DOWNLOAD PDF : Kawasaki 92ZV-2 WHEEL LOADER SHOP MANUAL 93221-00061

92ZV-2

93221-00061

SHOP MANUAL Disassembly & Reassembly Service Standard

Printed in Japan (k) ( ヨーロッパ・オセアニア用 )

93221-00061

©2011 KCM Corporation. All rights reserved.

May 2011

SHOP MANUAL WHEEL LOADER

92ZV-2 Disassembly & Reassembly Service Standard

Powered by CUMMINS QSM11 ENGINE Serial No. 92C1-9001 and up

93221-00061 May 2011

Foreword To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.

To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.

Disassembly & Reassembly Service Standard For the engine, refer to the engine Shop Manual provided by the engine manufacturer.

The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service.

This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.

Safety precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below.

- This manual is intended for properly trained and equipped service technicians.

- Any work on the machine must be performed by the trained personnel only.

- Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine.

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

- Just after stopping operation, be careful not to directly touch a hot component. You may get burned.

- Contact tire manufacturer's local dealer for tire servicing and changing.

- Always store the tools in good condition, and use them properly.

- Keep the work area clean. Clean up spills immediately.

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

- Avoid the use of flammable solvents and cleaners.

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

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

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

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

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

- Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe.

- Be sure to apply the articulation stopper before starting work.

- While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks.

- When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping.

- Do not start to work in an enclosed area if adequate ventilation is not provided.

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

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.

CONTENTS 92ZV-2 General Information .................................................................................................................................. 00-1 Symbols ............................................................................................................................................................ 00-2 Weight of Main Components ............................................................................................................................. 00-3 Bolt Tightening Torque ...................................................................................................................................... 00-4 Hose Band Tightening Torque ........................................................................................................................... 00-8 Liquid Gasket and Screw Lock Agent ............................................................................................................... 00-9 Cautions regarding parts removal ............................................................................................................... 00-9 Cautions regarding reassembly .................................................................................................................. 00-9 Screw lock agent application procedure ................................................................................................... 00-10 How to wind a seal tape ............................................................................................................................ 00-10 Cautions Regarding Welding Repair Service ...................................................................................................00-11 Cautions Regarding Handling of Bearing ........................................................................................................ 00-13 Bearing installation cautions ..................................................................................................................... 00-13 Interference fits for a bearing .................................................................................................................... 00-13 Bearing removal cautions ......................................................................................................................... 00-14 Applying and Storing Articulation Stopper ....................................................................................................... 00-15 Applying articulation stopper ..................................................................................................................... 00-15 Storing articulation stopper ....................................................................................................................... 00-16 92ZV-2 Disassembly & Reassembly Chassis Group ............................................................................................ 14-1 Deck .................................................................................................................................................................. 14-2 Deck removing and installing ...................................................................................................................... 14-2 Fuel Tank .......................................................................................................................................................... 14-4 Fuel tank removing and installing ............................................................................................................... 14-4 Hydraulic Tank .................................................................................................................................................. 14-5 Hydraulic tank removing and installing ....................................................................................................... 14-5 Engine Room .................................................................................................................................................... 14-7 Engine room removing and installing .......................................................................................................... 14-7 Cab ................................................................................................................................................................. 14-10 Cab removing and installing ...................................................................................................................... 14-10 Floor Board ..................................................................................................................................................... 14-12 Floor board removing and installing .......................................................................................................... 14-12 Boom ............................................................................................................................................................... 14-15 Boom removing and installing ................................................................................................................... 14-15

Center Pin ....................................................................................................................................................... 14-18 Upper center pin ........................................................................................................................................ 14-18 Lower center pin ........................................................................................................................................ 14-19 Center pin removing and installing ............................................................................................................ 14-20 Partition Plate .................................................................................................................................................. 14-24 Partition plate removing and installing ...................................................................................................... 14-24 Lower Cover .................................................................................................................................................... 14-26 Lower cover removing and installing ......................................................................................................... 14-26 92ZV-2 Service Standard Chassis Group ............................................................................................................. 15-1 Linkage .............................................................................................................................................................. 15-2 Linkage Pin Standard Clearance Values ........................................................................................................... 15-3 Liner clearance adjustment ......................................................................................................................... 15-3 Center Pin ......................................................................................................................................................... 15-4 Center pin shim adjustment ........................................................................................................................ 15-4 Bearing cover installing ............................................................................................................................... 15-4 Lower center pin bearing outer ring installing ............................................................................................. 15-5 Attachment Leveler ........................................................................................................................................... 15-6 Attachment leveler ...................................................................................................................................... 15-7 92ZV-2 Disassembly & Reassembly Power Group ............................................................................................... 24-1 Power Line ........................................................................................................................................................ 24-2 Power line tightening torque ........................................................................................................................ 24-2 Radiator ............................................................................................................................................................. 24-3 Radiator tightening torque ........................................................................................................................... 24-3 Radiator removing and installing ................................................................................................................. 24-4 Radiator core removing and installing ......................................................................................................... 24-7 Fan .................................................................................................................................................................... 24-9 Fan removing and installing ........................................................................................................................ 24-9 Engine ............................................................................................................................................................. 24-11 Engine removing and installing ................................................................................................................. 24-11 Propeller Shaft ................................................................................................................................................ 24-14 Propeller shaft removing and installing ..................................................................................................... 24-14 Air Cleaner ...................................................................................................................................................... 24-16 Air cleaner removing and installing ........................................................................................................... 24-16 Muffler ............................................................................................................................................................. 24-18 Muffler removing and installing ................................................................................................................. 24-18

Front Axle Assembly ....................................................................................................................................... 24-19 Front axle assembly tightening torque ...................................................................................................... 24-19 Front axle assembly removing and installing ............................................................................................ 24-21 Front axle disassembling and assembling ................................................................................................ 24-24 Front axle assembly cautions ................................................................................................................... 24-27 Internal Gear Hub ........................................................................................................................................... 24-32 Internal gear hub disassembling and assembling ..................................................................................... 24-32 Internal gear hub assembly cautions ........................................................................................................ 24-34 Spider Assembly ............................................................................................................................................. 24-35 Spider assembly disassembling and assembling ...................................................................................... 24-35 Special Tool ..................................................................................................................................................... 24-37 Special tool for axle ................................................................................................................................... 24-37 Rear Axle Assembly ........................................................................................................................................ 24-41 Rear axle assembly tightening torque ....................................................................................................... 24-41 Rear axle assembly removing and installing ............................................................................................. 24-43 Rear axle disassembling and assembling ................................................................................................. 24-45 Axle Support ................................................................................................................................................... 24-46 Axle support tightening torque .................................................................................................................. 24-46 Axle support disassembling and assembling ............................................................................................ 24-47 Axle support assembly cautions ............................................................................................................... 24-48 Differential Assembly ...................................................................................................................................... 24-49 Differential assembly removing and installing ........................................................................................... 24-49 Differential assembly disassembling and assembling ............................................................................... 24-52 92ZV-2 Service Standard Power Group ................................................................................................................ 25-1 Propeller Shaft Service Standard ...................................................................................................................... 25-2 Axle and Differential Service Standard .............................................................................................................. 25-3 Axle group ................................................................................................................................................... 25-3 Differential ................................................................................................................................................... 25-4 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group ............................................... 34-1 Torque Converter and Transmission Assembly ................................................................................................ 34-2 Torque converter and transmission assembly tightening torque ................................................................. 34-2 Torque converter and transmission assembly removing and installing ....................................................... 34-3

Torque Converter Assembly ............................................................................................................................ 34-11 Torque converter assembly tightening torque ........................................................................................... 34-11 Torque converter assembly disassembling and assembling ..................................................................... 34-12 Lock-up torque converter disassembling and assembling ........................................................................ 34-18 Transmission Assembly .................................................................................................................................. 34-20 Transmission assembly tightening torque ................................................................................................. 34-20 Transmission assembly disassembling and assembling ........................................................................... 34-21 Transmission Forward/Reverse Clutch Pack .................................................................................................. 34-27 Forward/reverse clutch pack disassembling and assembling ................................................................... 34-27 Transmission 1st/3rd Speed Clutch Pack ........................................................................................................ 34-30 Transmission 1st/3rd speed clutch pack disassembling and assembling ................................................. 34-30 Transmission 2nd Speed Clutch Pack ............................................................................................................. 34-32 Transmission 2nd speed clutch pack disassembling and assembling ...................................................... 34-32 Transmission 4th Speed Clutch Pack .............................................................................................................. 34-34 Transmission 4th speed clutch pack disassembling and assembling ....................................................... 34-34 Control Valve Assembly .................................................................................................................................. 34-37 Control valve tightening torque ................................................................................................................. 34-37 Control valve removing and installing ....................................................................................................... 34-38 Control valve disassembling and assembling ........................................................................................... 34-40 92ZV-2 Service Standard Torque Converter and Transmission Group ................................................................ 35-1 Transmission Assembly .................................................................................................................................... 35-2 Control Valve ..................................................................................................................................................... 35-4 Torque Converter Gear Pump ........................................................................................................................... 35-5 Gear pump specifications ............................................................................................................................ 35-5 Clutch Plate Thickness/Piston Stroke ............................................................................................................... 35-6 Clutch plate ................................................................................................................................................. 35-7 Piston stroke ............................................................................................................................................... 35-7 Clutch Oil Pressure ........................................................................................................................................... 35-8 Clutch oil pressure standard value .............................................................................................................. 35-8 92ZV-2 Disassembly & Reassembly Hydraulic Group .......................................................................................... 44-1 Hydraulic Parts Removal and Installation Warning ........................................................................................... 44-2 Hydraulic Parts Disassembly and Assembly Cautions ...................................................................................... 44-3 Hydraulic parts disassembly cautions ......................................................................................................... 44-3 Hydraulic parts assembly cautions .............................................................................................................. 44-3

Hydraulic Pump Assembly ................................................................................................................................ 44-4 Hydraulic pump assembly removing and installing ..................................................................................... 44-4 Hydraulic pump assembly disassembling and assembling ......................................................................... 44-5 Hydraulic Cylinder ........................................................................................................................................... 44-19 Boom cylinder removing and installing ..................................................................................................... 44-19 Bucket cylinder removing and installing .................................................................................................... 44-21 Steering cylinder removing and installing .................................................................................................. 44-24 Hydraulic cylinder disassembling and assembling .................................................................................... 44-26 Pilot Valve ....................................................................................................................................................... 44-32 Pilot valve removing and installing ............................................................................................................ 44-32 Pilot valve disassembling and assembling (S/N 9001~9017) ................................................................... 44-35 Pilot valve disassembling and assembling (S/N 9018~) ........................................................................... 44-45 Multiple Control Valve ..................................................................................................................................... 44-53 Multiple control valve removing and installing ........................................................................................... 44-53 Multiple control valve disassembling and assembling .............................................................................. 44-55 Orbitrol® .......................................................................................................................................................... 44-59 Orbitrol® removing and installing ............................................................................................................... 44-59 Orbitrol® disassembling and assembling .................................................................................................. 44-61 Steering Valve ................................................................................................................................................. 44-69 Steering valve removing and installing ...................................................................................................... 44-69 Steering valve disassembling and assembling ......................................................................................... 44-71 Stop Valve ....................................................................................................................................................... 44-74 Stop valve removing and installing ............................................................................................................ 44-74 Stop valve disassembling and assembling ............................................................................................... 44-76 Fan Motor ........................................................................................................................................................ 44-78 Fan motor removing and installing ............................................................................................................ 44-78 92ZV-2 Service Standard Hydraulic Group ........................................................................................................... 45-1 Hydraulic Cylinder ............................................................................................................................................. 45-2 Pilot Valve ......................................................................................................................................................... 45-4 Steering Valve ................................................................................................................................................... 45-6 \92ZV-2 Disassembly & Reassembly Brake Group .............................................................................................. 54-1 Unloader Valve .................................................................................................................................................. 54-2 Unloader valve removing and installing ...................................................................................................... 54-2 Unloader valve disassembling and assembling .......................................................................................... 54-4

Manifold Valve Assembly .................................................................................................................................. 54-7 Valve assembly removing and installing ..................................................................................................... 54-7 Valve assembly disassembling and assembling ......................................................................................... 54-8 Accumulator .................................................................................................................................................... 54-10 Accumulator removing and installing ........................................................................................................ 54-10 Accumulator disassembling and assembling ............................................................................................ 54-12 Nitrogen gas charging ............................................................................................................................... 54-14 Brake Valve ..................................................................................................................................................... 54-16 Brake valve removing and installing .......................................................................................................... 54-16 Brake valve disassembling and assembling ............................................................................................. 54-18 Service Brake .................................................................................................................................................. 54-23 Service brake disassembling and assembling .......................................................................................... 54-23 Parking Brake .................................................................................................................................................. 54-24 Parking brake removing and installing ...................................................................................................... 54-24 Parking brake disassembling and assembling .......................................................................................... 54-25 92ZV-2 Service Standard Brake Group ................................................................................................................. 55-1 Brake Valve ....................................................................................................................................................... 55-2 Service Brake .................................................................................................................................................... 55-3 Parking Brake .................................................................................................................................................... 55-4 92ZV-2 Disassembly & Reassembly Operator Station Group ............................................................................... 74-1 Air Conditioner .................................................................................................................................................. 74-2 Air conditioner removing and installing ....................................................................................................... 74-2 Air conditioner disassembling and assembling ........................................................................................... 74-4 92ZV-2 Service Standard Operator Station Group ................................................................................................ 75-1 Air Conditioner .................................................................................................................................................. 75-2 Periodical Inspection/Servicing ................................................................................................................... 75-2 Tightening Torque ....................................................................................................................................... 75-2

00-1 92ZV-2 General Information

92ZV-2 General Information Symbols .................................................................. 00-2 Weight of Main Components ................................... 00-3 Bolt Tightening Torque ............................................ 00-4 Hose Band Tightening Torque................................. 00-8 Liquid Gasket and Screw Lock Agent ..................... 00-9 Cautions Regarding Welding Repair Service .......... 00-11 Cautions Regarding Handling of Bearing ................ 00-13 Applying and Storing Articulation Stopper ............... 00-15

00-2 92ZV-2 General Information Symbols

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

Symbol

Item

Description

Reference

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

Weight

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

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

Coating

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

Oil or water supply

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

Drainage

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

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

The message shows the preventive measures.

Abbreviation To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the following abbreviation list.

E/G ........... Engine T/C ........... Torque converter T/M ........... Transmission SOL ........... Solenoid valve SW ........... Switch F ........... Front or Forward A/M ........... Auto/Manual B ........... Battery R ........... Rear or Reverse

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

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

00-3 92ZV-2 General Information Weight of Main Components

Weight of Main Components Item Unit name

Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

2,290

5,040

Boom

1,865

4,100

Lever

265/pc

585/pc

Link (Bucket to Lever)

45/pc

100/pc

Screen board

115

255

Roof

40

90

Engine room access panel

50

110

Chassis

175

385

Excluding oil

Fuel tank

200

440

Excluding fuel

Left side

75

165

With handrail

Right side

80

180

With handrail

500

1,100

Cab (ROPS)

Hydraulic system

Other

GSC bucket

Hydraulic tank

Deck

Power line

Remarks

Floor board

250

550

Front chassis

2,035

4,480

Rear chassis

2,095

4,610

Counter weight

2,670

5,880

Engine

940

2,070

Excluding oil

Transmission

1,260

2,770

Excluding oil

Second propeller shaft

70

155

Third propeller shaft

15

35

Radiator assembly

325

720

Excluding water and oil

T/C cooler

70

155

Excluding oil

Front axle assembly

1,275

2,810

Excluding tires and oil

Rear axle assembly

1,515

3,335

Excluding tires and oil (Including axle support)

Front differential

175

385

Rear differential

190

420

Multiple control valve

90

200

Steering valve

23

50

Hydraulic pump

35

80

For steering

Hydraulic pump

30

70

For loading

Fan motor

15

35

Boom cylinder

240/pc

530/pc

Bucket cylinder

130/pc

290/pc

Steering cylinder

40/pc

90/pc

Tire

670/pc

1,480/pc

Battery

35/pc

80/pc

With rim (26.5R25

)

00-4 92ZV-2 General Information Bolt Tightening Torque

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

Nominal dia.

Pitch

M8

8

(C) 1.25

26

38

(C) 1.5

53

76

(F) 1.25

55

80

(C) 1.75

90

132

M10

M12

M14

Metric thread

Unified thread

Bolt strength

Nominal dimension

10

12

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27

27

M30

30

M33

33

5/16

05

8.8 (8T)

10.9 (11T)

(F) 1.25

96

142

(C) 2.0

142

206

(F) 1.5

152

221

(C) 2.0

216

314

(F) 1.5

226

330

(C) 2.5

299

436

(F) 1.5

324

476

(C) 2.5

417

608

(F) 1.5

451

662

(C) 2.5

559

814

(F) 1.5

598

878

(C) 3.0

721

1,030

(F) 2.0

770

1,128

(C) 3.0

1,030

1,520

(F) 2.0

1,128

1,618

(C) 3.5

1,422

2,109

(F) 2.0

1,569

2,256

(C) 3.5

1,912

2,844

(F) 2.0

2,059

3,040

18 UNC

25

35

3/8

06

16 UNC

44

65

7/16

07

14 UNC

71

103

1/2

08

13 UNC

103

147

9/16

09

12 UNC

147

216

5/8

10

11 UNC

201

294

3/4

12

10 UNC

358

525

7/8

14

9 UNC

554

809

1

16

8 UNC

868

1,275

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

00-5 92ZV-2 General Information Bolt Tightening Torque

(kgf-m) Bolt size Type

Metric thread

Nominal dia.

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

2.7

3.9

(C) 1.5

5.4

7.8

(F) 1.25

5.6

8.2

(C) 1.75

9.2

13.5

(F) 1.25

9.8

14.5

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

24

27

30

(C) 2.0

14.5

21.0

(F) 1.5

15.5

22.5

(C) 2.0

22.0

32.0

(F) 1.5

23.0

33.7

(C) 2.5

30.5

44.5

(F) 1.5

33.0

48.5

(C) 2.5

42.5

62.0

(F) 1.5

46.0

67.5

(C) 2.5

57.0

83.0

(F) 1.5

61.0

89.5

(C) 3.0

73.5

105.0

(F) 2.0

78.5

115.0

(C) 3.0

105.0

155.0

(F) 2.0

115.0

165.0

(C) 3.5

145.0

215.0

(F) 2.0

160.0

230.0

(C) 3.5

195.0

290.0

M33

33

(F) 2.0

210.0

310.0

5/16

05

18 UNC

2.5

3.6

3/8

06

16 UNC

4.5

6.6

7/16

07

14 UNC

7.2

10.5

1/2

08

13 UNC

10.5

15.0

9/16

09

12 UNC

15.0

22.0

5/8

10

11 UNC

20.5

30.0

3/4

12

10 UNC

36.5

53.5

7/8

14

9 UNC

56.5

82.5

1

16

8 UNC

88.5

130.0

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

00-6 92ZV-2 General Information Bolt Tightening Torque

(lb-ft) Bolt size Type

Metric thread

Nominal dia.

Pitch

8.8 (8T)

M8

8

(C) 1.25

19.5

28

(C) 1.5

39

56

(F) 1.25

40

59

(C) 1.75

66

97

(F) 1.25

70

105

(C) 2.0

105

150

(F) 1.5

110

160

(C) 2.0

160

230

(F) 1.5

165

245

(C) 2.5

220

320

(F) 1.5

235

350

(C) 2.5

305

450

(F) 1.5

330

490

(C) 2.5

410

600

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

24

27

30

M33

33

5/16

05

10.9 (11T)

(F) 1.5

440

650

(C) 3.0

530

760

(F) 2.0

565

830

(C) 3.0

760

1,120

(F) 2.0

830

1,190

(C) 3.5

1,050

1,550

(F) 2.0

1,160

1,660

(C) 3.5

1,410

2,100

(F) 2.0

1,520

2,240

18 UNC

18.0

26

3/8

06

16 UNC

32

47

7/16

07

14 UNC

52

76

1/2

08

13 UNC

76

105

9/16

09

12 UNC

110

160

5/8

10

11 UNC

150

215

3/4

12

10 UNC

265

385

7/8

14

9 UNC

410

595

1

16

8 UNC

640

940

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

00-7 92ZV-2 General Information Bolt Tightening Torque

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

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

7

M6

1

12

M8

1.25

28

M10

1.5

53

M12

1.75

94

M16

2

231

M20

2.5

441

M24

3

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

0.7

M6

1

1.2

M8

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

2

23.5

M20

2.5

45.0

M24

3

78.0 (lb-ft)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

5.0

M6

1

8.6

M8

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

2

169.2

M20

2.5

324.0

M24

3

561.6

00-8 92ZV-2 General Information Hose Band Tightening Torque

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

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

16

1.2

4

40

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

16

1.2

4

40

2.9

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

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

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

16.5

8

18.5

9

20.5

9

22.0

12

24.5

12

26.0

15

29.0

15

30.5

19

32.0

19

34.0

25

39.5

25

41.5

32

46.0

32

48.0

38

54.0

50

70.5

50

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

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

Hose

Pipe

Hose band Center of pipe protrusion

10~20 mm

70ZV00003

00-9 92ZV-2 General Information Liquid Gasket and Screw Lock Agent

Liquid Gasket and Screw Lock Agent To reassemble the disassembled parts, be sure to use the specified liquid gasket or screw lock agent or the equivalent according to the following lists: Code AA01 Liquid Gasket

Screw Lock Agent

Manufacturer

Product name

®

Plastic Gasket 568

®

Loctite

AA02

Loctite

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

®

®

AB01

Loctite

Loctite 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

Cautions regarding reassembly To reassemble a screw Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw.

Note A piece of hardened lock agent may be peeled off and remain in the component. The remaining piece may cause malfunction during fastener installation.

To bond a plane or to fit a shaft

Cautions regarding parts removal

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

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

Antiseize Agent

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

Caution If there is a seal near the screw or shaft to be removed, carefully use the heating method for removal, to avoid damage to the seal.

If heat has been used to remove the bolt a new bolt should be used during reassembly.

Code

Manufacturer

AC01

Loctite®

Product name Loctite® 767 (Paste or spray)

00-10 92ZV-2 General Information Liquid Gasket and Screw Lock Agent

Screw lock agent application procedure

How to wind a seal tape

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

Seal tape

Screw lock agent Leave 1~2 screw

65ZV00004

65ZV00002

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

00-11 92ZV-2 General Information Cautions Regarding Welding Repair Service

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

1. Turn the starter switch OFF.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

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

3. Disconnect the connector for MCU (machine controller), ECM (engine controller) and air conditioner.

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

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

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

Example 1

Section to be welded Do not ground this section.

Electric current may flow through the cylinders.

Ground this section. (correct grounding)

35C00002

Example 2

Do not ground this section.

Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

35C00006

00-12 92ZV-2 General Information Cautions Regarding Welding Repair Service 1. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes.

Be sure to mask these units and parts before welding.

Hydraulic cylinder

Heat-resistant cloth Section to be welded

Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

35A00005

Plated section (Mask this section.)

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

Pin section with pin temporarily inserted

Note You must change the welding rod grade depending on the welding part and place. Should you have any question regarding the welding repair service, please contact KCM dealer in your area during business hours.

Pin

Plated section (Mask this section.)

35C00003

(a) Plated section Cover the plated sections with heat-resistant cloth, such as glass wool or canvas.

Note The weld spattered on the plated sections causes corrosion.

1m or more

Scrap material, etc.

Section to be welded

1m or more 35C00004

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

00-13 92ZV-2 General Information Cautions Regarding Handling of Bearing

Cautions Regarding Handling of Bearing Bearing installation cautions

Force

IMPORTANT Unwrap a new bearing just before installing it.

Metal pad

K65V2J00002

K65V2J00004

When installing a bearing to a shaft or a housing, it is important to insert the bearing by equally applying pressure on the bearing ring circumference.

Do not partially apply pressure on the bearing ring, as it may cause unstable and entangled bearing operation.

Do not apply pressure from the side, as it will apply load via the rolling element, making indentations on the bearing ring.

Do not hit the bearing directly with a hammer, etc. to prevent indentation and crack.

If the interference is rather small, put an appropriate tool on the bearing inner ring and press the tool, not directly the bearing, with a pressing machine or a hammer to fit the bearing on the shaft, while applying equal pressure onto the inner race circumference.

When installing the bearing on a shaft and also in a housing at the same time, put an appropriate metal pad both on the inner and outer rings as shown in the above figure (right), and press the bearing using the tool so that equal pressure is applied onto the inner and outer races.

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

Interference fits for a bearing

Heating to remove the interference

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

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

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

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

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

00-14 92ZV-2 General Information Cautions Regarding Handling of Bearing

Bearing operation test after installation Manually turn the shaft or housing after installing a bearing.

Verify that there is no abnormal noise, chattering, vibration, or unusual load. If any abnormality is observed, stop rotating and check the bearing.

Bearing removal cautions Pressing machine

Bearing puller

Bearing removal tool K65V2J00003

When removing bearing unit, use an appropriate tools as shown above.

Make sure to apply load only to the bearing ring to pull out the bearing, and DO NOT apply any load to the rolling element.

If any load is applied when removing the bearing unit because of its installation conditions, the bearing must not be reused.

00-15 92ZV-2 General Information Applying and Storing Articulation Stopper

Applying and Storing Articulation Stopper Applying articulation stopper 2

3

Locked position IL14-3(90ZV-D&R)

IL14-1(90ZV-D&R)

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.

WARNING Unexpected movement of machine could cause serious injury or death. There is a possibility that a service man could be crushed in the articulation area if the machine unexpectedly turns during repair work.

To prevent such an accident, be sure to apply the articulation stopper before starting work.

1

IL14-2(90ZV-D&R)

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

WARNING To align the pin with the pin hole, start the engine and slightly turn the steering wheel. Be careful! Your body or finger could be crushed in the machine when the machine turns.

Stay out of the articulation area while aligning the holes.

When inspecting or servicing machine in articulation area, do not start the engine without applying the articulation stopper and place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel.

00-16 92ZV-2 General Information Applying and Storing Articulation Stopper

Storing articulation stopper

3

1 2

Stored position IL14-4(90ZV-D&R)

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

14-1 92ZV-2 Disassembly & Reassembly Chassis Group

92ZV-2 Disassembly & Reassembly Chassis Group Deck ........................................................................ 14-2 Fuel Tank................................................................. 14-4 Hydraulic Tank......................................................... 14-5 Engine Room .......................................................... 14-7 Cab.......................................................................... 14-10 Floor Board ............................................................. 14-12 Boom ....................................................................... 14-15 Center Pin ............................................................... 14-18 Partition Plate .......................................................... 14-24 Lower Cover ............................................................ 14-26

14-2 92ZV-2 Disassembly & Reassembly Chassis Group Deck

Deck Deck removing and installing Deck removing Window washer liquid 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 deck removal: - Position the machine on level ground, and apply the parking brake.

- Lower the attachment onto the ground, and block the tires with chocks, etc. to prevent them from moving.

- Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

6 5 92V2U14002

2. Remove bolt (5) to remove the window washer liquid tank from deck (6).

8 7

1

Screen board

3

6 Fuel tank

9

Hydraulic tank

4

92V2U14003

Screen board

2

92V2U14001

1. Apply a sling to handrail (1) and deck (4), then remove bolts (2)(3). : Deck (4) (with handrails): 80 kg (175 lbs)

3. Apply a sling to handrail (7) and deck (6), then remove bolts (8)(9). : Deck (6) (with handrails): 85 kg (185 lbs) 4. While considering the balance, remove decks (4)(6) together with the handrails.

14-3 92ZV-2 Disassembly & Reassembly Chassis Group Deck

10

Fuel tank

11

92V2U14004

5. Remove bolt (10) to remove ladder (11). : Ladder: 9 kg (20 lbs)

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

14-4 92ZV-2 Disassembly & Reassembly Chassis Group Fuel Tank

Fuel Tank Fuel tank removing and installing

4

Fuel tank removing

WARNING

2

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

- Lower the attachment onto the ground, and block the tires with chocks, etc. to prevent them from moving.

- Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

Before starting work: - Drain fuel from the fuel tank.

(Fuel tank capacity: 424 L (112 gal)) - Remove the deck and the ladder.

Fuel tank

92V2U14006

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

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

1 2

Fuel tank installation cautions Rear chassis

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

3

92V2U14005

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

2. Temporarily sling fuel tank (2). : Fuel tank: 200 kg (441 lbs) (when empty) 3. Remove retainer bolt (3). : Bolt (3): 441 N-m (45.0 kgf-m) (326 lb-ft)

14-5 92ZV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic Tank Hydraulic tank removing and installing

1

Hydraulic tank removing 2 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 attachment onto the ground, and block the tires with chocks, etc. to prevent them from moving.

- Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

92V2U14007

1. Disconnect hoses (1)(2) from the oil cooler.

3

Before starting work: - Drain hydraulic oil from the hydraulic tank.

(Hydraulic tank capacity: 258 L (68 gal)) - Remove the deck.

- Clean the area around the tank.

(S/N 9001~9100) Breather valve

(S/N 9101~) Breather valve

Hydraulic tank 92V2U14008

2. Disconnect brake line hose (3).

Pump unit (option)

K92V2E14001

4 90V2E14009

3. When the optional secondary steering system is applicable, remove bolt (4) to remove the pump unit from the hydraulic tank.

14-6 92ZV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

9

13

5

6 11

8 13

7

12 92V2U14011

92V2U14009

4. Disconnect hose (5) to the pilot valve. Disconnect hose (6) to the fan motor. Disconnect hose (7) to the stop valve. Disconnect hose (8) to the orbitrol, and hose (9) to the combination valve.

6. Disconnect oil level sensor (11) and temperature sensor (12) couplers.

7. Temporarily sling the hydraulic tank, and remove bolts (13). : Hydraulic tank: 175 kg (385 lbs) (when empty)

10

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

92V2U14010

Hydraulic tank installation cautions 5. Disconnect hose (10) to the oil pump.

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

14-7 92ZV-2 Disassembly & Reassembly Chassis Group Engine Room

Engine Room Engine room removing and installing 3

Engine room removing

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

- Lower the attachment onto the ground, and block the tires with chocks, etc. to prevent them from moving.

- Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

Before starting work: - Recover/recycle refrigerant on machine with optional air conditioner, if required.

Note If the quick coupler is attached, no recovery/recycling will be needed.

90ZV14009

2. Remove covers (3) at both right and left sides.

5

4

Engine roof Muffler K90V2U14012

2

3. Remove bolt (4) and exhaust pipe (5).

1

: Bolt (4): 53 N-m (5.4 kgf-m) (39 lb-ft)

90ZV14008

1. Remove right and left decks (1) together with handrail (2).

14-8 92ZV-2 Disassembly & Reassembly Chassis Group Engine Room

10 7 Condenser

9

Engine

6

Receiver tank

92V2U14012

92V2U14014

4. Disconnect hoses (6)(7) from the condenser and the receiver tank.

6. Remove hose (9) between the air cleaner and turbocharger at the turbocharger side.

Disconnect indicator wire coupler (10).

Note Before disconnecting the hoses, be sure to recover/ recycle the refrigerant.

(If the quick coupler is attached, no recovery/recycling will be needed.)

Screen board

Note Cover the hose and port of the turbocharger to protect the turbocharger from dust and dirt.

11

8

12

13

Air cleaner

K92V2E14002 92V2U14013

5. Remove precleaner (option) and duct (8), when installed.

Note The precleaner is an optional unit.

7. Remove nut (11) and bolt (12) of engine access panel (13). Sling engine access panel (13). : Nut (11): 53 N-m (5.4 kgf-m) (39 lb-ft) : Engine access panel: 75 kg (165 lbs)

14-9 92ZV-2 Disassembly & Reassembly Chassis Group Engine Room

Engine room installing 14

For reinstallation, follow the above procedure in reverse order.

15 14

17

16

Engine room installation cautions - After reinstallation, be sure to check the air conditioner for refrigerant leakage.

K92V2E14003

8. Remove nut (14) for engine roof (15) and lift the roof. Remove bolt (16) and guide rail (17) at both right and left sides. : Nut (14)(16): 53 N-m (5.4 kgf-m) (39 lb-ft) : Engine roof: 50 kg (110 lbs)

Screen board

18

18

92V2U14017

9. Remove screen board retainer bolt (18) and lift the screen board.

Note Slowly lift the screen board while checking that there are no obstacles. : Bolt (18): 230 N-m (23.5 kgf-m) (169 lb-ft) : Screen board (with condenser and air cleaner) 155 kg (340 lbs)

- Check that the air cleaner rubber hose connection band is properly positioned and tightened with proper torque.

14-10 92ZV-2 Disassembly & Reassembly Chassis Group Cab

Cab Cab removing and installing Cab removing 3

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

- Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving.

- Lower the attachment onto the ground, and apply the parking brake.

- Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

Before starting work: - Remove the deck both right and left side.

- Disconnect the electrical line couplers.

65ZV14013J

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

2

Filter 65ZV14014J

1 K70V2U14008

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

3. Remove the filter from the cab.

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

14-11 92ZV-2 Disassembly & Reassembly Chassis Group Cab

9

4

95ZV14016

4. Remove cover (4).

5

6

7 8 K92V2J14002

6. Remove bolts (7)(8).

95ZV14017

: Bolt (7): 721 N-m (73.5 kgf-m) (532 lb-ft) 5. Remove bolt (5). Tilt steering shaft (6) backward.

7. Remove bolt (9) and install the eye bolt (M16 x 2.0) instead.

Attach sling and remove the cab. : Cab: 500 kg (1,100 lbs) Note When tightening bolt (9) with the washer, make sure that the rubber-coated side of the washer faces down to the cab.

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

14-12 92ZV-2 Disassembly & Reassembly Chassis Group Floor Board

Floor Board Floor board removing and installing Floor board removing

1

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

- Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving.

- Lower the attachment onto the ground, and release the residual pressure from the hydraulic tank and lines.

- Disconnect the (-) side of the battery.

- Disconnect the (+) side of the battery.

2 2 92V2U14018

1. Remove stand assembly (1). Disconnect air duct hose (2) by releasing the hose band.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

Before starting work: - Remove the decks on both right and left sides of the machine.

- Remove the cab.

- Collect the air conditioner refrigerant (option) using the proper recovery method.

Note - Before disconnecting the electrical couplers, hoses and pipes, put match marks on them.

- Prepare a can for the oil.

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

3

6

4 5

92V2U14019

2. Disconnect brake line hoses (3)~(6) from the brake valve.

Air conditioner unit

8

Floor board

9

7 92V2U14020

3. Disconnect hose (7)~(9) from the air conditioner unit.

14-13 92ZV-2 Disassembly & Reassembly Chassis Group Floor Board

Pilot valve Control box

14 15

12

16

10 Hydraulic tank

11

Rear chassis Combination valve

92V2U14021

4. Disconnect pilot hydraulic line hose (10) from the pilot valve at the port located on the hydraulic tank.

Disconnect pilot hydraulic line hose (11) from the multiple control valve at the chassis side. Disconnect the hose (12) to the combination valve.

92V2U14023

6. Remove elastic plug (14) and floor board retaining nut (15). Temporarily sling then gradually lift the floor board while checking that there are no obstacles and that all pipes, cables, pins, etc. are disconnected.

Operation stand

13

Orbitrol®

: Nut (15): 441 N-m (45.0 kgf-m) (324 lb-ft) : Floor board assy including ope. stand, control box, etc.: 350 kg (770 lbs)

13 13

92V2U14022

5. Put matchmarks and disconnect pilot hydraulic line hose (13) from the Orbitrol®.

Reference : Bolt (16) for the rubber cushion: 90 N-m (9.2 kgf-m) (67 lb-ft)

14-14 92ZV-2 Disassembly & Reassembly Chassis Group Floor Board

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

Floor board installation cautions After reinstallation, start the engine, and then check the refrigerant, and oil lines for leakage.

Check operation of the electrical equipment.

14-15 92ZV-2 Disassembly & Reassembly Chassis Group Boom

Boom Boom removing and installing 2

Boom removing

3

1

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

- Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving.

- Lower the attachment onto the ground, and release the residual pressure from the hydraulic tank and lines.

- Apply the parking brake and remove the starter key.

WARNING Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer could cause a breakage resulting in injury or death.

- Keep persons away from working area.

- Use a support plate in case a steel hammer is used.

- Use a copper-hammer or a plastic hammer.

- Always wear protection goggles.

5

4 90ZV14016

1. Remove pin (3) connecting bucket (1) and link (2).

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

2. Remove connection pin (5) from boom (4) and bucket (1) to remove the bucket. : Bucket: 2,290 kg (5,050 lbs)

7 6

2 90ZV14017

3. Temporarily sling link (2), and then remove connection pin (6) from lever (7) and link (2). : Link (for 1 pc): 45 kg (100 lbs)

14-16 92ZV-2 Disassembly & Reassembly Chassis Group Boom

11 7

8 7 8 92V2U14024

90ZV14038

6. Start the engine and shorten bucket cylinder rod (11). Stop the engine.

Lower bucket cylinder rod (11) on the machine.

4. Remove grease pipe (8) from lever (7).

CAUTION You have to work at a high position to remove the grease pipe.

Always use a stepladder for this work.

9

12 7

10

90ZV14020

7. Temporarily sling lever (7), and then remove lever pin (12).

7 92V2U14025

8. Remove lever (7).

(The illustrations show the parts on the right side. On the left side, the parts are located at the same points.)

5. Temporarily sling the bucket cylinder (9), and then remove the connection pin (10) from the lever (7) and bucket cylinder (9). : Bucket cylinder: 130 kg (290 lbs)

: Lever (for 1 pc): 265 kg (585 lbs)

14-17 92ZV-2 Disassembly & Reassembly Chassis Group Boom

14 13

4

16

15

19

Wooden block

90ZV14039

9. Remove grease hose (14) from pin (13).

10. Place a wooden piece between boom cylinder (15) and hydraulic pipe (16), and then remove pin (13).

92V2U14027

12. Temporarily sling the cross pipe of boom (4), and then remove pins (19) from the boom on both the right and left side of the boom.

13. Slowly lift boom (4) to remove it from the machine.

Note Placing a wooden piece between the boom cylinder and the hydraulic pipe helps to reinstall the pin to the boom easily.

: Boom: 1,865 kg (4,112 lbs)

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.

17 18

Boom installing 92V2U14026

11. Remove cover (17) and boom kickout sensor (18).

For reinstallation, follow the above procedure in reverse order.

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

14-18 92ZV-2 Disassembly & Reassembly Chassis Group Center Pin

Center Pin Upper center pin

: T1: 230 N-m (23.5 kgf-m) (169 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) T1

L1: With lubrication oil (Engine oil or gear oil) Bearing cover Shim adjustment

Center pin shim adjustment

Front chassis

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

Rear chassis T2 L1

92V2U14028

T1

Shim

T2 L1 92V2U14029

14-19 92ZV-2 Disassembly & Reassembly Chassis Group Center Pin

Lower center pin

Front chassis

Bearing outer ring

Rear chassis

92V2U14030

92V2U14031

14-20 92ZV-2 Disassembly & Reassembly Chassis Group Center Pin

Center pin removing and installing Center pin removing 3

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting center pin removal: - Place the machine on level and paved ground.

- Lower the attachment onto the ground, and block the front tires with chocks, etc. to prevent them from moving.

- Apply 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.

Rear chassis Front chassis

4 Steering cylinder 92V2U14033

2. Remove right and left steering cylinder retainer pins (3) and shims (4).

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

3. Disconnect the hose. Disconnect the electrical line from the couplers.

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

Transmission

2

1

92V2U14032

1. Remove bolt (1) and disconnect second propeller shaft (2). : Bolt (1): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application Note If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner. Keep the flame away from the seals of the coupling. Do not reuse the bolts, always replace with new ones.

5

90ZV14027

4. Remove the upper center pin retainer bolt (5). : Bolt (5): 422 N-m (43.0 kgf-m) (311 lb-ft)

14-21 92ZV-2 Disassembly & Reassembly Chassis Group Center Pin

6

8

Jack screw

90ZV14029

90ZV14031

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

Remover bolt: M12 (Pitch 1.75), totally threaded M12 x 1.75

WARNING 70

65ZV14011

5. Screw the M12 (Pitch 1.75) bolt of approximately 70 mm (2.76 in) length into the center of bushing (6) to push out the bushing. This bolt is used as a jack screw.

When using a crane, insufficient signal and sling could cause an accident resulting in injury or death.

To prevent such an accident, observe the following items: - Check the sling before using it and do not use improper sling.

- Use the signals as agreed upon before starting work.

- Stay out of the working area while using a crane.

9

7

By Jack Jack

90ZV14032

90ZV14030

6. Before disconnecting front chassis (7) 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.

8. Push out upper center pin (9) using a jack or "Porto-power".

14-22 92ZV-2 Disassembly & Reassembly Chassis Group Center Pin

10

By Jack 92V2U14035

11 12

9. While supporting the bottom of the fuel tank using a garage jack, remove the lock bolt from the lower center pin (10), and then push out the lower center pin (10) using another jack to remove the pin.

13

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

14

92V2U14036

Front

Bar 90W14014

Grease nipple installation direction

10. 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.

92V2U14037

11. Remove ring (11).

12. Remove bolts (12) from bearing cover (13). : Bolt (12): 230 N-m (23.5 kgf-m) (169 lb-ft)

14-23 92ZV-2 Disassembly & Reassembly Chassis Group Center Pin

WARNING When the chassis is separated, unless the support for the chassis is sufficient, it could cause an accident resulting in injury or death.

To prevent such an accident, observe the following items: - Make sure the blocks, support and jack are placed in the right position to properly support the chassis.

13. Remove shim (14).

Bearing outer ring Front

Rear

Split of outer bearing

Grease nipple installation direction 90ZV14037

Note If the taper roller bearing is replaced, be sure to adjust the clearance using shims.

Thickness of shim: 0.1, 0.2, 0.3, 0.5, and 1.0 mm (0.004, 0.008, 0.012, 0.020 and 0.040 in)

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

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

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

(Top)

(Bottom)

Center pin installation cautions

90ZV14036

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

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

- Be sure to completely bleed the brake of air.

For air bleeding procedure, refer to the Section 24.

- Check each section for oil leakage.

- No oil leakage should be found in any part.

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

14-24 92ZV-2 Disassembly & Reassembly Chassis Group Partition Plate

Partition Plate Partition plate removing and installing

1

(S/N 9001~9002)

6 1

Partition plate removing 1

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

- Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving.

- Lower the attachment onto the ground, and release the residual pressure from the hydraulic tank and lines.

- Apply the parking brake, remove the starter key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

Note The partition plate should be removed prior to other parts and/or units around, and there is very limited space for the partition plates to take them out. When removing the partition plate, take care so that the plate does not damage the cooling unit, engine, etc.

5 8 5 1 2 3 7 11 2 4 9 10 Rear chassis

12 92V2E14001

1. Remove nuts (1) and bolts (2) to remove side partition plates (3)(4)(5) and then remove partition plate (6). : Partition plate (3): 5.3 kg (12 lbs) : Partition plate (4): 4.6 kg (10 lbs) : Partition plate (6): 6.5 kg (14 lbs) 2. Remove bolts (7) to remove partition plate (8). : Partition plate (8): 9.4 kg (21 lbs) 3. Remove bolts (9) to remove partition plate (10). : Partition plate (10): 4 kg (8.8 lbs) 4. Remove bolts (11) to remove bracket (12). : Bracket (12): 6.8 kg (15 lbs)

14-25 92ZV-2 Disassembly & Reassembly Chassis Group Partition Plate

Partition plate installing

1

(S/N 9003~9009)

6

1

1

1

5 8

5 1 7 3

2 10

11

2 4 9

Rear chassis

12 K92V2E14004

1

(S/N 9010~)

1

6

1

1

5 8

5 1 7 3

2 11 2 4 9 10

Rear chassis

12 K92V2E14005

For reinstallation, follow the above procedure in reverse order.

14-26 92ZV-2 Disassembly & Reassembly Chassis Group Lower Cover

Lower Cover Lower cover removing and installing

Rear chassis

Lower cover removing

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

- Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving.

- Lower the attachment onto the ground, and release the residual pressure from the hydraulic tank and lines.

- Apply the parking brake, remove the starter key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

D

A

C B

(S/N 9005~)

K92V2E14007

1. Remove lower covers (A)(B)(C)(D). : Lower cover (A): 7 kg (15 lbs) : Lower cover (B): 26 kg (57 lbs) : Lower cover (C): 34 kg (75 lbs) : Lower cover (D): 27 kg (60 lbs)

Rear chassis

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

D

A (S/N 9001~9002)

C B 92V2E14002

Rear chassis

D

A (S/N 9003~9004)

C B K92V2E14006

15-1 92ZV-2 Service Standard Chassis Group

92ZV-2 Service Standard Chassis Group Linkage.................................................................... 15-2 Linkage Pin Standard Clearance Values ................. 15-3 Center Pin ............................................................... 15-4 Attachment Leveler ................................................. 15-6

15-2 92ZV-2 Service Standard Chassis Group Linkage

Linkage 1. Attachment - Boom

2. Boom - Lever

4. Front chassis - Boom

5. Attachment - Link

6. Lever - Link

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

7

3

3. Boom - Boom cylinder

8

mm (in)

4

2

10 11 5

1

6

9 92V2U12002

15-3 92ZV-2 Service Standard Chassis Group Linkage Pin Standard Clearance Values

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

Item

Solution

Pin standard dimension

Standard clearance

Tolerance

1

Joint section between bucket and boom

ø90 (ø3.5433)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

2

Joint section between boom and lever

ø100 (ø3.9370)

0.120~0.290 (0.0047~0.0114)

1.0 (0.0393)

Replacement

3

Joint section between boom and boom cylinder

ø90 (ø3.5433)

0.120~0.290 (0.0047~0.0114)

1.0 (0.0393)

Replacement

4

Joint section between front chassis and boom

ø110 (ø4.3307)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

*

5

Joint section between bucket and link

ø70 (ø2.3622)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

*

6

Joint section between lever and link

ø70 (ø2.3622)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

7

Joint section between lever and bucket cylinder

ø80 (ø3.1496)

0.100~0.230 (0.0039~0.0090)

1.0 (0.0393)

Replacement

8

Joint section between bucket cylinder and front chassis

ø80 (ø3.1496)

0.100~0.230 (0.0039~0.0090)

1.0 (0.0393)

Replacement

9

Joint section between boom cylinder and front chassis

ø90 (ø3.5433)

0.120~0.290 (0.0047~0.0114)

1.0 (0.0393)

Replacement

*

10

Joint section between front chassis and steering cylinder

ø50 (ø1.9685)

0.080~0.205 (0.0031~0.0080)

1.0 (0.0393)

Replacement

*

11

Joint section between steering cylinder and rear chassis

ø50 (ø1.9685)

0.080~0.205 (0.0031~0.0080)

1.0 (0.0393)

Replacement

*

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

Liner clearance adjustment

*

*

Adjust the liner clearance (marked with "*") between the bosses to 1.2 mm (0.0472 in) or less using liner of 1 mm (0.0393 in) thickness.

For the steering cylinder, adjust the liner clearance on the rear chassis side first, and then adjust the liner clearance on the front chassis side while checking that the cylinder is not inclined. Liners should be placed on both sides of the linkage as much as possible.

95ZV12005

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.

15-4 92ZV-2 Service Standard Chassis Group Center Pin

Center Pin Center pin shim adjustment

Bearing cover installing

T1

Bearing cover Front Shim adjustment Front chassis

Rear chassis T2 L1

92V2U14028

The clearance between the front chassis and bearing cover is 0.75±0.5 mm (0.0295±0.0197 in) before shim adjustment.

Add shims so that the clearance is 0.1±0.05 mm (0.0039±0.0020 in). : T1: 230 N-m (23.5 kgf-m) (169 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) L1: With lubrication oil (Engine oil or gear oil)

Grease nipple installation direction 92V2U14037

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

15-5 92ZV-2 Service Standard Chassis Group Center Pin

Lower center pin bearing outer ring installing

Front chassis

Bearing outer ring

Rear chassis

92V2U14030

Bearing outer ring Front

Rear

Split of outer bearing

Grease nipple installation direction 90ZV14037

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

15-6 92ZV-2 Service Standard Chassis Group Attachment Leveler

Attachment Leveler

Attachment leveler

90V2E15002

15-7 92ZV-2 Service Standard Chassis Group Attachment Leveler

Attachment leveler

Angle

Adjusting plate

5

Direction of indicator lamp

Indicator lamp

Proximity switch

2

4

5 2

2.5 mm

Angle

3 1 92V2E15001

Attachment leveler adjustable angle

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

+10º

0 58 mm (2.283 in)

134 mm (5.275 in) K90ZV15001

No.

Item

Judgment standard

Solution

5 ± 2 (0.196 ± 0.078 in)

Adjustment

1

Clearance of attachment leveler switch

2

Adjusting plate mounting bolt tightening torque

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

Tightening

3

Switch mounting nut tightening torque

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

Tightening

4

Angle mounting bolt tightening torque

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

Tightening

5

Attachment leveler adjustable angle (distance * (5))

-7º ~ +10º (6 ~134 mm (0.24 ~ 5.27 in))

Adjustment

15-8 92ZV-2 Service Standard Chassis Group

MEMO

24-1 92ZV-2 Disassembly & Reassembly Power Group

92ZV-2 Disassembly & Reassembly Power Group Power Line .............................................................. 24-2 Radiator................................................................... 24-3 Fan .......................................................................... 24-9 Engine ..................................................................... 24-11 Propeller Shaft......................................................... 24-14 Air Cleaner .............................................................. 24-16 Muffler ..................................................................... 24-18 Front Axle Assembly ............................................... 24-19 Internal Gear Hub.................................................... 24-32 Spider Assembly ..................................................... 24-35 Special Tool ............................................................. 24-37 Rear Axle Assembly ................................................ 24-41 Axle Support............................................................ 24-46 Differential Assembly............................................... 24-49

24-2 92ZV-2 Disassembly & Reassembly Power Group Power Line

Power Line Power line tightening torque Engine

T1 L1

T3 L1

T6 L3

T3 L1

Rear chassis

T1 L1

T5 L3

Transmission

Rear axle

T4 L1

3rd propeller shaft

T2 L1 T4 L1

Front axle

T4 L1

2nd propeller shaft

92V2U24001

: T1: 441 N-m (45 kgf-m) (325 lb-ft) T2: 417 N-m (42.5 kgf-m) (307 lb-ft) T3: 230 N-m (23.5 kgf-m) (170 lb-ft) T4: 142 N-m (14.5 kgf-m) (105 lb-ft) T5: 67 N-m (6.8 kgf-m) (49 lb-ft) T6: 71 N-m (7.2 kgf-m) (52 lb-ft)

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

24-3 92ZV-2 Disassembly & Reassembly Power Group Radiator

Radiator Radiator tightening torque T2 L2 T/C oil cooler

T2

T3

Sub tank

T3 Radiator

T1

T3

Rear chassis

T2 L2

T3

Fan motor

T2 L2

T4 L1 92V2E24001

: T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 94 N-m (9.5 kgf-m) (69 lb-ft) T3: 53 N-m (5.4 kgf-m) (39 lb-ft) T4: 74 N-m (7.5 kgf-m) (54 lb-ft) L1: Screw lock agent (Loctite® 262) L2: With lubrication oil (Engine oil or gear oil)

24-4 92ZV-2 Disassembly & Reassembly Power Group Radiator

Radiator removing and installing

1

Radiator removing

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

- Apply the articulation stopper.

- 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

92V2U24003

1. Remove bolt (1). : Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft) 2. Sling radiator hood (2), and then remove it.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

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

- Remove the partition plate (Refer to Section 14).

- Remove the lower cover C, D (Refer to Section 14).

- Remove the fan assembly (Refer to Section 44). For easier work, release or remove the fan assembly.

: Radiator hood: 10 kg (22 lbs) 3. Drain the coolant from the engine and the radiator. : Coolant: 72 L (19 gal)

24-5 92ZV-2 Disassembly & Reassembly Power Group Radiator

Air cooler

4

10

3

5

9 11

Radiator

8

Torque converter oil cooler

7

Engine

Coolant drain line

6 92V2E24002

92V2E24003

5. Disconnect air cooler hoses (10)(11) from the air cooler. : Hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft) Note Cover the disconnected hoses and air cooler openings with caps, plugs, or vinyl to protect them from dust and dirt. During reassembly, carefully inspect and clean the hoses and air cooler of any contamination as it will go directly into the engine causing extensive engine damage.

4. Disconnect coolant hoses (3)~(9) from the radiator assembly.

Hydraulic cooler

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

12

15 13

Radiator

14 Torque converter oil cooler

16

92V2E24004

6. Remove hoses (12)(13)(14) from the hydraulic cooler. : Hydraulic oil: 3 L (0.8 gal) 7. Remove hoses (15)(16) from the radiator and torque converter oil cooler.

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

24-6 92ZV-2 Disassembly & Reassembly Power Group Radiator

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

Fuel cooler

17 18

92V2E24005

8. Disconnect the hose (17)(18) from the fuel cooler. : Fuel: 1.2 L (0.3 gal) Note Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

21

20

22 23 19 Rear chassis 92V2E24006

9. Temporarily sling radiator (19) and cooling unit (20).

Remove the right and left retainer bolts (21)(22)(23), and then lift the radiator (19) and cooling unit (20) together. : Radiator: 265 kg (585 lbs) : Cooling unit: 60 kg (132 lbs) : Bolt (21)(22): 53 N-m (5.4 kgf-m) (39 lb-ft) : Bolt (23): 230 N-m (23.5 kgf-m) (170 lb-ft)

24-7 92ZV-2 Disassembly & Reassembly Power Group Radiator

Radiator core removing and installing

8

Radiator core removing

7 1

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.

4

2

3

5

5

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

Before starting work: - Remove the radiator hood (Refer to page 24-4).

- Remove the lower cover C, D (Refer to Section 14).

- Drain the coolant from the engine and the radiator. : Coolant: 72 L (19 gal)

6 Radiator assembly

K92V2E24001

1. Disconnect coolant hoses (1)~(6) from the radiator assembly.

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

2. Remove bolt (7), and remove sub tank (8) from the radiator assembly. : Bolt (7): 94 N-m (9.5 kgf-m) (69 lb-ft) : Sub tank: 20 kg (44 lbs)

24-8 92ZV-2 Disassembly & Reassembly Power Group Radiator

Radiator core installing 9

For reinstallation, follow the above procedure in reverse order.

10

K92V2E24002

3. Temporarily sling radiator core (10), and remove bolt (9).

10

K92V2E24003

4. Lift radiator core (10) and remove it from the radiator assembly.

24-9 92ZV-2 Disassembly & Reassembly Power Group Fan

Fan Fan removing and installing Fan removing

4

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

3

Fan motor shroud 92V2U24010

2. Remove retainer bolts (3) for fan (4).

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

: Bolt (3): 94 N-m (9.55 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil) 3. Sling fan (4) and take it out. : Fan: 18 kg (40 lbs)

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

1

Fan motor shroud

2

92V2U24009

1. Remove bolts (1) and remove fan guards (2). Take the fan guards out of the machine.

24-10 92ZV-2 Disassembly & Reassembly Power Group Fan

Fan installation cautions Clearance 14 mm (0.6 in)

92V2U24011

Reinstall the fan while checking that the right and left clearances between the fan and the fan motor shroud are equal at both sides.

Refer to "Fan Motor" page 44-78 to remove and/or disassemble the fan motor.

24-11 92ZV-2 Disassembly & Reassembly Power Group Engine

Engine Engine removing and installing Engine removing

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

- Apply the articulation stopper.

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

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

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

- Remove the floor board with the cab (Refer to Section 14).

- Collect the air conditioner refrigerant (option) using the proper recovery method.

- Drain engine oil : Engine oil: Approx. 37 L (10 gal)

1

+

Battery K85V2U24002

1. Disconnect the negative side of battery cable (1).

Then remove the positive cable.

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 conditioner lines from the compressor.

3. Remove the engine oil drain hose.

24-12 92ZV-2 Disassembly & Reassembly Power Group Engine

3

92V2U24014

6. Remove two block mounting bolts (3) (both sides). : Bolt (3): 441 N-m (45 kgf-m) (325 lb-ft) : Screw lock agent (Loctite® 262) application 7. Disconnect the 2nd propeller shaft and the 3rd propeller shaft from the transmission assembly.

92V2U24012

4. Temporarily sling the engine and the transmission assembly. : Engine and transmission assembly: 2,300 kg (5,070 lbs)

2 92V2U24013

5. Remove engine assembly mounting bolts (2). : Bolt (2): 441 N-m (45 kgf-m) (325 lb-ft) : Screw lock agent (Loctite® 262) application

8. Carefully lift the engine and the transmission assembly while checking that there are no obstacles around them. : Engine and transmission assembly: 2,300 kg (5,070 lbs) 9. Remove the engine and the transmission assembly from the rear chassis.

Place them on the stand.

24-13 92ZV-2 Disassembly & Reassembly Power Group Engine

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

4

Engine installation cautions 5

92V2U24015

10. Remove four bracket mounting bolts (4) (both sides) on the flywheel side.

Loosen four bracket mounting bolts (5) (both sides) on the transmission side. : Bolt (4)(5): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent (Loctite® 262) application

8

7 92V2U24017

Note Take care not to loosen bolt (5) too much.

- There is O-ring (7) in the housing between the engine and torque converter. Be sure to replace the O-ring with a new one, and apply liquid gasket. : Liquid gasket (Three Bond 1215) application

6

- Make sure that bushing (8) is installed.

- Refill the engine with the proper quantity and type engine oil.

- After reinstalling the engine, completely bleed the fuel line of air.

92V2U24016

11. Sling the engine assembly and remove bolts (6) from the housing between the engine flywheel and transmission. : Bolt (6): 71 N-m (7.2 kgf-m) (52 lb-ft) : Engine assembly: 950 kg (2,100 lbs) 12. Move the engine assembly back side to disengage the flywheel ring gear.

13. After confirming that the ring gear is disengaged, remove the engine assembly by lifting it slowly.

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

- Set the starter key to ON, and then check the monitor lamps of electrical equipment.

- Operate the engine at the idling speed for 5 minutes.

After that, check the amount of the coolant.

- While gradually increasing the engine speed, check operation of the electrical equipment.

24-14 92ZV-2 Disassembly & Reassembly Power Group Propeller Shaft

Propeller Shaft Propeller shaft removing and installing

Second propeller shaft removing

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

- Apply the articulation stopper.

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

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

4 1 3

5

2

92V2U24018

1. Remove bolt (2) from the transmission side of propeller shaft (1).

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

: Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application 2. Remove bolt (4) from pillow unit (5). : Bolt (4): 417 N-m (42.5 kgf-m) (307 lb-ft) : Screw lock agent (Loctite® 262) application 3. Remove bolt (3) 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. : Bolt (3): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application : Second propeller shaft: 75 kg (165 lbs) 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.

24-15 92ZV-2 Disassembly & Reassembly Power Group Propeller Shaft

Third propeller shaft removing

Propeller shaft installation cautions

Before starting work: - Remove the lower cover B (Refer to Section 14).

Transmission

Engine

Rear differential Transmission

3rd propeller shaft

6 92V2U24019

1. Remove bolt (6). : Bolt (6): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application 2. Remove the third propeller shaft. : Third propeller shaft: 15 kg (35 lbs)

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

92V2U24020

2nd propeller shaft

3rd propeller shaft

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

24-16 92ZV-2 Disassembly & Reassembly Power Group Air Cleaner

Air Cleaner Air cleaner removing and installing Air cleaner removing

5 1 6 3

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

- 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.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

4 2

90ZV24022

1. Release wing nut (1), and then, remove cover (2).

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

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

4. Remove the rubber valve on the bottom of the air cleaner case, and inspect it for any damage.

Replace it if necessary.

Note Removing inside elements reduces the weight and makes air cleaner case removal work easier.

8

7

92V2U24021

5. Disconnect air duct (7).

Disconnect indicator wire coupler (8).

Inspect duct (7) and replace it if there is any damage or wear.

24-17 92ZV-2 Disassembly & Reassembly Power Group Air Cleaner

Air cleaner installing

12

9

Precleaner

For reinstallation, follow the above procedure in reverse order.

10

Air cleaner installation cautions 2~3 mm (1/8 in) 5 mm (1/4 in) or less

11 92V2U24022

Fix the bands avoiding the beading

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

Air duct

Note The precleaner is an optional unit.

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

(Air cleaner or Engine) Insertion amount: 35 mm (1 1/2 in)

K85V2U24005

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.

13

90ZV24026

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

24-18 92ZV-2 Disassembly & Reassembly Power Group Muffler

Muffler Muffler removing and installing 4

Muffler removing

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

Start the muffler removal work when the engine is cold enough.

3 5

K90V2U24007

3. Remove U-clamp (3) and remove exhaust pipe (4).

Also disconnect drain pipe (5).

2

1

6

7

6 Engine roof

Muffler K90V2U24006

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

92V2U24023

: Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft) 2. Remove the engine roof by referring to Section 14. : Engine roof: 25 kg (55 lbs)

4. Remove retainer bolt (6) for muffler (7), and lift it for removing. : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) : Muffler: 23 kg (50 lbs)

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

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

24-19 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front Axle Assembly Front axle assembly tightening torque

T2 L2 T4 L1

Floating seal

Front differential

T7 T9 T7 T7 T8 L1 B

A

T3 L1

T7 T5 L1

T6

T1

92V2U24024

: T1: 892 N-m (91.0 kgf-m) (658 lb-ft) T2: 721 N-m (73.5 kgf-m) (532 lb-ft) T3: 216 N-m (22 kgf-m) (159 lb-ft) T4: 132 N-m (13.5 kgf-m) (98 lb-ft) T5: 90 N-m (9.2 kgf-m) (67 lb-ft) T6: 86 N-m (8.8 kgf-m) (64 lb-ft) T7: 78 N-m (8.0 kgf-m) (58 lb-ft) T8: 53 N-m (5.4 kgf-m) (39 lb-ft) T9: 33 N-m (3.4 kgf-m) (25 lb-ft)

L1: Screw lock agent (Loctite® 262) application L2: With lubrication oil (Engine oil or gear oil)

24-20 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Axle nut tightening procedure

Floating seal installing

1. Tighten axle nut (A) with 2,300 N-m (235 kgf-m) (1,700 lb-ft) tightening torque to install the taper roller bearing.

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

2. Loosen axle nut (A).

3. Tighten axle nut (A) again with the same tightening torque as above 1.

4. Turn the wheel hub 2~3 turns back and forth, and measure the preload applied to the bolt screw hole in housing (B).

Preload at housing (B): 226~265 N (23~27 kgf) (50~59 lbf) Note This is "breakaway" force, which is required to start the wheel turning.

Refer to Front axle assembly, "Front axle assembly cautions" page 24-27 for details.

24-21 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly removing and installing

1

Front axle assembly removing

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

- Apply the parking brake and the articulation stopper.

90ZV24052

3. Remove right and left wheel and tire assemblies (1). : 1 tire: 670 kg (1,480 lbs)

Boom lock collar

: Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

Stand

2 Stand 90ZV24030

Front axle

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

Lift the boom until it is horizontal. Place a stand under the boom to support it or install a boom cylinder lock collar.

2. Press the hydraulic tank oil filler cap to release the trapped tank pressure.

Release the accumulator pressure, by slowly and fully depressing and releasing the brake pedal at least 40 times.

92V2U24025

4. Disconnect air breather tube (2) from the upper part of the axle housing.

Reassembly: Clean the nylon breather tube before reinstalling.

24-22 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

3 5

6 92V2U24026

5. Remove second propeller shaft retainer bolt (3). : Bolt (3): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application

90ZV24035

7. Temporarily sling axle assembly (5), and then remove eight retainer bolts (6). : Axle assembly: 1,275 kg (2,810 lbs) : Bolt (6): 721 N-m (73.5 kgf-m) (532 lb-ft) Note During reassembly be sure both mating surfaces are clean and free of paint.

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

4

90ZV24142

6. Disconnect brake pipes (4).

Note Cover the disconnected pipes with plastic caps or vinyl to avoid the dirt from entering the pipes or fittings.

24-23 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly installing

Service brake air bleeding procedure

For reinstallation, follow the above procedure in reverse order.

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

IMPORTANT Before bleeding the service brakes, it is important to remove all air from the brake valve manifold block, and all related valves.

These include the reducing valve and park brake valve. Failure to do this correctly will result in unsatisfactory brake modulation.

Air bleeder nipple

Spider Socket bolt

Vinyl tube 70ZV52019

92V2U24027

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.

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

2. Turn the parking brake solenoid valve release knob counterclockwise, then back to neutral five times at 5-second interval between each turn. Position this back to the normal position when finished.

3. Connect a clean vinyl tube to the air bleeder nipple, and place an oil can to receive the oil, or route to hydraulic tank.

4. Slightly loosen the air bleeder nipple, and then press the brake pedal several times. When the oil flows from the air bleeder nipple, close the nipple.

After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple.

Repeat this until there is no air in the oil. Completely bleed each wheel of air. : Air bleeder nipple: 9 N-m (0.9 kgf-m) (6.5 lb-ft)

24-24 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle disassembling and assembling

1

Front axle disassembling

WARNING Unexpected movement of the machine or components could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and then apply the parking brake.

- Apply the articulation stopper.

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

90ZV24052

3. Remove wheel and tire assembly (1) from the side to be disassembled (example: left side). : Tire of 1 wheel: 670 kg (1,480 lbs) : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

Boom lock collar

Stand Stand 90ZV24030

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

Lift the boom until it is horizontal. Place a stand under the boom to support it or install a boom cylinder lock collar.

2

Differential section 92V2U24028

4. Remove drain plug (2) from the differential section to drain oil. : Gear oil: Approx. 42 L (11.1 gal)

2. Press the hydraulic tank oil filler cap to release the trapped tank pressure.

Release the accumulator pressure, by slowly and fully depressing and releasing the brake pedal at least 40 times.

24-25 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

A 7

TOP

3 6

4

90ZV24054

92V2U24030

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

7. Temporarily sling the spider using hoisting tool (A).

Remove four spider retainer bolts (6) to remove spider assembly (7).

: Gear oil: Approx. 37 L (9.8 gal) Note To replace the oil, refer to the oil amount described below. : Wheel hub section: 18.5 L (4.9 gal) for left side, 18.5 L (4.9 gal) for right side

: Bolt (6): 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 110 kg (242 lbs) Note The brake backing plate is fixed behind the spider assembly. Do not forget the brake backing plate when reinstalling the spider assembly.

Differential section (front): 42 L (11.1 gal) Total oil amount for front axle: 79 L (21 gal) Reference Differential section (rear): 48 L (12.7 gal) Total oil amount for rear axle: 85 L (22.5 gal)

11 TOP

10

13

12

9

8

92V2U24031

8. Remove sun gear (8) and disc gear (9).

9. Remove friction plate (10) and steel plate (separation disc) (11) behind.

5

92V2U24029

6. Remove cover (5). : Retainer bolt: 90 N-m (9.2 kgf-m) (67 lb-ft) : Screw lock agent (Loctite® 262) application

10. Remove another set of friction plate (10) and steel plate (11), and plate (12), bushing (13).

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

Refer to the sections 52 and 55 (Brake Group) for additional information.

24-26 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

16

15

14

17

92V2U24032

11. Remove axle shaft (14). Remove retainer bolts (15) and then remove lock plate (16). : Bolt (15): 53 N-m (5.4 kgf-m) (39 lb-ft) : Screw lock agent (Loctite® 262) application Note When reassembling axle shaft (14) into the axle housing, applying the principle of leverage, insert axle shaft (14) making sure the toothing between the side gear of the differential and shaft (14).

92V2U24033

13. Remove axle nut (17).

Refer to "Axle nut tightening procedure" page 2420. : Nut (17): 2,300 N-m (235 kgf-m) (1,700 lb-ft) Note Axle nut width across flat: 160 mm (6.3 in) Extension

Turnbuckle

E

Jig (B)

18 3

Wooden block 92V2U24034 90ZV24060

12. Turn wheel hub (3) until the drain plug is positioned on the top. Connect the turnbuckle to eye bolt (E) to lock the wheel hub and then place a wooden block under the wheel hub to support it.

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.

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

24-27 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly cautions 18

IMPORTANT - Replace all the O-rings and seals with new ones.

- Clean and check all the parts. If a part is damaged, replace it.

C

Floating seal installing Wooden block 92V2U24035

15. Sling internal gear hub (18) using internal gear hub hoisting tool (C), and remove hub (18).

1. Checking before floating seal installation Bearing

O-ring Wheel hub

D

Axle housing

E 3

O-ring

19

Wooden block 92V2U24036

Seal ring

16. Install wheel hub hoisting tools (D) and (E) and remove the turn buckle.

Then remove wheel hub (3).

17. Remove taper roller bearing (19).

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

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

Ring

90ZV24065

(a) Checking seal - Check the seal ring for distortion and scratches.

- Check the O-ring for scratches. (b) Check the wheel hub and the ring for burr. If any remove it by sand paper etc.

24-28 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly (b) In case jig (F) is used Ring

1

2 3

Remove oil

4

Put thin gear oil (Do not use grease)

70ZV24095J

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

Do not touch (It may cause rusting) 90ZV24066

(c) Clean the O-ring installation part on the wheel hub and the seal ring, and remove oil on them.

Note The rotating ring and the fixing ring are exactly the same. They can be used on either side.

2. Assemble the floating seal as follows. (a) In case no jig is used.

- Install the O-ring on the seal ring.

- Put thin gear oil on the O-ring.

- Insert the O-ring and seal ring into the ring and the wheel hub pushing the O-ring by fingers. (Make subassembly) - Check if the seal ring is correctly positioned or the Oring is not twisted.

- Clean the surface and put thin gear oil on it.

- Install the ring, bearing and the wheel hub to the axle housing.

- Install the guide jig to the wheel hub and / or the ring.

- Put thin gear oil on the O-ring.

- Insert the floating seal into the guide jig.

- Fix the installation jig to the floating seal, and push it until it reaches to the guide jig. (Make sub assembly) - Remove the guide jig and the installation jig from the floating seal.

- Clean the surface and put thin gear oil on it.

- Install the ring and the wheel hub to the axle housing.

24-29 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Internal gear hub installing Guide jig Spring pin

18

92V2U24037

Before installation 95ZVE24011

Internal gear hub assembly

Guide jig

Brake oil holes at 2 locations

Installation jig

Example LF

Brake oil holes

Axle housing extension 92V2U24038

After installation 95ZVE24010

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 is necessary to disassemble the floating seal.

Before reinstalling internal gear hub assembly (18), align the brake oil hole of the axle housing extension with that of the internal gear hub assembly. Note that the spring pin is positioned at the top when the brake holes are properly aligned.

24-30 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Axle nut tightening

Brake adjustment

Brake oil inlet port

17 92V2U24039

90ZV24074

1. Tighten axle nut (17) with 2,300 N-m (235 kgf-m) (1,700 lb-ft) tightening torque to install the taper roller bearing and, after that, once loosen axle nut (17).

Jig (G) Shut off valve

2. Again tighten axle nut (17) so that the preload of the tire mounting hole section becomes 226~265 N (23~27 kgf) (50~59 lbf).

Note This is the force to start the wheel hub moving or "breakaway" force. Measure the minimum pulling force to rotate the wheel hub using a spring scale.

Air supply PT 1/4

Air pressure gauge

90ZV24071

1. Attach jig (G) to the brake oil inlet port on the axle housing.

2. Apply 588 kPa (6 kgf/cm2) (85 psi) air pressure for approximately 1 minute. Shut off the valve. Check that the pressure does not fall.

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

24-31 92ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

A

Wheel hub

Brake piston Spider "TOP" mark (at top)

Brake oil line

Wheel hub Drain plug (at bottom) 92V2U24040

90ZV24077

3. Adjust the piston position so that the distance A from the piston end face to the wheel hub end face falls within the following range.

5. Check that the wheel hub drain plug is at the bottom when the spider "TOP" mark is at top.

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

A......158.05~159.55 mm (6.22~6.28 in) Note Dimension A should be equal at the top and bottom sides.

Spring pin Friction plate

Align the black teeth with each other

Cooling holes Steel plate 90ZV24076

4. To reassemble the steel plates and friction plates, observe the following items. Note that the plates should be assembled to make possible the plate wear measurement after reassembling. (a) Insert the steel plate having 4-teeth sections first.

Then install a friction plate. (b) Insert the steel plate having two 2-teeth sections so that the spring pin is positioned at the midpoint between the 2-teeth sections. (c) Align the cooling holes of two friction plates with each other.

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

24-32 92ZV-2 Disassembly & Reassembly Power Group Internal Gear Hub

Internal Gear Hub Internal gear hub disassembling and assembling Internal gear hub disassembling

6

5 Lock nut

1 4 92V2U24042

2

3. Remove eight bolts (5) and return spring (6) from brake piston (4). : Locknut: 33 N-m (3.4 kgf-m) (25 lb-ft) 92V2U24041

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

4

11

3

11 92V2U24043

4. Insert two remover bolts (11) into brake piston (4) to remove the piston.

90ZV24093

2. Remove taper roller bearing (3).

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

24-33 92ZV-2 Disassembly & Reassembly Power Group Internal Gear Hub

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

13

12 92V2U24044

5. Remove brake piston O-rings (12)(13).

1

14 92V2U24045

6. There is snap ring (15) that connects internal gear (14) to internal gear hub (1). Shift the snap ring to the inside using a round bar or the like.

14

15 92V2U24046

7. Sling internal gear (14) to remove it. : Internal gear: 38 kg (83 lbs)

24-34 92ZV-2 Disassembly & Reassembly Power Group Internal Gear Hub

Internal gear hub assembly cautions IMPORTANT - Replace all the O-rings with new ones.

- Clean and check all the parts. If a part is damaged, replace it with a new one.

16

3

Be certain these plugs are tight.

90ZV24100

Oil holes Oil groove

- Before reinstallation of taper roller bearing (3), be sure to heat the bearing to 90ºC (194ºF) to 120ºC (248ºF) in oil.

- Apply grease to the O-rings.

14

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

Hub

4

92V2U24047

- When reassembling internal gear (14) and brake piston (4) to the internal gear hub, align the oil holes of the internal gear hub with that of the brake piston oil groove and spring pin (16).

Note To reinstall the internal gear hub on the axle, the brake oil path should be aligned to these oil grooves. In addition, the oil grooves are used for alignment of the spring pin.

Moreover, the aligned grooves are used for external measurement of brake disc wear.

24-35 92ZV-2 Disassembly & Reassembly Power Group Spider Assembly

Spider Assembly Spider assembly disassembling and assembling

5

Spider assembly disassembling 6 4

7 92V2U24048

2

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

1 90ZV24136

9

1. Remove lock bolts (1) and then plate (2). : Lock bolt (1): 216 N-m (22.0 kgf-m) (159 lb-ft) : Screw lock agent (Loctite® 262) application

8

1 3

92V2U24049

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

4

Spider assembly assembling 90ZV24137

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

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

Before starting work: - Clean all the parts.

- Check the brake backing plate, 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.

24-36 92ZV-2 Disassembly & Reassembly Power Group Spider Assembly

Spider assy assembly cautions - To reinstall the brake backing plate, check that there is no clearance between the spider and the brake backing plate.

- The brake backing plate may only be installed as it was removed. It may not be flipped over due to the roll pin hole design.

1 3

4

90ZV24137

- To insert planetary pin (3), align the core holes of the planetary gear with that of the wear ring.

- The lock bolt (1) hole of planetary pin (3) is shifted from the center. Check that the bolt hole is shifted to the inside.

- Manually turn planetary gear (4) to check that the gear smoothly rotates.

24-37 92ZV-2 Disassembly & Reassembly Power Group Special Tool

Special Tool Special tool for axle This tool may be available through your local Kawasaki loader dealer. Please contact them to talk to a parts or service representative and receive more information on how to purchase this tool or other tools.

(A) Spider hoisting tool mm (in)

(Material: SS41)

2)

(1.

4(0.2) C2(0.08)

R

30

8(

60(2.4)

3(0.1)

R

12 (0.5)

0.

3)

R (0 10 .4 )

10 (0.4)

46(1.8)

ø6 mm (0.2 in) dia. round steel

77(3.0)

t6(0.2)

6

t6

t6

6

(0.2)

(0.2)

(0.2)

(0.2)

d m rille 1m )d ø3 .2 in (1

61(2.4)

C2 (0.08)

25(1.0)

105(4.1)

10 (0.4)

3(0.1)

C 2(0.08)

C 2(0.08)

65(2.6) 92V2U24050

24-38 92ZV-2 Disassembly & Reassembly Power Group Special Tool (B) Internal gear hub puller mm (in)

(Material: SS41)

t12(0.5) plate (2) 50(2.0)

plate (1)

25(1.0)

40(1.6)

t12(0.5)

M16 x 2 ø10(0.4) drilled

C5(0.2)

100(3.9)

102(4.0)

C5(0.2)

240(9.5)

92V2U24051

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

(Material: SS41)

75(3.0)

ø13 mm (0.5 in) drilled

35(1.4)

t12(0.5)

20 R .8) R

15

(0

107(4.2)

235(9.3) 345(14)

0 R2 .8) (0

13 35

5 R1 .6) (0

270(10.6)

215(8.5)

15

7 (0.3)

15 (0.6) 25 (1.0)

3 15 (0.1) (0.6)

5 R1 .6) (0

0 R1 .4) (0

A

.4)

(0.4)

A

t9(0.4)

0(2

56(2.2)

R6

t9

10 (0.4)

35 (1.4)

(0.6)

292(11.5)

0 R2 .8) (0

434(17)

35 (1.4)

155(6.1) (1.4) (0.5)

25 (1.0)

)

.6

(0

27.5 (1.1)

35(1.4) 90(3.5)

27.5 (1.1)

A-A 90ZV24087

24-39 92ZV-2 Disassembly & Reassembly Power Group Special Tool (D) Wheel hub hoisting tool (Material: SS41) Cut the threaded area off the M10 eye bolt before use.

R 10

30

15

65

6

6

12

20

12

15

31

25

80

10

35

12

75 92V2U24060

(E) Eye bolt

M30 x 2

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

40

90V2E24044

24-40 92ZV-2 Disassembly & Reassembly Power Group Special Tool (F) Floating seal jig 1. For wheel hub

mm (in)

[ P/N for tool set: 99202-01850 ]

1.

(

2.

20(0.8)

15(0.6) 7±0.2 (0.28±0.008)

Ø260(10.2)

10±0.3 (0.4±0.01)

Ø220(8.7)

+0

Ø258(10.2)

3(0.1)

Ø24.6 +0 –0.1(9.7 –0.004 ) Ø242±0.1(9.5±0.004) Ø235±0.1(9.3±0.004)

Ø270(10.6)

Ø265(10.4)

+0.004

Ø247.2 +0.1 +0.05 (9.7 +0.002 )

+0.010

Ø241.8±0.1(9.5±0.004)

Ø253 +0.25 +0.3 (10.8 +0.012 )

3(0.1)

5(0.2)

)

12±0.3 (0.5±0.004) R0.3 (0.01)

C

R0.2~R0.5 (0.008~0.02)

90V2E24048

2. For ring

mm (in)

[ P/N for tool set: 99202-01820 ]

1.

10.9±0.2 (0.43±0.008) 3(0.1)

Ø220(8.7)

+0

Ø258(10.2)

Ø246 +0 –0.1 (9.7 –0.004 ) Ø242±0.1(9.5±0.004) Ø235±0.1(9.3±0.004)

+0.004 Ø247.2 ++0.1 0.05 (9.7 +0.002 ) Ø260(10.2)

–0.010 Ø256 –0.26 –0.3 (10.1 –0.012 ) Ø241±0.1(9.5±0.004)

3(0.1)

Ø260(10.2)

3C

C

)

20(0.8)

3(0.1)

10±0.3 (0.4±0.01)

(

2.

13(0.5)

12±0.1 (0.5±0.004)

R0.3 (0.01) R0.2~R0.5 (0.008~0.02) 90V2E24049

24-41 92ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear Axle Assembly Rear axle assembly tightening torque

Floating seal

T6

T8 T6 T3 L1 Rear differential

T6 B

T7 L1

A

T2 L1

T4 L1

T1 T6

T5

92V2U24052

: T1: 892 N-m (91.0 kgf-m) (658 lb-ft) T2: 216 N-m (22.0 kgf-m) (159 lb-ft) T3: 132 N-m (13.5 kgf-m) (98 lb-ft) T4: 90 N-m (9.2 kgf-m) (67 lb-ft) T5: 86 N-m (8.8 kgf-m) (64 lb-ft) T6: 78 N-m (8.0 kgf-m) (58 lb-ft) T7: 53 N-m (5.4 kgf-m) (39 lb-ft) T8: 33 N-m (3.4 kgf-m) (25 lb-ft)

L1: Screw lock agent (Loctite® 262) application

24-42 92ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Axle nut tightening procedure

Floating seal installing

1. Tighten axle nut (A) with 2,300 N-m (235 kgf-m) (1,700 lb-ft) tightening torque to install the taper roller bearing.

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

2. Loosen axle nut (A).

3. Tighten axle nut (A) again with the same tightening torque as 1 above.

4. Turn the wheel hub 2~3 turns back and forth, and measure the preload applied to the bolt screw hole in housing (B).

Preload at housing (B): 226~265 N (23~27 kgf) (50~59 lbf) Note This is "breakaway" force, which is required to start the wheel turning.

Refer to Front axle assembly, "Front axle assembly cautions" page 24-27 for details.

24-43 92ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear axle assembly removing and installing Rear axle assembly removing

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

- Apply the articulation stopper.

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

Before starting work: - Remove the lower cover B, C (Refer to Section 14).

B

90ZV24040

2. Lift the boom, and then roll the attachment back to level. Check that the rear wheels are off the ground.

Place stand (B) under the counter weight to support it.

Wooden blocks

A

90ZV24039

90ZV24041

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

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

WARNING The axle will not be balanced when a tire is removed.

If wooden blocks are not inserted, your fingers or body may be caught in the machine.

24-44 92ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

1

Breather fitting

4

Rear axle

92V2E24007

4. Remove right and left wheel and tire assemblies (1). : Tire of 1 wheel: 670 kg (1,480 lbs) (without hydro-inflation) : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

92V2E24009

6. Disconnect air breather tube (4).

Note Before disconnecting the tube, remove the cap of the hydraulic tank to vent tank pressure. Release the accumulator pressure by slowly and fully depressing and releasing the brake pedal at least 40 times. Remove and clean tube (4) before reinstalling.

Rear axle Transmission

5

2 Rear axle

3 92V2E24008

92V2E24010

5. Remove retainer bolts (3) to remove third propeller shaft (2). : Bolt (3): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application : Third propeller shaft: 15 kg (35 lbs) Note Replace propeller shaft retainer bolts (3) with new ones.

Do not reuse them when reassembling.

Clean all threads with a thread lock primer to assure a fast strong bond.

7. Disconnect the front and rear grease pipes.

8. Disconnect hose (5) from the brake oil inlet side.

Note Cover and plug the disconnected pipes, hoses and fittings to protect them from dust and dirt.

24-45 92ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear axle disassembling and assembling

6

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

7

92V2E24011

9. Temporarily sling rear axle assembly (7), and remove right and left retainer bolts (6) from the rear axle support. : Bolt (6): 721 N-m (73.5 kgf-m) (532 lb-ft) : Rear axle assembly (including axle supports): 1,515 kg (3,335 lbs) 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.

Be careful not to bend or damage the oil pipes.

Do not reuse the retainer bolts. Replace them with new ones.

10. Lower rear axle assembly (7) evenly on the carrier, and then, pull out the rear axle.

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.

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

Refer to "Service brake air bleeding procedure" page 24-23 for air bleeding in the service brake.

24-46 92ZV-2 Disassembly & Reassembly Power Group Axle Support

Axle Support Axle support tightening torque

T1 L2

T2 L1 Front

T3 L1

T1 L2

92V2U22055

: T1: 721 N-m (73.5 kgf-m) (532 lb-ft) T2: 608 N-m (62.0 kgf-m) (449 lb-ft) T3: 53 N-m (5.4 kgf-m) (39 lb-ft) L1: Screw lock agent (Loctite® 262) application L2: With lubricating oil (Engine oil or gear oil)

24-47 92ZV-2 Disassembly & Reassembly Power Group Axle Support

Axle support disassembling and assembling

8 10

Rear support

6

11 13

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

7

12 9

Rear axle

Front support

4

90V2E24032

4. Remove bolt (6).

3

Rear axle

2

: Bolt (6): 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Loctite® 262) application 5. Remove plate (7) and wear ring (8).

1 5 90V2E24031

1. Remove bolt (1).

6. Remove bolt (9). Remove plate (10) and wear ring (11). : Bolt (9): 608 N-m (62.0 kgf-m) (449 lb-ft) : Screw lock agent (Loctite® 262) application

: Bolt (1): 53 N-m (5.4 kgf-m) (40 lb-ft) 2. Remove ring (2), packing (3) and front support from the rear axle assembly.

7. Remove the rear support from the rear axle assembly. : Axle support (rear): 110 kg (243 lbs)

: Axle support (front): 90 kg (200 lbs) 3. Remove packing (4) and bushing (5) from the front support.

8. Remove packing (12) and bushing (13) front the rear support.

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

IMPORTANT - Replace all the O-rings and seals with new ones.

- Clean and check all the parts. If a part is damaged, replace it.

24-48 92ZV-2 Disassembly & Reassembly Power Group Axle Support

Axle support assembly cautions Bushing installing Front support

5 Front

Grease

Swing shaft 85ZVE24009

Rear support

13 Rear

Grease

Swing shaft 85ZVE24010

Before installing, put bushing (5)(13) into dry ice then install it on to the axle support.

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

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

Note - When installing the axle support, fill enough grease between the packing and the axle support as shown in the illustration.

- The side with a groove on bushing (13) should come to the rear side.

24-49 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential Assembly Differential assembly removing and installing

A

Spider assembly

Cover bolt

Differential assembly removing TOP

[ Front axle assembly ]

1

2

92V2U24056

1. Temporarily sling the spider using hoisting tool (A).

Remove the cover bolts and cover (1). Remove retainer bolts (2) to remove the spider assembly.

K90V2J24028

Before starting work: - Drain oil from the axle assembly.

- Remove the axle from the machine.

- Place the axle assembly on work benches. : Axle assembly (Front): 1,275 kg (2,810 lbs) : Axle assembly (Rear): 1,515 kg (3,335 lbs) - For the front axle, remove the parking brake.

Refer to "Front axle assembly removing and installing" page 24-21.

- For the rear axle, remove the axle supports.

Refer to "Rear axle assembly removing and installing" page 24-43.

: Cover bolt: 90 N-m (9.2 kgf-m) (67 lb-ft) : Bolt (2): 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 110 kg (242 lbs)

30 cm (1 foot)

3

92V2U24057

2. Pull out right and left axle shafts (3) 30 cm (1 ft).

24-50 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

4

4

5

6 90ZV24081

3. Remove bolts (5) from differential (4). : Bolt (5): 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application

90ZV24083

4. Temporarily sling differential (4), and insert bolts into remover tap (Jack Screw) holes (6) to slightly lift the differential. : Front differential: 175 kg (386 lbs) : Rear differential: 190 kg (420 lbs)

mark sections: Spacers are installed.

Note Be careful to sling the differential so that it is balanced and is lifted straight up.

90ZV24082

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

7

90ZV24084

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

24-51 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

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

Differential assembly installation cautions - After reinstallation, refill with the specified oil until the oil level reaches the level check plug. Also refill the oil in each planetary assy.

- Manually turn the flange yoke of the differential to check that the right and left wheel hubs turn smoothly.

- Check the differential for oil leakage.

24-52 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assembly disassembling and assembling Front differential tightening torque

Torque proportional differential

F T5 L1 T7 L1

Limited slip differential (opt)

T2 L1 T4 L1

F

D

C

F

T3 L1

T6 L1

A

Shim

E

~

(T=0.07)

L2

(T=0.50)

T1 L2 (T=14.70)

~

T4 L1

B (T=14.98)

K90V2U24014

: T1: 883 N-m (90.0 kgf-m) (651 lb-ft) T2: 515 N-m (52.5 kgf-m) (380 lb-ft) T3: 330 N-m (33.7 kgf-m) (244 lb-ft) T4: 314 N-m (32.0 kgf-m) (232 lb-ft) T5: 235 N-m (24.0 kgf-m) (174 lb-ft) T6: 132 N-m (13.5 kgf-m) (98 lb-ft) T7: 53 N-m (5.35 kgf-m) (39 lb-ft) L1: Screw lock agent (Loctite® 262) application L2: Liquid gasket (Three Bond 1215)

Note - To tighten nut (T1), measure the preload at the bolt screw hole in flange (A).

Preload at flange (A): 62~71 N (6.3~7.2 kgf) (14~16 lbf) Use spacer (B) to adjust the preload.

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

Adjust the backlash by nut (F).

24-53 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Rear differential tightening torque

T2 L1

Limited slip differential (opt)

T3 L1 D T7 L1 T4 L1

F Torque proportional differential

T5 L1

C

T6 L1

A T1 L2

E Shim (T=0.07~0.50)

B (T=14.70~14.98)

T4 L1

92V2U24059

: T1: 883 N-m (90.0 kgf-m) (651 lb-ft) T2: 515 N-m (52.5 kgf-m) (380 lb-ft) T3: 330 N-m (33.7 kgf-m) (244 lb-ft) T4: 314 N-m (32.0 kgf-m) (232 lb-ft) T5: 235 N-m (24.0 kgf-m) (174 lb-ft) T6: 132 N-m (13.5 kgf-m) (98 lb-ft) T7: 53 N-m (5.35 kgf-m) (39 lb-ft) L1: Screw lock agent (Loctite® 262) application L2: Liquid gasket (Three Bond 1215)

Note - To tighten nut (T1), measure the preload at the bolt screw hold in flange (A).

Preload at flange (A): 62~71 N (6.3~7.2 kgf) (14~16 lbf) Use spacer (B) to adjust the preload.

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

Use nut (F) to adjust the backlash.

24-54 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assembly disassembling Adjust nut

3

Shim

3 Nut (A)

4

Bevel gear

Pinion

2

Adjust nut

90ZV24103

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

Before starting work: - Fix the differential assembly onto the disassembly workbench.

- Insert a straight-end screwdriver or the like into the clearance between the pinion and the bevel gear to prevent the gear from rotation. Loosen nut (A). : Nut (A): 883 N-m (90 kgf-m) (651 lb-ft)

90V2E24038

: Bolt (3): 515 N-m (52.5 kgf-m) (380 lb-ft) : Screw lock agent (Loctite® 262) application

5

6

Note Nut width across flat: 57.1 mm (2.25 in)

90ZV24150

3. Remove bearing outer race (5). Lift differential cage assembly (6) to remove it. : Differential: 120 kg (265 lbs) 1 2 90V2E24037

1. Remove right and left lock plates (1) from adjustment nut (2). : Bolt: 53 N-m (5.35 kgf-m) (39 lb-ft) : Screw lock agent (Loctite® 262) application

24-55 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

7 8

10

9

Matchmark 90ZV24107

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

90ZV24108

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

: Retainer bolt (8, Torque proportional diff.)

235 N-m (24.0 kgf-m) (174 lb-ft) : Retainer bolt (8, Limited slip diff.)

314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Loctite® 262) application

Clutch assy 90V2E24039

Note For the limited slip differential, remove the clutch assy, which is assembled instead of thrust washer (9).

12

11 13

90ZV24109

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

24-56 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

17

14 16 90ZV24110

90ZV24112

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

7. Remove side gear (14).

: Bolt (17): 330 N-m (33.7 kgf-m) (244 lb-ft) : Screw lock agent (Loctite® 262) application

15

Trunnion

90ZV24111

8. Remove thrust washer (15).

19

18 90ZV24113

10. Remove bolts (18) to remove pinion (19). At the same time, remove the shim. : Bolt (18): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Loctite® 262) application Note The rear differential assembly has the trunnion installed with bolts (18) as shown.

Clutch assy 90V2E24039

Note For the limited slip differential, remove the clutch assy, which is assembled instead of thrust washer (15).

24-57 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

20

21

25

90ZV24114

90ZV24117

14. Remove taper roller bearing (25).

11. Remove nut (20) and O-ring (21). : Nut: 883 N-m (90.0 kgf-m) (651 lb-ft) : Screw lock agent (Loctite® 262) application Note Nut width across flat: 57.1 mm (2.25 in)

26

22

90ZV24118

15. Remove spacer (26).

90ZV24115

12. Remove flange yoke (22).

23

24 90ZV24116

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

24-58 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assembly assembling

(d) Install yoke (22) on pinion (23) and tighten nut (20).

Note Do not install the oil seal and O-ring of the nut.

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.

: Nut: 883 N-m (90.0 kgf-m) (651 lb-ft)

1. Check the preload of the pinion section by following the procedure below:

26

24

0

A

90ZV24119

20

(e) Measure the preload at section (A) (bolt hole).

25 27

23

28

: Standard preload∗: 62~71 N (6.3~7.2 kgf) (14~16 lbf)

A 22 90ZV24120

(a) Install new roller bearing (27) on pinion (23) if replacement is needed.

∗Preload here is the force required to start the cage moving-breakaway force (not a rolling force). (f)

Pinion

Bearing

Pinion Stake at 3 points

If the preload is out of the above range, replace spacer ring (26) to adjust the preload to the specified range.

Note There are 15 types of spacers (14.70~14.98 mm) (0.58~0.59 in) in increments of 0.02 mm (0.0008 in).

Thicker spacers reduce preload; thinner spacers increase preload. (g) Remove nut (20) and flange yoke (22).

90ZV24121

Note After attachment, stake the bearing at three points as shown in the above figure. (b) Install new taper roller bearing (28) and spacer (26) on pinion (23) if replacement is needed. (c) Install cage (24) and taper roller bearing (25).

24-59 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Rear

Front

Shim

Shim

18

18 Check direction of the lips

29 31

31

24

Apply liquid gasket (AA03) to these surfaces

30

30

90ZV24122

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

Trunnion K90V2U24016

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

Note Install the trunnion to the rear differential assembly.

22

: Bolt (18): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Loctite® 262) application Torque proportional diff.

Limited slip diff.

14

20

15

21 90ZV24123

32

3. Install flange yoke (22), and then O-ring (21). Apply liquid gasket to nut (20), and then tighten the nut.

(Nut width across flat: 57.1 mm) 90V2E24042

: Nut (20): 883 N-m (90.0 kgf-m) (651 lb-ft) : Liquid gasket (Three Bond 1215) application

5. Install wear ring or clutch assy (15) and side gear (14) to differential cage (32).

Note Different part is assembled according to the differential type.

24-60 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

12

11

8

13 7

Matchmark

90ZV24145

90ZV24147

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

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

Torque proportional diff.

: Retainer bolt (8, Torque proportional diff.): 235 N-m (24.0 kgf-m) (174 lb-ft) : Retainer bolt (8, Limited slip diff.): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Loctite® 262) application

Limited slip diff.

9

10 16 17

90V2E24043

7. Install side gear (10) and wear ring or clutch assy (9).

Note Different part is assembled according to the differential type.

90ZV24148

9. Tighten bolts (17) in bevel gear (16). : Bolt (17): 330 N-m (33.7 kgf-m) (244 lb-ft) : Screw lock agent (Loctite® 262) application

24-61 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly (b) Tighten opposite side adjustment nut (1). After you feel that the nut is tight, turn it one more notch.

6

(c) Attach the dial gauge stand to the carrier. Attach dial gauge (A) to a tooth of bevel gear (16). Read the backlash value indicated on the dial gauge. (d) Adjust the backlash.

Standard backlash: 0.26~0.38 mm (0.0102~0.0149 in) 90ZV24149

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

3

- Tighten adjustment nut (33) on the bevel gear side or loosen adjustment nut (1) on the opposite side to reduce the backlash.

- Loosen adjustment nut (33) on the bevel gear side or tighten adjustment nut (1) on the opposite side to increase the backlash.

34 4

3

2 4

Adjust nut

90ZV24131

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

(For both the right and left sides)

90ZV24133

13. Tighten bolts (3) of bearing cap (4). : Bolt (3): 515 N-m (52.5 kgf-m) (380 lb-ft) : Screw lock agent (Loctite® 262) application

1

14. Mount lock plate (2), and then tighten bolts (34) to fix the lock plate.

A

: Bolt (34): 53 N-m (5.35 kgf-m) (39 lb-ft) : Screw lock agent (Loctite® 262) application 16

33

90ZV24132

12. Adjust the backlash as follows: (a) Tighten adjustment nut (33) on the bevel gear side until the backlash is "0". Then back off the adjustment nut 2 to 3 notches.

24-62 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Adjusting tooth contact: Tooth contact

Possible cause

Adjusting method

A

Correct

B

Ring gear is too close to the drive pinion

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

C

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

D

Drive pinion is too close to the ring gear.

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

Check again the backlash and tooth contact.

2

2

2

1

E

Drive pinion is too far from the ring gear.

Decrease the thickness of shim reverse as D, and makes drive pinion approach the ring gear.

Check again the backlash and tooth contact.

2

1

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

24-63 92ZV-2 Disassembly & Reassembly Power Group Differential Assembly 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 HEEL

Pitch line

4~5

10

TOE BOTTOM

10 3 Pattern C

4 TOP

TOE

3 HEEL

4~5

10

Pitch line BOTTOM

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

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

24-64 92ZV-2 Disassembly & Reassembly Power Group

MEMO

25-1 92ZV-2 Service Standard Power Group

92ZV-2 Service Standard Power Group Propeller Shaft Service Standard ............................ 25-2 Axle and Differential Service Standard.................... 25-3

25-2 92ZV-2 Service Standard Power Group Propeller Shaft Service Standard

Propeller Shaft Service Standard 1

1

Third propeller shaft

a

2 Measurement of circumferential play

b

1

3 Measurement of transverse play

4

Second propeller shaft 92V2U25001

Unit: mm (in) No.

Item

Tolerance

Solution

1

Spider bearing play

Second, third propeller shaft

0.25 (0.0098)

Replacement

2

Spline circumferential play

Second propeller shaft

0.8 (0.0315)

Replacement

3

Spline transverse play

Second propeller shaft

1.0 (0.0394)

Replacement

4

Clearance

17.64±3 (0.69±0.12)

—

: a: 77 N-m (7.9 kgf-m) (57 lb-ft) b: 162 N-m (16.5 kgf-m) (119 lb-ft)

25-3 92ZV-2 Service Standard Power Group Axle and Differential Service Standard

Axle and Differential Service Standard Axle group

6 5 4

2, 3

1, 3

4 7

5

92V2U25002

Unit: mm (in) Judgment standard No.

Item

Solution Standard dimension

Tolerance

1

Backlash between sun gear and planetary gear

0.12~0.60 (0.0047~0.0236)

←

Replacement

2

Backlash between planetary gear and internal gear

0.14~0.73 (0.0055~0.0287)

←

Replacement

3

Tooth contact of gear

4

Replacement

No abnormality Front

(12.2241 +0.0032 ) ø 311 +0.081 0 0

Rear

Replacement

(8.110 +0.0028 ) ø 206 +0.072 0 0

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

Axle support wear

5

Bushing and wear ring wear

Oil groove 1.0 (0.0394)

No oil groove

Replacement

6

Trunnion wear

0 0 ø 300 -0.081 (11.8110 -0.0032 )

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

Replacement

7

Sleeve wear

0 0 ø 195 -0.115 (7.6772 -0.0045 )

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

Replacement

25-4 92ZV-2 Service Standard Power Group Axle and Differential Service Standard

Differential 1

2 3

4

5.6

5.6

85ZV25004J

Unit: mm (in) Judgment standard No.

Item

Solution Standard valve

Tolerance

1

Backlash between ring gear and drive pinion

0.26~0.38 (0.0102~0.0149)

←

Adjustment

2

Backlash between side gear and pinion gear

0.23~0.58 (0.0090~0.0228)

←

Adjustment

3

Clearance between pinion gear and spider

0.098~0.126 (0.0038~0.0049)

←

Replacement

4

Runout of ring gear rear surface (when assembled)

0.076 (0.0029)

←

Adjustment or replacement

5

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

6

Tooth contact

No abnormality

Replacement

34-1 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group

92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly....... 34-2 Torque Converter Assembly .................................... 34-11 Transmission Assembly .......................................... 34-20 Transmission Forward/Reverse Clutch Pack .......... 34-27 Transmission 1st/3rd Speed Clutch Pack................ 34-30 Transmission 2nd Speed Clutch Pack..................... 34-32 Transmission 4th Speed Clutch Pack...................... 34-34 Control Valve Assembly .......................................... 34-37

34-2 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

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

T1 L1

T3 L1

T6 L3

T3 L1

Rear chassis

T1 L1

T5 L3

Transmission

Rear axle

T4 L1

3rd propeller shaft

T2 L1 T4 L1

Front axle

T4 L1

2nd propeller shaft

92V2U24001

: T1: 441 N-m (45 kgf-m) (325 lb-ft) T2: 417 N-m (42.5 kgf-m) (307 lb-ft) T3: 230 N-m (23.5 kgf-m) (170 lb-ft) T4: 142 N-m (14.5 kgf-m) (105 lb-ft) T5: 67 N-m (6.8 kgf-m) (49 lb-ft) T6: 71 N-m (7.2 kgf-m) (52 lb-ft)

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

34-3 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

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

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

- Lower the attachment onto the ground, and then block the tires with chocks to prevent wheels from moving.

- Disconnect the ground cable from the negative side of the battery.

1

92V2U34001

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

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure.

- Press the hydraulic tank cap, and relieve the internal pressure from the hydraulic tank.

- Remove the cab and the floor board (Refer to Section 14).

- Remove the engine room (Refer to Section 14).

- Consider the type of failure and if the T/C oil cooler must also be removed for cleaning or replacement.

- If a small amount of contamination is found in the transmission strainer and filter the cooler does not need removal.

- If a large amount of contamination is found the cooler must be removed and thoroughly cleaned or replaced.

- Lines to cooler must also be replaced.

: Transmission oil: 43 L (11.4 gal)

34-4 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

2

7

3

4

5 92V2U34002

92V2U34004

4. Disconnect hose (7) from parking brake.

Accumulator assembly

6

92V2U34003

2. Disconnect bolts (3) from third propeller shaft (2) on the transmission side. : Bolt (3): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application Note If the retainer bolts are too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner.

Keep the flame away from the seals of the coupling.

Do not reuse the bolts, always replace with new ones.

3. Remove bolt (5) from second propeller shaft (4) on the transmission side only.

Disconnect electric wire (6) from the speed meter sensor and speed sensor. : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Loctite® 262) application

92V2U34005

5. Disconnect all the hoses and the pipes from the accumulator and then remove accumulator assembly.

Install plastic caps or plugs to prevent dirt entry into valve and hoses.

34-5 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

ELS valve

8 92V2U34006

92V2U34007

6. Disconnect hose (8) from the transmission level gauge.

8. Disconnect all the hoses and the pipes from the ELS valve and remove the ELS valve.

Install plastic caps or plugs to prevent dirt entry into valve and hoses.

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

Transmission

Steering valve

Oil pump

9

10

11 92V2E34001

90ZV34112

7. Disconnect all the hoses and the pipes from the steering valve and remove the steering valve with the bracket.

Install plastic caps or plugs to prevent dirt entry into valve and hoses.

9. Disconnect hoses and pipes (9)(10)(11) from the oil pump.

Note After removing the hoses, cover the hoses with plastic caps, and cover the pump ports with caps to protect them from dust and dirt.

34-6 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Transmission

19

12

14 13 18 15

19 92V2U34011

92V2E34002

10. Remove suction pipes (12)(13), and then remove oil pump assembly (14)(15). : Bolt: 90 N-m (92 kgf-m) (66 lb-ft) : Oil pump (14): 35 kg (77 lbs) : Oil pump (15): 30 kg (66 lbs) Note After removing the hoses, cover the hoses with plastic caps, and cover the pump ports with the caps to protect them from dust and dirt.

Refer to "Hydraulic pump assembly installing" page 444 for the reinstallation.

12. There are two hoses (18) between torque converter and the cooler. There are two hoses (19) between the line filter and the transmission. Disconnect hoses (18)(19).

Note After removing the hose, cover the fitting section with plastic caps or plugs to protect the fitting section from dust and dirt.

20

21 16 92V2U34012

17

13. Remove all electric wire couplers (21) from control valve (20).

92V2U34010

11. Disconnect the electrical wire for torque converter temperature switch sensor (16).

Disconnect main clutch pressure outlet hose (17).

Note After removing the hoses, cover the hoses with plastic caps to protect from dust and dirt.

Note Before disconnecting the couplers, be sure to put matchmarks on the couplers.

For reassembly, refer to the connection illustration on "Control valve installation cautions" page 34-39.

34-7 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Engine flywheel housing

23 Flywheel

22

Ring Pull to separate transmission

Pilot boss Ring gear

Transmission

92V2U34013

14. Attach sling to transmission assembly (22), and then remove 12 bolts (23) from the engine flywheel housing. : Bolt: 71 N-m (7.2 kgf-m) (52 lb-ft) : With lubrication oil (Engine oil or gear oil) : Transmission assembly: 1,260 kg (2,770 lbs)

26

25

24

92V2U34014

15. Loosen bolts (24) (10 mm (0.4 in)) (both sides).

Remove bolts (25)(26) (both sides). : Bolt (24)(26): 230 N-m (23.5 kgf-m) (170 lb-ft) Bolt (25): 441 N-m (45 kgf-m) (325 lb-ft) : Screw lock agent (Loctite® 262) application

Engine-transmission joint section

92V2U34015

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 to the front.

34-8 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

31

Wooden piece 92V2U34016

90ZV34016

17. Slowly lift transmission assembly (31) while avoiding contact with other parts.

Wooden piece

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

85V2E34024

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

Note Lift the transmission approximately 100 mm (4 in), and then insert a wooden piece of 200 mm (8 in) 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.

34-9 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Transmission assembly installation cautions Joint between the torque converter and the engine

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

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

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

1

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

90ZV34017

- Be sure to replace the O-ring (1) with new one.

- Be sure pilot boss bushing (ring) is installed.

Transmission side

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.

Engine side

Flywheel

O-ring (1) Ring gear Ring

92V2U34017

- Rotate the engine flywheel to align the ring gear.

34-10 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

DATE:

HOURS:

MACHINE MODEL & SERIAL NO.:

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO.:

AMBIENT TEMP:

COMPONENT SERIAL NO.:

CHECKLIST TO BE COMPLETED BEFORE START-UP TRANSMISSION COOLER CLEANED

TRANSMISSION PIPING CLEANED

IN-LINE PRESSURE FILTER REPLACED

TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

HIGH IDLE RPM LOW IDLE RPM T/C STALL RPM HYDRAULIC STALL RPM FULL STALL RPM CREEP WITH BRAKE (F1) RPM CREEP WITH BRAKE (R2) RPM CLUTCH PRESSURE AT LOW IDLE 2

F1

MPa (kgf/cm ) (psi)

N1

MPa (kgf/cm2) (psi)

R1

MPa (kgf/cm2) (psi)

F2

MPa (kgf/cm2) (psi)

N2

MPa (kgf/cm2) (psi)

R2

MPa (kgf/cm2) (psi)

F3

MPa (kgf/cm2) (psi)

N3

MPa (kgf/cm2) (psi)

R3

MPa (kgf/cm2) (psi)

F4

MPa (kgf/cm2) (psi)

N4

MPa (kgf/cm2) (psi)

R4

MPa (kgf/cm2) (psi)

CLUTCH PRESSURE AT HIGH IDLE 2

F1

MPa (kgf/cm ) (psi)

N1

MPa (kgf/cm2) (psi)

R1

MPa (kgf/cm2) (psi)

F2

MPa (kgf/cm2) (psi)

N2

MPa (kgf/cm2) (psi)

R2

MPa (kgf/cm2) (psi)

F3

MPa (kgf/cm2) (psi)

N3

MPa (kgf/cm2) (psi)

R3

MPa (kgf/cm2) (psi)

F4

MPa (kgf/cm2) (psi)

N4

MPa (kgf/cm2) (psi)

R4

MPa (kgf/cm2) (psi)

COMMENTS:

Serviceman’s Signature

KCM Corporation Copy as required. Make attachments if needed.

34-11 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque Converter Assembly Torque converter assembly tightening torque T4 L3

T4 L3

T4 L3

T5

T2 L3 T3 L3

T1 L3 92V2U34018

: T1: 50 N-m (5.1 kgf-m) (37 lb-ft) T2: 53 N-m (5.4 kgf-m) (39 lb-ft) T3: 55 N-m (5.6 kgf-m) (40 lb-ft) T4: 94 N-m (9.5 kgf-m) (69 lb-ft) T5: 245 N-m (25 kgf-m) (180 lb-ft)

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

34-12 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque converter assembly disassembling and assembling Torque converter assembly disassembling Before starting work: - Clean the torque converter assembly.

- Drain oil from the transmission and the torque converter.

6

[ Standard transmission ]

5 3

92V2U34020

1

2. Remove bolts (5) and T/C front housing (6).

Front

: Bolt: 94 N-m (9.5 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil)

2 Gasket

4 92V2U34019

[ Lock-up transmission ]

7 92V2U34021

1 Solenoid valve assembly Accumulator

2 3

3. Remove bolts and washer (7) from the pump impeller. (Number of bolts: 30) 1

Front

4

2 K92V2U34007

1. Remove pipes (1), bolts (2), cover (3) and then remove the hose (4). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) For the lock-up T/M, remove the solenoid valve assembly and accumulator.

Refer to page 34-40 for the disassembling and assembling of the solenoid valve assembly.

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

34-13 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

14

8

9 15 92V2U34022

92V2U34025

4. Remove socket bolts (8) and ring gear assembly (9).

Calking (Staking) (Point marked with )

: Socket bolt: 94 N-m (9.5 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil) 14

11 Collar 92V2U34026

10

7. Remove lock nut (14) and stator (15).

12

: Lock nut: 245 N-m (25 kgf-m) (180 lb-ft) 92V2U34023

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

5. Remove snap ring (10) and washer (11) and then remove T/C front cover (12).

mm Calking (Staking)

1.5 or more

Collar

2 Spline groove

92V2U34024

6. Remove turbine impeller assembly (13).

2.75

13

95ZIV3404

Note When reinstalling lock nut, after tightening lock nut, calk (stake) the collar of the nut against the spline groove. (4 equally divided portion on circumference)

34-14 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

23 17

16 24 92V2U34027

92V2U34029

8. Remove sleeve (16) and then remove pump impeller assembly (17).

10. Remove bolts (23) and then remove stator shaft assembly (24). : Bolt: 94 N-m (9.5 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil)

17

31 18

24

19 22

33

34 20

22 21

92V2U34028

27

9. Remove bolts (18), plate (19), gear (20), snap ring (21), bearing (22) from pump impeller assembly (17). : Bolt: 55 N-m (5.6 kgf-m) (40 lb-ft) : With lubrication oil (Engine oil or gear oil)

For lock-up T/C

32

30

29

26

25

28 K92V2U34008

11. Remove snap ring (25), bearing (26), spacer (27), gear (28), ring (29), snap ring (30), turbine shaft (31), bearing (32), piston ring (33)(34), from stator shaft assembly (24).

34-15 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

35

39

38

37

55

40 36

39

53

49 47

Oil seal

45

51

44

52

56 54

40 50 46

92V2U34031

12. Remove snap ring (35)(36) and gear (37)(38) from oil pump shaft (39)(40).

42

43

48 92V2U34033

14. Remove spacer (44), bearing (45)(46), ring (47)(48), snap ring (49)(50), bearing (51)(52), ring (53)(54), snap ring (55)(56) from oil pump shaft (39)(40).

40 41

39

Note Check direction of bearing (51). ∗: Remover bolt installation position Gasket

57

92V2U34032

57

13. Remove snap ring (41)(42)(43) and then remove oil pump shaft (39)(40).

Torque converter housing Transmission 92V2U34034 housing

57

15. Remove bolts (57) and then separate torque converter housing from transmission housing. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

34-16 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Gasket

72 73

71 70 69

59 58 61 75

68

67

74

76

60 92V2U34035

92V2U34037

16. Remove bolts (58) and oil pump (59).

Remove bolt (60) and oil pipe (61).

76

75

74

73

72

: Bolt (58): 69 N-m (7.0 kgf-m) (51 lb-ft) : With lubrication oil (Engine oil or gear oil) : Bolt (60): 28 N-m (2.9 kgf-m) (21 lb-ft) : Screw lock agent (Loctite® 262) application

34 mm (1.3 in)

92V2U34038

19. Remove adaptor (67), seal washer (68), spring (69)(70), plunger (71) from torque converter housing.

64 66 65 63 62

20. Remove nut (72) washer (73)(74), spring (75), bolt (76) from torque converter housing.

92V2U34036

: Screw lock agent (Loctite® 262) application 17. Remove bolts (62), plate (63), idle gear assembly (64).

18. Remove snap ring (65) and bearing (66) from idle gear assembly (64). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

IMPORTANT When reassembling, adjust the clearance between torque converter housing and bolt (76) to 34 mm (1.3 in).

34-17 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque converter assembly assembling For reassembling, follow the above procedure in reverse order.

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 ring and O-rings.

- To assemble the torque converter assembly be sure to apply transmission oil.

34-18 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Lock-up torque converter disassembling and assembling Lock-up torque converter disassembling To disassemble the lock-up torque converter, follow the steps 1. through 3. to disassemble the torque converter assembly. Refer to "Torque converter assembly disassembling" page 34-12. Here the steps thereafter are described.

6

1

3

2

5

4

3. Alternately remove friction plate (9) and steel plate (10).

Note - Number of friction plates: 2 Number of steel plates: 1 - Reinstall the friction plate first.

4. Gradually apply air pressure to the oil port, and remove piston (11).

11

12

13 6 K92V2U34002

1. Remove bolt (1), drive cover (2), o-rings (3)(4), snap ring (5) and drive cover assembly (6). : Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) : Drive cover assembly (6): 60 kg (132 lbs)

K92V2U34004

5. Remove piston ring (12)(13) from piston (11) and drive cover (6), respectively.

15 14 6 8

11

9,10

7

Oil port

K92V2U34005 K92V2U34003

2. Turn drive cover assembly (6) upside down, and then remove snap ring (7) and plate (8).

6. Remove turbine impeller (14), and then remove piston ring (15).

34-19 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

K92V2U34006

7. For the following disassembling steps, refer to "Torque converter assembly disassembling and assembling" from step 7).

Lock-up torque converter assy assembling For reassembling, follow the above procedure in reverse order.

Lock-up torque converter assy assembly cautions

IMPORTANT - Clean and check all the parts. If a part is damaged, replace it with a new one.

- Before reassembly, apply transmission oil to the parts.

- Replace all the seals and packings with new ones.

34-20 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission Assembly Transmission assembly tightening torque

T2 L3

T2 L3

T1 L3

T2 L3 T2 L3

T4 L3

Idler gear section

T2 L3

T3 L3

T2 L3

: T1: 11 N-m (1.1 kgf-m) (8.1 lb-ft) T2: 53 N-m (5.4 kgf-m) (39 lb-ft) T3: 230 N-m (23 kgf-m) (170 lb-ft) T4: 883 N-m (90 kgf-m) (651 lb-ft)

K92V2E34001

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

34-21 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission assembly disassembling and assembling Transmission assembly disassembling Before starting work: - Clean the transmission assembly.

- Remove the 3rd coupling yoke.

- Place the transmission assembly so that the parking brake side is up.

- For disassembling and reassembling for the parking brake, refer to "Brake Group 54".

5 7

8

6 92V2U34042

3. Remove bolts (5) and seal retainer (6). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

1

4. Remove bolts (7) and strainer assembly (8).

2 92V2U34040

1. Remove pipe (1) and hose (2).

Gasket

4

3 Do not remove this bolts

92V2U34041

2. Remove bolts (3).

Lift the control valve assy (4), and remove it. : Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft) : With lubrication oil (Engine oil or gear oil) : Control valve assembly: 20 kg (44 lb) Note Refer to "Control valve removing and installing" page 34-38 to remove control valve assy (2).

34-22 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

15

12

16

A A 9

10

11

12

A

A 12

17

12 14

13

92V2U34072

7. Remove bolt (14) and then remove parking brake assembly (15) and O-ring (16)(17).

13 12 A

: Bolt: 230 N-m (23 kgf-m) (170 lb-ft) : With lubrication oil (Engine oil or gear oil) : Parking brake assembly: 95 kg (210 lbs)

A

44.5 mm

54 mm

(1.8 in)

(2.1 in)

Note Refer to section 54 for the disassembling and reassembling of the parking brake assembly.

92V2U34043

19

5. Remove nut (9), O-ring (10) and then remove flange yoke (11).

20

18 21

T/M front cover

: Nut: 883 N-m (90 kgf-m) (651 lb-ft) 6. Remove bolts (12) and nuts (13). Install nuts (13) evenly for four rods (A) and stop tightening when the clearance becomes 54 mm (2.1 in). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

92V2U34045

8. Alternately remove the steel plates and the friction plates and then remove the rods and the hub from the transmission. Remove ring (18). Hit in output shaft (19) after that remove output shaft (19) with the ball bearing.

9. Remove snap ring (20) and bearing (21) from T/M front cover.

34-23 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

∗: Remover bolt installation position

22

∗ 23

25 Gasket

92V2U34046

10. Remove bolts (22) and separate T/M front cover (23) from the T/M housing.

92V2U34048

12. Remove bolt (25). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

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

26

27

24

92V2U34049 92V2U34047

11. Remove gear (24).

13. Remove bearing (26) and remove 4th speed clutch pack assembly (27).

28

92V2U34050

14. Remove the 1st speed clutch pack assembly (28).

34-24 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission assembly assembling 29

To reassembling the transmission, follow the above procedure in the reversed direction.

Cautions regarding reassembly 30

92V2U34051

15. Remove bolt (29) and then lift T/M housing (30) slowly. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) : T/M housing: 210 kg (460 lbs)

Note - For clutch pack disassembly and reassembly refer to "Disassembly 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 engaged properly.

Note Refer to the section for the torque converter disassembly for remover bolt installation position.

27 31

32

26 92V2U34053

92V2U34052

16. Remove the 3rd and the forward speed clutch pack assembly (31).

17. Remove the 2nd and the reverse speed clutch pack assembly (32).

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.

1. When installing front cover to transmission housing.

Measure and record the clearance between the 1st speed clutch pack gear (26) and the 4th speed clutch pack gear (27).

Note The clearance between them should be no less than 0.5~1.0 mm (0.02~0.04 in).

34-25 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

23

27

92V2U34054

92V2U34056

2. Measure the distance from the bearing of the 4th speed clutch pack (27) to the mounting face (including the gasket) of the housing.

Regard the obtained distance as dimension A.

4. Measure the distance from the mounting face of cover (23) to the end face of the bearing receiver for the 4th speed clutch pack.

Regard the obtained distance as dimension B.

23

26 92V2U34055

92V2U34057

3. Measure the distance from the bearing of the 1st speed clutch pack (26) to the mounting face (including the gasket) of the housing.

Regard the obtained distance as dimension A'.

5. Measure the distance from the mounting face of cover (23) to the end face of the bearing receiver for the 1st speed clutch pack.

Regard the obtained distance as dimension B'.

34-26 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

C

33

C

92V2U34058

92V2U34061

6. Adjust the difference between the distance B and the distance A (thrust clearance) to 0.5~1.0 mm using shim (33).

B – A = 0.5~1.0 mm (0.02~0.04 in)

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 0.5~1.0 mm (0.02~0.04 in).

Clutch shaft cover

34 O-ring

23

O-ring

Gasket

92V2U34059

92V2U34062

8. Install cover (23) onto the transmission housing and then install clutch shaft covers. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

34

92V2U34060

7. Adjust the difference between the distance B' and the distance A' (thrust clearance) to 0.5~1.0 mm using shim (34).

B' – A' = 0.5~1.0 mm (0.02~0.04 in) Remove clutch shaft covers.

34-27 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Forward/Reverse Clutch Pack

Transmission Forward/Reverse Clutch Pack Forward/reverse clutch pack disassembling and assembling Forward/reverse clutch pack disassembling Note The disassembling procedure for the reverse clutch pack is described below.

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

3 2 90ZV34059

3

4

2

92V2U34064 92V2U34063

1. Remove snap ring (1).

2. Attach the bearing puller to gear (2), and then remove the gear with bearing (3) as a unit. There is thrust washer (4) between gear (2) and the ball bearing. Remove thrust washer (4).

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

For inspection and wear standard refer to "Service standard".

34-28 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Forward/Reverse Clutch Pack

12 6 7

13

5

5

8 9 92V2U34065

92V2U34067

3. Remove two needle bearings (5) and spacer (6) and thrust washer (7). After that remove snap ring (8) and backing plate (9).

5. Slightly depress ring (13). Remove snap ring (12) and ring (13).

Note When reassembling, install thrust washers (4)(7) so that the notch faces gear (2).

14 15 16 18

17

19 10

92V2U34068

11

6. Remove 20 springs (14), and then turn clutch over and tap shaft on a wooden block to remove piston (15).

92V2U34066

7. Remove ring (16) from piston (15).

4. Alternately remove friction plates (10) and steel plates (11).

Note - Number of friction plates: 7 Number of steel plates: 6 - After reinstalling piston (15), be sure to insert friction plate (10) first.

8. Remove piston ring (17)(18) from shaft assy (19).

34-29 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Forward/Reverse Clutch Pack

Forward/reverse clutch pack assembling

Forward/reverse clutch pack assembly cautions

For reassembling follow the above procedure in reverse order.

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 forward/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.

Depth micrometer Straight edge

Air line

Backing plate 85W34041

After assembling clutch pack.

- Using a straight edge and depth micrometer apply pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Piston stroke Forward

3.3±0.5 mm (0.13±0.02 in)

Reverse

3.3±0.5 mm (0.13±0.02 in)

Note 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.

34-30 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 1st/3rd Speed Clutch Pack

Transmission 1st/3rd Speed Clutch Pack Transmission 1st/3rd speed clutch pack disassembling and assembling Transmission 1st/3rd speed clutch pack disassembling 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.

7

6

2

4

3

8

(3rd speed)

(1st speed)

5 10

9 90ZV34071

2. [3rd speed] - Remove thrust washer (2), and then remove rear gear (3).

- Using internal or blind hole puller remove needle bearings (4) and thrust washer (5).

Spacer

Note When reassembling install thrust washers (2)(5) so that the notch faces to gear (3).

1

85K34099

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

[1st speed] - Remove thrust washers (6) and thrust bearing (7).

- Using internal or blind hole puller remove needle bearings (8), thrust washers (9), and thrust bearing (10).

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

12 11

Shaft assembly

90ZV34072

3. Remove snap ring (11) and backing plate (12).

34-31 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 1st/3rd Speed Clutch Pack

Transmission 1st/3rd speed clutch pack assembling

14

For reassembling follow the above procedure in reverse order.

13

16 15

90ZV34073

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.

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

Note After reinstalling piston (18), be sure to insert friction plate (13) first.

Friction plates

Steel plates

1st speed

9

8

3rd speed

5

4

Transmission 1st/3rd speed clutch pack assembly cautions

5. Remove snap ring (15) and ring (16).

19

20

18 85K34107

17

After assembling clutch pack.

- Using a straight edge and depth micrometer apply pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Shaft assembly

90ZV34074

Piston stroke

6. Remove 20 springs (17), and then turn over the clutch and tap the shaft on a wooden block to remove piston (18).

7. Remove U-ring (19) from piston (18).

8. Remove piston ring (20) from the shaft assembly.

1st speed

3.5±0.5 mm (0.14±0.02 in)

3rd speed

2.1±0.5 mm (0.08±0.02 in)

Note 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.

34-32 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 2nd Speed Clutch Pack

Transmission 2nd Speed Clutch Pack Transmission 2nd speed clutch pack disassembling and assembling Transmission 2nd speed clutch pack disassembling 9

4

8

3

7

90ZV34084

3. Remove thrust washer (7), thrust bearing (9) and thrust washer (8). Store the thrust washers for possible reuse.

1

2

90ZV34082

1. Remove spacer (1) and gear (2). After that, remove snap ring (3) and backing plate (4).

12 11 10

5

90ZV34085

6

4. Depress plate (11) and remove snap ring (10), and plate (11).

5. Remove 20 springs (12).

90ZV34083

2. Remove friction plates (5) and steel plates (6).

Note - Number of friction plates: 5 Number of steel plates: 4 - After reinstalling piston (13), be sure to insert friction plate (5) first.

34-33 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 2nd Speed Clutch Pack

Transmission 2nd speed clutch pack assembly cautions 14

15

13

Shaft assembly

90ZV34086

6. Turn over clutch the and tap the shaft on a wooden block to remove piston (13).

7. Remove U-ring (14) from piston (13).

8. Remove piston ring (15) from the shaft assembly.

Transmission 2nd speed clutch pack assembling

85K34107

After assembling clutch pack.

- Using a straight edge and depth micrometer apply pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Piston stroke 2nd speed

For reassembling follow the above procedure in reverse order.

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.

2.1±0.5 mm (0.08±0.02 in)

Note 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.

34-34 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 4th Speed Clutch Pack

Transmission 4th Speed Clutch Pack Transmission 4th speed clutch pack disassembling and assembling

7 6

Transmission 4th speed clutch pack disassembling

90ZV34093

3. Remove snap ring (6) and backing plate (7).

1

8

90ZV34091

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

9

5 90ZV34094

4 2

4. Remove friction plates (8) and steel plates (9).

3

90ZV34092

2. Remove thrust washer (2) and gear (3). Use an internal or blind hole puller to remove needle bearing (4) from inside the gear.

Remove needle bearing (4) and thrust washer (5).

Note When reassembling install thrust washers (2)(5) so that notch faces to gear (3).

Note - Number of friction plates: 5 Number of steel plate: 4 - After reinstalling piston (13), be sure to insert friction plate (8) first.

34-35 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 4th Speed Clutch Pack

Transmission 4th speed clutch pack assembling For reassembling follow the above procedure in reverse order.

11 10

90ZV34095

5. Depress ring (11) and remove snap ring (10), and ring (11).

14

15

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.

Transmission 4th speed clutch pack assembly cautions

16

13 12 Shaft Shaft assembly Gear

90ZV34096

Clutch drum 90ZV34114

6. Remove 20 springs (12), and then turn over the clutch and tap the shaft on a wooden block to remove piston (13).

7. Remove U-ring (14) from piston (13).

8. Remove piston ring (15)(16) from the shaft assembly.

1. When installing the gear to the shaft, follow the procedure below.

- Assemble the gear onto the clutch drum with the bolts.

- Heat them up to 190ºC (374ºF).

- Insert the shaft into the clutch drum and gear. : Bolt: 86 N-m (8.8 kgf-m) (64 lb-ft) : With lubrication oil (Engine oil or gear oil)

34-36 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 4th Speed Clutch Pack

Depth micrometer Straight edge

Air line

Backing plate 85W34041

2. After assembling clutch pack.

- Using a straight edge and depth micrometer apply pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Piston stroke 4th speed

2.1±0.5 mm (0.08±0.02 in)

Note 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.

34-37 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control Valve Assembly Control valve tightening torque

T1

T1

T4

T2

T3

92V2U34069

: T1: 20 N-m (2.0 kgf-m) (14 lb-ft) T2: 39 N-m (4.0 kgf-m) (29 lb-ft) T3: 10 N-m (1.0 kgf-m) (7 lb-ft) (Solenoid valve nut) T4: 34 N-m (3.5 kgf-m) (24 lb-ft) (Solenoid valve body)

34-38 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve removing and installing 4

Control valve removing

WARNING

5

3

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

85V2E34023

2. Attach sling to control valve (3), and then remove valve bolts (4). : Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft) : With lubrication oil (Engine oil or gear oil) Note Do not remove two trimmer bolts (5).

3. Lower the control valve to remove it.

Be sure to replace the gasket.

2

IMPORTANT 1 90V2E34012

1. Disconnect all electric wire couplers (1) also disconnect hose (2) for checking the clutch pressure.

Note Put matchmarks on the electric wire couplers.

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. : Control valve: 20 kg (44 lbs)

34-39 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve installation cautions

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

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

LP

Control valve

TR

LO

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

3

LR LBr

(f)

(g) Check oil leakage.

F

R (h) Adjust the transmission oil level to the specified point with the dipstick.

2

LY 4

1

LG LW

K92V2U34001

(a) Be sure to replace all the O-rings and gaskets with new ones. (b) Sequentially tighten the bolts in the order from the center to the outside. Apply equal (specified) torque to all the bolts. (c) Align the matchmarks of the electric wire couplers, and then connect the couplers while checking that the electric wires are not tangled with each other. (d) Install the cover while checking that the emergency operation bolts are positioned over the center of the solenoid valves. (e) During installation, be careful not to damage the gasket.

34-40 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve disassembling and assembling Control valve disassembling Note Clean the control valve.

4 85V2E34031

3. Remove valve (4) using a 17 mm wrench. : Valve: 34 N-m (3.5 kgf-m) (24 lb-ft) 1

85V2E34029

5 7

1. Remove nut (1) using special tool (A). : Nut: 10 N-m (1.0 kgf-m) (7 lb-ft)

6

Note Nut width across flat: 30 mm Special tool (A) is described on the next page.

For other valves, follow the same procedure.

92V2U34070

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

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

3

2

85V2E34030

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

Note For other solenoid valves, follow the same procedure.

34-41 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

12 8

11 10 9

92V2U34071

5. Remove regulator valve (8), trimmer plug (9), springs (10), spring retainer (11), and plug (12).

Special tool (A) Material: SS41 North American dealer tool number: KL03-102-1 75 (3.0) 65 (2.6) 60 (2.4) 15 (0.6)

04 .0 -0 .008 0

.1 -0 .2 0

.7

0

ø7 (0.3) Drill

5 (0.2)

ø30 (1.2)

ø23 (0.9)

ø40 (1.6)

+0.008 +0.2

30 +0.1 1.2 +0.004

17

90ZV34111

34-42 92ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve assembling To reassemble the control valve, follow the disassembling procedure in reverse order.

Control valve assembly cautions - Before you insert the regulator valve, apply transmission oil to the valve. After insertion, check that the valve operates smoothly.

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

Check free lengths and if necessary replace them.

- Check the operation of the solenoid valves.

(Also check movement by pressing the manual plunger. The plunger should move freely and smoothly in both directions (spring return).)

- Replace all seals, O-rings and gaskets.

- Check coil resistance.

Resistance: Approx. 27 Ω

35-1 92ZV-2 Service Standard Torque Converter and Transmission Group

92ZV-2 Service Standard Torque Converter and Transmission Group Transmission Assembly .......................................... 35-2 Control Valve ........................................................... 35-4 Torque Converter Gear Pump ................................. 35-5 Clutch Plate Thickness/Piston Stroke ..................... 35-6 Clutch Oil Pressure ................................................. 35-8

35-2 92ZV-2 Service Standard Torque Converter and Transmission Group Transmission Assembly

Transmission Assembly 13 12

16

5

18

14

17 4

17

14 18 16

15 9

Torque converter gear pump section

11

10

92V2E35001

Note Numbers correspond to the REF. number on page 35-3.

35-3 92ZV-2 Service Standard Torque Converter and Transmission Group Transmission Assembly

mm (in), kgf (lbf) Judgement criteria REF.

ITEM

1 2

Clearance

3

Solution Standard clearance

Allowable limit

Control valve regulator valve ~ valve body

0.030~0.061 (0.0011~0.0024)

0.09 (0.0035)

Replacement

Control valve regulator valve ~ seal retainer

0.016~0.045 (0.0006~0.0017)

0.07 (0.0027)

Replacement

Control valve trimmer plug ~ valve body

0.025~0.066 (0.0010~0.0026)

0.09 (0.0035)

Replacement

Standard value

Allowable limit

ITEM Free length

Installed length

Installed load

Free length

Installed load

4

T/C inlet valve spring

4.2 (1.6535)

35 (1.3780)

16.6 (36.6)

41.2 (1.622)

15.3 (33.7)

Replacement

5

Clutch return spring (The same spring for all clutches) T/C

24.4 (0.9606)

21 (0.8267)

3.3 (7)

23.7 (0.9330)

3.0 (6)

Replacement

Control valve regulator spring A

89 (3.5039)

89 (3.5039)

0

87.5 (3.4448)

0

Replacement

7

Control valve regulator spring B

74.8 (2.9449)

74.8 (2.9449)

0

73.7 (2.9016)

0

Replacement

8

Control valve trimmer spring

73.5 (2.8937)

69 (2.7165)

2.2 (4.8)

72.4 (2.8504)

2.16 (4.7)

Replacement

6

Spring

Judgement criteria ITEM

9 10

Oil seal

11

12

13

Standard value

Allowable limit

Charge pump shaft dia.

39.984~40 (1.5742~1.5748)

39.8 (1.5670)

Rear yoke shaft dia.

94.965~95 (3.7388~3.7402)

94.8 (3.7323)

Front yoke shaft dia.

94.913~95 (3.7367~3.7402)

4.8 (3.7323)

W

0 0 (0.1929 -0.0039 ) 4.9 -0.1

4.7 (0.1850)

H

4.5±0.15 (0.1772±0.0059)

4.3 (0.1693)

W

0 0 (0.0944 -0.0039 ) 2.4 -0.1

2.2 (0.0866)

H

2.5±0.1 (0.0984±0.0039)

2.3 (0.0906)

W

0 0 (0.1532 -0.0039 ) 3.89 -0.1

3.69 (0.1453)

H

4.35±0.1 (0.1713±0.0039)

4.15 (0.1634)

Torque converter inlet

Seal ring

14

W

Torque converter outlet

Clutch shaft (The same for all clutches)

H

Replace oil seal when disassembling and reassembling

Replacement Replacement Replacement

Replacement

Replacement

Replacement

15

Piston outer dia. (F, R)

H

4.75±0.1 (0.1870±0.0039)

4.55 (0.1791)

Replacement

16

Piston outer dia. (1~4 speed)

H

4.75±0.1 (0.1870±0.0039)

4.55 (0.1791)

Replacement

17

Piston inner dia.

H

(0.1929 +0.0006 ) 4.9 +0.015 0 0

4.7 (0.1850)

Replacement

Thrust washer thickness

2.9~3.1 (0.1141~0.1220)

2.7 (0.1063)

Replacement

Gear backlash

0.2~0.3 (0.0078~0.0118)

0.5 (0.0196)

Replacement

18

35-4 92ZV-2 Service Standard Torque Converter and Transmission Group Control Valve

Control Valve

1

3

8

7

6

2 92V2U35004

Note Numbers correspond to the REF. number on page 35-3.

35-5 92ZV-2 Service Standard Torque Converter and Transmission Group Torque Converter Gear Pump

Torque Converter Gear Pump A 6

4

1

10

7

2

001A

8

9 3

5 11, 12 Section A-A Inlet

A 92V2U35002

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

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

Gear pump specifications Theoretical discharge

73.6 cm3/rev (4.49 in3/rev)

Maximum operation pressure

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

Maximum operation speed

2,600 min-1 (rpm)

Actual discharge

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

35-6 92ZV-2 Service Standard Torque Converter and Transmission Group Clutch Plate Thickness/Piston Stroke

Clutch Plate Thickness/Piston Stroke

T2 L3

T2 L3

T1 L3

T2 L3 T2 L3

T4 L3

Idler gear section

T2 L3

T3 L3

T2 L3

: T1: 11 N-m (1.1 kgf-m) (8.1 lb-ft) T2: 53 N-m (5.4 kgf-m) (39 lb-ft) T3: 230 N-m (23 kgf-m) (170 lb-ft) T4: 883 N-m (90 kgf-m) (651 lb-ft)

K92V2E34001

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

35-7 92ZV-2 Service Standard Torque Converter and Transmission Group 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.

Name of clutch

Friction plate

Steel plate

Return spring

Forward clutch

7

6

20

Reverse clutch

7

6

20

1st speed clutch

9

8

20

2nd speed clutch

5

4

20

3rd speed clutch

5

4

20

4th speed clutch

5

4

20

Outer dia.

ø192 (7.55 in)

ø203.2 (7.99 in)

—

Inner dia.

ø123.8 (4.87 in)

ø133.5 (5.25 in)

—

When new

3.3±0.1 (0.13±0.004 in)

2.6±0.1 (0.10±0.004 in)

—

Wear limit

3.1 (0.12 in)

2.4 (0.09 in)

—

Dimension (mm) (in) Thickness

Piston stroke mm (in) Clutch

Standard value

Forward clutch

3.3±0.5 (0.13±0.02)

Reverse clutch

3.3±0.5 (0.13±0.02)

1st speed clutch

3.5±0.5 (0.14±0.02)

2nd speed clutch

2.1±0.5 (0.08±0.02)

3rd speed clutch

2.1±0.5 (0.08±0.02)

4th speed clutch

2.1±0.5 (0.08±0.02)

35-8 92ZV-2 Service Standard Torque Converter and Transmission Group Clutch Oil Pressure

Clutch Oil Pressure

1 1 6 6 4 4

9 7 7

2

3 3

2

8 8 5 5

10

K92V2U33001 92V2U35003

Clutch oil pressure standard value (Oil temperature 50~80ºC (120~180ºF)) Oil pressure MPa (kgf/cm2) (psi) No.

Measuring port location

Measuring port size

Engine revolution (rpm) 800 (Low idle)

2,200 (High idle)

Shift lever position

Torque converter inlet

PF1/4

0.2~0.68 (2.0~7.0) (28~99.5)

0.4~0.7 (4.0~7.5) (57~107)

All speed range

2

Main oil pressure

PT1/8

1.8±0.15 (18±1.5) (256±21)

1.9±0.15 (19±1.5) (270±21)

All speed range

3

Forward clutch oil pressure

PF1/4

1.8±0.15 (18±1.5) (256±21)

1.9±0.15 (19±1.5) (270±21)

Forward

Reverse clutch oil pressure

PF1/4

1.8±0.15 (18±1.5) (256±21)

1.9±0.15 (19±1.5) (270±21)

Reverse

1st speed clutch oil pressure

PF1/4

1.8±0.15 (18±1.5) (256±21)

1.9±0.15 (19±1.5) (270±21)

1st speed

2nd speed clutch oil pressure

PF1/4

1.8±0.15 (18±1.5) (256±21)

1.9±0.15 (19±1.5) (270±21)

2nd speed

3rd speed clutch oil pressure

PF1/4

1.8±0.15 (18±1.5) (256±21)

1.9±0.15 (19±1.5) (270±21)

3rd speed

8

4th speed clutch oil pressure

PF1/4

1.8±0.15 (18±1.5) (256±21)

1.9±0.15 (19±1.5) (270±21)

4th speed

9

Lock-up clutch oil pressure (opt)

PT1/8

—

1.9±0.15 (19±1.5) (270±21)

All speed range

10

Transmission lubrication oil pressure

PT1/2

0.01~0.1 (0.1~1.0) (1.4~14)

0.05~0.2 (0.5~2.5) (7~36)

All speed range

4 5 6 7

Clutch oil pressure

1

44-1 92ZV-2 Disassembly & Reassembly Hydraulic Group

92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning ............................................................................. 44-2 Hydraulic Parts Disassembly and Assembly Cautions ............................................................................. 44-3 Hydraulic Pump Assembly ...................................... 44-4 Hydraulic Cylinder ................................................... 44-19 Pilot Valve................................................................ 44-32 Multiple Control Valve.............................................. 44-53 Orbitrol® ................................................................... 44-59 Steering Valve ......................................................... 44-69 Stop Valve ............................................................... 44-74 Fan Motor ................................................................ 44-78

44-2 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning

Hydraulic Parts Removal and Installation Warning Disassembly and reassembly work of hydraulic parts greatly depends on the working area and working condition (soon after operation or not).

Understand the following items well and work safely.

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

- Apply the parking brake and block tires with chocks to prevent wheels from moving.

- Be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

- Relieve the internal pressure from the hydraulic line and hydraulic tank.

- Use signals as agreed upon before starting work.

- Do not enter the hazardous area.

- When removing a heavy load over 20 kg (44 lbs), use a crane or a lift device.

- Stay out of the working area while using a crane.

- While working with the boom raised, put safety blocks or supports to prevent it from dropping suddenly.

- The temperature at each part may be high soon after the engine is stopped. Be careful not to get burned.

- When removing pipes, place a container to catch the drained oil.

IMPORTANT - Cover the disconnected hoses and pipes with plastic caps or plugs to protect them from dust, water and dirt.

- Apply the specified torque to tighten each part.

44-3 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Disassembly and Assembly Cautions

Hydraulic Parts Disassembly and Assembly Cautions Hydraulic parts may be very delicate. When disassembling or reassembling, handle with care.

Understand the following well to perform disassembly and reassembly work.

Hydraulic parts disassembly cautions - Completely drain hydraulic oil from parts. Clean unit before disassembly. Plug each open ports.

- Work in a well ventilated area.

- Before disassembling, put a matchmark on each alignment point.

- When clamping the part in a vice, use a copper plate so as not to damage it.

- Because hydraulic parts may be delicate, do not drop or scratch them.

- When disassembling, do not hit or pry the parts by force. The parts may be burred and scored, which may cause oil leakage or poor performance.

- Do not disassemble adjusting screws unless needed.

- When work is stopped, protect removed parts from dirt and debris.

- Preserve disassembled parts with oil. After cleaning, do not dry with compressed air. It may cause rust due to condensation.

- Carefully place the removed parts in the order it was removed so as to see how they came apart.

Hydraulic parts assembly cautions - Check the surface and inside of the parts for burrs, scores, dirt, or rust.

- Replace O-rings and seals with new ones.

- Before reassembly, apply a thin coat of hydraulic oil or grease to the O-rings and seals.

- Apply the specified torque to tighten parts.

- After reassembly, plug the ports so as not to allow foreign material to enter.

44-4 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic Pump Assembly Hydraulic pump assembly removing and installing

2. Remove the hydraulic pump retainer bolts.

Hydraulic pump assembly removing

3. Remove hydraulic pump (1)(2).

: Bolt: 90 N-m (9.2 kgf-m) (67 lb-ft)

: Hydraulic pump (1): 35 kg (80 lbs) Hydraulic pump (2): 30 kg (70 lbs)

DANGER Entering the articulation area while engine is running may cause serious injury or death.

So, when entering the area, stop the engine and place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel.

Hydraulic pump assembly installing To reinstall the hydraulic pump assembly, follow the above removal procedure in reverse order.

CAUTION Removing hoses and plugs without bleeding residual pressure could cause injuries or burns from hot oil under pressure.

Before removing hoses and plugs, relieve residual pressure. Relieve internal pressure from hydraulic tank to prevent oil from spraying.

Before starting work: - Remove the cab and the floor board by referring to Section 14.

- Clean the area around the hydraulic pump.

Hydraulic pump installation cautions - Replace all gaskets and O-rings during reinstallation.

- When replacing hydraulic pumps or when draining hydraulic oil for extended periods, it is important to prime the hydraulic system properly.

Air will be in the lines that go to and come from the pump. After a pump has been installed, or when the hydraulic oil has been drained for extended time periods, air will not purge easily from the lines, and this could lead to pump damage.

WARNING 4 1 3

4

2

3 92V2E44001

1. Disconnect outlet hoses (3) and suction pipes (4) from hydraulic pump (1)(2).

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

Oil injection hazard!

Hydraulic oil can penetrate skin. When performing this procedure: - Release all trapped circuit pressure prior to starting any procedure involving hydraulic oil.

- Wear protective gloves.

- Wear eye and face protection.

- Stay clear of areas where air may be purged.

- Route oil into a receiving canister [such as a 5 gallon bucket] by use of an additional hose.

- Rotate pump at a low RPM.

44-5 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

IMPORTANT - Fill the inlet port of the hydraulic pump with clean hydraulic oil and rotate the pump shaft by hand prior to installing the pump. It should rotate smoothly.

Prior to installing pump and plumbing to pump, remove all caps, plugs, and covers from pump and piping.

- While reinstalling the hydraulic pump, take care not to allow dust, dirt, or foreign material into the case.

- Check the oil level of the hydraulic tank.

- Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe. Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 L).

- Run the engine at low-idling speed for 5 minutes or more. Do not operate any hydraulic functions during this period.

Note If the engine speed is set to high-idling just after starting, the pump may be seized.

- Actuate cylinders 5 to10 times to almost full stroke, but do not fully extend or retract any of the cylinders at this time.

- Confirm that there is no abnormal noise or operation, and be sure that there is no excessive heat.

Inspect the hydraulic oil at the sight gauge to be sure that there are no bubbles which may indicate air being drawn in at the suction side of the pump.

If there are any bubbles, correct the cause prior to using the machine, as this may contribute to premature pump failure.

Hydraulic pump assembly disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

IMPORTANT - Handle pumps carefully.

- In case hydraulic system breaks down, do not disassemble the pump first.

Check the whole hydraulic circuit and find its cause. Confirm the cause, then repair.

- When the pump is broken down, not only fix or replace it but also inspect the failure cause to prevent recurrence.

WARNING Do not attempt to disassemble the pump assembly unless otherwise required, as it should significantly affect the pump performance or may cause secondary problems.

44-6 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic pump assembly cross section and tightening torque Loading and pilot and brake pump

T1 T2

92V2U44029

: T1: 177 N-m (18 kgf-m) (130 lb-ft) T2: 275 N-m (28 kgf-m) (203 lb-ft)

44-7 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Steering pump

T1

92V2U44030

: T1: 177 N-m (18 kgf-m) (130 lb-ft)

44-8 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Oil seal replacement procedure

[Example 2]

There are two kinds of the pump drive gear shaft unit.

One has one oil seal only, and the other has an additional dust seal or oil seal outside.

Replace the oil seals and O-rings between the double and triple pumps which are allowed to be separated.

Front cover

[Example 1] Oil seal

Snap ring

Drive gear shaft

Oil seal Drive gear shaft

Oil seal

Snap ring 90ZV44049

In case of Example 2 Front cover

90ZV44048

1. After removing the outer oil seal, remove the snap ring and the inner oil seal.

2. When removing the oil seals, remove any scores on the front cover and the drive gear shaft.

3. Cover the drive gear shaft with vinyl electrical tape to protect the splines.

4. Apply a thin coat of grease to the oil seal and the lip unit.

5. Install the seal straight.

44-9 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Loading and pilot and brake pump disassembling

IMPORTANT - If a pump must be repaired, be sure no pieces of damaged pump material has scatted through hydraulic system.

- New parts must be "broken in" and performance must be checked.

- Put appropriate matchmarks and/or place the disassembled parts and units in disassembled order to help and assure correct reassembling of them.

- Take great care not to damage the mating face and sliding surface of each part.

- Clean the pump surface and power input shaft while disassembling. Prevent foreign materials entering into the pump inside.

3 4 5

92V2U44032

2. Remove cover (3).

3. Remove seal kit (4)(5) from cover (3).

7

8 O-ring

6

Plate

92V2U44033

1 2 92V2U44031

1. Place the hydraulic pump assembly on a firm and flat workbench so the bracket comes bottom side as shown.

Remove cover fixing bolt (1). : Bolt (1): 275 N-m (28.0 kgf-m) (203 lb-ft) Note - It is recommended to fix the pump onto the bottom using the bracket mounting bolts.

- If you remove the plate on the second pump intake port, remove bolt (2). Remove the plate before removing bolt (1). : Bolt (2): 67 N-m (6.8 kgf-m) (49 lb-ft)

4. Put a matchmark and remove wear plate (6) on the cover side.

Note For easier removal of wear plate (6), slightly move up drive gear (7) or driven gear (8).

CAUTION Wear plate (6) is an asymmetric part. If it is installed incorrectly, it may cause serious pump damage.

Be sure to put a matchmark for correct installation.

5. Put matchmarks at the shaft end of drive gear (7) and driven gear (8), and pull out them to remove.

44-10 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

5

8

12,13 10

1

3

4

10

9

2 7

6

Pin

15

Nut removing order

11 14 92V2U44034

6. Put a matchmark and slowly separate gear case (9) and carrier (10).

Wear plate (11) in gear case (9) on the carrier side should remain there. Be careful not to drop it out of the case.

92V2U44035

9. Remove nut (14) and washer (5) from carrier (10).

Remove nut (14) diagonally as shown above. : Nut (14): 177 N-m (18.0 kgf-m) (130 lb-ft)

Note There is a locating pin on gear case (9).

16

7. Remove seal kit (12)(13) from carrier (10).

17 10

9 92V2U44036

11

10. Put a matchmark and slowly separate carrier (10) and gear case (16).

11. Remove seal kit (17) from carrier (10).

K90V2U44005

8. Put a matchmark and remove wear plate (11) from gear case (9).

CAUTION Wear plate (11) is an asymmetric part. If it is installed incorrectly, it may cause serious pump damage.

Be sure to put a matchmark for correct installation.

44-11 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

21

19 16

16 20

18

22

92V2U44039

92V2U44037

12. Put a matchmark and remove wear plate (18) on the cover side.

Note For easier removal of wear plate (18), slightly move up drive gear (19) or driven gear (20).

14. Put a matchmark and slowly separate gear case (16) and bracket (21).

Wear plate (22) in gear case (16) on the bracket side should remain there. Be careful not to drop it out of the case.

15. Remove wear plate (22) from gear case (16).

CAUTION Wear plate (18) is an asymmetric part. If it is installed incorrectly, it may cause serious pump damage.

Be sure to put a matchmark for correct installation.

CAUTION Wear plate (34) is an asymmetric part. If it is installed incorrectly, it may cause serious pump damage.

Be sure to put a matchmark for correct installation.

21

16

23

19

20 92V2U44038 92V2U44040

13. Put matchmarks at the shaft end of drive gear (19) and driven gear (20), and pull out them to remove.

16. Remove seal kit (23) from bracket (21).

44-12 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Loading and pilot and brake pump assembly cautions 21

- Clean each part carefully and avoid foreign material from entering the pump. Especially, clean the bolts and bolt holes carefully so that no dirt or oil remain.

- Fit in the oil seals at appropriate positions without kink or bend.

24 92V2U44041

- Apply grease on the sliding surfaces when installing gears.

Stud bolt installation

17. Remove stud bolts (24) from bracket (21). : Bolt (24): 78.5 N-m (8.0 kgf-m) (58 lb-ft)

Install stud bolts (24) to bracket (21) so that the chamfered side of stud bolt (24) is screwed into bracket (21).

Screw stud bolt (24) fully to the end of threaded portion. : Bolt (24): 78.5 N-m (8.0 kgf-m) (58 lb-ft)

21

Oil seal installation

26

25

21

92V2U44042

18. Remove snap ring (25) using plier.

Insert a screwdriver from the bearing hole for the drive gear, and push out oil seal (26) from its back side by hitting the screwdriver with a hammer, etc.

Note Take care not to scratch the parts around when inserting and hitting the screwdriver.

Loading and pilot and brake pump assembling To reassemble the hydraulic pump assembly, follow the above disassembling procedure in reverse order.

26

25

92V2U44042

Apply grease on the external surface for easier installation. This also prevent oil seal (26) from being torn.

Prepare and set a supporting tool (steel pipe) to oil seal (26), and press in or hit the tool with a hammer.

Fix oil seal (26) using snap ring (25).

Tool specifications Outer diameter: Oil seal outer diameter - 2 mm (0.08 in) Inner diameter: Input axis + 5 mm (0.20 in) Length: 100 mm (3.94 in) or longer

44-13 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Seal kit installation

Wear plate installation

Intake side

3 4 Wear plate (6) (18)

5

92V2U44032

92V2U44044

When installing seal kit (4)(5) to cover (3), insert backup ring (4) in the groove while wrapping it over the bush, then, insert seal (5) into the groove.

Incorrect installation of the seals may cause damage to the seal or the pump. Make sure to fit in the seals at appropriate positions without kink or bend.

Intake side

Gear case installation Wear plate (11) (22) 92V2U44045

16

9

The wear plates are asymmetric parts. If they are installed incorrectly, it may cause serious pump damage. Be sure to put matchmarks before removing them for correct installation.

Pin

Drive gear installation

Wear plate 92V2U44043

Gear cases (9)(16) have locating pin.

For easier installation, install the wear plate into the gear case before installing the gear case. If you install the wear plate after installing the gear case, be careful the wear plate and the gear plate do not get stuck.

Before installing drive gear (19) to gear case (16), apply grease to the lip of oil seal (26) to avoid being damaged by drive gear (19).

44-14 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Steering pump disassembling

IMPORTANT

3

- If a pump must be repaired, be sure no pieces of damaged pump material has scatted through hydraulic system.

- New parts must be "broken in" and performance must be checked.

- Put appropriate matchmarks and/or place the disassembled parts and units in disassembled order to help and assure correct reassembling of them.

- Take great care not to damage the mating face and sliding surface of each part.

- Clean the pump surface and power input shaft while disassembling. Prevent foreign materials entering into the pump inside.

4 5

92V2U44047

2. Remove cover (3).

3. Remove seal kit (4)(5) from cover (3).

Plate

7

8 6 2

O-ring

92V2U44048

1 92V2U44046

1. Place the hydraulic pump assembly on a firm and flat workbench so the bracket comes bottom side as shown.

Remove cover fixing bolt (1).

4. Put a matchmark and remove wear plate (6) on the cover side.

Note For easier removal of wear plate (6), slightly move up drive gear (7) or driven gear (8).

: Bolt (1): 177 N-m (18.0 kgf-m) (130 lb-ft) Note - It is recommended to fix the pump onto the bottom using the bracket mounting bolts.

- If you remove the plate on the second pump intake port, remove bolt (2). Remove the plate before removing bolt (1). : Bolt (2): 108 N-m (11 kgf-m) (80 lb-ft)

CAUTION Wear plate (6) is an asymmetric part. If it is installed incorrectly, it may cause serious pump damage.

Be sure to put a matchmark for correct installation.

5. Put matchmarks at the shaft end of drive gear (7) and driven gear (8), and pull out them to remove.

44-15 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

15

12,13

10 17 16

9

10

Pin

11 14

92V2U44049

6. Put a matchmark and slowly separate gear case (9) and carrier (10).

Wear plate (11) in gear case (9) on the carrier side should remain there. Be careful not to drop it out of the case.

92V2U44051

9. Remove sleeve (14).

10. Put a matchmark and slowly separate carrier (10) and gear case (15).

11. Remove seal kit (16)(17) from carrier (10).

Note There is a locating pin on gear case (9).

7. Remove seal kit (12)(13) from carrier (10).

9

18 11

92V2U44052

12. Put a matchmark and remove wear plate (18).

92V2U44050

8. Put a matchmark and remove wear plate (11) from gear case (9).

CAUTION Wear plate (11) is an asymmetric part. If it is installed incorrectly, it may cause serious pump damage.

Be sure to put a matchmark for correct installation.

CAUTION Wear plate (18) is an asymmetric part. If it is installed incorrectly, it may cause serious pump damage.

Be sure to put a matchmark for correct installation.

44-16 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

21

15

24

19 23 20 92V2U44053

13. Put matchmarks at the shaft end of drive gear (19) and driven gear (20), and pull out them to remove.

92V2U44055

16. Remove seal kit (23)(24) from bracket (21).

21 21

22

26

15 25

Pin

92V2U44056 92V2U44054

14. Put a matchmark and slowly separate gear case (15) and bracket (21).

Wear plate (22) in gear case (15) on the carrier side should remain there. Be careful not to drop it out of the case.

Note There is a locating pin on gear case (15).

15. Remove wear plate (22) from gear case (15).

17. Remove snap ring (25) using plier.

Insert a screwdriver from the bearing hole for the drive gear, and push out oil seal (26) from its back side by hitting the screwdriver with a hammer, etc.

Note Take care not to scratch the parts around when inserting and hitting the screwdriver.

44-17 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Steering pump assembling

Seal kit installation

To reassemble the hydraulic pump assembly, follow the above disassembling procedure in reverse order.

21

Steering pump assembly cautions

24

- Clean each part carefully and avoid foreign material from entering the pump. Especially, clean the bolts and bolt holes carefully so that no dirt or oil remain.

23

- Fit in the oil seals at appropriate positions without kink or bend.

- Apply grease on the sliding surfaces when installing gears.

Oil seal installation

92V2U44055

When installing seal kit (24)(23) to bracket (21), insert back-up ring (24) in the groove while wrapping it over the bush, then, insert seal (23) into the groove.

Incorrect installation of the seals may cause damage to the seal or the pump. Make sure to fit in the seals at appropriate positions without kink or bend.

Note Install the seal kits to cover (3) and carrier (10) in the same manner.

21

Gear case installation 26 25 92V2U44056

15

Apply grease on the external surface for easier installation. This also prevent oil seal (26) from being torn.

Prepare and set a supporting tool (steel pipe) to oil seal (26), and press in or hit the tool with a hammer.

Fix oil seal (26) using snap ring (25).

Tool specifications Outer diameter: Oil seal outer diameter - 2 mm (0.08 in) Inner diameter: Input axis + 5 mm (0.20 in) Length: 100 mm (3.94 in) or longer

9

Pin Wear plate

92V2U44057

Gear cases (9)(15) have locating pin.

For easier installation, install the wear plate into the gear case before installing the gear case. If you install the wear plate after installing the gear case, be careful the wear plate and the gear plate do not get stuck.

44-18 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Wear plate installation

Sleeve installation

15 17 Intake side

16

10 Wear plate (6) (18) 92V2U44044

14

92V2U44051

When installing sleeve (14) into carrier (10), press the sleeve lightly with your fingers and insert it into the sleeve hole of the carrier.

Install seal kit (16)(17) to carrier (10), and install carrier (10) to gear case (15). Be advised that the side with sleeves (14) should come to the pump rear side when installing carrier (10).

If sleeve (14) comes out while installing carrier (10), push it in after installing carrier (10).

Intake side

Wear plate (11) (22) 92V2U44045

The wear plates are asymmetric parts. If they are installed incorrectly, it may cause serious pump damage. Be sure to put matchmarks before removing them for correct installation.

Drive gear installation Before installing drive gear (19) to gear case (15), apply grease to the lip of oil seal (26) to avoid being damaged by drive gear (19).

44-19 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder removing and installing 3

Boom cylinder removing (The illustration shows the left side of the machine.)

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park 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 stand (A) under the boom to support it.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Use a stepladder or work platform, and do not stand on the machine.

2 1

90ZV44006

1. Attach sling to boom cylinder (1).

Disconnect grease hose (2) from pin (3), and then remove pin (3). : Boom cylinder: 240 kg (530 lbs)

Clean the area around the cylinder and piping.

4

Relieving residual pressure from pipe

5

90ZV44007

2. Disconnect hose (4) and pipe holder (5).

Stand (A)

90ZV44005

(a) Raise the boom. When the boom is approximately 30 cm (1 foot) above stand (A), stop the engine. (b) Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. (c) First press down on the hydraulic tank cap to vent residual pressure, then open the cap of the hydraulic tank. Leave hydraulic tank cap loosely on top of tank opening.

44-20 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

1

6

90ZV44008

90ZV44011

3. Remove oil pipe (6), and then push the rod into the cylinder to shorten the length of the cylinder.

6. Sling boom cylinder (1), and lower it onto the ground.

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

For the detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-26.

Boom cylinder installing To reinstall the boom cylinder, follow the above removal procedure in reverse order.

8

7

92V2U44002

Boom cylinder installation cautions Be sure the pins accept grease after installation.

IMPORTANT

4. Remove lock bolt (8) for pin (7).

After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Cylinder air bleeding procedure (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

9

Note Stop the piston about 100 mm (4.0 in) before stroking fully.

7

90ZV44010

5. Insert jack bolts (9) to pin (7), and then remove pin (7).

(b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-21 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder removing and installing Bucket cylinder removing 1

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

- Place the boom and the attachment onto the ground.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Use a step, and do not stand on the machine.

Clean the area around the cylinder and piping.

Relieving residual pressure from pipe (a) Lower the boom and the attachment onto the ground. (b) Stop the engine and move the attachment and boom levers back and forth. (c) Open the cap of the hydraulic tank to relieve the residual pressure.

90ZV44014

1. Remove the coupler of bucket leveler switch (1).

3 2

92V2U44003

2. Attach sling to bucket cylinder (3).

After that, remove pin (2). : Bucket cylinder: 130 kg (290 lbs)

3

4

90ZV44015

3. Lift bucket cylinder (3) and disconnect the bucket cylinder from the lever. Remove rod (4).

44-22 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

8 6

3

5

92V2U44004

90ZV44016

4. Start the engine and shorten the cylinder rod. Stop the engine and disconnect hose (5)(6).

6. Disconnect the grease pipe and then remove pin (8).

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

7. Slowly lift up bucket cylinder (3). Lower the bucket cylinder onto the ground.

For the detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-26.

Bucket cylinder installing To reinstall the bucket cylinder, follow the above removal procedure in reverse order.

7 90ZV44017

5. Remove bucket leveler bracket (7).

44-23 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder installation cautions - Be sure the pins accept grease after installation.

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

Refer to "Attachment Leveler" page 15-6.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Cylinder air bleeding procedure (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note Stop the piston about 100 mm (4.0 in) before stroking fully. (b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-24 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder removing and installing 5

Steering cylinder removing

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

- Place the boom and the attachment onto the ground.

- Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line.

- Press the cap of the hydraulic tank downward to vent, then open the cap to relieve the internal pressure from the tank.

- Place a "DO NOT START!" tag on the steering wheel or the operator's seat.

4

3 92V2U44005

2. There is pin (5) at the link between front chassis (3) and steering cylinder (4). Remove pin (5), and then push the rod into the cylinder to shorten the length of the cylinder. : Oil will be drained from the oil port of the cylinder. Place a container at the oil port to catch the drained oil.

6

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

7

1

4 92V2U44006

3. Disconnect grease pipe (6) and remove pin (7).

4. Remove the steering cylinder assembly (4).

2 90V2E44005

1. Disconnect hoses (1)(2).

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

: Steering cylinder: 40 kg (90 lbs) For detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-26.

44-25 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder installing

Steering cylinder installation cautions

To reinstall the steering cylinder, follow the above removal procedure in reverse order.

1. When reinstalling the pins Be sure the pins accept grease after installation.

IMPORTANT Insert shims so that the clearance between the chassis and the cylinder is 1.2 mm (0.047 in) or less.

Place approximately the same number of shims under the cylinder as on top of the cylinder. Refer to "Linkage Pin Standard Clearance Values" page 15-3.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area can cause injury or death.

When turning the steering wheel while engine is running, do not enter the articulation area of the machine.

If a person is in the articulation area, do not start the engine.

2. Bleed 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.

Cylinder air bleeding procedure (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note Stop the piston about 100 mm (4.0 in) before stroking fully. (b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-26 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling and assembling Hydraulic cylinder cross section and tightening torque

IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Boom cylinder

T1

T2 92V2U44007

: T1: 4,756 N-m (485 kgf-m) (3,509 lb-ft) T2: 330 N-m (33.7 kgf-m) (244 lb-ft)

Bucket cylinder

T3

T4

90V2E44007

: T3: 5,900±300 N-m (600±30.5 kgf-m) (4,320±220 lb-ft) T4: 880±90 N-m (89.7±9.2 kgf-m) (649±67 lb-ft)

44-27 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder

T6 T5 90ZV44004J

: T5: 1,275 N-m (130 kgf-m) (941 lb-ft) T6: 2,157 N-m (220 kgf-m) (1,592 lb-ft)

Cylinder

Piston nut width across flats

Boom

90 (3.54) – M60 x 2

Bucket

90 (3.54) – M60 x 2

Steering

55 (2.17) – M36 x 1.5

mm (in) – Thread size

44-28 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling Note The bucket cylinder disassembling procedure is described below. For other cylinders, follow the same procedure.

4

95ZV44006

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

Repair stand 95ZV44004

1. Install the bottom side of the cylinder to the repair stand.

Repair stand

4 Matchmark

3

Wooden block 95ZV44007

2 1 95ZV44005

2. Put the matchmarks on rod cover (1) and cylinder tube (2). Remove rod cover bolt (3). : Bolt (3): 330 N-m (33.7 kgf-m) (244 lb-ft) (Boom cylinder) 880 N-m (89.7 kgf-m) (649 lb-ft) (Bucket cylinder) Rod cover (1): 2,157 N-m (220.0 kgf-m) (1,592 lb-ft) (Steering cylinder)

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

44-29 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Matchmark

5

4

7

6

4

6

95ZV44008

95ZV44010

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

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

8

6

9

10

12

9 10

8

C

Hydraulic jack

11

11

(Boom cylinder)

(Steering cylinder)

Hydraulic cylinder

K90V2J44020 95ZV44009

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

Piston nut width across flats mm (in)

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

Boom cylinder

90 (3.54)

4,756 (485) (3,509)

Bucket cylinder

90 (3.54)

5,900 (600) (4,320)

Steering cylinder

55 (2.17)

1,275 (130) (941)

8

21

8

(Bucket cylinder)

90V2E44008

8. Remove wear ring (8), square ring (9), slipper ring (10), O-ring (11), wear ring (12) and piston packing (21).

(There is no wear ring (12) for steering cylinder.)

44-30 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

9

10 20 19

18 17 16 13

1

4 (Bucket cylinder) (S/N 9001~9003) 95ZV44013

90V2E44009

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

20 1 20 16 17

19

18

19

18

17

16

13

1 20 16 17 13

19

18

15

14

(Bucket cylinder) (S/N 9004~) K92V2E44001

(Steering cylinder)

(Boom cylinder) 90V2E44018

10. Remove dust seal (13), stop ring (14), scraper ring (15), back-up ring (16), U-packing (17), buffer ring (18), back-up ring (19) and O-ring (20) from rod cover (1).

Hydraulic cylinder assembling To reassembling the hydraulic cylinders, follow the above removal procedure in reverse order.

44-31 92ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder assembly cautions

Backup ring

Before starting work: - Be sure to replace all the seals and packings.

- Clean and check all the parts. If a part is damaged, replace it.

- Before reassembling the parts, apply a coat of hydraulic oil to the parts.

2

Ring installation

CAUTION

3

Hot oil can cause injury or burns.

Avoid contact with hot oil.

95ZV44017

Before installing back-up ring (2) and O-ring (3), heat the back-up ring.

Slipper ring

Note This is because the inner diameter of the back-up ring is smaller than the outer diameter of the rod cover. To easily attach the back-up ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.

10

Be careful not to over expand the back-up ring. After installation, wait until the back-up ring is cooled, and then insert the rod cover into the cylinder tube.

Rod cover installation K90V2J44021

Put slipper ring (10) into hot oil to heat the ring to 120~150ºC (250~300ºF).

Note This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston. Therefore, heat the slipper ring to expand its inner diameter for easy attachment.

Attach the slipper ring while taking care not to damage the ring by over expansion.

After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

K65V2E44013

Reinstall the rod cover of the steering cylinder, screw the rod cover using a spanner wrench. Screw in and tighten the set screw. Stake the set screw. : 2,157 N-m (220 kgf-m) (1,592 lb-ft)

44-32 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot Valve Pilot valve removing and installing

Downshift button

Pilot valve

Pilot valve removing 2

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

- Lower the attachment onto the ground, and then relieve the internal pressure from the line.

- Relieve the internal pressure from the hydraulic tank.

3

95ZVE44039

2. Disconnect electrical line (2) of the Downshift button.

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

Note Before disconnecting the electrical couplers, be sure to put matchmarks on them.

Control box

4

A

4

A

1 Cover mount

5

95ZVE44038

1. Open the cab door (the right hand side).

Remove cover (1) from the control box.

Pilot valve 95ZVE44040

4. Remove knob (4), and then, separate Downshift button (5).

44-33 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

10

8 9 6

7

95ZVE44041

5. Remove boot (6) and covers (7)~(10).

B

Pilot valve

A

11 B

A 11

11 11

92V2U44008

6. Disconnect hoses (11) from the pilot valve. : Drain oil: Approx. 1 L (0.3 gal) Note Before disconnecting the hoses, be sure to put matchmarks on them.

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

44-34 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

12 12

Adapter 2

13 14

Adapter 1

13

14

15 95ZVE44042

7. Loosen nut (14) and disconnect vinyl tube (12) and rod (13).

8. Remove nut (15) (4 pcs) and pull up the pilot valve to remove it. : Adapter 1: 29.4 N-m (3.0 kgf-m) (21.7 lb-ft) Adapter 2: 49.0 N-m (5.0 kgf-m) (38.0 lb-ft) : Pilot valve: 6.5 kg (14.3 lbs)

Pilot valve installing To reinstall the pilot valve, follow the removal procedure in reversed direction.

Pilot valve installation cautions After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage.

If the oil level is too low, add hydraulic oil to the tank.

44-35 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling and assembling (S/N 9001~9017) IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve cross section and tightening torque

T7 L1

T7 L1 T4

T4

T4

T4

T6

A

T6

B

T port:

T8 L1

T1

T

T5

T

T3

T3

T3

T

P port:

P

T3

T3

P

T3 Port 1

Port 2

P

T3

T2 A

Port 3

Cross section A-A

Port 4

Port 1, 2

B Port 3, 4

Cross section B-B 95ZVE44037

: T1: 49.0 N-m (5.0 kgf-m) (36.0 lb-ft) T2: 29.5 N-m (3.0 kgf-m) (22.0 lb-ft) T3: 20.5 N-m (2.1 kgf-m) (15.2 lb-ft) T4: 17.0 N-m (1.7 kgf-m) (12.3 lb-ft) T5: 14.5 N-m (1.5 kgf-m) (10.7 lb-ft) T6: 9.0 N-m (0.9 kgf-m) (6.5 lb-ft) T7: 7.0 N-m (0.7 kgf-m) (5.1 lb-ft) T8: 1.5 N-m (0.15 kgf-m) (1.1 lb-ft) L1: Screw lock agent (Loctite® 241) application : Pilot valve: 6.5 kg (14.5 lbs)

44-36 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling 2

(Illustrated on the boom side. Disassemble the bucket side in the same manner.)

1

3

4

1

5

4. Put match-marks on cover assembly (2) and case assembly (5). Then, remove the cover from the case assembly.

2 [Cross section view]

95ZVE44005

95ZVE44007

7 6

1. Plug all ports of the pilot valve and rinse it with illuminating kerosene.

5

2. Clamp the pilot valve in a vise.

Pull up boot (1) to remove it from cover (2).

95ZVE44004

7 4 3

95ZVE44006

3. Loosen socket bolts (3), which look deeper, with a hexagon (Allen) wrench.

6

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft) 95ZVE44003

Note Do not loosen bolt (4) here, which is later loosened in step 18.

5. Remove plug (6) by carefully pushing it up with a screwdriver while pressing push rod (7) with a cloth.

Note Carefully remove plug (6) as plug (6) and push rod (7) may spring out by the force of return spring inside.

44-37 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

8 6

7

11 5

12

10

9

95ZVE44011

95ZVE44010

6. Remove push rod (7), plug (6), reducing valve parts as an assembly, and return spring (8) from case assembly (5).

8. Remove spool (11), secondary pressure spring (10) and plane washer (12) if assembled.

Note Put a match-mark on plug (6) and case assembly (5).

Note Plane washer (12) is used for the preset adjustment of spring (10), and may be of a different thickness or not used depending on the spool assembly. Make sure to keep the disassembled parts per each port.

15

Slide

9 95ZVE44009

14

7. To disassemble the reducing valve assembly, push spring seat (9) to compress secondary pressure spring (10), and slide spring seat (9) so that spool (11) is released from the bigger hole of the spring seat.

Note - Do not damage the spool surface.

- Do not push spring seat (9) 6 mm (0.24 in) or more.

13

6

7 95ZVE44008

9. Pull out spring (13) and spring seat (14) from push rod (7).

Note Only the port 1 and port 3 have spring (13) and spring seat (14). Make sure to keep the disassembled parts per each port.

Refer to page 44-35 for the port location.

44-38 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

17

5

18

7

15

6

Port 1&2

20

Port 3&4

95ZVE44013

95ZVE44015

10. Remove push rod (7) from plug (6). Remove O-ring (15) from plug (6).

12. Put match-marks on case assembly (5) and plate (20). Remove socket bolt (17) and nut (18) using the hexagon (Allen) wrench, and separate case assembly (5) and plate (20).

16

: Socket bolt (17): 20.5 N-m (2.10 kgf-m) (15.2 lb-ft)

19 6 95ZVE44014

11. Remove seal (16) from plug (6) using a small screwdriver.

Note Take care not to damage the internal surface of plug (6).

20 95ZVE44012

13. Remove O-ring (19) from plate (20).

Note Take care not to damage O-ring (19).

44-39 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

24 21

5

95ZVE44019

95ZVE44017

14. Remove O-rings (21) from case assembly (5).

17. Remove O-ring (24) from case assembly (5).

Note Take care not to damage O-ring (21).

Note Take care not to damage O-ring (24).

22 26 26

23

2

27

25 22 5

95ZVE44018

95ZVE44016

15. Clamp case assembly (5) in a vise. Loosen and remove socket bolts (22) on port plate (23).

18. Clamp center plate (25) in a vise. Remove socket bolts (26) in the shallow pits with a hexagon (Allen) wrench.

: Socket bolt (20): 20.5 N-m (2.10 kgf-m) (15.2 lb-ft) 16. Remove port plate (23) from case assembly (5).

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft)

44-40 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

2

27

28 25

27 95ZVE44023

19. Remove cover (2) and detent casing (27) from center plate (25).

Be advised that fixing discs (29) on outer springs (28) may be stuck to detent casing (27) with grease, and could be dropped.

95ZVE44021

21. Remove detent casing (27) from cover (2).

Note The push rod may be fall off the detent bush without the steel ball.

29 27

28

25

30 95ZVE44022

95ZVE44020

20. Remove outer springs (28) and fixing discs (29) on center plate (25).

22. Remove solenoid coil (30) from detent casing (27).

Note While removing solenoid coil (30), do not pull the electrical harness.

44-41 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

32 31 31

34

95ZVE44028

23. Remove lever (31) by loosening socket bolt (32) with a hexagon (Allen) wrench.

95ZVE44026

26. Clamp lever (31) in a vise, and remove nuts (34). : Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)

: Socket bolt (32): 6.9 N-m (0.7 kgf-m) (5.1 lb-ft) Note Loctite® 241 is applied requiring bigger torque to loosen the bolt.

31

33

2

24. Remove cam shaft (33).

25. Take out lever (31) from cover (2).

95ZVE44027

44-42 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

35 (with pre-detent) 2 37

35 (without pre-detent)

36

2 F95ZVE44025

95ZVE44032

28. Remove O-rings (36) from cover (2).

Note Take care not to damage O-rings (36).

35

Tool

2

95ZVE44024

27. Remove assembled detent bush (35), push rod (37), etc. from cover (2) using the tool.

37 95ZVE44031

[Tool]

(Material: SS400)

29. [For the port without pre-detent] Remove push rod (37) from detent bush (35). Put a match-mark on them beforehand.

Center hole (ø2 or less)

30 35

2

45 115V2E44021

44-43 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

37

40

38

41

39

35 95ZVE44030

30. [For the port with pre-detent] Hold detent ring (38) and press to compress spring (39), and then take out balls (40).

Note Be sure to keep balls (40) (4 pcs.).

95ZVE44033

33. Remove scraper (41) from detent bush (35).

Note Be sure not to damage scraper (41) or the internal surface of detent bush (35).

31. Pull out push rod (37).

Pilot valve assembling To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

39 35

Pilot valve assembly cautions - Clean and check all the parts. If any part is defective, replace or repair it.

38

95ZVE44029

- Replace all the O-rings and seals with new ones.

- Apply the specified torque to tighten each main part.

32. Remove detent ring (38) and spring (39) from detent bush (35).

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Measure the resistance of each coil magnet assembly. The resistance should be 62 Ω at normal room temperature [(20ºC) (70ºF)].

If measured in extremely low temperatures the resistance will be less, and at operating temperature the resistance will be higher.

- Be aware that the assembled parts, such as the push rod, spring, etc. are different depending on the ports. Use the correct parts.

44-44 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Push rod (37)

Detent bush (35)

Scraper (41) Scraper (41)

A

Detail of A 95ZVE44035

- Insert scraper (41) in correct direction.

- Do not push push rod (37) too much with the set screw while adjusting the position of the lever (31). It may cause bumping at Neutral position, resulting in unexpected movement at starting the engine.

Push rod (7)

Plug (6) Seal (16) 95ZVE44034

- Install seal (16) in plug (6) in correct direction.

44-45 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling and assembling (S/N 9018~) IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve cross section and tightening torque

A

B

T5 L1 T3 T3

T5 L1

T3

T4

T1 T P T

P

4

2

Port 1

Port 2

Cross section A-A

Port 3

Port 4

Cross section B-B

A

B T2

Port 1, 2

Port 3, 4 K90Z544002

: T1: 49.0 N-m (5.0 kgf-m) (36.0 lb-ft) T2: 29.5 N-m (3.0 kgf-m) (22.0 lb-ft) T3: 17.0 N-m (1.7 kgf-m) (12.3 lb-ft) T4: 9.0 N-m (0.9 kgf-m) (6.5 lb-ft) T5: 7.0 N-m (0.7 kgf-m) (5.1 lb-ft) : Port 1~4 (adapter) 29.5 N-m (3.0 kgf-m) (22.0 lb-ft)

L1: Screw lock agent (Loctite® 241) application : Pilot valve: 6.5 kg (14.5 lbs)

44-46 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling 2

(Illustrated on the boom side. Disassemble the bucket side in the same manner.)

1

3

4 5

1

K90Z544010

4. Put match-marks on cover assembly (2) and case assembly (5). Then, remove the cover from the case assembly.

2 [Cross section view]

95ZVE44007

1. Plug all ports of the pilot valve and rinse it with illuminating kerosene.

7 6 5

2. Clamp the pilot valve in a vise.

Pull up boot (1) to remove it from cover (2).

K90Z544011

7 4 3

95ZVE44006

3. Loosen socket bolts (3), which look deeper, with a hexagon (Allen) wrench.

6

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft) K90Z544012

Note Do not loosen bolt (4) here, which is later loosened in step 18.

5. Remove plug (6) by carefully pushing it up with a screwdriver while pressing push rod (7) with a cloth.

Note Carefully remove plug (6) as plug (6) and push rod (7) may spring out by the force of return spring inside.

44-47 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

6 7

5 8

11

12

10

9

K90Z544013

95ZVE44010

6. Remove push rod (7), plug (6), reducing valve parts as an assembly, and return spring (8) from case assembly (5).

8. Remove spool (11), secondary pressure spring (10) and plane washer (12) if assembled.

Note Put a match-mark on plug (6) and case assembly (5).

Note Plane washer (12) is used for the preset adjustment of spring (10), and may be of a different thickness or not used depending on the spool assembly. Make sure to keep the disassembled parts per each port.

15

Slide

9 95ZVE44009

14

7. To disassemble the reducing valve assembly, push spring seat (9) to compress secondary pressure spring (10), and slide spring seat (9) so that spool (11) is released from the bigger hole of the spring seat.

Note - Do not damage the spool surface.

- Do not push spring seat (9) 6 mm (0.24 in) or more.

13

6

7 95ZVE44008

9. Pull out spring (13) and spring seat (14) from push rod (7).

Note Only the port 1 and port 3 have spring (13) and spring seat (14). Make sure to keep the disassembled parts per each port.

Refer to page 44-35 for the port location.

44-48 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

26 26

2

27

25

7

15

6

95ZVE44013

95ZVE44016

10. Remove push rod (7) from plug (6). Remove O-ring (15) from plug (6).

12. Clamp center plate (25) in a vise. Remove socket bolts (26) in the shallow pits with a hexagon (Allen) wrench. : Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft)

16

27

28 25

6 95ZVE44014

11. Remove seal (16) from plug (6) using a small screwdriver.

95ZVE44023

Note Take care not to damage the internal surface of plug (6).

Note Item numbers (17) through (24) are intentionally omitted in the following steps.

13. Remove cover (2) and detent casing (27) from center plate (25).

Be advised that fixing discs (29) on outer springs (28) may be stuck to detent casing (27) with grease, and could be dropped.

44-49 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

29 27

28

25

30 95ZVE44022

95ZVE44020

14. Remove outer springs (28) and fixing discs (29) on center plate (25).

16. Remove solenoid coil (30) from detent casing (27).

Note While removing solenoid coil (30), do not pull the electrical harness.

2

32

31 27 95ZVE44021

15. Remove detent casing (27) from cover (2).

95ZVE44028

Note The push rod may be fall off the detent bush without the steel ball.

17. Remove lever (31) by loosening socket bolt (32) with a hexagon (Allen) wrench. : Socket bolt (32): 6.9 N-m (0.7 kgf-m) (5.1 lb-ft) Note Loctite® 241 is applied requiring bigger torque to loosen the bolt.

44-50 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

35 (with pre-detent) 31 37

35 (without pre-detent)

33

2 2

95ZVE44027

F95ZVE44025

18. Remove cam shaft (33).

19. Take out lever (31) from cover (2).

31 Tool

2

95ZVE44024

34

21. Remove assembled detent bush (35), push rod (37), etc. from cover (2) using the tool.

95ZVE44026

20. Clamp lever (31) in a vise, and remove nuts (34). : Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)

[Tool]

(Material: SS400) Center hole (ø2 or less)

30 35

2

45 115V2E44021

44-51 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

2

37

40

38

39

36 95ZVE44032

95ZVE44030

24. [For the port with pre-detent] Hold detent ring (38) and press to compress spring (39), and then take out balls (40).

22. Remove O-rings (36) from cover (2).

Note Take care not to damage O-rings (36).

Note Be sure to keep balls (40) (4 pcs.).

25. Pull out push rod (37).

35 39 35

37 95ZVE44031

38

23. [For the port without pre-detent] Remove push rod (37) from detent bush (35). Put a match-mark on them beforehand.

95ZVE44029

26. Remove detent ring (38) and spring (39) from detent bush (35).

44-52 92ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

41

Push rod (37)

Detent bush (35)

Scraper (41) Scraper (41)

A

35

Detail of A 95ZVE44033

95ZVE44035

27. Remove scraper (41) from detent bush (35).

- Insert scraper (41) in correct direction.

Note Be sure not to damage scraper (41) or the internal surface of detent bush (35).

- Do not push push rod (37) too much with the set screw while adjusting the position of the lever (31). It may cause bumping at Neutral position, resulting in unexpected movement at starting the engine.

Pilot valve assembling To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

Push rod (7)

Pilot valve assembly cautions - Clean and check all the parts. If any part is defective, replace or repair it.

- Replace all the O-rings and seals with new ones.

- Apply the specified torque to tighten each main part.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Measure the resistance of each coil magnet assembly. The resistance should be 62 Ω at normal room temperature [(20ºC) (70ºF)].

If measured in extremely low temperatures the resistance will be less, and at operating temperature the resistance will be higher.

- Be aware that the assembled parts, such as the push rod, spring, etc. are different depending on the ports. Use the correct parts.

Plug (6) Seal (16) 95ZVE44034

- Install seal (16) in plug (6) in correct direction.

44-53 92ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple Control Valve Multiple control valve removing and installing Multiple control valve

Multiple control valve removing

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

- Lift the boom until it is horizontal, and then place stand (A) to support the bottom of the boom.

4 3 90V2E44011

2. Disconnect boom cylinder hose (3).

Remove pipe clamp (4) for the oil pipe.

7

6

8

6

5

5 92V2U44010

Stand

90ZV44028

3. Remove boom cylinder oil pipe (5).

Remove oil pipe (6)(7)(8). Clamp them on the front chassis.

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

1

2

92V2U44009

1. Remove nut (1) and then remove cover (2).

44-54 92ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve installing

9

To reinstall the multiple control valve, follow the above removal procedure in reverse order.

10

Multiple control valve installation cautions 1. Replace all the O-rings with new ones.

9

92V2U44011

4. Put matchmarks on pilot line hoses (9), and then disconnect them.

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

10

2. Wash the multiple control valve mounting area.

WARNING Unexpected movement of machine may cause serious injury or death.

To prevent such an accident, be sure to stop the engine before you start working. In addition, block tires with chocks to prevent wheels from moving.

While working, carefully keep contact with the person in the cab by giving signals to each other.

3. Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the Section 03.

11

4. Operate the bucket and the boom, and check that they operate correctly.

5. Check each section for oil leakage.

90ZV44033

5. Remove bolts (11) for multiple control valve (10).

Use a hoist to remove the multiple control valve. : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Multiple control valve: 90 kg (200 lbs)

6. Add hydraulic oil to the tank until the oil level rises to the specified point.

44-55 92ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Multiple control valve cross section and tightening torque T4 T2 Overload relief valve with make-up function

T3 L1

T5 T1

Make-up valve

T4

T5 Boom spool

T7 T5 Overload relief valve with makeup function

T4 T4

T6 Main relief valve

Bucket spool

T1

92V2U44012

: T1: 196 N-m (20.0 kgf-m) (145 lb-ft) T2: 226 N-m (23.0 kgf-m) (166 lb-ft) T3: 39 N-m (4.0 kgf-m) (29 lb-ft) T4: 54 N-m (5.5 kgf-m) (40 lb-ft) T5: 74 N-m (7.5 kgf-m) (54 lb-ft) T6: 127 N-m (13.0 kgf-m) (94 lb-ft) T7: 29 N-m (3.0 kgf-m) (22 lb-ft)

L1: Screw lock agent (Loctite® 262) application : 90 kg (200 lbs)

44-56 92ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling

4

3 97ZV44038

2 1 97ZV44036

1. Bucket spool disassembling Remove two socket head bolts (1) and cover (2).

Hexagon hole width across flat: 10 mm (0.39 in) : Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft)

3. Set spool (3) in a vise using copper plates and then loosen bolt (4).

Hexagon hole width across flat: 12 mm (0.47 in) : Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft) : Screw lock agent (Loctite® 262) application

6 4

5 9 8

7

97ZV44039

97ZV44037

2. Pull out the spool assembly from the bucket side.

Note Carefully pull out the spool so that it is not forced out or distorted. Handle the spool with extreme care, even a small nick, dent, or scratch can ruin the spool which requires replacement of the entire valve.

4. Remove bolt (4), spring retainer (5), outer spring (6), inner spring (7), stopper (8) and spring retainer (9).

44-57 92ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

11

97ZV44040

5. Boom spool disassembling To disassemble the boom spool, follow the bucket spool disassembling procedure.

97ZV44042

7. Remove main relief valve (11).

Hexagon width across flat: 41 mm (1.61 in) : Main relief valve: 127 N-m (13.0 kgf-m) (94 lb-ft) Note The main relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary.

10

97ZV44041

6. Remove two overload relief valves (10).

Hexagon width across flat: 34 mm (1.34 in) : Overload relief valve: 74 N-m (7.5 kgf-m) (54 lb-ft) Note The overload relief valve should be replaced as an assembly. Therefore, please do not disassemble it, unless absolutely necessary.

13 12

14

97ZV44043

8. Remove plug (12), and then remove spring (13) and poppet (14).

Hexagon hole width across flat: 14 mm (0.55 in) : Plug: 226 N-m (23.0 kgf-m) (166 lb-ft)

44-58 92ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve assembling To reassemble the multiple control valve, follow the above removal procedure in reverse order.

15

Multiple control valve assembly cautions

92V2U44013

9. Remove make up valve (15) from the body. : Main up valve: 74 N-m (7.5 kgf-m) (54 lb-ft)

- Clean and check all the parts. If a part is defective, replace or repair it.

- Replace all the O-rings with new ones.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Apply the specified torque to tighten each main part.

44-59 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® Orbitrol® removing and installing Orbitrol® removing

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

- Block the tires with chocks to prevent wheels from moving.

- Apply the articulation stopper.

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

- Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right.

- Relieve the internal pressure from the hydraulic tank.

1

85V2E44008

1. Remove cover (1).

2 85V2E44009

2. Remove floor mat (2).

44-60 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® installing 3

To reinstall the Orbitrol®, follow the above removal procedure in reverse order.

Orbitrol® installation cautions At the completion of reinstallation, check operation of the Orbitrol® by following the procedure below:

4 85V2E44010

WARNING 3. Put matchmarks on hoses (3), and then disconnect them from Orbitrol® (4).

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

Entering the articulation area while engine is running may cause serious injury or death.

So, when entering the area, stop the engine and place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel or the operator's seat.

1. Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise.

2. Check around the Orbitrol® for oil leakage.

5

85V2E44011

4. Remove bolt (5), and then remove the Orbitrol®. : Bolt: 29 N-m (3.0 kgf-m) (22 lb-ft) : Orbitrol®: 7 kg (15 lbs) Note One person should support the Orbitrol® under the machine. The person in the cab should remove the retainer bolt. This work should be done by two persons.

44-61 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Orbitrol® cross section and tightening torque

T1

90ZV44053

: T1: 23 N-m (2.3 kgf-m) (17 lb-ft) : 7 kg (15 lbs)

44-62 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® disassembling 4

[Disassembling rotor] 5

7 6

Copper plate 97ZV44048

3. Remove rotor assembly (4), spacer (5) and O-ring (6).

95ZV44025

1. Set the Orbitrol® in a vise so that the rotor side comes to the top position.

Use a copper plates on a vise and do not tighten the vise strongly.

Note Keep star (7) in rotor assembly (4).

8

1

9 10 2 97ZV44049

3

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

97ZV44047

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

44-63 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

[Disassembling valve] 14

13 15

11

97ZV44052

97ZV44050

1. Remove the housing from the vise and put it on a clean cloth not to damage the finished surface.

Remove retainer ring (11) by a screw driver.

3. Remove Y-packing seal (14) and dust seal (15) from seal retainer (13).

Note Take care not to damage seal retainer (13).

16

12

17 16

18 19 97ZV44051

97ZV44053

2. Rotate the spool and sleeve so that the pin can be in a horizontal position.

Remove seal retainer (12) by pressing the spool and sleeve from behind with your fingers.

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

44-64 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

24

22

22 23

19

23

20 97ZV44054

97ZV44056

5. Pull spool and sleeve assembly (19) out slowly, turning it clockwise and counterclockwise from housing (20).

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

Note Take care so that the spool and sleeve do not damage the housing.

26 27 19

21 25 97ZV44057

8. Remove O-ring (25) from the housing.

97ZV44055

9. Remove adapter (26) to take out ball (27).

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

Note Do not disassemble, unless absolutely necessary.

44-65 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® assembling

24

26 27

19 20 97ZV44060

25 97ZV44058

1. Assemble ball (27) and adapter (26) in housing (20).

3. Install springs (24) through the spring grooves in the sleeve and spool (19) using a spring insertion jig.

Note Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

Spring groove

22 Spring groove

22 23 23 Matchmark

95ZV44026

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

Note Align the matchmarks on the spool and sleeve.

21

97ZV44061

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

44-66 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

13

14

15

19 20

97ZV44062

97ZV44052

5. Insert spool and sleeve assembly (19) from the back of housing (20).

7. Insert dust seal (15) and Y-packing seal (14) in seal retainer (13).

Note - Take care not to tilt the assembly and cause damage during insertion.

- Insert the assembly until the back end of the assembly is flush with the back end of the housing.

- Confirm that the assembly can be turned easily in the housing.

17

11

13

23

16

97ZV44064

25

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

Screw driver 97ZV44063

Dust seal Retainer ring

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

Seal retainer Y-packing seal O-ring

90V2E44019

Note Be sure the position and direction of the seals.

44-67 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Grooves in rotor bore

A

9 B Drive shaft

C

10

D

Pin 97ZV44066

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

Port face

8 Pin parallel with port face

21 95ZV44028

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

4

6

97ZV44068

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

Port face

95ZV44029

12. Holding the rotor assembly with the O-ring side facing the plate, install the assembly so that the grooves in the star-shaped bore mesh with the drive shaft.

Note - Align the bolt holes in the rotor assembly with those in the housing without disengaging the drive shaft from the rotor assembly's star -shaped bore.

- Confirm that lines A, B, C and D are all parallel.

44-68 92ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

5

1 2 3

97ZV44070

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

Tightening order

95ZV44030

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

44-69 92ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering Valve Steering valve removing and installing

10

9 6

Steering valve removing 7

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

- Block the tires with chocks to prevent wheels from moving.

- Relieve the internal pressure from the hydraulic tank.

- Oil spilled on the parking brake shoe section may cause malfunction. To prevent such a problem, cover the shoe section with plastic before valve removal.

5

8

Steering valve 92V2E44002

2. Remove block (5) and hoses (6)~(10).

11 Steering valve

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

3 90ZV44039

2

3. Remove bolt (11) and then remove the steering valve.

4

: Bolt: 49 N-m (5.0 kgf-m) (36 lb-ft) : Steering valve: 23 kg (50 lbs) Steering valve

1 92V2U44022

1. Disconnect hoses (1)~(4) from the steering valve.

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

44-70 92ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve installing To reinstall the steering valve, follow the above removal procedure in reverse order.

Steering valve installation cautions At the completion of reinstallation, check operation of the steering valve by following the procedure below:

WARNING Entering the articulation area while engine is running may cause serious injury or death.

So, when entering the area, stop the engine and place "DO NOT START" or "DO NOT OPERATE" tag on steering wheel or the operator's seat.

1. Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise.

2. Check around the valve for oil leakage.

3. Measure various values for performance check.

Measure the time required for full steering.

Measure the relief valve setting pressure.

(Refer to the Section 03 - Measurement for Performance Check).

44-71 92ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Steering valve cross section and tightening torque

T3 T2

T1

T5

Flow control spool

T2

T6

Steering spool

T7

T4

T7

T3 90ZV44040

: T1: 255 N-m (26.0 kgf-m) (188 lb-ft) T2: 79 N-m (8.0 kgf-m) (58 lb-ft) T3: 62 N-m (6.3 kgf-m) (46 lb-ft)

T4: 60 N-m (6.1 kgf-m) (44 lb-ft) T5: 353 N-m (36 kgf-m) (260 lb-ft) T6: 127 N-m (13 kgf-m) (94 lb-ft) T7: 108 N-m (11 kgf-m) (80 lb-ft)

44-72 92ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve disassembling

1

6 5 1

4 90ZV44009J

90ZV44007J

1. Remove right and left overload relief valves (1).

Width across flat: 32 mm (1.26 in) : 79 N-m (8.0 kgf-m) (59 lb-ft)

3. Remove spring (4) and spring seat (5) to pull out steering spool (6).

Note Carefully pull out the steering spool so that it is not damaged. Put matchmark to make sure the direction of the steering spool.

7 2

3

90ZV44010J

90ZV44008J

2. Remove bolt (2). Remove end cover (3).

Hexagon hole width across flat: 8 mm (0.315 in) : 62 N-m (6.3 kgf-m) (46 lb-ft)

4. Slightly loosen plug (7).

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

44-73 92ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve assembling 7

To reassemble the steering valve, follow the above disassembly procedure in reverse order.

11 9

10

8 90ZV44011J

5. Remove relief valve (8) and plug (9). Pull out spring (10) and flow control spool (11) from the casing.

Note - Carefully remove plug (9). It may spring out by the spring force.

- Carefully pull out flow control spool (11) so that the casing and flow control spool are not scratched.

Width across flat: Relief valve (8): 19 mm (0.748 in) Plug (9): 41 mm (1.614 in) : (8)(9): 108 N-m (11 kgf-m) (80 lb-ft) 6. Remove plug (7) loosened on paragraph 4.

44-74 92ZV-2 Disassembly & Reassembly Hydraulic Group Stop Valve

Stop Valve Stop valve removing and installing Stop valve removing 3

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

- Relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

6

2 4

5

1

90V2E44015

(The illustration shows the machine right hand side.)

1. Remove hoses (1)~(4) from the stop valve.

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

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

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

44-75 92ZV-2 Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve installation cautions The stop valve works when the spool is pushed in 3 mm (0.118 in).

Adjust the stopper bolt by using the following procedure.

Stop valve (rear chassis)

Stopper (bolt)

Front chassis Reference dimension 31.6~36.2 mm (1.24~1.42 in) Stopper (bolt) length 90ZVE43005

38º 36º~

Front chassis

Rear chassis Reference dimension 9.6~19.3 mm (0.38~0.76 in) 90ZVE43006

- Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension "9.6~19.3 mm (0.38~0.76 in)" shown in the following table.

Reference dimension Articulation angle (º)

- When adjustment is completed, tighten the lock nut of the stopper (bolt). : 90 N-m (9.2 kgf-m) (67 lb-ft)

(LH, RH)

Clearance between machine body and stopper

- After adjustment, turn the steering wheel slowly at a rate of 5 seconds or more per turn, and confirm the clearance between the machine body and the stopper.

38

37

36

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

9.6 (0.38)

14.5 (0.57)

19.3 (0.76)

Stopper (bolt) length (mm) (in)

31.6 (1.24)

33.9 (1.33)

36.2 (1.42)

∗The target value should be the articulation angle "37º".

44-76 92ZV-2 Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Stop valve cross section and tightening torque

S/N ~9038)

T1

T2

T3 K92V244001

: T1: 206 N-m (21 kgf-m) (152 lb-ft) T2: 5 N-m (0.5 kgf-m) (3.6 lb-ft) T3: 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)

44-77 92ZV-2 Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve disassembling 12 10

13

11

2

1

A B

9 85V2E44017

97ZV44079

1. Remove boot (1) and plug (2).

4. Remove screw (9) to remove flange (10), dust seal (11), spacer (12) and U-packing (13). : Screw (9): 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)

WARNING The inner spring may spring out causing injury.

Do not point the spring toward your face. : Plug (2): 206 N-m (21 kgf-m) (152 lb-ft)

7

6

5

8 3

4

85V2E44016

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

3. Clamp spool assembly (4) at the bottom side in a vise and remove plug (5) using a screw driver.

Remove washer (6), spring (7) and check valve (8) from the spool. : Plug (5): 5 N-m (0.5 kgf-m) (3.6 lb-ft)

Stop valve assembling To reassemble the stop valve, follow the above procedure in reverse order.

44-78 92ZV-2 Disassembly & Reassembly Hydraulic Group Fan Motor

Fan Motor Fan motor removing and installing

4 3

Fan motor removing

Fan motor shroud

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

- Relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

4 4 92V2U44024

2. Remove bolts (3) and fan guards (4) from the fan motors shroud. : Bolt (4): 53 N-m (5.4 kgf-m) (39 lb-ft) Note Cover the disconnected hoses with plastic, plugs or caps to protect them from dust and dirt.

1 7

Fan motor shroud

2

92V2U24009

6

1. Remove bolts (1) and remove fan guards (2). Take the fan guards out of the machine.

5 92V2U44025

: Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft) 3. Remove hoses (5)~(7) from the fan motor.

Use a drain pan to catch all escaping oil.

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

44-79 92ZV-2 Disassembly & Reassembly Hydraulic Group Fan Motor

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

12

Flange installation procedure

63.2

Fan motor

15 23.3

8 9

10 11

92V2E44003

4. Disconnect the coupler (8).

5. Remove bolt (9) and washer (10)(11) and fan (12) from fan motor. : Bolt: 74 N-m (7.5 kgf-m) (54 lb-ft) : Screw lock agent (Loctite® 262) application : Fan: 23 kg (51 lbs)

Shaft Plate

Plane washer

Fan motor shroud

Flange Dimension L

13

92V2U44028

Fan motor 92V2E44004

6. Remove bolts (13) and then remove fan motor from the fan motor shroud. : Bolt: 94 N-m (9.5 kgf-m) (69 lb-ft) : With lubrication oil (engine oil or gear oil) : Fan motor: 15 kg (33 lbs)

1. Verify that position of the motor is correct, with the solenoid positioned to the top.

2. Thoroughly clean and remove all oil from tapered shaft of motor.

3. Thoroughly clean and remove all oil from tapered bore of flange.

4. Install flange on motor and measure dimension (L) as shown in the illustration.

5. Install the bolt into the shaft together with the plate and the plane washer.

6. Tighten the bolt with the specified torque. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft)

44-80 92ZV-2 Disassembly & Reassembly Hydraulic Group Fan Motor 7. Remove the bolt, plane washer and plate, and measure the dimension (L) again. Make sure it is 5 mm (0.197 in) smaller than the value measured at step 4.

Note If the amount of the dimension change is smaller than 5 mm (0.197 in), go to step 5 and tighten the bolt with the torque shown below, and then, repeat step 7. : Bolt: 88 N-m (9.0 kgf-m) (65 lb-ft) If it is again smaller than 5 mm (0.197 in), replace the flange with new one and go back to step 5.

Clearance 14 mm (0.6 in)

92V2U24011

8. Finally tighten the bolt with the torque below (either applicable). : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft), or : Bolt: 88 N-m (9.0 kgf-m) (65 lb-ft) : Screw lock agent (Loctite® 262) application Note - Do not reuse the flange, and always replace with a new one when the fan motor is replaced.

- Be sure that the right and left clearance between the fan and fan motor shroud must be equal.

45-1 92ZV-2 Service Standard Hydraulic Group

92ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder ................................................... 45-2 Pilot Valve................................................................ 45-4 Steering Valve ......................................................... 45-6

45-2 92ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder

2

1

3

92V2U45001

Steering cylinder

1

2

3

90ZV45002

Unit: mm (in) Judgment standard No.

Item

Standard value Rod

Bushing

Standard clearance

ø90 (ø3.5433)

-0.036 (-0.0014) ~ -0.090 (-0.0035)

+0.195 (+0.0076) ~ +0.060 (+0.0023)

Bucket cylinder

ø80 (ø3.1496)

-0.040 (-0.0016) ~ -0.100 (-0.0039)

Steering cylinder

ø50 (ø1.9685)

-0.025 (-0.0010) ~ -0.064 (-0.0025)

Boom cylinder

1

Standard dimension of rod dia.

Solution

Limit Bushing

Clearance

0.096 (0.0037) ~ 0.285 (0.0112)

+0.295 (+0.0116)

0.385 (0.0151)

Replacement

+0.210 (+0.0083) ~ +0.105 (+0.0041)

0.145 (0.0057) ~ 0.310 (0.0122)

+0.350 (+0.0138)

0.450 (0.0177)

Replacement

+0.110 (+0.0043) ~ 0 (0)

0.025 (0.0010) ~ 0.174 (0.0068)

+0.210 (+0.0082)

0.274 (0.0107)

Replacement

45-3 92ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder

No.

Item Piston nut tightening torque

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

Piston nut width across flat

mm (in)

2

3

Rod cover bolt tightening torque

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

Boom cylinder

Bucket cylinder

Steering cylinder

M60 x 2 4,756 (485) (3,509)

M60 x 2 5,900 (600) (4,320)

M36 x 1.5 1,275 (130) (941)

90 (3.54)

90 (3.54)

55 (2.17)

M16 330 (33.7) (244)

M24 880 (89.7) (649)

(Rod cover) 2,157 (220) (1,592)

45-4 92ZV-2 Service Standard Hydraulic Group Pilot Valve

Pilot Valve (S/N 9001~9017)

(S/N 9018~)

1

1

3

3

2

2

92V2E45001

45-5 92ZV-2 Service Standard Hydraulic Group Pilot Valve

Judgment standard No.

Item

Solution Standard valve

Allowable limit

87.7 mm (3.452 in)

86.7 mm (3.413 in)

Replacement

36 mm (1.417 in)

35 mm (1.378 in)

Replacement

ø8 mm (0.315 in)

ø7.5 mm (0.295 in)

Wear 1 mm (0.0394 in) 1

Push rod 85V2E45003

Wear 1 mm (0.0394 in) 2

Push rod 85V2E45003

3

Bush

85V2E45002

Replacement with detent solenoid sub

45-6 92ZV-2 Service Standard Hydraulic Group Steering Valve

Steering Valve

2 1

90ZV45001J

Tightening torque Unit: N-m (kgf-m) (lb-ft) No.

Item

1

Steering valve retainer bolt

2

Steering valve bracket retainer bolt

Standard value

Solution

94 (9.6) (69) Tightening 230 (23.5) (170)

54-1 92ZV-2 Disassembly & Reassembly Brake Group

92ZV-2 Disassembly & Reassembly Brake Group Unloader Valve ........................................................ 54-2 Manifold Valve Assembly ........................................ 54-7 Accumulator ............................................................ 54-10 Brake Valve ............................................................. 54-16 Service Brake .......................................................... 54-23 Parking Brake.......................................................... 54-24

54-2 92ZV-2 Disassembly & Reassembly Brake Group Unloader Valve

Unloader Valve Unloader valve removing and installing Unloader valve removing

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

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

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat, or disconnect the negative side of the battery.

2 3

1

Unloader valve 92V2U54001

1. Remove hoses (1)~(3) from the unloader valve.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

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

4

Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure.

- Press the hydraulic tank cap, and relieve the internal pressure from the hydraulic tank.

- Prepare a container to catch drained oil.

Unloader valve

5 92V2U54002

2. Remove hoses (4)(5) from the unloader valve.

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

54-3 92ZV-2 Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve installing To reinstall the unloader valve, follow the above removal procedure in reverse order.

Replace all O-rings and seals during reinstallation.

6

Unloader valve installation cautions Unloader valve 92V2U54003

- After reinstallation, completely bleed the brake line of air, and check performance of the unloader valve.

To bleed the brake line of air, refer to "Service brake air bleeding procedure" page 24-23.

3. Remove bolts (6) and then remove unloader valve. : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) : Unloader valve: 4 kg (8.8 lbs)

- To check performance of the unloader valve, refer to 92ZV-2 Shop Manual, Function and Structure, Section 53.

54-4 92ZV-2 Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Unloader valve cross section and tightening torque

T5 T1

T3 T2 L1

T4

T3

T6

T7

92V2U54004

54-5 92ZV-2 Disassembly & Reassembly Brake Group Unloader Valve : T1: 137 N-m (14 kgf-m) (101 lb-ft) T2: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T3: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T4: 58.8 N-m (6 kgf-m) (43 lb-ft) T5: 83.4 N-m (8.5 kgf-m) (62 lb-ft) T6: 118 N-m (12 kgf-m) (87 lb-ft) T7: 16.7 N-m (1.7 kgf-m) (12 lb-ft)

Width across flats 17 mm (0.669 in) Width across flats 5 mm (0.197 in) Width across flats 5 mm (0.197 in) Width across flats 8 mm (0.315 in) Width across flats 30 mm (1.181 in) Width across flats 36 mm (1.417 in) Width across flats 12 mm (0.472 in)

L1: Screw lock agent (Loctite® 262) application

54-6 92ZV-2 Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve disassembling

1

2 3

Pressure governor assembly

92V2U54005

Remove plug (1), then pull out spool (2) and spring (3).

Note Carefully remove plug (1). It may spring out by the spring force. : 137 N-m (14 kgf-m) (101 lb-ft) Note Do not disassemble the pressure governor assembly and the pressure switch assembly unless it is necessary. Because, readjustment of accumulator pressure and setting of shims are required.

Unloader valve assembling To reassemble the unloader valve, follow the above disassembly procedure in reverse order.

54-7 92ZV-2 Disassembly & Reassembly Brake Group Manifold Valve Assembly

Manifold Valve Assembly Valve assembly removing and installing 1

Valve assembly removing 2

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

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

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat, or disconnect the negative side of the battery.

Valve assembly

3

92V2U54006

2. Remove hoses (1)~(3) from the valve assembly.

6

IMPORTANT

4

If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

5 7

Valve assembly

Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure.

- Press the hydraulic tank cap, and relieve the internal pressure from the hydraulic tank.

- Prepare a container to catch drained oil.

92V2U54007

3. Remove hoses (4)~(7) from the valve assembly.

9

10

8

1. Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line.

11

12

13 Valve assembly 92V2U54008

4. Remove hoses (8)~(13) from the valve assembly.

54-8 92ZV-2 Disassembly & Reassembly Brake Group Manifold Valve Assembly

Valve assembly disassembling and assembling 11

IMPORTANT Rear chassis Valve assembly

92V2U54009

5. Remove bolt (11), and then, remove the valve assembly. : Bolt (11): 53 N-m (5.4 kgf-m) (39 lb-ft) : Valve assembly: 10 kg (22 lbs)

Valve assembly installing To reinstall the valve assembly, follow the above removal procedure in reverse order.

Replace all O-rings and seals during reinstallation.

Note After reinstallation, completely bleed the brake line of air, and check performance of the valve assembly.

To bleed the brake line from air, refer to "Service brake air bleeding procedure" page 24-23.

To check performance of the valve assembly, refer to 92ZV-2 Shop Manual, Function & Structure, Section 53.

Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

54-9 92ZV-2 Disassembly & Reassembly Brake Group Manifold Valve Assembly

Valve assembly cross section and tightening torque

T1

T1

T5

T1

(T) T4

(P)

(TA) (Parking)

(PI) (ACCR)

(ACCF)

ACF (PA) (Z1) (Z2)

(Z)

T2

High pressure test ports

(PPI)

T3

85V2E54007

: T1: 50 N-m (5.1 kgf-m) (37 lb-ft) T2: 23.5 N-m (2.4 kgf-m) (17 lb-ft) T3: 38 N-m (3.9 kgf-m) (28 lb-ft) T4: 11 N-m (1.1 kgf-m) (8 lb-ft) T5 : 8 N-m (0.8 kgf-m) (5.8 lb-ft)

CAUTION High pressure test ports contain accumulator pressure [11.8 MPa (1,706 psi)] that can escape from these 2 plugs.

Completely depress brake pedal 80~100 times to relieve all pressure before removing plugs.

54-10 92ZV-2 Disassembly & Reassembly Brake Group Accumulator

Accumulator Accumulator removing and installing

Accumulator

Accumulator removing

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

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

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat, or disconnect the negative side of the battery.

1

2

92V2U54010

2. Remove hoses (1)(2) from the accumulator.

4

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

Accumulator

3

5

Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure.

- Press the hydraulic tank cap, and relieve the internal pressure from the hydraulic tank.

- Prepare a container to catch drained oil.

1. Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line.

92V2U54011

3. Remove bolts (3)(4), nut (5) and then remove the accumulator. : Bolt (3)(4): 53 N-m (5.4 kgf-m) (39 lb-ft) : Accumulator: 19 kg (42 lbs)/pc

54-11 92ZV-2 Disassembly & Reassembly Brake Group Accumulator

Accumulator installing

Accumulator installation cautions

To reinstall the accumulator, follow the above removal procedure in reverse order.

Replace all O-rings and seals during reinstallation.

- After reinstallation, completely bleed the brake line of air, and check performance of the accumulator. To bleed the brake line of air, refer to "Service brake air bleeding procedure" page 24-23.

- To check performance of the accumulator, refer to 92ZV-2 Shop Manual, Function and Structure, Section 53.

54-12 92ZV-2 Disassembly & Reassembly Brake Group Accumulator

Accumulator disassembling and assembling

7 2

4

1

3 13

IMPORTANT

10

Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

12 11

5,6

Accumulator disassembling

WARNING Disassembly without breathing the inner gas could cause serious injury or death by explosion. To prevent such an accident, observe the following item: - Carefully handle the accumulator that has the high pressure.

- Before disassembly, completely reduce the gas pressure lower to the atmospheric pressure.

- Do not drill and weld the body.

- Do not use over the specified pressure.

- Use Nitrogen gas for charge.

8,9 97ZV54007

1. Loosen bolt (13) to remove gas valve guard (12).

2. Remove the cap of gas valve (10) and install the charging valve to gas valve (10), then bleed the gas completely from the accumulator.

Gas cap (3)

IMPORTANT - Take care not to scratch the cylinder to prevent gas leak.

- Carefully remove each part so that it is not scratched or dented.

95ZV54002

3. Insert three pins into gas cap (3). Remove the gas cap by using a long bar.

Pin hole: ø11.4 (0.4 in)

54-13 92ZV-2 Disassembly & Reassembly Brake Group Accumulator

Accumulator assembling 7 2

4

1

3

To reassemble the accumulator, follow the above disassembly procedure in reverse order.

13 10

After reassembly, carry out the gas charging by referring to the following procedure.

12 11

5,6

8,9 97ZV54007

Hydraulic cap

95ZV54003

4. Insert three bolts into hydraulic cap (2) and remove it by using a long bar.

Screw size: 1/2-20UNF-2B 5. Push out piston (4) toward the hydraulic end by using a bar.

54-14 92ZV-2 Disassembly & Reassembly Brake Group Accumulator

Nitrogen gas charging

Nitrogen gas charging procedure

WARNING

Nitrogen gas charging tools

Improper gas pressure can cause serious injury or death. To prevent such an accident, observe the following item: - Before measuring the gas pressure or charging the gas, stop the engine and release the oil pressure in the line by depressing the brake pedal until there is no brake pressure.

1 2

1-1

1-3

1-2 3

4 2

1-1

Accumulator Charging valve installation

1-2 95ZV54004

1. Charging valve assembly 1-1 Handle (for adjusting screw) 1-2 Handle (for bleeder plug) 1-3 Valve body 2. Pressure gauge (4,903 kPa (50 kgf/cm2) (1,000 psi)) 3. Hose assembly 4. Nitrogen (N2) gas cylinder

1-3 115ZVE54016

1. Turn handle (1-1) counterclockwise until it stops turning.

2. Turn handle (1-2) counterclockwise to open.

3. Remove the gas valve guard cap and then install charging valve assembly (1) to the gas valve.

4. Install pressure gauge (2) to the charging valve assembly and connect hose (3) to nitrogen gas cylinder (4).

5. Slightly open the valve of the nitrogen gas cylinder.

Turn handle (1-2) clockwise to close after confirming the gas comes out from handle (1-2) part.

6. Slowly turn handle (1-1) clockwise to open the piston of the gas valve.

7. Open the valve of the nitrogen gas cylinder more and put a charge into the accumulator.

Note Close the valve of the nitrogen gas cylinder when checking the gas pressure on the gauge to read the gauge needle at the stable condition.

54-15 92ZV-2 Disassembly & Reassembly Brake Group Accumulator [Charging pressure: 2.9 MPa (30 kgf/cm2) (427 psi) at 20ºC (68ºF)] Note Gas pressure is variable with temperature.

Use the following formula for the correct nitrogen charging pressure.

If the pressure on the gauge is too high, slowly turn the handle (1-2) counterclockwise.

PX = 30 (kgf/cm2) x {273 + t (ºC)} / {273 + 20 (ºC)} PX: Charging gas pressure t: Ambient temperature 30: Standard gas pressure 8. Turn handle (1-1) counterclockwise to return the piston of the gas valve. Then turn handle (1-2) counterclockwise to bleed the gas from the charging assembly and the hose.

9. After removing pressure gauge (2), remove the charging assembly from the accumulator.

Note - Apply soapy water to the gas valve on the accumulator to check for gas leakage.

- Recheck the gas pressure once within a week after the charging.

- Check the gas pressure at every 2,000 operation hours.

- A little gas is lost each time of the checking, so add the gas to compensate for the loss.

54-16 92ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake Valve Brake valve removing and installing Brake valve removing

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

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

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat, or disconnect the negative side of the battery.

Brake valve

92V2U54012

1. Remove all hoses and pipes shown on the above illustration.

IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the "OFF" position, it can corrupt the ECM program, which can disable the engine. Always wait 1 full minute to be sure to be past this "write to memory function" prior to removing battery terminals.

Before starting work: - Stop the engine. Depress the brake pedal many times until there is no brake pressure.

- Press the hydraulic tank cap, and relieve the internal pressure from the hydraulic tank.

- Remove the cover.

Brake valve

92V2U54013

2. Remove all adapters and fittings shown on the above illustration.

1

1

Cover

Cover

92V2U54014 K90V2E54001

3. Remove bolt (1) and then remove the brake valve. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

54-17 92ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake valve installing To reinstall the brake valve, follow the above removal procedure in reverse order.

Brake valve installation cautions After reinstallation, completely bleed the brake line of air, and check all the pipe-joints for oil leakage.

To check or adjust the brake valve, refer to 92ZV-2 Shop Manual, Function and Structure, Section 53.

54-18 92ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Brake valve cross section and tightening torque (main valve) T1

T2

T3

T4 T2

92V2U54015

: T1: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft) T2: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft) T3: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft) T4: 14.7 N-m (1.5 kgf-m) (10.8 lb-ft)

54-19 92ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake valve disassembling

4. Pull out pin (11), pedal pin (12), L-shape pin (13) and washer (14), and then, remove collar (15) and roller (16) from the right pedal.

Pedal cover

19

18 17

20 Shaft assembly

85V2E54015

21 85V2E54018

1. Remove the pedal covers.

5. Remove nut (17), washer (18) and bolt (19).

3

6

: Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)

2

1

6. Pull out the shaft assembly and remove left pedal (20) and pedal collar (21).

23 24

Shaft assembly

5

26

27

26

25

22

4 85V2E54016

2. Pull out pin (1). Remove washer (2), right pedal (3), mounting plate (4), pedal collar (5) and spring (6) from the shaft assembly.

85V2E54019

12 13 15

16

15

14

11

7. Pull out pin (22), pedal pin (23), L-shape pin (24) and washer (25), and then, remove collar (26) and roller (27).

9

10

8 7 85V2E54017

3. Remove nut (7), washer (8) and bolt (9) to remove plate (10). : Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)

54-20 92ZV-2 Disassembly & Reassembly Brake Group Brake Valve

32

31

29

28

33

Cover

30

Joint 85V2E54020

8. Remove ring (28) and pull out boot (29).

40

9. Remove ring (30) for the joint, and remove pin (31) by using a pressing machine or equivalent to separate shaft assembly (32)(33).

38 34

Body 2

37

36

35 41

Body 1

92V2U54016

39

10. Loosen bolt (34) and remove spring washer (35) and mounting plate (36). : Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft) 11. Remove dust cover (37) and seat (38).

92V2U54017

12. Loosen bolt (39), and separate the brake valve into the Body 1, Body 2 and the Cover. Remove springs (40)(41). : Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)

54-21 92ZV-2 Disassembly & Reassembly Brake Group Brake Valve

50

42

3.5 mm (0.14 in)

43

48 44 47 45

Pin hole

46

51 52 53

Body 2

Body 1

85V2E54023

92V2U54019

13. Place the Body 1 and Body 2 on a workbench upside down. Remove C-ring (42), and then, remove plug (43) and spring (44).

16. While pushing down case (50) by 3.5 mm or more using a pressing machine or equivalent, insert an appropriate available thin rod into the pinhole (of 1 mm diameter) in another case (51) to push up ring (52) to remove.

Then, release case (50) to remove it. Remove spring (53) inside case (51).

14. Slowly pull out spool (45) from the Body 1 and remove plunger (47). Also pull out spool (46) from the Body 2 and remove plunger (48).

Note Be advised that the spring inside the covers may jump out when disassembling.

Cover

54 51 55 56

49 92V2U54018

15. Place the Cover on a workbench upside down.

Slowly pull out spool input (49) together with the spring and the spring case.

49

92V2U54020

17. Remove spring (54), case (51), sleeve (55), spring retainer (56).

54-22 92ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake valve assembly cautions 58

57

Installation tool ø40 mm

59

ø20 mm

27

Adjusting screw

Reassembly process Nut

38

18. Place cover on a workbench.

Remove C-ring (57), plate (58) and oil seal (59).

Note Do not reuse the oil seal; replace it with a new one when reassembling.

Left pedal

Adjusting screw

16

Brake valve assembling To reassemble the brake valve, follow the above disassembly procedure in reverse order.

(0.067~0.079 in)

92V2U54021

1.7~2.0 mm

Cover

0.5 mm (0.02 in) or less

New seal

60

Right pedal

Nut 92V2U54022

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.

- Adjust the left pedal using the adjusting screws on the right and left pedals so that the opening between seat (38) and roller (27) for the left pedal becomes 0.5 mm (0.02 in) or less when the pedal is not depressed. Tighten the nut when adjusted.

Tightening torque: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft) - Adjust the right pedal using the bolt so that the opening between bolt (60) and roller (16) for the right pedal becomes 1.7~2.0 mm (0.067~0.079 in) when fully depressing the left pedal. Tighten the nut when adjusted.

Tightening torque: 58.8 N-m (6.0 kgf-m) (43.4 lb-ft)

54-23 92ZV-2 Disassembly & Reassembly Brake Group Service Brake

Service Brake Service brake disassembling and assembling

Service brake installation cautions

Refer to "Front axle disassembling and assembling" page 24-24 for the procedures.

Spider Socket bolt

92V2U24027

WARNING Before air bleeding in the brake oil line, be sure that the wheel and tire assemblies are installed on the wheel hub. If fail to do, the bolts (4 pcs) temporarily tighten the spider and the wheel hub may be broken by the brake piston. Finally the spider and the cover may fall off and it could cause serious injury or death.

A B Wheel hub

Brake piston

90ZV54013

1. Loosen the axle housing air bleeder nipple.

2. After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face.

A: 158.05~159.55 mm (6.222~6.281 in) Note Piston stroke B: 1.18~1.83 mm (0.046~0.072 in) 3. After finishing the installation work, bleed air completely from the brake line.

54-24 92ZV-2 Disassembly & Reassembly Brake Group Parking Brake

Parking Brake Parking brake removing and installing The parking brake is built in the transmission assembly.

To remove or reinstall the parking brake, refer to the procedure in Section 34 "Transmission assembly disassembling and assembling".

Parking brake cross section and tightening torque

Parking brake assembly

T1 L3 T2

Drain port

T1 L3

92V2U54031

: T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 147 N-m (15.0 kgf-m) (108 lb-ft)

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

54-25 92ZV-2 Disassembly & Reassembly Brake Group Parking Brake

Parking brake disassembling and assembling Parking brake disassembling Before starting work: - Drain parking brake oil.

12 13

17

14 16

∗: Remover bolt installation position

8

1 15

92V2U54028

4

5. Remove rods (12), O-rings (13)(14), pins (15), Orings (16)(17) from piston (8). : Rod: 147 N-m (15.0 kgf-m) (108 lb-ft)

2

3 92V2U54026

1. Remove bolts (3) and parking brake assembly (1) from housing (2).

21

: Bolt: 230 N-m (23.5 kgf-m) (170 lb-ft) : With lubrication oil (Engine oil or gear oil) : Parking brake assembly: 50 kg (110 lbs) : Housing: 42 kg (93 lbs) 2. Evenly install 4-remover bolts (4) to parking brake assembly (1).

8 7 6

10

11

Transmission

19 18 20

92V2U54025

6. Alternately remove steel plates (18) and friction plates (19) and then remove rods (20), hub (21) from transmission.

A

5

18

9 92V2U54027

3. Remove nuts (5) evenly from four rods (A).

4. Remove springs (6)(7) and O-ring (9) and oil seals (10)(11) from piston (8).

Note - Number of friction plates: 10 Number of steel plates: 11 - When reassembling parking brake, install the steel plate first.

54-26 92ZV-2 Disassembly & Reassembly Brake Group Parking Brake

Parking brake assembling To reassemble the parking brake, follow the above disassembly procedure in reverse order.

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.

To adjust and check performance of the parking brake, refer to the 92ZV-2 Shop Manual, Function and Structure, Section 53.

Single lip Double lip

Grease

Parking brake assembly assembling cautions Parking brake assembly Parking brake assembly

92V2U54030

A

Before installing oil seal, be sure to apply grease to the lips.

Be careful to the oil seal install direction.

A

A

Housing

A Housing

Parking brake assembly Nut

A

54 mm

From manifold valve assy

92V2U54029

(2.1 in)

92V2U54032

When installing parking brake assembly to housing, Evenly install nuts to four rods (A) until the distance becomes 54 mm (2.1 in).

Gradually apply air pressure to the oil port, and check the air leakage.

55-1 92ZV-2 Service Standard Brake Group

92ZV-2 Service Standard Brake Group Brake Valve ............................................................. 55-2 Service Brake .......................................................... 55-3 Parking Brake.......................................................... 55-4

55-2 92ZV-2 Service Standard Brake Group Brake Valve

Brake Valve

1 8 7

6

2

5

3

2 4

3 92V2U55001

55-3 92ZV-2 Service Standard Brake Group Service Brake

Service Brake

3

1, 5 4 6 2, 5

Slide caliper

3

1,5

Steel plate Retainer

2,5 Friction plate

92V2U55002

Unit: mm (in) Judgment standard No.

Item

Solution Standard dimension

Tolerance

Wear limit

1

Thickness of steel plate

4.9 (0.1929)

±0.1 (±0.0039)

4.4 (0.1732)

2

Thickness of friction plate

7.0 (0.2756)

±0.1 (±0.0039)

5.7 (0.2244)

3

Thickness of brake disc when measured by calipers (with brake applied)

28.8 (1.1339)

±0.3 (±0.0118)~ -0.5 (-0.0196)

25.1 (0.9881)

Outer dia.

(Manufacturing dimension) 355 (13.9763)

-0.210 (-0.0082)~ -0.299 (-0.0117)

—

Inner dia.

(Manufacturing dimension) 310 (12.2047)

+0 (+0)~ +0.081 (+0.0032)

—

0.30 (0.0118) or less

—

0.30 (0.0118) and more

Free length

Installation length

Installation load (kgf)

54 (2.1260)

49 (1.9291)

29.3 (64 lbs)

4

Piston seal contact face

5

Distortion of steel and friction plate

6

Return spring

Replacement

—

Replacement

55-4 92ZV-2 Service Standard Brake Group Parking Brake

Parking Brake

1

2

4 3

92V2U55003

Unit: mm (in) Judgment standard No.

1

2

Item

Solution Standard dimension

Tolerance

Wear limit

Thickness

3.5 (0.1378)

±0.1 (±0.0039)

3.3 (0.1299)

Flatness

—

—

3.3 (0.1299)

Thickness

4.0 (0.1575)

±0.1 (±0.0039)

3.8 (0.150)

Flatness

—

—

0.38 (0.0150)

Steel plate

Friction plate

No.

Item Return spring

3

Standard value

Allowable limit

Free length

86 (3.3858)

85.1 (3.3504)

Squareness

—

Within 2º

Appearance Return spring

4

Replacement

Solution

Replacement

Pitch deviation, flaw

Free length

92 (3.6220)

91.1 (3.5866)

Squareness

—

Within 2º

Appearance

Replacement

Pitch deviation, flaw

Replacement

74-1 92ZV-2 Disassembly & Reassembly Operator Station Group

92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner ........................................................ 74-2

74-2 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air Conditioner Air conditioner removing and installing Air conditioner removing

IMPORTANT In case that it is necessary to replace the air conditioner parts, be sure to set the air conditioner mode as below before removing the air conditioner unit from the machine.

Temperature control: Max cool Ventilation mode: Foot Air intake control: Inside air circulation Before starting work: - Remover the seat in the cab.

- Collect the air conditioner refrigerant using the proper recovery method.

- Remove the floor mat in the cab.

1

4

2 1 4 2 3

3 View from operator’s seat

95ZVE74001

74-3 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Cab

7 12

11 8

5

6

95ZVE74002

95ZVE74005

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

1. Remove box (1)(2).

2. Remove cover (3) and plate (4).

3. Remove cover (5)(6)(7) from the cab.

Air conditioner installing 4. Remove duct (8).

To reinstall the air conditioner, follow the above removal procedure in reverse order.

Reference After reinstalling the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

Air conditioner unit

9

95ZVE74003

Air conditioner unit

10 95ZVE74004

5. Disconnect refrigerant piping (9) and heater hose (10).

74-4 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air conditioner disassembling and assembling Air conditioner tightening torque [Cooling unit]

T2 T6 T4

T3

T2

T2

T6

T3

T6

T4

T4 T5

T6 T4

T2 T1 T5

T6

T5

97ZV74002

: T1: 5.4 N-m (0.55 kgf-m) (4 lb-ft) T2: 1.9 N-m (0.19 kgf-m) (1.4 lb-ft) T3: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T4: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft) T5: 1.9 N-m (0.19 kgf-m) (1.4 lb-ft) T6: 2.5 N-m (0.25 kgf-m) (1.8 lb-ft)

74-5 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner [Heater and accessories]

[Air distributor (hood & defroster selection box)]

T3

T1

T3 T2 T2

T2

T4 T1

97ZV74003

: T1: 4.0 N-m (0.4 kgf-m) (2.9 lb-ft) T2: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft) T3: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T4: 5.4 N-m (0.55 kgf-m) (4 lb-ft)

95V2U74001

: T1: 3.7 N-m (0.38 kgf-m) (2.7 lb-ft) T2: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T3: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft)

74-6 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner [Air compressor (with magnetic clutch)]

T1

T2

T1

97ZV74005

: T1: 4.9 N-m (0.5 kgf-m) (3.6 lb-ft) T2: 18 N-m (1.8 kgf-m) (13 lb-ft) [Condenser unit]

T1

T1

T1

T2

T1

95V2U74002

: T1: 12 N-m (1.2 kgf-m) (8.7 lb-ft) T2: 5.4 N-m (0.55 kgf-m) (4 lb-ft)

74-7 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air conditioner disassembling

5

[Blower assy]

3

4

Air conditioner unit assy

Blower assy

5

5

95V2U74005

3. Remove motor cooling pipe (3) from motor assy (4) and the blower case.

95V2U74003

4. Remove bolt (5) (3 pcs), and then remove motor assy (4) from the blower case.

1

2

5. Remove the packing from motor assy (4). This packing is reusable.

95V2U74004

1. Remove tapping screw (1) that fixes blower assy (2) to the air conditioner unit assy.

2. Pull blower assy (2) upward to separate it from the air conditioner unit assy.

74-8 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Screw driver Lever

8 9

6

7

Long-nose pliers

8

95V2U74006

6. Remove clamp (6) using a screw driver.

7. Carefully push the link shaft end using long-nose pliers and remove link shaft (7) from the lever.

Note Be careful not to break the link shaft claw.

8. Remove tapping screw (8) (3 pcs) and remove servo motor (9).

11

10

95V2U74007

9. Remove bolt (10) and then remove relay (11).

74-9 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner [Air conditioner unit assy] 6

Air conditioner unit assy

5

4

7 95V2U74010

95V2U74008

3

1

4. Remove tapping screw (4) and then remove plate (5).

5. Remove lever (6) and lever (7) respectively.

2

8

9 95V2U74009

1. Remove tapping screw (1) that fixes blower assy (2) to the air conditioner unit assy.

95V2U74011

2. Pull blower assy (2) upward to separate it from the air conditioner unit assy.

6. Remove clamp (8) using a screw driver. Then remove link shaft (9).

3. Remove thermistor assy (3) from the case.

10

10

95V2U74012

7. Remove tapping screw (10) (11 pcs) and separate the cooler case.

74-10 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

143.5 5 (5.6 in)

Packing 95V2U74013

Note When reassembling, make sure that the packing is placed in the case groove.

236 – 5 (9.3 in)

0

80 – 15 (3.1 in)

16

+10

Thermistor

95V2U74016

10. Remove clamp (16) (2 pcs) and remove the thermistor from the evaporator.

Note When reassembling, place clamps (16) in the positions as shown.

13 11 18 17

21 14

12 19 95V2U74014

20

8. Loosen joints (11)(12) and remove evaporator (13).

95V2U74017

: Joint (11): 32 N-m (3.3 kgf-m) (24 lb-ft) : Joint (12): 13 N-m (1.3 kgf-m) (9.4 lb-ft)

14

11. Remove tapping screw (17) and remove clamp 1 (18).

12. Remove tapping screw (19) and remove clamp 2 (20).

15

13. Pull heater core (21) upward and remove it.

95V2U74015

9. Remove bolt (15) (2 pcs) and then remove expansion valve (14).

74-11 92ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

27

22 28

27

95V2U74018

14. Remove the thermo sensor connector from the bracket and remove thermo sensor (22).

95V2U74021

18. Remove tapping screw (27) and remove servo motor (28).

24 29 30 24

24

24 25

31 32

23

95V2U74019

15. Remove clamp (23) by using a screw driver.

16. Remove tapping screw (24) and remove servo motor (25).

95V2U74022

19. Remove tapping screw (29) (2 pcs) and remove IC assy (30).

20. Remove pressure switch (31) from tube (32).

Air conditioner assembling To reassemble the air conditioner, follow the above procedure in reverse order.

26

95V2U74020

17. Remove plate (26).

74-12 92ZV-2 Disassembly & Reassembly Operator Station Group

MEMO

75-1 92ZV-2 Service Standard Operator Station Group

92ZV-2 Service Standard Operator Station Group Air Conditioner ........................................................ 75-2

75-2 92ZV-2 Service Standard Operator Station Group Air Conditioner

Air Conditioner Periodical Inspection/Servicing Inspection/maintenance item

Criteria

Solution

Refrigerant

Charge quantity

Air bubbles should not be seen through sight glass.

Inspection/adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Clean

Compressor

Operating status

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

Inspection/ adjustment/ replacement

Belt tension pulley

Operating status

Abnormal sounds and backlash should not be detected.

Inspection/ replacement

V belt

Damage and tension

Damages should not be detected.

Replacement

Blower motor and fan

Operating status

Abnormal sounds or vibration should not be detected.

Inspection/ replacement

Control mechanism

Operating status

Each part should operate in accordance with switch operations.

Inspection/ replacement

Air filter for inside/outside air

Clogging

Air quantity should not be so small as to hinder air conditioning.

Cleaning/replacement

Each mounting area and piping

Looseness, gas leak and damages

Looseness, gas leak and damages should not be detected.

Tightening/charge

Tightening Torque Tightening torque for hose and pipes

Connection type

Connection area

Condenserexpansion valve Nut type

Pipe size or bolt size

ø8 piping

Tightening torque N-m (kgf-m) (lb-ft) 15 (1.50) (11)

Compressorcondenser

D1/2 piping

25 (2.50) (18)

Evaporatorcompressor

D5/8 piping

34 (3.50) (25)

Receiver Block joint Evaporatorcompressor

M6 bolt in receiver (4T) Any M6 bolt (6T) other than above

7 (0.70) (5.1) 12 (1.20) (8.7)

Tightening torque for screws and bolts in special control regions

Special control area

Head bolt of magnetic clutch

Bolt size

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

M6

18 (1.8) (13)

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

0.8 (0.08) (0.6)

Fixing nut of blower motor and condenser fan

M6

5.4 (0.55) (4.0)

Fixing bolt of blower motor and condenser motor

M5

4 (0.4) (2.9)

INDEX A Accumulator ....................................................................54-10 Accumulator assembling .................................................54-13 Accumulator disassembling ............................................54-12 Accumulator disassembling and assembling ..................54-12 Accumulator installation cautions ...................................54-11 Accumulator installing .....................................................54-11 Accumulator removing ....................................................54-10 Accumulator removing and installing ..............................54-10 Air Cleaner ......................................................................24-16 Air cleaner installation cautions ......................................24-17 Air cleaner installing ........................................................24-17 Air cleaner removing .......................................................24-16 Air cleaner removing and installing .................................24-16 Air Conditioner ........................................................ 74-2, 75-2 Air conditioner assembling ..............................................74-11 Air conditioner disassembling ...........................................74-7 Air conditioner disassembling and assembling .................74-4 Air conditioner installing ....................................................74-3 Air conditioner removing ...................................................74-2 Air conditioner removing and installing .............................74-2 Air conditioner tightening torque .......................................74-4 Applying and Storing Articulation Stopper ......................00-15 Applying articulation stopper ...........................................00-15 Attachment Leveler ...........................................................15-6 Attachment leveler ............................................................15-7 Attachment leveler adjustable angle .................................15-7 Axle and Differential Service Standard .............................25-3 Axle group .........................................................................25-3 Axle nut tightening ..........................................................24-30 Axle nut tightening procedure ............................. 24-20, 24-42 Axle Support ...................................................................24-46 Axle support assembling .................................................24-47 Axle support assembly cautions .....................................24-48 Axle support disassembling ............................................24-47 Axle support disassembling and assembling ..................24-47 Axle support tightening torque ........................................24-46

B Bearing cover installing .....................................................15-4 Bearing installation cautions ...........................................00-13 Bearing operation test after installation ..........................00-14 Bearing removal cautions ...............................................00-14 Bolt Tightening Torque .....................................................00-4 Boom ..............................................................................14-15 Boom cylinder installation cautions .................................44-20 Boom cylinder installing ..................................................44-20 Boom cylinder removing .................................................44-19 Boom cylinder removing and installing ...........................44-19 Boom installation cautions ..............................................14-17 Boom installing ...............................................................14-17 Boom removing ...............................................................14-15 Boom removing and installing .........................................14-15 Brake adjustment ............................................................24-30 Brake Valve .......................................................... 54-16, 55-2 Brake valve assembling ..................................................54-22

Brake valve assembly cautions ...................................... 54-22 Brake valve cross section and tightening torque (main valve) ................................................................ 54-18 Brake valve disassembling ............................................. 54-19 Brake valve disassembling and assembling ................... 54-18 Brake valve installation cautions .................................... 54-17 Brake valve installing ...................................................... 54-17 Brake valve removing ..................................................... 54-16 Brake valve removing and installing ............................... 54-16 Bucket cylinder installation cautions ............................... 44-23 Bucket cylinder installing ................................................ 44-22 Bucket cylinder removing ............................................... 44-21 Bucket cylinder removing and installing ......................... 44-21 Bushing installing ........................................................... 24-48

C Cab ................................................................................. 14-10 Cab installing .................................................................. 14-11 Cab removing ................................................................. 14-10 Cab removing and installing ........................................... 14-10 Cautions Regarding Handling of Bearing ....................... 00-13 Cautions regarding parts removal .................................... 00-9 Cautions regarding reassembly ............................. 00-9, 34-24 Cautions Regarding Welding Repair Service ................. 00-11 Center Pin ............................................................. 14-18, 15-4 Center pin installation cautions ...................................... 14-23 Center pin installing ........................................................ 14-23 Center pin removing ....................................................... 14-20 Center pin removing and installing ................................. 14-20 Center pin shim adjustment ................................... 14-18, 15-4 Clutch Oil Pressure .......................................................... 35-8 Clutch oil pressure standard value ................................... 35-8 Clutch plate ...................................................................... 35-7 Clutch Plate Thickness/Piston Stroke .............................. 35-6 Control Valve .................................................................... 35-4 Control valve assembling ............................................... 34-42 Control Valve Assembly ................................................. 34-37 Control valve assembly cautions .................................... 34-42 Control valve disassembling ........................................... 34-40 Control valve disassembling and assembling ................ 34-40 Control valve installation cautions .................................. 34-39 Control valve removing ................................................... 34-38 Control valve removing and installing ............................. 34-38 Control valve tightening torque ....................................... 34-37

D Deck ................................................................................. 14-2 Deck installing .................................................................. 14-3 Deck removing ................................................................. 14-2 Deck removing and installing ........................................... 14-2 Differential ............................................................. 24-58, 25-4 Differential Assembly ...................................................... 24-49 Differential assembly assembling ................................... 24-58 Differential assembly disassembling .............................. 24-54 Differential assembly disassembling and assembling ................................... 24-52

Differential assembly installation cautions ..................... 24-51 Differential assembly installing ....................................... 24-51 Differential assembly removing ...................................... 24-49 Differential removing and installing ................................ 24-49

E Engine ............................................................................ 24-11 Engine installation cautions ............................................ 24-13 Engine installing ............................................................. 24-13 Engine removing ............................................................ 24-11 Engine removing and installing ...................................... 24-11 Engine Room ................................................................... 14-7 Engine room installation cautions .................................... 14-9 Engine room installing ...................................................... 14-9 Engine room removing ..................................................... 14-7 Engine room removing and installing ............................... 14-7

F Fan ................................................................................... 24-9 Fan installation cautions ................................................. 24-10 Fan installing .................................................................... 24-9 Fan Motor ....................................................................... 44-78 Fan motor installing ........................................................ 44-79 Fan motor removing ....................................................... 44-78 Fan motor removing and installing ................................. 44-78 Fan removing ................................................................... 24-9 Fan removing and installing ............................................. 24-9 Floating seal installing .............................. 24-20, 24-27, 24-42 Floor Board .................................................................... 14-12 Floor board installation cautions .................................... 14-14 Floor board installing ...................................................... 14-14 Floor board removing ..................................................... 14-12 Floor board removing and installing ............................... 14-12 Forward/reverse clutch pack assembling ....................... 34-29 Forward/reverse clutch pack assembly cautions ........... 34-29 Forward/reverse clutch pack disassembling .................. 34-27 Forward/reverse clutch pack disassembling and assembling ................................... 34-27 Front axle assembling .................................................... 24-27 Front Axle Assembly ...................................................... 24-19 Front axle assembly cautions ......................................... 24-27 Front axle assembly installation cautions ....................... 24-23 Front axle assembly installing ........................................ 24-23 Front axle assembly removing ....................................... 24-21 Front axle assembly removing and installing ................. 24-21 Front axle assembly tightening torque ........................... 24-19 Front axle disassembling ............................................... 24-24 Front axle disassembling and assembling ..................... 24-24 Front differential tightening torque ................................. 24-52 Fuel Tank ......................................................................... 14-4 Fuel tank installation cautions .......................................... 14-4 Fuel tank installing ........................................................... 14-4 Fuel tank removing ........................................................... 14-4 Fuel tank removing and installing ..................................... 14-4

G Gear pump specifications ................................................. 35-5

H Hose Band Tightening Torque ..........................................00-8 How to wind a seal tape .................................................00-10 Hydraulic Cylinder .................................................44-19, 45-2 Hydraulic cylinder assembling ........................................44-30 Hydraulic cylinder assembly cautions .............................44-31 Hydraulic cylinder cross section and tightening torque ....................................................................................44-26 Hydraulic cylinder disassembling ...................................44-28 Hydraulic cylinder disassembling and assembling ......... 44-26 Hydraulic parts assembly cautions ...................................44-3 Hydraulic Parts Disassembly and Assembly Cautions ..... 44-3 Hydraulic parts disassembly cautions ..............................44-3 Hydraulic Parts Removal and Installation Warning ..........44-2 Hydraulic Pump Assembly ................................................44-4 Hydraulic pump assembly cross section and tightening torque ..............................44-6 Hydraulic pump assembly disassembling and assembling .....................................44-5 Hydraulic pump assembly installing ................................. 44-4 Hydraulic pump assembly removing ................................. 44-4 Hydraulic pump assembly removing and installing ........... 44-4 Hydraulic pump installation cautions ................................44-4 Hydraulic Tank ..................................................................14-5 Hydraulic tank installation cautions ..................................14-6 Hydraulic tank installing ....................................................14-6 Hydraulic tank removing ...................................................14-5 Hydraulic tank removing and installing .............................14-5

I Interference fits for a bearing .......................................... 00-13 Internal Gear Hub ........................................................... 24-32 Internal gear hub assembling .........................................24-33 Internal gear hub assembly cautions ..............................24-34 Internal gear hub disassembling ..................................... 24-32 Internal gear hub disassembling and assembling ..........24-32 Internal gear hub installing .............................................24-29

L Liner clearance adjustment ..............................................15-3 Linkage .............................................................................15-2 Linkage Pin Standard Clearance Values ..........................15-3 Liquid Gasket and Screw Lock Agent ...............................00-9 Loading and pilot and brake pump assembling .............. 44-12 Loading and pilot and brake pump assembly cautions .......................................................44-12 Loading and pilot and brake pump disassembling ........... 44-9 Lock-up torque converter assy assembling .................... 34-19 Lock-up torque converter assy assembly cautions ......... 34-19 Lock-up torque converter disassembling ........................34-18 Lock-up torque converter disassembling and assembling ...................................34-18 Lower center pin .............................................................14-19 Lower center pin bearing outer ring installing ...................15-5 Lower Cover ...................................................................14-26 Lower cover installing .....................................................14-26 Lower cover removing ....................................................14-26 Lower cover removing and installing ..............................14-26

M Manifold Valve Assembly ..................................................54-7 Muffler .............................................................................24-18 Muffler installation cautions ............................................24-18 Muffler installing ..............................................................24-18 Muffler removing .............................................................24-18 Muffler removing and installing .......................................24-18 Multiple Control Valve .....................................................44-53 Multiple control valve assembling ...................................44-58 Multiple control valve assembly cautions ........................44-58 Multiple control valve cross section and tightening torque .............................44-55 Multiple control valve disassembling ..............................44-56 Multiple control valve disassembling and assembling ....................................................................................44-55 Multiple control valve installation cautions ......................44-54 Multiple control valve installing .......................................44-54 Multiple control valve removing ......................................44-53 Multiple control valve removing and installing ................44-53

N Nitrogen gas charging .....................................................54-14 Nitrogen gas charging procedure ...................................54-14

O Oil seal replacement procedure ........................................44-8 Orbitrol® ..........................................................................44-59 Orbitrol® assembling .......................................................44-65 Orbitrol® cross section and tightening torque .................44-61 Orbitrol® disassembling ..................................................44-62 Orbitrol® disassembling and assembling ........................44-61 Orbitrol® installation cautions ..........................................44-60 Orbitrol® installing ...........................................................44-60 Orbitrol® removing ..........................................................44-59 Orbitrol® removing and installing ....................................44-59

P Parking Brake ....................................................... 54-24, 55-4 Parking brake assembling ..............................................54-26 Parking brake assembly assembling cautions ................54-26 Parking brake disassembling ..........................................54-25 Parking brake disassembling and assembling ................54-25 Parking brake removing and installing ............................54-24 Partition Plate .................................................................14-24 Partition plate installing ...................................................14-25 Partition plate removing ..................................................14-24 Partition plate removing and installing ............................14-24 Periodical Inspection/Servicing .........................................75-2 Pilot Valve ............................................................. 44-32, 45-4 Pilot valve assembling ........................................ 44-43, 44-52 Pilot valve assembly cautions ............................. 44-43, 44-52 Pilot valve cross section and tightening torque ........................................................................ 44-35, 44-45 Pilot valve disassembling .................................... 44-36, 44-46 Pilot valve disassembling and assembling (S/N 9001~9017) .........................................................44-35 Pilot valve disassembling and assembling (S/N 9018~) .................................................................44-45

Pilot valve installation cautions ....................................... 44-34 Pilot valve installing ........................................................ 44-34 Pilot valve removing ....................................................... 44-32 Pilot valve removing and installing ................................. 44-32 Piston stroke ..................................................................... 35-7 Power Line ....................................................................... 24-2 Power line tightening torque ............................................. 24-2 Propeller Shaft ................................................................ 24-14 Propeller shaft installation cautions ................................ 24-15 Propeller shaft installing ................................................. 24-15 Propeller shaft removing and installing .......................... 24-14 Propeller Shaft Service Standard ..................................... 25-2

R Radiator ............................................................................ 24-3 Radiator core installing ..................................................... 24-8 Radiator core removing .................................................... 24-7 Radiator core removing and installing .............................. 24-7 Radiator installing ............................................................. 24-6 Radiator removing ............................................................ 24-4 Radiator removing and installing ...................................... 24-4 Radiator tightening torque ................................................ 24-3 Rear Axle Assembly ....................................................... 24-41 Rear axle assembly installing ......................................... 24-45 Rear axle assembly removing ........................................ 24-43 Rear axle assembly removing and installing .................. 24-43 Rear axle assembly tightening torque ............................ 24-41 Rear axle disassembling and assembling ...................... 24-45 Rear differential tightening torque .................................. 24-53

S Screw lock agent application procedure ......................... 00-10 Second propeller shaft removing .................................... 24-14 Service Brake ........................................................ 54-23, 55-3 Service brake air bleeding procedure ............................. 24-23 Service brake disassembling and assembling ............... 54-23 Service brake installation cautions ................................. 54-23 Special Tool .................................................................... 24-37 Special tool for axle ........................................................ 24-37 Spider Assembly ............................................................ 24-35 Spider assembly assembling .......................................... 24-35 Spider assembly disassembling ..................................... 24-35 Spider assembly disassembling and assembling ........... 24-35 Spider assy assembly cautions ...................................... 24-36 Steering cylinder installation cautions ............................ 44-25 Steering cylinder installing .............................................. 44-25 Steering cylinder removing ............................................. 44-24 Steering cylinder removing and installing ....................... 44-24 Steering pump assembling ............................................. 44-17 Steering pump assembly cautions ................................. 44-17 Steering pump disassembling ........................................ 44-14 Steering Valve ....................................................... 44-69, 45-6 Steering valve assembling ............................................. 44-73 Steering valve cross section and tightening torque ........ 44-71 Steering valve disassembling ......................................... 44-72 Steering valve disassembling and assembling ............... 44-71 Steering valve installation cautions ................................ 44-70 Steering valve installing .................................................. 44-70 Steering valve removing ................................................. 44-69

Steering valve removing and installing ........................... 44-69 Stop Valve ...................................................................... 44-74 Stop valve assembling ................................................... 44-77 Stop valve cross section and tightening torque .............. 44-76 Stop valve disassembling ............................................... 44-77 Stop valve disassembling and assembling .................... 44-76 Stop valve installation cautions ...................................... 44-75 Stop valve installing ....................................................... 44-74 Stop valve removing ....................................................... 44-74 Stop valve removing and installing ................................. 44-74 Storing articulation stopper ............................................ 00-16 Symbols ........................................................................... 00-2

T Third propeller shaft removing ....................................... 24-15 Tightening torque for hose and pipes ............................... 75-2 Tightening torque for screws and bolts in special control regions .............................................. 75-2 Torque Converter and Transmission Assembly ............... 34-2 Torque converter and transmission assembly installing ........................................................................ 34-8 Torque converter and transmission assembly removing ....................................................................... 34-3 Torque converter and transmission assembly removing and installing ................................................. 34-3 Torque converter and transmission assembly tightening torque ........................................................... 34-2 Torque Converter Assembly .......................................... 34-11 Torque converter assembly assembling ........................ 34-17 Torque converter assembly disassembling .................... 34-12 Torque converter assembly disassembling and assembling ................................... 34-12 Torque converter assembly tightening torque ................ 34-11 Torque Converter Gear Pump .......................................... 35-5 Transmission 1st/3rd speed clutch pack assembling .................................................................................... 34-31 Transmission 1st/3rd speed clutch pack assembly cautions ...................................................... 34-31 Transmission 1st/3rd speed clutch pack disassembling ............................................................. 34-30 Transmission 1st/3rd speed clutch pack disassembling and assembling ................................... 34-30 Transmission 2nd Speed Clutch Pack ........................... 34-32 Transmission 2nd speed clutch pack assembling .......... 34-33 Transmission 2nd speed clutch pack assembly cautions ...................................................... 34-33 Transmission 2nd speed clutch pack disassembling .................................................................................... 34-32 Transmission 2nd speed clutch pack disassembling and assembling ................................... 34-32 Transmission 4th Speed Clutch Pack ............................ 34-34 Transmission 4th speed clutch pack assembling ........... 34-35 Transmission 4th speed clutch pack assembly cautions ...................................................... 34-35 Transmission 4th speed clutch pack disassembling ...... 34-34 Transmission 4th speed clutch pack disassembling and assembling ................................... 34-34 Transmission Assembly ........................................ 34-20, 35-2 Transmission assembly assembling .............................. 34-24 Transmission assembly disassembling .......................... 34-21

Transmission assembly disassembling and assembling ...................................34-21 Transmission assembly installation cautions ....................34-9 Transmission assembly tightening torque ......................34-20 Transmission Forward/Reverse Clutch Pack .................34-27

U Unloader Valve .................................................................54-2 Unloader valve assembling ..............................................54-6 Unloader valve cross section and tightening torque .........54-4 Unloader valve disassembling ..........................................54-6 Unloader valve disassembling and assembling ................ 54-4 Unloader valve installation cautions ................................. 54-3 Unloader valve installing ...................................................54-3 Unloader valve removing .................................................. 54-2 Unloader valve removing and installing ............................ 54-2 Upper center pin .............................................................14-18

V Valve assembly cross section and tightening torque ........54-9 Valve assembly disassembling and assembling ..............54-8 Valve assembly installing .................................................54-8 Valve assembly removing .................................................54-7 Valve assembly removing and installing ...........................54-7

W Weight of Main Components ............................................ 00-3

MEMO

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