Kawasaki 65TMV-2 WHEEL LOADER SHOP MANUAL 93207-00620

65TMV-2 SHOP MANUAL Disassembly & Reassembly Service Standard

Printed in Japan (k) （オーストラリア用）

93207-00620

©2007 Kawasaki Heavy Industries, Ltd. All rights reserved.

93207-00620 December 2007

SHOP MANUAL WHEEL LOADER

65TMV-2 Disassembly & Reassembly Service Standard

Powered by Isuzu 4HK1X Engine Serial No. 65J4-8001~

93207-00620 December 2007

Foreword

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

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

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

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

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

(1)

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

(2)

Safety Symbols An accident may occur if you disregard safety rules.

In this manual, several expressions are used according to levels of danger for inspection and repair work as shown below. Read the work procedures and cautions described in this manual, and take preventive measures against possible problems before starting service work.

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

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

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

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

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

(3)

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

Symbol

Item

Description

Reference

Weight

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

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

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

Coating

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

Oil or water supply

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

Drainage

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

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

The message shows the preventive measures.

Abbreviation To save space, abbreviations are used in sentences. Refer to the following abbreviation list.

E/G T/C T/M SOL SW F A/M B R

Engine Torque converter Transmission Solenoid valve Switch Front or Forward Auto/Manual Battery Rear or Reverse

RH LH H L GND OPT Assy 1st 2nd

Right hand side Left hand side High Low Ground Option Assembly 1st speed 2nd speed (4)

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

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

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

26

38

M10

10

(C) 1.5

53

76

(F) 1.25

55

80

M12

12

(C) 1.75

90

132

(F) 1.25

96

142

M14

14

(C) 2.0

142

206

(F) 1.5

152

221

M16

16

(C) 2.0

216

314

(F) 1.5

226

330

M18

18

(C) 2.5

299

436

(F) 1.5

324

476

M20

20

(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

M22 M24 M27 M30

Unified thread

22 24 27 30

M33

33

(F) 2.0

2,059

3,040

5/16

05

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.

(5)

(kgf-m) Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

2.7

3.9

M10

10

(C) 1.5

5.4

7.8

(F) 1.25

5.6

8.2

M12

12

(C) 1.75

9.2

13.5

(F) 1.25

9.8

14.5

M14

14

(C) 2.0

14.5

21.0

(F) 1.5

15.5

22.5

M16

16

(C) 2.0

22.0

32.0

(F) 1.5

23.0

33.7

M18

18

(C) 2.5

30.5

44.5

(F) 1.5

33.0

48.5

M20

20

(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

M22 M24 M27 M30

Unified thread

22 24 27 30

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.

(6)

(lb-ft.)

Bolt strength

Bolt size Type

Metric thread

Nominal Dimension

Nominal Dia.

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

19.5

28

M10

10

(C) 1.5

39

56

(F) 1.25

40

59

M12

12

(C) 1.75

66

97

(F) 1.25

70

105

M14

14

(C) 2.0

105

150

(F) 1.5

110

160

M16

16

(C) 2.0

160

230

(F) 1.5

165

245

M18

18

(C) 2.5

220

320

(F) 1.5

235

350

M20

20

(C) 2.5

305

450

(F) 1.5

330

490

(C) 2.5

410

600

(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

M22 M24 M27 M30

Unified thread

22 24 27 30

M33

33

(F) 2.0

1,520

2,240

5/16

05

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.

(7)

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

(N-m) Bolt size Type

Metric thread

Bolt strength

Nominal Dimension

Pitch

8.8 (8T)

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 strength

Bolt size Type

Metric thread

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 strength

Bolt size Type

Metric thread

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

(8)

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

Tightening torque

Tightening torque

Tightening torque

(N-m)

(kgf-cm)

(lb-ft)

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

Hose band

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

69002-02200 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

Hose band

Center of pipe protrusion 10~20 mm

(9)

Pipe

70ZV00003

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

Liquid Gasket Screw Lock Agent

Code

Manufacturer

Product name

AA01

Loctite

®

Plastic Gasket 568

AA02

Loctite

®

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite ®

Loctite ® 262

AB03

Three Bond

Three Bond 1374

Screw lock agent application procedure Through-hole Screw lock agent

65ZV00002

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

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

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

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

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

Cautions regarding reassembly

How to wind a seal tape Seal tape

Leave 1~2 screw 65ZV00004

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

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 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.

Antiseize Agent Code

Manufacturer

Product name

AC01

Loctite ®

Loctite ® 767 (Paste or spray)

(10)

Cautions Regarding Welding Repair Service If welding is needed to repair the chassis, observe the following precautions to protect the hydraulic cylinders, hydraulic units, gear sets, and electrical units from possible damage.

Cautions 1) Turn the starter switch OFF. 2) Remove the battery terminals both positive and negative sides from the battery.

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

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

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

Cylinder head covers for some models have a lowconductive 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)

Example 2:

Do not ground this section.

Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding) 35C00002

(11)

7) The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes.

Be sure to mask these units and parts before welding.

Hydraulic cylinder

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

Note: The weld spattered on the plated sections causes corrosion.

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

Scrap material, etc.

1m or more

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

35C00003

Section to be welded

1m or more 35C00004

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

Section to be welded Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

(12)

35C00005

Weight of Main Components Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

750

1,655

Quick coupler

250

550

Item Unit name

Chassis

Boom

520

1,150

40/pc

88/pc

Link B

25/pc

55/pc

Link C

70/pc

155/pc

Link D

20/pc

44/pc

Engine room assembly

240

530

Including screen board

Hydraulic tank

100

220

Excluding oil

Fuel tank

150

330

Excluding fuel

Floor board

165

365

Including ope. board, instrument panel and control box

Cab (Rops)

500

1,100

Left side

20

45

With handrail

Right side

25

55

With handrail

Front chassis

1,005

2,215

Rear chassis

845

1,865

Counter weight

800

1,765

Engine

480

1,060

Excluding oil

Radiator assembly

130

285

Excluding water and oil

Torque converter oil cooler

11

24

Excluding oil

Transmission

535

1,180

Excluding oil

Second propeller shaft

35

77

Standard

Third propeller shaft

10

25

Front axle assembly

525

1,160

Excluding tires and oil

Rear axle assembly

670

1,480

Excluding tires and oil (Including axle support)

Differential

145

320

Multiple control valve

35

77

Pilot valve

6

13

Priority valve

6

13

Hydraulic

Orbitrol

7

15

system

Gear pump

20

45

Fan motor

15

35

Other

QGSN bucket

Link A

Deck

Power line

Remarks

®

Triple pump

Boom cylinder

95/pc

210/pc

Excluding oil

Bucket cylinder

60/pc

135/pc

Excluding oil

Steering cylinder

20/pc

45/pc

Excluding oil

Tire

200/pc

440/pc

With rim (20.5-25-12PR); No Hydro Inflation

Battery

30/pc

66/pc

(13)

Applying and Storing Articulation Stopper 1. Applying articulation stopper

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

1) Park the machine so that the frame is straight ahead.

Remove the pin (1) from the articulation stopper on the hydraulic tank.

1

2) Turn rod (2) (articulation stopper) to the front and then align the pin hole. Insert the pin (1) into the rod to lock the front chassis to the rear chassis.

WARNING

2 1

To align the pin with the pin hole, start the engine and slightly turn the steering wheel. Be careful!

Your body or finger may 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.

LOCKED POSITION

2

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

STORED POSITION

(14)

1

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

MEMO

CHASSIS GROUP 14 Disassembly and Reassembly Deck ............................................................................................................14-2 Fuel Tank ....................................................................................................14-4 Hydraulic Tank ............................................................................................14-6 Engine Room ..............................................................................................14-8 Cab ...........................................................................................................14-11 Floor Board ...............................................................................................14-13 Boom ........................................................................................................14-16 Center Pin .................................................................................................14-18

14-1

Deck

65TMV-2

CHASSIS 14

Deck Removing and reinstalling deck 1. Removing deck

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

- Lower the 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.

3 6

5

7

2

1

1) Apply a sling to fender (1) and handrail (2).

Remove bolt (3)(4). Carefully balance the assembly and remove fender (1).

4

8

K65V2U14001

: Fender (1) including handrail: 40 kg (90 lbs) 2) Apply a sling to deck (5) and handrail (6).

Remove bolt (7)(8). Carefully balance the assembly and remove deck (5). : Deck (5) including handrail: 25 kg (55 lbs) 3) Apply a sling to fender (9) and handrail (10).

Remove bolt (11)(12). Carefully balance the assembly and remove fender (9).

14 11 13

: Fender (9) including handrail: 40 kg (90 lbs) 4) Apply a sling to deck (13) and handrail (14).

Remove bolt (15). Carefully balance the assembly and remove deck (13).

15 10

: Deck (13) including handrail: 20 kg (45 lbs) 9 12 K65V2U14002

14-2

Deck

65TMV-2

2. Reinstalling deck For reinstallation, follow the above procedure in reverse order.

14-3

CHASSIS 14

Fuel Tank

65TMV-2

CHASSIS 14

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

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

- Lower the 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: 210 (55 gal)) - Remove the radiator (Refer to section 24).

1) Remove bolt (1) and disconnect the drain hose (2) from the fuel tank.

Engine

Radiator

2) Disconnect hose (3).

2 1

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

3 Fuel tank

2

Cooling unit 1 K65V2E14004

3) Remove bolt (4) to release the cooling unit from the fuel tank.

Put a matchmark on fuel hoses (5) and disconnect them from the fuel tank.

4 5

: Cooling unit: 11 kg (24 lbs) Note: Cover the disconnected hoses with caps or vinyl to protect them from dust and dirt.

K65V2E14005

14-4

Fuel Tank

65TMV-2

CHASSIS 14

4) Remove nut (6) to release the hose nipple from the fuel tank, and remove nut (7) to release the bracket from the fuel tank.

6

7

K65V2E14006

9

5) Disconnect fuel level sensor electrical line coupler (8).

6) Fix eye bolt (M16) to the fuel tank and attach sling to the tank. Then remove bolt (9) and slowly lower the fuel tank. : Fuel tank: 150 kg (330 lbs) Torque for assembly: : Bolt (4): 441 N-m (45.0 kgf-m) (325 lb-ft)

8

Eye bolt

K65V2E14007

2. Reinstalling fuel tank For reinstallation, follow the above procedure in reverse order.

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

14-5

Hydraulic tank

65TMV-2

CHASSIS 14

Hydraulic Tank Removing and reinstalling hydraulic tank 1. Removing hydraulic tank

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting 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 hydraulic oil from the hydraulic tank.

(Hydraulic tank capacity: 70 (18.5 gal)) - Remove the fender and deck.

- Clean the area around the tank.

Hydraulic tank

1) Remove hose band and remove hose (1).

1

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

K65V2U14003

3

2) Put matchmark and remove brake line hose (2)(3).

Remove pilot line hose (4) from the hydraulic tank.

2

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

3

4

K65V2U14004

14-6

Hydraulic tank

65TMV-2

CHASSIS 14

3) Remove hose band and remove hose (5) from the hydraulic tank.

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

5

K65V2U14005

4) Disconnect temperature sensor (6) and oil level sensor (7) connectors.

7

5) Attach sling to hydraulic tank and remove bolts (8). : Hydraulic tank: 100 kg (220 lbs) (empty) Torque for assembly: : Bolt (8): 230 N-m (23.5 kgf-m) (170 lb-ft)

8 6

2. Reinstalling hydraulic tank For reinstallation, follow the above procedure in reverse order.

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

Run the engine idle for five minutes to allow the pumps to become fully lubricated.

14-7

K65V2U14006

Engine Room

65TMV-2

CHASSIS 14

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

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting engine room removal: - Position the machine to 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 engine key, and hang a "DO NOT START ENGINE !" tag on steering wheel.

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

- Remove the fenders and decks with the handrails.

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

1

2

Torque for assembly: : Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft)

Muffler

K65V2E14013

2) Release split pin (3) and remove nut (4) to remove rear grill (5).

5

8

Screen board 7

: Rear grill mount (5): 25 kg (55 lbs) 3) Remove bolts (6)(7) to remove the radiator guard (8).

3 4 6

: Radiator guard (8): 60 kg (135 lbs)

7 K65V2U14007

14-8

Engine Room

65TMV-2

CHASSIS 14

4) Sling engine roof (9) and remove bolt (10) to remove the roof.

10

: Engine roof (9): 15 kg (35 lbs) 9

K65V2U14008

13

5) Remove round bar (11) and sling engine access panel (LH) (12).

Remove the bolt for hinge (13) and remove engine access panel (12).

Manually remove the small panel (14).

Remove the engine access panel (RH) in the same manner.

12

11

: Engine access panel (12): 26.5 kg (60 lbs)

14 K65V2U14009

6) Disconnect sub tank hose (15) for the radiator.

Remove nut (16) to release the band and remove sub tank (17).

15 15 16

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

17

Engine room K65V2U14010

7) Disconnect hose (18) between the air cleaner and the engine at the engine side.

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

18

Air cleaner K65V2U14011

14-9

Engine Room

65TMV-2

CHASSIS 14

8) Disconnect hoses (19)(20) from the condenser and the receiver tank.

Receiver tank Screen board

19 20 19

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

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

Condenser K65V2U14012

22

9) Remove bolt (21) and remove window washer liquid tank (22) from the screen board.

21

K65V2U14013

10) Sling the screen board together with the air cleaner and remove bolt (23).

Torque for assembly: : Bolt (23): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screen board (including air cleaner): 120 kg (265 lbs)

23

23

Note: Slowly lift the screen board while checking that there are no obstacles.

K65V2U14014

2~3 mm(1/10 in) 5 mm (1/5 in) or less

2. Reinstalling engine room For reinstallation, follow the above procedure in reverse order.

Fix the bands avoiding the beading.

Air duct

Note: After reinstallation, be sure to check the air conditioner for refrigerant leakage. Also check that the air cleaner rubber hose connection band is properly positioned and tightened with proper torque.

14-10

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

K85V2U24005

Cab

65TMV-2

CHASSIS 14

Cab Removing and reinstalling cab 1. Removing cab

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.

2

Before starting work: - Remove the decks and fenders.

- Disconnect the electrical line couplers.

1) Remove covers (1)(2).

1 K70V2U14008

2) Cover (3) for the filter is located in the left rear of the cab.

Turn the rings counterclockwise and then remove cover (3).

Remove the filter from the cab.

3

K70V2U14009

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

Filter

95ZV72034

14-11

Cab

65TMV-2

CHASSIS 14

3) Remove cover (4).

4

95ZV14016

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

5

6

95ZV14017

5) Remove bolts (7)(8).

9

Torque for assembly : : Bolt (7): 721 N-m (73.5 kgf-m) (532 lb-ft) 6) Remove bolt (9).

Install eye bolt (M16 x 2.0) on cab. 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.

2. Reinstalling cab For reinstallation, follow the above procedure in reverse order.

7 8 K90V2U14008

14-12

Floor Board

65TMV-2

CHASSIS 14

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

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

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

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

- Disconnect the side of the battery, and then, disconnect the side of the battery.

Before starting work: - Remove the decks and fenders.

- Remove the cab.

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

Note: Before disconnecting electrical couplers, hoses and pipes, put matchmarks on them to help during reassembly.

Prepare a drain pan for the oil.

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

The cab may be removed with the floor board assy.

Be sure to have an adequate overhead clearance and lifting capacity. : Floor board assy with cab: 700 kg (1,540 lbs)

1) Disconnect air duct hose (1) by releasing the hose band.

Note: Cover the disconnected hose with a plastic cap, plug or vinyl to protect it from dust, water and dirt.

1 1 K65V2U14015

14-13

Floor Board

65TMV-2

CHASSIS 14

2) Put matchmark and disconnect pilot hydraulic line hose (2) at the port located on the hydraulic tank.

Put matchmark and disconnect pilot hydraulic line hoses (3) at the control valve.

Disconnect the hose (4) to the brake line valve unit.

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

Pilot valve

Control box

2

3

Hydraulic tank

3

4 3 Control valve K65V2U14016

Air conditioner

3) Disconnect hoses (5)~(7) from the air conditioner unit.

7

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

Torque for assembly : : Nut (7): 40 N-m (4.1 kgf-m) (30 lb-ft) Floor board

5 6

K90V2U14010

4) Put matchmark on hoses (8), and then disconnect them from the Orbitrol®.

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

Operation stand

8

8 8 Orbitrol

R

K65V2U14017

14-14

Floor Board

65TMV-2

CHASSIS 14

5) Disconnect pipe (9) and brake line hoses (10) from the brake valve.

9

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

10

K65V2E14021

6) Disconnect hose (11) from the window washer liquid tank at the floor board.

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

11 11

K65V2U14018

7) Remove erastic plug (12) and floor board retaining nut (13).

Temporarily sling then gradually lift the floor board while checking that there are no obstacles and that all the pipes, cables, pins, etc. are disconnected. : Floor board assy including ope. stand, control box, etc.: 300 kg (660 lbs) Torque for assembly : : Nut (13): 230 N-m (23.5 kgf-m) (170 lb-ft)

12 13

Floor board

14

Rubber cushion

Ref.: Torque to mount the rubber cushion. : Bolt (14): 76 N-m (7.8 kgf-m) (56 lb-ft)

2. Reinstalling floor board For reinstallation, follow the above procedure in reverse order.

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

14-15

K65V2U14019

Boom

65TMV-2

CHASSIS 14

Boom Removing and reinstalling boom

WARNING

1. Removing boom

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 oil tank and lines.

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

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

6 10

7

1) Remove pins (1) to remove the bucket. : Bucket: 750 kg (1,655 lbs)

11

4

Note: There are shims in the pin sections.

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

2

3

8

9

2) Support bucket cylinder (5) by wooden block. Attach sling to link assembly (4), and remove pins (3)(2) to remove link assembly (4).

Bucket

: Link assembly: 90 kg (200 lbs)

1 K70T2U14001

3) Attach sling to bucket cylinder (5). Remove pin (6) and remove bucket cylinder (5). : Bucket cylinder : 60 kg (135 lbs)

4) Attach sling to rod (7), and then remove pin (8).

14-16

Boom

65TMV-2

5) Attach sling to boom (11), and remove pins (9)(10).

Slowly lift boom (11) to remove it from the front chassis. : Boom : 520 kg (1,150 lbs)

WARNING Loss of control of the boom structure during removal or installation could result in injury or death.

When you sling the boom, be sure to check that the boom is horizontal. If the boom is inclined, it may unexpectedly tilt the end of the boom resulting in loss of control. Stay clear of boom.

2. Reinstalling boom For reinstallation, follow the above procedure in reverse order.

Note: Be sure to adjust the clearance of the retainer pin sections using the liners.

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

14-17

CHASSIS 14

Center Pin

65TMV-2

CHASSIS 14

Center Pin Upper center pin

Split shim

Lower center pin T1

T2 L1

K65V2E14024

Upper center pin T1

T1: 206 N-m (21 kgf-m) (152 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) L1: With lubricating oil (Engine oil or gear oil) Plate Shim adjustment Front chassis

Shim adjustment: Adjust the clearance to 0.1±0.05 mm (0.0039±0.0020 in) using the appropriate shim.

After that, tighten the T1 bolt.

Rear chassis T2 L1

K65V2U14020

14-18

Center Pin

65TMV-2

CHASSIS 14

Removing and reinstalling center pin 1. Removing center pin

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

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

- Apply a stopper to the rear axle oscillation section to prevent the machine from oscillation.

- Release the residual pressure from the hydraulic lines, and also release the internal pressure from the hydraulic tank.

- Cover the steering cylinder rod to prevent it from being scratched.

2

1 65ZV14028J

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

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

Torque for assembly: : Bolt (2): 80 N-m (8.2 kgf-m) (59 lb-ft) : Screw lock agent application (Loctite® 262)

1

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

3

3) Disconnect brake hose (4), and disconnect the electrical line from the coupler. : Hydraulic oil : Approx. 1.5 (0.4 gal)

4

Note: Plug or cover the brake line hoses to protect them from dust and dirt.

65ZV14030J

14-19

65ZV14029J

Center Pin

65TMV-2

CHASSIS 14

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

5

65ZV14031J

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

6

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

7

65ZV14032J

6) Remove upper center pin retainer bolt (13).

Torque for assembly: : Bolt (13): 422 N-m (43.0 kgf-m) (311 lb-ft)

13

65ZV14035J

7) Screw the M10 (pitch 1.5) bolt of approximately 70 mm length into the center of bushing (14) to push out the bushing. This bolt is used as a jack screw.

Jack screw: M10 (Pitch 1.5), totally threaded 14

M10 x 1.5

70

Jack screw 65ZV14011

14-20

65ZV14012

Center Pin

65TMV-2

CHASSIS 14

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

15

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

Jack 65ZV14013

WARNING When using a crane, incorrect signals and insufficient sling capacity could cause an accident resulting in injury or death. To prevent such an accident, observe the following items : - Check sling capacity before using and do not use improper sling.

- Use signals as agreed upon before starting work.

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

16

65ZV14038J

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

17

Jack 65ZV14014

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

18

Rolling floor jack 65ZV14015

14-21

Center Pin

65TMV-2

CHASSIS 14

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

19

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

Jack 65ZV14017

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

Note: While turning the rear tires, check that the rolling floor jack under the hydraulic tank rolls backward together with the rear chassis.

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

Bar 65ZV14018

14) Remove ring (20).

Remove bolts (22) from plate (21).

Torque for assembly: : Bolt (22): 206 N-m (21.0 kgf-m) (152 lb-ft)

20

22

21

65ZV14043J

24

15) Remove shim (23).

Note: If taper roller bearing (24) is replaced, be sure to adjust the clearance using shims.

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

23 65ZV14044J

14-22

Center Pin

65TMV-2

CHASSIS 14

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

25

Note: Direction of the dust seal

Center pin

65ZV14044

65ZV14019

26

65ZV14046

2. Reinstalling center pin For reinstallation, follow the above procedure in reverse order.

3. Cautions regarding reassembly - After reinstallation, grease center pins, and operate them.

During operation, check the pins for abnormal noise and looseness.

- Be sure to completely bleed the brakes of air.

For air bleeding procedure, refer to the Section 24.

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

- Check each section for oil leakage.

- No oil leakage should be found in any part.

14-23

MEMO

CHASSIS GROUP 15 Service Standard Linkage .......................................................................................................15-2 Linkage Pin Standard Clearance Values ....................................................15-3 Center Pin ...................................................................................................15-5 Attachment Leveler .....................................................................................15-6

15-1

Linkage

65TMV-2

CHASSIS 15

Linkage mm (in) 1. Bucket - Boom

2. Boom - Link B

3. Boom - Boom cylinder

ø50 (1.97)

ø60 (2.36)

5. Bucket - Link A

ø70 (2.76)

6. Link A - Link B

ø60 (2.36)

ø80 (3.15)

7. Link A - Bucket cylinder

10. Boom - Link C

ø70 (2.76)

11. Link D - Front chassis

ø70 (2.76)

13. Front chassis Steering cylinder

8. Bucket cylinder - Link C

ø60 (2.36)

ø50 (1.97)

9. Boom cylinder Front chassis

4. Front chassis - Boom

ø60 (2.36)

12. Link C - Link D

ø70 (2.76)

ø60 (2.36)

14. Steering cylinder Rear chassis

K65T2U15001

ø40 (1.57)

ø40 (1.57) 8 4 10 11 9

7 6

12

5 13

14

3 2 1

65TMV12004

15-2

Linkage Pin Standard Clearance Values

65TMV-2

CHASSIS 15

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

ø60 (ø2.36)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

2

Joint section between boom and link B

ø50 (ø1.97)

0.167~0.211 (0.0066~0.0083)

1.0 (0.0393)

Replacement

3

Joint section between boom and boom cylinder

ø70 (ø2.76)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

∗∗

4

Joint section between front chassis and boom

ø80 (ø3.15)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

∗

5

Joint section between bucket and link A

ø60 (ø2.36)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

6

Joint section between link A and link B

ø50 (ø1.97)

0.167~0.211 (0.0066~0.0083)

1.0 (0.0393)

Replacement

7

Joint section between link A and bucket cylinder

ø60 (ø2.36)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

8

Joint section between bucket cylinder and link C

ø60 (ø2.36)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

9

Joint section between boom cylinder and front chassis

ø70 (ø2.76)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

10

Joint section between boom and link C

ø70 (ø2.76)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

11

Joint section between link D and front chassis

ø70 (ø2.76)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

∗

12

Joint section between link C and link D

ø60 (ø2.36)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

∗

13

Joint section between front chassis and steering cylinder

ø40 (ø1.57)

0.080~0.205 (0.0031~0.0080)

1.0 (0.0393)

Replacement

∗

14

Joint section between steering cylinder and rear chassis

ø40 (ø1.57)

0.080~0.205 (0.0031~0.0080)

1.0 (0.0393)

Replacement

∗

15-3

Linkage Pin Standard Clearance Values

65TMV-2

CHASSIS 15

Liner clearance adjustment ∗

∗∗

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

∗ Adjust the liner clearance between the bosses to 1.2 mm (0.047 in) or less using liner of 1 mm (0.039 in) thickness.

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

Wear then occurs on the liners and reduces wear on the chassis. Excessive vertical free play in the steering cylinders can result in loud knocking noises when the steering wheel is turned.

∗∗ Only in case the clearance at the machine center side is more than 4.5 mm (0.177 in), adjust using liner of 4.5 mm (0.177 in) thickness.

70ZV15001

15-4

Center Pin

65TMV-2

CHASSIS 15

Center Pin Shim adjustment The clearance between the front chassis and bearing cover (3) is 0.75±0.5 mm (0.03±0.02 in) before shim adjustment.

Add shims (5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in).

1 4

8

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

Upper

65ZV12008

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

Front

20

Grease nipple installation direction 65ZV15001

15-5

Attachment Leveler

65TMV-2

CHASSIS 15

Attachment Leveler

Attachment leveler

K65T2U15002

15-6

Attachment Leveler

65TMV-2

CHASSIS 15

Attachment leveler Outside boom Bucket cylinder (R.H)

Inside boom Indicator lamp

5±2

Indicator lamp

3 1

Rod (detected object) Proximity switch (for bucket)

2 Proximity switch (for fork attachment)

K65T2U15003

Unit: mm No.

Item

Judgment standard

Solution

1

Clearance of attachment leveler switch

5±2 (0.196±0.078 in)

Adjustment

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

15-7

MEMO

POWER GROUP 24 Disassembly and Reassembly Power Line ..................................................................................................24-2 Radiator ......................................................................................................24-3 Fan ..............................................................................................................24-6 Engine .........................................................................................................24-8 Propeller Shaft ..........................................................................................24-12 Air Cleaner ...............................................................................................24-14 Muffler .......................................................................................................24-16 Front Axle Assembly .................................................................................24-17 Rear Axle Assembly .................................................................................24-32 Axle Support .............................................................................................24-37 Differential Assembly ................................................................................24-39

24-1

Power Line

65TMV-2

POWER 24

Power Line Tightening torque T1 T5

T1

T1

T3 L1

T5 L3

T5 L1 T6 L3 Transmission T4 L1 T1

Second propeller shaft

Rear differential

T2 L1

T4 L1

T4 L1

T3 L1

Third propeller shaft

Front differential T4 L1

K65V2U24001 LK-DNB-201

: Bolt tightening torque T1: 417 N-m (42.5 kgf-m) (307 lb-ft) T2: 230 N-m (23.5 kgf-m) (170 lb-ft) T3: 216 N-m (22.0 kgf-m) (159 lb-ft) T4: 80 N-m (8.15 kgf-m) ( 59 lb-ft) T5: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft) T6: 44 N-m ( 4.5 kgf-m) ( 33 lb-ft)

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

L1: Screw lock agent (Loctite® 262) application L3: With lubrication oil (Engine oil or gear oil)

24-2

Radiator

65TMV-2

POWER 24

Radiator Tightening torque T3

T4

T4

T4

T3 L1 T3 L2

T2 T1 T3 L2

T5

T4 L2

K65V2E24002 LK-DLB-231

T3 L2

: Bolt tightening torque T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 117 N-m (12.0 kgf-m) ( 87 lb-ft) T3: 94 N-m ( 9.6 kgf-m) ( 69 lb-ft) T4: 53 N-m ( 5.4 kgf-m) ( 39 lb-ft)

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

24-3

Radiator

65TMV-2

POWER 24

Removing and reinstalling radiator 1. Removing radiator

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting radiator 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 form moving.

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

Before starting work: - Remove the engine roof (Refer to Chassis group.)

- Remove the fan guard (Refer to "Fan" pages within this section.) For easier work, release and/or remove the fan.

Rear grill

3

1) Remove bolts (1)(2) and remove the radiator guard (3) with rear grill.

1

Screen board

: Radiator guard (including rear grill): 85 kg (185 lbs)

1 2 K65V2E24003

2) Remove drain plug (4) to drain the coolant.

Radiator

6 Bracket

: Coolant 30

(8 gal)

8

3) Disconnect hoses (5)~(8) from the radiator.

5

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

Fuel tank K65V2E24004

24-4

4

7

Radiator

65TMV-2

POWER 24

4) Disconnect air cooler hose (9) from the air cooler.

Torque for assembly: : Hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft)

9

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

During reassembly, carefully inspect and clean the hoses and air cooler of any contaminates. Anything left in the lines or air cooler will go directly into the engine causing extensive engine damage.

9

K65V2E24005

5) Disconnect hose (10) from the hydraulic oil cooler. : Hydraulic oil 1.5

Hydraulic oil cooler

(0.4 gal) 10

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

10

K65V2E24006

6) Temporarily sling radiator assembly (11). Remove right and left retainer bolts (12) to remove radiator from the rear chassis. : Radiator assy: 130 kg (290 lbs) Torque for assembly: : Bolt (12): 230 N-m (23.5 kgf-m) (170 lb-ft) : With lubricating oil (Engine oil or gear oil)

11

12

K65V2U24002

2. Reinstalling radiator For reinstallation, follow the above procedure in reverse order.

Note: Reinstall the radiator assembly while checking that the clearances between the fan and the radiator shroud are about 7.5 mm (0.3 in) and equal at all ends.

24-5

Fan

65TMV-2

POWER 24

Fan Removing and reinstalling fan 1. Removing fan

WARNING If a person stars 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 ENGINE ! ” tag on the steering wheel, or disconnect the negative side of the battery.

2 1

Before starting work: - Remove the engine roof (Refer to section 14).

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

1 2

1

Note: For easier work, you may disconnect the hoses from the fan motor.

24-6

Air cooler Radiator

4

Torque for assembly: : Air hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft)

3) Temporarily sling the fan mount including the fan motor. : Fan mount: Approx. 40 kg (85 lbs)

K65V2E24009

3

2) Disconnect the hoses (3)~(5) at the top of the radiator mount to have the space from which you can take out the fan.

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

The condenser for the air conditioner is fixed to the radiator cover bracket (in the LH side). If you take out the fan from this side, disconnect the hoses and remove the condenser together with the cover.

(Refer to the previous section "Radiator" step 6) for the detail.)

2

5

K65V2E24010

Fan

65TMV-2

4) Remove bolts (6) and release plates (7) from the fan shroud. The fan mount becomes free.

POWER 24

6 7 Fan motor

Torque for assembly: : Bolt (6): 94 N-m (9.55 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil)

9 7 6 7

70V2E24012

5) Remove retainer bolts (10)(11) for fan (9).

Torque for assembly: : Bolt (10)(11): 94 N-m (9.55 kgf-m) (69 lb-ft) : Bolt (10): Screw lock agent (Loctite ® 262) application : Bolt (11): With lubrication oil (Engine oil or gear oil) Note: Bolt (10) is tightening the plate. To avoid loosening bolt (10), be sure to apply the screw lock agent.

6) Take out fan (9). : Fan: 7 kg (16 lbs) Note: Carefully remove the fan while checking that the fan will not damage the radiator fins. Inspect the fan and replace it if there are any signs of damage or cracks.

Fan blade breakage can cause extensive damage.

2. Reinstalling fan For reinstallation, follow the removing procedure in reverse order.

Note: Refer to "Fan Motor" in Section 44 to remove and/or disassemble the fan motor.

24-7

9 Fan motor Plate 10

11 K65V2E24011

Engine

65TMV-2

POWER 24

Engine Removing and reinstalling engine 1. Removing engine

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

- Apply the articulation stopper.

- Block the front wheels with chocks 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.

- Select correct tooling to remove the engine and the transmission.

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

- Remove the muffler (Refer to "Muffler" pages within this section.)

- Remove the fan guard and the fan (Refer to "Fan" pages within this section.)

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

Radiator

2

1

1) Remove plate (2) and remove hose (1) from the radiator, and remove hose (3) from the cooling unit both at engine side.

2) Remove the wires from all sensors, alternator, starter motor and air conditioner.

3) Remove air hose (4) from the air cooler and hose (5) from the air cleaner.

3

Cooling unit

K65V2E24012

Air cleaner

4

Torque for assembly: : Hose band for hose (4): 5.7 N-m (0.58 kgf-m) (4.2 lb-ft) 4 5 K65V2E24013

24-8

Engine

65TMV-2

POWER 24

4) Remove exhaust pipe (6) from the engine.

Remove bolts (7)(8) and remove muffler brackets (9)(10) from the engine.

7

9

Torque for assembly: : Bolt (7): 53 N-m (5.4 kgf-m) (39 lb-ft) : Bolt (8): 28 N-m (2.8 kgf-m) (21 lb-ft)

6 10

8

K65V2E24014

5) Remove filter line hoses (11) and fuel line hoses (12).

11

12

K65V2E24015

6) Remove cover (13) on the torque converter case. Turn the torque converter drive cover slowly, and remove bolt (14) connecting the engine flywheel and the torque converter flexible plate.

13

Torque for assembly: : Bolt (14): 44 N-m (4.5 kgf-m) (33 lb-ft) : With lubrication oil (Engine oil or gear oil) 14

24-9

K65V2E24016

Engine

65TMV-2

POWER 24

7) Temporarily sling the engine and the transmission, and then, remove engine assembly mounting bolts (15)(16).

16

CAUTION Because it is needed to sling engine obliquely when removing, install chain block to radiator side. : Engine: 480 kg (1,060 lbs) (Excluding oil) Transmission: 535 kg (1,180 lbs) Torque for assembly: : Bolt (15)(16): 53 N-m (5.4 kgf-m) (39 lb-ft) : Screw lock agent (Loctite® 262) application (*Bolt (15) only)

15

K65V2E24017

8) Place a support, like a block, under the transmission oil pan to hold the transmission.

Then remove bolt (17) connecting the torque converter case and engine flywheel housing.

17

Torque for assembly: : Bolt (17): 53 N-m (5.3 kgf-m) (39 lb-ft) : With lubricating oil (Engine oil or gear oil) K65V2E24018

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

Note: Lift the engine approximately 100 mm (4 in).

Insert wooden piece of approximately 200 mm (8 in) thickness into the clearance between the flywheel bottom and the rear axle to separate the engine and the transmission. Repeat this two to three times to completely separate the engine and the transmission from each other.

Carefully lift the engine while checking that there are no obstacles around it.

24-10

Engine

65TMV-2

2. Reinstalling engine For reinstallation, follow the above procedure in reverse order.

3. Cautions regarding engine reinstallation - Replace the o-ring between the engine and the torque converter with a new one.

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

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

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

- Operate the engine at idling speed for 5 minutes. After that, check the amount of coolant.

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

24-11

POWER 24

Propeller Shaft

65TMV-2

POWER 24

Propeller Shaft Removing and reinstalling propeller shaft WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting radiator removal: - Position 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 form moving.

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

1. Removing second propeller shaft

1

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

2

Torque for assembly: : Bolt (2): 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application

65ZV24014J

4

2) Disconnect grease pipe (3), and remove bolt (5) from pillow unit bearing (4).

5 3

Torque for assembly: : Bolt (5): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent (Loctite® 262) application

65ZV24015J

7

3) Remove bolt (7) to disconnect the propeller shaft from front differential (6). Support the shaft by cable or rolling floor jack. Take out the second propeller shaft to the front.

6

Torque for assembly: : Bolt (7): 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application : Second propeller shaft: 35 kg (77 lbs) 65ZV24016J

24-12

Propeller Shaft

65TMV-2

POWER 24

2. Removing third propeller shaft 1) Remove bolt (8).

Torque for assembly: : Bolt (8): 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application

8

2) Remove the third propeller shaft.

8 Rear differential

65ZV24017

: Third propeller shaft: 10 kg (25 lbs)

3. Reinstalling propeller shaft For reinstallation, follow the above procedure in the reversed direction.

Always replace drive shaft bolts with new bolts - Never reuse them.

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

Also adjust the shafts so that the grease nipples on them come to the same direction.

Transmission

Second propeller shaft

Third propeller shaft K65V2E24019

24-13

Air Cleaner

65TMV-2

POWER 24

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

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 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

3

2

1) Release cover latches (1) and then remove cover (2).

Carefully take out outer element (3), and then remove inner element (4).

Remove rubber valve (5). Inspect it for damage and replace if necessary.

1

5 K65V2E24020

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

2) Remove the engine roof.

3) Disconnect air duct (6) and disconnect indicator wire coupler (7). Inspect duct (6) for damage or wear.

Replace if there is any damage or wear.

7

6

Air cleaner K65V2E24021

4) While supporting air cleaner case (8) with your hand, remove band retainer bolts (9).

5) Lower the air cleaner case, and then, take it out from the opening.

9

8

K65V2E24023

24-14

Air Cleaner

65TMV-2

POWER 24

2~3 mm(1/ 8 in)

2. Reinstalling air cleaner

5 mm (1/4 in) or less

For reinstallation, follow the above procedure in reverse order.

Fix the bands avoiding the beading.

Air duct

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

(Air cleaner or Engine) Insertion amount: 35mm (1 1/2 in) K65T2U24001

24-15

Muffler

65TMV-2

POWER 24

Muffler Removing and reinstalling muffler 1. Removing muffler

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

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

1

2

Torque for assembly: : Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft)

4 3

2) Sling engine roof (3) and remove bolt (4) to remove the roof. : Engine roof (3): 15 kg (35 lbs)

Muffler

K65V2E24031

8

3) Disconnect drain pipe (5), remove U-clamp (6) and exhaust pipe (7).

9 5

Note: Cover the turbocharger side of the pipe with vinyl to protect from dust and dirt.

4) Remove bolt (8), and then remove muffler (9).

Torque for assembly: : Bolt (8): 53 N-m (5.4 kgf-m) (39 lb-ft) : Muffler: 18 kg (40 lbs)

6 7

2. Reinstalling muffler For reinstallation, follow the above procedure in reverse order.

Note: After reinstallation, check all the joints for gas leakage and vibration.

K65V2E24024

24-16

Front Axle Assembly

65TMV-2

POWER 24

Front Axle Assembly Tightening torque T2 L3

Front differential

T3 L1

L2 Joint surface

A T3 L1

T1 K65V2E24025

: Bolt tightening torque T1: 892 N-m (91.0 kgf-m) (658 lb-ft) T2: 721 N-m (73.5 kgf-m) (532 lb-ft) T3: 314 N-m (32.0 kgf-m) (232 lb-ft)

: L1: Screw lock agent (Loctite® 262) application L2: Liquid gasket (Three Bond 1215) application L3: With lubrication oil (Engine oil or gear oil) Preload of section (A): 93~129 N (9.5~13.2 kgf) (20.9~29.0 lbf)

24-17

Front Axle Assembly

65TMV-2

POWER 24

Removing and reinstalling front axle assembly 1. Removing front axle assembly

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

- Apply the parking brake and articulation stopper.

- Block the front wheels with chocks to prevent the wheels from moving - Stands must be able to support weight of the front chassis, boom, and attachment.

Before starting work: - Lift the front wheel using the attachment, and then place a stand under the front chassis to support the chassis.

- Lift the boom, and place a stand under the boom to support it or install a boom cylinder lock collar.

Stand Stand 70ZV24017

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

1

65ZV24029J

2) Remove the retainer bolt (3) for the second propeller shaft (2).

Torque for assembly: : Retainer bolt (3): 80 N-m (8.15 kgf-m) (59 lb-ft) : Screw lock agent (Loctite® 262) application 3

2

65ZV24030J

24-18

Front Axle Assembly

65TMV-2

POWER 24

3) Disconnect air bleeder tube (4) and brake pipe (5).

4

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

5

65ZV24031J

4) Attach sling to axle assembly (6), and then remove eight retainer bolts (7).

7

: Front axle assembly (6): 525 kg (1,160 lbs) Torque for assembly: : Bolt (7): 721 N-m (73.5 kgf-m) (532 lb-ft) Note: During reassembly be sure both joint surfaces are clean and free of paint. Apply liquid gasket (Three Bond 1215).

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

2. Reinstalling front axle assembly For reinstallation, follow the above procedure in reverse order.

After reinstallation, completely bleed air in the service brake line.

24-19

6 65ZV24032J

Front Axle Assembly

65TMV-2

POWER 24

3. Air bleeding procedure

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.

1) Verify that the wheels are securely blocked, and the articulation lock is in the "locked" position.

2) Charge accumulator to full pressure, then, shut off engine, and complete procedure.

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

4) Connect a vinyl tube to the air bleeder nipple provided in the differential gear housing, and place an oil can to receive the oil.

(The air bleeder nipple is equivalent to the one provided in the left brake valve.)

Vinyl tube length: 1.2~1.3 m (4 ft.)

Air bleeder nipple outside diameter: Approx. 8 mm (0.315 in)

Vinyl tube

Air bleeder nipple

Oil can 60ZV52011

K65V2E24032

5) Slightly loosen the air bleeder nipple, and then press and hold the brake pedal until no air is observed in the oil from the air bleeder nipple.

6) Tighten the air bleeder nipple.

7) Repeat this for all four wheels.

Torque for assembly: : Air bleeder nipple: 25 N-m (2.6 kgf-m) (19 lb-ft) 24-20

Front Axle Assembly

65TMV-2

POWER 24

Disassembling and reassembling front axle 1.Disassembling front axle

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

- Apply the parking brake and the articulation stopper.

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

- The stands must be able to support the gross weight of the front chassis, boom, and the bucket.

Before starting work: - Remove the axle assembly from the chassis.

- Drain gear oil (front, rear each) : Gear oil: 25 (6.6 gal)

2 1 65ZV24044J

1) Place axle assembly on work table using supports (1)(2).

Sling

2) Sling axle housing (4) and remove bolt (3).

Separate axle housing (4) from the differential assembly.

Note: Striking axle housing lightly by hammer may help to separate it from the differential assembly. : Axle housing: 180 kg (400 lbs)

WARNING

3

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

- Keep persons away from working area.

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

- Use a copper-hammer or a plastic hammer.

- Always wear protection goggles.

65ZV24019

4

6

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

5

24-21

65ZV24046J

Front Axle Assembly

65TMV-2

POWER 24

4) Remove steel plate (7).

7

65ZV24047J

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

4

Jig

65ZV24020

Jig ø18 bar (4 pcs) welded P.C.D.

60 ø350 220

80

14 100 P.C.D.230

Axle shaft 13-M24x2 65ZV24021

24-22

Front Axle Assembly

65TMV-2

POWER 24

6) Remove retainer (8).

8

65ZV24050J

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

10 9

65ZV24051J

8) Remove internal gear (11).

Note: When using the puller, temporarily install bolt (9) not to damage the axle shaft threaded part.

11

65ZV24052J

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

4

4

Axle shaft

12 65ZV24022

24-23

65ZV24054J

Front Axle Assembly

65TMV-2

POWER 24

10) Remove axle shaft (13) from jig.

13

65ZV24055J

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

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

- Keep persons away from working area.

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

- Use a copper-hammer or a plastic hammer.

- Always wear protection goggles.

24-24

14 15 65ZV24056J

Front Axle Assembly

65TMV-2

POWER 24

2. Reassembling axle assembly 13

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

- Be sure to replace O-rings and seals with new ones.

1) Install jig to axle shaft (13) and insert outer race (A) of oil seal (15) to the axle shaft.

Note: - Put gear oil to oil seal outer race(A).

- Insert race (A) to the place lower than the bearing installation end.

14 15

65ZV24057J

3.5

1.5

Inner race (B)

2) Put grease in lips of inner race (B) of oil seal (15).

Insert oil seal inner race (B) into the axle shaft and then assemble it with oil seal outer race (A).

Outer race (A)

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

Grease 65ZV24023

3) Insert bearing (14) into the axle shaft.

Axle shaft

Bearing installation end

Do not apply any oil here.

Oil seal details

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

- Keep persons away from working area.

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

- Use a copper-hammer or a plastic hammer.

- Always wear protection goggles.

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

4

13

65ZV24059J

24-25

Front Axle Assembly

65TMV-2

POWER 24

5) Insert the oil seal inner race into the axle housing.

65ZV24060J

6) Install bearing (12).

7) Put shim (16) on the end of axle shaft.

16 12

Shim: T= 0.1 mm (0.0039 in), 0.2 mm (0.0079 in), 0.3 mm (0.0118 in), 0.35 mm (0.0138 in), 0.5 mm (0.0197 in), 1.0 mm (0.0394 in)

65ZV24061J

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

Bolt(9)

Spider assembly 9 Axle shaft(13)

Shim (16)

10

Taper roller bearing(12)

65ZV24024 65ZV24063J

9) Measure the preload at the axle housing bolt hole.

Preload: 61~85 N (6.2~8.7 kgf) (14~19 lbf) In case the preload is not in correct range, shim adjustment (changing shim) is necessary.

Repeat steps 7) and 8) until you get the correct preload.

Disassemble and reassemble spider assembly for shim adjustment.

Refer to "Disassembling and reassembling spider assembly".

24-26

Spring balance

65ZV24025

Front Axle Assembly

65TMV-2

POWER 24

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

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

12) Install spider assembly (10). Apply liquid gasket to lock bolt (9) and tighten it.

11 17 65ZV24065J

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

10 8

13) Install retainer (8).

9 65ZV24066J

18

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

7 65ZV24067J

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

6

5 65ZV24068J

24-27

Front Axle Assembly

65TMV-2

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

POWER 24

Bolt

4

: 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Loctite® 262) application Liquid gasket (Three Bond 1215) application

WARNING After installing the axle housing to the differential assembly, axle assembly may be inclined when the sling is removed.

Loss of control of this axle assembly could result in injury.

Put appropriate support under the axle housing.

Refill gear oil after reassembling. : Gear oil: 25 (6.6 gal)

24-28

Liquid gasket application

65ZV24026

Front Axle Assembly

65TMV-2

POWER 24

Disassembling and reassembling spider assembly

1

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

65ZV24070J

2) Push spring pin (2) into planetary pin (3) using a bar.

Spring pin hole dia. ø6 +– 00.12

2

3) Strike out planetary pin (3) from the axle shaft side to the differential side.

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.

3 65ZV24071J

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

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

5 4 65ZV24072J

24-29

Front Axle Assembly

65TMV-2

POWER 24

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

4

6 65ZV24073J

7) Remove washer (7) with shim.

7

65ZV24074J

2. Reassembling spider assembly Clean and check all the parts. If a part is worn or damaged, replace it.

4

1) Install needle bearing (6) into planetary gear (4) after applying gear oil.

6 65ZV24073J

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

7

1

65ZV24075J

24-30

Front Axle Assembly

65TMV-2

POWER 24

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

1

5

4 65ZV24076J

4) Apply gear oil to planetary pin (3), and insert it into the spider. Align the spring pin holes on the planetary pin (3) and the spider.

3 Pin holes

65ZV24027

5) Insert spring pin (2).

The spring pin should not jut out from the spider.

Use a new spring pin.

2

65ZV24078J

24-31

Rear Axle Assembly

65TMV-2

POWER 24

Rear Axle Assembly Tightening torque

A

T1

T3 L1

L2 Joint surface

T3 L1

Rear axle support

Rear differential Front axle support

K65V2E24026

: Bolt tightening torque T1: 892 N-m (91.0 kgf-m) (658 lb-ft) T3: 314 N-m (32.0 kgf-m) (232 lb-ft)

: L1: Screw lock agent (Loctite® 262) application L2: Liquid gasket (Three Bond 1215) application Preload at section (A): 93~129 N (9.5~13.2 kgf) (20.9~29.0 lbf)

24-32

Rear Axle Assembly

65TMV-2

POWER 24

Removing and reinstalling rear axle assembly 1. Removing rear axle assembly

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.

1) Lower the attachment onto the ground.

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

A

65ZV24033J

2) Lift the boom, and then roll the attachment back to release the support.

Check that the rear wheels are off ground.

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

B

65ZV24034J

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

Wooden block

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

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

65ZV24028

24-33

Rear Axle Assembly

65TMV-2

POWER 24

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

1

65ZV24036J

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

Torque for assembly: : Retainer bolt: 80 N-m (8.2 kgf-m) (59 lb) : Screw lock agent (Loctite® 262) application

2

65ZV24037J

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

3

65ZV24038J

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

(0.4 gal) 4

65ZV24039J

24-34

Rear Axle Assembly

65TMV-2

POWER 24

8) Attach sling to rear axle (5), and remove right and left retainer bolts (6) from the rear axle support.

Lower rear axle (5) on a carrier and pull it out.

6

Torque for assembly: : Bolt (6): 721 N-m (73.5 kgf-m) (506 lb-ft)

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 is firmly secured onto the carrier.

5

65ZV24040J

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

7 65ZV24041J

10) Sling rear support (8) temporarily and remove bolts (9) from plate (10). Remove plate (10). Remove rear support (8).

Torque for assembly: : Bolt (9): 132 N-m (13.5 kgf-m) (98 lb-ft) : Axle support (rear): 80 kg (176 lbs)

8 10

9

Note: Remove and clean the breather fitting.

Place the breather fitting on the top position.

Lubricate after reassembly until grease comes out of the breather.

65ZV24042J

11) Remove packing (11).

11

65ZV24043J

24-35

Rear Axle Assembly

65TMV-2

2. Reinstalling rear axle assembly For reinstallation, follow the above procedure in reverse order.

Refer to "Reinstalling front axle assembly" for air bleeding in the service brake.

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

24-36

POWER 24

Axle Support

65TMV-2

POWER 24

Axle Support Tightening torque T1 L2

Front axle support FRONT

T1 L2

T2 L1 Rear axle support

T3 L1

K65V2E24027

: Bolt tightening torque T1: 721 N-m (73.5 kgf-m) (532 lb-ft) T2: 314 N-m (32.0 kgf-m) (232 lb-ft) T3: 132 N-m (13.5 kgf-m) ( 98 lb-ft)

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

24-37

Axle Support

65TMV-2

POWER 24

Disassembling and reassembling axle support

Grease piping 1

1. Disassembling axle support (front) 1) Remove packing (2) from axle support (1).

Remove bushing (3).

2

Note: To reinsert bushing, position large chamfer side of bushing at grease piping hole side, and position end gap of bushing at bottom.

Apply enough grease to inner surface of bushing.

Front 3

Large chamfer

65ZV24029

Small chamfer 30°

C1

Bushing section 65ZV24030

2. Disassembling axle support (rear) Grease piping

1) Remove packing (5) and bushing (6) from axle support (4).

Note: To reinsert bushing (6), insert it from the side with large chamfer for easier insertion (the large chamfer positions to the grease piping hole side of the axle support).

Apply enough grease to the inner surface of the bushing.

5 6 Front

4 5 65ZV24031

8

3. Reassembling axle support To reassemble the axle support, follow the above procedure in reverse order.

7

Note: Grease pipe (7) faces to the side, and grease pipe (8) should face downward.

After reassembling, manually operate the axle to check for any abnormal noise and looseness.

K65V2E24028

24-38

Differential Assembly

65TMV-2

POWER 24

Differential Assembly Tightening torque 1. Front differential T1 L2

A L2

T5

T3 L1

1 (T=14.68~15.08)

T3 L1 4 (T=0.076 ~0.800) 5

6 2 3

T3 L1

T2 L1

T4 L1

5

K65V2U24003

: Bolt tightening torque T1: 363 N-m (37.0 kgf-m) (268 lb-ft) T2: 206 N-m (21.0 kgf-m) (152 lb-ft) T3: 132 N-m (13.5 kgf-m) ( 98 lb-ft) T4: 26 N-m (2.65 kgf-m) ( 19 lb-ft) T5: 20 N-m ( 2.0 kgf-m) ( 14 lb-ft)

Note: Refer to the following "2. Rear differential" for the axle nut (T1) tightening procedure.

: L1: Screw lock agent (Loctite® 262) application L2: Liquid gasket (Three Bond 1215) 24-39

Differential Assembly

65TMV-2

2. Rear differential

POWER 24

T5

3 5

T3 L1 T3 L1

6 T3 L1

2

T4 L1

1 (T=14.68~15.08)

5 T2 L1

4 (T=0.076 ~0.800)

L2

T3 L1 A

K65V2U24004

T1 L2

Caulking(Stake)

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

Bearing

Preload of section A: 40~79 N (4.1~8.1 kgf) (9~18 lbf) Use spacer (1) to adjust preload.

2. Use shim (4) to adjust tooth contact of spiral bevel gears (2)(3).

Adjust backlash by nut (5).

3. Press bearing (6) (the ring part to be faced to the pinion) into the pinion and stake the end of the pinion at three points.

24-40

Diff. pinion Ring part

65ZV24032

Differential Assembly

65TMV-2

Disassembling and reassembling differential assembly

POWER 24

1

1. Disassembling differential assembly Before starting work: - Support the differential assembly to prevent it from tilting.

1) Fix the remover bolts into brake piston (1). Feed air through the brake pipe connecting port, and draw out brake piston (1).

Remover bolt

65ZV24033

CAUTION If extremely high air pressure is applied instantly, the piston may spring out unexpectedly.

To prevent this, apply low pressure 98~196 kPa (1~2 kgf/cm2) (14~28 psi) and install a stopper.

2

2) Remove differential carrier cover (2).

65ZV24082J

3) Lift the differential cage lightly by sling (A).

18 7 2

ø20

t9 20

ø11

Width across flat 10

M10x1.5

Pin

11

65ZV24083J

320

Nut

ø13

45

12

A

15 70

28

Pin

140

14

67

70

33

Material SS41

30

t6

11 abt 10 °

Sling A

38

65ZV24034

24-41

Differential Assembly

65TMV-2

POWER 24

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

4

5 65ZV24085J

5) Remove differential cage (6) from differential carrier (7).

Refer to "Disassembling and reassembling differential cage".

6 7

65ZV24086J

6) Remove bolts (8) and then remove pinion assembly (9) from the differential carrier.

Refer to "Disassembling and reassembling pinion assembly".

8 9

Top for remover bolt 65ZV24035

24-42

Differential Assembly

65TMV-2

POWER 24

2. Reassembling differential assembly

IMPORTANT

6

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

- Be sure to replace O-rings and seals with new ones.

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

7

65ZV24088J

2) Install pinion assembly (9) to differential carrier (7).

Note: Match holes of differential cage, differential carrier and shims.

8 9

Torque for assembly: : Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application 65ZV24089J

3) Place the differential carrier side ways.

Differential carrier

65ZV24036

4) Install O-ring (10) to the differential carrier.

Note: Apply hydraulic oil to the O-ring.

10 65ZV24091J

24-43

Differential Assembly

65TMV-2

POWER 24

5) Install bearing carrier (5) to differential carrier (7) and tighten bolts (6).

7 5

Torque for assembly: : Bolt (6): 206 N-m (21.0 kgf-m) (152 lb-ft) : Screw lock agent (Loctite® 262) application

6

65ZV24093J

Insert

6) Install O-ring to brake piston.

Note: Before installing the O-ring, apply hydraulic oil and avoid torsion.

O-ring

Piston

65ZV24049

7) Apply hydraulic oil to the differential carrier and brake piston (1).

Install brake piston (1) to the differential carrier.

1

Note: When installing piston (1), take care not to cut or damage the O-ring.

65ZV24095J

24-44

Differential Assembly

65TMV-2

POWER 24

8) Turn over the differential carrier and reassemble the opposite side in the same manner as the foregoing steps 4) through 7).

B

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

9-1) Install jig (B) to differential carrier using axle housing installation holes. t=16

40

65ZV24096J

ø18

ø18

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

25

ø210

ø390

ø290

120° Material SS41

Jig B

65ZV24037

9-2) Feed air pressure at about 588 kPa (6 kgf/cm2) (85 psi) through the brake pipe connecting port C. 9-3) Splash soapy water over brake piston (1) and the air bleeder nipple and then check for air leakage.

9-4) If there found no air leak at these check points, stop air feeding and loosen the air bleeder nipple to discharge air.

9-5) If air leaks at the brake piston, remove the piston, replace the O-ring with a new one, carry out the operation in the foregoing steps 4) through 8) and then conduct an airtight test.

9-6) If there' s no leak, remove jig and push in the brake piston completely.

Note: If brake piston is insufficiently pushed in, the axle housing cannot be attached. Be careful to fully push it in.

24-45

1

C 65ZV24098J

Differential Assembly

65TMV-2

10) Turn differential carrier (7) with the cover attached side upward and hold the differential carrier by supports to prevent it from tilting.

11) Adjust the backlash.

11-1) Remove lock plate (11) (on both the right and left sides).

11-2) Tighten adjusting nut (12) on the ring gear side until the backlash is reduced down to zero, and then loosen the nut by 2 to 3 notches.

11-3) Tighten adjusting nut (13) on the opposite side until you feel a touch, and then tighten the nut further by one notch.

11-4) Attach the dial gauge stand to the carrier, fit the dial gauge to the tooth surface of ring gear (14), and read the value of backlash.

11-5) Adjust the backlash to the standard value of 0.20 to 0.28 mm. (0.007~0.011 in) - Loosening the nut on the ring gear side and tighten that on the opposite side will increase the backlash.

- Tightening the nut on the ring gear side and loosening that on the opposite side will decrease the backlash.

POWER 24

7

65ZV24099J

Bolt

Adjusting nut 12 Ring gear Pinion assembly

Bolt Shim Lock plate 11

Adjusting nut 13

65ZV24038

12) Check for the tooth contact.

If the normal tooth contact is not obtained. Adjust the

14

thickness of shims at the pinion assembly attached part and the backlash to make it normal, referring to the item of "Adjusting tooth contact".

Thickness of shims: 0.075, 0.10, 0.25, 0.50, 0.80 mm (0.0029, 0.0039, 0.0098, 0.0196, 0.0314 in) Note: When adjusting with shims, match the holes of the carrier cage, the differential carrier and the shims to each other.

65ZV24101J

2

13) Mount lock plate (11), and then tighten the bolts to fix the lock plate. : Retainer bolt: 26 N-m (2.7 kgf-m) (20 lb-ft) : Screw lock agent (Loctite® 262) application 14) Install differential carrier cover (2).

65ZV24102J

24-46

Differential Assembly

65TMV-2

POWER 24

Adjusting tooth contact : After adjusting 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 the ring gear, and check tooth contact. To adjust the tooth contact, adjust thickness of shim between the pinion and the cage, and turn the adjustment nut.

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 the 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 the tooth contact.

C

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

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

Check again the backlash and the tooth contact.

D

E

Drive pinion is too far from the ring gear.

2

2

2

1

Decrease thickness of the shim in reverse as D, and make the drive pinion closer to the ring gear.

Check again the backlash and the tooth contact.

2

1

70ZV24033

24-47

Differential Assembly

65TMV-2

POWER 24

Three types of tooth contact shown below are acceptable as the best tooth contact.

Tooth contact position and length(rate) 10 1

Pattern A

5 TOP

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

3 HEEL

TOE Pitch line

4~5 BOTTOM

10 90ZV24135

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

Note: Individual sale of the bevel gear or the drive pinion is not available.

24-48

Differential Assembly

65TMV-2

POWER 24

Disassembling and reassembling differential assembly

3

1. Disassembling differential cage Note: Before starting work, put a matchmark on the alignment point of the differential cage.

1) Remove bolts (1) and then remove ring gear (2).

Torque for assembly: : Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application

2

Matchmark

1 3 65ZV24039

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

3) Remove bolts (4) and separate the cage.

Torque for assembly: : Retainer bolt: 132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application

4

Matchmark

65ZV24040

65ZV24105J

24-49

Differential Assembly

65TMV-2

POWER 24

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

Thrust washer Diff. cage

6 5

Diff. cage

8

7 65ZV24041

2. Reassembling differential cage To reassemble the differential cage, follow the above procedure in the reversed direction.

Note: - Clean and check all the parts.

If a part is worn or damaged, replace it with new one.

- Apply gear oil to the parts before reassembling.

- Warm bearing (3) in a oil bath up to 120~150°C (248~302°F) before installation.

24-50

Differential Assembly

65TMV-2

POWER 24

Disassembling and reassembling differential assembly 1. Disassembling pinion assembly

1

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

Torque for assembly: : Retainer bolt:132 N-m (13.5 kgf-m) (98 lb-ft) : Screw lock agent (Loctite® 262) application

65ZV24107J

2

2) Install removing bolt (2) and remove the pinion assembly from the differential carrier.

The pinion retainer bolt (1) can be used for removing bolt (2) (M12x1.75).

65ZV24108J

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

170 60

A

80

42.9

ø12

160

65ZV24109J

93.6

114.3 Bolt

40

5

70

170

Material SS41 4

Jig A 65ZV24042

3

6 7 65ZV24043

24-51

Differential Assembly

65TMV-2

POWER 24

4) Remove pinion gear (6) and pinion cage (7) together.

Tap pinion gear (6) out of pinion cage (7) with a plastic hammer.

7

WARNING 6

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.

Square ring

Nut 65ZV24044

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

Pinion cage

8

9

10

65ZV24113J

6) Remove spacer (11). Remove taper roller bearing (12) and roller bearing (13) from the pinion, using the bearing puller.

Note: Do not remove them unless they should be replaced.

13

12 11

65ZV24114J

24-52

Differential Assembly

65TMV-2

POWER 24

2. Reassembling pinion assembly 1) Warm roller bearing (13) in oil up to 120~150°C (248~302°F) and install it to the pinion.

After bearing cools, stake the pinion end at three points.

13

Caulking (stake)

65ZV24046

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

12 11

65ZV24116J

3) Fit taper roller bearing (10) and spacer (9) orderly into the pinion cage.

Note: Do not install the oil seal.

The oil seal should be installed after the preload of the bearing is adjusted.

9

10

Pinion cage 65ZV24047

Oil seal

65ZV24048

24-53

Differential Assembly

65TMV-2

POWER 24

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

5

65ZV24119J

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

14

7

5

65ZV24120J

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

6

7

65ZV24121J

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

4 3

65ZV24122J

24-54

Differential Assembly

65TMV-2

POWER 24

8) Tighten the nut.

Tightening torque: 363 N-m (37 kgf-m) (268 lb-ft)

65ZV24123J

9) Measure the preload.

Standard: 40~79 N (4.1~8.1 kgf) (9~18 lbf) If the measured preload exceeds the standard range, make an adjustment by replacing spacers.

Spacer: T=14.68~15.08 (0.5780~0.5937 in) (23 pieces at 0.02 pitch) (0.0007 in) Thicker spacers reduce preload ;thinner spacers increase preload.

65ZV24124J

10) After adjusting the preload, remove the nut and detach the flange from the pinion cage.

Install the oil seal to the pinion cage. : Liquid gasket (Three bond 1215) application

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

24-55

MEMO

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

25-1

Propeller Shaft Service Standard

65TMV-2

POWER 25

Propeller Shaft Service Standard

1

Third propeller shaft

2: Measurement of circumferential play

a

b

4 3: Measurement of transverse play

K65V2E25001

Second propeller shaft

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

Second propeller shaft

Standard: 51.6 (2.03)

----

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

25-2

Axle and Differential Service Standard

65TMV-2

POWER 25

Axle and Differential Service Standard Axle assembly 6

4

5

1,3

2,3

6

5

4

K65V2E25002

Unit : mm (in) Judgment standard No.

Solution

Item Standard dimension

Tolerance

1

Backlash between sun gear and planetary gear

0.18~0.54 (0.0071~0.0213)

←

Replacement

2

Backlash between planetary gear and internal gear

0.19~0.67 (0.0075~0.0264)

←

Replacement

3

Tooth contact of gear

No abnormality

4

Swing shaft wear

5

Bushing and wear ring wear

6

Axle support wear

160 -0.144 (6.30 -0.0057 )

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

Replacement

Depth of groove: 1.0 (0.04) or less

No oil groove

Replacement

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

Replacement

-0.044

-0.0017

Front 0.057

Rear

Replacement

0.0022

168.6 -0.006 (6.638 -0.0002 )

25-3

Axle and Differential Service Standard

65TMV-2

POWER 25

Differential

2

3

4

1

5

5 K65V2E25003

Unit : mm (in) Judgment standard Item

No.

Solution Standard valve

Tolerance

1

Backlash between ring gear and drive pinion

0.20~0.28 (0.0079~0.0110)

←

Adjustment

2

Backlash between side gear and pinion gear

0.23~0.45 (0.0091~0.0177)

←

Adjustment

3

Clearance between pinion gear and spider

0.112~0.153 (0.0044~0.0060)

←

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

25-4

TORQUE CONVERTER AND TRANSMISSION GROUP 34 Disassembly and Reassembly Torque Converter and Transmission Assembly ..........................................34-2 Torque Converter Assembly .......................................................................34-9 Transmission Assembly ............................................................................34-13 Forward/Reverse Clutch Pack ..................................................................34-18 2nd/3rd Speed Clutch Pack ......................................................................34-20 1st Speed Clutch Pack .............................................................................34-22 4th Speed Clutch Pack .............................................................................34-24 Special Tool ..............................................................................................34-26 Control Valve Assembly ............................................................................34-28

34-1

Torque Converter and Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter and Transmission Assembly Tightening torque T1 T5

T1

T1

T3 L1

T5 L3

T5 L1 T6 L3 Transmission T4 L1 T1

Second propeller shaft

Rear differential

T2 L1

T4 L1

T4 L1

T3 L1

Third propeller shaft

Front differential T4 L1

K65V2U24001

: Bolt tightening torque T1: 417 N-m(42.5 kgf-m)(307 lb-ft) T2: 230 N-m(23.5 kgf-m)(170 lb-ft) T3: 216 N-m(22.0 kgf-m)(159 lb-ft) T4: 80 N-m(8.15 kgf-m)( 59 lb-ft) T5: 53 N-m( 5.4 kgf-m)( 39 lb-ft) T6: 44 N-m( 4.5 kgf-m)( 33 lb-ft)

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

34-2

Torque Converter and Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

Before starting work: - Remove the cab and the floor board (Refer to Section 14).

- Remove the screen board (Refer to Section 14).

- Remove the steering valve by referring to section 44.

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

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

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

- Lines to cooler must also be replaced.

1

1) Remove drain plug (1) to drain the transmission oil. : Transmission oil: 20

(5.3 gal)

2

65ZV34001J

2) Disconnect hose (2) for the transmission oil level gauge.

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

Multiple control valve

3) Remove multiple control valve return pipe (3).

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

34-3

3 65V2E34001

Torque Converter and Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

4) Temporarily sling multiple control valve, and then remove bracket from rear chassis.

Bracket

Tightening torque for assembly: : Bolt: 53 N-m(5.4 kgf-m)(39 lb-ft) : Bracket with multiple control valve: 50 kg (110 lbs)

Multiple control valve

5) Remove pipes (4) and hoses (5) from hydraulic pump (1).

Remove bolts (6) and then remove hydraulic pump assembly.

65V2E34002

6 Torque converter

1 4

Tightening torque for assembly: : Bolt: 142 N-m(14.5 kgf-m)(105 lb-ft) Note: After removing the pipes and hoses, plug or cover the disconnected parts with clean vinyl to protect from dust and dirt.

5

4 65ZV34002

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

7

6) Disconnect hose (7) between torque converter pump and the line filter.

Disconnect hose (8) between the line filter and the torque converter.

8

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

65ZV34004J

9

10

7) Disconnect hoses (9)(10) between the torque converter and the oil cooler.

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

65ZV34005J

34-4

Torque Converter and Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

8) Disconnect clutch pressure measuring hose (11).

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

11

65ZV34006J

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

12 65ZV34007J

10) Remove bolts (13) from the second propeller shaft on the transmission side only.

Tightening torque for assembly: : Bolt: 80 N-m(8.15 kgf-m)(105 lb-ft) : Screw lock agent application (Loctite® 262)

13

65ZV34008J

11) Disconnect bolts (14) from the third propeller shaft on the transmission side.

Note: If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner.

Keep the flame away from the seals of the coupling.

Do not reuse the bolt once heated. : Bolt: 80 N-m(8.15 kgf-m)(59 lb-ft) : Screw lock agent application (Loctite® 262) 34-5

14

65ZV34009J

Torque Converter and Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

12) Attach sling to the transmission assembly and then remove bolts (15).

15

Tightening torque for assembly: : Bolt: 417 N-m(42.5 kgf-m)(307 lb-ft) : Transmission assembly: 535 kg(1,180 lbs)

65V2E34003

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

16

65ZV34011J

14) Remove 11 bolts (17) connecting the transmission housing and the engine flywheel. Remove 8 bolts (18) connecting the torque converter flexible plate and the flywheel.

Tightening torque for assembly: : Bolt (17): 53 N-m(5.4 kgf-m)(39 lb-ft) Bolt (18): 44 N-m(4.5 kgf-m)(33 lb-ft)

18

17

65ZV34012J

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

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

34-6

Torque Converter and Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

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

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

2) Check each section for oil leakage.

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

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

34-7

Torque Converter and Transmission Assembly

DATE:

HOURS:

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

MACHINE MODEL & SERIAL NO.:

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO.:

AMBIENT TEMP: COMPONENT SERIAL NO.:

CHECKLIST TO BE COMPLETED BEFORE START-UP TRANSMISSION COOLER CLEANED

TRANSMISSION PIPING CLEANED

IN-LINE PRESSURE FILTER REPLACED

TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

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

CLUTCH PRESSURE AT LOW IDLE F1

MPa (kgf/cm2) (psi)

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 F1

MPa (kgf/cm2) (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

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

34-8

Torque Converter Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Torque Converter Assembly Bolt tightening torque (Kawasaki CT140V03)

T3

T3

T3

50T

T4 F

55T

R

T1

28T 37T

T4

57T

2nd

T2

T1

65V2E34004

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

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

34-9

Torque Converter Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling torque converter assembly

Cover

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

- Drain oil from the transmission.

- Remove the cover from the torque converter housing.

3 1 2

1) Remove bolt (1) and then remove pilot boss (2).

Tightening torque for assembly: : Bolt: 28 N-m(2.85 kgf-m)(21 lb-ft)

4

2) Remove bolt (3) and then remove flexible plate (4).

Tightening torque for assembly: : Bolt: 28 N-m(2.85 kgf-m)(21 lb-ft)

65ZV34003

3) Remove bolt (5) for the drive cover.

Turbine shaft

Tightening torque for assembly: : Bolt: 29 N-m(3.00 kgf-m)(22 lb-ft) 10 9

4) Remove drive cover (6) and turbine (7) as an assembly.

Remove the snap ring (8) from the turbine shaft.

8

5) Remove lock nut (9).

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

IMPORTANT

7

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

6 11

5

6) Remove stator (10) and spacer (11).

34-10

65V2E34005

Torque Converter Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

7) Remove bolt (12) and then remove pump impeller assembly (13).

18

Tightening torque for assembly: : Bolt: 26 N-m(2.60 kgf-m)(19 lb-ft)

13

8) Remove four bolts (14). Remove cover (15).

Tightening torque for assembly: : Bolt: 34 N-m(3.5 kgf-m)(25 lb-ft)

Stator shaft

9) Remove pump boss (16). Remove gear (17) and 2 bearings (18) from pump boss (16).

12

17 15

14

16 65V2E34006

10) Remove bolt (19) and then remove the stator shaft.

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

19

Stator shaft

65V2E34007

34-11

Torque Converter Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

2. Reassembling torque converter assembly To reassemble the torque converter assembly, follow the above procedure in the reversed direction.

Before starting work: - Clean and check all the parts. If a part is worn or damaged, replace it with a new one.

- Before reassembly, apply transmission oil to the parts.

- Be sure to replace O-rings and seals with new ones.

- Install new bearing if replacement is needed.

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

34-12

Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly Bolt tightening torque (Kawasaki CT140V03) T3 T3 T3 50T

T4 T1

55T

R

F

28T

T4

37T 57T

2nd

1st

26T

T2

33T 43T

T1

47T

37T 23T

T6 38T

3rd 33T

4th

62T

T5 L1

T3 T5 L1

65V2E34008

: Bolt tightening torque T1: 28 N-m(2.85 kgf-m)( 21 lb-ft) T2: 29 N-m(3.00 kgf-m)( 22 lb-ft) T3: 69 N-m(7.00 kgf-m)( 51 lb-ft) T4: 34 N-m(3.50 kgf-m)( 25 lb-ft) T5: 255 N-m(26.0 kgf-m)(188 lb-ft) T6: 108 N-m(11.0 kgf-m)( 80 lb-ft)

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

34-13

Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling transmission assembly

Cover

1. Disassembling transmission assembly

1

Before starting work: - Clean the transmission assembly.

- Drain oil from the transmission - Remove the cover from the torque converter housing.

1) Remove bolt for pump suction pipe (1).

Tightening torque for assembly: : Bolt: 53 N-m(5.4 kgf-m)(39 lb-ft)

2) Remove pipe (2) and then remove the strainer.

2

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

65V2E34009

3) Remove bolt (3) and pilot boss, drive cover and the turbine.

3

Housing connection bolt Drive cover

Tightening torque for assembly: : Bolt: 29 N-m(3.00 kgf-m)(22 lb-ft)

50T

4) Remove the snap ring from the turbine shaft.

55T

Pilot boss

5) Remove the retainer bolt connecting the torque converter housing and the transmission housing.

Use a jacking bolt (M10x1.5) to separate the torque converter housing and the transmission housing.

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

Turbine Snap ring

34-14

65V2E34010

Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

6) Remove forward/reverse clutch pack (4) using a 16 mm eye bolt.

4

65V2E34011

7) Remove the 1st/2nd speed clutch pack (5) and the 3rd/4th speed clutch pack (6) at the same time using a special tool.

Special tool 5

6

65V2E34012

8) Remove bolt (7) and then remove drum (8).

Tightening torque for assembly: : Bolt: 108 N-m(11.0 kgf-m)(80 lb-ft)

9) Remove bolts (9)(10), flange (11) and the brake assembly.

Tightening torque for assembly: : Output flange bolt (9): 255 N-m(26.0 kgf-m) (188 lb-ft) Bolt (10): 255 N-m(26.0 kgf-m)(188 lb-ft) : Screw lock agent (Loctite® 262) application

13

10

12

9

11

10) Remove bolt (12), and then remove housing (13).

8 7

Tightening torque for assembly: : Bolt: 69 N-m(7.00 kgf-m)(51 lb-ft) 65V2E34013

34-15

Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

11) Remove speedometer drive gear (14).

Third prop. shaft

14

70ZV34006

12) Remove the bolt and then remove shroud (15) in the housing.

Bolt

Tightening torque for assembly: : Bolt: 28 N-m(2.85 kgf-m)(21 lb-ft) : Screw lock agent (Loctite® 262) application

15

65V2E34014

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

16

65ZV34026J

34-16

Transmission Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

2. Reassembling transmission assembly

Cautions for installation

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

- When installing oil seal apply grease to inner lip and liquid gasket (AA03) to outside seal.

- When installing O-ring, apply lithium grease to O-ring.

- Before installing the torque converter housing to the transmission housing, apply multipurpose EP/MOLY grease to (A) part.

Apply grease to the shaft (B and C) before installing seal ring.

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

- Before reassembly, apply transmission oil to the parts.

- Be sure to replace O-rings and seals with new ones.

- Install new bearing if replacement is needed.

IMPORTANT Make sure to rotate the shaft by hand during assembly and after assembly.

If it is hard to rotate the shaft by hand, disassemble and check the cause.

A

C B

65V2E34015

34-17

Forward/Reverse Clutch Pack

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Forward/Reverse Clutch Pack Disassembling and reassembling forward/reverse clutch pack 1. Disassembling forward/reverse clutch pack Note: This disassembling and reassembling procedures for the forward and reverse clutch packs are basically the same.

The different points are described for each procedure.

Forward clutch side

1) [Forward] [Reverse]

Remove snap ring (1), and then remove bearing (2), washer (3).

Remove bearing (2) and then remove washer (3), snap ring (4).

12

3

Clutch drum

5

2) Remove gear (5) from clutch drum.

4

3 2

5 Reverse clutch side 65V2E34016

3) Remove two bearings (6) and thrust washer (7), snap ring (8) from gear (5).

Forward clutch side

6 5

Note: When reassembling install the thrust washer (7) so that the groove faces to outside.

8

Outside

7 6

6

4) Remove snap ring (9) and then remove plate (10), back plate (11) from clutch drum.

Outside 5 8 Reverse clutch side

7 6

5) Alternately remove friction plate (12) and steel plate (13).

Forward clutch side

65V2E34017

Clutch drum

Note: When reassembling insert the friction plate (12) first.

Friction plates

Steel plates

Forward

9

8

Reverse

9

8

14 12

13

10 11 12 13

6) Remove plate (14) from clutch drum.

9

34-18

10

9

11 14

Reverse clutch side 65V2E34018

Forward/Reverse Clutch Pack

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

7) Pressing washer (15) using a special tool, then remove snap ring (16).

Forward clutch side 18 17 15 16

Clutch drum

8) Remove washer (15)(18) and spring (17), then feed air from the clutch oil port to remove clutch piston (19).

17

CAUTION

16

18

19

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

15

19 Reverse clutch side 65V2E34019

IMPORTANT Do not remove the clutch drum from the shaft.

2. Reassembling forward/reverse clutch pack For reassembling, follow the above procedure in the reversed direction.

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.

3. Cautions regarding reassembly 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.

Depth micrometer Straight edge

Piston stroke Forward, Reverse

Air line

3.0±0.2 mm (0.12±0.008 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.

Backing plate 85W34041

34-19

2nd/3rd Speed Clutch Pack

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

2nd/3rd Speed Clutch Pack Disassembling and reassembling 2nd/3rd speed clutch pack

2nd speed

3rd speed

1

1

2

2

1. Disassembling 2nd/3rd speed clutch pack 3

3

Note: This disassembling and reassembling procedures for the 2nd and 3rd clutch packs are basically the same.

The different points are described for each procedure.

4 4

5

5 65V2E34020

1) [2nd speed] Remove snap ring (1), bearing (2), washer (3), gear (4), snap ring (5).

[3rd speed] Remove snap ring (1), bearing (2), gear (3), gear (4), snap ring (5).

3rd speed clutch side 8 6

7

Clutch drum

2) Remove snap ring (6) and washer (7) and then remove gear (8) from clutch drum.

65V2E34021

3) Remove two bearings (9) and thrust washer (10), snap ring (11) from gear (8).

9

3rd speed clutch side 8

Note: When reassembling install the thrust washer (10) so that the groove faces to outside.

11 10 9

4) Remove washer (12) and snap ring (13) and then remove snap ring (14), plate (15), back plate (16) from clutch drum.

Outside 65V2E34022

5) Alternately remove friction plate (17) and steel plate (18).

3rd speed clutch side 12 13

Note: When reassembling insert the steel plate (18) first.

Friction plates

Steel plates

2nd speed

8

8

3rd speed

7

7

Clutch drum

18 14

34-20

15

16

17 65V2E34023

2nd/3rd Speed Clutch Pack

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

6) Pressing washer (19) using a special tool, then remove snap ring (20).

3rd speed clutch side

7) Remove washer (19)(22) and spring (21), then feed air from the clutch oil port to remove clutch piston (23).

23 22 20

CAUTION

19

21 Clutch drum

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

65V2E34024

IMPORTANT Do not remove the clutch drum from the shaft.

2. Reassembling 2nd/3rd speed clutch pack For reassembling, follow the above procedure in the reversed direction.

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 2nd/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.

3. Cautions regarding reassembly 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.

Depth micrometer

Piston stroke 2nd speed

2.4±0.2 mm (0.09±0.008 in)

3rd speed

2.4±0.1 mm (0.09±0.004 in)

Straight edge

Air line

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

Back plate size: 9.1, 9.7 mm (0.36, 0.38 in)

Backing plate 85W34041

34-21

1st Speed Clutch Pack

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

1st Speed Clutch Pack 1st speed clutch side

Disassembling and reassembling 1st speed clutch pack

7

8

9

6

1. Disassembling 1st speed clutch pack 1) Remove snap ring (1) and bearing (2) and then remove spacer (3), thrust bearing (4), thrust washer (5).

1

2

3

4

5

Clutch drum

2) Remove and gear (6), thrust washer (7), thrust bearing (8), spacer (9).

65V2E34025

3) Remove to needle bearing (10) from gear (6).

6 10

65V2E34026

4) Remove snap ring (11), plate (12), back plate (13) from clutch drum.

1st speed clutch side

5) Alternately remove friction plate (14) and steel plate (15).

Clutch drum

Note: When reassembling insert the steel plate (15) first.

1st speed

Friction plates

Steel plates

8

8

11

34-22

13 12

14

15 65V2E34027

1st Speed Clutch Pack

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

6) Pressing washer (17) using a special tool, then remove snap ring (16).

1st speed clutch side

7) Remove washer (17)(19) and spring (18), then feed air from the clutch oil port to remove clutch piston (20).

20 19

CAUTION

16

17

18

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

Clutch drum 65V2E34028

IMPORTANT Do not remove the clutch drum from the shaft.

2. Reassembling 1st speed clutch pack For reassembling, follow the above procedure in the reversed direction.

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 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.

3. Cautions regarding reassembly 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.

Depth micrometer

Piston stroke 1st speed

Straight edge

2.4±0.2 mm (0.09±0.008 in)

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

Back plate size: 9.1, 9.7 mm (0.36, 0.38 in)

Air line

Backing plate 85W34041

34-23

4th Speed Clutch Pack

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

4th Speed Clutch Pack Disassembling and reassembling 4th speed clutch pack

4

Clutch drum

1. Disassembling 4th speed clutch pack 1) Remove snap ring (1), and then remove bearing (2), ring (3).

3

2

1

4th speed clutch side

2) Remove gear (4) from clutch drum.

65V2E34029

3) Remove two bearings (5) and thrust washer (6), snap ring (7) from gear (4).

5

4

Outside

Note: When reassembling install the thrust washer (6) so that the groove faces to outside.

7 6 5

65V2E34030

4) Remove snap ring (8) and then remove plate (9), back plate (10) from clutch drum.

Clutch drum

5) Alternately remove friction plate (11) and steel plate (12).

Note: When reassembling insert the steel plate (12) first.

Friction plates

Steel plates

4

4

12

11

10

9

8

4th speed clutch side 4th speed

65V2E34031

34-24

4th Speed Clutch Pack

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

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

Clutch drum 13

7) Remove washer (13)(16) and spring (15), then feed air from the clutch oil port to remove clutch piston (17).

14

15 16 17

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

4th speed clutch side 65V2E34032

IMPORTANT Do not remove the clutch drum from the shaft.

2. Reassembling 4th speed clutch pack For reassembling, follow the above procedure in the reversed direction.

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 4th 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.

3. Cautions regarding reassembly 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.

Depth micrometer

Piston stroke 4th speed

Straight edge

1.8±0.1 mm (0.07±0.008 in)

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

Back plate size: 9.1, 9.7 mm (0.36, 0.38 in)

Air line

Backing plate 85W34041

34-25

Special Tool

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

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

1

7

3 5

2

1

4

6

1 Plate 15 20

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

250 ø7Drill

ø13Drill

R

R

28

ø7Drill 50

25

24 65

24

180

35.4

35.4

150 280

135 95 6

9

2 Lock 10 39

ø7Drill R

13

135

ø7Drill R

10 31

250

95 6

13

70ZV34004

34-26

Special Tool

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

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

(mm)

For speed clutch pack

(mm)

φ 100 φ 80±0.5 φ85

5

65

370

° 60

360

φ72±0.5

° 60

5

65

40 φ79±0.5

40 φ92±0.5

65ZV34031J

34-27

Control Valve Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Assembly Removing and reinstalling control valve

Solenoid valve 1

1. Removing control valve

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

- Apply the parking brake, and block tires with chocks to prevent wheels from moving.

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

1

3

1) Remove the electric wiring coupler for each solenoid valve.

2 Transmission control valve

Note: Put matchmark on each coupler to avoid misconnection when reassembling.

70ZV34013

2) Remove the main clutch pressure measuring hose.

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

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

SOL 1st SOL 2nd

Tightening torque for assembly: : Control valve retainer bolt: 34 N-m(3.5 kgf-m) (25 lb-ft)

SOL F

3) Remove bolt (1)(2)(3) and the control valve.

SOL R

1

2

3

T/M control valve

CAUTION

1

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

SOL 3rd/4th

3rd/4th solenoid valve 70ZV34014

34-28

Control Valve Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

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

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

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

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

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

6) Check oil leakage.

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

34-29

Control Valve Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and reassembling control valve

4

5

2

1. Disassembling control valve 6

Note: Clean the control valve.

3

1) Remove bolt (1).

Tightening torque for assembly: : Bolt: 32.3 N-m(3.30 kgf-m)(24 lb-ft)

2) Remove solenoid valve nut (2).

1

3) Remove solenoid valve (3).

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

7 8 5 65ZV34039J

4) Remove covers (6)(7) and then remove the spool and the spring from the valve body.

Tightening torque for assembly: : Bolt (4): 9.8 N-m(1.00 kgf-m)(7 lb-ft) Bolt (5): 15.7 N-m(1.60 kgf-m)(12 lb-ft)

CAUTION When removing the cover, the spring may jump out.

Slowly loosen the bolt for the cover.

IMPORTANT Do not loosen the screw and nut (8) when disassembling control valve unless necessary.

Mis-adjustment may cause shift shock or clutch plate slipping.

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

34-30

Control Valve Assembly

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 34

Main control valve

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

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

2) Check the operation of the solenoid valves.

(Also the movement by pressing the manual plunger.

The plunger should move freely and smoothly in both directions (spring return).)

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

65ZV34040J

Adjusting screw procedure a) Loosen nut (1). b) Loosen screw (2) until "A" comes to 20 mm. c) Screw in screw (2) until the tip of the screw contacts to piston (3).

A

3 1

d) From this position, turn the screw clockwise 5 turns.

Screw details

e) Tighten nut (1) to lock screw (2).

Nut tightening torque : 11 N-m(1.1 kgf-m)(8 lb-ft) After adjusting "A" should be 12 mm.

34-31

2 70ZV34015

MEMO

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

35-1

Clutch Oil Pressure

65TMV-2 TORQUE CONVERTER AND TRANSMISSION 35

Clutch Oil Pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items : - Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Determine the signals between the service men.

- Prohibit any person from walking into dangerous areas.

- Near articulation area of the machine - Under the machine - Around the engine - In front of or behind the machine

2

9 1 8 6

4

7 B

A 5 3

10

65V2E35001

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

Measuring port location

Measuring port size

1

Torque converter inlet pressure

G1/4

2

Torque converter outlet pressure

↑

0.1 (1.0) (14) or more

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

↑

3

Main oil press.

G1/4

1.5 (15) (213) or more

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

All speed range

4

F

↑

1.5 (15) (213) or more

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

F

5

R

↑

↑

↑

R

1ST

↑

↑

↑

1

7

2ND

↑

↑

↑

2

8

3RD

↑

↑

↑

3

9

4TH

↑

↑

↑

4

PF3/8

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

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

All speed range

6

10

Clutch oil pressure

Lub. oil pressure

Shift lever position

Engine revolution (min-1) (rpm) 800

2400

0.1 (1.3) (18) or more

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

35-2

All speed range

HYDRAULIC GROUP 44 Disassembly and Reassembly Warning Regarding Removing and Reinstalling Hydraulic Parts .....................................................................................44-2 Cautions Regarding Disassembly and Reassembly of Hydraulic Parts .....................................................................................44-3 Hydraulic Pump Assembly ..........................................................................44-4 Hydraulic Cylinder .......................................................................................44-9 Pilot Valve .................................................................................................44-21 Multiple Control Valve ...............................................................................44-31 Orbitrol® ...................................................................................................44-37 Priority Valve .............................................................................................44-48 Fan Motor .................................................................................................44-50

44-1

Warning Regarding Removing and Reinstalling Hydraulic Parts

65TMV-2

HYDRAULIC 44

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

Understand the following items well and work safely.

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

- Apply the parking brake and block tires with chocks to prevent wheels from moving.

- Be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

- Relieve the internal pressure from the hydraulic line and hydraulic tank.

- Use signals as agreed upon before starting work.

- Do not enter the hazardous area.

- When removing a heavy load over 20 kg(44 lbs), use a crane or a lift device.

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

- While working with the boom raised, put safety blocks or supports to prevent it from dropping suddenly.

- The temperature at each part may be high soon after the engine is stopped. Be careful not to get burned.

- When removing pipes, place a container to catch the drained oil.

IMPORTANT - Cover disconnected hoses and pipes with plastic caps or plugs to protect them from dust, water and dirt.

- Apply the specified torque to tighten each part.

44-2

Cautions Regarding Disassembly and Reassembly of Hydraulic Parts

65TMV-2

HYDRAULIC 44

Cautions Regarding Disassembly and Reassembly of Hydraulic Parts Hydraulic parts may be delicate. When disassembling or reassembling, handle with care.

Understand the following well to perform disassembly and reassembly work.

Cautions regarding disassembly

Cautions regarding reassembly

- Completely drain hydraulic oil from parts.

Clean unit before disassembly. Plug each open ports .

- Work in a well ventilated area.

- Before disassembling, put a matchmark on each alignment point.

- When clamping the part in a vice, use a copper plate as so not to damage it.

- Because hydraulic parts may be delicate, do not drop or scratch them - When disassembling, do not hit or pry the parts by force. The parts may get burred and scored which may cause oil leakage or poor performance.

- Do not disassemble adjusting screws unless needed.

- When work is stopped, protect removed parts from dirt and debris.

- Preserve disassembled parts with oil. After cleaning, do not dry with compressed air. It may cause rust due to condensation.

- Carefully place removed parts in the order it was removed so as to see how they came apart.

- Check the surface and inside of the parts for burrs, scores, dirt, or rust.

- Replace O-rings and seals with new ones.

- Before reassembly, apply a thin coat of hydraulic oil or grease to the O-rings and seals.

- Apply the specified torque to tighten parts.

- After reassembly, plug the ports so as not to allow foreign material to enter.

44-3

Hydraulic Pump Assembly

65TMV-2

HYDRAULIC 44

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

DANGER Entering the articulation area while engine is running may cause serious injury or death.

So, when entering the area, stop the engine and place "DO NOT START " or "DO NOT OPERATE" tag on steering wheel.

CAUTION Removing hoses and plugs without bleeding residual pressure could cause 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: a) Remove the cab and the floor board by referring to Section 14. b) Clean the area around the hydraulic pump.

4 Torque converter

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

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

2 1

65ZV44003

2) Remove hydraulic pump retainer bolts (4).

Torque for assembly: : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft)

1 3

3) Attach sling to hydraulic pump (1) and remove hydraulic pump (1). : Hydraulic pump: 20 kg (45 lbs) 3

65ZV44018J

44-4

Hydraulic Pump Assembly

65TMV-2

HYDRAULIC 44

2.Reinstalling hydraulic pump assembly To reinstall the hydraulic pump assembly, follow the above removal procedure in the reversed direction.

Replace all gaskets and O-rings during reinstallation.

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

WARNING Oil injection hazard!

Hydraulic oil can penetrate skin. When performing this procedure: - Release all trapped circuit pressure prior to starting any procedure involving hydraulic oil.

- Wear protective gloves.

- Wear eye and face protection.

- Stay clear of areas where air may be purged.

- Route oil into a receiving canister [such as a 5 gallon bucket] by use of an additional hose.

- Rotate pump at a low RPM.

44-5

IMPORTANT 1)Fill the inlet port of the hydraulic pump with clean hydraulic oil and rotate the pump shaft by hand prior to installing the pump. It should rotate smoothly.

Prior to installing pump and plumbing to pump, remove all caps, plugs, and covers from pump and piping.

2)While reinstalling the hydraulic pump, take care not to allow dust, dirt, or foreign material into the case.

3)Check the oil level of the hydraulic tank.

4)Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe.

Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 ).

5)Run the engine at low-idling speed for 5 minutes or more. Do not operate any hydraulic functions during this period.

Note: If the engine speed is set to high-idling just after starting, the pump may be seized.

6)Actuate cylinders 5 to10 times to almost full stroke, but do not fully extend or retract any of the cylinders at this time.

7)Confirm that there is no abnormal noise or operation, and be sure that there is no excessive heat. Inspect the hydraulic oil at the sight gauge to be sure that there are no bubbles which may indicate air being drawn in at the suction side of the pump. If there are any bubbles, correct the cause prior to using the machine, as this may contribute to premature pump failure.

Hydraulic Pump Assembly

65TMV-2

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

IMPORTANT - Handle pumps carefully, hydraulic system breaks down, do not disassemble the pump first.

Check the whole hydraulic circuit and find its cause. Confirm the cause, then repair.

- When the pump is broken down, not only fix or replace it but also inspect the failure cause to prevent recurrence.

If a pump must be repaired, be sure no pieces of damaged pump material has scattered through hydraulic system. New parts must be "broken in" and performance must be checked.

Do not disassemble the pump except when necessary to replace oil seals and O-rings between the double and triple pumps which are able to be separated.

44-6

HYDRAULIC 44

Hydraulic Pump Assembly

65TMV-2

HYDRAULIC 44

1.Cross section and tightening torque

T1

T2 T3 K65V2E44001

: T1: 309 N-m (31.5 kgf-m) (228 lb-ft) T2: 123 N-m (12.5 kgf-m) (90 lb-ft) T3: 34 N-m ( 3.5 kgf-m) (25 lb-ft)

44-7

Hydraulic Pump Assembly

65TMV-2

HYDRAULIC 44

2.Oil seal replacement procedure There are two kinds of the pump drive gear shaft unit.

One has only an oil seal, and another has an additional dust seal or oil seal outside.

[Example 1] Oil seal

In case of example 2 1) After removing the outer oil seal, remove the snap ring and the inner oil seal.

2) When removing the oil seals, remove any scores on the front cover and drive gear shaft.

3) Cover the drive gear shaft with vinyl electrical tape to protect splines.

4) Apply a thin coat of grease to the periphery of the oil seal and lip unit.

5) Install seal straight.

Snap ring

Drive gear shaft

Front cover

95ZV44002

[Example 2]

Front cover

Drive gear shaft

Oil seal

Oil seal

Snap ring 95ZV44003

44-8

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

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

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

- Raise the boom until it is horizontal, and then place stand (A) under the boom to support it.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Use a stepladder or work platform, and do not stand on the machine.

Stand

K70T2U44001

1 K70T2U44002

- Clean the area around the cylinder and piping.

Note: Relieving residual pressure from pipe 1.Raise the boom. When the boom is approximately 30 cm (1 foot) above the stand, stop the engine.

2.Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure.

3.First press down on the hydraulic tank cap to vent residual pressure, then open the cap of the hydraulic tank . Leave hydraulic tank cap loosely on top of tank opening.

1) Attach sling to boom cylinder (1).

Disconnect hose (2) and pipe (3). : Boom cylinder: 95 kg (210 lbs) 2) Remove lock bolt (4) and pin (5). : Bolt: 231 N-m (23.5 kgf-m) (169 lb-ft) 3) Remove lock bolt (6) from retainer pin (7) on the bottom side. Remove pin (7) and then sling boom cylinder (1). : Bolt: 231 N-m (23.5 kgf-m) (169 lb-ft)

2

3 K65T2U44001

7

5

4

K70T2U44004

44-9

1 6

Hydraulic Cylinder

65TMV-2

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

2.Reinstalling boom cylinder To reinstall the boom cylinder, follow the above removal procedure in the reversed direction.

Note: Be sure the pins accept grease after installation.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100 mm (4.0 in) before stroking fully. b)After that, stroke the cylinder piston fully to both ends 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-10

HYDRAULIC 44

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

Removing and reinstalling bucket cylinder 1.Removing bucket cylinder

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

- Place boom and bucket on ground.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Use a step, and do not stand on the machine.

Bucket cylinder

- Clean the area around the cylinder and piping.

Note: Relieving residual pressure from pipe 1.Lower the boom and bucket to the ground.

2.Stop the engine and move the bucket and boom levers back and forth.

3.Open the cap of the hydraulic tank to relieve the residual pressure.

6

1

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

2

2) Remove rod (6) for the bucket positioner.

K65T2U44002

3

3) Attach sling to bucket cylinder (3).

After that, remove lock bolt (4) and pin (5). : Bucket cylinder: 60 kg (135 lbs) : Bolt: 142 N-m (45.0 kgf-m) (324 lb-ft)

5 4 K70T2U44006

44-11

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

4) Start the engine and shorten cylinder rod (7).

Stop the engine and disconnect hoses (8)(9).

8

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

9 Bucket cylinder

7

K65T2U44003

5) Remove lock bolt (10) and pin (11). : Bolt: 142 N-m (45.0 kgf-m) (324 lb-ft) 6) Slowly lift up bucket cylinder (3).

Lower the bucket cylinder onto ground.

3

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

11 10

K70T2U44008

44-12

Hydraulic Cylinder

65TMV-2

2.Reinstalling bucket cylinder To reinstall the bucket cylinder, follow the above removal procedure in the reversed direction.

Note: Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation

WARNING During service work, do not stand on the machine.

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

➀Bleed the cylinder of air.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100 mm (3.9 in) before stroking fully. b)After that, stroke the cylinder piston fully to both ends 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

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

44-13

HYDRAULIC 44

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

Removing and reinstalling steering cylinder 1.Removing steering cylinder

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

- Place boom and bucket on ground.

- Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line.

- Press cap down ward to vent, then open the cap of the hydraulic tank to relieve the internal pressure from the tank.

- Place a "DO NOT START!" tag on the steering wheel or the operator's seat .

1 2

65ZV44031J

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

1) Disconnect hoses (1) (2).

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

7

2) There is pin (5) between front chassis (3) and steering cylinder (4). Remove pin (5), and then push rod (6) into the cylinder to shorten the length of the cylinder. : Oil will be drained from the oil port of the cylinder. Place a container at the oil port to catch the drained oil.

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

5

3 4 6 65ZV44032J

44-14

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

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

2.Reinstalling steering cylinder To reinstall the steering cylinder, follow the above removal procedure in the reversed direction.

Note: Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation 1) When reinstalling the pins

2) Bleed the cylinder of air

IMPORTANT

IMPORTANT

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

After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100 mm (4.0 in) before stroking fully. b)After that, stroke the cylinder piston fully to both ends 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area can cause injury or death.

When turning the steering wheel while engine is running, do not enter the articulation area of the machine.

If a person is in the articulation area, do not start the engine.

44-15

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

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

1.Cross section and tightening torque 1) Boom cylinder

T2

T1

65ZV44002J

2) Bucket cylinder

T4

T3

K65T2U44004

3) Steering cylinder

T6

T5

K65V2E44019

T1: 2,501 N-m (255 kgf-m) (1,845 lb-ft) T2: 481 N-m ( 49 kgf-m) ( 355 lb-ft) T3: 2,160 N-m (220 kgf-m) (1,592 lb-ft) T4: 863 N-m ( 88 kgf-m) ( 637 lb-ft) T5: 600 ± 30 N-m (61 ± 3 kgf-m) (441 ± 22 lb-ft) T6: 300 ± 30 N-m (31 ± 3 kgf-m) (224 ± 22 lb-ft)

Cylinder

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

Boom

75 (2.95) – M48 x 1.5

Bucket

60 (2.36) – M39 x 3

Steering

41 (1.61) – M27 x 2

44-16

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

2.Disassembling hydraulic cylinder Note: Boom cylinder disassembling procedure is described below. For other cylinders, follow the same procedure.

1) Install the bottom side of the cylinder to the repair stand.

Repair stand 95ZV44004

Matchmark

2) Put the matchmarks on rod cover (1) and cylinder tube (2).

Remove rod cover bolt (3). : Bolt: 481 N-m (49 kgf-m) (355 lb-ft) (Boom cylinder) Rod cover: 863 N-m (88 kgf-m) (637 lb-ft) (Bucket cylinder) 300 ±30 N-m (31 ±3 kgf-m) (224 ± 22 lb-ft)

3

2 1 95ZV44005

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

4

95ZV44006

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

Repair stand

4

Wooden block 95ZV44007

44-17

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

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

6 C

Piston nut width across flats mm (in)

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

Boom cylinder

75 (2.95)

2,501 (255) (1,845)

Bucket cylinder

60 (2.36)

2,160 (220) (1,592)

Steering cylinder

41 (1.61)

600 ± 30 (61 ± 3) (441 ± 22)

Hydraulic jack

Hydraulic cylinder 95ZV44009

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

7

6

4

95ZV44010

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

8

10

8

9

10

12

8

10

8

11 (Steering cylinder)

K65T2U44005

(Boom cylinder)

(Bucket cylinder) K65T2U44006

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

1

4

95ZV44013

44-18

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

9) (For boom and bucket cylinder) Remove snap ring (13), scraper ring (14), back-up ring (15), U-packing (16), back-up ring (17) and O-ring (18) from rod cover (1).

(There is no O-ring (19) for boom cylinder.)

16

18

17

15

1 14

13

(Boom cylinder) K65V2E44014

16

18 17

15 14 19

1

(Bucket cylinder)

(For steering cylinder) Remove dust seal (20), back-up ring (21), rod packing (22), buffer ring (23), snap ring (24), back-up ring (25), O-ring (26) and O-ring (27) from rod cover (1).

K65T2U44007

27 26

25

23

13

1

22 21

24 20

(Steering cylinder) K65T2U44008

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

Note: Refer to page 44-20 for the cautions when reassembling.

44-19

Hydraulic Cylinder

65TMV-2

HYDRAULIC 44

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

CAUTION Hot oil can cause injury or burns.

Avoid contact with hot oil.

10

Note: Put slipper ring (10) into hot oil to heat the ring to 120 to 150 °C. (This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston.

Therefore, heat the slipper ring to expand its inner diameter for easy attachment.) : Attach the slipper ring while taking care not to damage by over expansion. : After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

Note: Before installing back-up ring (2) and O-ring (3), heat the back-up ring.

(This is because the inner diameter of the back-up ring is smaller than the outer diameter of the rod cover. To easily attach the back-up ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.)

Be careful not to over expand the back-up ring. After installation, wait until the back-up ring is cooled, and then insert the rod cover into the cylinder tube.

(Boom cylinder) K65V2E44012

2

3 95ZV44017

Note: To reinstall the rod cover of the steering cylinder and the bucket cylinder, screw the rod cover using a spanner wrench. : Bucket cylinder: 863 N-m (88 kgf-m) (637 lb-ft) Steering cylinder: 300 ± 30 N-m (31 ± 3 kgf-m) (224 ± 22 lb-ft) K65V2E44013

44-20

Pilot Valve

65TMV-2

HYDRAULIC 44

Pilot Valve Removing and reinstalling pilot valve 1

1. Removing pilot valve

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

- Lower bucket to ground, and then relieve the internal pressure from the line.

6

- Relieve the internal pressure from the hydraulic tank.

Before starting work: - Stop the engine and lower the bucket to the ground.

After that move the lever back and forth, left and right and relieve inner pressure from pilot line.

5 60ZV44036

3

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

2 4 6

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

2

3) Remove covers (5)(6).

60ZV44037

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

8

Note: - Before disconnecting, put matchmarks on hoses.

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

7

8 60ZV44038

44-21

Pilot Valve

65TMV-2

HYDRAULIC 44

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

60ZV44039

9

7

2. Reinstalling pilot valve To reinstall the pilot valve, follow the removal procedure in reversed direction.

Note: After reinstallation, check operation of the pilot valve.

In addition, check the pilot valve for oil leakage.

If the oil level is too low, add hydraulic oil to the tank.

44-22

10

60ZV44040

Pilot Valve

65TMV-2

HYDRAULIC 44

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

1. Cross section and tightening torque T3

T2 L1

T4

L2

T4

T

T

P

P

T1

Port 4 (a2) Boom down

Port 2 (b2) Boom up

Port 3 (a1) Bucket roll back

Port 1 (b1) Bucket dump 60ZV44041

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

Apply grease when reassembling L1: Sliding surface L2: Top of plunger : Pilot valve 44-23

Approx. 6 kg (13 lbs)

Pilot Valve

65TMV-2

HYDRAULIC 44

2. Disassembling pilot valve 1

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

60ZV44042

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

2

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

3

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

A

3) Using jig A B , turn joint (4) counterclockwise to remove it.

Note: Refer to the next page for the detail of removing joint.

Torque for assembly: : (4): 50.0 N-m (5.1 kgf-m) (36.9 lb-ft)

4

B

When reassembling, apply grease to the sliding surface.

60ZV44044

60ZV44045

44-24

Pilot Valve

65TMV-2

HYDRAULIC 44

0.5x15°

Detail of removing joint (4)

R

4

C0.5

12 9.5

ø 26.5 23.5

6 ±0.1

R12

(Width across flat)

R5.2

C0.5

13

10.4 ±0.1

14.5

±0.1

Material; SCM415 N Carburizing and quenching

Material; SCM415 N 1 Carburizing and quenching

50

2 Material; S45C

42

Quantity; 2

A

19

25 17

Jig B

65

ø 19 ø 28

+0.2

ø 21 0 ø 25 ø 30

Section A - A +0.013 0

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

B

+0.028 +0.015

Turn jig A counterclockwise

A

B +0.2

15 0

Jig A

A

A

B Joint B

Jig A + B installation

Section B - B 60ZV44117

4) Remove plate (5).

5

60ZV44047

44-25

Pilot Valve

65TMV-2

HYDRAULIC 44

5) Loosen bolt (6) with the hexagon (allen) wrench and remove plate (7).

Hexagon wrench width across flat: 5 mm (3/16 in)

6

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

7

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

6

8 60ZV44048

9

6) The solenoid sub assembly in detent casing (8) might be contacted with suction board.

Press push rod (9) to separate them from solenoid sub assembly in detent casing (8).

8

60ZV44049

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

9 8

60ZV44118

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

10

11

60ZV44051

44-26

Pilot Valve

65TMV-2

HYDRAULIC 44

9) Remove spring seat (11) using pliers.

11

60ZV44042

10) Loosen bolt (12) with the hexagon (allen) wrench and remove it.

Hexagon wrench width across flat: 5 mm (3/16 in)

13

12

Note: When loosing bolt (12), center plate (13), push rod (14) and plug (15) might be lifted. When pulling out the bolt, be careful that parts do not get thrown from assembly.

Torque for assembly: : (12): 13.3 N-m (1.36 kgf-m) (9.8 lb-ft)

60ZV44043

11) Remove plate (13).

13

14

15 16

60ZV44054

12) Put a driver into the groove of plug (15) and pull out plug (15) from casing (16).

Note: - Be careful not to damage surfaces around the groove of the plug.

- Carefully place all plugs, springs and reducing valve spools in the order it was removed so as to assemble them into the casing port.

Screw driver

15

60ZV44055

44-27

Pilot Valve

65TMV-2

HYDRAULIC 44

Difference in reducing valve Port No. Parts

1

1~3

4

1. Spring

X

O

2. Spring seat

X

O

3. Return spring

1 pc

2 pcs

4. Spring seat

1 pc

2 pcs

5. Washer 2

X

O

2 4 3

T

5 P

Outside

Bucket dump (T)

Boom down

Port 4(a2)

Port 3(a1) A-A

A

Front

60ZV44120

41 T P 32

Rear Boom raise

(P)

A

Bucket roll back

Inside Oil port (Viewed from top)

60ZV44119

13) Fix casing (16) in a vice so that port board (17) can be on top. Loosen bolt (18) with the hexagon (allen) wrench.

18

17

Hexagon wrench width across flat: 6 mm (1/4 in)

16

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

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

17

19

60ZV44058

44-28

Pilot Valve

65TMV-2

HYDRAULIC 44

15) Disassembling reducing valve 1. Stand the bottom of the spool straight on the working table. Push down spring seat (20) and remove washer set (1 semicircle, 2 pcs) (21) using the head of a small screw driver.

Note: - Be careful not to damage the spool surface.

- Do not press down spring seat (20) more than 6 mm.

20

21 60ZV44059

2. Disconnect spool (22), spring seat (20), spring (23) and washer 2 (24).

20

23 24

22

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

60ZV44060

3. Pull out spring seat (25) and spring (26) from push rod (14) and then pull out push rod (14) from plug (15).

Remove O-ring (27) and the seal in the bore from plug (15).

27

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

25

26

15

14 60ZV44061

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

28

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

8

60ZV44042

44-29

Pilot Valve

65TMV-2

HYDRAULIC 44

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

Note: When reassembling seal (29) into plug (15), be careful about the direction of lip of seal (20).

Plug (15) Seal (29)

Push rod

Apply hydraulic oil

60ZV44063

44-30

Multiple Control Valve

65TMV-2

HYDRAULIC 44

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

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

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

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

1 1

1 1

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

1) Put matchmarks on hoses (1) of the pilot line,and then disconnect them.

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

Multiple control valve K65V2E44017

Multiple control valve

2

2) Put matchmarks on hoses (2) then disconnect them. : Hydraulic oil: Approx. 5 (1.32 gal.)

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

65ZV44009

3) Remove return pipe (3).

Multiple control valve

3 K65V2E44018

44-31

Multiple Control Valve

65TMV-2

HYDRAULIC 44

4) Disconnect inlet hose (4).

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

Multiple control valve

5) Remove retainer bolts (5) from the multiple control valve, and then remove multiple control valve (6).

Torque for assembly: : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Multiple control valve: 35 kg (77 lbs)

6

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

4 5

3. Cautions regarding reinstallation 65ZV44011

1) Replace all the O-rings with new ones.

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.

4) Operate the bucket and the boom, and check that they operate correctly.

5) Check each section for oil leakage.

6) Add hydraulic oil to the tank until the oil level rises to the specified point.

44-32

Multiple Control Valve

65TMV-2

HYDRAULIC 44

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

1.Cross section and tightening torque T5 L1 T7 T4 T3

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

T1

T6 T3

Overload relief valve with make-up function.

T1 T2

T7

:

Make-up valve T4

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

Overload relief valve with make-up function.

65ZV44001

: 35 kg (77 lbs)

L1: Screw lock agent AB01 application 44-33

Multiple Control Valve

65TMV-2

HYDRAULIC 44

2.Disassembling multiple control valve 1) Remove main relief valve (1).

Hexagon width across flat: 32 mm (1 17/64 in) Torque for assembly: : (1): 78 N-m (8.0 kgf-m) (58 lb-ft)

1 65ZV44007J

2) Remove overload relief valve (2).

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

2

65ZV44008J

3) Remove overload relief valve (3).

Remove make-up valve (4).

Hexagon width across flat: 32 mm (1 17/64 in) Torque for assembly: : (3)(4): 78 N-m (8.0 kgf-m) (58 lb-ft)

4

3 65ZV44009

4) Remove socket head bolts (5),(6) from the bucket and boom side of the cap.

Then remove caps (7),(8).

Hexagon hole width across flat: 6 mm (15/64 in) Torque for assembly: : (5)(6): 34 N-m (3.5 kgf-m) (25 lb-ft)

5

6 7 8

44-34

65ZV44010J

Multiple Control Valve

65TMV-2

5) Slowly pull out spool (9) from the boom side and spool (10) from the bucket side as an assembly.

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

HYDRAULIC 44

10

9 65ZV44011J

6) Remove socket head bolts (11),(12) to remove caps (13),(14). Also remove the O-ring of the flange from the cap.

Hexagon hole width across flat: 6 mm (15/64 in) Torque for assembly: : (11)(12): 34 N-m (3.5 kgf-m) (25 lb-ft)

12 14 13 11 65ZV44012J

7) Remove four socket head bolts (15), and then remove cover (16). Also remove the O-ring from the mating face.

Hexagon hole width across flat: 10 mm (25/64 in) Torque for assembly: : (15): 113 N-m (11.5 kgf-m) (83 lb-ft)

15

16

65ZV44013J

8) Remove plug (17) from the bucket side to remove spring (18) poppet (19). Also remove plug (20) from the boom side.

Remove the O-ring from the plug.

Hexagon hole width across flat: 27 mm (1 1/16 in) Torque for assembly: : (17)(20): 353 N-m (36.0 kgf-m) (260 lb-ft)

17 18

20

19

65ZV44014J

44-35

Multiple Control Valve

65TMV-2

HYDRAULIC 44

9)Remove plug assembly (21) and remove the O-ring.

Hexagon hole width across flat: 12 mm (15/32 in) Torque for assembly

21

: (21): 225 N-m (26.0 kgf-m) (188 lb-ft)

65ZV44015J

10)Set the spool assembly in a vise and then loosen bolt (22) to remove.

Hexagon hole width across flat: 10 mm (25/64 in) Torque for assembly : (22): 18 N-m (1.8 kgf-m) (13 lb-ft) : Screw lock agent AB01 application 11)Remove spring seat (23), spring (24), stopper (25) from each spool (there are two spools).

Note: Cover the spool to protect it from being scratched.

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

4.Cautions regarding reassembling - Clean and check all the parts. If a part is defective, replace or repair it.

- Replace all the O-rings with new ones.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Apply the specified torque to tighten each main part.

44-36

23 24 25

23

Spool 22

65ZV44002

Orbitrol®

65TMV-2

HYDRAULIC 44

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

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

- Block tires with chocks to prevent wheels from moving.

- Apply articulation stopper.

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

- Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right.

- Relieve the internal pressure from the hydraulic tank.

1

85V2E44008

1) Remove cover (1).

2) Remove floor mat (2).

2 85V2E44009

3) Put matchmarks on hoses (3), and then disconnect them from Orbitrol® (4).

3

4

70V2E44032

44-37

Orbitrol®

65TMV-2

HYDRAULIC 44

4) Remove bolt (5), and then remove the Orbitrol®.

5

Torque for assembly: : Bolt: 53 N-m (5.4 kgf-m) (38.9 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.

2. Reinstalling Orbitrol® To reinstall the Orbitrol ® , follow the above removal procedure in the reversed direction.

At the completion of reinstallation, check operation of the Orbitrol® by following the procedure below:

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 check around the Orbitrol® for oil leakage.

44-38

70V2E44013

Orbitrol®

65TMV-2

HYDRAULIC 44

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

1.Cross section and tightening torque Centering springs

Push spool

O-ring

Check value

Plate O-ring

Sleeve

T1

Make-up valve Needle bearing

Ball Housing

O-ring

Seal unit Spacer

End cap

OLRV

Drive shaft Retainer

: T1: 28 N-m (2.9 kgf-m) (21 lb-ft) : 7 kg (15 lbs)

44-39

Rotor assembly

70V2E44014

Orbitrol®

65TMV-2

2.Disassembling Orbitrol®

HYDRAULIC 44

Make matchmarks before disassembling unit.

(Disassembling rotor) 1) Set the Orbitrol® in a vise so that the rotor side comes to the top position.

Use copper plates on a vise and do not tighten the vise strongly.

25

mm

Housing

Copper plate 60ZV44123

2) Remove seven bolts (1), end cap (3), O-ring (4) and spacer (5).

Note: The make-up valve installed in the housing is tightened with bolts (A).

When removing the bolts, take care not to drop the make-up valve.

1

A

70V2E44015

1 5 1

3 4 70V2E44016

3) Remove rotor assembly (6) and O-ring (7).

Note: Keep star (8) in rotor assembly (6).

7

8

6

97ZV44049

44-40

Orbitrol®

65TMV-2

HYDRAULIC 44

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

10 9 11 60ZV44082

5) Remove the housing from the vise.

Remove adapter screw (12), Spring pin (14) and ball (13) of the emergency check valve by a screw driver.

Also remove pin (15) and ball (16) of the make-up valve.

14

13

12

16 15

70V2E44017

(Disassembling valve) 6) Remove retainer ring (17) with a screw driver.

Note: Carefully remove the retainer ring so that it does not spring out.

17

60ZV44084

7) Place the housing horizontally on clean cloth.

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

18

60ZV44085

44-41

Orbitrol®

65TMV-2

HYDRAULIC 44

8) Remove Y-packing seal (19) and dust seal (20) from seal retainer (18).

Note: Take care not to damage seal retainer (18).

18

19

20

60ZV44086

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

21

23

22 60ZV44087

10) Pull the spool and sleeve assembly out slowly, turning it clockwise and counterclockwise from the housing.

Note: Take care so that the spool and sleeve assembly do not damage the housing.

Housing

Spool / sleeve assembly 60ZV44088

11) Pull out pin (24) from the spool and sleeve assembly.

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

26

Spool / sleeve assembly

25 24

Matchmark 60ZV44089

44-42

Orbitrol®

65TMV-2

HYDRAULIC 44

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

27 26

25

60ZV44090

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

26

25

60ZV44091

14) Using the hexagon (allen) wrench (width across flat : 3/16 in), remove plug (27) to remove O-ring (28) from the plug.

Take out spring (29), poppet (30) and seat (31) (2 places).

29

30

31

28 27

OLRV units

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

70V2E44018

32

60ZV44093

44-43

Orbitrol®

65TMV-2

HYDRAULIC 44

3.Reassembling Orbitrol®

Spring groove

(Reassembling valve) 1) Assemble spool (25) and sleeve (26) so that the spring grooves in them are lined up. Use light oil for assembly of parts.

Note: ➀Confirm that the spool can be turned easily in the sleeve. ➁Align the matchmarks on the spool and sleeve.

26

Spring groove 25

Matchmark 60ZV44094

25

2) Install centering springs (27) through the spring grooves in spool (25) and sleeve (26) using a spring insertion jig.

Note: Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

27

26 60ZV44095

26

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

25

24

Matchmark 60ZV44096

4) Insert the spool and sleeve assembly squarely inward from the back of the housing.

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

Housing

Spool / sleeve assembly 60ZV44097

44-44

Orbitrol®

65TMV-2

HYDRAULIC 44

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

21

22

23

60ZV44099

6) Insert dust seal (20) and the Y-packing seal (19) in seal retainer (18).

18

19

20

60ZV44086

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

17

18 25

60ZV44099

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

Screw driver Dust seal Retainer ring Seal retainer Y-packing seal O-ring

80V2E44019

44-45

Orbitrol®

65TMV-2

HYDRAULIC 44

8) Insert O-ring (28) in plug (27). Apply grease to ball holder (30) and install ball (31).

Insert ball holder (30) and spring (29) into the housing and then insert plug (27) using the hexagon wrench (width across flat: 3/16 in)

OLRV units

27 28 29 30 31 Housing

70V2E44019

(Reassembling rotor) 9) Set the Orbitrol® in a vise so that the rotor side comes to the top position.

Use a copper plates on a vise and do not tighten the vise strongly.

25

mm

Housing

Plate

60ZV44102

10) Insert ball (16) and pin (15) of the make-up valve to the housing. Insert ball (13) and spring pin (14) of the emergency check valve and tighten adapter screw (12) by a screw driver. Then install O-ring (11) to the housing and put on spacer plate (10).

Align the bolt holes in the plate with those in the housing.

10

11

15

12 14

16

13

70V2E44020

11) Insert drive shaft (9) to mate its yoke with pin (24).

Rotate the spool and sleeve so that the pin (24) can be parallel with the port face.

Port face 9 Parallelize with port face

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

24 60ZV44111

44-46

Orbitrol®

65TMV-2

HYDRAULIC 44

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

6

7

60ZV44105

13) Holding the rotor assembly with the O-ring side facing the spacer plate, install the assembly so that the grooves in the star-shaped bore mesh with the drive shaft.

Note: ➀Align the bolt holes in the rotor assembly with those in the housing without disengaging the drive shaft from the rotor assembly's star -shaped bore. ➁Confirm that lines A, B, C and D are all parallel.

Grooves in rotor bore

A B

Drive shaft

C D

Pin

14) Install spacer (5), O-ring (4) and end cap (3).

Provisionally tighten bolt (1) and retainer screw (2).

Port face

95ZV44029

1 5

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

2

3 4

60ZV44106

15) Evenly tighten the seven bolts in the order shown at the right.

6

4

1

2 3

7 5 60ZV44112

44-47

Priority Valve

65TMV-2

HYDRAULIC 44

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

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

- Block tires with chocks to prevent the wheels from moving.

- Apply articulation stopper.

- Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

- Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right.

- Relieve the internal pressure from the hydraulic tank.

6

2

1 3

70V2E44021

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

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

2) Disconnect hose (4)(5) to the Orbitrol® and drain hose (6). : Approximately 1 (0.26 gal) of hydraulic oil will be drained from the disconnected hoses. Place a container to receive the drained oil.

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

3) Loosen bolt (7) to remove priority valve (1). : Priority valve: Approx. 6 kg (13 lbs)

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

44-48

4

7

5

70V2E44022

Priority Valve

65TMV-2

HYDRAULIC 44

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

1. Cross section and tightening torque

T2

T2

2

T1

1

3

70V2E44023

2. Caution regarding disassembly and reassembly - Carefully remove plug (1) or (2). It may spring out by the spring force. Alternately loosen plug (1)(2) to reduce the spring force and remove them.

44-49

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

Fan Motor

65TMV-2

HYDRAULIC 44

Fan Motor Removing and reinstalling fan motor

1

1. Removing fan motor

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

- 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.

70V2E44024

2

2

2

2

1) Remove roof (1) from the engine room.

2) Remove partition plate (2).

K65V2E44003

4

3

3) Remove fan guard (3) from the radiator assembly.

6

5

4) Remove hose (4) of air cooler.

5) Remove hoses (5)(6) of radiator assembly.

K65V2E44004

7

6) Remove hoses (7)(8)(9) from the fan motor.

Use a drain pan to catch all escaping oil.

8 9 K65V2E44005

44-50

Fan Motor

65TMV-2

HYDRAULIC 44

7) Attach sling to the fan motor assembly.

Remove bolt (10). The fan mount becomes free.

Torque for assembly: : Bolt (10): 93.7 N-m (9.55 kgf-m) (69 lb-ft) : Fan motor assembly: 35 kg (77 lbs)

10

K65V2E44006

8) Sling fan (12) and remove nut (11). Then take it out from the top opening.

12 Fan motor

Torque for assembly: : Nut (11): 117 N-m (11.5 kgf-m) (83 lb-ft) : Screw lock agent (Loctite® 262) application : Fan: 7 kg (38 lbs) Note: Carefully remove the fan while checking that the fan will not damage the radiator fins. Inspect the fan and replace it if there are any signs of damage or cracks.

Fan blade breakage can cause extensive damage.

11 K65V2E44007

9) Attach sling to the fan motor.

Remove bolt (13), and then remove the fan motor.

Torque for assembly: : Bolt (13): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (engine oil or gear oil) : Fan motor: 14.5 kg (33 lbs)

13

K65V2E44008

44-51

Fan Motor

65TMV-2

HYDRAULIC 44

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

Flange installation procedure 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.

Shaft

4) Install flange on motor and measure dimension (L) as shown in the illustration.

5) Install the nut into the shaft.

6) Tighten the nut with the specified torque. : Nut: 117.3 N-m (12 kgf-m) (87 lb-ft) 7) Remove the nut and remeasure the dimension (L).

Make sure it is 0.4~0.8 mm (0.016~0.032 in) larger than the value measured at step 4).

Note: If the amount of the dimension change is smaller than 0.4 mm (0.016 in), go to step 5) and tighten the bolt with the torque shown below. : Bolt: 140.8 N-m (14.4 kgf-m) (104 lb-ft) Remove the nut, and remeasure dimension (L).

Make sure it is 0.4~0.8 mm (0.016~0.032 in) larger than the value measured at step 4).

If it is again smaller than 0.4 mm (0.016 in), replace the flange with new one and go back to step 5).

44-52

Dimension L

Nut

Flange

K65V2E44009

Fan Motor

65TMV-2

HYDRAULIC 44

8) Finally tighten the nut with the torque below. : Bolt: 117.3 N-m (12 kgf-m) (87 lb-ft) or : Bolt: 140.8 N-m (14.4 kgf-m) (104 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 the radiator guard must be equal.

Clearance

K65V2E44010

44-53

MEMO

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

45-1

Hydraulic Cylinder

65TMV-2

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder

3

1

2

65ZV45002J

Bucket cylinder

2

1

3

K65T2U45001

Steering cylinder

2

1

3 K65V2E45002

Unit : mm (in) Judgment standard No

Standard dimension of rod dia.

Item

– 0.076 (0.0030)

0 (0)

0.184 (0.0072)

– 0.040 (0.0016)

+ 0.085 (0.0033)

0.004 (0.0002)

– 0.10 (0.0039)

– 0.036 (0.0014)

0.185 (0.0073)

+0.290 (0.0114)

+0.208 (0.0082)

+0.700 (0.0276)

Clearance 0.380 (0.0150) Replacement

0.556 (0.0219) 0.130 (0.0051) Replacement

0.284 (0.0112) 0.704 (0.0277) ~

0.030 (0.0011)

Bushing

Solution

~

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

+ 0.108 (0.0043)

Limit

~

3

– 0.030 (0.0011)

~

Piston nut width across flat mm (in.)

0.266 (0.0104)

~

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

+ 0.060 (0.0023)

~

2

Item

– 0.076 (0.0030)

~

No.

0.090 (0.0035)

~

Steering cylinder

ø 40 (1.5748)

+ 0.190 (0.0075)

~

Bucket cylinder

– 0.030 (0.0011)

~

1

ø 50 (1.9685)

Bushing

~

Boom cylinder

Rod

Standard clearance

~

ø 65 (2.5590)

Standard value

Replacement

0.885 (0.0348)

Boom cylinder

Bucket cylinder

Steering cylinder

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

M39 x 3 2,160 (220) (1,592)

M27 x 2 600 ± 30 (61 ± 3) (441 ± 22)

75 (2.95)

60 (2.36)

41 (1.61)

M22 481 (49) (355)

(Rod cover) M105 x 2 863 (88) (637)

(Rod cover) M70 x 2 300 ± 30 (31 ± 3) (224 ± 22)

45-2

Pilot Valve

65TMV-2

HYDRAULIC 45

Pilot Valve 5

2

4

3

T

1

P

60ZV45004

Unit : mm (in) No.

Item

Measuring condition

1

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

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

Leak quantity

2. Hydraulic oil………VG46

- Lever in operation

3. Oil temperature………60 °C

No.

Item

Solution

Judgment standard (limit)

1. Primary pressure………

replacement

……2,400 cm3/min and more

Judgment standard Standard dimension

Wear limit

Solution

61 mm(2.4016 in)

2 Length of push rod

1 mm(0.0394 in) and more

Replacement

6 mm(0.2362 in)

0.5 mm(0.0197 in) and more

Solenoid sub assembly replacement

–

2 mm(0.0787 in) and more

Replacement of related parts such as disc, joint etc.

36 mm(1.4173 in)

3 4

Inner diameter of solenoid bushing

5

Adjusting nut wear (upper part)

45-3

MEMO

BRAKE GROUP 54 Disassembly and Reassembly Unloader Valve ...........................................................................................54-2 Manifold Valve Assembly ............................................................................54-5 Accumulator ................................................................................................54-8 Brake Valve ..............................................................................................54-10 Service Brake ...........................................................................................54-17 Park Brake Actuator .................................................................................54-18 Parking Brake ...........................................................................................54-24

54-1

Unloader Valve

65TMV-2

BRAKE 54

Unloader Valve Removing and reinstalling unloader valve

3

1.Removing unloader valve

WARNING

2

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 front wheels with chocks to prevent wheels from moving.

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

Unloader valve

1 70ZV54002

4

Unloader valve

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

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

- Prepare a container to catch drained oil.

1) Remove hoses (1) (2) (3) from the unloader valve.

70ZV54003

5

2) Remove hoses (4) (5) from the unloader valve.

3) Remove bolts (6) and then remove the unloader valve.

Torque for assembly: : Bolt (6): 28 N-m (2.9 kgf-m) (21 lb-ft) : Unloader valve: 4 kg (8.8 lbs)

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

Replace all O-rings and seals during reinstallation.

Note: After reinstallation, completely bleed the brake line of air, and check performance of the unloader valve.

To bleed the brake line of air, refer to Section 24.

To check performance of the unloader valve, refer to Section 53.

54-2

Unloader valve 70ZV54004

6

65ZV54011J

Unloader Valve

65TMV-2

BRAKE 54

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

T1

1. Cross section and tightening torque

T8 T7 T6

T4

T3

T2 L1

T5 : T1: 137 N-m ( 14 kgf-m) (101 lb-ft) Width across flats 17 mm (0.669 in) T2: 14.7 N-m (1.5 kgf-m) ( 11 lb-ft) Width across flats 5 mm (0.197 in) T3: 14.7 N-m (1.5 kgf-m) ( 11 lb-ft) Width across flats 5 mm (0.197 in) T4: 58.8 N-m ( 6 kgf-m) ( 43 lb-ft) Width across flats 8 mm (0.315 in) T5: 98.1 N-m ( 10 kgf-m) ( 72 lb-ft) Width across flats 30 mm (1.181 in) T6: 118 N-m ( 12 kgf-m) ( 87 lb-ft) Width across flats 36 mm (1.417 in) T7: 16.7 N-m (1.7 kgf-m) ( 12 lb-ft) Width across flats 12 mm (0.472 in) T8: 78.5 N-m ( 8 kgf-m) ( 58 lb-ft) Width across flats 24 mm (0.945 in)

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

97ZV54002

Unloader Valve

65TMV-2

BRAKE 54

2.Disassembling unloader valve

1

1) Remove plug (1), then pull out spool (2) and spring (3).

Note: Carefully remove plug (1). It may spring out by the spring force.

3 2

Torque for assembly: : 137 N-m (14 kgf-m) (101 lb-ft) Note: Do not disassemble the pressure governor assembly and the pressure switch assembly unless it is necessary.

Because, readjustment of accumulator pressure and resetting of shims are required.

Pressure governor assembly

95ZV54001

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

54-4

Manifold Valve Assembly

65TMV-2

BRAKE 54

Manifold Valve Assembly Removing and reinstalling valve assembly

2

1

1.Removing valve assembly

WARNING

Valve assembly

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

- Block front wheels with chocks to prevent wheels from moving.

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

65ZV54001

4

3 5

Valve assembly

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

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

- Prepare a container to catch drained oil.

1) Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line.

7 6

65ZV54002

Valve assembly

9

2) Remove hoses (1) (2) (3) (4) (5) (6) (7) from the valve assembly.

3) Remove hose (8) from valve assembly.

8 65ZV54003

4) Remove bolt (9) and then remove the valve assembly.

Torque for assembly: : Bolt (9): 28 N-m (2.9 kgf-m) (21 lb-ft) : Valve assembly: 10 kg (22 lbs)

54-5

Manifold Valve Assembly

65TMV-2

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

Note: After reinstallation, completely bleed the brake line of air, and check performance of the valve assembly.

To bleed the brake line from air, refer to Section 24.

To check performance of the valve assembly, refer to Section 53.

54-6

BRAKE 54

Manifold Valve Assembly

65TMV-2

BRAKE 54

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

Cross section and tightening torque

T1

T5

T1

T1

(T) T4

(P)

(TA) (Parking)

(PI) (ACCR)

(ACCF)

ACF (PA) (Z1) (Z2)

(Z)

High pressure test ports

T2

(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) 8 N-m (0.8 kgf-m) (5.8 lb-ft) T5:

CAUTION High pressure test ports contain accumulator pressure [11.8 MPa (1,706 psi)] that can escape from these 2 plugs.

Completely depress brake pedal 80~100 times to relieve all pressure before removing plugs.

54-7

Accumulator

65TMV-2

BRAKE 54

Accumulator Removing and reinstalling accumulator 1.Removing accumulator

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

- Block front wheels with chocks to prevent wheels from moving.

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

3

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

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

2) Remove hose (1) from adapter (4).

3) Remove nut (2) and then remove accumulator (3) with adapter (4) from the chassis.

Valve assembly

A

1

K65V2E54001

3 4

2

WARNING 1

Never weld on or near gas charged accumulator.

Serious injury may result.

When disposing, wear protective glasses and loosen plug to release gas in the accumulator completely. Do not remove plug.

A - Detail

54-8

K65V2E54002

Accumulator

65TMV-2

2.Reinstalling accumulator To reinstall the accumulator, follow the above removal procedure in the reversed direction.

Replace all O-rings and seals during reinstallation.

Note: After reinstallation, completely bleed the brake line of air, and check performance of the accumulator.

To bleed the brake line of air, refer to Section 24.

To check performance of the accumulator, refer to Section 53.

54-9

BRAKE 54

Brake Valve

65TMV-2

BRAKE 54

Brake Valve Removing and reinstalling brake valve Cover

1. Removing brake valve

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

- Block front wheels with chocks to prevent wheels from moving.

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

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

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

- Remove the cover.

Cover 85V2E54010

Brake valve

70V2E54005

1) Remove all hoses and pipes shown on the illustration.

Brake valve

2) Remove all adapters and fittings shown on the illustration.

3) Remove bolt (1) and then remove the brake valve.

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

70V2E54006

1

1

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

Note: After reinstallation, completely bleed the brake line of air, and check all the pipe-joints for oil leakage.

To check or adjust the brake valve, refer to Section 53.

70V2E54007

54-10

Brake Valve

65TMV-2

BRAKE 54

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

1. Cross section and tightening torque (Main valve)

T1

T2

T4

T3

T2

: 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: 8.83 N-m (0.9 kgf-m) ( 6.5 lb-ft) T4: 11.8 N-m (1.2 kgf-m) ( 8.7 lb-ft)

70V2E54008

54-11

Brake Valve

65TMV-2

BRAKE 54

2. Disassembling brake valve

Pedal cover

1) Remove the pedal covers.

85V2E54015

2) Pull out the pin (1). Remove the washer (2), right pedal (3), mounting plate (4), pedal collar (5) and the spring (6) from the shaft assembly.

3

6

2

Shaft assembly

5

1

4 85V2E54016

3) Remove the nut (7), washer (8) and the bolt (9) to remove the plate (10).

Torque for assembly: : Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)

12 13 15

15

14

11

9

4) Pull out the pin (11), pedal pin (12), L-shape pin (13) and the washer (14), and then, remove the collar (15) and the roller (16) from the right pedal.

5) Remove the nut (17), washer (18) and the bolt (19).

Torque for assembly: : Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)

16

10

8 7

19

18 17

85V2E54017

20 Shaft assembly

6) Pull out the shaft assembly and remove the left pedal (20) and the pedal collar (21).

21 85V2E54018

54-12

Brake Valve

65TMV-2

BRAKE 54

7) Pull out the pin (22), pedal pin (23), L-shape pin (24) and the washer (25), and then, remove the collar (26) and the roller (27).

23 24

26

27

26

25

22

85V2E54019

8) Remove the ring (28) and pull out the boot (29).

32

31

29

28

33

9) Remove the ring (30) for the joint, and remove the pin (31) by using a pressing machine or equivalent to separate the shaft assembly (32)(33).

30

Joint 85V2E54020

10) Loosen the bolt (34) and remove the spring washer (35) and the mounting plate (36).

38 34

37

36

35

Torque for assembly: : Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)

11) Remove the dust cover (37) and the seat (38).

70V2E54009

54-13

Brake Valve

65TMV-2

BRAKE 54

12) Loosen the bolt (39), and separate the brake valve into the body 1, body 2 and the cover. Remove the spring (40)(41)(43) and spring seat (42).

Torque for assembly: : Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)

Cover

41 42

40

Body 2

43

Body 1

39

13) Place the body 1 and body 2 on a workbench upside down. Remove the C-ring (44), and then, remove the plug (45) and the spring (46).

45

70V2E54010

44 50

46 49 47

48

14) Slowly pull out the spool (47) from the body 1 and remove the plunger (49). Also pull out the spool (48) from the body 2 and remove the plunger (50).

Body 1

Body 2 70V2E54011

54-14

Brake Valve

65TMV-2

BRAKE 54

15) Place the cover on a workbench upside down. Slowly pull out the spool input (51) together with the spring and the spring case.

Cover

51

70V2E54012

16) Loosen the bolt (52) mounted in the spool input (51), and remove the retainer (53), spring (54), spring seat (55).

54 52 53

55

Torque for assembly: : Bolt: 8.83 N-m (0.9 kgf-m) (6.5 lb-ft) Note: If fixing the spool input (51) in a vise to loosen the bolt (52), make sure to protect the spool input with a cloth, etc. to avoid the damage on the surface of the spool.

51 70V2E54013

57

17) Place the cover on a workbench. Remove the C-ring (56), plate (57) and the oil seal (58).

56

Installation tool Ø40mm

58 New seal

Note: Do not reuse the oil seal; replace it with a new one when reassembling.

Ø22mm

Cover

Reassembly process 70V2E54014

54-15

Brake Valve

65TMV-2

BRAKE 54

To reassemble the brake valve, follow the above disassembly procedure in the reversed direction.

Note: - Clean and check all the parts. If a part is defective, replace or repair the part.

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

- Apply the specified torque to tighten each main parts.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

0.5mm or less

3. Reassembling valve 27

Adjusting screw

38

Nut

Adjusting screw

4. Cautions regarding reassembling - Adjust the left pedal using the adjusting screws on the right and left pedals so that the opening between the seat (38) and the roller (27) for the left pedal becomes 0.5 mm 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 the bolt (59) and the roller (16) for the right pedal becomes 3.0~3.5 mm 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)

54-16

3.0 ~ 3.5mm

Left pedal 16

59 Nut

Right pedal 70V2E54015

Service Brake

65TMV-2

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

54-17

BRAKE 54

Park Brake Actuator

65TMV-2

BRAKE 54

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

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

- In addition, block tires with chocks to prevent wheels from moving.

3 Hose installation port

7

1) If there is an oil source, release the parking brake, and then remove split pin (1) and pin (2).

Note: If there is no oil source, apply a cable to the link, and then pull it down using a bar to overcome the spring force, and then remove the pin.

Brake assembly

6 1 4 5

2) Release the residual air pressure in hydraulic tank.

Disconnect oil hose (3).

3) Loosen locknut (4) to remove joint (5).

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

54-18

2 70ZV54009

Park Brake Actuator

65TMV-2

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

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

To check performance of the parking brake, refer to Section 53.

54-19

BRAKE 54

Park Brake Actuator

65TMV-2

BRAKE 54

Adjusting park brake actuator Adjustment procedure of park brake actuator linkage

WARNING When remove the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park machine on level ground.

- Lower bucket to ground.

- Apply articulation stopper.

1

1) Release parking brake (OFF).

2) Measure dimension "A" if it is 98 mm (3 7/8 in).

4

3) If not, remove pin (5), split pin (6), and washer (7) and loosen lock nut (2).

And adjust the linkage length by turning link (3) so that dimension "A" is 98 mm (3 7/8 in).

2 A

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

5) Confirm the parking brake performance.

(Refer to Function & Structure section)

3

5, 6, 7

65ZV54023J

Parking brake "OFF" position 1. Park brake actuator 2. Lock nut 3. Link 4. Bracket 5. Pin 6. Split pin 7. Washer 54-20

Park Brake Actuator

65TMV-2

BRAKE 54

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

1.Cross section and tightening torque

97ZV54004J

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

54-21

Park Brake Actuator

65TMV-2

BRAKE 54

1.Disassembling park brake actuator

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

When reducing the pressure of the press, be sure to slowly reduce it.

Matchmark

90ZV54016

1) Removal of the set screw of rod cap Note: Since the set screw is locked by punching, cut off the punched area with 15 to 20 mm dia. drill.

Since it is necessary to install the set screw at the same position during reassembly, mark the positioning matchmark on the rod cap and cylinder tube.

2) Initial loosening of rod cap Using the threaded hole of the rod cap, unscrew the rod cap approx. 1/8 turn alone.

90ZV54006J

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

4) Slowly pull up the press until the spring loses the spring force.

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

90ZV54007J

3 4

1 2

54-22

90ZV54008J

Park Brake Actuator

65TMV-2

6) Put matchmarks on piston (4) and rod.

Remove set screw (5) to pull out piston (4).

Note: - Since the set screw is locked by punching, cut off the punched area with 15 to 20 mm dia. drill.

- During reassembling, align the matchmarks and install the set screw at the same position.

BRAKE 54

3 5 4

Matchmark 90ZV54017

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

8 4 9 10

7

6

1

90ZV54010J

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

CAUTION When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined.

Tighten the rod cap to the position where the matchmark was marked before disassembly, screw in the screw, and punch it for locking.

54-23

90ZV54011J

Parking Brake

65TMV-2

BRAKE 54

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

WARNING When remove the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park machine on level ground.

- Lower bucket to ground.

- Apply articulation stopper.

2

1) Drain the transmission oil.

1

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

3

65ZV54002J

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

4

5

70ZV54003J

4) Remove bolt (6) of brake adjustment hole and then remove brake drum (7).

Remove bolt (8) and flange yoke (9). : Bolt (6): 132 N-m (13.5 kgf-m) ( 98 lb-ft) Bolt (8): 883 N-m (90.0 kgf-m) (651 lb-ft) : Bolt (6): Screw lock agent AB01 application

9 8 7

6

54-24

65ZV54003J

Parking Brake

65TMV-2

BRAKE 54

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

Torque for assembly: : Bolt (10): 157 N-m (16 kgf-m) (116 lb-ft) : Bolt (10): Screw lock agent AB02 application

11 10

65ZV54004J

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

13 12

12

65ZV54005J

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

15

14

8) Remove spring (16), and then remove adjusting screw (17).

Note: Measure the wear of the brake shoes. If the shoes are extremely worn, replace them. Refer to Section 53 or 55 inspection standards.

65ZV54006J

2.Reinstalling and reassembling parking brake

16

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

Note: To adjust the parking brake, refer to Section 53.

To check performance of the parking brake, refer to Section 53.

54-25

17

65ZV54007J

MEMO

BRAKE GROUP 55 Service Standard Brake Valve ................................................................................................55-2 Service Brake .............................................................................................55-3 Parking Brake .............................................................................................55-4

55-1

Brake Valve

65TMV-2

BRAKE 55

Brake Valve

1 8 7 6

2 3

5 4

2 3

70V2E55001

Unit : mm (in) Judgment standard No.

Item

Standard dimension

Tolerance

Solution

Shaft

Hole +0.033~0 (+0.0013~0)

0.020~0.086 (0.0008~0.0034)

0.096 (0.0038)

Replacement

Standard clearance Allowable clearance

1

Clearance between spool input and cover

ø 22.4 (0.8819)

-0.020~-0.053 (-0.0008~-0.0020)

2

Clearance between spool and body 1, 2

ø 18 (0.7086)

—

—

0.005~0.012 (0.0002~0.0005)

0.014 (0.0006)

Assembly replacement

3

Clearance between plunger and spool

ø 12 (0.4724)

-0.005~-0.010 (-0.0002~-0.0004)

0.008~0 (0.0003~0)

0.005~0.018 (0.0002~0.0007)

0.020 (0.0008)

Assembly replacement

Judgment standard No.

Item

Standard dimension

Tolerance limit

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lb)

Free length mm (in)

Installation load N (kgf) (lb)

Solution

4

Spool return spring

28.3 (1.1142)

17.2 (0.6772)

15 (1.5) (3.4)

—

12.8 (1.3) (2.9)

5

Spool return spring

32.7 (1.2874)

17.2 (0.6772)

39.2 (4.0) (8.8)

—

33.3 (3.4) (7.5)

6

Control spring

41.9 (1.6496)

35.3 (1.3898)

204 (20.8) (45.9)

—

173 (17.6) (38.9) Replacement

7

Control spring

56.4 (2.2205)

48.8 (1.9212)

110 (11.2) (24.7)

—

94 (9.6) (21)

8

Return spring

81 (3.1890)

55 (2.1653)

118 (12) (26.5)

—

100 (10.2) (22.5)

55-2

Service Brake

65TMV-2

BRAKE 55

Service Brake

Differential gear

3

2

1

65ZV55001

Unit : mm (in.)

No.

Item

Judgment standard Standard dimension

Tolerance

Wear limit

8.0 (0.3150)

+ 0 (+ 0)~ – 0.2 (– 0.0078)

7.5 (0.2953)

Distortion of steel plate

–

–

0.3 (0.0118)

Thickness of friction plate

9.0 (0.3543)

± 0.1 (± 0.0039)

7.9 (0.3110)

Depth of lining groove

0.65 (0.0256) and more

–

0

Thickness of lining (both sides)

2.0 (0.0787)

± 0.1 (± 0.0039)

–

Thickness of brake retainer

32.8 (1.2913)

+ 0 (+ 0)~ – 0.1 (– 0.0118)

32.4 (1.2756)

Thickness of steel plate 1

2

3

Solution

55-3

Replacement

Parking Brake

65TMV-2

BRAKE 55

Parking Brake

2

1

5 3

4

65ZV55002J

Unit : mm (in.)

No.

Item

Judgment standard Standard dimension

Wear limit

5.45 (0.2146)

0.8 (0.0315) from the rivet head

Solution Replacement

1

Wear of lining

2

Deflection of drum

0.38 (0.0149) or more

Replacement

3

Lining inspection

Grease or oil on the lining

Replacement

4

Expansion of adjuster spring

There is clearance between spring and coil

5

Expansion of return spring

when spring is released.

55-4

Replacement

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

74-1

Air Conditioner

65TMV-2

OPERATOR STATION 74

Air Conditioner Removing and reinstalling air conditioner Air conditioner unit

1.Removing the air conditioner

Compressor Receiver

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

- Collect the air conditioner refrigerant using the proper recovery method.

- Remove the floor mat in the cab.

1

1) Disconnect tube (1)(2). : Nut 40 N-m (4.1 kgf-m) (30 lb-ft)

2 2

Engine K65V2U74001

4 Fuse box (Cab)

Air conditioner cover Relay

Air conditioner unit

4

3

Blower assy

6

5

5

K65V2U74002

2) Disconnect wires (3).

3) Remove screw (4) to remove the air conditioner cover.

4) Remove bolt (5) to remove the blower assy.

5) Remove bolt (6) to remove the air conditioner unit.

74-2

Air Conditioner

65TMV-2

2.Reinstalling the air conditioner To reinstall the air conditioner, follow the above removal procedure in reverse order.

Reference After rainstalling the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-3

OPERATOR STATION 74

Air Conditioner

65TMV-2

OPERATOR STATION 74

Disassembling and reassembling air conditioner Tightening torque 1. Air conditioner unit

Temperature sensor

Evaporator core

T2

Heater core T3 Low pressure switch

T4 High pressure switch

T5

T1

T2

K65V2U74003

: T1: 1.2 N-m (0.12 kgf-m) (0.89 lb-ft) T2: 1.7 N-m (0.17 kgf-m) (1.25 lb-ft) T3: 5.6 N-m (0.57 kgf-m) (4.13 lb-ft) T4: 8.0 N-m (0.82 kgf-m) (5.90 lb-ft) T5: 16.3 N-m (1.66 kgf-m) (12.0 lb-ft) 74-4

Air Conditioner

65TMV-2

OPERATOR STATION 74

2. Blower

T3

T2

T3 Blower

T2

T3 Shaft

Control unit T1

K65V2U74004

: T1: 1.7 N-m (0.17 kgf-m) (1.25 lb-ft) T2: 2.3 N-m (0.23 kgf-m) (1.70 lb-ft) T3: 5.0 N-m (0.51 kgf-m) (3.69 lb-ft)

74-5

Air Conditioner

65TMV-2

OPERATOR STATION 74

3. Condenser T1 T2

T2

Screen board

Receiver dryer tank

Condenser

K65V2U74005

Condenser

: T1: 4.5 N-m (0.46 kgf-m) (3.32 lb-ft) T2: 12 N-m (1.22 kgf-m) (8.85 lb-ft)

Fan assy

T1 K65V2U74006

4. Ambient temperature sensor

Outside air temperature sensor

K65V2U74007

74-6

Air Conditioner

65TMV-2

OPERATOR STATION 74

Compressor V-belt 4 4

6

6 7

7 5 2

8

1 3 5 3

2

K65V2U74008

1. Compressor assembly 2. V-belt 3. Bracket 4. Bolt 5. Plate 6. Lock nut 7. Adjusting nut 8. Bracket mounting nut

2

6 1

8 4

Engine

3

5

7

K65V2U74009

Belt adjustment procedure 1) Loosen four each of bracket mounting nut (8).

4) After the adjustment, tighten lock nut (6), adjusting nut (7) and bracket mounting nut (8) securely.

2) Loosen lock nut (6).

8~10 mm

3) While pressing V-belt (2) at the center of pulleys by 98.1 N (10 kgf), turn adjusting nut (7) for the belt tension adjustment.

Turn nut (7) clockwise moves up bracket (3) and the V-belt tension increases (tightened).

Turn nut (7) counterclockwise moves down bracket (3) and the belt tension decreases (loosened).

Adjustment target When pressing A by 98.1 N (10 kgf), the V-belt (2) should be moved down by 8~10 mm.

A

Pushing force 98.1 N (10 kgf)

K65V2U74010

74-7

MEMO

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes