Kawasaki 60ZV-2 WHEEL LOADER SHOP MANUAL 93206-00121 by www.heydownloads.com

60ZV-2

93206-00121

SHOP MANUAL Disassembly & Reassembly Service Standard

Printed in Japan (k) ( アメリカ用 )

93206-00121

February 2009

SHOP MANUAL WHEEL LOADER

60ZV-2 General Information Disassembly & Reassembly Service Standard

93206-00050 August 2004

Foreword

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

(1)

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

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

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

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

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

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

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

(3)

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

Item

Description

Reference

Weight

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

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

Coating

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

Oil or water supply

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

Drainage

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

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

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

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

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

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

Bolt size Type

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

(F) 1.25

132

(F) 1.25

142

206

(F) 1.5

152

221

216

314

(F) 1.5

226

330

299

436

(F) 1.5

324

476

417

608

(F) 1.5

451

662

559

814

(F) 1.5

598

878

721

1,030

(F) 2.0

770

1,128

1,030

1,520

(F) 2.0

1,128

1,618

1,422

2,109

(F) 2.0

1,569

2,256

1,912

2,844

M10 M12

Metric thread

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

M33

(F) 2.0

2,059

3,040

5/16

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

358

525

7/8

9 UNC

554

809

8 UNC

868

1,275

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

(5)

(kgf-m) Bolt strength

Bolt size Type

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

2.7

3.9

5.4

7.8

(F) 1.25

5.6

8.2

9.2

13.5

(F) 1.25

9.8

14.5

21.0

(F) 1.5

15.5

22.5

22.0

32.0

(F) 1.5

23.0

33.7

30.5

44.5

(F) 1.5

33.0

48.5

42.5

62.0

(F) 1.5

46.0

67.5

57.0

83.0

(F) 1.5

61.0

89.5

73.5

105.0

(F) 2.0

78.5

115.0

105.0

155.0

(F) 2.0

115.0

165.0

145.0

215.0

(F) 2.0

160.0

230.0

195.0

290.0

M10 M12

Metric thread

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

M33

(F) 2.0

210.0

310.0

5/16

18 UNC

2.5

3.6

3/8

16 UNC

4.5

6.6

7/16

14 UNC

7.2

10.5

1/2

13 UNC

10.5

15.0

9/16

12 UNC

15.0

22.0

5/8

11 UNC

20.5

30.0

3/4

10 UNC

36.5

53.5

7/8

9 UNC

56.5

82.5

8 UNC

88.5

130.0

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

(6)

(lb-ft.) Bolt strength

Bolt size Type

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

19.5

(F) 1.25

105

150

(F) 1.5

110

160

230

(F) 1.5

165

245

220

320

(F) 1.5

235

350

305

450

(F) 1.5

330

490

410

600

(F) 1.5

440

650

530

760

(F) 2.0

565

830

760

1,120

(F) 2.0

830

1,190

1,050

1,550

(F) 2.0

1,160

1,660

1,410

2,100

M10 M12

Metric thread

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

M33

(F) 2.0

1,520

2,240

5/16

18 UNC

18.0

3/8

16 UNC

7/16

14 UNC

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

410

595

8 UNC

640

940

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

(7)

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

(N-m) Bolt size Type

Metric thread

Bolt strength

Nominal Dimension

Pitch

0.8

8.8 (8T)

1.25

M10

1.5

M12

1.75

M16

231

M20

2.5

441

M24

765

(kgf-m) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Pitch

8.8 (8T)

0.8

0.7

1.2

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

23.5

M20

2.5

45.0

M24

78.0

(lb-ft) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Pitch

8.8 (8T)

0.8

5.0

8.6

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

(8)

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

Hose band

Tightening torque

(N-m)

(kgf-cm)

(lb-ft)

1.6

1.2

2.9

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

1.6

1.2

2.9

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

16.5

HH022W

7.9

18.5

HH022W

9.5

20.5

HH022W

12.7

24.5

HH027W

15.9

29.9

HH031W

19.0

30.0

HH031W

25.4

38.0

HH044W

31.8

45.8

HH052W

38.1

52.1

HH057W

50.8

67.8

HH071W

60.5

76.0

HH082W

75.5

93.0

HH095W

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

Hose band

16.5

HH022W

18.5

HH022W

20.5

HH022W

22.0

HH023W

24.5

HH027W

26.0

HH027W

29.0

HH031W

30.5

HH031W

32.0

HH038W

34.0

HH038W

39.5

HH044W

41.5

HH044W

46.0

HH052W

48.0

HH052W

54.0

HH057W

70.5

HH076W

73.0

HH076W

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

Pipe

Hose band

Center of pipe protrusion 10~20 mm

(9)

70ZV00003

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

Liquid Gasket

Screw Lock Agent

Code

Manufacturer

Product name

AA01

Loctite ®

Plastic Gasket 568

AA02

Loctite

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite ®

Loctite ® 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

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

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

65ZV00002

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

H Abt 1/3H

65ZV00003

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

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

Leave 1~2 screw 65ZV00004

Code

Manufacturer

Product name

AC01

Loctite ®

Loctite 767 (Paste or spray)

(10)

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

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

Example 2:

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

Section to be welded

Ground this section. (correct grounding)

(11)

35C00002

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

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

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

Scrap material, etc. 1m or more

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

35C00003

Section to be welded

1m or more 35C00004

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

Section to be welded Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

(12)

35C00005

Weight of Main Components Part name

Approx. Weight (kg)

Approx. Weight (lb)

Bucket

485

1,070

Item Unit name

Chassis

Power line

Boom

605

1,330

150

330

Link (Bucket to Lever)

Engine room assembly

170

375

Hydraulic tank

145

Excluding oil

Fuel tank

210

Excluding fuel

Floor board

135

300

Cab

550

1,210

ROPS cab

Engine

500

1,100

Including oil

Radiator

135

300

Excluding water and oil

Transmission

400

880

Excluding oil

Second propeller shaft

Third propeller shaft

Front axle assembly

480

1,060

Excluding tires and oil

Rear axle assembly

635

1,400

Excluding tires and oil (Including axle support)

Differentials

140

310

Weight each (Both Front and Rear)

Steering valve (Orbitrol )

Gear pump

Other

GSN bucket

" Z " -Lever

Multiple control valve

Hydraulic system

Remarks

Boom cylinder

70/pc

155/pc

Excluding oil

Bucket cylinder

135

Excluding oil

Steering cylinder

15/pc

35/pc

Excluding oil

Tire

175/pc

385/pc

With rim (15.5-25-12PR); No Hydro Inflation

Battery

35/pc

80/pc

(13)

Applying and Storing Articulation Stopper 1. Applying articulation stopper

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

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

2) Turn rod (1) (articulation stopper) until it comes in contact with pin (2). Insert the pin (2) into the rod to lock the front chassis to the rear chassis.

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

1 "LOCKED" position

60ZV US 3652L

2. Storing articulation stopper

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

"STORED" position

(14)

60ZV US 3652

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

MEMO

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

14-1

Fuel Tank

60ZV

CHASSIS 14

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

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

1 Fuel tank

Before starting work: - Drain fuel from the fuel tank. (Fuel tank capacity: 197 (52 Gal.)) - Remove the engine room. - Remove the radiator.

60ZV14001

1) Put a matchmark on fuel hoses (1) and disconnect them from the fuel tank. 2) Disconnect the level sensor electrical line coupler. Fix eye bolt (M12) to the fuel tank and attach sling to fuel tank. Then remove bolt (2) and slowly lower the fuel tank. : Fuel tank: 95 kg (210 lbs) Torque for assembly: : Bolt (4): 436 N-m (44.5 kgf-m) (322 lb-ft)

Rear chassis

Eye bolt

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

60ZV14002

14-2

Engine Room

60ZV

CHASSIS 14

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

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

Before starting work: - Remove the brake oil tank together with the hose from the engine room. Cap off parts of tank to avoid dust ingression. Cap off lines to tank for same reason. 1) Disconnect hose (1) between the air cleaner and the engine.

60ZV14003J

Note: Cover the hose and port of the engine to protect the engine from dust and dirt. 2) Remove bolts (2)(3) from the engine room. Torque for assembly: : Bolt (2)(3): 94 N-m (9.6 kgf-m) (69 lb-ft)

2 Sleeve 60ZV14003

60ZV14004J

3) Suspend the engine room with a sling. : Engine room: 170 kg (375 lbs) Note: Slowly lift the engine room while checking that there are no obstacles.

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

Cab

60ZV

CHASSIS 14

Cab Removing and reinstalling cab 1. Removing cab

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. - Position machine on level ground, and block tires with chocks, etc. to prevent them from moving. - Lower bucket to ground, and apply parking brake. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel. 4

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

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

60ZV14006J

3) Remove cover (5)

60ZV14007J

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

60ZV14004

14-4

Cab

60ZV

CHASSIS 14

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

10 11

Floor board

10 60ZV14005

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

11 Plug

11 Plug Floor board top view

: Cab: 550 kg (1,210 lbs)

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

14-5

60ZV14006

Floor Board

60ZV

CHASSIS 14

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

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

Pilot valve

2 1

3 60ZV14007

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

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

14-6

Floor Board

60ZV

CHASSIS 14

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

60ZV14013J

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

2. Reinstalling floor board For reinstallation, follow the above procedure in the reversed direction. Note: After reinstallation, start the engine, and then check the refrigerant, and oil lines for leakage. Also check operation of the electrical equipment.

60ZV14014J

14-7

Boom

60ZV

CHASSIS 14

Boom Removing and reinstalling boom

WARNING

1. Removing boom

Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer could cause a breakage resulting in injury or death. - Keep persons away from working area. - Use a support plate in case a steel hammer is used. - Use a copper-hammer or a plastic hammer. - Always wear protection goggles.

1) Remove pins (2)(3) for bucket (1) to remove the bucket. : Bucket: 480 kg (1,058 lbs) Note: There are shims in the pin sections. Carefully store removed shims, and correctly reinsert shims when reinstalling bucket. 2) Remove connection pin (6) from rod (4) and lever (5).

: Link : 35 kg (80 lbs)

3 1

6 4 2 60ZV14015J

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

: Bucket cylinder : 70 kg (155 lbs) 5

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

14-8

Boom

60ZV

CHASSIS 14

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

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

60ZV14017J

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

: Lever : 150 kg (330 lbs)

65ZV14024J

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

10 12

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

14-9

65ZV14025J

Boom

60ZV

CHASSIS 14

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

8) Slowly lift boom (10) to remove it from machine. : Boom: 605 kg (1,330 lbs)

10 13

60ZV14018J

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

2. Reinstalling boom For reinstallation, follow the above procedure in the reversed direction. Note: Be sure to adjust the clearance of the retainer pin sections using the liners. After reinstallation, grease the boom pins, and then operate boom. During operation, check the boom for abnormal noise.

14-10

Center Pin

60ZV

CHASSIS 14

Center Pin Upper center pin

Lower center pin

T2 60ZV14008

T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 456 N-m (46.5 kgf-m) (336 lb-ft) (with lubricating oil (Engine oil or gear oil)) Shim adjustment: Adjust the clearance to 0.1±0.05 mm (0.0039±0.0020 in.) using the appropriate shim. After that, tighten the T1 bolt.

14-11

MEMO

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

15-1

Linkage

60ZV

CHASSIS 15

Linkage 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

ø80 (3.15) ø50 (1.97)

4. Front chassis - Boom

mm (in)

ø60 (2.36)

5. Bucket - Rod

6. Lever - Rod

ø60 ø60 (2.36) (2.36)

ø65 (2.56)

7. Lever - Bucket cylinder

ø50 (1.97)

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

ø60 (2.36)

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

ø35 (1.38)

60ZV15001

8 4

11 10

6 65ZV12004

15-2

Linkage Pin Standard Clearance Values

60ZV

CHASSIS 15

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

No.

Solution

Pin standard dimension

Standard clearance

Tolerance

∗

Joint section between bucket and boom

ø50 (ø1.97)

0.167 ~ 0.211 (0.0066 ~ 0.0083)

1.0 (0.0393)

Replacement

∗

Joint section between boom and lever

ø80 (ø3.15)

0.224 ~ 0.276 (0.0088 ~ 0.0109)

1.0 (0.0393)

Replacement

Joint section between boom and boom cylinder

ø60 (ø2.36)

0.202 ~ 0.251 (0.0080 ~ 0.0099)

1.0 (0.0393)

Replacement

∗∗

Joint section between front chassis and boom

ø65 (ø2.56)

0.202 ~ 0.251 (0.0080 ~ 0.0099)

1.0 (0.0393)

Replacement

∗

Joint section between bucket and rod

ø60 (ø2.36)

0.202 ~ 0.251 (0.0080 ~ 0.0099)

1.0 (0.0393)

Replacement

∗

Joint section between lever and rod

ø60 (ø2.36)

0.202 ~ 0.251 (0.0080 ~ 0.0099)

1.0 (0.0393)

Replacement

∗

Joint section between lever and bucket cylinder

ø50 (ø1.97)

0.167 ~ 0.211 (0.0066 ~ 0.0083)

1.0 (0.0393)

Replacement

∗

Joint section between bucket cylinder and front chassis

ø60 (ø2.36)

0.202 ~ 0.251 (0.0080 ~ 0.0099)

1.0 (0.0393)

Replacement

Joint section between boom cylinder and front chassis

ø60 (ø2.36)

0.202 ~ 0.251 (0.0080 ~ 0.0099)

1.0 (0.0393)

Replacement

∗

Joint section between front chassis and steering cylinder

ø35 (ø1.38)

0.135 ~ 0.172 (0.0053 ~ 0.0068)

1.0 (0.0393)

Replacement

∗

Joint section between steering cylinder and rear chassis

ø35 (ø1.38)

0.135 ~ 0.172 (0.0053 ~ 0.0068)

1.0 (0.0393)

Replacement

Liner clearance adjustment ∗

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

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

∗∗ Only in case the clearance at the machine center side is more than 2.8 mm, adjust using liner of 2.8 mm thickness. 70ZV15001

15-3

Center Pin

60ZV

CHASSIS 15

Center Pin Shim adjustment The clearance between the front chassis and bearing cover (#3) is 0.5±0.5 mm (0.02±0.02 in) before shim adjustment. Add shims (#5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in). After that, tighten bolt (#10). #9: 456 N-m (46.5 kgf-m) (336 lb-ft) (with lubricating oil (Engine oil or gear oil)) #10: 230 N-m (23.5 kgf-m) (170 lb-ft)

[Upper] 1

3 5 Front chassis

Rear chassis

11 2

60ZV15002

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

Front

Grease nipple installation direction

15-4

65ZV15001

Bucket Positioner and Boom Kick-Out

60ZV

CHASSIS 15

Bucket Positioner and Boom Kick-Out

Bucket positioner

60ZV15003

15(0.6 in.)

5±2(0.2±0.09 in.)

2.2(0.09 in.)

Bucket positioner

✽

Plate Plate

Indicator lamp direction

Proximity switch 60ZV15005

15-5

Bucket Positioner and Boom Kick-Out

60ZV

CHASSIS 15

Unit : mm Item

No.

Judgment standard

Solution

5 ± 2 (0.196 ± 0.078 in.)

Adjustment

Clearance of bucket positioner switch

Adjusting plate mounting bolt tightening torque

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

Tightening

Switch mounting nut tightening torque

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

Tightening

Bucket positioner adjustable angle

-7° ~ 7°

Adjustment

Bucket positioner adjustable angle

-7°

0°

+7° 60ZV15004J

15-6

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

24-1

Power Line

60ZV

POWER 24

Power Line Tightening torque

T2 L3 T1 L3 T1 L3 T2 L3 T L 4

T3 L1

T8 L2

Rear differential

T4 L1 T2 L3

Third propeller shaft

T7 L2

T6 L2

T5 L2

Front differential Second propeller shaft

: Bolt tightening torque T1: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T2: 417 N-m (42.5 kgf-m) (307 lb-ft) T3: 55 N-m ( 5.6 kgf-m) ( 41 lb-ft) T4: 94 N-m (9.55 kgf-m) ( 69 lb-ft) T5: 80 N-m (8.15 kgf-m) ( 59 lb-ft) T6: 142 N-m (14.5 kgf-m) (105 lb-ft) T7: 230 N-m (23.5 kgf-m) (170 lb-ft) T8: 137 N-m (14.0 kgf-m) (101 lb-ft)

60ZV24001

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

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

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

Radiator

60ZV

POWER 24

Radiator Tightening torque

B C

Crank center

Fan center

T1 L3

A-A

T1 L3

B-B

C-Detail

: Bolt tightening torque T1: 49 N-m ( 5.0 kgf-m) (36 lb-ft) T2: 90 N-m (9.15 kgf-m) (66 lb-ft)

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

24-3

D-Detail

60ZV24002

Radiator

60ZV

POWER 24

Removing and reinstalling radiator 1. Removing radiator

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

Before starting work: - Remove the engine room (Refer to Chassis group.) 1) Remove drain plug (1) to drain the coolant. : Coolant: 8 (2.1 gal.) 2

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

3) Remove radiator guard (4).

4) Remove plate (5). Torque for assembly: : Bolt (Radiator side): 49 N-m (5.0 kgf-m) (36 lb-ft) Bolt (Chassis side): 90 N-m (9.15 kgf-m) (66 lb-ft) : With lubricating oil (Engine oil or gear oil) Bolt (Radiator side) 5) Attach sling to radiator (6). Remove right and left retainer bolts (7). : Radiator: 135 kg (300 lbs) Torque for assembly: : Retainer bolt (7): 49 N-m (5.0 kgf-m) (36 lb-ft) : With lubricating oil (Engine oil or gear oil) 24-4

3 1 60ZV24003J

Radiator

60ZV

POWER 24

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

(0.13 Gal.)

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

9 60ZV24003

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

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

24-5

Engine

60ZV

POWER 24

Engine Removing and reinstalling engine 1. Removing engine

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply articulation stopper. - Block front wheels with chocks to prevent wheels from moving. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery. - Select correct tooling to remove engine and transmission. Before starting work: a) Remove the engine room (with the air cleaner). (Refer to Chassis Group). b) Recover the air conditioner refrigerant (option) using the proper recovery method. c) Remove the radiator. 1) Disconnect the negative side of the battery cable. 2) Disconnect the wire from all sensors, alternator and air conditioner. 3) Disconnect fuel hose, heater / cooler hose, air compressor wiring and drain hose. 4) Disconnect the accelerator control cable from the engine.

5) Remove cover (1) on the torque converter case. Turn the torque converter drive cover slowly, and remove bolt (2) connecting the engine flywheel and the torque converter flexible plate. Torque for assembly: : Bolt (4): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) 60ZV24005J

24-6

Engine

60ZV

POWER 24

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

CAUTION Because it is needed to sling engine at an angle when removing, install chain block to radiator side. : Engine assembly: Approx. 500 kg (1,100 lbs) Torque for assembly: : Bolt (3): 417 N-m (42.5 kgf-m) (307 lb-ft) : With lubricating oil (Engine oil or gear oil) 7) Remove bolt (4) connecting torque converter case and engine flywheel housing. Torque for assembly: : Bolt (4): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) 8) Separate engine and transmission from each other, and then lift the engine. Note: Lift engine approximately 100 mm (4 in.). Insert wooden piece of approximately 200 mm (8 in.) thickness into clearance between flywheel bottom and rear axle to separate engine and transmission. Repeat this two to three times to completely separate engine and the transmission from each other. Carefully lift engine while checking that there are no obstacles around it.

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

3. Cautions regarding engine reinstallation - Refill engine with proper quantity and type engine oil. - Refill radiator with premixed coolant (approx 50 % water / 50 % antifreeze, or according to local requirements.). - After reinstalling engine, completely bleed fuel line of air. - Set starter key to ON, and then check monitor lamps of electrical equipment. - Operate engine at idling speed for 5 minutes. After that, check amount of coolant. - While gradually increasing engine speed, check operation of electrical equipment, and check for leaks. 24-7

60ZV24006J

60ZV24007J

Propeller Shaft

60ZV

POWER 24

Propeller Shaft Removing and reinstalling propeller shaft

2 3

1. Removing second propeller shaft 1) Remove bolt (2) from transmission side of propeller shaft (1). Torque for assembly: : Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application 2) Remove bolt (3) from pillow unit bearing (4). Torque for assembly: : Bolt (3): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent (Loctite® 262) application 3) Remove bolt (6) to disconnect propeller shaft from front differential (5). Support shaft by cable or rolling floor jack. Take out the second propeller shaft to the front. Torque for assembly: : Bolt (6): 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application : Second propeller shaft: 30 kg (70 lbs) Note: If retainer bolt is too tight due to screw lock agent, heat the bolt head to about 235 ˚C (450 ˚F) using low flame of a gas torch. Keep the flame away from seals of coupling. Do not reuse the bolts, always replace with new ones.

1 4

60ZV24004

60ZV24005

2. Removing third propeller shaft 1) Remove bolt (7). Torque for assembly: : Bolt (7): 137 N-m (14.0 kgf-m) (101 lb-ft) : Screw lock agent (Three bond 1327) application 2) Remove the third propeller shaft. : Third propeller shaft: 10 kg (25 lbs)

3. Reinstalling propeller shaft For reinstallation, follow the above procedure in the reversed direction. Note: During reinstallation, align the direction of the flange yokes on the second and third propeller shaft sides of the transmission. (Refer to Section 22) [Difference in the yoke phase (direction) will cause the propeller shaft damage.] 24-8

60ZV24006

Air Cleaner

60ZV

POWER 24

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

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

2. Reinstalling air cleaner For reinstallation, follow the above procedure in the reversed direction. Note: If the bands of the air duct are not properly positioned or tightened, the duct will draw in dust that will cause an engine problem. Carefully reinstall the air duct.

60ZV24011J

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

60ZV24025

24-9

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

Muffler

60ZV

POWER 24

Muffler Removing and reinstalling muffler 3

1. Removing muffler

CAUTION

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

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

60ZV24013J

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

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

60ZV24014J

2. Reinstalling muffler

For reinstallation, follow the above procedure in the reversed direction. Note: After reinstallation, check all the joints for gas leakage and vibration.

60ZV24015J

24-10

Axle Assembly

60ZV

POWER 24

Axle Assembly Tightening torque

T3 L 3

1. Front axle

T1 L 1 A

Mating face T2 L2

T1 L 1

2. Rear axle

60ZV24008

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

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

T3 L 3

T2: 892 N-m (91.0 kgf-m) (658 Ib-ft) T3: 721 N-m (73.5 kgf-m) (532 Ib-ft) T4: 132 N-m (13.5 kgf-m) ( 98 Ib-ft) : L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three bond 1215) application L3: With lubrication oil (Engine oil or gear oil) T4 L 3

Preload of section (A): 52~73 N (5.3~7.4 kgf) (11.7~16.3 lbf)

60ZV24017J

24-11

Front Axle Assembly

60ZV

POWER 24

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

Stand Stand 65ZV24018

1) Remove right and left wheel and tire assemblies (1). : 1 Tire: 175 kg (385 lbs) Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

65ZV24029J

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

65ZV24030J

24-12

Front Axle Assembly

60ZV

POWER 24

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

60ZV24018J

60ZV24019J

4) Attach sling to axle assembly (6), and then remove eight retainer bolts (7). : Axle assembly: Approx. 480 kg (1,060 lbs) Torque for assembly:

: Retainer bolt: 721 N-m (73.5 kgf-m) (532 lb-ft) Note: During reassembly be sure both mating surfaces are clean and free of paint. 6 65ZV24032J

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

24-13

Front Axle Assembly

60ZV

POWER 24

2. Reinstalling front axle assembly For reinstallation, follow the above procedure in the reversed direction. After reinstallation, completely bleed air in the service brake line. Reference Air bleeding procedure Connect a clean vinyl tube to the air bleeder nipple, and place an oil can to receive the oil, or route the hydraulic tank. Slightly loosen the air bleeder nipple, and then press the brake pedal several times. When the oil flows from the air bleeder nipple, close the nipple. After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple. Repeat this until there is no air in the oil. Completely bleed each wheel of air.

24-14

Front Axle Assembly

60ZV

POWER 24

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

2 1 65ZV24044J

Sling

1) Attach sling to axle housing (4) and remove bolts (3). Separate axle housing (4) from differential assembly. Note: Striking axle housing lightly by hammer may help to separate it from differential assembly. : Axle housing: 170 kg (375 lbs) 3

WARNING

65ZV24019

Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer may cause a breakage resulting in injury or death. - Keep persons away from working area. - Use a support plate in case a steel hammer is used. - Use a copper-hammer or a plastic hammer. - Always wear protection goggles.

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

24-15

65ZV24046J

Front Axle Assembly

60ZV

POWER 24

3) Remove steel plate (7). 7

65ZV24047J

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

Jig

65ZV24020

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

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

ø350 (13.8 in.)

100 (3.9 in.)

80 (3.1 in.)

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

Axle shaft 60ZV24021

24-16

Front Axle Assembly

60ZV

POWER 24

5) Remove retainer (8). 8

65ZV24050J

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

10 9

65ZV24051J

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

65ZV24052J

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

Axle shaft

12 65ZV24022

24-17

65ZV24054J

Front Axle Assembly

60ZV

POWER 24

9) Remove axle shaft (13) from jig.

65ZV24055J

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

WARNING Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer could cause a breakage resulting in injury or death. - Keep persons away from working area. - Use a support plate in case a steel hammer is used. - Use a copper-hammer or a plastic hammer. - Always wear protection goggles.

24-18

14 15 65ZV24056J

Front Axle Assembly

60ZV

POWER 24

2. Reassembling axle assembly 13

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

14 15

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

65ZV24057J

Inner race (B)

Axle shaft

Outer race (A)

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

Bearing installation end

Do not apply any oil here.

Oil seal details Grease

60ZV24010

3) Insert bearing (14) into axle shaft.

WARNING Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer may cause a breakage resulting in injury or death. - Keep persons away from working area. - Use a support plate in case a steel hammer is used. - Use a copper-hammer or a plastic hammer. - Always wear protection goggles.

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

65ZV24059J

24-19

Front Axle Assembly

60ZV

POWER 24

5) Insert oil seal inner race into axle housing.

65ZV24060J

6) Install bearing (12). 16

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

65ZV24061J

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

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

Shim (16)

Taper roller bearing(12)

60ZV24029

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

65ZV24063J

Spring balance

65ZV24025

24-20

Front Axle Assembly

60ZV

POWER 24

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

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

11 17 65ZV24065J

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

10 8

13) Install retainer (8).

9 65ZV24066J

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

7 65ZV24067J

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

5 65ZV24068J

24-21

Front Axle Assembly

60ZV

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

POWER 24

Bolt

: 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application Liquid gasket (Three Bond 1215) application

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

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

24-22

Liquid gasket application

65ZV24026

Front Axle Assembly

60ZV

POWER 24

Disassembling and reassembling spider assembly

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

65ZV24070J

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

3 65ZV24071J

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

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

5 4 65ZV24072J

24-23

Front Axle Assembly

60ZV

POWER 24

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

60ZV24022J

7) Remove washer (7) with shim.

65ZV24074J

2. Reassembling spider assembly

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

60ZV24022J

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

65ZV24075J

24-24

Front Axle Assembly

60ZV

POWER 24

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

4 65ZV24076J

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

3 Pin holes

65ZV24027

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

65ZV24078J

24-25

Rear Axle Assembly

60ZV

POWER 24

Rear Axle Assembly Removing and reinstalling rear axle assembly 1. Removing rear axle assembly

WARNING Unexpected movement of machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply articulation stopper.

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

A 60ZV24011

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

60ZV24026

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

Wooden block

WARNING The axle will not be balanced when a tire is removed. If wooden blocks are not inserted, your fingers or body may be caught in machine.

65ZV24028

24-26

Rear Axle Assembly

60ZV

POWER 24

4) Remove right and left wheel and tire assemblies (1). : Tire of 1 wheel: Approx. 170 kg (385 lbs) Torque for assembly: : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb)

60ZV24025J

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

65ZV24037J

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

60ZV24026J

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

65ZV24039J

24-27

Rear Axle Assembly

60ZV

POWER 24

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

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

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

65ZV24040J

9) Attach sling to front axle support (7), and remove it from rear axle. The support should slide off rear axle. : Axle support: Approx. 65 kg (143 lbs)

7 65ZV24041J

10) Attach sling to rear support (8) temporarily and remove bolts (9) from plate (10). Remove plate (10). Remove rear support (8). Torque for assembly: : Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Axle support: Approx. 120 kg (265 lbs) Remove and clean breather fitting. When fitting is reinstalled use Liquid gasket (Three Bond 1215) on threads. Place breather fitting on top position. Lubricate after reassembly to be sure grease comes out breather.

8 10

65ZV24042J

11) Remove packing (11). 11

65ZV24043J

24-28

Rear Axle Assembly

60ZV

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

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

24-29

POWER 24

Axle Support

60ZV

POWER 24

Axle Support Disassembling and reassembling axle support

Grease piping

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

4 3 2 1

Front

60ZV24012

Large chamfer

Small chamfer 30°

Bushing section 65ZV24030

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

7 Grease piping

Front

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

24-30

60ZV24013

Differential Assembly

60ZV

POWER 24

Differential Assembly Tightening torque

T1 L 3

(Front differential assembly shown)

T5 L 1 T3 A 4 1

3 2

T5 L 1 T2 L 1

T5 L 1 60ZV24029J

5 T4 L 1

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

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

: Front 140 kg (310 lbs) Rear 150 kg (330 lbs)

Ring part 65ZV24032

24-31

Differential Assembly

60ZV

Disassembling and reassembling differential assembly

POWER 24

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

Remover bolt

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

2) Remove differential carrier cover (2).

65ZV24033

60ZV24038J

3) Lift differential cage lightly by lifting tool A .

45(1.8) 12(0.5)

mm(in.)

20 (0.8) ø11 (0.4)

Width across flat 10

M10x1.5

70(2.8)

15 (0.6)

28(1.1) 320(12.6)

11(0.4)

Nut

ø13(0.5)

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

ø20(0.8)

t9 (0.4)

65ZV24083J

67(2.6)

33 (1.3)

70(2.8)

140(5.5)

14 (0.6)

Material SS41

30 11 (1.2) (0.4) abt 10 °

t6(0.2) 38 (1.5) 60ZV24027

Lifting tool A 24-32

Differential Assembly

60ZV

POWER 24

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

5 65ZV24085J

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

65ZV24086J

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

Tap for remover bolt 8 9

60ZV24014

24-33

Differential Assembly

60ZV

POWER 24

2. Reassembling differential assembly

IMPORTANT

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

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

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

65ZV24088J

8 9

60ZV24041J

3) Place differential carrier side ways. Differential carrier

65ZV24036

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

10 65ZV24091J

24-34

Differential Assembly

60ZV

POWER 24

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

7 5

65ZV24093J

Insert

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

O-ring

Piston

65ZV24049

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

65ZV24095J

24-35

Differential Assembly

60ZV

POWER 24

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

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

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

65ZV24096J

t=16

40 (1.6)

ø18(0.7)

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

ø210(8.3)

25(1.0) ø390(15.4)

ø290(11.4)

120° Material SS41

Jig B

60ZV24023

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

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

24-36

C 65ZV24098J

Differential Assembly

60ZV

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

POWER 24

65ZV24099J

Bolt

Adjusting nut 12 Ring gear Pinion assembly

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

Bolt Shim Lock plate 11

Adjusting nut 13

65ZV24038

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

65ZV24101J

14) Install differential carrier cover (2).

65ZV24102J

24-37

Differential Assembly

60ZV

POWER 24

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

Possible cause

Adjusting method

Correct

Ring gear is too close to the drive pinion

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

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

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

Drive pinion is too far from the ring gear.

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

90ZV24134

24-38

Differential Assembly

60ZV

POWER 24

Three types of tooth contact shown below are acceptable as best tooth contact. Tooth contact position and length(rate) 10 1

Pattern A

5 TOP

HEEL 4~5

Pitch line TOE

BOTTOM 10 2

Pattern B

4 TOP

Pitch line

HEEL 4~5

TOE BOTTOM 10 3 Pattern C

4 TOP

TOE Pitch line

HEEL 4~5

BOTTOM

10 90ZV24135

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

24-39

Differential Assembly

60ZV

POWER 24

Disassembling and reassembling differential assembly

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

Matchmark

1 3 65ZV24039

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

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

Matchmark

65ZV24040

65ZV24105J

24-40

Differential Assembly

60ZV

POWER 24

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

Thrust washer

Diff. cage

6 5 7 8 8 7 60ZV24016

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

24-41

Differential Assembly

60ZV

POWER 24

Disassembling and reassembling differential assembly 1. Disassembling pinion assembly

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

65ZV24107J

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

60ZV24043J

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

80(3.1)

43 (1.7)

A ø12 (0.5)

65ZV24109J

100(3.9)

89(3.5) Bolt 5 40 (1.6)

170(6.7)

170(6.7) 60(2.4)

70(2.8)

170(6.7)

Material SS41 4

Jig A 60ZV24024

6 7 65ZV24043

24-42

Differential Assembly

60ZV

POWER 24

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

6 7 60ZV24034J

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

Pinion cage

10 60ZV24018

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

12 11

65ZV24114J

24-43

Differential Assembly

60ZV

POWER 24

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

Caulking (stake)

65ZV24046

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

12 11

65ZV24116J

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

Oil seal 9

Pinion cage

10 60ZV24019

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

65ZV24119J

24-44

Differential Assembly

60ZV

POWER 24

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

65ZV24120J

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

65ZV24121J

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

65ZV24122J

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

65ZV24123J

24-45

Differential Assembly

60ZV

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

POWER 24

"Fish scale" tool for measuring preload.

60ZV24028

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

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

24-46

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

25-1

Propeller Shaft Service Standard

60ZV

POWER 25

Propeller Shaft Service Standard

Third propeller shaft

2 Measurement of circumferential play

3 Measurement of transverse play Second propeller shaft 60ZV25001

Unit : mm (in.) Item

No.

Tolerance

Solution

Spider bearing play

Second, third propeller shaft

0.25 (0.0098)

Replacement

Spline circumferential play

Second propeller shaft

0.8 (0.0315)

Replacement

Spline transverse play

Second propeller shaft

1.0 (0.0394)

Replacement

25-2

Axle and Differential Service Standard

60ZV

POWER 25

Axle and Differential Service Standard Axle assembly

60ZV25002J

Unit : mm (in.) Judgment standard Item

No.

Solution Standard dimension

Tolerance

Backlash between sun gear and planetary gear

0.112 ~ 0.488 (0.0044 ~ 0.0192)

←

Replacement

Backlash between planetary gear and internal gear

0.16 ~ 0.66 (0.0063 ~ 0.0260)

←

Replacement

Clearance between spider pin and pin hole

0.0 ~ 0.036 (0.0 ~ 0.0014)

0.1 (0.0394)

Replacement

Clearance between spider pin and needle bearing

0 ø40 -0.011 0 (ø1.6 -0.0004 )

←

Replacement

Tooth contact of gear

No abnormality

25-3

Replacement

Axle and Differential Service Standard

60ZV

POWER 25

Differential

3 1 4

60ZV25003J

Unit : mm (in.) Judgment standard Item

No.

Solution Standard valve

Tolerance

Backlash between ring gear and drive pinion

0.20 ~ 0.28 (0.0079 ~ 0.0110)

←

Adjustment

Backlash between side gear and pinion gear

0.23 ~ 0.45 (0.0091 ~ 0.0177)

←

Adjustment

Clearance between pinion gear and spider

0.013 ~ 0.038 (0.0005 ~ 0.0015)

←

Replacement

Runout of ring gear rear surface (when assembled)

0.076 (0.0029)

←

Adjustment or replacement

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

Tooth contact

No abnormality

Replacement

25-4

TORQUE CONVERTER AND TRANSMISSION GROUP 34 Disassembly and Reassembly Torque Converter and Transmission Assembly...........................................34-2 Torque Converter Assembly ........................................................................34-9 Transmission Assembly.............................................................................34-13 Clutch Pack................................................................................................34-19 Control Valve Assembly.............................................................................34-21

34-1

Torque Converter and Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly Tightening torque

T2 L3 T1 L3 T1 L3 T2 L3 T4 L1 T3 L1

T8 L2

Rear differential

T4 L1 T2 L3

Third propeller shaft

T7 L2

T6 L2

T5 L2

Front differential 60ZV24001

Second propeller shaft

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

L1: Screw lock agent (Loctite® 262) application L2: Screw lock agent (Three Bond 1327) application L3: With lubrication oil (Engine oil or gear oil) 34-2

Torque Converter and Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. Lower bucket to ground, and then block tires with chocks to prevent wheels from moving. - Disconnect the ground cable from the negative side of the battery. Before starting work: - Remove the cab and the floor board (Refer to Section 14). - Remove the engine room front plate. - Consider the type of failure and if the T/C oil cooler must also be removed for cleaning or replacement. - If a small amount of contamination is found in the transmission strainer and filter the cooler does not need removal. - If a large amount of contamination is found the cooler must be removed and thoroughly cleaned or replaced. - Lines to cooler must also be replaced. 1) Remove drain plug (1) to drain the transmission oil. : Transmission oil: 20

(5.3 Gal.)

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

60ZV34001J

Oil pump

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

2 60ZV34001

34-3

Torque Converter and Transmission Assembly

60ZV

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

TORQUE CONVERTER AND TRANSMISSION 34

Oil pump

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

Priority valve

60ZV34002

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

Boost master

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

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

9 60ZV34003

34-4

Torque Converter and Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

Boost master

60ZV34004

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

Control valve

60ZV34005

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

60ZV34006

11) Disconnect bolts (15) from the third propeller shaft on the transmission side. Note: If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner. Keep the flame away from the seals of the coupling. Do not reuse the bolt once heated. : Bolt: 80 N-m(8.2 kgf-m)(59 lb-ft) : Screw lock agent application (Three Bond 1327) 34-5

3rd propeller shaft 60ZV34007

Torque Converter and Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

60ZV34008

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

60ZV34009

14) Remove the cover (19) on the torque converter case. Remove bolts (20) connecting the torque converter flexible plate and the engine flywheel. Remove bolts (21) connecting the torque converter case and the flywheel housing. Tightening torque for assembly: : Bolt (20)(21): 53 N-m(5.4 kgf-m)(39 lb-ft) : With lubrication oil (Engine oil or gear oil)

60ZV34010

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

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

34-6

Torque Converter and Transmission Assembly

60ZV

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

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

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

34-7

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly

DATE:

HOURS:

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

MACHINE MODEL & SERIAL NO.:

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO.:

AMBIENT TEMP: COMPONENT SERIAL NO.:

CHECKLIST TO BE COMPLETED BEFORE START-UP TRANSMISSION COOLER CLEANED

TRANSMISSION PIPING CLEANED

IN-LINE PRESSURE FILTER REPLACED

TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

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

CLUTCH PRESSURE AT LOW IDLE F1

MPa (kgf/cm ) (psi)

MPa (kgf/cm2) (psi)

CLUTCH PRESSURE AT HIGH IDLE F1

MPa (kgf/cm2) (psi)

COMMENTS:

Serviceman's Signature

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

34-8

Torque Converter Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter Assembly

(Kawasaki CT110V01)

Bolt tightening torque

T5 35T

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

52T

T3 L1

41T

1st

31T

27T

T5 32T

61T 46T

2nd 46T

27T

22T

49T

42T

T5 3rd

T2 42T

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

L1 T3

L1: Screw lock agent (Loctite® 262) application

60ZV34026

34-9

Torque Converter Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

2) Remove hose (3).

For jack screw For jack screw

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

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

60ZV34011

60ZV34012

34-10

Torque Converter Assembly

60ZV

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

TORQUE CONVERTER AND TRANSMISSION 34

8 A

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

60ZV34015J

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

A-Detail 60ZV34013

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

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

60ZV34017J

34-11

Torque Converter Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

18 19

10) Remove cover (16). 22

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

21 60ZV34018J

11) Remove ring (18).

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

13) Remove ring (22).

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

65ZV34005

34-12

Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly

(Kawasaki CT110V01)

Bolt tightening torque

T5 35T

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

52T

T3 L1

41T

1st

31T

27T

T5 32T

61T 46T

2nd 46T

27T

22T

49T

42T

3rd

T2 42T

L1 T3

L1: Screw lock agent (Loctite® 262) application

60ZV34026

34-13

Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

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

Hose

For jack screw For jack screw

2) Remove hose.

1 60ZV34014

42T

49T

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

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

34-14

27T

31T

46T

42T

3rd

2nd

22T

61T

32T

1st

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

60ZV34020J

Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

60ZV34025

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

60ZV34022J

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

Jig

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

60ZV34015

34-15

Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

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

12) Place transmission case as illustrated.

60ZV34029J

13) Remove bolt (10).

17 12

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

14) Remove brake cover (11).

16 15 18

60ZV34029J

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

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

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

Transmission Assembly

60ZV

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

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

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

34-17

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

124

ø4

32.4

–

ø60

176.04±0.05

50 57.6

150

(mm)

3 – M10x1.5

100

100 60

ø17 0 ø40 – 0.2

Jig No.1

(t =16)

Jig No.2

ø60

Hexagon socket head cap screw (2 pcs)

: 50

M16 x 2 M10 Eye bolt

ø17 0 ø40 – 0.2

Jig No.3

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

60ZV34016

34-18

Clutch Pack

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

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

Outer race press fit

Inner race press fit

Outer race press fit 1ST

Inner race press fit

Washer

60ZV34016

Groove side

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

Outer race press fit Inner race press fit

2ND

Inner race press fit

Washer Groove side 60ZV34018

34-19

Clutch Pack

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

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

Inner race press fit Inner race press fit

3RD 60ZV34019

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

° 60

360

φ72±0.5

40 φ79±0.5

60ZV34027J

34-20

Control Valve Assembly

60ZV

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Assembly Removing and reinstalling control valve

1. Removing control valve

WARNING

Control valve

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

60ZV34020

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

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

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

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

3) Remove solenoid valve nut (4).

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

60ZV34022

34-21

Control Valve Assembly

60ZV

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

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

3) During installation, be careful not to damage gasket.

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, be sure to stop the engine, and block tires with chocks before you start service work . During the service work, clearly communicate with the person in the cab using signals as agreed upon before hand. 4) At the completion of installation, start the engine, and check that the shift lever properly functions at all the positions. 5) Check oil leakage. 6) Adjust the transmission oil level to the specified point with the dipstick.

34-22

TORQUE CONVERTER AND TRANSMISSION 34

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

35-1

Clutch Oil Pressure

60ZV

TORQUE CONVERTER AND TRANSMISSION 35

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

5 6 9 4 7 2

9 8

60ZV33001

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

Measuring port location

Measuring port size

800

2400

Torque converter inlet pressure

PT1/4

0.1 (1.3) (18) or more

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

All speed range

Torque converter outlet pressure

↑

0.1 (1.0) (14) or more

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

↑

Main oil press.

PF1/4

1.5 (15) (213) or more

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

All speed range

PT1/4

1.5 (15) (213) or more

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

Shift lever position

Engine revolution (min-1) (rpm)

↑

1ST

↑

2ND

↑

3RD

↑

PT1/8

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

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

All speed range

5 6

Clutch oil pressure

Lub. oil pressure

35-2

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

44-1

Warning Regarding Removing and Reinstalling Hydraulic Parts

60ZV

HYDRAULIC 44

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

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

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

44-2

Cautions Regarding Disassembly & Reassembly of Hydraulic Parts

60ZV

HYDRAULIC 44

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

Cautions regarding disassembly

Cautions regarding reassembly

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

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

44-3

Hydraulic Pump Assembly

60ZV

HYDRAULIC 44

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

DANGER

Entering the articulation area while engine is running may cause serious injury or death. So, when entering the area, stop the engine and place "DO NOT START " or "DO NOT OPERATE" tag on steering wheel.

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

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

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

6 4

Torqueconverter

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

4 60ZV44002

3 5

60ZV44003

44-4

Hydraulic Pump Assembly

60ZV

HYDRAULIC 44

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

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

WARNING Oil injection hazard!

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

44-5

IMPORTANT 1)Fill the inlet port of the hydraulic pump with clean hydraulic oil and rotate the pump shaft by hand prior to installing the pump. It should rotate smoothly. Prior to installing pump and plumbing to pump, remove all caps, plugs, and covers from pump and piping. 2)While reinstalling the hydraulic pump, take care not to allow dust, dirt, or foreign material into the case. 3)Check the oil level of the hydraulic tank. 4)Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe. Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 (1 Gal)). Reinstall the plug. 5)Run the engine at low-idling speed for 5 minutes or more. Do not operate any hydraulic functions during this period. Note: If the engine speed is set to high-idling just after starting, the pump may be seized. 6)Actuate cylinders 5 to10 times to almost full stroke, but do not fully extend or retract any of the cylinders at this time. 7)Confirm that there is no abnormal noise or operation, and be sure that there is no excessive heat. Inspect the hydraulic oil at the sight gauge to be sure that there are no bubbles which may indicate air being drawn in at the suction side of the pump. If there are any bubbles, correct the cause prior to using the machine, as this may contribute to premature pump failure.

Hydraulic Pump Assembly

60ZV

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

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

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

44-6

HYDRAULIC 44

Hydraulic Pump Assembly

60ZV

HYDRAULIC 44

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

[Example 1] Oil seal

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

Snap ring

Drive gear shaft

Front cover

95ZV44002

[Example 2]

Front cover

Drive gear shaft

Oil seal

Snap ring 95ZV44003

44-7

Hydraulic Cylinder

60ZV

HYDRAULIC 44

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

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Raise the boom until it is horizontal, and then place stand under the boom to support it. - Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Use a stepladder or work platform, and do not stand on the machine.

Stand

60ZV44004

- Clean the area around the cylinder and piping. Note: Relieving residual pressure from pipe 1.Raise the boom. When the boom is approximately 30 cm (1 foot) above stand, stop the engine. 2.Tilt the bucket all the way down. With the lever held in down position, lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. 3. Open the cap of the hydraulic tank to vent residual pressure. Leave hydraulic tank cap loosely on top of tank opening.

1 60ZV44003

1) Attach sling to boom cylinder (1). Remove lock bolt (2) and pin (3). Retract the cylinder to shorten piston rod (4). : Boom cylinder: 70 kg (154 lbs) 3

60ZV44113

44-8

Hydraulic Cylinder

60ZV

HYDRAULIC 44

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

6 5

60ZV44114

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

60ZV44115

2.Reinstalling boom cylinder To reinstall the boom cylinder, follow the above removal procedure in the reversed direction. Note: Be sure the pins and bushings are clean, free of surface irregularities, and accept grease after installation.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. Air bleeding procedure 1)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100 mm (4.0 in.) before stroking fully. 2)After that, stroke the cylinder piston fully to both ends 4 to 5 times. 3)Add hydraulic oil to tank, and check cylinder and its piping for oil leakage.

44-9

Hydraulic Cylinder

60ZV

HYDRAULIC 44

Removing and reinstalling bucket cylinder 1.Removing bucket cylinder

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Place boom and bucket on ground. - Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Use a step, and do not stand on the machine. - Clean the area around the cylinder and piping. Note: Relieving residual pressure from pipe 1.Lower the boom and bucket to the ground. 2.Stop the engine and move the bucket and boom levers back and forth. 3.Open the cap of the hydraulic tank to relieve the residual pressure.

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

2) Attach sling to bucket cylinder (3). After that, remove lock bolt (4) and pin (5). : Bucket cylinder: 60 kg (132 lbs)

5 4

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

60ZV44009

44-10

Hydraulic Cylinder

60ZV

HYDRAULIC 44

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

8 9

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

3 7

60ZV44010

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

11 10

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

60ZV44011

44-11

Hydraulic Cylinder

60ZV

2.Reinstalling bucket cylinder To reinstall the bucket cylinder, follow the above removal procedure in the reversed direction. Note: Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation

WARNING During service work, do not stand on machine. Standing on tire, boom or linkage may cause accidents and serious injury or death. Use a stepladder, ladder, or work platform, and do not stand on the machine.

➀Bleed the cylinder of air.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. Air bleeding procedure 1)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100 mm (3.9 in.) before stroking fully. 2)After that, stroke the cylinder piston fully to both ends 4 to 5 times. 3)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

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

44-12

HYDRAULIC 44

Hydraulic Cylinder

60ZV

HYDRAULIC 44

Removing and reinstalling steering cylinder 1.Removing steering cylinder

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Place boom and bucket on ground. - Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line. - Open the cap of the hydraulic tank to relieve the internal pressure from the tank. - Place a "DO NOT START!" tag on the steering wheel or the operator's seat .

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

60ZV44012

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

44-13

Rear

5 6

Front

3 60ZV44013

Hydraulic Cylinder

60ZV

HYDRAULIC 44

2.Reinstalling steering cylinder To reinstall the steering cylinder, follow the above removal procedure in the reversed direction. Note: Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation

➀When reinstalling the pins

➁Bleed the cylinder of air

IMPORTANT

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

After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. Air bleeding procedure 1)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100 mm (4.0 in.) before stroking fully. 2)After that, stroke the cylinder piston fully to both ends 4 to 5 times. 3)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area could cause injury or death. When turning the steering wheel while engine is running, do not enter the articulation area of the machine. If a person is in the articulation area, do not start the engine.

44-14

Hydraulic Cylinder

60ZV

HYDRAULIC 44

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

1.Cross section and tightening torque 1) Boom cylinder

T1 T3

2) Bucket cylinder

60ZV44014

T4 3) Steering cylinder

60ZV44015

T7 : N-m(kgf-m)(lb-ft) T1: 2,501(255)(1,844) T2: 863( 88)( 637) T3: 3,107(317)(2,293) T4: 1,060(108)( 781) T5: 31.5( 3.2)( 23) T6: 392( 40)( 289) T7: 304( 31)( 224) T8: 6.9( 0.7)( 5)

60ZV44016

Cylinder

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

Boom

75 (2.95) – M48 x 1.5

Bucket

70 (2.75) – M45 x 2

Steering

41 (1.61) – M24 x 1.5

44-15

Hydraulic Cylinder

60ZV

HYDRAULIC 44

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

Pipe Hook wrench 1.5m

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

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

Wood block

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

60ZV44018

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

1 2

Wood block

View A 60ZV44019

44-16

Hydraulic Cylinder

60ZV

HYDRAULIC 44

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

Screw

Piston nut width across flat Boom cylinder

75 mm(2.95 in.)

Bucket cylinder

70 mm(2.75 in.)

Steering cylinder

41 mm(1.61 in.) Piston nut 60ZV44020

Bucket cyl.

Steering cyl.

Piston nut

Wrench

Hydraulic jack

Hydraulic cylinder 60ZV44021

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

Bucket cyl. 2

60ZV44023

Steering cyl.

4 1 60ZV44024

44-17

Hydraulic Cylinder

60ZV

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

HYDRAULIC 44

Boom cyl.

5 4

60ZV44116

Bucket cyl.

5 4 6 5

60ZV44024

Steering cyl.

4 6 5

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

60ZV44025

10 9 1 13

12 11

60ZV44026

44-18

Hydraulic Cylinder

60ZV

HYDRAULIC 44

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

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

Push Tool

60ZV44027

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

1 11

60ZV44028

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

Tool

60ZV44029

44-19

Hydraulic Cylinder

60ZV

HYDRAULIC 44

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

Push while stretching back-up ring

60ZV44030

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

Rod cover

O-ring Pressure side 60ZV44033

60ZV44031

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

Press-fit-tool

60ZV44032

44-20

Hydraulic Cylinder

60ZV

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

HYDRAULIC 44

Boom cyl.

5 4

60ZV44116

Bucket cyl.

5 4 6 5

60ZV44024

Steering cyl.

4 6 5

44-21

60ZV44025

Hydraulic Cylinder

60ZV

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

HYDRAULIC 44

Bucket cyl. 2

60ZV44023

Steering cyl.

4 1 60ZV44024

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

Repair stand

1 2

Wood block

View A 60ZV44019

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

75 (2.95)

2,501 (255) (1,844)

Bucket cylinder

70 (2.75)

3,107 (317) (2,282)

Steering cylinder

41 (1.61)

392 ( 40) ( 288)

Piston nut

Wrench

Hydraulic jack

Hydraulic cylinder 60ZV44021

44-22

Hydraulic Cylinder

60ZV

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

HYDRAULIC 44

16 15

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

31.5 (3.21) (23.1)

Steering cylinder

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

Steering cyl. 60ZV44034

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

Wood block

60ZV44018

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

863 ( 88) (637)

Bucket cylinder

1,060 (108) (781)

Steering cylinder

304 ( 31) (224)

Hook wrench 1 60ZV44035

44-23

Pilot Valve

60ZV

HYDRAULIC 44

Pilot Valve Removing and reinstalling pilot valve 1

1.Removing pilot valve

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

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

5 60ZV44036

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

2 4 6

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

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

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

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

44-24

60ZV44038

Pilot Valve

60ZV

HYDRAULIC 44

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

60ZV44039

2.Reinstalling pilot valve To reinstall the pilot valve, follow the removal procedure in the reversed direction. After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage. If the oil level is too low, add hydraulic oil to the tank.

44-25

60ZV44040

Pilot Valve

60ZV

HYDRAULIC 44

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

1.Cross section and tightening torque T3

T2 L1

Port 4 (a2) Boom down

Port 2 (b2) Boom up

Port 3 (a1) Bucket roll back

Port 1 (b1) Bucket dump 60ZV44041

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

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

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

Pilot Valve

60ZV

HYDRAULIC 44

2.Disassembling pilot valve 1

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

60ZV44042

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

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

Torque for assembly: : #2, 3............73.5 N-m(7.5 kgf-m)(54.2 lb-ft) 60ZV44043

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

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

60ZV44045

44-27

Pilot Valve

60ZV

HYDRAULIC 44

0.5x15°

Detail of removing joint (4)

C0.5

12 9.5

ø 26.5 23.5

6 ±0.1

R12

(Width across flat)

R5.2

C0.5

10.4 ±0.1

14.5

±0.1

Material; SCM415 N Carburizing and quenching

Material; SCM415 N 1 Carburizing and quenching

2 Material; S45C

Quantity; 2

25 17

Jig B

ø 19 ø 28

+0.2

ø 21 0 ø 25 ø 30

Section A - A +0.013 0

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

+0.028 +0.015

Turn jig A counterclockwise

B +0.2

15 0

Jig A

B Joint B

Jig A + B installation

Section B - B 60ZV44117

4) Remove plate (5).

60ZV44047

44-28

Pilot Valve

60ZV

HYDRAULIC 44

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

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

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

8 60ZV44048

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

60ZV44049

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

9 8

60ZV44118

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

60ZV44051

44-29

Pilot Valve

60ZV

HYDRAULIC 44

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

60ZV44042

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

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

60ZV44043

11) Remove plate (13).

15 16

60ZV44054

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

Screw driver

60ZV44055

44-30

Pilot Valve

60ZV

HYDRAULIC 44

Difference in reducing valve Port No. Parts

1~3

➀ Spring

➁ Spring seat

➂ Return spring

1 pc

2 pcs

➃ Spring seat

1 pc

2 pcs

➄ Washer 2

2 4 3

5 Outside

Bucket dump (T)

Boom down

Port 4(a2)

Port 3(a1) A-A

Front

41 T P 32

60ZV44120

Rear Boom raise

(P)

Bucket roll back

Inside Oil port (Viewed from top)

60ZV44119

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

17 16

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

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

60ZV44058

44-31

Pilot Valve

60ZV

HYDRAULIC 44

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

21 60ZV44059

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

and washer 2 (24).

23 24

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

60ZV44060

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

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

14 60ZV44061

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

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

60ZV44042

44-32

Pilot Valve

60ZV

HYDRAULIC 44

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

Plug (15) Seal (29)

Push rod

Apply hydraulic oil

60ZV44063

44-33

Multiple Control Valve

60ZV

HYDRAULIC 44

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

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

Multiple control valve 65ZV44065

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

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

2 65ZV44065

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

Multiple control valve

65ZV44066

44-34

Multiple Control Valve

60ZV

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

HYDRAULIC 44

Multiple control valve

6 60ZV44067

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

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

WARNING Unexpected movement of machine may cause serious injury or death. To prevent such an accident, be sure to stop the engine before you start working. In addition, block tires with chocks to prevent wheels from moving. While working, carefully keep contact with the person in the cab by giving signals to each other. c) Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. d) Operate the bucket and the boom, and check that they operate correctly. e) Check each section for oil leakage. f ) Add hydraulic oil to the tank until the oil level rises to the specified point.

44-35

Multiple Control Valve

60ZV

HYDRAULIC 44

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

1.Cross section and tightening torque Inlet section

T1 Bucket spool section

T5 T

Pa1

Pb1

Pb2

Pa2 B2

T1 T1

Boom spool section T2

A-A D-D B

Load check valve T4

T4 Pa

Pa Pb

T5 L1

T 5 L1

T4 B-B

T4 C-C 60ZV44121

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

L1: Screw lock agent application (Loctite® 271) : Approx. 21 kg (46 lbs)

44-36

Multiple Control Valve

60ZV

HYDRAULIC 44

2.Disassembling multiple control valve

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

8 2

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

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

3 7 6

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

60ZV44069J

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

14 60ZV44070

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

20 16

18 19

15 60ZV44071

44-37

Multiple Control Valve

60ZV

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

HYDRAULIC 44

18 23

60ZV44100

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

7.8

70~100

mm(in.)

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

44-38

60ZV44073

Priority Valve

60ZV

HYDRAULIC 44

Priority Valve Removing and reinstalling priority valve 1. Removing priority valve

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

1 4

3 60ZV44074

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

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

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

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

5 60ZV44075

Priority Valve

60ZV

HYDRAULIC 44

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

1. Cross section and tightening torque

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

1 3

4 60ZV44076

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

44-40

60ZV

Orbitrol®

HYDRAULIC 44

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

95ZV44060

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

95ZV44061

3) Remove sound suppression sheet (3).

3 95ZV44062

44-41

Orbitrol®

60ZV

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

HYDRAULIC 44

Orbitrol R

4 70ZV14008

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

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

2.Reinstalling Orbitrol® To reinstall the Orbitrol ® , follow the above removal procedure in the reversed direction. At the completion of reinstallation, check around the Orbitrol® for oil leakage :

WARNING Entering the articulation area while engine is running may cause serious injury or death. So, when entering the area, stop the engine and place "DO NOT START " or "DO NOT OPERATE" tag on steering wheel or the operator's seat.

44-42

Orbitrol®

60ZV

HYDRAULIC 44

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

1.Cross section and tightening torque Centering springs

Push spool

O-ring

Check value

Plate O-ring

Sleeve

1 2 Make-up valve Needle bearing

Ball Housing

O-ring

Seal unit Spacer

End cap

OLRV

Drive shaft Retainer

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

44-43

Rotor assembly

60ZV44122

Orbitrol®

60ZV

2.Disassembling Orbitrol®

HYDRAULIC 44

Make matchmarks before disassembling unit.

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

Housing

Copper plate 60ZV44123

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

60ZV44079

1 5 2

3 4

60ZV44080

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

97ZV44049

44-44

Orbitrol®

60ZV

HYDRAULIC 44

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

10 9 11 60ZV44082

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

13 12

16 15 14

60ZV44083

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

60ZV44084

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

60ZV44085

44-45

Orbitrol®

65ZV

HYDRAULIC 44

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

60ZV44086

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

22 60ZV44087

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

Housing

Spool / sleeve assembly 60ZV44088

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

Spool / sleeve assembly

25 24

Matchmark 60ZV44089

44-46

Orbitrol®

60ZV

HYDRAULIC 44

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

27 26

60ZV44090

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

60ZV44091

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

29 28 27 31 30 60ZV44092

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

60ZV44093

44-47

Orbitrol®

60ZV

HYDRAULIC 44

3.Reassembling Orbitrol®

Spring groove

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

Spring groove 25

Matchmark 60ZV44094

2) Install centering springs (27) through the spring grooves in spool (25) and sleeve (26) using a spring insertion jig. Note: Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

26 60ZV44095

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

Matchmark 60ZV44096

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

Housing

Spool / sleeve assembly

60ZV44097

44-48

Orbitrol®

60ZV

HYDRAULIC 44

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

60ZV44099

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

60ZV44086

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

18 25

60ZV44099

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

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

60ZV44100

44-49

Orbitrol®

60ZV

HYDRAULIC 44

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

27 OLRV units

28 29

Housing

60ZV44124

(Reassembling rotor) 9) Set the Orbitrol® in a vise so that the rotor side comes to the top position. Use a copper plates on a vise and do not tighten the vise strongly.

Housing

Plate

60ZV44102

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

12 13

60ZV44103

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

Port face 9 Parallelize with port face

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

24 60ZV44111

44-50

Orbitrol®

60ZV

HYDRAULIC 44

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

60ZV44105

13) Holding the rotor assembly with the O-ring side facing the spacer plate, install the assembly so that the grooves in the star-shaped bore mesh with the drive shaft. Note: ➀Align the bolt holes in the rotor assembly with those in the housing without disengaging the drive shaft from the rotor assembly's star -shaped bore. ➁Confirm that lines A, B, C and D are all parallel.

Grooves in rotor bore

A B

Drive shaft

C D

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

Port face

95ZV44029

1 5

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

3 4

60ZV44106

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

2 3

7 5 60ZV44112

44-51

Cushion Valve

60ZV

HYDRAULIC 44

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

1 Front

Floor board

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

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

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

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

60ZV44108

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

44-52

Cushion Valve

60ZV

HYDRAULIC 44

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

1.Cross section and tightening torque B

A A B-B

T3 L1

T 3 L1

T2 A A-A

60ZV44109

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

44-53

MEMO

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

45-1

Hydraulic Cylinder

60ZV

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder

4 1

60ZV45001

Unit : mm (in.)

Standard valve No.

Item

Judgment standard Standard dimension

Standard clearance

Tolerance limit

Clearance between boom cylinder rod and bushing

ø65(2.5590)

0.100~0.250 (0.0039~0.0098)

0.5(0.0197)

Clearance between pin and inner diameter

ø60(2.3622)

0.100~0.250 (0.0039~0.0098)

1.0(0.0394)

Clearance between pin and bushing

ø60(2.3622)

0.100~0.250 (0.0039~0.0098)

1.0(0.0394)

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

Solution

Replacement

863(88)(637)

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

2,501(255)(1,845)

Width across flat mm(in)

75(2.95)

Piston nut

45-2

Tightening

Hydraulic Cylinder

60ZV

HYDRAULIC 45

Bucket cylinder

4 60ZV45002

Steering cylinder 5

3 2

60ZV45003

Unit : mm (in.)

Standard valve No.

Item

Judgment standard Standard dimension

Standard clearance

Tolerance limit

Clearance between bucket cylinder rod and bushing

ø60(2.3622)

0.100~0.250 (0.0039~0.0098)

0.5(0.0197)

Clearance between steering cylinder rod and bushing

ø40(1.5748)

0.080~0.205 (0.0031~0.0081)

0.5(0.0197)

Clearance between bucket cylinder piston rod pin and bushing

ø50(1.9685)

0.100~0.250 (0.0039~0.0098)

1.0(0.0394)

Clearance between steering cylinder piston rod pin and bushing

ø35(1.3780)

0.080~0.205 (0.0031~0.0081)

1.0(0.0394)

Clearance between bucket cylinder bottom pin and bushing

ø60(2.3622)

0.100~0.250 (0.0039~0.0098)

1.0(0.0394)

Clearance between steering cylinder bottom pin and bushing

ø35(1.3780)

0.080~0.205 (0.0031~0.0081)

1.0(0.0394)

Solution

Replacement

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

Bucket cylinder

1,060(108)(781)

Steering cylinder

304(31)(224)

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

3,107(317)(2,293) Bucket cylinder

Width across flat mm(in)

70(2.75)

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

392(40)(289) Steering cylinder

Width across flat mm(in)

41(1.61)

45-3

Tightening

Pilot Valve

60ZV

HYDRAULIC 45

Pilot Valve 5

60ZV45004

Unit : mm (in.) No.

Item

Measuring condition

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

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

Leak quantity

2. Hydraulic oil………VG46

- Lever in operation

3. Oil temperature………60 °C

No.

Item

Solution

Judgment standard (limit)

1. Primary pressure………

replacement

……2,400 cm /min and more 3

Judgment standard Standard dimension

Wear limit

Solution

61 mm(2.4016 in.)

2 Length of push rod

1 mm(0.0394 in.) and more

Replacement

6 mm(0.2362 in.)

0.5 mm(0.0197 in.) and more

Solenoid sub assembly replacement

–

2 mm(0.0787 in.) and more

Replacement of related parts such as disc, joint etc.

36 mm(1.4173 in.)

3 4

Inner diameter of solenoid bushing

Adjusting nut wear (upper part)

45-4

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

54-1

Hydraulic Servo Master

60ZV

BRAKE 54

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

3 1

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

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

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

60ZV54002

60ZV54003

54-2

Hydraulic Servo Master

60ZV

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

BRAKE 54

9 1

10 60ZV54004

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

11 60ZV54005

2. Reinstalling hydraulic servo master To reinstall the hydraulic servo master, follow the above removal procedure in the reversed direction. Note: After reinstallation, completely bleed the brake line of air, and check all the pipe-joints and hoses for oil leakage. To check or adjust the service brake linkage, refer to Section 53.

54-3

Hydraulic Servo Master

60ZV

BRAKE 54

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

1. Cross section and tightening torque

Hydraulic servo section

Master cylinder section

T4 T5

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

60ZV54006

54-4

Hydraulic Servo Master

60ZV

BRAKE 54

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

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

2 60ZV54007

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

60ZV54008

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

60ZV54009

54-5

Hydraulic Servo Master

60ZV

BRAKE 54

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

10 5 8

60ZV54010

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

12 13

60ZV54011

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

14 60ZV54012

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

17 18 19

60ZV54013

54-6

Hydraulic Servo Master

60ZV

BRAKE 54

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

60ZV54014

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

22 23 60ZV54015

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

23 22

60ZV54016

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

24 23

54-7

60ZV54017

Service Brake

60ZV

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

54-8

BRAKE 54

Parking Brake

60ZV

BRAKE 54

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

WARNING When removing the parking brake, machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park machine on level ground. - Lower bucket to ground, and then block tires with chocks to prevent wheels from moving. - Apply articulation stopper. - Remove the engine key, and hang a "DO NOT START Engine!" tag on the steering wheel.

Control cable 3 1

1) Drain the transmission oil. 2 Parking brake

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

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

60ZV54018

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

4 60ZV54019

42T

8 9 6

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

60ZV54020

54-9

Parking Brake

60ZV

BRAKE 54

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

42T

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

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

60ZV54021

60ZV54022

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

60ZV54023

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

16 17

60ZV54024

54-10

Parking Brake

60ZV

BRAKE 54

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

18 19

60ZV54025

60ZV54026

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

54-11

MEMO

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

55-1

Hydraulic Servo Master

60ZV

BRAKE 55

Hydraulic Servo Master 4

REF.

ITEM

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

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

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

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

Judgment criteria Standard value

Allowable limit

119 (12.1) (27)

95 (9.7) (21)

Outside 226 (23) (51)

180 (18.4) (40)

Inside

86 (8.8) (19)

108 (11) (24)

Correction

Replacement

118 (12) (26)

Replacement

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

211 (21.5) (47)

169 (17.2) (38)

Replacement

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

172 (17.5) (39)

137 (14.0) (31)

Replacement

Clearance to body (mm) (in)

—

0.2 (0.0079)

Replacement

Seat surface

—

No abnormality

Replacement

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

—

0.15 (0.0059)

Replacement • Overhaul

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

—

0.20 (0.0079)

Replacement • Overhaul

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

—

0.20 (0.0079)

Replacement • Overhaul

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

—

0.20 (0.0079)

Replacement • Overhaul

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

—

0.43 (0.0169)

Replacement • Overhaul

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

0.035 ~ 0.127 (0.0013 ~ 0.005)

0.20 (0.0079)

Replacement • Overhaul

Hydraulic servo master plunger play (mm) (in)

0.5 ~ 2.0 (0.0197 ~ 0.0787)

3.00 (0.1181)

Replacement • Overhaul

55-2

Remarks

Replacement

147 (15) (33)

Hydraulic servo relief valve

60ZV55001

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

Service Brake

60ZV

BRAKE 55

Service Brake

60ZV55002

Unit : mm (in.) No.

Item Thickness of steel plate

Standard dimension

0 0 – 0.2 – 0.0078

(

6 (0.2362)

1 Distortion of steel plate (flatness)

Judgment standard Tolerance

)

Wear limit

Solution

5.5 (0.2165)

—

0.3 (0.0118) and more

Thickness of friction plate

8.5 (0.3346)

± 0.15 (± 0.0059)

7.5 (0.2953)

Depth of lining groove

0.4 (0.0157) and more

—

Thickness of lining (both sides)

1.5 (0.0591)

0.1 (0.0039) and less

—

Thickness of brake retainer

27.5 (1.0827)

0 0 – 0.1 – 0.0039

Replacement

(

55-3

)

27.1 (1.0669)

Parking Brake

60ZV

BRAKE 55

Parking Brake

60ZV55003

Unit : mm (in.) No.

Item

Wear of lining

Lining inspection

Expansion of adjuster spring

Expansion of return spring

Judgment standard Standard dimension Wear limit 5.1 (0.2008)

1.0 (0.0394) from the rivet head

Grease or oil on the lining

Solution Replacement Replacement

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

55-4

Replacement

Brake Pedal Linkage

60ZV

BRAKE 55

Brake Pedal Linkage

3 Brake pedal assembly

48˚

218 – 50 mm (8.58 in.)

Reference dimension: 251 mm (9.88 in.)

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

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

6 10

15 mm (0.59 in)

16 mm (0.63 in)

8 11

11 7

115 mm (4.528 in.)

55-5

60ZV53004

MEMO

Notes

93206-00121 February 2009

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

Safety precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below. - This manual is intended for properly trained and equipped service technicians. - Any work on the machine must be performed by the trained personnel only. - Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine.

- To remove a heavy unit (20 kgf (40 lbs) or more), be sure to use a crane or other lifting device. - Just after stopping operation, be careful not to directly touch a hot component. You may get burned. - Contact tire manufacturer's local dealer for tire servicing and changing. - Always store the tools in good condition, and use them properly. - Keep the work area clean. Clean up spills immediately.

- Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles.

- Avoid the use of flammable solvents and cleaners.

- Place the machine on level and solid ground, and place chocks against the wheels to prevent movement.

- When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud.

- Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the steering wheel.

- Use safe work platforms to reach higher areas of the machine.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the “OFF” position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this “write to memory function” prior to removing battery terminals. - Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe. - Be sure to apply the articulation stopper before starting work. - While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks. - When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping. - Do not start to work in an enclosed area if adequate ventilation is not provided.

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

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

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

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

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

CONTENTS 60ZV-2 General Information .................................................................................................................................. 00-1 Symbols ............................................................................................................................................................ 00-2 Weight of Main Components ............................................................................................................................. 00-3 Bolt Tightening Torque ...................................................................................................................................... 00-4 Hose Band Tightening Torque ........................................................................................................................... 00-8 Liquid Gasket and Screw Lock Agent ............................................................................................................... 00-9 Cautions regarding parts removal ............................................................................................................... 00-9 Cautions regarding reassembly .................................................................................................................. 00-9 Screw lock agent application procedure ................................................................................................... 00-10 How to wind a seal tape ............................................................................................................................ 00-10 Cautions Regarding Welding Repair Service ...................................................................................................00-11 Applying and Storing Articulation Stopper ....................................................................................................... 00-13 Applying articulation stopper ..................................................................................................................... 00-13 Storing articulation stopper ....................................................................................................................... 00-13 60ZV-2 Disassembly & Reassembly Chassis Group ............................................................................................ 14-1 Fuel Tank .......................................................................................................................................................... 14-2 Fuel tank removing and installing ............................................................................................................... 14-2 Hydraulic Tank .................................................................................................................................................. 14-4 Hydraulic tank removing and installing ....................................................................................................... 14-4 Engine Room .................................................................................................................................................... 14-6 Engine room removing and installing .......................................................................................................... 14-6 Cab ................................................................................................................................................................... 14-7 Cab removing and installing ........................................................................................................................ 14-7 Floor Board ....................................................................................................................................................... 14-9 Floor board removing and installing ............................................................................................................ 14-9 Boom ............................................................................................................................................................... 14-12 Boom removing and installing ................................................................................................................... 14-12 Center Pin ....................................................................................................................................................... 14-15 60ZV-2 Service Standard Chassis Group ............................................................................................................. 15-1 Linkage ............................................................................................................................................................. 15-2 Linkage Pin Standard Clearance Values ........................................................................................................... 15-3 Liner clearance adjustment ......................................................................................................................... 15-3 Center Pin ......................................................................................................................................................... 15-4 Center pin shim adjustment ........................................................................................................................ 15-4 Bearing cover installing ............................................................................................................................... 15-4

Attachment Leveler ........................................................................................................................................... 15-5 Attachment leveler ...................................................................................................................................... 15-6 60ZV-2 Disassembly & Reassembly Power Group ............................................................................................... 24-1 Power Line ........................................................................................................................................................ 24-2 Power line tightening torque ....................................................................................................................... 24-2 Radiator ............................................................................................................................................................. 24-3 Radiator tightening torque ........................................................................................................................... 24-3 Radiator removing and installing ................................................................................................................. 24-4 Engine ............................................................................................................................................................... 24-6 Engine removing and installing ................................................................................................................... 24-6 Propeller Shaft .................................................................................................................................................. 24-9 Propeller shaft removing and installing ....................................................................................................... 24-9 Air Cleaner .......................................................................................................................................................24-11 Air cleaner removing and installing ............................................................................................................24-11 Muffler ............................................................................................................................................................. 24-13 Muffler removing and installing ................................................................................................................. 24-13 Front Axle Assembly ....................................................................................................................................... 24-14 Front axle assembly tightening torque ...................................................................................................... 24-14 Front axle assembly removing and installing ............................................................................................ 24-15 Front axle disassembling and assembling ................................................................................................ 24-18 Spider Assembly ............................................................................................................................................. 24-25 Spider assy disassembling and assembling ............................................................................................. 24-25 Rear Axle Assembly ........................................................................................................................................ 24-28 Rear axle assembly tightening torque ....................................................................................................... 24-28 Rear axle assembly removing and installing ............................................................................................. 24-29 Axle Support .................................................................................................................................................... 24-32 Axle support disassembling and assembling ............................................................................................ 24-32 Differential Assembly ...................................................................................................................................... 24-33 Differential assy disassembling and assembling ...................................................................................... 24-35 Differential cage disassembling and assembling ...................................................................................... 24-42 Differential pinion disassembling and assembling .................................................................................... 24-43 60ZV-2 Service Standard Power Group ................................................................................................................ 25-1 Propeller Shaft Service Standard ...................................................................................................................... 25-2

Axle and Differential Service Standard .............................................................................................................. 25-3 Axle assembly ............................................................................................................................................. 25-3 Differential ................................................................................................................................................... 25-4 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group ............................................... 34-1 Torque Converter and Transmission Assembly ................................................................................................ 34-2 Torque converter and transmission assembly mounting bolt tightening torque .......................................... 34-2 Torque converter and transmission assembly removing and installing ....................................................... 34-3 Torque converter and transmission assembly assembling bolt tightening torque ....................................... 34-9 Torque Converter Assembly ............................................................................................................................ 34-10 Torque converter assembly disassembling and assembling ..................................................................... 34-10 Transmission Assembly .................................................................................................................................. 34-13 Transmission assembly disassembling and assembling .......................................................................... 34-13 Clutch Pack ..................................................................................................................................................... 34-17 Clutch pack disassembling and assembling ............................................................................................. 34-17 Special Tools ................................................................................................................................................... 34-19 Control Valve Assembly .................................................................................................................................. 34-21 Control valve removing and installing ....................................................................................................... 34-21 60ZV-2 Service Standard Torque Converter and Transmission Group ................................................................ 35-1 Clutch Oil Pressure ........................................................................................................................................... 35-2 Measuring clutch oil pressure ..................................................................................................................... 35-2 60ZV-2 Disassembly & Reassembly Hydraulic Group .......................................................................................... 44-1 Hydraulic Parts Removal and Installation Warning ........................................................................................... 44-2 Hydraulic Parts Disassembly and Assembly Cautions ...................................................................................... 44-3 Hydraulic parts disassembly cautions ......................................................................................................... 44-3 Hydraulic parts assembly cautions ............................................................................................................. 44-3 Hydraulic Pump Assembly ................................................................................................................................ 44-4 Hydraulic pump assembly removing and installing ..................................................................................... 44-4 Hydraulic pump assembly disassembling and assembling ......................................................................... 44-6 Hydraulic Cylinder ............................................................................................................................................. 44-8 Boom cylinder removing and installing ....................................................................................................... 44-8 Bucket cylinder removing and installing .................................................................................................... 44-10 Steering cylinder removing and installing .................................................................................................. 44-12 Hydraulic cylinder disassembling and assembling .................................................................................... 44-14

Pilot Valve ....................................................................................................................................................... 44-21 Pilot valve removing and installing ............................................................................................................ 44-21 Pilot valve disassembling and assembling ................................................................................................ 44-23 Multiple Control Valve ..................................................................................................................................... 44-30 Multiple control valve removing and installing ........................................................................................... 44-30 Multiple control valve disassembling and assembling .............................................................................. 44-32 Orbitrol® .......................................................................................................................................................... 44-35 Orbitrol® removing and installing ............................................................................................................... 44-35 Orbitrol® disassembling and assembling .................................................................................................. 44-37 Priority Valve ................................................................................................................................................... 44-46 Priority valve removing and installing ........................................................................................................ 44-46 Priority valve disassembling and assembling ........................................................................................... 44-47 Cushion Valve ................................................................................................................................................. 44-48 Cushion valve removing and installing ...................................................................................................... 44-48 Cushion valve disassembling and assembling ......................................................................................... 44-49 60ZV-2 Service Standard Hydraulic Group ........................................................................................................... 45-1 Pilot Valve ......................................................................................................................................................... 45-2 Hydraulic Cylinder ............................................................................................................................................. 45-4 60ZV-2 Disassembly & Reassembly Brake Group ............................................................................................... 54-1 Hydraulic Servo Master ..................................................................................................................................... 54-2 Hydraulic servo master removing and installing ......................................................................................... 54-2 Hydraulic servo master disassembling and assembling ............................................................................. 54-4 Service Brake .................................................................................................................................................... 54-7 Service brake disassembling and assembling ............................................................................................ 54-7 Parking Brake .................................................................................................................................................... 54-8 Parking brake removing and installing / disassembling and assembling .................................................... 54-8 60ZV-2 Service Standard Brake Group ................................................................................................................ 55-1 Hydraulic Servo Master ..................................................................................................................................... 55-2 Service Brake .................................................................................................................................................... 55-3 Parking Brake .................................................................................................................................................... 55-4 Brake Pedal Linkage ......................................................................................................................................... 55-5

00-1 60ZV-2 General Information

60ZV-2 General Information Symbols .................................................................. 00-2 Weight of Main Components ................................... 00-3 Bolt Tightening Torque ............................................ 00-4 Hose Band Tightening Torque................................. 00-8 Liquid Gasket and Screw Lock Agent ..................... 00-9 Cautions Regarding Welding Repair Service .......... 00-11 Applying and Storing Articulation Stopper ............... 00-13

00-2 60ZV-2 General Information Symbols

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

Item

Description

Reference

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

Weight

Shows the weight of a part or unit. The weight should be considered in selecting wire rope or cable for slinging work or determining the working posture.

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

Coating

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

Oil or water supply

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

Drainage

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

Abbreviation To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the following abbreviation list. E/G ........... Engine T/C ........... Torque converter T/M ........... Transmission SOL ........... Solenoid valve SW ........... Switch F ........... Front or Forward A/M ........... Auto/Manual B ........... Battery R ........... Rear or Reverse

RH ........... Right hand side LH ........... Left hand side H ........... High L ........... Low GND ........... Ground OPT ........... Option Assy ........... Assembly 1st ........... 1st speed 2nd ........... 2nd speed

3rd ............3rd speed 4th ............4th speed M/C ............Machine min-1 ............RPM ELS ............Efficient loading system MODM ........Machine operation diagnostic module MCU............Machine control unit

00-3 60ZV-2 General Information Weight of Main Components

Weight of Main Components

Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

485

1,070

Boom

605

1,330

Z-Lever

150

330

Item Unit name

Chassis

Power line

Hydraulic system

Other

Remarks GSN bucket

Link (Attachment - Lever)

Engine room assembly

170

375

Hydraulic tank

145

Excluding oil

Fuel tank

210

Excluding fuel

Floor board

135

300

Cab (ROPS)

550

1,210

Engine

400

880

Including oil

Radiator assembly

Excluding water

Transmission

400

880

Excluding oil

Second propeller shaft

Third propeller shaft

Front axle assembly

480

1,060

Excluding tires and oil

Rear axle assembly

635

1,400

Excluding tires and oil (Including axle support)

Differential

140

310

Multiple control valve

Steering valve (Orbitrol®)

Gear pump

Boom cylinder

70/pc

155/pc

Excluding oil

Bucket cylinder

135

Excluding oil

Steering cylinder

15/pc

35/pc

Excluding oil

Tire

175/pc

385/pc

With rim (17.5-25-12 PR), No hydro inflation

Battery

35/pc

80/pc

00-4 60ZV-2 General Information Bolt Tightening Torque

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

Metric thread

Nominal dia.

Pitch

8.8 (8T)

10.9 (11T)

M10

(F) 1.25

M12

M14

M16

M18

M20

M22

M24

M27

M30

M33

Unified thread

Bolt strength

Nominal dimension

132

(F) 1.25

142

206

(F) 1.5

152

221

216

314

(F) 1.5

226

330

299

436

(F) 1.5

324

476

417

608

(F) 1.5

451

662

559

814

(F) 1.5

598

878

721

1,030

(F) 2.0

770

1,128

1,030

1,520

(F) 2.0

1,128

1,618

1,422

2,109

(F) 2.0

1,569

2,256

1,912

2,844

(F) 2.0

2,059

3,040

5/16

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

358

525

7/8

9 UNC

554

809

8 UNC

868

1,275

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

00-5 60ZV-2 General Information Bolt Tightening Torque

(kgf-m) Bolt size Type

Nominal dimension

Nominal dia.

Pitch

8.8 (8T)

10.9 (11T)

2.7

3.9

M10

M12

M14

M16

M18 Metric thread

M20

M22

Unified thread

Bolt strength

M24

M27

M30

M33

5.4

7.8

(F) 1.25

5.6

8.2

9.2

13.5

(F) 1.25

9.8

14.5

21.0

(F) 1.5

15.5

22.5

22.0

32.0

(F) 1.5

23.0

33.7

30.5

44.5

(F) 1.5

33.0

48.5

42.5

62.0

(F) 1.5

46.0

67.5

57.0

83.0

(F) 1.5

61.0

89.5

73.5

105.0

(F) 2.0

78.5

115.0

105.0

155.0

(F) 2.0

115.0

165.0

145.0

215.0

(F) 2.0

160.0

230.0

195.0

290.0

(F) 2.0

210.0

310.0

5/16

18 UNC

2.5

3.6

3/8

16 UNC

4.5

6.6

7/16

14 UNC

7.2

10.5

1/2

13 UNC

10.5

15.0

9/16

12 UNC

15.0

22.0

5/8

11 UNC

20.5

30.0

3/4

10 UNC

36.5

53.5

7/8

9 UNC

56.5

82.5

8 UNC

88.5

130.0

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

00-6 60ZV-2 General Information Bolt Tightening Torque

(lb-ft) Bolt size Type

Nominal dimension

Nominal dia.

Pitch

8.8 (8T)

10.9 (11T)

19.5

M10

M12

M14

M16

M18 Metric thread

M20

M22

Unified thread

Bolt strength

M24

M27

M30

M33

(F) 1.25

105

150

(F) 1.5

110

160

230

(F) 1.5

165

245

220

320

(F) 1.5

235

350

305

450

(F) 1.5

330

490

410

600

(F) 1.5

440

650

530

760

(F) 2.0

565

830

760

1,120

(F) 2.0

830

1,190

1,050

1,550

(F) 2.0

1,160

1,660

1,410

2,100

(F) 2.0

1,520

2,240

5/16

18 UNC

18.0

3/8

16 UNC

7/16

14 UNC

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

410

595

8 UNC

640

940

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

00-7 60ZV-2 General Information Bolt Tightening Torque

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

Metric thread

Bolt strength

Nominal dimension

Pitch

0.8

8.8 (8T)

1.25

M10

1.5

M12

1.75

M16

231

M20

2.5

441

M24

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

0.8

0.7

1.2

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

23.5

M20

2.5

45.0

M24

78.0 (lb-ft)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

0.8

5.0

8.6

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

00-8 60ZV-2 General Information Hose Band Tightening Torque

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

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

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

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

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

16.5

18.5

20.5

22.0

24.5

26.0

29.0

30.5

32.0

34.0

39.5

41.5

46.0

48.0

54.0

70.5

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

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

Hose

Pipe

Hose band Center of pipe protrusion

10~20 mm

70ZV00003

00-9 60ZV-2 General Information Liquid Gasket and Screw Lock Agent

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

Screw lock agent

Manufacturer

Product name

AA01

Loctite

Plastic Gasket 568

AA02

Loctite®

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite®

Loctite® 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

Cautions regarding reassembly To reassemble a screw Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw. Note A piece of hardened lock agent may be peeled off and remain in the component. The remaining piece may cause malfunction during fastener installation.

To bond a plane or to fit a shaft

Cautions regarding parts removal

Remove the hardened lock agent using a wire brush or the like, and polish the surface using sand paper. Use of a Loctite® primer like Locquic ® Primer T prepares metal surface of the threads and speeds curing time.

If a screw or shaft to be removed has been locked by one of the above agents, remove the screw or shaft using a general tool, such as a wrench or puller.

Antiseize Agent Code

If it is difficult to remove the screw or shaft, heat the bolt to soften the agent (200~250°C) using a soldering iron or gas torch.

Caution If there is a seal near the screw or shaft to be removed, carefully use the heating method for removal, to avoid damage to the seal. If heat has been used to remove the bolt a new bolt should be used during reassembly.

AC01

Manufacturer Loctite

Product name Loctite® 767 (Paste or spray)

00-10 60ZV-2 General Information Liquid Gasket and Screw Lock Agent

Screw lock agent application procedure

How to wind a seal tape

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

Seal tape

Screw lock agent Leave 1~2 screw

65ZV00004

65ZV00002

To avoid a piece of seal tape left in the circuit, leave 1 or 2 screws from the end of the thread and start threading it clockwise.

00-11 60ZV-2 General Information Cautions Regarding Welding Repair Service

Cautions 1. Turn the starter switch OFF.

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

5. To ground the welder, check that the electric current will not flow through the cylinders. Cylinder head covers for some models have a low conductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod. 6. Calibrate throttle pedal to ECM. (a) Turn the starter switch to "ON". (b) Fully depress and release the throttle pedal three times. (c) Turn the starter switch to "OFF".

Example 1

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

35C00002

Example 2

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

Section to be welded

Ground this section. (correct grounding)

35C00006

00-12 60ZV-2 General Information Cautions Regarding Welding Repair Service 7. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes. Be sure to mask these units and parts before welding.

Hydraulic cylinder

Heat-resistant cloth Section to be welded

Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

35A00005

Plated section (Mask this section.)

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

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.) 35C00003

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

1m or more

Scrap material, etc.

Section to be welded

1m or more 35C00004

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

00-13 60ZV-2 General Information Applying and Storing Articulation Stopper

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

IL14-1(90ZV-D&R)

Storing articulation stopper

1 2

1. Park the machine so that the frame is straight ahead. Using a 17 mm wrench remove bolt from the articulation stopper on the rear chassis. “STORED” position

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

1 “LOCKED” position

60ZV US 3652L

2. Turn rod (1) (articulation stopper) until it comes in contact with pin (2). Insert the pin (2) into the rod to lock the front chassis to the rear chassis.

60ZV US 3652

00-14 60ZV-2 General Information

MEMO

14-1 60ZV-2 Disassembly & Reassembly Chassis Group

60ZV-2 Disassembly & Reassembly Chassis Group Fuel Tank................................................................. 14-2 Hydraulic Tank......................................................... 14-4 Engine Room .......................................................... 14-6 Cab.......................................................................... 14-7 Floor Board ............................................................. 14-9 Boom ....................................................................... 14-12 Center Pin ............................................................... 14-15

14-2 60ZV-2 Disassembly & Reassembly Chassis Group Fuel Tank

Fuel Tank Fuel tank removing and installing Fuel tank removing

Rear chassis

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

Fuel level sensor

Eye bolt

Before starting work: - Remove the engine room. - Remove the radiator.

1. Drain fuel from the fuel tank, and disconnect the hose between the fuel tank and the engine. : 197 L (52 gal)) Note Cover the disconnected hose with cap or vinyl to protect it from dust and dirt.

K60V2U14001

2. Put a matchmark on fuel hose (1) and disconnect them from the fuel tank. Note Cover the disconnected hoses with caps or vinyl to protect them from dust and dirt. 3. Disconnect the level sensor electrical line coupler. 4. Fix eye bolt (M12) to the fuel tank and attach sling to the tank. Then, remove bolt (2) and slowly lower the fuel tank. : Bolt (2): 436 N-m (44.5 kgf-m) (322 lb-ft) : Fuel tank: 95 kg (210 lbs) (when empty)

14-3 60ZV-2 Disassembly & Reassembly Chassis Group Fuel Tank

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

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

14-4 60ZV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic Tank Hydraulic tank removing and installing Hydraulic tank

Hydraulic tank removing

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

K60V2U14009

2. Put a matchmark and remove oil cooler line hose (2) from the hydraulic tank. Note Cover the disconnected hose with a cap or vinyl to protect it from dust and dirt.

Before starting work: - Drain hydraulic oil from the hydraulic tank. - Remove both fenders (RH, LH). - Clean the area around the tank.

Pilot valve

1 3

K60V2U14010

3. Remove hose band and remove suction hose (3) from the hydraulic tank. Hydraulic tank K60V2U14008

1. Put a matchmark and remove pilot line hose (1) from the hydraulic tank. Note Cover the disconnected hose with a cap or vinyl to protect it from dust and dirt.

Note Cover the disconnected hose with a cap or vinyl to protect it from dust and dirt.

14-5 60ZV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic tank installing 4

For reinstallation, follow the above procedure in reverse order.

Hydraulic tank installation cautions Rear chassis

K60V2U14011

4. Attach sling to hydraulic tank and remove bolts (4). : Hydraulic tank (when empty): 65 kg (145 lbs) : Bolt (4): 93.7 N-m (9.55 kgf-m) (69 lb-ft)

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

14-6 60ZV-2 Disassembly & Reassembly Chassis Group Engine Room

Engine Room Engine room removing and installing Engine room removing

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

K60V2U14003

2 Sleeve

Detail of bolt (2) 60ZV14003

2. Sling engine room and remove bolts (2)(3) from the engine room. Engine

Air cleaner

: Bolt (2)(3): 94 N-m (9.6 kgf-m) (69 lb-ft) : Engine room: 170 kg (375 lbs) Note Slowly lift the engine room while checking that there are no obstacles.

K60V2U14002

1. Disconnect hose (1) between the air cleaner and the engine. Note Cover the hose and port of the engine to protect the engine from dust and dirt.

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

14-7 60ZV-2 Disassembly & Reassembly Chassis Group Cab

Cab Cab removing and installing Cab removing

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

60ZV14007J

3. Remove cover (5).

Before starting work: - Remove both fenders (RH, LH). - Disconnect the electrical line couplers. - Fix the air conditioner filter with tapes so that it is not fallen down. 6 7 4

K60V2U14004

4. Remove bolt (6). Tilt steering shaft (7) backward.

3 1

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

60ZV14006J

14-8 60ZV-2 Disassembly & Reassembly Chassis Group Cab 6. Remove four each of bolt (10), and install the eye bolt (M16 x 2.0). Attach sling and remove the cab.

: Cab: 550 kg (1,210 lbs) Note When tightening bolt (10) with the washer, make sure that the rubber-coated side of the washer faces down to the cab.

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

Floor board

8 9

8 K60V2U14005

5. Remove bolts (8)(9). : Bolt (8): 721 N-m (73.5 kgf-m) (532 lb-ft) 9

9 Plug

9 Floor board top view

Plug K60V2U14006

Note Be noticed that bolt (9) is a flanged bolt to be tightened without washer in the middle among three bolts (front side), and the second from the front among four (rear side). The other bolts (8) are tightened with plane washer.

14-9 60ZV-2 Disassembly & Reassembly Chassis Group Floor Board

Floor Board Floor board removing and installing Floor board removing

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

Air duct hose K60V2U14012

1. Disconnect the air duct hoses under the floor board by releasing the hose band. Note Cover the disconnected hoses with plastic caps, plugs or vinyl to protect them from dust, water and dirt. Pilot valve

2 1

3 60ZV14007

2. Disconnect hoses (1)~(3). Note - Before disconnecting the electrical couplers, hoses and pipes, put match marks on them to help during reassembly. - Prepare a drain pan for the oil. - Cover the disconnected hoses and pipes with vinyl to protect them from dust and dirt.

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

14-10 60ZV-2 Disassembly & Reassembly Chassis Group Floor Board

Install eye bolt.

3 Orbitrol®

3 Priority valve Cushion valve

Rubber cushion

Steering cylinder

60ZV14012J

K60V2U14007

3. Put matchmark and disconnect the hose between the Orbitrol® and the steering cylinder. Disconnect the hose between the Orbitrol® and the cushion valve, and the hose between Orbitrol® and the priority valve.

4. Remove erastic plug and floor board retaining nut (3) for floor board (4).

: Hydraulic oil: 0.5 L (0.15 gal) Note Cover the disconnected hoses with plastic caps, plugs or vinyl to protect them from dust, water and dirt.

5. Install eye bolt (M16x2) to floor board (4) at 4 places. Attach sling to them, then, gradually lift the floor board while checking that there are no obstacles and that all the pipes, cables, pins, etc. are disconnected. : Nut (3): 230 N-m (23.5 kgf-m) (170 lb-ft) : Floor board assy including air conditioner, seat, etc.: 340 kg (750 lbs) Reference : Retaining bolt for rubber cushion (with plate): 76 N-m (7.8 kgf-m) (56 lb-ft)

14-11 60ZV-2 Disassembly & Reassembly Chassis Group Floor Board

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

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

14-12 60ZV-2 Disassembly & Reassembly Chassis Group Boom

Boom Boom removing and installing 5

Boom removing 3

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

6 4 2 60ZV14015J

1. Remove pins (2)(3) to remove bucket (1). : Bucket: 485 kg (1,070 lbs) Note There are shims in the pin sections. Carefully store the removed shims, and correctly reinsert the shims when reinstalling the bucket. 2. Remove connection pin (6) from rod (4) and lever (5). : Link: 35 kg (80 lbs)

14-13 60ZV-2 Disassembly & Reassembly Chassis Group Boom

7 5

5 9

60ZV14016J

65ZV14024J

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

5. Attach sling to lever (5), and then, remove lever pin (9). : Lever: 150 kg (330 lbs)

: Bucket cylinder: 60 kg (135 lbs) 10

CAUTION

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

65ZV14025J

60ZV14017J

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

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

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

14-14 60ZV-2 Disassembly & Reassembly Chassis Group Boom

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

10 13

Boom installation cautions - Be sure to adjust the clearance of the retainer pin sections using the liners. 60ZV14018J

7. Attach sling to cross pipe of boom (10), and then, remove pins (13) from the boom on both the right and left sides. Note The pin sections are adjusted (to 1.2 mm or less clearance) using liners. Do not lose the liners during the service work. 8. Slowly lift boom (10) to remove it from the machine. : Boom: 605 kg (1,330 lbs)

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

- After reinstallation, grease the boom, and then, operate it. During operation, check the boom for abnormal noise.

14-15 60ZV-2 Disassembly & Reassembly Chassis Group Center Pin

Center Pin [ Upper center pin ]

[ Lower center pin ]

Split shim

60ZV14008

: T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 456 N-m (46.5 kgf-m) (336 lb-ft) : T2: With lubricating oil (engine oil or gear oil)

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

14-16 60ZV-2 Disassembly & Reassembly Chassis Group

MEMO

15-1 60ZV-2 Service Standard Chassis Group

60ZV-2 Service Standard Chassis Group Linkage.................................................................... 15-2 Linkage Pin Standard Clearance Values ................. 15-3 Center Pin ............................................................... 15-4 Attachment Leveler ................................................. 15-5

15-2 60ZV-2 Service Standard Chassis Group Linkage

Linkage 1. Attachment - Boom

2. Boom - Lever

3. Boom - Boom cylinder

4. Front chassis - Boom

5. Attachment - Rod

6. Lever - Rod

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

8 7

mm (in)

9 2

3 10 6

60ZV12003

15-3 60ZV-2 Service Standard Chassis Group Linkage Pin Standard Clearance Values

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

Item

Solution

Pin standard dimension

Standard clearance

Tolerance

Joint section between attachment and boom

ø50 (ø1.97)

0.167~0.211 (0.0066~0.0083)

1.0 (0.0393)

Replacement

Joint section between boom and lever

ø80 (ø3.15)

0.224~0.276 (0.0088~0.0109)

1.0 (0.0393)

Replacement

Joint section between boom and boom cylinder

ø60 (ø2.36)

0.202~0.251 (0.0080~0.0099)

1.0 (0.0393)

Replacement

Joint section between front chassis and boom

ø65 (ø2.56)

0.202~0.251 (0.0080~0.0099)

1.0 (0.0393)

Replacement

Joint section between attachment and rod

ø60 (ø2.36)

0.202~0.251 (0.0080~0.0099)

1.0 (0.0393)

Replacement

Joint section between lever and rod

ø60 (ø2.36)

0.202~0.251 (0.0080~0.0099)

1.0 (0.0393)

Replacement

Joint section between lever and bucket cylinder

ø50 (ø1.97)

0.167~0.211 (0.0066~0.0083)

1.0 (0.0393)

Replacement

Joint section between bucket cylinder and front chassis

ø60 (ø2.36)

0.202~0.251 (0.0080~0.0099)

1.0 (0.0393)

Replacement

Joint section between boom cylinder and front chassis

ø60 (ø2.36)

0.202~0.251 (0.0080~0.0099)

1.0 (0.0393)

Replacement

Joint section between front chassis and steering cylinder

ø35 (ø1.38)

0.135~0.172 (0.0053~0.0068)

1.0 (0.0393)

Replacement

Joint section between steering cylinder and rear chassis

ø35 (ø1.38)

0.135~0.172 (0.0053~0.0068)

1.0 (0.0393)

Replacement

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

Liner clearance adjustment

Adjust the liner clearance (marked with "*") between the bosses to 1.2 mm (0.047 in) or less using liner of 1 mm (0.039 in) thickness. For the steering cylinder, adjust the liner clearance on the rear chassis side first, and then adjust the liner clearance on the front chassis side while checking that the cylinder is not inclined. Liners should be placed on both sides of the linkage as much as possible. Wear then occurs on the liners and reduces wear on the chassis. Excessive vertical free play in the steering cylinders can result in loud knocking noises when the steering wheel is turned. 70ZV15001

At pin No. 4 (marked with "**"), only in case where the clearance at the machine center side is more than 2.8 mm (0.110 in), adjust using liner of 2.8 mm (0.110 in) thickness.

15-4 60ZV-2 Service Standard Chassis Group Center Pin

Center Pin Center pin shim adjustment 1

Bearing cover installing

Front

3 5

Front chassis Grease nipple installation direction

11 2

[Upper]

Rear chassis 60ZV12005

The clearance between the front chassis and bearing cover (3) is 0.5±0.5 mm (0.02±0.02 in) before shim adjustment. Add shims (5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in). : Bolt (9): 456 N-m (46.5 kgf-m) (336 lb-ft) : Bolt (10): 230 N-m (23.5 kgf-m) (170 lb-ft) : Bolt (9): With lubricating oil (Engine oil or gear oil)

65ZV15001

Install bearing cover (3) so that the grease nipple mounting hole is positioned at the specified angle as shown in the figure above.

15-5 60ZV-2 Service Standard Chassis Group Attachment Leveler

Attachment Leveler

Attachment leveler

K65V2E15002

15-6 60ZV-2 Service Standard Chassis Group Attachment Leveler

Attachment leveler

Adjusting plate

Proximity switch

15 mm (0.6 in)

5±2 mm (0.2±0.09 in)

2.2 mm (0.09 in)

K60V2U15001

Adjusting plate Plate

Direction of indicator lamp

Proximity switch

60ZV15005

15-7 60ZV-2 Service Standard Chassis Group Attachment Leveler

Attachment leveler adjustable angle [ For bucket ]

-7º Adjusting length: 22 mm (0.866 in)

0 60 mm (2.362 in)

+7º 99 mm (3.898 in) K90ZV15001

No.

Item

Judgment standard

Solution

Clearance of attachment leveler switch

5±2 mm (0.196±0.078 in)

Adjustment

Adjusting plate mounting bolt tightening torque

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

Tightening

Switch mounting nut tightening torque

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

Tightening

Attachment leveler adjustable angle

-7º ~ +7º

Adjustment

15-8 60ZV-2 Service Standard Chassis Group

MEMO

24-1 60ZV-2 Disassembly & Reassembly Power Group

60ZV-2 Disassembly & Reassembly Power Group Power Line .............................................................. 24-2 Radiator................................................................... 24-3 Engine ..................................................................... 24-6 Propeller Shaft......................................................... 24-9 Air Cleaner .............................................................. 24-11 Muffler ..................................................................... 24-13 Front Axle Assembly ............................................... 24-14 Spider Assembly ..................................................... 24-25 Rear Axle Assembly ................................................ 24-28 Axle Support............................................................ 24-32 Differential Assembly............................................... 24-33

24-2 60ZV-2 Disassembly & Reassembly Power Group Power Line

Power Line Power line tightening torque

Engine

T6 L1

T1 L3 T1 L3

T2 L3 T3 L1 Transmission

Rear differential

T3 L1

T7 L2 T2 L3 T4 L2

T6 L2

T5 L2

3rd propeller shaft

2nd propeller shaft Front differential

K60V2U24001

: Bolt tightening torque T1: 53 N-m (5.4 kgf-m) (39 lb-ft) T2: 417 N-m (42.5 kgf-m) (307 lb-ft) T3: 94 N-m (9.55 kgf-m) (69 lb-ft) T4: 80 N-m (8.2 kgf-m) (59 lb-ft) T5: 142 N-m (14.5 kgf-m) (105 lb-ft) T6: 230 N-m (23.5 kgf-m) (170 lb-ft) T7: 137 N-m (14.0 kgf-m) (101 lb-ft)

L1, L2: Screw lock agent (Loctite® 262) L3: With lubrication oil (Engine oil or gear oil) Note Always replace drive shaft bolts with new ones - never reuse them.

24-3 60ZV-2 Disassembly & Reassembly Power Group Radiator

Radiator Radiator tightening torque

Radiator assembly

Fan guard

K60V2U24017

: Bolt tightening torque T1: 94 N-m (9.55 kgf-m) (69 lb-ft) T2: 90 N-m (9.15 kgf-m) (66 lb-ft)

24-4 60ZV-2 Disassembly & Reassembly Power Group Radiator

Radiator removing and installing 2

Radiator

Radiator removing

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

Engine

Before starting work: - Remove the engine room (Refer to Section 14). Fuel tank

1 K60V2U24003

1. Remove drain plug (1) to drain the coolant. : Coolant: 10 L (2.7 gal) 2. Disconnect coolant hoses (2)(3) from the radiator. : Coolant: 10 L (2.7 gal) Note Cover the disconnected hoses with caps or vinyl to protect them from dust and dirt.

24-5 60ZV-2 Disassembly & Reassembly Power Group Radiator

9 4

Fan guard assembly

To engine

10 To sub tank

K60V2U24018

3. Disconnect water line hose (4) to the engine from the radiator. Disconnect hose (5) to the sub tank. Note Cover the disconnected hoses with caps or vinyl to protect them from dust and dirt.

K60V2U24019

5. Remove the fan guard assembly. 6. Temporarily sling radiator assembly (9). Remove right and left retainer bolts (10). : Bolt (10): 94 N-m (9.6 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil) : Radiator: 85 kg (190 lbs) 7. Remove radiator (9) from the rear chassis.

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

K60V2U24005

4. Disconnect air cooler hoses (7)(8) from the air charge cooler. : Hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft) Note - Cover the disconnected hoses with caps, plugs, or vinyl to protect them from dust and dirt. - During reassembly, carefully inspect and clean the hoses and air cooler of any contaminates. Anything left in the lines or air cooler will go directly into the engine causing extensive engine damage.

24-6 60ZV-2 Disassembly & Reassembly Power Group Engine

Engine Engine removing and installing

To radiator

Engine removing

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

Cooling unit

K60V2U24011

1. Remove hoses (1)~(3) from the radiator mount and the cooling unit. : Coolant: 10 L (2.7 gal) Note Cover the disconnected hoses with caps or vinyl to protect them from dust and dirt. 2. Remove the wires from all sensors, alternator, starter motor and air conditioner (if equipped). Disconnect the battery cables from the battery. 3. Disconnect the heater hose and the fuel hose, and also disconnect the air conditioner lines from the compressor. Note Cover the disconnected hoses with caps or vinyl to protect them from dust and dirt.

24-7 60ZV-2 Disassembly & Reassembly Power Group Engine

Radiator

7 11 5

K60V2U24014

K60V2U24008

4. Remove air hoses (4)(5) and air pipes (6)(7) from the air charge cooler.

6. Temporarily sling the engine and remove engine mounting bolts (11). : Engine assembly: 400 kg (880 lbs) : Bolt (11): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent (Loctite® 262) application

: Air cooler hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft) Note Cover the disconnected hoses and pipes with caps or vinyl to protect them from dust and dirt.

10 9 10 12

8 K60V2U24009

K60V2U24007

5. Remove cover (8) on the torque converter case. Turn the torque converter drive cover slowly, and remove bolt (9), which is connecting the engine flywheel and the torque converter flexible plate. : Bolt (9): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubricating oil (Engine oil or gear oil)

7. Remove bolts (10) from the housing between the engine flywheel housing and the transmission. : Bolt (10): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (engine oil or gear oil) 8. Separate the engine and the transmission from each other, and then, lift the engine. Note Lift the engine approximately 100 mm (4 in). Insert a wooden piece of approximately 200 mm (8 in) thickness into the clearance between the flywheel bottom and the rear axle to separate the engine and the transmission. Repeat this two or three times to completely separate the engine and the transmission from each other. Carefully lift the engine while checking that there are no obstacles around it.

24-8 60ZV-2 Disassembly & Reassembly Power Group Engine

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

Engine installation cautions

K60V2U24009

- Be sure to install bearing (12) when reassembly. - Refill the engine with the proper quantity and type of the engine oil. - Refill radiator with premixed coolant (approx 50% water / 50% antifreeze, or according to local requirements). - After reinstalling the engine, completely bleed the fuel line of air. - Set the starter key to ON, and then, check the monitor lamps of electrical equipment. - Operate the engine at the idling speed for 5 minutes. After that, check the amount of the coolant. - While gradually increasing the engine speed, check operation of the electrical equipment, and check for leakage.

24-9 60ZV-2 Disassembly & Reassembly Power Group Propeller Shaft

Propeller Shaft Propeller shaft removing and installing

2 3

Second propeller shaft removing

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

1 4 Front differential

60ZV24004

1. Remove bolt (2) at the transmission side of second propeller shaft (1). : Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application 2. Remove bolt (3) from pillow unit bearing (4). : Bolt (3): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent (Loctite® 262) application

24-10 60ZV-2 Disassembly & Reassembly Power Group Propeller Shaft

Third propeller shaft removing 6

Second propeller shaft Rear differential

60ZV24005

3. Remove bolt (6) to disconnect the propeller shaft from front differential (5). Support the shaft by cable or rolling floor jack. Take out the second propeller shaft to the front. : Bolt (6): 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application : Second propeller shaft: 30kg (70 lbs) Note If the retainer bolt is too tight due to the screw lock agent, heat the bolt head to about 235ºC (450ºF) using slow flame of a gas burner. Keep the flame away from the seals of the coupling. Do not reuse the bolts, always replace with new ones.

Transmission

60ZV24006

1. Remove bolt (7). : Bolt (7): 137 N-m (14.0 kgf-m) (101 lb-ft) : Screw lock agent (Loctite® 262) application 2. Remove the third propeller shaft. : Third propeller shaft: 10 kg (25 lbs)

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

Propeller shaft installation cautions - Always replace the drive shaft bolts with new ones. Do not reuse them. - During reinstallation, align the direction of the flange yokes on the second and third propeller shaft sides of the transmission. (Refer to Section 22.) [Difference in the yoke phase (direction) will cause the propeller shaft damage and "knocking" during a turn.]

24-11 60ZV-2 Disassembly & Reassembly Power Group Air Cleaner

Air Cleaner Air cleaner removing and installing

7 5

Air cleaner removing

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

6 K60V2U24010

2. Disconnect air hose (5) and disconnect indicator wire coupler (6). Inspect air hose (5) for damage or wear. Replace it if there is any damage or wear. 4 K60V2U24015

1. Remove cover (1). Carefully take out outer element (2), and then, remove inner element (3). Remove rubber valve (4). Inspect it for damage and replace, if necessary. Note Removing inside elements reduces the weight and makes air cleaner case removal work easier.

3. While supporting air cleaner case (7) with your hand, remove band retainer bolts (8), and then, lower the air cleaner case.

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

24-12 60ZV-2 Disassembly & Reassembly Power Group Air Cleaner

Air cleaner installation cautions 2~3 mm (1/8 in) 5 mm (1/4 in) or less Fix the bands avoiding the beading Air duct

(Air cleaner or Engine) Insertion amount: 35 mm (1 1/2 in)

K85V2U24005

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

24-13 60ZV-2 Disassembly & Reassembly Power Group Muffler

Muffler Muffler removing and installing Muffler removing

4 5 3

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

Engine

K60V2U24012

3. Disconnect drain pipe (3), and then, remove Uclamp (4) and exhaust pipe (5).

6 7

Engine room

K60V2U24016

1. Remove bolt (1), and then, remove exhaust pipe (2). : Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft) 2. Remove the engine room by referring to Section 14.

K60V2U24013

4. Remove bolt (6), and then, remove muffler (7). : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) : Muffler: 13 kg (29 lbs)

: Engine room: 170 kg (375 lbs)

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

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

24-14 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front Axle Assembly Front axle assembly tightening torque T3 L 3

Front differential

T1 L 1 A

Joint surface

T2 L2

T1 L 1 60ZV24008

: T1: 314 N-m (32.0 kgf-m) (232 lb-ft) T2: 892 N-m (91.0 kgf-m) (658 lb-ft) T3: 721 N-m (73.5 kgf-m) (532 lb-ft) T4: 132 N-m (13.5 kgf-m) (98 lb-ft) L1: Screw lock agent (Loctite® 262) application L2: Liquid gasket (Three Bond 1215) application L3: With lubrication oil (Engine oil or gear oil) Preload at section (A): 52~73 N (5.3~7.4 kgf) (11.7~16.3 lbf)

24-15 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly removing and installing Front axle assembly removing

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

65ZV24029J

1. Remove right and left wheel and tire assemblies (1). : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) : Tire/pc: 175 kg (385 lbs)

Before starting work:

Stand

Stand 65ZV24030J 70ZV24017

- Lift the front wheel using the attachment, and then, place a stand under the front chassis to support the chassis. - Lift the boom until it is horizontal, and place a stand under the boom to support it or install a boom cylinder lock collar.

2. Remove the retainer bolt (3) for the second propeller shaft (2). : 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application

24-16 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

6 60ZV24018J

65ZV24032J

4. Attach sling to axle assembly (6), and then, remove eight retainer bolts (7).

: Bolt (7): 721 N-m (73.5 kgf-m) (532 lb-ft) : Front axle assembly (6): 480 kg (1,060 lbs) Note - During reassembly be sure both mating surfaces are clean and free of paint. - Apply liquid gasket (Three Bond 1215).

60ZV24019J

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

3. Disconnect air bleeder tube (4) and brake pipe (5). Note Cover the disconnected tube and pipe with caps or vinyl to protect them from dust and dirt.

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

Front axle assembly installation cautions After reinstallation, completely bleed air in the service and parking brake lines. Refer to the following section for the procedure.

24-17 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Service brake air bleeding procedure

WARNING Vinyl tube

Unexpected movement of the machine may cause a severe accident. To prevent such an accident, take the following safety measures when performing air bleeding with the engine running. - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the wheel from moving. - Determine the signals between the persons related to this work for engine starting to prevent an accident. - When moving up the boom, install a safety column under the boom. - Apply the articulation stopper.

IMPORTANT Before bleeding the service brakes, it is important to remove all air from the brake valve manifold block, and all related valves. These include the reducing valve and park brake valve. Failure to do this correctly will result in unsatisfactory brake modulation.

Air bleeder nipple

Oil can 65ZV52009

3. Connect a clean vinyl tube to the air bleeder nipple, and place an oil can to receive the oil, or route the hydraulic tank. 4. Slightly loosen the air bleeder nipple, and then, press the brake pedal several times. 5. When the oil flows from the air bleeder nipple, close the nipple.

1. Verify that the wheels are securely blocked, and the articulation stopper is in the "locked" position.

6. After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then, immediately close the nipple.

2. Charge the accumulator to full pressure, then shut off the engine, and complete the procedure.

7. Repeat this until there is no air in the oil. Completely bleed each wheel of air.

24-18 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle disassembling and assembling

Sling

Front axle disassembling

WARNING Unexpected movement of the machine or components could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and then, apply the parking brake. - Apply the articulation stopper. - Block the rear wheels with chocks or the like to prevent the wheels from moving. - The stands must be able to support the gross weight of the front chassis, boom, and the attachment. Before starting work: - Remove the axle assembly from the chassis. - Drain gear oil (front, rear each) : Gear oil: 20 L (5.3 gal)

3 4

65ZV24019

2. Sling axle housing (4) and remove bolt (3). Separate axle housing (4) from the differential assembly. Note Striking axle housing lightly by hammer may help to separate it from the differential assembly. : Axle housing: 170 kg (375 lbs)

2 1 6 65ZV24044J

1. Place axle assembly on work table using supports (1)(2).

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

65ZV24046J

24-19 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Material: SS41 Unit: mm (in)

18 (0.7) Bar (4 pcs) (welded) P.C.D. 210 (8.3)

60 (2.4) 220 (8.7)

350 (13.8)

65ZV24047J

100 (3.9)

4. Remove steel plate (7).

80 (3.1)

P.C.D. 210 (8.3)

14 (0.55)

Jig Jig

Axle shaft

60ZV24021

65ZV24020

5. Sling axle housing (4) and install jig to end.

65ZV24050J

6. Remove retainer (8).

24-20 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

4 10 9

Jig

65ZV24051J

65ZV24020

7. Remove bolt (9), and then, remove spider assembly (10). Axle shaft

65ZV24022

65ZV24052J

9. Sling axle housing (4) and remove it together with bearing (12) from the axle shaft.

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

65ZV24055J

10. Remove axle shaft (13) from jig.

24-21 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembling

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

14 15 65ZV24056J

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

14 15

65ZV24057J

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

Inner race (B) Axle shaft

Outer race (A)

Bearing installation end

Do not apply any oil here.

Oil seal detail Grease

60ZV24010

2. Put grease in the lips of inner race (B) of oil seal (15). Insert oil seal inner race (B) into the axle shaft, and then, assemble it with oil seal outer race (A). 3. Insert bearing (14) into the axle shaft.

24-22 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

16 12

65ZV24061J

6. Install bearing (12). 4

7. Put shim (16) on the end of axle shaft. 13

Shim: T= 0.1, 0.2, 0.3, 0.35, 0.5, 1.0 mm (0.0039, 0.0079, 0.0118, 0.0138, 0.0197, 0.0394 in)

65ZV24059J

4. Assemble axle shaft (13) to axle housing (4). 10 9

65ZV24051J

Bolt (9)

Spider assembly

65ZV24060J

Axle shaft (13)

5. Insert the oil seal inner race into the axle housing. Shim (16)

Taper roller bearing (12)

65ZV24024

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

24-23 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Spring balance

10 8

9 65ZV24025

9. Measure the preload at the axle housing bolt hole.

65ZV24066J

12. Install spider assembly (10). Apply liquid gasket to lock bolt (9) and tighten it.

Preload: 52~73 N (5.3~7.4 kgf) (12~16 lbf) In case the preload is not in correct range, shim adjustment (changing shim) is necessary. Repeat steps 7) and 8) until you get the correct preload.

: Bolt (9): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Loctite® 262) application 13. Install retainer (8).

7 65ZV24067J

17 65ZV24065J

14. Install steel plate (7) to differential assembly (18). 10. When the preload is in correct range, remove the lock bolt and spider assembly. 6

11. Insert one knock pin (17), and then, insert internal gear (11). Insert the rest three knock pins.

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

65ZV24046J

24-24 60ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Bolt

Liquid gasket application

65ZV24026

16. Install axle housing (4) to the differential assembly. : Bolt: 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Loctite® 262) application : Liquid gasket (Three Bond 1215) application

WARNING After installing the axle housing to the differential assembly, axle assembly may be inclined when the sling is removed. Loss of control of this axle assembly could result in injury. Put an appropriate support under the axle housing. Refill gear oil after reassembling. : Gear oil: 20 L (5.3 gal) Note Use anti-chatter oil additive.

24-25 60ZV-2 Disassembly & Reassembly Power Group Spider Assembly

Spider Assembly Spider assy disassembling and assembling

Spider assy disassembling

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

65ZV24070J

1. Put spider assembly (1) on wooden blocks. 5 2

4 65ZV24076J

5. Remove planetary gear (4) and thrust washer (5) from spider (1).

3 4

65ZV24071J

2. Push spring pin (2) into planetary pin (3) using a bar. Spring pin hole diameter: 6 +0.12 mm (0.24 +0.004 in) -0 -0 3. Strike out planetary pin (3) from the axle shaft side to the differential side.

60ZV24022J

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

24-26 60ZV-2 Disassembly & Reassembly Power Group Spider Assembly

Spider assy assembling To reassemble the spider assembly, follow the above procedure in reverse order. Before starting work: - Clean and check all the parts. If any part is worn or damaged, replace it.

65ZV24074J

7. Remove washer (7) with shim.

60ZV24022J

1. Apply gear oil to planetary gear (4) and needle bearing (6). Install needle bearing (6) into planetary gear (4).

65ZV24075J

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

24-27 60ZV-2 Disassembly & Reassembly Power Group Spider Assembly

4 65ZV24076J

65ZV24078J

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

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

3 Pin holes

65ZV24027

4. Apply gear oil to planetary pin (3), and insert it into the spider. Align the spring pin holes on the planetary pin (3) and the spider.

24-28 60ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear Axle Assembly Rear axle assembly tightening torque T3 L 3

Rear differential

Front axle support

T4 L 3

FRONT

Rear axle support 60ZV24017J

24-29 60ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear axle assembly removing and installing

Wooden block

Rear axle assembly removing

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground. - Apply the articulation stopper.

65ZV24028

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

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

A 60ZV24011

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

Steel block

60ZV24026

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

60ZV24025J

4. Remove right and left wheel and tire assemblies (1). : Tire of 1 wheel: 170 kg (385 lbs) : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

24-30 60ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

65ZV24037J

5. Remove retainer bolts (2) to remove the third propeller shaft.

65ZV24039J

7. Disconnect air breather tube and brake hose (4). : Oil: Approx. 1.5 L (0.4 gal)

: Bolt (2): 137 N-m (14.0 kgf-m) (101 lb-ft) : Screw lock agent (Loctite® 262) application : Third propeller shaft: 10 kg (25 lbs)

Note Cover and plug the hose and fittings to prevent dirt entry.

Note - Replace propeller shaft retainer bolts (2) with new ones. Do not reuse them when reassembling. - Clean all threads with a thread lock primer to assure a fast strong bond.

5 65ZV24040J

60ZV24026J

6. Disconnect grease pipe (3) both front and rear sides. Note Remove and clean hose (3) before reinstalling. Install plastic cap on the breather fitting.

8. Temporarily sling rear axle (5), and remove right and left retainer bolts (6) from the rear axle support. Lower rear axle assembly (5) on the carrier, and then, pull out the rear axle. : Bolt (6): 721 N-m (73.5 kgf-m) (532 lb-ft) : Rear axle: 635 kg (1,400 lbs)

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

24-31 60ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

7 65ZV24041J

9. Sling front axle support (7), and remove it from the rear axle. The support should slide off the rear axle.

65ZV24043J

11. Remove packing (11).

: Axle support (front): 65 kg (143 lbs)

Rear axle assembly installing 8

For reinstallation, follow the above procedure in reverse order. Refer to "Service brake air bleeding procedure" page 24-17 for air bleeding in the service brake.

Rear axle disassembling and assembling

65ZV24042J

10. Temporarily sling rear support (8) and remove bolts (9) from plate (10). Remove plate (10) and rear support (8). : Bolt (9): 132 N-m (13.5 kgf-m) (98 lb-ft) : Axle support (rear): 80 kg (176 lbs) Note Remove and clean the breather fitting. Place the breather fitting on the top position. Lubricate after reassembly until grease comes out of the breather.

For disassembling and reassembling the rear axle assembly, refer to "Front axle disassembling and assembling" page 24-18.

24-32 60ZV-2 Disassembly & Reassembly Power Group Axle Support

Axle Support Axle support disassembling and assembling

6 7

Axle support disassembling

Grease piping

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

FRONT

Grease piping

60ZV24013

2. Remove packings (6) and bushing (7) from axle support (5).

4 3 2 1 FRONT 60ZV24012

Note - To reinsert bushing (7), position the large chamfer side of bushing at the grease piping hole side, and position the end gap of bushing at the bottom. - Apply enough grease to the inner surface of bushing (7).

1. Remove packings (2), bushing (3) and packing (4) from axle support (1).

Axle support assembling Large chamfer

Small chamfer

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

Axle support assembly cautions

After reassembling, manually operate the axle to check for any abnormal noise and looseness.

Bushing (3) 65ZV24030

Note - To reinsert bushing, position the large chamfer side of bushing (3) at grease piping hole side, and position the end gap of bushing at bottom. - Apply enough grease to inner surface of bushing (3).

24-33 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential Assembly Front differential tightening torque

T1 L 3

T5 L 1 T3 A 4 1

3 2

T5 L 1 T2 L 1

T5 L 1 5 T4 L 1 60ZV24029J

L1: Screw lock agent (Loctite® 262) application L2: Liquid gasket (Three Bond 1215, or a locally procured RTV that does not contain acetic acid.) L3: With lubrication oil (Engine oil or gear oil)

24-34 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly Axle nut tightening procedure 1. To tighten nut (T1), measure the preload at the bolt screw hold in flange (A). Preload at flange (A): 16~30 N (1.6~3.1 kgf) (4~7 lbf) Use spacer (B) to adjust the preload. 2. Use shim (4) to adjust the tooth contact of spiral bevel gears (2)(3). Use nut (5) to adjust the backlash.

Caulking (Stake)

Bearing Differential pinion

Ring part

65ZV24032

3. Press bearing (6) (the ring part to be faced to the pinion) into the pinion and stake the end of the pinion at three points.

24-35 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assy disassembling and assembling A

Differential assy disassembling Before starting work: - Support the differential assembly to prevent it from tilting.

65ZV24083J

(0.5)

(1.8)

t9 (0.4)

Remover bolt

Material: SS41 Unit: mm (in)

(0.8)

(0.4)

11 (0.4)

Nut

320 28

(1.1)

33 (1.3)

(2.8)

(0.6)

(2.6)

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

(5.5)

140

CAUTION

(2.8)

1. Fix the remover bolts into brake piston (1). Feed air through the brake pipe connecting port, and draw out brake piston (1).

(0.6)

(12.6)

65ZV24033

30 (1.2) (0.4)

(0.2)

(1.5)

(0.7) (0.3) 2 (0.08)

18 7

13 (0.5) 20 (0.8)

About 10º

Sling (A)

M10x1.5 (M0.4x0.06)

3. Lift the differential cage lightly by sling (A).

65ZV24082J

2. Remove differential carrier cover (2).

Width across flat: 10 (0.4) 65ZV24034

24-36 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assy assembling

IMPORTANT

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

5 65ZV24085J

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

6 7

6 7 65ZV24086J

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

65ZV24086J

5. Remove differential cage (6) from differential carrier (7). (Refer to "Differential cage disassembling and assembling" page 24-42.)

For remover bolt

65ZV24035

2. Install pinion assembly (9) to differential carrier (7). Note Match holes of differential cage, differential carrier and shims.

For remover bolt 65ZV24035

6. Remove bolts (8), and then, remove pinion assembly (9) from the differential carrier. (Refer to "Differential pinion disassembling and assembling" page 24-43.)

: Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application

24-37 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Insert Differential carrier

O-ring

Piston

65ZV24036

3. Place the differential carrier side ways.

65ZV24049

6. Install the O-rings to the brake piston. Note Before installing the O-ring, apply gear oil and avoid torsion.

10 65ZV24091J

4. Install O-ring (10) to the differential carrier. 65ZV24095J

Note Apply gear oil to the O-ring.

7. Apply gear oil to the differential carrier and brake piston (1). Install brake piston (1) to the differential carrier.

7 5

65ZV24093J

5. Install bearing carrier (5) to differential carrier (7) and tighten bolts (6). : Bolt (6): 206 N-m (21.0 kgf-m) (152 lb-ft) : Screw lock agent (Loctite® 262) application

Note When installing piston (1), take care not to cut or damage the O-ring.

24-38 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

B 1

C 65ZV24096J

65ZV24098J

8. Turn over the differential carrier and reassemble the opposite side in the same manner as the foregoing steps 4) through 7).

9. After reassembling, conduct an airtight test for brake piston (on both right and left side). Material: SS41 Unit: mm (in)

(1.6)

(e) If air leaks at the brake piston, remove the piston, replace the O-ring with a new one, carry out the operation in the foregoing steps 4) through 8), and then, conduct an airtight test.

t=16 (0.7)

40 18 (0.7)

P.C.D.330

P.C.D.254

(13.0)

(10.0)

390 (15.4)

(0.7) (8.3)

(11.4)

210

290

(d) If there found no air leak at these check points, stop air feeding and loosen the air bleeder nipple to discharge air.

25 (1.0)

(f)

If there' s no leak, remove jig and push in the brake piston completely.

Note If brake piston is insufficiently pushed in, the axle housing cannot be attached. Be careful to fully push it in.

120

Jig (B) 60ZV24023

(a) Install jig (B) to differential carrier using axle housing installation holes. (b) Feed air pressure at about 588 kPa (6 kgf/cm2) (85psi) through the brake pipe connecting port C. 65ZV24099J

10. Turn differential carrier (7) with the cover attached side upward and hold the differential carrier by supports to prevent it from tilting.

24-39 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Adjusting nut (12) Ring gear

Bolt

Pinion assembly

Thickness of shims: 0.075, 0.10, 0.25, 0.50, 0.80 mm (0.0029, 0.0039, 0.0098, 0.0196, 0.0314 in)

Bolt Shim Lock plate (11)

Adjusting nut (13)

12. Check for the tooth contact. If the normal tooth contact is not obtained, adjust the thickness of shims at the pinion assembly attached part, and adjust the backlash to make it normal (Refer to the following “Adjusting tooth contact”.)

65ZV24038

11. Adjust the backlash. (a) Remove lock plate (11) (on both the right and left sides). (b) Tighten adjusting nut (12) on the ring gear side until the backlash is reduced down to zero, and then, loosen the nut by 2 to 3 notches.

Note When adjusting with shims, match the holes of the carrier cage, the differential carrier and the shims to each other. 13. Mount lock plate (11), and then, tighten the bolts to fix the lock plate. : Retainer bolt: 26 N-m (2.7 kgf-m) (20 lb-ft) : Screw lock agent (Loctite® 262) application

(c) Tighten adjusting nut (13) on the opposite side until you feel a touch, and then, tighten the nut further by one notch.

14 65ZV24102J

14. Install differential carrier cover (2).

65ZV24101J

(d) Attach the dial gauge stand to the carrier, fit the dial gauge to the tooth surface of ring gear (14), and read the value of backlash. (e) Adjust the backlash to the standard value of 0.20~0.28 mm. (0.007~0.011 in) - Loosening the nut on the ring gear side, and tightening nut on the opposite side will increase the backlash. - Tightening the nut on the ring gear side and loosening the nut on the opposite side will decrease the backlash.

24-40 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Adjusting tooth contact Tooth contact

Possible cause

Adjusting method

Correct

Ring gear is too close to the drive pinion

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

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

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

Drive pinion is too far from the ring gear.

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

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

24-41 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly Three types of tooth contact shown below are acceptable as the best tooth contact. Tooth contact position and length (rate)

10 1

Pattern A

5 TOP

HEEL

4~5

Pitch line TOE

BOTTOM

10 2 Pattern B

4 TOP

4 HEEL

Pitch line

4~5

TOE BOTTOM

10 3 Pattern C

4 TOP

TOE

3 HEEL

4~5

Pitch line BOTTOM

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

24-42 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential cage disassembling and assembling Differential cage disassembling Before starting work: - Put a matchmark on the alignment point of the differential cage.

3 65ZV24105J

Matchmark

4. Separate the cage. Differential cage

Thrust washer

6 1 3

65ZV24039

7 8

1. Remove bolts (1), and then, remove ring gear (2). 8

: Bolt (1): 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application

7 60ZV24016

2. If bearing (3) is damaged, remove the bearing. 5. Remove spider (5), differential pinion (6), side gear (7) and thrust washer (8) from the differential cage. 4

Differential cage assembling Matchmark

65ZV24040

3. Remove bolts (4). : Bolt (4): 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application

To reassemble the differential cage, follow the above procedure in reverse order.

Differential cage assembly cautions - Clean and check all the parts. If any part is worn or damaged, replace it with new one. - Apply gear oil to the parts before reassembling. - Warm bearing (3) in an oil bath to 120~150ºC (248~302ºF) before installation.

24-43 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential pinion disassembling and assembling Differential pinion disassembling A

1 65ZV24109J

170 (6.7)

Material: SS41 Unit: mm (in)

(3.1)

(1.7)

: Bolt (1): 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application

(3.5)

(0.5)

89 100

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

(6.7)

170

65ZV24107J

(3.9)

(2.4)

(1.6)

(2.8)

170 (6.7) 60ZV24024

3. Install the pinion assembly to working jig (A) and fix it with a vise.

Bolt

65ZV24108J

2. Install bolt (1), as a remover bolt, to bolt hole (2) and remove the pinion assembly from the differential carrier. Remove bolt: M12 x 1.75

6 7 65ZV24043

4. Remove nut (3), square ring (4) and flange yoke (5).

24-44 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

12 11

6 7

60ZV24034J

65ZV24114J

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

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

8 9

Pinion cage

10 60ZV24018

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

24-45 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential pinion assembling

8 9

Pinion cage

Caulking (Stake)

10 60ZV24018

65ZV24046

1. Warm roller bearing (13) in oil up to 120~150ºC (248~302ºF) and install it to the pinion. After bearing becomes cool, stake the pinion end at three points.

3. Fit taper roller bearing (10) and spacer (9) in order into the pinion cage. Note Do not install oil seal (8) here. The oil seal should be installed after the preload of the bearing is adjusted.

12 11

65ZV24116J

65ZV24119J

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

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

65ZV24120J

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

24-46 60ZV-2 Disassembly & Reassembly Power Group Differential Assembly

“Fish scale” tool to measure the preload.

65ZV24121J

60ZV24028

9. Measure the preload. If the measured preload exceeds the following standard range, make an adjustment by replacing spacers.

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

Standard: 16~30 N (1.6~3.1 kgf) (4~7 lbf)

4 3

Spacer (23 types at 0.02 mm (0.0007 in) pitch): T=14.68~15.08 (0.5780~0.5937 in) Thicker spacers reduce preload, and thinner spacers increase preload.

65ZV24122J

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

10. After adjusting the preload, remove the nut and detach the flange from the pinion cage. Install the oil seal to the pinion cage. : Liquid gasket (Three Bond 1215) application 11. Install the flange yoke to the pinion cage and tighten the fixing nut. : Nut: 363 N-m (37 kgf-m) (268 lb-ft) : Nut width across flat: 38.1 mm (1.50 in) : Liquid gasket (Three Bond 1215) application

65ZV24123J

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

25-1 60ZV-2 Service Standard Power Group

60ZV-2 Service Standard Power Group Propeller Shaft Service Standard ............................ 25-2 Axle and Differential Service Standard.................... 25-3

25-2 60ZV-2 Service Standard Power Group Propeller Shaft Service Standard

Propeller Shaft Service Standard

1. Bearing play

Third propeller shaft

2: Circumferential play

3: Transverse play

Second propeller shaft K60V2U25001

Unit: mm (in) No.

Item

Tolerance

Solution

Spider bearing play

Second, third propeller shaft

0.25 (0.0098)

Replacement

Spline circumferential play

Second propeller shaft

0.8 (0.0315)

Replacement

Spline transverse play

Second propeller shaft

1.0 (0.0394)

Replacement

Clearance

9.4 (0.37)

—

25-3 60ZV-2 Service Standard Power Group Axle and Differential Service Standard

Axle and Differential Service Standard Axle assembly

60ZV25002J

Unit: mm (in) Judgment standard No.

Item

Solution Standard dimension

Tolerance

Backlash between sun gear and planetary gear

0.112 ~ 0.488 (0.0044 ~ 0.0192)

Replacement

Backlash between planetary gear and internal gear

0.16 ~ 0.66 (0.0063 ~ 0.0260)

Replacement

Tooth contact of gear

Clearance between spider pin and pin hole

Clearance between spider pin and needle bearing

Replacement

No abnormality 0.0 ~ 0.036 (0.0 ~ 0.0014)

0.1 (0.0394)

0 ø 40 -0.011

0 ( ø 1.6 -0.0004 )

Replacement Replacement

25-4 60ZV-2 Service Standard Power Group Axle and Differential Service Standard

Differential 3 1 4

60ZV25003J

Unit: mm (in) Judgment standard No.

Item

Solution Standard valve

Tolerance

Backlash between ring gear and drive pinion

0.20 ~ 0.28 (0.0079 ~ 0.0110)

Adjustment

Backlash between side gear and pinion gear

0.23 ~ 0.45 (0.0091 ~ 0.0177)

Adjustment

Clearance between pinion gear and spider

0.013 ~ 0.038 (0.0005 ~ 0.0015)

Replacement

Runout of ring gear rear surface (when assembled)

0.076 (0.0030)

Adjustment or replacement

Tooth surface wear (each gear)

Tooth contact

Abnormal wear or missing

Replacement

No abnormality

Replacement

34-1 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group

60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly....... 34-2 Torque Converter Assembly .................................... 34-10 Transmission Assembly .......................................... 34-13 Clutch Pack ............................................................. 34-17 Special Tools ........................................................... 34-19 Control Valve Assembly .......................................... 34-21

34-2 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque Converter and Transmission Assembly Torque converter and transmission assembly mounting bolt tightening torque

Engine

T6 L1

T1 L3 T1 L3

T2 L3 T3 L1 Transmission

Rear differential

T3 L1

T7 L2 T2 L3 T4 L2

T6 L2

T5 L2

3rd propeller shaft

2nd propeller shaft Front differential

K60V2U24001

L1, L2: Screw lock agent (Loctite® 262) L3: With lubrication oil (Engine oil or gear oil) Note Always replace drive shaft bolts with new ones - never reuse them.

34-3 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

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

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

60ZV34001J

1. Remove drain plug (1) to drain the transmission oil. Before starting work: - Remove the cab and the floor board (Refer to Section 14). - Remove the engine room front plate. - Consider the type of failure and if the T/C oil cooler must also be removed for cleaning or replacement. - If a small amount of contamination is found in the transmission strainer and filter, the cooler does not need removal. - If a large amount of contamination is found, the cooler must be removed and thoroughly cleaned or replaced. - Lines to cooler must be also replaced.

: Transmission oil: 20 L (5.3 gal) 2. Disconnect the hose for the transmission oil level gauge. Note Cover the disconnected hoses with plastic caps or vinyl to protect them from dust and dirt. Oil pump

2 60ZV34001

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

34-4 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque converter

7 8

Oil cooler

Boost master

6 10 Oil pump

3 11

Priority valve

Line filter

60ZV34002

60V2U34002

4. Remove hoses (3)(4) from hydraulic pump. Remove bolts (5), and then, remove hydraulic pump assembly.

5. Disconnect hose (6) between the torque converter pump and the line filter.

: Bolt: 90 N-m (9.15 kgf-m) (66 lb-ft) : Hydraulic pump assembly: 5 kg (11 lbs) Note - After removing the pipes and hoses, plug or cover the disconnected parts with clean vinyl to protect them from dust and dirt. - Be sure to replace the gasket of the hydraulic pump flange with a new one.

6. Disconnect hoses (7)(8) between the torque converter and the oil cooler. 7. Disconnect hose (9) between the boost master and the line filter. Disconnect hoses (10)(11) between the boost master and the transmission. Note Cover the disconnected hoses with plastic caps or vinyl to protect them from dust and dirt.

34-5 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Brake oil tank

Boost master Transmission 2nd propeller shaft

60V2U34003

60ZV34006

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

10. Remove bolts (14) from the second propeller shaft at the transmission side only.

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

: Bolt (14): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application

Rear differential Control valve

3rd propeller shaft Transmission

15 K60V2U34001

60ZV34005

9. Disconnect electric wire coupler (13) for the solenoid valve on the control valve. Note Put matchmarks on the couplers before disconnecting them.

11. Disconnect bolts (15) from the third propeller shaft at the transmission side. : Bolt (15): 80 N-m (8.2 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application Note If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner. Keep the flame away from the seals of the coupling. Do not reuse the bolt.

34-6 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

20 21 17

16 19 16

60ZV34008

60V2U34004

12. Attach sling to the transmission assembly, and then, loosen bolts (16). Remove bolt (17).

14. Remove cover (19) on the torque converter case. Remove bolts (20) connecting the torque converter flexible plate and the engine flywheel. Remove bolts(21) connecting the torque converter case and the flywheel housing.

: Bolt (17): 417 N-m (42.5 kgf-m) (307 lb-ft) : Transmission assembly: 400 kg (880 lbs)

: Bolt (20)(21): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) 15. Pull the transmission assembly straight out approximately 100 mm (4 in) to the front, then, slowly lift it. 18

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

60ZV34009

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

34-7 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

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

Torque converter and transmission assy installation cautions After reinstallation, check operation of the transmission assembly by the following procedure.

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

34-8 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

DATE:

HOURS:

MACHINE MODEL & SERIAL NO.:

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO.:

AMBIENT TEMP:

COMPONENT SERIAL NO.:

CHECKLIST TO BE COMPLETED BEFORE START-UP TRANSMISSION COOLER CLEANED

TRANSMISSION PIPING CLEANED

IN-LINE PRESSURE FILTER REPLACED

TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

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

MPa (kgf/cm2) (psi) 2

MPa (kgf/cm2) (psi)

MPa (kgf/cm ) (psi)

MPa (kgf/cm2) (psi)

CLUTCH PRESSURE AT HIGH IDLE

MPa (kgf/cm2) (psi) 2

MPa (kgf/cm ) (psi)

MPa (kgf/cm2) (psi)

COMMENTS:

Serviceman’s Signature

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

34-9 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque converter and transmission assembly assembling bolt tightening torque (Kawasaki CT110X01) T2 T5 L3 35T

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

L1 52T

T3 L1

41T

1st

31T

27T

T5 L3 32T

61T 46T

2nd 46T

T5 L3 T1 L3 27T

22T

49T

42T

T5 L3 3rd

T2 L3 42T

T4 L3

T5 L3

: T1: 27.4 N-m (2.80 kgf-m) (20 lb-ft) T2: 53 N-m (5.40 kgf-m) (39 lb-ft) T3: 216 N-m (22.0 kgf-m) (159 lb-ft) T4: 34 N-m (3.50 kgf-m) (25 lb-ft) T5: 69 N-m (7.00 kgf-m) (51 lb-ft) : L1: Screw lock agent (Loctite® 262) application L3: With lubrication oil (Engine oil or gear oil)

T3 L1

T4 L3 T5 60V2U34005

34-10 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque Converter Assembly Torque converter assembly disassembling and assembling

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

3 60ZV34012

For jack screw

3. Remove bolt (4) connecting the torque converter housing and the transmission housing. Separate the torque converter housing and the transmission housing by using jack screw (M10x1.5). : Bolt (4): 69 N-m (7.00 kgf-m) (51 lb-ft) : With lubrication oil (Engine oil or gear oil)

1 60ZV34011

1. Remove bolt (1), and then, remove pipe (2). : Bolt (1): 69 N-m (7.00 kgf-m) (51 lb-ft) : With lubrication oil (Engine oil or gear oil) 2. Remove hose (3). : Bolt (3): 28 N-m (2.85 kgf-m) (21 lb-ft) Note Cover the disconnected pipes and hoses with plastic caps or vinyl to protect them from dust and dirt.

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

34-11 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

8 A

60ZV34017J

60ZV34015J

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

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

18 19

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

9 10 11, 12, 13 22 B

21 20

60ZV34018J

9. Remove bolt (15). Detail of A 60ZV34013

7. Remove snap ring (9) and washer (10). Remove shims (11)(12)(13). Note Adjust the clearance B using shims (11)(12)(13) as to be 0~0.2 mm (0~0.008 in) when assembling.

: Bolt (15): 27.4 N-m (2.8 kgf-m) (20 lb-ft) : With lubrication oil (Engine oil or gear oil) 10. Remove cover (16). Note When reassembling, replace oil seal (17) and the O-ring with new ones. 11. Remove ring (18). 12. Tap turbine shaft (19) lightly by plastic hammer. Remove it with gear (20) and bearing (21) from torque converter case. 13. Remove ring (22).

34-12 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque converter assy assembling To reinstall the torque converter assembly, follow the above removal procedure in reverse order.

Torque converter assy assembly cautions - Clean and check all the parts. If any part is damaged, replace it with a new one. - Before reassembly, apply transmission oil to the parts. - Be sure to replace O-rings and seals with new ones. - Install new bearing if replacement is needed. - After reassembling, make sure that the drive cover is smoothly rotated by hand.

34-13 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission Assembly Transmission assembly disassembling and assembling

42T

49T

3rd 42T

46T

27T

31T

46T

1st

Before starting work: - Clean the transmission assembly.

2nd

22T

61T

32T

Transmission assy disassembling

60ZV34020J

3. Place transmission assembly as end cover (3) faces up. Remove bolt (4). Remove end cover (3) by using jack screw (M10x1.5).

Hose

: Bolt (4): 69 N-m (7.00 kgf-m) (51 lb-ft) : With lubrication oil (Engine oil or gear oil) 4. Remove snap ring (5)(6)(7) on each bearing outer race.

For jack screw

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

1 60ZV34014

1. Remove bolt (1), and then, remove pipe (2). : Bolt (1): 69 N-m (7.00 kgf-m) (51 lb-ft) : With lubrication oil (Engine oil or gear oil) 2. Remove the hose. Note Cover the disconnected pipes and hoses with plastic caps or vinyl to protect them from dust and dirt.

34-14 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

60ZV34022J

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

Jig

60ZV34025

6. Place the transmission assembly as illustrated. Remove bolt (8) connecting the torque converter housing and the transmission housing. Separate the torque converter housing and the transmission housing by using jack screw (M10x1.5). : Bolt (8): 69 N-m (7.00 kgf-m) (51 lb-ft) : With lubricating oil (Engine oil or gear oil) 7. Lift torque converter housing (9) slowly. : Torque converter assembly: 190 kg (420 lbs)

60ZV34015

9. Lift the F&2nd clutch shaft and the 3rd clutch shaft at the same time using the special jig. : F&2nd and 3rd clutch: 60 kg (135 lbs)

34-15 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly 17. Remove speedometer drive gear (16) and ball (17) from the output shaft. 18. Remove the snap ring on the bearing outer race, and then, remove the bolt for shroud.

3 4

: Bolt: 34 N-m (3.50 kgf-m) (25 lb-ft) : With lubricating oil (Engine oil or gear oil) 19. Tap output shaft (19) lightly to rear side, then remove shroud (18). 60ZV34029J

10. Place the transmission case as end cover (3) faces up. 11. Remove bolt (4), and then, remove end cover (3). 14

17 12

11 13

16 15 18

60ZV34035J

12. Place the transmission case as illustrated. 13. Remove bolt (10). 60ZV34025J

: Bolt (10): 216 N-m (22.0 kgf-m) (159 lb-ft) : Screw lock agent (Loctite® 262) application 14. Remove brake cover (11). 15. Remove bolt (12), and then, remove brake assembly (13). : Bolt (12): 53 N-m (5.40 kgf-m) (39 lb-ft) : With lubricating oil (Engine oil or gear oil) 16. Remove bolt (14), and then, remove speedometer case (15). : Bolt (14): 69 N-m (7.00 kgf-m) (51 lb-ft) : With lubricating oil (Engine oil or gear oil)

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

34-16 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission assy assembling To reassemble the transmission assembly, follow the above procedure in reverse order.

Transmission assy assembly cautions - Clean and check all the parts. If any part is worn or damaged, replace it with a new one. - Before reassembly, apply transmission oil to the parts. - Be sure to replace all O-rings and seals with new ones. - Install new bearing if replacement is needed. - When installing the oil seal, apply lithium grease to the inner lip. - When installing O-rings, apply lithium grease to the O-ring. - Apply grease into the groove of the shaft seal ring before installing the seal ring.

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

34-17 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Clutch Pack

Clutch Pack Clutch pack disassembling and assembling Clutch pack assembly cautions Reverse/1st speed clutch pack

Plate (The chamfer on the inner circumference faces to the clutch disc.) Outer race press fit Inner race press fit

Outer race press fit

1ST

Inner race press fit

Washer Groove side

60ZV34017

34-18 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Clutch Pack Forward/2nd speed clutch pack

Plate (The chamfer on the inner circumference faces to the clutch disc.) Outer race press fit Inner race press fit

2ND

Inner race press fit

Washer Groove side

60ZV34018

3rd speed clutch pack

Plate (The chamfer on the inner circumference faces to the clutch disc.) Inner race press fit Inner race press fit

3RD

60ZV34019

34-19 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Special Tools

Special Tools Tool A: Clutch shaft lifting tool mm (in) (M0.4 x 0.06) M10 x 1.5

20 C

(0.4)

176.04 0.05 (6.93±0.002)

60 (2.36)

Jig No. 1

Jig No. 2 Hexagon socket head cap screw (2 pcs)

17 (0.67) 40 00.2 0 (1.57 -0.008 )

60 (2.36)

M16 x 2 : 50 (1.97) (M0.6 x 0.08)

28 (1.10)

60 (2.36)

34 (1.34)

100 (3.94)

(t =16) (0.63)

M10 (0.4) Eye bolt

60 (2.36) 10

50 (1.97)

) .6

(0.4)

41 2

(0 C20 .7 9)

25 50 50 (1.97) (1.97) (0.98)

50 (1.97) 150 (5.91)

124 (4.88)

32.4 60 57.6 (2.27) (1.28) (2.36)

124 (4.88)

25 (0.98)

100 (3.94)

17 (0.67) 40 00.2 0 ) (1.57 -0.008

Jig No. 3

Clutch (F&2nd) assembly

Clutch (3rd) assembly

60ZV34016

34-20 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Special Tools Tool B: Clutch piston return spring snap ring remover mm (in)

85 (3.35)

65 (2.56)

5 (0.20)

360 (14.2)

72 0.5 (2.83±0.02)

40 (1.57) 79 0.5 (3.11±0.02)

60ZV34027J

34-21 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control Valve Assembly Control valve removing and installing Control valve removing

WARNING

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

Transmission control valve

60ZV34021

Transmission control valve

2. Remove bolts (2)(3) and the control valve. : Bolt (2): 34 N-m (3.5 kgf-m) (25 lb-ft) Bolt (3): 16 N-m (1.6 kgf-m) (12 lb-ft) 60ZV34020

1. Disconnect electric wiring coupler (1) for the solenoid valves on the control valve. Note Put matchmark on each coupler to avoid mis-connection when reassembling.

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

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

34-22 60ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve installation

4 5

For reinstallation, follow the above procedure in reverse order.

Control valve installation cautions - Be sure to replace all the O-rings and gaskets with new ones. 60ZV34022

3. Remove solenoid valve nut (4). 4. Remove solenoid valve (5). : Nut (4): 9.8 N-m (1.00 kgf-m) (7 lb-ft) Valve (5): 29 N-m (3.0 kgf-m) (22 lb-ft)

- Sequentially tighten the bolts in the order from the center to the outside. Apply equal (specified) torque to all the bolts. - Align the matchmarks of the electric wire couplers, and then, connect the couplers while checking that the electric wires are not tangled with each other. - During installation, be careful not to damage the gasket.

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, be sure to stop the engine, and block the tires with chocks before you start service work. During the service work, clearly communicate with the person in the cab using signals as agreed upon before hand. - At the completion of installation, start the engine, and check that the shift lever properly functions at all the positions. - Check oil leakage. - Adjust the transmission oil level to the specified point with the dipstick.

35-1 60ZV-2 Service Standard Torque Converter and Transmission Group

60ZV-2 Service Standard Torque Converter and Transmission Group Clutch Oil Pressure ................................................. 35-2

35-2 60ZV-2 Service Standard Torque Converter and Transmission Group Clutch Oil Pressure

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

35-3 60ZV-2 Service Standard Torque Converter and Transmission Group Clutch Oil Pressure

1 5 6 9 4 7 2

9 8

60ZV33001

Engine revolution (min-1) (rpm) No.

Measuring port location

Measuring port size

800

2,300

Shift lever position

Oil pressure MPa (kgf/cm ) (psi) 1

Torque converter inlet pressure

PT1/4

0.1 (1.3) (18) or more

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

All speed range

Torque converter outlet pressure

PT1/4

0.1 (1.0) (14) or more

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

All speed range

Main oil press.

PF1/4

0.8 (8) (114) or more

1.3~1.6 (13~16) (185~228)

All speed range

4 5 6 7 8 9

Clutch oil pressure

1st

PT1/4

0.8 (8) (114) or more

1.3~1.6 (13~16) (185~228)

2nd

3rd Lubricating oil pressure

1 3

PT1/8

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

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

All speed range

35-4 60ZV-2 Service Standard Torque Converter and Transmission Group

MEMO

44-1 60ZV-2 Disassembly & Reassembly Hydraulic Group

60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning ............................................................................. 44-2 Hydraulic Parts Disassembly and Assembly Cautions ............................................................................. 44-3 Hydraulic Pump Assembly ...................................... 44-4 Hydraulic Cylinder ................................................... 44-8 Pilot Valve................................................................ 44-21 Multiple Control Valve.............................................. 44-30 Orbitrol® ................................................................... 44-35 Priority Valve ........................................................... 44-46 Cushion Valve ......................................................... 44-48

44-2 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning

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

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

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

44-3 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Disassembly and Assembly Cautions

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

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

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

44-4 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic Pump Assembly Hydraulic pump assembly removing and installing

Torque converter

6 4

Hydraulic pump assembly removing

DANGER Entering the articulation area while engine is running may cause serious injury or death. So, when entering the area, stop the engine and place "DO NOT START" or "DO NOT OPERATE" tag on the steering wheel.

4 60ZV44002

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

3 5

60ZV44003

2. Disconnect outlet hose (4) and suction pipe (5) from hydraulic pump (3). Note Cover the disconnected hoses and pipe with plastic, plugs or caps to protect them from dust and dirt. 3. Attach sling to hydraulic pump (3) and remove retainer bolt (6) to remove the pump. : Bolt (6): 89.7 N-m (9.15 kgf-m) (66.2 lb-ft) : Hydraulic pump: 14 kg (31 lbs) 2

60ZV44001

1. Remove covers (1)(2).

44-5 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic pump assembly installing

IMPORTANT To reinstall the hydraulic pump assembly, follow the above removal procedure in reverse order. Replace all gaskets and O-rings during reinstallation.

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

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

- Fill the inlet port of the hydraulic pump with clean hydraulic oil and rotate the pump shaft by hand prior to installing the pump. It should rotate smoothly. Prior to installing pump and plumbing to pump, remove all caps, plugs, and covers from pump and piping. - While reinstalling the hydraulic pump, take care not to allow dust, dirt, or foreign material into the case. - Check the oil level of the hydraulic tank. - Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe. Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 L). - Run the engine at low-idling speed for 5 minutes or more. Do not operate any hydraulic functions during this period. Note If the engine speed is set to high-idling just after starting, the pump may be seized. - Actuate cylinders 5 to10 times to almost full stroke, but do not fully extend or retract any of the cylinders at this time. - Confirm that there is no abnormal noise or operation, and be sure that there is no excessive heat. Inspect the hydraulic oil at the sight gauge to be sure that there are no bubbles which may indicate air being drawn in at the suction side of the pump. If there are any bubbles, correct the cause prior to using the machine, as this may contribute to premature pump failure.

44-6 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic pump assembly disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

IMPORTANT - Handle pumps carefully. - In case hydraulic system breaks down, do not disassemble the pump first. Check the whole hydraulic circuit and find its cause. Confirm the cause, then repair. - When the pump is broken down, not only fix or replace it but also inspect the failure cause to prevent recurrence. If a pump must be repaired, be sure no pieces of damaged pump material has scatted through hydraulic system. New parts must be "broken in" and performance must be checked. Do not disassemble the pump except when necessary to replace oil seals and O-rings between the double and triple pumps which are able to be separated.

44-7 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Oil seal replacement procedure

There are two kinds of the pump drive gear shaft unit. One has one oil seal only, and the other has an additional dust seal or oil seal outside.

[Example 1] Snap ring

Oil seal

In case of example 2 1. After removing the outer oil seal, remove the snap ring and the inner oil seal. 2. When removing the oil seals, remove any scores on the front cover and the drive gear shaft. 3. Cover the drive gear shaft with vinyl electrical tape to protect the splines.

Drive gear shaft

4. Apply a thin coat of grease to the oil seal and the lip unit. 5. Install the seal straight.

Front cover

95ZV44002

[Example 2]

Front cover

Drive gear shaft

Oil seal

Snap ring 95ZV44003

44-8 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder removing and installing Boom cylinder removing (The illustration shows the left side of the machine.)

WARNING Unexpected movement of the machine, attachment, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Raise the boom until it is horizontal, and then, place stand (A) under the boom to support it. - Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Use a stepladder or work platform, and do not stand on the machine.

60ZV44113

1. Attach sling to boom cylinder (1). Remove lock bolt (2) and pin (3). Retract the cylinder to shorten piston rod (4). : Boom cylinder: 70 kg (154 lbs)

Before starting work: - Clean the area around the cylinder and piping.

60ZV44114

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

60ZV44004

Relieving residual pressure from pipe (a) Raise the boom. When the boom is approximately 30 cm (1 foot) above stand (A), stop the engine. (b) Tilt the bucket all the way down, and then, lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. (c) First press down on the hydraulic tank cap to vent residual pressure, then open the cap of the hydraulic tank. Leave hydraulic tank cap loosely on top of tank opening.

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

44-9 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Boom cylinder installing

To reinstall the boom cylinder, follow the above removal procedure in reverse order.

Boom cylinder installation cautions 1

8 60ZV44115

Be sure the pins and bushings are clean, no abnormalities observed on the surface, and accept grease after installation.

3. Remove lock bolt (7) from retainer pin (8) on the bottom side. Remove pin (8), and then, lift boom cylinder (1).

Cylinder air bleeding procedure

Note For the detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-14.

After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

IMPORTANT

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

44-10 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder removing and installing

3 5 4

Bucket cylinder removing

WARNING Unexpected movement of the machine, attachment, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving. - Lower the boom and the attachment onto the ground. - Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Use a step, and do not stand on the machine.

60ZV44009

2. Attach sling to bucket cylinder (3). After that, remove lock bolt (4) and pin (5). : Bucket cylinder: 60 kg (132 lbs) 3. Remove plate (6) for the attachment leveler.

Before starting work: - Clean the area around the cylinder and piping.

8 9

Relieving residual pressure from pipe (a) Lower the boom and the attachment onto the ground. (b) Stop the engine and move the bucket and boom levers back and forth. (c) Open the cap of the hydraulic tank to relieve the residual pressure.

3 7

60ZV44010

Bucket cylinder

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

Note Cover the disconnected hoses and the cylinder with plastic, caps or plugs to protect them from dust, water and dirt. 6 1 60ZV44008

1. Remove the coupler of attachment leveler switch (1), and then, remove bracket (2).

44-11 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder installation cautions 3

WARNING

During service work, do not stand on the machine. Standing on tire, boom or linkage may cause accidents and serious injury or death. Use a stepladder, ladder, or work platform, and do not stand on the machine. - Be sure the pins accept grease after installation. 60ZV44011

5. Disconnect the grease pipe. Remove lock bolt (10) and pull out pin (11). 6. Slowly lift up bucket cylinder (3). Lower the bucket cylinder onto the ground. For the detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-14.

- Adjust the bucket leveler so that the clearance between the switch and the rod is 5 ± 2 mm (0.196 ± 0.078 in). Refer to "Attachment Leveler" page 15-5.

Cylinder air bleeding procedure

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Bucket cylinder installing To reinstall the bucket cylinder, follow the above removal procedure in reverse order.

44-12 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder removing and installing

Rear

Steering cylinder removing

WARNING

Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent the wheels from moving. - Place the boom and the attachment onto the ground. - Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line. - Press cap downward to vent, then open the cap of the hydraulic tank to relieve the internal pressure from the tank. - Place a "DO NOT START!" tag on the steering wheel or the operator's seat. Before starting work: - Clean the area around the cylinder to be removed.

Front

3 60ZV44013

2. There is pin (5) between front chassis (3) and steering cylinder (4). Remove pin (5), and then, push piston rod (6) into the cylinder to shorten the length of the cylinder. Note Oil will be drained from the oil port of the cylinder. Place a container at the oil port to catch the drained oil. 3. Disconnect the grease pipe, and then, remove pin (7). 4. Remove steering cylinder assembly (4). Note that two persons are needed to remove and lift the assembly. : Steering cylinder: 15 kg (33 lbs)

Note For detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-14. 2

60ZV44012

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

44-13 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder installing

Steering cylinder installation cautions

To reinstall the steering cylinder, follow the above removal procedure in reverse order.

Pin installation Be sure the pins accept grease after installation.

IMPORTANT Insert shims so that the clearance between the chassis and the cylinder is 1.2 mm (0.047 in) or less. Place approximately the same number of shims under the cylinder as on top of the cylinder. Refer to "Linkage Pin Standard Clearance Values" page 15-3.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area can cause injury or death. When turning the steering wheel while engine is running, do not enter the articulation area of the machine. If a person is in the articulation area, do not start the engine.

Cylinder air bleeding procedure

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note Stop the piston about 100 mm (4.0 in) before stroking fully. (b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-14 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Hydraulic cylinder cross section and tightening torque Boom cylinder

T1 60ZV44014

: T1: 2,501 N-m (255 kgf-m) (1,845 lb-ft) T2: 863 N-m (88 kgf-m) (637 lb-ft) Bucket cylinder

T4 : T3: 2,600 N-m (265 kgf-m) (1,919 lb-ft) T4: 1,100 N-m (112 kgf-m) (810 lb-ft)

60V2U44001

44-15 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder Steering cylinder

60V2U44002

: T5: 313 N-m (32 kgf-m) (229 lb-ft) T6: 304 N-m (31 kgf-m) (224 lb-ft) T7: 6.9 N-m (0.7 kgf-m) (5 lb-ft)

Hydraulic cylinder specifications Cylinder

Piston nut width across flats mm (in)

Thread size

Boom

75 (2.95)

M48 x 1.5

Bucket

75 (2.95)

M48 x 2

Steering

41 (1.61)

M27 x 2

44-16 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

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

Wooden block 60ZV44018

2. Pull piston rod (2). Note - Make sure all ports are open. - Place an oil container under the port on the rod cover side to catch oil. 3. With the piston rod fully extended, unscrew and remove the rod cover from the cylinder tube.

Note Pull the rod horizontally on the wood blocks. Hook wrench

1 Repair stand 60ZV44035

A 2

1. Loosen rod cover (1) one or two turns with a hook wrench. Tightening torque Boom cylinder

863 N-m (88 kgf-m) (637 lb-ft)

Bucket cylinder

1,100 N-m (112 kgf-m) (810 lb-ft)

Steering cylinder

304 N-m (31 kgf-m) (224 lb-ft)

Wooden block

View A 60ZV44019

4. Install the piston rod to the repair stand.

44-17 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Screw

1 Steering cylinder Bucket cylinder

60V2U44003

60V2U44004

5. Loosen the screw and remove the piston nut. : Screw (for steering cylinder): 6.9 N-m (0.7 kgf-m) (5.0 lb-ft)

Piston nut

4 Wrench

1 Steering cylinder

Hydraulic jack

60ZV44023

7. Remove piston (4), then, remove rod cover (1) in this order from the piston rod.

Hydraulic cylinder 60ZV44021

6. The piston nut (piston) is tightened to a specified torque. About 1.5 times torque is required to loosen the nut. Use a wrench powered by a hydraulic jack or cylinder. Piston (nut) width across flats mm (in)

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

Boom cylinder

75 (2.95)

2,501 (255) (1,845)

Bucket cylinder

75 (2.95)

2,600 (265) (1,919)

Steering cylinder

41 (1.61)

313 (32) (229)

Note DO NOT let the threads damage the rod seal when removing the rod cover from the piston rod.

44-18 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

5 4 10 9 1 6

12 11

Boom cylinder

60ZV44116

60ZV44026

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

5 4 6 Bucket cylinder

60V2U44005

Hydraulic cylinder assembling To reassembling the hydraulic cylinders, follow the above removal procedure in reverse order.

4 6 5

Steering cylinder 60ZV44025

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

44-19 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder assembly cautions 1

Before starting work: - Be sure to replace all the seals and packings. - Clean and check all the parts. If any part is damaged, replace it. - Before reassembling the parts, clean and apply a coat of hydraulic oil to the parts.

Tool

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

60ZV44029

3. Push the opposite side of U-ring (11) with your fingers until the whole U-ring fits in groove (B).

Rod cover installation

Note - Use a tool (aluminum or plastic) if difficult to push with your fingers. - After inserting, push the inner circumference of the U-ring outward to check the fit in the groove.

Push

Tool

12 Push the backup ring while stretching it.

60ZV44027

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

60ZV44030

4. Immerse back-up ring (12) in hot water (30~50ºC (86~125ºF)) for two to three minutes. Install it in the rod cover while stretching it.

1 11

Note Cool down the back-up ring so that it shrinks to its original size before proceeding to the next step.

60ZV44028

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

44-20 60ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder Piston nut screw installation 9

13 Screw

Rod cover

Ball

60ZV44031

Steering cylinder

K60V2U44001

Insert the ball and screw in the screw. After tightening the screw, caulk the screw at 2points to prevent the screw coming out. Back-up ring

O-ring

: Screw (for steering cylinder): 6.9 N-m (0.7 kgf-m) (5.0 lb-ft)

Pressure side

60ZV44033

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

Press-fit tool

1 60ZV44032

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

44-21 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot Valve Pilot valve removing and installing

Pilot valve removing

4 6

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and then, block tires with chocks to prevent wheels from moving. - Apply the parking brake. - Lower the attachment onto the ground, and then, relieve the internal pressure from the line. - Relieve the internal pressure from the hydraulic tank. Before starting work: - Stop the engine and lower the attachment onto the ground. After that move the lever back and forth, left and right to relieve inner pressure from pilot line.

60ZV44037

2. Remove screw (2) and pull out boot (3) and plate (4) from the control lever. 3. Remove covers (5)(6).

1 7

8 60ZV44038

4. Remove all hoses (8) from pilot valve (7). Note - Before disconnecting the hoses, be sure to put matchmarks on them. - Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

60ZV44036

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

44-22 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve installing To reinstall the pilot valve, follow the removal procedure in reverse order.

Pilot valve installation cautions After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage. If the oil level is too low, add hydraulic oil to the tank.

60ZV44039

7 60ZV44040

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

44-23 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve cross section and tightening torque

T2 L1

Port 4 (a2) Boom down

Port 3 (a1) Bucket roll back

Port 2 (b2) Boom up

Port 1 (b1) Bucket dump

60ZV44041

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

: Pilot valve: 6 kg (13 lbs) : Apply grease when reassembling. L1: Sliding surface L2: Top of plunger

44-24 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling A 4 1

60ZV44044

60ZV44042

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

60ZV44045

3. Using jig (A)(B), turn joint (4) counterclockwise to remove it. 60ZV44043

2. Loosen adjusting nut (2) and circular plate (3) with wrenches and remove adjusting nut (2) and circular plate (3). : Adjusting nut (2): 73.5 N-m (7.5 kgf-m) (54.2 lb-ft) Width across flat: 22 mm (0.87 in) : Circular plate (3): 73.5 N-m (7.5 kgf-m) (54.2 lb-ft) Width across flat: 36 mm (1.42 in)

: (4): 50.0 N-m (5.1 kgf-m) (36.9 lb-ft) Note - Refer to the following page for the detail to remove the joint. - When reassembling, apply grease to the sliding surface.

6 –0.1

R12

C0.5

12 9.5

0.5x15

44-25 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

R5.2

23.5 (Width across flat)

C0.5

10.4 –0.1

14.5 –0.1 Material: SCM415N 1 Carburizing and quenching

Material: SCM415N Carburizing and quenching Quantity: 2

Jig (B)

2 Material: S45C

25 17

(A)

+0.2 0

X-X

+0.028 Fit tolerance: H6 +0.013 / n6 +0.015 0 Press in (1) and (2).

(B) Turn jig (A) counterclockwise.

(A)

+0.2

15 0

Jig (A)

(B) Joint

Jig (A) + (B) installation

Unit: mm

Y-Y

Detail of removing joint (4) 60ZV44117

4. Remove plate (5).

60ZV44047

44-26 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

6 9 8

7 6

8 60ZV44048

60ZV44118

5. Loosen bolt (6) with the hexagon (allen) wrench and remove plate (7).

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

Hexagon wrench width across flat: 5 mm (0.2 in) Note At this time detent casing (8) is lifted by inner spring force. Be careful not to fly up and strike someone.

: Bolt (6): 13.3 N-m (1.36 kgf-m) (9.8 lb-ft) 11 9

60ZV44051

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

11 60ZV44049

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

60ZV44052

9. Remove spring seat (11) using pliers.

44-27 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Screw driver

13 15 12

60ZV44053

60ZV44055

10. Loosen bolt (12) with the hexagon (allen) wrench and remove it.

12. Put a driver into the groove of plug (15) and pull out plug (15) from casing (16).

Hexagon wrench width across flat: 5 mm (0.2 in)

Note - Be careful not to damage surfaces around the groove of the plug. - Carefully place all plugs, springs and reducing valve spools in the order it was removed so as to assemble them into the casing port. Refer to the following figures and table.

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

[Difference in reducing valve] OUTSIDE

14 Port 1 (Bucket dump)

Port 4 (Boom down)

(T)

16 FRONT

41 T P 32

REAR Port 2 (Boom raise)

(P)

Port 3 (Bucket roll over)

60ZV44054

11. Remove plate (13).

INSIDE Oil port (view from top)

Parts

60ZV44119

Port No. 1~3

Spring (1)

None

1 pc

Spring seat (2)

None

1 pc

Return spring (3)

1 pc

2 pcs

Spring seat (4)

1 pc

2 pcs

Washer (5)

None

1 pc

44-28 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

2 4 3

60ZV44058

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

Port 4 (a2)

Port 3 (a1)

A-A

60ZV44120

21 60ZV44059

15. Disassembling reducing valve

(a) Stand the bottom of the spool straight on the working table. Push down spring seat (20) and remove washer set (1 semicircle, 2 pcs.) (21) using the head of a small screw driver.

17 16

60ZV44057

13. Fix casing (16) in a vice so that port board (17) faces up. Loosen bolt (18) with the hexagon (Allen) wrench. Hexagon wrench width across flat: 6 mm (0.24 in) : Bolt (18): 32.3 N-m (3.3 kgf-m) (23.9 lb-ft)

Note - Be careful not to damage the spool surface. - Do not press down spring seat (20) more than 6 mm (0.24 in).

44-29 60ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

20 23 24 22

60ZV44060

60ZV44062

(b) Disconnect spool (22), spring seat (20), spring(23) and washer (24).

16. Remove solenoid sub (28) from detent casing (8). Note When removing the solenoid sub, do not pull the electrical harness.

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

Pilot valve assembling

To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

Pilot valve assembly cautions

14 60ZV44061

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

Plug (15) Seal (29)

Push rod

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

Apply hydraulic oil

60ZV44063

When reassembling seal (29) into plug (15), be careful about the direction of lip of seal (29).

44-30 60ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple Control Valve Multiple control valve removing and installing Multiple control valve removing

WARNING Unexpected movement of the machine, attachment, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground. - Apply the parking brake. In addition, block the tires with chocks to prevent the wheels from moving. - Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Remove the engine key, and hang a “DO NOT START ENGINE!” tag on the steering wheel.

Multiple control valve

2 60ZV44065

2. Disconnect pump port hose (2) to the multiple control valve and tank port hose (3). Note Cover the disconnected hoses with plastic, plugs or caps to protect them from dust and dirt.

Before starting work: - Release residual pressure in the pilot line, loading line and tank. 5

1 Multiple control valve

60ZV44066

Multiple control valve

60ZV44064

1. Put matchmarks on hoses (1) of the pilot line, and then, disconnect them. Note Cover the disconnected hoses with plastic, cap or plug to protect them from dust, water and dirt.

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

44-31 60ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve installing

6 Multiple control valve

To reinstall the multiple control valve, follow the above removal procedure in reverse order.

Multiple control valve installation cautions

WARNING 6

60ZV44067

4. Remove four retainer bolts (6) from the multiple control valve, and then, remove multiple control valve. : Bolt (6): 94 N-m (9.6 kgf-m) (69 lb-ft) : Multiple control valve: 20 kg (44 lbs)

Unexpected movement of the machine may cause serious injury or death. To prevent such an accident, be sure to stop the engine before you start working. In addition, block tires with chocks to prevent wheels from moving. While working, carefully keep contact with the person in the cab by giving signals to each other. - Replace all the O-rings with new ones. - Wash the multiple control valve mounting area. - Attach the pressure gauge, and then, start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the 60ZV-2 Shop Manual, Function & Structure, Section 03. - Operate the attachment and the boom, and check that they operate correctly. - Check each section for oil leakage. - Add hydraulic oil to the tank until the oil level rises to the specified point.

44-32 60ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Multiple control valve cross section and tightening torque

Inlet section

T1 Bucket spool

T5 T

Pa1

Pb1

Pb2

Pa2 B2

C T1 T1

Boom spool

T3 B

A-A D-D B

Load check valve B

T4 Pb

Pa Pb

T5 L1

T4 C-C

B-B

60ZV44121

: T1: 78 N-m (8.0 kgf-m) (58 lb-ft) T2: 353 N-m (36.0 kgf-m) (260 lb-ft) T3: 34 N-m (3.5 kgf-m) (25 lb-ft) T4: 113 N-m (11.5 kgf-m) (83 lb-ft) T5: 18 N-m (1.8 kgf-m) (13 lb-ft)

: L1: Screw lock agent (Loctite 262) application : 21 kg (46 lbs)

44-33 60ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling

[Disassembling bucket spool section]

1 4

8 2

9 12

14 60ZV44070

3. Pull out O-ring (12), spring (13) and poppet (14) from the mating face.

20 11 16

3 7 6 60ZV44069

1. Remove main relief valve (1), overload relief valve (2) and make-up valve (3).

18 19

15 60ZV44071

: Valve (1)~(3): 88 N-m (9.0 kgf-m) (65 lb-ft) 4. Remove bolt (15) to remove cap (16)(17). 2. Remove nut (4)(5) from tie rod (6)(7), and then, pull out inlet section (8), bucket spool section (9), boom spool section (10) and outlet section (11) as an assembly. Note The poppet, spring and O-ring of the load check valve are at mating face. Carefully pull out each assembly so that they are not damaged or distorted.

: Bolt (15): 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) 5. Pull out spool (19) with cap screw (18) from valve housing (20). Note Carefully pull out the spool so that it is not scratched or damaged. Be sure to keep direction and placement of spool as it was originally.

44-34 60ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

(1.18~1.57) 30~40 7.8~9 (0.31~0.35)

mm (in)

Multiple control valve assembling

70~100 (2.76~3.94)

To reassemble the multiple control valve, follow the above removal procedure in reverse order.

Multiple control valve assembly cautions - When tightening each section with the tie rod, work on a flat plate or table. 60V2U44011

- Clean and check all the parts. If a part is defective, replace or repair it. - Replace all the O-rings with new ones. - Apply a thin coat of hydraulic oil or grease to each part before reassembly. - Apply the specified torque to tighten each main part.

18 23

60ZV44110

6. Insert spool (19) between wooden blocks (21) so that the periphery of the spool is not damaged, and set it in a vise. Loosen cap screw (18) and remove spring seat (22) and spring (23). : Screw (18): 7.8 N-m (0.8 kgf-m) (5.8 lb-ft) : Screw lock agent (Loctite® 262) application Note Screw lock is applied to the thread of cap screw (18) and so heat the periphery of the thread to 200~250ºC (392~482ºF) to remove it. In case that the thread of cap screw is overheated, replace spring (23) with new one.

44-35 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® Orbitrol® removing and installing Orbitrol® removing

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and lower the attachment onto the ground. - Block tires with chocks to prevent wheels from moving. - Apply the articulation stopper. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat. - Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right. - Relieve the internal pressure from the hydraulic tank. Note This work should be done by two persons. One person should support the Orbitrol® under the machine. The person in the cab should remove the retainer bolt.

1 2

60ZV44035J

1. Remove cover (2) from steering tilt case (1). Remove the floor mat.

44-36 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® installing

To reinstall the Orbitrol®, follow the above removal procedure in reverse order.

5 7

Orbitrol® installation cautions At the completion of reinstallation, start the engine and check around the Orbitrol® for oil leakage.

3 4

60ZV44036J

WARNING ®

2. Put matchmarks on the hoses from Orbitrol (3). Remove pump port hose (4), cylinder port hose (5), tank hose port (6) and LS port hose (7) from Orbitrol® (3). Note Cover the disconnected hoses with plastic, plugs or caps to protect them from dust and dirt.

60ZV44037J

3. Remove bolt (8), and then, remove Orbitrol® (3). : Bolt (8): 29 N-m (3.0 kgf-m) (22 lb-ft) : Orbitrol®: 5 kg (10 lbs)

44-37 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Orbitrol® cross section and tightening torque

Centering springs

Push spool

O-ring Plate

Check value Sleeve

O-ring

Make-up valve

Ball

Needle bearing Housing

O-ring

Seal unit

Spacer

Overload relief valve

End cap

Rotor assembly Drive shaft Retainer 60V2U44007

: Bolt (1)(2): 28 N-m (2.9 kgf-m) (21 lb-ft)

44-38 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® disassembling 1

(Disassembling rotor)

5 2

Make matchmarks before disassembling unit.

25 (1 m m in)

3 4

Housing 60ZV44106

3. Remove end cap (3), O-ring (4) and spacer (5).

Copper plate 60ZV44123

1. Set the Orbitrol® in a vise so that the rotor side comes to the top position. Use a copper plates on a vise and do not tighten the vise too strong. 6

1 60ZV44081

4. Remove rotor assembly (6) and O-ring (7).

Note Keep rotor (8) in rotor assembly (6). 60ZV44079

2. Remove six bolts (1) and one retainer bolt (2). Note The make-up valve installed in the housing is tightened with bolts (A). When removing the bolts, take care not to drop the make-up valve.

10 9 11 60ZV44082

5. Remove drive shaft (9), spacer plate (10) and Oring (11).

44-39 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

13 12 18 16 15 14

60ZV44083

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

60ZV44085

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

(Disassembling valve) 18

60ZV44086

17 60ZV44084

7. Remove retainer ring (17) with a screw driver. Note Carefully remove the retainer ring so that it does not spring out.

9. Remove Y-packing seal (19) and dust seal (20) from seal retainer (18). Note Take care not to damage seal retainer (18).

44-40 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Spool / sleeve assembly

25 24

Matchmark

60ZV44087

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

60ZV44089

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

Housing

27 26 Spool / sleeve assembly

60ZV44088

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

60ZV44090

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

60ZV44091

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

44-41 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® assembling (Reassembling valve)

Spring groove

31 26

28 27 Spring groove Overload relief valve units

70V2E44018

15. Remove plug (27) to remove O-ring (28) from the plug using a hexagon (allen) wrench (width across flat: 0.2 in). Take out spring (29), poppet (30) and seat (31) (2 places).

Matchmark 60ZV44094

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

25 27

60ZV44093

Note Inlet check valve (32) built in port P is connected with the housing and cannot be removed. 26 60ZV44095

2. Install centering springs (27) through the spring grooves in spool (25) and sleeve (26) using a spring insertion jig. Note Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

44-42 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

26 21

23 25 24

Matchmark 60ZV44096

60ZV44098

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

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

Housing

Spool / sleeve assembly 60ZV44086 60ZV44097

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

6. Insert dust seal (20) and Y-packing seal (19) in seal retainer (18).

18 25

60ZV44099

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

44-43 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (Reassembling rotor) Screw driver Dust seal Retainer ring 25 ( 1 mm in )

Seal retainer Y-packing seal O-ring Housing

Plate 60V2U44009

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

Overload relief valve units

27 28 29

60ZV44102

9. Set the Orbitrol® in a vise so that the rotor side comes to the top position. Use a copper plates on a vise and do not tighten the vise too strong.

30 31 14

Housing

15 16

11 12 13

70V2E44019

8. Insert O-ring (28) in plug (27). Apply grease to poppet (30) and install seat (31). Insert ball poppet (30) and spring (29) into the housing, and then, insert plug (27) using the hexagon wrench (width across flat: 0.2 in).

60ZV44103

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

44-44 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Grooves in rotor bore

Port face

9 Drive shaft

Parallelize with port face

Port face

60ZV44111

11. Insert drive shaft (9) to mate its yoke with pin (24). Rotate the spool and sleeve so that the pin (24) can be parallel with the port face. Note Put a matchmark on the end face of the drive shaft parallel with the pin.

95ZV44029

13. Holding the rotor assembly with the O-ring side facing the spacer plate, install the assembly so that the grooves in the star-shaped bore mesh with the drive shaft. Note - Align the bolt holes in the rotor assembly with those in the housing without disengaging the drive shaft from the rotor assembly's star -shaped bore. - Confirm that lines A, B, C and D are all parallel.

6 1 5 2

3 60ZV44105

12. Put O-ring (7) in rotor assembly (6). 60ZV44106

14. Install spacer (5), O-ring (4) and end cap (3). Provisionally tighten bolt (1) and retainer screw (2). Note Insert retainer screw (2) to the hole where the ball of the emergency check valve is inserted to. : Provisional tightening torque: 15 N-m (1.5 kgf-m) (11 lb-ft) Tightening torque: 28 N-m (2.9 kgf-m) (21 lb-ft)

44-45 60ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

2 3

7 5 60ZV44112

15. Evenly tighten the seven bolts in the order shown above.

44-46 60ZV-2 Disassembly & Reassembly Hydraulic Group Priority Valve

Priority Valve Priority valve removing and installing

Priority valve removing

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and lower the attachment onto the ground. - Block tires with chocks to prevent wheels from moving. - Apply the articulation stopper. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat. - Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right. - Relieve the internal pressure from the hydraulic tank. Before starting work: - Release residual pressure in the loading and steering lines.

5 60ZV44075

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

Priority valve installing To reinstall the priority valve, follow the above removal procedure in reverse order.

1 4

3 60ZV44074

1. Disconnect hose (2) from the pump, and hose (3) to the multiple control valve, and drain hose (4). Note Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

44-47 60ZV-2 Disassembly & Reassembly Hydraulic Group Priority Valve

Priority valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Priority valve cross section and tightening torque

1 3

50ZV44011A

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

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

44-48 60ZV-2 Disassembly & Reassembly Hydraulic Group Cushion Valve

Cushion Valve Cushion valve removing and installing Cushion valve removing

WARNING Unexpected movement of the machine, attachment, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent the wheels from moving. - Relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. - Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel. Before starting work: - Release residual pressure in the loading and steering lines.

3 K60V2U44003

2. Remove retainer bolt (3) to remove cushion valve (1). : Cushion valve: Approx. 4 kg (9 lbs)

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

FRONT

1 Floor board

K60V2U44002

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

44-49 60ZV-2 Disassembly & Reassembly Hydraulic Group Cushion Valve

Cushion valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Cushion valve cross section and tightening torque

A A B-B

T3 L1

A T2

T2 A A-A

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

60ZV44109

44-50 60ZV-2 Disassembly & Reassembly Hydraulic Group

MEMO

45-1 60ZV-2 Service Standard Hydraulic Group

60ZV-2 Service Standard Hydraulic Group Pilot Valve................................................................ 45-2 Hydraulic Cylinder ................................................... 45-4

45-2 60ZV-2 Service Standard Hydraulic Group Pilot Valve

Pilot Valve

60ZV45004

45-3 60ZV-2 Service Standard Hydraulic Group Pilot Valve

Judgment standard No.

Item

Solution Lever position

Allowable limit

Neutral

1,200 cm3/min or more

Leak quantity 1

Replacement of valve assembly

< Measuring conditions > Primary pressure: 3.5 MPa (36 kgf/cm2) (512 psi) Hydraulic oil: VG46 Oil temperature: 60ºC (140ºF)

Operation

2,400 cm /min or more

Judgment standard No.

Item

Solution Standard dimension

Wear limit

61 mm (2.4016 in) Length of push rod

1 mm (0.0394 in) or more

Replacement

6 mm (0.2362 in)

0.5 mm (0.0197 in) or more

Replacement of solenoid sub assembly

—

2 mm (0.0787 in) or more

Replacement of related parts (disc, joint, etc.)

36 mm (1.4173 in)

Inner diameter of solenoid bushing

Adjusting nut wear (upper part)

45-4 60ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder

4 1

5 60ZV45001

mm (in) Judgment standard No.

Item

Solution Standard dimension

Standard clearance

Limit

Clearance between cylinder rod and bushing

ø65 (ø2.5590)

0.100~0.250 (0.0039~0.0098)

0.5 (0.0197)

Replacement

Clearance between pin and inner diameter of pin hole

ø60 (ø2.3622)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

Clearance between pin and bushing

ø60 (ø2.3622)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

No.

Item

Judgment standard

Solution

Rod cover bolt tightening torque

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

863 (88) (637)

Tightening

Piston nut tightening torque

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

2,501 (255) (1,845)

Tightening

Piston nut width across flat

mm (in)

75 (2.95)

—

45-5 60ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder Bucket cylinder 1

4 60V2U45001

mm (in) Judgment standard No.

Item

Solution Standard dimension

Standard clearance

Limit

Clearance between cylinder rod and bushing

ø60 (ø2.3622)

0.100~0.250 (0.0039~0.0098)

0.5 (0.0197)

Replacement

Clearance between piston rod pin and bushing

ø50 (ø1.9685)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

Clearance between bottom pin and bushing

ø60 (ø2.3622)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

No.

Item

Judgment standard

Solution

Rod cover bolt tightening torque

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

1,100 (112) (810)

Tightening

Piston nut tightening torque

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

2,600 (265) (1,919)

Tightening

Piston nut width across flat

mm (in)

75 (2.95)

—

45-6 60ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder Steering cylinder

4 60V2U45002

mm (in) Judgment standard No.

Item

Solution Standard dimension

Standard clearance

Limit

Clearance between cylinder rod and bushing

ø40 (ø1.5748)

0.080~0.205 (0.0031~0.0081)

0.5 (0.0197)

Replacement

Clearance between piston rod pin and bushing

ø35 (ø1.3780)

0.080~0.205 (0.0031~0.0081)

1.0 (0.0393)

Replacement

Clearance between bottom pin and bushing

ø35 (ø1.3780)

0.080~0.205 (0.0031~0.0081)

1.0 (0.0393)

Replacement

No.

Item

Rod cover bolt tightening torque

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

Piston tightening torque

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

Piston width across flat

mm (in)

Judgment standard

Solution

304 (31) (224)

Tightening

313 (32) (229)

Tightening

41 (1.61)

—

54-1 60ZV-2 Disassembly & Reassembly Brake Group

60ZV-2 Disassembly & Reassembly Brake Group Hydraulic Servo Master ........................................... 54-2 Service Brake .......................................................... 54-7 Parking Brake.......................................................... 54-8

54-2 60ZV-2 Disassembly & Reassembly Brake Group Hydraulic Servo Master

Hydraulic Servo Master Hydraulic servo master removing and installing Hydraulic servo master removing

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

60ZV54002

2. Loosen locknut (4) to remove rod (5) from hydraulic servo master (1).

6 60ZV54003J

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

Note - Bend and hold the end of the hose from the brake oil tank to protect oil leakage. - Cover the disconnected hoses and pipes with plastic, plugs or caps to protect them from dust and dirt.

60ZV54001J

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

54-3 60ZV-2 Disassembly & Reassembly Brake Group Hydraulic Servo Master

Hydraulic servo master installing 1

To reinstall the unloader valve, follow the above removal procedure in reverse order.

Hydraulic servo master installation cautions

8 60ZV54004J

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

11 60ZV54005J

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

- After reinstallation, completely bleed the brake line of air, and check all the pipe-joints and hoses for oil leakage. To bleed the brake line of air, refer to "Service brake air bleeding procedure" page 24-17. - To check or adjust the service brake linkage, refer to the 60ZV-2 Shop Manual, Function and Structure, Section 53.

54-4 60ZV-2 Disassembly & Reassembly Brake Group Hydraulic Servo Master

Hydraulic servo master disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Hydraulic servo master cross section and tightening torque

T3 60ZV54006J

: T1: 32.4 N-m (3.3 kgf-m) (23.8 lb-ft) T2: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T3: 12.7 N-m (1.3 kgf-m) (9.4 lb-ft)

54-5 60ZV-2 Disassembly & Reassembly Brake Group Hydraulic Servo Master

Hydraulic servo master disassembling 6

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

1 5 60ZV54009J

3. While pushing cylinder cover (5), remove C-ring (6). Remove cylinder cover (5). 2

3 60ZV54007J

Note Be careful that cylinder cover (5) is pushed out by the spring.

1. Loosen bolt (1) and separate hydraulic servo (2) and master cylinder (3).

12 13

: Bolt (1): 32.4 N-m (3.3 kgf-m) (23.8 lb-ft) [ Hydraulic servo section ]

8 7

10 11

60ZV54010J

4. Remove power piston (7) together with spool (8) and connector (9). Remove spring seats (10)(11) and springs (12)(13).

60ZV54008J

2. Remove dust cover (4).

54-6 60ZV-2 Disassembly & Reassembly Brake Group Hydraulic Servo Master [ Master cylinder section ] 14 7

17 9 60ZV54011J

5. Remove power piston (7). Remove C-ring (14) to separate spool (8) and connector (9). Remove spacer (15), spring (16) and rod (17). : Set screw: 15 N-m (1.5 kgf-m) (11 lb-ft)

22 60ZV54013J

7. Remove C-ring (23) from master cylinder body (22). Pull out secondary piston assembly (24). 8. Remove stopper bolt (25) and pull out primary piston assembly (26).

19 18

: Stopper bolt (25): 12.7 N-m (1.3 kgf-m) (9.4 lb-ft) Note Do not disassemble the primary piston and the secondary piston, which are both functionally important parts. (If necessary, replace them with their respective repair kits.)

60ZV54012J

6. Record the height of plug (18) before removing set screw (19). Remove set screw (19) and plug (18), and then, remove spring (20) and valve (21).

Hydraulic servo master assembling To reassemble the hydraulic servo master, follow the above disassembly procedure in reverse order.

54-7 60ZV-2 Disassembly & Reassembly Brake Group Service Brake

Service Brake Service brake disassembling and assembling Refer to "Front axle disassembling and assembling" page 24-18 for the procedures.

54-8 60ZV-2 Disassembly & Reassembly Brake Group Parking Brake

Parking Brake Parking brake removing and installing / disassembling and assembling Parking brake removing and disassembling 5

WARNING When removing the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park the machine on level ground. - Lower the attachment onto the ground, and block the tires with chocks to prevent them from moving. - Apply the articulation stopper. - Remove the engine key, and hang a “DO NOT START Engine!” tag on the steering wheel.

4 60ZV54019

3. Remove bolts (5) of propeller shaft (4). : Bolt (5): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application

1. Drain the transmission oil.

Brake lever 42T

8 9 6

Control cable

2 60ZV54020

Parking brake assembly Transmission assy 60ZV54018

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

4. Remove bolt (6), and then, remove flange yoke (7) and brake drum (8) all together. If necessary, remove bolt (9) to disconnect flange yoke (7) and brake drum (8). : Bolt (6): 216 N-m (22 kgf-m) (159 lb-ft) : Screw lock agent (Loctite® 262) application : Bolt (9): 34.5 N-m (3.5 kgf-m) (25 lb-ft)

54-9 60ZV-2 Disassembly & Reassembly Brake Group Parking Brake

42T

11 60ZV54021

60ZV54023

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

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

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

13 16 17

60ZV54024 60ZV54022

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

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

54-10 60ZV-2 Disassembly & Reassembly Brake Group Parking Brake

Parking brake installing and assembling To reinstall and reassemble the parking brake, follow the above removal and disassembly procedure in reverse order. 18 19

60ZV54025

60ZV54026

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

Note To adjust and check performance of the parking brake, refer to the 60ZV-2 Shop Manual, Function & Structure, Section 53.

55-1 60ZV-2 Service Standard Brake Group

60ZV-2 Service Standard Brake Group Hydraulic Servo Master ........................................... 55-2 Service Brake .......................................................... 55-3 Parking Brake.......................................................... 55-4 Brake Pedal Linkage ............................................... 55-5

55-2 60ZV-2 Service Standard Brake Group Hydraulic Servo Master

Hydraulic Servo Master 6

3 4

11 12

10 60ZV55001J

mm (in) Judgment standard No.

Item

Tolerance

Standard value

Axis

Bore

Standard clearance

Allowable clearance

Clearance between body and connector

ø22.4 (0.8819)

-0.020 (-0.0008) -0.053 (-0.0021)

+0.033 (+0.0013) 0 (0)

0.020~0.086 (0.0008~0.0034)

0.096 (0.0038)

Clearance between spool and cylinder cover bushing

ø22.4 (0.8819)

-0.020 (-0.0008) -0.053 (-0.0021)

+0.033 (+0.0013) 0 (0)

0.020~0.086 (0.0008~0.0034)

0.096 (0.0038)

Clearance between spool and connector

ø22.4 (0.8819)

-0.020 (-0.0008) -0.053 (-0.0021)

+0.033 (+0.0013) 0 (0)

0.020~0.086 (0.0008~0.0034)

0.096 (0.0038)

Clearance between spool and connector

ø14 (0.5512)

-0.040 (-0.0016) -0.073 (-0.0029)

+0.052 (+0.0020) 0 (0)

0.040~0.125 (0.0016~0.0049)

0.138 (0.0054)

Clearance between connector and rod

ø8 (0.3150)

-0.200 (-0.0079) -0.250 (-0.0098)

+0.250 (+0.0098) +0.200 (+0.0079)

0.040~0.500 (0.0016~0.0120)

0.515 (0.0203)

Clearance between body and valve

ø14 (0.5512)

-0.030 (-0.0012) -0.050 (-0.0020)

+0.073 (+0.0029) +0.030 (+0.0012)

0.060~0.123 (0.0024~0.0048)

0.132 (0.0052)

Clearance between body and power piston

ø70 (2.7559)

-0.060 (-0.0024) -0.106 (-0.0042)

+0.074 (+0.0029) 0 (0)

0.060~0.180 (0.0024~0.0071)

0.198 (0.0078)

Clearance between body and primary piston

ø41.3 (1.6260)

-0.025 (-0.0010) -0.064 (-0.0025)

+0.062 (+0.0024) 0 (0)

0.025~0.126 (0.0010~0.0050)

0.141 (0.0056)

Clearance between body and secondary piston

ø41.3 (1.6260)

-0.025 (-0.0010) -0.064 (-0.0025)

+0.062 (+0.0024) 0 (0)

0.025~0.126 (0.0010~0.0050)

0.141 (0.0056)

No.

Item

Standard value

Solution

Replacement

Allowable limit

Spring free length mm (in)

Installed length mm (in)

Installed load N (kgf) (lbf)

Spring

46.2 (1.82)

40 (1.57)

98.1 (10) (22.1)

83.4 (8.5) (18.7)

Spring

143.75 (5.66)

80.25 (3.16)

196 (20) (44.1)

167 (17) (37.5)

Spring

199.2 (7.84)

86 (3.39)

294 (30) (66.1)

250 (25.5) (56.2)

Spring

55 (2.17)

47.5 (1.87)

128 (13.1) (28.8)

109 (11.1) (24.5)

Solution

Replacement

55-3 60ZV-2 Service Standard Brake Group Service Brake

Service Brake

Differential gear 60ZV55002

Unit: mm (in) Judgment standard No.

Item

Solution Standard dimension

Tolerance

Wear limit

Thickness

6.0 (0.2362)

0 (0) ~ -0.2 (-0.0078)

5.5 (0.2165)

Distortion

—

0.3 (0.0118) or more

8.7 (0.3425)

±0.15 (±0.0059)

7.5 (0.2953)

0.4 (0.0157) or more

—

Thickness of lining (both sides)

1.7 (0.0670)

0.1 (0.0039) or less

—

Thickness of brake backing plate

27.5 (1.0827)

0 (0) ~ -0.1 (-0.0039)

27.1 (1.0669)

Steel plate Thickness of friction plate

Replacement 2

Depth of lining groove

55-4 60ZV-2 Service Standard Brake Group Parking Brake

Parking Brake

3 60ZV55003

Unit: mm (in) No. 1

Item

Judgment standard Standard dimension

Wear limit

5.1 (0.2008)

1.0 (0.0394) from the rivet head

Wear of lining

Lining inspection

Expansion of adjuster spring

Expansion of return spring

Grease or oil on the lining There is a clearance between the spring and the coil when the spring is released.

Solution

Replacement

55-5 60ZV-2 Service Standard Brake Group Brake Pedal Linkage

Brake Pedal Linkage

Adjusting bolt

Lock nut

218 05 mm (8.58 in)

Brake pedal assembly

Right brake pedal rod

Hydraulic servo master

Standard thread engagement Minimum: 9 mm (0.35 in)

16.5 mm (0.65 in)

Elbow joint

Standard thread engagement Minimum: 11 mm (0.43 in)

16 mm (0.63 in) Lock nut Elbow joint

Lock nut

115 mm (4.528 in)

K60V2U55001

55-6 60ZV-2 Service Standard Brake Group

MEMO

INDEX A Air Cleaner ......................................................................24-11 Air cleaner installation cautions ......................................24-12 Air cleaner installing ........................................................24-11 Air cleaner removing .......................................................24-11 Air cleaner removing and installing .................................24-11 Applying and Storing Articulation Stopper ......................00-13 Applying articulation stopper ...........................................00-13 Attachment Leveler ...........................................................15-5 Attachment leveler ............................................................15-6 Attachment leveler adjustable angle .................................15-7 Axle and Differential Service Standard .............................25-3 Axle assembly ...................................................................25-3 Axle Support ...................................................................24-32 Axle support assembling .................................................24-32 Axle support assembly cautions .....................................24-32 Axle support disassembling ............................................24-32 Axle support disassembling and assembling ..................24-32

Cushion valve cross section and tightening torque ........ 44-49 Cushion valve disassembling and assembling ............... 44-49 Cushion valve installing .................................................. 44-48 Cushion valve removing ................................................. 44-48 Cushion valve removing and installing ........................... 44-48

D Differential ........................................................................ 25-4 Differential Assembly ...................................................... 24-33 Differential assembly disassembling .............................. 24-35 Differential assy assembling ........................................... 24-36 Differential assy disassembling and assembling ............ 24-35 Differential cage assembling .......................................... 24-42 Differential cage assembly cautions ............................... 24-42 Differential cage disassembling ...................................... 24-42 Differential cage disassembling and assembling ........... 24-42 Differential pinion assembling ........................................ 24-45 Differential pinion disassembling .................................... 24-43 Differential pinion disassembling and assembling .......... 24-43

B Bolt Tightening Torque .....................................................00-4 Boom ..............................................................................14-12 Boom cylinder installation cautions ...................................44-9 Boom cylinder installing ....................................................44-9 Boom cylinder removing ...................................................44-8 Boom cylinder removing and installing .............................44-8 Boom installation cautions ..............................................14-14 Boom installing ...............................................................14-14 Boom removing ...............................................................14-12 Boom removing and installing .........................................14-12 Brake Pedal Linkage .........................................................55-5 Bucket cylinder installation cautions ...............................44-11 Bucket cylinder installing ................................................44-11 Bucket cylinder removing ................................................44-10 Bucket cylinder removing and installing ..........................44-10

C Cab ...................................................................................14-7 Cab installing ....................................................................14-8 Cab removing ...................................................................14-7 Cab removing and installing .............................................14-7 Cautions regarding parts removal .....................................00-9 Cautions regarding reassembly ........................................00-9 Cautions Regarding Welding Repair Service .................00-11 Center Pin ............................................................. 14-15, 15-4 Center pin shim adjustment .................................. 14-15, 15-4 Clutch Oil Pressure ...........................................................35-2 Clutch Pack .....................................................................34-17 Clutch pack assembly cautions ......................................34-17 Clutch pack disassembling and assembling ...................34-17 Control Valve Assembly ..................................................34-21 Control valve installation .................................................34-22 Control valve installation cautions ..................................34-22 Control valve removing ...................................................34-21 Control valve removing and installing .............................34-21 Cushion Valve .................................................................44-48

E Engine .............................................................................. 24-6 Engine installation cautions .............................................. 24-8 Engine installing ............................................................... 24-8 Engine removing .............................................................. 24-6 Engine removing and installing ........................................ 24-6 Engine Room .................................................................... 14-6 Engine room installing ...................................................... 14-6 Engine room removing ..................................................... 14-6 Engine room removing and installing ............................... 14-6

F Floor Board ....................................................................... 14-9 Floor board installation cautions ..................................... 14-11 Floor board installing ...................................................... 14-11 Floor board removing ....................................................... 14-9 Floor board removing and installing ................................. 14-9 Front axle assembling .................................................... 24-21 Front Axle Assembly ...................................................... 24-14 Front axle assembly installation cautions ....................... 24-16 Front axle assembly installing ........................................ 24-16 Front axle assembly removing ....................................... 24-15 Front axle assembly removing and installing ................. 24-15 Front axle assembly tightening torque ........................... 24-14 Front axle disassembling ................................................ 24-18 Front axle disassembling and assembling ..................... 24-18 Front differential tightening torque .................................. 24-33 Fuel Tank ......................................................................... 14-2 Fuel tank installation cautions .......................................... 14-3 Fuel tank installing ............................................................ 14-3 Fuel tank removing ........................................................... 14-2 Fuel tank removing and installing ..................................... 14-2

H Hose Band Tightening Torque ......................................... 00-8 How to wind a seal tape ................................................. 00-10 Hydraulic Cylinder ................................................... 44-8, 45-4 Hydraulic cylinder assembling ........................................ 44-18 Hydraulic cylinder assembly cautions ............................ 44-19 Hydraulic cylinder cross section and tightening torque .................................................................................... 44-14 Hydraulic cylinder disassembling ................................... 44-16 Hydraulic cylinder disassembling and assembling ......... 44-14 Hydraulic parts assembly cautions ................................... 44-3 Hydraulic Parts Disassembly and Assembly Cautions ...................................................................................... 44-3 Hydraulic parts disassembly cautions .............................. 44-3 Hydraulic Parts Removal and Installation Warning .......... 44-2 Hydraulic Pump Assembly ............................................... 44-4 Hydraulic pump assembly disassembling and assembling ..................................... 44-6 Hydraulic pump assembly installing ................................. 44-5 Hydraulic pump assembly removing ................................ 44-4 Hydraulic pump assembly removing and installing .......... 44-4 Hydraulic pump installation cautions ................................ 44-5 Hydraulic Servo Master ........................................... 54-2, 55-2 Hydraulic servo master assembling ................................. 54-6 Hydraulic servo master cross section and tightening torque .............................. 54-4 Hydraulic servo master disassembling ............................. 54-5 Hydraulic servo master disassembling and assembling ..................................... 54-4 Hydraulic servo master installation cautions .................... 54-3 Hydraulic servo master installing ...................................... 54-3 Hydraulic servo master removing ..................................... 54-2 Hydraulic servo master removing and installing ............... 54-2 Hydraulic Tank ................................................................. 14-4 Hydraulic tank installation cautions .................................. 14-5 Hydraulic tank installing .................................................... 14-5 Hydraulic tank removing ................................................... 14-4 Hydraulic tank removing and installing ............................. 14-4

L Liner clearance adjustment .............................................. 15-3 Linkage ............................................................................. 15-2 Linkage Pin Standard Clearance Values .......................... 15-3 Liquid Gasket and Screw Lock Agent .............................. 00-9

M Measuring clutch oil pressure ........................................... 35-2 Muffler ............................................................................ 24-13 Muffler installation cautions ............................................ 24-13 Muffler installing ............................................................. 24-13 Muffler removing ............................................................. 24-13 Muffler removing and installing ....................................... 24-13 Multiple Control Valve .................................................... 44-30 Multiple control valve assembling ................................... 44-34 Multiple control valve assembly cautions ....................... 44-34 Multiple control valve cross section and tightening torque ............................ 44-32 Multiple control valve disassembling .............................. 44-33

Multiple control valve disassembling and assembling ....................................................................................44-32 Multiple control valve installation cautions ......................44-31 Multiple control valve installing .......................................44-31 Multiple control valve removing ......................................44-30 Multiple control valve removing and installing ................44-30

O Oil seal replacement procedure ........................................44-7 Orbitrol® ..........................................................................44-35 Orbitrol® assembling .......................................................44-41 Orbitrol® cross section and tightening torque .................44-37 Orbitrol® disassembling ..................................................44-38 Orbitrol® disassembling and assembling ........................44-37 Orbitrol® installation cautions ..........................................44-36 Orbitrol® installing ...........................................................44-36 Orbitrol® removing ..........................................................44-35 Orbitrol® removing and installing ....................................44-35

P Parking Brake ......................................................... 54-8, 55-4 Parking brake installing and assembling ........................54-10 Parking brake removing and disassembling .....................54-8 Parking brake removing and installing / disassembling and assembling .....................................54-8 Pilot Valve ............................................................. 44-21, 45-2 Pilot valve (for loading) assembling ................................44-29 Pilot valve (for loading) assembly cautions .....................44-29 Pilot valve cross section and tightening torque ...............44-23 Pilot valve disassembling ................................................44-24 Pilot valve disassembling and assembling .....................44-23 Pilot valve installation cautions .......................................44-22 Pilot valve installing ........................................................44-22 Pilot valve removing ........................................................44-21 Pilot valve removing and installing ..................................44-21 Power Line ........................................................................24-2 Power line tightening torque .............................................24-2 Priority Valve ...................................................................44-46 Priority valve cross section and tightening torque ..........44-47 Priority valve disassembling and assembling .................44-47 Priority valve disassembly cautions ................................44-47 Priority valve installing ....................................................44-46 Priority valve removing ...................................................44-46 Priority valve removing and installing .............................44-46 Propeller Shaft ..................................................................24-9 Propeller shaft installation cautions ................................24-10 Propeller shaft installing ..................................................24-10 Propeller shaft removing and installing .............................24-9 Propeller Shaft Service Standard .....................................25-2

R Radiator ............................................................................24-3 Radiator installing .............................................................24-5 Radiator removing ............................................................24-4 Radiator removing and installing ......................................24-4 Radiator tightening torque ................................................24-3 Rear Axle Assembly .......................................................24-28 Rear axle assembly installing .........................................24-31 Rear axle assembly removing ........................................24-29

Rear axle assembly removing and installing ..................24-29 Rear axle assembly tightening torque ............................24-28 Rear axle disassembling and assembling ......................24-31

S Screw lock agent application procedure .........................00-10 Second propeller shaft removing ......................................24-9 Service Brake ......................................................... 54-7, 55-3 Service brake air bleeding procedure .............................24-17 Service brake disassembling and assembling ..................54-7 Special Tools ..................................................................34-19 Spider Assembly .............................................................24-25 Spider assy assembling ..................................................24-26 Spider assy disassembling .............................................24-25 Spider assy disassembling and assembling ...................24-25 Steering cylinder installation cautions .............................44-13 Steering cylinder installing ..............................................44-13 Steering cylinder removing .............................................44-12 Steering cylinder removing and installing .......................44-12 Storing articulation stopper .............................................00-13 Symbols ............................................................................00-2

T Third propeller shaft removing ........................................24-10 Torque Converter and Transmission Assembly ................34-2 Torque converter and transmission assembly assembling bolt tightening torque ..................................34-9 Torque converter and transmission assembly mounting bolt tightening torque .....................................34-2 Torque converter and transmission assembly removing and installing ..................................................34-3 Torque converter and transmission assy installation cautions .......................................................34-7 Torque converter and transmission assy installing ...........34-7 Torque converter and transmission assy removing ..........34-3 Torque Converter Assembly ...........................................34-10 Torque converter assembly disassembling and assembling ...................................34-10 Torque converter assy assembling .................................34-12 Torque converter assy assembly cautions .....................34-12 Torque converter assy disassembling ............................34-10 Transmission Assembly ..................................................34-13 Transmission assembly disassembling and assembling ....................................................................................34-13 Transmission assy assembling .......................................34-16 Transmission assy assembly cautions ...........................34-16 Transmission assy disassembling ..................................34-13

W Weight of Main Components ............................................00-3

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes