DOWNLOAD PDF :Kawasaki 80ZIV-2 WHEEL LOADER SHOP MANUAL AAA-S80N3E14-00Z (1)

AAA-S80N3E14-00Z (93209-00122)

WHEEL LOADER SHOP MANUAL

80 Z

Powered by NISSAN NE6T14 Engine.

SERIAL NUMBERS 80N3-9001 and up.

Disassembly & Reassembly Service Standard

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 Note: ① For General Information and Functions and Structure, refer to the 80ZⅣ -2 Shop Manual AAA-S80N3E00-00Z (93209-00102). ② For Troubleshooting and Measurement for Performance Check, refer to the 80ZⅣ -2 Shop Manual AAA-S80N3E01-00Z (93209-00112).

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 opinions 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 a 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 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 Reference

Description 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

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

l

Oil or water supply

Drainage

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

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

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

（4）

Hexagon Bolt Tightening Torque 少 Bolt type: 6 1 0 0 1 - 1 2 0 3 0 ① Thread type: Metric thread=0 少 ① ②③ ④ ⑤ Unified thread=2 ② Bolt strength: 4〜11 T ③ Thread pitch: Metric thread: Coarse pitch thread (C), fine pitch thread (F) Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF) ④ Diameter: 12 → 12mm Metric ; 12 → 12/16 → 3/4 inch Unified ⑤ Length: 030=30mm (Length is always given in mm for metric or unified bolts.)

Bolt size Type

Nominal dimension

Nominal dia.

Pitch

M8

8

(C) 1.25

9

26

38

(C) 1.5

19

53

76

(F) 1.25

20

55

80

(C) 1.75

32

90

132

(F) 1.25

34

96

142

(C) 2.0

51

142

206

(F) 1.5

54

152

221

(C) 2.0

76

216

314

(F) 1.5

80

226

330

(C) 2.5

103

299

436

(F) 1.5

113

324

476

(C) 2.5

147

417

608

(F) 1.5

162

451

662

(C) 2.5

196

559

814

(F) 1.5

211

598

878

(C) 3.0

255

721

1,030

(F) 2.0

270

770

1,128

(C) 3.0

373

1,030

1,520

(F) 2.0

397

1,128

1,618

(C) 3.5

510

1,422

2,109

(F) 2.0

549

1,569

2,256

(C) 3.5

686

1,912

2,844

M10 M12 M14 M16

Metric thread

Unified thread

(N-m)

Bolt strength

10 12 14 16

4.6 (4T)

8.8 (8T)

10.9T (11T)

M18

18

M20

20

M22

22

M24

24

M27

27

M30

30

M33

33

(F) 2.0

736

2,059

3,040

5/16

05

18 UNC

9

25

35

3/8

06

16 UNC

16

44

65

7/16

07

14 UNC

25

71

103

1/2

08

13 UNC

36

103

147

9/16

09

12 UNC

52

147

216

5/8

10

11 UNC

72

201

294

3/4

12

10 UNC

127

358

525

7/8

14

9 UNC

196

554

809

1

16

16 UNC

309

868

1,275

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

（5）

(kgf-m) Bolt size Type

Nominal dia.

Pitch

4.6 (4T)

8.8 (8T)

10.9T (11T)

M8

8

(C) 1.25

0.9

2.7

3.9

M10

10

(C) 1.5

1.9

5.4

7.8

(F) 1.25

2.0

5.6

8.2

M12

12

(C) 1.75

3.3

9.2

13.5

(F) 1.25

3.5

9.8

14.5

M14

14

(C) 2.0

5.2

14.5

21.0

(F) 1.5

5.5

15.5

22.5

M16

16

(C) 2.0

7.8

22.0

32.0

(F) 1.5

8.2

23.0

33.7

(C) 2.5

10.5

30.5

44.5

(F) 1.5

11.5

33.0

48.5

(C) 2.5

15.0

42.5

62.0

(F) 1.5

16.5

46.0

67.5

(C) 2.5

20.0

57.0

83.0

(F) 1.5

21.5

61.0

89.5

(C) 3.0

26.0

73.5

105.0

(F) 2.0

27.5

78.5

115.0

(C) 3.0

38.0

105.0

155.0

(F) 2.0

40.5

115.0

165.0

(C) 3.5

52.0

145.0

215.0

(F) 2.0

56.0

160.0

230.0

(C) 3.5

70.0

195.0

290.0

(F) 2.0

75.0

210.0

310.0

M18 Metric thread

M20 M22 M24

Unified thread

Bolt strength

Nominal dimension

18 20 22 24

M27

27

M30

30

M33

33

5/16

05

18 UNC

0.9

2.5

3.6

3/8

06

16 UNC

1.6

4.5

6.6

7/16

07

14 UNC

2.6

7.2

10.5

1/2

08

13 UNC

3.7

10.5

15.0

9/16

09

12 UNC

5.3

15.0

22.0

5/8

10

11 UNC

7.3

20.5

30.0

3/4

12

10 UNC

13.0

36.5

53.5

7/8

14

9 UNC

20.0

56.5

82.5

1

16

16 UNC

31.5

88.5

130.0

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

（6）

Flanged Hexagon Bolt Tightening Torque 1. Bolt Type 2. Bolt strength

Metric thread 4〜8T

3. Thread pitch

Coarse pitch thread(C)

(N-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

M5

0.8

4

7

M6

1

7

12

M8

1.25

15

28

M10

1.5

28

53

M12

1.75

50

94

M16

2

-

230

M20

2.5

-

441

M24

3

−

765

(kgf-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

M5

0.8

0.4

0.7

M6

1

0.7

1.2

M8

1.25

1.5

2.9

M10

1.5

2.9

5.4

M12

1.75

5.1

9.6

M16

2

-

23.5

M20

2.5

-

45.0

M24

3

−

78.0

（7）

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

Hose band

Tightening torque

Tightening torque

(N-m)

(kgf-cm)

1.6

16

4

40

Tightening torque (N-m)

Tightening torque (kgf-cm)

1.6

16

4

40

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

6

16.5

HH022W

8

18.5

HH022W

9

20.5

HH022W

9

22.0

HH023W

12

24.5

HH027W

12

26.0

HH027W

15

29.0

HH031W

15

30.5

HH031W

19

32.0

HH038W

19

34.0

HH038W

25

39.5

HH044W

25

41.5

HH044W

32

46.0

HH052W

32

48.0

HH052W

38

54.0

HH057W

50

70.5

HH076W

50

73.0

HH076W

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

Hose band Center of pipe protrusion 10〜20mm

（8）

Pipe

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

Liquid Gasket Code

Manufacturer

Product name

ＡＡ０１

Loctite

Plastic Gasket 568

ＡＡ０２

Loctite

Hydraulic sealant

ＡＡ０３

Three Bond

Three Bond 1215

Code

Manufacturer

Product name

ＡＢ０１

Loctite

Loctite 262

ＡＢ０２

Three Bond

Three Bond 1327

ＡＢ０３

Three Bond

Three Bond 1374

Screw Lock Agent

・Cautions regarding parts removal

・Cautions regarding reassembly

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 ℃ ) 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.

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 operation.

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 Code

Manufacturer

ＡＣ０１

Loctite

Product name Loctite 767 (Paste or spray)

（9）

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) Remove the ground terminal from the battery.

2) The controller circuit breaker should be turned "OFF" .

3)Ground the welder near the section to be welded.

4) To ground the welder, check that the electric current will not flow through the cylinders.

Cylinder head covers for some models have a low-conductive metal that will cause spark if the welding current flows. The spark may damage the cylinder rod.

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)

（ 10 ）

5) 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.

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.

Hydraulic cylinder

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

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.

1m or more

Scrap material, etc.

Section to be welded

1

1m or more

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

（ 11 ）

80Z Ⅳ -2

Weight of Main Components

Part name

Approx.

Weight (kg)

Bucket

1,130

GSN bucket

Boom

1,060

Standard

" Z " -Lever

285

Link (Bucket to Lever)

55

Engine room assembly

305

Hydraulic tank

130

Excluding oil

Fuel tank

130

Excluding fuel

Deck

65

Including hand rail

Cab

560

ROPS cab

Floor board

340

Including air conditioner unit and seat

Front chassis

1,470

Bare chassis

Rear chassis

1,330

Bare chassis

Counterweight

805/500

External / Internal counterweight

Engine

715

Excluding oil

Radiator

200

Excluding water and oil

Transmission

530

Excluding oil

Second propeller shaft

55

Third propeller shaft

10

Air cleaner

14

Exhaust silencer (Muffler)

11

Front axle assembly

1,000

Excluding tires and oil

Rear axle assembly

1,150

Excluding tires and oil (Including axle support)

Differential

165

Multiple control valve

54

Steering valve

22

Hydraulic

Gear pump

47

system

Boom cylinder

139/pc

Excluding oil

Bucket cylinder

198

Excluding oil

Steering cylinder

26/pc

Excluding oil

Tire

320/pc

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

Air conditioner unit

40

Battery

36/pc

Item Unit name

Chassis

Remarks

Power line

Other

(In cab portion)

（ 12 ）

Applying and Storing Articulation Stopper 1.Applying articulation stopper

WARNING Unexpected movement of the 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 17mm wrench remove bolt (1) from the articulation stopper on the front chassis.

１

2) Turn rod (2) (articulation stopper) until it comes in contact with pin (3). Insert the pin (3) into the rod to lock the front chassis to the rear chassis.

２

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.

３

LOCKED POSITION

３

2.Storing articulation stopper

２

Store the rod (2) and pin (3) as shown.

STORED POSITION

（ 13 ）

CHASSIS GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-1 CHASSIS GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15-1 POWER GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-1 POWER GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 25-1 TORQUE CONVERTER & TRANSMISSION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-1 TORQUE CONVERTER & TRANSMISSION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 35-1 HYDRAULIC GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-1 HYDRAULIC GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-1 BRAKE GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-1 BRAKE GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-1 ELECTRICAL GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-1 ELECTRICAL GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 65-1 OPERATOR STATION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 74-1 OPERATOR STATION GROUP ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 75-1

CHASSIS GROUP 14 Removing and Reinstalling Deck ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-2 Removing and Reinstalling Fuel Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-3 Removing and Reinstalling Hydraulic Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-4 Removing and Reinstalling Engine Room ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-5 Removing and Reinstalling Floor Board ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-8 Removing and Reinstalling Boom ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-10 Removing and Reinstalling Bushing ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-13 Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-15 Removing and Reinstalling Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-16

14-1

Removing and Reinstalling Deck

80ZIV-2

CHASSIS 14

Removing and Reinstalling Deck 1.Removing deck

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

Note : The illustration shows the parts on the left side. On the right side, the parts are located at the same points.

Cab

1)While considering the balance, apply a sling to the hand rail (1). Remove the retainer bolts (2)(3)(4).

Remove the deck (5) together with the hand rail.

５

１ ４

２

Torque for assembly: : Bolt : 90N-m (9.2kgf-m) : Deck (with hand rail) : 65kg ３ ６５Ｋ１４０４８

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

14-2

Removing and Reinstalling Fuel Tank

80ZIV-2

CHASSIS 14

Removing and Reinstalling Fuel Tank 1.Removing fuel tank

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

Before starting work: a) Drain fuel from the fuel tank. capacity: 240 l ) b) Remove the deck. c) Clean the area around the tank.

(Fuel tank

４ ３

１

1) Remove the cover (1).

2) Disconnect the level sensor electrical line coupler (2).

２

８０Ｋ１４００１

3) Temporarily sling the fuel tank (3) and remove the bolts (4). : Fuel tank : 130kg (empty) Torque for assembly: : Retainer bolt (5) : 216N-m (22.0kgf-m)

５

4) Slightly pull out the fuel tank to disconnect the suction/return hose (5). Plug the fuel line to prevent leakage and dirt entry. Be careful not to damage the fitting on the tank.

３ ８０Ｗ１４１０１

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

Note : After reinstallation, be sure to completely bleed air in the fuel line.

14-3

Removing and Reinstalling Hydraulic Tank

80ZIV-2

CHASSIS 14

Removing and Reinstalling Hydraulic Tank 1.Removing hydraulic tank

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

Before starting work: a) Drain hydraulic oil from the hydraulic tank.

(Hydraulic tank capacity. : 92 l) b) Remove the deck by referring to "Removing and Reinstalling Deck". c) Clean the area around the tank.

４

１

５

２

1) Disconnect the electrical line (3) and the vinyl tube (2) for the window washer liquid tank (1) (option).

Remove the hose (4) from the pilot valve.

３

８０Ｗ１４１０２

2) Disconnect the hose (5). ・Plug or cover the hoses to prevent leakage and dirt entry.

3) Disconnect the suction hose (6) at the tank side.

4) Temporarily sling the hydraulic tank (7), and remove the bolts (8). ８ ６

: Hydraulic tank : 130kg(empty) Torque for assembly: : Retainer bolt (8) : 216N-m (22.0kgf-m)

７

2.Reinstalling hydraulic tank

８０Ｋ１４００４

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

Note : After reinstallation, be sure to check the pipes for leakage, and also check the oil level of the hydraulic tank.

14-4

Removing and Reinstalling Engine Room

80ZIV-2

CHASSIS 14

Removing and Reinstalling Engine Room 1.Removing engine room

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

Before starting work: a) Remove the right and left decks together with the hand rail.

1) Remove the cover (2) of the screen board (1) from both the right and left sides.

１ ２ ８０Ｋ１４００５

2) Remove the clamp (3) and the exhaust pipe (4).

４

３

８０Ｋ１４００６

3) Disconnect the sub tank hose (5) for the radiator. ５

８０Ｋ１４００７

14-5

Removing and Reinstalling Engine Room

80ZIV-2

CHASSIS 14

4) Disconnect the hose (6) between the air cleaner and the turbo-charger at the turbo-charger side.

Note : Cover the hose and port of the turbo-charger to protect the turbo-charger from dust and dirt.

Engine

６ ８０Ｋ１４００８

5) Remove the band (8) of the brake oil tank (7).

Temporarily clamp the brake oil tank to the rear chassis side.

Note : The brake oil tank does not have to be drained.

８ ７

８０Ｋ１４００９

6) Disconnect the electrical coupler (9) for level sensor of brake oil tank. ９

８０Ｋ１４０１０

7) Remove the clamp for the rear axle breather tube (10).

１０

Rear axle ８０Ｗ１４１１０

14-6

Removing and Reinstalling Engine Room

80ZIV-2

CHASSIS 14

8)Open the radiator grill.

Disconnect the electrical line coupler (11).

Remove the bolts (12).

Torque for assembly: : Bolt (M12) 98N-m (10.0kgf-m) (M16) 216N-m (22.0kgf-m)

１１ １２

８０Ｗ１４１１１

Note : (M12) Retainer bolts : Qty : 6 (M16) Retainer bolts : Qty : 10 9) Lift the engine room together with the air cleaner. : Engine room : 305kg (Including air cleaner and condenser) Note : Slowly lift the engine room while checking that there are no obstacles.

Ｍ１６

Ｍ１２ Ｍ１６

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

Note : After reinstallation, check that the air cleaner rubber hose connection band is properly positioned and tightened with proper torque.

14-7

８０Ｗ１４１１２

Removing and Reinstalling Floor Board

80ZIV-2

CHASSIS 14

Removing and Reinstalling Floor Board 1.Removing Floor Board

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

Before starting work: a) Remove the deck from both the right and left sides of the machine. b) Disconnect the hose and the electrical coupler between the floor board and the chassis.

Note : Before disconnecting the electrical coupler, hoses and pipes, put match mark on them.

Prepare a can for the oil.

Cover the disconnected hoses and pipes with vinly to protect them from dust and dirt.

1) Disconnect the rod (1) from the drop arm (2).

２

１

６５Ｋ１４０１７

2) Disconnect the accelerator control cable (3) at the engine side. ３

８０Ｋ１４０３０

14-8

Removing and Reinstalling Floor Board

80ZIV-2

3) Remove the floor board (4) retaining nut (5).

Install the eye bolt (M16 × 2.0) to the 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, seat, etc.

CHASSIS 14

４ ５

260kg

Torque for assembly : : Nut (4) : 417N-m (42.5kgf-m)

８０Ｗ１４００１

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

Note : After reinstallation, start the engine, and then check the air, refrigerant, and oil lines for leakage. Also check operation of the electrical equipment.

14-9

Removing and Reinstalling Boom

80ZIV-2

CHASSIS 14

Removing and Reinstalling Boom 1.Removing boom

WARNING

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket onto the ground, and release the residual pressure from the hydraulic oil tank and lines. ・ Apply the parking brake and remove the starter key.

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 the pins (2) (3) for the bucket (1) to remove the bucket.

１

３

: Bucket : Approx. 1,130kg Note : There are shims in the pin sections.

Carefully store the removed shims, and correctly reinsert the shims when reinstalling the bucket.

２

６５Ｋ１４０２２

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

５

: Link : 55kg

６ ４ ８０Ｗ１４１１４

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

８

: Bucket cylinder : 190kg ５ ７

６５Ｋ１４０２４

14-10

Removing and Reinstalling Boom

80ZIV-2

CHASSIS 14

4) Lift the 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 will 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 ６５Ｋ１４０２５

5) Temporarily sling the lever (5), and then remove the lever pin (9). ５

: Lever : 285kg

９

６５Ｋ１４０２６

6) Start the engine. Lift the boom (10) until it is horizontal, and then place a stand (A) to support the bottom of the boom.

１０ １２

CAUTION Stop the engine when the boom is approximately 30cm 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.

Ａ

１１

６５Ｋ１４０２７

7) Temporarily sling the boom cylinders (11), and then remove the pins (12) from the cylinder rods on both the right and left sides of the boom.

8) Lower the boom cylinder (11) onto the machine.

Note : Supporting the boom cylinders with a wooden block eases sling removal and attachment. It also prevents metal to metal contact with the frame.

14-11

Removing and Reinstalling Boom

80ZIV-2

CHASSIS 14

9) Temporarily sling the cross pipe of the boom (10). : Boom : 1,060kg １０

10)Remove the pins (13) from the boom on both the right and left side of the boom.

CAUTION Loss of control of the boom structure during removal or installation could result in injury or machine damage.

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.

１３

６５Ｋ１４０２８

11)Slowly lift the boom (10) to remove it from the machine.

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

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

14-12

Removing and Reinstalling Bushing

80ZIV-2

Removing and Reinstalling Bushing 1.Removing dust seal Remove the seal using a screw driver as illustrated.

2.Reinstalling dust seal

CAUTION Make sure that the direction of the seal lip is as shown.

Use tool and install the seal.

14-13

CHASSIS 14

Removing and Reinstalling Bushing

80ZIV-2

CHASSIS 14

3.Removing bushing Use a hydraulic jack (A), adapter (1) and (2).

Remove two bushings at once.

Ａ Pulling direction

Adapter (1) material SS41

Diameter(mm) φA φC

φB

20

A

Bushing outside dia. -2

B

Bushing inside dia. -1

C

Jack rod dia. + 2

１ ２

20

Adapter (2) material SS41

φA φB

30

30

Dimension(mm) 30

A

Bushing outside dia. +20

B

Bushing outside dia. +5

L

Bushing length × 2

L Inspection hole

4.Reinstalling bushing Put clean grease on the bushings then use a hydraulic jack (A) and adapter (1). Install them from each side. Make sure to prepare the space for dust seal.

New bushing

CAUTION If there is a grease hole or groove on the bushing, make sure to align the hole or groove before installing the bushing. １

14-14

Ａ

Center Pin

80ZIV-2

CHASSIS 14

Center Pin Upper center pin

Shim adjustment

T1: 216N-m (22.0kgf-m) T2: 476N-m (48.5kgf-m) Shim adjustment: Adjust the clearance to 0.1± 0.05mm using the shim. After that, tighten the T1 bolt.

Split shim

Lower center pin

Rear

Front

Spherical plain bearing outer ring split position

Direction of grease nipple 20 °

14-15

Removing and Reinstalling Center Pin

80ZIV-2

CHASSIS 14

Removing and Reinstalling Center Pin 1.Removing center pin

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting center pin removal: ・ Place the machine on level and paved ground. ・ Lower the bucket onto the ground, and block the front tires with chocks, etc to prevent them from moving. ・ Apply the stopper to the rear wheel oscillation section to prevent the machine from oscillation. ・ Release the residual pressure from the hydraulic line, and also release the internal pressure from the hydraulic tank. ・ Cover the steering cylinder rod to prevent it from being scratched. １

Before starting work: a) Remove the parking brake link pin.

1) Remove the bolts and disconnect the second propeller shaft (1).

Torque for assembly: : Bolts : 142N-m (14.5kgf-m) : Screw lock agent application (Three bond 1327)

Bolt

８０Ｋ１４０１５

2) Disconnect the brake hose (2), and disconnect the electrical line (3) from the coupler. ２

: Brake oil : Approx. 3 l Note : Plug or cover the brake line hose to protect the hose from dust and dirt.

３

3) Disconnect the high-pressure hoses (4). ４

: Hydraulic oil : Approx. 5 l Note : Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

８０Ｋ１４０１６

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

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

５

６ ８０Ｋ１４０１７

14-16

Removing and Reinstalling Center Pin

80ZIV-2

5) The upper center pin will come in contact with the steering rod (7) as the upper center pin is removed. To smoothly remove the upper center pin, separate the steering rod (7), the drop arm (8) and the steering rod (9) from the steering valve and remove the bolt (10) for the bracket.

Torque for assembly: : Castle nut : 255N-m (26.0kgf-m) Retainer bolt : 216N-m (22.0kgf-m)

CHASSIS 14

９ １０ ８

Steering valve

７ Castle nut

８０Ｋ１４０１８

6) Remove the upper center pin retainer bolt (11).

Torque for assembly: : Retainer bolt : 471N-m (48.0kgf-m)

１１

８０Ｋ１４０１９

7) Screw the M12 (P1.75) bolt of approximately 70mm length into the center of the bushing (12) to push out the bushing. This bolt is used as a jack screw.

Remover bolt : M12(P1.75), totally threaded １２

70 ８０Ｋ１４０２０

8) Before disconnecting the front chassis (13) from the rear chassis, be sure to support the front chassis using the jack and blocks so that the front chassis will not fall backward.

１３

Jack ８０Ｋ１４０２１

14-17

Removing and Reinstalling Center Pin

80ZIV-2

CHASSIS 14

9) Before disconnecting the front chassis from the rear chassis, be sure to sling the rear chassis using a crane (apply the rope to the hook (14)) so that the rear chassis will not fall backward.

１４

８０Ｋ１４０２２

10)Push the upper center pin (15) out using a jack.

１５

Jack ８０Ｋ１４０２３

11)Support the bottom of the fuel tank (16) using a garage jack. １６

Garage jack ８０Ｋ１４０２４

12)Remove the lock bolt from the lower center pin (17). Push the lower center pin (17) out using another jack to remove the pin.

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

１７

８０Ｋ１４０３１

14-18

Removing and Reinstalling Center Pin

80ZIV-2

CHASSIS 14

13)Slowly turn the rear tires both the right and the left sides using a bar to separate the rear chassis.

Note : While turning the rear tires, check that the garage jack under the fuel tank shifts backward together with the rear chassis.

In addition, adjust the height using the rear crane whenever the height adjustment is necessary.

Bar ９０Ｋ１４０２２

14)Remove the ring (18) and remove the bolts (20) from the plate (19).

Torque for assembly: : Retainer bolt : 216N-m (22.0kgf-m)

１８ ２０

１９ ８０Ｋ１４０２５

15)Remove the shim (21).

Note : If the taper roller bearing (22) is replaced, be sure to adjust the clearance using the shim.

Thickness of shim(mm) : 0.1,0.2,0.3,0.5, and 1.0

２２

２１

８０Ｋ１４０２６

16)Check the dust seal (23) of the plate and the front chassis for distortion and scratches. If the dust seal is extremely distorted or scratched, replace it.

Note : Direction of dust seal.

(Top)

２３

(Bottom)

８０Ｋ１４０２７

14-19

Removing and Reinstalling Center Pin

80ZIV-2

CHASSIS 14

17)Check and replace the dust seal (24) of the lower center pin in the same way as described above.

２４

８０Ｗ１４１１７

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

After reinstallation, grease the center pins, and operate them. During operation, check the pins for abnormal noise and looseness.

14-20

CHASSIS GROUP 15 Linkage ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15-2 Linkage Pin Standard Clearance Values ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15-3 Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15-4 Bucket ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15-5 Bucket Positioner and Boom Kick-Out ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 15-6

15-1

Linkage

80ZIV-2

CHASSIS 15

Linkage 1. Bucket〜Boom

2. Boom〜Lever

3. Boom〜Boom cylinder

φ１２０

φ８０

φ７０

4. Front chassis〜Boom

5. Bucket〜Link

6. Lever〜Link

φ８０

φ９０

8. Bucket cylinder〜 Front chassis

7. Lever〜Bucket cylinder

10. Front chassis〜 Steering cylinder

9. Boom cylinder〜 Front chassis

φ８０

φ１００

φ１００

φ８０

11. Steering cylinder〜 Rear chassis

８０ＺⅣ１５０１

φ４５

φ４５

8

4

7

9 2

5

10

11

3 6

８０ＺⅣ１５０２

１

15-2

Linkage Pin Standard Clearance Values

80ZIV-2

CHASSIS 15

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

※

Item

Solution

Pin standard dimension

Standard clearance

Tolerance

1

Joint section between bucket and boom

φ 70

0.104〜0.213

1.0

Replacement

2

Joint section between boom and lever

φ 120

0.127〜0.256

1.0

Replacement

3

Joint section between boom and boom cylinder

φ 80

0.101〜0.217

1.0

Replacement

4

Joint section between front chassis and boom

φ 90

0.117〜0.237

1.0

Replacement

※

5

Joint section between bucket and link

φ 80

0.101〜0.217

1.0

Replacement

※

6

Joint section betwen lever and link

φ 80

0.101〜0.217

1.0

Replacement

7

Joint section between lever and bucket cylinder

φ 100

0.117〜0.242

1.0

Replacement

φ 100

0.117〜0.242

1.0

Replacement

φ 80

0.101〜0.217

1.0

Replacement

φ 45

0.078〜0.177

1.0

Replacement

φ 45

0.078〜0.177

1.0

Replacement

8

9

※

10

※

11

Joint section between bucket cylinder and front chassis Joint section between boom cylinder and front chassis Joint section between front chassis and steering cylinder Joint section between steering cylinder and rear chassis

Liner clearance adjustment ※

※ Adjustment procedure (for adjustment of liner clearance marked with asterisk): Adjust the liner clearance (marked with " ※ ") between the bosses to 1.2mm or less using liner of 1mm 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.

15-3

Center Pin

80ZIV-2

CHASSIS 15

Center Pin Adjusting Shim(#5)

〔Upper section〕

The clearance between the front chassis and bearing cover (#3) is 0.75 ± 0.5mm before shim adjustment.

Add shims so that the clearance is 0.1±0.05mm.

After adjusting shim, tighten bolt (#10).

4

11

7

8 10

#9・ ・ ・ ・476N-m (48.5kgf-m) #10・ ・216N-m (22.0kgf-m)

3 5 6 Front chassis

Rear chassis

12

9

2

1

7

〔Lower section〕

Installing bearing outer ring(#3)

6

8

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

7 5 2

#6・ ・ ・ ・216N-m (22.0kgf-m) 4

Grease nipple installation direction Install the both grease nipples (for the upper center pin and the lower center pin) as illustrated.

1 3 5 Rear chassis Front chassis ８０ＺⅣ１２０６

Front

Rear

3

Grease nipple installation direction

15-4

40 °

Split of outer bearing

Bucket

80ZIV-2

CHASSIS 15

Bucket (Tooth mounting section)

5 2

52

17.5 Tooth

１５−００５−０１ ８０ＺＡ

１５−００５ ７０ＺＡ

(Wear edge mounting section) 6

(Wear plate mounting section) Edge

7

25 17.5

Center 28 Side 32

Wear edge １５−００５−０２ ８０ＺＡ

1. Tooth mounting bolt 834N-m (85.0kgf-m) 2. Wear edge mounting bolt 834N-m (85.0kgf-m) 3. Wear plate mounting bolt 834N-m (85.0kgf-m)

15-5

25

17.5

Wear plate (option)

１５−００５−０３ ８０ＺＡ

Bucket Positioner and Boom Kick-Out

80ZIV-2

CHASSIS 15

Bucket Positioner and Boom Kick-Out Kick-out adjusting plate

6 5

3

A

A

(Bucket positioner)

(Boom kick-out) 3 2

Connector

3 4

4 1

Proximity switch ８０ＺⅣ１５０３

Section A-A

Unit : mm No.

Item

Judgment standard

Solution

1

Clearance of bucket positioner switch

5±2

Adjustment

2

Clearance of boom kick-out switch

5±2

Adjustment

3

Adjusting plate mounting bolt tightening torque

98N-m (10.0 kgf-m)

Tightening

4

Switch mounting nut tightening torque

20N-m (2.0 kgf-m)

Tightening

5

Bucket positioner adjustable angle

-7 ° 〜12 °

Adjustment

6

Boom kick-out adjustable angle

0〜43 °

Adjustment

15-6

Bucket Positioner and Boom Kick-Out

80ZIV-2

CHASSIS 15

Bucket angle adjustment

-7° 12°

Kick-out angle adjustment

0〜43

８０Ｗ１５００１

15-7

POWER GROUP 24 Power Line Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-2 Radiator Mount Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-3 Removing and Reinstalling Radiator ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-4 Removing and Reinstalling Engine ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-7 Removing and Reinstalling Propeller Shaft ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-10 Removing and Reinstalling Air Cleaner ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-11 Removing and Reinstalling Muffler ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-13 Front Axle Assembly Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-14 Removing and Reinstalling Front Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-15 Rear Axle Assembly Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-18 Axle Support Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-19 Removing and Reinstalling Rear Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-20 Disassembling and Reassembling Planetary Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-24 Floating seal ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-30 Removing and Reinstalling Differential ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-33 Special Jigs for Disassembling Axle ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-35 Disassembling and Reassembling Internal Gear Hub ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-38 Front Differential Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-40 Rear Differential Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-41 Disassembling and Reassembling Differential Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-42 Disassembling and Reassembling Spider Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-52

24-1

Power Line Tightening Torque

80ZIV-2

POWER 24

Power Line Tightening Torque T3 L 1

T2 L 3

Radiator

Engine

T1 L 3 T3 L 1

T2 L 1 T1 L 3 Front differential

T4 L 1 T5 L 2

Rear differential

T5 L 2

T6 L 2

Transmission

T4 L 1

T2 L 1

Third propeller shaft

T2 L 1

Second propeller shaft

８０Ｋ２４００１

: Bolt tightening torque T1 : 53N-m (5.4kgf-m) T2 : 417N-m (42.5kgf-m) T3 : 94N-m (9.6kgf-m) T4 : 216N-m (22.0kgf-m) T5 : 142N-m (14.5kgf-m) T6 : 80N-m (8.2kgf-m)

L1 : With liquid adhesive (Loctite 262 or equivalent) L2 : With liquid adhesive (Three Bond 1327 or equivalent) L3 : With lubricating oil (Engine oil or gear oil)

24-2

Radiator Mount Tightening Torque

80ZIV-2

POWER 24

Radiator Mount Tightening Torque T2 L 1

Radiator

Engine

T1 L 2

T2 L 1

８０Ｋ２４００２

: Bolt tightening torque T1 : 49N-m (5.0kgf-m) T2 : 216N-m (22.0kgf-m)

L1 : With liquid adhesive (Loctite 262 or equivalent) L2 : With lubricating oil (Engine oil or gear oil)

24-3

Removing and Reinstalling Radiator

80ZIV-2

POWER 24

Removing and Reinstalling Radiator 1.Removing radiator

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

Before starting work: a) Remove engine room (Refer to Section 14).

1) Remove the drain plug (1) to drain the coolant. : Capacity for coolant in system: 55 l １

８０Ｋ２４００３

2) Disconnect the coolant hoses (2) from the radiator.

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

２

８０Ｋ２４００４

3) Remove the fan guard (3).

３

８０Ｋ２４００５

24-4

Removing and Reinstalling Radiator

80ZIV-2

POWER 24

4) Remove the cover (4). ４

８０Ｋ２４００６

5) Disconnect the transmission cooler hose (5) and water hose (6), then disconnect the hydraulic oil cooler hose (7) and radiator drain hose (8). : Hydraulic oil : Approx. 2 l Transmission oil : Approx. 2 l Note : Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

７ ６ ８ ５ ８０Ｋ２４００７

6) Remove the plate (9) for both L & R side.

Torque for assembly: : Retainer bolt : 216N-m (22kgf-m) : With liquid adhesive (Loctite 262 equivalent)

or

９

８０Ｋ２４００８

7) Temporarily sling the radiator (10). Remove the right and left retainer bolts (11), and then lift the radiator.

１０

: Radiator : 200kg Torque for assembly: : Retainer bolt : 49N-m (5.0kgf-m) : With lubricating oil (Engine oil, gear oil etc.)

１１

８０Ｋ２４００９

24-5

Removing and Reinstalling Radiator

80ZIV-2

POWER 24

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

Note : Reinstall the radiator while checking that the right and left clearances between the fan and the radiator guard are equal to each other.

Clearance

８０Ｗ２４０１１

24-6

Removing and Reinstalling Engine

80ZIV-2

POWER 24

Removing and Reinstalling Engine 1.Removing engine

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

Before starting work: a) Refer to Section 14 "Removing engine room". b) Refer to Section 24 "Removing radiator".

Note : After removing the cooling fan, the engine may be removed without removing radiator. c) Drain the air in the air tank.

１

1) Disconnect the negative side (1) of the battery cable. Then remove the positive cable. ６５Ｋ２４０１３

2) Remove the wires from the alternator, starter motor and the oil pressure switch.

Remove the connector for the engine pressure switch, tachometer and the coolant temperature gauge.

Disconnect the heater hose and the fuel hose also disconnect the air lines from the compressor.

２

Engine

3) Disconnect the accelerator control cable. ２

4) Temporarily sling the engine and remove engine assembly mounting bolts (2).

Torque for assembly: : Retainer bolt : 417N-m (42.5kgf-m) : Engine assy : Approx. 765kg (Excluding oil) : ♯ 2・ ・ ・With liquid adhesive (Loctite 262 or equivalent)

８０Ｋ２４０１１

24-7

Removing and Reinstalling Engine

80ZIV-2

5) Remove the retainer bolts (3) from the housing between the engine flywheel and transmission.

Torque for assembly: : Retainer bolt : 52.5N-m (5.35kgf-m)

POWER 24

Engine

３

Rear differential

6) Separate the engine and the transmission from each other, and then lift the engine.

Note : Lift the engine approximately 100mm. Insert wooden piece of approximately 200mm thickness into the clearance between the flywheel bottom and rear axle to separate the engine and the transmission. Repeat this two to three times to completely separate the engine and the transmission from each other. Carefully lift the engine while checking that there are no obstacles around it.

Wooden piece

7)When the engine is exchanged, remove the bolts (4) and the ring gear (5) to use them for the engine newly installed.

Torque for assembly: : Retainer bolt : 44N-m (4.5kgf-m) : With lubricating oil (Engine oil or gear oil)

８０Ｗ２４０１９

８０Ｗ２４００９

Engine flywheel housing

Flywheel

４ T/M

６

５

Engine -to- transmission connection section ８０Ｗ２４０１０

24-8

Removing and Reinstalling Engine

80ZIV-2

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

Cautions regarding engine reinstallation ①There is an O-ring (6) in the housing between the engine and torque converter. Be sure to replace the O-ring with a new one. ②Refill the engine with the proper quantity and type engine oil. ③Refill the radiator with premixed coolant. ④After reinstalling the engine, completely bleed the fuel line of air. ⑤Set the starter key to ON, and then check the monitor lamps of electrical equipment. ⑥Operate the engine at the idling speed for 5 minutes. After that, check the amount of the coolant. ⑦While gradually increasing the engine speed, check operation of the electrical equipment.

24-9

POWER 24

Removing and Reinstalling Prop. Shaft

80ZIV-2

POWER 24

Removing and Reinstalling Propeller Shaft 1.Removing second propeller shaft

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

1) Disconnect the pillow unit grease pipe, and remove the bolt (2) from the pillow unit (1).

Torque for assembly: : Retainer bolt : 216N-m (22.0kgf-m) : With lubrication oil

２ １

2) Remove the bolt (3) from the transmission side of the propeller shaft.

Torque for assembly: : Retainer bolt : 142N-m (14.5kgf-m) : Screw lock agent (Loctite 262) application

４ ３ Transmission 2nd propeller shaft ８０Ｋ２４０１３

3) Remove the bolt (4) to disconnect the propeller shaft from the front differential. Support the shaft by cable or garage jack. Take out the second propeller shaft to the front.

Torque for assembly: : Retainer bolt : 142N-m (14.5kgf-m) : Screw lock agent (Loctite 262) application : Second propeller shaft : 55kg

2.Removing third propeller shaft 1) Remove the bolt (5).

Torque for assembly: : Retainer bolt : 80N-m (8.2kgf-m) : Screw lock agent (Loctite 262) application : Third propeller shaft : 10kg

3.Reinstalling second and third 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 23) 〔 Difference in the yoke phase (direction)will cause the propeller shaft damage. 〕

Rear differential 3rd propeller shaft

５

24-10

８０Ｋ２４０１４

Removing and Reinstalling Air Cleaner

80ZIV-2

POWER 24

Removing and Reinstalling Air Cleaner 1.Removing air cleaner 1) Remove the cap nut (1), and then remove the cover (2).

Note : Removing inside elements reduces the weight and facilitates air cleaner case removal work.

2) Remove the wing nut (3), and then remove the outer element (4).

１ ５

3) Remove the wing nut (5), and then remove the inner element (6).

３

６

４

２

７０Ｋ２４００７

4) Disconnect the air duct (7) and disconnect the indicator wire coupler (8). ８

７

８０Ｋ２４０１５

5) Remove the cover (9) from the top of the engine room (8).

９

８ ８０Ｋ２４０１６

24-11

Removing and Reinstalling Air Cleaner

80ZIV-2

POWER 24

6)While supporting the air cleaner case (10) with your hand, remove the band retainer nuts (11), and then lower the air cleaner case. １１ １０

８０Ｋ２４０１７

7) Take out the air cleaner case (10) from the opening. １０

８０Ｋ２４０１８

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

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

Carefully reinstall the air duct.

24-12

Removing and Reinstalling Muffler

80ZIV-2

POWER 24

Removing and Reinstalling Muffler 1.Removing muffler

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

Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ 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. ２ ３

1) Remove the clamp (1), exhaust pipe (2) and the drain pipe (3). : Clamp bolt tightening torque 29N-m (3.0kgf-m)

１

８０Ｋ２４０１９

2) Remove the bolt (5) of the exhaust pipe (4). ５

3) Remove the bolt (6) and band (7), then remove the muffler. : Muffler : 11kg Note : After disconnection, cover the pipe and the turbocharger side with vinyl, plugs or the like to protect the turbocharger from dust and dirt.

４

８０Ｋ２４０２０

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.

７

６

８０Ｋ２４０２１

24-13

Front Axle Assembly Tightening Torque

80ZIV-2

POWER 24

Front Axle Assembly Tightening Torque T4 L 1

T1 L 3

B

T5

T5

T9 L 2

A

T6 L 1

T5 T3 L 1

T5 T8

T2

T7 L 1

: Bolt tightening torque T1 : 687N-m (70.0kgf-m) T2 : 892N-m (91.0kgf-m) T3 : 216N-m (22.0kgf-m) T4 : 132N-m (13.5kgf-m) T5 : 79N-m (8.1kgf-m) T6 : 53N-m (5.4kgf-m) T7 : 90N-m (9.2kgf-m) T8 : 86N-m (8.8kgf-m) T9 : 10N-m (1.0kgf-m)

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

Note : 1. Axle nut tightening procedure 1)Tighten the axle nut (A) with 1177N-m (120 kgf-m) tightening torque to install the taper roller bearing.

2)Loosen the axle nut (A).

3)Tighten the axle nut (A) again with 1177N-m (120 kgf-m) tightening torque.

4)Turn the wheel hub 2 〜 3 turns back and forth, and measure the preload applied to section (B).

Preload of section (B) : 206〜 245N (21〜 25kgf) ＊ ＊ This is "breakaway" force. The force required to start the wheel turning.

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

24-14

Removing and Reinstalling Front Axle

80ZIV-2

POWER 24

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

WARNING ・ Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting axle removal. ・ Park the machine on level ground. Apply the parking brake and the articulation stopper. ・ Lift the front wheel using the bucket, and then place a stand under the front chassis to support the chassis.

Block the rear wheels with chocks. ・ Lift the boom, and place a stand under the boom to support it or install a boom cylinder lock collar.

Stand Stand

１

1) Disconnect the air breather tube (1) from the upper part of the axle.

Reassembly : Clean the nylon breather tube before reinstalling.

７０Ｋ２４０１９

2) Remove the second propeller shaft retainer bolt (2).

Torque for assembly: : Retainer bolt : 142N-m (14.5kgf-m) : Screw lock agent (Three Bond 1327) application

２

７０Ｋ２４０２０

3) Remove the right and left wheel and tire assemblies (3).

３

: 1 Tire : 320kg Torque for assembly: : Retainer bolt : 892N-m (91.0kgf-m)

７０Ｋ２４０２１

24-15

Removing and Reinstalling Front Axle

80ZIV-2

POWER 24

4) Disconnect the right and left brake pipes (4). : Brake oil : 3 l

４ ７０Ｋ２４０２２

5) Temporarily sling the axle assembly (5), and then remove eight retainer bolts (6). : Axle assembly : 1,000kg Torque for assembly: : Retainer bolt : 687N-m (70kgf-m) Note : During reassembly be sure both mating surfaces are clean and free of paint.

５

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

６ ７０Ｋ２４０２３

24-16

Removing and Reinstalling Front Axle

80ZIV-2

POWER 24

2.Reinstalling front axle assembly For reinstallation, follow the above procedure in the reversed direction.

After reinstallation the brake, be sure to completely bleed the brake of air.

For air bleeding procedure, refer to the following.

Brake oil

CAUTION Before air bleeding in the brake oil line, be sure that the wheel and tire assemblies are installed on the wheel hub.

If fail to do, the bolts (4 pcs) temporarily tighten the spider and the wheel hub may be broken by the brake piston.

Finally the spider and the cover may fall off.

Cover

Spider

Note : After reinstalling tires, check that manual rotation of the tires is possible. Also check the wheels for oil leakage.

Wheel hub

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

Fill the brake oil 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. When the oil level in the reservoir lowers, add oil to the tank.

Completely bleed each wheel of air.

24-17

Rear Axle Assembly Tightening Torque

80ZIV-2

POWER 24

Rear Axle Assembly Tightening Torque

B T5 T6 L 1 T5

T4 L 2 A

T5

T6 L 1

T2 L 1

T3 L 1

T6

T8

T1

T7 L 1

: Bolt tightening torque T1 : 892N-m (91.0kgf-m) T2 : 314N-m (32.0kgf-m) T3 : 216N-m (22.0kgf-m) T4 : 10N-m (1.0kgf-m) T5 : 79N-m (8.0kgf-m) T6 : 53N-m (5.4kgf-m) T7 : 90N-m (9.2kgf-m) T8 : 86N-m (8.8kgf-m)

Note : Tighten item A while measuring the preload applied to section B .

Preload of section B : 206 〜245N (21〜25kgf) ＊ ＊ This is "breakaway" force. The force required to start the wheel turning - not the force to keep the wheel turning.

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

24-18

Axle Support Tightening Torque

80ZIV-2

POWER 24

Axle Support Tightening Torque

T1 L 2

Rear axle

T2 L 1

T1 L 2

Front

８０Ｗ２４０１６

: Bolt tightenning torque T1: 687N-m (70.0kgf-m) With lubrication oil (Engine oil or gear oil) T2: 231N-m (23.5kgf-m)

L1 : Screw lock agent (Three Bond 1327) application L2 : With lubricating oil (Engine oil or gear oil)

24-19

Removing and Reinstalling Rear Axle Assy

80ZIV-2

POWER 24

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

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

Block here

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

Ａ

８０Ｋ２４０２９

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

Ｂ

８０Ｋ２４０３０

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

Wooden block

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

８０Ｋ２４０３１

24-20

Removing and Reinstalling Rear Axle Assy

80ZIV-2

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

POWER 24

１

: Tire of 1 wheel : 320kg (without hydroinflation) Torque for assembly: : Retainer bolt : 892N-m (91.0kgf-m)

８０Ｋ２４０３２

5) Remove the third propeller shaft retainer bolts (3) to remove the propeller shaft (2).

Torque for assembly: : Retainer bolt : 80N-m (8.2kgf-m) : Screw lock agent (Loctite 262) application : Third propeller shaft : 10kg

２

Rear differential

３

6) Disconnect the air breather tube (4).

Note : Remove and clean the tube (4) before reinstalling.

3rd propeller shaft ８０Ｋ２４０３３

４

Rear axle

８０Ｋ２４０３４

7) Remove the brake hose (5). : Brake oil : Approx. 3 l ５

８０Ｋ２４０３５

24-21

Removing and Reinstalling Rear Axle Assy

80ZIV-2

POWER 24

8) Temporarily sling the rear axle (6), and remove the right and left retainer bolts (7) from the axle support.

Torque for assembly: : Retainer bolt : 687N-m (70.0kgf-m) : Rear axle : 1150kg Note : Be careful not to bend or damage the oil pipes.

７

9) Lower the rear axle (6) on the carrier and pull out the rear axle on the carrier.

Note : The rear support is locked by not only the bolts but also dowel pins. Carefully remove or reinstall the support while checking the dowel pins.

６

８０Ｋ２４０３６

CAUTION The axle assembly could fall off the carrier causing injury.

Before pulling out the rear axle, carefully position the axle onto the carrier using a strap so that the axle will not fall from the carrier.

10)Sling the front support (9), and remove it from the rear axle. The support should slide off the rear axle.

９

: Axle support : 60kg 11)Remove the packing (10) and O-ring (11).

８

１０

１１ Rear axle

１４ １３

12)Remove the bushing (12), O-ring (13) and the packing (14).

Front

24-22

１２

８０Ｋ２４０３７

Removing and Reinstalling Rear Axle Assy

80ZIV-2

13)Temporarily sling the rear axle support (15) and remove the bolts (16).

Then remove the plate (17), packing (18), wearing (19) and O-ring (20).

Torque for assembly: : Retainer bolt : 231N-m (23.5kgf-m) Remove and clean the breather fitting. When the fitting is reinstalled use Liquid gasket AA03 (Three Bond 1215) on the threads.

Lubricate after reassembly to be sure grease comes out the breather. : Axle support : 75kg

POWER 24

Breather

１５ ２３ ２０ Grease piping

１６ １７

２４ ２２

２１

１９ １８

２５

８０Ｋ２４０３８

14)Remove the rear axle support (15) from the rear axle. Remove the packing (21) and the wearing (22).

15)Remove the bushing (23), ring (25) and the O-ring (24).

2.Reinstalling rear axle assembly For reinstallation, follow the above procedure in the reversed direction.

Note : After reinstallation, completely bleed the brake of air.

Ｆｒｏｎ ｔ ｓｕｐｐｏｒ ｔ

Axle support

[Bushing installation procedure] 1.Front support [Rear support] 1) Install the packing (1) and O-ring (2) [packing (3), wearing (4), ring (5) and O-ring (6)] on the swing shaft.

８

Bushing

２

９

2) Put the bushing into hot water to heat the bushing to 80 ° C. Install the bushing onto the swing shaft as shown in the illustration.

１

７ ３１ｍｍ

３８ｍｍ

Swing shaft ７０Ｋ２４０３４

3) After installing the axle support onto the swing shaft, install the O-ring (7), packing (8) and the snap ring (9). [Install the O-ring (10), wearing (11) and then install the packing (13) to the plate (12)].

Ｒｅａｒ ｓｕｐｐｏｒ ｔ

Axle support

CAUTION When installing the bushing onto the swing shaft, make sure no oil left on the inner surface of the bushing or the swing shaft surface.

If oil is left on them, the bushing may turn alone causing the bushing wear.

１３ ３

Bushing

１２

１１

４ ５

１０

Swing shaft

６

24-23

６８． １ｍｍ

４． ５ｍｍ

７０Ｋ２４０３５

Disassembling and Reassembling Planetary Assembly80ZIV-2

POWER 24

Disassembling and Reassembling Planetary Assembly 1.Disassembling planetary Notes :・Front axle is shown. To raise the rear axle off the ground follow steps of "Removing and Reinstalling Rear Axle Assy". ・Drawings of the required jigs are shown in "Special Jigs for Disassembling Axle".

WARNING Unexpected movement of the machine or components could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then apply the parking brake. ・ Apply the articulation stopper. ・ Block the rear wheels with chocks or the like to prevent the wheels from moving.

1) Lower the bucket onto the ground. Lift the front wheels while supporting the machine with the bucket. Place a stand (A) under the front chassis to support it. Check that the tires are off the ground.

Stand Stand

2) Remove the wheel and tire assembly (1) from the side to be disassemblied (example: left side).

１

: Tire of 1 wheel (for 20.5-25-16PR.) : 320kg(without hydroinflation) Torque for assembly: : Retainer bolt : 892N-m (91.0kgf-m)

７０Ｋ２４０３６

3) Remove the drain plug (2) from the differential section to drain oil. : Gear oil : Approx. 32 l

２ ７０Ｋ２４０３７

24-24

Disassembling and Reassembling Planetary Assembly80ZIV-2

POWER 24

4) Turn the drain plug (4) to the bottom of the wheel hub (3) to drain oil. : Gear oil : Front : Approx. 32 l Rear : Approx. 36 l Note : To replace the oil, refer to the oil amount described below.

Wheel hub section : 11 l for left side, 11 l for right side Differential section : Front : 32 l Rear : 36 l Total oil amount for front axle : 54 l Total oil amount for rear axle : 58 l

３ ４

5) Remove the cover (5).

Torque for assembly: : Retainer bolt : 90N-m (9.2kgf-m) : Screw lock agent (Three Bond 1327) application

７０Ｋ２４０３８

５

７０Ｋ２４０３９

6) Temporarily sling the spider using the hoisting tool (A) and (E). Remove four spider retainer bolts (8) to remove the spider assembly (9).

Torque for assembly: : Retainer bolt : 86N-m (8.8kgf-m) : Spider assembly : 80kg

Ａ ９

Ｅ

８ ７

６

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

７０Ｋ２４０４０

１０

8) Remove the friction plate (10).

７０Ｋ２４０４１

24-25

Disassembling and Reassembling Planetary Assembly80ZIV-2

9) Remove the steel plate (11) and the disc gear (12).

Note : Clean the brake plates, and then check the plates for distortion, discoloration and wear.

Refer to the section 54 and 55(Brake Group)for additional information.

POWER 24

１１ １２

７０Ｋ２４０４２

１５

10)Remove the axle shaft (13) and the wear ring (14).

Remove the retainer bolts (15) and then remove the lock plate (16).

１４

１６

１３

11)Turn the wheel hub (3) until the drain plug is positioned on the top. Connect the turnbuckle to the eye bolt (E) to lock the wheel hub.

Note : Be sure to lock the wheel hub, or the hub will drop when the axle nut is removed and the internal gear hub is removed.

７０Ｋ２４０４３

Turnbuckle

Ｅ

３ ７０Ｋ２４０４４

12)Remove the axle nut (17).

Note : Axle nut width across flat : 120mm

１７ ７０Ｖ２４０３１

24-26

Disassembling and Reassembling Planetary Assembly80ZIV-2

13)Pull out the internal gear hub (18) to the extension end face using the internal gear hub puller (B).

POWER 24

１８

Ｂ

７０Ｖ２４０２０

14)Sling the internal gear hub (18) using the internal gear hub hoisting tool (C).

And remove the hub (18).

Ｃ

１８

７０Ｋ２４０４７

15)Install the wheel hub hoisting tool (D) and remove the turn buckle.

Then remove the wheel hub (3).

Ｄ

Ｅ

３

７０Ｋ２４０４８

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

To reassemble the axle, follow the above procedure in the reversed direction.

24-27

Disassembling and Reassembling Planetary Assembly80ZIV-2

POWER 24

3.Cautions regarding reassembly 1) Reinstall the internal gear hub assembly.

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

2) Tighten the axle nut (1) so that the preload of the tire mounting hole section is 206 〜 245N (21 〜 25kgf).

Note : Measure the minimum pulling force to rotate the wheel hub using spring scale.

１

Torque for assembly: : Nut : 1,177N-m (120kgf-m)

3) Disconnect the brake pipe (2) and elbow (3).

３

24-28

２

Disassembling and Reassembling Planetary Assembly80ZIV-2

POWER 24

4) Attach the jig (B) for brake oil leakage test.

2 Apply 588kPa (6kgf/cm ) air pressure for approximately 1 minute. Shut off the valve.

Check that the pressure does not fall.

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

Ｂ

７０Ｋ２４０５１

Shut off valve

Air supply PT 1/4

Air pressure gauge

5) Check that the wheel hub drain plug is diagonal to the spider top mark. Fill the oil to the specified level.

Wheel hub Spider TOP mark

6) After reinstalling the brake, be sure to completely bleed the brake of air.

Note : After reinstalling tires, check that manual rotation of the tires is possible. Also check the wheels for oil leakage.

Drain plug (at bottom)

24-29

Floating Seal

80ZIV-2

POWER 24

Floating Seal Construction Floating seal location (3)Clean the seal installation part on the wheel hub and the seal ring, and remove oil on them.

Floating seal Wheel hub Axle housing

Ring

Remove oil

Ring

Seal cross section

Put thin gear oil (Do not use grease)

Do not touch by hand (It may cause rusting) O-ring

Seal Ring

Note : The rotating ring and the fixing ring are exactly the same. They can be used both ways.

Assembling procedure 1.Checking before seal installation (1)Checking seal ・Check the seal ring for distortion and scratches. ・Check the O-ring for scratches.

(2)Check the wheel hub and the ring for bur. If any remove it by sand paper etc.

24-30

Floating Seal

80ZIV-2

POWER 24

・Install the guide jig to the wheel hub and / or the ring. ・Put thin gear oil on the O-ring. ・Insert the floating seal into the guide jig.

2.Assembling procedure (1)In case no jig is used ・Install the O-ring on the seal ring. ・Put thin gear oil on the O-ring. ・Insert the floating seal into the ring and the wheel hub pushing the O-ring by fingers. (Make sub-assembly) ・Check if the seal ring is correctly positioned or the O-ring is not twisted. ・Clean the surface and put thin gear oil on it. ・Install the ring and the wheel hub to the axle housing.

Guide jig

(2)In case jig is used

１

２

Before installation

３

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

４

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

Guide jig

After installation

24-31

Installation

Floating Seal

80ZIV-2

POWER 24

3.Caution before operation ・After assembling, turn the wheel hub 2 〜3 turns by hands. ・Check if it turns lightly by hands. If it is tight to turn the wheel hub, the O-ring may be twisted.

In this case it may be necessary to disassemble the floating seal.

4.Jigs

Ｆｏｒ ｗｈｅｅ ｌ ｈｕｂ １．

２． １５

Ｆｏｒ ｒ ｉ ｎｇ （ ）

８±０．

３

２０

１３ ３

３Ｃ

（ ）

２．

１．

２０

１１±０． ２

３

３

５

１０±０． ３

Φ２３０

Φ１９０

Φ２２４． ８ ０ Φ２１４． ６−０． １ Φ２０９． ６±０． １ Φ２０１． １±０． １

Φ２１４． Φ２７０

３０ Φ２２６−０． −０． ３５ Φ２０９． ４±０． １

Φ２３０

Φ１９０

Φ２２４． Φ２１４． Φ２０９． Φ２０１． １±０．

Φ２３５

Φ２４０

１ Φ２１４＋０． ＋０． ０５

＋０． ２５ Φ２２３＋０． ３

Φ２０９． ４±０．

３

１０±０．

１０±０．

１０． ４±０．

Ｃ

Ｒ０． ３

Ｃ

Ｒ０． ２〜Ｒ０．

Ｒ０． ３ Ｒ０． ２〜Ｒ０． ５

24-32

Removing and Reinstalling Differential

80ZIV-2

POWER 24

Removing and Reinstalling Differential 1.Removing differential Before starting work: a) Drain oil from the axle assembly. b) Remove the axle from the machine. c) Place the axle assembly on work- benches. d)For the rear axle, remove the axle supports. For axle support removal, refer to "Removing and Reinstalling Rear Axle Assembly".

1) Temporarily sling the spider using the hoisting tool (A). Remove the retainer bolts (2) to remove the spider assembly (1).

Torque for assembly: : Retainer bolt : 86N-m (8.8kgf-m) : Spider assembly : 80kg

Ａ １

２

2) Pull out the right and left axle shafts (3) 30cm.

３

3) Remove the bolts (5) from the differential (4).

Torque for assembly: : Front differential retainer bolts : 132N-m (13.5kgf-m) : Rear differential retainer bolts : 314N-m (32kgf-m) : Screw lock agent (Loctite 262) application

４

５

24-33

Removing and Reinstalling Differential

80ZIV-2

POWER 24

4) Temporarily sling the differential (4), and insert bolts into the remover tap (Jack Screw) holes (6) to slightly lift the differential. : Differential : 165kg Note : Be careful to sling the differential so that it is balanced and is lifted straight up. ４

６ ８０Ｗ２４０１９

5) Lift the differential using the sling, and then remove the O-ring (7).

７

８０Ｗ２４０２０

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

Note : After reinstallation, refill with the specified oil until the oil level rises to the level check plug.

Also refill each planetary assy. Manually turn the flange yoke of the differential to check that the right and left wheel hubs turn smoothly.

Also check the differential for oil leakage.

24-34

Special Jigs for Disassembling Axle

80ZIV-2

POWER 24

Special Jigs for Disassembling Axle (A) Spider hoisting tool

(Material: SS41)

46

6-mm dia.round steel 4 10

C2

12

6

t6

t6

6

105

10

75

3

3 65

22

46

t6

65

(B)Internal gear hub puller & Brake piston remover

(Material: SS41)

25

25

Thickness: 12mm

M12

4

1.75

156

12

80

160 312 345

７０Ｋ２４０７９

24-35

Special Jigs for Disassembling Axle

80ZIV-2

POWER 24

(C) Internal gear hub hoisting tool

(Material: SS41) φ 13-mm drilled

75

35

t12

35

235 107

345

25

①

452

35

13

155

288

②

35 t9

31

27.5

35 90 A-A

A

A

24-36

27.5

25

15

3 15

7

10

t9

15

310

215

Special Jigs for Disassembling Axle

80ZIV-2

(D) Wheel hub hoisting tool

POWER 24

Cut the threaded area off the M8 eye bolt before use.

(Material: SS41)

10

4

4

3

20

t6

3

10

t6

3

25 ※

55

45 ※ The inside of this area should not be welded (for both sides).

3

4

20

t6

60

(E) Eye bolt

M24 × 2

The eye bolt (E) is used with the spider hoisting tool.

Cut the threaded area off the M10 eye bolt before use.

30

24-37

Internal Gear Hub

80ZIV-2

POWER 24

Disassembling and Reassembling Internal Gear Hub 1.Disassembling internal gear hub

１

３０４２８

1) Put internal gear hub assembly on a platform or a level place.

There is a snap ring (A) that connects the internal gear (1) to the internal gear hub (2). Shift the snap ring to the inside using a screwdriver or the like.

Ａ

Ｋ：６ ９１

２ Screwdriver Bend slightly

2) Sling the internal gear hub (2) to remove the internal gear (1).

１

３

3) Remove the O-ring (3).

３

８０Ｗ２４０２１

4) Remove the taper roller bearing (4).

Removal method : For easy removal, heat the inner race using a gas burner with slow flame.

5) Remove the brake piston fron internal gear hub (2). ４ ８０Ｗ２４０２２

24-38

Internal Gear Hub

80ZIV-2

POWER 24

2.Reassembling internal gear hub To reassemble the internal gear hub, follow the procedure described in the reversed direction.

3.Cautions regarding reassembly IMPORTANT ・ Replace the O-rings with new ones. ・ Clean and check all the parts. If a part is damaged, replace it with a new one.

1) Before reinstallation of the taper roller bearing (4), be sure to heat the bearing to 120 to 150 ℃ in oil.

2) Apply grease to the O-rings.

3) Check that the snap ring is properly inserted into the groove of the internal gear.

４

24-39

８０Ｗ２４０２３

Front Differential Tightening Torque

80ZIV-2

POWER 24

Front Differential Tightening Torque

7

〜

Shim (T=0.07) (T=0.50) 〜

(T=16.70) (T=16.98)

８０Ｗ２４０１７

: Bolt tightening torque T1 : 883N-m (90.0kgf-m) T2 : 515N-m (52.5kgf-m) T3 : 331N-m (33.7kgf-m) T4 : 314N-m (32.0kgf-m) T5 : 235N-m (24.0kgf-m) T6 : 55N-m (5.6kgf-m) T7 : 132N-m (13.5kgf-m)

Note : 1) To tighten T1 , measure the preload of section A .

Preload of section A : 57 to 66N (5.8 to 6.7kgf).

Use spacer B to adjust the preload.

2) Use shim E to adjust the tooth contact of spiral bevel gears C D .

Adjust the backlash by nut F .

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

165kg

24-40

Rear Differential Tightening Torque

80ZIV-2

POWER 24

Rear Differential Tightening Torque

7

〜

Shim (T=0.07) (T=0.50) 〜

(T=16.70) (T=16.98) ８０Ｗ２４０１８

: Bolt tightening torque T1 : 883N-m (90.0kgf-m) T2 : 515N-m (52.5kgf-m) T3 : 331N-m (33.7kgf-m) T4 : 314N-m (32.0kgf-m) T5 : 235N-m (24.0kgf-m) T6 : 55N-m (5.6kgf-m) T7 : 314N-m (32.0kgf-m)

Note : 1) To tighten T1 , measure the preload of section A .

Preload of section : 57 to 66N (5.8 to 6.7kgf).

Use spacer B to adjust the preload.

2) Use shim E to adjust the tooth contact of spiral bevel gears C D .

Use nut F to adjust the backlash.

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

170kg

24-41

Differential Assy

80ZIV-2

POWER 24

Disassembling and Reassembling Differential Assembly 1.Disassembling differential assembly

Adjust nut

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

Torque for assembly: : Nut : 883N-m (90kgf-m) Note : Nut width across flat : 57.1mm

Shim

Bevel gear Nut

Pinion

Adjust nut

1) Remove right and left lock plates (2) from the adjustment nuts (1).

1

2

2) Remove right and left bolts (3), bearing cap (4), and adjustment nut (1).

3

4

1 ７０Ｖ３４０３４

3) Remove the bearing outer race (5). Lift the differential cage assembly (6) to remove it.

5 6

24-42

Differential Assy

80ZIV-2

POWER 24

4) Put a match mark on the alignment point of the differential cage (7). Remove the bolts (8), and then separate the differential cage.

７

８ Ｍａ ｔ ｃｈ ｍａｒｋ ７０Ｋ２４０６４

5) Remove the thrust washer (9) and the side gear (10).

１０ ９ ７０Ｋ２４０６５

6) Remove the spider (11) with the pinion gears (12) and the thrust washers (13) as a unit.

１２

１３ １１ ７０Ｋ２４０６６

7) Remove the side gear (14).

１４ ７０Ｋ２４０６７

24-43

Differential Assy

80ZIV-2

POWER 24

8) Remove the thrust washer (15). １５

７０Ｋ２４０６８

9) Turn the differential upside down. Remove the bolts (17) from the bevel gear (16) to separate the gear.

１７

１６ ７０Ｋ２４０６９

10)Remove the bolts (18) to remove the pinion (19).

At the same time, remove the shim.

１９

１８

11)Remove the nut (20) and the O-ring (21).

Note : Nut width across flat:57.1mm. ２０

24-44

２１

Differential Assy

80ZIV-2

POWER 24

12)Remove the flange yoke (22).

２２

７０Ｖ２４０３５

13)Remove the pinion (23) from the cage (24).

２３

２４

14)Remove the taper roller bearing (25).

２５

15)Remove the spacer (26). ２６

24-45

Differential Assy

80ZIV-2

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) Check the preload of the pinion section by following the procedure below: ①Install the new roller bearing (27) on the pinion (23) if replacement is needed.

Note : After attachment, stake the bearing at three points as shown in the right figure. ②Install the new tapered roller bearing (28) and the spacer (26) on the pinion (23) if replacement is needed. ③Install the cage (24) and the tapered roller bearing (25). ④Put the yoke (22) and install the nut (20) on the pinion (23).

Note : Do not install the oil seal and O-ring of the nut. : Nut : 883N-m (90kgf-m) ⑤Measure the preload at section (A) (bolt hole).

２４ ２６

２０

２５ ２７

２３

Ａ

２８

２２ ７０Ｖ２４０３６

Pinion

Bearing

Pinion Stake at 3 points

Standard preload * : 57 to 66N (5.8 to 6.7kgf).

If the preload is out of the above range, replace the spacer (26) to adjust the preload to the specified range. * Preload is the force required to start the cage moving-breakaway force.

Note : There are 15 types of spacers from 16.70 to 16.98mm in increments of 0.02mm. Thicker spacers reduce preload; thinner spacers increase preload. ⑥Remove the nut (20) and the flange yoke (22).

2) Install the oil seal (29) to the cage (24). : Before installing oil seal, be sure to apply grease to the lip and liquid gasket the outside of the seal.

Check the direction of the lips Apply liquid gasket (AA03) to these surfaces

２９ ２４

24-46

Differential Assy

80ZIV-2

POWER 24

3) Install the flange yoke (22), and then the O-ring (21).

Apply liquid gasket to the nut (20), and then tighten the nut.

(Nut width across flat : 57.1mm)

22 20

: Nut : 883N-m (90kgf-m) : Liquid gasket (Three Bond 1215) application

21

4) Install the O-ring (30) and the shims (the one(s) removed during disassembly) to the cage. Insert the cage into the differential case (31), and tighten the retainer bolt (18).

Shim

18

: Bolt : 314N-m (32.0kgf-m) : Screw lock agent (Three Bond 1327) application

31

30

5) Install the thrust washer (15) and the side gear (14) to the differential cage (32).

15 14 32

７０Ｋ２４０７３

6) Attach the spider (11) with the side gears (12) and the thrust washers (13) as a unit.

12 13 11

24-47

Differential Assy

80ZIV-2

POWER 24

7) Install the side gear (10) and the thrust washer (9).

9 10

７０Ｋ２４０７４

8) Align the differential cage (7) with the match mark, and then tighten the bolts (8).

8

: Retainer bolt : 235N-m (24.0kgf-m) : Screw lock agent (Three Bond 1327) application

7

Match mark

9) Tighten the bolts (17) in the bevel gear (16). : Retainer bolt : 331N-m (33.7kgf-m) : Screw lock agent (Three Bond 1327) application 17 16 ８０Ｗ２４０２４

10)Install the differential cage assembly (6) in the carrier assembly.

6

24-48

Differential Assy

80ZIV-2

POWER 24

11)Reinstall the bearing cap (4), and then temporarily tighten the bolts (3). Reinstall the adjustment nut.

(For both the right and left sides)

3

4

Adjust nut 1

８０Ｗ２４０２５

12)Adjust the backlash as follows: ①Tighten the adjustment nut (33) on the bevel gear side until the backlash is "0". Then back off the adjustment nut 2 to 3 notches. ②Tighten the right adjustment nut (1). After you feel that the nut is tight, turn it one more notch. ③Attach the dial gauge stand to the carrier. Attach the dial gauge (A) to a tooth of the bevel gear (16).

Read the backlash value indicated on the dial gauge. ④Adjust the backlash.

Standard backlash : 0.26 to 0.38mm ・ Tighten the adjustment nut (33) on the bevel gear side or loosen the adjustment nut (1) on the opposite side to reduce the backlash. ・ Loosen the adjustment nut (33) on the bevel gear side or tighten the adjustment nut (1) on the opposite side to increase the backlash.

1

A

16

33

2

８０Ｗ２４０２６

34 3 4

13)Tighten the bolts (3) of the bearing cap (4). : Retainer bolt : 515N-m (52.5kgf-m) : Screw lock agent (Three Bond 1327) application 14)Mount the lock plate (2), and then tighten the bolts (34) to fix the lock plate. : Retainer bolts : 55N-m (5.6kgf-m) : Screw lock agent (Three Bond 1327) application

24-49

Differential Assy

80ZIV-2

POWER 24

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

Tooth contact

A

Adjusting method

Correct

Loosen the bearing adjuster on the rear side of 2

ring gear, and tighten the adjuster of tooth side at B

the same quantity as loosening, so that the ring gear is far apart from the drive pinion.

Check again the backlash and tooth contact.

2

C

Do the reverse adjusting as B.

Decrease the thickness of shim at the part of D

2

bearing cage being installed and makes drive pinion approach the ring gear.

Check again the backlash and tooth contact.

1

E

2

Increase the thickness of shim reverse as D, and makes drive pinion apart from the ring gear.

1

24-50

Differential Assy

80ZIV-2

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

4

HEEL 4〜5

Pitch line TOE

10

BOTTOM 10 2

Pattern B

4 TOP

4

Pitch line

HEEL 4〜5

10

TOE BOTTOM 10 3 Pattern C

4 TOP

3

TOE Pitch line

HEEL 4〜5

10

BOTTOM

Service parts: After adjusting the tooth contact and backlash in our factory, we will wrap the bevel gear and drive pinion as a unit. Therefore, replace the bevel gear and drive pinion as a unit.

Note : Single sale of the bevel gear or the drive pinion is not possible.

24-51

Spider Assy

80ZIV-2

POWER 24

Disassembling and Reassembling Spider Assembly 1.Disassembling spider assembly 1) Remove the lock bolts (1) and then the plate (2).

Torque for assembly: : Lock bolts : 216N-m (22.0kgf-m) : Screw lock agent (Three bond 1327) application ２ １

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

１ ３

４

3) Remove the wear rings (7) and the bearing (5), (6) from the planetary gear (4).

Bearing (5) : width 20mm Bearing (6) : width 25mm When assembling the bearing into the planetary gear, the bearing with width 20mm should be placed at outside (cover side) and the bearing with width 25mm to be placed at inside (brake retainer side).

５ ６

４

７

4) Turn the spider (9) upside down. Using a plastic hammer, tap the brake retainer (8) off the spider.

８

９ ８０Ｗ２４０２７

24-52

Spider Assy

80ZIV-2

2.Reassembling spider assembly Before starting work: ・ Clean all the parts. ・ Check the brake retainer, pins, bearings, planetary gears, wear ring, for distortion and wear. ・ Replace the O-ring and defective parts with new ones. ・ Inspect the internal bores of the spider for wear.

3.Cautions regarding reassembly ・ To reinstall the brake retainer, check that there is no clearance between the spider and the brake retainer. ・ The brake retainer may only be installed as it was removed. It may not be flipped over due to the roll pin hole design. ・ To insert the planetary pin, align the core holes of the planetary gear with that of the wear ring. ・ The lock bolt hole of the planetary pin is shifted from the center. Check that the bolt hole is shifted to the inside. ・ Manually turn the planetary gear to check that the gear smoothly rotates.

24-53

POWER 24

POWER GROUP 25 Propeller Shaft Service Standard ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 25-2 Axle Service Standard ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 25-3 Differential Service Standard ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 25-4

25-1

Propeller Shaft Service Standard

80ZIV-2

POWER 25

Propeller Shaft Service Standard

Third propeller shaft

１

１

Second propeller shaft １

２ Measurement of circumferential play

勝

匠

３ Measurement of transverse play

No.

Item

Tolerance mm

Solution

1

Spider bearing play

Second, third propeller shaft

0.25

Replacement

2

Spline circumferential play

Second propeller shaft

0.8

Replacement

3

Spline transverse play

Second propeller shaft

1.0

Replacement

Note : Bolt tightening torque 勝 69N-m (7.0kgf-m) 匠 147N-m (15.0kgf-m)

25-2

Axle Service Standard

80ZIV-2

POWER 25

Axle Service Standard Axle group

４

２， ３

１， ３

４

７０Ｋ２５００１

mm Judgment standard No.

Item

Solution Standard dimension

Tolerance

1

Backlash between sun gear and planetary gear

0.12〜0.60

←

Replacement

2

Backlash between planetary gear and internal gear

0.14〜0.73

←

Replacement

3

Tooth contact of gear

No abnormality

Replacement

4

Bushing and wear ring wear

No oil groove

Replacement

25-3

Differential Service Standard

80ZIV-2

POWER 25

Differential Service Standard Differential

１

２ ３

４

８０ＺⅣ２４１１

mm Judgment standard No.

Item

Solution Standard valve

Tolerance

1

Backlash between ring gear and drive pinion

0.26〜0.38

←

Adjustment

2

Backlash between side gear and pinion gear

0.23〜0.58

←

Adjustment

3

Clearance between pinion gear and spider

0.098〜0.153

←

Replacement

4

Runout of ring gear rear surface (when assembled)

0.076

←

Adjustment or replacement

5

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

6

Tooth contact

No abnormality

Replacement

25-4

TORQUE CONVERTER AND TRANSMISSION GROUP 34 Removing and Reinstalling Transmission Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-2 Bolt Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-11 Disassembling and Reassembling Torque Converter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-12 Disassembling and Reassembling Transmission Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-18 Forward/Reverse Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-28 1st/3rd Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-32 2nd Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-36 4th Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-39 Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-43 Control Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-44 Removing and Reinstalling Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-45 Disassembling and Reassembling Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-47

34-1

Removing and Reinstalling T / M Assy

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Removing and Reinstalling Transmission Assembly 1.Removing transmission assembly

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. Lower the bucket onto the ground, and then block the tires with chocks to prevent wheels from moving. ・ Disconnect the ground cable from the negative side of the battery. ・ Release the residual pressure from the hydraulic line, and also release the internal pressure from the hydraulic tank.

Before starting work: a) Remove the cab and the floor board by referring to Section 14. b) Remove the engine room by referring to Section14. c) 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 - Refer to Section 24.

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

１ ８０Ｋ３４１０１

: Transmission oil : 25 l 2) Disconnect the bolts (3) from the third propeller shaft (2) on the transmission side. Slide the yoke toward the transmission to release the drive shaft.

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 bolts, always replace with new ones.

Tightening torque for assembly : Bolt : 80N-m (8.2kgf-m) : Screw lock agent application (Three Bond 1327)

２

３

８０Ｋ３４１０２

４

3) Disconnect the electric wire from the speed sensor (4) and the shift sensor (5).

Note : The speed sensor (5) is for the machines S/N 80N3 - 9001 〜9150.

５

８０Ｋ３４１０３

34-2

Removing and Reinstalling T / M Assy

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4) Disconnect the hose (6) from the transmission level gauge.

Note : After removing the hose, plug or cover the disconnected part with clean vinyl to protect from dust and dirt.

６

８０Ｋ３４１０４

5) Remove the parking cylinder air hose (7). ７

Air cylinder

IMPORTANT When the transmission is lifted, it will come in contact with the steering valve. To prevent this, remove the steering valve before lifting the transmission.

８０Ｋ３４１０５

6) Disconnect all the hoses (8) from the steering valve.

Note : Cover the disconnected hose with vinyl to protect the hose from dust and dirt.

８

８０Ｋ３４１０６

7) Disconnect the hoses (9) and pipe (10).

Note : Cover the disconnected hoses and pipe with vinyl to protect them from dust and dirt.

９

１０

８０Ｋ３４１０７

34-3

Removing and Reinstalling T / M Assy

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

8) Remove the split pin (11), castle nut (12) and pin (13).

After that, disconnect the steering link (14).

Torque for assembly: : Castle nut : 255N-m (26.0kgf-m)

１６ １３ １４

9) Remove the retainer bolt (15), and then remove the steering valve (16) with the bracket (17).

Torque for assembly: : Bolt : 216N-m (22.0kgf-m) : Steering valve : 30kg

１７ １５ １２

１１ ８０Ｋ３４１０８

10)Disconnect the suction hose (19) and the outlet hose (20) from the gear pump (18). Remove the gear pump retainer bolts (21).

Torque for assembly: : Bolt : 245N-m (25.0kgf-m)

２１ １９

11)Remove the gear pump (18). １８

２０

: Gear pump : 47kg Note : Be sure to replace the gasket of the gear pump flange with a new one.

８０Ｋ３４１０９

IMPORTANT When the transmission assembly is lifted, it will come in contact with the gear pump suction hose. To prevent this, remove the hose before lifting the transmission assembly.

１９

12)Disconnect the gear pump suction hose (19) from the tank side.

Note : Cover the disconnected pipe with vinyl to protect the pipe from dust and dirt.

８０Ｋ３４１０９

IMPORTANT

２２

When the transmission assembly is lifted, it will come in contact with the multiple control valve. To prevent this, remove the multiple control valve before lifting the transmission assembly.

13)Put match marks on the hoses (22) 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.

８０Ｋ３４１１０

34-4

Removing and Reinstalling T / M Assy

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

14)Disconnect the hose (23) and the hoses (24). : Hydraulic oil : Apprix. 5 l Note : Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

２４

２３

８０Ｋ３４１１１

15)Remove the return pipe (25).

２５

８０Ｋ３４１１２

16)Use a hoist and strap to support the control valve (27) and remove the control valve (27) by removing the bolts (26).

Torque for assembly: : Bolt : 98N-m (10.0kgf-m) : Multiple control valve : 54kg

２８

２７

17)Remove the bracket (28) for the control valve.

Torque for assembly: : Bolt : 90N-m (9.2kgf-m)

２９ ２６ ８０Ｋ３４１１３

18)Remove the pipe (30).

Note : Cover the disconnected pipe with vinyl to protect the hose from dust and dirt.

３０

８０Ｋ３４１１４

34-5

Removing and Reinstalling T / M Assy

80ZIV-2

19)Remove the bolt (32) from the second propeller shaft (31) on the transmission side only.

Remove the bolt (33)(34) and then remove the third propeller shaft (35).

Tightening torque for assembly : Bolt : 142N-m (14.5kgf-m) : Screw lock agent application (Three Bond 1327)

TORQUE CONVERTER AND TRANSMISSION 34

３５ ３１

３３

３４

３２

20)Disconnect the electric wire from torque converter oil temperature switch sensor (36)(37).

Disconnect the hose (38)(39) between the torque converter and the cooler.

Note : Some oil will drain from the hoses and cooler - be prepared to drain the oil into a container. (about 10 l ) After removing the hose, cover the fitting section with clean vinyl to protect the fitting section from dust and dirt.

８０Ｋ３４１１５

３８

３６

３７

３９ ８０Ｋ３４１１６

21)Disconnect the hoses (40) between the torque converter and the line filter. ４０

８０Ｋ３４１１７

22)Remove all the electric wire couplers (42) from the control valve (41).

Note : Before disconnecting the couplers, be sure to put match marks on the couplers.

４２

４１

８０Ｋ３４１１８

34-6

Removing and Reinstalling T / M Assy

80ZIV-2

23)Disconnect the main clutch pressure outlet hose (43).

Note : After removing the hose, cover the fitting section with clean vinyl to protect the fitting section from dust and dirt.

TORQUE CONVERTER AND TRANSMISSION 34

４３

８０Ｋ３４１１９

24)Temporarily sling the transmission assembly (44), and then remove 12 bolts (45) from the engine flywheel housing.

Tightening torque for assembly : Bolt : 53N-m (5.4kgf-m) : Transmission assembly : 530kg

４４ ４５

８０Ｋ３４１２０

25)Remove the right and left side bolts (46), and then remove the plain washers (47) and the bushings (48).

Tightening torque for assembly : Bolt : 417N-m (42.5kgf-m)

４８

４６

Note : The joint section between the engine and the transmission consists of the pilot boss and the gear coupling as shown in the figure.

The pilot boss is inserted for centering, and the gear coupling is used for power transmission. To separate the transmission from the engine, remove the bolts from the engine flywheel housing, and then pull the transmission straight out approximately 50mm to the front.

４７

Engine flywheel housing

Flywheel Pull 50mm to separate transmission Transmission

Pilot boss Ring gear

Engine-transmission joint section

34-7

８０Ｗ３４００９

Removing and Reinstalling T / M Assy

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

26)Separate the transmission assembly from the engine, and then put the engine on the rear axle housing.

Note : Lift the transmission approximately 100mm, and then insert a wooden piece of 200mm into the clearance between the bottom of the engine flywheel housing and the rear axle housing. Lower the transmission to make a slight clearance between the engine and the transmission.Repeat the above procedure 2 to 3 times while pulling the transmission away from the engine to separate them.

Wooden block

27)Slowly lift the transmission assembly (44) while avoiding contact with other parts. ４４

2.Reinstalling transmission assembly １

To reinstall the transmission assembly, follow the above removal procedure in the reverse direction.

3.Cautions for installation ① Be sure to replace the O-ring (1) with new one.

② Rotate the engine flywheel to align the ring gear.

８５Ｋ３４０１９

34-8

Removing and Reinstalling T / M Assy

80ZIV-2

③ After reinstallation, check operation of the transmission assembly by the following procedure.

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death.

To prevent such an accident, be sure to stop the engine, and block to the tires with chocks before you start service work under the machine. During the service work under the machine, contact with the person in the operator seat using signals as agreed upon before hand.

1)At the completion of reinstallation, start the engine, and check that the shift lever properly functions at all the positions.

2)Check each section for oil leakage.

3)Adjust the transmission oil level to the specified point with the level gauge.

4)Perform the start-up tests as shown on the attached sheet.

34-9

TORQUE CONVERTER AND TRANSMISSION 34

Removing and Reinstalling T / M Assy

DATE:

80ZIV-2

HOURS:

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

-1

HIGH IDLE SPEED(min ) LOW IDLE SPEED(min-1) T/C STALL SPEED(min-1) HYDRAULIC STALL SPEED(min-1) FULL STALL SPEED(min-1) -1

CREEP WITH BRAKE (F1) SPEED(min ) CREEP WITH BRAKE (R2) SPEED(min-1)

CLUTCH PRESSURE AT IDLE F1

2

MPa (kgf/cm )

N1

MPa (kgf/cm2)

R1

MPa (kgf/cm2)

F2

MPa (kgf/cm2)

N2

MPa (kgf/cm2)

R2

MPa (kgf/cm2)

F3

MPa (kgf/cm2)

N3

MPa (kgf/cm2)

R3

MPa (kgf/cm2)

F4

MPa (kgf/cm2)

N4

MPa (kgf/cm2)

R4

MPa (kgf/cm2)

F1

2

MPa (kgf/cm )

N1

MPa (kgf/cm2)

R1

MPa (kgf/cm2)

F2

MPa (kgf/cm2)

N2

MPa (kgf/cm2)

R2

MPa (kgf/cm2)

F3

MPa (kgf/cm2)

N3

MPa (kgf/cm2)

R3

MPa (kgf/cm2)

F4

MPa (kgf/cm2)

N4

MPa (kgf/cm2)

R4

MPa (kgf/cm2)

CLUTCH PRESSURE AT HIGH IDLE

COMMENTS:

Serviceman's Signature

KAWASAKI HEAVY INDUSTRIES, LTD. CONSTRUCTION MACHINERY DIVISION Copy as required

34-10

Bolt Tightening Torque

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Bolt Tightening Torque T1 : 29N-m (3.0kgf-m) T2 : 59N-m (6.0kgf-m) T3 : 216N-m (22.0kgf-m) T4 : 392N-m (40.0kgf-m)(Molybdenum disulfide grease / MOS2 application) L1 : Screw lock agent application (Loctite 262)

T1 L1 T2

T2 L1

T2

T2 T3 L1 T2

T2

T4

T2

34-11

Torque Converter

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and Reassembling Torque Converter 1.Disassembling torque converter

２

Before starting work: a) Clean the transmission assembly. b) Drain oil from the transmission.

３

1) Remove the control valve (2), and then separate the torque converter (3) from the transmission assembly (1). : Control valve : 20kg : Torque converter : 150kg

１

８０Ｋ３４１２１

2) Remove the bolts (4), and then remove the cover (5).

５ ４

８０Ｋ３４１２２

3) Remove the bolts (6) connecting the front cover and the pump impeller. (Number of bolts : 18) Tightening torque for assembly : Bolt : 53N-m (5.4kgf-m)

６

4) Remove the front cover (7).

After removing the front cover, remove the ball bearing (8).

Note : If a shim is attached, remove the shim from the bearing and store it for reassembly.

７

Shim

８

８０Ｋ３４１２３

34-12

Torque Converter

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

5) Remove the turbine impeller assembly (9).

９

８０Ｋ３４１２４

6) Remove the needle bearing (10), thrust washer (11), and spacer (12). １０ １１ １２

８０Ｋ３４１２５

7) Remove the snap ring (13) and the stator (14).

１３ １４

８０Ｋ３４１２６

8) Remove the bolt (15) and the plate (16). １５ １６

８０Ｋ３４１２７

34-13

Torque Converter

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

9) Remove the pump impeller assembly (17), gear (18), thrust washer (19), thrust bearing (20), spacer (21), snap ring (22)(24) and the needle bearing (23) in order.

１８ １９ ２０ ２１ ２２ ２３ ２４

１７

８０Ｋ３４１２８

10)Remove the seal ring (25), bolts (26), and then stator shaft (27).

２５ ２６

２７

８０Ｋ３４００８

11)Remove the seal ring (28).

２８ ８０Ｋ３４００９

12)Remove the bolt (29) and then remove the torque converter pump (30).

Remove the bolt assy (relief valve) (31). ３０

３１ ２９ ８０Ｋ３４１２９

34-14

80ZIV-2

Torque Converter

TORQUE CONVERTER AND TRANSMISSION 34

2.Reassembling torque converter assembly ４

IMPORTANT ・ Clean and check all the parts. If a part is damaged, replace it with a new one. ・ Before reassembly, apply transmission oil to the parts.

１

1) Install the pump (1) and retainer bolts (2).

Install the bolt assy (3).

３ ２ ８０Ｋ３４１３０

IMPORTANT ・ Adjust the distance between the bolt (3) and the housing (4) so that the distance is 39.0mm.

３９． ０

５

８０Ｗ３４００９

８０Ｋ３４００６

2) Attach the seal ring (5). : Apply grease to the seal ring, and then insert into the groove. ６

3) Tighten bolts (7) to fix the stator shaft (6). : Bolt : 59N-m (6.0kgf-m) : Screw lock agent application (Loctite 262)

７

８

Attach the seal ring (8). : Apply grease to the seal ring, and then insert into the groove. ８０Ｋ３４００７

IMPORTANT ９

Adjusting thrust clearance ① Temporarily assemble the pump impeller (9) on the PTO drive gear, stator, bearing washers etc. and the turbine impeller (10). ② Measure the distance from the ball bearing (11) to the mounting face of the pump impeller assembly. Regard the obtained distance as dimension A.

１１

１０ ８５Ｋ３４０３０

34-15

80ZIV-2

Torque Converter

TORQUE CONVERTER AND TRANSMISSION 34

IMPORTANT ③ Measure the distance from the mounting face of the front cover (12) to the end face of the bearing receiver.

Regard the obtained distance as dimension B. ④ Adjust the difference between distance B and distance A (thrust clearance) to 0.2 to 0.4 mm using a shim as shown in the figure below. ⑤ After shim adjustment, remove the ball bearing (step (2) above), and then sequentially attach the shim and then the ball bearing to the front cover.

１２

８５Ｋ３４０３１

A

B-A = 0.2〜0.4mm Front cover

B

Ball bearing (11)

Adjusting shim ８０Ｗ３４０１０ ３４−０１５ ８５ＺⅣ

4) Install the needle bearing (13) and the snap ring (14)(15) into the gear (12).

Install the plate (17) to the pump impeller (16), and then attach the spacer (19), needle bearing (20), and thrust washer (21) in order.

１７

１６

１８ １２ ２０ １９ １５

２１

１３

１４

5) Install the stator (22), and attach the snap ring (23).

８０Ｋ３４１３１

２２

２３

IMPORTANT If the stator is installed upside down, the stator will not properly function.

Correctly install the stator (22) as shown in the photo.

８０Ｋ３４１３２

34-16

80ZIV-2

Torque Converter

TORQUE CONVERTER AND TRANSMISSION 34

6) Attach the spacer (24), thrust washer (25), and needle bearing (26). ２６ ２５ ２４ ２５

２６

２４ ８０Ｋ３４１３３

7) Install the turbine impeller assembly (27).

２８

２７

８０Ｋ３４１３４

8) Install the front cover (28), and then tighten the bolts (29) to connect the front cover to the pump impeller assembly.

Number of bolts : 18

２９

: Bolt : 29N-m (3.0kgf-m)

9) Install the cover (30), and then tighten the bolts (31).

３０

: Bolt : 39N-m (4.0kgf-m) Note : At the completion of reassembly, manually turn the front cover to check that it rotates smoothly.

３１

８０Ｋ３４１２２

34-17

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and Reassembling Transmission Assembly 1.Disassembling transmission assembly Before starting work: a) Clean the transmission assembly. b) Remove the coupling yoke, the seal retainer and the snap ring of ball bearing for the third propeller shaft. Unless removed, they will fall off. c) Place the transmission assembly so that the parking brake side is up. d) For disassembling and reassembling the parking brake, refer to Section 54.

１

1) Sling the control valve (2), and then remove the valve bolt (1). : Control valve : 20kg

２

８０Ｋ３４１３５

2) Remove the bolts (3) and the brake drum (4).

Remove the nut (5) and the flange yoke (6).

６ ４

５

３

８０Ｋ３４１３６

3) Remove the bolts (7) and then remove the brake assembly (8). ８

７

34-18

８０Ｋ３４１３７

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4) Remove the bolt (9) and the drive cover assembly (10).

１０

９ ８０Ｋ３４１３８

5) Remove the bolts (11), and then remove the cover (12).

Torque for assembly : Bolt : 59N-m (6.0kgf-m)

１２

１１ ８０Ｋ３４１３９

6) Remove the gear (13).

Remove the snap ring (14) and slide the flange yoke (15) to remove it. １３ １５

１４

８０Ｋ３４１４０

7) Remove the bolt (16) and separate the housing (17) and the torque converter. １６ １７

Torque converter

８０Ｋ３４１４１

34-19

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

8) Remove the snap ring (18) and then remove the output shaft (19) and the bearing (20) from the housing.

１８ ２０

１９

８０Ｋ３４１４２

9) Remove the 4th speed clutch pack assembly (21).

２１ ８０Ｋ３４００１

10)Remove the 1st speed clutch pack assembly (22).

Note : Pull out the 1st speed clutch pack assembly.

It is tight due to the ball bearing between the housing and the shaft. ２２

８０Ｋ３４００２

11)Remove the 3rd and the forward speed clutch pack assembly (23).

Note : Pull out the 3rd and the forward speed clutch pack assembly. It is tight due to the roller bearing between the housing and the shaft.

２３

８０Ｋ３４００３

34-20

Transmission

80ZIV-2

12)Remove the 2nd and the reverse speed clutch pack assembly (24).

Note : Pull out the 2nd and the reverse speed clutch pack assembly. It is tight due to the ball bearing between the housing and the shaft.

TORQUE CONVERTER AND TRANSMISSION 34

２４

８０Ｋ３４００４

13)Remove the bolts (25), and then remove the torque converter gear pump (26). ２６

２５ ８０Ｋ３４１４３

34-21

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

2.Reassembling transmission assembly Note : ・For clutch pack disassembly and reassembly refer to "Disassembling and Reassembling Clutch Pack". ・Clean and check all the parts. If a part is damaged, replace it with a new one.Refer to section 35 for wear limits. ・When assembling, apply transmission oil to the parts. ・Replace all the seals and packings with new ones. ・When installing each clutch pack assembly, manually turn the gears to check that the gears are properly engaged.

1) Install the torque converter gear pump (1).

Note : Check the thrust clearance (0.5 to 1.0mm) at the pump shaft (3)(PTO shaft). Tap the shaft with a soft hammer to check the thrust clearance, if necessary.

３ １

: Bolt : 59N-m (6.0kgf-m) ２ ８０Ｋ３４１４４

2) Install the 2nd and the reverse speed clutch pack assembly (4).

４

８０Ｋ３４００４

3) Install the 3rd and the forward speed clutch pack assembly (5).

５

８０Ｋ３４００３

34-22

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4) Install the housing (4), and then tighten the bolts (5)(6) to fix the housing. : Bolt : 59N-m (6.0kgf-m) ５ ４

６

８０Ｋ３４１４５

5) Install the 1st speed clutch pack assembly (8).

８

８０Ｋ３４００２

6) Install the 4th speed clutch pack assembly (7).

７

８０Ｋ３４００１

7) Install the small end bearing (10) on the output shaft (9) and install the snap ring (11).

Position the output gear (12) in the case.

Using a hoist lift the output shaft (9) up through the splines of the output gear (12). Support the bottom side of the shaft with a block or floor jack.

１０ １２ ９ １１

８０Ｋ３４１４６

34-23

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

8)Measure and records the clearance between the 1st speed clutch pack gear (13) and the 4th speed clutch pack gear (14).

１４

Note : The clearance between them should be 0.3〜0.5mm.

１３ ８５Ｋ３４０７６

9)Measure the distance from the bearing of the 4th speed clutch pack (14) to the mounting face (including gasket) of the housing.

Regarding the obtained distance as dimension A.

１４

８５Ｋ３４０７７

10)Measure the distance from the bearing of the 1st speed clutch pack (13) to the mounting face (including gasket) of the housing.

Regarding the obtained distance as dimension A ´.

１３ ８５Ｋ３４０７８

11)Measure the distance from the mounting face of the cover (15) to the end face of the bearing receiver for the 4th speed clutch pack.

Regarding the obtained distance as dimension B. １５

８５Ｋ３４０７９

34-24

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

12)Measure the distance from the mounting face of the cover (15) to the end face of the bearing receiver for the 1st speed clutch pack.

Regarding the obtained distance as dimension B ´.

１５

８５Ｋ３４０８０

13)Adjust the difference between the distance B and the distance A (thrust clearance) to 0.5 〜 1.0mm using a shim (16).

B-A=0.5〜1.0mm Shim thickness : 0.3mm

１６ ８５Ｋ３４０８１

14)Adjust the difference between the distance B ´ and the distance A ´ (thrust clearance) to 0.5 〜 1.0mm using a shim (17).

B ´ -A ´ =0.5〜1.0mm Shim thickness : 0.3mm

１７

８５Ｋ３４０８２

Note : Insert the shim into the section C so that the difference between the distance A(A´) and the distance B(B´) is adjusted to a clearance of 0.5 to 1.0mm.

Ｃ

34-25

Ｃ

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

15)Install the cover assembly (18) onto the housing and tighten the bolts (19).

１８

１９ ８０Ｋ３４１４７

16)Install the ball bearing (20) and the gear (21) into the cover assembly (18).

１８

２０ ２１

８０Ｋ３４１４８

17)Install the meter drive assembly (22) and tighten the bolt (23).

２２

: Bolt : 53N-m (5.4kgf-m) ２３

８０Ｋ３４１４９

18)Install the brake assembly (24) and thighten the bolt (25).

２４

: Bolt : 59N-m (6.0kgf-m)

２５ ８０Ｋ３４１５０

34-26

Transmission

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

19)Install the brake drum (26) and tighten the bolt (27).

Install the flange yoke (28) and tighten the nut (29). : Bolt : 59N-m (6.0kgf-m) : Nut : 392N-m (40kgf-m) (Molybdenum disulfide application)

２８ ２６

grease

２９

２７

３１

８０Ｋ３４１５１

３０

20)Install the control valve assembly to the housing and tighten the bolts (30)(31). : Bolt (30) : 39N-m (4.0kgf-m) : Bolt (31) : 20N-m (2.0kgf-m)

８０Ｋ３４１５２

34-27

Forward / Reverse Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Forward/Reverse Clutch Pack 1.Disassembling forward/reverse clutch pack (The disassembling procedure for the reverse clutch pack is described below.)

Note : The structure of the forward clutch pack is the same as to that of the reverse clutch pack.

Therefore, to disassemble or reassemble the forward clutch pack, follow the reverse clutch pack procedure.

1) Attach the bearing puller to the gear (1), and then remove the gear with the bearing (2) as a unit.

There is a thrust washer (3) between the gear (1) and the ball bearing. Remove the thrust washer.

Note : To disassemble the forward clutch pack, remove the roller bearing inner race.

For inspection and wear standards refer to . ２ １ ８５Ｋ３４０９２

２

３

１

2) Remove two needle bearings (4) and the thrust washer (5). After that remove the snap ring (6) and the pressure plate (7).

７

６ ５

４

８０Ｋ３４１５３

34-28

Forward / Reverse Clutch Pack

80ZIV-2

3) Alternately remove the friction plates (8) and the steel plates (9).

Note : Number of friction plates: 8 Number of steel plates: 7

TORQUE CONVERTER AND TRANSMISSION 34

８

９

８０Ｋ３４１５４

4) Slightly depress the spring retainer (12). Remove the snap ring (10), ring (11), and spring retainer (12).

１０ １１ １２

８０Ｋ３４１５５

5) Remove 20 springs (13), and then feed compressed air to the clutch oil port at the end of the shaft to remove the piston (14).

Note : If extremely high air pressure is applied instantly, the piston may spring out unexpectedly. To prevent this, apply low pressure first, and then gradually raise the air pressure.

１４

１３

８０Ｋ３４１５６

34-29

80ZIV-2

Forward / Reverse Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

2.Reassembling reverse clutch pack

２

１

Note : ・Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings. ・To reassemble the reverse clutch pack, be sure to apply transmission oil. ・Be sure the residual pressure prevention orifices are not plugged. Pass a small wire through the orifices.

1) Install the piston (1), and 20 springs (2). If necessary gently and evenly tap the piston into place using a plastic hammer or driver.

８０Ｋ３４１５７

３

2) Slightly depress the spring retainer (3). Insert the ring (4), and snap ring (5).

Note : When inserting the snap ring into the groove, use a screwdriver or the like to press the snap ring fully into the groove.

４

５

８０Ｋ３４１５８

3) Alternately insert the friction plates (6) and steel plates (7).

Note : Number of friction plates: 8 Number of steel plates: 7 After installing the piston, be sure to insert the friction plate first.

６ ７ ８０Ｋ３４１５９

1

6 2

3

4

7

7

6

5

３４−０２４ ８５ＺⅣ

34-30

Forward / Reverse Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4) Insert the pressure plate (8) and the snap ring (9).

９ ８ ８０Ｋ３４１６０

5) Using a straight edge and depth micrometer apply ) to the pressure (approx. 0.59MPa 〔6kgf/cm2 〕 clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Note :

Depth micro meter

Air

Piston stroke Forward

3.8±0.3mm

Reverse

4.3±0.3mm

If the piston stroke value is beyond the above range, replace the parts, or check that the parts not warped and are correctly assembled.

８５Ｋ３４０９７

6) Insert the thrust washer (10).

Note : When inserting the thrust washer (10), put the notch side up.

１１

１３

１０

7) Install the gear (11), and then insert two needle bearings (12) and the thrust washer (13).

Note : When inserting the thrust washer (13), put the notch side down.

１２

８０Ｋ３４１６１

8) Install the ball bearing (14).

Note : To assemble the forward clutch pack, install the roller bearing inner race.

１４

８０Ｋ３４１６２

34-31

1st / 3rd Speed Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

1st/3rd Speed Clutch Pack 1.Disassembling 1st/3rd speed clutch pack Note : This disassembling and reassembling procedures for the 1st and 3rd clutch packs are basically the same.

The different points are described for each procedure.

1) Remove the ball bearing (1) using a puller.

Note : Use a spacer over the shaft to protect the shaft and inner bearing from damage.

Spacer

１ ８５Ｋ３４０９９

2)〔3rd speed〕 a) Remove the thrust washer (2), and then remove the gear (3). b) Using internal or blind hole puller remove the needle bearings (4) and the thrust washer (5). 〔1st speed〕 a) Remove the thrust washers (6), and the thrust bearing (7). b) Using internal or blind hole puller remove the needle bearings (8), the thrust washers (9), and the thrust bearing (10).

７

６

２

３

８

４

５ 3rd speed

１０

９

1st speed

８０Ｗ３４０１１

3) Remove the snap ring (11) and the pressure plate (12).

１１ １２ ８０Ｋ３４１６３

34-32

80ZIV-2

1st / 3rd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

4) Alternately remove the friction plates (13) and steel plate (14).

Note : Friction plates

Steel plates

1st speed

10

9

3rd speed

5

4 １３

１４ ８０Ｋ３４１６４

5) Remove the snap ring (15), ring (16), and spring retainer (17). １５ １６ １７

８０Ｋ３４１６５

6) Remove 16 springs (18), and then feed compressed air to the oil port to remove the piston (19).

Note : If extremely high air pressure is applied instantly, the piston may spring out unexpectedly. To prevent this, apply low pressure first, and then gradually raise the air pressure.

１８ １９

８０Ｋ３４１６６

34-33

80ZIV-2

1st / 3rd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

2.Reassembling 1st/3rd speed clutch pack Note : ・Clean and check all the parts. If a part is damaged, replace it with a new one.Be sure to use new piston rings and seal rings. ・To assemble the 1st/3rd speed clutch pack, be sure to apply transmission oil. ・Be sure the residual pressure prevention orifices are not plugged. Pass a small wire through the orifices.

２ １

８０Ｋ３４１６７

1) Install the piston(1), and insert 16 springs (2).

Note : If necessary gently and evenly tap the piston into place using a plastic hammer or driver. ５

2) Slightly depress the spring retainer (3). Install the spacer (4), and snap ring (5).

Note : When inserting the snap ring into the groove, use a screwdriver or the like to press the snap ring fully into the groove.

４

３

８０Ｋ３４１６８

3) Alternately insert the friction plates (6) and steel plates (7).

Note : Friction plates

Steel plates

1st speed

10

9

3rd speed

5

4 ６

After installing the piston, be sure to insert the friction plate first. ７

1

6 2

3

4

7

7

6

5

３４−０２４ ８５ＺⅣ

34-34

８０Ｋ３４１６９

80ZIV-2

1st / 3rd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

4) Insert the pressure plate (8) and the snap ring (9).

８

９ ８０Ｋ３４１７０

5) Using a straight edge and depth micrometer apply air from the oil port, and then measure and record the piston stroke.

Note : Piston stroke + 0.5

1st speed

3.8 -1.0

mm

3rd speed

3.0±1.0mm

If the piston stroke value is beyond the above range, replace the parts, or check that the parts are not warped and are correctly reassembled.

８５Ｋ３４１０７

6)〔3rd speed〕Insert the thrust washer (10).

Note : Put the notch side up. 〔1st speed〕Insert the thrust washer (11), thrust bearing (12), and then thrust washer (13) as shown below.

13 12 11 １０

7)〔3rd speed〕Align and install the gear (14). After that, sequentially press in the two needle bearings (15), install thrust washer (16), and the ball bearing (17).

Note : When installing the thrust washer, put the notch side up. 〔1st speed〕Insert the gear (14). After that, sequentially press in the two needle bearings (18), install thrust washer (19), thrust bearing (20), thrust washer (19), and the ball bearing (21).

８０Ｋ３４１７１

２１ １７

１９ ２０ １９

１６ 3rd speed

１５

１８ １４

34-35

1st speed

2nd Speed Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

2nd Speed Clutch Pack 1.Disassembling 2nd speed clutch pack

1) Remove the gear (1). After that, remove the snap ring (2) and pressure plate (3). ３ ２

１

８０Ｋ３４１７２

2) Remove the friction plates (4) and steel plates (5).

Note : Number of friction plates: 5 Number of steel plates: 4 ４

５ ８０Ｋ３４１７３

3) Remove the thrust washer (6), thrust bearing (8), and thrust washer (7). Store the thrust washers for possible reuse.

６

８

７

８０Ｋ３４１７４

34-36

2nd Speed Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4) Depress the spring retainer (10) and remove the snap ring (9), and spring retainer (10).

5) Remove 16 springs (11).

１１ １０ ９

８０Ｋ３４１７５

6) Apply compressed air to the clutch oil port at the end of the shaft to remove the piston (12).

Note : If extremely high air pressure is applied instantly, the piston may spring out unexpectedly. To prevent this, apply low pressure first, and then gradually raise the air pressure.

１２

８０Ｋ３４１７６

2.Reassembling 2nd speed clutch pack Note :・Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings. ・To reassemble the 2nd speed clutch pack, be sure to apply transmission oil.

1) Reinstall the piston (1), and insert 16 springs (2).

If necessary gently and evenly tap the piston into place using a plastic hammer or driver. １ ２

８０Ｋ３４１７７

34-37

2nd Speed Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

2) Depress the spring retainer (3) and the install the snap ring (4).

3) Insert the thrust washer (5), thrust bearing (6), and thrust washer (7).

７

６

５

４

３

８０Ｋ３４１７８

4) Alternately insert the friction plates (8) and steel plates (9).

Note : Number of friction plates: 5 Number of steel plates: 4 After reinstalling the piston, be sure to insert the friction plate first.

８

９ １１

１０

８０Ｋ３４１７９

5) Insert the pressure plate (10) and the snap ring (11).

6) Using a straight edge and depth micrometer apply air to the clutch oil port at the end of the shaft, and measure and record the piston stroke.

Note : (Measure the stroke at the top surface of the pressure plate.)

Piston stroke:3.0±1.0mm : If the piston stroke value is beyond the above range, replace the parts, or check that the parts are not warped and are correctly reassembled.

１１ １０ ８５Ｋ３４１０７

7) Install the gear (12). １２

８０Ｋ３４２００

34-38

4th Speed Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4th Speed Clutch Pack 1.Disassembling 4th speed clutch pack

1) Using a puller remove the ball bearing (1).

１

８０Ｋ３４１８０

2) Remove the gear (2) and the thrust washer (3).

Use an internal or blind hole puller to remove the needle bearing (4) from inside the gear.

３ ４

５ ６

８０Ｗ３４００１

3) Remove the needle bearing (5) and the thrust washer (6). ２

６

８０Ｗ３４００２

34-39

4th Speed Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4) Remove the snap ring (7) and the pressure plate (8).

８ ７

８０Ｗ３４００３

5) Remove the friction plates (9) and steel plates (10).

Note : Number of friction plates: 5 Number of steel plate: 4

９

１０

８０Ｗ３４００４

6) Depress the spring retainer and remove the snap ring (11), ring (12), and spring retainer (13).

１２ １１

１３

８０Ｗ３４００５

7) Remove 16 springs (14), and then blow air to the clutch oil port at the end of the shaft to remove the piston (15).

Note : If extremely high air pressure is applied instantly, the piston may spring out unexpectedly. To prevent this, apply low pressure first, and then gradually raise the air pressure.

１５ １４

８０Ｗ３４００６

34-40

4th Speed Clutch Pack

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

2.Reassembling 4th speed clutch pack Note : ・ Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings. ・To reassemble the 4th speed clutch pack, be sure to apply transmission oil.

1) Reinstall the piston (1), and insert 16 springs (2).

１ ２

８０Ｋ３４１８６

2) Insert the spring retainer (3), ring (4), and snap ring (5).

Note : When inserting the snap ring into the groove, use a screwdriver or the like to press the snap ring fully into the groove.

５

４

３

８０Ｋ３４１８７

3) Alternately insert the friction plates (6) and steel plates (7).

Note : Number of friction plates: 5 Number of steel plates: 4 After reinstalling the piston, be sure to insert the friction plate first.

６

７

８０Ｋ３４１８８

34-41

80ZIV-2

4th Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

4) Insert the pressure plate (8) and the snap ring (9). ８ ９

８０Ｋ３４１８９

5) Using a straight edge and a depth micrometer, apply air through the clutch oil port at the end of the shaft, and measure and record the piston stroke.

Note : (Measure the stroke at the top surface of the pressure plate.)

Piston stroke: 2.95±1.0mm : If the piston stroke value is beyond the above range, replace the parts, or check that the parts not warped and are correctly reassembled.

８０Ｋ３４００５

6) Insert the thrust washer (10) and press in the needle bearing (11).

１０ １１

Needle bearing Thrust washer

Note : When inserting the thrust washer, put the notch side up.

１０

7) Align and install the gear (12). After that, press in the needle bearing (13) and insert the thrust washer (14).

８０Ｋ３４１９０

１４ １３ １２ １２ １４１３ １５

Note : When inserting the thrust washer, put the notch side down.

8) Install the ball bearing (15).

８０Ｋ３４１９１

34-42

80ZIV-2

Control Valve

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve

4 A

A

10

7 5

8

9

6 ８０Ｗ３４００７

4

1

Section A-A

2

８０Ｗ３４００８

3

34-43

1. Clutch pressure regulator valve 2. Trimmer plug mm 3. Orifice (1.3 -dia.)

4. Trimmer solenoid valve 5. Forward clutch solenoid valve 6. Reverse clutch solenoid valve 7. 1st speed clutch solenoid valve 8. 2nd speed clutch solenoid valve 9. 3rd speed clutch solenoid valve 10. 4th speed clutch solenoid valve

Control Valve Tightening Torque

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Tightening Torque

T1

T2

T4

T2

T3

８０Ｋ３４１９３

T1: 20N-m (2.0kgf-m) T2: 39N-m (4.0kgf-m) T3: 10N-m (1.0kgf-m)(Solenoid valve nut) T4: 32N-m (3.3kgf-m)(Solenoid valve body)

34-44

Removing and Reinstalling Control Valve

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Removing and Reinstalling Control Valve 1.Removing control valve

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

1) Disconnect all the electric wire couplers (1). Also disconnect the hoses (2 pcs) and the hose for checking the clutch pressure.

Note : Put match marks on the electric wire couplers.

1

８０Ｋ３４１９４

2) Temporarily sling the control valve (2), and then remove the valve bolts (3).

Also remove the clamp bracket (4).

Note : Do not remove two trimmer bolts.

Tightening torque for assembly : Bolt : 39N-m (4.0kgf-m)

３

２

４

８０Ｋ３４１９５

3) Lower the control valve (2) to remove it.

Be sure to replace the gasket (5).

２

CAUTION After removing or while reinstalling the control valve, take care not to allow foreign material into the main body or the control valve. Carefully remove or reinstall the control valve and gasket.

５

: Control valve : 20kg

８０Ｋ３４１９６

34-45

Removing and Reinstalling Control Valve

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

2.Reinstalling control valve Cautions for installation 1) Be sure to replace all the O-rings and gaskets with new ones.

BrL

2) Sequentially tighten the bolts in the order from the center to the outside. Apply equal (specified) torque to all the bolts.

BrGy

Control Valve

TR

④

BrY

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

BrR BrB

4) Install the cover while checking that the emergency operation bolts are positioned over the center of the solenoid valves.

BrW BrG

5) During installation, be careful not to damage the gasket.

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death.

To prevent such an accident, be sure to stop the engine, and block the tires with chocks before you start service work under the machine. During the service work under the machine, closely contact with the person in the cab using signals preliminarily determined.

6) At the completion of installation, start the engine, and check that the shift lever properly functions at all the positions.

7) Check oil leakage.

8) Adjust the transmission oil level to the specified point with the dipstick.

34-46

① F R

③

②

Control Valve

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and Reassembling Control Valve 1.Disassembling control valve Note: Clean the control valve.

1) Remove the nut (1).

Note : Nut width across flat : 30mm Tightening torque for assembly : Bolt : 10N-m (1.0kgf-m) １

2) Remove the coil (2), and then remove the O-rings (3).

Note : For other solenoid valves, follow the same procedure.

１ ２

３ ８０ＺⅣ３４０４

3) Remove the valve (4) using special tool (A).

Note : Special tool (A) is described on the next page.

For other valves, follow the same procedure.

Tightening torque for assembly : Valve : 32N-m (3.3kgf-m)

Ａ

４

８０ＺⅣ３４０５

4) Remove the plugs (5) (6), and then remove the parts from the inside.

Note : Do not remove the trimmer body (7) unless absolutely necessary.

５ ７

６

34-47

Control Valve

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

5) Remove the regulator valve (1), trimmer plug (2), springs (3), spring retainer (4).

１

４

３

２

2.Special tool(A) Material : SS41 North American dealer tool number : KL03-102-1

８０ＺⅣ３４０６

75 65 60 15

φ 30

φ 23

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

Cautions for assembly 1) Before inserting the regulator valve, apply transmission oil to the valve. After insertion, check that the valve operates smoothly.

2) Placing shims under the springs to increase pressure or change modulation is not recommended.

Check free lengths and if necessary replace them.

3) 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).)

4) Replace all seals, O-rings and gaskets.

5) Check coil resistance.

Resistance : Approx. 26 Ω

34-48

φ 7 Drill

.1 -0 .2 -0 7 1

5 φ 40

30

+ 0.2 + 0.1

C1

TORQUE CONVERTER AND TRANSMISSION GROUP 35 Transmission Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 35-2 Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 35-3 Gear Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 35-5 Clutch Plate Thickness Piston Stroke ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 35-6 Oil Pressure ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 35-7

35-1

Transmission Assembly

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Transmission Assembly １３

１４

９

４・５

１７

６

１８ １９ １５

１５１９ ６ １６ １８ １７

１１

１０

１２

８０Ｗ３５００１

35-2

Control Valve

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Control Valve

１

２

７ ８

３

８５ＺＡ３２０９

35-3

Control Valve

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Judgement criteria REF.

ITEM Allowable limit (mm)

0.030〜0.061

0.09

Replace

0.016〜0.045

0.07

Replace

0.025〜0.066

0.09

Replace

Standard value

Allowable limit

Control valve regulator valve〜valve body

1

2

Correction

Standard clearance (mm)

Clearance

Control valve regulator valve〜 seal retainer Control valve trimmer plug〜valve body

3

ITEM 4

Free Installed Installed load length (mm) length (mm) N (kgf)

T/C inlet valve spring Clutch return spring

5 Spring 6

(The same spring for all clutches)T/C Control valve regulator spring

7

Control valve trimmer spring

Installed load N (kgf)

43.6

9.0 (9.2)

100 (10.2)

44.6

35.2

24.4

21

89

89

0

69

49 (5)

81.4

Free length (mm)

32

23.7

(3.3)

29 (3.0)

Replace Replace

87.5

0

Replace

80

44 (4.5)

Replace

Judgement criteria ITEM Standard value (mm)

Allowable limit (mm)

8

Charge pump shaft dia.

41.93〜42.0

41.8

Replace

9

Rear yoke shaft dia.

79.92〜80.0

79.8

Front yoke shaft dia.

64.92〜65.0

79.8

11

Speedometer driven gear shaft dia.

11.95〜12.0

11.8

Replace oil Replace seal when disassembling Replace and reassembling Replace

W

2.8 ± 0.1

2.5

12

Torque converter inlet H

2.5 ± 0.05

2.3

W

2.8 ± 0.1

2.5

H

2.2 ± 0.05

2.0

Clutch shaft

W

3.8 ± 0.05

3.6

(The same for all clutches)

H

4.75 ± 0.05

4.55

15

Piston outer dia. (F,R)

H

4.3 ± 0.1

4.1

Replace

16

Piston outer dia. (1〜4 speed)

H

4.3 ± 0.1

4.1

Replace

17

Piston inner dia.

H

3.0 ± 0.1

2.8

Replace

Thrust washer thickness

2.9〜3.1

2.7

Replace

Gear backlash

0.2〜0.3

0.5

Replace

10

13

Oil seal

Seal ring

W

14 H

18

Torque converter outlet

35-4

Replace

Replace

Replace

Gear Pump

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Gear Pump 2 4

1

3

Gear pump specifications Theoretical discharge

64.5cc/rev

Maximum operation pressure Maximum operation speed (pump speed)

2.0MPa (20kgf/cm2)

Actual discharge

1

2400min-1 Approx.120 l/min.

Conditions : Pump speed: 2200min-1 Oil temperature: 80 to 100 ℃ Oil viscosity: 40CST (SAE10W) Discharge pressure: 1.4 to 1.6MPa (14 to 16kgf/cm2)

2

Unit : mm No.

Item

Standard value

Solution

1

Top clearance between gear and housing

0.08〜0.11

Replacement

2

Side clearance between gear and housing

0.03〜0.073

Replacement

3

Backlash between gears

0.2〜0.3

Replacement

4

Tightening torque for pump fixing bolt

59N-m (6.0kgf-m)

Tightening

Note : To measure the side clearance of item 2 above, with the gasket removed.

35-5

Clutch Plate Thickness・Piston Stroke

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Clutch Plate Thickness・Piston Stroke Clutch plate Number of clutch plates.

Note : All the friction plates, steel plates, and return springs are interchangeable for each clutch.

Friction plate

Steel plate

Return spring

Forward clutch

8

7

20

Reverse clutch

8

7

20

1st speed clutch

10

9

16

2nd speed clutch

5

4

16

3rd speed clutch

5

4

16

4th speed clutch

5

4

16

Outer dia.

φ 167

φ 182

Inner dia.

φ 104.8

φ 116

When new

2.0 ± 0.1

1.8 ± 0.1

Wear limit

1.8

1.6

T1

Dimension

L1 T2

T2 L1

(mm)

Thickness

Name of clutch

T2

T2 T3 L1

T4

Piston stroke

(mm) Judgement criteria Correction

Standard value

Allowable limit

Forward clutch

3.8 ± 0.3

5.0

Replace

Reverse clutch

4.3 ± 0.3

5.0

Replace

1st speed clutch

3.8 ± 0.5 1.0

5.0

Replace

2nd speed clutch

3.0 ± 1.0

5.0

Replace

3rd speed clutch

3.0 ± 1.0

5.0

Replace

4th speed clutch

2.95 ± 1.0

5.0

Replace

Clutch

T2 ８０Ｗ３５００１

L : Screw lock agent application (Loctite 262)

35-6

Bolt tightening torque T1 :29N-m (3.0kgf-m) T2 :59N-m (6.0kgf-m) T3 :216N-m (22.0kgf-m) T4 :392N-m (40.0kgf-m)

Oil Pressure

80ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Oil Pressure

１

９ ９ ３ ５ ６

７

１０ ４ ８ ５

６

７

８０Ｋ３５１０２

Standard Value

(Oil temperature 50〜80 ° C (120〜180 °F))

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

Measuring port location

Measuring port

Engine revolution (min-1)

size

800 (Low idle)

2450 (High idle)

Shift lever position

PF1/2

0.03〜0.54 (0.3〜5.5)

0.2〜0.54 (2.0〜5.5)

All speed range

2

Torque converter outlet pressure

ー

0.02〜0.2 (0.2〜2.0)

0.1〜0.39 (1.0〜4.0)

All speed range

Main oil pressure

PT1/8

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

All speed range

Forward clutch oil pressure Reverse clutch oil pressure 1st speed clutch oil pressure 2nd speed clutch oil pressure

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

Forward

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

Reverse

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

1st speed

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

2nd speed

3rd speed clutch oil pressure 4th speed clutch oil pressure

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

3rd speed

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

4th speed

Transmission lubrication oil pressure

PT1/4

0.01〜0.1 (0.1〜1.0)

0.05〜0.25 (0.5〜2.5)

All speed range

3 4 5 6 7 8 9 10

outlet pressure

Torque converter inlet pressure

Clutch oil pressure Torque converter

1

35-7

HYDRAULIC GROUP 44 Removing and Reinstalling Hydraulic Tank Return Filter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-2 Disassembling and Reassembling Hydraulic Tank Breather Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-3 Hydraulic Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-4 Removing and Reinstalling Hydraulic Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-5 Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-6 Removing and Reinstalling Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-7 Disassembling and Reassembling Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-9 Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-13 Removing and Reinstalling Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-14 Disassembling and Reassembling Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-16 Boom Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-24 Removing and Reinstalling Boom Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-25 Bucket Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-27 Removing and Reinstalling Bucket Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-28 Steering Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-31 Removing and Reinstalling Steering Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-32 Hydraulic Cylinder Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-35 Disassembling and Reassembling Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-36 Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-41 Pilot Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-42 Removing and Reinstalling Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-43 Disassembling and Reassembling Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-45

44-1

Hydraulic Tank Return Filter

80ZIV-2

HYDRAULIC 44

Removing and Reinstalling Hydraulic Tank Return Filter 1.Removing hydraulic tank return filter

WARNING Unexpected movement of the machine could 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. ・ Let the hydraulic oil become cool. ・ Release the internal pressure from the piping and the hydraulic tank. １

Reference: Releasing residual pressure from pipe Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30cm above the ground.

Tilt down the bucket until it comes in contact with the ground, and then lower the boom.

Move the bucket and boom levers back and forth fully to relive the pressure.

Press the tank cap to release the residual pressure from the tank.

２ ３ ４ ５

６

６５Ｋ４４００５

Before starting work: : Drain the hydraulic oil from the tank. : Approx. 92 l 1) Remove the bolt (1) of the cover (2).

Use these bolts as a remover bolt and remove the cover (2).

2) Remove the O-ring (3), the spring (4), the relief valve (5) and the return filter (6).

2.Reinstalling hydraulic tank return filter For reinstallation, follow the above procedure in the reversed direction.

Cautions for installation Be sure to replace the O-ring with new one.

44-2

Hydraulic Tank Breather Valve

80ZIV-2

HYDRAULIC 44

Disassembling and Reassembling Hydraulic Tank Breather Valve 1.Disassembling breather valve

１

1) Un-locking cap key.

Insert the starter key and then turn the cap key (starter key) 180 ° counter-clockwise.

2) Remove the cap (1) by turning the cap counter-clockwise while pushing load. 〔 186 〜 216N (19〜 22kgf) 〕

Ｓｔ ａ ｒ ｔ ｅ ｒ ｋｅｙ

６５Ｖ４４００２

3) Remove the bolts (2) and then remove the body (3) and the packing (4).

２

３

4) Remove the filter (6) by removing the stop ring (5).

４

Note : After removing the parts, cover the tank port with vinyl to protect it from dust and dirt.

５

６

６５Ｋ４４００７

5) Remove the stop ring (7), then remove the valve assembly (8).

6) Remove the filter element (10) and the spring (9) from the cover (1).

１０ ９

Note : Do not disassemble the valve assembly (8) further since the valve is being setting 1kPa (0.01kgf/cm2) for the inlet pressure and 2 78kPa (0.8kgf/cm ) for the exhaust pressure.

８

７ ６５Ｋ４４００８

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

44-3

Hydraulic Pump

80ZIV-2

HYDRAULIC 44

Hydraulic Pump Tightening Torque

T2

T1

T1 ８０Ｋ４４００２

Bolt tightening torque T1 : 69N-m (7.0kgf-m) T2 : 196N-m (20.0kgf-m)

44-4

Removing and Reinstalling Hydraulic Pump

80ZIV-2

HYDRAULIC 44

Removing and Reinstalling Hydraulic Pump 1.Removing hydraulic pump

WARNING Unexpected movement of the machine may cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Disconnect the negative side of the cable from the battery. ・ Release the residual pressure from the hydraulic line.

Before starting work: ・ Remove the cab (option) and the floor board. ・ Clean the area around the hydraulic pump.

３

１

２

1) Disconnect the outlet hose (2) and the suction pipe (3) from the pump (1).

８０Ｋ４４００３

2) Remove the pump retainer bolts (4). : Bolt

１

４

245N-m (25.0kgf-m)

3) Remove the pump (1). : Gear pump 47kg

８０Ｋ４４００４

4) Remove the retainer bolts (6) for the torque converter charge pump (5) removal.

５

６

８０Ｋ４４００５

44-5

Steering Valve

80ZIV-2

HYDRAULIC 44

Steering Valve

８０ＺⅣ４４０５

T1 : 137N-m (14.0kgf-m) T2 : 93N-m (9.5kgf-m) T3 : 74N-m (7.5kgf-m) T4 : 42N-m (4.3kgf-m) T5 : 83N-m (8.5kgf-m) T6 : 64N-m (6.5kgf-m)

1. Steering plunger 2. Flow control plunger 3.Main relief valve 4.Overload relief valves 5. Check valves 6. Cap 7. Screw 8. Spring seats 9. Spring 10.Plate

: 22kg

44-6

11.Wipers 12.Oil seals 13.Plugs 14.O-ring 15.Valve body

Removing and Reinstalling Steering Valve

80ZIV-2

HYDRAULIC 44

Removing and Reinstalling Steering Valve 1.Removing steering valve

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the 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 vinyl before valve removal.

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

1) Disconnect the hoses (2) from the steering valve (1). ２

１ ８０Ｋ４４００６

2) Remove the hoses (3). : Hydraulic oil : Approx. 1 l

３

８０Ｋ４４０２７

3) Remove the split pin (4), castle nut (5), and pin (6). After that, disconnect the steering link (7).

６

Torque for assembly: : Castle nut : 255N-m (26.0kgf-m) ６ ７ ５ ４ ８０Ｋ４４００７

44-7

Removing and Reinstalling Steering Valve

80ZIV-2

4) Remove the steering valve retainer bolt (8), and then remove the steering valve (9).

HYDRAULIC 44

８

９

Torque for assembly: : Bolt : 88N-m (9.0kgf-m) : Steering valve : 22kg Note : Cover the disconnected hoses and the valve with vinyl, plugs or caps to protect them from dust and dirt. ８０Ｋ４４００８

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:

Drop arm Drop arm stopper bolts

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.

1) Start the engine and confirm that the drop arm 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).

44-8

Disassembling and Reassembling STV

80ZIV-2

HYDRAULIC 44

Disassembling and Reassembling Steering Valve 1.Disassembling steering valve

１

Before starting work: a) Clean the valve body.

1) Remove the right and left overload relief valves (1). : Torque for assembly : 83N-m (8.5kgf-m)

2) Loosen the lock nut (2), and then remove the ball joint (3).

Note : To ease reassembly of the ball joint, count the number of turns required to remove the ball joint and record. During reassembly screw the ball joint in the same number of turns.

３

２

3) Remove the retainer bolt (4), and then remove the plate (5). : Torque for assembly : 42N-m (4.3kgf-m) ５

４

4) Remove the retainer bolt from the cap (6), and then remove the cap. : Torque for assembly : 42N-m (4.3kgf-m)

６

44-9

Disassembling and Reassembling STV

80ZIV-2

HYDRAULIC 44

5) Slowly pull out the plunger assembly (7).

Note : Always handle the plunger with extreme care. Even a small nick, dent or scratch can ruin the plunger which requires replacement of the entire valve.

７

８０Ｗ４４００６

6) Remove the front and rear wipers (8) and seals (9).

８ ９

８０Ｗ４４００７

7)Gently clamp the two flats of the plunger assembly using wooden blocks in a vice, and then loosen the screw (10).

Remove the spring seat (11), spring (12), plate (13), spring (14), poppet (15), O-ring (16), backup ring (17), and plug (18) from the plunger (19). : Screw (10), (18) : 10N-m (1.0kgf-m) (Loctite No. 271) Note : a) Cover the spool to protect it from being scratched. b) A thread adhesive is applied to the threaded section of the spool end. To disassemble the spool, heat the adhesive of the threaded section using an industrial drier (heat gun) or the equivalent. Do not heat the threaded section to 200 ° C(390 °F) for more. If it is overheated, replace the spring with a new one. c) All seals should be replaced with new ones because they were heated.

１１１２ １４ １３ １５

１０ １１１６

１９

１６ １８ １７

１４

１５ ８０Ｗ４４００８

２０

8) Remove the plug (20). ８０Ｗ４４００９

44-10

Disassembling and Reassembling STV

80ZIV-2

HYDRAULIC 44

9) Remove the main relief valve (21).

２１ ８０Ｗ４４０１０

10)Disassemble the main relief valve (21).

２１ ８０Ｗ４４０１１

11)Pull out the spring (22) and the flow control valve (23) from the inside of the valve.

Note : Be sure to reinstall the same number of shims (24) and in the same location upon reassembly. ２１

２２

２３ ２４

８０Ｗ４４０１２

44-11

Disassembling and Reassembling STV

80ZIV-2

HYDRAULIC 44

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

Cautions regarding reassembly: Before starting work: a) Clean and check all the parts. Replace all O-rings and seals. b) Before reassembly, apply a coating of hydraulic oil to all the parts. c) Be sure to apply the specified torque to tighten each part. d) Attach the seal and wiper to the valve body as shown in the right figure.

Note : Carefully insert the plunger so that the seals are not scratched or cut.

Plate

Valve body

Seal

e) To insert the ball joint, adjust the distance as shown in the right figure.

Wiper

Ball joint

Main Relief and Overload Inspection: (Pilot valve is defective.)

Rod

Foreign matter gets caught.

Steering valve

Adj. Screw Orifice clogged.

58mm

Spring is broken.

Poppet has worn out.

During disassembly and inspection of the main relief valve and overload relief valves be sure to check the pilot valve, valve seat, and orifices as shown the above.

44-12

Multiple Control Valve

80ZIV-2

HYDRAULIC 44

Multiple Control Valve 13 T2

25 T6 18 T3

T2

15

21 19

12

22 T1 14

20 26 T5

11

27 T5

16

28

2

17 T4

13 T2 12

12

T5 26 4 5

11

24

4

3 14 22 T1

1

12 23

7 T7

4

9

6

13 T2 24

4 8 T7 10

13 T2 ７０ＺＡ４４０４

1.Valve housing 2.Spool (Bucket) 3.Spool (Boom) 4.Spring seats 5.Spring (Bucket) 6.Spring (Boom) 7.Spool end (Bucket) 8.Spool end (Boom) 9.Cap (Bucket) 10.Cap (Boom)

11. Caps 12.O-rings 13. Socket head bolts 14.O-ring 15. Cover 16.O-ring 17. Socket head bolts 18. Plugs 19. Springs 20. Poppets

: Tightening torque T1 : 98N-m (10.0kgf-m) T2 : 42N-m (4.3kgf-m) T3 : 132N-m (13.5kgf-m) T4 : 157N-m (16.0kgf-m) T5 : 83N-m (8.5kgf-m) T6 : 103N-m (10.5kgf-m) T7 : 12N-m (1.2kgf-m)

21.O-rings 22.Plug assembly 23.Plug 24.Plugs 25.Main relief valve 26.Overload relief valves with make-up function 27.Make-up valve 28.Cap

: Multiple control valve : 54kg

44-13

Removing and Reinstalling MCV

80ZIV-2

HYDRAULIC 44

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

WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death.

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

Reference: Releasing residual pressure from pipe Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30cm above the ground.

Tilt down the bucket until it comes in contact with the ground, and then lower the boom.

Open the cap of the hydraulic oil tank.

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

１

1) Put match marks on the 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.

８０Ｋ４４０１０

2) Put match marks on the hoses (2) of the pilot line, then disconnect them.

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

２

８０Ｋ４４０１１

3) Disconnect the hose (3) and the hoses (4). : Hydraulic oil : Approx. 5 l Note : Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

３

４ ８０Ｋ４４０１２

44-14

Removing and Reinstalling MCV

80ZIV-2

HYDRAULIC 44

4) Remove the return hose (5).

5) Use a hoist and strap to support the control valve (7) and remove the control valve (7) by removing the bolts (6).

Torque for assembly: : Bolt : 90N-m (9.2kgf-m) : Multiple control valve : 54kg

５

８０Ｋ４４０１３

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

６

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

７

WARNING Unexpected movement of the machine could cause serious injury or death.

To prevent such an accident, be sure to stop the engine before you start working under the machine. In addition, block the tires with chocks to prevent the wheels from moving. While working under the machine, carefully keep contact with the person in the cab by giving signals to each other.

６

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.

44-15

８０Ｗ４４００１

Disassembling and Reassembling MCV

80ZIV-2

HYDRAULIC 44

Disassembling and Reassembling Multiple Control Valve 1.Disassembling multiple control valve IMPORTANT ・ Place the removed parts, in order, on a clean paper or cloth. ・ Do not disassemble any section unless disassembly is absolutely necessary for repair or adjustment. ・ As a rule, the main relief valve or overload relief valve once disassembled should be replaced as an assembly.

Therefore, do not disassemble these valves, unless absolutely necessary.

a) Clean the valve body 1) Remove the main relief valve (1).

Hexagon width across flat: 38mm

１

2) Remove the overload relief valves (2).

Hexagon width across flat: 32mm

２

3) Remove the make-up valve (3).

Hexagon width across flat: 32mm

３

44-16

Disaasembling and Reassembling MCV

80ZIV-2

HYDRAULIC 44

4) Remove the socket head bolt (4) from the bucket side of the cap.

Hexagon hole width across flat: 8mm

４

８０Ｗ４４０１３

5) Remove the cap (5) with the O-ring of the flange as a unit.

５ ８０Ｗ４４０１４

6) Remove the socket head bolt (6) from the boom side of the cap.

Hexagon hole width across flat: 8mm

６ ８０Ｗ４４０１５

7) Remove the cap (7) with the O-ring of the flange as a unit.

７ ８０Ｗ４４０１６

44-17

Disaasembling and Reassembling MCV

80ZIV-2

HYDRAULIC 44

8) Pull out the spool assembly (8) from the bucket side.

Note : Carefully pull out the spool so that it is not forced out or distorted.

Handle the spool with extreme care, even a small nick, dent, or scratch can ruin the spool which requires replacement of the entire valve.

１

9) Pull out the spool assembly (9) from the boom side in the same way. ９

８０Ｗ４４０１７

10)Remove the socket head bolts (10), and then remove the cap (11). Also remove the O-ring from the cap.

Hexagon hole width across flat: 8mm

１１

１０

８０Ｗ４４０１８

11)Remove the socket head bolts (12), and then remove the cover (13). Also remove the O-ring (14) from the mating face.

Hexagon hole width across flat: 12mm

１４

１３

８０Ｗ４４０１９

44-18

１２

Disaasembling and Reassembling MCV

80ZIV-2

HYDRAULIC 44

12)Remove out the plug (15), and then remove the spring (16) and the poppet (17).

Also remove the O-ring from the plug.

Hexagon hole width across flat: 19mm

１５ １６

１７

８０Ｗ４４０２０

13)Remove the hexagon bolt, and then remove the cap kit (18).

Hexagon bolt width across flat: 14mm １８

８０Ｗ４４０２１

14)Remove the plug assembly (19), and remove the O-ring.

Hexagon hole width across flat: 17mm

１９

15)Gently clamp the spool assembly using wooden blocks in a vice. After that loosen the spool end (20) to remove it.

Hexagon bolt width across flat: 22mm ８０Ｗ４４０２２

16)Remove the spring seats (21) and the spring (22) from each spool (there are two spools).

Note : a) Cover the spool to protect it from being scratched. b) A thread adhesive is applied to the threaded section of the spool end. To disassemble the spool, heat the adhesive of the threaded section using an industrial drier (heat gun)or the equivalent. Do not heat the threaded section to 200 ℃ (390 ° F) or more. If it is overheated, replace the spring with a new one.

２０

２１ ２２

２１ Adhesive Apply heat

Spool ８０Ｗ４４０２３

44-19

Disaasembling and Reassembling MCV

80ZIV-2

HYDRAULIC 44

2.Reassembling multiple control valve Note : ・ 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.

1) Attach the spring seats (1) and the spring (2) to the spool, and then tighten bolt head at the spool end (3).

Spool end hexagon bolt head width across flat: 22mm : Spool end bolt : 12N-m (1.2kgf-m) : Apply thread lock (Loctite No. 271) Note : Carefully clean all threads of any oil film using a non-oil based solvent or locquic primer.

３ １ ２ １ Spool

2) Reinsert the plug assembly (4).

Hexagon hole width across flat: 17mm : Plug : 98N-m (10.0kgf-m)

４

3) Reinstall the cap kit (5).

Hexagon bolt width across flat: 14mm : Bolt : 42N-m (4.3kgf-m) Note : Carefully tighten the bolts so that the O-ring of the flange is not caught and damaged.

５

44-20

Disaasembling and Reassembling MCV

80ZIV-2

HYDRAULIC 44

4) Sequentially insert the poppet (6) and then the spring (7) into the housing seat section. After that, attach a new O-ring (8) to the plug (9), and then reinstall the plug.

Hexagon hole width across flat: 19mm : Plug : 132N-m (13.5kgf-m) Note : Excessive torque on these plugs can cause the body to crack or the poppets to stick.

９ ８

７ ６

８０Ｗ４４０２４

5) Attach a new O-ring to the groove of the cover (10), and then reinstall the cover on the valve housing. Tighten the socket head bolts (11).

Hexagon hole width across flat: 12mm : Bolt : 157N-m (16.0kgf-m) Note : Before reinstalling the cover, be sure to check the mating faces of the valve housing and the cover for foreign material or sharp pointed material.

１１ １０ ８０Ｗ４４０２５

6) Insert the O-rings to the caps (12), and then reinstall the caps on the valve housing. Tighten the socket head bolts (13).

Hexagon hole width across flat: 8mm : Bolt : 42N-m (4.3kgf-m) １２ １２

１３ ８０Ｗ４４０２６

7) Slowly and carefully insert the spool assembly of the bucket side into the valve housing.

Spool

: Apply hydraulic oil to the spool.

44-21

Disaasembling and Reassembling MCV

80ZIV-2

HYDRAULIC 44

8) Slowly and carefully insert the spool assembly of the boom side into the valve housing in the same way. : Apply hydraulic oil to the spool.

Spool

9) Insert a new O-ring to the cap (14), and then reinstall the cap on the spool of the bucket side.

Do not confuse the spools or caps since they are similar but different.

１４

８０Ｗ４４０２７

10)Tighten the socket head bolts (15). : Bolt : 42N-m (4.3kgf-m)

１５

８０Ｗ４４０２８

11)Attach a new O-ring to the cap (16), and then install the cap on the spool of the boom side.

１６ ８０Ｗ４４０２９

44-22

Disaasembling and Reassembling MCV

80ZIV-2

HYDRAULIC 44

12)Tighten the socket head bolts (17). : Bolt : 42N-m (4.3kgf-m)

１７ ８０Ｗ４４０３０

13)Reinstall the make-up valve (18).

Hexagon nut width across flat: 32mm : Make-up valve : 83N-m (8.5kgf-m) １８

８０Ｗ４４０３１

14)Reinstall the right and left overload relief valves (19).

Hexagon nut width across flat: 32mm : Overload relief valve : 83N-m (8.5kgf-m) Note : If the overload relief valves or main relief valve have been disassembled back the adjusting screws out and readjust after start up. １９ ８０Ｗ４４０３２

15)Reinstall the main relief valve (20).

Hexagon nut width across flat: 38mm : Main relief valve 103N-m (10.5kgf-m)

２０ ８０Ｗ４４０３３

44-23

Boom Cylinder

80ZIV-2

HYDRAULIC 44

Boom Cylinder

6

22

22 6 12 1 13 14 7

23 15 20 18

3

19 16 17 4 2 5 24

21

9

11 10 ８０Ｎ４４００１

1. Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 7. Piston nut 9. Stop ring 10. Bolt 11. Spring washer 12.Wear ring

13. Square ring 14. Slipper ring 15.O-ring 16.O-ring 17. Back-up ring 18. U-packing 19. Back-up ring 20. Buffer ring 21. Scraper ring 22. Dust seal 23.Wear ring 24. Stop ring

: Boom cylinder : 139kg For torque values refer to "Hydraulic cylinder tightening torque".

44-24

Removing and Reinstalling Boom Cylinder

80ZIV-2

HYDRAULIC 44

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

WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death.

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Raise the boom until it is horizontal, and then place a 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 step, ladder, or work platform, and do not stand on the machine.

a) Clean the area around the cylinder and piping.

Note : Relieving residual pressure from pipe 1. Raise the boom. When the boom is approximately 30cm above stand (A), stop the engine.

2. Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure.

3. Open the cap of the hydraulic tank to relieve the residual pressure.

Stand (A) ６５Ｋ４４０５２

１

1) Temporarily sling the boom cylinder (1).

３

: Boom cylinder : 139kg

2) Disconnect the hoses (2), (3).

２ ８０Ｗ４４００１

: Drain oil : Approx. 10 l Cover the disconnected hoses with vinyl, plugs, or caps to protect them from dust, water, and dirt.

44-25

Removing and Reinstalling Boom Cylinder

80ZIV-2

HYDRAULIC 44

3) Remove the lock bolt (4) and the pin (5).

4) Remove the lock bolt (6) and the pin (7).

5) Sling the boom cylinder (1), and lower it onto the ground.

After that, remove the pipe from the cylinder.

７ １

For a detailed description of cylinder disassembly and reassembly, refer to "Disaasemblling and reassenbling hydraulic cylinder".

６ ５

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 100mm before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-26

４

７０Ｋ４４０２６

Bucket Cylinder

80ZIV-2

HYDRAULIC 44

Bucket Cylinder 11 2

22 6

12

22

24 3

15 16 22

17 20

6

6

18 19 4

6 1

22

5 23 21

13 14 25 7

26

8

10 9 ８０Ｎ４４００２

1. Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 7. Piston nut 8. Stop ring 9. Bolt 10. Spring washer 11.Wear ring 12. Seal set 13. Plug

14.O-ring 15.O-ring 16.O-ring 17. Back-up ring 18. U-packing 19. Back-up ring 20. Buffer ring 21. Scraper ring 22. Dust seal 23. Stop ring 24.Wear ring 25.O-ring 26. Plug : Bucket cylinder : 198kg For torque valves refer to tightening torque".

44-27

"Hydraulic

cylinder

Removing and Reinstalling Bucket Cyl.

80ZIV-2

HYDRAULIC 44

Removing and Reinstalling Bucket Cylinder 1.Removing bucket cylinder

WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death.

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Place the boom and bucket on the ground. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Use a step, and do not stand on the machine.

a) 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.

２

１ ３

1) Remove the coupler of the bucket positioner switch (1), and then remove the bracket (2) and the rod (3).

７０Ｋ４４０２８

2) Disconnect the hoses (4) (5). : Drain : Approx. 0.5 l Cover the disconnected hoses and the cylinder with vinyl, cap or plugs to protect them from dust, water and dirt.

４

５ ７０Ｋ４４０２９

3) Temporarily sling the bucket cylinder (6). After that, remove the lock bolt (7), and then remove the pin (8). : Bucket cylinder : 198kg

６ ８

７

７０Ｋ４４０５９

44-28

Removing and Reinstalling Bucket Cyl.

80ZIV-2

HYDRAULIC 44

4) Disconnect the grease pipe (9).

９ ７０Ｋ４４０３１

5) Remove the lock bolt (10) and the pin (11). ６

6) Slowly lift up the bucket cylinder (6) and remove the shim.

7) Lower the bucket cylinder onto the ground.

For a detailed description of cylinder assembly and reassembly, refer to "Disassembling and Reassembling hydraulic cylinder".

１０ １１

７０Ｖ４４００３

44-29

Removing and Reinstalling Bucket Cyl.

80ZIV-2

2.Reinstalling bucket cylinder To reinstall the bucket cylinder, follow the above removal procedure in the reversed direction.

Note : Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation

WARNING During service work, do not stand on the machine.

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

①Bleed 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 100mm before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

②Adjust the bucket positioner so that the clearance between the switch and the rod is 5±2mm.

44-30

HYDRAULIC 44

Steering Cylinder

80ZIV-2

HYDRAULIC 44

Steering Cylinder

11

6 11

1

12 13 14 15 16

8

17 18 19

3

20 21

7

2

4 5 9 11

11 6

８０Ｎ４４００３

1. Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 7. Scraper ring 8. Piston nut 9. Stop ring 11. Dust seal

12.Wear ring 13. Square ring 14. Slipper ring 15.O-ring 16.O-ring 17. Back-up ring 18. U-packing 19. Back-up ring 20. Back-up ring 21.O-ring

: Steering cylinder : 26kg

44-31

Removing and Reinstalling Steering Cyl.

80ZIV-2

HYDRAULIC 44

Removing and Reinstalling Steering Cylinder 1.Removing steering cylinder

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

２ １

a) Clean the area around the cylinder to be removed.

1) Disconnect the hoses (1) (2). : Cover the disconnected hoses with vinyl, caps, or plugs to protect them from dust, water, and dirt.

８０Ｋ４４０１７

2) There is a pin (5) at the between the front chassis (3) and the steering cylinder (4). Remove the pin (5), and then push the rod into the cylinder to shorten the length of the cylinder.

５ ３

４

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

Approx. 2 l ８０Ｋ４４０１８

3) Disconnect the grease pipe (6) and remove the lock bolt (7).

６

７

８０Ｋ４４０１９

44-32

Removing and Reinstalling Steering Cyl.

80ZIV-2

HYDRAULIC 44

4) Remove the pin (8). ８

８０Ｋ４４０２０

5) Remove the steering cylinder assembly (4). : Steering cylinder : 26kg For detailed description of cylinder disassembly and reassembly, refer to "Disasembling 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.

44-33

Removing and Reinstalling Steering Cyl.

80ZIV-2

3.Cautions regarding reinstallation ①When reinstall the pins

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.

②Bleed the cylinder of air

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or backup ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100mm before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

44-34

HYDRAULIC 44

Hydraulic Cylinder Tightening Torque

80ZIV-2

HYDRAULIC 44

Hydraulic Cylinder Tightening Torque Boom cylinder T1

T2 ８０Ｎ４４００４

Bucket cylinder T3

T4

８０Ｎ４４００５

Steering cylinder T5

８０Ｎ４４００６

T6

T1 : 3,923N-m (400kgf-m) T2 : 451N-m (46kgf-m) T3 : 4,904N-m (500kgf-m) T4 : 686N-m (70kgf-m) T5 : 1,471N-m (150kgf-m) T6 : 1,569N-m (160kgf-m)

Cylinder

Piston nut width across flat (S)

Boom

90mm

Bucket

100mm

Steering

50mm

44-35

s

Disassembling and Reassembling Hyd. Cyl.

80ZIV-2

HYDRAULIC 44

Disassembling and Reassembling Hydraulic Cylinder 1.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

2) Put the match marks on the rod cover (1) and the cylinder tube (2).

Remove the rod cover bolt (3).

Match mark

３

: Bolt : 687N-m (70.0kgf-m)

２ １

3) Remove the piston rod assembly (4) from the cylinder tube. ４

: Hydraulic oil will be drained, so place a container to receive the drain oil.

９０ＺⅣ４４０８

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

Repair stand

４

Wooden block

44-36

Disassembling and Reassembling Hyd. Cyl.

80ZIV-2

HYDRAULIC 44

5) Remove the stop ring (5) and put match marks on the rod and the piston nut for alignment with the stop ring holes.

５

４

Match mark

６

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

Note : Refer to "Hydraulic Cylinder Tightening Torque" for the tightening torque and the size of the piston nuts.

６ Ｃ

Hydraulic jack

Hydraulic cylinder

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

７

４

６５Ｖ４４０２０

8) Remove the wear ring (8), the backup ring (20), the square ring (9), the slipper ring (10), the O-ring (11) and the wear ring (12).

(There is no wear ring (12) for steering cylinder.)

８ ９

１０ １２

８

１０ ９

２０ １０２０ １２ ８ ９

１１ (Boom cylinder)

１１ (Bucket cylinder)

44-37

１１ (Steering cylinder)

Disassembling and Reassembling Hyd. Cyl.

80ZIV-2

HYDRAULIC 44

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

４

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

Note : Ring(18)is not for steering cylinder.

１

１７ １６

１８

１５

１４

１３

For boom and bucket cylinder

１

１６

１７

１５

１４

2.Reinstalling cylinder To reinstall the cylinders, follow the above removal procedure in the reversed direction.

44-38

１３

Disassembling and Reassembling Hyd. Cyl.

80ZIV-2

HYDRAULIC 44

3.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.

1) Put the slipper ring (10) into hot oil to heat the ring to 120 to 150 ℃ .

(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 extremely expand it. : After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

１０

2) Before installing the backup ring (2) and the O-ring (3), heat the backup ring.

(This is because the inner diameter of the backup ring is smaller than the outer diameter of the rod cover. To easily attach the backup ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.)

Be careful not to extremely expand the backup ring. After installation, wait until the backup ring is cooled, and then insert the rod cover into the cylinder tube.

２

３

3) Reinstall the rod cover of the steering cylinder, screw the rod cover using a spanner wrench.

Screw in and tighten the set screw. : 1,569N-m (160kgf-m)

44-39

Disassembling and Reassembling Hyd. Cyl.

80ZIV-2

HYDRAULIC 44

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

１

Caulking

１３

６５Ｋ４４０６７

１

１３

Caulking

44-40

７０Ｖ４４００５

Pilot Valve

80ZIV-2

HYDRAULIC 44

Pilot Valve For bucket control

Neutral

1 Dump

Roll back

For bucket control

For boom control

8 2

3

T

To tank port

4 5 6

From pump port

7

P

８５Ｗ４２１１

To MCV oil packs

８５Ｗ４２１８

View from the rear

For boom control

Raise

Neutral

Down

1. Lever 2. Disc 3. Push rod 4. Spring seat 5. Spring for secondary pressure 6. Return spring 7. Spool 8. Detent magnet solenoid

Float

To tank port ８５Ｗ４２１９

44-41

Pilot Valve Tightening Torque

80ZIV-2

HYDRAULIC 44

Pilot Valve Tightening Torque : Tightening torque T1 : 29N-m (3.0kgf-m) T2 : 36N-m (3.7kgf-m) T3 : 17N-m (1.7kgf-m) T4 : 29N-m (3.0kgf-m) T5 : 29N-m (3.0kgf-m) T6 : 17N-m (1.7kgf-m) T7 : 42N-m (4.3kgf-m) T8 : 12N-m (1.2kgf-m)

For boom control Front

For bucket control

T3

: Pilot valve 9.5kg : L1 : Screw lock agent application (Three Bond 1327)

T3

T5

T5 T6 L1

T6 L1

T7

T8

T7

T8

T7

T7

T4

T4 T4 T4

T2 ９０Ｋ４４０９０

T1

T1

44-42

Removing and Reinstalling Pilot Valve

80ZIV-2

HYDRAULIC 44

Removing and Reinstalling Pilot Valve 1.Removing pilot valve

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

1)Open the cab door (the right hand side).

Remove the cover (1) from the control box.

１

Control box ８０Ｗ４４００２

2) Remove the knobs, boot (2) and the cover (3) (4) (5) and then separate the PUS switch.

５

４

２ ３

７０Ｋ４４０４１

3) Disconnect the electrical line (6) of PUS switch.

Disconnect the electrical line coupler (7) from the pilot valve. ６

７

８０Ｗ４４０３４

44-43

Removing and Reinstalling Pilot Valve

80ZIV-2

4) Disconnect the hoses (8)(9)(10) from the pilot valve.

HYDRAULIC 44

９

: Drain oil : Approx. 1 l Note : Before disconnecting the electrical coupler and hoses, be sure to put match marks on them.

After disconnection, cover the discon- nected hoses with vinyl, caps, or plugs to protect them from dust and dirt.

１０

８

８０Ｗ４４００４

5) Remove the nut (11), then disconnect the rod from the pilot valve.

Remove the bolt (12) (4 pcs) and pull up the pilot valve to remove it.

１１ １１

: Pilot valve : 9.5kg

１２

８０Ｗ４４００５

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.

44-44

Disassembling and Reassembling P / V

80ZIV-2

HYDRAULIC 44

Disassembling and Reassembling Pilot Valve 1.Disassembling pilot valve Note : ・ Put plug on each port then clean the outer surface of the vlave. ・Place the removed parts, in order, on a clean paper or cloth. ・Carefully disassemble the pilot valve so that the parts are not scratched.

1) Clamp the pilot valve in a vise.

Pull up the boot (1) to remove it from the cover (2).

For boom control Front For bucket control

７０Ｋ４４０４５

2) Loosen the lock nut for the solenoid (3) and then remove the solenoid from the cover (2).

Torque for assembly : : Solenoid : 42N-m (4.3kgf-m) Note : Before removing the solenoid (3), measure the distance "A".

A

１

３ ４

Lock nut

２

７０Ｋ４４０４６

７０ＺⅣ４２０７

Carefully store the ball (4).

44-45

Disassembling and Reassembling P / V

80ZIV-2

HYDRAULIC 44

3) Remove the socket bolt (5).

Torque for assembly: : Bolt : 29N-m (3.0kgf-m)

５ ６ ７

4) Remove the lever (6) from the disc (7).

７０Ｋ４４０４７

5) Loosen the socket bolt (8).

８

Torque for assembly: : Retainer bolt : 17N-m (1.7kgf-m) : Screw lock agent (Three Bont 1327) application 6) Remove the cam shaft (9).

Note : ・ Temporarily install the socket bolt (5) into the disc. ・ Pull the cam shaft to the direction shown.

９ ７０Ｋ４４０４８

7) Pull up the socket bolt (5) with the disc (7) and remove it.

１０

７

8) Put match mark on the cover (2) and the case assembly.

Remove the socket bolt (10). ２

７０Ｋ４４０４９

9) Remove the cover (2) from the case assembly. ２

７０Ｋ４４０５０

44-46

Disassembling and Reassembling P / V

80ZIV-2

10)Remove the plug (11) together with the push rod (12).

Note : ・ Carefully store the spring and spring seat in the push rod. ・Carefully remove the plug so that the parts are not scratched. ・In case the plug(11)does not come out, use the screw driver to remove it.

HYDRAULIC 44

１１ １２ １３ １４

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.

７０Ｋ４４０５１

11)Remove the springs (15) (16) from the case assembly (14).

１６

１４

１５

７０Ｋ４４０５２

Note : When installing, carefully install the spool assembly so that the end of the spool does not hit the hole corner in the case assembly.

Carefully install into the case

７０ＺＡ４４０９

12)Clamp the case assembly (14) in the vise up side down.

Remove the socket bolt (17), then remove the plate (18) from the case assembly.

Torque for assembly: : Bolt : 29N-m (3.0kgf-m)

１７ １８

１４ ７０Ｋ４４０５３

44-47

Disassembling and Reassembling P / V

80ZIV-2

HYDRAULIC 44

13)Remove the spring (19) and the spring seat (20) from the push rod (12).

Note : The spring (19) and the spring seat (20) are used in the following position.

Boom down/Float 70Z Ⅳ〜115Z Ⅳ Boom raise 70Z Ⅳ〜85Z Ⅳ Roll back 70Z Ⅳ〜85Z Ⅳ Dump 70Z Ⅳ〜85Z Ⅳ

１１

１２

１９

14)Remove the push rod (12) from the plug (11).

２０ ７０Ｋ４４０５４

15)Push down the spring seat (23), and then remove the plane washer (24).

Note : ・ Carefully remove the plane washer so that the spool is not scratched. ・ Do not push the spring seat (23) down more than 4mm.

２４ ２３

２５

16)Remove the spring seat (23), spring (25), plane washer (24) and the shim from the spool (22).

Note : Shim for adjusting secondary pressure.

Some spool need shim, but others may not need it.

２６ ２２ ７０Ｋ４４０５５

2.Reassembling pilot valve

２４

To reassemble the pilot valve, follow the above disassemble 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 238Ω ±10 at normal room temperature (20 ° C). If measured in extremely low temperatures the resistance will be less.

At operating temperature the resistance will be higher.

２３

Sharp edge side

７０ＺＡ４４０８

Cautions regarding reassembling : Install the plane washer (24) so that the plane washer sharp edge side comes to the top position.

Note : Do not push the spring seat (23) down more than 4mm.

44-48

HYDRAULIC GROUP 45 Steering Linkage ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-2 Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-4 Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-5 Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-6

45-1

Steering Linkage

80ZIV-2

HYDRAULIC 45

Steering Linkage Standard dimensions

2

18.5

1 5 32

6

7

103

Center of center pin

６５ＺⅣ４４０１

3

Drop arm

4

Left-turn position

387.5 16.2°

13.5 °

58

45-2

Steering Linkage

80ZIV-2

HYDRAULIC 45

Tightening torque No.

Item

Standard value

1

Steering valve retainer bolt

88N-m (9.0kgf-m)

2

Link bracket retainer bolt

216N-m (22.0kgf-m)

3

Ball joint retainer nut

260N-m (26.5kgf-m)

4

Ball joint lock nut

162N-m (16.5kgf-m)

5

Steering valve bracket retainer bolt

216N-m (22.0kgf-m)

6

Overload relief valve

83N-m (8.5kgf-m)

7

Main relief valve

103N-m (10.5kgf-m)

45-3

Solution

Tightening

Multiple Control Valve

80ZIV-2

HYDRAULIC 45

Multiple Control Valve

１

６ ８

２ ２

３ ５ ９ ４

７

Tightening torque No.

Item

Standard value

1

Main relief valve

103N-m (10.5kgf-m)

2

Overload relief valve

83N-m (8.5kgf-m)

3

Make-up valve

83N-m (8.5kgf-m)

4

Check valve plug

132N-m (13.5kgf-m)

5

Cap retainer bolt

42N-m (4.3kgf-m)

6

Cover retainer bolt

157N-m (16.0kgf-m)

7

Cap kit retainer bolt

42N-m (4.3kgf-m)

8

Plug

98N-m (10.0kgf-m)

9

Multiple control valve retainer bolt

88N-m (9.0kgf-m)

45-4

Solution

Tightening

Hydraulic Cylinder

80ZIV-2

HYDRAULIC 45

Hydraulic Cylinder 4

(Note)The cylinder shown in the above figure is the boom cylinder.

1

2

3

4

(Note)The cylinder shown in the above figure is the steering cylinder. ７０Ｋ４５００１

Unit : mm Judgment standard No.

Standard dimension of rod dia.

Item

3 4

Rod cover bolt tightening torque N-m (kgf-m) Piston stroke mm

0.266

-0.036

+0.195

0.096

-0.090

+0.060

0.285

-0.025

+0.105

0.025

-0.046

0

0.151

〜

Piston nut width across flat mm

+0.060

〜

2

-0.076

〜

Piston nut tightening torque N-m (kgf-m)

0.090

〜

Item

+0.190

〜

No.

-0.030

〜

φ 45

Steering cylinder

clearance

〜

φ 90

Bucket cylinder

Bushing

〜

1

Limit

Standard

Rod

〜

φ 75

Boom cylinder

Standard value

Solution

Bushing

Clearance

+0.290

0.366

Replacement

+0.295

0.385

Replacement

+0.205

0.251

Replacement

Boom cylinder

Bucket cylinder

Steering cylinder

M58 × 2

M68 × 2

M33 × 3

3,923 (400)

4,904 (500)

1,471 (150)

90

100

50

M22

M22

(Rod cover)

451 (46)

686 (70)

1,569 (160)

788

523

405

45-5

Pilot Valve

80ZIV-2

HYDRAULIC 45

Pilot Valve

212-1

７０Ｖ４５００２

Judgement standard No.

Item

Solution Standard value

Allowable limit

36mm

35mm

Wear 1mm 212-1

Push rod

(φ7)

45-6

Replacement

BRAKE GROUP 54 Brake Valve Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-2 Removing and Reinstalling Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-3 Disassembling and Reassembling Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-4 Air Master Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-6 Removing and Reinstalling Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-7 Disassembling and Reassembling Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-8 Removing and Reinstalling Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-11 Air Cylinder for Parking ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-12 Removing and Reinstalling Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-13 Disassembly and Reassembly of Air Cyilnder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-14 Removing and Reinstalling Parking Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-16

54-1

Brake Valve Assembly

80ZIV-2

BRAKE 54

Brake Valve Assembly

16

: Torque T1 : 12N-m (1.2kgf-m) T2 : 6N-m (0.6kgf-m) T3 : 34N-m (3.5kgf-m) L2 15 13

12

L1 : Liquid gasket application (Loctite gasket 568) L2 : Anti-seize compound

14

11

T1

T2

5

T3 10

L1

7 9 4

T3

L1

T2 3 8

2

6

1

54-2

1.Diaphragm 2.Cover 3.Inlet / exhaust valve assembly 4.Body 5.Piston 6.Relay piston assembly 7.Valve assembly 8.Body 9.Upper piston assembly 10.Spring seat 11.Boot 12.Plunger 13.Roller 14.Spring 15.Pin 16.Pedal

Removing and Reinstalling Brake Valve

80ZIV-2

BRAKE 54

Removing and Reinstalling Brake Valve 1.Removing brake valve

WARNING ２

Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. ・ Drain the air pressure from the air tank.

１

Before starting work, clean the area around the brake valve.

1) Disconnect the air pipes (1), the tee (2), and then disconnect the air hose (3).

Note : Cover the disconnected pipes with clean vinyl to protect them from dust and dirt.

３ ６５Ｋ５４００１

2)One person should support the brake valve under the machine, and another person should enter the cab. The person in the cab should remove three connection bolts (5) from the brake pedal (4), and the person under the machine should remove the brake valve. Remove the pedal assembly (4) from the top side.

５ ４

６５Ｋ５４００２

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

Note : After reinstallation, check all the pipe- joints for air leakage.

To check or adjust the brake valve, refer to Section 53.

54-3

Disassembling and Reassembling Brake / V

80ZIV-2

BRAKE 54

Disassembling and Reassembling Brake Valve 1.Disassembling brake valve

２

Before starting work: a) Clean the outer surface of the valve.

１

1) Remove the diaphragm (1) and the cover (2).

2) Remove the inlet exhaust valve assembly (3). ３

１

２

3) Disassemble the inlet exhaust valve assembly (3).

３

4) Remove the retainer ring (4), spring seat (5), O-rings (6) (7), retainer (8), valve spring (9), and inlet exhaust valve (10). Also remove the body retainer bolt (11).

１１ ６

４

５

８ １０

７

９ ６５Ｋ５４０１９

54-4

Disassembling and Reassembling Brake / V

80ZIV-2

5) Separate the body into two sections (12) (13).

BRAKE 54

１２

１３

８０Ｗ５４００９

6) Loosen and remove the nut (14), and then remove the spring set (15), piston assemblies (16) (17), rubber spring (18), and piston return springs (19) (20).

１９

１６ １５

１７ ２０

１８

１４ ８０Ｗ５４０１０

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

3.Cautions regarding reassembly 1) Clean and check the disassembled parts. If a part is defective, replace it.

Note : All the rubber parts should be replaced annually. Certain cleaners and solvents can damage rubber parts, use only approved cleaners and solvents.

2) Apply lithium-based grease to all the sliding surfaces of the body, O-rings, and O-ring grooves.

3) After reassembly, reinstall the brake valve on the machine, and check that no air is leaking. Also check operation of the brake valve referring to "Checking Brake Valve" in Section 52.

54-5

Air Master Assembly

80ZIV-2

BRAKE 54

Air Master Assembly Tightening Torque

68

T1

7

25

1 22

3 2 9

10

5 19

T2

24

17

23

18

16 15

4 20

21

14 27 T5 L 2 26 12

30 T4 29 28

11

T3

13

1. Pressure plate 2. Non-pressure plate 3. Diaphragm 4. Return spring 5. Push rod assembly 6. Clamp ring 7. Bolt 8. Nut 9. Push nut 10. Nut 11. Spring nut 12. Nut 13. Cylinder 14. Return spring 15.O-ring

16. ST seal 17. SKY seal 18.O-ring 19. Piston 20. Valve assembly 21.Gasket 22. Piston stopper plate 23. C-ring 24. Spring guide 25.Gasket 26. Stroke indicator 27. Bolt 28. Ball 29. Bleeder screw 30. Cap

54-6

: Tightening torque T1 : 20N-m (2.0kgf-m) T2 : 64N-m (6.5kgf-m) T3 : 88N-m (9.0kgf-m) T4 : 10N-m (1.0kgf-m) T5 : 29N-m (3.0kgf-m) L2 : Screw lock (Three bond 1327 or the equivalent)

Removing and Reinstalling Air / M

80ZIV-2

BRAKE 54

Removing and Reinstalling Air Master 1.Removing air master

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. ・ Use a stepladder or the like to reach a high position of the machine. ・ Drain the air pressure from the air tank.

Before starting work: a) Remove the left (Refer to the Section 14).

side

deck １

1) Disconnect the air hoses (1) and the brake hose (2).

Disconnect the stroke indicator connectors, and remove the brake pipe (3).

Note : The brake oil will be drained. Place a container to catch the drained oil. : Brake oil : 3.5 l

３ ２ ８０Ｗ５４００１

2) Remove the bolts (4) and then remove the air master (5).

５

５

４

８０Ｗ５４０１１

2.Reinstalling air master To reinstall the air master, follow the above removal procedure in the reserved direction.

Note : After reinstallation, completely bleed the brake line of air, and check performance of the air master.

To bleed the brake line of air, refer to Section 53.

To check performance of the air master, refer to Section 53.

54-7

Disassembling and Reassembling Air / M

80ZIV-2

BRAKE 54

Disassembling and Reassembling Air Master 1.Disassembling air master

２

３

IMPORTANT ・ Clean the outer surface of the air master. ・ Put match marks on the parts before disassembly. ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

１

1) Put match marks on the air master body to show the direction of the fitting (1), (2), (3) for reassembling.

2) Remove the stroke indicator (4) and the nut (5), and then separate the chamber (6) and the cylinder (7) .

Torque for reassembly : Nut (5) 88N-m (9.0kgf-m) : Stroke indicator 29N-m (3.0kgf-m) : Screw lock agent application (Three Bond 1327 or the equivalent)

５

６

７

４

3) Remove the bleeder screw (8) and then remove the ball.

Torque for reassembly : Bleeder screw 10N-m (1.0kgf-m)

８

4) Disassembling cylinder (7).

WARNING

Press machine

The inner spring could spring out causing injury. To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the snap ring. When reducing the pressure of the press, be sure to slowly reduce it. ７

Snap ring

８０Ｗ５４０１２

54-8

Disassembling and Reassembling Air / M

80ZIV-2

BRAKE 54

5) Remove the snap ring (9), the piston stopper plate (11) and the piston (10).

９ １１ １０

８０Ｗ５４０１３

6) Remove the return spring (12). １２

１０

１１

7) Do not disassemble the valve assembly (13) in the piston (10). １３

１０

54-9

９

Disassembling and Reassembling Air / M

80ZIV-2

BRAKE 54

8) Disassembling chamber

Press machine

１４

WARNING The inner spring may spring out causing injury. To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the bolts.

When reducing the pressure of the press, be sure to slowly reduce it.

Match Mark

Put match marks on the section and remove the bolts (14), and then remove the clamp (15).

Torque for reassembly : Bolt (14) 20N-m (2.0kgf-m)

１５

9) Slowly reduce the pressure of the press and then remove the inner parts.

10)Remove the pressure plate (16), diaphragm (17), push rod (18) and return spring (19).

１６

１７

2.Reassembling air master To reassemble the air master, follow the above disassembly procedure in the reversed direction.

Notes : ・Clean the metal parts using approved brake cleaning solvent, and then blow the compressed air to dry them. ・After cleaning, check the parts for damage and wear. If a part is defective, replace it with a new one. ・Replace all the O-rings and seals with new ones. ・Use brake oil (engine oil SAE 5W or Mobil Delvac1). ・Use lithium grease.

１９

54-10

１８

Removing and Reinstalling Service Brake

80ZIV-2

BRAKE 54

Removing and Reinstalling Service Brake Follow the steps in the Section 24 (Power Group) for removing and reinstalling service brake.

CAUTION Before air bleeding in the brake oil line, be sure that the wheel and tire assemblies are installed on the wheel hub.

If fail to do, the bolts (4 pcs) temporarily tighten the spider and the wheel hub may be broken by the brake piston.

Finally the spider and the cover may fall off.

Note : After reinstalling tires, check that manual rotation of the tires is possible. Also ckeck the wheels for oil leakage.

Bolt

Spider

７０Ｋ５４００４

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

Fill the brake oil 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. When the oil level in the reservoir lowers, add oil to the tank.

Completely bleed each wheel of air.

54-11

Air Cylinder for Parking

80ZIV-2

BRAKE 54

Air Cylinder for Parking 14

4 10 8 3

2

7 13 11 5 9 6

12 15

1

1. Cylinder tube 2. Piston rod 3. Rod cover 4. Rod cap 5. Piston 6. U-nut 7. Spring 8. Bushing 9. U-packing 10. Dust seal

11.O-ring 12.O-ring 13. Filter 14. Set screw 15. Retainer bolt : Air cylinder

54-12

8.0kg

Removing and Reinstalling Cylinder

80ZIV-2

BRAKE 54

Removing and Reinstalling Cylinder 1.Removing air cylinder

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ When removing the air cylinder, the machine may move.

To prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

６

５

1) If there is an air source, release the parking brake, and then remove the split pin (1) and the pin (2).

Note : If there is no air source, apply a cable to the link, and then pull it down using a bar to overcome the spring force, and then remove the pin.

３ １

４ ２

2) Release the air pressure. Disconnect the air hose.

3) Loosen the locknut (3) to remove the joint (4).

Remove the retainer bolts (5) to remove the air cylinder (6). ８０Ｗ５４００３

: Retainer bolts 49〜 59N-m (5.0 〜6.0kgf-m) : Air cylinder 8kg

2.Reinstalling air cylinder To reinstall the air cylinder, follow the above removal procedure in the reversed direction.

Note : To insert the connection pin to connect the air cylinder to the parking brake, observe the following items: ①Start the engine to build air pressure in the air tank. ②Release the parking brake. ③Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the air cylinder 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.

54-13

Disassembly and Reassembly of Cylinder

80ZIV-2

BRAKE 54

Disassembly and Reassembly of Air Cylinder 1.Disassembling air cylinder

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

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 20mm dia. drill.

Since it is necessary to install the set screw at the same position during reassembly, mark the positioning match- mark 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.

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

Tightening torque for reassembly : Piston nut 245N-m (25.0kgf-m)

１

Component parts of air cylinder 1. Cylinder tube 2. Rod Cap 3. Spring 4. Piston 5. Piston rod 6. Rod cover 7. Piston nut

２ ３

７

５ ４

54-14

６

Disassembly and Reassembly of Cylinder

80ZIV-2

BRAKE 54

2.Assembling air cylinder For assembly, 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.

Adjustment procedure of air cylinder linkage.

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ When removing the air cylinder, the machine may move.

To prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

1

4

A 2

4

3 A 2

1) Release parking brake (OFF).

2)Measure dimension "A" if it is 84mm.

3

3) If not, remove pin (5), split pin (6), and washer (7) and loosen lock nut (2).

And adjust the linkage length by turning link (3) so that dimension "A" is 84mm.

5, 6, 7

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

5) Confirm the parking brake performance referring to Section 53.

Parking brake "OFF" position.

1. Air cylinder 2. Lock nut 3. Link 4. Bracket 5. Pin 6. Split pin 7. Washer

54-15

Removing and Reinstalling Parking Brake

80ZIV-2

BRAKE 54

Removing and Reinstalling Parking Brake 1.Removing parking brake

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

Note : Drain the transmission oil before removing the parking brake.

1) Release the parking brake, and disconnect the second propeller shaft (1) at the transmission end.

Torque for reassembly : Retainer bolt : 142N-m (14.5kgf-m) : Screw lock agent application (Three Bond 1327)

１

８０Ｗ５４００４

2) Remove the retainer nut (2) and then remove the washer, O-ring and the back-up ring.

Torque for reassembly : Retainer nut : 392N-m (40kgf-m) : MOLY grease (Anti seizure)

２

８０Ｋ５４００４

3) Remove the flange yoke (3) with the brake drum (4).

３

４

８０Ｋ５４００５

54-16

Removing and Reinstalling Parking Brake

80ZIV-2

BRAKE 54

4) Remove the ball joint (5) to separate the air cylinder and the parking brake.

５

８０Ｗ５４００５

5) Remove the retainer bolts (6) and then remove the brake assembly (7).

Torque for reassembly : Retainer bolt : 216N-m (22.0kgf-m) : Screw lock agent application (Three Bond 1327 or the equivalent)

７

６

８０Ｋ５４００７

6) Remove the springs (8) using pliers.

９ ８

7) Remove the plate (9).

８

８０Ｗ５４００６

54-17

Removing and Reinstalling Parking Brake

80ZIV-2

7) Remove the shoe hold pins (10) by turning 90 degree.

BRAKE 54

１１

8) Remove the brake shoes (11).

１０

８０Ｗ５４００７

9) Remove the spring (12) and the adjust screw (13).

１２

１３

2.Reinstalling parking brake To reinstall the parking brake, follow the above removal procedure in the reserved direction.

Note : To adjust the parking brake, refer to Section 53.

To check performance of the parking brake, refer to Section 53.

54-18

８０Ｗ５４００８

BRAKE GROUP 55 Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-2 Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-4 Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-5 Parking Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-6

55-1

Brake Valve

80ZIV-2

BRAKE 55

Brake Valve

17 7

6

9 2

5

1

17

8 10 11 13

4

12

14

15 16

3

No.

Item

Standard value

Solution

1

Mounting plate retainer bolt tightening torque

14N-m (1.4kgf-m)

Tightening

2

Rubber spring setting nut tightening torque

7N-m (0.7kgf-m)

Tightening

3

Lower body retainer bolt tightening torque

7N-m (0.7kgf-m)

Tightening

4

Plug tightening torque

39N-m (4.0kgf-m)

Tightening

55-2

Brake Valve

80ZIV-2

BRAKE 55

Unit : mm No. 5

6

7

Item Pedal pin hole dia

Nominal

Service standard

Wear limit

10

10.25

10

9.85

Inner dia.

10

10.1

Outer dia.

23.2

23

Inner dia. of pin bushing

10

10.25

Inner dia. of plunger bushing

26.5

26.65

Outer dia. of pin (pins for both roller and mounting plate)

Note

Roller

Mounting plate 8

9

Outer dia. of plunger

26.5

26.16

10

Free height of rubber spring

14

12

11

12

13

14

15

16

17

Spring

Free length mm

71.4

(piston return)

Load N (kgf)

113 (11.5)

Spring

Free length mm

41.3

(upper valve)

Load N (kgf)

44 (4.5)

Spring

Free length mm

35.6

(inner valve)

Load N (kgf)

28 (2.8)

Spring

Free length mm

41.0

(outer stem)

Load N (kgf)

39 (4.0)

Spring

Free length mm

39.5

(relay piston)

Load N (kgf)

46 (4.7)

Spring

Free length mm

21.7

(lower valve)

Load N (kgf)

53 (5.4)

Spring

Free angle

140deg

(pedal return)

Set angle

115deg

55-3

When the length is 14.6mm

When the length is 14.3mm

When the length is 16.0mm

When the length is 16.0mm

When the length is 12.1mm

When the length is 10.2mm

When the pedal is returned

Air Master

80ZIV-2

BRAKE 55

Air Master 2

5 4 8 6

3

7 ８０ＺＡ５４０３−１

No.

Item

Judgment standard

Solution

1.0 mm

Replacement

45 ± 1.5 mm

-

40 mm

-

1

Clearance between push nut and piston

2

Stroke of air chamber push rod

3

Stroke to overstroke switch

4

Hydraulic cylinder retainer nut tightening torque

88N-m (9.0kgf-m)

-

5

Clamp ring retainer nut tightening torque

20N-m (2.0kgf-m)

Tightening

6

Locknut tightening torque

64N-m (6.5kgf-m)

Tightening

7

Overstroke switch tightening torque

29N-m (3.0kgf-m)

Tightening

8

Air bleeder nipple tightening torque

10N-m (1.0kgf-m)

Tightening

55-4

Service Brake

80ZIV-2

BRAKE 55

Service Brake

２

４ ３

１

７０ＺＡ５４０３

Unit : mm Judgment standard No.

1

Item

Solution

Standard dimension

Tolerance

Wear limit

Thickness

5.0

+0 -0.2

4.4

Distortion

0.3 or less

0.3

-

Steel plate

Replacement

2

Thickness of friction plate

7.0

±0.1

5.9

Replacement

3

Thickness of brake disc when measured by calipers (with brake applied)

17.4

±0.2

15.1

Replacement

Outer diameter

355

-0.22〜-0.29

-

Inner diameter

285

0.05〜0.15

-

4

Piston

-

55-5

Parking Brake

80ZIV-2

BRAKE 55

Parking Brake

2

1 5 3

Clearance

Spring (4) released

4

Unit : mm No.

Item

Judgment standard Standard dimension

1

Solution

Wear limit

Wear of lining

Replacement 5.45

4.0

2

Deflection of drum

0.38 or more

Replacement

3

Lining inspection

Grease or oil on the lining

Replacement

4

Expansion of adjuster spring

5

There is clearance between the coils when the spring is released

Expansion of return spring

55-6

Replacement

ELECTRICAL GROUP 64 Removing and Reinstalling Wiper Motor ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-2 Removing and Reinstalling Controller ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-6 Removing and Reinstalling Fuse ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-7

64-1

Removing and Reinstalling Wiper Motor

80ZIV-2

ELECTRICAL 64

Removing and Reinstalling Wiper Motor 1.Removing front wiper motor 1) Remove the cover (1).

１

６５Ｋ６４００７

2) Remove the nut (2) and then remove the wiper arm (3).

２

３

3) Remove the nut (4) and the bolt (5).

After that, remove the wiper arm (3).

６５Ｋ６４００８

４

５ ３

６５Ｋ６４００９

4) Remove the cover (6) and the cover (7). ６， ７

６５Ｋ６４０１０

64-2

Removing and Reinstalling Wiper Motor

80ZIV-2

5) Remove the defroster hose (8).

ELECTRICAL 64

９

6) Disconnect the electrical line coupler (9) from the wiper motor.

８

６５Ｋ６４０１１

7) Remove the motor retainer bolt (10), and remove the ground cable (11).

8) Disconnect the coupler (12) for the relay. １３

9) Remove the wiper motor (13).

１１ １０ １２ ６５Ｋ６４０１２

2.Reinstalling front wiper motor To reinstall the front wiper motor, follow the above removal procedure in the reversed direction.

Note : When reinstalling the wiper arm, adjust the operation angle by the nut (2).

64-3

Removing and Reinstalling Wiper Motor

80ZIV-2

ELECTRICAL 64

1.Removing rear wiper motor 1) Remove the cover (1).

１

2) Remove the nut (2), and then remove the wiper arm (3). ３

２

3) Remove the nut (4) and then remove the wiper arm (3). ４

３

６５Ｖ６４００１

4) Remove the cover (5). ５

６５Ｋ６４０１６

64-4

Removing and Reinstalling Wiper Motor

80ZIV-2

ELECTRICAL 64

5) Disconnect the coupler (6) for the wiper motor (8).

７

6) Remove the motor retainer bolts (7).

7) Remove the wiper motor (8). ６ ８ ６５Ｋ６４０１７

2.Reinstalling rear wiper motor To reinstall the rear wiper motor, follow the above removal procedure in the reversed direction.

Note : When reinstalling the wiper arm, adjust the operation angle by the nut(2).

64-5

Removing and Reinstalling Controller

80ZIV-2

ELECTRICAL 64

Removing and Reinstalling Controller 1.Removing controller

１

WARNING ２

Before you remove the controller, be sure to stop the engine, and remove the starter key. In addition, hang a "DO NOT START THE ENGINE!" tag on the instrument panel.

1) Remove the catch (1), and then remove the cover (2).

６５Ｋ６４０１８

2) Disconnect the electrical coupler (3).

３

６５Ｖ６４００２

3) Remove the bolt (4) 4pcs, and then remove the controller (5).

５

４

2.Reinstalling controller To reinstall the controller, follow the above removal procedure in the reversed direction.

Note : After reinstallation, set the starter key to the ON position, and check the function of the LED indicator. In addition, run the machine, and check operation of the machine.

Note : The following items may have caused the controller to fail. Test and correct any problems before installing a new controller. ① Short in the output circuit (Refer to Section 62) ② Defective diode allowing voltage surges.

Identify and test each diode using procedures on Section 62.

６５Ｖ６４００３

64-6

Removing and Reinstalling Fuse

80ZIV-2

ELECTRICAL 64

Removing and Reinstalling Fuse 1.Removing fuse from inside of control box.

CAUTION Before removing a fuse, be sure to turn off the starter key.

1) Remove the catch (1), then open the cover (2). ●

１

２

６５Ｖ６４００４

2) Remove the cover (3) (4), then remove the fuses (5) (6).

5A

LIGHTING HEAD LIGHT

FR. WIPER

5A

R. WORK LIGHT

F. WORK LIGHT

10A 10A 10A

BACK LAMP STOP LAMP TURN SIGNAL

RADIO

3A

SPARE

F. WIPER CIGARETTE LIGHTER

STOP MOTOR

5A

NEUTRAL RELAY

5A

BATTERY RELAY

5A

SPARE

5A

AIRCON (OPTION)

SAFETY RELAY

20A 20A 20A

AIRCON (OPTION)

15A 15A 15A 15A 15A

AIRCON (OPTION)

PREHEAT

5A

SPARE

4 WAY FLASHER HORN

5A

SPARE

5A

SPARE

10A 10A

SPARE

PARKING BRAKE CONTROLLER BUZZER INSTRUMENT PANEL

SPARE SPARE

３

４

６ ５

5A

5A

BOOM KICKOUT BUCKET POSITIONER

R. WIPER

20A 10A 10A 15A 10A

FL. WIPER

2.Reinstalling fuse from inside of control box To reinstall the fuse, follow the above removal procedure in the reversed direction.

64-7

６５Ｋ６４０２２

OPERATOR STATION GROUP 74

Air Conditioner .............................................................................................74-2

74-1

80ZIV _ 2

Air conditioner

OPERATOR STATION 74

Air Conditioner Air conditioner mount

Cover unit

Air damper unit

Air conditioner unit

Seat stand

Floor board

74-2

80ZIV _ 2

Air conditioner

OPERATOR STATION 74

Removing and installing of air conditioner Removing the air conditioner

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on level ground, and apply the parking brake.

• Lower the bucket to the ground, and block the tires.

• Pull out the engine key, and attach a tag indicating that startup is prohibited.

Before starting the work, •Recover the gas using a gas recovery unit.

•Remove the seat and the seat stand.

•Disconnect the air conditioner piping at the self-sealing coupling.

２ ３ １

1) Remove the covers (1) to (5).

４

５

2) Disconnect the wiring (7) of the air conditioner (6) and the wiring (9) of the air damper (8) at each coupler.

９

８ ６

７

74-3

Air conditioner

80ZIV _ 2

OPERATOR STATION 74

3) Disconnect the refrigerant piping (10) and the heater hose (11).

10

11

4) Remove the air conditioner mounting bolts (12) and the air damper mounting bolts (13). Then, remove the air conditioner (6) and the air damper (8).

８ ６

13

12

Installing the air conditioner 1) Install the air conditioner in the reverse order of the removing procedure.

Reference After installing the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-4

80ZIV _ 2

Air conditioner

OPERATOR STATION 74

Condenser mount (S/N 80N3-9001~9100) Receiver dryer

Condenser unit

Engine room Bracket

Condenser unit 1. Core 2. Fan shroud 3. Bracket 4. Bracket 5. Fan 6. Motor 7. Bolt 8. Resistor 9. Cable

7 6

2

8

5 1

9

4

74-5

3

80ZIV _ 2

Air conditioner

OPERATOR STATION 74

Condenser mount (S/N 80N3-9101~)

Receiver dryer

Condenser unit

Condenser unit 1. Core 2. Fan shroud 3. Bracket 4. Bracket 5. Fan 6. Motor 7. Bolt 8. Resistor 9. Cable

7 6

2

8

5 1

9

4

74-6

3

80ZIV _ 2

Air conditioner

OPERATOR STATION 74

Removing and installing of condensers Removing the condensers

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on level ground, and apply the parking brake.

• Lower the bucket to the ground, and block the tires.

• Pull out the engine key, and attach a tag indicating that startup is prohibited.

１

Before starting the work, •Recover the gas using a gas recovery unit.

•Remove the air cleaner, etc. which may hinder removal.

1) Disconnect the condenser hose (1).

２

2) Disconnect the condenser wiring at the coupler (2).

Remove the condenser mounting nut (3), and remove the condensers.

(S/N 80N3-9001~9100)

３

Receiver dryer Condenser ２

Installing the condensers 1) Install the condensers in the reverse order of the removal procedure.

Reference After installing the condensers, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-7

３

(S/N 80N3-9101~)

80ZIV _ 2

Air conditioner

OPERATOR STATION 74

Compressor mount

５ ６ T2

１ ７

４

３ T1

２

80K74001

1. Compressor 2. Bracket 3. Idler pulley shaft 4. Belt tension pulley 5. V belt 6. Compressor mounting bolt 7. Adjustment bolt

: Tightening torque T1 : 31N·m (3.2kgf·m) T2 : 29N·m (3.0kgf·m)

74-8

80ZIV _ 2

Air conditioner

OPERATOR STATION 74

Removing and installing of compressor Removing the compressor

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on level ground, and lower the bucket, etc. to the ground • Block the tires, and apply the parking brake.

• In the starter key area, put up an indication that startup is prohibited.

4

5

Before starting the work, •Recover the gas using a gas recovery unit.

1

2

1) Loosen the tension pulley (1) lock nut and the lock bolt (2). Turn the adjustment bolt (3) to make the V belt (4) slack, then remove the V belt from the compressor.

Tightening torque during assembly : Pulley (1) lock nut ....................31N·m (3.2kgf·m) 2) Disconnect the compressor wiring and the cooler piping (5). Remove the compressor mounting nut (6), and remove the compressor (7).

Tightening torque during assembly : Nut (6)..........29N·m (3.0kgf·m)

Installing the compressor 1) Install the compressor in the reverse order of the removing procedure.

Reference •After installing the compressor, adjust the tension of the V belt.

•Charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leak.

•The quantity of the compressor lubricating oil (NDO1L2) is 180 cm3. Never use or mix any other oil.

74-9

3 6 7

80K74002

OPERATOR STATION GROUP 75

Air Conditioner .............................................................................................75-2

75-1

80ZIV _ 2

Air conditioner

OPERATION 75

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

Criteria

Action

Refrigerant

Charge quantity

Inspection/ Air bubbles should not be seen through sight glass. adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Compressor

Operating status

Belt tension pulley

Operating status

V belt

Damage and tension

Magnetic clutch should operate. Abnormal sounds Inspection/ adjustment/ should not be detected. replacement Abnormal sounds and backlash should not be Inspection/ detected. replacement Damages should not be detected.

Adjustment/ Tension should be proper. replacement

Blower motor and fan

Operating status

Abnormal sounds or vibration should not be detected.

Control mechanism

Operating status

Inspection/ replacement Each part should operate in accordance with switch Inspection/ operations. replacement Air quantity should not be so small as to hinder air Cleaning/ conditioning. replacement

Air filter for inside/outside air Blockage Each mounting area and piping

Clean

Looseness, gas leak and Looseness, gas leak and damage should not be damages detected.

Tightening/charge

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

Nut type

Connection area

Pipe size or bolt size

Tightening torque N·m (kgf·m)

Condenserexpansion valve

ø8 piping

15 (1.50)

Compressorcondenser

D1/2 piping

25 (2.50)

Evaporatorcompressor

D5/8 piping

34 (3.50)

Receiver

M6 bolt in receiver (4T) Any M6 bolt (6T) other than above

Special control region

Bolt size

Tightening torque N·m (kgf·m)

Head bolt of magnetic clutch

M6

13 (1.35)

Mounting bolt for servo motor for inside/outside air selection

M5

0.5 (0.05)

Fixing nut of blower motor and condenser fan

M6

5 (0.55)

Fixing bolt of blower motor and condenser motor

M5

3 (0.30)

7 (0.70)

Block joint Evaporatorcompressor

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

12 (1.20)

75-2

80ZIV _ 2

Air conditioner

OPERATOR STATION 75

3. Compressor A

1

Fan pulley

4

2

Crank pulley

3

A-A 80ZA7204

80ZA7202

No.

Item

Standard value

Remedy

8~10mm 98N (10kgf)

Adjustment

1

V-Belt tension

2

Tension pulley mounting nut tightening torque

31N·m (3.2kgf·m)

Tightening

3

Compressor mounting bolt tightening torque

29N·m (3.0kgf·m)

Tightening

4

Compressor lubricating oil amount

180cm3

Adjustment

✽

✽✽

✽ Refer to the section 72 for V-belt tension adjustment ✽✽ -Refer to the section 72 for adjustment of compressor lubrication oil quantity -Compressor lubricating oil······ND-OIL8 (Never mix any other oil)

75-3

80Z Ⅳ -2 Disassembly & Reassembly, Service Standard AAA-S80N3E14-004 AAA-S80N3E14-00Z

① 2000.5.1

K

② 2000.12.15

KAWASAKI HEAVY INDUSTRIES, LTD. Rolling Stock, Construction Machinery & Crushing Plant Company Construction Machinery Division Tokyo Head Office

W.T.C. Bldg., 2-4-1 Hamamatsu-cho Minato-ku, Tokyo 105-6116

Kobe Head Office

Kobe Crystal Tower, 1-1-3 Higashi Kawasaki-cho Chuo-ku, Kobe, Hyogo 650-0044

Banshu Works

2680 Oka Inami-cho Kako-gun, Hyogo 675-1113

All rights reserved. No copy allowed without written consent.