Kawasaki WHEEL LOADER 65ZV SHOP MANUAL 93207 E00240 (1) by www.heydownloads.com

93207-00240 January 2004

Foreword

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

(1)

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

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

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

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

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

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

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

(3)

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

Item

Description

Reference

Weight

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

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

Coating

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

Oil or water supply

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

Drainage

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

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

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

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

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

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

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

M10

(F) 1.25

M12

132

(F) 1.25

142

M14

142

206

(F) 1.5

152

221

M16

216

314

(F) 1.5

226

330

M18

299

436

(F) 1.5

324

476

M20

417

608

(F) 1.5

451

662

559

814

(F) 1.5

598

878

721

1,030

(F) 2.0

770

1,128

1,030

1,520

(F) 2.0

1,128

1,618

1,422

2,109

(F) 2.0

1,569

2,256

1,912

2,844

M22 M24 M27 M30

Unified thread

22 24 27 30

M33

(F) 2.0

2,059

3,040

5/16

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

358

525

7/8

9 UNC

554

809

8 UNC

868

1,275

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

(5)

(kgf-m) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

2.7

3.9

M10

5.4

7.8

(F) 1.25

5.6

8.2

M12

9.2

13.5

(F) 1.25

9.8

14.5

M14

14.5

21.0

(F) 1.5

15.5

22.5

M16

22.0

32.0

(F) 1.5

23.0

33.7

M18

30.5

44.5

(F) 1.5

33.0

48.5

M20

42.5

62.0

(F) 1.5

46.0

67.5

57.0

83.0

(F) 1.5

61.0

89.5

73.5

105.0

(F) 2.0

78.5

115.0

105.0

155.0

(F) 2.0

115.0

165.0

145.0

215.0

(F) 2.0

160.0

230.0

195.0

290.0

M22 M24 M27 M30

Unified thread

22 24 27 30

M33

(F) 2.0

210.0

310.0

5/16

18 UNC

2.5

3.6

3/8

16 UNC

4.5

6.6

7/16

14 UNC

7.2

10.5

1/2

13 UNC

10.5

15.0

9/16

12 UNC

15.0

22.0

5/8

11 UNC

20.5

30.0

3/4

10 UNC

36.5

53.5

7/8

9 UNC

56.5

82.5

8 UNC

88.5

130.0

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

(6)

(lb-ft.) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

19.5

M10

(F) 1.25

M12

(F) 1.25

105

M14

105

150

(F) 1.5

110

160

M16

160

230

(F) 1.5

165

245

M18

220

320

(F) 1.5

235

350

M20

305

450

(F) 1.5

330

490

410

600

(F) 1.5

440

650

530

760

(F) 2.0

565

830

760

1,120

(F) 2.0

830

1,190

1,050

1,550

(F) 2.0

1,160

1,660

1,410

2,100

M22 M24 M27 M30

Unified thread

22 24 27 30

M33

(F) 2.0

1,520

2,240

5/16

18 UNC

18.0

3/8

16 UNC

7/16

14 UNC

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

410

595

8 UNC

640

940

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

(7)

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

(N-m) Bolt size Type

Metric thread

Bolt strength

Nominal Dimension

Pitch

8.8 (8T)

0.8

1.25

M10

1.5

M12

1.75

M16

231

M20

2.5

441

M24

765

(kgf-m) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Pitch

8.8 (8T)

0.8

0.7

1.2

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

23.5

M20

2.5

45.0

M24

78.0

(lb-ft) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Pitch

8.8 (8T)

0.8

5.0

8.6

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

(8)

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

Hose band

Tightening torque

(N-m)

(kgf-cm)

(lb-ft)

1.6

1.2

2.9

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

1.6

1.2

2.9

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

16.5

HH022W

7.9

18.5

HH022W

9.5

20.5

HH022W

12.7

24.5

HH027W

15.9

29.9

HH031W

19.0

30.0

HH031W

25.4

38.0

HH044W

31.8

45.8

HH052W

38.1

52.1

HH057W

50.8

67.8

HH071W

60.5

76.0

HH082W

75.5

93.0

HH095W

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

Hose band

16.5

HH022W

18.5

HH022W

20.5

HH022W

22.0

HH023W

24.5

HH027W

26.0

HH027W

29.0

HH031W

30.5

HH031W

32.0

HH038W

34.0

HH038W

39.5

HH044W

41.5

HH044W

46.0

HH052W

48.0

HH052W

54.0

HH057W

70.5

HH076W

73.0

HH076W

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

Pipe

Hose band

Center of pipe protrusion 10~20 mm

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70ZV00003

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

Liquid Gasket

Screw Lock Agent

Code

Manufacturer

Product name

AA01

Loctite

Plastic Gasket 568

AA02

Loctite

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite ®

Loctite ® 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

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

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

65ZV00002

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

H Abt 1/3H

65ZV00003

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

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

Leave 1~2 screw 65ZV00004

Code

Manufacturer

Product name

AC01

Loctite ®

Loctite 767 (Paste or spray)

(10)

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

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

Example 2:

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

Section to be welded

Ground this section. (correct grounding)

(11)

35C00002

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

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

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

Scrap material, etc. 1m or more

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

35C00003

Section to be welded

1m or more 35C00004

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

Section to be welded Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

(12)

35C00005

Weight of Main Components Part name

Approx. Weight (kg)

Approx. Weight (lb)

Bucket

730

1,610

GSC bucket Standard

Item Unit name

Boom

670

1,480

" Z " -Lever

180/pc

400/pc

Link (Bucket to Lever)

40/pc

90/pc

Engine room assembly

205

455

Including screen board and radiator guard

Hydraulic tank

110

245

Excluding oil

Fuel tank

135

300

Excluding fuel

Floor board

165

365

Including ope. board, instrument panel and control box

Cab (Rops)

500

1,100

Left side

With handrail

Right side

With handrail

Front chassis

945

2,085

Rear chassis

835

1,840

Counter weight

425

940

Engine

470

1,040

Excluding oil

Radiator assembly

275

610

Excluding water and oil

Transmission

535

1,180

Excluding oil

Second propeller shaft

Third propeller shaft

Front axle assembly

525

1,160

Excluding tires and oil

Rear axle assembly

670

1,480

Excluding tires and oil (Including axle support)

Differential

145

320

Multiple control valve

Chassis

Deck

Power line

Remarks

Pilot valve

Steering valve

Hydraulic

Gear pump

system

Fan motor

Boom cylinder

95/pc

210/pc

Excluding oil

Bucket cylinder

105/pc

230/pc

Excluding oil

Steering cylinder

20/pc

45/pc

Excluding oil

Tire

200/pc

440/pc

With rim (17.5-25-12PR); No Hydro Inflation

Battery

30/pc

66/pc

Other

(13)

Triple pump

Applying and Storing Articulation Stopper 1. Applying articulation stopper

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

1) Park the machine so that the frame is straight ahead. Using a 17 mm wrench remove 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

2. Storing articulation stopper Store rod (1) and pin (2) as shown. 1 STORED POSITION

(14)

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

MEMO

CHASSIS GROUP 14 Disassembly and Reassembly Deck ............................................................................................................14-2 Fuel Tank ....................................................................................................14-3 Engine Room ..............................................................................................14-4 Cab .............................................................................................................14-7 Floor Board .................................................................................................14-9 Boom ........................................................................................................14-11 Center Pin .................................................................................................14-14

14-1

Deck

65ZV

CHASSIS 14

Deck Removing and reinstalling deck 1. Removing deck

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

(

Screen board

)

The illustration shows the parts on the left side. On the right side, the parts are located at the same points.. Remove the parts on the right side alike. 1

1) Attach sling to handrail (1) and remove bolt (2). Then remove deck (3) together with the handrail while considering the balance. Torque for assembly: : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) 2) Attach sling to the fender and remove bolt (5)(6). Carefully balance the assembly and remove fender (4). Torque for assembly: : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Fender: 20 kg (44 lbs)

6 65ZV14001

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

14-2

Fuel Tank

65ZV

CHASSIS 14

Fuel Tank an

Removing and reinstalling fuel tank

il p

o ine

1. Removing fuel tank

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.

Radiator drain hose

65ZV14002

Before starting work: - Drain fuel from the fuel tank. (Fuel tank capacity: 210 (55 Gal.)) - Remove the engine room. - Remove the radiator.

Fuel tank

1) Remove bolt (1) and disconnect the engine oil drain hose from the fuel tank. Remove nut (2) and disconnect the radiator drain hose from the fuel tank.

65ZV14003

2) Put a matchmark on fuel hoses (3) and disconnect them from the fuel tank. 3) Disconnect the level sensor electrical line coupler. Fix eye bolt (M16) to the fuel tank and attach sling to fuel tank. Then remove bolt (4) and slowly lower the fuel tank. : Fuel tank: 135 kg (300 lbs) Torque for assembly: : Bolt (4): 231 N-m (23.5 kgf-m) (170 lb-ft) 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. 65ZV14004

14-3

Engine Room

65ZV

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.

Screen board

Before starting work: - Recover/recycle refrigerant on machine with optional air conditioner, if required. - Remove the right and left decks together with the handrail. 1

1) Remove covers (1) from both the right and left sides.

65ZV14005

2) Remove exhaust pipe (2).

65ZV14006J

3) Disconnect sub tank hose (3) for the radiator. 3

65ZV14007J

14-4

Engine Room

65ZV

CHASSIS 14

4) Disconnect hose (4) (5) from condenser and receiver tank. Note: Before hose disconnection, be sure to recover/ recycle the refrigerant.

5 Condenser

4 65ZV14006

5) Disconnect hose (6) between the air cleaner and the engine at the engine side. Note: Cover the hose and port of the engine to protect the engine from dust and dirt.

6 65ZV14009J

6) Remove bolt (7).

7 65ZV14010J

7) Open the radiator grill and remove hose band (8) in the fuel inlet. Remove bolt (9) for the engine room. Torque for assembly: : Bolt (M12) : 94 N-m ( 9.6 kgf-m) ( 69 lb-ft) Bolt (M16) : 231 N-m (23.5 kgf-m) (170 lb-ft)

9 8 65ZV14011J

14-5

Engine Room

65ZV

CHASSIS 14

8) Remove the screen board together with the air cleaner and the air conditioner condenser.

Engine room M16 (2 pcs) Screen board

: Screen board (Including air cleaner/air conditioner condenser) : 105 kg (230 lbs) M16 (2 pcs)

9) Sling the engine room. : Engine room: 125 kg (280 lbs) Note: Slowly lift the screen board and the engine room while checking that there are no obstacles.

2. Reinstalling engine room For reinstallation, follow the above procedure in the reversed direction. Note: After reinstallation, be sure to check the air conditioner for refrigerant leakage. Also check that the air cleaner rubber hose connection band is properly positioned and tightened with proper torque.

14-6

M16 (1 pc)

M12 (2 pcs)

65ZV14007

Cab

65ZV

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

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

1 95ZV14013

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

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

K95ZV14014

Filter K95ZV14015

14-7

Cab

65ZV

CHASSIS 14

3) Remove cover (4).

95ZV14016

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

95ZV14017

5) Remove bolt (7). Front Right/Left 3pcs each Rear Right/Left 4pcs each Torque for assembly :

: Bolt (Front Right/Left): 231 N-m (23.5 kgf-m) (170 lb-ft) : Bolt (Rear Right/Left): 765 N-m (78.0 kgf-m) (562 lb-ft) 6) Remove bolts (8). Install eye bolt (M16 x 2.0) on cab. Attach sling and remove cab. : Cab: 500 kg (1,100 lbs)

2. Reinstalling cab For reinstallation, follow the above procedure in the reversed direction. Floor board 95ZV14018

14-8

Floor Board

65ZV

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.

1) Put matchmark on hoses (2)(3) and then separate them from pilot valve (1). : 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.

65ZV14016J

Orbitrol R

2) Put matchmark on hose (4), and then disconnect them from the Orbitrol®. Note: Cover the disconnected hoses with plastic caps or plug to protect them from dust, water and dirt.

4 70ZV14008

14-9

Floor Board

65ZV

CHASSIS 14

3) Disconnect accel. control cable (5) at the engine side. 5

65ZV14008

4) Remove floor board (6) retaining nut (7). Install eye bolt (Front right/left M16x2, Rear right/left M24x3) 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 (7): 231 N-m (23.5 kgf-m) (170 lb-ft)

65ZV14009

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

14-10

Boom

65ZV

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: 730 kg (1,609 lbs)

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

65ZV14020J

2) Remove connection pin (6) from rod (4) and lever (5). 5

: Link : 40 kg (90 lbs)

4 65ZV14021J

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

: Bucket cylinder : 105 kg (231 lbs) 5

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

70ZV14003J

14-11

Boom

65ZV

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.

7 65ZV14023J

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

: Lever : 180 kg (400 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). Open the hydraulic oil tank to release the internal pressure.

14-12

65ZV14025J

Boom

65ZV

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 of the boom. 10

Note: The pin sections are adjusted (to 1.2 mm or less clearance) using liners. Do not lose the liners during the service work. 13

8) Slowly lift boom (10) to remove it from machine. : Boom: 670 kg (1,480 lbs)

65ZV14026J

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.

14-13

Center Pin

65ZV

CHASSIS 14

Center Pin Upper center pin

Lower center pin

T1: 206 N-m (21 kgf-m) (152 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubricating oil (Engine oil or gear oil))

65ZV14010

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.

14-14

Center Pin

65ZV

CHASSIS 14

Removing and reinstalling center pin 1. Removing center pin

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

Before starting work : - Pull out the connecting pin for the parking brake.

1 65ZV14028J

1) Remove bolts (2) and disconnect the second propeller shaft (1). Torque for assembly: : Bolts: 80 N-m (8.2 kgf-m) (59 lb-ft) : Screw lock agent application (Three bond 1327)

2) Remove bolts (3) and separate the second propeller shaft (1). 3

3) Disconnect brake hose (4), and disconnect the electrical line from the coupler. : Hydraulic oil : Approx. 1.5 (0.4 Gal.) Note: Plug or cover the brake line hose to protect the hose from dust and dirt.

65ZV14030J

14-15

65ZV14029J

Center Pin

65ZV

CHASSIS 14

4) Disconnect high pressure hoses (5). : Hydraulic oil : Approx. 2 (0.5 Gal.) Note: Plug or cover the hoses to protect them from dust and dirt.

65ZV14031J

5) Remove right and left steering cylinder retainer pins (6) and shims (7).

Note: Wrap the steering cylinder rods to prevent accidental damage to the chrome rods. 7

65ZV14032J

6) Remove upper center pin retainer bolt (13). Torque for assembly: : Retainer bolt: 422 N-m (43.0 kgf-m) (311 lb-ft)

65ZV14035J

7) Screw the M10 (Pitch1.5) bolt of approximately 70 mm length into the center of bushing (14) to push out the bushing. This bolt is used as a jack screw. Jack screw: M10 (Pitch 1.5), totally threaded 14

M10 x 1.5

Jack screw 65ZV14011

14-16

65ZV14012

Center Pin

65ZV

CHASSIS 14

8) Before disconnecting front chassis (15) from rear chassis, be sure to support front chassis using a jack and blocks so that front chassis will not fall backward.

9) Before disconnecting front chassis from rear chassis, be sure to sling rear chassis using a crane (apply the rope to hook (16)) so that rear chassis will not fall backward.

Jack 65ZV14013

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

65ZV14038J

10) Push upper center pin (17) out using a jack.

Jack 65ZV14014

11) Support the bottom of hydraulic tank (18) using a rolling floor jack.

Rolling floor jack 65ZV14015

14-17

Center Pin

65ZV

CHASSIS 14

12) Remove lock bolt from lower center pin (19). Push lower center pin (19) out using another jack to remove the pin.

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

Jack 65ZV14017

13) Slowly turn rear tires to both right and left sides using a bar to separate the rear chassis. Note: While turning rear tires, check that the rolling floor jack under hydraulic tank rolls backward together with the rear chassis. In addition, adjust the height using rear crane whenever height adjustment is necessary. Bar 65ZV14018

14) Remove ring (20). Remove bolts (22) from plate (21). Torque for assembly: : Retainer bolt: 206 N-m (21.0 kgf-m) (152 lb-ft)

65ZV14043J

15) Remove shim (23). Note: If taper roller bearing (24) is replaced, be sure to adjust the clearance using shims. Thickness of shim (mm): 0.1, 0.2, 0.3, 0.5, and 1.0

23 65ZV14044J

14-18

Center Pin

65ZV

CHASSIS 14

16) Replace dust seals (25)(26) in upper center pin and lower center pin with new ones. 25

Note: Direction of dust seal

Center pin

65ZV14044

65ZV14019

65ZV14046

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

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

14-19

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

MEMO

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

15-1

Linkage

65ZV

CHASSIS 15

Linkage 1. Bucket - Boom

2. Boom - Lever

3. Boom - Boom cylinder

ø100 (3.94) ø60 (2.36)

4. Front chassis - Boom

mm (in)

ø70 (2.76)

5. Bucket - Rod

6. Lever - Rod

ø60 ø60 (2.36) (2.36)

ø80 (3.15)

7. Lever - Bucket cylinder

ø70 (2.76)

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

ø70 (2.76)

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

ø40 (1.57)

65ZV12003

8 4

11 10

6 65ZV12004

15-2

Linkage Pin Standard Clearance Values

65ZV

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

ø60 (ø2.36)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

∗

Joint section between boom and lever

ø100 (ø3.94)

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

Joint section between boom and boom cylinder

ø70 (ø2.76)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

∗∗

Joint section between front chassis and boom

ø80 (ø3.15)

0.120 ~ 0.295 (0.0047 ~ 0.0116)

1.0 (0.0393)

Replacement

∗

Joint section between bucket and rod

ø60 (ø2.36)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

∗

Joint section between lever and rod

ø60 (ø2.36)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

∗

Joint section between lever and bucket cylinder

ø70 (ø2.76)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

∗

Joint section between bucket cylinder and front chassis

ø70 (ø2.76)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

Joint section between boom cylinder and front chassis

ø70 (ø2.76)

0.100 ~ 0.250 (0.0039 ~ 0.0098)

1.0 (0.0393)

Replacement

∗

Joint section between front chassis and steering cylinder

ø40 (ø1.57)

0.080 ~ 0.205 (0.0031 ~ 0.0080)

1.0 (0.0393)

Replacement

∗

Joint section between steering cylinder and rear chassis

ø40 (ø1.57)

0.080 ~ 0.205 (0.0031 ~ 0.0080)

1.0 (0.0393)

Replacement

Liner clearance adjustment ∗

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

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

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

15-3

Center Pin

65ZV

CHASSIS 15

Center Pin Shim adjustment The clearance between the front chassis and bearing cover (#3) is 0.75±0.5 mm (0.03±0.02 in) before shim adjustment. Add shims (#5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in).

1 4

10,11 3 5 6 Front chassis 7 Rear chassis 2 9,11

Upper 65ZV12008

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 65ZV15001

15-4

Bucket Positioner and Boom Kick-Out

65ZV

CHASSIS 15

Bucket Positioner and Boom Kick-Out

Bucket Positioner

Kick-Out

65ZV15002

Bucket positioner

Adjusting plate

Direction of indicator lamp

5 Indicator lamp

Proximity switch

5±2

2.5

4 65ZV15003

15-5

Bucket Positioner and Boom Kick-Out

65ZV

CHASSIS 15

Boom kick-out (OPT) Boom highest position Adjusting plate 3

Connector

Proximity switch

Direction of indicator lamp

65ZV15004

Unit : mm Item

No.

Judgment standard

Solution

Clearance of bucket positioner switch

5 ± 2 (0.196 ± 0.078 in.)

Adjustment

Clearance of boom kick-out switch

5 ± 1 (0.196 ± 0.039 in.)

Adjustment

Adjusting plate mounting bolt tightening torque

Switch mounting nut tightening torque

Bucket positioner adjustable angle

Boom kick-out adjustable angle

Positioner

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

Kick-out

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

Tightening

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

Tightening

-7° ~ 15°

Adjustment

13 ~ 43° Adjustment (Adjusting plate counterturn)

15-6

0 ~ 13°

Bucket Positioner and Boom Kick-Out

65ZV

CHASSIS 15

Bucket positioner adjustable angle

-7°

+15°

0°

60ZV15004J

43°

Boom kick-out hoist angle

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

15-7

65ZV15005J

MEMO

POWER GROUP 24 Disassembly and Reassembly Power Line...................................................................................................24-2 Radiator .......................................................................................................24-3 Engine..........................................................................................................24-7 Propeller Shaft ...........................................................................................24-10 Air Cleaner.................................................................................................24-11 Muffler........................................................................................................24-13 Axle Assembly ...........................................................................................24-14 Front Axle Assembly..................................................................................24-15 Axle Support ..............................................................................................24-33 Differential Assembly .................................................................................24-34

24-1

Power Line

65ZV

POWER 24

Power Line Tightening torque T5 L 1

T1 L3

T2 L 1 Transmission

T4 L 1

T3 L 3

T2 L 1

Second propeller shaft

T6 L 2 T7 L1

Rear differential

T6 L 2

T4 L 1 Front differential

T L 6

Third propeller shaft

65ZV24001

: 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: 44 N-m( 4.5 kgf-m)( 33 lb-ft) T4: 216 N-m(22.0 kgf-m)(159 lb-ft) T5: 90 N-m(9.15 kgf-m)( 66 lb-ft) T6: 80 N-m(8.15 kgf-m)( 59 lb-ft) T7: 230 N-m(23.5 kgf-m)(170 lb-ft)

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

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

Radiator

65ZV

POWER 24

Radiator Tightening torque

T1 L3

65ZV24002J

: Bolt tightening torque T1: 78.5 N-m(8.0 kgf-m)(58 lb-ft)

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

24-3

Radiator

65ZV

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 31 (8.2 gal.)

65ZV24003J

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

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

65ZV24004J

24-4

Radiator

65ZV

POWER 24

4) Disconnect air cooler hose (4) (5) from the air cooler. Note: Cover disconnected hoses with plastic caps to protect hoses from dust and dirt.

Air cooler 4

5) Disconnect hoses (6) (7) from the hydraulic oil cooler. : Hydraulic oil 1.5 (0.4 Gal.)

65ZV24005

Hydraulic oil cooler

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

65ZV24006

6) Disconnect hoses (8) (9) (10) from the fan motor. 9

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

7) Remove the fan motor together with the fan and the bracket from the radiator.

8 65ZV24007

8) Attach sling to radiator (11). Remove right and left retainer bolts (12). : Radiator: 275 kg(610 lbs) Torque for assembly: : Retainer bolt (12): 78.5 N-m(8.0 kgf-m) (58 lb-ft) : With lubricating oil (Engine oil or gear oil)

65ZV24008J

24-5

Radiator

65ZV

POWER 24

9) Lift the radiator about 10 cm (4 in.) and then disconnect transmission cooler hoses (13)(14). : Engine oil (or ATF): 1

(0.26 Gal.)

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

13 14

65ZV24009J

10) Remove radiator (11) from the rear chassis.

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

24-6

Engine

65ZV

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.

Air cooler 1

Before starting work: a) Remove the engine room and the screen board. b) Collect the air conditioner refrigerant (option) using the proper recovery method.

65ZV24010

1) Disconnect the negative side of the battery cable. Then remove the positive cable. 2) Disconnect hoses (1)(2) for the air cooler. 3) Disconnect the wire from all sensors, alternator and air conditioner. 4) Disconnect fuel hose, heater / cooler hose, air compressor wiring and drain hose. 5) Disconnect the accelerator control cable from the engine. 3

6) Remove cover (3) on the torque converter case. Turn the torque converter drive cover slowly, and remove bolt (4) connecting the engine flywheel and the torque converter flexible plate. Torque for assembly: : Bolt (4): 44 N-m(4.5 kgf-m)(33 lb-ft) : With lubrication oil (Engine oil or gear oil) 24-7

65ZV24011J

Engine

65ZV

POWER 24

7) Sling engine to remove engine mounting bolt (5). Slowly lift engine about 100 mm (3.9 in.) while checking that there are no obstacles.

CAUTION Because it is needed to sling engine obliquely when removing, install chain block to radiator side. : Engine assembly: Approx. 470 kg(1,036 lbs) Torque for assembly: : Bolt (5): 90 N-m(9.15 kgf-m)(66 lb-ft) : Screw lock agent (Loctite® 262) application

65ZV24012J

8) Place a support, like a block, under transmission oil pan to hold transmission. Then remove bolt (6) connecting torque converter case and engine flywheel housing. Torque for assembly: : Bolt (6): 53 N-m(5.4 kgf-m)(39 lb-ft) : With lubrication oil (Engine oil or gear oil) 9) Separate engine and transmission from each other, and then lift the engine. Note: Lift engine approximately 100 mm. Insert wooden piece of approximately 200 mm 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.

24-8

65ZV24013J

Engine

65ZV

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). - 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.

24-9

POWER 24

Propeller Shaft

65ZV

POWER 24

Propeller Shaft Removing and reinstalling propeller shaft 1. Removing second propeller shaft 1) Remove bolt (2) from transmission side of propeller shaft (1). Torque for assembly: : Bolt (2): 80 N-m(8.15 kgf-m)(59 lb-ft) : Screw lock agent (Three bond 1327) application

2 65ZV24014J

2) Disconnect grease pipe (3), and remove bolt (5) from pillow unit bearing (4). Torque for assembly: : Bolt (5): 230 N-m(23.5 kgf-m)(170 lb-ft) : Screw lock agent (Loctite® 262) application 3) Remove bolt (7) to disconnect propeller shaft from front differential (6). Support shaft by cable or rolling floor jack. Take out the second propeller shaft to the front. Torque for assembly: : Bolt (7): 80 N-m(8.15 kgf-m)(59 lb-ft) : Screw lock agent (Three bond 1327) application : Second propeller shaft: 35 kg(77 lbs)

4 5 3

65ZV24015J

2. Removing third propeller shaft 1) Remove bolt (8). Torque for assembly: : Bolt (8): 80 N-m(8.15 kgf-m)(59 lb-ft) : Screw lock agent (Three bond 1327) application 2) Remove the third propeller shaft. : Third propeller shaft: 10 kg(22 lbs)

65ZV24016J

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.]

65ZV24017

24-10

8 Rear differential

Air Cleaner

65ZV

POWER 24

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

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply articulation stopper. - Block front wheels with chocks to prevent wheels from moving. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery. 1) Remove wing nut (1), and then remove cover (2). Remove wing nut (3), and then remove outer element (4). Remove wing nut (5), and then remove inner element (6). Disconnect indicator wire coupler (7).

1 5 3

65ZV24018J

2) Disconnect air duct (8).

65ZV24019J

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

65ZV24020J

24-11

Air Cleaner

65ZV

POWER 24

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

65ZV24021J

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

65ZV24022J

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.

Air duct insertion amount and hose band position Tighten the center of the insertion amount

Tighten on the bead

Air duct Insertion amount more than 30 mm (1.2 in.) Air cleaner side

Insertion amount more than 30 mm (1.2 in.) Engine side 70ZV24014

24-12

Muffler

65ZV

POWER 24

Muffler Removing and reinstalling muffler 1. Removing muffler

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

1) Remove bolt (1) and then remove exhaust pipe (2). 2

2) Remove engine room by referring to Section 14. : Engine room: 125 kg(276 lbs)

65ZV24024J

3) Remove four bolts (3), exhaust pipe (4), and then remove muffler (5). Torque for assembly: : Bolt: 53 N-m(5.4 kgf-m)(39 lb-ft) Note: Cover the turbocharger side with vinyl to protect from dust and dirt.

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

65ZV24025J

24-13

Axle Assembly

65ZV

POWER 24

Axle Assembly Tightening torque

T3 L 3

1) Front axle

T1 L 1 B

Mating face L2

T1 L 1 A

65ZV24008

2) Rear axle 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) 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)

T3 L 3

: L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three bond 1215) application L3: With lubrication oil (Engine oil or gear oil)

T4 L 3

Preload of section (A): 93~129 N(9.5~13.2 kgf) (20.9~29.0 lbf) Preload of section (B): 61~85 N(6.2~8.7 kgf) (13.6~19.1 lbf) 65ZV24027J

24-14

Front Axle Assembly

65ZV

POWER 24

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

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Apply parking brake and articulation stopper. - Block front wheels with chocks to prevent wheels from moving - Stands must be able to support weight of front chassis, boom, and bucket. Before starting work: - Lift the front wheel using the bucket, and then place a stand under the front chassis to support the chassis. - Lift the boom, and place a stand under the boom to support it or install a boom cylinder lock collar.

Stand Stand 65ZV24018

1) Remove right and left wheel and tire assemblies (1). : 1 Tire: 200 kg(440 lbs) Torque for assembly: : Retainer bolt: 892 N-m(91.0 kgf-m)(658 lb-ft)

65ZV24029J

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

65ZV24030J

24-15

Front Axle Assembly

65ZV

POWER 24

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

65ZV24031J

4) Attach sling to axle assembly (6), and then remove eight retainer bolts (7). : Axle assembly: 525 kg(1,157 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.

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

24-16

65ZV24032J

Front Axle Assembly

65ZV

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 Start and run engine to build brake accumulator pressure. Shut "off" engine. Rebuild brake accumulator pressure as often is needed. 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.

24-17

Front Axle Assembly

65ZV

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". Refer to "Removing rear axle assembly". b)Drain gear oil : Gear oil: 25 (6.6 Gal.) (front, rear each) c)Place axle assembly on work table using support (1) (2).

2 1 65ZV24044J

Sling

1) Sling 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: 180 kg(400 lbs)

3 65ZV24019

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.

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

24-18

65ZV24046J

Front Axle Assembly

65ZV

POWER 24

3) Remove steel plate (7). 7

65ZV24047J

4) Sling axle housing (4) and install jig to end.

Jig

65ZV24020

Jig ø18 bar (4 pcs) welded P.C.D.

60 ø350 220

14 100 P.C.D.230

Axle shaft 13-M24x2 65ZV24021

24-19

Front Axle Assembly

65ZV

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) Sling axle housing (4) and remove it together with bearing (12) from axle shaft.

Axle shaft

12 65ZV24022

24-20

65ZV24054J

Front Axle Assembly

65ZV

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.

24-21

14 15 65ZV24056J

Front Axle Assembly

65ZV

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. 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.

14 15

65ZV24057J

3.5

1.5

Inner race (B)

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). Clearance between outer race and inner race: 3.5mm(0.137 in)

Outer race (A)

Grease 65ZV24023

Axle shaft

Bearing installation end

Do not apply any oil here.

Oil seal details

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

24-22

Front Axle Assembly

65ZV

POWER 24

5) Insert oil seal inner race into axle housing.

65ZV24060J

6) Install bearing (12).

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 9 Axle shaft(13)

Shim (16)

Taper roller bearing(12)

65ZV24024 65ZV24063J

9) Measure the preload at section (A) (bolt hole). Preload: 61~85 N(6.2~8.7 kgf)(14~19 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". 24-23

Spring balance

65ZV24025

Front Axle Assembly

65ZV

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.

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

11 17 65ZV24065J

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

24-24

Front Axle Assembly

65ZV

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

POWER 24

Bolt

: 314N-m(32.0kgf-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: 25 (6.6 Gal.)

24-25

Liquid gasket application

65ZV24026

Front Axle Assembly

65ZV

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

24-26

Front Axle Assembly

65ZV

POWER 24

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

6 65ZV24073J

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.

6 65ZV24073J

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

65ZV24075J

24-27

Front Axle Assembly

65ZV

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

24-28

Rear Axle Assembly

65ZV

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. - Block front wheels with chocks or the like to prevent wheels from moving. 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.

65ZV24033J

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.

65ZV24034J

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.

24-29

65ZV24028

Rear Axle Assembly

65ZV

POWER 24

4) Remove right and left wheel and tire assemblies (1). : Tire of 1 wheel: Approx. 200 kg(440 lbs) Torque for assembly: : Retainer bolt: 892 N-m(91.0 kgf-m)(658 lb)

65ZV24036J

5) Remove the third propeller shaft retainer bolts (2) to remove propeller shaft. Torque for assembly: : Retainer bolt: 80 N-m(8.2 kgf-m)(59 lb) : Screw lock agent (Three Bond 1327) application

65ZV24037J

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

65ZV24038J

7) Disconnect air breather tube and brake hose (4). : Brake oil: Approx. 1.5 (0.4 Gal.)

65ZV24039J

24-30

Rear Axle Assembly

65ZV

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) Sling front axle support (7), and remove it from rear axle. The support should slide off rear axle. : Axle support: Approx. 57 kg(125 lbs)

7 65ZV24041J

10) Sling rear support (8) temporarily and remove bolts (9) from plate (10). Remove plate (10). Remove rear support (8). Torque for assembly: : Retainer bolt: 132 N-m(13.5 kgf-m)(98 lb-ft) : Axle support: Approx. 80 kg(176 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

24-31

Rear Axle Assembly

65ZV

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".

24-32

POWER 24

Axle Support

65ZV

POWER 24

Axle Support Disassembling and reassembling axle support

Grease piping 1

1. Disassembling axle support (front) 1) Remove packings (2) from axle support (1). Remove bushing (3). Note: To reinsert bushing, 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.

Front 3

Large chamfer

65ZV24029

Small chamfer 30°

Bushing section 65ZV24030

2. Disassembling axle support (rear) Grease piping

1) Remove packings (5) and bushing (6) from axle support (4). Note: To reinsert bushing (6), 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.

5 6 Front

4 5 65ZV24031

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.

24-33

Differential Assembly

65ZV

POWER 24

Differential Assembly Tightening torque (Front differential assembly shown)

T1 L 2

T3 T5 L1

T5 L1 5

(T=14.68) 1

(T=15.08)

4 (T=0.076) (T=0.800) 6 2 3

T5 L1

T2 L 1

65ZV24079J

T4 L1

: 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)

Note: 1) To tighten T1, measure preload of section A. Preload of section A: 40~79 N(4.1~8.1 kgf) (9~18 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

: Front 145 kg(320 lbs) Rear 160 kg(352 lbs)

Diff. pinion Ring part 65ZV24032

24-34

Differential Assembly

65ZV

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.

65ZV24033

2) Remove differential carrier cover (2). 2

65ZV24082J

18 7 2

ø20

t9 20

ø11

Width across flat 10

M10x1.5

11 320

Nut

ø13

3) Lift differential cage lightly by sling A .

15 70

65ZV24083J

140

Material SS41

11 abt 10 °

Sling A

38 65ZV24034

24-35

Differential Assembly

65ZV

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".

8 9

Top for remover bolt 65ZV24035

24-36

Differential Assembly

65ZV

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

65ZV24089J

3) Place differential carrier side ways. Differential carrier

65ZV24036

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

10 65ZV24091J

24-37

Differential Assembly

65ZV

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 hydraulic oil to O-ring and install O-ring with no torsion.

O-ring

Piston

65ZV24049

7) Apply hydraulic 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

24-38

Differential Assembly

65ZV

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. t=16

65ZV24096J

ø18

P.C.D.350 P.C.D.254

ø210

ø390

ø290

120° Material SS41

Jig B

65ZV24037

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.

24-39

C 65ZV24098J

Differential Assembly

65ZV

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

24-40

Differential Assembly

65ZV

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

24-41

Differential Assembly

65ZV

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.

24-42

Differential Assembly

65ZV

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

24-43

Differential Assembly

65ZV

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

Diff. cage

7 65ZV24041

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.

24-44

Differential Assembly

65ZV

POWER 24

Disassembling and reassembling differential assembly 1. Disassembling pinion assembly

1) Remove bolts (1) from the differential carrier. Torque for assembly: : Retainer bolt:132 N-m(13.5 kgf-m)(98 lb-ft) : Screw lock agent (Three Bond 1327) application 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).

65ZV24108J

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

170 60

42.9

ø12

160

65ZV24109J

93.6

114.3 Bolt

170

Material SS41 4

Jig A 65ZV24042

6 7 65ZV24043

24-45

Differential Assembly

65ZV

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.

WARNING 6

Square ring

Nut 65ZV24044

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

65ZV24113J

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

24-46

Differential Assembly

65ZV

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 loller 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.

Pinion cage 65ZV24047

Oil seal

65ZV24048

24-47

Differential Assembly

65ZV

POWER 24

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

65ZV24119J

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). 6

65ZV24121J

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

65ZV24122J

24-48

Differential Assembly

65ZV

POWER 24

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

65ZV24123J

9) Measure the preload. Standard: 40~79 N(4.1~8.1 kgf)(9~18 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.

65ZV24124J

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.)

24-49

MEMO

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

25-1

Propeller Shaft Service Standard

65ZV

POWER 25

Propeller Shaft Service Standard

Third propeller shaft

Measurement of circumferential play 9

Measurement of transverse play 65ZV25001

Second propeller shaft

Unit : mm (in.) Item

No.

Tolerance

Solution

Spider bearing play

Second, third propeller shaft

0.25 (0.0098)

Replacement

Spline circumferential play

Second propeller shaft

0.8 (0.0315)

Replacement

Spline transverse play

Second propeller shaft

1.0 (0.0394)

Replacement

Note: Bolt tightening torque a: 304 N-m(31.0 kgf-m)(224 lb-ft) b: 77 N-m( 7.9 kgf-m)( 57 lb-ft)

25-2

Axle and Differential Service Standard

65ZV

POWER 25

Axle and Differential Service Standard Axle assembly 4

1,3

2,3

65ZV25002

Unit : mm (in.) Judgment standard Item

No.

Solution Standard dimension

Tolerance

Backlash between sun gear and planetary gear

0.18 ~ 0.54 (0.0071 ~ 0.0213)

←

Replacement

Backlash between planetary gear and internal gear

0.19 ~ 0.67 (0.0075 ~ 0.0264)

←

Replacement

Tooth contact of gear

No abnormality

Replacement

Swing shaft wear

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

Replacement

Bushing and wear ring wear

No oil groove

Replacement

25-3

Axle and Differential Service Standard

65ZV

POWER 25

Differential

65ZV25003J

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

0.112 ~ 0.153 (0.0044 ~ 0.0060)

←

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 ........................................................................34-8 Transmission Assembly.............................................................................34-11 Clutch Pack................................................................................................34-17 Control Valve Assembly.............................................................................34-22

34-1

Torque Converter and Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly Tightening torque T5 L 1

T1 L3

T2 L 1 Transmission

T4 L 1

T3 L 3

T2 L 1

Second propeller shaft

T6 L 2 T7 L1

Rear differential

T6 L 2

T4 L 1 Front differential

Third propeller shaft

T6 L 2

65ZV24001

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

65ZV

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 screen board (Refer to Section 14). - Remove the steering valve by referring to section 44. - 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 throghly 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.)

65ZV34001J

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

3) Remove multiple control valve return pipe (3). Note: Cover the disconnected pipe with plastic caps to protect the pipe from dust and dirt.

Control valve

65ZV34001

34-3

Torque Converter and Transmission Assembly

65ZV

4) Remove pipes (4) and hoses (5) from hydraulic pump (1). Remove bolts (6) and then remove hydraulic pump assembly. Tightening torque for assembly: : Bolt: 142 N-m(14.5 kgf-m)(105 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

6 Torque converter

1 4

4 65ZV34002

: Hydraulic pump assembly: 25 kg(55 lbs) Note: Be sure to replace the gasket of the hydraulic pump flange with a new one. 7

5) Disconnect hose (7) between torque converter pump and the line filter. Disconnect hose (8) between the line filter and the torque converter. Note: Cover the disconnected hose with plastic caps to protect the hose from dust and dirt.

65ZV34004J

6) Disconnect hoses (9)(10) between the torque converter and the oil cooler. Note: Cover the disconnected hose with plastic cap to protect the hose from dust and dirt.

65ZV34005J

7) Disconnect clutch pressure measuring hose (11). Note: Cover the disconnected hose with plastic cap to protect the hose from dust and dirt.

65ZV34006J

34-4

Torque Converter and Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

8) Disconnect electric wire coupler (12) for the solenoid valve on the control valve.

12 65ZV34007J

9) Remove bolts (13) 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)

65ZV34008J

10) Disconnect bolts (14) 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) 11) Attach sling to the transmission assembly and then remove bolts (15). Tightening torque for assembly: : Bolt: 417 N-m(42.5 kgf-m)(307 lb-ft) : Transmission assembly: 535 kg(1,180 lbs)

65ZV34009J

65ZV34010J

34-5

Torque Converter and Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

12) Insert wooden pieces (16) into the clearance between the bottom of the engine flywheel housing and the rear axle housing. 16

65ZV34011J

13) Remove 11 bolts (17) connecting the transmission housing and the engine flywheel. Remove 8 bolts (18) connecting the torque converter flexible plate and the flywheel. Tightening torque for assembly: : Bolt (17): 53 N-m(5.4 kgf-m)(39 lb-ft) Bolt (18): 44 N-m(4.5 kgf-m)(33 lb-ft)

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

65ZV34012J

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

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. 34-6

Torque Converter and Transmission Assembly

DATE:

HOURS:

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

MACHINE MODEL & SERIAL NO.:

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO.:

AMBIENT TEMP: COMPONENT SERIAL NO.:

CHECKLIST TO BE COMPLETED BEFORE START-UP TRANSMISSION COOLER CLEANED

TRANSMISSION PIPING CLEANED

IN-LINE PRESSURE FILTER REPLACED

TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

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

CLUTCH PRESSURE AT LOW IDLE F1

MPa (kgf/cm2) (psi)

CLUTCH PRESSURE AT HIGH IDLE F1

MPa (kgf/cm2) (psi)

COMMENTS:

Serviceman's Signature

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

34-7

Torque Converter Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter Assembly (Kawasaki CT140V01)

Bolt tightening torque

50T

55T

28T

37T 57T 2nd

1st

26T

33T

62T 43T

47T

37T

23T

38T

4th

3rd 33T

T6 L 1

T7 T6 L 1 65ZV34013J

: Bolt tightening torque T1: 28 N-m(2.85 kgf-m)(21 lb-ft) T2: 29 N-m(3.00 kgf-m)(22 lb-ft) T3: 69 N-m(7.00 kgf-m)(51 lb-ft) T4: 34 N-m(3.50 kgf-m)(25 lb-ft)

T5: 69 N-m(7.00 kgf-m)( 51 lb-ft) T6: 255 N-m(26.0 kgf-m)(188 lb-ft) T7: 108 N-m(11.0 kgf-m)( 80 lb-ft)

34-8

: L1: Screw lock agent (Loctite® 262) application

Torque Converter Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

Cover

Disassembling and reassembling torque converter assembly 1. Disassembling torque converter assembly Before starting work: - Clean the transmission assembly. - Drain oil from the transmission. - Remove the cover from the torque converter housing.

3 1 2

1) Remove bolt (1) and then remove pilot boss (2). Tightening torque for assembly: : Bolt: 28 N-m(2.85 kgf-m)(21 lb-ft)

2) Remove bolt (3) and then remove flexible plate (4). Tightening torque for assembly: : Bolt: 28 N-m(2.85 kgf-m)(21 lb-ft)

65ZV34003

3) Remove bolt (5) for the drive cover. Tightening torque for assembly: : Bolt: 29 N-m(3.00 kgf-m)(22 lb-ft) 9

4) Remove drive cover (6) and turbine (7) as an assembly. Remove the snap ring from the turbine shaft.

5) Remove lock nut (8). Tightening torque for assembly: : Lock nut: 69 N-m(7.00 kgf-m)(51 lb-ft)

IMPORTANT When reassembling, use a new lock nut and stake it at 2 points.

6) Remove stator (9) and spacer (10).

34-9

65ZV34015J

Torque Converter Assembly

65ZV

7) Remove bolt (11) and then remove pump impeller assembly (12). Tightening torque for assembly: : Bolt: 26 N-m(2.60 kgf-m)(19 lb-ft)

TORQUE CONVERTER AND TRANSMISSION 34

17 12

8) Remove four bolts (13). Remove cover (14). Tightening torque for assembly: : Bolt: 34 N-m(3.5 kgf-m)(25 lb-ft) Stator shaft

9) Remove pump boss (15). Remove gear (16) and 2 bearings (17) from pump boss (15).

16 14

15 65ZV34004

10) Remove bolt (18) and then remove the stator shaft. Tightening torque for assembly: : Bolt: 69 N-m(7.00 kgf-m)(51 lb-ft)

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.

Stator shaft

After reassembling, make sure to rotate the drive cover by hand.

65ZV34005

34-10

Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly (Kawasaki CT140V01)

Bolt tightening torque

50T

55T

28T

37T 57T 2nd

1st

26T

33T

62T 43T

47T

37T

23T

38T

4th

3rd 33T

T6 L 1

T7 T6 L 1 65ZV34013J

: Bolt tightening torque T1: 28 N-m(2.85 kgf-m)(21 lb-ft) T2: 29 N-m(3.00 kgf-m)(22 lb-ft) T3: 69 N-m(7.00 kgf-m)(51 lb-ft) T4: 34 N-m(3.50 kgf-m)(25 lb-ft)

T5: 69 N-m(7.00 kgf-m)( 51 lb-ft) T6: 255 N-m(26.0 kgf-m)(188 lb-ft) T7: 108 N-m(11.0 kgf-m)( 80 lb-ft)

34-11

: L1: Screw lock agent (Loctite® 262) application

Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling transmission assembly

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

1) Remove the bolt for pump suction pipe (1). Tightening torque for assembly: : Bolt: 53 N-m(5.4 kgf-m)(39 lb-ft) 2) Remove pipe (2) and then remove the strainer. Tightening torque for assembly: : Bolt: 69 N-m(7.00 kgf-m)(51 lb-ft)

3) Remove the pilot boss, drive cover and the turbine. 2 65ZV34018J

4) Remove the snap ring from the turbine shaft. Drive cover 50T

5) Remove the retainer bolt connecting the torque converter housing and the transmission housing. Use a jacking bolt (M10x1.5) to separate the torque converter housing and the transmission housing. Tightening torque for assembly: : Housing connection bolt: 69 N-m(7.00 kgf-m) (51 lb-ft)

55T

Pilot boss

Turbine Snap ring

34-12

65ZV34006

Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

6) Remove forward/reverse clutch pack (3) using a 16 mm eye bolt. 3

65ZV34020J

Special tool for removing speed range clutch North American dealer tool number : KL03-200-1 1

3 5

1 Plate 15 20

1. Plate 2. Lock 3. Eye bolt 4. Nut(M12) 5. Bolt(M6) 6. Nut(M6) 7. Split pin

250 ø7Drill

ø13Drill

ø7Drill 50

24 65

180

35.4

150 280

135 95 6

2 Lock 10 39

ø7Drill R

135

ø7Drill R

10 31

250

95 6

70ZV34004

34-13

Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

7) Remove the 1st/2nd speed clutch pack (4) and the 3rd/4th speed clutch pack (5) at the same time using a special tool.

Special tool 4

70ZV34005

8) Remove bolt (6) and then remove drum (7). Tightening torque for assembly: : Bolt: 108 N-m(11.0 kgf-m)(80 lb-ft) 13

9) Remove bolts (8)(9), flange (10) and the brake assembly. Tightening torque for assembly: : Output flange bolt (8): 255 N-m(26.0 kgf-m) (188 lb-ft) Bolt (9): 255 N-m(26.0 kgf-m)(188 lb-ft) : Screw lock agent (Loctite® 262) application

8 12 10

10) Remove bolt (12), and then remove housing (13). Tightening torque for assembly: : Bolt: 69 N-m(7.00 kgf-m)(51 lb-ft)

65ZV34023J

11) Remove speedometer drive gear (14). Third prop. shaft

70ZV34006

34-14

Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

12) Remove the bolt and then remove shroud (15) in the housing. Tightening torque for assembly: : Bolt: 28 N-m(2.85 kgf-m)(21 lb-ft) : Screw lock agent (Loctite® 262) application Bolt

70ZV34007

13) Remove output shaft (16) using a 16 mm eye bolt.

65ZV34026J

34-15

Transmission Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

2.Reassembling transmission assembly

Cautions for installation

To reassemble the transmission assembly, follow the above procedure in the reversed direction.

- When installing oil seal apply grease to inner lip and liquid gasket (AA03) to outside seal. - When installing O-ring, apply lithium grease to O-ring. - Before installing the torque converter housing to the transmission housing, apply multipurpose EP/MOLY grease to (A) part. Apply grease to the shaft (B and C) before installing seal ring.

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.

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.

65ZV34027J

34-16

Clutch Pack

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

Clutch Pack Disassembling and reassembling clutch pack 1. Disassembling forward/reverse clutch pack (The disassembling procedure for the forward/reverse clutch pack is described below.) Note: - Follow the same step for the other clutch pack.

1) Remove seal ring (1) from the turbine shaft.

2) Remove bearing (2), washer (3) and gear (4) with bearings. T/C side R-clutch

3) Remove snap ring (6) from clutch drum (5).

1 3 2 4

4) Remove the plate (7), back plate (8), disc (9), clutch plate (10), disc (11) and plate (12) in order.

70ZV34008

12 R-clutch

6 11 10 9

11 10

70ZV34009

5) Pressing washer (13) using a special tool, then remove snap ring (14).

13 13

65ZV34030J

34-17

Clutch Pack

65ZV

Special tool to remove snap ring For forward/reverse clutch pack

(mm)

TORQUE CONVERTER AND TRANSMISSION 34

For speed clutch pack

(mm)

φ 100 φ 80±0.5 φ85

370

° 60

360

φ72±0.5

° 60

40 φ79±0.5

40 φ92±0.5

65ZV34031J

6) Remove washer (13) and spring (15), then feed air from the clutch oil port to remove clutch piston (16).

CAUTION If the air pressure is applied suddenly, the piston may jump out from the clutch. Feed air slowly.

IMPORTANT 13

Do not remove the clutch drum from the shaft.

15 16 13

34-18

Clutch Pack

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

7) Remove seal ring (17) from both piston (16) and the shaft.

8) Follow the same steps for the forward clutch assembly.

34-19

65ZV34033J

Clutch Pack

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

2.Reassembling clutch pack

Cautions for installation

To reassemble the clutch pack, follow the above procedure in the reversed direction.

- When installing O-ring, apply lithium grease to O-ring. - Apply grease to the seal ring 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.

Specific direction when reassembling Note that the following parts need to be assembled so as to face in the specific direction when reassembling 1) Forward/Reverse clutch pack

Convex part faces to inside clutch pack

Groove side

F clutch washer

R clutch washer

Groove side

70ZV34010

34-20

Clutch Pack

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

2) 1st/2nd speed clutch pack

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

Groove side Washer 1ST

2ND 70ZV34011

3) 3rd/4th speed clutch pack

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

Groove side

Groove side Washer

Washer 3RD

4TH 70ZV34012

34-21

Control Valve Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Assembly Removing and reinstalling control valve

Solenoid valve 1

1. Removing control valve

WARNING Unexpected movement of machine could cause an accident, resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and then lower bucket to 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. 1) Remove the electric wiring coupler for each solenoid valve. Note: Put matchmark on each coupler to avoid misconnection when reassembling.

2 Transmission control valve 70ZV34013

2) Remove the main clutch pressure measuring hose. Note: Cover the disconnected hoses with plastic cap to protect the hoses from dust and dirt.

SOL 1st SOL 2nd

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.

SOL F

SOL R

3) Remove bolt (1)(2)(3) and the control valve. Tightening torque for assembly: : Control valve retainer bolt: 34 N-m(3.5 kgf-m) (25 lb-ft) Note: Cover the disconnected parts with vinyl to protect them from dust, water and dirt.

T/M control valve 1 SOL 3rd/4th

3rd/4th solenoid valve 70ZV34014

34-22

Control Valve Assembly

65ZV

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) Align the matchmarks of the electric wire couplers, and then connect the couplers while checking that electric wires are not tangled with each other. 4) 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.

5) At the completion of installation, start the engine, and check that the shift lever properly functions at all the positions. 6) Check oil leakage. 7) Adjust the transmission oil level to the specified point with the dipstick.

34-23

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Assembly

65ZV

Disassembling and reassembling control valve

TORQUE CONVERTER AND TRANSMISSION 34

1. Disassembling control valve Note: Clean the control valve.

6 3

1) Remove bolt (1). Tightening torque for assembly: : Bolt: 32.3 N-m(3.30 kgf-m)(24 lb-ft) 2) Remove solenoid valve nut (2). 3) Remove solenoid valve (3). 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) 4) Remove covers (6)(7) and then remove the spool and the spring from the valve body. Tightening torque for assembly: : Bolt (4): 9.8 N-m(1.00 kgf-m)(7 lb-ft) Bolt (5): 15.7 N-m(1.60 kgf-m)(12 lb-ft)

CAUTION When removing the cover, the spring may jump out. Slowly loosen the bolt for the cover.

IMPORTANT Do not loosen the screw and nut (8) when disassembling control valve unless necessary. Mis-adjustment may cause shift shock or clutch plate slipping.

5) Follow the same steps for the 3rd/4th speed control valve.

34-24

7 8 5

65ZV34039J

Control Valve Assembly

65ZV

TORQUE CONVERTER AND TRANSMISSION 34

Main control valve

2. Reassembling control valve To reassemble the control valve, follow the above procedure in the reversed direction.

Cautions for assembly 1) Before you insert the regulator valve, apply transmission oil to the valve. After insertion, check that the valve operates smoothly. 2) Check the operation of the solenoid valves. (Also the movement by pressing the manual plunger. The plunger should move freely and smoothly in both directions (spring return).) 3) Replace all seals, O-rings and gaskets. 65ZV34040J

Adjusting screw procedure a) Loosen nut (1). b) Loosen screw (2) until "A" comes to 20 mm. c) Screw in screw (2) until the tip of the screw contacts to piston (3). d) From this position, turn the screw clockwise 5 turns. e) Tighten nut (1) to lock screw (2). Nut tightening torque : 11 N-m(1.1 kgf-m)(8 lb-ft) After adjusting "A" should be 12 mm.

34-25

3 1

Screw details

2 70ZV34015

MEMO

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

35-1

Clutch Oil Pressure

65ZV

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 2

View from A 7 4

View from B 65ZV32006

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

Measuring port location

Measuring port size

Torque converter inlet pressure

PF1/4

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

↑

1.5 (15) (213) or more

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

↑

1ST

↑

2ND

↑

3RD

↑

4TH

↑

PF3/8

0.002~0.07 (0.02~0.7) (0.3~10)

0.08~0.2 (0.8~2.4) (11~34)

All speed range

Clutch oil pressure

Lub. oil pressure

Shift lever position

Engine revolution (min-1) (rpm) 800

2400

0.1 (1.3) (18) or more

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

35-2

All speed range

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 .......................................................................................44-9 Pilot Valve .................................................................................................44-22 Multiple Control Valve ...............................................................................44-29 Orbitrol® .....................................................................................................44-35 Steering Valve ..........................................................................................44-45 Stop Valve ................................................................................................44-50 Fan Motor .................................................................................................44-54

44-1

Warning Regarding Removing and Reinstalling Hydraulic Parts

65ZV

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

HYDRAULIC 44

Cautions Regarding Disassembly & Reassembly of Hydraulic Parts

65ZV

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

65ZV

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.

Torque converter

2 1

Before starting work: a) Remove the cab and the floor board by referring to Section 14. b) Clean the area around the hydraulic pump.

65ZV44017J

1 3

1) Disconnect outlet hose (2) and suction pipe (3) from hydraulic pump (1). Note: Cover the hoses with plastic, plugs or caps to protect from dust and dirt. 3

2) Remove hydraulic pump retainer bolts (4). Torque for assembly: : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft)

65ZV44018J

3) Attach sling to hydraulic pump (1) and remove hydraulic pump (1). : Hydraulic pump: 25 kg (55 lbs)

44-4

Hydraulic Pump Assembly

65ZV

HYDRAULIC 44

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

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

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

44-5

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

Hydraulic Pump Assembly

65ZV

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 recurrence.

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

44-6

HYDRAULIC 44

Hydraulic Pump Assembly

65ZV

HYDRAULIC 44

1.Cross section and tightening torque

65ZV44019J

: N-m (kgf-m) (lb-ft) T1: 275 (28) (203) T2: 108 (11) ( 80)

44-7

Hydraulic Pump Assembly

65ZV

HYDRAULIC 44

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

[Example 1] Oil seal

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

Snap ring

Drive gear shaft

Front cover

95ZV44002

[Example 2]

Front cover

Drive gear shaft

Oil seal

Snap ring 95ZV44003

44-8

Hydraulic Cylinder

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HYDRAULIC 44

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

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

Stand

85ZV44003

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

1 65ZV44023J

1) Attach sling to boom cylinder (1). Disconnect hoses (2)(3). : Boom cylinder: 95 kg (210 lbs)

3 65ZV44024J

44-9

Hydraulic Cylinder

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HYDRAULIC 44

2) Remove lock bolt (4) and pin (5). 3) Remove lock bolt (6) from retainer pin (7) on the bottom side. Remove pin (7) and then sling boom cylinder(1). For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

65ZV44050J

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

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. Air bleeding procedure 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 tank, and check cylinder and its piping for oil leakage.

44-10

Hydraulic Cylinder

65ZV

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.

Bucket cyl. 3 1

1) Remove the coupler of bucket positioner switch (1), and then remove bracket (2). 2 6 65ZV44004

2) Attach sling to bucket cylinder (3). After that, remove lock bolt (4) and pin (5). : Bucket cylinder: 105 kg (230 lbs)

5 4

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

65ZV44028J

44-11

Hydraulic Cylinder

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HYDRAULIC 44

4) Start the engine and shorten cylinder rod (7). Stop the engine and disconnect hose (8)(9). Note: Cover the disconnected hose and the cylinder with plastic caps or plugs to protect them from dust, water and dirt.

7 8 65ZV44029J

6) Disconnect the grease pipe. After that remove lock bolt (10) and pin (11).

7) Slowly lift up bucket cylinder (3). Lower bucket cylinder onto ground. For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

65ZV44030J

44-12

Hydraulic Cylinder

65ZV

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 a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes. Note: Stop the piston about 100 mm (3.9 in.) before stroking fully. b)After that, stroke the cylinder piston fully to both ends 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

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

44-13

HYDRAULIC 44

Hydraulic Cylinder

65ZV

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. - Press cap down ward 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 .

1 2

65ZV44031J

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

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 rod (6) into the cylinder to shorten the length of the cylinder. 5

: Oil will be drained from the oil port of the cylinder. Place a container at the oil port to catch the drained oil. 3

3) Disconnect the grease pipe and then remove pin (7).

4 6 65ZV44032J

44-14

Hydraulic Cylinder

65ZV

HYDRAULIC 44

4) Remove steering cylinder assembly (4). Note that two persons are needed to remove and lift the assembly. : Steering cylinder: 20 kg (45 lbs) For detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

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

3.Cautions regarding reinstallation

➀When reinstalling the pins

➁Bleed the cylinder of air

IMPORTANT

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

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

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

44-15

Hydraulic Cylinder

65ZV

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

65ZV44002J

2) Bucket cylinder

T4 65ZV44003J

3) Steering cylinder

65ZV44004J

: N-m (kgf-m) (lb-ft) T1: 2,501 (255) (1,845)

Cylinder

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

T2: 481 ( 49) ( 355) T3: 2,354 (240) (1,736) T4: 686 ( 70) ( 506) T5: 490 ( 50) ( 362) T6: 785 ( 80) ( 579)

Boom

75 (2.95) – M48 x 1.5

Bucket

75 (2.95) – M48 x 1.5

Steering

41 (1.61) – M27 x 1.5

44-16

Hydraulic Cylinder

65ZV

HYDRAULIC 44

2.Disassembling hydraulic cylinder Note: The bucket cylinder disassembling procedure is described below. For other cylinders, follow the same procedure. 1) Install the bottom side of the cylinder to the repair stand.

Repair stand 95ZV44004

Matchmark

2) Put the matchmarks on rod cover (1) and cylinder tube (2). Remove rod cover bolt (3). : Bolt: 481 N-m (49.0 kgf-m) (355 lb-ft) (Boom cylinder) 686 N-m (70.0 kgf-m) (506 lb-ft) (Bucket cylinder) Rod cover: 785 N-m (80.0 kgf-m) (579 lb-ft) (Steering cylinder)

2 1 95ZV44005

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

95ZV44006

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

Repair stand

Wooden block 95ZV44007

44-17

Hydraulic Cylinder

65ZV

HYDRAULIC 44

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

Matchmark

95ZV44008

6) Use a hydraulic jack or hydraulic cylinder to loosen piston nut (6).

6 C

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)

2,354 (240) (1,736)

Steering cylinder

41 (1.61)

490 ( 50) ( 362)

Hydraulic jack

Hydraulic cylinder 95ZV44009

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

95ZV44010

8) Remove wear ring (8), square ring (9), slipper ring (10), O-ring (11) and wear ring (12).

10 9

11 (Bucket cylinder)

11 (Steering cylinder) 95ZV44012

44-18

Hydraulic Cylinder

65ZV

HYDRAULIC 44

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

95ZV44013

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

For boom and bucket cylinder 95ZV44014

14 95ZV44015

3.Reassembling hydraulic cylinder To reassemble the hydraulic cylinders, follow the above disassembling procedure in the reversed direction.

44-19

Hydraulic Cylinder

65ZV

HYDRAULIC 44

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

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

Note: Put slipper ring (10) into hot oil to heat the ring to 120 to 150 °C. (This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston. Therefore, heat the slipper ring to expand its inner diameter for easy attachment.) : Attach the slipper ring while taking care not to damage by over expansion. : After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size. Note: Before installing back-up ring (2) and O-ring (3), heat the back-up ring. (This is because the inner diameter of the back-up ring is smaller than the outer diameter of the rod cover. To easily attach the back-up ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.) Be careful not to over expand the back-up ring. After installation, wait until the back-up ring is cooled, and then insert the rod cover into the cylinder tube.

95ZV44016

3 95ZV44017

Note: Reinstall the rod cover of the steering cylinder, screw the rod cover using a spanner wrench. Screw in and tighten the set screw. Stake the set screw. : 785 N-m (80 kgf-m) (579 lb-ft)

95ZV44018

44-20

Hydraulic Cylinder

65ZV

HYDRAULIC 44

Note: Stake the rod cover (1) at 4 points to prevent scraper ring (13) coming out.

Stake

13 95ZV44019

Stake 95ZV44020

44-21

Pilot Valve

65ZV

HYDRAULIC 44

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

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

Control box

- Relieve the internal pressure from the hydraulic tank.

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

Cover mount 90ZV44022

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

Pilot valve

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

90ZV44023

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

Pilot valve 4 A

44-22

90ZV44024

Pilot Valve

65ZV

HYDRAULIC 44

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

7 90ZV44025

6) Disconnect hoses (11) from the pilot valve.

Pilot valve

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

90ZV44026

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

Pilot valve

Adapter

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

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

Adapter

Torque for assembly: : Adapter: 36 N-m (3.7 kgf-m) (27 lb-ft) 95ZV44049

: Pilot valve: 10 kg (22 lbs)

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

44-23

Pilot Valve

65ZV

HYDRAULIC 44

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

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

Boom side

T3 T1

T1 T3 L1

T3 L1 T5

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

9.5 kg (21 lbs) T2

L1: Screw lock agent application (Three Bond 1327)

K70V44001

44-24

Pilot Valve

65ZV

HYDRAULIC 44

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

1) Clamp the pilot valve in a vise. Pull up boot (1) to remove it from cover (2).

Loosen the lock nut for solenoid (3) and then remove the solenoid from cover (2). Torque for assembly: : Solenoid: 42 N-m (4.3 kgf-m) (31 lb-ft) Note: Before removing solenoid (3), measure the distance between solenoid (3) and cover (2). Adjustment procedure is in the function and structure section of shop manual.

97ZV44023

Lock nut

95ZV44076

5 6

Carefully store ball (4). 7

2) Loosen socket bolt (5). Remove lever (6) from disc (7). Torque for assembly: : Bolt: 29 N-m (3.0 kgf-m) (22 lb-ft) Note: Put matchmark on lever (6) and disc (7). 3) Loosen socket bolt (8). Remove cam shaft (9). Torque for assembly: : Retainer bolt: 17 N-m (1.7 kgf-m) (12 lb-ft) : Screw lock agent (Three Bond 1327) application Note: - Three Bond 1327 is applied, and more torque is needed to loosen. - Temporarily tighten socket bolt (5) to remove disc (7). - In case the cam shaft does not pull out, use the hexagon wrench to push it out. 44-25

97ZV44024

97ZV44025

Pilot Valve

65ZV

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

HYDRAULIC 44

97ZV44026

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

K70V44002

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

11 12

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

44-26

K70V44003

CAUTION Be careful! The spring inside the case assembly may spring out and hit your face. Do not point the plug assembly toward your face.

Pilot Valve

65ZV

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

HYDRAULIC 44

14 15

K70V44004

Carefully install into the case

95ZV44022

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

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

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

19 20 97ZV44032

44-27

Pilot Valve

65ZV

HYDRAULIC 44

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

24 23

25 26

22 97ZV44033

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

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

Sharp edge side

22 97ZV44023

Multiple Control Valve

65ZV

HYDRAULIC 44

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

1 1

Multiple control

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

65ZV44008

Multiple control valve

2) Put matchmarks on hoses (2) then disconnect them. : Hydraulic oil: Approx. 5 (1.32 gal.) Note: Cover the disconnected hoses and valve with plastic, plugs or caps to protect them from dust and dirt.

65ZV44009

3) Remove return pipe (3).

Multiple control valve 65ZV44010

44-29

Multiple Control Valve

65ZV

HYDRAULIC 44

4) Disconnect inlet hose (4). Note: Cover the disconnected hoses with plastic, cap or plug to protect them from dust, water and dirt.

Multiple control valve

5) Remove retainer bolts (5) from the multiple control valve, and then remove multiple control valve (6). Torque for assembly: : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Multiple control valve: 35 kg (77 lbs)

2.Reinstalling multiple control valve To reinstall the multiple control valve, follow the above removal procedure in the reversed direction. 4 5

3.Cautions regarding reinstallation 65ZV44011

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

WARNING Unexpected movement of machine may cause serious injury or death. To prevent such an accident, be sure to stop the engine before you start working. In addition, block tires with chocks to prevent wheels from moving. While working, carefully keep contact with the person in the cab by giving signals to each other. c) Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the Section 03. d) Operate the bucket and the boom, and check that they operate correctly. e) Check each section for oil leakage. f ) Add hydraulic oil to the tank until the oil level rises to the specified point.

44-30

Multiple Control Valve

65ZV

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 T5 L1 T7 T4 T3

Boom spool Main relief valve Bucket spool T1 T5 L1 T3 T3

T6 T3

Overload relief valve with make-up function.

T1 T2

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

Make-up valve T4

T1: 78 ( 8.0) ( 58) T2: 353 (36.0) (260) T3: 34 ( 3.5) ( 25) T4: 113 (11.5) ( 83) T5: 18 ( 1.8) ( 13) T6: 255 (26.0) (188) T7: 39 ( 4.0) ( 29)

Overload relief valve with make-up function. 65ZV44001

: 35 kg (77 lbs)

L1: Screw lock agent AB01 application 44-31

Multiple Control Valve

65ZV

HYDRAULIC 44

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

1 65ZV44007J

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

65ZV44008J

3) Remove overload relief valve (3). Remove make-up valve (4). Hexagon width across flat: 32 mm (1 17/64 in.) Torque for assembly: : #3,4: 78 N-m (8.0 kgf-m) (58 lb-ft)

3 65ZV44009

4) Remove socket head bolts (5),(6) from the bucket and boom side of the cap. Then remove caps (7),(8). Hexagon hole width across flat: 6 mm (15/64 in.) Torque for assembly: : #5,6: 34 N-m (3.5 kgf-m) (25 lb-ft)

6 7 8

44-32

65ZV44010J

Multiple Control Valve

65ZV

5) Slowly pull out spool (9) from the boom side and spool (10) from the bucket side as an assembly. Note: Carefully pull out the spool so that it is not forced out or distorted.

HYDRAULIC 44

9 65ZV44011J

6) Remove socket head bolts (11),(12) to remove caps (13),(14). Also remove the O-ring of the flange from the cap. Hexagon hole width across flat: 6 mm (15/64 in.) Torque for assembly: : #11,12: 34 N-m (3.5 kgf-m) (25 lb-ft)

12 14 13 11 65ZV44012J

7) Remove four socket head bolts (15), and then remove cover (16). Also remove the O-ring from the mating face. Hexagon hole width across flat: 10 mm (25/64 in.) Torque for assembly: : #15: 113 N-m (11.5 kgf-m) (83 lb-ft)

65ZV44013J

8) Remove plug (17) from the bucket side to remove spring (18) and poppet (19). Also remove plug (20) from the boom side. Remove the O-ring from the plug. Hexagon width across flat: 27 mm (1 1/16 in.) Torque for assembly: : #17, 20: 353 N-m (36.0 kgf-m) (260 lb-ft)

17 18

65ZV44014J

44-33

Multiple Control Valve

65ZV

HYDRAULIC 44

9) Remove plug assembly (21) and remove the O-ring. Hexagon hole width across flat: 12 mm (15/32 in.) Torque for assembly : #21: 225 N-m (26.0 kgf-m) (188 lb-ft)

65ZV44015J

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

23 24 25

Spool 22

11) Remove spring seat (23), spring (24), stopper (25) from each spool (there are two spools). Note: Cover the spool to protect it from being scratched.

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

4.Cautions regarding reassembling - Clean and check all the parts. If a part is defective, replace or repair it. - Replace all the O-rings with new ones. - Apply a thin coat of hydraulic oil or grease to each part before reassembly. - Apply the specified torque to tighten each main part.

44-34

65ZV44002

65ZV

Orbitrol®

HYDRAULIC 44

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

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and lower 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.

95ZV44060

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

95ZV44061

3) Remove sound suppression sheet (3).

3 95ZV44062

44-35

Orbitrol®

65ZV

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 operation of the Orbitrol® by following the procedure below:

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

44-36

Orbitrol®

65ZV

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

97ZV44045

: N-m (kgf-m) (lb-ft) T1: 23 (2.3) (17) : 5.8 kg (12.8 lbs)

44-37

Orbitrol®

65ZV

HYDRAULIC 44

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

Copper plate

95ZV44025

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

2 3

97ZV44047

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

7 6

65ZV44019

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

9 10

97ZV44049

44-38

Orbitrol®

65ZV

HYDRAULIC 44

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

11 97ZV44050

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

97ZV44051

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

97ZV44052

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

18 19 97ZV44053

44-39

Orbitrol®

65ZV

HYDRAULIC 44

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

19 20 97ZV44054

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

97ZV44055

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

22 23 23

97ZV44056

12) Remove O-ring (25) from the housing. 26 27

13) Remove adapter (26) to take out ball (27). Note: Do not disassemble, unless absolutely necessary.

25 97ZV44057

44-40

Orbitrol®

65ZV

HYDRAULIC 44

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

20 25 97ZV44058

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

Spring groove 22 Spring groove 23

Matchmark

95ZV44026

3) Install springs (24) through the spring grooves in sleeve and spool (19) using a spring insertion jig. Note: Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

19 97ZV44060

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

97ZV44061

44-41

Orbitrol®

65ZV

HYDRAULIC 44

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

19 20

97ZV44062

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

97ZV44063

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

97ZV44052

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

23 97ZV44064

44-42

Orbitrol®

65ZV

HYDRAULIC 44

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

95ZV44027

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

97ZV44066

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

Port face 8 Pin parallel with port face

21 95ZV44028

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

97ZV44068

44-43

Orbitrol®

65ZV

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

HYDRAULIC 44

Grooves in rotor bore

B Drive shaft

C D

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

Port face

95ZV44029

1 2

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

65ZV44020

Tightening order

95ZV44030

44-44

Steering Valve

65ZV

HYDRAULIC 44

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

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park machine on level ground, and lower bucket to ground. - Block tires with chocks to prevent wheels from moving. - Relieve the internal pressure from the hydraulic tank. - Oil spilled on the parking brake shoe section may cause malfunction. To prevent such a problem, cover the shoe section with plastic before valve removal.

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

70ZV44011

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

2) Remove hoses (4)(5)(6).

6 70ZV44012

3) Remove oil pipe (7). Steering valve

7 65ZV44017

44-45

Steering Valve

65ZV

HYDRAULIC 44

4) Remove hoses(8)(9)(10)(11). 5) Remove bolt (12), and then remove the steering valve. Torque for assembly: : Bolt: 49 N-m (5.0 kgf-m) (36 lb-ft) : Steering valve: 25kg (55 lbs) Note: Cover the disconnected hoses and the valve with plastic, plugs or caps to protect them from dust and dirt.

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

WARNING Entering the articulation area while engine is running may cause serious injury or death. So, when entering the area, stop the engine and place "DO NOT START " or "DO NOT OPERATE" tag on steering wheel or the operator's seat. 1) Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise. 2) Check around the valve for oil leakage. 3) Measure various values for performance check. Measure the time required for full steering. Measure the relief valve setting pressure. (Refer to the Section 03 - Measurement for Performance Check). 44-46

70ZV44016

Steering Valve

65ZV

HYDRAULIC 44

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

1.Cross section and tightening torque

Flow control spool T2

Steering spool T7

T4 90ZV44040

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

Steering Valve

65ZV

HYDRAULIC 44

2.Disassembling steering valve 1

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

90ZV44007J

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

90ZV44008J

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

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

90ZV44010J

44-48

Steering Valve

65ZV

HYDRAULIC 44

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

11 9

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

90ZV44011J

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

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

44-49

Stop Valve

65ZV

HYDRAULIC 44

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

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

1 5

2 6

65ZV44018

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

44-50

Stop Valve

65ZV

HYDRAULIC 44

3.Cautions regarding reinstalling stop valve:

Stopper (bolt)

Adjust the stopper bolt by using the following procedure. - Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension “9.1 to 17.9 mm (0.36~0.71in)” shown in the table below.

Front chassis

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

Reference dimension 38.6~43.3 mm (1.52~1.71 in) Stopper (bolt) length

65ZV44012

Reference dimension Articulation angle ( °)

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

9.1 13.5 17.9 (0.36) (0.53) (0.71)

Stopper (bolt) length (mm) (in)

38.6 41.0 43.3 (1.52) (1.61) (1.71)

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

44-51

36°~

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

38°

Front chassis

Rear chassis Reference dimension 9.1~17.9 mm (0.36~0.71 in) Clearance between machine body and stopper 65ZV44013

Stop Valve

65ZV

HYDRAULIC 44

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

1.Cross section and tightening torque

T4 T3

97ZV44078

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

44-52

Stop Valve

65ZV

HYDRAULIC 44

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

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

A B

Torque for assembly: : #2: 21 N-m (2.1 kgf-m) (15.2 lb-ft) 97ZV44079

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

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

7 3 4

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

Two flats 95ZV44032

4) Remove screw (9) to remove flange (10), dust seal (11), spacer (12) and U-packing (13). 12

Torque for assembly: :#9: 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)

9 97ZV44081

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

44-53

Fan Motor

65ZV

HYDRAULIC 44

Fan Motor Removing and reinstalling fan motor 1. Removing fan motor

Fan motor

1) Remove hoses (1) (2) (3) from the fan motor. 2 70ZV44010

2) Attach sling to the fan bracket. Remove bolt (4) and then remove bracket with the fan motor and the fan. Torque for assembly: : Bolt: 93.7 N-m (9.55 kgf-m) (69 lb-ft) : Bracket(with fan motor and fan): 35 kg (77lbs)

Fan motor

70ZV44009

3) Remove flange nut (5) and then remove the fan. Torque for assembly: : Flange nut: 355 N-m (36 kgf-m) (260 lb-ft) 4) Remove bolt (6), and then remove the fan motor from the bracket. Torque for assembly: : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft)

Fan Bracket

Fan motor

2.Reinstalling fan motor For reinstallation,follow the above procedure in the reversed direction. 44-54

70ZV44008

Fan Motor

65ZV

HYDRAULIC 44

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

Cross section and tightening torque Follow the same procedure for the hydraulic pump disassembling / reassembling.

70ZV44008

: N-m (kgf-m) (lb-ft) T1: 47.5 ( 4.8) (35) T2: 102 (10.4) (75)

44-55

MEMO

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

45-1

Steering Valve

65ZV

HYDRAULIC 45

Steering Valve

Steering valve

Bolt (#1)

Bushing

Bracket

Plane washer Nut

65ZV45001

Tightening torque No.

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

Standard value

Steering valve retainer bolt

94 ( 9.6) ( 69)

Steering valve bracket retainer bolt

230 (23.5) (170)

Solution Tightening

45-2

Hydraulic Cylinder

65ZV

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder

65ZV45002J

Steering cylinder

65ZV45003J

Unit : mm (in.) Judgment standard No

Standard dimension of rod dia.

Item

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

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

– 0.030 (0.0011)

+ 0.035 (0.0013)

0.030 (0.0011)

– 0.076 (0.0030)

0 (0)

0.111 (0.0043)

– 0.025 (0.0009)

+ 0.085 (0.0033)

0.025 (0.0009)

– 0.046 (0.0018)

0 (0)

0.149 (0.0058)

0.266 (0.0104)

Item

+ 0.060 (0.0023)

No.

– 0.076 (0.0030)

Steering cylinder

0.090 (0.0035)

ø 40 (1.5748)

+ 0.190 (0.0075)

Bucket cylinder

– 0.030 (0.0011)

ø 80 (3.1496)

Bushing

Boom cylinder

Rod

Standard clearance

ø 65 (2.5590)

Standard value

Standard

Solution

Bushing

Clearance

+0.290 (0.0114)

0.366 (0.0144)

Replacement

+0.170 (0.0067)

0.246 (0.0097)

Replacement

+0.185 (0.0073)

0.249 (0.0098)

Replacement

Boom cylinder

Bucket cylinder

Steering cylinder

M48 x 1.5 2,501 (255) (1,845)

M48 x 1.5 2,354 (240) (1,736)

M27 x 1.5 490 (50) (362)

75 (2.9528)

41 (1.6142)

M22 686 (70) (506)

(Rod cover) M12 785 (80) (579)

M22 481 (49) (355)

45-3

Pilot Valve

65ZV

HYDRAULIC 45

Pilot Valve

212-1

97ZV45002

Judgment standard No.

212-1

Item

Push rod ø 7(0.276 in)

Solution

Wear 1 mm(0.0394 in)

45-4

Standard value

Allowable limit

36 mm (1.417 in)

35 mm (1.378 in)

Replacement

BRAKE GROUP 54 Disassembly and Reassembly Unloader Valve ............................................................................................54-2 Manifold Valve Assembly ............................................................................54-5 Accumulator.................................................................................................54-7 Brake Valve .................................................................................................54-8 Service Brake ............................................................................................54-14 Park Brake Actuator...................................................................................54-15 Parking Brake ............................................................................................54-20

54-1

Unloader Valve

65ZV

BRAKE 54

Unloader Valve Removing and reinstalling unloader valve

1.Removing unloader valve

WARNING

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

Unloader valve

1 70ZV54002

Unloader valve

Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure. - Press the hydraulic oil tank cap, and relieve the internal pressure from the hydraulic oil tank. - Prepare a container to catch drained oil. 1) Remove hoses (1) (2) (3) from the unloader valve.

70ZV54003

2) Remove hoses (4) (5) from the unloader valve. 3) Remove bolts (6) and then remove the unloader valve. Torque for assembly: : Bolt (6): 28 N-m (2.9 kgf-m) (21 lb-ft) : Unloader valve: 4 kg (8.8 lbs)

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

Unloader valve 70ZV54004

65ZV54011J

Unloader Valve

65ZV

BRAKE 54

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

1.Cross section and tightening torque

T8 T7 T4

T2 L1

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

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

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

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

97ZV54002

Unloader Valve

65ZV

BRAKE 54

2.Disassembling unloader valve

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

3 2

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

Pressure governor assembly

95ZV54001

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

54-4

Manifold Valve Assembly

65ZV

BRAKE 54

Manifold Valve Assembly Removing and reinstalling valve assembly

1.Removing valve assembly

WARNING

Valve assembly

65ZV54001

3 5

Valve assembly

7 6

65ZV54002

Valve assembly

1) Repeatedly depress brake pedal till you feel pedal becomes light. That will release oil pressure in brake line. 2) Remove hoses (1) (2) (3) (4) (5) (6) (7) from valve assembly. 3) Remove hose (8) from valve assembly. 4) Remove bolt (9) and then remove valve assembly. Torque for assembly: : Bolt (10): 28 N-m (2.9 kgf-m) (21 lb-ft) : Valve assembly: 10 kg (22 lbs)

8 65ZV54003

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

Note: After reinstallation, completely bleed the brake line of air, and check performance of the valve assembly. To bleed the brake line from air, refer to Section 24. To check performance of the valve assembly, refer to Section 53.

54-5

Manifold Valve Assembly

65ZV

BRAKE 54

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

1.Cross section and tightening torque T5 T1

T1 T1

(T)

(P)

T4 (TA)

(PI)

(PARKING) (ACCR)

(ACCF)

ACF (PA) (Z1)

(Z)

(Z2)

(PPI)

High pressure test ports

70ZV54012

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

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

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

Accumulator

65ZV

BRAKE 54

Accumulator Removing and reinstalling accumulator 1.Removing accumulator

Valve assembly

65ZV54004

3 4

1) Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line. 2) Remove hose (1) from the accumulator. 3) Remove nut (2) and then remove accumulator (3) with adapter (4) from the chassis.

1 B-Detail

WARNING

65ZV54005

Never weld on or near gas charged accumulator. Serious injury may result. When disposing, wear protective glasses and loosen plug to release gas in the accumulator completely. Do not remove plug.

2.Reinstalling accumulator To reinstall the accumulator, follow the above removal procedure in the reversed direction. Replace all O-rings and seals during reinstallation.

Note: After reinstallation, completely bleed the brake line of air, and check performance of the accumulator. To bleed the brake line of air, refer to Section 24. To check performance of the accumulator, refer to Section 53.

54-7

Brake Valve

65ZV

BRAKE 54

Brake Valve Removing and reinstalling brake valve Cover

1.Removing brake valve

WARNING Unexpected movement of machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park machine on level ground. - Block front wheels with chocks to prevent wheels from moving. - Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat, or disconnect the negative side of the battery. Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure. - Press the hydraulic oil tank cap, and relieve the internal pressure from the hydraulic oil tank. - Remove the cover.

Cover 95ZV54006

1 2

4 3 65ZV54017J

1) Remove brake pipes (1) (2) and brake hoses (3)(4) from the brake valve.

2) Remove brake hose (5) 3) Remove all adapters and fittings shown on the illustration from the brake valve. 4) Remove bolt (6) and then remove the brake valve. Tightening torque : Bolt: 28 N-m (2.9 kgf-m) (21 lb-ft)

65ZV54018J

2.Reinstalling brake valve To reinstall the brake valve, follow the above removal procedure in the reversed direction. Note: After reinstallation, completely bleed the brake line of air, and check all the pipe-joints for oil leakage. To check or adjust the brake valve, refer to Section 53. 70ZV54010

54-8

Brake Valve

65ZV

BRAKE 54

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

1.Cross section and tightening torque (Main valve)

A A-A

T1 L 1 A

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

9.8 (1.0) ( 7.2) T2: 176.4 ( 18) (130) T3: 73.5 (7.5) ( 54)

70ZV54011

L1: Screw lock agent 1303N application 54-9

Brake Valve

65ZV

BRAKE 54

Pedal

2.Disassembling brake valve Use a copper plate in vise and do not tighten the brake valve in vise strongly. [Main valve] 1) Pull out the snap pin to remove the pedal, seat, boot and pedal stopper. Note: At this step, the pin (L-Shaped) is dropped. Take care not to lose it.

Pin Seat Pedal stopper Boot

Snap pin Pin(L-shaped) 95ZV54010

2) Loosen four bolts and disconnect the bracket from the valve assembly.

Bolt (4 pcs)

Bracket

Valve assembly

95ZV54011

3) Turn the valve upside down. Loosen four bolts and separate the valve assembly into the S cylinder assembly, P cylinder assembly and T flange assembly. Note: Carefully separate the valve assembly. It may spring out by the spring force.

Bolt (4 pcs) S cylinder assembly

4) Remove the spring sub assembly from the T flange assembly. Remove the return spring and retainer all together.

P cylinder assembly

Spring sub assembly Return spring + retainer T flange assembly

95ZV54012

54-10

Brake Valve

65ZV

BRAKE 54

[Pilot Valve] Follow the same disassembling procedure for main valve. Disassembly step diagram [Main valve]

[Pilot valve]

S cylinder assembly

Spool return spring Return spring P cylinder assembly Spring sub assembly

Spring sub assembly

S flange assembly

Return spring + retainer

T flange assembly 95ZV54021

95ZV54020

54-11

Brake Valve

65ZV

3.Reassembling brake valve

BRAKE 54

S cylinder assembly

1) Install the return spring and retainer to the T flange assembly all together. Install the spring sub assembly to the T flange assembly. Note: Confirm that the rod of the spring sub assembly is at the center. Be sure to install them in the proper direction.

Spool return spring

P cylinder assembly

2) Install the P cylinder assembly to the T flange assembly. Spring sub assembly

3) Install the spool return spring to the spool of the P cylinder assembly.

4) Install the S cylinder assembly to the P cylinder assembly.

Return spring + retainer

T flange assembly

95ZV54020

5) Tighten four bolts. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft) Bolt (4 pcs) S cylinder assembly

P cylinder assembly

95ZV54022

54-12

Brake Valve

65ZV

6) Tighten four bolts to install the bracket. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft)

BRAKE 54

Bolt (4 pcs)

Bracket

Valve assembly 95ZV54011

Pedal

7) Install the boot, stopper and the seat to the valve assembly.

8) Install the pedal to the bracket. Turn the stopper bolt until the clearance between the seat and the roller is zero, then tighten the stopper bolt lock nut to fix the stopper bolt.

Lock nut

Seat Pedal stopper Boot

Snap pin Pin(L-shaped)

: Lock nut: 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) 95ZV54023

Stopper bolt: Screw lock agent 1303N application

9) Fix the pin (L) to the pin, and insert the pin to the bracket. At this time, the pin (L) should be in the pedal hole.

10) Making sure of the direction, install the snap pin to the pin.

54-13

Stopper bolt

Service Brake

65ZV

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

54-14

BRAKE 54

Park Brake Actuator

65ZV

BRAKE 54

Park Brake Actuator Removing and reinstalling park brake actuator 1.Removing park brake actuator

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - When removing the park brake actuator, the machine may move. To prevent the machine from moving, park the machine on level ground, and lower bucket to ground. - In addition, block tires with chocks to prevent wheels from moving.

3 Hose installation port

1) If there is an oil source, release the parking brake, and then remove split pin (1) and pin (2). Note: If there is no oil source, apply a cable to link, and then pull it down using a bar to overcome spring force, and then remove pin.

1 4 5

2) Release the residual air pressure in hydraulic tank. Disconnect oil hose (3).

3) Loosen locknut (4) to remove joint (5). Remove retainer bolts (6) to remove park brake actuator (7). : Retainer bolts: 53 N-m (5.4 kgf-m) (39 lb-ft) : Park brake actuator: 10 kg (22 lbs)

2.Reinstalling park brake actuator To reinstall the park brake actuator, follow the above removal procedure in the reversed direction.

Brake assembly

70ZV54009

Note: To insert the connection pin to connect the park brake actuator to the parking brake, observe the following items: ➀Start the engine to build oil pressure in the accumulator. ➁Release the parking brake. ➂Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the park brake actuator and the parking brake. After that, insert the connection pin into the joint hole. To check performance of the parking brake, refer to Section 53.

54-15

Park Brake Actuator

65ZV

BRAKE 54

Adjusting park brake actuator 1.Adjustment procedure of park brake actuator linkage

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. - Apply articulation stopper. 1

1) Release parking brake (OFF). 4

2) Measure dimension "A" if it is 98 mm (3 7/8 in.). 3) If not, remove pin (5), split pin (6), and washer (7) and loosen lock nut (2). And adjust linkage length by turning link (3) so that dimension "A" is 98 mm (3 7/8 in.).

2 A

4) Tighten lock nut (2) and reinstall pin (5), split pin (6) and washer (7). 3

5) Confirm parking brake performance. (Refer to Function & Structure)

5, 6, 7

65ZV54023J

Parking brake "OFF" position 1. Park brake actuator 2. Lock nut 3. Link 4. Bracket 5. Pin 6. Split pin 7. Washer

54-16

Park Brake Actuator

65ZV

BRAKE 54

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

1.Cross section and tightening torque

97ZV54004J

No specified torque When disassembling, put matchmarks on the rod cover cap and piston. During reassembling, align the matchmarks and install the set screw.

54-17

Park Brake Actuator

65ZV

BRAKE 54

1.Disassembling park brake actuator

WARNING The inner spring could spring out causing serious injury. To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the rod cap. When reducing the pressure of the press, be sure to slowly reduce it.

Matchmark

90ZV54016

1) Removal of the set screw of rod cap Note: Since the set screw is locked by punching, cut off the punched area with 15 to 20 mm dia. drill. Since it is necessary to install the set screw at the same position during reassembly, mark the positioning matchmark on the rod cap and cylinder tube. 2) Initial loosening of rod cap Using the threaded hole of the rod cap, unscrew the rod cap approx. 1/8 turn alone.

90ZV54006J

3) Removal of rod cap Using the press, press down the rod cover with the pipe (outer dia.: 50 mm or less, inner dia.: 30 mm or more, length: 80 mm), and it will be allowed to loosen the rod cap with hand. So, remove the rod cap. 4) Slowly pull up the press until the spring loses the spring force.

5) Pull out rod cover (1), spring (2), piston rod (3) and piston (4) from the cylinder tube.

90ZV54007J

3 4

1 2

54-18

90ZV54008J

Park Brake Actuator

65ZV

6) Put matchmarks on piston (4) and rod. Remove set screw (5) to pull out piston (4). Note: - Since the set screw is locked by punching, cut off the punched area with 15 to 20 mm dia. drill. - During reassembling, align the matchmarks and install the set screw at the same position.

BRAKE 54

3 5 4

Matchmark 90ZV54017

7) Remove dust seal (6) and bushing (7) from rod cover (1). Remove wear ring (8), U-packing (9) and O-ring (10) from piston (4).

8 4 9 10

90ZV54010J

3.Reassembling park brake actuator To reassemble the park brake actuator, follow the disassembly procedure in the reversed direction.

CAUTION When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined. Tighten the rod cap to the position where the matchmark was marked before disassembly, screw in the screw, and punch it for locking.

54-19

90ZV54011J

Parking Brake

65ZV

BRAKE 54

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

1) Drain the transmission oil. 1

2) Release the parking brake, and then remove pin (3) to disconnect link (1) and the lever (2).

65ZV54002J

3)Remove bolts (5) of propeller shaft (4). : Bolt (5): 80 N-m (8.2 kgf-m) (59 lb-ft) : Screw lock agent AB02 application

70ZV54003J

4) Remove bolt (6) of brake adjustment hole and then remove brake drum (7). Remove bolt (8) and flange yoke (9). : Bolt (6): 132 N-m (13.5 kgf-m) ( 98 lb-ft) Bolt (8): 883 N-m (90.0 kgf-m) (651 lb-ft) : Bolt (8): Screw lock agent AB01 application

9 8 7

54-20

65ZV54003J

Parking Brake

65ZV

BRAKE 54

5) Remove bolt (10) to remove parking brake assembly (11). Torque for assembly: : Bolt (10): 157 N-m (16 kgf-m) (116 lb-ft) : Bolt (10): Screw lock agent AB02 application

11 10

65ZV54004J

6) Remove right and left springs (12) using pliers. Remove plate (13).

13 12

65ZV54005J

7) Turn shoes hold-down pin (14) go degrees and remove it. Remove brake shoes (15).

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.

65ZV54006J

2.Reinstalling and reassembling parking brake

To reinstall and reassemble the parking brake, follow the above removal and disassembly procedure in the reversed direction. Note: To adjust the parking brake, refer to Section 53. To check performance of the parking brake, refer to Section 53. 54-21

65ZV54007J

MEMO

BRAKE GROUP 55 Service Standard Brake Valve .................................................................................................55-2 Service Brake ..............................................................................................55-4 Parking Brake ..............................................................................................55-5

55-1

Brake Valve

65ZV

BRAKE 55

Brake Valve 2 1 3 9 12

6 4 7 5 8 10 8 11 97ZV55001

Unit : mm (in.) Judgment standard No.

Item

Standard dimension

Tolerance Shaft

Hole

Solution

Standard clearance Allowable clearance

Clearance between pedal installation hole and bracket hole

ø 10 (0.3937)

-0.025~-0.075 (-0.0010~-0.0030)

+0.1 (0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Clearance between roller and pin

ø 10 (0.3937)

-0.025~-0.075 (-0.0010~-0.0030)

+0.1 (0.0039) 0

0.175~0.025 (0.0069~0.0010)

0.25 (0.010)

Outer diameter of roller

ø 30 (1.1811)

Replacement

0 -0.5 (-0.0197) Judgment standard

No.

Item

Standard dimension

Tolerance limit

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lb)

Free length mm (in)

Control spring

54.4 (2.1417)

49.7 (1.9567)

39 (4.0) (29)

53.0 (2.0866)

Control spring

27.2 (1.0709)

56.2 (2.2126)

Return spring

69.0 (2.7165)

58.0 (2.2835)

103 (10.5) (23.1)

62.1 (2.4449)

Balance spring

17.0 (0.6693)

15.0 (0.5906)

70 (7.1) (15.7)

16.2 (0.6378)

Spool return spring

31.5 (1.2402)

19.5 (0.7677)

17 (1.7) (3.7)

28.0 (1.1024)

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Bracket installation bolt tightening torque Cylinder installation bolt tightening torque

Plug tightening torque

176.4 N-m (18 kgf-m) (130 lb-ft)

Stopper bolt lock nut tightening torque

Solution

Installation load N (kgf) (lb)

Replacement

73.5 N-m (7.5 kgf-m) (54 lb-ft) Tightening 9.8 N-m (1.0 kgf-m) (7.2 lb-ft)

55-2

Brake Valve

65ZV

BRAKE 55

6 4 5

7 10

97ZV55002

Unit : mm (in.) Judgment standard No.

Item

Standard dimension

Solution

Tolerance Shaft

Hole

Standard clearance Allowable clearance

Clearance between pedal installation hole and bracket hole

ø 10 (0.3937)

+0.1 (0.0039) -0.025~-0.075 (-0.0010~-0.0030) 0

0.175~0.025 (0.0069~0.0010)

0.25(0.010)

Clearance between roller and pin

ø 10 (0.3937)

+0.1 (0.0039) -0.025~-0.075 (-0.0010~-0.0030) 0

0.175~0.025 (0.0069~0.0010)

0.25(0.010)

Outer diameter of roller

ø 30 (1.1811)

0 -0.5 (-0.0197)

Replacement

29.2(1.150)

Judgment standard No.

Item

Standard dimension

Tolerance limit

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lb)

Free length mm (in)

Control spring

54.4 (2.1417)

49.7 (1.9567)

39 (4.0) (29)

53.0 (2.0866)

Control spring

27.2 (1.0709)

56.2 (2.2126)

Return spring

65.0 (2.5591)

58.0 (2.2835)

71 (7.2) (15.9)

58.5 (2.3031)

Spool return spring

31.5 (1.2402)

19.5 (0.7677)

17 (1.7) (3.7)

28.0 (1.1024)

73.5 N-m (7.5 kgf-m) (54 lb-ft)

Bracket installation bolt tightening torque Cylinder installation bolt tightening torque

Plug tightening torque

176.4 N-m (18 kgf-m) (130 lb-ft)

Stopper bolt lock nut tightening torque

Solution

Installation load N (kgf) (lb)

Replacement

73.5 N-m (7.5 kgf-m) (54 lb-ft) Tightening 9.8 N-m (1.0 kgf-m) (7.2 lb-ft)

55-3

Service Brake

65ZV

BRAKE 55

Service Brake

Differential gear

65ZV55001

Unit : mm (in.) No.

Item

Judgment standard Standard dimension

Tolerance

Wear limit

8.0 (0.3150)

+ 0 (+ 0)~ – 0.2 (– 0.0078)

7.5 (0.2953)

Distortion of steel plate

–

0.3 (0.0118)

Thickness of friction plate

9.0 (0.3543)

± 0.1 (± 0.0039)

7.9 (0.3110)

Depth of lining groove

0.65 (0.0256) and more

–

Thickness of lining (both sides)

2.0 (0.0787)

± 0.1 (± 0.0039)

–

Thickness of brake retainer

32.8 (1.2913)

+ 0 (+ 0)~ – 0.1 (– 0.0118)

32.4 (1.2756)

Thickness of steel plate 1

Solution

55-4

Replacement

Parking Brake

65ZV

BRAKE 55

Parking Brake

5 3

65ZV55002J

Unit : mm (in.) Item

No.

Judgment standard Standard dimension

Wear limit

5.45 (0.2146)

0.8 (0.0315) from the rivet head

Solution Replacement

Wear of lining

Deflection of drum

0.38 (0.0149) or more

Replacement

Lining inspection

Grease or oil on the lining

Replacement

Expansion of adjuster spring

There is clearance between spring and coil

Expansion of return spring

when spring is released.

55-5

Replacement

MEMO

OPERATOR STATION GROUP 74 Disassembly and Reassembly Air Conditioner ............................................................................................74-2

74-1

Air Conditioner

65ZV

OPERATOR STATION 74

Air Conditioner Removing and reinstalling air conditioner 1.Removing the air conditioner Before starting work: a)Remover the seat in the cab. b)Collect the air conditioner refrigerant using the proper recovery method. c)Remove the floor mat in the cab. 1

2 1 4 2 3

View from operator's seat

95ZVE74001

1) Remove the box (1) (2). 2) Remove the cover (3) and the plate (4). 3) Remove the cover (5) (6) (7) from the cab. 4) Remove the duct (8).

Cab

74-2

95ZVE74002

Air Conditioner

65ZV

OPERATOR STATION 74

5) Disconnect the refrigerant piping (9) and the heater hose (10). Air conditioner unit

95ZVE74003

Air conditioner unit

10 95ZVE74004

6) Remove the air conditioner mounting bolts (11). Then, remove the air conditioner (12) from the floor board. 12

95ZVE74005

2.Reinstalling the air conditioner 1) To reinstall the air conditioner, follow the above removal procedure in the reversed direction. Reference After rainstalling the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-3

Air Conditioner

65ZV

OPERATOR STATION 74

Disassembling and reassembling air conditioner Tightening torque 1) Cooling unit

T2 T6 T4

T4 T5

T6 T4

T2 T1 T5

97ZV74002

: N-m (kgf-m) T1: 5.4 (0.55) T2: 1.9 (0.19) T3: 1.0 ( 0.1) T4: 0.8 (0.08) T5: 1.9 (0.19) T6: 2.5 (0.25) 74-4

Air Conditioner

65ZV

OPERATOR STATION 74

2) Heater and accessories

T1: T2: T3: T4:

: N-m (kgf-m) 4.0 ( 0.4) 0.8 (0.08) 1.0 ( 0.1) 5.4 (0.55)

T3 T2 T2

T4 T1

97ZV74003

3) Air distributor (hood & defroster selection box)

: N-m (kgf-m) T1: 3.7 (0.38) T2: 1.0 ( 0.1) T3: 0.8 (0.08)

97ZV74004

74-5

Air Conditioner

65ZV

OPERATOR STATION 74

4) Air compressor (with magnetic clutch) T1

T2 97ZV74005

: N-m (kgf-m) T1: 4.9 (0.5) T2: 18 (1.8)

5) Condenser unit T1

T1 T2 T1

97ZV74006

T1 : N-m (kgf-m) T1: 12 ( 1.2) T2: 5.4 (0.55)

74-6

OPERATOR STATION GROUP 75 Service Standard Air Conditioner ............................................................................................75-2

75-1

Air Conditioner

65ZV

OPERATOR STATION 75

Air Conditioner 1.Periodical Inspection/Servicing Inspection/maintenance item

Criteria

Solution

Refrigerant

Charge quantity

Air bubbles should not be seen through sight glass.

Inspection/ adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Clean

Compressor

Operating status

Belt tension pulley

Operating status

Magnetic clutch should operate. Abnormal sounds should not be detected. Abnormal sounds and backlash should not be detected.

Inspection/ adjustment/ replacement Inspection/ replacement

V belt

Damage and tension

Damages should not be detected.

Replacement

Abnormal sounds or vibration should not be Inspection/ detected. replacement Each part should operate in accordance with switch Inspection/ Control mechanism Operating status operations. replacement Air quantity should not be so small as to hinder air Cleaning/ Air filter for inside/outside air Clogging conditioning. replacement Each mounting area and Looseness,gas leak and Looseness,gas leak and damages should not be Tightening/charge piping damages detected. Blower motor and fan

Operating status

2.Tightening Torque 1) Tightening torque for hose and pipes Connection Connection area type

Nut type

Pipe size or bolt size

Tightening torque N-m

2) Tightening torque for screws and bolts in special control regions Special control area

(kgf-m)

Condenserexpansion valve

ø8 piping

Compressorcondenser

D1/2 piping

25 (2.50)

Evaporatorcompressor

D5/8 piping

34 (3.50)

Receiver

M6 bolt inreceiver (4T)

7 (0.70)

Any M6 bolt(6T) other than above

12 (1.20)

(kgf-m)

15 (1.50)

Head bolt of magnetic clutch

Mounting bolt for servo motor for inside/outside air selection (Tapping screw)

Block joint Evaporatorcompressor

Bolt size

Tightening torque N-m

75-2

18 (1.8) 0.8 (0.08)

Fixing nut of blower motor and condenser fan

5.4 (0.55)

Fixing bolt of blower motor and condenser motor

4 (0.4)

Notes