Hitachi ZW 140 150 Wheel Loader Workshop Manual - PDF DOWNLOAD by www.heydownloads.com

INTRODUCTION TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.

• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7084 FAX: 81-29-831-1162 E-mail: dc@hitachi-kenki.com

ADDITIONAL REFERENCES • Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

MANUAL COMPOSITION • This manual consists the Technical Manual and the Workshop Manual. • Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.

PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

•

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

•

NOTE: Indicates supplementary technical information or know-how.

UNITS USED • SI Units (International System of Units) are used in

Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L m3 kg N N N⋅m N⋅m

Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft

A table for conversion from SI units to other system units is shown below for reference purposees.

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-02

To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev

Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in operator`s manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices.

001-E01A-0001

SA-688

UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. • DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. • WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. • CAUTION indicates a potentially hazardous situation • which, if not avoided, may result in minor or moderate injury. • DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. • Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

•

NOTE indicates an additional explanation for an element of information. 002-E01A-1223

SA-1

SA-1223

SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the •

• • •

•

machine and all safety messages in operator`s manual. Safety signs should be installed, maintained and replaced when necessary. • If a safety sign or operator`s manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). Learn how to operate the machine and its controls correctly and safely. Allow only trained, qualified, authorized personnel to operate the machine. Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life. • Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy. The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

SA-003

003-E01B-0003

PREPARE FOR EMERGENCIES

004-E01A-0437

• Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone. SA-437

SA-2

SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438

PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

006-E01A-0434

SA-434

NSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. • In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.

007-E01A-0435 SA-435

SA-3

SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt

• •

• • • •

and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. Do not leave parts and/or tools lying around the operator’s seat. Store them in their specified locations. Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. Keep all flammable objects and/or explosives away from the machine. After using the ashtray, always cover it to extinguish the match and/or tobacco. Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. 524-E01A-0000

SA-4

SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

008-E01A-0439

SA-439

ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again. • Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one. 009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT • Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death. • Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine. • Before leaving the machine, close all windows, doors, and access covers and lock them up.

SA-5

SA-462

SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. • Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. • We recommend that the seat belt be replaced every three years regardless of its apparent condition.

SA-237

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. • Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.

SA-398

011-E01A-0398

HANDLE STARTING AIDS SAFELY Starting fluid:

• Starting fluid is highly flammable. • Keep all sparks and flame away when using it. • Keep starting fluid well away from batteries and cables.

• Remove container from machine if engine does not need starting fluid.

• To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location. • Do not incinerate or puncture a starting fluid container. 036-E01A-0293-3

SA-6

SA-293

SAFETY OPERATE SEAT

ONLY

FROM

OPERATOR'S

• Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral. • Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-431

012-E01B-0431

JUMP STARTING • Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to • • • •

follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual. The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. Never use a frozen battery. Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. SA-032 S013-E01A-0032 SA-032

SA-7

SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. • Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing. • Make a work plan. Use machines appropriate to the work and job site. • Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders. • When working on an incline or on a road shoulder, employ a signal person as required. • Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist. • When the footing is weak, reinforce the ground before starting work. • When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery. • Beware the possibility of fire when operating the machine near flammable objects such as dry grass.

015-E01B-0447

SA-8

SA-447

SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-521

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481 SA-481

SA-9

SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. 014-E01B-0427

SA-427

DRIVE SAFELY

• Beware of the possibility of slipping and/or turning over the machine when driving on a slope. • When driving on level ground, hold the bucket at mark (A) 400 to 500 mm above the ground as illustrated. • Avoid driving over any obstacles. • Drive the machine slowly when driving on rough terrain. • Avoid quick direction changes. Failure to do so may cause the machine to turn over. • If the engine stops while driving, the steering function becomes inoperative. Immediately stop the machine by applying the bake to prevent personal accident.

SA-448

019-E07A-0448

DRIVE MACHINE SAFELY (WORK SITE) • Before driving the machine, always confirm that the steering wheel/F-N-R lever direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions.

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. • When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in) (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-449

SA-450

• Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation. 019-E05B-0515 SA-451

SA-10

SAFETY DRIVE SAFELY WITH BUCKET LOADED • If the machine is incorrectly operated while driving with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions indicated below. • When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility. • Do not exceed the rated load capacity. Always operate the machine within the rated load capacity. • Avoid fast starts, stops, and quick turns. Failure to do so may result in personal injury and/or death. • Avoid rapid drive direction changes which could possibly cause personal injury and/or death.

SA-400

051-E02A-0400

DRIVE ON SNOW SAFELY • Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces. • The machine may slip more easily than expected on frozen snow surfaces even if the inclination is small. Reduce speed when driving. Avoid fast starts, stops and quick turns. • Road shoulder and/or set-up utilities covered with snow are difficult to locate. Be sure where they are before removing snow. • Be sure to use tire chains when driving on snow. • Avoid applying the brake for quick stops on snow. If a quick stop is required, lower the bucket to the ground.

SA-452

052-E02A-0452

TRAVEL ON PUBLIC ROADS SAFELY • This machine is not allowed to drive on public loads with the bucket loaded. • Be sure to empty the bucket. • Hold the bucket at mark (A) 400 to 500 mm above the road surface as illustrated.

053-E02A-0453

SA-453

SA-11

SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. • Lower the bucket to the ground. • Place the F-N-R lever in neutral, and put the park brake switch in the ON (parking brake) position. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the lock lever to LOCK position. • Block both tires and lower the bucket to the ground. • Position the machine to prevent rolling. • Park a reasonable distance from other machines.

SA-457

020-E02A-0516

SA-458

SA-12

SAFETY AVOID ACCIDENTS FROM BACKING UP AND TURNING • Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine. • Keep all personnel away from the machine by sounding the horn and/or using hand signals. Use extra care to be sure no one is in from the articulation area before turning the machine. • Keep windows, mirrors, and lights in good condition. • Reduce travel speed when dust, heavy rain, fog, etc., reduce the visibility. • In case good visibility is not obtained, use a signal person to guide you.

SA-383

021-E02A-0517

SA-312

SA-13

SAFETY AVOID POSITIONING ANYONE

BUCKET

OVER

• Never allow the bucket to pass over co-workers and/or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket may cause serious personal accidents and/or damage to the machine. • Avoid carrying the bucket over the co-workers to ensure safe operation.

023-E02A-0518

SA-518

AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: • Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine. • Reduce operating speeds to avoid tipping or slipping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable. • Reduce swing speed as necessary when swinging loads.

• Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable.

SA-14

SA-463

SAFETY NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.

026-E01A-0519

SA-519

DIG WITH CAUTION Before digging, check the location of cables, gas lines, and water lines.

027-E01A-0396

SA-396

PERFORM TRUCK LOADING SAFELY • Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and/or death. • Do not lower the bucket with the loader control lever in the FLOAT position. The bucket may free fall, possibly causing personal injury and/or death. • Always select a level surface for truck loading.

028-E01A-397

SA-397

SA-15

SAFETY AVOID POWER LINES Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length. 29-E01A-0455 SA-455

PRECAUTIONS FOR OPERATION • If the front attachment or any part of the machine comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result. • Take care to avoid coming in contact with overhead obstacles with the bucket or arm during operation.

PRECAUTIONS FOR LIGHTENING • The machine is vulnerable to lighting strikes. • In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine. • After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. • When using the machine for craning operations, be sure to comply with all local regulations. • Do not use damaged chains or frayed cables, sables, slings, or ropes. • Before craning, position the upperstructure with the position of the bucket support located on the chassis at the front. • Move the load slowly and carefully. Never move it suddenly. • Keep all persons well away from the load. • Never move a load over a person's head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. • Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. 032-E01A-0132

SA-16

SA-132

SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object.

031-E01A-0432

SA-432

PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Place the F-N-R lever in neutral, and put the park brake switch in the ON (parking brake) position. • Run engine at slow idle speed without load for 5 minutes. • Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Lower the lock lever to the LOCK position. • Close windows, roof vent, and cab door. • Lock all access doors and compartments. 033-E07B-0456

SA-17

SA-456

SAFETY STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

504-E01A-0034

SA-034

TRANSPORT SAFELY • Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe transportation. • Select an appropriate truck or trailer for the machine to be transported. • Be sure to use a signal person. • Always follow the following precautions for loading or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3. Use the low speed gear. 4. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again. 5. After loading, install the lock bar to securely hold the articulation mechanism. 6. Wedge the front and rear of tires. Securely hold the machine to the truck or trailer deck with wire ropes. Be sure to further follow the details described in the TRANSPORTING section.

035-E07A-0454

SA-18

Less than 15°

SA-454

SAFETY HANDLE FLUIDS SAFELY-AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. • Always stop the engine before refueling the machine. • Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flammable. • Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously. • Securely tighten the fuel and oil filler cap.

SA-018

034-E01A-0496

SA-019

SA-19

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Lower the lock lever to the LOCK position. 10. Lock bar connects the front and rear frames. 11. Allow the engine to cool.

SA-028

• If a maintenance procedure must be performed • •

• • • •

with the engine running, do not leave machine unattended. Never work under a machine raised by the lift arm. Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of operator`s manual. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. Disconnect battery ground cable (-) before making adjustments to electrical systems or before performing welding on the machine.

SA-312

SA-134

500-E02C-0520

SA-527

SA-20

SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. • Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. • Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

501-E01A-0287

SS2045102

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing the machine first. • Always lower the attachment to the ground before you work on the machine. • If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. 519-E01A-0527

SA-527

STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026

SA-026

SA-21

SAFETY SUPPORT MAINTENANCE PROPERLY • Explosive separation of a tire and rim parts can cause serious injury or death. • Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service. • Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure. • When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available. • Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts. • Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

SA-249

521-E02A-0249

PREVENT PARTS FROM FLYING • Travel reduction gears are under pressure. • As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. • GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure. 503-E03A-0344

SA-344

SA-22

SAFETY PREVENT BURNS Hot spraying fluids:

• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting any maintenance or inspection work. SA-225 505-E01B-0498

REPLACE CALLY

RUBBER

HOSES

PERIODI-

• Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019

SA-23

SA-019

SAFETY AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection. • If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031

507-E03A-0499

SA-292

SA-044

SA-24

SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses. Check for Shorts: • Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires. • Check before each shift or after eight(8) to ten(10) hours operation for missing or damaged terminal caps. • DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: • Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. Check Key Switch: • If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019

Check Heat Shields: • Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02A-0393

SA-25

SA-019

SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine.

518-E01A-0393

SA-393

BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. 509-E01A-0016

SA-016

PRECAUTIONS GRINDING

FOR

WELDING

AND

• Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. • Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering. 523-E01A-0818

SA-26

SA-818

SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fireresistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. • Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 511-E01A-0029

SA-27

SA-029

SAFETY BEWARE OF ASBESTOS DUST • Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. • Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air. • When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos. • Keep bystanders out of the work site during operation. • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts.

SA-029

PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. • Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first. • Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. • Loose terminals may produce sparks. Securely tighten all terminals.

SA-032

• Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the instructions described on the container for proper use when handling the refrigerant. • Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. • Never touch the refrigerant. 513-E01A-0405

SA-28

SA-405

SAFETY HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. • A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. • Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. • See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine.

SA-309

515-E01A-0309

DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source. • Air conditioning refrigerants escaping into the air can • damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. • Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

516-E01A-0226

SA-29

SA-226

SAFETY BEFORE RETURNING THE MACHINE TO THE CUSTOMER • After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced.

S517-E01A-0435 SA-435

SA-30

SECTION AND GROUP CONTENTS

SECTION 1 GENERAL Group 1 Precautions for disassembling and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank

WORKSHOP MANUAL SECTION 2 BODY Group 1 Cab Group 2 Counterweight Group 3 Center Hinge Group 4 Hydraulic Oil Tank Group 5 4-Unit Gear Pump Group 6 Control Valve Group 7 Pilot Valve Group 8 Pilot Shut-Off Valve Group 9 Fan Pump Group 10 Fan Motor

SECTION 3 TRAVEL SYSTEM

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

Group 1 Tire Group 2 HST Pump Group 3 HST Motor Group 4 Transmission Group 5 Axle Group 6 Propeller Shaft Group 7 Brake Valve Group 8 Charging Block Group 9 Steering Valve Group 10 Steering Cylinder Group 11 Priority Valve

SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder

TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL Group 1 Specifications Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Control System Group 2 ECM System Group 3 Hydraulic System Group 4 Electrical System

SECTION 3 COMPONENT OPERATION Group 1 Priority Valve Group 2 Control Valve Group 3 Fan Device Group 4 Steering Valve Group 5 Pilot Valve Group 6 Charging Block Group 7 Ride Control Valve Group 8 HST Pump Group 9 HST Motor Group 10 Transmission Group 11 Axle Group 12 Brake Valve Group 13 Others

TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Wheel Loader Test Group 5 Component Test Group 6 Adjustment

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Dr. ZX Group 3 e-Wheel Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Troubleshooting C Group 8 Electrical System Inspection

SECTION 1

GENERAL ⎯ CONTENTS ⎯ Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ............................................ W1-1-1 Maintenance Standard Terminology......... W1-1-7

Group 2 Tightening Tightening Torque Specifications ............. W1-2-1 Torque Chart............................................ W1-2-3 Piping Joint.............................................. W1-2-8 Periodic Replacement of Parts .............. W1-2-12

Group 3 Painting Painting ................................................... W1-3-1

Group 4 Bleeding Air from Hydraulic Oil Tank Bleeding Air from Hydraulic Oil Tank........ W1-4-1

4FCW-1-1

(Blank)

4FCW-1-2

GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING

DISASSEMBLING

Precautions for Disassembling and Assembling

• Clean the Machine

• Precautions for Disassembling

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

• Inspect the Machine Be sure to thoroughly understand all disassem-bling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts.

• Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.

W1-1-1

• To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.

GENERAL / Precautions for Disassembling and Assembling • Precautions for Assembling

Bleeding Air from Hydraulic System

• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine.

When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine.

• Bleeding Air from Hydraulic Pump

W1-1-2

• Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug.

GENERAL / Precautions for Disassembling and Assembling • Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

W1-1-3

W4GB-01-01-001

GENERAL / Precautions for Disassembling and Assembling Floating Seal Precautions A

1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check sliding surface (C) on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for deformation or hardening.

tears,

W105-03-05-019

breaks,

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air.

Correct

Incorrect

(2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with touch. (3) Check that O-ring (B) is not twisted, and that it is installed correctly on seal ring (A). (4) After installing the floating seal, check that seal ring surface (C) is parallel with seal mating face (D) by measuring the distances (C) and (D) at point (a) and (b), as illustrated. If these distances differ, correct O-ring (B) seating.

Correct

W105-03-05-020

Incorrect

C B

a=b

aâ&#x2030; b W110-03-05-004

W1-1-4

GENERAL / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.

Correct Eyehole Lifting Method

W102-04-02-016

Incorrect Eyehole Lifting Method

W105-04-01-008

Bent Sling

W1-1-5

W162-01-01-009

GENERAL / Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.

Damaged Appearance

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.

Broken Sewing Thread

W162-01-01-002

Scuffing

W162-01-01-003

Fuzz Broken Sewing Thread

W162-01-01-004

Broken Sewing Thread

W162-01-01-005

Broken Sewing Thread

Scoring

Fuzz

Separation of Belt

Scuffing

W162-01-01-006

W162-01-01-007

Broken Warp

W162-01-01-008

W1-1-6

GENERAL / Precautions for Disassembling and Assembling MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification.

“Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is impossible after exceeding this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.

W1-1-7

GENERAL / Precautions for Disassembling and Assembling (Blank)

W1-1-8

GENERAL / Tightening TIGHTENING TORQUE SPECIFICATIONS Bolts and Nuts of Machine: Standard Tightening Torque Chart Bolt Wrench NO. Locations Quantity Diameter Size 1 Front axle mounting bolt 24 8 36 2 Rear axle support mounting bolt(Front) 20 4 30 Rear axle support mounting bolt(Rear) 24 4 36 3 Wheel rim mounting bolt 24 48 36 4 Propeller shaft mounting bolt 10 20 17 5 Propeller shaft support bearing mounting bolt 16 2 24 6 Transmission mounting bolt; Bracket 16 8 24 7 Transmission mounting bolt; Cushion rubber 18 4 27 8 HST Motor mounting bolts 16 8 24 9 HST Pump mounting bolts 16 6 24 10 Engine mounting bolt; Bracket(Front) 12 12 17 Engine mounting bolt; Bracket(Rear) 12 6 17 11 Engine mounting bolt; Cushion rubber 16 4 24 12 Muffler mounting bolt ZW140 10 29 14 ZW150 12 2 17 13 Counterweight mounting bolt 30 4 46 14 Top center pen upper flange lock ZW140 24 1 36 ZW150 16 7 24 15 Bottom center pen lock ZW140 12 1 17 ZW150 16 1 24

W1-2-1

Torque N⋅m (kgf⋅m, lbf⋅ft) 785 (80, 580) 529 (54, 390) 890 (91, 660) 890 (91, 660) **74 (7.5, 55) 223.4 (23, 165) **205 (21, 151) 315 (32, 230) 232 (24, 170) 232 (24, 170) **81.2 (8, 60) **81.2 (24, 60) 232 (24, 170) **46.4 (4.7, 34) **81.2 (8.3, 60) 1176 (120, 870) 548.8 (56, 410) 224 (23, 165) 34.2 (3.5, 25) 86.9 (9, 64)

GENERAL / Tightening Bolt Wrench Torque Quantity Diameter Size N⋅m (kgf⋅m, lbf⋅ft) 16 Loader front pin lock ZW140 12 10 17 34.2 (3, 25) ZW150 16 3 24 86.9 (9, 64) 17 Steering cylinder pin lock 12 4 17 34.2 (3, 25) 18 Radiator frame mounting bolt 16 6 24 86.9 (9, 64) 19 Radiator mounting bolt 8 4 12 17.6 (1.8, 13) 20 Intercooler mounting bolt 8 2 12 17.6 (1.8, 13) 21 Oil cooler mounting bolt 10 4 14 36.2 (3.7, 27) 22 Air conditioner condenser mounting bolt 10 4 14 19.5 (2, 14) 23 Air conditioner compressor mounting bolt 8 4 12 25~30 (2~3, 18~22) 24 Cab cushion rubber 16 4 14 **205 (21, 151) 25 Bucket tooth mounting bolt ZW140 *1” 14 11/2 1068 (109, 790) (Optional) ZW150 *1” 16 11/2 1068 (109, 790) 26 Cutting edge mounting bolt ZW140 *1” 7 11/2 1068 (109, 790) ZW150 *1” 8 11/2 1068 (109, 790) As for the bolt Dia. with mark *, the dimension is indicated in inch. As for torque with mark **, LOCTITE #262 is used. NOTE: When tightening, apply lubricant in order to reduce friction coefficient of bolts and nuts. (Ex. white zinc B dissolved into spindle oil) Remove rust, dirt and dust before installing fasteners. NO.

Locations

W1-2-2

GENERAL / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. The make-do tools or parts are dangerous. As the incorrect size tools are slipped or removed, personal injury may be caused. Bolt Types Tighten the nuts or bolts correctly to the torque specifications. As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the machine or components. SA-040

Specified Tightening Torque Hexagon Wrench

Bolt Dia. (mm)

Wrench M4GB-07-121

Standard torque N⋅m

Size mm

Allowable torque range

kgf⋅cm

lbf⋅ft

N⋅m

kgf⋅cm

lbf⋅ft

1.15

11.7

0.8

0.92 to 1.38

9.4 to 14.1

0.7 to 1

2.36

24.1

1.7

1.89 to 2.82

19.3 to 28.8

1.4 to 2.1

7 8

3.98

40.6

2.9

3.20 to 4.79

32.6 to 48.8

2.4 to 3.5

9.81

100

7.2

7.84 to 11.7

79.9 to 119

5.8 to 8.6

19.5

199

14.5

15.6 to 23.4

159 to 239

11.5 to 17

34.2

349

27.5 to 41.1

280 to 419

20 to 30.5

561

43.9 to 65.9

448 to 672

32.5 to 49

86.9

886

69.5 to 104

709 to 1060

51 to 77

118

1200

94.6 to 142

965 to 1450

70 to 105

171

1740

126

136. to 204

1390 to 2080

100 to 150

234

2390

175

187 to 281

1910 to 2870

138 to 205

293

2990

215

234 to 352

2390 to 3590

170 to 260

436

4450

320

349 to 524

3560 to 5340

260 to 390

588

6000

430

471 to 706

4800 to 7200

350 to 520

810

8260

600

648 to 972

6610 to 9910

480 to 720

1030

10500

760

828 to 1250

8440 to 1270

610 to 920

1350

13800

1000

1080 to 1620

11000 to 16500

800 to 1200

W1-2-3

GENERAL / Tightening Hexagon Wrench

Bolt Dia. (mm)

Wrench M4GB-07-122

Standard torque

Size mm

Allowable torque range

N⋅m

kgf⋅cm

lbf⋅ft

N⋅m

kgf⋅cm

lbf⋅ft

3.06

31.2

2.3

2.45 to 3.67

25.0 to 37.4

1.8 to 2.7

6.30

64.2

4.6

5.03 to 7.55

51.3 to 77.0

3.7 to 5.6

10.6

108

7.8

8.50 to 12.7

86.7 to 130

6.3 to 9.4

26.1

266

20.9 to 31.0

213 to 319

15.5 to 23

52.1

531

41.6 to 62.5

424 to 638

31 to 46

91.2

930

73.1 to 109

745 to 1110

54 to 80

146

1490

108

117 to 177

1190 to 1800

86 to 131

232

2370

170

185 to 279

1890 to 2840

136 to 205

315

3210

230

252 to 379

2570 to 3860

185 to 280

452

4610

330

362 to 543

3690 to 5540

265 to 400

624

6360

460

499 to 749

5090 to 7640

370 to 550

782

7970

580

626 to 938

6380 to 9560

460 to 690

1160

11800

860

931 to 1400

9490 to 14300

690 to 1030

1570

16000

1160

1260 to 1880

12800 to 19200

930 to 1390

2160

22000

1590

1730 to 2590

17600 to 26400

1280 to 1910

2770

28200

2040

2210 to 3310

22500 to 33800

1630 to 2440

3600

36700

2660

2880 to 4320

29400 to 44100

2120 to 3190

W1-2-4

GENERAL / Tightening Hexagon Wrench

Bolt Dia. (mm)

Wrench M4GB-07-123

Standard torque

Size mm

Allowable torque range

N⋅m

kgf⋅cm

lbf⋅ft

N⋅m

kgf⋅cm

lbf⋅ft

4.49

45.8

3.3

3.60 to 5.39

36.7 to 55.0

2.7 to 4

9.24

94.2

6.8

7.40 to 11.1

75.5 to 113

5.5 to 8.2

15.6

159

11.5

12.6 to 18.7

128 to 191

9.3 to 13.5

38.3

391

30.7 to 46.0

313 to 469

22.5 to 34

76.5

780

61.2 to 91.8

624 to 936

45 to 68

133

1360

108 to 161

1100 to 1640

80 to 119

216

2200

159

173 to 258

1760 to 2630

128 to 190

341

3480

250

272 to 409

2770 to 4170

200 to 300

463

4720

340

370 to555

3770 to 5660

270 to 410

665

6780

490

534 to 797

5440 to 8130

390 to 590

918

9360

680

734 to 1100

7480 to 11200

540 to 810

1150

11700

850

919 to 1380

9370 to 14100

680 to 1020

1720

17500

1270

1370 to 2050

14000 to 20900

1010 to 1510

2300

23500

1700

1840 to 2770

18800 to 28200

1360 to 2040

3170

32300

2340

2540 to 3810

25900 to 38800

1870 to 2810

4060

41400

2990

3240 to 4860

33000 to 49600

2390 to 3580

5290

53900

3900

4240 to 6350

43200 to 64800

3130 to 4680

W1-2-5

GENERAL / Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. When tightening, apply lubricant in order to reduce friction coefficient of bolts and nuts. (Ex. white zinc B dissolved into spindle oil) 2. Torque tolerance is ±20 %. 3. Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of bolt hole. The bolts that are too short cannot develop sufficient tightening force. 4. The torques given in table on the previous page are for general use only. Do not use these torques if a different torque is given for a specific application. 5. Clean the nut and bolt threads and remove dirt or corrosion before installing.

Specified Tightening Torque Socket Bolt

Wrench

N⋅m

kgf⋅cm

lbf⋅ft

Size (mm)

4.49

45.8

3.3

9.24

94.2

6.8

15.6

159

11.5

Bolt Dia. (mm) 4 5 6 8

38.3

391

76.5

780

133

1360

216

2200

159

341

3480

250

463

4720

340

665

6780

490

918

9360

680

1150

11700

850

1720

17500

1270

2300

23500

1700

3170

32300

2340

4060

41400

3000

5290

53900

3900

Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. Equally tighten upper and lower alternately

Tighten diagonally 1

1.4

6 4 2.3

Tighten from center and diagonally

5 2

W105-01-01-003

W1-2-6

GENERAL / Tightening Precautions for Spilt Flange IMPORTANT: 1. Clean the sealing surfaces. Check if the scratches / roughness that cause leaks and damage of O-ring are found. 2. Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces. When installing O-ring into a groove, use grease in order to hold O-ring in place. 3. While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring. 4. Tighten the bolts alternately and diagonally, in order to ensure even tightening to the specified torque. 5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.

W105-01-01-015

Incorrect

W105-01-01-016

W105-01-01-008

Incorrect

Correct

Nut and Bolt Locking

• Lock Plate IMPORTANT: Do not reuse the lock plates. Do not try to bend the same point twice. • Split Pin IMPORTANT: Do not align the holes in the bolt and nut while loosening. Tighten and align anytime. Do not reuse the split pins. • Wire IMPORTANT: Attach a wire to bolts in the bolt-tightening direction. Do not reuse the wire.

Do not bend it round

Bend along edge sharply Correct

Correct

Incorrect

Bend along edge sharply W105-01-01-009

Correct

Incorrect

Loosen

Incorrect

Tighten

W105-01-01-010

W1-2-7

GENERAL / Tightening PIPING JOINT

IMPORTANT: The torques given in the chart below are for general use only. Do not use these torques if a different torque is given for a specific application.

M202-07-051

Joint Body

Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

37° 30°

IMPORTANT: 1. Do not over-tighten nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifications. 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting.

Description 30° male

37° female

Male Union Joint

Female Union Joint W105-01-01-017

Wrench Size mm Union Nut 17 19 22 27 32 36 41 17 19 22 27 32 36 41

Wrench Size mm

Tightening Torque

Hose Fittings 17 19 22 27 32 36 41 14 17 19 22 27 32 36

N⋅m (kgf⋅m, lbf⋅ft) 24.5 (2.5, 18) 29.5 (3.0, 21.5) 39 (4.0, 28.5) 93 (9.5, 69) 137 (14.0, 101) 175 (18.0, 129) 205 (21.0, 151) 24.5 (2.5, 18) 29.5 (3.0, 21.5) 39 (4.0, 28.5) 93 (9.5, 69) 137 (14.0, 101) 175 (18.0, 129) 205 (21.0, 151)

NOTE: Tightening torque of 37° male coupling without union is similar to tightening torque of 37° female.

W1-2-8

GENERAL / Tightening O-ring Seal Joint O-ring (6) is installed against the end face of adapter (7) and seals pressure oil. IMPORTANT: 1. Replace O-ring (6) with a new one when reinstalling. 2. Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Do not damage O-ring groove (8) or sealing surface (10) in adapter (7). Damage to O-ring (6) may cause oil leakage. 4. If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in place.

8 10

Joint Body M104-07-033

Wrench Size mm Union Nut 19 22 27 32 36 41 46

W1-2-9

Wrench Size mm Hose Fittings 17 19 22 27 30,32 36 41

Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 29.5 (3.0,21.5) 69 (7.0,51) 93 (9.5,69) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151) 205 (21.0,151)

GENERAL / Tightening Screw-In Connection Depending on types of screw and sealing, different types of screw-in connection are used.

IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. (In general, the screw-in connection of male tapered thread is used except when measuring.))

Seal Tape Application Seal tape is used in order to seal clearances between male and female threads so that any leaks between threads may be prevented. Apply just enough seal tape to fill up thread clearances. Do not overwrap.

• Application Procedure Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave one to two pitch threads uncovered. Wrap the seal tape in the same direction as the threads.

30°

Male Tapered Thread Male Straight Thread

W105-01-01-018

Wrench Size mm Hose Fittings 19 22 27 36 41 50 60

Male Tapered Thread Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) FC material SS material 14.5 (1.5,10.5) 34 (3.5,25) 29.5 (3.0,21.5) 49 (5.0,36) 49 (5.0,36) 93 (9.5,69) 69 (7.0,51) 157 (16,116) 108 (11,80) 205 (21,151) 157 (16,116) 320 (33,235) 195 (20,144)

Internal Thread

External Thread

Clearance

Low-Pressure-Hose Clamp Tightening W105-01-01-019

Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

Leave one to two pitch threads uncovered

M114-07-041

T-Bolt Type Band Clamp

M114-07-042

W1-2-10

Worm Gear Type Band Clamp

M114-07-043

GENERAL / Tightening Connecting Hose Correct

Incorrect

CAUTION: When replacing the hoses, use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose from being kinked.

W105-01-01-011

Correct

Incorrect Rubbing Against Each Other

Take necessary measures to protect hoses from rubbing against each other. If the hoses rub against each other, wear to the hoses may result and lead to hose rupture. Take care so that the hoses do not come into contact with the moving parts or sharp objects.

W105-01-01-012

Correct

Incorrect Clamp

Clamp

Rubbing Against Each Other W105-01-01-013

Incorrect

Rubbing Against Each Other

Correct

Clamp W105-01-01-014

W1-2-11

GENERAL / Tightening PERIODIC REPLACEMENT OF PARTS 1. Periodic Replacement Parts (1) (Safety Inspection Object) In order to ensure safe operation, the users must conduct daily checking before starting operation and periodic inspection of the machine by law. In order to ensure safe operation, conduct periodic replacement of the security parts below. Periodic Replacement Parts Fuel hose (Fuel tank to filter) Fuel hose (Fuel tank to injection pump) Engine Oil filter hose (Engine to oil filter) Heater hose (Heater to engine) Breake valve seals (Rubber parts) Wet type brake (D-ring for piston) Brakes Accumulator Stop liqht switch Brake hose Steering hose Steering Machanism Steering cylinder seals (Rubber parts) Steering valve seals (Rubber parts) Pump suction hose Pump delivery hose Base Machine Hydraulic oil tank return hose Hydraulic Hydraulic oil cooler line hose System Lift arm cylinder line hose Front Bucket cylinder line hose Attachment Pilot hose Cab Seat belt 1. Theses parts deteriorate, fatigue and weaken with time. As it is very difficult to gauge extent of the damaged parts according to periodic inspection, replace them with the new ones regardless of defect in the interval. 2. If any of these parts are found to be defective regardless of the interval, repair or replace these parts.

W1-2-12

Replacement Intervals Every 2 years Every 2 years Every 2 years Every 2 years Every 1 years Every 4 years Every 2 years Every 2 years Every 2 years Every 2 years Every 4 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 3 years

GENERAL / Tightening 2. Periodic Replacement Parts (2) In order to ensure safe operation, conduct periodic inspection of the machine.In order to ensure safe operation further, conduct periodic replacement of the parts below specially related to safety. Theses parts deteriorate, fatigue and weaken with time. This may cause serious personal/impersonal hazard. As it is very difficult to gauge remnant life of these parts according to driving sensation or appearance inspection , replace them with the new ones regardless of defect in the interval. If any of these parts are found to be defective according to periodic inspection regardless of the interval, replace these parts Replacement Parts Name Pump Hydraulic system Working system

Driverâ&#x20AC;&#x2122;s seat

Seat belt

Suction hose Delivery hose Bucket cylinder hose Pilot hose Lift arm cylinder line hose Hydraulic oil tank return hose Hydraulic oil cooler line hose Seat belt

NOTE: Replace O-rings and the gaskets when replacing the hoses.

W1-2-13

Replacement Intervals Every 2 years

Every 2 years

Every 3 years

GENERAL / Tightening (Blank)

W1-2-14

GENERAL / Painting PAINTING 1

9 10 11 12 13 14

16 W4FC-01-03-001

Surfaces to Be Painted Painting Color 1 Front Attachment YR-01[TAXI Yellow] 2 Front Fender YR-01[TAXI Yellow] 3 Lamp Bracket Warm Gray 4 Inside of Cab HG Beige Deep 5 Outside of Cab HG Beige Deep Cockpit and mounting parts 6 HG Beige Deep (Valve control box and so on) 7 Tail Pipe Not painted 8 Pre-Cleaner Not painted 9 Side Cover Not painted 10 Full Fender HG Beige Deep IMPORTANT: When cleaning around front attachment or cylinder, etc. fitted with HN bushing, do not pour washing liquid directly on the bushing. The ambient temperature should not exceed 70 °C (158 °F) when painting and drying.

11 12 13 14 15 16 17 18 19 20

W1-3-1

Surfaces to Be Painted Rear Grill Lower Cover Counter weight Battery Box Rim Fender Cover Step Cover Articulate Lock Bar Cockpit Skirt

Painting Color Not painted HG Beige Deep YR-01[TAXI Yellow] YR-01[TAXI Yellow] YR-01[TAXI Yellow] Not painted Warm Gray YR-01[TAXI Yellow] Red HG Beige Deep

GENERAL / Painting

7 10 9 11 13

11 12 13 14 15 16 17 18 19 20

W1-3-2

Surfaces to Be Painted Rear Grill Lower Cover Counter weight Battery Box Rim Fender Cover Step Cover Articulate Lock Bar Cockpit Skirt

W4FC-01-03-002

Painting Color Not painted HG Beige Deep YR-01[TAXI Yellow] YR-01[TAXI Yellow] YR-01[TAXI Yellow] Not painted Warm Gray YR-01[TAXI Yellow] Red HG Beige Deep

GENERAL / Bleeding Air From Hydraulic Oil Tank BLEEDING AIR FROM HYDRAULIC OIL TANK CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before removing hydraulic or other lines. Hot hydraulic oil just after operation may spout and cause severe burns. Wait for oil in order to cool before starting any work. Do not turn the cap on hydraulic oil tank quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap. Preparation 1. Park the machine on a solid, level surface. Lower the front attachment onto the ground.

W4GB-01-01-001

2. Stop the engine. Push valve (1) on hydraulic oil tank (3) and release any remaining pressure.

3. Remove cap (2) on hydraulic oil tank (3). 2

4. Install a vacuum pump to the hole without cap (2). Operate the vacuum pump and maintain negative pressure in hydraulic oil tank (3). NOTE: Run the vacuum pump continuously while working.

W4FC-01-04-001

Vacuum Pump Hose

Adapter

W562-02-03-008

W1-4-1

GENERAL / Bleeding Air From Hydraulic Oil Tank (Blank)

W1-4-2

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

SECTION 2

BODY — CONTENTS — Group 1 Cab

Group 7 Pilot Valve

Removal and Installation of Cab ................. W2-1-1

Group 2 Counterweight Removal and Installation of Counterweight ........................................... W2-2-1

Group 3 Center Hinge Disassembly of Center Hinge (ZW140) ...... W2-3-1 Assembly of Center Hinge (ZW140) ........... W2-3-6 Disassembly of Center Hinge (ZW150) .... W2-3-10 Assembly of Center Hinge (ZW150) ......... W2-3-14

Group 4 Hydraulic Oil Tank Removal and Installation of Hydraulic Oil Tank ..................................... W2-4-1

Removal and Installation of Joy-Stick Type Pilot Valve..........................W2-7-1 Removal and Installation of Pilot Valve (Two-Lever Type) .....................W2-7-6 Disassembly of Pilot Valve (Two-Lever Type).....................................W2-7-12 Assembly of Pilot Valve (Two-Lever Type).....................................W2-7-20 Maintenance Standard ..............................W2-7-28 Disassembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional)................W2-7-30 Assembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional)................W2-7-34

Group 8 Pilot Shut-Off Valve

Group 5 4-Unit Gear Pump Removal and Installation of 4-Unit Gear Pump ................................................ W2-5-1 Disassembly of 4-Unit Gear Pump ............. W2-5-6 Assembly of 4-Unit Gear Pump ................ W2-5-14

Removal and Installation of Pilot Shut-Off Valve....................................W2-8-1 Disassembly of Pilot Shut-Off Valve ............W2-8-6 Assembly of Pilot Shut-Off Valve.................W2-8-8

Group 9 Fan Pump

Group 6 Control Valve Removal and Installation of Control Valve .. W2-6-1 Disassembly of Control Valve ..................... W2-6-4 Assembly of Control Valve .......................... W2-6-8

Removal and Installation of Fan Pump .......W2-9-1 Structure of Fan Pump ................................W2-9-4

Group 10 Fan Motor Removal and Installation of Fan Motor......W2-10-1 Structure of Fan Motor...............................W2-10-6

4FCW-2-1

(Blank)

4FCW-2-2

BODY / Cab REMOVAL AND INSTALLATION OF CAB CAUTION: Hydraulic pressure is accumulated in the hydraulic system by an accumulator. Reduce pressure according to the work point for each before disconnecting the main, steering, and brake system hoses. CAUTION: Before doing any work, lower the lift arm and place the bucket onto the ground. Stop the engine. Release the remaining pressure while operating the control lever with the front control lever lock in the Unlock position. Removal 1. Loosen bolt (2) from the negative terminal of battery (1). Disconnect cable (3) from battery (1). : 12 mm 1

W4FC-02-01-001

2. Open door (4).

W4FC-03-09-002

W2-1-1

BODY / Cab Front Control Lever Lock

3. Operate handle (7) and move lever stand (6) forward.

4. Remove screws (9) (6 used) from covers (5) (2 used). Remove covers (5) (2 used) from bracket (8).

5. Remove bolt (12) and washer (13) from clip (14). Remove clip (14) from hose (11). : 14 mm

W4FC-02-07-015

6. Disconnect hoses (11) (6 used) from pilot valve (10). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm

11 12, 13 14

7. Disconnect hoses (16) (4 used) from pilot shut-off valve (15). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm

W4FC-02-07-009

W4FC-02-08-001

8. Remove bolts (17) (8 used) and washers (18) (8 used) from right and left brackets (22) (4 used). Remove rear fenders (21) (2 used) from brackets (22) (4 used). : 14 mm

17, 18

9. Remove bolts (20) (4 used) from right and left covers (23) (2 used). Remove covers (23) (2 used) from floor plate (19). : 14 mm

W2-1-2

W4FC-02-01-008

BODY / Cab 24

10. Remove bolts (24) (5 used) from covers (25) (2 used). Remove covers (25) (2 used) from floor plate (19). : 14 mm

11. Remove clip (27) from connector (26). Disconnect connector (26).

W4FC-03-07-001

12. Disconnect connectors (28) (4 used).

W4FC-02-01-005

13. Remove bolts (29) (8 used) from covers (30) (3 used). Remove covers (30) (3 used) from floor plate (19). : 14 mm

29 19 30

W4FC-02-04-001

14. Disconnect connectors (31) (2 used).

15. Disconnect hoses (38) (2 used) from washer tank (32). Cap the open ends. 16. Remove bolts (35) (2 used), spring washers (36) (2 used), and washers (37) (2 used) from bracket (33). Remove the bracket (33) assembly from frame (34). : 17 mm

34 35, 36, 37

W4FC-02-04-003

W2-1-3

BODY / Cab 39

17. Remove clip (40) from connector (39). Disconnect connector (39).

18. Disconnect connectors (41) (4 used).

W4FC-02-01-004

19. Remove bolt (43) from duct (44). Remove duct (44) from bracket (42). : 14 mm

42 43

W4FC-03-09-008

20. Disconnect hoses (46) (5 used) from steering valve (45). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 27 mm 45

W4FC-03-09-009

21. Disconnect hoses (47) (6 used) from brake valve (48). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 22 mm, 27 mm

W2-1-4

W4FC-03-07-003

BODY / Cab 49

22. Open cover (49).

W4FC-02-01-006

23. Disconnect hoses (51) (2 used) from receiver tank (52). Cap the open ends. : 10 mm, 24 mm

24. Disconnect connector (50). 52

W4FC-02-01-011

25. Open cover (53).

W4FC-02-01-007

26. Disconnect hoses (55) (2 used) from heater pipings (54). Cap the open ends.

W4FC-02-01-012

W2-1-5

BODY / Cab CAUTION: Cab (58) weight: 960 kg (2100 lb)

56 57

27. Remove caps (56) (4 used) and plates with the packing attached (57) (4 used) from the top of cab (58). Install eyebolts (M16, Pitch 2.0 mm) (4 used) to cab (58).

28. Attach a nylon sling onto the eyebolt (4 places). Hoist and hold cab (58). 29. Remove nuts (61) (2 used) and washers (60) (2 used) from cockpit mounts (59) (2 used). : 24 mm

W4FC-02-01-002

30. Remove bolts (63) (2 used), plates (62) (2 used), and spacers (64) (2 used) from the bottom front of cab (58). : 30 mm

63 65

31. Remove bolts (65) (2 used) and spacers (69) (2 used) from the bottom rear of cab (58) and frame (34). : 46 mm

W4FC-02-01-009

62 58

66, 67, 68

32. Remove nuts (67) (2 used) and washers (68) (2 used) from cockpit mounts (66) (2 used). : 24 mm

34 69

W4FC-02-01-010

CAUTION: Cab (58) weight: 960 kg (2100 lb) 33. Hoist and remove cab (58) from frame (34).

34 34

W4FC-02-01-003

W2-1-6

BODY / Cab Installation CAUTION: Cab (58) weight: 960 kg (2120 lb) 58

1. Attach a nylon sling onto the eyebolts installed to cab (58) (4 places). Hoist cab (58). Fit cab (58) to the mounting hole on frame (34).

34 34

W4FC-02-01-003

2. Apply LOCTITE #262 onto bolts (65) (2 used). Install the bottom rear of cab (58) to frame (34) with spacers (69) (2 used) and bolts (65) (2 used). : 46 mm : 1570 N⋅m (160 kgf⋅m, 1160 lbf⋅ft)

66, 67, 68

3. Apply LOCTITE #262 onto the thread part of cockpit mounts (66) (2 used). Install cockpit mounts (66) (2 used) to frame (34) with nuts (67) (2 used) and washers (68) (2 used). : 24 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

4. Apply LOCTITE #262 onto bolt (63). Install the bottom front of cab (58) to frame (34) with spacers (64) (2 used), plates (62) (2 used), and bolts (63) (2 used). : 30 mm : 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft) 5. Apply LOCTITE #262 onto the thread part of cockpit mounts (59) (2 used). Install cockpit mounts (59) (2 used) to frame (34) with nuts (61) (2 used) and washers (60) (2 used). : 24 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

W2-1-7

34 69

W4FC-02-01-010

59 60

34 63

W4FC-02-01-009

BODY / Cab 6. Remove eyebolts (4 used) from the top of cab (58). Install caps (56) (4 used) and plates with the packing attached (57) (4 used) to cab (58).

56 57

W4FC-02-01-002

7. Connect connector (50).

8. Connect hoses (51) (2 used) to receiver tank (52). : 10 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2.4 to 3.1 lbf⋅ft) : 24 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)

9. This machine uses new fron R134a as refrigerant. Check for any gas leakage after adding gas for the required amount. W4FC-02-01-011

Type

Refrigerant No.

HFC

R134a

Amount kg (lb) 1.05±0.05 (2.31±0.11) 49

10. Shut cover (49).

W4FC-02-01-006

11. Connect hoses (55) (2 used) to heater pipings (54). 55

W4FC-02-01-012

W2-1-8

BODY / Cab 12. Shut cover (53).

W4FC-02-01-007

13. Connect hoses (47) (6 used) to brake valve (48). : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W4FC-03-07-003

14. Connect hoses (46) (5 used) to steering valve (45). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

15. Install cover (44) to bracket (42) with bolt (43). : 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W4FC-03-09-009

42 43

W4FC-03-09-008

W2-1-9

BODY / Cab 39

16. Connect connectors (41) (4 used).

17. Connect connector (39). Secure connector (39) with clip (40).

W4FC-02-01-004

18. Install the bracket (33) assembly to frame (34) with bolts (35) (2 used), spring washers (36) (2 used), and washers (37) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

34 35, 36, 37

19. Connect hoses (38) (2 used) to washer tank (32). 20. Connect connectors (31) (2 used) to washer tank (32).

21. Install covers (30) (3 used) to floor plate (19) with bolts (29) (8 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W4FC-02-04-003

29 19 30

W4FC-02-04-001

22. Connect connectors (28) (4 used).

23. Connect connector (26). Secure connector (26) to cab (58) with clip (27).

W4FC-02-01-005

W2-1-10

BODY / Cab 24

24. Install covers (25) (2 used) to floor plate (19) with bolts (24) (5 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

25. Install right and left covers (23) (2 used) to floor plate (19) with bolts (20) (4 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

17, 18

W4FC-03-07-001

17, 18

26. Install rear fenders (21) (2 used) to right and left brackets (22) (4 used) with bolts (17) (8 used) and washers (18) (8 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 27. Connect hoses (16) (4 used) to pilot shut-off valve (15). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)

W4FC-02-01-008

W4FC-02-08-001

28. Connect hoses (11) (6 used) to pilot valve (10). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)

29. Connect hoses (11) (6 used) with clip (14). Install clip (14) to bracket (8) with bolt (12) and washer (13). : 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

11 12, 13 14 8

W2-1-11

W4FC-02-07-009

BODY / Cab 30. Install covers (5) (2 used) to bracket (8) with screws (9) (6 used).

31. Operate handle (7) and move lever stand (6) backward.

W4FC-02-07-015

32. Shut door (4).

W4FC-03-09-002

33. Connect cable (3) to the negative terminal of battery (1) with bolt (2). : 12 mm : 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft) 1

W2-1-12

W4FC-02-01-001

BODY / Counterweight REMOVAL AND COUNTERWEIGHT

INSTALLATION

Removal IMPORTANT: If removing counterweight (4) with rear grill (1) closed, rear grill (1) may be damaged. 1. Open rear grill (1). 1

W4FC-02-10-001

CAUTION: Counterweight (4) weight: ZW140: 670 kg (1480 lb) ZW150: 1160 kg (2560 lb) 2. Attach a wire rope onto counterweight (4). Hoist and hold counterweight (4).

2, 3 4

3. Remove bolts (2) (4 used) and washers (3) (4 used) from counterweight (4). Remove counterweight (4) from frame (5). 5 W4FC-02-02-001

W2-2-1

BODY / Counterweight Installation CAUTION: Counterweight (4) weight: ZW140: 670 kg (1480 lb) ZW150: 1160 kg (2560 lb) 2, 3

1. Attach a wire rope onto counterweight (4). Hoist counterweight (4). Align counterweight (4) with the mounting hole on frame (5). 2. Install counterweight (4) to frame (5) with bolts (2) (4 used) and washers (3) (4 used). : 46 mm : 1078 to 1274 N⋅m (110 to 130 kgf⋅m, 800 to 940 lbf·ft)

5 W4FC-02-02-001

3. Close rear grill (1). 1

W4FC-02-10-001

W2-2-2

BODY / Center Hinge DISASSEMBLY OF CENTER HINGE (ZW140) A

Upper Hinge Pin

W4FC-02-03-003

8 1

9a, 9b 10 11

12 7

14 13

W4FC-02-03-001

Section A

Lower Hinge Pin

19 20 7

21 11

22 7 W4FC-02-03-002

Section B 123456-

Front Frame Bolt (6 Used) Dust Seal (2 Used) Flange Bolt Bushing

789a 9b 10 11 -

Rear Frame Cap Shim (4 Used) Shim Bearing Grease Fitting (2 Used)

12 13 14 15 16 17 -

W2-3-1

Bushing Nut Pin Washer (6 Used) Bushing Pin

18 19 20 21 22 -

Bolt Washer Plate Retaining Ring Bearing

BODY / Center Hinge

Upper Hinge Pin

W4FC-02-03-003

14 13

W4FC-02-03-001

Section A

Lower Hinge Pin

19 20 7

7 Section B

W2-3-2

W4FC-02-03-002

BODY / Center Hinge Disassembly of Center Hinge (ZW140) CAUTION: The center hinge is required to disassemble for the major maintenance work such as removal of the front frame from the rear frame. At this time, move the machine to the workshop.

2. Remove nut (13) from bolt (5). Remove bolt (5) and flange (4) from rear frame (7). Remove pin (14) from rear frame (7). : 36 mm 4

Preparation When disassembling the center hinge, set the machine to the following conditions.

1. Remove the cab and the cockpit. 2. Remove the connecting parts between the front frame and the rear frame. • Propeller shaft • Steering cylinder • Hydraulic hose • Brake piping • Harness

14 13

W4FC-02-03-005

3. Remove bolt (18), washer (19), and plate (20) from pin (17). Remove pin (17) from rear frame (7).

Removal of Hinge Pin 1. Support the front frame and the rear frame by using the solid support.

19 20 17 7 W4FC-02-03-006

W4GB-02-03-002

4. Remove bushing (6) from rear frame (7). (Remove bushing (6) after cutting by gas or using arc welding.)

W2-3-3

BODY / Center Hinge

Upper Hinge Pin

W4FC-02-03-003

8 1

9a, 9b 10

12 7

W4FC-02-03-001

Section A

Lower Hinge Pin

7 1

22 7 Section B

W2-3-4

W4FC-02-03-002

BODY / Center Hinge CAUTION: The front frame (1) assembly weight: 4350 kg (9590 lb) 5. Attach a nylon sling onto front frame (1). Hoist front frame (1). Remove front frame (1) from rear frame (7). 6. Remove bushing (12) from front frame (1). 7. Remove bolts (2) (6 used) and washers (15) (6 used) from cap (8). Remove cap (8), shims (9a) (4 used), and shim (9b) from front frame (1). : 17 mm 8. Remove dust seals (3) (2 used) from cap (8) and front frame (1). 9. Remove bearing (10) from front frame (1). 10. Remove retaining ring (21) and bearing (22) from front frame (1). 11. Remove bushings (16) (2 used) from rear frame (7).

W2-3-5

BODY / Center Hinge ASSEMBLY OF CENTER HINGE (ZW140) A

Upper Hinge Pin

W4FC-02-03-003

8 1

9a, 9b 10 11

12 7

14 13

W4FC-02-03-001

Section A

Lower Hinge Pin

19 20 7

21 11

22 7 W4FC-02-03-002

Section B 123456-

Front Frame Bolt (6 Used) Dust Seal (2 Used) Flange Bolt Bushing

789a 9b 10 11 -

Rear Frame Cap Shim (4 Used) Shim Bearing Grease Fitting (2 Used)

12 13 14 15 16 17 -

W2-3-6

Bushing Nut Pin Washer (6 Used) Bushing Pin

18 19 20 21 22 -

Bolt Washer Plate Retaining Ring Bearing

BODY / Center Hinge Assembly of Center Hinge (ZW140) IMPORTANT: Check the direction of dust seal (3). Install dust seal (3) with the wider rubber side facing the unpainted surfaces of cap (8) and front frame (1). 1. Apply LOCTITE #262 onto the outer surface of dust seals (3) (2 used). Lightly tap and insert dust seal (3) into cap (8) by using a hammer. Wipe out the stick-out LOCTITE #262 by using a waste. Install dust seal (3) to front frame (1) in the same way. 1, 8

6. Install shims (9a) (4 used) and shim (9b) to the upper hinge part of front frame (1). Apply LOCTITE #262 onto bolts (2) (6 used). Install cap (8), bolts (2) (6 used), and washers (15) (6 used) to front frame (1). : 17 mm : 62.6±3.8 N⋅m (6.4±0.38 kgf⋅m, 46±2.8 lbf⋅ft) 7. Install pin (14) to the upper hinge part of front flame (1). Check the spherical part of bearing (10) can move in all directions. If it is not able to move, add shim (9a) and repeat from item 6. 8. Remove pin (14) from front flame (1). 9. Tap the position between cap (8) and dust seals (3) (2 used) by using an iron nail.

Face the lip outside (the painted surface of the cap). W4GB-02-03-005

10. Install bushing (12) to front frame (1).

2. Install bearing (10) to the upper hinge part of front frame (1). 3. Add grease to the inside of bearing (10) through grease fitting (11) while rotating bearing (10). 4. Install bearing (22) and retaining ring (21) to the lower hinge part of front frame (1). 5. Add grease to the inside of bearing (22) through grease fitting (11) while rotating bearing (22).

W2-3-7

BODY / Center Hinge

Upper Hinge Pin

W4FC-02-03-003

14 13

W4FC-02-03-001

Section A

Lower Hinge Pin

19 20 7

Section B

W2-3-8

W4FC-02-03-002

BODY / Center Hinge 11. Install bushings (16) (2 used) to the lower hinge part of rear frame (7). CAUTION: The front frame (1) assembly weight: 4350 kg (9590 lb) 12. Attach a nylon sling onto front frame (1). Hoist front frame (1). Fit the pin (14, 17) holes on front frame (1) and rear frame (7). 13. Install pin (14), bushing (6), and flange (4) to the upper hinge part. 14. Apply LOCTITE #262 onto bolt (5). Install front frame (1) to rear frame (7) with bolt (5) and nut (13). : 36 mm : 548.8±39.2 N⋅m (56±4 kgf⋅m, 400±29 lbf⋅ft) 15. Install pin (17) to the lower hinge part. Install pin (17) to rear frame (7) with bolt (18), washer (19), and plate (20). : 17 mm : 62.6±3.8 N⋅m (6.4±0.4 kgf⋅m, 46±2.8 lbf⋅ft) 18

19 20 17 7 W4FC-02-03-006

W2-3-9

BODY / Center Hinge DISASSEMBLY OF CENTER HINGE (ZW150) A

W4FC-02-03-003

Upper Hinge Pin

4 5 17 6 7

8 9 15

11 Section A

Lower Hinge Pin

W4GD-02-03-002

12 19

20 21

28 27

25 24

Section B 1234567-

Bolt (4 Used) Washer (7 Used) Bolt (3 Used) Flange Shim (2 Used) Bolt (6 Used) Cap

8910 11 12 13 14 -

Shim (2 Used) Grease Fitting (2 Used) Cap Bushing Rear Frame Pin Dust Seal (2 Used)

15 16 17 18 19 20 21 -

W2-3-10

Front Frame Bearing Bushing Pin Bolt Washer Plate

W4GD-02-03-003

22 23 24 25 26 27 28 -

Dust Seal (2 Used) Bearing Bushing (2 Used) Cap Shim (2 Used) Cap Bolt (6 Used)

BODY / Center Hinge Disassembly of Center Hinge (ZW150) CAUTION: The center hinge is required to disassemble for the major maintenance work such as removal of the front frame from the rear frame. At this time, move the machine to the workshop.

2. Remove bolts (3) (3 used), bolts (1) (4 used), and washers (2) (7 used) from flange (4). Remove flange (4), shims (5) (2 used), and pin (13) from rear frame (12). : 24 mm 1, 2

Preparation When disassembling the center hinge, set the machine to the following conditions. 1. Remove the cab and the cockpit.

2, 3

2. Remove the connecting parts between the front frame and the rear frame. • Propeller shaft • Steering cylinder • Hydraulic hose • Brake piping • Harness

3. Remove bolt (19), washers (20), and plate (21) from pin (18). Remove pin (18) from rear frame (12). : 24 mm

Removal of Hinge Pin 1. Support the front frame and the rear frame by using the solid support.

4. Remove bushing (17) from front frame (15). (Remove bushing (17) after cutting by gas or using arc welding.)

W4FC-02-03-007

CAUTION: The front frame (15) assembly weight: 5120 kg (11300 lb) 5. Attach a nylon sling onto front frame (15). Hoist front frame (15). Remove front frame (15) from rear frame (12). W4GB-02-03-002

6. Remove bushing (11) from front frame (15). 7. Remove bolts (6) (6 used) from cap (7). Remove caps (7, 10) and shims (8) (2 used) from front frame (15). : 17 mm

W2-3-11

BODY / Center Hinge

W4FC-02-03-003

Upper Hinge Pin

7 16

14 Section A

W4GD-02-03-002

Lower Hinge Pin 24 28 27 26

25 24 Section B

W2-3-12

W4GD-02-03-003

BODY / Center Hinge 8. Remove dust seals (14) (2 used) from caps (7, 10). 9. Remove bearing (16) from front frame (15). 10. Remove bolts (28) (6 used) from cap (27). Remove caps (27, 25) and shims (26) (2 used) from front frame (15). : 17 mm 11. Remove dust seals (22) (2 used) from caps (27, 25). 12. Remove bearing (23) from front frame (15). 13. Remove bushings (24) (2 used) from rear frame (12).

W2-3-13

BODY / Center Hinge ASSEMBLY OF CENTER HINGE (ZW150) A

W4FC-02-03-003

Upper Hinge Pin

4 5 17 6 7

8 9 15

11 Section A

Lower Hinge Pin

W4GD-02-03-002

12 19

20 21

28 27

25 24

Section B 1234567-

Bolt (4 Used) Washer (7 Used) Bolt (3 Used) Flange Shim (2 Used) Bolt (6 Used) Cap

8910 11 12 13 14 -

Shim (2 Used) Grease Fitting (2 Used) Cap Bushing Rear Frame Pin Dust Seal (2 Used)

15 16 17 18 19 20 21 -

W2-3-14

Front Frame Bearing Bushing Pin Bolt Washer Plate

W4GD-02-03-003

22 23 24 25 26 27 28 -

Dust Seal (2 Used) Bearing Bushing (2 Used) Cap Shim (2 Used) Cap Bolt (6 Used)

BODY / Center Hinge Assembly of Center Hinge (ZW150) IMPORTANT: Check the direction of dust seal (22). Install dust seal (22) with the wider rubber side facing the unpainted surfaces of caps (27, 25). 1. Apply LOCTITE #262 onto the outer surface of dust seals (22) (2 used). Lightly tap and install dust seal (22) to cap (27) by using a hammer. Wipe out the stick-out LOCTITE #262 by using a waste. Install dust seal (22) to cap (25) in the same way. 27, 25

Face the lip outside (the painted surface of the cap).

7. Install shims (8) (2 used) to the upper hinge part of front frame (15). Apply LOCTITE #262 onto bolts (6) (6 used). Install caps (7, 10) to front frame (15) with bolts (6) (6 used). : 17 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 8. Install dust seals (14) (2 used) to caps (7, 10). 9. Install shims (26) (2 used) to the lower hinge part of front frame (15). Apply LOCTITE #262 onto bolts (28) (6 used). Install caps (27, 25) to front frame (15) with bolts (28) (6 used). : 17 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 10. Install dust seals (22) (2 used) to caps (27, 25).

W4GB-02-03-005

2. Install dust seals (14) (2 used) to caps (7, 10) in the same way. 3. Install bearing (16) to the upper hinge part of front frame (15). 4. Add grease to the inside of bearing (16) through grease fitting (9) while rotating bearing (16). 5. Install bearing (23) to the lower hinge part of front frame (15). 6. Add grease to the inside of bearing (23) through grease fitting (9) while rotating bearing (23).

W2-3-15

BODY / Center Hinge

Upper Hinge Pin

W4FC-02-03-003

4 5

15 11 13

Section A

Lower Hinge Pin 24

W4GD-02-03-002

20 21

24 Section B

W2-3-16

W4GD-02-03-003

BODY / Center Hinge 11. Install bushings (24) (2 used) to the lower hinge part of rear frame (12). CAUTION: The front frame (15) assembly weight: 5120 kg (1130 lb) 12. Attach wire ropes onto front frame (15). Hoist front frame (15). Fit the pin (13, 18) holes on front frame (15) and rear frame (12). 13. Install pin (13), bushings (17, 11), shims (5) (2 used), and flange (4) to the upper hinge part. Install pin (13) to rear frame (12) with bolts (3) (3 used), bolts (1) (4 used), and washers (2) (7 used). The order of tightening the bolts are bolts (3) (3 used), bolts (1) (4 used) then bolts (3) (3 used). : 24 mm : 224 N⋅m (23 kgf⋅m, 165 lbf⋅ft) 1, 2

2, 3

W4FC-02-03-007

14. Install pin (18) to the lower hinge part. Install pin (18) to rear frame (12) with bolt (19), washer (20), and plate (21). : 24 mm : 86.9 N⋅m (8.9 kgf⋅m, 64 lbf⋅ft)

W2-3-17

BODY / Center Hinge (Blank)

W2-3-18

BODY / Hydraulic Oil Tank REMOVAL AND INSTALLATION HYDRAULIC OIL TANK

OF 1, 2

Removal 1. Remove bolts (1) (4 used) and washers (2) (4 used) from step (3). Remove step (3) and collars (5) (4 used) from hydraulic oil tank (4). : 14 mm

2. Remove bolts (6) (8 used) from covers (7) (3 used). Remove covers (7) (3 used) from floor plate (8). : 14 mm

W4FC-02-04-002

7 8

W4FC-02-04-001

3. Push valve (9) and bleed air from hydraulic oil tank (4). Remove socket bolts (10) (3 used) from the valve (9) assembly. Remove the valve (9) assembly from hydraulic oil tank (4). : 5 mm 9 10

W4FC-02-04-004

4. Place a container under hydraulic oil tank (4). Remove plug (11) from hydraulic oil tank (4). Drain hydraulic oil from hydraulic oil tank (4). Install plug (11) to hydraulic oil tank (4). NOTE: Hydraulic oil: 105 L (27.7 US gal) : 36 mm : 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

W4FC-02-04-008

W2-4-1

BODY / Hydraulic Oil Tank 5. Remove bolts (13) (4 used) from brackets (12) (2 used). Remove fender (14) from brackets (12) (2 used). : 14 mm

6. Disconnect connectors (16) (2 used) from washer tank (17).

7. Disconnect hoses (22) (2 used) from washer tank (17). Cap the open ends.

13 15

W4FC-02-04-005

8. Remove bolts (19) (2 used), spring washers (20) (2 used), and washers (21) (2 used) from bracket (18). Remove the bracket (18) assembly from frame (15). : 17 mm

19, 20, 21

9. Loosen bands (23) (4 used) from rubber hose (25). Remove pipes (24) (2 used) from rubber hoses (25) (2 used). : 11 mm

W4FC-02-04-003

22 24

W4FC-02-04-004

25 26

10. Disconnect hoses (28) (3 used) from hydraulic oil tank (4). Cap the open ends. : 17 mm, 22 mm, 41 mm 11. Loosen band (26) from rubber hose (27). Disconnect rubber hose (27) from hydraulic oil tank (4). : 11 mm

28 4

W4FC-02-04-006

W2-4-2

BODY / Hydraulic Oil Tank 12. Disconnect connector (32). 13. Remove bolt (29) and washer (30) from clip (31). Remove clip (31) from frame (15). : 8 mm

15 29, 30 31

CAUTION: Hydraulic oil tank (4) weight: 120 kg (270 lb)

32 W4FC-02-04-006

14. Attach a nylon sling onto hydraulic oil tank (4). Hoist and hold hydraulic oil tank (4). 15. Remove bolts (33) (3 used) and washers (34) (3 used) from hydraulic oil tank (4). Remove hydraulic oil tank (4) from frame (15). : 30 mm

33, 34 4

W2-4-3

W4FC-02-04-007

BODY / Hydraulic Oil Tank Installation CAUTION: Hydraulic oil tank (4) weight: 120 kg (270 lb)

33, 34

1. Attach a nylon sling onto hydraulic oil tank (4). Hoist hydraulic oil tank (4). Fit hydraulic oil tank (4) to the mounting hole on frame (15). Install hydraulic oil tank (4) to frame (15) with bolts (33) (3 used) and washers (34) (3 used). : 30 mm : 452 N⋅m (45 kgf⋅m, 330 lbf⋅ft)

W4FC-02-04-007

2. Connect rubber hose (27) to hydraulic oil tank (4) with band (26). : 11 mm : 4 N⋅m (0.4 kgf⋅m, 3 lbf⋅ft) 3. Connect hoses (28) (3 used) to hydraulic oil tank (4). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

28 4

W4FC-02-04-006

4. Install clip (31) to frame (15) with bolt (29) and washer (30). Connect connector (32). : 8 mm : 2 N⋅m (0.2 kgf⋅m, 1.5 lbf⋅ft)

15 29, 30 31 32 W4FC-02-04-006

W2-4-4

BODY / Hydraulic Oil Tank 5. Install the valve (9) assembly to hydraulic oil tank (4) with socket bolts (10) (3 used). : 5 mm : 3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2.4 to 3.1 lbf⋅ft)

6. Connect pipes (24) (2 used) to rubber hoses (25) (2 used). Connect pipes (24) (2 used) to rubber hoses (25) (2 used) with band (23). : 11 mm : 4 N⋅m (0.4 kgf⋅m, 3 lbf⋅ft)

9 10

7. Remove bolts (36) (4 used) and washers (37) (4 used) from cover (35). Remove cover (35) from hydraulic oil tank (4). : 10 mm

36, 37

8. Add hydraulic oil through the mounting part of cover (35). NOTE: Hydraulic oil: 105 L (27.7 US gal)

W4FC-02-04-004

19, 20, 21

9. Install cover (35) to hydraulic oil tank (4) with bolts (36) (4 used) and washers (37) (4 used). : 10 mm : 4 N⋅m (0.4 kgf⋅m, 3 lbf⋅ft) 10. Install the bracket (18) assembly to frame (15) with bolts (19) (2 used), spring washers (20) (2 used), and washers (21) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 11. Connect connectors (16) (2 used) and hoses (22) (2 used) to washer tank (17).

W4FC-02-04-003

7 8

12. Install covers (7) (3 used) to floor plate (8) with bolts (6) (8 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W4FC-02-04-001

W2-4-5

BODY / Hydraulic Oil Tank 13. Install fender (14) to brackets (12) (2 used) with bolts (13) (4 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

14. Install step (3) to hydraulic oil tank (4) with collars (5) (4 used), washers (2) (4 used), and bolts (1) (4 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

W4FC-02-04-005

1, 2

W2-4-6

W4FC-02-04-002

BODY / 4-Unit Gear Pump REMOVAL AND INSTALLATION OF 4-UNIT GEAR PUMP Removal CAUTION: Cab (1) weight: 960 kg (2120 lb) 1. Remove cab (1). (Refer to REMOVAL AND INSTALLATION OF CAB on W2-1-1.)

W4FC-02-01-003

2. Remove socket bolts (5) (4 used) from pipe (2). : 10 mm

2, 3

4 5

W4FC-02-05-001

3. Loosen hose bands (8) (2 used) from rubber hose (6). Remove the pipe (2) assembly and O-ring (3) from 4-unit gear pump (4) and hydraulic oil tank (7). Cap the open ends.

W4FC-02-04-004

W2-5-1

BODY / 4-Unit Gear Pump 9

4. Remove bolts (12) (8 used) from split flanges (9) (4 used). Remove split flanges (9) (4 used) from 4-unit gear pump (4).

10, 11

5. Disconnect hoses (10) (2 used) from 4-unit gear pump (4). Cap the open ends. Remove O-rings (11) (2 used) from hoses (10) (2 used). : 12 mm

W4FC-02-05-001

6. Loosen hose band (13) from rubber hose (14). Disconnect rubber hose (14) from 4-unit gear pump (4). Cap the open ends.

16, 17, 18

7. Disconnect hoses (20) (2 used) from 4-unit gear pump (4). Cap the open ends. : 27 mm

15, 19

CAUTION: 4-unit gear pump (4) weight: 31 kg (68 lb) 8. Attach a nylon sling onto 4-unit gear pump (4). Hoist and hold 4-unit gear pump (4). 9. Remove bolts (16) (4 used), spring washers (17) (4 used), and washers (18) (4 used) from 4-unit gear pump (4). Remove 4-unit gear pump (4) and O-ring (15) from HST pump (19). : 19 mm

W2-5-2

W4FC-02-05-001

BODY / 4-Unit Gear Pump Installation CAUTION: 4-unit gear pump (4) weight: 31 kg (68 lb) 4

1. Apply grease onto O-ring (15). Install O-ring (15) to HST pump (19). Attach a nylon sling onto 4-unit gear pump (4). Hoist 4-unit gear pump (4). Align 4-unit gear pump (4) with the mounting hole on HST pump (19).

16, 17, 18

2. Install 4-unit gear pump (4) to HST pump (19) with washers (18) (4 used), spring washers (17) (4 used), and bolts (16) (4 used). : 19 mm : 91.2 N⋅m (9.3 kgf⋅m, 67 lbf⋅ft)

15, 19 W4FC-02-05-001

3. Connect hoses (20) (2 used) to 4-unit gear pump (4). : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 4. Connect rubber hose (14) to 4-unit gear pump (4) with hose band (13). : 6±0.6 N⋅m (0.6±0.06 kgf⋅m, 4.4±0.4 lbf⋅ft)

W2-5-3

5. Apply grease onto O-rings (11) (2 used). Install O-rings (11) (2 used) to hoses (10) (2 used). 6. Connect hoses (10) (2 used) to 4-unit gear pump (4) with split flanges (9) (4 used) and bolts (12) (8 used). : 12 mm : 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

10, 11

W4FC-02-05-001

BODY / 4-Unit Gear Pump 7. Apply grease onto O-ring (3). Install O-ring (3) to pipe (2).

2, 3

8. Align the pipe (2) assembly with the mounting holes on 4-unit gear pump (4) and hydraulic oil tank (7).

4 5

9. Install pipe (2) to 4-unit gear pump (4) with socket bolts (5) (4 used). : 10 mm : 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

W4FC-02-05-001

10. Install rubber hose (6) to hydraulic oil tank (7) with bands (8) (2 used). : 6±0.6 N⋅m (0.6±0.06 kgf⋅m, 4.4±0.4 lbf⋅ft) 2

W4FC-02-04-004

CAUTION: Cab (1) weight: 960 kg (2120 lb) 11. Install cab (1). (Refer to REMOVAL AND INSTALLATION OF CAB on W2-1-1.)

W4FC-02-01-003

W2-5-4

BODY / 4-Unit Gear Pump (Blank)

W2-5-5

BODY / 4-Unit Gear Pump DISASSEMBLY OF 4-UNIT GEAR PUMP 17

14 13

12 11 10 9 8 12

7 5

3 1

1 30 35

26 21 22

25 1

26 23

23 43

24 29

41 26

40 39

42 39 40

W4FC-02-06-001

W2-5-6

BODY / 4-Unit Gear Pump 12345678910 11 12 13 -

Knock Pin (4 Used) Carrier Washer (4 Used) Bolt (4 Used) Snap Ring Oil Seal Knock Pin (2 Used) Bracket Washer (4 Used) Bolt (4 Used) O-Ring (2 Used) Side Plate (2 Used) Gear Case

14 15 16 17 18 19 20 21 22 23 24 25 26 -

Drive Gear Driven Gear Knock Pin (2 Used) Cover Washer (4 Used) Bolt (4 Used) Plate Coupling Seal Seal (2 Used) Backup Ring (2 Used) Side Plate (2 Used) Knock Pin (4 Used)

27 28 29 30 31 32 33 34 35 36 37 38 39 -

W2-5-7

Gear Case Drive Gear Driven Gear Stud (4 Used) Washer (4 Used) Nut (4 Used) Gear Case Drive Gear O-Ring (2 Used) Side Plate (2 Used) Driven Gear Carrier O-Ring (2 Used)

40 41 42 43 44 45 46 47 48 49 50 51 -

Side Plate (2 Used) Drive Gear Knock Pin (4 Used) Gear Case Stud (8 Used) Washer (8 Used) Nut (8 Used) Carrier Driven Gear Bracket Oil Seal Snap Ring

BODY / 4-Unit Gear Pump 17

14 13

8 12

11 33

36 37 25 28

25 43

41 47

W4FC-02-06-001

W2-5-8

BODY / 4-Unit Gear Pump Disassembly of 4-Unit Gear Pump IMPORTANT: Put the matching marks onto brackets (8, 49), cover (17), gear cases (13, 27, 33, and 43), and carriers (2, 38, and 47) for assembling. IMPORTANT: Put the matching marks onto side plates (12, 25, 36, and 40) for assembling. When installing side plates (12, 25, 36, and 40) in a wrong direction, the pump may get damaged. IMPORTANT: Remove drive gears (14, 28, 34, and 41) and driven gears (15, 29, 37, and 48) after putting matching marks (a). Displacement of gearing locations decreases volumetric efficiency.

1. Secure 4-unit gear pump with bracket (49) facing downward in vise (a) by using wooden pieces. Do not pinch port section (b).

a 49 W4FC-02-06-003

2. Remove socket bolts (19) (4 used) and washers (18) (4 used) from cover (17). : 10 mm 3. Remove cover (17) from gear case (13). W4FC-02-06-002

4. Remove O-ring (11) from cover (17). 5. Remove side plate (12) from gear case (13). 6. Remove driven gear (15) and drive gear (14) from gear case (13). 7. Remove gear case (13) from bracket (8).

W2-5-9

BODY / 4-Unit Gear Pump

13 12 11 10 9 34

2 30 35 36

20 37 21 22

25 28

36 35

25 23 24 29

W4FC-02-06-001

W2-5-10

BODY / 4-Unit Gear Pump 8. Remove side plate (12) from bracket (8).

20. Remove driven gear (37) and drive gear (34) from gear case (33).

9. Remove O-ring (11) from bracket (8). 21. Remove gear case (33) from carrier (38). 10. Remove socket bolts (10) (4 used) and washers (9) (4 used) from bracket (8). : 6 mm

22. Remove side plate (36) from carrier (38). 23. Remove O-ring (35) from carrier (38).

11. Remove bracket (8) from carrier (2). 24. Remove nuts (32) (4 used) and washers (31) (4 used) from studs (30) (4 used). : 24 mm

12. Remove snap ring (5) from bracket (8). IMPORTANT: Do not damage bracket (8) when removing oil seal (6). 13. Remove oil seal (6) and plate (20) from bracket (8) by using a screwdriver and a hammer.

25. Remove carrier (38) from gear case (27). 26. Remove backup ring (24) and seal (23) from carrier (38).

14. Remove seal (22) from carrier (2). 27. Remove side plate (25) from gear case (27). 15. Remove coupling (21) from carrier (2). 16. Remove socket bolts (4) (4 used) and washers (3) (4 used) from carrier (2). : 10 mm

28. Remove driven gear (29) and drive gear (28) from gear case (27). 29. Remove gear case (27) from carrier (47).

17. Remove carrier (2) from gear case (33).

30. Remove side plate (25) from carrier (47).

18. Remove O-ring (35) from carrier (2).

31. Remove backup ring (24) and seal (23) from carrier (47).

19. Remove side plate (36) from gear case (33).

W2-5-11

BODY / 4-Unit Gear Pump

46 45 44

41 47

40 39 39 40

W4FC-02-06-001

W2-5-12

BODY / 4-Unit Gear Pump 32. Remove nuts (46) (8 used) and washers (45) (8 used) from studs (44) (8 used). : 22 mm 33. Remove carrier (47) from gear case (43). 34. Remove O-ring (39) from carrier (47). 35. Remove side plate (40) from gear case (43). IMPORTANT: If oil seal (50) is not replaced, install tape onto the input shaft spline at drive gear (41) in order not to damage oil seal (50). 36. Remove driven gear (48) and drive gear (41) from gear case (43). 37. Remove gear case (43) from bracket (49). 38. Remove side plate (40) from bracket (49). 39. Remove O-ring (39) and retaining ring (51) from bracket (49). IMPORTANT: Do not damage bracket (49) when removing oil seal (50). 40. Remove oil seal (50) from bracket (49) by using a screwdriver and a hammer.

W2-5-13

BODY / 4-Unit Gear Pump ASSEMBLY OF 4-UNIT GEAR PUMP 50

44, 45, 46

30, 31, 32

8 13 16 11

12 14

17 20

18, 19

23, 24

33 21

3, 4 22

9, 10 W4FC-02-06-004

12345678910 11 12 13 -

Knock Pin (4 Used) Carrier Washer (4 Used) Bolt (4 Used) Snap Ring Oil Seal Knock Pin (2 Used) Bracket Washer (4 Used) Bolt (4 Used) O-Ring (2 Used) Side Plate (2 Used) Gear Case

14 15 16 17 18 19 20 21 22 23 24 25 26 -

Drive Gear Driven Gear Knock Pin (2 Used) Cover Washer (4 Used) Bolt (4 Used) Plate Coupling Seal Seal (2 Used) Backup Ring (2 Used) Side Plate (2 Used) Knock Pin (4 Used)

27 28 29 30 31 32 33 34 35 36 37 38 39 -

Gear Case Drive Gear Driven Gear Stud (4 Used) Washer (4 Used) Nut (4 Used) Gear Case Drive Gear O-Ring (2 Used) Side Plate (2 Used) Driven Gear Carrier O-Ring (2 Used)

W2-5-14

40 41 42 43 44 45 46 47 48 49 50 51 -

Side Plate (2 Used) Drive Gear Knock Pin (4 Used) Gear Case Stud (8 Used) Washer (8 Used) Nut (8 Used) Carrier Driven Gear Bracket Oil Seal Snap Ring

BODY / 4-Unit Gear Pump Assembly of 4-Unit Gear Pump IMPORTANT: Assemble brackets (8, 49), cover (17), gear cases (13, 27, 33, and 43), and carriers (2, 38, and 47) in a correct direction by using matching marks put during disassembly. IMPORTANT: Install side plates (12, 25, 36, and 40) in a correct direction by using matching marks put during disassembly. When installing side plates (12, 25, 36, and 40) in a wrong direction, the pump may get damaged. IMPORTANT: Install drive gears (14, 28, 34, and 41) and driven gears (15, 29, 37, and 48) after applying hydraulic oil onto sliding surface. Install by aligning matching marks (a) that were put during disassembly. Displacement of gearing locations decreases volumetric efficiency.

IMPORTANT: Applied grease on outer periphery of oil seal (50) eases installation of oil seal (50) and protects outer periphery from getting scratched. 1. Install oil seal (50) to bracket (49) by using special tool (a) and a press. After installing, check the outer periphery of oil seal (50) for scratches. a

W4FC-02-06-005

x: Oil seal (50) outer diameter - 2 mm (0.08 in) y: Input shaft outer diameter + 5 mm (0.2 in) z: 100 mm (3.9 in) or more

2. Install retaining ring (51) to bracket (49). 3. Install O-ring (39) to bracket (49). 4. Install side plate (40) to the bracket (49) side of gear case (43). 5. Install gear case (43) to bracket (49). W4FC-02-06-002

W2-5-15

BODY / 4-Unit Gear Pump

44, 45, 46

30, 31, 32

35 36 41

23, 24

38 34

2 W4FC-02-06-004

W2-5-16

BODY / 4-Unit Gear Pump 6. Secure the gear case (43) assembly with bracket (49) facing downward in vise (a) by using a wooden piece. 43

14. Install gear case (27) to carrier (47). 15. Install drive gear (28) and driven gear (29) to gear case (27).

16. Install side plate (25) to gear case (27). 17. Install seal (23) and backup ring (24) to carrier (38). 18. Install carrier (38) to gear case (27). 49

19. Install O-ring (35) to carrier (38).

W4FC-02-06-006

IMPORTANT: When installing drive gear (41), apply grease to the oil seal (50) lip section in order to protect oil seal (50) from getting scratched. 7. Install drive gear (41) and driven gear (48) to gear case (43).

20. Install washers (31) (4 used) and nuts (32) (4 used) to studs (30) (4 used). : 24 mm : 245 to 310 N⋅m (25.0 to 31.5 kgf⋅m, 180 to 230 lbf⋅ft) 21. Install side plate (36) to the carrier (38) side of gear case (33). 22. Install gear case (33) to carrier (38).

8. Install side plate (40) to gear case (43).

23. Install drive gear (34) and driven gear (37) to gear case (33).

9. Install O-ring (39) to carrier (47). 10. Install carrier (47) to gear case (43).

24. Install side plate (36) to gear case (33).

11. Install seal (23) and backup ring (24) to carrier (47).

25. Install O-ring (35) to carrier (2).

12. Install washers (45) (8 used) and nuts (46) (8 used) to studs (44) (8 used). : 22 mm : 157 to 195 N⋅m (16.0 to 20.0 kgf⋅m, 116 to 144 lbf⋅ft) 13. Install side plate (25) to the carrier (47) side of gear case (27).

W2-5-17

BODY / 4-Unit Gear Pump

13 16 11 12 14 15

18, 19 20

3, 4 22

9, 10 W4FC-02-06-004

W2-5-18

BODY / 4-Unit Gear Pump 26. Install carrier (2) to gear case (33) with washers (3) (4 used) and socket bolts (4) (4 used). : 10 mm : 98 to 123 N⋅m (10.0 to 12.5 kgf⋅m, 72 to 91 lbf⋅ft)

32. Install O-ring (11) to bracket (8). 33. Install side plate (12) to the bracket (8) side of gear case (13). 34. Install gear case (13) to bracket (8).

27. Install coupling (21) onto carrier (2). 28. Install seal (22) onto carrier (2). IMPORTANT: Applied grease on outer periphery of oil seal (6) eases installation of oil seal (6) and protects outer periphery from getting scratched. 29. Install oil seal (6) and plate (20) to bracket (8) by using special tool (a) and a press. After installing, check the outer periphery of oil seal (6) for scratches.

36. Install side plate (12) to gear case (13). 37. Install O-ring (11) to cover (17). 38. Install cover (17) to gear case (13) with washers (18) (4 used) and socket bolts (19) (4 used). : 10 mm : 98 to 123 N⋅m (10.0 to 12.5 kgf⋅m, 72 to 91 lbf⋅ft)

IMPORTANT: When installing drive gear (14), apply grease to the oil seal (6) lip section in order to protect oil seal (6) from getting scratched. 35. Install drive gear (14) and driven gear (15) to gear case (13).

IMPORTANT: After assembly, check that rotation torque of the input shaft is 12.0 to 23.5 N⋅m (1.2 to 2.4 kgf⋅m, 8.9 to 17.5 lbf⋅ft).

W4FC-02-06-005

x: Oil seal (6) outer diameter - 2 mm (0.08 in) y: Input shaft outer diameter + 5 mm (0.2 in) z: 100 mm (3.9 in) or more 30. Install snap ring (5) to bracket (8). 31. Install bracket (8) to carrier (2) with washers (9) (4 used) and socket bolts (10) (4 used). : 6 mm : 27.5 to 34 N⋅m (2.8 to 3.5 kgf⋅m, 20.5 to 25 lbf⋅ft)

W2-5-19

BODY / 4-Unit Gear Pump (Blank)

W2-5-20

BODY / Control Valve REMOVAL AND CONTROL VALVE

INSTALLATION

Removal 1. Raise lift arm (1). Install a stopper to the piston rod of lift arm cylinder (2).

Stopper

W4FC-03-01-006

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 3

2. Remove bolts (5) (4 used) from cover (4). Remove cover (4) from frame (3). : 14 mm

W4FC-03-06-007

3. Remove bolt (8) from clamp (7). Remove clamp (7) from pipes (9) (2 used). : 17 mm

7, 8, 9

4. Disconnect hoses (6) (7 used) and pipes (9) (2 used) from control valve (10). Cap the open ends. Attach an identification tag onto the removed hoses for assembling. : 22 mm, 36 mm, 41 mm, 51 mm

6 W4FC-02-06-008

W2-6-1

BODY / Control Valve 5. Disconnect connector (13) from control valve (10).

11, 12

10, 13

Eyebolt Mounting Hole

CAUTION: Control valve (10) weight: 42 kg (93 lb) 6. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to control valve (10). Attach a nylon sling onto the eyebolt. Hoist and hold control valve (10). 7. Remove socket bolts (11) (3 used) and washers (12) (3 used) from control valve (10). Remove control valve (10) from bracket (14). : 10 mm

11, 12

W4FC-02-06-008

W2-6-2

BODY / Control Valve Installation CAUTION: Control valve (10) weight: 42 kg (93 lb)

11, 12

1. Attach a nylon sling onto control valve (10). Hoist control valve (10). Fit control valve (10) with the mounting hole on bracket (14). Install control valve (10) to bracket (14) with socket bolts (11) (3 used) and washers (12) (3 used). : 10 mm : 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

11, 12

W4FC-02-06-008

7, 8, 9

2. Connect hoses (6) (7 used) and pipes (9) (2 used) to control valve (10). : 22 mm : 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft) : 36 mm : 157 N⋅m (16 kgf⋅m, 116 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft) : 50 mm : 255 N⋅m (26 kgf⋅m, 190 lbf⋅ft)

10, 13

3. Install pipes (9) (2 used) to frame (3) with clamp (7) and bolt (8). : 17 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

6 W4FC-02-06-008

4. Connect connector (13) to control valve (10).

5. Install cover (4) to frame (3) with bolts (5) (4 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W4FC-03-06-007S

W2-6-3

BODY / Control Valve DISASSEMBLY OF CONTROL VALVE 1

2 3

15 14

14 17

42 12

19 20 21

30 37

30 14 34

28 29 31

30 14 33

16 W4FC-02-07-001

12345678910 11 -

Plug O-Ring (3 Used) Spring (2 Used) Poppet Plug Poppet Poppet Poppet Spring Plug Plug

12 13 14 15 16 17 18 19 20 21 22 -

O-Ring (2 Used) Plug O-Ring (5 Used) Pilot Housing (2 Used) Socket Bolt (9 Used) Spool Spool Relief Valve Relief Valve O-Ring O-Ring

23 24 25 26 27 28 29 30 31 32 33 -

W2-6-4

Plug (2 Used) Socket Bolt (4 Used) End Plate Plug Housing Plug (2 Used) Relief Valve Spring Collar (4 Used) Spring Bolt Pilot Housing

34 35 36 37 38 39 40 41 42 43 44 -

Pilot Housing Socket Bolt (2 Used) Bolt Spring Pilot Housing Backup Ring O-Ring Spring Poppet Main Relief Valve Plug

BODY / Control Valve Disassembly of Control Valve 1. Remove socket bolts (24) (4 used). Remove end plate (25) from housing (27). : 10 mm

9. Secure spools (17, 18) in a vise by using wooden pieces as shown in the figure below.

2. Remove plug (10) from housing (27). : 17 mm 3. Remove plug (11), spring (9), and poppet (8) from housing (27). Remove O-ring (2) from plug (11). : 36 mm IMPORTANT: Put a spanner to the hexagonal section at the housing (27) side in relief valve (29). 4. Remove relief valve (29) from housing (27). : 32 mm 5. Remove socket bolts (16) (6 used). Remove pilot housings (15) (2 used) and pilot housing (33) from housing (27). : 8 mm 6. Remove socket bolts (35) (2 used). Remove pilot housing (34) from pilot housing (38). : 8 mm 7. Remove O-rings (14) (4 used) from pilot housings (33, 34) and pilot housings (15) (2 used). 8. Remove spools (17, 18) from housing (27) by rotating.

W4FC-02-07-003

10. Remove bolts (32, 36) from spools (17, 18). Remove spring collars (30) (4 used) and springs (31, 37) from spools (17, 18). : 19 mm 11. Remove O-ring (12) from bolt (36). 12. Remove plug (13) from spool (18). Remove O-ring (12) from plug (13). : 8 mm 13. Remove socket bolts (16) (3 used). Remove pilot housing (38) from housing (27). : 8 mm 14. Remove O-rings (14, 40) and backup ring (39) from pilot housing (38).

W2-6-5

BODY / Control Valve

2 3

42 19 20 21 22 27

23 23

W4FC-02-07-001

W2-6-6

BODY / Control Valve 15. Remove spring (41) and poppet (42) from housing (27). 16. Remove plug (26) from end plate (25). : 12 mm 17. Remove plugs (23) (2 used) from end plate (25). : 8 mm IMPORTANT: As set pressures of relief valves (19, 20) are different, record identification codes before removal. 18. Remove relief valves (19, 20) from housing (27). : 27 mm 19. Remove main relief valve (43) from housing (27). : 27 mm 20. Remove plug (5) from housing (27). Remove spring (3) and poppets (6, 7) from housing (27) by using a magnet. Remove O-ring (2) from plug (5). : 36 mm 21. Remove plug (1) from housing (27). Remove spring (3) and poppet (4) from housing (27) by using a magnet. Remove O-ring (2) from plug (1). : 36 mm 22. Remove plugs (28) (2 used) and plug (44) from housing (27). : 10 mm 23. Remove O-rings (21, 22) from end plate (25).

W2-6-7

BODY / Control Valve ASSEMBLY OF CONTROL VALVE 16

16 B C

23 27

A C

23 10

19 W4FC-02-07-004

W2-6-8

BODY / Control Valve Section A-A

Section B-B

39, 40

Section D-D

30 9

4 12

41 34

Section C-C

14 15

30 28

17 W4FC-02-07-005

12345678910 11 -

Plug O-Ring (3 Used) Spring (2 Used) Poppet Plug Poppet Poppet Poppet Spring Plug Plug

12 13 14 15 16 17 18 19 20 21 22 -

O-Ring (2 Used) Plug O-Ring (5 Used) Pilot Housing (2 Used) Socket Bolt (9 Used) Spool Spool Relief Valve Relief Valve O-Ring O-Ring

23 24 25 26 27 28 29 30 31 32 33 -

W2-6-9

Plug (2 Used) Socket Bolt (4 Used) End Plate Plug Housing Plug (2 Used) Relief Valve Spring Collar (4 Used) Spring Bolt Pilot Housing

34 35 36 37 38 39 40 41 42 43 44 -

Pilot Housing Socket Bolt (2 Used) Bolt Spring Pilot Housing Backup Ring O-Ring Spring Poppet Main Relief Valve Plug

BODY / Control Valve

Section B-B

39, 40

Section D-D

14 21

36 12 Section C-C

18 3

13 6

17 W4FC-02-07-006

W2-6-10

BODY / Control Valve Assembly of Control Valve 1. Install O-rings (21, 22) to end plate (25). 2. Install plugs (28) (2 used) and plug (44) to housing (27). : 10 mm : 118 to 138 N⋅m (12 to 14 kgf⋅m, 87 to 102 lbf⋅ft) 3. Install poppet (4) and spring (3) to housing (27). Install O-ring (2) to plug (1). Install plug (1) to housing (27). : 36 mm : 275 to 300 N⋅m (28 to 31 kgf⋅m, 205 to 215 lbf⋅ft) 4. Install poppets (6, 7) and spring (3) to housing (27). Install O-ring (2) to plug (5). Install plug (5) to housing (27). : 36 mm : 275 to 300 N⋅m (28 to 31 kgf⋅m, 205 to 215 lbf⋅ft) 5. Install main relief valve (43) to housing (27). : 27 mm : 175 to 206 N⋅m (18 to 21 kgf⋅m, 129 to 152 lbf⋅ft)

7. Install plug (26) to end plate (25). : 12 mm : 175 to 205 N⋅m (18 to 21 kgf⋅m, 129 to 151 lbf⋅ft) 8. Install poppet (42) and spring (41) to housing (27). 9. Install O-rings (14, 40) and backup ring (39) to pilot housing (38). Install pilot housing (38) to housing (27) with socket bolts (16) (3 used). : 8 mm : 49 to 54 N⋅m (5 to 5.5 kgf⋅m, 36 to 40 lbf⋅ft) 10. Install O-ring (12) to plug (13). Install plug (13) to the edge of the chamfered sides of spool (18). : 8 mm : 25 to 30 N⋅m (2.5 to 3 kgf⋅m, 18.5 to 21.5 lbf⋅ft) 11. Install O-ring (12) to bolt (36). 12. Secure spools (17, 18) in a vise by using wooden pieces.

6. Install plugs (23) (2 used) to end plate (25). : 8 mm : 69 to 74 N⋅m (7 to 7.5 kgf⋅m, 51 to 55 lbf⋅ft)

W4FC-02-07-003

W2-6-11

BODY / Control Valve

16 19

16 C

29 16 25

Section B-B

Section A-A

2 14 34

30 8

Section C-C

30 17 W4FC-02-07-007

W2-6-12

BODY / Control Valve 13. Install spring collars (30) (4 used) and springs (31, 37) to spools (17, 18) with bolts (32, 36). : 19 mm : 25 to 30 N⋅m (2.5 to 3 kgf⋅m, 18.5 to 21.5 lbf⋅ft) 14. Apply hydraulic oil onto spools (17, 18). Install spools (17, 18) to housing (27) by rotating.

IMPORTANT: As set pressures of relief valves (19, 20) are different, check identification codes before installing. 18. Install relief valves (19, 20) to housing (27). : 27 mm : 235 to 265 N⋅m (24 to 27 kgf⋅m, 175 to 195 lbf⋅ft)

15. Install O-ring (14) to pilot housing (34). Install pilot housing (34) to pilot housing (38) with socket bolts (35) (2 used). : 8 mm : 49 to 54 N⋅m (5 to 5.5 kgf⋅m, 36 to 40 lbf⋅ft)

IMPORTANT: Put a spanner to the hexagonal section at the housing (27) side in relief valve (29). 19. Install relief valve (29) to housing (27). : 32 mm : 83 to 88 N⋅m (8.5 to 9 kgf⋅m, 61 to 65 lbf⋅ft)

16. Install O-ring (14) to pilot housing (33). Install pilot housing (33) to housing (27) with socket bolts (16) (2 used). : 8 mm : 49 to 54 N⋅m (5 to 5.5 kgf⋅m, 36 to 40 lbf⋅ft)

20. Install poppet (8) and spring (9) to housing (27). Install O-ring (2) to plug (11). Install plug (11) to housing (27). : 36 mm : 175 to 205 N⋅m (18 to 21 kgf⋅m, 129 to 151 lbf⋅ft)

17. Install O-rings (14) (2 used) to pilot housings (15) (2 used). Install pilot housings (15) (2 used) to housing (27) with socket bolts (16) (4 used). : 8 mm : 49 to 54 N⋅m (5 to 5.5 kgf⋅m, 36 to 40 lbf⋅ft)

21. Install plug (10) to housing (27). : 36 mm : 175 to 205 N⋅m (18 to 21 kgf⋅m, 129 to 151 lbf⋅ft) 22. Install end plate (25) to housing (27) with socket bolts (24) (4 used). : 10 mm : 88 to 93 N⋅m (9 to 9.5 kgf⋅m, 65 to 69 lbf⋅ft)

W2-6-13

BODY / Control Valve (Blank)

W2-6-14

BODY / Pilot Valve REMOVAL AND INSTALLATION JOY-STICK TYPE PILOT VALVE

CAUTION: Before doing any work, lower the lift arm and lower the bucket on the ground. Stop the engine. Release the remaining pressure while operating the control lever with the front control lever lock (2) in the Unlock position. CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) IMPORTANT: Replace pilot valve as an assembly. Removal 1. Open door (1). 1

W4FC-03-09-002

2. Operate handle (6) and move lever stand (5) forward. 5

3. Remove screws (3) (4 used) from cover (4). Remove cover (4) from bracket (7).

W4FC-02-07-015

4. Remove bolt (10) and washer (11) from clip (12). Remove clip (12) from hoses (9). : 14 mm 5. Disconnect hoses (9) (6 used) from pilot valve (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm

9 10, 11 12 W4FC-02-07-009

ďźˇ2-7-1

BODY / Pilot Valve 13

6. Disconnect connectors (14) (3 used). 7. Extend clip (13). Disconnect harnesses (15) (3 used) from bracket (7).

W4FC-02-07-010

8. Raise boot (16). Remove screws (17) (4 used) from boot (16). Remove boot (16) from bracket (18).

9. Extend clip (22). Disconnect harness (15) from bracket (18).

W4FC-02-07-011

19 15

10. Loosen lock nut (20). Remove the lever (19) assembly from screw joint (21). : 22 mm

20 21 22

8 23, 24

W4FC-02-07-014

11. Remove bolts (23) (4 used) and washers (24) (4 used) from bracket (18). Remove pilot valve (8) from bracket (18). : 12 mm 18

ďźˇ2-7-2

23, 24

W4FC-02-07-012

BODY / Pilot Valve Installation 1. Install pilot valve (8) to bracket (18) with bolts (23) (4 used) and washers (24) (4 used). : 12 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

23, 24

2. Install the lever (19) assembly to screw joint (21). Fit the lever (19) position. Secure lever (19) to screw joint (21) with lock nut (20). : 22 mm : 55 N⋅m (5.5 kgf⋅m, 41 lbf⋅ft)

W4FC-02-07-012

19 15 20

3. Secure harness (15) with clip (22).

21 22 18

23, 24

4. Install boot (16) to bracket (18) with screws (17) (4 used).

5. Connect connectors (14) (3 used).

W4FC-02-07-014

W4FC-02-07-011

6. Secure harnesses (15) (3 used) with clip (13). 14

W4FC-02-07-010

Ｗ2-7-3

BODY / Pilot Valve 7. Connect hoses (9) (6 used) to pilot valve (8). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

8. Install clip (12) to hoses (9) (4 used). Install clip (12) to bracket (7) with bolt (10) and washer (11). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

9 10, 11 12

7 W4FC-02-07-009

9. Install cover (4) to bracket (7) with screws (3) (4 used).

10. Operate handle (6) and move lever stand (5) backward.

W4FC-02-07-015

11. Shut door (1).

W4FC-03-09-002

Ｗ2-7-4

BODY / Pilot Valve (Blank)

ï¼·2-7-5

BODY / Pilot Valve REMOVAL AND INSTALLATION OF PILOT VALVE (TWO-LEVER TYPE) CAUTION: Before doing any work, lower the lift arm and lower the bucket on the ground. Stop the engine. Release the remaining pressure while operating the control lever with the front control lever lock (2) in the Unlock position. CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Open door (1).

W4FC-03-09-002

2. Operate handle (6) and move lever stand (5) forward. 5

3. Remove screws (3) (4 used) from cover (4). Remove cover (4) from bracket (7).

4. Disconnect hoses (9) (6 used) from pilot valve (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm

W4FC-02-07-019

W4FC-02-07-016

ďźˇ2-7-6

BODY / Pilot Valve 10

5. Disconnect connectors (11) (3 used). 6. Extend clip (10). Disconnect harnesses (12) (3 used) from bracket (7).

W4FC-02-07-010

7. Remove adjusting handles (15) (2 used) and disc springs (16) (2 used) from armrest (13). Remove armrest (13) from bracket (14).

15, 16

8. Remove screws (17) (4 used) from cover (18). Remove cover (18) from bracket (14).

W4FC-02-08-002

17 18

W4FC-02-08-003

9. Remove grips (23) (2 used) from levers (22) (2 used). 10. Remove cap (19) and screws (20) (4 used) from cover (21). Remove cover (21) from bracket (14).

19, 20

14 W4FC-02-07-017

ďźˇ2-7-7

BODY / Pilot Valve 11. Remove socket bolts (24) (4 used) from pilot valves (8) (2 used). Remove pilot valves (8) (2 used) from bracket (14). : 8 mm

W4FC-02-07-018

ďźˇ2-7-8

BODY / Pilot Valve Installation 1. Install pilot valves (8) (2 used) to bracket (14) with socket bolts (24) (4 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W4FC-02-07-018

2. Install cover (21) to bracket (14) with screws (20) (4 used) and cap (19). 3. Install grips (23) (2 used) to levers (22) (2 used).

19, 20

14 W4FC-02-07-017

4. Install cover (18) to bracket (14) with screws (17) (4 used).

17 18

W4FC-02-08-003

5. Install armrest (13) to bracket (14) with adjusting handles (15) (2 used) and coned disc springs (16) (2 used).

15, 16

Ｗ2-7-9

W4FC-02-08-002

BODY / Pilot Valve 10

6. Connect connectors (11) (3 used). 7. Secure harnesses (12) (3 used) with clip (10).

W4FC-02-07-010

8. Connect hoses (9) (6 used) to pilot valve (8). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

9. Install cover (4) to bracket (7) with screws (3) (4 used).

W4FC-02-07-016

10. Operate handle (6) and move lever stand (5) backward.

W4FC-02-07-019

11. Shut door (1).

W4FC-03-09-002

Ｗ2-7-10

BODY / Pilot Valve (Blank)

ï¼·2-7-11

BODY / Pilot Valve DISASSEMBLY OF PILOT VALVE (TWO-LEVER TYPE) 5

5 6 2 3 7

2 3 4

3 7

14 15 16 17

19 14

25 26

27 28

30 31

25 26

27 28

40 34

41 40 36

36 37

14 15

14 15 16 17

35 39

W4GB-02-06-011

W2-7-12

BODY / Pilot Valve 12345678910 11 12 -

Socket Bolt (8 Used) Lock Nut (4 Used) Screw (4 Used) Lever (2 Used) Boot (2 Used) Lock Plug (2 Used) Bushing (4 Used) Camshaft (2 Used) Cover (2 Used) Detent Ring (3 Used) Spring (3 Used) Push Rod (3 Used)

13 14 15 16 17 18 19 20 21 22 23 24 -

O-Ring (4 Used) Bushing (5 Used) Detent Bushing (4 Used) Steel Ball (12 Used) Scraper (4 Used) Push Rod Solenoid Detent Casing Spring Guide (4 Used) Spring (4 Used) Plate (2 Used) Seal (4 Used)

25 26 27 28 29 30 31 32 33 34 35 36 -

Plug (4 Used) O-Ring (4 Used) Push Rod (4 Used) Spring Seat (4 Used) Spring (2 Used) Spring (4 Used) Washer (4 Used) Spool (4 Used) Plug Casing Socket Bolt (2 Used) Bushing (2 Used)

W2-7-13

37 38 39 40 41 42 43 44 45 46 47 48 -

O-Ring (2 Used) Port Plate (2 Used) Socket Bolt (4 Used) O-Ring (4 Used) Sub Plate Solenoid Solenoid Detent Casing Spring Spring Nut (2 Used) Casing

BODY / Pilot Valve

5 6 2 3 7

2 3 4

3 7

14 15 16 17

19 14

25 26

27 28

30 31

25 26

27 28

40 34

41 40 36

36 37

14 15

14 15 16 17

35 39

W4GB-02-06-011

W2-7-14

BODY / Pilot Valve Disassembly of Pilot Valve (Two-lever type) IMPORTANT: Install a plug to each port. 1. Secure the casing (34, 48) parts of the valve assembly in a vise by using a buffer plate. Remove boots (5) (2 used) from covers (9) (2 used). 2. Remove socket bolts (1) (4 used) from the deeper hole on covers (9) (2 used). : 5 mm 3. Remove the cover (9) assemblies (2 used) from casings (34, 48). NOTE: Record the positions for casings (34, 48), detent casings (20, 44), covers (9) (2 used) and port plates (38) (2 used). IMPORTANT: When disassembling, prevent push rods (27) (4 used) and plugs (25) (4 used) from flying out by spring (30). 4. Insert a screwdriver into the groove on plugs (25) (4 used). While holding push rod (27) by using a waste cloth, remove plugs (25) (4 used) from casings (34, 48).

6. When disassembling the spring seat (28) assemblies (4 used), push spring seats (28) (4 used) compress springs (29) (2 used) and (45, 46). Slide and remove spring seats (28) (4 used) from spools (32) (4 used) through the larger hole. NOTE: Do not damage the surface of spool (32). Do not push spring seats (28) (4 used) to 6 mm (0.24 in) or more. 7. Separate springs (29) (2 used), springs (45, 46) and washers (31) (4 used) from spools (32) (4 used). NOTE: Record the installed position for spools (32) (4 used), springs (30) (2 used), springs (45, 46) and washers (31) (4 used). 8. Remove push rods (27) (4 used) from plugs (25) (4 used). 9. Remove O-rings (26) (4 used) from plugs (25) (4 used). 10. Remove seal (24) (4 used) from plugs (25) (4 used).

5. Remove push rods (27) (4 used), the spring seat (28) assemblies (4 used) and springs (30) (4 used) from casings (34, 48).

W2-7-15

BODY / Pilot Valve

2 3 4

2 3

2 3 4

14 15 16

14 15

15 16

40 34

41 40

37 37 38

35 39

W4GB-02-06-011

W2-7-16

BODY / Pilot Valve 11. Remove socket bolts (35) (2 used) and nuts (47) (2 used) from casings (34, 48). Separate casings (34, 48) and sub plate (41). : 6 mm 12. Remove O-rings (40) (2 used) from sub plate (41). 13. Remove O-rings (40) (2 used) from casing (34). 14. Secure casings (34, 48) in a vise. Remove socket bolts (39) (4 used) from port plates (38) (2 used). : 6 mm 15. Remove port plates (38) (2 used) and O-rings (37) (2 used) from casings (34, 48). 16. Secure plates (23) (2 used) in a vise. Remove socket bolts (1) (4 used) from the shallower hole on cover (9). : 5 mm 17. Remove covers (9) (2 used) and detent casings (20, 44) from plates (23) (2 used). NOTE: As spring guides (21) (4 used) may be installed to detent casings (20, 24) by grease, do not drop spring guides (21) (4 used). 18. Remove springs (22) (4 used) and spring guides (21) (4 used) from plates (23) (2 used).

19. Remove detent casings (20, 44) from covers (9) (2 used). NOTE: Do not drop push rod (18) which is inserted into detent bushing (15) without steel balls (16) (3 used). 20. Remove solenoids (19, 42, and 43) from detent casings (20, 44). NOTE: When removing solenoids (19, 42, and 43), do not pull a lead wire. 21. Remove lock plugs (6) (2 used) from levers (4) (2 used). : 3 mm 22. Remove camshafts (8) (2 used) from covers (9) (2 used). 23. Remove levers (4) (2 used) from covers (9) (2 used). 24. Remove nuts (2) (4 used) and screws (3) (4 used) from levers (4) (2 used). : 13 mm 25. Remove of an assembly detent bushings (15) (4 used), push rods (12) (3 used), push rod (18) and bushings (14) (4 used) from the mounting side by using the special tool.

-0.3

-0.2

Dia. 8 -0.3 mm 30Â° (Dia. 0.32 -0.008 -0.012 in)

Dia. 10 -0.4 mm -0.012 (Dia. 0.39 -0.016 in) 30 mm (1.18 in) 40 mm (1.58 in)

2 mm (0.079 in) W4GB-02-06-012

W2-7-17

BODY / Pilot Valve

13 15

18 13

15 16 17

12 13 15

15 17

16 17

W4GB-02-06-011

W2-7-18

BODY / Pilot Valve 26. Remove O-rings (13) (4 used) from covers (9) (2 used). [A port without a detent] 27. Remove push rod (18) from detent bushing (15). NOTE: Record the combination of detent bushing (15) and push rod (18). [A port with a detent] 28. Hold detent rings (10) (3 used) and compress springs (11) (3 used). Remove steel balls (16) (12 used). NOTE: Prevent steel ball (16) from falling off. 29. Remove push rods (12) (3 used) from detent bushing (15). NOTE: Record the combination of detent bushing (15) and push rod (12). 30. Remove detent rings (10) (3 used) and springs (11) (3 used) from detent bushings (15) (3 used). 31. Remove scrapers (17) (4 used) from detent bushings (15) (4 used). NOTE: When removing scraper (17), do not damage the inner surface of detent bushing (15).

W2-7-19

BODY / Pilot Valve ASSEMBLY OF (TWO-LEVER TYPE)

PILOT

VALVE 47

41 A

4 5 3

6 1 13

11 17 15

42 44

27 22

20 34

30 29

32 36 37

39 Section A-A

38 Section B-B W4GB-02-06-013

W2-7-20

BODY / Pilot Valve 12345678910 11 12 -

13 14 15 16 17 18 19 20 21 22 23 24 -

O-Ring (4 Used) Bushing (5 Used) Detent Bushing (4 Used) Steel Ball (12 Used) Scraper (4 Used) Push Rod Solenoid Detent Casing Spring Guide (4 Used) Spring (4 Used) Plate (2 Used) Seal (4 Used)

25 26 27 28 29 30 31 32 33 34 35 36 -

Plug (4 Used) O-Ring (4 Used) Push Rod (4 Used) Spring Seat (4 Used) Spring (2 Used) Spring (4 Used) Washer (4 Used) Spool (4 Used) Plug Casing Socket Bolt (2 Used) Bushing (2 Used)

W2-7-21

37 38 39 40 41 42 43 44 45 46 47 48 -

O-Ring (2 Used) Port Plate (2 Used) Socket Bolt (4 Used) O-Ring (4 Used) Sub Plate Solenoid Solenoid Detent Casing Spring Spring Nut (2 Used) Casing

BODY / Pilot Valve

4 3 2

16 10

17 15

Section A-A

Section B-B W4GB-02-06-013

W2-7-22

BODY / Pilot Valve Assembly of Pilot Valve (Two-lever type) 1. Apply grease onto scrapers (17) (4 used). Install scrapers (17) (4 used) to detent bushings (15) (4 used). NOTE: Check the direction to install scrapers (17) (4 used). 15 17

W4GB-02-06-014

2. Apply grease onto the sliding parts of detent bushings (15) (3 used) and detent rings (10) (3 used). Install detent rings (10) (3 used) and springs (11) (3 used) to detent bushings (15) (3 used). [A port with a detent] 3. Install push rods (12) (3 used) to detent bushings (15) (3 used). (Check the up and down directions of the rod.) CAUTION: Prevent detent rings (10) (3 used) from flying out by springs (11) (3 used).

4. Hold detent rings (10) (3 used) and compress springs (11) (3 used). Install steel balls (16) (12 used). NOTE: Apply grease onto steel balls (16) (12 used). Grease prevents steel balls (16) (12 used) from falling off. Thus, the installation is carried out easily. Adjust the positions of push rods (12) (3 used) so that the steel balls (16) (12 used) can be inserted into the constriction part of push rods (12) (3 used). [A port without a detent] 5. Install push rod (18) to detent bushing (15). (Check the up and down directions of the rod.) 6. Install O-rings (13) (4 used) to covers (9) (2 used). 7. Install detent bushings (15) (4 used) to covers (9) (2 used) at the original position. 8. Temporarily tighten screws (3) (4 used) and nuts (2) (4 used) to levers (4) (2 used). 9. Apply grease onto the top and the bottom sides of push rods (12) (3 used) and push rod (18), the sliding part at the side surfaces of levers (4) (2 used) and the sliding parts of camshafts (8) (2 used). Secure covers (9) (2 used) in a vise. Install levers (4) (2 used) and camshafts (8) (2 used) to covers (9) (2 used).

W2-7-23

BODY / Pilot Valve 47

41 A

44 27 20 34

30 29

32 37

39 Section A-A

38 Section B-B W4GB-02-06-013

W2-7-24

BODY / Pilot Valve 10. Apply LOCTITE #241 onto lock plugs (6) (2 used). Install lock plugs (6) (2 used) to lever (4). : 3 mm : 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)

17. Install port plates (38) (2 used) to casings (34, 48) with socket bolts (39) (4 used). : 6 mm : 20.6 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft)

11. Install solenoids (19, 42, and 43) to detent casings (20, 44) at the original position. NOTE: Insert the rubber bushing for the lead wire hole into the groove on the detent case.

18. Install O-rings (40) (2 used) to sub plate (41).

12. Install detent casings (20, 44) to push rods (12) (3 used) and push rod (18) of cover (9). NOTE: Check the direction to install detent casings (20, 44). 13. Apply grease onto the attached surface of spring guides (21) (4 used). Install springs (22) (4 used) and the attached plate to plates (23) (2 used) at the original position. CAUTION: Prevent springs (22) (4 used) from flying out when installing covers (9) (2 used). 14. Install covers (9) (2 used) and detent casings (20, 44) to plates (23) (2 used). Insert and temporarily tighten socket bolts (1) (4 used) into the shallower hole on covers (9) (2 used).

19. Install O-rings (40) (2 used) to casing (34). 20. Temporarily install sub plate (41) with socket bolts (35) (2 used) and nuts (47) (2 used) to casings (34, 48). Secure the casing (34, 48) parts in a vise. Tighten socket bolts (35) (2 used). : 6 mm : 20.6 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft) NOTE: Check the mating direction of casings (34, 48) and sub plate (41). 21. Install O-rings (26) (4 used) to plugs (25) (4 used). 22. Install seals (24) (4 used) to plugs (25) (4 used). NOTE: Check the direction to install seal (24).

15. Secure plates (23) (2 used) in a vise. Tighten socket bolts (1) (4 used) to the specified torque. Spray rust proof oil inside the spring chambers in detent casings (20, 44). : 5 mm : 8.8 N⋅m (0.9 kgf⋅m, 6.5 lbf⋅ft)

16. Install O-rings (37) (2 used) to casings (34, 48). W4GB-02-06-015

W2-7-25

BODY / Pilot Valve 47

41 A

44 27 20 34

30 29

32 37

39 Section A-A

38 Section B-B W4GB-02-06-013

W2-7-26

BODY / Pilot Valve 23. Install push rods (27) (4 used) to the plug (25) assemblies (4 used).

CAUTION: When push rods (12) (3 used) and push rod (18) are pushed too much by using screws (3) (4 used), looseness may occur at the neutral position. This may cause sudden machine movement when starting the engine.

24. Install springs (29) (2 used), springs (45, 46) and washers (31) (4 used) to spools (32) (4 used) at the original position. 25. Insert spools (32) (4 used) through the larger hole on spring seats (28) (4 used). Push spring seats (28) (4 used), and compress springs (29) (2 used) and springs (45, 46). Slide and install spring seats (28) (4 used) to spools (32) (4 used). NOTE: Do not push spring seats (28) (4 used) to 6 mm (0.24 in) or more. 26. Install springs (30) (4 used) to casings (34, 48). Install the spool (32) assemblies (4 used) and the plug (25) assemblies (4 used) to casing (34, 48). Apply grease onto the top of push rods (27) (4 used). NOTE: Do not hit the lower ends of spools (32) (4 used) against casings (34, 48) strongly. 27. Install covers (9) (2 used) and the detent casing (20, 44) assemblies to casings (34, 48). Insert and tighten socket bolts (1) (4 used) into the deeper hole on covers (9) (2 used). : 5 mm : 8.8 N⋅m (0.9 kgf⋅m, 6.5 lbf⋅ft) NOTE: Check the positions to install cover (9) and the detent casing (20, 44) assemblies to casing (34).

28. Adjust the heights of screws (3) (4 used). Set levers (4) (2 used) in the vertical position to the upper surface of cover (9). By rotating lever (4) clockwise and counterclockwise, check that no looseness occurs at the neutral position. Tighten screws (3) (4 used) with nuts (2) (4 used). : 13 mm : 16.7 N⋅m (1.7 kgf⋅m, 12.5 lbf⋅ft) NOTE: If clearance exists, it may cause looseness in the angle at beginning of control lever (4) operation. Check that no looseness found after tightening nut (2). 29. Spray rust proof oil onto the inner parts of boot (5). Insert the upper end of boot (5) into the groove on lever (4). Insert the lower end into the groove on cover (9). NOTE: Waterproof degradation may occur unless boot (5) is correctly inserted into the groove.

W2-7-27

BODY / Pilot Valve MAINTENANCE STANDARD 1. Spool (32) diameter Difference between diameter of non-sliding part (a) and sliding part (b) a-b Unit: mm (in) Allowable Limit 0.01 (0.0004) NOTE: In case the value is beyond the allowable limit, replace the pilot valve assembly. a b

2. Push rods (12, 18, 27) length

c d

Standard 87.7 (3.45) 36 (1.42)

W4GB-02-06-016

12, 18

Unit: mm (in) Allowable Limit 86.7 (3.41) 35 (1.38)

3. Bushing (14) inner diameter e Unit: mm (in) Standard Allowable Limit 8 (0.32) 8.5 (0.34)

W4GB-02-06-017

NOTE: When the bushing in the sub assembly of the solenoid is worn away, replace the solenoid valve assembly. 4. Looseness in the control part When looseness on the upper end of lever (4) is 2 mm (0.08 in) or more due to the wear of screw (3), camshaft (8) or DU busing (7), replace the solenoid valve assembly.

W2-7-28

W4GD-02-08-001

BODY / Pilot Valve (Blank)

W2-7-29

BODY / Pilot Valve DISASSEMBLY OF JOY-STICK TYPE PILOT VALVE FOR ADDITIONAL CIRCUIT (OPTIONAL)

17 16 15

13 12 11 10 18

9 8 7 6

5 4

20 21

2 1

W178-02-07-064

123456-

Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used)

78910 11 12 -

Spring Guide (4 Used) Retaining Ring (4 Used) Pusher A (2 Used) Pusher B (2 Used) Oil Seal (4 Used) Sleeve (4 Used)

13 14 15 16 17 -

O-Ring (4 Used) Plate Universal Joint Cam Screw Joint

W2-7-30

18 19 20 21 22 -

Casing Spool (4 Used) O-Ring Plug Retaining Ring

BODY / Pilot Valve Disassembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional) IMPORTANT: Casing (18) is made of aluminium. Too strong a force can deform or damage casing (18). Be careful while handling casing (18). IMPORTANT: Spool (19) has been selected to match the hole of casing (18). The dimensions of balance springs A (3), B (4) and return springs A (5), B (6) as well as those of pushers A (9), B (10) are slightly different. Clearly identify port numbers disassembled parts. Port numbers are stamped on the outer surface of casing (18). IMPORTANT: Do not remove screw joint (17) while securing casing (18) in a vise. The strong torque may act on screw joint (17). 1. Secure screw joint (17) in a vise. Rotate cam (16) by using a spanner. Remove screw joint (17). : 19 mm, 32 mm 2. Lightly secure the flat surface of casing (18) in a vise. Remove cam (16) from universal joint (15). : 32 mm

3. Attach a spanner onto the upper part of universal joint (15). Remove universal joint (15) from plate (14). : 17 mm NOTE: Universal joint (15) is secured on casing (18) by using LOCTITE #262. 4. Remove plate (14) from casing (18). IMPORTANT: Do not damage the surface of sleeve (12). Insert a soft rubber between sleeve (12) and the tool. Oil seal (11) cannot be removed from sleeve (12). Sleeve (12) and oil seal (11) must be replaced as an assembly. 5. Remove sleeve (12) upward by clipping the side of sleeve (12) by using a pair of pliers. IMPORTANT: The dimensions of pushers (9, 10) for ports (1, 3) and ports (2, 4) are different. Clearly identify port numbers of disassembled parts. 6. Remove pushers (9, 10) (3 used for each) from casing (18).

W2-7-31

BODY / Pilot Valve

18 8 7 6

5 4

2 1

W178-02-07-064

W2-7-32

BODY / Pilot Valve 7. Prevent spool (19) (4 used) from lowering when compressing spring (3, 4, 5, and 6) (2 used for each). Install the special tool (ST 4145) to the port hole on casing (18) as illustrated. : 6 mm

IMPORTANT: The quantity of shims (2) has been determined for each port during the performance testing at the factory. Do not lose shim (2). Keep shim (2) carefully in order to install shim (2) to the original port when assembling. 9. Remove the special tool (ST 4146) from casing (18). Remove spring guides (7) (4 used), return springs A (5) (2 used), return springs B (6) (2 used), balance springs A (3) (2 used) and balance springs B (4) (2 used) from casing (18). 10. Remove shim (2) and spacers (1) (4 used) from spools (19) (4 used).

W178-02-07-048

ST 4145

8. Install the special tool (ST 4146) to the pusher hole on casing (18). Push the special tool and compress spring (3, 4, 5, and 6) (2 used for each). Tighten the special tool (ST 4146) by using a socket bolt (M14, Pitch 2.0 mm). Remove retaining rings (8) (4 used) from spools (19) (4 used) by using a screwdriver. : 12 mm ST 4146

IMPORTANT: Spool (19) has been selected to match the hole of casing (18). Replace spool (19) and casing (18) as an assembly. 11. Remove the special tool (ST 4145) from casing (18). Slowly rotate and remove spool (19) from casing (18). IMPORTANT: Retaining ring (22) may come off while disassembling. Prevent retaining ring (22) from falling inside casing (18). If retaining ring (22) falls inside casing (18), remove retaining ring (22) completely. Removed retaining ring (22) cannot be reused. 12. Remove retaining ring (22) from casing (18) by using a screwdriver. Install a bolt (M8, Pitch 1.25 mm) to plug (21). Remove plug (21) from casing (18). : 13 mm

W178-02-07-048

W2-7-33

BODY / Pilot Valve ASSEMBLY OF JOY-STICK TYPE PILOT VALVE FOR ADDITIONAL CIRCUIT (OPTIONAL)

17 15

9, 10 12

8 7 3, 4 5, 6 2

21 20

22 W1V1-02-07-001

123456-

Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used)

78910 11 12 -

Spring Guide (4 Used) Retaining Ring (4 Used) Pusher A (2 Used) Pusher B (2 Used) Oil Seal (4 Used) Sleeve (4 Used)

13 14 15 16 17 -

W2-7-34

O-Ring (4 Used) Plate Universal Joint Cam Screw Joint

18 19 20 21 22 -

Casing Spool (4 Used) O-Ring Plug Retaining Ring

BODY / Pilot Valve Assembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional) IMPORTANT: The pilot valve is susceptible hydraulic component to contamination. Keep the parts clean when assembling. NOTE: The table below shows the relation between each port and component. Do not confuse them when assembling. Port No. 1 2 3

Spool (19)

Shim (2)

Same to the original one

4 Port No. 1 2 3 4

Return Springs (5, 6) Short Long Short Long

Pushers A, B (9, 10) Outer grooves (3 used) Without outer groove Outer grooves (3 used) Without outer groove

IMPORTANT: Refer to the table on the left in order to carry out assembling correctly. 3. Install spacers (1) (4 used), shim (2) and balance springs (3, 4) (2 used for each) to spools (19) (4 used). Install return springs (5, 6) (2 used for each) to casing (18). 4. Install spring guides (7) (4 used) to return springs (5, 6) (2 used for each) with the protrusion facing upward. 5. Install the special tool (ST 4146) to the pusher (9, 10) hole on casing (18). Push the special tool (ST 4146) and compress the spring. Tighten the special tool (ST 4146) by using a bolt (M14, Pitch 2.0 mm). : 12 mm ST 4146

Balance Springs A, B (3, 4) Short Long Short Long

ST 4144

1. Check the port hole number and insert spools (19) (4 used) into the original port. Install the thinner end of spool (19) into the port hole on casing (18) while slowly rotating. NOTE: Spool (19) has been selected to match the port hole. Spool (19) and casing (18) must be replaced as an assembly.

ST 4145

W178-02-07-049

6. Install retaining ring (8) to the ring holder (ST 4144).

2. Install the special tool (ST 4145) to the port hole on casing (18) in order to prevent spool (19) (4 used) from lowering when pushing spring (3, 4, 5, and 6) (2 used for each). : 6 mm

W2-7-35

BODY / Pilot Valve

11 13

9, 10 12 8

3, 4

W1V1-02-07-001

W2-7-36

BODY / Pilot Valve 7. Install retaining rings (8) (4 used) attached to the ring holder (ST 4144) to the groove on the head of spool (21) extended from the special tool (ST 4146). IMPORTANT: Check the mounting positions of pushers (9, 10) (2 used for each). 8. Install pushers (9, 10) (2 used for each). Remove pushers (9, 10) (2 used for each) after pushing several times by hand. Check if retaining ring (8) falls off or balance springs (3, 4) (2 used for each) are located correctly. After checking, install pushers (9, 10) (2 used for each) to casing (18). 9. Apply grease onto the ball part at the ends of pushers (9, 10) (2 used for each).

IMPORTANT: Fit the bolt hole on plate (14) with the screw hole on casing (18). 14. Apply LOCTITE #262 onto the screw part of universal joint (15). Place plate (14) on casing (18). Install universal joint (15). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) IMPORTANT: Check the tighteness of cam (16). 15. Install cam (16) to universal joint (15). The clearance between cam (16) and pushers (9, 10) (2 used for each) should be 0 to 0.2 mm (0 to 0.008 in). 16. Secure cam (16) by using a spanner. Tighten screw joint (17) by using a spanner. : 19 mm, 32 mm : 68.4 N⋅m (6.98 kgf⋅m, 50 lbf⋅ft)

10. Apply grease onto the joint part of universal joint (15). 11. Apply grease onto the inner surface of oil seals (11) (4 used). NOTE: Sleeve (12) and oil seal (11) must be replaced as an assembly. 12. Install oil seals (11) (4 used) to sleeves (12) (4 used). Push the sleeve (12) assemblies (4 used) by hand until O-ring (13) is inserted into the hole on sleeves (12) (4 used). 13. Secure casing (18) in a vise lightly.

W2-7-37

BODY / Pilot Valve (Blank)

W2-7-38

BODY / Pilot Shut-Off Valve REMOVAL AND INSTALLATION OF PILOT SHUT-OFF VALVE CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Open door (1).

W4FC-03-09-002

2. Operate lever (4) and move lever stand (3) forward. 3. Remove screws (2) (6 used) from covers (6) (2 used). Remove covers (6) (2 used) from bracket (5).

4. Remove bolts (8) (2 used) and washers (9) (2 used) from lever (7). Remove lever (7) and block (10) from pilot shut-off valve (11). : 14 mm

W4FC-02-07-008

8, 9

5. Disconnect hoses (12) (4 used) from pilot shut-off valve (11). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 22 mm

W2-8-1

W4FC-02-08-001

BODY / Pilot Shut-Off Valve 6. Open door (13).

W4FC-03-09-001

7. Remove adjuster handles (15) (2 used) and coned disc springs (16) (2 used) from armrest (14). Remove armrest (14) from bracket (5).

15, 16

W4FC-02-08-002

8. Remove screws (18) (4 used) from cover (17). Remove cover (17) from bracket (5).

W4FC-02-08-003

9. Remove bolts (19) (2 used) and washers (20) (2 used) from bracket (5). Remove pilot shut-off valve (11) from bracket (5). : 14 mm 11 5 19, 20

W2-8-2

W4FC-02-08-004

BODY / Pilot Shut-Off Valve Installation 1. Install pilot shut-off valve (11) to bracket (5) with bolts (19) (2 used) and washers (20) (2 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 11 5 W4FC-02-08-004

19, 20

2. Install cover (17) to bracket (5) with screws (18) (4 used).

W4FC-02-08-003

18 14

3. Install armrest (14) to bracket (5) with adjuster handles (15) (2 used) and coned disc springs (16) (2 used).

15, 16

4. Connect hoses (12) (4 used) to pilot shut-off valve (11). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

W4FC-02-08-002

8, 9

5. Install block (10) and lever (7) to pilot shut-off valve (11) with bolts (8) (2 used) and washers (9) (2 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 12

W2-8-3

W4FC-02-08-001

BODY / Pilot Shut-Off Valve 6. Install covers (6) (2 used) to bracket (5) with screws (2) (6 used).

7. Operate lever (4) and move lever stand (3) backward.

W4FC-02-07-008

8. Shut doors (1, 13).

W4FC-03-09-002

W4FC-03-09-001

W2-8-4

BODY / Pilot Shut-Off Valve (Blank)

W2-8-5

BODY / Pilot Shut-Off Valve DISASSEMBLY VALVE

PILOT

SHUT-OFF

1 2 3

9 10 11

1 - Retaining Ring 2 - Washer 3 - Backup Ring

456-

O-Ring Body Socket Bolt

789-

W2-8-6

Spool O-Ring Backup Ring

10 - Washer 11 - Retaining Ring

W4GB-02-08-001

BODY / Pilot Shut-Off Valve Disassembly of Pilot Shut-Off Valve 1. Remove retaining rings (1, 11) and washer (2) from spool (7). Remove spool (7) from body (5) to the direction of socket bolt (6). NOTE: Record the direction to install spool (7). 2. Remove washer (10), backup rings (3, 9) and O-rings (4, 8) from body (5). 3. Remove socket bolt (6) from body (5). : 6 mm

W2-8-7

BODY / Pilot Shut-Off Valve ASSEMBLY OF PILOT SHUT-OFF VALVE

6 Z

11 10

Section Z-Z W4GB-02-08-002

1 - Retaining Ring 2 - Washer 3 - Backup Ring

456-

O-Ring Body Socket Bolt

789-

W2-8-8

Spool O-Ring Backup Ring

10 - Washer 11 - Retaining Ring

BODY / Pilot Shut-Off Valve Assembly of Pilot Shut-Off Valve 1. Apply LOCTITE #262 onto socket bolt (6). Install socket bolt (6) to body (5). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 2. Install O-ring (8), backup ring (9) and washer (10) to body (5). 3. Apply hydraulic oil onto spool (7). Install spool (7) to body (5) from the direction of socket bolt (6) by rotating. At this time, check the direction to install spool (7). 4. Install O-ring (4), backup ring (3) and washer (2) to body (5). Install retaining rings (1, 11) to spool (7).

W2-8-9

BODY / Pilot Shut-Off Valve (Blank)

W2-8-10

BODY / Fan Pump REMOVAL AND INSTALLATION OF FAN PUMP CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal 1. Open cover (1).

W4FC-02-01-006

2. Disconnect hoses (2) (2 used) and O-rings (3) (2 used) from fan pump (4). Cap the open ends. : 27 mm, 41 mm 3. Remove socket bolts (5) (2 used), spring washers (6) (2 used) and washers (7) (2 used) from fan pump (4). Remove fan pump (4) and gasket (9) from engine (8). : 8 mm

2, 3

4 5, 6, 7 8 9

W4FC-02-09-001

W2-9-1

BODY / Fan Pump Installation 1. Install fan pump (4) and gasket (9) to engine (8) with washers (7) (2 used), spring washers (6) (2 used) and socket bolts (5) (2 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2, 3

4 5, 6, 7 8

2. Apply grease onto O-rings (3) (2 used). Install O-rings (3) (2 used) to hoses (2) (2 used).

3. Connect hoses (2) (2 used) to fan pump (4). : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

W4FC-02-09-001

4. Shut cover (1).

W4FC-02-01-006

W2-9-2

BODY / Fan Pump (Blank)

W2-9-3

BODY / Fan Pump STRUCTURE OF FAN PUMP

2, 3

6, 3

9 W4FC-02-09-002

W2-9-4

BODY / Fan Pump

No. 1 2 3 4 5 6 7 8 9 10 11 12

Part Name Socket bolt Front Cover Knock Pin Side Plate Body Rear Cover Driven Gear Drive Gear Retaining Ring Oil Seal Backup ring Seal Plate

Q’ty

Wrench Size (mm)

4 1 4 2 1 1 1 1 1 1 2 2

W2-9-5

Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft)

Remark

BODY / Fan Pump (Blank)

W2-9-6

BODY / Fan Motor REMOVAL AND INSTALLATION OF FAN MOTOR CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Open rear grill (1). 1

W4FC-02-10-001

2. Disconnect hoses (4) (3 used) from fan motors (3). Cap the open ends. : 19 mm, 27 mm

3. Open the cover (2) assembly.

W4FC-02-10-002

4. Remove washer (6) and split pin (7) from stopper (5). Remove stopper (5) from bracket (8). Open the cover (2) assembly.

W4FC-02-10-003

W2-10-1

5, 6, 7

BODY / Fan Motor 5. Remove bolts (10) (8 used), spring washers (11) (8 used), and washers (12) (8 used) from guard (9). Remove guard (9) from cover (2). : 14 mm

10, 11, 12

W4FC-02-10-004

6. Remove bolt (14), spring washer (15), and washer (16) from retainer (13). Remove the fan (17) assembly from fan motor (3) by using a puller. : 14 mm

13 14, 15, 16 17

W4FC-02-10-005

7. Remove bolts (19) (20 used) and washers (20) (2 used) from fan motor (3). Remove fan motor (3) from bracket (18). : 14 mm

3 19, 20

W4FC-02-10-002

W2-10-2

BODY / Fan Motor Installation 1. Install fan motor (3) to bracket (18) with bolts (19) (2 used) and washers (20) (2 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3 19, 20

IMPORTANT: Before connecting hose (4), add 0.12 to 0.2 L (0.03 to 0.05 US gal) of hydraulic oil through port P in fan motor (3). 2. Connect hoses (4) (3 used) to fan motor (3). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W4FC-02-10-002

3. Install the fan (17) assembly to fan motor (3) with bolt (14), spring washer (15), and washer (16). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

14, 15, 16 17

W4FC-02-10-005

4. Install guard (9) to cover (2) with bolts (10) (8 used), spring washers (11) (8 used), and washers (12) (8 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

10, 11, 12

W4FC-02-10-004

W2-10-3

BODY / Fan Motor 5. Install stopper (5) to bracket (8) with washer (6) and split pin (7). 6. Shut the cover (2) assembly.

W4FC-02-10-003

7. Shut rear grill (1).

5, 6, 7

W4FC-02-10-001

W2-10-4

BODY / Fan Motor (Blank)

W2-10-5

BODY (Travel System) / Fan Motor STRUCTURE OF FAN MOTOR 3

26 View A

W2-10-6

W4FC-02-10-006

BODY (Travel System) / Fan Motor Item

Part Name

Q’ty

Port block

O-ring

Valve plate

Cylinder block

Plunger

Spherical bushing

Swash plate

Ball bearing

Oil seal

Shaft

Case

Retainer

Spring seat

Spring

Washer

Retaining ring

Socket bolt

Ball bearing

Plug

O-ring

Spring

Check valve

Wrench Size (mm)

: 8 : 8

N⋅m

Tightening Torque (kgf⋅m) (lbf⋅ft)

61.3±2.45 (6.2±0.25) 39.2±2

W2-10-7

(4±0.2)

(45±1.8) (29±1.5)

Remark

BODY (Travel System) / Fan Motor (Blank)

W2-10-8

SECTION 3

TRAVEL SYSTEM — CONTENTNS — Group 1 Tire

Group 5 Axle

Removal and Installation of Tire.................. W3-1-1

Group 2 HST Pump Removal and Installation of HST Pump ...... W3-2-1 Disassembly of HST Pump ......................... W3-2-6 Assembly of HST Pump ............................ W3-2-14 Structure of Forward/Reverse Selector Control Valve ........................................... W3-2-24 Structure of DA Valve ................................ W3-2-24 Structure of Cutoff Valve ........................... W3-2-25 Structure of Low-Pressure Relief Valve .... W3-2-25 List of Tightening Torque........................... W3-2-26

Group 3 HST Motor

Removal and Installation of Front Axle........W3-5-1 Removal and Installation of Rear Axle ........W3-5-6 Disassembly of Axle ..................................W3-5-12 Assembly of Axle .......................................W3-5-24 Disassembly of Differential (TPD Type Axle).......................................W3-5-40 Assembly of Differential (TPD Type Axle).......................................W3-5-42 Disassembly of Differential (LSD Type Axle).......................................W3-5-44 Assembly of Differential (LSD Type Axle).......................................W3-5-46

Group 6 Propeller Shaft

Removal and Installation of HST Motor ...... W3-3-1 Disassembly of HST Motor 1 and HST Motor 2 .............................................. W3-3-6 Assembly of HST Motor 1 and HST Motor 2 ............................................ W3-3-12 Structure of HST Motor 1 Displacement Angle Control Valve.......... W3-3-16 Structure of HST Motor 2 Displacement Angle Control Valve.......... W3-3-16 Structure of Cover Block ........................... W3-3-17 Structure of Rotary Block .......................... W3-3-18 List of Tightening Torque........................... W3-3-19

Removal and Installation of Propeller Shaft ...........................................W3-6-1

Group 7 Brake Valve Removal and Installation of Brake Valve.....W3-7-1 Structure of Brake Valve ..............................W3-7-4

Group 8 Charging Block Removal and Installation of Charging Block ..........................................W3-8-1 Structure of Charging Block.........................W3-8-6

Group 9 Steering Valve Group 4 Transmission Removal and Installation of Transmission .. W3-4-1 Disassembly of Transmission ................... W3-4-10 Assembly of Transmission ........................ W3-4-22 Disassembly of Clutch Assembly.............. W3-4-34 Assembly of Clutch Assembly................... W3-4-36 Disassembly of Valve Assembly ............... W3-4-38 Assembly of Valve Assembly .................... W3-4-40

Removal and Installation of Steering Valve............................................W3-9-1 Disassembly of Steering Valve ....................W3-9-8 Assembly of Steering Valve .......................W3-9-12

4FCW-3-1

Group 10 Steering Cylinder Removal and Installation of Steering Cylinder..................................... W3-10-1 Disassembly of Steering Cylinder ............. W3-10-4 Assembly of Steering Cylinder .................. W3-10-8

Group 11 Priority Valve Removal and Installation of Priority Valve ........................................... W3-11-1 Structure of Priority Valve.......................... W3-11-4

4FCW-3-2

TRAVEL SYSTEM / Tire REMOVAL AND INSTALLATION OF TIRE

Removal 1. Secure the front and the rear frames with the articulate lock bar and the pin. 2. When removing the rear tires, insert wooden block (1) between the rear frame and the rear axle on both left and right sides in order to prevent the axle from moving.

W4FC-03-01-005

3. Loosen wheel bolts (2) (ZW140: 12 used, ZW150: 15 used) of tire (3) by about one turn. : 36 mm

ZW140

CAUTION: Machine weight: ZW140: 10370 kg (22900 lb) ZW150: 11960 kg (26400 lb) 4. Raise the machine until tire (3) slightly gets away from the road surface. Support the machine securely by using the blocks. W4FC-03-01-001

ZW150

W4FC-03-01-002

W3-1-1

TRAVEL SYSTEM / Tire CAUTION: Tire (3) weight: ZW140: 205 kg (460 lb) ZW150: 310 kg (690 lb) 5. Attach a lifting tool onto tire (3). Hoist and hold tire (3). 6. Remove wheel bolts (2) (ZW140: 12 used, ZW150: 15 used) and washers (4) (ZW140: 12 used, ZW150: 15 used). Remove tire (3) from the axle. : 36 mm

3 2

4 W4GB-03-01-003

W3-1-2

TRAVEL SYSTEM / Tire Installation CAUTION: Tire (3) weight: ZW140: 205 kg (460 lb) ZW150: 310 kg (690 lb) 1. Hoist and install tire (3) to the axle with the air valve side facing outside. 3

2. Install wheel bolts (2) (ZW140: 12 used, ZW150: 15 used) and washers (4) (ZW140: 12 used, ZW150: 15 used) to tire (3). Lightly tighten wheel bolts (2) (ZW140: 12 used, ZW150: 15 used) and washers (4) (ZW140: 12 used, ZW150: 15 used)

4 W4GB-03-01-003

ZW140

3. Lower the machine. Tighten wheel bolts (2) wheel bolts (2) (ZW140: 12 used, ZW150: 15 used) according to the order as illustrated. : 36 mm : 890 N⋅m (91 kgf⋅m, 660 lbf⋅ft)

5 7

8 6

9 4

W4FC-03-01-003

ZW150

3 5

6 4

13 2

W4FC-03-01-004

W3-1-3

TRAVEL SYSTEM / Tire 4. Remove wooden block (1) between the rear frame and the rear axle on both left and right sides.

W4FC-03-01-005

W3-1-4

TRAVEL SYSTEM / HST Pump REMOVAL AND INSTALLATION OF HST PUMP Removal CAUTION: Cab (1) weight: 960 kg (2120 lb) 1

1. Remove cab (1). (Refer to REMOVAL AND INSTALLATION OF CAB on W2-1-1.)

CAUTION: 4-unit pump (2) weight: 31 kg (68 lb)

W4FC-02-01-003

2. Remove 4-unit pump (2). (Refer to REMOVAL AND INSTALLATION OF 4-UNIT PUMP on W2-5-1.)

W4FC-02-05-001

3. Disconnect hoses (3) (2 used) from HST pump (4). Cap the open ends. : 32 mm, 36 mm 4. Remove bolts (12) (8 used) from split flanges (10) (4 used). Remove split flanges (10) (4 used) and hoses (13) (2 used) from block (5) (2 used). Cap the open ends. : 17 mm 5. Remove bolts (7) (8 used), spring washers (8) (8 used) and washers (9) (8 used) from split flanges (6) (4 used). Remove hoses (11) (2 used), split flanges (6) (4 used) and blocks (5) (2 used) from HST pump (4). Cap the open ends. : 17 mm

7, 8, 9

10 11

W4FC-03-02-022

7, 8, 9

W3-2-1

TRAVEL SYSTEM / HST Pump 4

6. Disconnect connectors (14) (2 used).

7. Disconnect hoses (15) (2 used) from HST pump (4). Cap the open ends. : 27 mm

W4FC-03-02-023

8. Loosen hose clamps (18) (2 used) from rubber hoses (16) (2 used). Remove the pipe (17) assembly from HST pump (4) and hydraulic oil tank (19).

CAUTION: The HST pump (4) assembly weight: 80 kg (180 lb) HST pump (4) weight: 67 kg (150 lb)

W4FC-03-02-026

21, 22

9. Attach a nylon sling onto HST pump (4). Hoist and hold HST pump (4).

10. Remove bolts (21) (12 used) and washers (22) (12 used) from flange (20). Remove HST pump (4) assembly from engine (23). : 14 mm W4FC-03-02-024

11. Remove socket bolt (25) from gear coupling (24). Remove gear coupling (24) from HST pump (4). : 10 mm 25

W4FC-03-02-025

W3-2-2

TRAVEL SYSTEM / HST Pump CAUTION: The HST pump (4) assembly weight: 80 kg (180 lb) HST pump (4) weight: 67 kg (150 lb) 20

12. Place HST pump (4) with the flange (20) side facing downward on a wooden block. Attach a nylon sling onto HST pump (4). Hoist and hold HST pump (4).

13. Remove bolts (26) (6 used) and washers (27) (6 used) from HST pump (4). Remove HST pump (4) from flange (20). : 24 mm W4FC-03-02-024

26, 27

Installation CAUTION: HST pump (4) weight: 67 kg (150 lb) 1. Attach a nylon sling onto HST pump (4). Hoist HST pump (4). Fit HST pump (4) with the mounting hole on flange (20).

2. Install HST pump (4) to flange (20) with bolts (26) (6 used) and washers (27) (6 used). : 24 mm : 232 N⋅m (24 kgf⋅m, 170 lbf⋅ft)

CAUTION: The HST pump (4) assembly weight: 80 kg (180 lb) 3. Attach a nylon sling onto the HST pump (4) assembly. Hoist the HST pump (4) assembly. Turn over the HST pump (4) assembly. 4. Install gear coupling (24) to HST pump (4) with socket bolt (25). : 10 mm : 86 N⋅m (8.8 kgf⋅m, 63 lbf⋅ft)

W4FC-03-02-024

26, 27 4

W4FC-03-02-025

W3-2-3

TRAVEL SYSTEM / HST Pump CAUTION: The HST pump (4) assembly weight: 80 kg (180 lb)

21, 22

5. Attach a nylon sling onto the HST pump (4) assembly. Hoist the HST pump (4) assembly. Fit the hole on flange (20) with the mounting hole of engine (23).

6. Install flange (20) to engine (23) with bolts (21) (12 used) and washers (22) (12 used). : 14 mm : 52 N⋅m (5 kgf⋅m, 38 lbf⋅ft) W4FC-03-02-024

7. Connect the pipe (17) assembly to the mounting holes on HST pump (4) and hydraulic oil tank (19).

8. Install rubber hoses (16) (2 used) to HST pump (4) and hydraulic oil tank (19) with hose clamps (18) (2 used). : 6 N⋅m (0.6 kgf⋅m, 4.4 lbf⋅ft) 19

9. Connect connectors (14) (2 used).

W4FC-03-02-026

10. Connect hoses (15) (2 used) to HST pump (4). : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W4FC-03-02-023

W3-2-4

TRAVEL SYSTEM / HST Pump 11. Connect hoses (13) (2 used) to blocks (5) (2 used) with split flanges (10) (4 used) and bolts (12) (8 used). : 17 mm : 52 N⋅m (5 kgf⋅m, 38 lbf⋅ft) 12. Connect the block (5) assemblies (2 used) and hoses (11) (2 used) to HST pump (4) with split flanges (6) (4 used), bolts (7) (8 used), spring washers (8) (8 used) and washers (9) (8 used). : 17 mm : 52 N⋅m (5 kgf⋅m, 38 lbf⋅ft)

7, 8, 9

10 11

13. Connect hoses (3) (2 used) to HST pump (4). : 32 mm : 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

W4FC-03-02-022

7, 8, 9

CAUTION: 4-unit pump (2) weight: 31 kg (68 lb) 2

14. Install 4-unit pump (2). (Refer to REMOVAL AND INSTALLATION OF 4-UNIT PUMP on W2-5-1.)

W4FC-02-05-001

CAUTION: Cab (1) weight: 960 kg (2120 lb) 15. Install cab (1). (Refer to REMOVAL AND INSTALLATION OF CAB on W2-1-1.)

W4FC-02-01-003

W3-2-5

TRAVEL SYSTEM / HST Pump DISASSEMBLY OF HST PUMP 15

13 12

4 5

8 7

2 1

9 45

10 17

35 24

16 25

20 27

26 25

39 38

30 31

36 54

35 34

51 47

41 43

33 32

52 58

46 77

76 66

57 56

67 68 72 69 73

70 W4FC-03-02-001

W3-2-6

TRAVEL SYSTEM / HST Pump 1 - Housing 2 - Plug (3 Used) 3 - Forward/Reverse Selector Control Valve 4 - Socket Bolt (2 Used) 5 - Socket Bolt (4 Used) 6 - Drive Shaft 7 - Bearing 8 - Retaining Ring 9 - Bearing Cup (2 Used) 10 - Bearing (2 Used) 11 - Swash Plate

21 - Spring 22 - Disc Spring 23 - Shim

41 - Adjusting Screw 42 - Joint Pin (2 Used) 43 - Retaining Ring (2 Used)

61 - O-Ring 62 - Wheel Gear 63 - Through Drive Shaft

24 - Plug 25 - Retaining Ring (2 Used) 26 - Spring Collar (2 Used) 27 - Ring (2 Used) 28 - Positioning Piston 29 - O-Ring 30 - Cover 31 - Nut

64 - Wear Plate 65 - O-Ring 66 - Bushing 67 - Plug (2 Used) 68 - DA Valve 69 - Low-Pressure Relief Valve 70 - Plug 71 - Plug

12 - Pin (2 Used) 13 - Lever 14 - Retainer 15 - Piston (9 Used) 16 - Guide 17 - Cylinder 18 - Control Plate 19 - Retaining Ring 20 - Shim (2 Used)

32 - Socket Bolt (8 Used) 33 - O-Ring (2 Used) 34 - Guide Ring (2 Used) 35 - Seal Ring (2 Used) 36 - Adjusting Screw 37 - Spring (2 Used) 38 - Spring (2 Used) 39 - Spring Collar (2 Used) 40 - Lock Nut

44 - Shaft Seal 45 - Cover 46 - Port Plate 47 - Cutoff Valve 48 - Plug 49 - Plug 50 - Orifice 51 - High-Pressure Relief Valve (2 Used) 52 - Socket Bolt (4 Used) 53 - Holding Element (2 Used) 54 - Key 55 - Bushing 56 - O-Ring 57 - Spacer 58 - O-Ring 59 - Socket Bolt (4 Used) 60 - Flange

W3-2-7

72 - Metal 73 - O-Ring 74 - Bushing 75 - O-Ring 76 - Orifice 77 - Plug (2 Used) 78 - Ring (2 Used) 79 - Plug (2 Used)

TRAVEL SYSTEM / HST Pump

4 5

41 40

53 52 58

76 66

57 56

72 61 73

71 W4FC-03-02-001

W3-2-8

TRAVEL SYSTEM / HST Pump Disassembly of HST Pump IMPORTANT: Refer to the end section pages of this group for tightening torque values of the nuts unless otherwise specified.

IMPORTANT: Record the adjusting screw (41) dimension (x) and put the mark of groove position. x

â&#x20AC;˘ When disassembling HST pump, hold the bare minimum of disassembling. Record the dimensions of adjusting parts such as an adjusting screw completely. Return the dimensions of adjusting parts to the original dimensions when reassembling.

1. Remove socket bolts (4) (2 used) and (5) (4 used). Remove forward/reverse control valve (3) from housing (1). W4FC-03-02-002

2. Put the mating marks on port plate (46) and flange (60). 3. Remove socket bolts (59) (4 used). Remove the flange (60) assembly from port plate (46). 4. Remove wheel gear (62), through drive shaft (63), key (54), bushing (55), O-rings (56, 58, and 61), and spacer (57) from flange (60). 5. Remove holding elements (53) (2 used), wear plate (64), O-ring (65) and bushing (66) from port plate (46).

6. Loosen lock nut (40). Adjust the groove of adjusting screw (41) to the clock hand position at three oâ&#x20AC;&#x2122;clock (disassembling position). 7. Put the matching marks on housing (1) and port plate (46). 8. Remove socket bolts (52) (4 used). Remove port plate (46) and control plate (18) from housing (1). 9. While pushing cylinder (17) downward, remove adjusting screw (41) from housing (1). 17

W4FC-03-02-003

10. Remove bushing (74), metal (72), O-rings (73, 75), plug (71), and orifice (76) from port plate (46).

W3-2-9

TRAVEL SYSTEM / HST Pump 15

13 12 10

8 7 1

6 9

10 17

42 20

22 23 43

42 79

W4FC-03-02-001

W3-2-10

TRAVEL SYSTEM / HST Pump 11. Remove the cylinder (17) assembly from housing (1).

17. Remove drive shaft (6) from housing (1) by using a plastic hammer. 1

12. Remove retainer (14), pistons (15) (9 used), guide (16), shim (23), and disc spring (22) from cylinder (17). IMPORTANT: Do not fly out spring (21). 13. Remove retaining ring (19), shims (20) (2 used) and spring (21) from cylinder (17).

14. Remove retaining ring (43) from housing (1). 15. Install screws (a) (2 used) to the shaft seal (44) hole. Remove shaft seal (44) from housing (1). W4FC-03-02-005

a 44

18. Remove retaining ring (8) and bearing (7) from front drive shaft (6).

19. Remove plugs (79) (2 used) and joint pins (42) (2 used) from housing (1). 20. Remove swash plate (11), bearings (10) (2 used) and bearing cups (9) (2 used) from housing (1). 21. Remove lever (13) and pins (12) (2 used) from swash plate (11). W4FC-03-02-004

16. Remove retaining ring (43) from housing (1).

W3-2-11

TRAVEL SYSTEM / HST Pump

27 28

26 25

39 38

29 31

36 35 34

51 47

33 32

69 51 W4FC-03-02-001

W3-2-12

TRAVEL SYSTEM / HST Pump 22. Put the matching marks on housing (1) and covers (30, 45). IMPORTANT: Record the adjusting screw (36) dimension (x).

IMPORTANT: Do not fly out spring collar (26). 28. While pushing spring collar (26), remove rings (27) (2 used) and retaining ring (25) from spring collar (26). Remove rings (78) (2 used) and retaining ring (25) on the opposite side in the same procedures.

27, 78

25 26

W4FC-03-02-006 W4FC-03-02-007

23. Secure adjusting screw (36). Remove nut (31) from adjusting screw (36). 24. Remove socket bolts (32) (8 used). Remove covers (30, 45) and O-rings (33) (2 used) from housing (1). 25. Remove the positioning piston (28) assembly from housing (1).

29. Remove spring collars (26, 39) (2 used for each), springs (37, 38) (2 used for each) and adjusting screw (36) from positioning piston (28). IMPORTANT: Remove cutoff valve (47), high-pressure relief valves (51) (2 used), DA valve (68), low-pressure relief valve (69), plug (49) and orifice (50) as necessary.

26. Remove guide rings (34) (2 used) and seal rings (35) (2 used) from housing (1). 27. Remove O-ring (29) from adjusting screw (36).

W3-2-13

TRAVEL SYSTEM / HST Pump ASSEMBLY OF HST PUMP B

75, 76

58 56 61

14 7 8

64 54

6 55 62

52 53

43 B

12 16

18 72 66

60 W4FC-03-02-008

Section A-A 32

36 28 35

26 25 29 32

40, 41 W4FC-03-02-009

W3-2-14

TRAVEL SYSTEM / HST Pump Section B-B

51 67 71

69 67 51

W4FC-03-02-010

1 - Housing 2 - Plug (3 Used) 3 - Forward/Reverse Selector Control Valve 4 - Socket Bolt (2 Used) 5 - Socket Bolt (4 Used) 6 - Drive Shaft 7 - Bearing 8 - Retaining Ring 9 - Bearing Cup (2 Used) 10 - Bearing (2 Used) 11 - Swash Plate

21 - Spring 22 - Disc Spring 23 - Shim

41 - Adjusting Screw 42 - Joint Pin (2 Used) 43 - Retaining Ring (2 Used)

61 - O-Ring 62 - Wheel Gear 63 - Through Drive Shaft

24 25 26 27 28 29 30 31 -

*Plug Retaining Ring (2 Used) Spring Collar (2 Used) Ring (2 Used) Positioning Piston O-Ring Cover Nut

44 45 46 47 48 49 50 51 -

64 65 66 67 68 69 70 71 -

Wear Plate O-Ring Bushing Plug (2 Used) DA Valve Low-Pressure Relief Valve *Plug Plug

12 13 14 15 16 17 18 19 20 -

32 33 34 35 36 37 38 39 40 -

Socket Bolt (8 Used) O-Ring (2 Used) Guide Ring (2 Used) Seal Ring (2 Used) Adjusting Screw Spring (2 Used) Spring (2 Used) Spring Collar (2 Used) Lock Nut

52 53 54 55 56 57 58 59 60 -

72 73 74 75 76 77 78 79 -

Metal O-Ring Bushing O-Ring Orifice Plug (2 Used) Ring (2 Used) Plug (2 Used)

Pin (2 Used) Lever Retainer Piston (9 Used) Guide Cylinder Control Plate Retaining Ring Shim (2 Used)

Shaft Seal Cover Port Plate Cutoff Valve *Plug *Plug *Orifice High-Pressure Relief Valve (2 Used) Socket Bolt (4 Used) Holding Element (2 Used) Key Bushing O-Ring Spacer O-Ring Socket Bolt (4 Used) Flange

NOTE: As for the parts with mark *, refer to W3-2-2.

W3-2-15

TRAVEL SYSTEM / HST Pump

W4FC-03-02-008

Section A-A 32

36 28 35

26 25 29 32

30 W4FC-03-02-009

W3-2-16

TRAVEL SYSTEM / HST Pump Assembly of HST Pump 1. Install seal rings (35) (2 used) to housing (1). 2. Install guide rings (34) (2 used) to housing (1). 3. Install adjusting screw (36), spring collars (26, 39) (2 used for each) and springs (37, 38) (2 used for each) to positioning piston (28).

IMPORTANT: Install so that lever (13) and groove (a) on positioning piston (28) are positioned as illustrated. 6. Install the positioning piston (28) assembly to housing (1). 28 a

4. While pushing spring collar (26), install retaining ring (25) and rings (78) (2 used) to spring collar (26). Install retaining ring (25) and rings (27) (2 used) on the opposite side in the same procedures. 13

5. Install O-ring (29) to adjusting screw (36).

W4FC-03-02-011

7. Install O-rings (33) (2 used) to covers (30, 45). 8. Install covers (30, 45) onto housing (1) with socket bolts (32) (8 used) while aligning the matching marks made when disassembling. 9. Install nut (31) to adjusting screw (36). Adjust the adjusting screw (36) to the recorded dimension before disassembling with nut (31).

W3-2-17

TRAVEL SYSTEM / HST Pump

9 7 8

12 W4FC-03-02-008

W3-2-18

TRAVEL SYSTEM / HST Pump 10. Place housing (1) with the drive shaft (6) side in housing (1) facing downward. Install bearing cups (9) (2 used) and bearing (10) (2 used).

15. Secure swash plate (11) by using the special tools (2 used). Securing special tool Unit: mm 50

11. Install lever (13) and pins (12) (2 used) to swash plate (11).

M16, Length 30

12. Install swash plate (11) to housing (1). 13. Adjust swash plate (11) to the center position by using measuring devices (dial gauge or depth meter). The dimensions at points (a, b) should be the same.

20 90

10 70

30 M10

a W4FC-03-02-013

16. Install bearing (7) to drive shaft (6) with retaining ring (8).

17. Install the drive shaft (6) assembly to housing (1).

W4FC-03-02-012

18. Install retaining rings (43) (2 used) and shaft seal (44) to housing (1).

14. Install joint pins (42) (2 used) and plugs (79) (2 used) to housing (1).

W3-2-19

TRAVEL SYSTEM / HST Pump

75, 76

15 52

18 72

46 W4FC-03-02-008

Section B-B

W4FC-03-02-010

W3-2-20

TRAVEL SYSTEM / HST Pump 19. Install shims (20) (2 used) and spring (21) to cylinder (17) with retaining ring (19). 20. Install disc spring (22), shim (23), and guide (16) to cylinder (17).

24. While pushing cylinder (17) downward, install adjusting screw (41). Adjust the adjusting screw (41) to the recorded dimension before disassembling. Set the groove to the position (disassembling position) as illustrated below.

21. Install retainer (14) and piston (15) (9 used) to cylinder (17).

22. Place housing (1) with the drive shaft (6) in housing (1) facing downward. Remove securing special tools (2 used) of swash plate (11). 23. Hold the cylinder (17) assembly by using an O-ring. Install the cylinder (17) assembly to housing (1).

W4FC-03-02-015

25. Install control plate (18) to cylinder (17) as illustrated.

Clockwise Rotation Control Plate (18) W4FC-03-02-016 W4FC-03-02-014

26. Install metal (72), bushing (74), plug (71), orifice (76), and O-rings (73, 75), to port plate (46). 27. Install port plate (46) onto housing (1) with socket bolts (52) (4 used) while aligning the matching marks made when disassembling.

W3-2-21

TRAVEL SYSTEM / HST Pump

65 58 56 61 64 54 55 62 53

60 W4FC-03-02-008

Section A-A

40, 41 W4FC-03-02-009

W3-2-22

TRAVEL SYSTEM / HST Pump 28. Align the groove of adjusting screw (41) with the matching marks for assembling. Adjust the adjusting screw (41) to the recorded dimension before disassembling again. Secure adjusting screw (41) with lock nut (40). 29. Install bushing (66), O-ring (65), wear plate (64), and holding elements (53) (2 used) to port plate (46).

33. Install the flange (60) assembly to port plate (46) with socket bolts (59) (4 used) while aligning the matching marks made when disassembling. NOTE: When HST pump is clockwise rotation, install crescent (a) on the flange (60) assembly with crescent (a) facing to the illustrated direction below. 46

30. Install O-rings (56, 58) and spacer (57) to flange (60). 31. Install key (54) and wheel gear (62) to through drive shaft (63). 32. Install bushing (55), O-ring (61), and the wheel gear (62) assembly to flange (60). 62

W4FC-03-02-017

34. Install forward/reverse selection solenoid valve (3) to housing (1) with socket bolts (5) (4 used) and socket bolts (4) (2 used).

W3-2-23

TRAVEL SYSTEM / HST Pump STRUCTURE OF FORWARD/REVERSE SELECTOR CONTROL VALVE

W4FC-03-02-018

1 - O-Ring (3 Used) 2 - O-Ring 3 - O-Ring

4 - Plug 5 - Solenoid (2 Used) 6 - Plug (4 Used)

7 - Housing 8 - Piston 9 - Spring Collar (2 Used)

10 - Spring (2 Used)

STRUCTURE OF DA VALVE 1

14 W4FC-03-02-019

1234-

Lock Nut Adjusting Screw Casing O-Ring

5678-

Plunger Retaining Ring Ring Retaining Ring

9 - Spring Collar (2 Used) 10 - Spring 11 - Washer 12 - Nut

W3-2-24

13 - Bushing 14 - Retaining Ring

TRAVEL SYSTEM / HST Pump STRUCTURE OF CUTOFF VALVE 1

W4FC-03-02-020

1 - Lock Nut 2 - Adjusting Screw 3 - Plug

4 - O-Ring 5 - Spring 6 - Spring Collar (2 Used)

7 - Poppet 8 - Piston 9 - Barrel

10 - Spool 11 - Valve Seat 12 - O-Ring

STRUCTURE OF LOW-PRESSURE RELIEF VALVE

W4FC-03-02-021

1 - Lock Nut 2 - Plug

3 - O-Ring 4 - Adjusting Screw

5 - Valve Piston 6 - Spring Collar

W3-2-25

7 - Spring

TRAVEL SYSTEM / HST Pump LIST OF TIGHTENING TORQUE Bolt and Socket Bolt Bolt Dia mm

Strength Category 8.8

10.9

12.9

N⋅m

(kgf⋅m)

(lbf⋅ft)

N⋅m

(kgf⋅m)

(lbf⋅ft)

N⋅m

(kgf⋅m)

(lbf⋅ft)

1.1

(0.1)

(0.8)

1.6

(0.2)

(1.2)

1.9

(0.2)

(1.4)

3.1

(0.3)

(2.3)

4.5

(0.5)

(3.3)

5.3

(0.5)

(3.9)

6.1

(0.6)

(4.5)

8.9

(0.9)

(6.6)

10.5

(1.1)

(7.7)

10.5

(1.1)

(7.7)

15.5

(1.6)

(11.5)

18.0

(1.8)

(13.5)

(2.6)

(18.5)

(3.8)

(27.5)

(4.4)

(31.5)

M10

(5.2)

(38)

(7.7)

(55)

(8.9)

(64)

M12

(8.9)

(64)

130

(13.5)

(96)

150

(15.5)

(111)

M14

140

(14.5)

(101)

205

(21)

(151)

240

(24.5)

(175)

M16

215

(22)

(159)

310

(31.5)

(230)

370

(38)

(275)

M18

300

(30.5)

(215)

430

(44)

(320)

510

(52)

(380)

M20

430

(44)

(320)

620

(63)

(460)

720

(73)

(530)

M22

580

(59)

(430)

830

(85)

(610)

970

(99)

(720)

M24

740

(75)

(550)

1060

(108)

(780)

1240

(126)

(910)

Bolt Dia mm

N⋅m

(kgf⋅m)

(lbf⋅ft)

Bolt Dia in

N⋅m

(kgf⋅m)

(lbf⋅ft)

M8, Pitch 1

5.0

(0.5)

(3.7)

G1/8A

(1.0)

(7.2)

M10, Pitch 1

(1.0)

(7.2)

G1/4A

(3.1)

(21.5)

M12, Pitch 1.5

(2.0)

(14.5)

G3/8A

(3.6)

(25.5)

M14, Pitch 1.5

(3.1)

(21.5)

G1/2A

(6.1)

(44)

M16, Pitch 1.5

(3.6)

(26)

G3/4A

(9.2)

(65)

M18, Pitch 1.5

(4.1)

(29.5)

G1A

140

(14.5)

(101)

M20, Pitch 1.5

(5.1)

(36)

G1-1/4A

240

(24.5)

(175)

M22, Pitch 1.5

(6.1)

(44)

G1-1/2A

300

(30.5)

(215)

M26, Pitch 1.5

(7.1)

(52)

M27, Pitch 2

(9.2)

(65)

M30, Pitch 1.5

100

(10.0)

(74)

M33, Pitch 2

140

(14.5)

(101)

M42, Pitch 2

240

(24.5)

(175)

M48, Pitch 2

300

(30.5)

(215)

Square Ring Seal Plug

W3-2-26

TRAVEL SYSTEM / HST Pump O-Ring Seal Plug Bolt Dia mm

N⋅m

(kgf⋅m)

(lbf⋅ft)

Bolt Dia in

N⋅m

(kgf⋅m)

(lbf⋅ft)

M12, Pitch 1.5

(2.0)

(14.5)

G1/8A

13.0 to 17.5

(1.3 to 1.8)

(9.6 to 13)

M14, Pitch 1.5

(3.1)

(21.5)

G1/4A

31 to 41

(3.2 to 4.2)

(23 to 30)

M27, Pitch 1.5

(9.2)

(65)

G3/8A

62 to 82

(6.3 to 8.4)

(46 to 60)

G1/2A

106 to 141

(11 to 14.5)

(78 to 104)

G3/4A

212 to 282

(21.5 to 29) (156 to 210)

G1A

220 to 260 (22.5 to 26.5) (162 to 190)

G1-1/4A

420 to 520

(43 to 53)

(310 to 380)

G1-1/2A

590 to 740

(60 to 75)

(440 to 550)

Unify Thread Plug Bolt Dia mm

N⋅m

(kgf⋅m)

(lbf⋅ft)

Bolt Dia in

N⋅m

(kgf⋅m)

(lbf⋅ft)

7/16-20UNF

(1.5)

(11)

1-1/16-12UN

147

(15)

(108)

1/2-20UNF

(2.0)

(14.5)

1-3/16-12UN

175

(18)

(129)

9/16-18UNF

(2.6)

(18.5)

1-5/16-12UN

200

(20.5)

(148)

3/4-16UNF

(7.3)

(53)

1-5/8-12UN

320

(32.5)

(235)

7/8-14UN

127

(13)

(94)

1-7/8-12UN

390

(40)

(290)

Bolt Dia mm

N⋅m

(kgf⋅m)

(lbf⋅ft)

Bolt Dia mm

N⋅m

(kgf⋅m)

(lbf⋅ft)

(1.0)

(7.2)

M12

(7.0)

(51)

M6, Pitch 0.5

(1.1)

(8.1)

M12, Pitch 1.5

(7.3)

(53)

(2.2)

(16)

M14

110

(11)

(80)

M8, Pitch 1

(2.4)

(17.5)

M14, Pitch 1.5

120

(12)

(87)

M10

(4.1)

(29.5)

M16

170

(17.5)

(123)

M10, Pitch 1

(4.5)

(32.5)

M16, Pitch 1.5

180

(18.5)

(130)

Lock Nut

W3-2-27

TRAVEL SYSTEM / HST Pump (Blank)

W3-2-28

TRAVEL SYSTEM / HST Motor REMOVAL AND INSTALLATION OF HST MOTOR Preparation 1. Place the machine on a firm and level surface. Lower the bucket to the ground. 2. Place a block in front of and behind the axle in order to secure the machine. CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Removal 1. Remove propeller shaft (1). (Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-6-1.)

W4GB-03-04-001

W4FC-03-06-001

2. Place a container under HST motors (2, 3). Disconnect hoses (4) (2 used) from HST motors (2, 3). Cap the open ends. : 36 mm

2, 3

W4FC-03-03-018

W3-3-1

TRAVEL SYSTEM / HST Motor 3. Remove bolts (6) (16 used) from split flanges (7) (8 used). Remove split flanges (7) (8 used) from hoses (5) (4 used). ZW140 : 19 mm ZW150 : 22 mm

6 7

4. Disconnect hoses (5) (4 used) from HST motors (2, 3). Cap the open ends. Attach identification tags onto the disconnected hoses for assembling. 7

5. Disconnect connector (8).

W4FC-03-03-017

6. Disconnect hoses (9) (2 used) from HST motors (2, 3). Cap the open ends. : 36 mm

CAUTION: HST motors (2, 3) weight: ZW140 HST motors (2, 3): 47 kg (110 lb) ZW150 HST motor (2): 60 kg (140 lb) HST motor (3): 47 kg (110 lb)

W4FC-03-03-016

7. Support the lower side of HST motors (2, 3) by using a forklift.

10, 11

8. Remove bolts (10) (8 used) and washers (11) (8 used) from HST motors (2, 3). Remove HST motors (2, 3) from transmission (12). : 24 mm 12

W3-3-2

W4FC-03-03-017

TRAVEL SYSTEM / HST Motor Installation CAUTION: HST motors (2, 3) weight: ZW140 HST motors (2, 3): 47 kg (110 lb) ZW150 HST motor (2): 60 kg (140 lb) HST motor (3): 47 kg (110 lb) 1. Fit HST motors (2, 3) with the mounting hole on transmission (12) by using a forklift.

10, 11

2. Install HST motors (2, 3) to transmission (12) with bolts (10) (8 used) and washers (11) (8 used). : 24 mm : 232 N⋅m (23 kgf⋅m, 170 lbf⋅ft) 12

3. Connect hoses (4) (2 used) to HST motors (2, 3). : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

W4FC-03-03-017

2, 3

W4FC-03-03-018

4. Connect hoses (5) (4 used) to HST motors (2, 3) with split flanges (7) (8 used) and bolts (6) (16 used). ZW140 : 19 mm : 80 N⋅m (8 kgf⋅m, 58 lbf⋅ft) ZW150 : 22 mm : 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

6 7

W3-3-3

W4FC-03-03-017

TRAVEL SYSTEM / HST Motor 5. Connect hoses (9) (2 used) to HST motors (2, 3). : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) NOTE: Add hydraulic oil into HST motors (2, 3) before installing hoses (9) (2 used).

6. Connect connector (8).

7. Install propeller shaft (1). (Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-6-1.)

W4FC-03-03-016

W4FC-03-06-001

W3-3-4

TRAVEL SYSTEM / HST Motor (Blank)

W3-3-5

TRAVEL SYSTEM / HST Motor DISASSEMBLY OF HST MOTOR 1 AND HST MOTOR 2 A

17 12

18 19

11 10

9 8 7 21

5 4 6 10 3

25 26 27

28 29

ZW150

ZW140

35 A

34 B W4FC-03-03-001

A: HST Motor 1 B: HST Motor 2 123456-

Retaining Ring Shim Shaft Seal Ring Housing Lock Nut Adjusting Screw

7 - O-Ring 8 - Rotary Group 9 - Valve Plate

10 - Knock Pin (2 Used) 11 - Valve Block 12 - O-Ring (6 Used) 13 - Bolt (4 Used) 14 - Cover Block 15 - Socket Bolt (4 Used)

19 - Thread Pin 20 - Positioning Piston 21 - Socket Bolt (8 Used) 22 - O-Ring (4 Used) 23 - Positioning Trunnion 24 - Valve Seat

16 - Cover Block 17 - Socket Bolt 18 - Piston

25 - Poppet 26 - Valve Guide 27 - O-Ring

W3-3-6

28 - Backup Ring 29 - O-Ring 30 - Valve Seat 31 - Check Valve 32 - O-Ring 33 - HST Motor 2 Displacement Angle Control Solenoid Valve 34 - Socket Bolt (4 Used) 35 - Socket Bolt (4 Used) 36 - HST Motor 1 Displacement Angle Control Solenoid Valve

TRAVEL SYSTEM / HST Motor Disassembly of HST Motor 1 and HST Motor 2 IMPORTANT: In addition, do not disassemble each adjusting screw part. The setting changes and the machine malfunctions. IMPORTANT: Refer to the end section pages of this group for tightening torque values of nuts unless otherwise specified.

4. Install screws (b) (2 used) to the shaft seal ring (3) hole. Remove shaft seal ring (3) from housing (4). b 3

1. Remove retaining ring (1) from housing (4). 2. Install special tool (a) to rotary group (8). Put the mark of press fitting depth on the special tool (a).

W4FC-03-03-003

5. Remove socket bolts (13 or 15) (4 used). Remove cover block (14 or 16) and O-ring (12) (6 used) from valve block (11).

W4FC-03-03-002

3. Remove shim (2).

IMPORTANT: Do not fly out the parts of HST motor 1 displacement angle control valve (36) and HST motor 2 displacement angle control valve (33). 6. Remove socket bolts (34 or 35) (4 used). Remove HST motor 1 displacement angle control valve (36) and HST motor 2 displacement angle control valve (33) from valve block (11). Remove O-ring (22) from valve block (11). 7. (ZW140) Remove O-ring (32), check valve (31), and valve seat (30) from valve block (11). (ZW150) Remove O-rings (27, 29), backup ring (28), valve guide (26), poppet (25), and valve seat (24) from valve block (11).

W3-3-7

TRAVEL SYSTEM / HST Motor A

9 8 7 21

5 4 6

ZW140

ZW150

B W4FC-03-03-001

W3-3-8

TRAVEL SYSTEM / HST Motor 8. Put the matching marks on valve block (11) and housing (4).

11. Set rotary group (8) vertically.

9. Place the housing (4) assembly with the rotary group (8) shaft facing downward vertically. IMPORTANT: Record the adjusting screw (6) dimension (x). 10. Remove lock nut (5) and adjusting screw (6) from housing (4).

W4FC-03-03-005

6 5 W4FC-03-03-004

IMPORTANT: After removing valve block (11), do not tilt rotary group (8). IMPORTANT: When removing valve block (11), do not drop valve plate (9). 12. Remove socket bolts (21) (8 used). Remove valve block (11) from housing (4). 13. Put the mating marks on valve plate (9) and valve block (11). 14. Remove valve plate (9) from valve block (11). 15. Remove O-ring (7) from housing (4).

W3-3-9

TRAVEL SYSTEM / HST Motor A

17 18 19

ZW140

ZW150

B W4FC-03-03-001

W3-3-10

TRAVEL SYSTEM / HST Motor 16. Remove socket bolt (17). Remove piston (18), thread pin (19), positioning piston (20), and positioning trunnion (23) from valve block (11). 17. Install bolt (c), washer (b), and lock nut (a) to center pin part (e) of rotary group (8). Secure cylinder block (d). a b

W4FC-03-03-006

Bolt (c): ZW140 : M6, Length 92 mm ZW150 HST motor 1 : M8, Length 105 mm ZW150 HST motor 2 : M6, Length 92 mm 18. Remove rotary group (8) from housing (4) by using a press or a pulley puller.

W3-3-11

TRAVEL SYSTEM / HST Motor ASSEMBLY OF HST MOTOR 1 AND HST MOTOR 2 5 8

14, 16

13, 15

12 21

11 17 18 19 20 10

9 23

1 2

34, 35 33, 36

25 31

27 29 ZW150

ZW140

W4FC-03-03-007

123456-

Retaining Ring Shim Shaft Seal Ring Housing Lock Nut Adjusting Screw

7 - O-Ring 8 - Rotary Group 9 - Valve Plate

10 11 12 13 14 15 -

Knock Pin (2 Used) Valve Block O-Ring (6 Used) Bolt (4 Used) Cover Block Socket Bolt (4 Used)

16 - Cover Block 17 - Socket Bolt 18 - Piston

19 20 21 22 23 24 -

Thread Pin Positioning Piston Socket Bolt (8 Used) O-Ring (4 Used) Positioning Trunnion Valve Seat

25 - Poppet 26 - Valve Guide 27 - O-Ring

W3-3-12

28 29 30 31 32 33 -

Backup Ring O-Ring Valve Seat Check Valve O-Ring HST Motor 2 Displacement Angle Control Solenoid Valve 34 - Socket Bolt (4 Used) 35 - Socket Bolt (4 Used) 36 - HST Motor 1 Displacement Angle Control Solenoid Valve

TRAVEL SYSTEM / HST Motor Assembly of HST Motor 1 and HST Motor 2 IMPORTANT: After removing bolt (c), washer (b) and lock nut (a), which secure cylinder block (d), do not tilt rotary group (8). 4. Place rotary group (8) vertically. Remove bolt (c), washer (b) and lock nut (a), which secure cylinder block (d).

1. Warm housing (4) to 80 Â°C (176 Â°F). 4

a b

d W4FC-03-03-008

2. Install special tool (a) to rotary group (8). a

W4FC-03-03-006

5. Install positioning piston (20), thread pin (19), piston (18), socket bolt (17), and positioning trunnion (23) to valve block (11). 6. Install O-ring (7) to housing (4).

W4FC-03-03-009

3. Place housing (4) vertically. Install rotary group (8) to housing (4).

W3-3-13

TRAVEL SYSTEM / HST Motor 5 8 4

14, 16

13, 15

12 21

1 2 3

34, 35 33, 36

25 31

27 29 ZW140

ZW150 W4FC-03-03-007

W3-3-14

TRAVEL SYSTEM / HST Motor IMPORTANT: Install valve plate (9) to the same direction before disassembling. 7. Apply grease onto both surfaces and side of valve plate (9) in order not to fall off valve plate (9). Install valve plate (9) to valve block (11). 8. Install valve block (11) onto housing (4) with socket bolts (21) (8 used) while aligning the matching marks made when disassembling.

13. Install cover blocks (14, 16) to valve block (11) with socket bolts (13, 15) (4 used for each). 14. Remove the special tool from rotary group (8). IMPORTANT: Install shaft seal ring (3) and shim (2) to the depth marked on special tool (a) when disassembling. 15. Install shaft seal ring (3) and shim (2) to housing (4) by using special tool (a).

9. Install adjusting screw (6) to housing (4). Adjust the adjusting screw (6) to the recorded dimension before disassembling. Secure adjusting screw (6) with lock nut (5).

10. (ZW140) Install valve seat (30), check valve (31), and O-ring (32) to valve block (11). (ZW150) Install valve seat (24), poppet (25), valve guide (26), O-rings (27, 29), and backup ring (28) to valve block (11).

2 4

11. Install O-rings (12) (6 used) and O-rings (22) (4 used) to valve block (11). 12. Install HST motor 1 displacement angle control valve (33) and HST motor 2 displacement angle control valve (36) with socket bolts (34, 35) (4 used for each) to valve block (11).

W4FC-03-03-002

16. Install retaining ring (1) to housing (4).

W3-3-15

TRAVEL SYSTEM / HST Motor STRUCTURE OF HST MOTOR 1 DISPLACEMENT ANGLE CONTROL VALVE 1

11 W4FC-03-03-011

12345-

Spring Spring Spring Collar Spring Pin

6 - Nut (Seal Lock) 7 - Socket Bolt 8 - Plug 9 - Plug Assembly 10 - Plug (2 Used)

11 - Socket Bolt (4 Used) 12 - Solenoid 13 - Housing 14 - Spool 15 - Bushing

16 - Retaining Ring 17 - O-Ring 18 - Spring Collar 19 - Spring Collar

STRUCTURE OF HST MOTOR 2 DISPLACEMENT ANGLE CONTROL VALVE

5 4

13 W4FC-03-03-012

12345-

Solenoid Control Piston Spring Housing Plug (5 Used)

678910 -

Bushing Spool Retaining Ring Spring Collar Spring Collar

11 - Spring 12 - Spring 13 - Spring Collar 14 - Spring 15 - O-Ring

W3-3-16

16 17 18 19 20 -

Pin Socket Bolt Nut (Seal Lock) Solenoid Socket Bolt (4 Used)

TRAVEL SYSTEM / HST Motor STRUCTURE OF COVER BLOCK For HST Motor 1 3

4 W4FC-03-03-013

1 - Cover

2 - Socket Bolt (4 Used)

3 - Plug Assembly

4 - O-Ring

For HST Motor 2 7

8 9 10

3 2

11 4

12 A

16 13 15

A-A W4FC-03-03-014

1234-

Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Spring Collar (2 Used)

5678-

O-Ring Shim Plug Spring

9 - Plunger 10 - Orifice 11 - Spool 12 - Plug Assembly

W3-3-17

13 - O-Ring 14 - Housing 15 - Socket Bolt (4 Used) 16 - Retaining Ring

TRAVEL SYSTEM / HST Motor STRUCTURE OF ROTARY BLOCK

7 8 9 10

11 W4FC-03-03-015

1234-

Shaft Retaining Ring Shim Bearing

5678-

Distance Piece Bearing Plate Center Pin

9 - Piston Assembly (7 Used) 10 - Cylinder Block 11 - Shim 12 - Spring

NOTE: Adhesive has been applied onto torque screw (13). When removing torque screw (13), warm up to 120 °C (248 °F) before removing. NOTE: Remove torque screw (13) by using a special tool.

W3-3-18

13 - Torque Screw (14 Used)

TRAVEL SYSTEM / HST Motor LIST OF TIGHTENING TORQUE Bolt and Socket Bolt Strength Category

Bolt Dia mm

8.8

10.9

12.9

N⋅m

(kgf⋅m)

(lbf⋅ft)

N⋅m

(kgf⋅m)

(lbf⋅ft)

N⋅m

(kgf⋅m)

(lbf⋅ft)

1.1

(0.1)

(0.8)

1.6

(0.2)

(1.2)

1.9

(0.2)

(1.4)

3.1

(0.3)

(2.3)

4.5

(0.5)

(3.3)

5.3

(0.5)

(3.9)

6.1

(0.6)

(4.5)

8.9

(0.9)

(6.6)

10.5

(1.1)

(7.7)

10.5

(1.1)

(7.7)

15.5

(1.6)

(11.5)

(1.8)

(13.5)

(2.6)

(18.5)

(3.8)

(27.5)

(4.4)

(31.5)

M10

(5.2)

(38)

(7.7)

(55)

(8.9)

(64)

M12

(8.9)

(64)

130

(13.5)

(96)

150

(15.5)

(111)

M14

140

(14.5)

(101)

205

(21)

(151)

240

(24.5)

(175)

M16

215

(22)

(159)

310

(31.5)

(230)

370

(38)

(275)

M18

300

(30.5)

(220)

430

(44)

(320)

510

(52)

(380)

M20

430

(44)

(320)

620

(63)

(460)

720

(73)

(530)

M22

580

(59)

(430)

830

(85)

(610)

970

(99)

(720)

M24

740

(75)

(550)

1060

(108)

(780)

1240

(126)

(910)

Lock Nut Bolt Dia mm

N⋅m

(kgf⋅m)

(lbf⋅ft)

(1)

(7.2)

M6, Pitch 0.5

(1.1)

(8.1)

(2.2)

(16)

M8, Pitch 1

(2.4)

(17.5)

M10

(4.1)

(29.5)

M10, Pitch 1

(4.5)

(32.5)

M12

(7)

(51)

M12, Pitch 1.5

(7.3)

(53)

M14

110

(11)

(80)

M14, Pitch 1.5

120

(12)

(87)

M16

170

(17.5)

(123)

M16, Pitch 1.5

180

(18.5)

(130)

W3-3-19

TRAVEL SYSTEM / HST Motor (Blank)

W3-3-20

TRAVEL SYSTEM / Transmission REMOVAL AND TRANSMISSION

INSTALLATION

Removal CAUTION: Cab (1) weight: 960 kg (2120 lb) 1. Remove cab (1). (Refer to REMOVAL AND INSTALLATION OF CAB on W2-1-1.)

W4FC-02-01-003

CAUTION: 4-unit pump (2) weight: 31 kg (68 lb)

2. Remove 4-unit pump (2). (Refer to REMOVAL AND INSTALLATION OF 4-UNIT PUMP on W2-5-1.)

W4FC-02-05-001

CAUTION: HST pump (3) assembly weight: 80 kg (180 lb)

3. Remove the HST pump (3) assembly. (Refer to REMOVAL AND INSTALLATION OF HST PUMP on W3-2-1.)

W4FC-03-02-016

W3-4-1

TRAVEL SYSTEM / Transmission 4. Remove propeller shaft (4). (Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-6-1.)

W4FC-03-06-001

5. Remove HST motors (5). (Refer to REMOVAL AND INSTALLATION OF HST MOTOR on W3-3-1.)

W4FC-03-03-017

W3-4-2

TRAVEL SYSTEM / Transmission 6. Disconnect hoses (16) (2 used) from transmission (17). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 27 mm

13, 14, 15

7. Disconnect connector (12). 8. Remove bolt (13) from clips (14) (2 used). Remove clips (14) (2 used) and spacer (15) from bracket (18). : 14 mm

W4FC-03-04-051

13, 14, 15

W4FC-03-04-053

12 19

9. Remove bolts (19) (8 used) from flanges (21) (4 used). Remove universal joint (20) from transmission (17) and shaft (22). : 14 mm

20 21 Axle Support

W4FC-03-04-054

10. Place a container under pipe (23) mounting part of transmission (17). Disconnect pipe (23) from transmission (17). Cap the open ends. : 41 mm 17

W3-4-3

W4FC-03-04-055

TRAVEL SYSTEM / Transmission CAUTION: Transmission (17) weight: 210 kg (470 lb) CAUTION: The transmission (17) assembly weight: ZW140: 305 kg (680 lb) ZW150: 317 kg (700 lb) 11. Attach a nylon sling onto transmission (17). Hoist and hold transmission (17). 12. Remove nuts (28) (4 used) and washers (27) (4 used) from bolts (29) (4 used). Remove plates (25) (4 used), cushion (26) (8 used) and washers (27) (4 used) from frame (24). : 27 mm 13. Remove the transmission (17) assembly from frame (24).

W4FC-03-04-052

30, 31

14. Remove bolts (30) (8 used) and washers (31) (8 used) from brackets (18) (2 used). Remove brackets (18) (2 used) from transmission (17). : 24 mm

26 28

17 Detail A

W3-4-4

W4FC-03-04-056

TRAVEL SYSTEM / Transmission Installation CAUTION: Transmission (17) weight: 210 kg (470 lb) CAUTION: The transmission (17) assembly weight: ZW140: 305 kg (680 lb) ZW150: 317 kg (700 lb) 1. Apply LOCTITE #262 onto bolts (30) (8 used). Install bracket (18) (2 used) to transmission (17) with bolts (30) (8 used) and washers (31) (8 used). : 24 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

2. Attach a nylon sling onto the transmission (17) assembly. Hoist the transmission (17) assembly. Align the transmission (17) assembly with the mounting hole on frame (24).

W4FC-03-04-052

A 25

30, 31

29 27

26 28

3. Install the transmission (17) assembly to frame (24) with bolts (29) (4 used), plates (25) (4 used), cushion (26) (8 used), washers (27) (8 used) and nuts (28) (4 used). : 27 mm : 315 N⋅m (32 kgf⋅m, 230 lbf⋅ft)

4. Connect pipe (23) to transmission (17). : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft) NOTE: After connecting pipe (23), transmission oil.

17 Detail A

W4FC-03-04-056

add

23 19

5. Apply LOCTITE #262 onto bolts (19) (8 used). Install universal joint (20) to shaft (22) and transmission (17) with flanges (21) (4 used) and bolts (19) (8 used). : 14 mm : 74±3.4 N⋅m (7.5±0.3 kgf⋅m, 55±2.5 lbf⋅ft)

20 21 Axle Support

W3-4-5

W4FC-03-04-055

W4FC-03-04-054

TRAVEL SYSTEM / Transmission 6. Connect hoses (16) (2 used) to transmission (17). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

13, 14, 15

7. Install clips (14) (2 used) to bracket (18) with bolts (13) and spacer (15). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

8. Connect connector (12).

W4FC-03-04-051

13, 14, 15

W4FC-03-04-053

9. Install HST motors (5). (Refer to REMOVAL AND INSTALLATION OF HST MOTOR on W3-3-1.)

W4FC-03-03-017

W3-4-6

TRAVEL SYSTEM / Transmission 4

10. Install propeller shaft (4). (Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-6-1.)

W4FC-03-06-001

CAUTION: HST pump (3) assembly weight: 80 kg (59 lb)

11. Install the HST pump (3) assembly. (Refer to REMOVAL AND INSTALLATION OF HST PUMP on W3-2-1.)

W4FC-03-02-016

CAUTION: 4-unit pump (2) weight: 31 kg (23 lb)

12. Install 4-unit pump (2). (Refer to REMOVAL AND INSTALLATION OF 4-UNIT PUMP on W2-5-1.)

W4FC-02-05-001

W3-4-7

TRAVEL SYSTEM / Transmission CAUTION: Cab (1) weight: 960 kg (2120 lb) 13. Install cab (1). (Refer to REMOVAL AND INSTALLATION OF CAB on W2-1-1.)

W4FC-02-01-003

W3-4-8

TRAVEL SYSTEM / Transmission (Blank)

W3-4-9

TRAVEL SYSTEM / Transmission DISASSEMBLY OF TRANSMISSION 1

4 12

7 85 86

82 14

81 79

15 16 19

18 88

38 37

31 40

30 41

28 29

42 43

49 75

73 57 58

55 69

73 59

73 72 71

56 57

61 66

65 64

62 W4FC-03-04-001

W3-4-10

TRAVEL SYSTEM / Transmission 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -

Bolt (3 Used) Retainer Plate Shim O-Ring Flange Bearing Cup Rotation Sensor Socket Bolt (2 Used) Sensor Transmission Case Socket Bolt (8 Used) Valve Assembly Gasket Pin (2 Used) Bolt (27 Used) Retaining Ring Plug O-Ring Distributor Cap Bolt (4 Used) Elbow Adapter Pipe Elbow Pipe Adapter Tee Orifice Pipe Adapter

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 -

Pipe Adapter Orifice Plug Orifice Bolt (4 Used) Plug Distributor Cap Gasket Washer (5 Used) Bolt (5 Used) Flange Plug Retaining Ring Bearing Cup O-Ring Brake Housing O-Ring Plate (7 Used) Plug O-Ring D-Ring D-Ring Pin (2 Used) Spring (24 Used) Washer (4 Used) Socket Bolt (4 Used) O-Ring Plug Washer

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 -

Orifice Bolt (2 Used) Washer (2 Used) Bolt Nut Washer Washer Brake Cap O-Ring Piston Piston Housing End Plate Disc (6 Used) Pin (2 Used) Socket Bolt (2 Used) Plug O-Ring Plug Breather Transmission Cover Strainer O-Ring Gasket Bolt (4 Used) Suction Tube Bolt (5 Used) Gasket Retaining Ring Retaining Ring Bearing

W3-4-11

91 - Input Gear 1 92 - Bearing 93 - Spacer 94 - Retaining Ring 95 - Clutch Assembly 96 - Spacer 97 - O-Ring 98 - Oil Seal 99 - Spacer 100 - Bearing 101 - Spacer 102 - Output Gear 103 - Oil Baffle 104 - Washer (2 Used) 105 - Washer (2 Used) 106 - Bolt (2 Used) 107 - Output Shaft 108 - Bearing 109 - Spacer 110 - Retaining Ring 111 - Spacer 112 - Oil Seal 113 - O-Ring 114 - Retaining Ring 115 - Bearing 116 - Input Gear 2 117 - Bearing 118 - Retaining Ring 119 - Disc Hub 120 - Retaining Ring

TRAVEL SYSTEM / Transmission

89 90 91 92 93 94 95

97 98 99

100 101 102

103 104

105

106

107 108 109 110 111 112 113

114 115 116

117 118 119 120 W4FC-03-04-002

W3-4-12

TRAVEL SYSTEM / Transmission 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 -

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 -

W3-4-13

TRAVEL SYSTEM / Transmission

7 85 84 a

83 82 81 79

31 29

56 52

53 60

55 69

56 57

68 63

62 W4FC-03-04-001

W3-4-14

TRAVEL SYSTEM / Transmission Disassembly of Transmission CAUTION: Transmission assembly weight: 210 kg (470 lb) 1. Disconnect pipes (23, 25, 29, and 31) from the transmission assembly. : 22 mm

8. Remove socket bolts (57) (4 used), washers (56) (4 used) and washer (60). Remove the brake cap (68) assembly from brake housing (47). : 8 mm 56, 57

2. Remove breather (79) from transmission cover (80). : 24 mm

56, 57, 60

3. Loosen the lock nut of rotation sensor (7). Remove rotation sensor (7) from transmission case (10). : 24 mm, 27 mm

68 W4FC-03-04-003

4. Remove socket bolts (8) (2 used). Remove sensor (9) from transmission case (10). : 5 mm 5. Remove socket bolts (11) (8 used). Remove valve assembly (12) and gasket (13) from transmission case (10). : 6 mm 6. Remove bolts (84) (4 used). Remove suction tube (85), gasket (83), O-ring (82), and strainer (81) from transmission case (10). : 17 mm 7. Place the transmission assembly transmission cover (80) side up.

with

the

CAUTION: Spring (55) may fly out if loosening bolts (62) (2 used) quickly. Loosen bolts (62) (2 used) alternately. 9. Remove bolts (62) (2 used) and washers (63) (2 used). Remove brake cap (68) and O-ring (69) from piston housing (71). : 17 mm 10. Remove springs (55) (24 used) from piston (70). 11. Remove piston (70) from piston housing (71). Remove D-rings (52, 53) from piston (70).

W3-4-15

TRAVEL SYSTEM / Transmission

80 107

39 19 109

110 111

112 113

116

119 38

120

36 46 47

42 43

49 49 75

45 49 49 44

73 73 73 72

W4FC-03-04-006

W3-4-16

TRAVEL SYSTEM / Transmission 12. Remove O-ring (48) and end plate (72) from brake housing (47). 13. Remove socket bolts (75) (2 used). Remove brake housing (47) from transmission cover (80). : 8 mm 14. Remove O-ring (46) from brake housing (47). 15. Remove plates (49) (7 used) and disc (73) (6 used) from disc hub (119). 16. Remove retaining ring (120) and disc hub (119) from input gear 2 (116).

19. Remove bolts (20) (4 used). Remove distributor cap (19) and gasket (39) from transmission cover (80). : 17 mm 20. Remove retaining ring (44) and plug (43) from flange (42). Remove flange (42) from the output shaft (107) assembly. 21. Remove bolts (41) (5 used) and washers (40) (5 used). Install bolts (41) (2 used) to thread part (b) (2 places) of bearing cup (45). Tighten the bolts evenly. Remove bearing cup (45) and spacer (111) from transmission cover (80). : 19 mm

17. Remove bolts (36) (4 used). Remove distributor cap (38) and gasket (87) from transmission cover (80). : 17 mm

18. Remove retaining ring (88) from clutch assembly (95). 95 b

W4FC-03-04-005

22. Remove oil seal (112) and O-ring (113) from bearing cup (45). 23. Remove retaining ring (110) and spacer (109) from the output shaft (107) assembly.

W4FC-03-04-004

W3-4-17

TRAVEL SYSTEM / Transmission 10

89 90 91

92 93

107 108

116

16 117 118

80 W4FC-03-04-009

W3-4-18

TRAVEL SYSTEM / Transmission CAUTION: Transmission cover (80) weight: 42 kg (93 lb)

25. Remove retaining ring (16) from bearing (92). Remove the input gear 1 (91) assembly from transmission cover (80).

24. Remove bolts (15) (27 used). Hoist transmission cover (80). Remove transmission cover (80) from transmission case (10). : 19 mm NOTE: Remove the input gear 1 (91) assembly together with transmission cover (80). Clutch assembly (95), the output shaft (107) assembly and the input gear 2 (116) assembly should be left in transmission case (10). 116

16 W4FC-03-04-008

26. Remove retaining ring (94) and spacer (93) from input gear 1 (91). Remove bearing (92) from input gear 1 (91) by using a puller.

107

27. Remove retaining ring (89) from input gear 1 (91). Remove bearing (90) from input gear 1 (91) by using a puller. 28. Remove retaining ring (118) and bearing (117) from transmission cover (80). 29. Remove bearing (108) from transmission cover (80). CAUTION: The clutch assembly (95) weight: 29 kg (64 lb) 10

91 W4FC-03-04-007

30. Hoist and remove clutch assembly (95) from transmission case (10).

W3-4-19

TRAVEL SYSTEM / Transmission

1 2

4 5 6

96 99 100

101 102 103

104

105 106

107

114 115 116

W4FC-03-04-011

W3-4-20

TRAVEL SYSTEM / Transmission 31. Remove the input gear 2 (116) assembly from transmission case (10). 32. Remove retaining ring (114) from input gear 2 (116). Remove bearing (115) from input gear 2 (116) by using a separator or a puller.

34. Remove bolts (86) (5 used). Install bolts (86) (2 used) to thread part (c) (2 places) of bearing cup (6). Tighten the bolts evenly. Remove bearing cup (6) from transmission case (10). : 17 mm

115

6 116

W4FC-03-04-010

35. Remove O-ring (97) and oil seal (98) from bearing cup (6). W4FC-03-04-027

CAUTION: Transmission case (10) weight: ZW140: 66 kg (150 lb) ZW150: 65 kg (150 lb)

36. Remove spacer (99) from the output shaft (107) assembly. 37. Place transmission case (10) with the transmission cover (80) mounting surface facing upward.

33. Hoist and place transmission case (10) vertically. Remove bolts (1) (3 used). Remove retainer plate (2), shims (3) (several), O-ring (4) and flange (5) from output shaft (107). : 19 mm

38. Remove bolts (106) (2 used), washers (105) (2 used) and washers (104) (2 used). Remove the output shaft (107) assembly and oil baffle (103) from transmission case (10). : 19 mm 39. Remove bearing (100), spacer (101), output gear (102), and spacer (96) from output shaft (107) by using a puller.

W3-4-21

TRAVEL SYSTEM / Transmission ASSEMBLY OF TRANSMISSION C

Section A-A

12, 13

7 82

6 1

Section B-B

103

5 A

W4FC-03-04-012

Section C-C

109

92 19, 39 88 38, 87 33 35

95 108

37 110 44 43

101 99 111

112 113 73 49 72 119

3 4

107 98 97

120

100 102 114

115

116

117

118

W3-4-22

61 55 58, 59 W4FC-03-04-013 70

TRAVEL SYSTEM / Transmission 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 -

Pipe Adapter Orifice Plug Orifice Bolt (4 Used) Plug Distributor Cap Gasket Washer (5 Used) Bolt (5 Used) Flange Plug Retaining Ring Bearing Cup O-Ring Brake Housing O-Ring Plate (7 Used) Plug O-Ring D-Ring D-Ring *Pin (2 Used) Spring (24 Used) Washer (4 Used) Socket Bolt (4 Used) O-Ring Plug Washer

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 -

Orifice Bolt (2 Used) Washer (2 Used) Bolt Nut Washer Washer Brake Cap O-Ring Piston Piston Housing End Plate Disc (6 Used) *Pin (2 Used) *Socket Bolt (2 Used) Plug O-Ring Plug Breather Transmission Cover Strainer O-Ring Gasket Bolt (4 Used) Suction Tube Bolt (5 Used) Gasket Retaining Ring Retaining Ring Bearing

NOTE: As for the parts with mark *, refer to W3-4-2.

W3-4-23

TRAVEL SYSTEM / Transmission 50, 51

17, 18

23 30

32 62, 63 56, 57

27 20

26 64, 65, 66, 67

56, 57, 60

104, 105, 106 76, 77

W3-4-24

40, 41

W4FC-03-04-014

TRAVEL SYSTEM / Transmission 12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 -

Pipe Adapter Orifice Plug Orifice Bolt (4 Used) Plug Distributor Cap Gasket Washer (5 Used) Bolt (5 Used) Flange Plug Retaining Ring Bearing Cup O-Ring Brake Housing O-Ring Plate (7 Used) Plug O-Ring D-Ring D-Ring *Pin (2 Used) Spring (24 Used) Washer (4 Used) Socket Bolt (4 Used) O-Ring Plug Washer

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 -

NOTE: As for the parts with mark *, refer to W3-4-2.

W3-4-25

TRAVEL SYSTEM / Transmission C

Section B-B

104, 105, 106

103 B

W4FC-03-04-016

Section C-C

101

107

100 102

114

115

116

W3-4-26

W4FC-03-04-013

TRAVEL SYSTEM / Transmission Assembly of Transmission 1. Install spacers (96, 101), output gear (102), and bearing (100) to output shaft (107). CAUTION: Transmission case (10) weight: ZW140: 61 kg (140 lb) ZW150: 60 kg (140 lb)

CAUTION: Transmission cover (80) weight: 35 kg (77 lb) 8. Hoist transmission cover (80) with the transmission case (10) mounting surface down.

2. Hoist transmission case (10). Place transmission case (10) with the transmission cover (80) mounting surface facing upward. 3. Install oil baffle (103) to the output shaft (107) assembly. Install the output shaft (107) assembly to transmission case (10). Install oil baffle (103) to transmission case (10) with washers (104, 105) (2 used for each) and bolts (106) (2 used). : 19 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

9. Install transmission cover (80) to input gear 1 (91). Install retaining ring (16) to the input gear 1 (91) assembly. CAUTION: The clutch assembly (95) weight: 29 kg (64 lb) 10. Hoist clutch assembly (95). Place clutch assembly (95) with the retaining ring (88) mounting side up. Install transmission cover (80) to clutch assembly (95). Install retaining ring (88) to clutch assembly (95).

4. Install bearing (115) and retaining ring (114) to input gear 2 (116).

5. Install the input gear 2 (116) assembly to transmission case (10). 6. Install bearing (90) and retaining ring (89) to input gear 1 (91). 7. Install bearing (92), spacer (93) and retaining ring (94) to input gear 1 (91). W4FC-03-04-015

11. Install the transmission cover (80) assembly to transmission case (10) with bolts (15) (27 used). : 19 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

W3-4-27

TRAVEL SYSTEM / Transmission C C

62, 63

80 20

36 W4FC-03-04-014

Section C-C

19, 39

38, 87

73 49 69 72 119 120 68

116

55 70 117

118

W3-4-28

W4FC-03-04-013

TRAVEL SYSTEM / Transmission 12. Install gasket (39) and distributor cap (19) to transmission cover (80) with bolts (20) (4 used). : 17 mm : 19.5 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 13. Install gasket (87) and distributor cap (38) to transmission cover (80) with bolts (36) (4 used). : 17 mm : 19.5 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 14. Install bearing (117) and retaining ring (118) to transmission cover (80).

17. Install plates (49) (7 used) and discs (73) (6 used) to disc hub (119) alternately. 18. Install O-ring (48) and end plate (72) to brake housing (47). 19. Install D-rings (52, 53) to piston (70). IMPORTANT: Install piston housing (71) and piston (70) as illustrated direction below. TOP

15. Install disc hub (119) and retaining ring (120) to input gear 2 (116). IMPORTANT: Install brake housing (47) as illustrated direction below. 16. Install O-ring (46) to brake housing (47). Install brake housing (47) to transmission cover (80) with socket bolts (75) (2 used). : 8 mm : 52 N⋅m (5.3 kgf⋅m, 38 lbf⋅ft)

W4FC-03-04-018

20. Install piston (70) and O-ring (69) to piston housing (71). 21. Install springs (55) (24 used) to piston (70).

TOP

75 W4FC-03-04-017

IMPORTANT: Fit springs (55) (24 used) with the brake cap (68) hole (24 places). Tighten bolts (62) (2 used) alternately. 22. Install brake cap (68) to piston housing (71) with washers (63) (2 used) and bolts (62) (2 used). : 17 mm : 52 N⋅m (5.3 kgf⋅m, 38 lbf⋅ft)

W3-4-29

TRAVEL SYSTEM / Transmission C C

56, 57

56, 57, 60 W4FC-03-04-014

Section C-C

109 97 110 98 4

44 43

3 5 40, 41 6

86 99

107

108

111

112

113

W3-4-30

W4FC-03-04-013

TRAVEL SYSTEM / Transmission 23. Install the piston housing (71) assembly to brake housing (47) with washer (60), washers (56) (4 used), and socket bolts (57) (4 used). : 8 mm : 52 N⋅m (5.3 kgf⋅m, 38 lbf⋅ft) 24. Install bearing (108) and transmission cover (80).

spacer

(111)

25. Install spacer (109) and retaining ring (110) to the output shaft (107) assembly. 26. Install oil seal (112) and O-ring (113) to bearing cup (45). 27. Install bearing cup (45) to transmission cover (80) with washers (40) (5 used) and bolts (41) (5 used). : 19 mm : 91 N⋅m (9.3 kgf⋅m, 67 lbf⋅ft)

31. Install O-ring (97) and oil seal (98) to bearing cup (6). 32. Install bearing cup (6) to transmission case (10) with bolts (86) (5 used). : 17 mm : 19.5 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 33. Install flange (5) and retainer plate (2) to output shaft (107) with bolts (1) (3 used). NOTE: This is the temporary assembly in order to select shim (3). : 19 mm : 135 N⋅m (14.0 kgf⋅m, 100 lbf⋅ft) 34. Remove bolts (1) (3 used) and retainer plate (2). Measure the end of output shaft (107) and step (X) of flange (5). Select shim (3) so that step (X) is within 0 to 0.09 mm (0 to 0.004 in). 107

28. Install flange (42) to the output shaft (107) assembly. Install plug (43) and retaining ring (44) to flange (42).

CAUTION: Transmission assembly weight: 190 kg (420 lb) 29. Hoist and place the transmission assembly vertically. 30. Install spacer (99) to the output shaft (107) assembly.

W4FC-03-04-019

35. Apply LOCTITE #262 onto bolts (1) (3 used). Install O-ring (4), shims (3) (several) and retainer plate (2) to output shaft (107) with bolts (1) (3 used). : 19 mm : 135 N⋅m (14.0 kgf⋅m, 100 lbf⋅ft)

W3-4-31

TRAVEL SYSTEM / Transmission

Section A-A

83 12, 13

7 82

Section B-B

85 B A

102

W4FC-03-04-012

W4FC-03-04-014

W3-4-32

TRAVEL SYSTEM / Transmission 36. Install strainer (81) and O-ring (82), gasket (83) and suction tube (85) to transmission case (10) with bolts (84) (4 used). : 17 mm : 19.5 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 37. Install gasket (13) and valve assembly (12) to transmission case (10) with socket bolts (11) (8 used). : 6 mm : 26 N⋅m (2.7 kgf⋅m, 19 lbf⋅ft)

40. Apply LOCTITE #572 onto the thread part of breather (79). Install breather (79) to transmission cover (80). : 24 mm 41. Connect pipes (23, 25, 29, and 31) to the transmission assembly. : 22 mm : 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)

38. Install sensor (9) to transmission case (10) with socket bolts (8) (2 used). : 5 mm : 10 N⋅m (1.0 kgf⋅m, 7.4 lbf⋅ft) IMPORTANT: Contact rotation sensor (7) to output gear (102). Return rotation sensor (7) CCW 2 turns. 39. Install and secure rotation sensor (7) to transmission case (10) with the lock nut. : 24 mm, 27 mm 7 102

W4FC-03-04-020

W3-4-33

TRAVEL SYSTEM / Transmission DISASSEMBLY OF CLUTCH ASSEMBLY 1

3 4 5

23 22

21 20

19 19

18 17

9 10

12 14

W4FC-03-04-021

1234567-

Retaining Ring Spacer Bearing Needle Bearing (2 Used) Thrust Washer (2 Used) Hub Gear Plate (7 Used)

8910 11 12 13 14 -

Disc (6 Used) Plug Seal Ring (2 Used) Bearing Spacer Retaining Ring Shaft Drum

15 16 17 18 19 20 21 -

W3-4-34

Orifice Seal Ring Seal Ring Piston Return Spring (6 Used) End Plate Retaining Ring

22 23 24 25 -

Thrust Bearing Thrust Washer Thrust Bearing Spacer

TRAVEL SYSTEM / Transmission Disassembly of Clutch Assembly CAUTION: The clutch assembly weight: 29 kg (64 lb)

6. Push end plate (20) by using a press. Remove retaining ring (21). Remove end plate (20) from shaft drum (14) by releasing a press gradually.

1. Remove seal rings (10) (2 used) from shaft drum (14).

7. Remove plates (7) (7 used), disc (8) (6 used) and return springs (19) (6 used) from shaft drum (14).

2. Remove retaining ring (13) and spacer (12) from shaft drum (14). Remove bearing (11) from shaft drum (14) by using a puller.

8. Add the compressed air through port (a) of shaft drum (14). Float and remove piston (18) from shaft drum (14).

3. Remove retaining ring (1) and spacer (2) from shaft drum (14). Remove bearing (3) from shaft drum (14) by using a puller.

4. Remove spacer (25), thrust bearing (24), thrust washer (23), and hub gear (6) from shaft drum (14).

5. Remove needle bearings (4) (2 used), thrust washers (5) (2 used) and thrust bearing (22) from shaft drum (14). IMPORTANT: Push end plate (20) downward by using a press as the force of return springs (19) (6 used) is applied to end plate (20).

W4FC-03-04-023

9. Remove seal ring (17) from piston (18). 10. Remove seal ring (16) from shaft drum (14).

20 14

W4FC-03-04-022

W3-4-35

TRAVEL SYSTEM / Transmission ASSEMBLY OF CLUTCH ASSEMBLY

13 W4FC-03-04-024

1234567-

Retaining Ring Spacer Bearing Needle Bearing (2 Used) Thrust Washer (2 Used) Hub Gear Plate (7 Used)

8910 11 12 13 14 -

Disc (6 Used) Plug Seal Ring (2 Used) Bearing Spacer Retaining Ring Shaft Drum

15 16 17 18 19 20 21 -

Orifice Seal Ring Seal Ring Piston Return Spring (6 Used) End Plate Retaining Ring

W3-4-36

22 23 24 25 -

Thrust Bearing Thrust Washer Thrust Bearing Spacer

TRAVEL SYSTEM / Transmission Assembly of Clutch Assembly 1. Place shaft drum (14) with orifice (15) facing upward.

9. Install bearing (3) and spacer (2) to shaft drum (14) with retaining ring (1).

2. Install seal ring (16) to shaft drum (14).

CAUTION: The shaft drum (14) assembly weight: 29 kg (64 lb)

3. Install seal ring (17) to piston (18). 4. Install piston (18) to shaft drum (14). IMPORTANT: Install return spring (19) so that the slits of return spring (19) are not in the same position in a row. 5. Install plates (7) (7 used), disc (8) (6 used) and return springs (19) (6 used) to shaft drum (14) alternately.

10. Attach a nylon sling onto shaft drum (14). Hoist shaft drum (14). Turn over the shaft drum (14) assembly. 11. Install bearing (11) and spacer (12) to shaft drum (14) with retaining ring (13). 12. Install seal rings (10) (2 used) to shaft drum (14).

6. Install end plate (20) to shaft drum (14). Push end plate (20) downward by using a press until the retaining ring (21) groove can be seen. Install retaining ring (21) to shaft drum (14). 7. Install thrust washers (5) (2 used), thrust bearing (22), and needle bearings (4) (2 used) to shaft drum (14). 8. Install hub gear (6), thrust washer (23), thrust bearing (24), and spacer (25) to shaft drum (14).

W3-4-37

TRAVEL SYSTEM / Transmission DISASSEMBLY OF VALVE ASSEMBLY 7

5 4 3

1 15 13

14 18

12 11 9

23 24

27 28 29 26

31 32

33 34 W4FC-03-04-025

123456789-

Plug O-Ring Spring Spring Valve Piston Valve Body Plug Gasket Plug

10 11 12 13 14 15 16 17 18 -

Gasket Spring Spool Filter O-Ring Solenoid Valve Body Washer (4 Used) Bolt (4 Used) Washer

19 20 21 22 23 24 25 26 27 -

W3-4-38

Plate O-Ring O-Ring O-Ring O-Ring Solenoid Valve Assembly Socket Bolt (2 Used) Plug Orifice

28 29 30 31 32 33 34 -

Piston Spring Socket Bolt (6 Used) Valve Body Gasket Valve Cover Bolt (4 Used)

TRAVEL SYSTEM / Transmission Disassembly of Valve Assembly 1. Remove socket bolts (25) (2 used). Remove solenoid valve assembly (24), O-ring (23), plate (19), and washer (18) from solenoid valve body (15). : 4 mm

8. Remove spool (12), springs (11, 29), and piston (28) from valve body (31). 9. Remove bolts (34) (4 used). Remove valve cover (33) and gasket (32) from valve body (31). : 13 mm

2. Remove O-rings (20, 21, and 22) from solenoid valve assembly (24). 3. Remove socket bolts (30) (6 used). Remove the valve body (31) assembly and gasket (8) from valve body (6). : 6 mm 4. Remove plug (1), springs (3, 4) and valve piston (5) from valve body (6). : 12 mm 5. Remove O-ring (2) from plug (1). 6. Remove bolts (17) (4 used) and washers (16) (4 used). Remove solenoid valve body (15) and gasket (10) from the valve body (31) assembly. : 13 mm 7. Remove filter (13) and O-ring (14) from solenoid valve body (15).

W3-4-39

TRAVEL SYSTEM / Transmission ASSEMBLY OF VALVE ASSEMBLY 15

25 16, 17

32 34 33

26 8 7 A

6 B

Section A-A

Section B-B

23 22

20 19 18

2 W4FC-03-04-026

123456789-

Plug O-Ring Spring Spring Valve Piston Valve Body Plug Gasket Plug

10 11 12 13 14 15 16 17 18 -

Gasket Spring Spool Filter O-Ring Solenoid Valve Body Washer (4 Used) Bolt (4 Used) Washer

19 20 21 22 23 24 25 26 27 -

Plate O-Ring O-Ring O-Ring O-Ring Solenoid Valve Assembly Socket Bolt (2 Used) Plug Orifice

W3-4-40

28 29 30 31 32 33 34 -

Piston Spring Socket Bolt (6 Used) Valve Body Gasket Valve Cover Bolt (4 Used)

TRAVEL SYSTEM / Transmission Assembly of Valve Assembly 1. Install valve cover (33) and gasket (32) to valve body (31) with bolts (34) (4 used). : 13 mm : 10 N⋅m (1.0 kgf⋅m, 7.4 lbf⋅ft) 2. Install springs (11, 29), spool (12), and piston (28) to valve body (31).

8. Install O-rings (20, 21, and 22) to solenoid valve assembly (24). 9. Install washer (18), plate (19), O-ring (23), and solenoid valve assembly (24) to solenoid valve body (15) with socket bolts (25) (2 used). : 4 mm : 5.0 N⋅m (0.5 kgf⋅m, 3.7 lbf⋅ft)

3. Install O-ring (14) and filter (13) to solenoid valve body (15). 4. Install solenoid valve body (15) and gasket (10) to the valve body (31) assembly with washers (16) (4 used) and bolts (17) (4 used). : 13 mm : 10 N⋅m (1.0 kgf⋅m, 7.4 lbf⋅ft) 5. Install O-ring (2) to plug (1). 6. Install valve piston (5), springs (3, 4), and plug (1) to valve body (6). : 12 mm : 50 N⋅m (5.0 kgf⋅m, 37 lbf⋅ft) 7. Install the valve body (31) assembly and gasket (8) to valve body (6) with socket bolts (30) (6 used). : 6 mm : 10 N⋅m (1.0 kgf⋅m, 7.4 lbf⋅ft)

W3-4-41

TRAVEL SYSTEM / Transmission (Blank)

W3-4-42

TRAVEL SYSTEM / Axle REMOVAL AND INSTALLATION OF FRONT AXLE

Preparation for Removal of Front Axle 1. Secure articulate lock bar (2) to the hole on front frame (3) with set pin (1) and Î² (beta) pin (4). Hole

3 4

M4GB-01-135

Machine Front

M4GB-01-136

CAUTION: Machine weight: ZW140: 10370 kg (22900 lb) ZW150: 11960 kg (26400 lb) 3

2. Place a hydraulic jack on both sides of front frame (3). Raise front frame (3). Place stand (5) under front frame (3). Set wheel stopper (6) to the rear wheel. Lower the bucket end on the ground. Stop the engine.

6 W4FC-03-05-051

W3-5-1

TRAVEL SYSTEM / Axle Removal of Front Axle CAUTION: As the accumulator is installed to the brake hydraulic circuit, depress the brake pedal at least 50 strokes in order to reduce the pressure. CAUTION: Tire (7) weight: ZW140: 205 kg (460 lb) ZW150: 310 kg (690 lb) 1. Remove front tires (7) (2 used). (Refer to REMOVAL AND INSTALLATION OF TIRE on W3-1-1.)

ZW140

ZW150

W4FC-03-05-058

2. Remove propeller shaft (8). (Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-6-1.)

W4FC-03-05-059

W4FC-03-06-001

3. Disconnect hose (10) from front axle (9). Cap the open ends. : 19 mm

W4FC-03-05-054

W3-5-2

TRAVEL SYSTEM / Axle 4. Remove clip (12) from hose (11). Disconnect hose (11) from front axle (9). Cap the open ends. 11 12

CAUTION: Front axle (9) weight: ZW140: 650 kg (1440 lb) ZW150: 690 kg (1530 lb)

W4GB-03-03-103

5. Attach wire ropes onto front axle (9). Hoist and hold front axle (9).

14 14, 15

6. Remove nuts (15) (16 used) and washers (14) (8 used) from bolts (13) (8 used). Remove bolts (13) (8 used) and washers (14) (8 used) from front frame (3). : 36 mm 9

W4FC-03-05-053

7. Remove front axle (9) from front frame (3). Place front axle (9) on stand (16). Remove front axle (9) from the machine.

9 16

CAUTION: When leaving front axle (9) removed for prolonged time, place stand (16) to the front axle (9) secured position of front frame (3) in order to stabilize the machine. W4GB-03-03-106

W3-5-3

TRAVEL SYSTEM / Axle Installation of Front Axle 1. Place front axle (9) on stand (16). Push front axle (9) to the mounting position in front frame (3).

9 16

W4GB-03-03-106

CAUTION: Front axle (9) weight: ZW140: 650 kg (1440 lb) ZW150: 690 kg (1530 lb) 2. Attach a wire rope onto front axle (9). Hoist front axle (9). Align front axle (9) with the mounting hole on front frame (3).

14 14, 15

3. Install front axle (9) to front frame (3) with bolts (13) (8 used), washers (14) (16 used) and nuts (15) (16 used). : 36 mm : 785 N⋅m (80 kgf⋅m, 580 lbf⋅ft)

W4FC-03-05-053

4. Connect hose (11) to front axle (9) with clip (12).

11 12

W4GB-03-03-103

W3-5-4

TRAVEL SYSTEM / Axle 9

5. Connect hose (10) to front axle (9). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

W4FC-03-05-054

6. Install propeller shaft (8). (Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-6-1.)

CAUTION: Tire (7) weight: ZW140: 205 kg (460 lb) ZW150: 310 kg (690 lb)

W4FC-03-06-001

7. Install front tires (7) (2 used). (Refer to REMOVAL AND INSTALLATION OF FRONT TIRE on W3-1-1.)

CAUTION: Machine weight: ZW140: 10370 kg (22900 lb) ZW150: 11960 kg (26400 lb)

ZW140

W4FC-03-05-058

8. After completing the work, check the hydraulic oil level. Start the engine and check for any oil leaks. Bleed air from the brake circuit. (Refer to T5-6 in Technical Manual.) Raise the bucket. Set a hydraulic jack on both sides of the front frame. Raise the front frame side. Remove stand (5) and rear wheel stopper (6).

ZW150

W4FC-03-05-059

6 W4FC-03-05-051

W3-5-5

TRAVEL SYSTEM / Axle REMOVAL AND INSTALLATION OF REAR AXLE

Preparation for Removal of Rear Axle 1. Secure articulate lock bar (2) to the hole on front frame (3) with set pin (1) and Î˛ (beta) pin (4). Hole

3 4

M4GB-01-135

Machine Front

M4GB-01-136

CAUTION: Machine weight: ZW140: 10370 kg (22900 lb) ZW150: 11960 kg (26400 lb) 2. Place a hydraulic jack on both sides of rear frame (5). Raise rear frame (5). Insert stand (8) under rear frame (5). Check for the looseness of the counterweight mounting bolt. Place stands (6, 7) fitted to the V-shaped weight in order not to apply the machine weight excessively. Lower the bucket on the ground. Stop the engine.

6 7 W4FC-03-05-052

W3-5-6

TRAVEL SYSTEM / Axle Removal of Rear Axle CAUTION: As the accumulator is installed to the brake hydraulic circuit, depress the brake pedal at least 50 strokes in order to reduce the pressure. CAUTION: Tire (9) weight: ZW140: 205 kg (460 lb) ZW150: 310 kg (690 lb)

ZW140

ZW150

1. Remove rear tires (9) (2 used). (Refer to REMOVAL AND INSTALLATION OF TIRE on W3-1-1.)

W4FC-03-05-058

W4FC-03-05-059

2. Remove bolts (10) (4 used) from flanges (12) (2 used). Remove flanges (12) (2 used) from shaft (13). Remove universal joint (11) from shaft (13). : 14 mm

W4FC-03-04-054

3. Disconnect hose (15) and pipe (16) (2 used) from block (14) and axle support (17) (2 used). Cap the open ends. : 19 mm

16 17

W4FC-03-05-055

4. Remove clip (18) from hose (19). Disconnect hose (19) from rear axle (20). Cap the open ends.

18 19

W4GB-03-03-110

W3-5-7

TRAVEL SYSTEM / Axle CAUTION: The rear axle weight: ZW140: 750 kg (1660 lb) ZW150: 770 kg (1700 lb)

(20)

assembly

5. Attach wire ropes onto the rear axle (20) assembly. Hoist and hold the rear axle (20) assembly. 6. Remove nuts (22) (16 used) and washers (21) (8 used) from bolts (23) (8 used). Remove bolts (23) (8 used) and washers (21) (8 used) from rear frame (5) and axle support (17) (2 used). : 36 mm

22 23

W4FC-03-05-057

7. Remove the rear axle (20) assembly from rear frame (5). Place rear axle (20) on stand (24). Remove the rear axle (20) assembly from the machine.

22, 21 5

W4FC-03-05-056

20 24

W4GB-03-03-113

W3-5-8

TRAVEL SYSTEM / Axle Installation of Rear Axle 1. Place rear axle (20) on stand (24). Push rear axle (20) to the mounting position in rear frame (5). 20 24

CAUTION: The rear axle weight: ZW140: 750 kg (1660 lb) ZW150: 770 kg (1700 lb)

(20)

assembly W4GB-03-03-113

22, 21

2. Attach a wire rope onto the rear axle (20) assembly. Hoist the rear axle (20) assembly. Align the rear axle (20) assembly with the mounting hole on rear frame (5).

W4FC-03-05-056

3. Install axle supports (17) (2 used) to rear frame (5) with bolts (23) (8 used), washers (21) (16 used) and nuts (22) (16 used). : 36 mm : 890 N⋅m (91 kgf⋅m, 660 lbf⋅ft)

22 23

W4FC-03-05-057

4. Connect hose (19) to rear axle (20) with clip (18).

18 19

W4GB-03-03-110

W3-5-9

TRAVEL SYSTEM / Axle 14

5. Connect hose (15) and pipes (16) (2 used) to block (14) and axle supports (17) (2 used). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

16 17

W4FC-03-05-055

6. Apply LOCTITE #262 onto bolts (10) (4 used). Install universal joint (11) to shaft (13) with flanges (12) (2 used) and bolts (10) (4 used). : 14 mm : 74±3.4 N⋅m (7.5±0.3 kgf⋅m, 55±2.5 lbf⋅ft)

W4FC-03-04-054

CAUTION: Tire (9) weight: ZW140: 205 kg (460 lb) ZW150: 310 kg (690 lb) 7. Install rear tires (9) (2 used). (Refer to REMOVAL AND INSTALLATION OF TIRE on W3-1-1.)

ZW140

W4FC-03-05-058

CAUTION: Machine weight: ZW140: 10370 kg (22900 lb) ZW150: 11960 kg (26400 lb) 8. After completing the work, check the hydraulic oil level. Start the engine and check for any oil leaks. Bleed air from the brake circuit. (Refer to T5-6 in Technical Manual.) Raise the bucket. Set a hydraulic jack on both sides of the rear frame. Raise rear frame (5). Remove stands (6, 7, and 8).

ZW150

W4FC-03-05-059

6 7 W4FC-03-05-052

W3-5-10

TRAVEL SYSTEM / Axle (Blank)

W3-5-11

TRAVEL SYSTEM / Axle DISASSEMBLY OF AXLE 14

8 7 6 5

2 1

9 10 24

26 23 20

25 29

37 42 41

48 49

22 25

40 39

21 23

50 51

26 24

27 30

55 56

55 34

58 30

33 32

35 1

31 2 3

8 5

60 59 61 59 60

53 9

54, 55, 56

59 60 54, 55, 56 W4FC-03-05-001

W3-5-12

TRAVEL SYSTEM / Axle 12345678910 11 12 13 14 15 16 -

Axle Shaft (2 Used) Shim (Several) Bolt (2 Used) Oil Seal (2 Used) Bearing (2 Used) Level Gauge Axle Tube Knock Pin (4 Used) Washer (32 Used) Bolt (32 Used) Differential Gear Body Cover Washer (24 Used) Bolt (24 Used) Air Breather Bush (Only Front Axle)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Differential Assembly Drain Plug Bearing (2 Used) Shaft (2 Used) Pin (8 Used) Ring Gear (2 Used) End Plate (2 Used) Brake Ring (4 Used) Brake Disc (2 Used) Spring (4 Used) D-Ring (4 Used) Piston (2 Used) Bolt (20 Used) Washer (20 Used) D-Ring (2 Used) Bearing Retainer (2 Used)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -

Seal (2 Used) Bearing (2 Used) Adjusting Nut (2 Used) Lock Plate (2 Used) Washer (18 Used) Bolt (18 Used) Bearing Cage Bearing O-Ring Pinion Gear Shim (Several) Oil Seal Spacer Spacer Bearing Dust Cover (Only Front Axle)

W3-5-13

49 50 51 52 53 54 55 56 57 58 59 60 61 -

Flange O-Ring Washer Bolt Axle Tube Thrust Washer (12 Used) Bearing (12 Used) Planetary Gear (6 Used) Carrier (2 Used) Retainer Plate (2 Used) Shaft (6 Used) Steel Ball (6 Used) Retaining Ring (6 Used)

TRAVEL SYSTEM / Axle

20 A

53 9

10 54, 55, 56 W4FC-03-05-001

W3-5-14

TRAVEL SYSTEM / Axle Disassembly of Axle ● The procedure to disassemble the front axle is explained here as an example. Though the rear axle differs from axle tubes (7, 53) in shape, the procedure to disassemble is the same as that of the front axle unless otherwise specified.

2. Attach a nylon sling onto axle tube (7). Hoist and hold axle tube (7). Place axle tube (53) onto wooden block (a).

53 7

CAUTION: The axle assembly weight: ZW140 TPD front : 645 kg (1430 lb) TPD rear : 635 kg (1400 lb) LSD front : 650 kg (1440 lb) LSD rear : 635 kg (1400 lb) ZW150 TPD front : 685 kg (1510 lb) TPD rear : 660 kg (1460 lb) LSD front : 690 kg (1530 lb) LSD rear : 665 kg (1470 lb)

a W4GB-03-03-004

1. Remove drain plug (18) from differential gear body (11). Drain gear oil from differential gear body (11). : 14 mm • Gear oil amount ZW140 Front : 24 L (6.3 US gal) Rear : 25 L (6.6 US gal) ZW150 Front : 27 L (7.1 US gal) Rear : 27 L (7.1 US gal)

3. Remove bolts (10) (16 used) and washers (9) (16 used) from axle tube (7). : 24 mm 4. Remove the axle tube (7) assembly from differential gear body (11). 5. Remove shaft (20) from differential gear body (11).

CAUTION: The axle tube (7) assembly weight: ZW140 Front : 180 kg (400 lb) Rear : 165 kg (370 lb) ZW150 Front : 200 kg (450 lb) Rear : 180 kg (400 lb)

CAUTION: The axle tube (53) assembly weight: ZW140 Front : 180 kg (400 lb) Rear : 165 kg (370 lb) ZW150 Front : 200 kg (450 lb) Rear : 180 kg (400 lb) 6. Remove axle tube (53) and shaft (20) in the same way as steps 2 to 5.

W3-5-15

TRAVEL SYSTEM / Axle

W4FC-03-05-001

W3-5-16

TRAVEL SYSTEM / Axle 7. Place axle tube (7) vertically with the mounting surface of differential gear body (11) up. Secure axle shaft (1) to the special tool (ST 5113) with special tools (5112) (2 used) and bolts (M16, Pitch 2.0 mm) (2 used). : 36 mm

11. Remove oil seal (4) from the axle tube (7) assembly by using a screwdriver. 7 4

7 Bolt 1 ST 5112

W4GB-03-03-008

ST 5113 W4FC-03-05-013

8. Remove bolt (3) from axle shaft (1). : 36 mm

12. Place the axle tube (7) assembly vertically with the mounting surface for differential gear body (11) up. Hoist and remove axle tube (7) from axle shaft (1). 13. Remove the inner race of bearing (19) from axle tube (7).

CAUTION: The carrier (57) assembly weight: ZW140: 25 kg (55 lb) ZW150: 30 kg (66 lb)

14. Remove the inner race of bearing (5) from axle shaft (1) by using a separator (b).

9. Hoist and hold the carrier (57) assembly. Remove the carrier (57) assembly from axle tube (7) by using a pry bar. CAUTION: The axle tube (7) assembly weight: ZW140 Front : 150 kg (340 lb) Rear : 140 kg (310 lb) ZW150 Front : 165 kg (370 lb) Rear : 150 kg (340 lb) 10. Hoist and remove the axle tube (7) assembly from the special tool (ST 5113). Place the axle tube (7) assembly horizontally.

W3-5-17

W4GB-03-03-010

TRAVEL SYSTEM / Axle

14 13 12 7

26 23 21

25 37

21 22 25

23 A

26 24

55 56 55 57

58 60 59 31 32

61 59 60 61

61 54, 55, 56

59 60 54, 55, 56 W4FC-03-05-001

W3-5-18

TRAVEL SYSTEM / Axle 15. Remove the outer race of bearings (5, 19) from axle tube (7). 16. Disassemble the axle tube (53) assembly in the same way as steps 7 to 15. IMPORTANT: Do not loose pin (21) when removing ring gear (22). 17. Remove ring gears (22) (2 used) and pins (21) (8 used) from axle tubes (7, 53) by using a puller. 18. Remove retainer plates (58) (2 used) and shims (2) (several) from carriers (57) (2 used).

24. Install stopper (c) on axle tubes (7, 53) mounting surface of differential gear body (11) with bolt (M16). : 24 mm NOTE: Hole diameters of stopper (c): 2-Ď&#x2020;18 Distance (L): 400 mm (15.7 in)

11 28

19. Remove retaining rings (61) (6 used) from carriers (57) (2 used). IMPORTANT: Do not loose steel ball (60) when removing shaft (59). 20. Remove shafts (59) (6 used) and steel balls (60) (6 used) from carriers (57) (2 used) to retaining ring (61) side by using a bar and a hammer. 21. Remove the planetary gear (56) assemblies (6 used) from carriers (57) (2 used). 22. Remove thrust washers (54) (12 used) and bearings (55) (12 used) from planetary gears (56) (6 used). 23. Remove end plates (23) (2 used), brake rings (24) (4 used), brake discs (25) (2 used) and springs (26) (4 used) from differential gear body (11).

W4GB-03-03-017

25. Add compressed air through hydraulic port (d) of differential gear body (11). Remove pistons (28) (2 used) from differential gear body (11). 26. Remove D-rings (27) (2 used) from pistons (28) (2 used). 27. Remove D-rings (31) (2 used) from bearing retainers (32) (2 used). 28. Remove bolts (14) (24 used) and washers (13) (24 used) from cover (12). Remove cover (12) from differential gear body (11). : 19 mm 29. Remove bolts (38) (18 used) and washers (37) (18 used) from bearing cage (39). : 19 mm

W3-5-19

TRAVEL SYSTEM / Axle

38 43 42 41

40 39

48 49

50 51

52 A

W4FC-03-05-001

W3-5-20

TRAVEL SYSTEM / Axle 30. Install bolts (38) (2 used) on the thread parts (e) (2 places) of bearing cage (39). Tighten bolts (38) (2 used) evenly. Remove the bearing cage (39) assembly and shims (43) (several) from differential gear body (11). : 19 mm

34. Remove pinion gear (42) from bearing cage (39) by using a press.

42 39

W4GB-03-03-019

35. Remove spacers (46, 45) from pinion gear (42).

W4FC-03-05-012

36. Remove the inner race of bearing (40) from pinion gear (42) by using a separator.

31. Place the bearing cage (39) assembly vertically with flange (49) side up. Remove bolt (52), washer (51), and O-ring (50) from pinion gear (42). : 24 mm

37. Remove oil seal (44) and the inner race of bearing (47) from bearing cage (39).

32. Remove flange (49) from pinion gear (42).

39. Remove O-ring (41) from bearing cage (39).

33. (Only front axle) Remove dust cover (48) from flange (49).

40. Attach a nylon sling onto differential gear body (11). Hoist and hold differential gear body (11).

38. Remove the outer race of bearings (40, 47) from bearing cage (39).

W3-5-21

TRAVEL SYSTEM / Axle

30 29

36 34

33 32

W4FC-03-05-001

W3-5-22

TRAVEL SYSTEM / Axle 41. Remove bolts (29) (20 used), washers (30) (20 used) and lock plates (36) (2 used) from bearing retainers (32) (2 used). : 19 mm 42. Remove bearing retainers (32) (2 used) from differential gear body (11) by using a puller. 43. Remove adjusting nuts (35) (2 used), the outer races (2 used) of bearing (34) and seals (33) (2 used) from bearing retainers (32) (2 used). CAUTION: The differential assembly (17) weight: TPD: 60 kg (140 lb) LSD: 65 kg (150 lb) 44. Attach a nylon sling onto differential assembly (17). Hoist differential assembly (17). 45. Remove differential assembly differential gear body (11).

(17)

from

W3-5-23

TRAVEL SYSTEM / Axle ASSEMBLY OF AXLE 1

53 A

9, 10 12

13, 14

15, 16

23 24

26 24 27 28 33 34

View A

29, 30 3

36 35

2 58 57 61 59

60 54

43 37, 38 42 47

40 45 55

56 21

46 48 50

39 44 49

W3-5-24

W4FC-03-05-005

TRAVEL SYSTEM / Axle 12345678910 11 12 13 14 15 16 -

Axle Shaft (2 Used) Shim (Several) Bolt (2 Used) Oil Seal (2 Used) Bearing (2 Used) Level Gauge Axle Tube *Knock Pin (4 Used) Washer (32 Used) Bolt (32 Used) Differential Gear Body Cover Washer (24 Used) Bolt (24 Used) Air Breather Bush (Only Front Axle)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -

NOTE: As for the parts with mark *, refer to W3-5-13.

W3-5-25

49 50 51 52 53 54 55 56 57 58 59 60 61 -

TRAVEL SYSTEM / Axle

53 A

View A

29, 30 36 35

40 45 32

42 47

39 44

W3-5-26

W4FC-03-05-005

TRAVEL SYSTEM / Axle Assembly of Axle ● The procedure to assemble front axle is explained here as an example. Though the rear axle differs from axle tubes (7, 53) in shape, the procedure of assembly is the same as the front axle unless otherwise specified.

6. Tighten adjusting nuts (35) (2 used) by using the special tool (a). : 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft) a

CAUTION: Differential assembly (17) weight: TPD: 60 kg (140 lb) LSD: 65 kg (150 lb) 1. Attach a nylon sling onto differential assembly (17). Hoist and hold differential assembly (17). 2. Insert differential assembly (17) to differential gear body (11). Hold differential assembly (17). 3. Install seals (33) (2 used), the outer races (2 used) of bearing (34) and adjusting nuts (35) (2 used) to bearing retainers (32) (2 used). 4. Align the inner race of bearing (34) of differential assembly (17) and the outer race of bearing (34) of the bearing retainer (32) assembly, and install the bearing retainer (32) assemblies (2 used) to differential gear body (11). 5. Install washers (30) (20 used) and bolts (29) (20 used) to bearing retainers (32) (2 used). NOTE: Install lock plate (36) after the backlash of the ring gear and the teeth contact condition adjustment. : 19 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

W4GB-03-03-051

7. Install O-ring (41) to bearing cage (39). 8. Install the outer races of bearings (40, 47) to bearing cage (39) by using a press. 9. Install the inner race of bearing (40) to pinion gear (42). 10. Install spacers (45, 46) to pinion gear (42). 11. Install pinion gear (42) to bearing cage (39). 12. Install the inner race of bearing (47) and oil seal (44) to bearing cage (39).

W3-5-27

TRAVEL SYSTEM / Axle

11 A

35d

35e View A

43 37, 38 42 47

46 48 50

39 W4FC-03-05-005

W3-5-28

TRAVEL SYSTEM / Axle 13. Install bolt (38) (1 used) on the thread part (b) of bearing cage (39). Apply load about 93 N (9.5 kgf, 21 lbf) to the inner race of bearing (47) by using a press. Measure the rotational resistance by using a spring balance. • Rotational resistance standard value 1.5 to 2.5 N (0.15 to 0.26 kgf, 0.34 to 0.56 lbf)

19. Install shim (43) (several) and the bearing cage (39) assembly to differential gear body (11) with washers (37) (18 used) and bolts (38) (18 used). : 19 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) IMPORTANT: The backlash of ring gear (c) and the teeth contact are adjusted by adjusting nuts (35) (2 used) on the left and right. In the following procedure, adjusting nut (35d) is on ring gear (c) side and adjusting nut (35e) is on the opposite side.

38 35e

35d b

W4GB-03-03-045

14. If the rotational resistance value is below the standard value, remove pinion gear (42) from bearing cage (39). Adjust the rotational resistance value by grinding spacer (46). 15. (Only the front axle) Install dust cover (48) on flange (49).

16. Install flange (49) to pinion gear (42).

W4FC-03-05-011

17. Install O-ring (50) to flange (49). 18. Install flange (49) to pinion gear (42) with washer (51) and bolt (52). : 24 mm : 225 N⋅m (23 kgf⋅m, 166 lbf⋅ft)

W3-5-29

TRAVEL SYSTEM / Axle

35d

35e View A

W4FC-03-05-005

W3-5-30

TRAVEL SYSTEM / Axle 20. Install a dial gauge onto the teeth outer end of ring gear (c). Secure pinion gear (42). Turn ring gear (c). Measure the backlash. â&#x20AC;˘ Backlash standard value: 0.25 to 0.36 mm (0.01 to 0.014 in)

22. Apply a red lead on 3 or 4 teeth contacts of ring gear (c). Turn ring gear (c) and check the teeth contact. â&#x20AC;˘ Normal contact The teeth contact starts from the toe part and is approx. 80% length of teeth to the direction of the heel part. Toe Part Heel Part

c Face Flank

W4GB-03-03-055

W4GB-03-03-053

21. If the backlash loosen adjusting nut (35d). If the backlash loosen adjusting nut (35e).

is above the standard value, nut (35e) and tighten adjusting is below the standard value, nut (35d) and tighten adjusting

c W4GB-03-03-056

W3-5-31

TRAVEL SYSTEM / Axle

35d

35e

View A

43 c

W4FC-03-05-005

W3-5-32

TRAVEL SYSTEM / Axle • Toe part contact Loosen adjusting nut (35d) and tighten adjusting nut (35e). Reduce the thickness of shim (43).

• Face part contact Reduce the thickness of shim (43). Loosen adjusting nut (35d) and tighten adjusting nut (35e).

W4GB-03-03-057

W4GB-03-03-059

• Heel part contact Loosen adjusting nut (35e) and tighten adjusting nut (35d). Increase the thickness of shim (43).

• Flank part contact Increase the thickness of shim (43). Loosen adjusting nut (35e) and tighten adjusting nut (35d).

42 c

W4GB-03-03-060

W4GB-03-03-058

23. Measure the backlash again and adjust.

W3-5-33

TRAVEL SYSTEM / Axle

53 A

23 24

13, 14

26 24 27 28 View A

29, 30 36

57 61 59 60 54 55

W4FC-03-05-005

W3-5-34

TRAVEL SYSTEM / Axle 24. Remove bolts (29) (2 used) and washers (30) (2 used) from bearing retainers (32) (2 used). Install lock plates (36) (2 used) to bearing retainers (32) (2 used) with washers (30) (2 used) and bolts (29) (2 used). : 19 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

IMPORTANT: Align and install the notch of retaining ring (61) to the mounting groove (f) of steel ball (60). 32. Install retaining rings (61) (6 used) to carriers (57) (2 used). f

25. Install cover (12) to differential gear body (11) with washers (13) (24 used) and bolts (14) (24 used). : 19 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

26. Install D-rings (31) (2 used) to bearing retainers (32) (2 used). 27. Install D-rings (27) (2 used) to pistons (28) (2 used). Install pistons (28) (2 used) to differential gear body (11).

W4GB-03-03-074

28. Install springs (26) (4 used), brake discs (25) (2 used), brake rings (24) (4 used), and end plates (23) (2 used) to differential gear body (11).

33. Install ring gears (22) (2 used) to axle tubes (7, 53) by using a press. Install pins (21) (8 used) to the outer surface of the ring gear.

29. Install bearings (55) (12 used) to planetary gear (56) (6 used).

CAUTION: Axle tube (7, 53) weight: ZW140 Front : 95 kg (210 lb) Rear : 80 kg (180 lb) ZW150 Front : 105 kg (240 lb) Rear : 85 kg (190 lb)

30. Install the planetary gear (56) assemblies (6 used) and thrust washers (54) (12 used) to carriers (57) (2 used). 31. Install steel balls (60) (6 used) to shafts (59) (6 used). Install shafts (59) (6 used) to carriers (57) (2 used).

34. Hoist the axle tubes (7, 53). Place axle tubes (7, 53) vertically with differential gear body (11) down. 35. Install bearings (5) (2 used) to axle tubes (7, 53) by using a press. 36. Apply grease onto the lip part in oil seals (4) (2 used). Install oil seals (4) (2 used) to axle tubes (7, 53).

W3-5-35

TRAVEL SYSTEM / Axle

53 A

19 View A

3 2 58 57

W4FC-03-05-005

W3-5-36

TRAVEL SYSTEM / Axle 37. Place axle shafts (1) (2 used) vertically with bolt (3) side down. Hoist and hold the axle tube (7, 53) assemblies with differential gear body (11) side facing upward. Install the axle tube (7, 53) assemblies to axle shafts (1) (2 used).

41. Remove bolts (3) (2 used) and retainer plates (58) (2 used). Measure dimension (x) of axle shaft (1) end and carrier (57). Adjust shims (2) (several) so that dimension (x) is 0.03 to 0.10 mm (0.001 to 0.004 in).

38. Install bearings (19) (2 used) to the axle tube (7, 53) assemblies. x

CAUTION: Carrier (57) assembly weight: ZW140: 25 kg (55 lb) ZW150: 30 kg (66 lb)

57 1

39. Hoist and install the carrier (57) assemblies (2 used) to the axle tube (7, 53) assemblies. 40. Install retainer plates (58) (2 used) to axle shafts (1) (2 used) with bolts (3) (2 used). ZW140 : 27 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) ZW150 : 36 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W4FC-03-05-014

42. Install shims (2) (several) to the edge of axle shafts (1) (2 used). Install retainer plates (58) (2 used) to axle shafts (1) (2 used) with bolts (3) (2 used). ZW140 : 27 mm : 640 N⋅m (66 kgf⋅m, 470 lbf⋅ft) ZW150 : 36 mm : 1090 N⋅m (111 kgf⋅m, 800 lbf⋅ft)

W3-5-37

TRAVEL SYSTEM / Axle

53 A

9, 10

20 View A

W4FC-03-05-005

W3-5-38

TRAVEL SYSTEM / Axle 43. Attach a spring balance onto knock pin (8) of axle tube (7). Measure the rotational resistance of bearings (5, 19). • Rotational resistance standard value 20.0 to 40.0 N (2.04 to 4.08 kgf, 4.5 to 9 lbf)

CAUTION: The axle tube (7, 53) assembly weight: ZW140 Front : 180 kg (400 lb) Rear : 165 kg (370 lb) ZW150 Front : 200 kg (450 lb) Rear : 180 kg (400 lb)

47. Hoist and hold the axle tube (7, 53) assemblies. Install the axle tube (7, 53) assemblies to differential gear body (11) with washers (9) (32 used) and bolts (10) (32 used). : 24 mm : 225 N⋅m (23 kgf⋅m, 166 lbf⋅ft) 7

W4GB-03-03-068

44. If the rotational resistance is below the standard value, reduce the thickness of shim (2). If the rotational resistance is larger than the standard value, increase the thickness of shim (2).

48. Install drain plug (18) to differential gear body (11). Add gear oil to differential gear body (11). : 14 mm Gear oil amount: ZW140 Front : 24 L (6.3 US gal) Rear : 25 L (6.6 US gal) ZW150 Front : 27 L (7.1 US gal) Rear : 27 L (7.1 US gal)

45. Adjust shims (2) (several) of the axle tube (53) assembly in the same as steps 42 and 43. 46. Install shafts (20) (2 used) to differential gear body (11).

W3-5-39

TRAVEL SYSTEM / Axle DISASSEMBLY OF DIFFERENTIAL (TPD TYPE AXLE) 14 13 12 11 5 6 7

8 7 6

5 4 3

2 8 9 8 5

1 1234-

Bearing (2 Used) Bolt (16 Used) Washer (16 Used) Differential Case

5678-

W4FC-03-05-002

Knock Pin (4 Used) Thrust Washer (2 Used) Side Gear (2 Used) Thrust Washer (4 Used)

910 11 12 -

Pinion Gear (4 Used) Spider Differential Case Washer (12 Used)

W3-5-40

13 - Bolt (12 Used) 14 - Ring Gear

TRAVEL SYSTEM / Axle Disassembly of Differential (TPD type axle) CAUTION: The differential assembly weight (TPD type): 60 kg (140 lb) 1. Hoist the differential assembly. Place the differential assembly vertically with the differential case (4) side up. 2. Remove bolts (2) (16 used) and washers (3) (16 used). Remove ring gear (14) from differential case (4). : 24 mm 3. Place the differential assembly vertically with the differential case (11) side up. 4. Put the matching marks on differential cases (4, 11). 5. Remove bolts (13) (12 used) and washers (12) (12 used). Remove differential case (11) from differential case (4). : 19 mm 6. Remove thrust washers (6) (2 used), side gears (7) (2 used), thrust washers (8) (4 used), pinion gears (9) (4 used), and spider (10) from differential cases (4, 11). 7. Remove inner races (2 used) of bearing (1) from differential cases (4, 11) by using a puller.

W3-5-41

TRAVEL SYSTEM / Axle ASSEMBLY OF DIFFERENTIAL (TPD TYPE AXLE)

6 7 6 7 5

1234-

Bearing (2 Used) Bolt (16 Used) Washer (16 Used) Differential Case

5678-

Knock Pin (4 Used) Thrust Washer (2 Used) Side Gear (2 Used) Thrust Washer (4 Used)

910 11 12 -

Pinion Gear (4 Used) Spider Differential Case Washer (12 Used)

W3-5-42

W4FC-03-05-006

13 - Bolt (12 Used) 14 - Ring Gear

TRAVEL SYSTEM / Axle Assembly of Differential (TPD type axle) 1. Install the inner races (2 used) of bearing (1) to differential cases (4, 11). 2. Place differential case (4) vertically with the differential case (11) mounting surface up.

10. Install ring gear (14) to differential case (4) with washers (3) (16 used) and bolts (3) (16 used). : 24 mm : 225 N⋅m (23 kgf⋅m, 166 lbf⋅ft)

3. Fit two holes of thrust washer (6) to knock pins (5) (2 used). Install thrust washer (6) to differential case (4). 4. Install side gear (7) to differential case (4). 5. Install pinion gears (9) (4 used) and thrust washers (8) (4 used) to spider (10). Install the spider (10) assembly to differential case (4). 6. Place differential case (11) vertically with the differential case (4) mounting surface up. 7. Apply grease onto thrust washer (6) in order not to fall off. Fit two holes of thrust washer (6) with knock pins (5) (2 used). Install thrust washer (6) to differential case (11). 8. Install side gear (7) to differential case (11). 9. Install the differential case (11) assembly to the differential case (4) assembly with washers (12) (12 used) and bolts (13) (12 used) while aligning the matching marks made when disassembling. : 19 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

W3-5-43

TRAVEL SYSTEM / Axle DISASSEMBLY OF DIFFERENTIAL (LSD TYPE AXLE) 13 1 12 5 6 7 6 7 8 11

10 8

1234-

W4FC-03-05-003

Bearing (2 Used) Bolt (16 Used) Washer (16 Used) Differential Case

5678-

Plate (2 Used) Plate (4 Used) Disc (4 Used) Pressure Ring (2 Used)

910 11 12 -

Side Gear (2 Used) Pinion Gear (4 Used) Spider Differential Case

W3-5-44

13 - Ring Gear

TRAVEL SYSTEM / Axle Disassembly of Differential (LSD type axle) CAUTION: The differential assembly weight (LSD attached): 65 kg (150 lb)

7. Remove the inner races (2 used) of bearing (1) from differential cases (4, 12) by using a puller.

1. Hoist the differential assembly. Place the differential assembly vertically with the differential case (4) side up. 2. Remove bolts (2) (16 used) and washers (3) (16 used). Remove ring gear (13) from differential case (4). : 24 mm 3. Put the matching marks on differential cases (4, 12). 4. Install bolts (2 used) to thread part (a) (M12, Pitch 1.25 mm) of differential case (4). Tighten bolts (2 used) evenly. Remove differential case (4) from differential case (12). : 19 mm 4

W4FC-03-05-004

5. Remove plate (5) from differential case (4). 6. Remove plates (6) (4 used), discs (7) (4 used), pressure rings (8) (2 used), side gears (9) (2 used), pinion gears (10) (4 used), spider (11), and plate (5) from differential case (12).

W3-5-45

TRAVEL SYSTEM / Axle ASSEMBLY OF DIFFERENTIAL (LSD TYPE AXLE)

2 9 1

5 5

W4FC-03-05-007

1234-

Bearing (2 Used) Bolt (16 Used) Washer (16 Used) Differential Case

5678-

Plate (2 Used) Plate (4 Used) Disc (4 Used) Pressure Ring (2 Used)

910 11 12 -

Side Gear (2 Used) Pinion Gear (4 Used) Spider Differential Case

W3-5-46

13 - Ring Gear

TRAVEL SYSTEM / Axle Assembly of Differential (LSD type axle) 1. Install the inner races (2 used) of bearing (1) to differential cases (4, 12).

5. Install side gear (9), pressure ring (8), discs (7) (2 used) and plates (6) (2 used) to the differential case (12) assembly.

2. Place differential case (12) vertically with the differential case (4) mounting surface up. IMPORTANT: Place plate (5) with the groove surface up. 3. Install plate (5), plates (6) (2 used), discs (7) (2 used), pressure ring (8), and side gear (9) to differential case (12).

12 7

8 12

W4FC-03-05-009

5 W4FC-03-05-008

4. Install pinion gears (10) (4 used) to spider (11). Install the spider (11) assembly to the differential case (12) assembly.

IMPORTANT: Place plate (5) with the groove surface facing upward. 6. Apply grease onto plate (5) in order not to fall off. Place differential case (4) with the differential case (12) mounting surface up. Install plate (5) to differential case (4). 7. Install the differential case (4) assembly to the differential case (12) assembly while aligning the matching marks made when disassembling. 8. Install ring gear (13) to the differential case assembly with washers (3) (16 used) and the bolts (2) (16 used). : 24 mm : 225 N⋅m (23 kgf⋅m, 166 lbf⋅ft)

W3-5-47

TRAVEL SYSTEM / Axle (Blank)

W3-5-48

TRAVEL SYSTEM / Propeller Shaft REMOVAL AND INSTALLATION PROPELLER SHAFT

Preparation 1. Park the machine on a solid and level surface. Lower the front attachment onto the ground. 2. Place blocks in front and behind the axle in order to secure the machine.

W4GB-03-04-001

Removal

W4FC-03-06-001

1. Remove grease fitting (3) from propeller shaft (1). : 10 mm IMPORTANT: If separating and removing propeller shaft (1), spline seal (2) may be damaged. Remove propeller shaft (1) as an assembly. 2. Remove bolts (4) (4 used) from flange (5). : 14 mm 3. Insert a screwdriver into the clearance between flange (5) and propeller shaft (6). Remove the propeller shaft (1) assembly. Lower one side of the propeller shaft (1) assembly onto the ground.

WCEB-03-10-007

Detail B

Detail C

W3-6-1

W4FC-03-06-004

TRAVEL SYSTEM / Propeller Shaft

W4FC-03-06-001

4. Remove bolts (7) (4 used) from flange (8). : 14 mm 5. Insert a screwdriver into the clearance between flange (8) and shaft (9). Remove the propeller shaft (1) assembly from shaft (9).

7 1

8 Detail A

6. Disconnect lubrication pipe (10) from bearing (14). : 14 mm

W4FC-03-06-003

7. Remove nuts (18) (2 used), spring washers (17) (2 used), washers (16) (4 used), and bolts (15) (2 used) from bearing (14). Remove bearing (14) from frame (19). : 24 mm

11 14 15, 16, 17, 18

8. Remove bolts (11) (4 used) from flange (12). : 14 mm

9. Insert a screwdriver into the clearance between flange (12) and shaft (13). Remove the propeller shaft (6) assembly from shaft (13).

W3-6-2

Detail D

W4FC-03-06-002

TRAVEL SYSTEM / Propeller Shaft Installation 1. Apply LOCTITE #262 onto bolts (11) (4 used). 2. Fit flange (12) of the propeller shaft (6) assembly to the mounting part of shaft (13). Install flange (12) to shaft (13) with bolts (11) (4 used). : 14 mm : 74±3.4 N⋅m (7.5±0.3 kgf⋅m, 55±2.5 lbf⋅ft) W4FC-03-06-001

3. Install bearing (14) to frame (19) with bolts (15) (2 used), washers (16) (4 used), spring washers (17) (2 used), and nuts (18) (2 used). : 24 mm : 223.4 N⋅m (22.8 kgf⋅m, 165 lbf⋅ft)

4. Connect lubrication pipe (10) to bearing (14). : 14 mm : 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)

14 15, 16, 17, 18 19

Detail D

W4FC-03-06-002

W4FC-03-06-001

5. Apply LOCTITE #262 onto bolts (7) (4 used). 6. Fit flange (8) of the propeller shaft (1) assembly to the mounting part of shaft (9). Install flange (8) to shaft (9) with bolts (7) (4 used). : 14 mm : 74±3.4 N⋅m (7.5±0.3 kgf⋅m, 55±2.5 lbf⋅ft)

7 1

8 Detail A

W3-6-3

W4FC-03-06-003

TRAVEL SYSTEM / Propeller Shaft

W4FC-03-06-001

7. Apply LOCTITE #262 onto bolts (4) (4 used).

8. Fit flange (5) of the propeller shaft (1) assembly to the mounting part of propeller shaft (6). Install flange (5) to propeller shaft (6) with bolts (4) (4 used). : 14 mm : 74±3.4 N⋅m (7.5±0.3 kgf⋅m, 55±2.5 lbf⋅ft) Detail C

W4FC-03-06-004

9. Install grease fitting (3) to propeller shaft (1). Add grease. : 10 mm 3

W3-6-4

WCEB-03-10-007

TRAVEL SYSTEM / Brake Valve REMOVAL AND BRAKE VALVE

INSTALLATION

CAUTION: Before doing any work, stop the engine and depress/release the brake pedal about 80 times in order to release the pressure in the service brake circuit. (The pedal can be depressed lightly when the pressure is released.)

Removal 1. Remove bolts (3) (5 used) from covers (1) (2 used). Remove covers (1) (2 used) from floor plate (2). : 14 mm

W4FC-03-07-001

2. Remove split pin (5) and washer (6) from pin (4). Remove pin (4) from hawk end (7). Remove fork end (7) from lever (8).

3. Disconnect hoses (10) (6 used) from brake valve (11). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 22 mm, 27 mm

W4FC-03-07-002

4. Remove bolts (12) (4 used) and washers (13) (4 used) from bracket (9). Remove brake valve (11) from bracket (9). : 14 mm 12, 13

W3-7-1

W4FC-03-07-003

TRAVEL SYSTEM / Brake Valve Installation 1. Install brake valve (11) to bracket (9) with bolts (12) (4 used) and washers (13) (4 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 2. Connect hoses (10) (6 used) to brake valve (11). : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

12, 13

W4FC-03-07-003

3. Align fork end (7) with the mounting hole on lever (8). Install hawk end (7) to lever (8) with pin (4), washer (6), and split pin (5).

4. Install covers (1) (2 used) to floor plate (2) with bolts (3) (5 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W4FC-03-07-002

W3-7-2

W4FC-03-07-001

TRAVEL SYSTEM / Brake Valve (Blank)

W3-7-3

TRAVEL SYSTEM / Brake Valve STRUCTURE OF BRAKE VALVE

20 21

19 27

W3-7-4

18 29

16 31

15 32

W4FC-03-07-004

TRAVEL SYSTEM / Brake Valve No. 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Part Name O-ring Plug C-ring Spring seat Plate Socket bolt Spool Orifice Spring seat Snap ring Plunger C-ring O-ring Plug Spring O-ring Spring seat Spring Spring Fork end Nut Snap ring Washer Boot Spool input Cover O-ring Guide

Q’ty 1 1 1 1 1 1 2 2 2 2 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1

Wrench Size (mm)

N⋅m

Tightening Torque (kgf⋅m) (lbf⋅ft)

44.1 to 58.8 (5.0 to 6.0) (32.5 to 43)

6.86 to 8.83 (0.7 to 0.9) (5.1 to 6.5)

9.81 to 14.7 (1.0 to 1.5) (7.2 to 11)

: 14 24.5 to 37.3 (2.5 to 3.8) (18 to 27.5)

W3-7-5

Remark

TRAVEL SYSTEM / Brake Valve

W3-7-6

W4FC-03-07-004

TRAVEL SYSTEM / Brake Valve No. 31 32 33 34 35 36 37 38 39 40 41

Part Name Body Socket bolt Body O-ring Plug O-ring Spring Oil sheet Plate C-Ring Push Rods

Q’ty 1 4 1 2 2 1 1 1 1 1 1

Wrench Size (mm)

N⋅m

Tightening Torque (kgf⋅m) (lbf⋅ft)

19.6 to 25.5 (2.0 to 2.6) (14.5 to 19)

29.4 to 39.2 (3.0 to 4.0) (21.5 to 29)

W3-7-7

Remark

TRAVEL SYSTEM / Brake Valve (Blank)

W3-7-8

TRAVEL SYSTEM / Charging Block REMOVAL AND INSTALLATION CHARGING BLOCK

CAUTION: Before doing any work, stop the engine and depress/release the brake pedal about 80 times in order to release the brake pressure. Move the front attachment control lever in all directions several times in order to release the pilot pressure. Turn the steering wheel to the right and the left several times in order to release the pressure in the circuit. Removal 1. Remove bolts (3) (5 used) from covers (1) (2 used). Remove covers (1) (2 used) from floor plate (2). : 14 mm

W4FC-03-07-001

2. Remove bolts (4) (8 used) from covers (5) (2 used). Remove covers (5) (2 used) from covers (6, 8). : 14 mm

5 4

3. Remove bolts (9) (4 used) from cover (8). Remove cover (8) from step (7). : 14 mm

6 9 5

W3-8-1

W4FC-03-08-001

TRAVEL SYSTEM / Charging Block 10

4. Disconnect connector (12). 5. Disconnect connectors (10) (2 used) from pressure sensors (13) (2 used). Remove pressure sensors (13) (2 used) from charging block (11). : 27 mm

W4FC-03-08-002

6. Remove accumulator (14) from charging block (11). : 41 mm

W4FC-03-08-003

7. Disconnect hoses (16) (8 used) from charging block (11). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 17 mm, 19 mm, 22 mm, 27 mm

CAUTION: The charging block (11) assembly weight: 19 kg (42 lb) 8. Remove bolts (15) (4 used) from charging block (11). Remove charging block (11) from bracket (17). : 14 mm

W3-8-2

W4FC-03-08-002

TRAVEL SYSTEM / Charging Block Installation CAUTION: The charging block (11) assembly weight: 19 kg (42 lb) 1. Fit charging block (11) with the mounting hole on bracket (17). Install charging block (11) to bracket (17) with bolts (15) (4 used). : 14 mm : 26 N⋅m (2.6 kgf⋅m, 19 lbf⋅ft)

2. Install pressure sensors (13) (2 used) to charging block (11). : 27 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

W4FC-03-08-002

3. Install accumulator (14) to charging block (11). : 41 mm : 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)

W4FC-03-08-003

4. Connect hoses (16) (8 used) to charging block (11). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W3-8-3

W4FC-03-08-002

TRAVEL SYSTEM / Charging Block 10

5. Connect connectors (10) (2 used) to pressure sensors (13) (2 used). Connect connector (12).

W4FC-03-08-002

6. Install cover (8) to step (7) with bolts (9) (4 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 7. Install covers (5) (2 used) to covers (6, 8) with bolts (4) (8 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

6 9 5

8. Install covers (1) (2 used) to floor plate (2) with bolts (3) (5 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W4FC-03-08-001

W4FC-03-07-001

W3-8-4

TRAVEL SYSTEM / Charging Block (Blank)

W3-8-5

TRAVEL SYSTEM / Charging Block STRUCTURE OF CHARGING BLOCK 1

2, 3

4, 5

Section A

6, 7

4, 5 2, 3

2, 3

4, 5

10, 11

6, 7

E F

2, 3 10, 11

6, 7 8, 9

6, 7

2, 3

W3-8-6

6, 7

W4FC-03-08-004

TRAVEL SYSTEM / Charging Block No. 1 2 3 4 5 6 7 8 9 10 11 48

Part Name Orifice Plug O-ring Plug O-ring Plug O-ring Plug O-ring Plug O-ring Body

Q’ty 1 6 6 7 7 9 9 4 6 3 3 1

Wrench Size (mm) :5 : 1/4 : 5/16-24 : 1/8

: 3/8

W3-8-7

N⋅m

Tightening Torque (kgf⋅m) (lbf⋅ft)

Remark

TRAVEL SYSTEM / Charging Block

7 6

36, 37 10 Section B-B

Section F-F

39 7 6 48

6 40

5 Section C-C

Section G-G

Section D-D

7 14

48 28

6 15

3 24

7 12

Section H-H

10 Section E-E

W4FC-03-08-005

W3-8-8

TRAVEL SYSTEM / Charging Block No. 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 48

Part Name Plug O-ring Plug O-ring Plug O-ring Plug O-ring Plug O-ring Plug O-ring Spring Plunger Plug Spring Plunger Sleeve Spring Needle valve Screw Nut Body O-ring Backup ring O-ring Backup ring O-ring Sleeve Piston Plunger Spring Poppet Spring Shim Shim Body

Q’ty 6 6 7 7 9 9 4 6 3 3 4 6 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Wrench Size (mm) : 1/4 : 5/16-24

Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft)

4.9

(0.5)

(3.6)

(2.14)

(15.5)

Remark

: 1/8

: 3/8

0.5 mm (0.02 in) 0.2 mm (0.008 in)

W3-8-9

TRAVEL SYSTEM / Charging Block

10 Section B-B

11 42

Section F-F

38 46

39 7 6 48 6

40 Section C-C

Section G-G

Section H-H

Section D-D

Section E-E

W4FC-03-08-005

W3-8-10

TRAVEL SYSTEM / Charging Block No. 6 7 38 39 40 41 42 43 44 45 46 47 48

Part Name Plug O-ring O-ring Plug Socket bolt Solenoid O-ring Sleeve Spool Washer Spring Stopper Body

Q’ty 9 9 1 1 2 1 1 1 1 1 1 1 1

Wrench Size (mm) : 1/8

: 30 :4

W3-8-11

N⋅m 4.9

98 3.92

Tightening Torque (kgf⋅m) (lbf⋅ft) (0.5) (3.6)

(10) (0.4)

(72) (2.9)

Remark

TRAVEL SYSTEM / Charging Block (Blank)

W3-8-12

TRAVEL SYSTEM / Steering Valve REMOVAL AND STEERING VALVE

INSTALLATION

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.) CAUTION: In order to release the hydraulic pressure in the steering hydraulic circuit, stop the engine and turn the steering wheel to the right and the left several times. The steering wheel turns heavily when the hydraulic pressure is released. Preparation 1. Park the machine on a solid and level ground. Turn the steering cylinder to its stroke end. Lower the bucket onto the ground horizontally. 2. Place blocks in front and behind the tire in order to secure the machine. Removal 1. Remove bolts (2) (5 used) from covers (1) (2 used). Remove covers (1) (2 used) from floor plate (3). : 14 mm

W4FC-02-04-001

2. Remove bolt (5) and washer (6) from duct (7). Remove duct (7) from bracket (4). : 14 mm

4 5, 6 7

W4FC-03-09-008

W3-9-1

TRAVEL SYSTEM / Steering Valve 3. Disconnect hoses (8) (5 used) from steering valve (9). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 27 mm

W4FC-03-09-009

4. Open door (10).

W4FC-03-09-001

5. Remove mat (11) from floor plate (3).

11 3

W4FC-03-09-003

W3-9-2

TRAVEL SYSTEM / Steering Valve 6. Remove screws (12) (10 used) from covers (13) (2 used). Remove covers (13) (2 used) from steering column (14). 12

W4FC-03-09-004

W4FC-03-09-005

W4FC-02-07-013

W3-9-3

TRAVEL SYSTEM / Steering Valve 7. Remove bolts (15) (4 used) and washers (16) (4 used) from brake pedal (17). Remove the brake pedal (17) assembly from floor plate (3). : 12 mm

15, 16

8. Remove bolts (19) (4 used) and washers (20) (4 used) from stand (18). Remove steering valve (9) from stand (18). : 14 mm

W4FC-03-09-006

18 Sponge

19, 20

W4FC-03-09-007

W4FC-03-09-009

W3-9-4

TRAVEL SYSTEM / Steering Valve Installation

1. Install steering valve (9) to stand (18) with bolts (19) (4 used) and washers (20) (4 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

Sponge

19, 20

W4FC-03-09-007

W4FC-03-09-009

2. Install the brake pedal (17) assembly to floor plate (3) with bolts (15) (4 used) and washers (16) (4 used). : 12 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 15, 16

15, 16

W3-9-5

W4FC-03-09-006

TRAVEL SYSTEM / Steering Valve 3. Install covers (13) (2 used) to steering wheel column (14) with screws (12) (10 used).

W4FC-03-09-004

W4FC-03-09-005

W4FC-02-07-013

4. Install mat (11) to floor plate (3).

W4FC-03-09-003

W3-9-6

TRAVEL SYSTEM / Steering Valve 5. Connect hoses (8) (5 used) to steering valve (9). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W4FC-03-09-009

6. Install duct (7) to bracket (4) with bolt (5) and washer (6). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

4 5, 6 7

W4FC-03-09-008

7. Install covers (1) (2 used) to floor plate (3) with bolts (2) (5 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W4FC-02-04-001

8. Shut door (10).

W4FC-03-09-001

W3-9-7

TRAVEL SYSTEM / Steering Valve DISASSEMBLY OF STEERING VALVE

1 20

3 21 4 22

11 24

12 13

14 15

26 27

23 16 28

30 31

33 18 19 18 W4FC-03-09-010

32 123456789-

Dust Seal Retaining Ring Bushing O-Ring Seal Bearing Race (2 Used) Thrust Needle Housing Orifice Plate

10 11 12 13 14 15 16 17 18 -

Sleeve Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Poppet (2 Used) Sheet (2 Used) Check Valve Pin Center Spring (4 Used)

19 20 21 22 23 24 25 26 -

W3-9-8

Flat Spring (2 Used) Spool O-Ring Plate O-Ring (2 Used) Drive Rotor Star

27 28 29 30 31 32 33 34 -

Spacer Cap Ball Spring Pin Screw Screw (7 Used) Pin (2 Used) Ball (2 Used)

TRAVEL SYSTEM / Steering Valve Disassembly of Steering Valve 1. Remove orifice plate (9) and check valve (16) from housing (8). 2. Remove plugs (11) (2 used), springs (13) (2 used), poppets (14) (2 used), and sheets (15) (2 used) from housing (8). 3. Remove O-rings (12) (2 used) from plugs (11) (2 used). IMPORTANT: Attach a cloth to the open end of a vise. Hold the steering valve lightly. Do not get pinched tightly. 4. Secure housing (8) with the cap (28) side up in a vise. 28

Vise

6. Remove rotor (25) from housing (8). Remove O-ring (23) and spacer (27) from rotor (25). NOTE: Do not drop star (26) when removing rotor (25). 7. Remove drive (24) and plate (22) from housing (8). Remove O-ring (21) from housing (8). Remove screw (31) from housing (8) by using a screwdriver. IMPORTANT: Wear a pair of protective glasses as retaining ring (2) may fly out from housing (8). 8. Remove housing (8) from a vise. Turn over housing (8). Remove spring pin (30), pins (33) (2 used), ball (29), and balls (34) (2 used). Place the housing (8) assembly on a clean cloth in order not to damage the finished surface. Remove retaining ring (2) from housing (8) by using a screwdriver. NOTE: Do not drop or lose ball (29) and balls (34) (2 used). Check the hole positions where ball (29) and balls (34) (2 used) were installed.

8 W202-02-14-002

5. Remove screws (32) (7 used) from cap (28). Remove cap (28) from housing (8). Remove O-ring (23) from cap (28). : 8 mm 2 W202-02-14-006

W3-9-9

TRAVEL SYSTEM / Steering Valve 1 20

4 5 6 7 6

W4FC-03-09-010

W3-9-10

TRAVEL SYSTEM / Steering Valve 9. Rotate spool (20) and sleeve (10). Set pin (17) horizontally. Push spool (20) and sleeve (10) from the cap (28) side. Remove bushing (3) from housing (8). 10. Remove seal (5) and dust seal (1) from bushing (3). NOTE: Do not damage bushing (3) when removing seal (5).

IMPORTANT: Wear a pair of protective glasses as center spring (18) and flat spring (19) may fly out. 14. Push spool (20) in sleeve (10) forward. Remove center springs (18) (4 used) and flat springs (19) (2 used) from spool (20).

11. Remove bearing races (6) (2 used) and thrust needle (7) from spool (20). 12. Remove spool (20) and the sleeve (10) assembly from housing (8). NOTE: Remove the sleeve (10) assembly from housing (8). While removing, rotate the sleeve (10) assembly in order to prevent sleeve (10) from getting caught in housing (8). 12. Remove pin (17) from the sleeve (10) assembly. NOTE: Put the matching marks onto the sleeve (10) assembly by using an oil-based pen before removing pin (17).

20 10

W4GB-03-07-002

15. Remove spool (20) from sleeve (10) while rotating spool (20). 16. Remove O-ring (4) from housing (8).

Matching Mark

W202-02-14-021

W3-9-11

TRAVEL SYSTEM / Steering Valve ASSEMBLY OF STEERING VALVE 5

29 30

16 31

25, B

27 28

18 17

8 21

9 D

E E E

D E View A

View C

Detail B 123456789-

Dust Seal Retaining Ring Bushing O-Ring Seal Bearing Race (2 Used) Thrust Needle Housing Orifice Plate

Section E-E 10 11 12 13 14 15 16 17 18 -

Sleeve Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Poppet (2 Used) Sheet (2 Used) Check Valve Pin Center Spring (4 Used)

19 20 21 22 23 24 25 26 -

W3-9-12

Flat Spring (2 Used) Spool O-Ring Plate O-Ring (2 Used) Drive Rotor Star

Section D-D 27 28 29 30 31 32 33 34 -

Spacer Cap Ball Spring Pin Screw Screw (7 Used) Pin (2 Used) Ball (2 Used)

W4FC-03-09-011

TRAVEL SYSTEM / Steering Valve Assembly of Steering Valve IMPORTANT: Set the spring grooves on spool (20) and sleeve (10) to the same side. 1. Install spool (20) to sleeve (10) while rotating spool (20). Align the matching marks on spool (20) and sleeve (10).

3. Insert pin (17) into the holes on spool (20) and sleeve (10). Align both ends of pin (17) with the outer diameter surface of sleeve (10).

Spring Groove

W202-02-14-021

Matching Mark

W202-02-14-019

IMPORTANT: Wear a pair of protective glasses as center spring (18) and flat spring (19) may fly out. 2. Align the spring groove positions of spool (20) and sleeve (10), and place them on a flat plate. Set center springs (18) (2 used) back-to-back. Set center springs (18) (2 used for each) to special tool (ST 2497) as flat springs (19) (2 used) come at the center position. Install center springs (18) (4 used) and flat springs (19) (2 used) to the spring grooves on spool (20) and sleeve (10) by using special tool (ST 2497).

4. Install the sleeve (10) assembly from the cap (28) side of housing (8). NOTE: When installing the sleeve (10) assembly, do not get caught in housing (8). Rotate pin (17) to the right and the left while holding pin (17) horizontally. Insert pin (17) until both rear end surfaces of the sleeve (10) assembly and housing (8) are located at the same position.

20 ST 2497

18 19 18 W4GB-03-07-003

W3-9-13

TRAVEL SYSTEM / Steering Valve

29 30

20 21

E E E E View A

View C

Section E-E

W3-9-14

W4FC-03-09-011

TRAVEL SYSTEM / Steering Valve 5. Install O-rings (4), bearing races (6) (2 used) and thrust needle (7) to housing (8).

IMPORTANT: Wear a pair of protective glasses as retaining ring (2) may fly out from housing (8). 9. Secure housing (8) in a vise lightly. 10. Install O-ring (21) to housing (8). Install ball (29), balls (34) (2 used), spring pin (30), pin (33), and screw (31) to housing (8) as illustrated below. Place plate (22) to housing (8). NOTE: Do not drop or lose ball (29), balls (34) (2 used), spring (30), and pin (33).

6 4 8

W202-02-14-023

30 29

6. Install dust seal (1) and seal (5) to bushing (3).

7. Insert bushing (3) into spool (20) by tapping lightly by using a plastic hammer. NOTE: Check that bushing (3) comes in contact with bearing race (6) horizontally. 8. Install retaining ring (2) to housing (8). NOTE: After installing retaining ring (2), extend the inner diameter of retaining ring (2) by using a screwdriver in order to install retaining ring (2) correctly to the groove on housing (8). Screwdriver

1 5 6

2 8 4 3

W212-02-14-002

W3-9-15

W4FC-03-09-012

TRAVEL SYSTEM / Steering Valve

25, B

27 28

9 D

D View A

View C

Detail B

Section D-D

W3-9-16

W4FC-03-09-011

TRAVEL SYSTEM / Steering Valve 11. Rotate the sleeve (10) assembly and set pin (17) and the port surface of housing (8) in parallel. Put line B onto the spline side end so that line B is parallel to line C on the yoke part of drive (24). Install drive (24). Assemble the yoke part of drive (24) and pin (17). Set line B on the spline side end in drive (24) and the port surface of housing (8) in parallel.

14. Install spacer (27) to rotor (25). Install O-ring (23) to cap (28). Place cap (28) on rotor (25). 15. Install cap (28) to housing (8) with screws (32) (7 used). : 8 mm : 20 Nâ&#x2039;&#x2026;m (2 kgfâ&#x2039;&#x2026;m, 15 lbfâ&#x2039;&#x2026;ft) 25

Line B

Concaved Section

C B

Bolt Hole

C D

Yoke Part

W487-03-08-006

Port Surface

24 Set pin (10) and port surface in parallel.

Yoke Part

W487-03-08-007

Port Surface W202-02-14-031

12. Install O-ring (23) to rotor (25).

16. Install O-rings (12) (2 used) to plugs (11) (2 used).

13. Face the O-ring (23) side of rotor (25) to the plate (22) side. Install star (26) while aligning the splines of star (26) and drive (24) so that line A connecting the concave parts of star (26) is parallel to line B on drive (24). Check that the lines A, B, C, and D are in parallel as illustrated in the right. Fit the bolt holes on rotor (25) while mating drive (24) and star (26).

17. Install sheets (15) (2 used), poppets (14) (2 used), springs (13) (2 used), and plugs (11) (2 used) to housing (8). 18. Install check valve (16) and orifice plate (9) to housing (8).

W3-9-17

TRAVEL SYSTEM / Steering Valve (Blank)

W3-9-18

TRAVEL SYSTEM / Steering Cylinder REMOVAL AND INSTALLATION STEERING CYLINDER

Preparation 1. Park the machine on a solid and level ground. Turn the steering cylinder to its stroke end. Lower the bucket onto the ground horizontally. 2. Place blocks in front and behind the tire in order to secure the machine. 1

Removal 1. Disconnect lubrication pipe (5) from pin (1). Cap the open ends. : 14 mm

2, 3, 4

W4FC-04-02-002

2. Remove bolt (2), spring washer (3), and washer (4) from pin (1). Remove pin (1) from bracket (7). : 17 mm 3. Start the engine and retract the piston rod of steering cylinder (6). Remove shims (8) (2 used) from bracket (7). CAUTION: In order to release the hydraulic pressure in the steering hydraulic circuit, stop the engine and turn the steering wheel to the right and the left several times. The steering wheel turns heavily when the hydraulic pressure is released. 9

4. Disconnect hoses (9) (2 used) from steering cylinder (6). Cap the open ends. : 22 mm

W3-10-1

W4FC-04-02-001

TRAVEL SYSTEM / Steering Cylinder CAUTION: Steering cylinder (6) weight: 24 kg (53 lb)

11, 12, 13

5. Attach a nylon sling onto steering cylinder (6). Hoist and hold steering cylinder (6). 6. Remove bolt (11), spring washer (12), and washer (13) from pin (10). Remove pin (10) from bracket (14). : 17 mm 7. Remove steering cylinder (6) and shims (15) (several used) from bracket (14).

15 6

W4FC-04-02-001

8. Remove steering cylinder (6) on the opposite side in the same way.

Installation CAUTION: Steering cylinder (6) weight: 24 kg (53 lb)

IMPORTANT: If the clearance is 1.0 mm (0.039 in) or more, change the shim tickness (0.5 mm (0.02 in), 1.0 mm (0.039 in)) or the quantity of the shims. 1. Install shims (15) (several used) to the mounting hole of steering cylinder (6) on bracket (14). 2. Attach a nylon sling onto steering cylinder (6). Hoist steering cylinder (6). Align steering cylinder (6) with the mounting hole of bracket (14). 3. Install steering cylinder (6) to bracket (14) with pin (10), washer (13), spring washer (12), and bolt (11). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W3-10-2

11, 12, 13

15 6

W4FC-04-02-001

TRAVEL SYSTEM / Steering Cylinder 4. Connect hoses (9) (2 used) to steering cylinder (6). : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

5. Install shims (8) (several used) to the mounting hole of steering cylinder (6) on bracket (7).

2, 3, 4

W4FC-04-02-001

IMPORTANT: If the clearance is 1.0 mm (0.039 in) or more, change the shim tickness (0.5 mm (0.02 in), 1.0 mm (0.039 in)) or the quantity of the shims. 6. Start the engine. Extend the piston rod of steering cylinder (6) and fit with the mounting hole of bracket (7). 7. Install steering cylinder (6) to bracket (7) with pin (1), washer (4), spring washer (3), and bolt (2). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 8. Connect lubrication pipe (5) to pin (1). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 9. Install steering cylinder (6) on the opposite side in the same way.

W3-10-3

W4FC-04-02-002

TRAVEL SYSTEM / Steering Cylinder DISASSEMBLY OF STEERING CYLINDER

2 1 4

4 1

2 1

8 7

11 12 13 16

17 18 19

W4FC-04-02-005

12345-

O-Ring (4 Used) Plug (2 Used) Pipe Bolt (2 Used) Pipe

678910 -

Cylinder Tube Steel Ball Set Screw Slide Ring (2 Used) Seal Ring Assembly

11 12 13 14 15 -

W3-10-4

Piston Piston Rod U-Ring Bushing O-Ring

16 17 18 19 -

Backup Ring O-Ring Head Cover Wiper Ring

TRAVEL SYSTEM / Steering Cylinder Disassembly of Steering Cylinder CAUTION: Steering cylinder weight: 24 kg (53 lb) 1. Hoist and secure the cylinder horizontally on a workbench. Drain hydraulic oil from the cylinder.

IMPORTANT: The lock washer forms an integral part with cylinder tube (6). Do not damage cylinder tube (6) and head cover (18) when extending the lock washer. 4. Pull out piston rod (12) about 50 mm (2 in) from cylinder tube (6). Install a protective cover on piston rod (12). Extend the lock washer in head cover (18) by using a chisel and a hammer. 6 Lock Washer

W102-04-02-027

2. Remove bolts (4) (2 used) from pipes (3, 5). : 12 mm 3. Remove plugs (2) (2 used) from pipes (3, 5). Remove pipes (3, 5) and O-rings (1) (2 used) from cylinder tube (6). : 32 mm

18 W506-04-02-003

5. Loosen head cover (18) by using a hook wrench. Remove the piston rod (12) assembly from cylinder tube (6). Head cover (18) diameter: 84 mm (3.3 in) Hooked Spanner

18 W506-04-02-004

W3-10-5

TRAVEL SYSTEM / Steering Cylinder

8 7

11 12 13 16

17 18 19

W4FC-04-02-005

W3-10-6

TRAVEL SYSTEM / Steering Cylinder IMPORTANT: Loosen set screw (8) after cutting the crimped part (2 places) by using a hand drill. 6. Secure piston rod (12) horizontally. Remove set screw (8) and steel ball (7) from piston (11). : 4 mm

12. Remove wiper ring (19) from head cover (18). Hammer

Screwdriver

7. Remove piston (11) from piston rod (12). : 50 mm

Vise W4GB-04-02-009

8. Remove head cover (18) from piston rod (12). 9. Remove slide rings (9) (2 used) and sealing assembly (10) from piston (11).

IMPORTANT: Do not remove bushing (14) unless necessary. 13. Remove bushing (14) from head cover (18).

10. Place head cover (18) on the workbench which is covered with an anti-skid waste cloth. 11. Remove O-rings (15, 17) and backup ring (16) from head cover (18).

W3-10-7

TRAVEL SYSTEM / Steering Cylinder ASSEMBLY OF STEERING CYLINDER

17 14

7 W4FC-03-10-001

1 Section with a Hole

1, 2

W4FC-03-10-004

12345-

O-Ring (4 Used) Plug (2 Used) Pipe Bolt (2 Used) Pipe

678910 -

Cylinder Tube Steel Ball Set Screw Slide Ring (2 Used) Seal Ring Assembly

11 12 13 14 15 -

Piston Piston Rod U-Ring Bushing O-Ring

W3-10-8

16 17 18 19 -

Backup Ring O-Ring Head Cover Wiper Ring

TRAVEL SYSTEM / Steering Cylinder Assembly of Steering Cylinder 1. Install bushing (14) to head cover (18) by using special tool (ST 8057). ST 8057

5. Adjust the extended seal ring (10) by using special tool (ST 2633).

14 ST 2633

W4GB-04-02-012 W4FC-03-10-003

2. Install U-ring (13) and wiper ring (19) to head cover (18). 3. Install O-rings (15, 17) and backup ring (16) to head cover (18). 4. Install seal ring (10) to piston (11) by using the special tool (ST 2932). ST 2634

ST 2632

10 ST 2631

6. Secure piston horizontally.

rod

(12)

workbench

7. Apply a little amount of hydraulic oil onto the piston rod (12) surface. Install head cover (18) to piston rod (12). 8. Apply hydraulic oil onto the thread part of piston rod (12). Install piston (11) to piston rod (12). : 50 mm : 586 N⋅m (60 kgf⋅m, 430 lbf⋅ft) 9. Secure piston (11) to piston rod (12) with steel ball (7) and set screw (8). Crimp set screws (8) by using a punch (2 places). : 4 mm : 16.2 N⋅m (1.6 kgf⋅m, 12 lbf⋅ft)

O-Ring

11 W4FC-03-10-002

W3-10-9

TRAVEL SYSTEM / Steering Cylinder

W4FC-03-10-001

1 Section with a Hole

1, 2

W4FC-03-10-004

W3-10-10

TRAVEL SYSTEM / Steering Cylinder 10. Apply THREEBOND #1901 onto the thread part of head cover (18). Apply hydraulic oil onto the packing parts. Secure cylinder tube (6) in a vise horizontally. Install piston rod (12) to cylinder tube (6). 11. Apply hydraulic oil onto the packing parts. Tighten head cover (18) to cylinder tube (6) by using a hook wrench. Bend the lock washer in order not to loosen. Head cover (18) diameter: 84 mm (3.3 in) : 343 N⋅m (35 kgf⋅m, 255 lbf⋅ft)

Hook Wrench

18 W506-04-02-019

12. Connect pipes (3, 5) to cylinder tube (6) with O-rings (1) (4 used) and plugs (2) (2 used). : 32 mm : 76.4±3.8 N⋅m (7.8±0.4 kgf⋅m, 56±2.8 lbf⋅ft) 13. Secure pipes (3, 5) to cylinder tube (6) with bolts (4) (2 used). : 12 mm : 17.2±0.9 N⋅m (1.7±0.1 kgf⋅m, 12.5±0.7 lbf⋅ft)

W3-10-11

TRAVEL SYSTEM / Steering Cylinder (Blank)

W3-10-12

TRAVEL SYSTEM / Priority Valve REMOVAL AND PRIORITY VALVE

INSTALLATION

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

W3-11-1

TRAVEL SYSTEM / Priority Valve 1

Removal 1. Remove bolts (1) (5 used) from covers (2) (2 used). Remove covers (2) (2 used) from floor plate (3). : 14 mm

W4FC-02-04-001

2. Disconnect connectors (12) (2 used).

5, 6

8, 9

3. Remove bolt (5) and washer (6) from clip (7). Remove clip (7) from frame (4). : 12 mm 4. Remove bolt (8), washer (9), and spacer (11) from clips (10) (2 used). Remove clips (10) (2 used) from frame (4). : 12 mm

10 11

5. Disconnect hoses (15) (5 used) from priority valve (13). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling. : 19 mm, 36 mm, 41 mm

W4FC-03-11-001

14 15

6. Remove nuts (17) (2 used) and washers (18) (2 used) from bolts (14) (2 used). Remove bolts (14) (2 used) and priority valve (13) from bracket (16). : 12 mm

17, 18

W3-11-2

W4FC-03-11-002

TRAVEL SYSTEM / Priority Valve Installation 1. Install priority valve (13) to bracket (16) with bolts (14) (2 used), washers (18) (2 used), and nuts (17) (2 used). : 12 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

14 15

2. Connect hoses (15) (5 used) to priority valve (13). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

W4FC-03-11-002

17, 18

3. Connect connectors (12) (2 used).

5, 6

8, 9

4. Install clip (7) to frame (4) with bolt (5) and washer (6). : 12 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 5. Install clips (10) (2 used) to frame (4) with spacers (11), washer (9), and bolt (8). : 12 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

6. Install covers (2) (2 used) to floor plate (3) with bolts (1) (5 used). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

10 11

10 1

12 2

W4FC-03-11-001

W4FC-02-04-001

W3-11-3

TRAVEL SYSTEM / Priority Valve STRUCTURE OF PRIORITY VALVE

W4FC-03-11-003

W3-11-4

TRAVEL SYSTEM / Priority Valve

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Name Plug Adjuster Screw O-Ring Spring Guide Spring Poppet Valve Seat Ring Screen Housing O-Ring Plug Orifice Spool Orifice Spring Plug

Q’ty 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1

Wrench Size (mm) ：24

：26

N⋅m 21

Tightening Torque (kgf⋅m) (lbf⋅ft) (2.1) (15.5)

(4.5)

Remark

(32.5) Orifice Dia.: 0.9 Orifice Dia.: 0.65

：26

W3-11-5

(4.5)

(32.5)

TRAVEL SYSTEM / Priority Valve (Blank)

W3-11-6

SECTION 4

FRONT ATTACHMENT ⎯ CONTENTS ⎯ Group 1 Front Attachment Removal and Installation of Front Attachment ................................... W4-1-1

Group 2 Cylinder Removal and Installation of Cylinder ....... W4-2-1 Disassembly of Lift Cylinder .................. W4-2-10 Assembly of Lift Cylinder ....................... W4-2-14 Disassembly of Bucket Cylinder ............ W4-2-18 Assembly of Bucket Cylinder ................. W4-2-22 Maintenance Standard........................... W4-2-26

4FCW-4-1

(Blank)

4FCW-4-2

FRONT ATTACHMENT / Front Attachment REMOVAL AND INSTALLATION OF FRONT ATTACHMENT Preparation 1. Park the machine on a solid and level surface. Lower the bucket onto the ground horizontally. 2. Place blocks in front and behind the axle in order to secure the machine.

W4GB-03-04-001

3. Disconnect connector (2).

4, 5

4. Remove bolts (4) (2 used) and washer (10) from bracket (3). Remove the bracket (3) assembly and spacers (5) (2 used) from front frame (1). : 14 mm 5. Remove bolts (8) (3 used) and washers (9) (3 used) from bracket (6). Remove bracket (6) from lift arm (7). : 14 mm

8, 9 10

W4FC-04-02-015

6. Disconnect connectors (11) (3 used). 11

7. Remove nuts (12) (8 used), spring washers (13) (8 used), washers (14) (8 used) and clips (16) (2 used) from head light brackets (15) (2 used). Remove the head light brackets (15) (2 used) assembly from front frame (1). : 17 mm

12, 13, 14

W4FC-04-02-004

W4-1-1

FRONT ATTACHMENT / Front Attachment Removal CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. 1

1. Stop the engine. Operate the bucket control lever and the lift arm control lever. Release the remaining pressure in bucket cylinder (2) and lift arm cylinder (3).

2. Move O-rings (5) (2 used) of the bucket (1) and bucket link (4) connection part to the bucket (1) side.

W4FC-04-02-013

1 Section A

W183-04-01-002

3. Remove bolt (6), spring washer (7), and washer (8) from pin (9). : 17 mm

6, 7, 8

W4FC-04-01-001

5 1

4. Remove pin (9) from bucket (1). Remove spacers (10) (2 used) from bucket link (4).

10 Section B

W4-1-2

W4GB-04-01-014

FRONT ATTACHMENT / Front Attachment 1 C

5. Move O-rings (12) (4 used) of the bucket (1) and lift arm (11) connection part to the bucket (1) side.

W4FC-04-02-013

1 Section C

W183-04-01-002

CAUTION: Bucket (1) weight: ZW140: 845 kg (1870 lb) ZW150: 1095 kg (2420 lb) 6. Attach a wire rope onto the spill guard of bucket (1). Hoist and hold the spill guard.

13, 14, 15

W4FC-04-01-001

12 1

7. Remove bolt (13), spring washer (14), and washer (15) from pin (16). : 17 mm

8. Remove pin (16) from bucket (1). Remove spacers (17) (4 used) from lift arm (11). Remove bucket (1) from lift arm (11).

17 Section D

W4-1-3

W4GB-04-01-013

FRONT ATTACHMENT / Front Attachment 9. Attach a nylon sling onto bucket cylinder (2). Hoist and hold bucket cylinder (2). 2

10. Remove bolt (19), spring washer (20), and washer (21) from pin (22). Remove pin (22) and spacers (23) (2 used) from bell crank (18). : 17 mm

W4GB-04-01-005

19, 20, 21

11. Lay down bucket cylinder (2) to the cab side.

CAUTION: Bell crank (18) weight: ZW140: 120 kg (270 lb) ZW150: 170 kg (380 lb)

Section E

W4FC-04-02-011

CAUTION: Bucket link (4) weight: ZW140: 40 kg (88 lb) ZW150: 45 kg (99 lb) 12. Install pin (22) to the pin (22) hole on bell crank (18). Attach a nylon sling onto pin (22). Hoist and hold pin (22). 13. Remove bolt (27), spring washer (28), and washer (26) from pin (24). : 24 mm

24, 25

27, 28

14. Remove pin (24), spacers (25) (2 used) and the bell crank (18) assembly from lift arm (11).

W4-1-4

W4FC-04-01-002

FRONT ATTACHMENT / Front Attachment CAUTION: Lift arm (11) weight: ZW140: 740 kg (1640 lb) ZW150: 780 kg (1720 lb) 15. Start the engine. Raise lift arm (11) until lift arm cylinder (3) is located at horizontal position.

16. Place a stand under lift arm cylinders (3) (2 used). 17. Install pin (24) to lift arm (11). Attach a nylon sling onto pin (24). Hoist and hold pin (24).

18. Remove bolts (29) (2 used), spring washers (30) (2 used), and washers (31) (2 used) from pins (32) (2 used). : 17 mm

W4FC-04-02-014

Stand

29, 30, 31

3 11

19. Remove pins (32) (2 used) and spacers (33) (4 used) from lift arm cylinders (3) (2 used).

32 33 Section F

W4GB-04-01-010

CAUTION: Lift arm (11) weight: ZW140: 740 kg (1640 lb) ZW150: 780 kg (1720 lb) 20. Remove bolts (35) (2 used), spring washers (36) (2 used), and washers (37) (2 used) from pins (38) (2 used). : 24 mm

W4FC-04-02-004

35, 36, 37

21. Remove pins (38) (2 used) from front frame (34). Remove lift arm (11) from front frame (34). Remove spacers (39) (4 used) from lift arm (11).

38 39 Section G

W4-1-5

W4GB-04-01-009

FRONT ATTACHMENT / Front Attachment Installation CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury. IMPORTANT: Check for the outer and inner diameters, wear and damage of all pins and bushings before installation. If any damage is found, replace the parts. (Refer to OPERATIONAL PERFORMANCE TEST.) IMPORTANT: When installing the pin, apply grease onto the inside of the bushing and the dust seal. Apply the rust-inhibiting oil onto the inside of the boss. IMPORTANT: Install the bushing as illustrated.

Bushing

CAUTION: Lift arm (11) weight: ZW140: 740 kg (1640 lb) ZW150: 780 kg (1720 lb)

W4GB-04-01-018

1. Install pin (24) to lift arm (11). Attach a nylon sling onto pin (24). Hoist lift arm (11). Fit lift arm (11) with the mounting hole on front frame (34). Install spacers (39) (4 used) to the mounting hole on lift arm (11) and front arm (34).

2. Install lift arms (11) (2 used) to front frame (34) with pins (38) (2 used), washers (37) (2 used), spring washers (36) (2 used), and bolts (35) (2 used). : 24 mm : 86.9 N⋅m (9 kgf⋅m, 64 lbf⋅ft)

35, 36, 37

W4FC-04-02-014

38 39 Section F

W4-1-6

W4GB-04-01-009

FRONT ATTACHMENT / Front Attachment CAUTION: Lift arm (11) weight: ZW140: 740 kg (1640 lb) ZW150: 780 kg (1720 lb)

1. Suspend lift arm (11). Fit lift arm (11) with the mounting hole on lift arm cylinder (3).

W4FC-04-02-014

Stand

29, 30, 31

2. Install spacers (33) (4 used) to the pin (32) holes (2 used) on lift arm (11).

3 11

3. Install lift arm cylinders (3) (2 used) to lift arm (11) with pins (32) (2 used), washers (31) (2 used), spring washers (30) (2 used) and bolts (29) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

32 33 Section F

4. Remove a nylon sling from lift arm (11). Start the engine and raise lift arm (11). Remove the stands (2 used) from the lower side of lift arm cylinders (3) (2 used). Lower lift arm (11). Stop the engine.

W4GB-04-01-010

CAUTION: Bell crank (18) weight: ZW140: 120 kg (270 lb) ZW150: 170 kg (380 lb) CAUTION: Bucket link (4) weight: ZW140: 40 kg (88 lb) ZW150: 50 kg (110 lb) 7. Install pin (22) to bell crank (18). Attach a nylon sling onto pin (22). Hoist the bell crank (18) assembly. Fit the bell crank (18) assembly with the mounting hole on lift arm (11).

22 18

W4GB-04-01-006

W4-1-7

FRONT ATTACHMENT / Front Attachment 24, 25

CAUTION: Bell crank (18) weight: ZW140: 120 kg (270 lb) ZW150: 170 kg (380 lb)

27, 28

CAUTION: Bucket link (4) weight: ZW140: 40 kg (88 lb) ZW150: 50 kg (110 lb) 8. Install spacers (25) (2 used) to the pin (24) hole on bell crank (18). 9. Install bell crank (18) to lift arm (11) with pin (24), washer (26), spring washer (28), and bolt (27). : 24 mm : 86.9 N⋅m (9 kgf⋅m, 64 lbf⋅ft)

10. Attach a nylon sling onto bucket cylinder (2). Hoist bucket cylinder (2). Fit bucket cylinder (2) with the mounting hole on bell crank (18).

W4FC-04-01-002

W4GB-04-01-005

11. Install spacers (23) (2 used) to the pin (22) hole on bucket cylinder (2).

19, 20, 21

12. Install bucket cylinder (2) to bell crank (18) with pin (22), washer (21), spring washer (20), and bolt (19). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

22 23 Section E

W4-1-8

W4FC-04-02-011

FRONT ATTACHMENT / Front Attachment CAUTION: Bucket (1) weight: ZW140: 845 kg (1870 lb) ZW150: 1095 kg (2420 lb) 13. Attach a wire rope onto the spill guard of bucket (1). Hoist the spill guard. Fit bucket (1) with the mounting hole on lift arm (11).

W4GB-04-01-004

W4FC-04-02-010

14. Install spacers (17) (4 used) to the pin (16) hole on lift arm (11).

13, 14, 15

15. Install lift arms (11) (2 used) to bucket (1) with pins (16) (2 used), washers (15) (2 used), spring washers (14) (2 used), and bolts (13) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

16 17 Section D

16. Move O-rings (12) (4 used) which were moved to the bucket (1) side to the bucket (1) and lift arm (11) connection part.

W4GB-04-01-013

11 Section C W183-04-01-004

W4-1-9

FRONT ATTACHMENT / Front Attachment CAUTION: Bucket link (4) weight: ZW140: 40 kg (88 lb) ZW150: 50 kg (110 lb) 17. Install spacers (10) (2 used) to the pin (9) hole on bucket link (4).

18. Attach a nylon sling onto bucket link (4). Hoist bucket cylinder (1). Fit bucket link (4) with the mounting hole on bucket (1).

19. Install bucket link (4) to bucket (1) with washer (8), spring washer (7), and bolt (6). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

6, 7, 8

W4FC-04-02-010

9 10 Section B

20. Move O-rings (5) (2 used) which were moved to the bucket (1) side to the bucket (1) and the bucket link (4) connection part.

W4GB-04-01-014

4 Section A W183-04-01-004

W4-1-10

FRONT ATTACHMENT / Front Attachment Install the disassembled parts in preparation. 1. Connect connectors (11) (3 used).

12, 13, 14

2. Install head light brackets (15) (2 used) to front frame (1) with clips (16) (2 used), washers (14) (8 used), spring washers (13) (8 used), and nuts (12) (8 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W4FC-04-02-004

3. Install bracket (6) to lift arm (7) with bolts (8) (3 used) and washers (9) (3 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

4, 5

4. Install the bracket (3) assembly to front frame (1) with spacers (5) (3 used), washer (10) and bolts (4) (2 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 8, 9

5. Connect connector (2).

W4-1-11

W4FC-04-02-015

FRONT ATTACHMENT / Front Attachment (Blank)

W4-1-12

FRONT ATTACHMENT / Cylinder REMOVAL CYLINDER

AND

INSTALLATION

Preparation 1. Park the machine on a solid and level surface. Place the bucket on a stand of 500 to 800 mm (19.7 to 31.5 in) height. 2. Place blocks in front and behind the axle in order to secure the machine. W4FC-04-02-012

Stand

Removal of Lift Cylinder ZW150 Only 1. Remove nuts (2) (8 used) and washers (3) (8 used) from front fenders (1) (2 used). Remove front fenders (1) (2 used) from front frame (4). : 17 mm

W4FC-04-02-020

2, 3

2. Stop the engine. Operate the control lever several times and release any remaining pressure in the circuit. Bleed air from the hydraulic oil tank. (Refer to BLEED AIR From HYDRAULIC OIL TANK on W1-4-1)

W4FC-04-02-021

CAUTION: Lift cylinder (5) weight: 85 kg (190 lb) 3. Attach a nylon sling onto lift cylinders (5) (2 used). Hoist and hold lift cylinders (5) (2 used). 4. Disconnect hoses (6) (4 used) from lift cylinders (5) (2 used). Cap the open ends. : 36 mm W4FC-04-01-003

W4-2-1

FRONT ATTACHMENT / Cylinder 5. Remove bolts (7) (2 used), spring washers (8) (2 used), and plates (9) (2 used) from pins (11) (2 used). Remove pins (11) (2 used) from lift cylinders (5) (2 used). : 17 mm

4 11, 12

CAUTION: Lift cylinder (5) weight: 85 kg (190 lb)

W4FC-04-02-003

6. Remove bolts (13) (2 used), spring washers (14) (2 used), and plates (15) (2 used) from pins (16) (2 used). Remove pins (16) (2 used) from front frame (4). : 17 mm 7. Remove lift cylinders (5) (2 used) and spacers (12, 17) (4 used for each) from front frame (4) and lift arm (10).

13, 14, 15 16, 17

W4FC-04-02-004

W4-2-2

FRONT ATTACHMENT / Cylinder Installation of Lift Cylinder CAUTION: Lift cylinder (5) weight: 85 kg (190 lb)

1. Attach a nylon sling onto lift cylinders (5) (2 used). Hoist lift cylinders (5) (2 used). Align lift cylinder (5) with the mounting hole on front frame (4). Install spacers (17) (4 used) to the clearance between the bottom side of lift cylinders (5) (2 used) and front frame (4). 13, 14, 15

2. Install lift cylinders (5) (2 used) to front frame (4) with pins (16) (2 used). Install pins (16) (2 used) to front frame (4) with plates (15) (2 used), spring washers (14) (2 used), and bolts (13) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5, 16, 17

W4FC-04-02-004

3. Stop the engine. Operate the control lever several times and release any remaining pressure in the circuit. Bleed air from the hydraulic oil tank. (Refer to BLEED AIR From HYDRAULIC OIL TANK on W1-4-1) Connect hoses (6) (4 used) to lift cylinders (5) (2 used). : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) W4FC-04-01-003

4. Start the engine. Extend the piston rod of lift cylinders (5) (2 used). Align the pin (11) holes on lift cylinders (5) (2 used) and lift arm (10). Install spacers (12) (4 used) to the rod side of lift cylinders (5) (2 used). 5. Install the piston rod side of lift cylinders (5) (2 used) to lift arm (10) with pins (11) (2 used), plates (9) (2 used), spring washers (8) (2 used), and bolts (7) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

11, 12

W4-2-3

W4FC-04-02-003

FRONT ATTACHMENT / Cylinder ZW150 Only 1. Align front fenders (1) (2 used) with the mounting hole on front frame (4). Install front fenders (1) (2 used) to front frame (4) with nuts (2) (8 used) and washers (3) (8 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2, 3

W4FC-04-02-021

W4FC-04-02-020

W4-2-4

FRONT ATTACHMENT / Cylinder Removal of Bucket Cylinder CAUTION: Bucket cylinder (3) weight: 115 kg (260 lb)

1, 2

1. Attach a nylon sling onto the rod side and the bottom side of the bucket cylinder (3) tube. Hoist and hold bucket cylinder (3). 2. Remove bolt (7), spring washer (6), and plate (5) from pin (1). Remove pin (1) and shims (2) (2 used) from bell crank (4). : 17 mm 7

3. Start the engine. Retract the piston rod of bucket cylinder (3).

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

W4FC-04-02-016

4. Remove nuts (9) (2 used) and washers (10) (2 used) from bolts (8) (2 used). Remove bolts (8) (2 used) from bar (11). Remove bar (11) from bucket cylinder (3). : 14 mm

11 12

10 3

W4FC-04-02-017

5. Remove clip bands (14) (3 used) from harness (13) and pipe (15). 15

6. Remove bolt (16) and washer (17) from clip (18). Disconnect clip (18) from bracket (20). : 14 mm

16, 17 18

7. Disconnect connector (19). 8. Disconnect hoses (12) (2 used) from bucket cylinder (3). Cap the open ends. : 36 mm

W4-2-5

W4FC-04-02-018

FRONT ATTACHMENT / Cylinder 3

9. Remove bolts (21) (2 used) and washers (22) (2 used) from bracket (20). Remove the bracket (20) assembly from bucket cylinder (3). : 14 mm

21, 22

W4FC-04-02-018

CAUTION: Bucket cylinder (3) weight: 115 kg (260 lb) 23

10. Disconnect lubrication pipe (23) from pin (24). : 14 mm

24, 25

11. Remove bolt (26), spring washer (27), and plate (28) from pin (24). Remove pin (24) and spacers (25) (2 used) from front frame (10). : 17 mm 12. Remove bucket cylinder (3) from front frame (10). 10

W4-2-6

26, 27, 28

W4FC-04-02-019

FRONT ATTACHMENT / Cylinder Installation of Bucket Cylinder CAUTION: Bucket cylinder (3) weight: 115 kg (260 lb) 1. Attach a nylon sling onto bucket cylinder (3). Hoist bucket cylinder (3). Align bucket cylinder (3) with the mounting hole on front frame (10). Install spacers (25) (2 used) to the clearance between the bottom side of bucket cylinder (3) and front frame (10).

2. Install bucket cylinder (3) to front frame (10) with pin (24). Install pin (24) to front frame (10) with plate (28), spring washer (27), and bolt (26). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

24, 25

26, 27, 28

W4FC-04-02-019

3. Connect lubrication pipe (23) to pin (24). : 14 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

4. Install the bracket (20) assembly to bucket cylinder (3) with bolts (21) (2 used) and washers (22) (2 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

21, 22

15 16, 17

5. Connect hoses (12) (2 used) to bucket cylinder (3). : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) 6. Install clip (18) to harness (13). Install clip (18) to bracket (20) with bolt (16) and washer (17). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

W4-2-7

W4FC-04-02-018

FRONT ATTACHMENT / Cylinder 7. Connect connector (19).

8. Secure harness (13) to pipe (15) with clip band (14). 15

W4FC-04-02-018

9. Install bar (11) to the piston rod side of bucket cylinder (3) with bolts (8) (2 used), washers (10) (2 used), and nuts (9) (2 used). : 14 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

10. Start the engine. Extend the piston rod of bucket cylinder (3). Align the piston rod of bucket cylinder (3) with the mounting hole on bell crank (4).

1, 2

W4FC-04-02-017

11. Install spacers (2) (2 used) to the piston rod side of bucket cylinder (3). 12. Install bucket cylinder (3) to bell crank (4) with pin (1), plate (5), spring washer (6), and bolt (7). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W4-2-8

W4FC-04-02-016

FRONT ATTACHMENT / Cylinder (Blank)

W4-2-9

FRONT ATTACHMENT / Cylinder DISASSEMBLY OF LIFT CYLINDER

8 9

8 7

5 12

4 3 2 1 6

W4FC-04-02-007

1234567-

Dust Ring Packing Piston Wear Ring Nut Set Screw Pipe

8910 11 12 13 -

Clamp (2 Used) Bolt (2 Used) Washer (2 Used) Pipe Cylinder Tube Backup Ring (2 Used)

14 15 16 17 18 19 -

W4-2-10

O-Ring Piston Rod Retaining Ring Bushing O-Ring Backup Ring

20 21 22 23 24 25 -

O-Ring Head Cover Buffer Seal U-Packing Dust Seal Retaining Ring

FRONT ATTACHMENT / Cylinder Disassembly of Lift Cylinder CAUTION: Lift cylinder weight: 85 kg (190 lb) 1. Remove bolts (9) (2 used) and washers (10) (2 used) from clamps (8) (2 used). Remove clamps (8) (2 used) from pipes (7, 11). : 17 mm

6. Secure piston rod (15) on the special tool (ST 5908). Put the matching marks on piston rod (15) and the end of nut (5). ST 5908

2. Remove pipes (7, 11) from cylinder tube (12). 3. Hoist the lift cylinder. Secure the lift cylinder horizontally on a workbench. Drain hydraulic oil from the lift cylinder.

W158-04-02-022

7. Remove set screw (6) from nut (5). : 4 mm NOTE: As set screw (6) has been crimped by using a punch at 2 places after installing, cut away the crimped parts by using a hand drill and remove set screw (6).

W102-04-02-027

8. Remove nut (5) by using the special tool (ST 5908). Remove piston (3) from piston rod (15).

4. Raise a detent (a part of cylinder tube (12)) pushed (engaged) in the groove on head cover (21). Loosen head cover (21) one to two turns by using the hook wrench. hook wrench 150 mm IMPORTANT: Remove piston rod (15) straight in order not to damage the piston rod (15) surface. 5. Fully extend piston rod (15). Attach a nylon sling onto piston rod (15). Hold piston rod (15). Remove head cover (21) from cylinder tube (12). Remove piston rod (15) from cylinder tube (12).

W4-2-11

FRONT ATTACHMENT / Cylinder

4 3 2 1

W4FC-04-02-007

W4-2-12

FRONT ATTACHMENT / Cylinder 9. Remove head cover (21) from piston rod (15). IMPORTANT: When removing the seals, do not damage the parts. IMPORTANT: Packing (2) and wear ring (4) cannot be reused. When disassembling the cylinder, replace them with new ones. 10. Remove dust ring (1), packing (2), and wear ring (4) from piston (3). 11. Remove retaining rings (16, 25), dust seal (24), U-packing (23), buffer seal (22), and bushing (17) from the inside of head cover (21). 12. Remove backup ring (19) and O-rings (18, 20) from the outside of head cover (21). 13. Remove backup rings (13) (2 used) and O-ring (14) from piston rod (15).

W4-2-13

FRONT ATTACHMENT / Cylinder ASSEMBLY OF LIFT CYLINDER

9, 10

25 W4FC-04-02-009

24 23 22

1234567-

Dust Ring Packing Piston Wear Ring Nut Set Screw Pipe

8910 11 12 13 -

Clamp (2 Used) Bolt (2 Used) Washer (2 Used) Pipe Cylinder Tube Backup Ring (2 Used)

14 15 16 17 18 19 -

W4-2-14

O-Ring Piston Rod Retaining Ring Bushing O-Ring Backup Ring

20 21 22 23 24 25 -

O-Ring Head Cover Buffer Seal U-Packing Dust Seal Retaining Ring

FRONT ATTACHMENT / Cylinder Assembly of Lift Cylinder 1. Install bushing (17) to head cover (21) by using the special tool (ST 8074). ST 8074

6. Install the back ring of packing (2) to piston (3) by using the special tools (ST 2091, ST 2094, and ST 2084). ST 2084

ST 2094

ST 2091 W4GB-04-02-012

Back Ring

2. Install retaining ring (16) to head cover (21).

3. Install buffer seal (22) and U-packing (23) to head cover (21).

W4FC-03-10-002

4. Install dust seal (24) to head cover (21) by using a plastic hammer. Install retaining ring (25) to head cover (21).

CAUTION: Warm up the seal ring of packing (2) by using oil heated by an electric heater. Avoid direct heating by using fire.

5. Install O-rings (18, 20) and backup ring (19) on the outer circumference of head cover (21).

7. Warm up the seal ring of packing (2) to 150 to 180Â°C (302 to 356 Â°F). Install the seal ring of packing (2) to the seal groove on piston (3). 8. Adjust the seal ring of extended packing (2) by using the special tool (ST 2088).

ST 2088

W4FC-03-10-003

W4-2-15

FRONT ATTACHMENT / Cylinder

9, 10

W4FC-04-02-009

W4-2-16

FRONT ATTACHMENT / Cylinder 9. Install dust ring (1) and wear ring (4) to piston (3). 10. Install O-ring (14) and backup rings (13) (2 used) to piston (3). 11. Secure piston horizontally.

rod

(15)

workbench

12. Apply a small amount of hydraulic oil onto the piston rod (15) surface. Install the head cover (21) assembly to piston rod (15). 13. Apply hydraulic oil onto the inner surface of piston (3). 14. Install piston (3) to piston rod (15). Align the matching marks and tighten nut (5) by using the special tool (ST 5908).

IMPORTANT: When inserting piston rod (15), do not damage the rings. Align with the center of cylinder tube (12) and insert the piston rod (15) assembly straight. IMPORTANT: Apply LOCTITE #242 onto the thread part of head cover (21). 16. Secure cylinder tube (12) on a workbench horizontally. Install the piston rod (15) assembly to cylinder tube (12). 17. Tighten head cover (21) to cylinder tube (12) by using an hook wrench. Bend the detent and secure head cover (21) to cylinder tube (12). Hook wrench 150 mm : 736±74 N⋅m (75±7.5 kgf⋅m, 540±55 lbf⋅ft) 18. Connect pipes (7, 11) to cylinder tube (12). : 108 to 116 N⋅m (11 to 11.8 kgf⋅m, 80 to 86 lbf⋅ft)

ST 5908

W158-04-02-022

19. Secure pipes (7, 11) to cylinder tube (12) with clamps (8) (2 used), washers (10) (2 used), and bolts (9) (2 used). : 54 to 59 N⋅m (5.5 to 6.0 kgf⋅m, 40 to 44 lbf⋅ft)

15. Align the holes on piston rod (15) and nut (5). Secure nut (5) to piston rod (15) with set screw (6). Crimp set screw (6) at 2 places by using a punch in order not to loosen. Nut (15) : 980±98 N⋅m (100±10 kgf⋅m, 720±72 lbf⋅ft) Set screw (6) : 4 mm : 14.7 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

W4-2-17

FRONT ATTACHMENT / Cylinder DISASSEMBLY OF BUCKET CYLINDER 11 12 10 13

9 8 7

5 1 14

4 3 2 1

17 18 19 21

22 23

W4FC-04-02-006

12345678-

Dust Ring (2 Used) Packing Piston Wear Ring Nut Set Screw Pipe Clamp

910 11 12 13 14 15 -

Washer Bolt Socket Bolt (4 Used) Washer (4 Used) O-Ring Cylinder Tube Backup Ring (2 Used)

16 17 18 19 20 21 22 -

W4-2-18

O-Ring Piston Rod Retaining Ring Bushing O-Ring Backup Ring O-Ring

23 24 25 26 27 28 29 -

Head Cover Set Screw Socket Bolt (14 Used) Buffer Seal U-Packing Dust Seal Retaining Ring

FRONT ATTACHMENT / Cylinder Disassembly of Bucket Cylinder CAUTION: Bucket cylinder weight: 115 kg (260 lb) 1. Remove bolt (10), washer (9), and clamp (8) from pipe (7). : 19 mm 2. Remove socket bolts (11) (4 used) and washers (12) (4 used) from pipe (7). Remove pipe (7) and O-ring (13) from cylinder tube (14). : 8 mm

IMPORTANT: Loosen set screw (24) after cutting the crimped parts (2 places) by using a hand drill. 7. Secure piston rod (17) horizontally. Remove set screw (6) from nut (5). : 4 mm 8. Secure piston rod (17) on the special tool (ST 5908). Put the matching marks on piston rod (17) and the end of nut (5). ST 5908

3. Hoist the bucket cylinder. Secure the bucket cylinder horizontally on a workbench. Drain hydraulic oil from the bucket cylinder.

W158-04-02-022

9. Remove nut (5) and piston (3) from piston rod (17) by using the special tool (ST 5908). 10. Remove head cover (23) from piston rod (17). W102-04-02-027

4. Fully extend and hold piston rod (17). Remove socket bolts (25) (14 used) from head cover (23). : 14 mm

11. Remove dust rings (1) (2 used) and wear ring (4) from piston (3).

5. Tighten set screw (24) installed to the flange part of head cover (23) and make clearance between the mating surfaces. Remove head cover (23) from cylinder tube (14) by using a screwdriver. : 6 mm 6. Remove the piston rod (17) assembly from cylinder tube (14).

W4-2-19

FRONT ATTACHMENT / Cylinder

3 2

18 19 21

22 23

27 29

28 W4FC-04-02-006

W4-2-20

FRONT ATTACHMENT / Cylinder IMPORTANT: Do not damage the seal groove by a cutting tool. 12. Place piston (3) on a V-shaped stable stand. Remove the backup rings at both sides of packing (2) from piston (3). Cut and remove the seal ring and the back ring in the center part of packing (2).

Hammer Screwdriver Detail

Seal Ring

Back Ring W4GB-04-02-004

13. Remove backup rings (15) (2 used) and O-ring (16) from piston (3). 14. Remove backup ring (21) and O-rings (20, 22) from head cover (23). 15. Remove U-packing (27) and buffer seal (26) from head cover (23). 16. Remove retaining ring (29) and dust seal (28) from head cover (23). IMPORTANT: Do not remove bushing (19) unless necessary. 17. Remove retaining ring (18) and bushing (19) from head cover (23).

W4-2-21

FRONT ATTACHMENT / Cylinder ASSEMBLY OF BUCKET CYLINDER

9, 10

11, 12

23 29

W4FC-04-02-008

12345678-

Dust Ring (2 Used) Packing Piston Wear Ring Nut Set Screw Pipe Clamp

910 11 12 13 14 15 -

Washer Bolt Socket Bolt (4 Used) Washer (4 Used) O-Ring Cylinder Tube Backup Ring (2 Used)

16 17 18 19 20 21 22 -

NOTE: As for parts with mark *, refer to W4-2-18.

W4-2-22

O-Ring Piston Rod Retaining Ring Bushing O-Ring Backup Ring O-Ring

23 24 25 26 27 28 29 -

Head Cover *Set Screw Socket Bolt (14 Used) Buffer Seal U-Packing Dust Seal Retaining Ring

FRONT ATTACHMENT / Cylinder Assembly of Bucket Cylinder 1. Install bushing (19) to head cover (23) by using the special tool (ST 8075). ST 8075

6. Install the back ring of packing (2) to piston (3) by using the special tools (ST 2185, ST 2197, and ST 2221). ST 2221

ST 2197

ST 2185 W4GB-04-02-012

Back Ring

2. Install retaining ring (18) to head cover (23).

3. Install buffer seal (26) and U-packing (27) to head cover (23).

W4FC-03-10-002

4. Install dust seal (28) to head cover (23) by using a plastic hammer. Install retaining ring (29) to head cover (23).

CAUTION: Warm up the seal ring of packing (2) by using oil heated by an electric heater. Avoid direct heating by using fire.

5. Install O-rings (20, 22) and backup ring (21) on the outer circumference of head cover (23).

ST 2209

W4FC-03-10-003

W4-2-23

FRONT ATTACHMENT / Cylinder

9, 10

11, 12

W4FC-04-02-008

W4-2-24

FRONT ATTACHMENT / Cylinder 9. Install dust ring (1) and wear ring (4) to piston (3). 10. Install O-ring (16) and backup rings (15) (2 used) to piston (3). 11. Secure piston horizontally.

rod

(17)

workbench

12. Apply hydraulic oil onto the piston rod (17) surface. Install the head cover (23) assembly to piston rod (17). 13. Apply hydraulic oil onto the inner surface of piston (3). 14. Install piston (3) to piston rod (17). Align the matching marks and tighten nut (5) by using the special tool (ST 5908).

IMPORTANT: When inserting piston rod (17), do not damage the rings. Align with the center of cylinder tube (14) and insert the piston rod (17) assembly straight. IMPORTANT: Apply LOCTITE #242 onto the thread part of head cover (23). 16. Secure cylinder tube (14) in a vise horizontally. Install piston rod (17) to cylinder tube (14). 17. Apply LOCTITE #242 onto the thread part of socket bolts (25) (14 used). Install head cover (23) to cylinder tube (8) with socket bolts (25) (14 used). : 14 mm : 344 to 363 N⋅m (35 to 37 kgf⋅m, 255 to 265 lbf⋅ft) 18. Add the low-pressure air to the port in the rod side of cylinder tube (14). Retract piston rod (17).

ST 5908

W158-04-02-022

15. Align the holes on piston rod (17) and nut (5). Secure nut (5) to piston rod (17) with set screw (6). Crimp set screw (6) at 2 places by using a punch in order not to loosen. Nut (5) : 1865±186 N⋅m (190±19 kgf⋅m, 1380±137 lbf⋅ft) Set screw (6) : 4 mm : 14.7 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

19. Install pipe (7) to cylinder tube (14) with O-ring (13), washers (12) (4 used) and socket bolts (11) (4 used). : 8 mm : 54 to 59 N⋅m (5.5 to 6.0 kgf⋅m, 40 to 44 lbf⋅ft) 20. Secure pipe (7) to cylinder tube (14) with clamp (8), washer (9), and bolt (10). : 19 mm : 54 to 59 N⋅m (5.5 to 6.0 kgf⋅m, 40 to 44 lbf⋅ft)

W4-2-25

FRONT ATTACHMENT / Cylinder MAINTENANCE STANDARD Rod Bend and Straightness Dial Gage Cylinder Rod

W166-04-02-022

1m V Block

Bend Straightness 0.5 (0.02) 1.0 (0.04) 1.0 (0.04) 2.0 (0.08)

Unit: mm (in) Remedy Repair Replace

W4-2-26

Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Tel: 81-29-982-7084 Fax: 81-29-831-1162 E-mail: dc@hitachi-kenki.com

Hitachi Ref. No.

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