) (304 lb-ft) T3: 255 N-m (26 kgf-m) (188 lb-ft) T4: 98 N-m (10 kgf-m) (72 lb-ft) T5: 62 N-m (6.3 kgf-m) (46 lb-ft)

T6: 83 N-m (8.5 kgf-m) (61 lb-ft) T7: 79 N-m (8 kgf-m) (59 lb-ft) T8: 12 N-m (1.2 kgf-m) (8.7 lb-ft) T9: 31 N-m (3.2 kgf-m) (23 lb-ft) T10: 314 N-m (32 kgf-m) (232 lb-ft)

44-70 95ZV Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve cross section and tightening torque (S/N 0186~, 9004~) T7 T8

Main relief valve

Flow control spool Overload relief valve

T1 T2

Steering spool T10

T6 T9

Overload relief valve T5 K95V2E44004

: T1: 39 N-m (4 kgf-m) (29 lb-ft) T2: 412 N-m (42 kgf-m) (304 lb-ft) T3: 255 N-m (26 kgf-m) (188 lb-ft) T4: 98 N-m (10 kgf-m) (72 lb-ft) T5: 62 N-m (6.3 kgf-m) (46 lb-ft) T6: 83 N-m (8.5 kgf-m) (61 lb-ft) T7: 79 N-m (8 kgf-m) (59 lb-ft) T8: 12 N-m (1.2 kgf-m) (8.7 lb-ft) T9: 31 N-m (3.2 kgf-m) (23 lb-ft) T10: 314 N-m (32 kgf-m) (232 lb-ft)

44-71 95ZV Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve disassembling 1

6 4

5 K95V2E44007

1 K95V2E44005

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

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

3 7 7 (S/N 0186~) (S/N 9004~) K95V2E44006 97ZV44076a

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

4. Slightly loosen plug (7). : (S/N ~0185, ~9003) 98 N-m (10 kgf-m) (72 lb-ft) Head width across flat: 41 mm (1.614 in) : (S/N 0186~, 9004~) 314 N-m (32 kgf-m) (232 lb-ft) Hole width across flat: 17 mm (0.669 in) Note Carefully loosen plug (7). It may spring out by the spring force.

44-72 95ZV Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve assembling 8 10 11

K95V2E44009

5. Remove relief valve (8) and plug (9). Pull out spring (10) and flow control spool (11) from the casing. Width across flat: (8): 19 mm (0.748 in) (9): 41 mm (1.614 in) : (8): 79 N-m (8 kgf-m) (59 lb-ft) (9): 98 N-m (10 kgf-m) (72 lb-ft) Note - Carefully remove plug (9). It may spring out by the spring force. - Carefully pull out flow control spool (11) so that the casing and flow control spool are not scratched. 6. Remove plug (7) loosened on paragraph 4.

To reassemble the steering valve, follow the above disassembly procedure in reverse order.

44-73 95ZV Disassembly & Reassembly Hydraulic Group Stop Valve

Stop Valve Stop valve removing and installing 1

Stop valve removing

2 8

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

95ZV44070a

1. Remove hoses (1)~(4). 2. Disconnect hose (5)~(7). Remove hose (5) at both ends. 3. Remove bolt (8), and then remove stop valve (9). Note Cover the disconnected hoses with vinyl to protect them from dust and dirt.

Stop valve installing For reinstallation, follow the above procedure in reverse order.

44-74 95ZV Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve installation cautions

Reference dimension

The stop valve works when the spool is pushed in 3 mm (0.118 in). Adjust the stopper bolt by using the following procedure.

Articulation angle (º)

Stop valve (rear chassis) (LH, RH)

Stopper (bolt)

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

28 (1.10)

38 (1.49)

48 (1.89)

Stopper (bolt) length (mm) (in)

23 (0.90)

25 (0.98)

27.5 (1.08)

∗The target value should be the articulation angle "36º". - After adjustment, turn the steering wheel slowly at a rate of 5 seconds or more per turn, and confirm the clearance between the machine body and the stopper.

Front chassis

- When adjustment is completed, tighten the lock nut of the stopper (bolt).

Reference dimension 23~27.5 mm (0.9~1.1 in) Stopper (bolt) length

95V2E44032

35º~

37º

Front chassis

Rear chassis Reference dimension 28~48 mm (1.1~1.9 in) Clearance between machine body and stopper

95ZV42035

- Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension "28~48 mm (1.1~1.9 in)" shown in the table below.

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

44-75 95ZV Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Stop valve cross section and tightening torque (S/N 0101~0290, 9001~9080)

T3 85V2E44015

: T1: 206 N-m (21 kgf-m) (152 lb-ft) T2: 5 N-m (0.5 kgf-m) (3.6 lb-ft) T3: 0.4 N-m (0.04 kgf-m) (0.3 lb-ft) T4: 26.0 N-m (2.7 kgf-m) (19.2 lb-ft)

44-76 95ZV Disassembly & Reassembly Hydraulic Group Stop Valve (S/N 0291~, 9081~)

(S/N 0291~0410) (S/N 9081~)

T3 K92V244001

: T1: 206 N-m (21 kgf-m) (152 lb-ft) T2: 5 N-m (0.5 kgf-m) (3.6 lb-ft) T3: 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)

44-77 95ZV Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve disassembling 12 10

A B

9 85V2E44017

97ZV44079

1. Remove boot (1) and plug (2).

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

WARNING The inner spring may spring out causing injury. Do not point the spring toward your face. : Plug (2): 206 N-m (21 kgf-m) (152 lb-ft)

8 3

85V2E44016

2. Remove spring (3) and pull out spool assembly (4). 3. Clamp spool assembly (4) at the bottom side in a vise and remove plug (5) using a screw driver. Remove washer (6), spring (7) and check valve (8) from the spool. : Plug (5): 5 N-m (0.5 kgf-m) (3.6 lb-ft)

Stop valve assembling To reassemble the stop valve, follow the above procedure in reverse order.

44-78 95ZV Disassembly & Reassembly Hydraulic Group Fan Motor

Fan Motor Fan motor removing and installing

Fan motor removing

WARNING

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

6 K95ZV44007

3. Remove hoses (5)~(7) from the fan motor. Use a drain pan to catch all escaping oil. Note Cover the disconnected hoses with vinyl to protect them from dust and dirt.

1 8

4 9 2

4 11

13 3 95ZV44071 95ZV44072a

1. Remove bolts (1)~(3). : Bolt (1): 94 N-m (9.6 kgf-m) (69 lb-ft) Bolt (2)(3): 53 N-m (5.4 kgf-m) (39 lb-ft) 2. Remove fan guard (4).

4. Sling fan (9), remove bolt (8) and take out the fan. : Bolt (8): 94 N-m (9.6 kgf-m) (69 lb-ft) : With lubrication oil (engine oil or gear oil) : Fan: 32.5 kg (72 lbs) Note Carefully remove the fan while checking that the fan will not damage the radiator fins. Inspect the fan and replace it if there are any signs of damage or cracks. Fan blade breakage can cause extensive damage.

44-79 95ZV Disassembly & Reassembly Hydraulic Group Fan Motor

Fan motor installing 13

For reinstallation, follow the above procedure in reverse order. 10

Fan motor installation cautions 11 12 8 K95ZV44009

Fan

Fan guard

5. Attach sling to fan motor (13). Remove nut (10) and flange (11). : Nut (10): 765 N-m (78 kgf-m) (564 lb-ft) : With lubrication oil (engine oil or gear oil)

6. Remove bolt (12) and remove fan motor (13). K95ZV44008

: Bolt (12): 142 N-m (14.5 kgf-m) (105 lb-ft) : With lubrication oil (engine oil or gear oil) : Fan motor: 25 kg (60 lbs)

- Reinstall the fan motor while checking that the clearances (A) between the fan and the fan guard are equal and fall within 8.0~10.0 mm (0.3~0.4 in). - Before operation, bleed the motor case of air and fill the motor with hydraulic oil.

44-80 95ZV Disassembly & Reassembly Hydraulic Group

MEMO

45-1 95ZV Service Standard Hydraulic Group

95ZV Service Standard Hydraulic Group Hydraulic Cylinder ................................................... 45-2 Pilot Valve................................................................ 45-4 Steering Valve ......................................................... 45-6

45-2 95ZV Service Standard Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder

97ZV45004

Bucket cylinder

95V2E45001

Steering cylinder

97ZV45005

45-3 95ZV Service Standard Hydraulic Group Hydraulic Cylinder

Unit: mm (in) Judgment standard No.

Standard dimension of rod dia.

Item

Standard value

Solution

Standard

Rod

Bushing

Standard clearance

Bushing

Clearance

+0.195 (+0.0076) ~ +0.060 (+0.0023)

0.096 (0.0037) ~ 0.285 (0.0112)

+0.295 (+0.0116)

0.385 (0.0151)

Replacement

Boom cylinder

ø100 (ø3.9373)

-0.036 (-0.0014) ~ -0.090 (-0.0035)

Bucket cylinder

ø80 (ø3.1496)

-0.030 (-0.0011) ~ -0.076 (-0.0030)

+0.190 (+0.0074) ~ +0.060 (+0.0023)

0.096 (0.0037) ~ 0.271 (0.0107)

+0.295 (+0.0116)

0.371 (0.0146)

Replacement

Steering cylinder

ø50 (ø1.9685)

-0.025 (-0.0010) ~ -0.064 (-0.0025)

+0.110 (+0.0043) ~ 0 (0)

0.025 (0.0010) ~ 0.174 (0.0068)

+0.210 (+0.0083)

0.274 (0.0108)

Replacement

No.

Item

Boom cylinder

Bucket cylinder (S/N ~0272, ~9065)

Bucket cylinder (S/N 0273~, 9066~)

Steering cylinder

6,669 (680) (4,920)

4,217 (430) (3,111)

5,900 (602) (4,353)

1,275 (130) (941)

Piston nut Tightening torque

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

2 Thread size

mm (in)

M76 x 2

M60 x 2

M36 x 1.5

Width across flat

mm (in)

110 (4.33)

90 (3.53)

55 (2.17)

843 (86) (622)

883 (90) (651)

(S/N ~0450) 880 (89.7) (649) (S/N 0451~) 550 (56) (406)

1,765 (180) (1,302)

M24 x 3

M24 x 3 - 65L

(S/N ~0450) M24 x 3 - 55L (S/N 0451~) M24 x 3 - 65L

--(Rod cover)

Rod cover mounting bolt

Tightening torque

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

Thread size

mm (in)

45-4 95ZV Service Standard Hydraulic Group Pilot Valve

Pilot Valve (S/N 0101~0290) (S/N 9001~9080)

97ZV45002a

Judgment standard No.

Item

Solution Standard valve

Allowable limit

87.7 mm (3.452 in)

86.7 mm (3.413 in)

Replacement

36 mm (1.417 in)

35 mm (1.378 in)

Replacement

ø8 mm (0.315 in)

ø7.5 mm (0.295 in)

Replacement with detent solenoid sub

Wear 1 mm (0.0394 in) 1

Push rod 85V2E45003

Wear 1 mm (0.0394 in) 2

Push rod 85V2E45003

Bush

85V2E45002

45-5 95ZV Service Standard Hydraulic Group Pilot Valve

(S/N 0291~0410) (S/N 9081~)

(S/N 0411~)

92V2E45001

45-6 95ZV Service Standard Hydraulic Group Steering Valve

Steering Valve

97ZV45001

Tightening torque No.

Item

Standard value

Steering valve retainer bolt

230 N-m (23.5 kgf-m) (170 lb-ft)

Steering valve bracket retainer bolt

230 N-m (23.5 kgf-m) (170 lb-ft)

Solution Tightening

54-1 95ZV Disassembly & Reassembly Brake Group

95ZV Disassembly & Reassembly Brake Group Unloader Valve ........................................................ 54-2 Manifold Valve Assembly ........................................ 54-8 Accumulator ............................................................ 54-11 Brake Valve ............................................................. 54-16 Service Brake .......................................................... 54-23 Parking Brake (Rear)............................................... 54-25 Parking Brake Actuator ........................................... 54-27 Parking Brake (Front) (for Europe only) .................. 54-31

54-2 95ZV Disassembly & Reassembly Brake Group Unloader Valve

Unloader Valve Unloader valve removing and installing Unloader valve removing 2 1

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

95ZV54013

Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure. - Press the hydraulic tank cap, and relieve the internal pressure from the hydraulic tank. - Prepare a container to catch drained oil.

7 95ZV54014

1. Remove hoses (1)~(5) and bolts (6). Remove unloader valve (7). Note Cover the disconnected hoses with clean plastic to protect them from dust and dirt. : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) : Unloader valve: 4 kg (8.8 lbs)

54-3 95ZV Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve installing To reinstall the unloader valve, follow the above removal procedure in reverse order. Replace all O-rings and seals during reinstallation.

Unloader valve installation cautions - After reinstallation, completely bleed the brake line of air, and check performance of the unloader valve. - To bleed the brake line of air, refer to "Service brake air bleeding procedure" page 24-20. - To check the performance of the unloader valve, refer to the 95ZV Shop Manual, Function and Structure, Section 53.

54-4 95ZV Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Unloader valve cross section and tightening torque (S/N 0101~0328, 9001~)

T8 T7 T6

T2 L1

97ZV54002

54-5 95ZV Disassembly & Reassembly Brake Group Unloader Valve : T1: 137 N-m (14 kgf-m) (101 lb-ft) T2: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T3: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T4: 58.8 N-m (6 kgf-m) (43 lb-ft) T5: 98.1 N-m (10 kgf-m) (72 lb-ft) T6: 118 N-m (12 kgf-m) (87 lb-ft) T7: 16.7 N-m (1.7 kgf-m) (12 lb-ft) T8: 78.5 N-m (8 kgf-m) (58 lb-ft)

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

L1: Screw lock agent (Loctite® 262) application

54-6 95ZV Disassembly & Reassembly Brake Group Unloader Valve (S/N 0329~)

T2 L1

K95V2E54014

: T1: 137 N-m (14 kgf-m) (101 lb-ft) T2: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T3: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T4: 58.8 N-m (6 kgf-m) (43 lb-ft) T5: 83.4 N-m (8.5 kgf-m) (62 lb-ft) T6: 118 N-m (12 kgf-m) (87 lb-ft) T7: 16.7 N-m (1.7 kgf-m) (12 lb-ft)

Width across flats 17 mm (0.669 in) Width across flats 5 mm (0.197 in) Width across flats 5 mm (0.197 in) Width across flats 8 mm (0.315 in) Width across flats 10 mm (0.394 in) Width across flats 36 mm (1.417 in) Width across flats 12 mm (0.472 in)

L1: Screw lock agent (Loctite® 262) application

54-7 95ZV Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve disassembling

3 2

(S/N 9049~) 0329~) (S/N Pressure governor assembly

K95V2E54015

Remove plug (1), then pull out spool (2) and spring (3). : 137 N-m (14 kgf-m) (101 lb-ft) Note Carefully remove plug (1). It may spring out by the spring force. Note Do not disassemble the pressure governor assembly and the pressure switch assembly unless it is necessary. Because, readjustment of accumulator pressure and setting of shims are required.

Unloader valve assembling To reassemble the unloader valve, follow the above disassembly procedure in reverse order.

54-8 95ZV Disassembly & Reassembly Brake Group Manifold Valve Assembly

Manifold Valve Assembly Valve assembly removing and installing Valve assembly removing

4 1

2 3

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

95ZV54015a

1. Remove hoses (1)~(6). Note Cover the disconnected hoses with plastic, plugs or caps to protect them from dust and dirt.

8 7

95ZV54016

2. Remove hoses (7)(8). Note Cover the disconnected hoses with plastic, plugs or caps to protect them from dust and dirt.

54-9 95ZV Disassembly & Reassembly Brake Group Manifold Valve Assembly

Valve assembly installing 9

To reinstall the valve assembly, follow the above removal procedure in reverse order.

Valve assembly installation cautions - Replace all O-rings and seals during reinstallation. 95ZV54017

3. Remove hose (9). Note Cover the disconnected hoses with plastic, plugs or caps to protect them from dust and dirt.

95ZV54018a

4. Remove hose (10). 5. Remove bolt (11) and then remove valve assembly from the chassis. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : Valve assembly: 10 kg (22 lbs)

- Completely bleed the brake line of air, and check performance of the valve assembly. To bleed the brake line from air, refer to "Service brake air bleeding procedure" page 24-20. - To check performance of the valve assembly, refer to Section 53.

54-10 95ZV Disassembly & Reassembly Brake Group Manifold Valve Assembly

Valve assembly disassembling and assembling IMPORTANT

CAUTION

Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

High pressure test ports contain accumulator pressure [11.8 MPa (1,706 psi)] that can escape from these 2 plugs. Completely depress brake pedal until you feel the pedal becomes light (about 8~10 times) to relieve all pressure before removing plugs.

Valve assembly cross section and tightening torque

T5 T1

T1 T1 Solenoid (S/N 0266~, 9066~)

(T)

(P)

T4 (TA)

(PI)

(PARKING) (ACCR)

(ACCF)

ACF (PA) (Z1)

(Z)

(Z2)

(PPI)

High pressure test ports

: T1: 50 N-m (5.1 kgf-m) (37 lb-ft) T2: 23.5 N-m (2.4 kgf-m) (17 lb-ft) T3: 38 N-m (3.9 kgf-m) (28 lb-ft) T4: 11 N-m (1.1 kgf-m) (8 lb-ft) T5: 8 N-m (0.8 kgf-m) (5.8 lb-ft) 70ZV54012a

54-11 95ZV Disassembly & Reassembly Brake Group Accumulator

Accumulator Accumulator removing and installing

2 1a

Accumulator removing

WARNING 1b

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

2 95ZV54019a

2. Disconnect hoses (1a)(1b) from accumulators (2). Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure. - Press the hydraulic tank cap, and relieve the internal pressure from the hydraulic tank. - Prepare a container to catch drained oil. 1. Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line.

Note - Hoses (1a) are connected with the manifold valve assembly, and hoses (1b) are connected with the brake valve. - Cover the disconnected hoses with plastic, plugs or caps to protect them from dust and dirt. 3. Remove bands (3), and then remove accumulators (2). : Accumulator: 17 kg (37.5 lbs)/pc

54-12 95ZV Disassembly & Reassembly Brake Group Accumulator

Accumulator installing To reinstall the accumulator, follow the above removal procedure in reverse order.

Accumulator disassembling and assembling IMPORTANT

Accumulator installation cautions After reinstallation, completely bleed the brake line of air, and check performance of the accumulator. To bleed the brake line of air, refer to "Service brake air bleeding procedure" page 24-20. To check performance of the accumulator, refer to Section 53.

Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Accumulator disassembling

WARNING Disassembly without breathing the inner gas could cause serious injury or death by explosion. To prevent such an accident, observe the following item: - Carefully handle the accumulator that has the high pressure. - Before disassembly, completely reduce the gas pressure lower to the atmospheric pressure. - Do not drill and weld the body. - Do not use over the specified pressure. - Use Nitrogen gas for charge.

IMPORTANT - Take care not to scratch the cylinder to prevent gas leak. - Carefully remove each part so that it is not scratched or dented.

54-13 95ZV Disassembly & Reassembly Brake Group Accumulator

7 2

3 13 Hydraulic cap (2)

12 11

5,6

8,9 97ZV54007

95ZV54003

4. Insert three bolts into hydraulic cap (2) and remove it by using a long bar. Screw size: 1/2-20UNF-2B Gas cap

5. Push out piston (4) toward the hydraulic end by using a bar.

Accumulator assembling 95ZV54002

1. Loosen bolt (13) to remove gas valve guard (12).

To reassemble the accumulator, follow the above disassembly procedure in reverse order.

2. Remove the cap of gas valve (10) and install the charging valve to gas valve (10), then bleed the gas completely from the accumulator.

Note After reassembly, carry out the gas charging by referring to the following procedure.

3. Insert three pins into gas cap (3). Remove the gas cap by using a long bar. Pin hole: ø11.4 mm (0.4 in)

54-14 95ZV Disassembly & Reassembly Brake Group Accumulator

Nitrogen gas charging

Nitrogen gas charging procedure

WARNING

Nitrogen gas charging tools

Improper gas pressure can cause serious injury or death. To prevent such an accident, observe the following item: - Before measuring the gas pressure or charging the gas, stop the engine and release the oil pressure in the line by depressing the brake pedal until there is no brake pressure.

1 2

1-1

1-3

1-2 3

Accumulator Charging valve installation

95ZV54004

1. Charging valve assembly 1-1 Handle (for adjusting screw) 1-2 Handle (for bleeder plug) 1-3 Valve body 2. Pressure gauge (4,900 kPa (50 kgf/cm2) (1,000 psi)) 3. Hose assembly 4. Nitrogen (N2) gas cylinder

Accumulator

95ZV54005

1. Turn handle (1-1) counterclockwise until it stops turning. 2. Turn handle (1-2) counterclockwise to open. 3. Remove the gas valve guard and then install charging valve assembly (1) to the gas valve. 4. Install pressure gauge (2) to the charging valve assembly and connect hose (3) to nitrogen gas cylinder (4). 5. Slightly open the valve of the nitrogen gas cylinder. Turn handle (1-2) clockwise to close after confirming the gas comes out from handle (1-2) part. 6. Slowly turn handle (1-1) clockwise to open the piston of the gas valve. 7. Open the valve of the nitrogen gas cylinder more and put a charge into the accumulator. Note Close the valve of the nitrogen gas cylinder when checking the gas pressure on the gauge to read the gauge needle at the stable condition.

54-15 95ZV Disassembly & Reassembly Brake Group Accumulator [Charging pressure: 2.9 MPa (30 kgf/cm2) (427 psi) at 20ºC (68ºF)] Note Gas pressure is variable with temperature. Use the following formula for the correct nitrogen charging pressure. If the pressure on the gauge is too high, slowly turn the handle (1-2) counterclockwise. PX = 30 (kgf/cm2) x {273 + t (ºC)} / {273 + 20 (ºC)} PX: Charging gas pressure t: Ambient temperature 30: Standard gas pressure 8. Turn handle (1-1) counterclockwise to return the piston of the gas valve. Then turn handle (1-2) counterclockwise to bleed the gas from the charging assembly and the hose. 9. After removing pressure gauge (2), remove the charging assembly from the accumulator. Note - Apply soapy water to the gas valve on the accumulator to check for gas leakage. - Recheck the gas pressure once within a week after the charging. - Check the gas pressure at every 2,000 operation hours. - A little gas is lost each time of the checking, so add the gas to compensate for the loss.

54-16 95ZV Disassembly & Reassembly Brake Group Brake Valve

Brake Valve Brake valve removing and installing Brake valve removing

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

95ZV54007

1. Remove pressure switches (1)(2).

IMPORTANT

3 3

4 3

95ZV54008

2. Disconnect hoses (3) and pipes (4) from the brake valve. Note Cover the disconnected hoses and pipes with plastic, plugs or caps to protect them from dust and dirt.

Cover

Cover K90V2E54001

- Remove the covers.

54-17 95ZV Disassembly & Reassembly Brake Group Brake Valve

Brake valve installing

To reinstall the brake valve, follow the above removal procedure in reverse order.

Brake valve installation cautions 6

95ZV54009

3. Remove bolt (5) and then remove brake valve (6). : Bolt (5): 28 N-m (2.9 kgf-m) (21 lb-ft)

After reinstallation, completely bleed the brake line of air, and check all the pipe-joints for oil leakage. To check or adjust the brake valve, refer to 95ZV Shop Manual, Function and Structure, Section 53.

54-18 95ZV Disassembly & Reassembly Brake Group Brake Valve

Brake valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Brake valve cross section and tightening torque (main valve)

A A-A

T1 L1 A

T2 70ZV54011

: T1: 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) T2: 176.4 N-m (18 kgf-m) (130 lb-ft) T3: 73.5 N-m (7.5 kgf-m) (54 lb-ft)

: L1: Screw lock agent 1303N application

54-19 95ZV Disassembly & Reassembly Brake Group Brake Valve

Brake valve disassembling Note Use a copper plate in vise and do not fix the brake valve in vise strongly. Bolt (4 pcs)

[ Main valve ] S cylinder assembly

Pedal Pin

P cylinder assembly

Seat Pedal stopper

Spring sub assembly

Boot Return spring + retainer

T flange assembly

Snap pin Pin (L-shaped)

95ZV54012 95ZV54010

1. Pull out the snap pin to remove the pedal, seat, boot and pedal stopper. Note During this step, the L-shaped pin is dropped. Take care not to lose it. Bolt (4 pcs)

3. Turn the valve upside down. Loosen four bolts and separate the valve assembly into the S cylinder assembly, P cylinder assembly, and T flange assembly. Note Carefully separate the valve assembly. It may spring out by the spring force.

Bracket

4. Remove the spring sub assembly from the T flange assembly. Remove the return spring and retainer together.

[ Pilot valve ] Follow the same disassembling procedure as the main valve. Valve assembly 95ZV54011

2. Loosen four bolts and disconnect the bracket from the valve assembly.

54-20 95ZV Disassembly & Reassembly Brake Group Brake Valve

Disassembly step diagram [ Main valve ]

[ Pilot valve ]

S cylinder assembly

Spool return spring Return spring

P cylinder assembly

Spring sub assembly

S flange assembly

Return spring + retainer

T flange assembly

95ZV54020

95ZV54021

54-21 95ZV Disassembly & Reassembly Brake Group Brake Valve

Brake valve assembling - Clean and check all the parts. If a part is defective, replace or repair the part. - Replace all the O-rings and seals with new ones. - Apply the specified torque to tighten each main parts. - Apply a thin coat of hydraulic oil or grease to each part before reassembly.

1. Install the return spring and retainer to the T flange assembly all together. Install the spring sub assembly to the T flange assembly. Note Confirm that the rod of the spring sub assembly is at the center. Be sure to install them in the proper direction. 2. Install the P cylinder assembly to the T flange assembly. 3. Install the spool return spring to the spool of the P cylinder assembly.

S cylinder assembly

4. Install the S cylinder assembly to the P cylinder assembly. Spool return spring

Bolt (4 pcs)

P cylinder assembly

S cylinder assembly

Spring sub assembly

P cylinder assembly

95ZV54022

5. Tighten four bolts. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft) Return spring + retainer Bolt (4 pcs)

Bracket

T flange assembly

Valve assembly 95ZV54020

95ZV54011

6. Tighten four bolts to install the bracket. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft)

54-22 95ZV Disassembly & Reassembly Brake Group Brake Valve

Pedal Pin Lock nut Seat Pedal stopper Boot

Pin (L-shaped) Snap pin Stopper bolt

95ZV54023

7. Install the boot, stopper and the seat to the valve assembly. 8. Install the pedal to the bracket. Turn the stopper bolt until the clearance between the seat and the roller becomes zero, then tighten the stopper bolt lock nut to fix the stopper bolt. : Lock nut: 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) : Stopper bolt: Screw lock agent 1303N application 9. Fix the pin (L) to the pin, and insert the pin to the bracket. At this time, the pin (L) should be in the pedal hole. 10. Making sure of the direction, install the snap pin to the pin.

54-23 95ZV Disassembly & Reassembly Brake Group Service Brake

Service Brake Service brake disassembling and assembling

Service brake installation cautions

Refer to "Front axle disassembling and assembling" page 24-21 for the procedures.

Socket bolt

Spider

95ZV54024

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

54-24 95ZV Disassembly & Reassembly Brake Group Service Brake

A Upper side

Brake piston Wheel hub

Brake piston 95ZV24038

For pushing down brake piston

3. After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face. Note Dimension A should be equal at the top and bottom sides. A: 162.45 ~ 163.85 mm (6.4 ~ 6.45 in) A

4. After confirming that the piston is fully retracted (that Dimension A is correct) remove all four bolts. K95ZV52037

5. After finishing the installation work, bleed air completely from the brake line.

CAUTION When only the friction plates or the steel plates are to be replaced, if the brake piston and brake stroke adjusting mechanism are installed as they are, the brake may drag and the brake discs may seize. Push back the brake piston and brake stroke adjusting mechanism by using the following procedure.

Wheel hub

1. Loosen the axle housing air bleeder nipple. Separation disc

2. Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly. Bolt size for pushing brake piston back: M10 x 1.5 - 45~50 mm L (1.8~1.97 in) (fully threaded)

Brake piston 95ZV24038a

Note On the machine S/N 0312~ or S/N 9096~ without the piston stroke adjuster, dimension B should be adjusted in the following range using shims. B: 1.20 ~ 1.90 mm (0.047 ~ 0.075 in)

54-25 95ZV Disassembly & Reassembly Brake Group Parking Brake (Rear)

Parking Brake (Rear) Parking brake (rear) disassembling and assembling Parking brake (rear) removing and disassembling

WARNING

When removing the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park the machine on level ground. - Lower the attachment onto the ground. - Apply articulation stopper.

Parking brake 95ZV54028

1. Drain the transmission oil. 3. Remove bolt (5) of propeller shaft (4). : Bolt (5): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three bond 1327)

7 2 8

3 97ZV54022

2. Release the parking brake, and then remove pin (3) to disconnect link (1) and lever (2).

97ZV54024

4. Remove bolt (6) of brake adjustment hole and then remove brake drum (7). : Bolt (6): 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Three bond 1327) 5. Remove nut (8) and flange yoke (9). : Nut (8): 883 N-m (90.0 kgf-m) (651 lb-ft) : With lubricating oil (Engine oil or gear oil)

54-26 95ZV Disassembly & Reassembly Brake Group Parking Brake (Rear)

97K54012

6. Remove right and left springs (10) using pliers. Remove plate (11).

Upper guide

Side guide

97ZV54026

8. Remove spring (15), and then remove adjusting screw (16) Note Measure the wear of the brake shoes. If the shoes are extremely worn, replace them. Refer to Section 53 or 55 for inspection standards.

Parking brake (rear) assembling and installing 12 14

95ZV54029

7. Pull out upper guides to the front to open brake shoes (12), and then remove shoes (12) from the side guides. If it is necessary to remove back plate (13), remove bolt (14). : Bolt (14): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent application (Loctite® 262)

To reassemble and reinstall the rear parking brake, follow the above procedure in the reverse order. To check performance of the parking brake, refer to 95ZV Shop Manual, Function and Structure, Section 53.

54-27 95ZV Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking Brake Actuator Parking brake actuator removing and reinstalling Parking brake actuator removing 3

Valve assembly

95ZV54025

2. Release the residual air pressure in hydraulic tank.Disconnect oil hose (3). 3. Loosen lock nut (4) to remove joint (5). 4. Remove retainer nuts (6) to remove park brake actuator(7).

: Parking brake actuator: 10 kg (22 lbs)

Parking brake actuator installing 4

To reinstall the parking brake actuator, follow the above removal procedure in reverse order.

5 2

K95ZV54001

1. If there is an oil pressure source, release the parking brake, and then remove split pin (1) and pin (2). Note If there is no oil pressure source, apply a cable to the link, and then pull it down using a bar to overcome the spring force, and then remove the pin.

Parking brake actuator installation cautions To insert the connection pin to connect the parking brake actuator to the parking brake, observe the following items: (a) Start the engine to build oil pressure in the accumulator. (b) Release the parking brake. (c) Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the parking brake actuator and the parking brake. (d) Insert the connection pin into the joint hole. To check performance of the parking brake, refer to 95ZV Shop Manual, Function and Structure, Section 53.

54-28 95ZV Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking brake actuator disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Parking brake actuator cross section and tightening torque

T1 : T1: 29 N-m (3.0 kgf-m) (22 lb-ft) T2: 441 N-m (45 kgf-m) (326 lb-ft)

97ZV54021

54-29 95ZV Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking brake actuator disassembling 4

WARNING The inner spring could spring out causing injury. To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the rod cap. When reducing the pressure of the press, be sure to slowly reduce it.

6 97K54006

3. Remove oil cylinder from the press and remove rod cover (4), spring (5) and piston rod (6).

3 1 2

97K54004

1. Set park brake actuator (1) in a press and remove nut (3) of tie-rod (2). : Nut (3): 29 N-m (3.0 kgf-m) (22 lb-ft)

97K54007

4. Remove dust seal (7) and remove grand metal (8) from rod cover (4) if necessary.

7 8 9 10 1 2

4 5 6

1 2 3

90 mm (3.54 in)

97K54005

2. Slowly reduce the press until the spring loses the spring force [approx. 90 mm (3.54 in.)] and then remove four tie-rods (2).

97K54008

5. Remove head cover (9) from cylinder tube (1).

54-30 95ZV Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking brake actuator assembling

To reassemble the parking brake actuator, follow the above procedure in the reverse order.

13 11 12

Parking brake actuator assembly cautions

CAUTION 97K54009

When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined.

6. Clamp the area of the two chamfered flats of piston rod (6). Remove nut (10) and then remove U-packing (12) and the wear ring (13). : Nut (10): 441 N-m (45.0 kgf-m) (326 lb-ft)

95ZV54027

To check performance of the parking brake, refer to 95ZV Shop Manual, Function and Structure, Section 53.

54-31 95ZV Disassembly & Reassembly Brake Group Parking Brake (Front) (for Europe only)

Parking Brake (Front) (for Europe only) Parking brake (front) removing and reinstalling Parking brake (front) removing

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting parking brake removal: - Park the machine on level ground. - Lower the attachment onto the ground, and block the tires with chocks, etc. to prevent them from moving. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the operation board. Before starting work: Prepare a container to catch the drained oil.

3 1 2

1. Stop the engine and set the parking brake switch to "OFF" position to discharge the oil pressure in the line. 95ZV54037

2. Disconnect hose (1) and remove adapter (2). Note Cover the disconnected hose with clean plastic to protect the hose from dust and dirt.

54-32 95ZV Disassembly & Reassembly Brake Group Parking Brake (Front) (for Europe only)

Parking brake (front) installing

Front differential Bracket

To reinstall the front parking brake, follow the above removal procedure in reverse order. Brake disc

3 95ZV54030

3. Attach sling to disc brake assembly (3), and then remove four bolts (4). : Bolt (4): 451 N-m (46.0 kgf-m) (333 lb-ft) : With lubricating oil : Disc brake assembly: 30 kg (65 lbs) 4. Place disc brake assembly (3) on a carrier. Note If it is necessary to remove the brake disc and the bracket, remove bolts (5)(6). : Bolt (5): 132 N-m (13.5 kgf-m) (98 lb-ft) : Bolt (6): 721 N-m (73.5 kgf-m) (532 lb-ft) : With lubricating oil : Brake disc: 20 kg (45 lbs) : Bracket: 11.5 kg (25 lbs)

54-33 95ZV Disassembly & Reassembly Brake Group Parking Brake (Front) (for Europe only)

Parking brake (front) installation cautions 6

1 8

Air bleeding procedure

7 3 4

18 7 6

Brake oil

13 7 16

8 12 21

17 15

13 Brake disc

- Connect a vinyl tube to the air bleeder nipple, and place an oil can to receive the oil. - Apply parking brake to build-up pressure in the disc brake head and slightly loosen air bleeder valve (2) to slightly discharge oil. - When the oil flows from the air bleeder nipple, close the nipple. - Repeat this until there is no air in the oil. 4. Confirm the performance of the parking brake. Refer to Section 53 for the checking procedure.

14 20 19

22 9

3. After reinstalling the disc brake assembly, completely bleed air in the line as the following procedure.

95ZV54034

1. The brake pad assemblies (5) should be free, not pressed against disc. If not free, remove brake pad assemblies (5) as per the following step 2, and use a pry bar to push pistons (10) back into torque plate assembly (1). Reinstall brake pad assemblies (5). 2. If torque pins (4) of installed brake heads contact the disc, loosen bolts (3) and move pins away from disc, within limits of the outer diameter groove in the pin. Make sure the bolt fully engages groove in pin and torque bolt to 51 N-m (5.2 kgf-m) (38 lb-ft).

54-34 95ZV Disassembly & Reassembly Brake Group Parking Brake (Front) (for Europe only)

Parking brake (front) disassembling and assembling Parking brake (front) cross section and tightening torque

Brake oil

1 6

18 2

7 6

14 20 19

22 9

3 7 13 7 16

8 10

12 21

17 15

13 Brake disc 95ZV54035

1. Torque plate assembly 2. Bleeder valve 3. Bolt 4. Pin 5. Pad assembly 6. Bolt 7. Washer 8. Inlet cap 9. Packing * 10. Piston 11. Boot * 12. Packing * Note - Torque plate assembly (1) is not a repairable or replaceable item. - Items with an asterisk (*) are contained in the parts kit, and are not sold separately : Valve (2): 25 N-m (2.6 kgf-m) (19 lb-ft) Bolt (3): 51 N-m (5.2 kgf-m) (38 lb-ft) Bolt (6): 54 N-m (5.5 kgf-m) (40 lb-ft)

13. Nut 14. Spring 15. Washer 16. Retaining ring 17. Sleeve, adjuster 18. Guide, adjuster 19. Guide, adjuster 20. Packing * 21. Back-up ring * 22. Back-up ring *

54-35 95ZV Disassembly & Reassembly Brake Group Parking Brake (Front) (for Europe only)

Parking brake (front) disassembling and assembling 3 5

17 14

15 8

20 19

16 12

16 15

14 17

7b 6 12 9 21

1. Loosen bolts (3) and slide pins (4) back from the center of the brake head, and then remove brake pad assemblies (5) from brake head. 2. Attach the brake head to a hydraulic pressure source. Restrain piston (10) opposite cap (8) with a Cclamp and apply the hydraulic pressure until the piston in inlet side becomes free of piston bore. Release pressure, disconnect the brake head from the pressure source and remove the C-clamp. 3. Remove nut (13), washer (7a) and press piston (10) from torque plate assembly (1) by pushing guide (19) towards the center of the brake head. 4. Remove bolts (6), washers (7b) and cap (8) with attached guide (18). Remove packing (9) and backup ring (22) from cap (8). Note Do not remove guide (18) from cap (8) except to replace it when damaged.

21 11 K95ZV54002

5. Remove packings (12) (20), boots (11) and bleeder valve (2) from torque plate assembly (1). 6. Replace all rubber parts (9) (11) (12) (20) (21) (22), available as a kit. Refer to 95ZV parts catalog. 7. Clean, degrease, repair or replace damaged or excessively worn parts, as required. 8. Inspect brake pad assemblies (5) for excessive wear. Replace if lining is worn to the wear limit. Refer to Section 55 for the wear limit. 9. Inspect pistons (10) for minor scratches or nicks and blend with crocus cloth. Replace pistons that are badly nicked or scratched. 10. Pins (4) that are deeply grooved should be replaced or rotated so that the grooved surface is opposite to brake pad assembly (5) ends. 11. Lubricate packings (9) (12) (20) and the outer diameter of pistons (10) with hydraulic fluid specified in applicable brake head parts catalog sheet.

54-36 95ZV Disassembly & Reassembly Brake Group Parking Brake (Front) (for Europe only)

1 8

7 3 4

18 7 6

Note Pistons (10) must be installed from center of the brake head. Any other method will damage boots (11) and packings (12). 17. Install bleeder valve screw (2).

14 20 19

22 9

18. Install new brake pad assemblies (5) by placing friction material next to the disc and rotating into position in the brake head.

Brake oil

19. Lubricate the outer diameter of pins (4) with a good anti-seize compound and install in torque plate assembly (1). Push the pins toward the disc.

13 7 16

8 10

16. Center and insert pistons (10) with attached adjuster parts over guides (18) (19). Push pistons through previously installed boots (11) and packings (12) by hand. With pistons centered over guides, use a C-clamp or other suitable device to force pistons over guides and into piston bores.

12 21

17 15

13 Brake disc

95ZV54034

12. Reassemble the brake head in reverse order of disassembly. 13. Install packings (12) and boots (11) in the piston bore grooves of torque plate assembly (1). Install packing (9) in the groove of cap (8). Note If guide (18) was removed from cap (8), clean the screw threads. Coat the screw threads with Loctite® sealant and reinstall it in cap (8), tightening securely. 14. Install cap (8) with guide (18) and secure it in place with four each bolts (6) and washers (7b). 15. Assemble packing (20) over the threaded end of guide (19) and seat against the shoulder of guide. Insert the guide through closed piston bore (opposite the capped piston bore) with threaded end protruding from back of torque plate assembly (1). Secure in place with nut (13) and washer (7a).

Note Lubricate pins (4) with a corrosion resistant lubricant prior to installation for easier pin removal. 1. Tighten the loosened bolts (3) until they fit in the pin (4) grooves. This can be checked by limited axial movement of pins as the bolts are being seated in the grooves. 2. After bolts (3) are fit in grooves, tighten to 51 N-m (5.2 kgf-m) (38 lb-ft).

55-1 95ZV Service Standard Brake Group

95ZV Service Standard Brake Group Brake Valve ............................................................. 55-2 Service Brake .......................................................... 55-6 Parking Brake.......................................................... 55-7

55-2 95ZV Service Standard Brake Group Brake Valve

Brake Valve [ Main valve (left pedal) ]

2 1 3

9 12

6 4 7 5 8

97ZV55001

55-3 95ZV Service Standard Brake Group Brake Valve

Unit: mm (in) Judgment standard No.

Item

Standard dimension

Tolerance

Solution

Shaft

Hole

Standard clearance

Allowable clearance

Clearance between pedal installation hole and bracket hole

ø10 (0.3937)

-0.025 ~ -0.075 (-0.0011~-0.0030)

+0.1 (+0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Clearance between roller and pin

ø10 (0.3937)

-0.025 ~ -0.075 (-0.0011~-0.0030)

+0.1 (+0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Outer diameter of roller

ø30 (1.1811)

0 -0.5 (-0.0197)

Replacement

0.020 (0.0008)

Judgment standard Standard dimension No.

Item

Tolerance limit Solution

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lbf)

Free length mm (in)

Installation load N (kgf) (lbf)

Control spring

59.0 (2.3228)

49.7 (1.9567)

64 (6.5) (14.3)

57.5 (2.2638)

—

Control spring

27.2 (1.0709)

56.2 (2.2126)

—

Return spring

59.0 (2.3228)

58.0 (2.2835)

103 (10.5) (23.1)

62.1 (2.4449)

—

Balance spring

17.0 (0.6693)

15.0 (0.5906)

70 (7.1) (15.7)

16.2 (0.6378)

—

Spool return spring

31.5 (1.2402)

19.5 (0.7677)

17 (1.7) (3.7)

28.0 (1.1024)

—

Bracket installation bolt tightening torque

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Cylinder installation bolt tightening torque

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Plug tightening torque

176.4 N-m (18 kgf-m) (130 lb-ft)

Stopper bolt lock nut tightening torque

9.8 N-m (1.0 kgf-m) (7.2 lb-ft)

Replacement

Tightening

55-4 95ZV Service Standard Brake Group Brake Valve

[ Pilot valve (right pedal) ]

6 4 5

9 7 10

97ZV55002

55-5 95ZV Service Standard Brake Group Brake Valve

Unit: mm (in) Judgment standard No.

Item

Standard dimension

Tolerance

Solution

Shaft

Hole

Standard clearance

Allowable clearance

Clearance between pedal installation hole and bracket hole

ø10 (0.3937)

-0.025 ~ -0.075 (-0.0011~-0.0030)

+0.1 (+0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Clearance between roller and pin

ø10 (0.3937)

-0.025 ~ -0.075 (-0.0011~-0.0030)

+0.1 (+0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Outer diameter of roller

ø30 (1.1811)

0 -0.5 (-0.0197)

Replacement

0.8 (0.032)

Judgment standard Standard dimension No.

Item

Tolerance limit Solution

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lbf)

Free length mm (in)

Installation load N (kgf) (lbf)

Control spring

59.0 (2.3228)

49.7 (1.9567)

64 (6.5) (14.3)

57.5 (2.2638)

—

Control spring

27.2 (1.0709)

56.2 (2.2126)

—

Return spring

65.0 (2.5591)

58.0 (2.2835)

71 (7.2) (15.9)

58.5 (2.3031)

—

Spool return spring

31.5 (1.2402)

19.5 (0.7677)

17 (1.7) (3.7)

28.0 (1.1024)

—

Bracket installation bolt tightening torque

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Cylinder installation bolt tightening torque

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Plug tightening torque

176.4 N-m (18 kgf-m) (130 lb-ft)

Stopper bolt lock nut tightening torque

9.8 N-m (1.0 kgf-m) (7.2 lb-ft)

Replacement

Tightening

55-6 95ZV Service Standard Brake Group Service Brake

Service Brake

Air bleeder nipple

1, 5

Slide caliper

1, 5

Brake backing plate

Steel plate

2, 5

Friction plate

95ZV55001

Unit: mm (in) Judgment standard No.

Item

Solution Standard dimension

Tolerance

Wear limit

0 (0)~ -0.2 (-0.0078)

4.4 (0.1732)

Thickness of steel plate

5.0 (0.1968)

Thickness of friction plate

6.8 (0.2677)

±0.1 (±0.0039)

5.7 (0.2244)

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

28.6 (1.1260)

±0.3 (±0.0118)~ -0.5 (-0.0196)

25.1 (0.9881)

Outer diameter

(Work dimension) 375 (14.7638)

-0.210 (-0.0082)~ -0.299 (-0.0117)

—

Inner diameter

(Work dimension) 305 (12.0079)

+0 (+0)~ +0.081 (+0.0032)

—

0.3 (0.0118) or less

—

0.30 (0.0118) and more

Free length

Installation length

Installation load (kgf)

54 (2.1260)

49 (1.9291)

29.3 (64 lbs)

Piston seal contact face

Distortion of steel and friction plate

Return spring

Replacement

—

Replacement

55-7 95ZV Service Standard Brake Group Parking Brake

Parking Brake [ Parking brake (rear) ]

1 3

Clearance

Spring (4) when released

95ZV55002

No.

Item

Judgment standard

Solution

Standard dimension

Wear limit

6.15 mm (0.2421 in)

2.95 mm (0.1161 in)

Wear of lining

Replacement

Deflection of drum

0.38 mm (0.0149 in) or more

Replacement

Lining inspection

Grease or oil on the lining

Replacement

Expansion of adjuster spring

Replacement

Expansion of return spring

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

55-8 95ZV Service Standard Brake Group Parking Brake

[ Parking brake (front) ]

Front differential gear

Brake disc

15.5 mm 21.5 mm

Disc brake

Brake pad

95ZV55003

Judgment standard No.

Item

Standard dimension mm (in)

Wear limit mm (in)

Solution

Wear of brake disc

+0.0039 13.5 +0.1 -0.4 (0.5315 -0.0157)

10.5 (0.4134)

Replacement

Wear of brake pad

3.2 (0.1260)

Replacement

15.5 (0.6102)

74-1 95ZV Disassembly & Reassembly Operator Station Group

95ZV Disassembly & Reassembly Operator Station Group Air Conditioner ........................................................ 74-2

74-2 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner

Air Conditioner Air conditioner removing and installing Air conditioner removing

IMPORTANT In case that it is necessary to replace the air conditioner parts, be sure to set the air conditioner mode as below before removing the air conditioner unit from the machine. Temperature control: Max cool Ventilation mode: Foot Air intake control: Inside air circulation Before starting work: - Remover the seat in the cab. - Collect the air conditioner refrigerant using the proper recovery method. - Remove the floor mat in the cab.

2 1 4 2 3

3 View from operator’s seat

95ZVE74001

74-3 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner

Cab

7 12

11 8

95ZVE74002

95ZVE74005

6. Remove air conditioner mounting bolts (11). Then remove air conditioner (12) from the floor board.

1. Remove box (1)(2). 2. Remove cover (3) and plate (4). 3. Remove cover (5)(6)(7) from the cab.

Air conditioner installing 4. Remove duct (8). To reinstall the air conditioner, follow the above removal procedure in reverse order. Reference After reinstalling the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

Air conditioner unit

95ZVE74003

Air conditioner unit

10 95ZVE74004

5. Disconnect refrigerant piping (9) and heater hose (10).

74-4 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner

Air conditioner disassembling and assembling Air conditioner tightening torque [Cooling unit]

T2 T6 T4

T4 T5

T6 T4

T2 T1 T5

97ZV74002

: T1: 5.4 N-m (0.55 kgf-m) (4 lb-ft) T2: 1.9 N-m (0.19 kgf-m) (1.4 lb-ft) T3: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T4: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft) T5: 1.9 N-m (0.19 kgf-m) (1.4 lb-ft) T6: 2.5 N-m (0.25 kgf-m) (1.8 lb-ft)

74-5 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner [Heater and accessories]

[Air distributor (hood & defroster selection box)]

T3 T2 T2

T4 T1

97ZV74003

: T1: 4.0 N-m (0.4 kgf-m) (2.9 lb-ft) T2: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft) T3: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T4: 5.4 N-m (0.55 kgf-m) (4 lb-ft)

95V2U74001

: T1: 3.7 N-m (0.38 kgf-m) (2.7 lb-ft) T2: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T3: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft)

74-6 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner [Air compressor (with magnetic clutch)]

97ZV74005

: T1: 4.9 N-m (0.5 kgf-m) (3.6 lb-ft) T2: 18 N-m (1.8 kgf-m) (13 lb-ft) [Condenser unit]

95V2U74002

: T1: 12 N-m (1.2 kgf-m) (8.7 lb-ft) T2: 5.4 N-m (0.55 kgf-m) (4 lb-ft)

74-7 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner

Air conditioner disassembling

[Blower assy]

Air conditioner unit assy

Blower assy

95V2U74005

3. Remove motor cooling pipe (3) from motor assy (4) and the blower case. 95V2U74003

4. Remove bolt (5) (3 pcs), and then remove motor assy (4) from the blower case. 1

5. Remove the packing from motor assy (4). This packing is reusable.

95V2U74004

1. Remove tapping screw (1) that fixes blower assy (2) to the air conditioner unit assy. 2. Pull blower assy (2) upward to separate it from the air conditioner unit assy.

74-8 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner

Screw driver Lever

8 9

Long-nose pliers

95V2U74006

6. Remove clamp (6) using a screw driver. 7. Carefully push the link shaft end using long-nose pliers and remove link shaft (7) from the lever. Note Be careful not to break the link shaft claw. 8. Remove tapping screw (8) (3 pcs) and remove servo motor (9).

95V2U74007

9. Remove bolt (10) and then remove relay (11).

74-9 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner [Air conditioner unit assy] 6

Air conditioner unit assy

7 95V2U74010

95V2U74008

4. Remove tapping screw (4) and then remove plate (5). 5. Remove lever (6) and lever (7) respectively.

9 95V2U74009

1. Remove tapping screw (1) that fixes blower assy (2) to the air conditioner unit assy.

95V2U74011

2. Pull blower assy (2) upward to separate it from the air conditioner unit assy.

6. Remove clamp (8) using a screw driver. Then remove link shaft (9).

3. Remove thermistor assy (3) from the case.

95V2U74012

7. Remove tapping screw (10) (11 pcs) and separate the cooler case.

74-10 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner

143.5 5 (5.6 in)

Packing 95V2U74013

Note When reassembling, make sure that the packing is placed in the case groove.

236 – 5 (9.3 in)

80 – 15 (3.1 in)

+10

Thermistor

95V2U74016

10. Remove clamp (16) (2 pcs) and remove the thermistor from the evaporator. Note When reassembling, place clamps (16) in the positions as shown. Incorrect positioning of the thermistor may cause frost or temperature control malfunction.

13 11

18 17

95V2U74014

8. Loosen joints (11)(12) and remove evaporator (13). : Joint (11): 32 N-m (3.3 kgf-m) (24 lb-ft) : Joint (12): 13 N-m (1.3 kgf-m) (9.4 lb-ft)

19 20 95V2U74017

11. Remove tapping screw (17) and remove clamp 1 (18). 14

12. Remove tapping screw (19) and remove clamp 2 (20). 13. Pull heater core (21) upward and remove it.

95V2U74015

9. Remove bolt (15) (2 pcs) and then remove expansion valve (14).

74-11 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner

22 28

95V2U74018

14. Remove the thermo sensor connector from the bracket and remove thermo sensor (22).

95V2U74021

18. Remove tapping screw (27) and remove servo motor (28).

24 29 30 24

24 25

31 32

95V2U74019

15. Remove clamp (23) by using a screw driver. 16. Remove tapping screw (24) and remove servo motor (25).

95V2U74022

19. Remove tapping screw (29) (2 pcs) and remove IC assy (30). 20. Remove pressure switch (31) from tube (32).

Air conditioner assembling To reassemble the air conditioner, follow the above procedure in reverse order. 26

95V2U74020

17. Remove plate (26).

74-12 95ZV Disassembly & Reassembly Operator Station Group Air Conditioner

Compressor V-belt

Compressor

V-belt

K95V2U74006

V-belt Compressor

K95V2U74007

: T1: 27.9 N-m (2.85 kgf-m) (20.6 lb-ft)

75-1 95ZV Service Standard Operator Station Group

95ZV Service Standard Operator Station Group Air Conditioner ........................................................ 75-2

75-2 95ZV Service Standard Operator Station Group Air Conditioner

Air Conditioner Periodical Inspection/Servicing Inspection/maintenance item

Criteria

Solution

Refrigerant

Charge quantity

Air bubbles should not be seen through sight glass.

Inspection/adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Clean

Compressor

Operating status

Magnetic clutch should operate. Abnormal sounds should not be detected.

Inspection/ adjustment/ replacement

Belt tension pulley

Operating status

Abnormal sounds and backlash should not be detected.

Inspection/ replacement

V belt

Damage and tension

Damages should not be detected.

Replacement

Blower motor and fan

Operating status

Abnormal sounds or vibration should not be detected.

Inspection/ replacement

Control mechanism

Operating status

Each part should operate in accordance with switch operations.

Inspection/ replacement

Air filter for inside/outside air

Clogging

Air quantity should not be so small as to hinder air conCleaning/replacement ditioning.

Each mounting area and piping

Looseness, gas leak and damages

Looseness, gas leak and damages should not be detected.

Tightening/charge

Tightening Torque Tightening torque for hose and pipes

Connection type

Connection area

Condenserexpansion valve Nut type

Pipe size or bolt size

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

ø8 piping

15 (1.50) (11)

Compressorcondenser

D1/2 piping

25 (2.50) (18)

Evaporatorcompressor

D5/8 piping

34 (3.50) (25)

Receiver Block joint Evaporatorcompressor

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

7 (0.70) (5.1) 12 (1.20) (8.7)

Tightening torque for screws and bolts in special control regions

Special control area

Head bolt of magnetic clutch

Bolt size

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

18 (1.8) (13)

Mounting bolt for servo motor for inside/outside air selection (Tapping screw)

0.8 (0.08) (0.6)

Fixing nut of blower motor and condenser fan

5.4 (0.55) (4.0)

Fixing bolt of blower motor and condenser motor

4 (0.4) (2.9)

INDEX 1st Clutch Assembly .......................................................34-40 1st clutch assembly assembling .....................................34-41 1st clutch assembly disassembling .................................34-40 1st clutch assembly disassembling and assembling ....................................................................................34-40 2nd clutch spider assembling .........................................34-38 2nd clutch spider disassembling .....................................34-38 2nd clutch spider disassembling and assembling ...........34-38

A Accumulator ....................................................................54-11 Accumulator assembling .................................................54-13 Accumulator disassembling ............................................54-12 Accumulator disassembling and assembling ..................54-12 Accumulator installation cautions ...................................54-12 Accumulator installing .....................................................54-12 Accumulator removing ....................................................54-11 Accumulator removing and installing ..............................54-11 Air Cleaner ......................................................................24-12 Air cleaner installation cautions ......................................24-13 Air cleaner installing ........................................................24-13 Air cleaner removing .......................................................24-12 Air cleaner removing and installing .................................24-12 Air Conditioner ........................................................ 74-2, 75-2 Air conditioner assembling ..............................................74-11 Air conditioner disassembling ...........................................74-7 Air conditioner disassembling and assembling .................74-4 Air conditioner installing ....................................................74-3 Air conditioner removing ...................................................74-2 Air conditioner removing and installing .............................74-2 Air conditioner tightening torque .......................................74-4 Applying and Storing Articulation Stopper ......................00-15 Applying articulation stopper ...........................................00-15 Axle and Differential Service Standard .............................25-3 Axle group .........................................................................25-3 Axle nut tightening procedure ............................. 24-17, 24-46 Axle Support ...................................................................24-50 Axle support assembling .................................................24-54 Axle support assembly cautions .....................................24-54 Axle support disassembling (S/N 0101~0290, 9001~9080) .....................................24-52 Axle support disassembling (S/N 0291~, 9081~) ...........24-53 Axle support disassembling and assembling ..................24-52 Axle support tightening torque ........................................24-50

B Bearing cover installing .....................................................15-4 Bearing installation cautions ...........................................00-13 Bearing operation test after installation ..........................00-14 Bearing removal cautions ...............................................00-14 Bolt Tightening Torque .....................................................00-4 Boom ..............................................................................14-13 Boom cylinder installation cautions .................................44-12 Boom cylinder installing ..................................................44-12 Boom cylinder removing .................................................44-10 Boom cylinder removing and installing ...........................44-10

Boom installation cautions .............................................. 14-15 Boom installing ............................................................... 14-15 Boom kick-out ................................................................... 15-8 Boom kick-out hoist angle ................................................ 15-8 Boom removing .............................................................. 14-13 Boom removing and installing ........................................ 14-13 Brake Valve ........................................................... 54-16, 55-2 Brake valve assembling ................................................. 54-21 Brake valve cross section and tightening torque (main valve) ................................................................ 54-18 Brake valve disassembling ............................................. 54-19 Brake valve disassembling and assembling ................... 54-18 Brake valve installation cautions .................................... 54-17 Brake valve installing ...................................................... 54-17 Brake valve removing ..................................................... 54-16 Brake valve removing and installing ............................... 54-16 Bucket cylinder installation cautions ............................... 44-14 Bucket cylinder installing ................................................ 44-14 Bucket cylinder removing ............................................... 44-13 Bucket cylinder removing and installing ......................... 44-13 Bucket positioner .............................................................. 15-7 Bucket positioner adjustable angle ................................... 15-7 Bucket Positioner and Boom Kick-Out ............................. 15-6

C Cab ................................................................................... 14-9 Cab installing .................................................................. 14-10 Cab removing ................................................................... 14-9 Cab removing and installing ............................................. 14-9 Cautions Regarding Handling of Bearing ....................... 00-13 Cautions regarding parts removal .................................... 00-9 Cautions regarding reassembly ........................................ 00-9 Cautions Regarding Welding Repair Service ................. 00-11 Center Pin ............................................................. 14-16, 15-4 Center pin assembly cautions ........................................ 14-21 Center pin installing ........................................................ 14-21 Center pin removing ....................................................... 14-18 Center pin removing and installing ................................. 14-18 Center pin shim adjustment ................................... 14-16, 15-4 Clutch Assembly ............................................................. 34-24 Clutch assembly assembling .......................................... 34-28 Clutch assembly disassembling ..................................... 34-24 Clutch assembly disassembling and assembling ........... 34-24 Clutch Oil Pressure .......................................................... 35-6 Clutch oil pressure measuring port ................................... 35-6 Clutch specifications ......................................................... 35-5 Clutch Spider Assembly ................................................. 34-37 Compressor V-belt ......................................................... 74-12 Control Valve Assembly ................................................. 34-49 Control valve assembly installation cautions .................. 34-50 Control valve assembly installing ................................... 34-50 Control valve assembly removing .................................. 34-49 Control valve assembly removing and installing ............ 34-49

D Deck ................................................................................. 14-2 Deck installing .................................................................. 14-2 Deck removing ................................................................. 14-2 Deck removing and installing ........................................... 14-2 Differential ........................................................................ 25-4 Differential Assembly ..................................................... 24-57 Differential assembly assembling ................................... 24-64 Differential assembly disassembling .............................. 24-61 Differential assembly disassembling and assembling .................................................................................... 24-59 Differential assembly installation cautions ..................... 24-58 Differential assembly installing ....................................... 24-58 Differential assembly removing ...................................... 24-57 Differential assy assembly cautions ............................... 24-65 Differential removing and installing ................................ 24-57

E Engine .............................................................................. 24-7 Engine installation cautions .............................................. 24-9 Engine installing ............................................................... 24-9 Engine removing .............................................................. 24-7 Engine removing and installing ........................................ 24-7 Engine Room ................................................................... 14-7 Engine room installation cautions .................................... 14-8 Engine room installing ...................................................... 14-8 Engine room removing ..................................................... 14-7 Engine room removing and installing ............................... 14-7

F Fan ................................................................................. 24-15 Fan installing .................................................................. 24-15 Fan Motor ....................................................................... 44-78 Fan motor installation cautions ...................................... 44-79 Fan motor installing ........................................................ 44-79 Fan motor removing ....................................................... 44-78 Fan motor removing and installing ................................. 44-78 Fan removing ................................................................. 24-15 Fan removing and installing ........................................... 24-15 Floating Seal .................................................................. 24-31 Floating seal installing ......................................... 24-17, 24-46 Floating seal location ..................................................... 24-31 Floor Board .................................................................... 14-11 Floor board installation cautions .................................... 14-12 Floor board installing ...................................................... 14-12 Floor board removing ..................................................... 14-11 Floor board removing and installing ............................... 14-11 Front axle assembling .................................................... 24-24 Front Axle Assembly ...................................................... 24-16 Front axle assembly cautions ......................................... 24-25 Front axle assembly installation cautions ....................... 24-19 Front axle assembly installing ........................................ 24-19 Front axle assembly removing ....................................... 24-18 Front axle assembly removing and installing ................. 24-18 Front axle assembly tightening torque ........................... 24-16 Front axle disassembling ............................................... 24-21 Front axle disassembling and assembling ..................... 24-21 Front differential tightening torque ................................. 24-59 Fuel Tank ......................................................................... 14-3

Fuel tank installation cautions ..........................................14-4 Fuel tank installing ............................................................14-4 Fuel tank removing ...........................................................14-3 Fuel tank removing and installing .....................................14-3

G Gear pump specifications .................................................35-4 Gear Train and Number of Teeth .....................................35-5

H High Clutch Assembly ....................................................34-44 High clutch assembly assembling ..................................34-46 High clutch assembly disassembling ..............................34-44 High clutch assembly disassembling and assembling ....................................................................................34-44 Hose Band Tightening Torque ..........................................00-8 How to wind a seal tape .................................................00-10 Hydraulic Cylinder .................................................44-10, 45-2 Hydraulic cylinder assembling ........................................44-20 Hydraulic cylinder assembly cautions .............................44-20 Hydraulic cylinder cross section and tightening torque ....................................................................................44-15 Hydraulic cylinder disassembling ...................................44-17 Hydraulic cylinder disassembling and assembling ......... 44-15 Hydraulic parts assembly cautions ...................................44-3 Hydraulic Parts Disassembly and Assembly Cautions ......................................................................................44-3 Hydraulic parts disassembly cautions ..............................44-3 Hydraulic Parts Removal and Installation Warning ..........44-2 Hydraulic Pump Assembly ................................................44-4 Hydraulic pump assembly cross section and tightening torque ..............................44-8 Hydraulic pump assembly disassembling and assembling .....................................44-7 Hydraulic pump assembly installing ................................. 44-5 Hydraulic pump assembly removing ................................. 44-4 Hydraulic pump assembly removing and installing ........... 44-4 Hydraulic pump installation cautions ................................44-6 Hydraulic Tank ..................................................................14-5 Hydraulic tank installation cautions ..................................14-6 Hydraulic tank installing ....................................................14-6 Hydraulic tank removing ...................................................14-5 Hydraulic tank removing and installing .............................14-5

I Interference fits for a bearing .......................................... 00-13 Internal Gear Hub ........................................................... 24-33 Internal gear hub assembling .........................................24-35 Internal gear hub assembly cautions ..............................24-35 Internal gear hub disassembling ..................................... 24-33 Internal gear hub disassembling and assembling ..........24-33

L Liner clearance adjustment ..............................................15-3 Linkage .............................................................................15-2 Linkage Pin Standard Clearance Values ..........................15-3 Liquid Gasket and Screw Lock Agent ...............................00-9 Low and 3rd clutch spider assembling ...........................34-37

Low and 3rd clutch spider disassembling .......................34-37 Low and 3rd clutch spider disassembling and assembling ...................................34-37 Lower center pin .............................................................14-17 Lower center pin bearing outer ring installing ...................15-5

M Manifold Valve Assembly ..................................................54-8 Muffler .............................................................................24-14 Muffler installation cautions ............................................24-14 Muffler installing ..............................................................24-14 Muffler removing .............................................................24-14 Muffler removing and installing .......................................24-14 Multiple Control Valve .....................................................44-50 Multiple control valve assembling ...................................44-56 Multiple control valve assembly cautions ........................44-56 Multiple control valve cross section and tightening torque .............................44-53 Multiple control valve disassembling ..............................44-54 Multiple control valve disassembling and assembling ....................................................................................44-53 Multiple control valve installation cautions ......................44-52 Multiple control valve installing .......................................44-52 Multiple control valve removing ......................................44-50 Multiple control valve removing and installing ................44-50

N Nitrogen gas charging .....................................................54-14 Nitrogen gas charging procedure ...................................54-14

O Oil seal replacement procedure ........................................44-9 Orbitrol® ..........................................................................44-57 Orbitrol® assembling .......................................................44-63 Orbitrol® cross section and tightening torque .................44-59 Orbitrol® disassembling ..................................................44-60 Orbitrol® disassembling and assembling ........................44-59 Orbitrol® installation cautions ..........................................44-58 Orbitrol® installing ...........................................................44-58 Orbitrol® removing ..........................................................44-57 Orbitrol® removing and installing ....................................44-57

P Parking Brake ...................................................................55-7 Parking Brake (Front) (for Europe only) ..........................54-31 Parking brake (front) cross section and tightening torque .............................54-34 Parking brake (front) disassembling and assembling ....................... 54-34, 54-35 Parking brake (front) installation cautions .......................54-33 Parking brake (front) installing ........................................54-32 Parking brake (front) removing .......................................54-31 Parking brake (front) removing and reinstalling ..............54-31 Parking Brake (Rear) ......................................................54-25 Parking brake (rear) assembling and installing ...............54-26 Parking brake (rear) disassembling and assembling ....................................................................................54-25 Parking brake (rear) removing and disassembling .........54-25

Parking Brake Actuator .................................................. 54-27 Parking brake actuator assembling ................................ 54-30 Parking brake actuator assembly cautions ..................... 54-30 Parking brake actuator cross section and tightening torque ............................ 54-28 Parking brake actuator disassembling ........................... 54-29 Parking brake actuator disassembling and assembling ................................... 54-28 Parking brake actuator installation cautions ................... 54-27 Parking brake actuator installing .................................... 54-27 Parking brake actuator removing ................................... 54-27 Parking brake actuator removing and reinstalling .......... 54-27 Periodical Inspection/Servicing ........................................ 75-2 Pilot Valve ............................................................. 44-22, 45-4 Pilot valve assembling ..............................44-30, 44-39, 44-49 Pilot valve assembly cautions ..................44-30, 44-40, 44-49 Pilot valve cross section and tightening torque ......44-26, 44-31, 44-42 Pilot valve disassembling .........................44-27, 44-32, 44-43 Pilot valve disassembling and assembling (S/N ~0290, ~9080) .................................................... 44-26 S/N 0291~0410, 9081~) ............................................. 44-31 (S/N 0411~) ................................................................ 44-42 Pilot valve installation cautions ....................................... 44-25 Pilot valve installing ........................................................ 44-25 Pilot valve removing (S/N ~0290, ~9080) ....................... 44-22 Pilot valve removing (S/N 0291~, 9081~) ....................... 44-24 Pilot valve removing and installing ................................. 44-22 Power Line ....................................................................... 24-2 Power line tightening torque ............................................. 24-2 Propeller Shaft ................................................................ 24-10 Propeller shaft installation cautions ................................ 24-11 Propeller shaft installing ................................................. 24-11 Propeller shaft removing and installing .......................... 24-10 Propeller Shaft Service Standard ..................................... 25-2

R Radiator ............................................................................ 24-3 Radiator installing ............................................................. 24-6 Radiator removing ............................................................ 24-4 Radiator removing and installing ...................................... 24-4 Radiator tightening torque ................................................ 24-3 Rear Axle Assembly ....................................................... 24-45 Rear axle assembly installing ......................................... 24-49 Rear axle assembly removing ........................................ 24-47 Rear axle assembly removing and installing .................. 24-47 Rear axle assembly tightening torque ............................ 24-45 Rear axle disassembling and assembling ...................... 24-49 Rear differential tightening torque .................................. 24-60 Reverse Clutch Spider ................................................... 34-39 Reverse clutch spider assembling .................................. 34-39 Reverse clutch spider disassembling ............................. 34-39 Reverse clutch spider disassembling and assembling ................................... 34-39

S Screw lock agent application procedure ........................ 00-10 Second propeller shaft removing ................................... 24-10 Service Brake ........................................................ 54-23, 55-6 Service brake air bleeding procedure ............................ 24-20 Service brake disassembling and assembling ............... 54-23 Service brake installation cautions ................................. 54-23 Special Tool ................................................................... 24-39 Special tool for axle ........................................................ 24-39 Spider Assembly ............................................................ 24-37 Spider assembly assembling ......................................... 24-37 Spider assembly disassembling ..................................... 24-37 Spider assembly disassembling and assembling ........... 24-37 Spider assy assembly cautions ...................................... 24-38 Steering Valve ....................................................... 44-67, 45-6 Steering valve assembling ............................................. 44-72 Steering valve cross section and tightening torque (S/N ~0185, ~9003) .................................................... 44-69 (S/N 0186~, 9004~) .................................................... 44-70 Steering valve disassembling ......................................... 44-71 Steering valve disassembling and assembling .............. 44-69 Steering valve installation cautions ................................ 44-68 Steering valve installing ................................................. 44-68 Steering valve removing ................................................. 44-67 Steering valve removing and installing ........................... 44-67 Stop Valve ...................................................................... 44-73 Stop valve assembling ................................................... 44-77 Stop valve cross section and tightening torque .............. 44-75 Stop valve disassembling ............................................... 44-77 Stop valve disassembling and assembling .................... 44-75 Stop valve installation cautions ...................................... 44-74 Stop valve installing ....................................................... 44-73 Stop valve removing ....................................................... 44-73 Stop valve removing and installing ................................. 44-73 Storing articulation stopper ............................................ 00-16 Symbols ........................................................................... 00-2

T Third propeller shaft removing ....................................... 24-11 Tightening torque for hose and pipes ............................... 75-2 Tightening torque for screws and bolts in special control regions .............................................. 75-2 Torque Converter and Transmission Assembly ............... 34-2 Torque converter and transmission assembly installing ........................................................................ 34-7 Torque converter and transmission assembly removing ....................................................................... 34-3 Torque converter and transmission assembly removing and installing ................................................. 34-3 Torque converter and transmission assembly tightening torque ........................................................... 34-2 Torque Converter Assembly .......................................... 34-10 Torque converter assembly assembling ........................ 34-15 Torque converter assembly bolt tightening torque ......... 34-10 Torque converter assembly disassembling .................... 34-11 Torque converter assembly disassembling and assembling ................................... 34-11 Torque converter assy assembly cautions ..................... 34-15 Torque Converter Gear Pump .......................................... 35-4

Transmission Assembly .........................................34-16, 35-2 Transmission assembly assembling ............................... 34-19 Transmission assembly bolt tightening torque ...............34-16 Transmission assembly disassembling .......................... 34-17 Transmission assembly disassembling and assembling ...................................34-17 Transmission assembly installation cautions ....................34-8 Transmission assy assembly cautions ...........................34-20

U Unloader Valve .................................................................54-2 Unloader valve assembling ..............................................54-7 Unloader valve cross section and tightening torque .........54-4 Unloader valve disassembling ..........................................54-7 Unloader valve disassembling and assembling ................ 54-4 Unloader valve installation cautions ................................. 54-3 Unloader valve installing ...................................................54-3 Unloader valve removing .................................................. 54-2 Unloader valve removing and installing ............................ 54-2 Upper center pin .............................................................14-16

V Valve assembly cross section and tightening torque ......54-10 Valve assembly disassembling and assembling ............54-10 Valve assembly installation cautions ................................54-9 Valve assembly installing .................................................54-9 Valve assembly removing .................................................54-8 Valve assembly removing and installing ...........................54-8

W Weight of Main Components ............................................ 00-3

MEMO

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes

93215-00210 September 2003

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)

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.

(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.

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

B …………Battery R …………Rear or Reverse RH …………Right hand side LH …………Left hand side H …………High L …………Low GND ………Ground [ or E ] 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 size Type

Metric thread

Bolt strength

Nominal Dimension

Pitch

8.8 (8T)

0.8

5.0

8.6

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

(8)

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

Hose band

Tightening torque

(N-m)

(kgf-cm)

(lb-ft)

1.6

1.2

2.9

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

1.6

1.2

2.9

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

16.5

HH022W

7.9

18.5

HH022W

9.5

20.5

HH022W

12.7

24.5

HH027W

15.9

29.9

HH031W

19.0

30.0

HH031W

25.4

38.0

HH044W

31.8

45.8

HH052W

38.1

52.1

HH057W

50.8

67.8

HH071W

60.5

76.0

HH082W

75.5

93.0

HH095W

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

Hose band

16.5

HH022W

18.5

HH022W

20.5

HH022W

22.0

HH023W

24.5

HH027W

26.0

HH027W

29.0

HH031W

30.5

HH031W

32.0

HH038W

34.0

HH038W

39.5

HH044W

41.5

HH044W

46.0

HH052W

48.0

HH052W

54.0

HH057W

70.5

HH076W

73.0

HH076W

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

Pipe

Hose band

Center of pipe protrusion 10~20 mm

(9)

70ZV00003

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

Liquid Gasket

Screw Lock Agent

Code

Manufacturer

Product name

AA01

Loctite ®

Plastic Gasket 568

AA02

Loctite

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite ®

Loctite ® 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

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

Screw lock agent application procedure 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), and K-Link controller if equipped with this option. 4) Engines equipped with ECM: Unplug ECM and tachometer converter as per Cummins Engine Co. 5) Ground the welder near the section to be welded. 6) To ground the welder, check that the electric current will not flow through the cylinders. Cylinder head covers for some models have a lowconductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod.

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

Example 2:

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

Section to be welded

Ground this section. (correct grounding)

(11)

35C00002

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

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

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

Scrap material, etc. 1m or more

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

35C00003

Section to be welded

1m or more 35C00004

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

Section to be welded Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

(12)

35C00005

Weight of Main Components Part name

Approx. Weight (kg)

Approx. Weight (lb)

Bucket

2,850

6,280

GSC bucket Standard

Item Unit name

Boom

2,150

4,740

" Z " -Lever

290/pc

640/pc

Link (Bucket to Lever)

60/pc

130/pc

Screen board

180

400

Roof

150

Radiator guard

200

440

Side cover

35/pc

Hydraulic tank

280

620

Excluding oil

Fuel tank

240

530

Excluding fuel

Floor board

250

550

Including ope. board, instrument panel and control box

Cab (Rops)

620

1,370

Left side

180

With handrail

Right side

130

With handrail

Front chassis

2,410

5,310

Rear chassis

2,520

5,560

Counter weight

1,920

4,230

Engine

1,700

3,750

Excluding oil

Radiator assembly

650

1,430

Excluding water and oil

Transmission

1,310

2,890

Excluding oil

Second propeller shaft

100

220

Third propeller shaft

Front axle assembly

1,970

4,340

Excluding tires and oil

Rear axle assembly

2,130

4,700

Excluding tires and oil (Including axle support)

Front

350

770

Rear

360

790

Multiple control valve

100

220

Pilot valve

Steering valve

110

Double pump Single pump

Engine room

Chassis

Deck

Power line

Differential

Hydraulic

Gear pump

Fan motor

Boom cylinder

360/pc

790/pc

Excluding oil

Bucket cylinder

180/pc

400/pc

Excluding oil

Steering cylinder

40/pc

90/pc

Excluding oil

Tire

790/pc

1,740/pc

With rim (29.5-25-22PRL3); No Hydro Inflation

Battery

60/pc

130/pc

system

Other

Remarks

(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 may be crushed in the articulation area if the machine unexpectedly turns during repair work. To prevent such an accident, be sure to apply the articulation stopper before starting work.

1) Park the machine so that the frame is straight ahead. Remove the pin (1) from the articulation stopper on the hydraulic tank. 1

2) Turn rod (2) (articulation stopper) to the front and then align the pin hole. Insert the pin (1) into the rod to lock the front chassis to the rear chassis.

WARNING

2 1

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

LOCKED POSITION

2. Storing articulation stopper Store rod (2) and pin (1) as shown.

STORED POSITION

(14)

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

MEMO

CHASSIS GROUP 14 Disassembly and Reassembly Deck ............................................................................................................14-2 Fuel Tank ....................................................................................................14-3 Hydraulic Tank ............................................................................................14-4 Engine Room ..............................................................................................14-5 Cab .............................................................................................................14-8 Floor Board ...............................................................................................14-10 Boom ........................................................................................................14-11 Center Pin .................................................................................................14-14

14-1

Deck

95ZV

CHASSIS 14

Deck Removing and reinstalling deck 1. Removing deck

1 4 95ZV14001

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

1) Remove bolt (1). Torque for assembly: : Bolt (1): 94 N-m(9.6 kgf-m)(69 lb-ft) 2) Attach sling to handrails and remove bolts (2), (3). Lift the deck (4) with the handrails Torque for assembly: : Bolt (2), (3): 94 N-m(9.6 kgf-m)(69 lb-ft) : Deck (with handrails): 80 kg (180 lbs) left 60 kg (130 lbs) right

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

14-2

Fuel Tank

95ZV

CHASSIS 14

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

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting fuel tank removal: - Position machine on level ground, and apply the parking brake. - Lower bucket to ground, and block tires with chocks, etc. to prevent them from moving. - Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel. Before starting work: - Drain fuel from the fuel tank. (Fuel tank capacity: 425 (112.3 Gal.)) - Remove the deck.

1 3

1) Disconnect level sensor electrical line coupler (1). 2) Attach sling to the fuel tank (2). : Fuel tank: 240 kg (530 lbs) (Empty)

3) Remove retainer bolt (3). Torque for assembly: : Retainer bolt (3): 765 N-m (78.0 kgf-m) (562 lb-ft)

3 95ZV14002

4) Slightly pull out fuel tank (2) to disconnect suction hose (4) and return hose (5). Plug the fuel line to prevent dirt entry.

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. 14-3

95ZV14003

Hydraulic Tank

95ZV

CHASSIS 14

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

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

2 3

Oil tank

Before starting work: - Drain hydraulic oil from hydraulic tank. (Hydraulic tank capacity: 150 (40 Gal.)) - Remove the deck. - Clean the area around the tank.

95ZV14004

1) Remove hose band (1) and bolt (2). Remove hose (3) from hydraulic tank (4).

2) Remove bolts (5) and disconnect pipe (6) (7) from hydraulic tank.

3) Attach sling to hydraulic tank (4) and remove bolts (8). 5

: Hydraulic tank: 280 kg (620 lbs) (Empty) Torque for assembly: : Retainer bolt (8): 765 N-m (78.0 kgf-m) (562 lb-ft)

Oil tank 95ZV14005

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

4 8

Note: After reinstallation, be sure to check the pipes for leakage, and also check the oil level of the hydraulic tank.

95ZV14006

14-4

Engine Room

95ZV

CHASSIS 14

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

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting engine room removal: - Position machine on level ground, and apply the parking brake. - Lower bucket to ground, and block tires with chocks, etc. to prevent them from moving. - Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel. Before starting work: - Recover/recycle refrigerant on machine with optional air conditioner, if required. - Remove the right and left decks together with the hand rail.

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

95ZV14007

14-5

Engine Room

95ZV

CHASSIS 14

2) Remove round bar (2) and wire (3) of side cover (4). Sling the side cover, and remove bolt (5). Remove side cover (4).

3) Remove nut (6) for the roof cushion and lift the roof. : Engine cover (roof): 70 kg (150 lbs) Torque for assembly: : Nut (6): 94 N-m (9.6 kgf-m) (69 lb-ft)

5 2

95ZV14008

95ZV14009

4) Remove the wiring of the inside screen board. Remove hose (7) (8) for receiver tank (9) and condenser (10). Note: Before hose disconnection, be sure to recover/recycle the refrigerant.

95ZV14010

14-6

Engine Room

95ZV

CHASSIS 14

5) Remove hose band (11) for air cleaner rubber hose (12), and then remove hose (12).

12 95ZV14011

6) Disconnect screen board retainer bolt (13) and lift the screen board. Note: Slowly lift the screen board while checking that there are no obstacles.

: Screen board (with condenser and air cleaner): 250 kg (550 lbs) Torque for assembly: : Bolt: 230 N-m (23.5 kgf-m) (169 lb-ft) 95ZV14012

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

14-7

Cab

95ZV

CHASSIS 14

Cab Removing and reinstalling cab 1. Removing cab

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. - Position machine on level ground, and block tires with chocks, etc. to prevent them from moving. - Lower bucket to ground, and apply the parking brake. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel. Before starting work: - Remove the deck both right and left side. - Disconnect the electrical line coupler

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

1 95ZV14013

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

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

95ZV14014

Filter 95ZV14015

14-8

Cab

95ZV

CHASSIS 14

3) Remove cover (4).

95ZV14016

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

95ZV14017

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

6) Remove the bolts (8). Install eye bolt (M16 x 2.0) on cab. Attach sling and remove cab. : Cab: 620 kg (1,370 lbs)

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

Floor board 95ZV14018

14-9

Floor Board

95ZV

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

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

2. Reinstalling floor board For reinstallation, follow the above procedure in the reversed direction. Note: After reinstallation, start the engine, and then check the refrigerant, and oil lines for leakage. Also check operation of the electrical equipment. 14-10

95ZV14019

Boom

95ZV

CHASSIS 14

Boom Removing and reinstalling boom 1. Removing boom

WARNING

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

Unexpected movement of 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 the residual pressure from the hydraulic oil tank and lines. - Apply the parking brake, remove starter key, and hang a "DO NOT START ENGINE!" tag on steering wheel.

Note: The illustration shows the parts on right side. On left side, the parts are located at the same points. 1) Remove pin (3) connecting bucket (1) and the link (2).

3 2 95V14002

Note: There are shims in the pin sections. Carefully store removed shims, and correctly reinsert shims when reinstalling the bucket. 2) Remove connection pin (5) from bucket (1) and boom (4) to remove bucket. : Bucket: 2,850 kg (6,280 lbs)

95V14003

3) Attach sling to link (2), and then remove connection pin (7) from lever (6) and link (2). : Link: 60 kg (130 lbs) 6

7 2 95V14004

14-11

Boom

95ZV

CHASSIS 14

4) Disconnect grease pipe (8) for lever (6). 9

CAUTION

You have to work at a high position to remove the grease pipe. Always use a stepladder for this work. 8

5) Attach sling to bucket cylinder (9), and then remove connection pin (10) from lever (6) and bucket cylinder (9).

95ZV14020

: Bucket cylinder: 180 kg (400 lbs)

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

6) Start engine and shorten bucket cylinder rod. Stop engine.

7) Attach sling to the lever (6), and then remove lever pin (11).

8) Remove lever (6). : Lever: 290 kg (640 lbs)

95ZV14021

9) Remove grease hose (13) from pin (12). Insert a wooden block between the boom cylinders and the hydraulic piping. Remove pins (12) from cylinder rods on both right and left sides of boom.

12 13

Note: Placing a wooden support piece between the boom cylinder and the hydraulic pipe helps to reinstall the pin to the boom easily. 95ZV14022

14-12

Boom

95ZV

10) Attach sling to torque tube of boom (4), and then remove pins (14) from the boom on both the right and left sides of the boom.

CHASSIS 14

11) Slowly lift boom (4) to remove it from machine. : Boom: 2,150 kg (4,740 lbs)

95ZV14023

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

14-13

Center Pin

95ZV

CHASSIS 14

Center Pin Upper center pin

Bearing cover Front chassis Shim adjustment T1

Rear chassis

95ZV14024

T1: 441 N-m (45.0 kgf-m) (324 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubricating oil (Engine oil or gear oil))

Split shim T2

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.

95ZV14025

Lower center pin T3

Front chassis

Rear chassis 95ZV14026

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

95ZV14027

14-14

Center Pin

95ZV

CHASSIS 14

Removing and reinstalling center pin 1. Removing center pin

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

Transmission

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

95ZV14028

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

2 3 Steering cylinder

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

95ZV14029

4) Remove upper center pin retainer bolt (4). Torque for assembly: : Retainer bolt: 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubricating oil) 4 95ZV14030

14-15

Center Pin

95ZV

CHASSIS 14

5) Screw M18 (Pitch 1.5) bolt of approximately 70 mm length into the center of bushing (5) to push out the bushing. This bolt is used as a jack screw.

Jack screw: M18 (Pitch 1.5), totally threaded Jack screw

M18 x 1.5

70 95ZV14039

95ZV14037

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

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

7 6 Jack 95V14018

WARNING When using a crane, incorrect signals and insufficient sling capacity could cause an accident resulting in injury or death. To prevent such an accident, observe the following items : - Check sling capacity before using and do not use improper sling. - Use signals as agreed upon before starting work. - Stay out of the working area while using a crane.

97K14028

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

By jack

14-16

95ZV14031

Center Pin

95ZV

CHASSIS 14

9) Support the rear chassis using a rolling floor jack. Push the lower center pin (10) out using another jack to remove pin.

WARNING Chassis separation is dangerous work. To ensure your safety, be careful in doing this work. 10) Slowly turn rear tires to both right and left sides using a bar to separate the rear chassis.

By jack

95ZV14032

Note: While turning rear tires, check that the rolling floor jack under fuel tank rolls backward together with the rear chassis. In addition, adjust the height using rear crane whenever height adjustment is necessary. 11) Remove ring (11) and remove bolts (12) from the bearing cover (13). When reinstalling, install bearing cover so that the direction of grease nipple is positioned as illustrated.

Bar 95V14021

Front

12 Grease nipple installation direction

11 95ZV14033

Torque for assembly: : Bolts: 441 N-m (45.0 kgf-m) (324 lb-ft)

WARNING When the chassis is separated, unless support for the chassis is sufficient, it could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Make sure blocks, support and jack are placed in the right position to properly support the chassis. 14-17

14 95ZV14034

Center Pin

95ZV

CHASSIS 14

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

13) Replace dust seals in upper center pin and lower center pin with new ones. Note: Direction of dust seal 14 97K14032

Center pin

Front

95ZV14038

14) When spherical bearing (16) for the lower center pin is replaced, install the bearing outer ring so that the split is perpendicular to the front - rear line of the machine.

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

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

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

14-18

Rear

16 Split of outer bearing 95ZV14036

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

95ZV

CHASSIS 15

Linkage (mm) 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

ø110 ø100

ø90

4. Front chassis - Boom

5. Bucket - Rod

6. Lever - Rod

ø80

ø110

8. Bucket cylinder Front chassis

7. Lever - Bucket cylinder

ø90

ø80

9. Boom cylinder Front chassis

ø90

ø100

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

ø50

97ZA1202

5 10

15-2

95ZV12003

Linkage Pin Standard Clearance Values

95ZV

CHASSIS 15

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

No.

Pin standard dimension

Bushing standard dimension

Standard clearance

Tolerance

Solution

∗

Joint section between bucket and boom

ø90 -0.120 -0.155

ø90 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

∗

Joint section between boom and lever

ø110 -0.120 -0.155

ø110 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

Joint section between boom and boom cylinder

ø100 -0.120 -0.155

ø100 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

∗∗

Joint section between front chassis and boom

ø110 -0.120 -0.155

ø110 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

∗

Joint section between bucket and link

ø80 -0.120 -0.155

ø80 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

∗

Joint section between lever and link

ø80 -0.120 -0.155

ø80 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

∗

Joint section between lever and bucket cylinder

ø90 -0.120 -0.155

ø90 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

∗

Joint section between bucket cylinder and front chassis

ø90 -0.120 -0.155

ø90 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

Joint section between boom cylinder and front chassis

ø100 -0.120 -0.155

ø100 +0.140 0

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

∗

Joint section between front chassis and steering cylinder

ø50 -0.100 -0.130

ø50 +0.120 0

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

∗

Joint section between steering cylinder and rear chassis

ø50 -0.100 -0.130

ø50 +0.120 0

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

Liner clearance adjustment ∗

∗∗ Adjustment procedure (for adjustment of liner clearance marked with asterisk): ∗ Adjust the liner clearance between the bosses to 1.2 mm or less using liner of 1 mm thickness. For the steering cylinder, adjust the liner clearance on the rear chassis side first, and then adjust the liner clearance on the front chassis side while checking that the cylinder is not inclined. Liners should be placed on both sides of the linkage as much as possible. Wear then occurs on the liners and reduces wear on the chassis. Excessive vertical free play in the steering cylinders can result in loud knocking noises when the steering wheel is turned. ∗∗ Only in case the clearance at the machine center side is more than 4.5 mm, adjust using liner of 4.5 mm thickness.

70ZV15001

15-3

Center Pin

95ZV

CHASSIS 15

Center Pin T1

Shim adjustment The clearance between the front chassis and bearing cover is 0.75 ± 0.5 mm (0.0295 ± 0.0197 in.) before shim adjustment. Add shims so that the clearance is 0.1 ± 0.05 mm (0.0039 ± 0.0020 in.). : Bolts T1: 441 N-m (45.0 kgf-m) (324 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubricating oil (Engine oil or gear oil))

Bearing cover Front chassis Shim adjustment

95ZV14024

Rear chassis

Front

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.

Grease nipple installation direction

Installing lower center pin bearing outer ring

95ZV14033

Bearing outer ring

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

Rear chassis 95ZV15001

Front

Rear Bearing outer ring Split of outer bearing

95ZV15002

15-4

Bucket Positioner and Boom Kick-Out

95ZV

CHASSIS 15

Bucket Positioner and Boom Kick-Out

Bucket positioner

Boom kick-out

90ZV15005

Bucket positioner

Adjusting plate

Direction of indicator lamp 5

Indicator lamp

Note: The illustration shows on the right side

Proximity switch

5±2

2.5

4 95ZV15003

15-5

Bucket Positioner and Boom Kick-Out

95ZV

CHASSIS 15

Boom kick-out

45°

5°

Adjust ing p l

Kick-ou t ad jus ta 43. ble an 6° gl e

ate ad ju 43. 6° stab le

ar e

Adjusting plate

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

Direction of indicator lamp

Proximity switch Proximity switch

95ZV15004

Unit : mm Item

No.

Judgment standard

Solution

Clearance of bucket positioner switch

5 ± 2 (0.196 ± 0.078 in.)

Adjustment

Clearance of boom kick-out switch

7 ± 1 (0.276 ± 0.039 in.)

Adjustment

Adjusting plate mounting bolt tightening torque

Switch mounting nut tightening torque

Positioner

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

Kick-out

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

Tightening

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

Tightening

Bucket positioner adjustable angle

-7° ~ +7°

Adjustment

Boom kick-out adjustable angle

0 ~ 43.6°

Adjustment

15-6

Bucket Positioner and Boom Kick-Out

95ZV

CHASSIS 15

Bucket positioner adjustable angle

-7°

+7°

0°

95ZV15006

.6°

Boom kick-out hoist angle

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

15-7

95ZV15005

MEMO

POWER GROUP 24 Disassembly and Reassembly Power Line...................................................................................................24-2 Radiator .......................................................................................................24-3 Engine..........................................................................................................24-6 Propeller Shaft .............................................................................................24-8 Air Cleaner.................................................................................................24-10 Muffler........................................................................................................24-11 Fan.............................................................................................................24-12 Front Axle Assembly..................................................................................24-13 Floating Seal..............................................................................................24-24 Internal Gear Hub ......................................................................................24-27 Special Tool ...............................................................................................24-34 Rear Axle Assembly ..................................................................................24-38 Axle Support ..............................................................................................24-42 Differential Assembly .................................................................................24-46

24-1

Power Line

95ZV

POWER 24

Power Line Tightening torque T2 L 1

T1 L 3 T3 L 1

T4 L 3

T5 L 3 T1 L3

T1 L1

Transmission

T6 L 2

Rear differential

2nd propeller shaft 3rd propeller shaft

95ZV24001

Front differential

: Bolt tightening torque T1: 441 N-m (45.0 kgf-m) (325 lb-ft) T2: 230 N-m (23.5 kgf-m) (170 lb-ft) T3: 201 N-m (20.5 kgf-m) (148 lb-ft) T4: 67 N-m (6.85 kgf-m) ( 50 lb-ft) T5: 157 N-m (16.0 kgf-m) (116 lb-ft) T6: 142 N-m (14.5 kgf-m) (105 lb-ft)

T6 L 2

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

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

24-2

Radiator

95ZV

POWER 24

Radiator Tightening torque T2 L3

T3 L3

T5 L3 Radiator

T4 L3

T1 L1

T3 L3 T3 L3

Rear chassis 95ZV24002

: Bolt tightening torque T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 49 N-m ( 5.0 kgf-m) ( 36 lb-ft) T3: 94 N-m ( 9.6 kgf-m) ( 69 lb-ft) T4: 142 N-m (14.5 kgf-m) (105 lb-ft) T5: 474 N-m (48.5 kgf-m) (349 lb-ft)

L1: With liquid adhesive (Loctite® 262) L3: With lubricating oil (Engine oil or gear oil)

24-3

Radiator

95ZV

POWER 24

Removing and reinstalling radiator 1. Removing radiator

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

Before starting work: - Remove engine roof (Refer to Section 14). - Remove fan.

1 95ZV24003

Rear chassis

1) Remove bolt (1). Torque for assembly: : Bolt: 230 N-m (23.5 kgf-m) (170 lb-ft) 3

2) Attach sling to radiator guard (2), and remove. : Radiator guard: 200 kg (440 lbs)

Radiator

3) Drain coolant from radiator. : Coolant: 61.4 (16.2 gal.)

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

95ZV24004

Air cooler

95ZV24005

24-4

Radiator

95ZV

POWER 24

6) Remove hoses (8) (9) from the hydraulic cooler. : Hydraulic oil: 8.2 (2.2 gal.) Note: Cover disconnected hoses with plastic caps to protect hoses from dust and dirt.

Radiator

8 95ZV24006

7) Disconnect fuel hoses (10) (11) from the fuel cooler. : Fuel: 2.1 (0.6 gal.) Note: Cover disconnected hoses with plastic caps to protect hoses from dust and dirt.

Radiator 10

Fuel tank 95ZV24007

8) Remove retainer bolts (12). Remove plate (13). Torque for assembly: : Bolt: 230 N-m (23.5 kgf-m) (170 lb-ft)

14 12

9) Attach sling to radiator (14). Remove retainer bolts (15), and lift the radiator assembly. Torque for assembly: : Bolt: 49 N-m (5.0 kgf-m) (36 lb-ft) : Radiator assembly: 650 kg (1,430 lbs)

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

24-5

95ZV24008

Engine

95ZV

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. Engine

2 95ZV24009

Before starting work: - Refer to Section 14. "Removing engine room". - Remove the fan guard and the fan. - Remove the hydraulic pumps. - Collect the air conditioner refrigerant (option) using the proper recovery method. 1) Disconnect the negative side of the battery cable. Then remove the positive cable.

3) Disconnect heater hose and fuel hose also disconnect the air conditioner lines from the compressor. 4) Support the bottom of the transmission using a rolling floor jack. Attach sling to the engine. Remove retainer bolt (1) (right side and left side). Torque for assembly: : Bolt (1): 201 N-m (20.5 kgf-m) (148 lb-ft) : With liquid adhesive (Loctite® 262)

2) Remove wires from alternator, starter motor and the oil pressure switch. 24-6

Engine

95ZV

5) Remove retainer bolt (2) both right and left. Torque for assembly: : Bolt (2): 441 N-m (45.0 kgf-m) (325 lb-ft) : With lubricating oil 6) Loosen retainer bolt (3) for transmission both side. Torque for assembly: : Bolt (3): 230 N-m (23.5 kgf-m) (170 lb-ft) : With liquid adhesive (Loctite® 262) 7) Loosen retainer bolt (4) (right side and left side). Torque for assembly: : Bolt (1): 441 N-m (45.0 kgf-m) (325 lb-ft) : With lubricating oil 8) Remove retainer bolts (5) connecting the engine flywheel housing and the transmission. Torque for assembly: : Bolt (5): 67 N-m (6.85 kgf-m) (50 lb-ft) 9) Separate the engine and the transmission from each other, and then lift the engine. Note: Carefully lift the engine while checking that there are no obstacles around it. : Engine assy: approx 1,700 kg (3,750 lbs)

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

3. Cautions regarding engine reinstallation - There is an O-ring in the housing between engine and torque converter. Be sure to replace O-ring with a new one. - After reinstalling engine, completely bleed fuel line of air. - Set starter key to ON, and then check monitor lamps of electrical equipment. - Operate engine at idling speed for 5 minutes. After that, check the amount of coolant. - While gradually increasing engine speed, check operation of electrical equipment, and check for leaks. 24-7

POWER 24

Propeller Shaft

95ZV

POWER 24

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

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Lower bucket to 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.

Transmission

Rear differential 3 2 4

1) Disconnect the grease pipe, and remove bolt (2) from pillow unit bearing (1), remove bolt (3) from transmission. Remove bolt (4) to disconnect the propeller shaft from the front differential. Support the shaft by cable or rolling floor jack. Take out the second propeller shaft to the front. : Second propeller shaft: 100 kg (220 lbs) Torque for assembly: : Bolt (2): 441 N-m (45.0 kgf-m) (325 lb-ft) Bolt (3) (4): 142 N-m (14.5 kgf-m) (105 Ib-ft) : Bolt (2)(3)(4): Screw lock agent (Loctite ® 262) application Note: If retainer bolt is too tight due to screw lock agent, heat the bolt head to about 235 °C (450 °F) using low flame of a gas torch. Keep the flame away from seals of coupling. Do not reuse the bolts, always replace with new ones.

24-8

Front differential

5 1 2nd propeller shaft

95ZV24010

3rd propeller shaft

Propeller Shaft

95ZV

2. Removing third propeller shaft 1) Remove bolt (5). Torque for assembly: : Bolt (5): 142 N-m (14.5 kgf-m) (105 Ib-ft) : Screw lock agent (Loctite® 262) application : Third propeller shaft: 25 kg (55 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.]

24-9

POWER 24

Air Cleaner

95ZV

POWER 24

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

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

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

3 4 1 5

95ZV24011

2) Disconnect air duct (7) and disconnect indicator wire coupler (8). 3) While supporting air cleaner case (9) with your hand, remove bolts (10), and then lower the air cleaner case.

8 7

4) Take out air cleaner case (9) from the opening. 9 7

2. Reinstalling air cleaner For reinstallation, follow the above procedure in the reversed direction. Note: If the bands of the air duct are not properly positioned or tightened, the duct will draw in dust that will cause an engine problem. Carefully reinstall the air duct.

24-10

95ZV24012

Muffler

95ZV

POWER 24

Muffler Removing and reinstalling muffler 1. Removing muffler

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

1) Remove retainer bolts (1) then remove exhaust pipe (2). Torque for assembly: : 29.4 N-m (3.0 kgf-m) (22 Ib-ft)

2 5 1

2) Remove exhaust pipe (3) between turbocharger and muffler (4).

5 4

3) Remove retainer bolt (5) for muffler (4) and lift it for removing. : Muffler: 30 kg (66 lbs) Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) Note: After disconnection, cover pipe at the turbocharger side with vinyl, plugs to protect turbocharger from dust and dirt.

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

24-11

95ZV24013

Fan

95ZV

POWER 24

Fan Removing and reinstalling fan 1. Removing fan

1) Remove retainer bolts (2).

Radiator grille

Torque for assembly: : Retainer bolt: 93 N-m (9.55 kgf-m) (69 lb-ft) : With lubrication oil (engine oil or gear oil)

95ZV24014

2) Take fan (1) out. Note: Carefully remove the fan while checking that the fan will not damage the radiator fins. Inspect the fan for any signs damage or cracks. Replace the fan if there are any signs of damage or cracks. Fan blade breakage can cause extensive damage.

Oil motor

Detail

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

24-12

95ZV24015

Front Axle Assembly

95ZV

POWER 24

Front Axle Assembly Tightening torque T8 L1 Front differential T1 L 3

R. H

T8 L1

T7 T5 T5 T5 B T6 L 1

T3 L 1 T9 L 1

L. H T2 T4

: Bolt tightening torque T1: 1,420 N-m (145.0 kgf-m) (1,049 lb-ft) T2: 892 N-m ( 91.0 kgf-m) ( 658 lb-ft) T3: 417 N-m ( 42.5 kgf-m) ( 307 lb-ft) T4: 86 N-m ( 8.8 kgf-m) ( 64 lb-ft) T5: 78 N-m ( 8.0 kgf-m) ( 58 lb-ft) T6: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T7: 33 N-m ( 3.4 kgf-m) ( 25 lb-ft) T8: 314 N-m ( 32.0 kgf-m) ( 232 lb-ft) T9: 90 N-m ( 9.15 kgf-m) ( 66 lb-ft)

95ZV24016

Note: Tighten A while measuring the preload applied to section B . Preload of section B : 324 ~ 363 N (33 ~ 37 kgf) (73 ~ 81 lbs) ✽This is "breakaway" force. The force required to start the wheel turning.

L1: Screw lock agent (Three Bond 1327) application L3: With lubricating oil (Engine oil or gear oil) 24-13

Front Axle Assembly

95ZV

POWER 24

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

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

Before starting work - Lift the front wheel using the bucket, and then place a stand under the front chassis to support the chassis. Block the rear wheels with chocks. - Drain the oil from axle. (100 ) (26 gal.) Stand Stand 95ZV24017

1) Remove right and left wheel and tire assemblies (1). Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) without lubrication oil : Tire: 790 kg/pc (1,740 lbs/pc)

1 95ZV24085

2) Remove second propeller shaft retainer bolt (2). Remove cover (3) and brake pipe (4). Disconnect air breather hose from the hydraulic tank. Reassembly: Clean air breather hose before reinstalling. Torque for assembly: : Retainer bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application : Brake line oil: Approx. 0.3 (0.1 gal.)

2 4

95ZV24018

24-14

Front Axle Assembly

95ZV

POWER 24

3) Attach sling to axle assembly (6), and then remove twelve retainer bolts (7). Place axle assembly (6) on a carrier to smoothly pull out. Torque for assembly: : Retainer bolt: 1,420 N-m (145.0 kgf-m) (1,049 lb-ft) : Axle assembly: 1,970 kg (4,340 lbs) Note: During reassembly be sure both mating surfaces are clean and free of paint.

6 95V24026

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

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

Socket bolt

Spider

95ZV24019

Reference Air bleeding procedure Start and run engine to build brake accumulator pressure. Shut "off" engine. Rebuild brake accumulator pressure as often as is needed. Connect a clean vinyl tube to the air bleeder nipple, and place an oil can to receive the oil, or route to hydraulic tank. Slightly loosen the air bleeder nipple, and then press the brake pedal several times. When the oil flows from the air bleeder nipple, close the nipple. After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple. Repeat this until there is no air in the oil. Completely bleed each wheel of air.

24-15

Front Axle Assembly

95ZV

POWER 24

Disassembling and reassembling front axle 1. Disassembling front axle

WARNING Unexpected movement of machine or components could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and then apply the parking brake. - Apply articulation stopper. - Block rear wheels with chocks to prevent wheels from moving. - Stands must be able to support weight of front chassis, boom, and bucket. Note: Refer to page 24-33~24-36 for tooling and jigs. Before starting work: - Lower bucket to ground. Lift the front wheels while supporting the machine with the bucket. Place a stand under the front chassis to support it. Check that the tires are off the ground. - Lift the boom until it is horizontal, and place a stand under the boom to support it or install a boom cylinder lock collar.

Stand Stand 95ZV24017

1) Remove wheel and tire assembly (1) from the side to be disassembled (example: left side). Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) without lubrication oil : Tire: 790 kg/pc (1,740 lbs/pc)

1 95ZV24085

2) Remove drain plug (2) from the differential section to drain oil. : Gear oil: Approx. 60 (16 gal.)

2 97K24044

24-16

Front Axle Assembly

95ZV

POWER 24

3) Turn drain plug (4) to the bottom of wheel hub (3) to drain oil. : Gear oil: Approx. 20 (5.3 gal.) Note: To replace the oil, refer to the oil amount described below. : Wheel hub section: 20 (5.3 gal.) for left side, 20 (5.3 gal.) for right side Differential section: 60 (15.9 gal.) Total oil amount for front axle: 100 (26.4 gal.)

4 97K24045

4) Remove cover (5). Torque for assembly: : Retainer bolt: 90 N-m (9.15 kgf-m) (66 lb-ft) : Screw lock agent (Three Bond 1327) application

97K24046

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

6) Attach sling to spider using hoisting hook. Remove four spider retainer bolts (8) to remove spider assembly (9). Torque for assembly: : Retainer bolt: 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 125 kg (275 lbs)

95ZV24020

9 8

Note: The brake retainer is fixed behind the spider assembly. Do not forget the brake retainer when reinstalling the spider assembly. 95ZV24021

24-17

Front Axle Assembly

95ZV

POWER 24

7) Remove friction plate (10). Remove steel plate (11). Remove friction plate (12) and remove steel plate (13). Note: Clean brake plates, and then check the plates for distortion, discoloration and wear. Refer to Section 55 for additional information.

13 12 11 10

95ZV24022

8) Remove axle shaft (14), disc gear (15) and wear ring (behind disc gear (15)). 15 14

95ZV24023

9) Remove bolt (16), lock plate (17) and then remove axle nut (18). Note: Axle nut width across flat: 160 mm : Retainer bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : Screw lock agent: Three bond 1327

Torque for assembly: : Nut (18): 2,746 N-m (280 kgf-m) (2,026 Ib-ft) 16

95ZV24024

10) Pull out internal gear hub (19) to the extension end face using internal gear hub puller (A). 19 A

95ZV24025

24-18

Front Axle Assembly

95ZV

POWER 24

11) Attach sling to internal gear hub assembly (19) using internal gear hub hoisting tool (B). Remove internal gear hub assembly (19). : Internal gear hub assembly: 120 kg (264 lbs) Note: Be sure to support the wheel hub, or the wheel hub will drop when the internal gear hub assembly is removed.

B 19

95ZV24026

12) Attach sling to wheel hub (3) using wheel hub hoisting tool (D), and then remove wheel hub (3). : Wheel hub: 140 kg (308 lbs)

97ZV24016

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

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

24-19

Front Axle Assembly

95ZV

POWER 24

3. Cautions regarding reassembly 1) Install O-ring (1) to ring (2). 2) Install ring (2) to the axle housing extension.

Axle housing extension

1 2 95ZV24028

3) Install wheel hub bearing (3) to the axle housing extension using jig (E). E

Axle housing extension 95ZV24029

4) Install wheel hub (4) to the axle housing extension. Note: Be sure to support the wheel hub, or the wheel hub will drop.

97ZV24019

24-20

Front Axle Assembly

95ZV

POWER 24

5) Reinstall internal gear hub assembly (6). Note: Before reinstallation, align the brake oil hole of the axle housing extension with that of the internal gear hub assembly. For brake oil air bleeder

Spring pin 6

Match these holes.

Upper

Internal gear hub

95ZV24032

Brake oil inlet

Spring pin

Upper Internal gear

Axle housing extension

Example LF

95ZV24031

The spring pins should be at the upper position.

95ZV24033

6) Tighten axle nut (7) using jig (F) so that the preload of the tire mounting hole section is 324 ~ 363 N (33 kg ~ 37 kgf) (73 ~ 81 Ibs) Note: Measure the minimum pulling force to rotate wheel hub using spring scale.

Torque for assembly: : Nut (7): 2,746 N-m (280 kgf-m) (2,026 lb-ft)

. 7) Checking the brake oil leakage test. Use jig (C) to hold the brake piston not to come out. Attach jig (H) to the brake oil inlet port on the axle housing.

95ZV24034

Brake oil inlet port

Jig (H) Shut off valve

Air supply PT 3/8

Air pressure gauge

95ZV24036

24-21

95ZV24035

Front Axle Assembly

95ZV

8) Apply 588 kPa (6 kgf/cm 2) (85 psi) air pressure for approximately 1 minute. Shut off the valve. Check that the pressure does not fall. Note: If the pressure falls, air is leaking from the brake piston O-rings or internal gear hub O-rings. Disassemble the internal gear hub again to repair leakage.

POWER 24

Jig (C)

97ZV24027

9) Loosen the axle housing air bleeder nipple.

Upper side Brake piston

10) Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly. Bolt size for pushing brake piston back (4 required) M10 x 1.5 - 45 to 50 (1.8 to 1.97 in.) (Fully threaded)

For pushing down brake piston

11) After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face. Note: A dimension should be equal at top and bottom. A......162.45 to 163.85 mm (6.4 to 6.45 in.) 95ZV24037

12) After confirming that the piston is fully retracted (Dimension A is correct) remove all four bolts.

Wheel hub

Brake piston

95ZV24038

Upper side

13) Install steel plate with 6-teeth section (8) first. Internal gear

Spring pins

95ZV24039

24-22

Front Axle Assembly

95ZV

POWER 24

14) Install friction plate (9). 9

95ZV24040

15) Install steel plate with two 2-teeth sections (10).

Upper side Spring pins

16) Install friction plate (11). Note: Align the cooling holes of two friction plates with each other.

95ZV24041

Spring pins Friction plate 11 Cooling holes

Steel plate 95ZV24042 95ZV24043

17) The spider TOP mark should be placed as shown. Spider TOP mark

18) Fill the oil to the specified level. : Wheel hub (right and left) 20 Differential 60

Wheel hub

( 5 gal.) (16 gal.)

19) After reinstalling the tires, be sure to completely bleed the brake from air. Note: Check that manual rotation of the tires is possible. Also check the wheels for oil leakage. 95ZV24044

24-23

Drain plug (at bottom)

Floating Seal

95ZV

POWER 24

Floating Seal Construction Floating seal location

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

Floating seal Wheel hub Axle housing

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

Ring Ring 95ZV24045

Seal cross section

Remove oil

Put thin gear oil (Do not use grease)

O-ring

Seal ring

95ZV24046

Do not touch (It may cause rusting) 95ZV24089

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

24-24

Floating Seal

95ZV

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

POWER 24

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

(2) In case jig is used 1

Before installation

2 3

90ZV24068

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

70ZV24095J

1. Wheel hub

Guide jig

Installation jig

2. Guide jig 3. Installation jig 4. Floating seal

After installation 85ZV24027

24-25

Floating Seal

95ZV

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

24-26

POWER 24

Internal Gear Hub

95ZV

POWER 24

Internal Gear Hub Disassembling and reassembling internal gear hub 1. Disassembling internal gear hub

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

95ZV24090

2) Remove taper roller bearing (3). Removal method: Unless the taper roller bearing is removed the return spring for the brake piston and the brake stroke adjusting mechanism do not come out. For easy removal, heat inner race using a gas torch with low flame.

95ZV24052

3) Remove twelve bolts (5) from brake piston (4). Torque for assembly: : Locknut: 34 N-m (3.5 kgf-m) (25 lb-ft)

4 95ZV24091

4) Remove return spring (6).

6 5

95ZV24054

24-27

Internal Gear Hub

95ZV

POWER 24

5) Remove socket bolts (7). Torque for assembly: : Socket bolt (7): 50.0 N-m (5.10 kgf-m) (37 lb-ft)

6) Remove bushing (8) and sleeve (9).

7) Remove tolerance ring (10) from bushing (8).

Piston

10 95ZV24055

Installation procedure - Attach the tolerance ring to the boss (bushing). - Press-fit the shaft (sleeve).

Boss (bushing)

Tolerance ring

Shaft (sleeve)

95ZV52021

8) Insert bolts into two holes for removing the brake piston, then tighten two bolts evenly. The piston should come

Upper side Brake piston

out evenly. Bolt size for removing piston (2 required) M10 x 1.5 - 45 to 50 (1.8 to 1.97 in.) (Fully threaded) For removing brake piston

95ZV24092

24-28

Internal Gear Hub

95ZV

POWER 24

9) Remove brake piston O-rings (13) (14). 13

14 95ZV24057

10) There is snap ring (15) that connects internal gear (16) to internal gear hub (1). Shift the snap ring to the inside using a round bar or the like.

95ZV24058

11) Attach sling to internal gear (16) to remove it.

24-29

95ZV24059

Internal Gear Hub

95ZV

POWER 24

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

3. Cautions regarding reassembly

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

Oil groove

1) When reassembling internal gear (3) and brake piston (2) to internal gear hub (1), align the oil plug groove of the internal gear hub with that of the brake piston and spring pin (4). 3

(Reason) To reinstall the internal gear hub on the axle, the brake oil path should be aligned to these oil grooves. In addition, the oil grooves are used for alignment of the spring pin. Moreover, the aligned grooves are used for external measurement of brake disc wear. Note: Check that the snap ring is properly inserted into the groove of the internal gear.

95ZV24086

Upper side Brake piston

For pushing down brake piston

2) Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly. Bolts size for pushing brake piston back (4 required) M10 x 1.5 - 45 to 50 (1.8 to 1.97 in.) (Fully threaded)

95ZV24037

3) Install the socket bolts (5). Torque for assembly: : Socket bolt: 50.0 N-m (5.10 kgf-m) (37 lb-ft) Note: There is clearance of approximately 1.2 mm (0.047 in.) between the sleeve and the socket bolt (5).

1.2 mm (0.047 in.)

Piston

Sleeve 95ZV24093

24-30

Internal Gear Hub

95ZV

POWER 24

4) Before reinstallation of taper roller bearing (6), be sure to heat bearing to 90 °C (194 °F) to 120 °C (248 °F) in oil. 5) Apply grease to the O-rings. 6

95V24015

24-31

Spider Assembly

95ZV

POWER 24

Spider Assembly Disassembling and reassembling spider assembly 1. Disassembling spider assembly 1) Remove lock bolts (1) and then plate (2). Torque for assembly: : Lock bolts: 417 N-m (42.5 kgf-m) (307 lb-ft) : Screw lock agent (Three bond 1327) application

1 95ZV24061

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

1 3

95ZV24062

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

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

97ZA2422

7 95ZV24063

24-32

Spider Assembly

95ZV

2. Reassembling spider assembly To reassemble the spider assembly, follow the procedure described in the reversed direction. Before starting work: - Clean all the parts. - Check the brake retainer, pins, bearings, planetary gears for distortion and wear. - Replace the wear rings and defective parts with new ones. - Inspect the internal bores of the spider for wear.

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

24-33

POWER 24

Special Tool

95ZV

POWER 24

Special Tool Special tool for axle (A) Internal gear hub puller

(Material: SS41) 2-12 Drill

t 16

5C 204 230 95ZV24094

(B) Internal gear hub hoisting tool

(Material: SS41)

t15

200

240

X-X

135

300

t 2.3

Y-Y 45 45

24-34

95ZV24065

Special Tool

95ZV

POWER 24

(Material: SS41)

t16 4 - ø12

M16 x 2

131.5

102

204 263 330

100 95ZV24066

M16 x 2 (Totally threaded)

(D) Wheel hub hoisting tool

(Material: SS41) . Cut the threaded area off the M10 eye bolt before use.

ø3

M30 x 2

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

24-35

95ZV24095

Special Tool

95ZV

POWER 24

(E) Bearing insertion jig

(Material: SS41)

ø160

280

ø180

ø164

95ZV24068

(F) Axle nut tightening jig

(Material: SS41) ø80 38 5C 30

5C Hexagon (Width across flat 160 mm)

ø229

24-36

95ZV24069

Special Tool

95ZV

POWER 24

(G) Floating seal jig For wheel hub 17

20 10.2±0.2

ø325

ø280

ø340 ø308 +0.30 +0.25 ø297±0.1

ø303.4 +0.10 +0.05 ø350

ø315 0 ø304 -0.1 ø297.6±0.1 ø291±0.1

10.5±0.1 5

12±0.3

R0.3

R0.2~R0.5

95ZV24070

For ring 13

11.2±0.2 3

20 3

ø330

ø280

ø320 0 ø304 -0.1 ø297.6±0.1 ø291±0.1

ø303.4 +0.10 +0.05 ø355

ø297±0.1

ø310 -0.25 -0.30

10.5±0.1 12± 0.3

R0.3

24-37

R0.2~R0.5

95ZV24071

Rear Axle Assembly

95ZV

POWER 24

Rear Axle Assembly Tightening torque R. H

Rear differential T2 L 1 T5

T5 T7 T5 B T6 L1

T3 L1

T8 L 1

L. H T1 T4 95ZV24072

: Bolt tightening torque T1: 892 N-m (91.0 kgf-m) (658 lb-ft) T2: 608 N-m (62.0 kgf-m) (449 lb-ft) T3: 417 N-m (42.5 kgf-m) (307 lb-ft) T4: 86 N-m ( 8.8 kgf-m) ( 64 lb-ft) T5: 78 N-m ( 8.0 kgf-m) ( 58 lb-ft) T6: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T7: 33 N-m ( 3.4 kgf-m) ( 25 lb-ft) T8: 90 N-m (9.15 kgf-m) ( 66 lb-ft)

Note: Tighten A while measuring the preload applied to section B . Preload of section B : 324 ~ 363 N (33 ~ 37 kgf) (73 ~ 81 Ibs) ✽ ✽This is "breakaway" force. The force required to start the wheel turning.

L1: Screw lock agent (Three Bond 1327) application

24-38

Rear Axle Assembly

95ZV

POWER 24

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

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

97K24032

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

97K24033

3) Remove under cover (1). : Under cover: 30 kg (66 lbs)

95ZV24073

24-39

Rear Axle Assembly

95ZV

POWER 24

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

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

95V24017

5) Remove right and left wheel and tire assemblies (2). Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) : Tire: 790 kg/pc (1,740 lbs/pc)

97K24035

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

Transmission Rear differential

: Third propeller shaft: 23 kg (55 lbs) 3

3rd propeller shaft

3 95ZV24074

7) Disconnect hose (4) to the hydraulic tank. Note: Install plastic cap on breather fitting.

Breather fitting

Rear axle 95ZV24075

24-40

Rear Axle Assembly

95ZV

POWER 24

8) Disconnect the front and rear grease pipes and then remove brake hose (5) and brake pipe (6). : Hyd. oil: approx. 4 (1 gal.)

95ZV24076

9) Attach sling to rear axle (7), and remove front (R&L, 2 pieces) and rear (R&L, 4 pieces) retainer bolts (8) from the rear axle support. Lower the rear axle on the carrier. Note: The rear support is locked by not only the bolts but also dowel pins. Carefully remove or reinstall the support while checking the dowel pins. Torque for assembly: : Retainer bolt: 721 N-m (73.5 kgf-m) (532 lb-ft) : Rear axle and axle support: 2,750 kg (6,050 lbs) : With lubricating oil (Engine oil or gear oil) Note: Be careful not to bend or damage the brake oil pipes.

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

3. For disassembling and reassembling the rear axle assembly, refer to "Disassembling and reassembling front axle". 24-41

Rear axle

7 8

95ZV24077

Axle Support

95ZV

POWER 24

Axle Support Tightening torque T1 L2

T2 L1 Front

T2 L1

95ZV24078

: Bolt tightening torque T1: 721 N-m (73.5 kgf-m) (532 lb-ft) T2: 608 N-m (62.0 kgf-m) (449 lb-ft)

L1: Screw lock agent L2: With lubricating oil (Engine oil or gear oil)

24-42

Axle Support

95ZV

POWER 24

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

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

5 4 3

2) Remove plate (2), ring (3), packing (4) and O-ring (5).

2 6

Front

95ZV24079

3) Remove axle support (6) from the rear axle assembly. : Axle support: 90 kg (200 lbs) 7

4) Remove O-ring (7), packing (8) and ring (9). 8

5) Remove bolt (10). Torque for assembly: : Bolt: 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application

95ZV24080

6) Remove plate (11) and wear ring (12).

11 12

7) Remove bolt (13). Remove plate (14) and wear ring (15). Torque for assembly: : Bolt: 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application 24-43

14 15

95ZV24081

Axle Support

95ZV

POWER 24

8) Remove axle support (16) from the rear axle assembly. : Axle support: 120 kg (265 lbs)

9) Remove packing (17) and snap ring (18).

17 18

95ZV24082

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

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

3. Cautions regarding reassembly - Front support 1) Install ring (1), packing (2) and O-ring (3) on the swing shaft.

2 1

2) Put bushing (4) into hot water to heat the bushing to 80 °C (175 °F). Install the bushing onto the swing shaft as shown in the illustration.

Swing shaft Axle support

8 7

3) After installing the axle support onto the swing shaft, install O-ring (5), packing (6) and ring (7).

27.5

81 4 95ZV24083

CAUTION When installing the bushing onto the swing shaft, make sure no oil left on the inner surface of the bushing or the swing shaft surface. If oil is left on them, the bushing may turn causing bushing wear. 4) Install plate (8) and tighten bolts (9). Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (40 lb-ft)

24-44

Axle Support

95ZV

POWER 24

- Rear support 1) Before installing put bushing (10) into dry ice then install it on to the rear axle support.

Swing shaft

2) Install packing (11) on to the axle support and install snap ring (12).

12 Axle support

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

CAUTION

95ZV24084

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

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

24-45

Differential Assembly

95ZV

POWER 24

Differential Assembly Removing and reinstalling differential 1. Removing differential Before starting work: - Drain oil from the axle assembly. - Remove the axle from the machine. - Place the axle assembly on work-benches. - For the rear axle, remove the axle supports.

95ZV25005

1) Remove retainer bolts (1) to remove cover (2). Torque for assembly: : Retainer bolt: 90 N-m (9.15 kgf-m) (66 lb-ft)

2 1

2) Pull out right and left axle shafts with sun gears 30 cm (1 ft).

3) Remove retainer bolt (3) to remove the spider assembly. : Spider assembly: 125 kg (275 lbs)

95ZV25006

4) Remove bolts (4) from differential (5). Torque for assembly: : Front differential retainer bolts: 314 N-m (32.0 kgf-m) (232 lb-ft) : Rear differential retainer bolts: 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Three Bond 1327) application

5 4 95ZV25007

Note: Spacers are inserted in six "✽" mark sections of the front differential.

Spacers in mark sections

95ZV25008

24-46

Differential Assembly

95ZV

POWER 24

5) Attach sling to differential (5), and insert bolts into remover tap (Jack screw) holes (6) to slightly lift the differential. : Differential (Front): 350 kg (770 lbs) (Rear): 360 kg (790 lbs) Note: Be careful to sling the differential so that it is balanced and is lifted straight up.

6 95ZV25009

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

7 95ZV25010

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

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

24-47

Axle Assembly

95ZV

POWER 24

T3 L 2

Disassembling and reassembling differential assembly 1. Tightening torque (T=22.20) ~

(T=22.48) T2 L 1

E (T=0.1~1.0)

T1 L 1

T4 L 1 D

T5 L 1 F

: Bolt tightening torque T1: 216 N-m (22.0 kgf-m) (159 lb-ft) T2: 314 N-m (32.0 kgf-m) (232 lb-ft) T3: 883 N-m (90.0 kgf-m) (651 lb-ft) T4: 873 N-m (89.0 kgf-m) (644 lb-ft) T5: 55 N-m ( 5.6 kgf-m) ( 41 lb-ft) T6: 441 N-m (45.0 kgf-m) (326 lb-ft)

95ZV25004

Note: 1) To tighten T3 , measure the preload of section A . Preload of section A : 36 to 45 N (3.7 to 4.6 kgf) (8 to 10 lbs) B Use spacer to adjust the preload. 2) Use shim E to adjust the tooth contact of spiral bevel gears C D . Use nut F to adjust the backlash.

L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three Bond 1215) 24-48

Differential Assembly

95ZV

POWER 24

Shim

2. Disassembling differential assembly Before starting work: - Fix the differential assembly onto the disassembly workbench. - Insert a straight-end screwdriver or the like into the clearance between the pinion and bevel gear to prevent the gear from rotating. Loosen pinion nut A . Torque for assembly: : Nut: 883 N-m (90 kgf-m) (651 lb-ft)

Nut A Bevel gear

Pinion

Adjusting nut

95ZV25031

1) Remove right and left lock plates (2) from adjustment nuts (1). Torque for assembly: : Retainer bolt: 55 N-m (5.6 kgf-m) (41 lb-ft) : Screw lock agent (Three Bond 1327) application

2 95ZV25012

2) Remove right and left nuts (3), bearing cap (4), and adjustment nut (1). Torque for assembly: : Retainer nut: 441 N-m (45.0 kgf-m) (326 lb-ft) : Screw lock agent (Three Bond 1327) application

1 95ZV25013

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

95ZV25014

24-49

Differential Assembly

95ZV

POWER 24

4) Put a matchmark on the alignment point of differential cage (1). Remove bolts (2), and then separate the differential cage. Torque for assembly: : Retainer bolt: 216 N-m (22.0 kgf-m) (159 lb-ft) : Screw lock agent (Three Bond 1327) application

Matchmark 95ZV25015

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

4 3 95ZV25016

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

6 7 5 95ZV25017

7) Remove side gear (8).

95ZV25018

24-50

Differential Assembly

95ZV

POWER 24

8) Remove bushing (1). 1

95ZV25019

9) Turn the differential upside down. Remove bolts (3) from bevel gear (2) to separate the gear. Torque for assembly: : Retainer bolt: 873 N-m (89.0 kgf-m) (644 lb-ft) : Screw lock agent (Three Bond 1327) application

2 95ZV25020

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

4 95ZV25021

11) Remove nut (6) and O-ring (7). Nut width across flat: 65 mm (2.559 in.) Torque for assembly: : Nut: 883 N-m (90.0 kgf-m) (651 lb-ft) : Liquid gasket (Three Bond 1215)

24-51

95ZV24096

Differential Assembly

95ZV

POWER 24

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

3 4

13) Remove taper roller bearings (7) and spacer (8).

14) Remove snap ring (9) and roller bearing (10) from the pinion.

Pinion

9 7

95ZV25023

24-52

Differential Assembly

95ZV

POWER 24

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

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

4. Cautions regarding reassembly 1) Check the preload of the pinion section by following the procedure below: ➀ Install new roller bearing (2) and snap ring (9) on pinion (1) if replacement is needed. Note: The bearing ring part should be faced to the pinion. ➁ Install new taper roller bearing (3) and spacer (4) on pinion (1) if replacement is needed. ➂ Install cage (5) and taper roller bearing (6). ➃ Put yoke (7) and nut (8) on pinion (1). Note: Do not install the oil seal and O-ring of the nut. : Nut: 883 N-m (90 kgf-m) (651 lb-ft) ➄ Secure yoke in a vise. Measure the preload at section (A) (bolt hole).

95Z42459-55

: Standard preload*: 36 to 45 N (3.7 to 4.6 kgf) (8 to 10 lbs) If the preload is out of the above range, replace spacer (4) to adjust the preload to the specified range. * Preload is the force required to start the cage movingbreakaway force. (Not rolling force.) Note: There are 15 types of spacers from 22.20 mm (0.874 in.) to 22.48 mm (0.885 in.) in increments of 0.02 mm (0.0007 in.). Thicker spacers reduce preload; thinner spacers increase preload. ➅ Remove nut (8) and flange yoke (7). 24-53

4 6

5 7

2 9

95ZV25024

Differential Assembly

95ZV

POWER 24

2) Before installing the oil seal, be sure to apply grease to the lip and liquid gasket at the outside of the seal. Grease nipple Check the direction of the lips

Apply liquid gasket (AA03) to these surfaces Apply grease 95ZV25026

Oil seal installation

95ZV25025

Shim

3) Install O-ring (10) and the shim to the cage. Install the cage to differential case (11) and tighten bolts (12) temporarily. After adjusting tooth contact, tighten the bolts (12) with the specified tightening torque. : Bolt: 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application Note: Shims should be selected to adjust the tooth contact. For adjusting tooth contact, refer to "Adjusting tooth contact". 4) Adjust the backlash as follows: ➀ Tighten adjustment nut (13) on the bevel gear side until the backlash is "0". Then back off the adjustment nut 2 to 3 notches. ➁ Tighten the opposite adjustment nut (14). After you feel that the nut is tight, turn it one more notch. ➂ Attach the dial gauge stand to the carrier. Attach dial gauge (A) to a tooth of bevel gear (15). Read the backlash value indicated on the dial gauge. ➃ Adjust the backlash. Standard backlash: 0.30 to 0.41 mm (0.0118 to 0.0161 in.) - Tighten adjustment nut (13) on the bevel gear side or loosen adjustment nut (14) on the opposite side to reduce the backlash. - Loosen adjustment nut (13) on the bevel gear side or tighten adjustment nut (14) on the opposite side to increase the backlash.

24-54

10 11

95ZV24087

95ZV24088

Differential Assembly

95ZV

POWER 24

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

Flange yoke

Direction of grease nipple (Straight for front differential)

Bleeder

Flange yoke

Grease

A Detail 95ZV25029

Grease nipple

24-55

Differential Assembly

95ZV

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

24-56

Differential Assembly

95ZV

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

3 HEEL 4~5

BOTTOM

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

24-57

MEMO

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

25-1

Propeller Shaft Service Standard

95ZV

POWER 25

Propeller Shaft Service Standard 1

Third propeller shaft 95ZV25032

1 5

2 Measurement of circumferential

3 Measurement of tranverse

Second propeller shaft

95ZV25033

mm (inch) No.

Item

Tolerance mm (inch)

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

Bolt tightening torque

162 N-m (16.5 kgf-m)(119 lb-ft)

Tightening

Bolt tightening torque

162 N-m (16.5 kgf-m)(119 lb-ft)

Tightening

25-2

Axle and Differential Service Standard

95ZV

POWER 25

Axle and Differential Service Standard Axle group 5 2,3

1,3 4

95ZV25001

95ZV25002

mm (inch) Judgment standard No.

Item

Solution

Standard dimension 0.188 ~ 0.662 (0.0074 ~ 0.0260)

Tolerance ←

Replacement

←

Replacement

Backlash between sun gear and planetary gear

Backlash between planetary gear and internal gear

0.17 ~ 0.89 (0.0067 ~ 0.0350)

Tooth contact of gear

No abnormality

Replacement

Axle support wear

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

Replacement

Bushing and wear ring wear

No oil groove

Replacement

25-3

Axle And Differential Service Standard

95ZV

POWER 25

Differential 1

5, 6 5, 6

95ZV25003

mm (inch) Judgment standard No.

Solution

Item Standard valve

Tolerance

Backlash between ring gear and drive pinion

0.30 ~ 0.41 (0.0118 ~ 0.0161)

←

Adjustment

Backlash between side gear and pinion gear

0.25 ~ 0.66 (0.0098 ~ 0.0260)

←

Adjustment

Clearance between pinion gear and spider

0.10 ~ 0.17 (0.0039 ~ 0.0067)

←

Replacement

Runout of ring gear rear surface (when assembled)

0.075 (0.0029)

←

Adjustment or replacement

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

Tooth contact

No abnormality

Replacement

25-4

TORQUE CONVERTER AND TRANSMISSION GROUP 34 Disassembly and Reassembly Torque Converter and Transmission Assembly ..........................................34-2 Torque Converter Assembly .....................................................................34-10 Transmission Assembly ............................................................................34-15 Clutch Assembly .......................................................................................34-23 Clutch Spider Assembly ............................................................................34-39 Reverse Clutch Spider ..............................................................................34-42 1st Clutch Assembly .................................................................................34-43 High Clutch Assembly ...............................................................................34-47 Control Valve Assembly ............................................................................34-52

34-1

Torque Converter and Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly Tightening torque T2 L 1

T1 L 3 T3 L 1

T4 L 3

T5 L 3 T1 L3

T1 L1

Transmission

T6 L 2

Rear differential

2nd propeller shaft 3rd propeller shaft

95ZV24001

Front differential

T6 L 2

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

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

34-2

Torque Converter and Transmission Assembly

95ZV

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 cap from hydraulic tank to vent tank pressure. - Remove the cab and the floor board by referring to Section 14. - Remove the engine room by referring to Section 14. - Before ordering parts record and use the model and serial number on the serial number plate. - Consider the type of failure and if the torque converter oil cooler must also be removed for cleaning or replacement. - If a small amount of contamination is found in the transmission strainer and filter the cooler does not need removal. - If a large amount of contamination is found the cooler must be removed and throughly cleaned or replaced. - Lines to cooler must also be replaced. 1) Remove drain plug (1) to drain the transmission oil. : Transmission oil: 55 (14.5 gal.)

2) Disconnect bolts (2) and remove the third propeller shaft. Note: If the retainer bolts are too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner. Keep flame away from the seals of the coupling. Do not reuse bolts, always replace with new ones. Tightening torque for assembly : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327)

Transmission Rear differential

2 2nd propeller shaft

95ZV34001

34-3

97K34001

3rd propeller shaft

Torque Converter and Transmission Assembly

95ZV

3) Remove bolts (3) 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)

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Rear differential 3

2nd propeller shaft

3rd propeller shaft 95ZV34001

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

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

Valve unit Oil cylinder

95ZV34002

Parking brake cylinder

5) Remove split pin (5), and then remove pin (6). 6) Remove bolts (7) from the actuator mounting bracket. Disconnect the oil source, and then remove actuator.

IMPORTANT

When the transmission is lifted, it will come in contact with the steering valve. To prevent this, remove the steering valve before lifting the transmission.

5 6 95ZV34003

7) Disconnect all the hoses and the pipes from steering valve (8) and remove the steering valve with the bracket. Note: After removing hose, plug or cover disconnected part with plastic caps to protect from dust and dirt. Tightening torque for assembly : Bolt: 231 N-m (23.5 kgf-m) (169 lb-ft) : Steering valve: 65 kg (143 lbs) (with bracket)

Bracket 95ZV34004

34-4

Torque Converter and Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

IMPORTANT

When the transmission is lifted, it will come in contact with the accumulators. To prevent this, remove the accumulators before lifting the transmission.

8) Remove accumulators (9) with bracket. : Brake accumulator: 20 kg (44 lbs) Bracket

95ZV34005

9) Remove all the connected hoses from gear pumps (10) and (11), and then remove the pump assembly. Note: After removing hoses, cover the hoses with plastic caps, and cover pump ports with the caps to protect them from dust and dirt. Refer to the Section 44 "Hydraulic Group" for the reinstallation. Tightening torque for assembly : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Gear pump, double: 40 kg (88 lbs) : Gear pump, single: 30 kg (66 lbs) 10) Disconnect the electrical wire for torque converter temperature switch and sensor (12), speed sensor connector (13), and then remove oil level gauge pipe (14).

Torque converter

10 95ZV34006

95ZV34007

11) Remove hoses (15) between the torque converter and the line filter. Note: After removing hoses, cover the hoses with plastic caps to protect from dust and dirt.

Torque converter

95ZV34008

34-5

Torque Converter and Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

12) Remove hoses (16) between the torque converter and the oil cooler. Note: After removing hoses, cover the hoses with plastic caps to protect from dust and dirt.

16 95ZV34009

13) Remove hose (17) between the flywheel housing and the transmission. Note: After removing hoses, cover the hoses with plastic caps to protect from dust and dirt.

95ZV34010

14) Disconnect all the connectors (18) of the control valve solenoid. Note: Put matchmarks on them to avoid miswiring. 18

95ZV34011

15) Lift the transmission assembly temporarily, remove eight bolts (19) (right / left) and insert support (A) to the underside of engine flywheel housing. Note: Be sure to lift the transmission assembly through chain block (B) at front side. Tightening torque for assembly : Bolt: 230 N-m (23.5 kgf-m) (170 lb-ft)

34-6

95ZV34012

Torque Converter and Transmission Assembly

95ZV

16) Remove retainer bolt (20) (right and left side). Torque for assembly: : Bolt (20): 201 N-m (20.5 kgf-m) (148 lb-ft) : With liquid adhesive (Loctite® 262)

TORQUE CONVERTER AND TRANSMISSION 34

20 21

17) Remove retainer bolt (21) both right and left. Torque for assembly: : Bolt (21): 441 N-m (45.0 kgf-m) (325 lb-ft) : With lubricating oil A

18) Remove twelve bolts (22) (both sides) between the torque converter and the flywheel housing. Torque for assembly: : Bolt (22): 67 N-m (6.85 kgf-m) (50 lb-ft) : With lubricating oil

95ZV34153

95ZV34013

19) Move the transmission assembly to front chassis side to disengage the ring gear connection with flywheel. 20) Lift and remove the transmission assembly. : Transmission assembly: 1,310 kg (2,890 lbs) Note: In this case, lift the transmission assembly slowly, while avoiding contact with other parts.

34-7

Torque Converter and Transmission Assembly

95ZV

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

3. Cautions for installation - Be sure to replace the O-ring at the connecting part between engine and transmission with new one. - 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 the 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 engine, and check that the shift lever properly functions at all the positions. 2) Check each section for oil leakage. 3) Adjust the transmission oil level to the specified point with the level gauge. 4) Perform the start-up tests as shown on the attached sheet.

34-8

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly

DATE:

HOURS:

95ZV

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.

34-9

Torque Converter Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter Assembly T2 L2

T2 L2

Bolt tightening torque T8 T8 L2 T3 L2

T4 L2

T2 L2

T9 L2

Check dowel pin depth T8 L1

T8 L2

T7 L2

T10 L1 T8 L2

T11 L1 T2 L2 T1

95ZV34014

T2 L2

T1: 882 N-m (90.0 kgf-m) (651 lb-ft) T2: 53 N-m (5.40 kgf-m) ( 39 lb-ft) T3: 132 N-m (13.5 kgf-m) ( 98 lb-ft) T4: 76 N-m (7.80 kgf-m) ( 56 lb-ft) T5: 27.9 N-m (2.85 kgf-m) ( 21 lb-ft) T6: 54.9 N-m (5.60 kgf-m) ( 41 lb-ft)

T7 : 52.5 N-m (5.35 kgf-m) ( 39 lb-ft) T8 : 93.7 N-m (9.55 kgf-m) ( 69 lb-ft) T9 : 177 N-m (18.0 kgf-m) (130 lb-ft) T10: 132 N-m (13.5 kgf-m) ( 98 lb-ft) T11: 230 N-m (23.5 kgf-m) (170 lb-ft)

L1: Screw lock agent application (Loctite® 262) L2: With lubricating oil (Engine oil or gear oil) 34-10

Torque Converter Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling torque converter assembly

1. Disassembling torque converter assembly Before starting work: - Drain oil from the transmission drain port and also from the torque converter drain port. - Clean the transmission assembly. 1) Remove pipe (1) and the hoses (2) (3). Remove nut, spring and plunger for T/C outlet relief valve (A). Nut

Spring

View from machine right side

95ZV34157

Plunger

95ZV34162

2) Remove control valve (4) to install the transmission assembly to the work bench or roll-over stand. Torque for assembly: : Socket bolt: 50 N-m (5.10 kgf-m) (37 lb-ft) 95ZV34016

3) Install the transmission assembly to the work bench or roll-over stand as shown. Remove plugs (3 pcs). Note: When reinstalling, apply Teflon tape to plugs for sealant. Do not use Loctite® or other thread lock compounds.

95ZV34017

Plug

95ZV34156

34-11

Torque Converter Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

4) Remove twelve bolts (5) and gear (6). Torque for assembly: : Bolt: 93.7 N-m (9.55 kgf-m) (69 lb-ft)

95ZV34018

5) Remove snap ring (7) and washer (8). 15

6) Remove thirty bolts (9) connecting drive cover (10) and pump impeller (11) to remove drive cover (10). Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubricating oil (Engine oil or gear oil)

9 11

1.5 or more

7) Raise the calked (staked) collar part of nut (12). Loosen nut (12) and remove stator (13). Torque for assembly: : Nut: 245 N-m (25.0 kgf-m) (181 lb-ft) When assembling, calk (stake) the collar of the nut against the spline.

Stake Nut collar

95ZV34019

12 13

Stake 6

Spline

2.75

95ZV34020

95ZV34021

8) Remove collar (14). 9) Separate pump impeller (11) and the stator shaft.

95ZV34022

34-12

Torque Converter Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

10) Separate the assembly into drive cover (10) and turbine impeller (15).

15 10

95ZV34023

11) Remove bolts (16) (5 pcs). Torque for assembly: : Bolt: 93.7 N-m (9.55 kgf-m) (69 lb-ft) : Screw lock agent application (Loctite® 262) 16

95ZV34024

12) Remove twelve bolts (17) connecting the torque converter housing and the transmission. Torque for assembly: : Bolt: 93.7 N-m (9.55 kgf-m) (69 lb-ft) : With lubricating oil (Engine oil or gear oil)

95ZV34025

13) Separate the torque converter housing from the transmission. : Torque converter housing 250 kg (550 lbs) Torque converter housing

95ZV34026

34-13

Torque Converter Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

14) Turn the torque converter housing up side down and place it on the block as shown.

17,18

15) Remove snap ring (17) and washer (18). Shim adjustment necessary when assembling:

Clearance (0~0.2mm) Shim(T0.1/0.2/0.3)

17 Block 21

95ZV34159

95ZV34158

16) Remove socket bolt (19). Torque for assembly: : Socket bolt: 89.7 N-m (9.15 kgf-m) (66 lb-ft) 17) Support turbine shaft (20) from the bottom side. Gear

18) Remove turbine shaft (20) with stator shaft (21) from the torque converter case.

Shaft Bearing

19) At the same time, separate gear (22) from turbine shaft (20). Do not forget washer (23) is behind gear (22). Bearing

Gear

20) Remove PTO gears, shafts and bearings in order.

Shaft Bearing

2. Reassembling torque converter assembly For reassembling, follow the above procedure in the reversed direction.

Bearing

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

34-14

95ZV34163

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly T2 L2

Bolt tightening torque

T2 L2

T8 T8 L2 T3 L2

T4 L2

T2 L2

T9 L2

Check dowel pin depth T8 L1

T8 L2

T7 L2

T10 L1 T8 L2

T11 L1 T2 L2 T1

95ZV34014

T2 L2

T7 : 52.5 N-m (5.35 kgf-m) ( 39 lb-ft) T8 : 93.7 N-m (9.55 kgf-m) ( 69 lb-ft) T9 : 177 N-m (18.0 kgf-m) (130 lb-ft) T10: 132 N-m (13.5 kgf-m) ( 98 lb-ft) T11: 230 N-m (23.5 kgf-m) (170 lb-ft)

L1: Screw lock agent application (Loctite® 262) L2: With lubricating oil (Engine oil or gear oil) 34-15

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling transmission assembly 1. Disassembling transmission assembly

Torque converter housing

Before starting work: - Separate the torque converter housing from the transmission.

95ZV34026

1) Remove cover (1). 2) Remove bolt (2). Torque for assembly: : Bolt: 93.7 N-m (9.55 kgf/cm2) (69 lb-ft) : With lubricating oil (Engine oil or gear oil)

95ZV34029

2 3

95ZV34030

3) Remove four sleeves (3).

95ZV34031

4) Remove twelve bolts (4) of the clutch pack assembly. Torque for assembly: : Bolt: 93.7 N-m (9.55 kgf-m) (69 lb-ft) : With lubricating oil (Engine oil or gear oil)

4 95ZV34032

34-16

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) Lift and remove the clutch pack assembly. : Clutch pack assembly: 390 kg (860 lbs)

95ZV34033

6) Remove bolts (5) and then remove the parking brake drum. Torque for assembly: : Bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent application (Loctite® 262) 7) Remove nut (6) and then remove the output flange. Torque for assembly: : Nut: 882 N-m (90.0 kgf-m) (651 lb-ft) (Nut width across flats: 60 mm (2.362 in.))

Output flange

Parking brake drum

5 95ZV34034

8) Remove bolts (7) and then remove the parking brake. Torque for assembly: : Bolt: 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent application (Loctite® 262)

Parking brake

7 95ZV34035

9) Remove bolts (8) and then remove housing (9). Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubricating oil (Engine oil or gear oil)

34-17

95ZV34036

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

10) Remove the output flange from the output shaft. Remove bolts (10) and then remove the retainer (11). Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubricating oil (Engine oil or gear oil)

Output flange 10 95ZV34037

11) Remove output shaft (12) from the transmission rear side. : Output shaft: 26 kg (60 lbs)

95ZV34038

12) Remove gear (13) from the transmission case. : Gear: 40 kg (90 lbs)

95ZV34039

34-18

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

2. Reassembling transmission assembly For reassembling, follow the above procedure in the reversed direction. Note: - Clean and check all the parts. If a part is damaged, replace it with a new one. Refer to Section 35 for wear limits. - When assembling, apply transmission oil to the parts. - Replace all the seals and packings with new ones. - When installing each clutch pack assembly, manually turn the gears to check that the gears are engaged properly.

3. Cautions regarding reassembling 1) Install oil seal (1), grease seal (2) and O-ring (3) to seal retainer (4) and then install seal retainer (4) to the housing with bolts (5).

IMPORTANT Be careful, not to mistake direction of the oil seal and the grease seal.

5 95ZV34041

2 Apply grease

1 2

95ZV34040

: Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft) 34-19

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

2) Install oil seal (6) (7) and O-ring (8) to housing (9) and then install housing (9) to the transmission housing with bolts (10). Note: Apply grease to oil seal before installing them to the housing. : Bolt (10): 53 N-m (5.4 kgf-m) (39 lb-ft)

7 6 9

Apply grease

IMPORTANT Be careful, not to mistake direction of the oil seal lip.

3) Adjust output flanges (11) (12) to the same direction (phase).

8 95ZV34042

11 12

95ZV34043

4) Lift the clutch pack assembly, install two O-rings to the 1st clutch pack and install the guide rod to the bearing retainer, and then install the clutch pack assembly to the transmission housing.

Clutch pack assy

1st clutch pack

Guide rod O-rings

95V34026

O-ring

95ZV34044

: Clutch pack assembly: 390 kg (860 lbs) Oil hole

IMPORTANT Be sure to align the oil holes of the clutch pack assembly with that of the transmission housing.

95V34028

34-20

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) Tighten clutch pack retainer bolts (13). : Bolts (16): 93.7 N-m (9.55 kgf-m) (69 lb-ft)

13 95ZV34045

6) Calk (stake) the clutch pack body at two points around knock pin (4 pcs) as shown in the illustration.

95ZV34046

7) Attach O-ring (15) to each of four sleeves (14), and install each sleeve into the oil hole of transmission housing.

15 15

95ZV34047

95ZV34048

8) Tighten bolt (16) and install cover (17). Torque for assembly: : Bolt: 93.7 N-m (9.55 kgf-m) (69 lb-ft) : With lubricating oil (Engine oil or gear oil)

16 17

34-21

95ZV34049

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

9) Install two piston rings to the shaft of the clutch pack assembly.

Piston ring Knock pin

10) Attach the O-ring to the connection of torque converter housing and install the torque converter housing to the transmission assembly.

O-ring

95V34031

Note: Before installing the torque converter housing to the transmission assembly, check the dowel pin depth.

ø12 +0.05 0

6 Drill

Check dowel pin depth

8 95ZV34050 95ZV34051

Note: Insert two guide rods with the knock pin of transmission side high clutch sleeve directed right upward. Sleeve

Guide rod

Knock pin

Guide rod Guide rod 95ZV34052 95ZV34053

34-22

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Clutch Assembly Disassembling and reassembling clutch assembly 1. Disassembling clutch assembly Before starting work: - Remove the clutch assembly from the transmission housing, and set it on the work bench.

95ZV34054

1) Remove snap ring (1).

1 95ZV34055

2) Lift and remove high clutch assembly (2). 2

95ZV34056

3) Remove snap ring (3).

95ZV34057

34-23

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

4) Fix the clutch assembly on the work bench up side down.

5) Remove lock nut (4). Note: Be sure to raise the calked (staked) nut parts (4 points).

Calking (Staking) (Point marked with • ) 4

Collar

95ZV34058

95ZV34059

6) Lift and remove the 1st clutch assembly (5). 5

95ZV34060

7) Remove eleven housing connecting bolts (7) and ring (6). 6

95ZV34061

34-24

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

8) Put a matchmark to each housing prior to disassembling. Remove housing (8).

Matchmark

95V34034

9) Remove twelve spring (9), two friction plates (11) and steel plates (10).

10, 11 9 97K34062

10) Remove ring gear (12) and one remaining friction plate. Remove six anchor pins (13).

97K34063

11) Remove the 2nd clutch housing (14) and 3rd clutch housing.

97K34064

34-25

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

12) Remove twelve springs (15) and then remove friction plate (16) and steel plate (17).

16, 17 15 95ZV34062

13) Remove the 2nd spider assembly (18).

95ZV34063

14) Loosen two bolts (19) and remove housing (20).

20 19

95ZV34064

15) Remove six springs (21) and then remove one friction plate (22) and steel plate (23).

22, 23

21 95ZV34065

34-26

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

16) Remove ring gear (24). 17) Remove five remaining friction plates (25) and then remove four steel plates (26). 24

25, 26

95ZV34066

18) Remove low and reverse clutch housing (27). 27

95ZV34067

19) Remove six friction plates (28) and five steel plates (29), and six anchor pins (30) and twelve springs (31).

28, 29 31 95ZV34068

20) Remove the low and 3rd spider assembly (32) with main shaft (33).

95ZV34069

34-27

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

21) Remove snap ring (34) and spacer (35) from main shaft (33). Push main shaft (33) to remove it from the low and 3rd spider assembly (32).

33 34 35

32 34, 35 95ZV34071

95ZV34070

22) Remove snap ring (36) and sun gear (37) from main shaft (33). 36

95ZV34072

23) Turn over the reverse housing. Remove snap ring (38) then pull out clutch gear (39).

38 39

24) Remove reverse housing (41) from reverse spider assembly (40).

40 95ZV34073

34-28

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

2. Reassembling clutch assembly Before starting work: - Clean and check each part, and replace part with a new one if necessary. (Refer to Section 35 for the limit.) - Be sure to apply transmission oil to each necessary point when reassembling the clutch assembly. - Measure each piston stroke of 2nd, 3rd, low and reverse. - Replace the packing and the seals with new ones. - Check each steel plate for flatness. If there is any warpage replace the plate. Measurement of piston stroke ➀ Assemble the desired clutch piston to each clutch housing, and measure the dimension as shown in the illustration. (This is dimension A.) ➁ Set the necessary quantity of friction plates and steel plates referring to the following table and measure the total thickness. (This is dimension B.) Friction plate

Steel plate

2nd

3 pcs

2 pcs

3rd

3 pcs

Low

6 pcs

5 pcs

Reverse

6 pcs

5 pcs

95ZV34074

➂ The dimension A-B is the piston stroke and the piston stroke should be within the range shown in the following table. 95ZV34075

Piston stroke

2nd

2.0 ± 0.5 (0.0787 ± 0.0196)

3rd

2.5 ± 0.5 (0.0984 ± 0.0196)

Low

3.5 ± 0.5 (0.1378 ± 0.0196)

Reverse

3.5 ± 0.5 (0.1378 ± 0.0196)

34-29

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

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

Lip Piston

95V34029

Note: - Apply sufficient coat of transmission oil to the seal ring. - Install the clutch piston proportionally. - When assembling the low clutch piston into the housing in advance, be careful not to mistake assembling position. (Check matchmarks marked at time of disassembling.) 95ZV34076

2) Install bearing (1) and snap ring (2) to the reverse housing.

95ZV34077

3) Install reverse housing (3) onto reverse spider assembly (4).

4) Install clutch gear (5) with snap ring (6).

3 4

34-30

95ZV34078

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) Fix reverse housing (3) on the work bench up side down.

3 95ZV34079

6) Install sun gear (7) and snap ring (8) to main shaft (9). 8

95ZV34080

7) Install main shaft (9) to the low and 3rd spider assembly (10). After that install spacer (11) and snap ring (12) to main shaft (9).

9 12 11

10 11, 12 95ZV34081

95ZV34082

8) Install the low and 3rd spider assembly (10) onto reverse housing assembly (3). 10

3 95ZV34083

34-31

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

9) Install six anchor pins (13), twelve springs (14), six friction plates (15) and five steel plates (16) alternately. Note: Start installing the friction plate first. Apply transmission oil between the friction plate and the steel plate.

15, 16 95ZV34084

10) Install low and reverse clutch housing (17).

97K34087

11) Turn the spring by hand to check that it is fitted properly in upper/lower spring holes. (If it is fitted properly in the hole, the spring will turn easily.)

95ZV34085

12) Install eleven damper springs (18) to the low and reverse clutch housing bolt hole. Install five friction plates (19) and four steel plates (20) alternately. Note: Start installing from friction plate. Apply transmission oil between the friction plate and the steel plate.

34-32

95ZV34086

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

13) Install ring gear (21) with addendum notch up.

95ZV34087

14) Install one remaining friction plate and one steel plate. After that, install six springs (22).

22 95ZV34088

15) After putting housing (23) temporarily, turn spring with hands check that it is fitted properly in upper/lower spring holes. Tighten two housing connecting bolts (24) located at diagonal position.

Note: When installing the housing, be careful for two alignment dowel pins. : Bolt (24): 90 N-m (9.15 kgf-m) (66 lb-ft) : With lubrication oil (Engine oil or gear oil) 24 95ZV34089

16) Apply air pressure of 0.6 MPa (6 kgf/cm 2) (85 psi) through the oil hole to check for piston operation and air leakage.

95ZV34090

34-33

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

17) Install the sun gear shaft assembly into 2nd carrier. Sun gear shaft assembly

95ZV34091

18) Install the 2nd spider assembly (25). Install the sun gear with 2nd carrier onto the main shaft. Install the needle bearing assembly, sleeve, snap ring and bushing.

95ZV34092

19) Install three steel plates (26) and three friction plates (27) alternately. Note: Start installing from steel plate. Apply transmission oil between the friction plate and the steel plate.

95ZV34093

20) Install twelve springs (28).

28 95ZV34094

34-34

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

21) Assemble the 2nd clutch housing (29). Note: - Check the matchmark and align oil hole position. - After assembling, turn spring with hands to check that it is fitted properly in upper/lower spring holes.

Oil hole

95ZV34095

22) Install six pins (30). And install one friction plate (31) and one steel plate (32). Note: Apply transmission oil between the friction plate and the steel plate.

30 95ZV34096

23) Install ring gear (33).

95ZV34097

24) Install two remaining friction plates and one steel plate. 25) Install twelve springs (34).

34 95ZV34098

34-35

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

26) After putting housing (35) temporarily turn the spring with hands check that it is fitted properly in upper/lower spring holes. Note: When installing the housing, be careful for two alignment dowel pins.

95ZV34099

27) Install eleven housing connecting bolts (36). : Bolt (36): 132 N-m (13.5 kgf-m) (98 lb-ft) (Check at the nut side) : With lubrication oil (Engine oil or gear oil)

37 36

28) Apply air pressure of 0.6 MPa (6 kgf/cm 2) (85 psi) through the oil hole to check for piston operation and air leakage.

95ZV34100

29) Install ring (37). 37

Clutch gear

Spider

95ZV34101

30) Install the 1st clutch assembly (38). 38

95ZV34102

34-36

Clutch Assembly

95ZV

31) Attach and tighten lock nut (39). : Lock nut: 176 N-m (18.0 kgf-m) (130 lb-ft) : With lubrication oil (Engine oil or gear oil)

TORQUE CONVERTER AND TRANSMISSION 34

Preload

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

95ZV34103

Calking (Staking) (4 points)

80 Collar Calking (Staking)

2 Spline groove

2.75

1.5 or more

Collar

95ZIV3404

33) Fix the clutch pack assembly on the work bench up side down.

34-37

95ZV34104

Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

34) Install snap ring (41).

95ZV34105

35) Install bearing (42) and sleeve (43) on hub (44). Attach and tighten lock nut (45). Note: Preload: 78.5 ~ 88.3 N (8 ~ 9 kgf) (18 ~ 20 lbs)

43 B

95ZV34106

36) Install high clutch assembly (46).

95ZV34107

37) Install snap ring (47).

47 95ZV34108

34-38

Clutch Spider Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Clutch Spider Assembly Disassembling and reassembling low and 3rd clutch spider

1. Disassembling low and 3rd clutch spider

1) Remove snap ring (1), and separate spider assembly (2) and internal gear (3). Then, remove snap ring (4) and ring plate (5).

4 5 3 95ZV34109

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

95ZV34110

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

9 10 9 10

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

34-39

8 95ZV34111

Clutch Spider Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling 2nd clutch spider

4 5

1. Disassembling 2nd clutch spider

1) Force snap ring (1) inward using a round bar to separate spider (2) and ring gear (3). 1

2) Remove snap ring (4), then remove plate (5). 3

95ZV34113

3) Drive spring pin (7) that locks pin (6) all the way into the pin to unlock it (3 locations). 7 6

95ZV34114

4) Pull out planetary pin (6), and then remove planetary gear (8), wearings (9), and needle bearing (10). Note: Once the planetary pin has been removed, take the spring pin out.

10 9

5) Force snap ring (11) inward with a round bar to separate spider (12) and the 1st speed clutch gear (13).

8 95ZV34115

12 13 11

95ZV34116

34-40

Clutch Spider Assembly

95ZV

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

34-41

TORQUE CONVERTER AND TRANSMISSION 34

Reverse Clutch Spider

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Reverse Clutch Spider Disassembling and reassembling reverse clutch spider

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

95ZV34118

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

95ZV34119

8 8 6

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

34-42

7 95ZV34120

1st Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

1st Clutch Assembly Disassembling and reassembling 1st clutch assembly 1. Disassembling 1st clutch assembly

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

95ZV34121

95ZV34122

5 2

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

3 6

95ZV34123

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

11 11 10

8 9 10

95ZV34124

34-43

1st Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

97K34111

17 14 18 12 15

95ZV34125

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

22 19

95ZV34126

34-44

1st Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

1) Assemble clutch drum (1) and clutch hub (2) with snap ring (3).

95ZV34127

2) Install drop gear (4) to clutch hub (2) with bolts (5). : Torque for assembly: 76 N-m (7.8 kgf-m) (56 lb-ft)

2 5

95ZV34128

3) Install seal rings (7) (8) on the piston (6). 6 7

Direction of the seal lip

95ZV34129

97ZA3444

4) Install piston (6), springs (9), and ring plate (10), in that order, on the clutch drum (1). Then, push down ring plate (10) with a press (11), and assemble plate (10) with snap ring (12). 10 6

12 1

95ZV34131 95ZV34130

34-45

1st Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

5) After installing piston, reassemble alternate layers of plates, starting with friction plate (13), steel plate (14), then friction plate (13), etc. in the clutch drum (1). Then install pressure plate (15), and assemble it with snap ring (16). Standard piston stroke: 4.5 ± 0.5 mm (0.18 ± 0.02")

14 14 13 1 16 15 13

95ZV34132

6) Install two seal rings (17) in the clutch hub (2), and install bearing (18). Install bearing retainer (21) after putting two O-rings on it, and then install bearing (19) and bearing nut (22) in turn. Note: Apply grease to the seal rings, and bend them inward as much as possible. : Bearing nut (22) Tighten nut so as to the pre-load at the point A is between 98 and 118 N (10 ~ 12 kgf) (22 ~ 26 lbs). 7) After confirming the pre-load of bearing (18) (19), calk (stake) nut (22) to lock it.

34-46

17 21

19 22 2

95ZV34133

High Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

High Clutch Assembly Disassembling and reassembling high clutch assembly

1. Disassembling high clutch assembly 1) Remove lock nut (1). Note: Raise the calking (staking) of nut collar at key groove.

95ZV34135

Raise the calked (staked) part

95ZV34134

2) Remove sleeve (2).

2 95ZV34136

3) Turn clutch assembly (3) up side down.

4 3

4) Remove snap ring (4) and then pressure plate (5).

5 95ZV34137

5) Remove three friction plates (6) and two steel plates (7). 6

95ZV34138

34-47

High Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

6) Push down spring retainer (8) by using the press, and remove snap ring (9). 7) Remove the press, and then spring retainer (8). 9

95ZV34139

8) Remove twelve springs (10).

95ZV34140

9) Remove piston (11).

95ZV34141

10) Remove sixteen bolts (12) and drop gear (13).

13 95ZV34142

34-48

High Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

11) Remove snap ring (14) to separate the assembly into clutch hub (15) and clutch drum (16).

15 16

95ZV34143

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

1) Install clutch hub (1) to clutch drum (2) with snap ring (3).

1 2

95ZV34144

2) Install drop gear (4) to clutch hub (1) with sixteen bolts (5). : Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft)

4 95ZV34145

34-49

High Clutch Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

3) Install seal rings (7) (8) to piston (6).

IMPORTANT

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

Piston Lip

95ZV34146

95ZV34155

4) Install piston (6) to clutch drum (2). 6 2

97K34122

5) Install spring (9).

97K34123

6) Attach spring retainer (10), and push down spring retainer by press to assemble snap ring (11).

97K34124

34-50

High Clutch Assembly

95ZV

7) Install three friction plates (12) and two steel plates (13) alternately after the piston. Note: Be sure that the friction plate comes after piston.

TORQUE CONVERTER AND TRANSMISSION 34

97K34125

8) Install pressure plates (14) and then install snap ring (15).

9) Measure piston stroke. Standard piston stroke: 2.5 ± 0.5 mm (0.0984 ± 0.0196 in.)

14 97K34126

10) Invert clutch assembly (16) and install sleeve (17). 17 16

11) Install bearing nut (18). : Tighten the bearing nut so as to the pre-load at the point (A) is between 78.5 and 88.3 N (8 ~ 9 kgf) (18 ~ 20 lbf). 95V34045

12) After confirming the pre-load, stake bearing nut (18) to lock it. 18 Calked (staked)

95ZV34147

34-51

97K34128

Control Valve Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Assembly 2

Removing and reinstalling control valve assembly 1. Removing control valve assembly

1) Clean the area carefully. Remove hose (1) (2). Note: Cover disconnected hoses with vinyl, plugs, or caps to protect them from dust, water, and dirt.

95ZV34148

2) Disconnect all the wire harness coupler (3). Note: Put matchmarks on them to avoid miswiring when reassembling.

95ZV34149

3) Remove cover (4). 6

4) Remove ten retainer bolts (5) and then remove modulator valve unit. Tightening torque for assembly : Bolt (5): 25.5 N-m (2.6 kgf-m) (19 lb-ft) : With lubrication oil (Engine oil or gear oil) 5) Remove nine bolts (6) of the solenoid valve block and then remove the block. Tightening torque for assembly : Bolt (6): 50.0 N-m (5.1 kgf-m) (37 lb-ft) : With lubrication oil (Engine oil or gear oil)

4 5

95ZV34150

6) Cover disconnected valve unit, block and the connecting surface of the transmission side with vinyl to protect them from dust, water and dirt. Note: Be careful to prevent the O-rings from falling out during repair.

95ZV34151

34-52

Control Valve Assembly

95ZV

7) Remove solenoid coil nut (7) and remove solenoid (8). Tightening torque for assembly : Nut (7): 10 N-m (1.0 kgf-m) (7.2 lb-ft) : With lubricating oil (Engine oil)

8) Remove valve holder (9). Tightening torque for assembly : Spool: 39 N-m (4.0 kgf-m) (29 lb-ft) : With lubricating oil (Engine oil)

TORQUE CONVERTER AND TRANSMISSION 34

7 8 9

95ZV34152

8 95ZV34160

34-53

Control Valve Assembly

95ZV

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

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

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

34-54

TORQUE CONVERTER AND TRANSMISSION 34

TORQUE CONVERTER AND TRANSMISSION GROUP 35 Service Standard Transmission Assembly ..............................................................................35-2 Gear Pump .................................................................................................35-4 Gear Train and Number of Teeth ................................................................35-5 Clutch Oil Pressure .....................................................................................35-6

35-1

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 35

Transmission Assembly 2, 3

12 12 11

10 12 12

4 12 12 5 12 6

7 12 8 95ZV35001

Note: Numbers correspond to page 35-3.

35-2

Transmission Assembly

95ZV

TORQUE CONVERTER AND TRANSMISSION 35

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

ITEM

Solution Standard value

Clearance (Pump impeller ~ Turbine impeller)

Standard clearance

Allowable limit

4.5 (0.1772)

Repair

Standard value Free length

Allowable limit

Installed length Installed load

Free length

Installed load

Transmission oil regulator spring

95 (3.7402)

85 (3.3465)

3.48 (0.1370)

Replace

Transmission oil regulator spring

97 (3.8189)

85 (3.3465)

10.0 (0.3937)

Replace

High clutch piston return spring

37 (1.4567)

30 (1.1811)

32.19 (1.2673)

±0.74 (±0.02913)

±1.7 (±0.0670)

Replace

Reverse clutch piston return spring

60 (2.3622)

55 (2.1654)

26.84 (1.0567)

±1.2 (±0.04724)

±3.2 (±0.1260)

Replace

Low clutch piston return spring

60 (2.3622)

55 (2.1654)

26.84 (1.0567)

±1.2 (±0.04724)

±3.2 (±0.1260)

Replace

3rd clutch piston return spring

37 (1.4567)

30 (1.1811)

32.19 (1.2673)

±0.74 (±0.02913)

±1.7 (±0.0670)

Replace

2nd clutch piston return spring

37 (1.4567)

30 (1.1811)

32.19 (1.2673)

±0.74 (±0.02913)

±1.7 (±0.0670)

Replace

1st clutch piston return spring

37 (1.4567)

30 (1.1811)

32.19 (1.2673)

±0.74 (±0.02913)

±1.7 (±0.0670)

Replace

Standard value

Standard clearance

Allowable limit

Seal width

3.8 (0.1496)

0 – 0.1 (– 0.0039)

– 0.15 (– 0.0059)

Seal thickness

4.0 (0.1575)

0 – 0.1 (– 0.0039)

– 0.15 (– 0.0059)

Seal width

4.3 (0.1693)

0 – 0.1 (– 0.0039)

– 0.15 (– 0.0059)

Seal thickness

5.0 (0.1968)

0 – 0.1 (– 0.0039)

– 0.15 (– 0.0059)

Seal width

2.8 (0.1102)

±0.1 (±0.0039)

– 0.15 (– 0.0059)

Seal thickness

4.55 (0.1791)

±0.1 (±0.0039)

– 0.15 (– 0.0059)

Seal width Seal thickness

95ZV35002

35-3

Replace

Gear Pump

95ZV

TORQUE CONVERTER AND TRANSMISSION 35

Gear Pump 10

1. Pump body 2. Pump cover 3. Drive gear 4. Driven gear 5. Needle bearing 6. Needle bearing 7. Bearing retainer 8. Bearing retainer 9. Snap ring 10. Dowel pin 11. Bolt 12. Washer

2 4 6

Hydraulic pump side

11,12 95ZV32015

Gear pump specifications Theoretical discharge

73.6 cm3/rev (4.49 in3/rev)

Maximum operation pressure

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

Maximum operation speed

2,600 min-1 (rpm)

Actual discharge

Approx. 40 / min (10.5gpm) Conditions: Pump speed 830 min-1 (rpm) Oil temp. 80 to 100 °C (176 ~ 212 °F) Oil viscosity 10CST (SAE10W) Discharge pressure 3.4 MPa (35 kgf/cm2) (498 psi)

35-4

Gear Train and Number of Teeth

95ZV

TORQUE CONVERTER AND TRANSMISSION 35

Gear Train and Number of Teeth L : Low range clutch H : High range clutch R : Reverse clutch 1 : 1st speed clutch 2 : 2nd speed clutch 3 : 3rd speed clutch

T/C

82 82

E/G 63

1 38

H 35

2nd propeller shaft

3rd propeller shaft

95ZV32004

Clutch specifications

mm (in.) Steel plate

Friction plate

Name of clutch

Piston stroke (mm)

Low range clutch

3.5±0.5 (0.1378±0.0196)

Reverse clutch

3.5±0.5 (0.1378±0.0196)

High range 2.5±0.5 clutch (0.0984±0.0196)

1st speed clutch

4.5±0.5 (0.1772±0.0196)

2nd speed clutch

2.0±0.5 (0.0787±0.0196)

3rd speed clutch

2.5±0.5 (0.0984±0.0196)

Number of plate

Outer dia. (mm)

Inner dia. (mm)

Thickness(mm) New/Wear limit

Number of plate

4±0.13/3.5 360ø 279ø (0.1575±0.0051 /0.1378) (14.1732) (10.9842) (Sintered)

4±0.1/3.4 236ø 159ø (0.1575±0.0039 /0.1339) (9.2913) (6.2598) (Sintered)

4±0.13/3.8 360ø 279ø (0.1575±0.0051 /0.1496) (14.1732) (10.9842) (Paper)

Limit for distortion (flatness)

Outer dia. (mm)

Number of Thickness(mm) return spring New/Wear limit

3.5±0.1/3.3 426ø 298ø (0.1378±0.0039 (16.7716) (11.7323) /0.1299)

6 12

3.2±0.1/3.0 252ø 173ø (0.1260±0.0039 (9.9212) (6.8110) /0.1181)

3.5±0.1/3.3 426ø 298ø (0.1378±0.0039 (16.7716) (11.7323) /0.1299)

~0.25 (~0.0098)

35-5

Inner dia. (mm)

Clutch Oil Pressure

95ZV

TORQUE CONVERTER AND TRANSMISSION 35

Clutch Oil Pressure Measurement port size

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

Shift lever position

Main clutch oil pressure

PF 3/8

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

at any position

Low clutch oil pressure

PF 1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

F-1 ~ 3

High clutch oil pressure

PF 1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

F-4

PF 1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

1st clutch oil pressure

PF 3/8

2.5 ~ 2.8 (26 ~ 29) (370 ~ 412)

1st speed

2nd clutch oil pressure

PF 1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

2nd speed

3rd clutch oil pressure

PF 1/4

2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

3rd speed

Measuring port location

Reverse clutch oil pressure

1st speed clutch oil pressure measurement port: PF3/8 Main clutch oil pressure measurement port: PF3/8 95ZV35003

Low range clutch oil pressure measurement port: PF1/4

- Torque converter oil temperature: 50 to 80 °C (120 ~ 180 °F) - Engine revolution: at high idle

3rd speed clutch oil pressure measurement port: PF1/4 Reverse clutch oil pressure measurement port: PF1/4

95ZV35004

2nd speed clutch oil pressure measurement port: PF1/4 95ZV35005

Clutch oil pressure measuring port

35-6

HYDRAULIC GROUP 44 Disassembly and Reassembly Warning Regarding Removing and Reinstalling Hydraulic Parts .......................................................................................44-2 Cautions Regarding Disassembly and Reassembly of Hydraulic Parts .......................................................................................44-3 Hydraulic Pump Assembly...........................................................................44-4 Hydraulic Cylinder......................................................................................44-10 Pilot Valve..................................................................................................44-23 Multiple Control Valve................................................................................44-30 Orbitrol® ......................................................................................................44-37 Steering Valve ...........................................................................................44-47 Stop Valve .................................................................................................44-52 Fan Motor ..................................................................................................44-56

44-1

Warning Regarding Removing & Reinstalling Hydraulic Parts

95ZV

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 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 Hyd. Parts

Cautions Regarding Disassembly and Reassembly of Hydraulic Parts Hydraulic parts may be very 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 so as not to damage it. - Because hydraulic parts may be delicate, do not drop or scratch them. - When disassembling, do not hit or pry the parts by force. The parts may be 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

95ZV

HYDRAULIC 44

Hydraulic Pump Assembly WARNING

Removing and reinstalling hydraulic pump assembly

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 wheels from moving. - Disconnect the negative side of the cable from the battery. - Release the residual pressure from the hydraulic line.

1.Removing hydraulic pump assembly Before starting work: a) Remove the cab and floor board by referring to Section 14. b) Clean the area around the hydraulic pump assembly.

1) Disconnect outlet hose (2) (3) from hydraulic pump (1) and outlet hose (5) from hydraulic pump (4). Note: Cover the hoses with plastic, plugs or caps to protect from dust and dirt.

8 5 3 9

2 95ZV44034

2) Disconnect suction side pipe (6) for hydraulic pump (1), and disconnect pipe (7) for hydraulic pump (4).

Transmission 1

7 6

3) Remove hydraulic pump (4) retainer bolts (8). Torque for assembly: : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft)

Oil tank

44-4

95ZV44035

Hydraulic Pump Assembly

95ZV

HYDRAULIC 44

4) Sling hydraulic pump (1), and remove retainer bolt (9) for the hydraulic pump. Torque for assembly: : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) 1

5) Remove hydraulic pump (1).

95ZV44075

44-5

Hydraulic Pump Assembly

95ZV

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

IMPORTANT

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.

1)Fill the inlet port of the hydraulic pump with clean hydraulic oil and rotate the pump shaft by hand prior to installing the pump. It should rotate smoothly. Prior to installing pump and plumbing to pump, remove all caps, plugs, and covers from pump and piping. 2)While reinstalling the hydraulic pump, take care not to allow dust, dirt, or foreign material into the case. 3)Check the oil level of the hydraulic tank. 4)Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe. Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 ). 5)Run the engine at low-idling speed for 5 minutes or more. Do not operate any hydraulic functions during this period. Note: If the engine speed is set to high-idling just after starting, the pump may be seized. 6)Actuate cylinders 5 to10 times to almost full stroke, but do not fully extend or retract any of the cylinders at this time. 7)Confirm that there is no abnormal noise or operation, and be sure that there is no excessive heat. Inspect the hydraulic oil at the sight gauge to be sure that there are no bubbles which may indicate air being drawn in at the suction side of the pump. If there are any bubbles, correct the cause prior to using the machine, as this may contribute to premature pump failure.

44-6

Hydraulic Pump Assembly

95ZV

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

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

44-7

HYDRAULIC 44

Hydraulic Pump Assembly

95ZV

HYDRAULIC 44

1.Cross section and tightening torque Double pump

T1 T2

95V44033

Single pump : N-m (kgf-m) (lb-ft)

T1: 81 ( 8.3) ( 60) T2: 210 (21.4) (155)

95ZV44001

44-8

Hydraulic Pump Assembly

95ZV

HYDRAULIC 44

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

[Example 1] Oil seal

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

Snap ring

Drive gear shaft

Front cover

95ZV44002

[Example 2]

Front cover

Drive gear shaft

Oil seal

Snap ring 95ZV44003

44-9

Hydraulic Cylinder

95ZV

HYDRAULIC 44

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

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Raise the boom until it is horizontal, and then place stand (A) under the boom to support it. - Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Use a stepladder or work platform, and do not stand on the machine. a)Clean the area around the cylinder and piping. Note: Relieving residual pressure from pipe 1.Raise the boom. When the boom is approximately 30cm (1 foot) above stand (A), stop the engine. 2.Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. 3.First press down on the hydraulic tank cap to vent residual pressure, then open the cap of the hydraulic tank. Leave hydraulic tank cap loosely on top of tank opening. 1) Attach sling to boom cylinder (4). Disconnect grease hose (1) from pin (3). Remove bolt (2) to remove pin (3). : Boom cylinder: 360 kg (790 lbs) 2) Disconnect hose (5). : Drain oil: Approx. 13 (3.4 gal.) 3) Push cylinder rod into the cylinder to shorten the length of the cylinder. Note: Cover disconnected hoses plastic vinyl, plugs, or caps to protect them from dust, water and dirt.

Stand

90ZV44028

Boom

4 95ZV44036

3 2 95ZV44037

5 95ZV44038

44-10

Hydraulic Cylinder

95ZV

HYDRAULIC 44

4) Remove lock bolt (6) for pin (7). 7 6

95ZV44039

5) Insert jack bolts (8) to pin (7), and then remove pin (7). 7

6) Sling boom cylinder (4), and lower it onto the ground.

8 95ZV44040

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

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

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or backup ring may be seized. Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100 mm (4.0 in.) before stroking fully. b)After that, stroke the cylinder piston fully to both ends 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage. 44-11

95ZV44041

Hydraulic Cylinder

95ZV

HYDRAULIC 44

Removing and reinstalling bucket cylinder 1.Removing bucket cylinder

1) Remove clamp (1) and coupler of bucket positioner switch (2). Remove the rod (3) from the cylinder.

95ZV4442

2) Attach sling to bucket cylinder. After that, remove bolt (4) to remove pin (5). : Bucket cylinder: 180 kg (400 lbs) 5

4 95ZV44043

44-12

Hydraulic Cylinder

95ZV

HYDRAULIC 44

3) Start engine and shorten cylinder rod (6).

4) Stop engine and disconnect hoses (7) (8). 6

: Drain: Approx. 1 (0.26 gal.) Note: Cover the disconnected hose and the cylinder with plastic caps or plugs to protect them from dust, water and dirt.

95ZV44044

5) Remove bolt (9) to remove pin (10). 9

95ZV44074

6) Slowly lift up bucket cylinder. Lower bucket cylinder to ground. For a detailed description of cylinder assembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

44-13

Hydraulic Cylinder

95ZV

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

3.Cautions regarding reinstallation

WARNING During service work, do not stand on the machine. Standing on tire, boom or linkage could cause accidents and serious injury or death. Use a stepladder or work platform, and do not stand on the machine.

➀Bleed the cylinder of air.

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

44-14

HYDRAULIC 44

Hydraulic Cylinder

95ZV

HYDRAULIC 44

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

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Place the boom and bucket on ground. - Stop engine, and turn steering wheel clockwise and counterclockwise to relieve the pressure from the line. - Press cap downward to vent, then open the cap of the hydraulic tank to relieve the internal pressure from the tank. - Place a "DO NOT START!" tag on the steering wheel or the operator's seat. Before starting work: a)Clean the area around the cylinder to be removed. b)Disconnect grease pipe from the pin. 1

1) Disconnect hose (1). : Cover the disconnected hose with plastic, caps, or plugs to protect them from dust, water, and dirt. 2) There is pin (4) between front chassis (2) and steering cylinder (5). Remove bolt (3) and pin (4), and then push rod into the cylinder to shorten the length of the cylinder. : Oil will be drained from the oil port of the cylinder. Place a container at the oil port to catch the drained oil. Approx. 2 (0.53 gal.) 3) Remove the bolt (6) and the pin (7). 4) Remove the steering cylinder assembly. : Steering cylinder: 40 kg (90 lbs)

95ZV44045

7 3

5 4

For detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder". 44-15

2 95ZV44046

Hydraulic Cylinder

95ZV

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

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.

WARNING Articulation area is a crush zone. Moving machine with a person in this area can cause injury or death. When turning 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 engine.

➁Bleed the cylinder of air

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

44-16

HYDRAULIC 44

Hydraulic Cylinder

95ZV

HYDRAULIC 44

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

1.Cross section and tightening torque 1) Boom cylinder

97ZV44007

2) Bucket cylinder

97ZV44008

3) Steering cylinder

97ZV44009

: N-m (kgf-m) (lb-ft) T1: 6,669 (680) (4,920)

Cylinder

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

T2: 843 ( 86) ( 622) T3: 4,217 (430) (3,111) T4: 883 ( 90) ( 651) T5: 1,275 (130) ( 941) T6: 1,765 (180) (1,302)

Boom

110 (4.33) – M76 x 2

Bucket

90 (3.54) – M62 x 2

Steering

55 (2.17) – M36 x 1.5

44-17

Hydraulic Cylinder

95ZV

HYDRAULIC 44

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

Repair stand 95ZV44004

Matchmark

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

2 1 95ZV44005

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

95ZV44006

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

Repair stand

Wooden block 95ZV44007

44-18

Hydraulic Cylinder

95ZV

HYDRAULIC 44

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

Matchmark

95ZV44008

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

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

Boom cylinder

110 (4.33)

6,669 (680) (4,920)

Bucket cylinder

90 (3.54)

4,217 (430) (3,111)

Steering cylinder

55 (2.17)

1,275 (130) ( 941)

Hydraulic jack

Hydraulic cylinder 95ZV44009

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

95ZV44010

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

10 9

10 20 12

11 (Bucket cylinder)

11 (Boom cylinder)

95ZV44011

44-19

11 (Steering cylinder) 95ZV44012

Hydraulic Cylinder

95ZV

HYDRAULIC 44

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

95ZV44013

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

For boom and bucket cylinder 95ZV44014

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

14 95ZV44015

44-20

Hydraulic Cylinder

95ZV

HYDRAULIC 44

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

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

Note: Put slipper ring (10) into hot oil to heat ring to 120 to 150 °C. (This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston. Therefore, heat slipper ring to expand its inner diameter for easy attachment.) : Attach the slipper ring while taking care not to damage by over expansion. : After attaching slipper ring, cool slipper ring so that it is contracted to the original size. Note: Before installing back-up ring (2) and O-ring (3), heat back-up ring. (This is because the inner diameter of the back-up ring is smaller than the outer diameter of the rod cover. To easily attach back-up ring to the rod cover, heat ring to soften it. The soft ring can be easily expanded.) Be careful not to over expand back-up ring. After installation, wait until the back-up ring is cooled, and then insert rod cover into the cylinder tube.

95ZV44016

3 95ZV44017

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

95ZV44018

44-21

Hydraulic Cylinder

95ZV

HYDRAULIC 44

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

Stake

13 95ZV44019

Stake 95ZV44020

44-22

Pilot Valve

95ZV

HYDRAULIC 44

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

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

Control box

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

Cover mount 90ZV44022

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

Pilot valve

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

90ZV44023

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

Pilot valve 4 A

44-23

90ZV44024

Pilot Valve

95ZV

HYDRAULIC 44

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

7 90ZV44025

6) Disconnect hoses (11) from the pilot valve.

Pilot valve

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

90ZV44026

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

Pilot valve

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

9) Remove bolt (15) (4 pcs) and pull up the pilot valve to

remove it. Adapter

Torque for assembly: : Adapter: 36 N-m (3.7 kgf-m) (27 lb-ft) 90ZV44027 14

: Pilot valve: 10 kg (22 lbs)

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

44-24

Adapter

Pilot Valve

95ZV

HYDRAULIC 44

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

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

Boom side

T3 T1

T1 T3 L1

T3 L1 T5

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

9.5 kg (21 lbs) T2

L1: Screw lock agent application (Three Bond 1327)

95ZV44021

44-25

Pilot Valve

95ZV

HYDRAULIC 44

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

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

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

97ZV44023

Lock nut

95ZV44076

5 6

Carefully store ball (4). 7

2) Loosen socket bolt (5). Remove lever (6) from disc (7). Torque for assembly: : Bolt: 29 N-m (3.0 kgf-m) (22 lb-ft) Note: Put matchmark on lever (6) and disc (7). 3) Loosen socket bolt (8). Remove cam shaft (9). Torque for assembly: : Retainer bolt: 17 N-m (1.7 kgf-m) (12 lb-ft) : Screw lock agent (Three Bond 1327) application Note: - Three Bond 1327 is applied, and more torque is needed to loosen. - Temporarily tighten socket bolt (5) to remove disc (7). - In case the cam shaft does not pull out, use the hexagon wrench to push it out. 44-26

97ZV44024

97ZV44025

Pilot Valve

95ZV

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

HYDRAULIC 44

97ZV44026

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

97ZV44027

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

11 12

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

44-27

13 14

97ZV44028

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

Pilot Valve

95ZV

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

HYDRAULIC 44

14 15

97ZV44029

Carefully install into the case

95ZV44022

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

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

9) Disassemble the plug assembly removed on paragraph 7). Remove spring (19) and spring seat (20) from push rod (12). (Not for all the types and ports.) Remove push rod (12) from plug (11).

19 20 97ZV44032

44-28

Pilot Valve

95ZV

HYDRAULIC 44

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

24 23

25 26

22 97ZV44033

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

4.Cautions regarding reassembling Install plane washer (24) so that the plane washer sharp edge side comes to the top position. Note: Do not push spring seat (23) down more than 4 mm (5/32 in.). 44-29

Sharp edge side

22 97ZV44023

Multiple Control Valve

95ZV

HYDRAULIC 44

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

Stand

90ZV44028

1) Remove cover (1). 95ZV44053

2) Loosen nuts (2) for U-bolts. (The illustration shows the machine left hand side.)

2 95ZV44054

3) Remove bolts (3) (4) (5) (6) (7) for the oil pipe flange.

: Oil will be drained from the pipes. Place a container to catch the drained oil. 4

95ZV44055

44-30

Multiple Control Valve

95ZV

HYDRAULIC 44

4) Slide boom cylinder oil pipes (8) (9) to the right. 8 9

95ZV44056

5) Put matchmarks on pilot line hoses (10) (11), and then disconnect them. Note: Cover disconnected hoses with plastic, caps or plugs to protect them from dust, water and dirt.

95ZV44057

6) Remove pipe (12) and hose (13), and then clamp them on the front chassis. : Hydraulic oil :Approx. 8

13 12

(2.1 gal.)

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

95ZV44058

7) Remove bolts (15) for control valve (14). Use a hoist to remove the control valve. 14

Torque for assembly: : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Multiple control valve: 100 kg (220 lbs)

95ZV44059

44-31

Multiple Control Valve

95ZV

2.Reinstalling multiple control valve To reinstall 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 multiple control valve mounting area.

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, be sure to stop the engine before you start working. In addition, block tires with chocks to prevent wheels from moving. While working, carefully keep contact with the person in the cab by giving signals to each other. c)Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the Section 03. d)Operate the bucket and the boom, and check that they operate correctly. e)Check each section for oil leakage. f )Add hydraulic oil to the tank until the oil level rises to the specified point.

44-32

HYDRAULIC 44

Multiple Control Valve

95ZV

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

T2 Overload relief valve with make-up function

T3 L1

T5 T1

Make-up valve T4

T6 Boom spool

T7 T5 T6 Bucket spool

Main relief valve T4

: N-m (kgf-m) (lb-ft) T1: 196 (20.0) (145) T2: 226 (23.0) (166) T3: 39 ( 4.0) ( 29) T4: 54 ( 5.5) ( 40) T5: 74 ( 7.5) ( 54) T6: 127 (13.0) ( 94) T7: 29 ( 3.0) ( 22)

T1 95ZV44024

: 100 kg (220 lbs)

L1: Screw lock agent application (Three Bond 1327) 44-33

Multiple Control Valve

95ZV

HYDRAULIC 44

2.Disassembling multiple control valve 1) Bucket spool disassembling Remove two socket head bolts (1) and cover (2). Hexagon hole width across flat: 8 mm (5/16 in.) Torque for assembly: : Bolt: 54 N-m (5.5 kgf-m) (40 lb-ft) 2 1 97ZV44036

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

97ZV44037

3) Set spool (3) in a vise using copper plates and then loosen bolt (4). Hexagon hole width across flat: 12 mm (1/2 in.) Torque for assembly: : Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft) : Screw lock agent application (Three Bond 1327)

3 97ZV44038

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

6 4

5 9 8

44-34

7 97ZV44039

Multiple Control Valve

95ZV

HYDRAULIC 44

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

97ZV44040

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

97ZV44041

7) Remove main relief valve (11). Hexagon width across flat: 41 mm (1 5/8 in.) Torque for assembly: : Main relief valve: 127 N-m (13.0 kgf-m) (94 lb-ft) Note: The main relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary. 11

97ZV44042

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

13 12

44-35

97ZV44043

Multiple Control Valve

95ZV

9) Remove make up valve (15) from the body. Hexagon width across flat: 34 mm (1 11/32 in.) Torque for assembly: : Make up valve: 127 N-m (13.0 kgf-m) (94 lb-ft)

HYDRAULIC 44

97ZV44052

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

4.Cautions regarding reassembling - Clean and check all the parts. If a part is defective, replace or repair it. - Replace all the O-rings with new ones. - Apply a thin coat of hydraulic oil or grease to each part before reassembly. - Apply the specified torque to tighten each main part.

44-36

Orbitrol®

95ZV

HYDRAULIC 44

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

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

95ZV44060

1) Remove cover (1).

2) Remove plate (2).

95ZV44061

3) Remove the sound suppression sheet (3).

3 95ZV44062

44-37

Orbitrol®

95ZV

HYDRAULIC 44

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

95ZV44063

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

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

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

44-38

Orbitrol®

95ZV

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

97ZV44010J

: N-m (kgf-m) (lb-ft) T1: 23 (2.3) (17) : 5.8 kg (12.8 lbs)

44-39

Orbitrol®

95ZV

HYDRAULIC 44

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

Copper plate

95ZV44025

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

2 3

97ZV44047

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

7 6

97ZV44048

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

9 10

97ZV44049

44-40

Orbitrol®

95ZV

HYDRAULIC 44

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

11 97ZV44050

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

97ZV44051

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

97ZV44052

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

18 19 97ZV44053

44-41

Orbitrol®

95ZV

HYDRAULIC 44

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

19 20 97ZV44054

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

97ZV44055

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

22 23 23

97ZV44056

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

26 27

25 97ZV44057

44-42

Orbitrol®

95ZV

HYDRAULIC 44

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

20 25 97ZV44058

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

Spring groove 22 Spring groove 23

Matchmark

95ZV44026

3) Install springs (24) through the spring grooves in the sleeve and spool (19) using a spring insertion jig. Note: Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

19 97ZV44060

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

97ZV44061

44-43

Orbitrol®

95ZV

HYDRAULIC 44

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

19 20

97ZV44062

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

97ZV44063

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

97ZV44052

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

23 97ZV44064

44-44

Orbitrol®

95ZV

HYDRAULIC 44

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

95ZV44027

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

97ZV44066

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

Port face 8 Pin parallel with port face

21 95ZV44028

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

97ZV44068

44-45

Orbitrol®

95ZV

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

HYDRAULIC 44

Grooves in rotor bore

B Drive shaft

C D

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

Port face

95ZV44029

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

2 3

97ZV44070

Tightening order

95ZV44030

44-46

Steering Valve

95ZV

HYDRAULIC 44

Steering Valve Removing and reinstalling steering valve

2 1

1.Removing steering valve 5

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

6 3

95ZV44065

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

95ZV44066

1) Disconnect hoses (1) (2) (3) (4). 9

: Hydraulic oil: Approx. 1

(0.3 gal.) 8

2) Disconnect pipes (5) (6) (7).

3) Disconnect hoses (8) (9). 95ZV44067

4) Remove hoses (10) (11) (12).

12 95ZV44068

44-47

Steering Valve

95ZV

HYDRAULIC 44

5) Remove bolt (13) and then remove steering valve (14). 13

Torque for assembly: : Bolt: 231 N-m (23.5 kgf-m) (169 lb-ft) : Steering valve: 50 kg (110 lbs) Note: Cover disconnected hoses and the valve with plastic, plugs or caps to protect them from dust and dirt.

95ZV44069

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

WARNING Entering the articulation area while engine is running may cause serious injury or death. So, when entering the area, stop the engine and place "DO NOT START " or "DO NOT OPERATE" tag on steering wheel or the operator's seat. 1) Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise. 2) Check around the valve for oil leakage. 3) Measure various values for performance check. Measure the time required for full steering. Measure the relief valve setting pressure. (Refer to the Section 03 - Measurement for Performance Check).

44-48

Steering Valve

95ZV

HYDRAULIC 44

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

T7 T8

Main relief valve

1.Cross section and tightening torque T4 Flow control spool Overload relief valve T5 T7 T2 T3

T1 T2

Steering spool T4 T6

95ZV44031

Overload relief valve

: N-m (kgf-m) (lb-ft) T1: 39 ( 4) ( 29) T2: 412 ( 42) (304) T3: 255 ( 26) (188) T4: 98 ( 10) ( 72) T5: 62 (6.3) ( 46) T6: 83 (8.5) ( 61) T7: 79 ( 8) ( 59) T8: 12 (1.2) ( 8.7) T9: 31 (3.2) ( 23)

44-49

Steering Valve

95ZV

HYDRAULIC 44

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

97ZV44073

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

97ZV44074

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

4) Slightly loosen plug (7). Note: Carefully loosen plug (7). It may spring out by the spring force. Width across flat: 41 mm (1.614 in) : Torque for assembly: 98 N-m (10 kgf-m) (72 lb-ft)

5 97ZV44075

97ZV44076

44-50

Steering Valve

95ZV

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

Width across flat: #8: 19 mm (0.748 in) #9: 41 mm (1.614 in) Torque for assembly: : #8: 79 N-m ( 8 kgf-m) (59 lb-ft) #9: 98 N-m (10 kgf-m) (72 lb-ft)

HYDRAULIC 44

8 10 11

97ZV44077

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

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

44-51

Stop Valve

95ZV

HYDRAULIC 44

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

1 6

7 95ZV44070

(The illustration shows the machine left hand side.) 1) Remove hoses (1) (2) (3) (4). 2) Disconnect hose (5). Remove bolt (6) and then remove stop valve (7).

2.Reinstalling stop valve For reinstallation, follow the above procedure in the reversed procedure. 44-52

Stop Valve

95ZV

HYDRAULIC 44

3.Caution regarding reinstalling: The stop valve works when the spool is pushed in 3 mm. Adjust the stopper bolt by using the following procedure. - Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension “28 to 48 mm (1.1~1.9 in)” shown in the table below.

Front chassis Reference dimension 23~27.5 mm (0.9~1.1 in)

Reference dimension

Stopper (bolt) length 36

Clearance between machine body and stopper (mm) 28

Stopper (bolt) length (mm)

25 27.5

✽ The target value should be the articulation angle “36°”. - After adjustment, turn the steering wheel slowly at a rate of 5 sec or more per turn, and confirm the clearance between the machine body and the stopper. - When adjustment is completed, tighten the lock nut of the stopper (bolt).

95ZV42034

Front chassis 37°

35°~

Articulation angle ( °)

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

Stopper (bolt)

Rear chassis Reference dimension 28~48 mm (1.1~1.9 in)

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

Clearance between machine body and stopper

95ZV42035

44-53

Stop Valve

95ZV

HYDRAULIC 44

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

1.Cross section and tightening torque

T4 T3

97ZV44078

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

44-54

Stop Valve

95ZV

HYDRAULIC 44

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

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

A B

Torque for assembly: : #2: 21 N-m (2.1 kgf-m) (15.2 lb-ft) 97ZV44079

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

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

7 3 4

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

Two flats 95ZV44032

4) Remove screw (9) to remove flange (10), dust seal (11), spacer (12) and U-packing (13). 12

Torque for assembly: :#9: 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)

9 97ZV44081

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

44-55

Fan Motor

95ZV

HYDRAULIC 44

Fan Motor Removing and reinstalling fan motor 1. Removing fan motor

WARNING If a person starts engine without informing the service man who is repairing machine, an accident resulting in injury or death could occur. To prevent such an accident: - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery. 1) Remove retainer bolts (1) (2) (3). Torque for assembly: : Retainer bolt (1): 94 N-m (9.6 kgf-m) (69 lb-ft) Retainer bolt (2) (3): 53 N-m (5.4 kgf-m) (39 lb-ft) 2) Remove fan guard (4). 3) Remove bolt (5) for the fan, and then take fan (6) out. Note: Carefully remove the fan while checking that the fan will not damage the radiator fins. Inspect the fan for any signs damage or cracks. Replace the fan if there are any signs of damage or cracks. Fan blade breakage can cause extensive damage. Torque for assembly: : Retainer bolt: 93.7 N-m (9.55 kgf-m) (69 lb-ft) 4) Remove nut (7), and then remove flange (8). Torque for assembly: : Nut: 765 N-m (78 kgf-m) (564 lb-ft) 5) Remove retainer bolt (9) for fan motor (10). Remove fan motor (10). Torque for assembly: : Retainer bolt: 142 N-m (14.5 kgf-m) (105 lb-ft)

1 4 2 4

3 95ZV44071

5 9

95ZV44072

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

8 9 5 95ZV44073

44-56

Fan Motor

95ZV

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

44-57

HYDRAULIC 44

MEMO

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

45-1

Steering Valve

95ZV

HYDRAULIC 45

Steering Valve

97ZV45001

Tightening torque No.

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

Standard value

Steering valve retainer bolt

230 (23.5) (170)

Steering valve bracket retainer bolt

230 (23.5) (170)

Solution Tightening

45-2

Hydraulic Cylinder

95ZV

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder

97ZV45004

Steering cylinder

3 97ZV45005

Unit : mm (in.) Judgment standard No

Standard dimension of rod dia.

Item

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

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

– 0.030 (– 0.0011)

+ 0.195 (+ 0.0076)

0.096 (0.0037)

– 0.076 (– 0.0030)

+ 0.060 (+ 0.0023)

0.271 (0.0107)

– 0.025 (– 0.0010)

+ 0.110 (+ 0.0043)

0.025 (0.0010)

– 0.064 (– 0.0025)

0 (0)

0.174 (0.0068)

0.285 (0.0112)

Item

+ 0.060 (+ 0.0023)

No.

– 0.090 (– 0.0035)

Steering cylinder

0.096 (0.0037)

ø 50 (1.9685)

+ 0.195 (+ 0.0076)

Bucket cylinder

– 0.036 (– 0.0014)

ø 80 (3.1496)

Bushing

Boom cylinder

Rod

Standard clearance

ø 100 (3.937)

Standard value

Standard

Solution

Bushing

Clearance

+0.295 (+ 0.0116)

0.385 (0.0151)

Replacement

+0.295 (+ 0.0116)

0.371 (0.0146)

Replacement

+0.210 (+ 0.0083)

0.274 (0.0108)

Replacement

Boom cylinder

Bucket cylinder

Steering cylinder

M75 x 2 6,669 (680) (4,920)

M62 x 2 4,217 (430) (3,111)

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

110 (4.33)

90 (3.54)

55 (2.17)

M24 x 3 843 (86) (622)

M24 x 3 883 (90) (651)

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

45-3

Pilot Valve

95ZV

HYDRAULIC 45

Pilot Valve

212-1

97ZV45002

Judgment standard No.

212-1

Item

Push rod ø 7(0.276 in)

Solution

Wear 1 mm(0.0394 in)

45-4

Standard value

Allowable limit

36 mm (1.417 in)

35 mm (1.378 in)

Replacement

BRAKE GROUP 54 Disassembly and Reassembly Unloader Valve ............................................................................................54-2 Manifold Valve Assembly.............................................................................54-5 Accumulator.................................................................................................54-7 Brake Valve ...............................................................................................54-12 Service Brake ............................................................................................54-19 Park Brake Actuator...................................................................................54-20 Parking Brake ............................................................................................54-24

54-1

Unloader Valve

95ZV

BRAKE 54

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

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

2 1

Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure. - Press the hydraulic oil tank cap, and relieve the internal pressure from the hydraulic oil tank. - Prepare a container to catch drained oil. 1) Remove hoses (1) (2) (3) (4) (5) and bolts (6). Remove unloader valve (7). Note: Cover disconnected hoses with clean plastic to protect them from dust and dirt. Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

95ZV54013

7 95ZV54014

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

Unloader Valve

95ZV

BRAKE 54

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

1.Cross section and tightening torque

T8 T7 T6

T2 L1

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

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

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

97ZV54002

Unloader Valve

95ZV

BRAKE 54

2.Disassembling unloader valve

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

3 2

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

Pressure governor assembly

95ZV54001

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

54-4

Manifold Valve Assembly

95ZV

BRAKE 54

Manifold Valve Assembly 4

Removing and reinstalling valve assembly

1.Removing valve assembly

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

6 Valve assembly 95ZV54015

8 7

95ZV54016

1) Remove hoses (1) (2) (3) (4) (5) (6). 2) Remove hoses (7) (8). 3) Remove hose (9).

4) Remove hose (10). 95ZV54017

5) Remove bolt (11) (see the top illustration) and then remove valve assembly from the chassis. Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

2.Reinstalling valve assembly To reinstall valve assembly, follow the above removal procedure in the reversed direction. Note: After reinstallation, check all the hose joints for oil leakage. 54-5

95ZV54018

Manifold Valve Assembly

95ZV

BRAKE 54

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

1.Cross section and tightening torque T5 T1

T1 T1

(T)

(P)

T4 (TA)

(PI)

(PARKING) (ACCR)

(ACCF)

ACF (PA) (Z1)

(Z)

(Z2)

(PPI)

High pressure test ports

: N-m (kgf-m) (lb-ft) T1: 50 (5.1) ( 37) T2: 23.5 (2.4) ( 17) T3: 38 (3.9) ( 28) T4: 11 (1.1) ( 8) T5: 8 (0.8) (5.8)

70ZV54012

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

Accumulator

95ZV

BRAKE 54

Accumulator Removing and reinstalling accumulator 1.Removing accumulator

WARNING

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

1) Disconnect hoses (1) from accumulators (2). 2

2) Remove bands (3), and then remove accumulators. 95ZV54019

2.Reinstalling accumulator To reinstall the accumulator, follow the above removal procedure in the reversed direction. Note: After reinstallation, completely bleed the brake line of air, and check performance of the accumulator. To bleed the brake line of air, refer to Section 24. To check performance of the accumulator, refer to Section 53.

54-7

Accumulator

95ZV

BRAKE 54

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

1.Disassembling accumulator

IMPORTANT

- Take care not to scratch cylinder to prevent gas leak. - Carefully remove each part so that it is not scratched or dented.

13 10

1) Loosen bolt (13) to remove gas valve guard (12).

5,6

8,9

97ZV54007

2) Remove the cap of gas valve (10) and install the charging valve to gas valve (10), then bleed the gas completely from the accumulator. Gas cap

3) Insert three pins into gas cap (3). Remove the gas cap by using a long bar. Pin hole : ø 11.4 (0.4 in)

95ZV54002

54-8

Accumulator

95ZV

4) Insert three bolts into hydraulic cap (2) and remove it by using a long bar.

BRAKE 54

7 2

3 13

Screw size: 1/2-20UNF-2B

5) Push out piston (4) toward the hydraulic end by using a bar.

5,6

2.Reassembling accumulator To reassemble the accumulator, follow the above disassembly procedure in the reversed direction. After reassembly, carry out the gas charging.

8,9

97ZV54007

Hydraulic cap

95ZV54003

54-9

Accumulator

95ZV

BRAKE 54

Procedure for charging nitrogen gas - Nitrogen gas charging tools:

1 2

1.Charging valve assembly 1-1 Handle (for adjusting screw) 1-2 Handle (for bleeder plug) 1-3 Valve body 2.Pressure gauge (4,900 kPa(50 kgf/cm2)(1,000 psi)) 3.Hose assembly 4.Nitrogen (N2) gas cylinder

1-1

1-3

1-2 3

Accumulator

Charging valve installation 95ZV54004

1.Charging nitrogen gas

WARNING Improper gas pressure can cause serious injury or death. To prevent such an accident, observe the following item: - Before measuring the gas pressure or charging the gas, stop the engine and release the oil pressure in the line by depressing the brake pedal until there is no brake pressure. 1) Turn handle (1-1) counterclockwise until it stops turning. 2) Turn handle (1-2) counterclockwise to open. 3) Remove the gas valve guard and then install charging valve assembly (1) to the gas valve. 4) Install pressure gauge (2) to the charging valve assembly and connect hose (3) to nitrogen gas cylinder (4). 5) Slightly open the valve of the nitrogen gas cylinder. Turn handle (1-2) clockwise to close after confirming the gas comes out from handle (1-2) part. 6) Slowly turn handle (1-1) clockwise to open the piston of the gas valve. 7) Open the valve of the nitrogen gas cylinder more and put a charge into the accumulator. Note: Close the valve of the nitrogen gas cylinder when checking the gas pressure on the gauge to read the gauge needle at the stable condition.

54-10

Accumulator

95ZV54005

Accumulator

95ZV

[Charging pressure: 2.9 MPa (30 kgf/cm 2) (427 psi) at 20 °C (68 °F)] Note: Gas pressure is variable with temperature. Use the following formula for the correct nitrogen charging pressure. If the pressure on the gauge is too high, slowly turn the handle (1-2) counterclockwise. PX = 30 (kgf/cm2) x {273 + t (°C)} / {273 + 20 (°C)} PX : Charging gas pressure t : Ambient temperature 30 : Standard gas pressure 8) Turn handle (1-1) counterclockwise to return the piston of the gas valve. Then turn handle (1-2) counterclockwise to bleed the gas from the charging assembly and the hose. 9) After removing pressure gauge (2), remove the charging assembly from the accumulator. Notes: - Apply soapy water to the gas valve on the accumulator to check for gas leakage. - Recheck the gas pressure once within a week after the charging. - Check the gas pressure at every 2000 operation hours. - A little gas is lost each time of the checking, so add the gas to compensate for the loss.

54-11

BRAKE 54

Brake Valve

95ZV

BRAKE 54

Brake Valve Removing and reinstalling brake valve 1.Removing brake valve

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

Cover

Cover 95ZV54006

(The illustrations show the parts on the left side. On the right side, the parts are located at the same points.) 1) Remove pressure switches (1) (2).

95ZV54007

2) Disconnect hoses (3) and pipes (4) from the brake valve. Note: Cover disconnected pipes with clean plastic to protect them from dust and dirt.

4 3

3 3 95ZV54008

54-12

4 3

Brake Valve

95ZV

BRAKE 54

3) Remove bolts (5) in the cabin and then remove brake valve (6).

Tightening torque : Bolt (4): 28 N-m (2.9 kgf-m) (21 lb-ft)

95ZV54009

2.Reinstalling brake valve To reinstall the brake valve, follow the above removal procedure in the reversed direction. After reinstallation: a)Check all the pipe and hose joints for oil leakage. b)Completely bleed the brake line of air following the procedure of Section 52. c)Check the brake performance following the procedure of Section 53.

54-13

Brake Valve

95ZV

BRAKE 54

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

1.Cross section and tightening torque (Main valve)

A A-A

T1 L 1 A

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

9.8 (1.0) ( 7.2) T2: 176.4 ( 18) (130) T3: 73.5 (7.5) ( 54)

70ZV54011

L1: Screw lock agent 1303N application 54-14

Brake Valve

95ZV

BRAKE 54

Pedal

2.Disassembling brake valve Use a copper plate in vise and do not tighten the brake valve in vise strongly. [Main valve] 1) Pull out the snap pin to remove the pedal, seat, boot and pedal stopper. Note: At this step, the pin (L-Shaped) is dropped. Take care not to lose it.

Pin Seat Pedal stopper Boot

Snap pin Pin(L-shaped) 95ZV54010

2) Loosen four bolts and disconnect the bracket from the valve assembly.

Bolt (4 pcs)

Bracket

Valve assembly

95ZV54011

3) Turn the valve upside down. Loosen four bolts and separate the valve assembly into the S cylinder assembly, P cylinder assembly and T flange assembly. Note: Carefully separate the valve assembly. It may spring out by the spring force.

Bolt (4 pcs) S cylinder assembly

4) Remove the spring sub assembly from the T flange assembly. Remove the return spring and retainer all together.

P cylinder assembly

Spring sub assembly Return spring + retainer T flange assembly

95ZV54012

54-15

Brake Valve

95ZV

BRAKE 54

[Pilot Valve] Follow the same disassembling procedure for main valve. Disassembly step diagram [Main valve]

[Pilot valve]

S cylinder assembly

Spool return spring Return spring P cylinder assembly Spring sub assembly

Spring sub assembly

S flange assembly

Return spring + retainer

T flange assembly 95ZV54021

95ZV54020

54-16

Brake Valve

95ZV

3.Reassembling brake valve

BRAKE 54

S cylinder assembly

1) Install the return spring and retainer to the T flange assembly all together. Install the spring sub assembly to the T flange assembly. Note: Confirm that the rod of the spring sub assembly is at the center. Be sure to install them in the proper direction.

Spool return spring

P cylinder assembly

2) Install the P cylinder assembly to the T flange assembly. Spring sub assembly

3) Install the spool return spring to the spool of the P cylinder assembly.

4) Install the S cylinder assembly to the P cylinder assembly.

Return spring + retainer

T flange assembly

95ZV54020

5) Tighten four bolts. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft) Bolt (4 pcs) S cylinder assembly

P cylinder assembly

95ZV54022

54-17

Brake Valve

95ZV

6) Tighten four bolts to install the bracket. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft)

BRAKE 54

Bolt (4 pcs)

Bracket

Valve assembly 95ZV54011

Pedal

7) Install the boot, stopper and the seat to the valve assembly.

8) Install the pedal to the bracket. Turn the stopper bolt until the clearance between the seat and the roller is zero, then tighten the stopper bolt lock nut to fix the stopper bolt.

Lock nut

Seat Pedal stopper Boot

Snap pin Pin(L-shaped)

: Lock nut: 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) 95ZV54023

Stopper bolt: Screw lock agent 1303N application

9) Fix the pin (L) to the pin, and insert the pin to the bracket. At this time, the pin (L) should be in the pedal hole.

10) Making sure of the direction, install the snap pin to the pin.

54-18

Stopper bolt

Service Brake

95ZV

BRAKE 54

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

Socket bolt Spider

95ZV54024

Upper side Brake piston

Cautions on installing brake discs CAUTION When only the friction plates or the steel plates are to be replaced, if the brake piston and brake stroke adjusting mechanism are installed as they are, the brake may drag and the brake discs may seize. Push back the brake piston and brake stroke adjusting mechanism by using the following procedure.

For pushing down brake piston

1) Loosen the axle housing air bleeder nipple.

Bolt size for pushing brake piston back (4 required) M10 x 1.5 - 45 to 50 (1.8 to 1.97 in.) (Fully threaded)

95ZV52037

2) Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly. A

B Wheel hub

3) After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face. A ... 162.45 to 163.85 mm (6.4 to 6.45 in.) Note: Piston stroke B 1.15 to 3.65 mm (0.045 to 0.144 in.)

Brake piston 95ZV52038

4) After finishing the installation work, bleed air completely from the brake line. 54-19

Park Brake Actuator

95ZV

BRAKE 54

Park Brake Actuator Removing and reinstalling park brake actuator 1.Removing park brake actuator

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - When removing the park brake actuator, the machine may move. To prevent the machine from moving, park the machine on level ground, and lower bucket to the ground. - In addition, block tires with chocks to prevent wheels from moving.

1) If there is an oil pressure source, release the parking brake, and then remove split pin (1) and pin (2). Note: If there is no oil pressure source, apply a cable to the link, and then pull it down using a bar to overcome the spring force, and then remove the pin. 2) Release the residual air pressure in hydraulic tank. Disconnect oil hose (3). 3) Loosen lock nut (4) to remove joint (5). Remove retainer nuts (6) to remove park brake actuator (7).

Valve assembly

95ZV54025

4 7

1 5

: park brake actuator 10 kg (22 lbs) 6

2.Reinstalling park brake actuator To reinstall the park brake actuator, follow the above removal procedure in the reversed direction. Note: To insert the connection pin to connect the park brake actuator to the parking brake, observe the following items: ➀ Start the engine to build oil pressure in the accumulator. ➁ Release the parking brake. ➂ Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the park brake actuator and the parking brake. After that, insert the connection pin into the joint hole. To check performance of the parking brake, refer to Section 53. 54-20

95ZV54026

Park Brake Actuator

95ZV

BRAKE 54

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

1.Cross section and tightening torque

97ZV54021

: N-m (kgf-m) (lb-ft) T1: 29 (3.0) ( 22) T2: 441 ( 45) (326)

54-21

Park Brake Actuator

95ZV

BRAKE 54

2.Disassembling park brake actuator 3

1 2

97K54004

1) Set park brake actuator (1) in a press and remove nuts (3) of tie-rod (2). 2

4 5 6

7 8 9 10 1 2

Torque for assembly: : #3: 29 N-m (3.0 kgf-m) (22 lb-ft)

90 mm

1 2 3

2) Slowly reduce the press until the spring loses the spring force [approx. 90 mm (3.54 in.)] and then remove four tie-rods (2).

97K54005

3) Remove oil cylinder from the press and remove rod cover (4), spring (5) and piston rod (6).

6 97K54006

4) Remove dust seal (7) and remove grand metal (8) from rod cover (4) if necessary.

97K54007

54-22

Park Brake Actuator

95ZV

BRAKE 54

5) Remove head cover (9) from cylinder tube (1). 1 9

97K54008

6) Clamp the area of the two chamfered flats of piston rod (6), and remove nut (10) and then remove U-packing (12) and the wear ring (13). Torque for assembly: : Nut: 441 N-m (45.0 kgf-m) (326 lb-ft)

10 13 11 12

97K54009

3.Reassembling park brake actuator To reassemble park brake actuator, follow the disassembly procedure in the reversed direction.

CAUTION When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined.

95ZV54027

54-23

Parking Brake

95ZV

BRAKE 54

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

WARNING When removing the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park machine on level ground. - Lower bucket to the ground. - Apply articulation stopper. 2

1) Drain the transmission oil.

2) Release the parking brake, and then remove pin (3) to disconnect link (1) and lever (2).

3 1

95ZV54022

3)Remove bolts (5) of propeller shaft (4). : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three bond 1327)

Parking brake

95ZV54028

4) Remove bolt (6) of brake adjustment hole and then remove brake drum (7). Remove nut (8) and flange yoke (9). : Bolt (6): 132 N-m (13.5 kgf-m) ( 98 lb-ft) Nut (8): 883 N-m (90.0 kgf-m) (651 lb-ft) : Bolt (6): Screw lock agent (Three bond 1327) Nut (8): With lubricating oil (Engine oil or gear oil)

54-24

97ZV54024

Parking Brake

95ZV

BRAKE 54

5) Remove right and left springs (10) using pliers. Remove plate (11).

6) Pull out upper guides to the front to open brake shoes (12), and then remove shoes (12) from the side guides. - If it is necessary to remove back plate (13), remove bolt (14).

97K54012

Upper guide

Side guide

Torque for assembly: : #14: 230 N-m (23.5 kgf-m) (170 lb-ft) : #14: Screw lock agent application (Loctite® 262)

12 14

95ZV54029

7) Remove spring (15), and then remove adjusting screw (16). Note: Measure the wear of the brake shoes. If the shoes are extremely worn, replace them. Refer to Section 53 or 55 inspection standards.

2.Reinstalling and reassembling parking brake To reinstall and reassemble the parking brake, follow the above removal and disassembly procedure in the reversed direction. Note: To adjust the parking brake, refer to Section 53. To check performance of the parking brake, refer to Section 53.

54-25

97ZV54026

Parking Brake

95ZV

BRAKE 54

Removing and reinstalling parking brake(for front) 1.Removing parking brake(for front)

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: - Stop the engine and set the parking brake switch to "OFF" position to discharge the oil pressure in the line. - Prepare a container to catch the drained oil.

3 1 2

1) Disconnect hose (1) and remove adapter (2). Note: Cover disconnected hose with clean plastic to protect the hose from dust and dirt.

95ZV54037

Front differential

2) Attach sling to disc brake assembly (3), and then remove four bolts (4).

Bracket

: Disc brake assembly Approx. 35 kg (77 lbs) Torque for assembly : #4: 451 N-m (46.0 kgf-m) (333 lb-ft)

Brake disc

#4: With lubricating oil 6

3) Place disc brake assembly (3) on a carrier. 5

- If it is necessary to remove the brake disc and the bracket. Torque for assembly : #5: 132 N-m (13.5 kgf-m) ( 98 lb-ft) #6: 721 N-m (73.5 kgf-m) (532 lb-ft) #5, 6: With lubricating oil

4 3 95ZV54030

54-26

Parking Brake

95ZV

BRAKE 54

2.Reinstalling parking brake (for front)

1 6

For reinstallation, follow the above procedure in the reversed direction.

2 4 3

3.Cautions regarding reinstallation

1) The brake pad assemblies (5) should be free, not pressed against disc. If not free, remove brake pad assemblies (5) as per the following step 3-02, and use a pry bar to push pistons (10) back into torque plate assembly (1). Reinstall brake pad assemblies (5). 18

2) If torque pins (4) of installed brake heads contact the disc, loosen bolts (3) and move pins away from disc, within limits of the O.D. groove in the pin. Make sure bolt fully engages groove in pin and torque bolt to 51 N-m (5.2kgf-m) (38 lb-ft).

14 20 19

22 9

Brake oil 13 7 16

3) After reinstall the disc brake assembly, complete bleed air in the line as the following procedure. Air bleeding procedure Connect a vinyl tube to the air bleeder nipple, and place an oil can to receive the oil. Apply parking brake to build-up pressure in the disc brake head and slightly loosen air bleeder valve (2) to slightly discharge oil. When the oil flows from the air bleeder nipple, close the nipple. Repeat this until there is no air in the oil.

4) Confirm the performance of the parking brake. Refer to Section 53 for the checking procedure.

54-27

12 21 17 15

13 Brake disc 95ZV54034

Parking Brake

95ZV

BRAKE 54

4.Procedure of replacing the brake pad assemblies.

Before starting work: - Stop the engine.

1 6 2 4

1) Connect a vinyl tube to air bleeder (2). Open bleeder.

3 7

2) Loosen bolts (3) and slide pins (4) back from center or brake head. Remove brake pad assemblies (5) down from brake head. 3) Using a wrench, rotate a 1/4 x 7/8 x 7 inch steel bar between disc and piston (10) face to retract the pistons into the piston bores of torque plate assembly (1).

14 20 19

22 9

4) Install new brake pad assemblies (5) by placing friction material next to disc and rotating into position in the brake head. 5) Lubricate O.D. of pins (4) with a good anti-seize compound and install in torque plate assembly (1). Push the pins toward the disc.

Brake oil 13 7 16

8 10

12 21 17 15

13 Brake disc

6) Tighten loosened bolts (3) until they seat in pin (4) grooves. This can be checked by limited axial movement of pins as the bolts are being seated in the grooves. After bolts are seated in grooves, tighten to 51 N-m (5.2 kgf-m) (38 lb-ft).

54-28

95ZV54034

Parking Brake

95ZV

BRAKE 54

Disassembling and reassembling parking brake (for front) 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 6

14 20 19

2 22 9 4 3 7

Brake oil 13 7

16 10

12 21 17 15

13 Brake disc 95ZV54035

+ 1. Torque plate assembly 2. Bleeder valve 3. Bolt 4. Pin 5. Pad assembly 6. Bolt 7. Washer 8. Cap, inlet

★ 9. Packing 10. Piston ★ 11. Boot ★ 12. Packing 13. Nut 14. Spring 15. Washer 16. Retaining ring

+ Not a repairable or replaceable item. ★ These items are not sold separately; The parts kit contains the following components; item 9, 11, 12, 20, 21, 22. Torque for assembly : #2: 25 N-m (2.6 kgf-m) (19 lb-ft) #3: 51 N-m (5.2 kgf-m) (38 lb-ft) #6: 54 N-m (5.5 kgf-m) (40 lb-ft) 54-29

17. Sleeve, adjuster 18. Guide, adjuster 19. Guide, adjuster ★ 20. Packing ★ 21. Ring, back-up ★ 22.Ring, back-up

Parking Brake

95ZV

BRAKE 54

2.Disassembling and reassembling parking brake (for front) 1) Loosen bolts (3) and slide pins (4) back from center of brake head, and then remove brake pad assemblies (5) from brake head. 2) Attach brake head to hydraulic pressure source. Restrain piston (10) opposite cap (8) with a C-clamp and apply hydraulic pressure until piston in inlet side is free of piston bore. Release pressure, disconnect brake head from pressure source and remove C-clamp. 3) Remove nut (13), washer (7) and press piston (10) from torque plate assembly (1) by pushing guide (19) towards center of brake head. 4) Remove bolts (6), washers (7) and cap (8) with attached guide (18). Remove packing (9) from cap (8). Note: Do not remove guide (18) from cap (8) except to replace if damaged. 5) Remove packings (9), (20), boots (11) and bleeder screws (2) from torque plate assembly (1).

1 6 2 4 3 7

14 20 19

22 9

Brake oil 13 7 16

6) Replace all rubber parts (9), (11), (12), (20), (21), (22), using kits specified in applicable parts catalog. 7) Clean, degrease, repair or replace damaged or excessively worn parts, as required. 8) Inspect brake pad assemblies (5) for excessive wear. Replace if lining is worn to wear limit. Refer to Section 55 for the wear limit. 9) Inspect pistons (10) for minor scratches or nicks and blend with crocus cloth. Replace pistons that are badly nicked or scratched. 10) Pins (4) that are deeply grooved should be replaced or rotated so grooved surface is opposite brake pad assembly (5) ends. 11) Reassemble brake head in reverse sequence of disassembly noting the following. 12) Lubricate packings (9), (12), (20) and O.D. of pistons (10) with hydraulic fluid specified in applicable brake head parts catalog sheet, prior to installation.

54-30

12 21 17 15

13 Brake disc 95ZV54034

Parking Brake

95ZV

13) Install packings (12) and boots (11) in piston bore grooves of torque plate assembly (1). Install packing (9) in groove of cap (8). Note: If guide (18) was removed from cap (8), clean the screw threads. Coat screw threads with Loctite ® sealant and reinstall in cap, tightening securely. 14) Install cap (8) with attached guide (18) and secure in place with four each bolts (6) and washers (7). 15) Assemble packing (20) over threaded end of guide (19) and seat against shoulder of guide. Insert guide through closed piston bore (opposite capped piston bore) with threaded end protruding from back of torque plate assembly (1). Secure in place with nut (13) and washer (7). 16) Center and insert pistons (10) with attached adjuster parts over guides (18), (19). Push pistons through previously installed boots (11) and packings (12) by hand. With pistons centered over guides, use a Cclamp or other suitable device to force pistons over guides and into piston bores. Note: Pistons (10) must be installed from center of brake head. Any other method will damage boots (11) and packings (12). 17) Install bleeder screws (2). 18) Install new brake pad assemblies (5) by placing friction material next to disc and rotating into position in the brake head. 19) Lubricate O.D. of pins (4) with a good anti-seize compound and install in torque plate assembly (1). Push the pins toward the disc. 20) Tighten the loosened bolts (3) until they seat in the pin (4) grooves. This can be checked by limited axial movement of pins as the bolts are being seated in the grooves. After bolts are seated in grooves, tighten to 51 N-m (5.2 kgf-m) (38 lb-ft). Note: Lubricate pins (4) with a corrosion resistant lubricant prior to installation, to facilitate next pin removal.

54-31

BRAKE 54

1 6 2 4 3 7

14 20 19

22 9

Brake oil 13 7 16

8 10

12 21 17 15

13 Brake disc 95ZV54034

MEMO

BRAKE GROUP 55 Disassembly and Reassembly Brake Valve ................................................................................................55-2 Service Brake .............................................................................................55-4 Parking Brake .............................................................................................55-5

55-1

Brake Valve

95ZV

BRAKE 55

Brake Valve 2 1 3 9 12

6 4 7 5 8 10 8 11 97ZV55001

Unit : mm (in.) Judgment standard No.

Item

Standard dimension

Solution

Tolerance Standard clearance Allowable clearance

Shaft

Hole +0.1 (0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

+0.1 (0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Clearance between pedal installation hole and bracket hole

ø 10 (0.3937)

-0.025~-0.075 (-0.0010~-0.0030)

Clearance between roller and pin

ø 10 (0.3937)

-0.025~-0.075 (-0.0010~-0.0030)

Outer diameter of roller

ø 30 (1.1811)

Replacement

0 -0.5 (-0.0197) Judgment standard

No.

Item

Standard dimension

Tolerance limit

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lb)

Free length mm (in)

Control spring

59.0 (2.3228)

49.7 (1.9567)

64 (6.5) (14.3)

57.5 (2.2638)

Control spring

27.2 (1.0709)

56.2 (2.2126)

Return spring

59.0 (2.3228)

58.0 (2.2835)

103 (10.5) (23.1)

62.1 (2.4449)

Balance spring

17.0 (0.6693)

15.0 (0.5906)

70 (7.1) (15.7)

16.2 (0.6378)

Spool return spring

31.5 (1.2402)

19.5 (0.7677)

17 (1.7) (3.7)

28.0 (1.1024)

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Bracket installation bolt tightening torque Cylinder installation bolt tightening torque

Plug tightening torque

176.4 N-m (18 kgf-m) (130 lb-ft)

Stopper bolt lock nut tightening torque

Solution

Installation load N (kgf) (lb)

Replacement

73.5 N-m (7.5 kgf-m) (54 lb-ft) Tightening 9.8 N-m (1.0 kgf-m) (7.2 lb-ft)

55-2

Brake Valve

95ZV

BRAKE 55

6 4 5

7 10

97ZV55002

Unit : mm (in.) Judgment standard No.

Item

Standard dimension

Tolerance Shaft

Hole

Solution

Standard clearance Allowable clearance

Clearance between pedal installation hole and bracket hole

ø 10 (0.3937)

+0.1 (0.0039) -0.025~-0.075 (-0.0010~-0.0030) 0

0.175~0.025 (0.0069~0.0010)

0.25(0.010)

Clearance between roller and pin

ø 10 (0.3937)

+0.1 (0.0039) -0.025~-0.075 (-0.0010~-0.0030) 0

0.175~0.025 (0.0069~0.0010)

0.25(0.010)

Outer diameter of roller

ø 30 (1.1811)

0 -0.5 (-0.0197)

Replacement

0.8(0.032)

Judgment standard No.

Item

Standard dimension

Tolerance limit

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lb)

Free length mm (in)

Control spring

59.0 (2.3228)

49.7 (1.9567)

64 (6.5) (14.3)

57.5 (2.2638)

Control spring

27.2 (1.0709)

56.2 (2.2126)

Return spring

65.0 (2.5591)

58.0 (2.2835)

71 (7.2) (15.9)

58.5 (2.3031)

Spool return spring

31.5 (1.2402)

19.5 (0.7677)

17 (1.7) (3.7)

28.0 (1.1024)

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Bracket installation bolt tightening torque Cylinder installation bolt tightening torque

Plug tightening torque

176.4 N-m (18 kgf-m) (130 lb-ft)

Stopper bolt lock nut tightening torque

Solution

Installation load N (kgf) (lb)

Replacement

73.5 N-m (7.5 kgf-m) (54 lb-ft) Tightening 9.8 N-m (1.0 kgf-m) (7.2 lb-ft)

55-3

Service Brake

95ZV

BRAKE 55

Service Brake

Air bleeder nipple

1, 5

Slide caliper

1, 5

Retainer

Steel plate

2, 5

Friction plate

95ZV55001

Unit : mm (in.) Judgment standard No.

Solution

Item Standard dimension

Tolerance

Wear limit

Thickness of steel plate

5.0 (0.1968)

0 (0)~ – 0.2 (– 0.0078)

4.4 (0.1732)

Thickness of friction plate

7.0 (0.2756)

±0.1 (±0.0039)

5.7 (0.2244)

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

29.0 (1.1417)

± 0.3 (± 0.0118)~ – 0.5 (– 0.0196)

25.1 (0.9881)

Outer dia.

(Work dimension) 375 (14.7638)

– 0.210 (– 0.0082)~ – 0.299 (– 0.0117)

–

Inner dia.

(Work dimension) 305 (12.0079)

+ 0 (+ 0)~ + 0.081 (+ 0.0032)

–

0.3 (0.0118) or less

–

0.30 (0.0118) and more

Free length

Installation length

Installation load (kgf)

54 (2.1260)

49 (1.9291)

29.3 (64 lbs)

Piston seal contact face

Distortion of steel and friction plate

Return spring

55-4

Replacement

–

Replacement

Parking Brake

95ZV

BRAKE 55

Parking Brake [Rear]

1 3

Clearance

Spring (4) released 4

95ZV55002

Unit : mm (in.) No.

Item

Judgment standard Standard dimension

Wear limit

6.15 (0.2421)

2.95 (0.1161)

Solution Replacement

Wear of lining

Deflection of drum

0.38 (0.0149) or more

Replacement

Lining inspection

Grease or oil on the lining

Replacement

Expansion of adjuster spring

There is clearance between the spring and the coil

Expansion of return spring

when the spring is released.

55-5

Replacement

Parking Brake

95ZV

BRAKE 55

[Front] Front differential gear

Brake disc

15.5 21.5

Brake pad

Disc brake

95ZV55003

Unit : mm (in.) Judgment standard No.

Item

Solution Standard dimension

Wear limit

Wear of brake disc

0.1 0.0039 13.5 +– 0.4 (0.5315 +– 0.0157 )

10.5 (0.4134)

Replacement

Wear of brake pad

15.5 (0.6102)

3.2 (0.1260)

Replacement

55-6

Notes