Kawasaki 80ZV-2 WHEEL LOADER SHOP MANUAL 93209-00451

80ZV-2

93209-00451

SHOP MANUAL Disassembly & Reassembly Service Standard

All rights reserved.

Printed in Japan (K) ( ヨーロッパ・オセアニア用 )

93209-00451

©2011 KCM Corporation

August 2011

SHOP MANUAL WHEEL LOADER

80ZV-2 General Information Disassembly & Reassembly Service Standard

Powered by CUMMINS QSC8.3 ENGINE Serial No. 80C5-9001~

93209-00451 August 2011

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- Avoid the use of flammable solvents and cleaners.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

MEMO

CONTENTS 80ZV-2 General Information .................................................................................................................................. 00-1 Symbols ............................................................................................................................................................ 00-2 Weight of Main Components ............................................................................................................................. 00-3 Bolt Tightening Torque ...................................................................................................................................... 00-4 Hose Band Tightening Torque ........................................................................................................................... 00-8 Liquid Gasket and Screw Lock Agent ............................................................................................................... 00-9 Cautions regarding parts removal ............................................................................................................... 00-9 Cautions regarding reassembly .................................................................................................................. 00-9 Screw lock agent application procedure ................................................................................................... 00-10 How to wind a seal tape ............................................................................................................................ 00-10 Cautions Regarding Welding Repair Service ...................................................................................................00-11 Cautions Regarding Handling of Bearing ........................................................................................................ 00-13 Bearing installation cautions ..................................................................................................................... 00-13 Interference fits for a bearing .................................................................................................................... 00-13 Bearing removal cautions ......................................................................................................................... 00-14 Applying and Storing Articulation Stopper ....................................................................................................... 00-15 Applying articulation stopper ..................................................................................................................... 00-15 Storing articulation stopper ....................................................................................................................... 00-15 80ZV-2 Disassembly & Reassembly Chassis Group ............................................................................................ 14-1 Deck .................................................................................................................................................................. 14-2 Deck removing and installing ...................................................................................................................... 14-2 Fuel Tank .......................................................................................................................................................... 14-4 Fuel tank removing and installing ............................................................................................................... 14-4 Hydraulic Tank .................................................................................................................................................. 14-5 Hydraulic tank removing and installing ....................................................................................................... 14-5 Engine Room .................................................................................................................................................... 14-8 Engine room removing and installing .......................................................................................................... 14-8 Cab ................................................................................................................................................................. 14-12 Cab removing and installing ...................................................................................................................... 14-12 Floor Board ..................................................................................................................................................... 14-14 Floor board removing and installing .......................................................................................................... 14-14 Boom ............................................................................................................................................................... 14-17 Boom removing and installing ................................................................................................................... 14-17

Center Pin ....................................................................................................................................................... 14-20 Upper center pin ........................................................................................................................................ 14-20 Lower center pin ........................................................................................................................................ 14-21 Center pin removing and installing ............................................................................................................ 14-22 Partition Plate .................................................................................................................................................. 14-26 Partition plate removing and installing ...................................................................................................... 14-26 80ZV-2 Service Standard Chassis Group ............................................................................................................. 15-1 Linkage .............................................................................................................................................................. 15-2 Linkage Pin Standard Clearance Values ........................................................................................................... 15-3 Liner clearance adjustment ......................................................................................................................... 15-4 Center Pin ......................................................................................................................................................... 15-5 Center pin shim adjustment ........................................................................................................................ 15-5 Bearing cover installing ............................................................................................................................... 15-5 Lower center pin bearing outer ring installing ............................................................................................. 15-6 Attachment Leveler ........................................................................................................................................... 15-7 Attachment leveler ...................................................................................................................................... 15-8 Attachment leveler adjustable angle ........................................................................................................... 15-8 80ZV-2 Disassembly & Reassembly Power Group ............................................................................................... 24-1 Power Line ........................................................................................................................................................ 24-2 Power line tightening torque ........................................................................................................................ 24-2 Radiator ............................................................................................................................................................. 24-3 Radiator tightening torque ........................................................................................................................... 24-3 Radiator removing and installing ................................................................................................................. 24-5 Fan .................................................................................................................................................................... 24-8 Fan removing and installing ........................................................................................................................ 24-8 Engine ............................................................................................................................................................. 24-10 Engine removing and installing ................................................................................................................. 24-10 Propeller Shaft ................................................................................................................................................ 24-13 Propeller shaft removing and installing ..................................................................................................... 24-13 Air Cleaner ...................................................................................................................................................... 24-15 Air cleaner removing and installing ........................................................................................................... 24-15 Muffler ............................................................................................................................................................. 24-17 Muffler removing and installing ................................................................................................................. 24-17

Front Axle Assembly ....................................................................................................................................... 24-18 Front axle assembly tightening torque ...................................................................................................... 24-18 Front axle assembly removing and installing ............................................................................................ 24-20 Front axle disassembling and assembling ................................................................................................ 24-23 Front axle assembly cautions ................................................................................................................... 24-27 Internal Gear Hub ........................................................................................................................................... 24-32 Internal gear hub disassembling and assembling ..................................................................................... 24-32 Spider Assembly ............................................................................................................................................. 24-35 Spider assembly disassembling and assembling ...................................................................................... 24-35 Special Tool ..................................................................................................................................................... 24-37 Special tool for axle ................................................................................................................................... 24-37 Rear Axle Assembly ........................................................................................................................................ 24-42 Rear axle assembly tightening torque ....................................................................................................... 24-42 Rear axle assembly removing and installing ............................................................................................. 24-44 Rear axle disassembling and assembling ................................................................................................. 24-46 Axle Support ................................................................................................................................................... 24-47 Axle support tightening torque .................................................................................................................. 24-47 Axle support disassembling and assembling ............................................................................................ 24-48 Differential Assembly ...................................................................................................................................... 24-50 Differential assembly removing and installing ........................................................................................... 24-50 Differential assembly disassembling and assembling ............................................................................... 24-52 80ZV-2 Service Standard Power Group ................................................................................................................ 25-1 Propeller Shaft Service Standard ...................................................................................................................... 25-2 Axle and Differential Service Standard .............................................................................................................. 25-3 Axle group ................................................................................................................................................... 25-3 Differential ................................................................................................................................................... 25-4 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group ............................................... 34-1 Torque Converter and Transmission Assembly ................................................................................................ 34-2 Torque converter and transmission assembly tightening torque ................................................................. 34-2 Torque converter and transmission assembly removing and installing ....................................................... 34-3 Transmission assembly installation cautions .............................................................................................. 34-9 Torque Converter Assembly ............................................................................................................................ 34-12 Torque converter assembly bolt tightening torque .................................................................................... 34-12 Torque converter assembly disassembling and assembling ..................................................................... 34-13

Transmission Assembly .................................................................................................................................. 34-20 Transmission assembly bolt tightening torque .......................................................................................... 34-20 Transmission assembly disassembling and assembling ........................................................................... 34-22 Transmission Forward/Reverse Clutch Pack .................................................................................................. 34-33 Forward/reverse clutch pack disassembling and assembling ................................................................... 34-33 Transmission 1st/3rd Speed Clutch Pack ........................................................................................................ 34-36 Transmission 1st/3rd speed clutch pack disassembling and assembling ................................................. 34-36 Transmission 2nd Speed Clutch Pack ............................................................................................................. 34-38 Transmission 2nd speed clutch pack disassembling and assembling ...................................................... 34-38 Transmission 4th Speed Clutch Pack .............................................................................................................. 34-40 Transmission 4th speed clutch pack disassembling and assembling ....................................................... 34-40 Control Valve Assembly .................................................................................................................................. 34-43 Control valve tightening torque ................................................................................................................. 34-43 Control valve removing and installing ....................................................................................................... 34-44 Control valve disassembling and assembling ........................................................................................... 34-46 80ZV-2 Service Standard Torque Converter and Transmission Group ................................................................ 35-1 Transmission Assembly .................................................................................................................................... 35-2 Control Valve ..................................................................................................................................................... 35-3 Gear Pump ........................................................................................................................................................ 35-5 Gear pump specifications ............................................................................................................................ 35-5 Clutch Plate Thickness/Piston Stroke ............................................................................................................... 35-6 Clutch plate ................................................................................................................................................. 35-7 Piston stroke ............................................................................................................................................... 35-7 Clutch Oil Pressure ........................................................................................................................................... 35-8 Clutch oil pressure standard value .............................................................................................................. 35-8 80ZV-2 Disassembly & Reassembly Hydraulic Group .......................................................................................... 44-1 Hydraulic Parts Removal and Installation Warning ........................................................................................... 44-2 Hydraulic Parts Disassembly and Assembly Cautions ...................................................................................... 44-3 Hydraulic parts disassembly cautions ......................................................................................................... 44-3 Hydraulic parts assembly cautions .............................................................................................................. 44-3 Hydraulic Pump Assembly ................................................................................................................................ 44-4 Hydraulic pump assembly removing and installing ..................................................................................... 44-4 Hydraulic pump assembly disassembling and assembling ......................................................................... 44-6

Hydraulic Cylinder ............................................................................................................................................. 44-8 Boom cylinder removing and installing ....................................................................................................... 44-8 Bucket cylinder removing and installing .................................................................................................... 44-10 Steering cylinder removing and installing .................................................................................................. 44-13 Hydraulic cylinder disassembling and assembling .................................................................................... 44-15 Pilot Valve (S/N 9001~9205) ........................................................................................................................... 44-21 Pilot valve removing and installing ............................................................................................................ 44-21 Pilot valve disassembling and assembling ................................................................................................ 44-23 Pilot Valve (S/N 9206~) ................................................................................................................................... 44-32 Pilot valve removing and installing ............................................................................................................ 44-32 Pilot valve disassembling and assembling ................................................................................................ 44-34 Multiple Control Valve ..................................................................................................................................... 44-42 Multiple control valve removing and installing ........................................................................................... 44-42 Multiple control valve disassembling and assembling .............................................................................. 44-44 Orbitrol® .......................................................................................................................................................... 44-48 Orbitrol® removing and installing ............................................................................................................... 44-48 Orbitrol® disassembling and assembling .................................................................................................. 44-50 Steering Valve ................................................................................................................................................. 44-58 Steering valve removing and installing ...................................................................................................... 44-58 Steering valve disassembling and assembling ......................................................................................... 44-60 Stop Valve ....................................................................................................................................................... 44-63 Stop valve removing and installing ............................................................................................................ 44-63 Stop valve disassembling and assembling ............................................................................................... 44-65 Fan Motor ........................................................................................................................................................ 44-67 Fan motor removing and installing ............................................................................................................ 44-67 80ZV-2 Service Standard Hydraulic Group ........................................................................................................... 45-1 Hydraulic Cylinder ............................................................................................................................................. 45-2 Pilot Valve ......................................................................................................................................................... 45-4 Steering Valve ................................................................................................................................................... 45-6 80ZV-2 Disassembly & Reassembly Brake Group ............................................................................................... 54-1 Unloader Valve .................................................................................................................................................. 54-2 Unloader valve removing and installing ...................................................................................................... 54-2 Unloader valve disassembling and assembling .......................................................................................... 54-4

Manifold Valve Assembly .................................................................................................................................. 54-8 Valve assembly removing and installing ..................................................................................................... 54-8 Valve assembly disassembling and assembling ......................................................................................... 54-9 Accumulator .................................................................................................................................................... 54-11 Accumulator removing and installing ........................................................................................................ 54-11 Accumulator disassembling and assembling ............................................................................................ 54-13 Nitrogen gas charging ............................................................................................................................... 54-15 Brake Valve ..................................................................................................................................................... 54-17 Brake valve removing and installing .......................................................................................................... 54-17 Brake valve disassembling and assembling ............................................................................................. 54-19 Service Brake .................................................................................................................................................. 54-25 Service brake disassembling and assembling .......................................................................................... 54-25 Parking Brake Actuator ................................................................................................................................... 54-26 Parking brake actuator removing and installing ........................................................................................ 54-26 Parking brake actuator disassembling and assembling ............................................................................ 54-28 Parking Brake .................................................................................................................................................. 54-31 Parking brake removing and installing / disassembling and assembling .................................................. 54-31 80ZV-2 Service Standard Brake Group ................................................................................................................. 55-1 Brake Valve ....................................................................................................................................................... 55-2 Service Brake .................................................................................................................................................... 55-4 Parking Brake .................................................................................................................................................... 55-5 80ZV-2 Disassembly & Reassembly Operator Station Group ............................................................................... 74-1 Air Conditioner .................................................................................................................................................. 74-2 Air conditioner removing and installing ....................................................................................................... 74-2 Air conditioner disassembling and assembling ........................................................................................... 74-4 80ZV-2 Service Standard Operator Station Group ................................................................................................ 75-1 Air Conditioner .................................................................................................................................................. 75-2 Periodical Inspection/Servicing ................................................................................................................... 75-2 Tightening Torque ....................................................................................................................................... 75-2

00-1 80ZV-2 General Information

80ZV-2 General Information Symbols .................................................................. 00-2 Weight of Main Components ................................... 00-3 Bolt Tightening Torque ............................................ 00-4 Hose Band Tightening Torque ................................. 00-8 Liquid Gasket and Screw Lock Agent ..................... 00-9 Cautions Regarding Welding Repair Service .......... 00-11 Cautions Regarding Handling of Bearing ................ 00-13 Applying and Storing Articulation Stopper ............... 00-15

00-2 80ZV-2 General Information Symbols

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

Symbol

Item

Description

Reference

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

Weight

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

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

Coating

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

Oil or water supply

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

Drainage

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

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

The message shows the preventive measures.

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

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

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

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

00-3 80ZV-2 General Information Weight of Main Components

Weight of Main Components

Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

1,430

3,150

Boom

1,130

2,490

Item Unit name

"Z" -Lever

310/pc

685/pc

Link (Bucket to Lever)

65/pc

145/pc

Engine room assembly

280

620

Chassis

Hydraulic system

Other

GSC bucket

Hydraulic tank

125

275

Excluding oil

Fuel tank

150

330

Excluding fuel

Floor board

160

355

Cab (ROPS)

500

1,100

Left side

65

145

With handrail

Right side

65

145

With handrail

Front chassis

1,445

3,180

Rear chassis

1,355

2,980

Counter weight

1,670

3,680

Engine

695

1,530

Excluding oil

Radiator assembly

380

840

Excluding water and oil

Transmission

600

1,320

Excluding oil

Second propeller shaft

50

110

Deck

Power line

Remarks

Third propeller shaft

15

35

Front axle assembly

960

2,110

Excluding tires and oil

Rear axle assembly

1,120

2,460

Excluding tires and oil (Including axle support)

Differential

170

375

Multiple control valve

55

120

Pilot valve

10

25

Steering valve

25

55

Orbitrol®

6

15

Gear pump

35

80

Fan motor

15

35

Boom cylinder

140/pc

310/pc

Triple pump

Excluding oil

Bucket cylinder

200/pc

440/pc

Excluding oil

Steering cylinder

25/pc

55/pc

Excluding oil

Tire

520/pc

1,150/pc

Battery

30/pc

65/pc

With rim (23.5R25

)

00-4 80ZV-2 General Information Bolt Tightening Torque

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

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

26

38

(C) 1.5

53

76

M10

M12

M14

Metric thread

Unified thread

Bolt strength

Nominal dimension

10

12

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27

27

M30

30

M33

33

5/16

05

(F) 1.25

55

80

(C) 1.75

90

132

(F) 1.25

96

142

(C) 2.0

142

206

(F) 1.5

152

221

(C) 2.0

216

314

(F) 1.5

226

330

(C) 2.5

299

436

(F) 1.5

324

476

(C) 2.5

417

608

(F) 1.5

451

662

(C) 2.5

559

814

(F) 1.5

598

878

(C) 3.0

721

1,030

(F) 2.0

770

1,128

(C) 3.0

1,030

1,520

(F) 2.0

1,128

1,618

(C) 3.5

1,422

2,109

(F) 2.0

1,569

2,256

(C) 3.5

1,912

2,844

(F) 2.0

2,059

3,040

18 UNC

25

35

3/8

06

16 UNC

44

65

7/16

07

14 UNC

71

103

1/2

08

13 UNC

103

147

9/16

09

12 UNC

147

216

5/8

10

11 UNC

201

294

3/4

12

10 UNC

358

525

7/8

14

9 UNC

554

809

1

16

8 UNC

868

1,275

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

00-5 80ZV-2 General Information Bolt Tightening Torque

(kgf-m) Bolt size Type

Metric thread

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

2.7

3.9

(C) 1.5

5.4

7.8

(F) 1.25

5.6

8.2

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27

M30

Unified thread

Bolt strength

Nominal dimension

27

30

M33

33

5/16

05

(C) 1.75

9.2

13.5

(F) 1.25

9.8

14.5

(C) 2.0

14.5

21.0

(F) 1.5

15.5

22.5

(C) 2.0

22.0

32.0

(F) 1.5

23.0

33.7

(C) 2.5

30.5

44.5

(F) 1.5

33.0

48.5

(C) 2.5

42.5

62.0

(F) 1.5

46.0

67.5

(C) 2.5

57.0

83.0

(F) 1.5

61.0

89.5

(C) 3.0

73.5

105.0

(F) 2.0

78.5

115.0

(C) 3.0

105.0

155.0

(F) 2.0

115.0

165.0

(C) 3.5

145.0

215.0

(F) 2.0

160.0

230.0

(C) 3.5

195.0

290.0

(F) 2.0

210.0

310.0

18 UNC

2.5

3.6

3/8

06

16 UNC

4.5

6.6

7/16

07

14 UNC

7.2

10.5

1/2

08

13 UNC

10.5

15.0

9/16

09

12 UNC

15.0

22.0

5/8

10

11 UNC

20.5

30.0

3/4

12

10 UNC

36.5

53.5

7/8

14

9 UNC

56.5

82.5

1

16

8 UNC

88.5

130.0

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

00-6 80ZV-2 General Information Bolt Tightening Torque

(lb-ft) Bolt size Type

Metric thread

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

19.5

28

(C) 1.5

39

56

(F) 1.25

40

59

(C) 1.75

66

97

(F) 1.25

70

105

(C) 2.0

105

150

(F) 1.5

110

160

(C) 2.0

160

230

(F) 1.5

165

245

(C) 2.5

220

320

(F) 1.5

235

350

(C) 2.5

305

450

(F) 1.5

330

490

(C) 2.5

410

600

(F) 1.5

440

650

(C) 3.0

530

760

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27

M30

Unified thread

Bolt strength

Nominal dimension

27

30

M33

33

5/16

05

(F) 2.0

565

830

(C) 3.0

760

1,120

(F) 2.0

830

1,190

(C) 3.5

1,050

1,550

(F) 2.0

1,160

1,660

(C) 3.5

1,410

2,100

(F) 2.0

1,520

2,240

18 UNC

18.0

26

3/8

06

16 UNC

32

47

7/16

07

14 UNC

52

76

1/2

08

13 UNC

76

105

9/16

09

12 UNC

110

160

5/8

10

11 UNC

150

215

3/4

12

10 UNC

265

385

7/8

14

9 UNC

410

595

1

16

8 UNC

640

940

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

00-7 80ZV-2 General Information Bolt Tightening Torque

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

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

7

M6

1

12

M8

1.25

28

M10

1.5

53

M12

1.75

94

M16

2

231

M20

2.5

441

M24

3

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

M5

0.8

0.7

M6

1

1.2

8.8 (8T)

M8

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

2

23.5

M20

2.5

45.0

M24

3

78.0 (lb-ft)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

5.0

M6

1

8.6

M8

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

2

169.2

M20

2.5

324.0

M24

3

561.6

00-8 80ZV-2 General Information Hose Band Tightening Torque

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

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

16

1.2

4

40

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

16

1.2

4

40

2.9

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

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

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

16.5

8

18.5

9

20.5

9

22.0

12

24.5

12

26.0

15

29.0

15

30.5

19

32.0

19

34.0

25

39.5

25

41.5

32

46.0

32

48.0

38

54.0

50

70.5

50

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

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

Fix the band avoiding the beading.

2~3 mm (1/8 in) Pipe

Hose Hose band

K50V200002

00-9 80ZV-2 General Information Liquid Gasket and Screw Lock Agent

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

Screw Lock Agent

Product name

Loctite

®

Plastic Gasket 568

AA02

Loctite

®

Hydraulic sealant

AA03

Three Bond

AA01 Liquid Gasket

Manufacturer

®

Three Bond 1215 ®

AB01

Loctite

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

Loctite 262

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

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

To bond a plane or to fit a shaft

Cautions regarding parts removal

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

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

Antiseize Agent

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

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

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

Code

Manufacturer

Product name

AC01

Loctite®

Loctite® 767 (Paste or spray)

00-10 80ZV-2 General Information Liquid Gasket and Screw Lock Agent

Screw lock agent application procedure

How to wind a seal tape

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

Seal tape

Leave 1~2 screw

Screw lock agent

65ZV00004a

65ZV00002

As the screw is tightened by turning clockwise, seal tape must be wound up clockwise direction as shown above. If not, the tape will be loosened or removed while tightening the screw, resulting in oil leakage.

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

Slightly stretch the tape when cutting it out, and press to fit the tape onto the screw thread.

00-11 80ZV-2 General Information Cautions Regarding Welding Repair Service

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

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

1. Turn the starter switch OFF.

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

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

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

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

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

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

Example 1

Section to be welded Do not ground this section.

Electric current may flow through the cylinders.

Ground this section. (correct grounding)

35C00002

Example 2

Do not ground this section.

Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

35C00006

00-12 80ZV-2 General Information Cautions Regarding Welding Repair Service 7. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes.

Be sure to mask these units and parts before welding.

Hydraulic cylinder

Heat-resistant cloth Section to be welded

Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

35A00005

Plated section (Mask this section.)

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

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

35C00003

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

Note The weld spattered on the plated sections causes corrosion.

1m or more

Scrap material, etc.

Section to be welded

1m or more 35C00004

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

00-13 80ZV-2 General Information Cautions Regarding Handling of Bearing

Cautions Regarding Handling of Bearing Bearing installation cautions

Force

IMPORTANT Unwrap a new bearing just before installing it.

Metal pad

K65V2J00002

K65V2J00004

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

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

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

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

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

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

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

Interference fits for a bearing

Heating to remove the interference

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

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

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

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

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

00-14 80ZV-2 General Information Cautions Regarding Handling of Bearing

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

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

Bearing removal cautions Pressing machine

Bearing puller

Bearing removal tool K65V2J00003

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

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

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

00-15 80ZV-2 General Information Applying and Storing Articulation Stopper

Applying and Storing Articulation Stopper Applying articulation stopper 2

3

Locked position IL12-2(70ZV-D&R)

IL14-1(90ZV-D&R)

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

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

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

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

Stay out of the articulation area while aligning the holes.

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

1

Storing articulation stopper

IL12-1(70ZV-D&R)

2

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

3

Stored position

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

IL12-3(70ZV-D&R)

00-16 80ZV-2 General Information

MEMO

14-1 80ZV-2 Disassembly & Reassembly Chassis Group

80ZV-2 Disassembly & Reassembly Chassis Group Deck ........................................................................ 14-2 Fuel Tank................................................................. 14-4 Hydraulic Tank......................................................... 14-5 Engine Room .......................................................... 14-8 Cab.......................................................................... 14-12 Floor Board ............................................................. 14-14 Boom ....................................................................... 14-17 Center Pin ............................................................... 14-20 Partition Plate .......................................................... 14-26

14-2 80ZV-2 Disassembly & Reassembly Chassis Group Deck

Deck Deck removing and installing

2

4

Deck removing

Screen board

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

4 K80V2J14002

2. Apply a sling to handrail (2) and deck (3), then remove bolts (4). : Deck (3) (with handrails): 70 kg (155 lbs)

5 Screen board

7

Window washer liquid tank

5 Deck (RH)

6 7 1

Fuel tank K80V2J14003 K80V2J14001

1. Remove bolt (1) and remove the window washer liquid tank from deck (RH).

3. Apply a sling to handrail (5) and deck (6), then remove bolts (7). : Deck (6) (with handrails): 65 kg (140 lbs) 4. While considering the balance, remove decks (3)(6) together with the handrails.

14-3 80ZV-2 Disassembly & Reassembly Chassis Group Deck

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

8

80V2E14004

5. Remove bolt (8) to remove ladder from the fuel tank. : Ladder: 9 kg (20 lbs)

14-4 80ZV-2 Disassembly & Reassembly Chassis Group Fuel Tank

Fuel Tank Fuel tank removing and installing

4

4

Fuel tank removing

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting 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: 290 L (80 gal)) - Remove the deck and the ladder.

Fuel tank 80V2E14006

5. Slightly pull out the fuel tank to disconnect suction/ return hoses (4).

Plug the fuel line to prevent dirt entry. Be careful not to damage the fitting on the tank.

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

Fuel tank installing

Rear chassis

For reinstallation, follow the above procedure in reverse order.

3 1 Cover

3

Fuel tank

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

2 80V2E14005

1. Remove bolt (1) and then remove the cover.

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

3. Temporarily sling the fuel tank. : Fuel tank: 150 kg (330 lbs) (when empty) 4. Remove retainer bolts (3). : Bolt (3): 441 N-m (45.0 kgf-m) (325 lb-ft)

14-5 80ZV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic Tank Hydraulic tank removing and installing

(S/N ~9250)

Breather valve

(S/N 9251~)

Breather valve

Hydraulic tank removing

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

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

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

K80V2E14003

2

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

(Hydraulic tank capacity: 85 L (23 gal)) - Remove the deck.

- Clean the area around the tank.

1 80V2E14007

1. Disconnect hoses (1)(2).

Note Cover or plug the disconnected hoses and the fittings to prevent leakage and dirt entry.

14-6 80ZV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

5 Pump unit (for secondary steering)

7

4

3

80V2E14008

80V2E14010

2. Disconnect hose (3) to the fan motor.

Disconnect brake line hose (4) and pilot hydraulic line hose (5).

4. Remove bolt (7) to remove the pump unit for the optional secondary steering system.

Note Cover or plug the disconnected hoses and the fittings to prevent leakage and dirt entry.

8 6

80V2E14011

5. Disconnect hose (8) to the oil pump.

80V2E14009

3. Disconnect brake line hose (6).

Note Cover or plug the disconnected hoses and the fittings to prevent leakage and dirt entry.

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

14-7 80ZV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

10

12

11

9

80V2E14012

6. Disconnect temperature sensor coupler (9).

7. Remove bolt (10) to remove the cover plate, and disconnect oil level sensor (11).

8. Temporarily sling the hydraulic tank, and remove bolt (12). : Hydraulic tank: 130 kg (290 lbs) (when empty) : Bolt (12): 230 N-m (23.5 kgf-m) (170 lb-ft)

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

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

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

14-8 80ZV-2 Disassembly & Reassembly Chassis Group Engine Room

Engine Room Engine room removing and installing 3

Engine room removing

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

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

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

90ZV14009

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

5

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

4

2 1

85V2E14015

3. Remove bolt (4) and exhaust pipe (5). : Bolt (4): 53 N-m (5.4 kgf-m) (39 lb-ft)

6

90ZV14008

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

6

7

8

85V2E14016

4. Disconnect sub tank hoses (6) for the radiator.

Remove nut (7) and remove tank (8).

14-9 80ZV-2 Disassembly & Reassembly Chassis Group Engine Room

Condenser

12 13

9

Receiver tank

9

Engine access panel

Screen board

80V2E14013

5. Remove wires (9) for the engine access panel.

11

K80V2J14008

7. Disconnect hoses (12)(13) from the condenser and the receiver tank.

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

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

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

Engine

15

14 Radiator guard

10 85ZV14012

6. Remove hose (10) between the air cleaner and turbocharger at the turbocharger side.

Disconnect indicator wire coupler (11).

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

14

Screen board

K80V2J14009

8. Remove nut (14) for engine roof (15) and lift the roof. : Nut (14): 53 N-m (5.4 kgf-m) (39 lb-ft) : Engine roof: 32 kg (70 lbs)

14-10 80ZV-2 Disassembly & Reassembly Chassis Group Engine Room

18

16

20

16

20 Rear chassis

Screen board

17

17 K80V2J14010

80V2E14017

9. Remove round bar (16) of engine access panel (17).

Sling engine access panel (17), and remove bolt (18) to remove the panel.

11. Remove screen board retainer bolt (20) and lift the screen board.

: Engine access panel: 21 kg (50 lbs) 19

Note Slowly lift the screen board while checking that there are no obstacles. : Bolt (20): 230 N-m (23.5 kgf-m) (169 lb-ft) : Screen board (with condenser and air cleaner) 130 kg (290 lbs)

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

Cover assembly

80V2E14016

10. Remove bolt (19) and the cover assembly mounted on the screen board.

14-11 80ZV-2 Disassembly & Reassembly Chassis Group Engine Room

Engine room installation cautions 2~3 mm (1/8 in) 5 mm (1/4 in) or less Fix the bands avoiding the beading Air duct

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

K85V2U24005

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.

14-12 80ZV-2 Disassembly & Reassembly Chassis Group Cab

Cab Cab removing and installing Cab removing 3

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

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

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

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

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

- Disconnect the electrical line couplers.

65ZV14013J

2. Cover (3) for the filter is located on the right rear side of the cab.

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

2

Filter 65ZV14014J

1 95V2E14013

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

3. Remove the filter from the cab.

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

14-13 80ZV-2 Disassembly & Reassembly Chassis Group Cab

9

4

95ZV14016

4. Remove cover (4).

5

6

8 7

85V2E14023

6. Remove bolts (7)(8).

95ZV14017

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

Note Be advised that bolt (8) is a flanged bolt to be tightened without a washer, and bolt (7) is tightened with a plane washer.

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

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

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

14-14 80ZV-2 Disassembly & Reassembly Chassis Group Floor Board

Floor Board Floor board removing and installing Floor board removing

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

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

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

- Disconnect the (-) side of the battery.

- Disconnect the (+) side of the battery.

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

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

- Remove the cab.

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

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

Prepare a can for the oil.

1

1 1

1 85V2E14024

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

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

Operation stand

2

Orbitrol® 95V2E14016

2. Put matchmarks and disconnect pilot hydraulic line hose (2) from the Orbitrol®.

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

14-15 80ZV-2 Disassembly & Reassembly Chassis Group Floor Board

3 To pilot valve

Brake valve

Control box

4 To pilot valve

9

3 80V2E14018

8

3. Disconnect brake line hose (3) and pipe (4) from the brake valve.

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

10 Combination valve Hydraulic tank

10

Air conditioner

Multiple control valve

7 80V2E14020

6

5. Disconnect pilot hydraulic line hose (8) from the pilot valve at the port located on the hydraulic tank.

Disconnect hose (9) to the combination valve.

Disconnect pilot hydraulic line hose (10) from the multiple control valve.

5

Floor board

K80V2J14014

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

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

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

14-16 80ZV-2 Disassembly & Reassembly Chassis Group Floor Board

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

11

Floor board

12

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

Rubber cushions

80V2E14021

6. Remove elastic plug (11) and floor board retaining nut (12).

Temporarily sling then gradually lift the floor board while checking that there are no obstacles and that all pipes, cables, pins, etc. are disconnected. : Nut (12): 230 N-m (23.5 kgf-m) (170 lb-ft) : Floor board assy including ope. stand, control box, etc.: 300 kg (660 lbs) Reference : Bolt (13) for the rubber cushion: 76 N-m (7.8 kgf-m) (56 lb-ft)

14-17 80ZV-2 Disassembly & Reassembly Chassis Group Boom

Boom Boom removing and installing

2

Boom removing 4

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

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

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

- Apply the parking brake and remove the starter key.

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

- Keep persons away from working area.

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

- Use a copper-hammer or a plastic hammer.

- Always wear protection goggles.

3 1

5 85ZV14015

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

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

2. Remove connection pin (5) from boom (4) and bucket (1) to remove the bucket. : Bucket: 1,500 kg (3,300 lbs)

7 6

2 90ZV14017

3. Temporarily sling link (2), and then remove connection pin (6) from lever (7) and link (2). : Link: 65 kg (145 lbs)

14-18 80ZV-2 Disassembly & Reassembly Chassis Group Boom

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

Always use a stepladder for the following work.

7

11 8

80ZV14013

6. Temporarily attach a sling to lever (7), and then remove lever pin (11).

9

7. Remove lever (7).

7

: Lever: 310 kg (685 lbs)

85ZV14017

4. Temporarily sling bucket cylinder (8), and then remove connection pin (9) from lever (7) and bucket cylinder (8). : Bucket cylinder: 200 kg (440 lbs)

12 13

10

K80ZV14001

8. Temporarily attach sling to boom cylinders (12), and then, remove pins (13) from the cylinder rod, on both the right and left sides of the boom.

85ZV14018

5. Start the engine and shorten bucket cylinder rod (10). Stop the engine.

Lower bucket cylinder rod (10) on the machine.

14-19 80ZV-2 Disassembly & Reassembly Chassis Group Boom

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

14

Boom installation cautions Boom cylinder

85ZV14021

9. Start the engine and shorten boom cylinder rod (14). Stop the engine.

Lower boom cylinder rod (14) on the machine.

4

15

85ZV14022

10. Temporarily sling the cross pipe of boom (4), and then remove pins (15) from the boom on both the right and left side of the boom.

11. Slowly lift boom (4) to remove it from the machine. : Boom: 1,135 kg (2,500 lbs)

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

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

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

14-20 80ZV-2 Disassembly & Reassembly Chassis Group Center Pin

Center Pin Upper center pin

: T1: 216 N-m (22 kgf-m) (159 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) T1

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

Shim adjustment

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

Front chassis Rear chassis

T2 L1

80V2E14022

T1

Shim

T2 L1 80V2E14023

14-21 80ZV-2 Disassembly & Reassembly Chassis Group Center Pin

Lower center pin

Front chassis

Bearing outer ring

Rear chassis80V2E14024

80V2E14025

14-22 80ZV-2 Disassembly & Reassembly Chassis Group Center Pin

Center pin removing and installing Center pin removing

3

WARNING

4

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

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

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

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

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

Front chassis

Steering cylinder 80ZV14020

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

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

3. Disconnect the hoses. line from the couplers.

Disconnect the electrical

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

Transmission

2

1 5 80ZV14019

1. Remove bolt (1) and disconnect second propeller shaft (2).

80ZV14021

: Bolt (1): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent application (Three Bond 1327) Note If the retainer bolt is too tight due to the screw lock agent, heat the bolt head to about 235ºC (450ºF) using slow flame of a gas burner.

Keep the flame away from the seals of the coupling.

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

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

14-23 80ZV-2 Disassembly & Reassembly Chassis Group Center Pin

8

6

Jack screw 80ZV14022

90ZV14031

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

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

WARNING 70

65ZV14011

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

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

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

- Use the signals as agreed upon before starting work.

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

9

7

Jack

By Jack 80ZV14023 90ZV14030

8. Push out upper center pin (9) using a jack.

6. Before disconnecting front chassis (7) from the rear chassis, be sure to support front chassis (7) using the jack and blocks so that the front chassis will not fall backward.

14-24 80ZV-2 Disassembly & Reassembly Chassis Group Center Pin

10

12

By Jack 80ZV14024

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

11

13

14

80ZV14025

11. Remove ring (11).

12. Remove bolts (12) from bearing cover (13).

Bar

: Bolt (12): 216 N-m (22.0 kgf-m) (159 lb-ft)

90W14014

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

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

To prevent such an accident, make sure the blocks, support and jack are placed in the right position to properly support the chassis.

Grease nipple installation direction

B Front

30

Note While turning the rear tires, check that the garage jack under the fuel tank shifts backward together with the rear chassis. In addition, adjust the height using the rear crane whenever the height adjustment is necessary.

22.5

Grease nipple installation direction

B

B

B

80V2E14026

Note When reinstalling bearing cover (13), be careful with the installation direction.

14-25 80ZV-2 Disassembly & Reassembly Chassis Group Center Pin 13. Remove shim (14).

Center pin installing

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

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

For reinstallation, follow the above procedure in reverse order.

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

(Top)

(Bottom)

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

- Check each section for oil leakage.

- No oil leakage should be found in any part.

- Be sure to completely bleed the brake of air.

For air bleeding procedure, refer to the "Service brake air bleeding procedure" page 24-22.

WARNING

90ZV14036

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

Bearing outer ring

Front

Split of outer bearing Grease nipple installation direction

40 80ZV14026

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

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

14-26 80ZV-2 Disassembly & Reassembly Chassis Group Partition Plate

Partition Plate Partition plate removing and installing

(S/N 9101~)

Partition plate removing

4

6

WARNING 1

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.

7 8

2 10

9

5 3

Note The partition plates should be removed prior to other parts and/or units around, and there is very limited space for the partition plates to take them out.

When removing the partition plates, take care so that the plates do not damage the fan motor, engine, etc.

(S/N 9001~9100)

K80V2E14001

6

1. Remove nut (1) and bolt (2) to remove partition plate (3).

4

: Partition plate (3): 4 kg (9 lbs)

1

8 7

2. Remove nut (4) and bolt (5) to remove partition plate (6).

2

10

9

: Partition plate (6): 4 kg (9 lbs) 3. Remove nut (7) to remove partition plate (8).

5

: Partition plate (8): 3.5 kg (8 lbs) (S/N 9001~9100) 6.5 kg (14 lbs) (S/N 9101~)

3

4. Finally remove bolt (9) to remove partition plate (10). : Partition plate (10): 10.5 kg (23 lbs) (S/N 9001~9100) 7.5 kg (16.5 lbs) (S/N 9101~) 80V2E14027

14-27 80ZV-2 Disassembly & Reassembly Chassis Group Partition Plate

Rear chassis

13 12 11

14

15 16

11 K80V2E14002

5. Remove bolt (11) to remove partition plate (12).

6. Remove bolt (13) and nut (14) to remove partition plates (15)(16). : Partition plate (12): 21 kg (46 lbs) : Partition plate (15): 2 kg (4.5 lbs) : Partition plate (16): 3 kg (6.5 lbs)

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

14-28 80ZV-2 Disassembly & Reassembly Chassis Group

MEMO

15-1 80ZV-2 Service Standard Chassis Group

80ZV-2 Service Standard Chassis Group Linkage.................................................................... 15-2 Linkage Pin Standard Clearance Values ................. 15-3 Center Pin ............................................................... 15-5 Attachment Leveler ................................................. 15-7

15-2 80ZV-2 Service Standard Chassis Group Linkage

Linkage 1. Attachment - Boom

2. Boom - Lever

4. Front chassis - Boom

5. Attachment - Link

6. Lever - Link

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

mm (in)

3. Boom - Boom cylinder

8

4

7 9 2

5 10

11

3

6 1

80ZV12002

15-3 80ZV-2 Service Standard Chassis Group Linkage Pin Standard Clearance Values

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

Item

Solution

Pin standard dimension

Standard clearance

Tolerance

*

1

Joint section between attachment and boom

ø70 (ø2.7559)

0.104~0.213 (0.0041~0.0083)

1.0 (0.0393)

Replacement

*

2

Joint section between boom and lever

ø120 (ø4.7244)

0.127~0.256 (0.0050~0.0100)

1.0 (0.0393)

Replacement

3

Joint section between boom and boom cylinder

ø80 (ø3.1496)

0.101~0.217 (0.0039~0.0085)

1.0 (0.0393)

Replacement

**

4

Joint section between front chassis and boom

ø90 (ø3.5433)

0.117~0.237 (0.0046~0.0093)

1.0 (0.0393)

Replacement

*

5

Joint section between attachment and link

ø80 (ø3.1496)

0.101~0.217 (0.0039~0.0085)

1.0 (0.0393)

Replacement

*

6

Joint section between lever and link

ø80 (ø3.1496)

0.101~0.217 (0.0039~0.0085)

1.0 (0.0393)

Replacement

*

7

Joint section between lever and bucket cylinder

ø100 (ø3.9370)

0.117~0.242 (0.0046~0.0095)

1.0 (0.0393)

Replacement

*

8

Joint section between bucket cylinder and front chassis

ø100 (ø3.9370)

0.117~0.242 (0.0046~0.0095)

1.0 (0.0393)

Replacement

9

Joint section between boom cylinder and front chassis

ø80 (ø3.1496)

0.101~0.217 (0.0039~0.0085)

1.0 (0.0393)

Replacement

*

10

Joint section between front chassis and steering cylinder

ø45 (ø1.7716)

0.078~0.1778 (0.0030~0.0069)

1.0 (0.0393)

Replacement

*

11

Joint section between steering cylinder and rear chassis

ø45 (ø1.7716)

0.078~0.1778 (0.0030~0.0069)

1.0 (0.0393)

Replacement

15-4 80ZV-2 Service Standard Chassis Group Linkage Pin Standard Clearance Values

Liner clearance adjustment

80ZV15009

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

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

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.

At pin No. 4 (marked with "**"), only in case where the clearance at the machine center side is more than 4.5 mm (0.1772 in), adjust using liner of 4.5 mm (0.1772 in) thickness.

15-5 80ZV-2 Service Standard Chassis Group Center Pin

Center Pin Center pin shim adjustment

Bearing cover installing

T1

Grease nipple installation direction

Bearing cover

B 30

Shim adjustment

Front

22.5

T2 L1

Front chassis Rear chassis

80V2E14022

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

Add shims so that the clearance is 0.1±0.05 mm (0.0039±0.0020 in). : T1: 216 N-m (22.0 kgf-m) (159 lb-ft) T2: 422 N-m (43.0 kgf-m) (311 lb-ft) L1: With lubrication oil (Engine oil or gear oil)

Grease nipple installation direction

B

B

B

80V2E14026

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

15-6 80ZV-2 Service Standard Chassis Group Center Pin

Lower center pin bearing outer ring installing

Front chassis

Bearing outer ring

Rear chassis80V2E14024

Bearing outer ring

Front

Split of outer bearing Grease nipple installation direction

40 80ZV14026

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

15-7 80ZV-2 Service Standard Chassis Group Attachment Leveler

Attachment Leveler

Attachment leveler

80V2E15002

15-8 80ZV-2 Service Standard Chassis Group Attachment Leveler

Attachment leveler

Adjusting plate

5

4

Direction of indicator lamp

Indicator lamp

2

5 2

2.5

Proximity switch

3 1 85V2E15003

Attachment leveler adjustable angle

-7º Adjusting length: 6 mm (0.236 in)

0 51 mm (2.008 in)

+12º 134 mm (5.275 in) K90ZV15001

No.

Item

Judgment standard

Solution

1

Clearance of attachment leveler switch

5±2 mm (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

4

Attachment leveler adjustable angle (distance ∗)

-7º~+12º (6~134 mm) (0.236~5.275 in)

Adjustment

5

Angle mounting bolt tightening torque

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

Tightening

24-1 80ZV-2 Disassembly & Reassembly Power Group

80ZV-2 Disassembly & Reassembly Power Group Power Line .............................................................. 24-2 Radiator................................................................... 24-3 Fan .......................................................................... 24-8 Engine ..................................................................... 24-10 Propeller Shaft......................................................... 24-13 Air Cleaner .............................................................. 24-15 Muffler ..................................................................... 24-17 Front Axle Assembly ............................................... 24-18 Internal Gear Hub.................................................... 24-32 Spider Assembly ..................................................... 24-35 Special Tool ............................................................. 24-37 Rear Axle Assembly ................................................ 24-42 Axle Support............................................................ 24-47 Differential Assembly............................................... 24-50

24-2 80ZV-2 Disassembly & Reassembly Power Group Power Line

Power Line Power line tightening torque T1 L1 T5 L1

Rear chassis Engine

T6 L3

T7 L3

Rear differential 3rd propeller shaft

T4 L2

T2 L1

T1 L1

T4 L2

2nd propeller shaft

Transmission

T3 L1 T4 L2

Front differential

: T1: 441 N-m (45 kgf-m) (325 lb-ft) T2: 417 N-m (42.5 kgf-m) (307 lb-ft) T3: 230 N-m (23.5 kgf-m) (170 lb-ft) T4: 142 N-m (14.5 kgf-m) (105 lb-ft) T5: 94 N-m (9.6 kgf-m) (69 lb-ft) T6: 67 N-m (6.8 kgf-m) (49 lb-ft) T7: 53 N-m (5.4 kgf-m) (39 lb-ft)

80V2E24001

L1: Screw lock agent (Loctite® 262) L2: Screw lock agent (Three Bond 1327) L3: With lubrication oil (Engine oil or gear oil) Note Always replace drive shaft bolts with new ones - never reuse them.

24-3 80ZV-2 Disassembly & Reassembly Power Group Radiator

Radiator Radiator tightening torque (S/N 9001~9100)

T4 L2

T1 L1

Fan guard

Radiator

Fan T2 L2

Fan motor T3 L1

T2 L2

T2 L2 T2 L2

Rear chassis

80V2E24002

: T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 94 N-m (9.5 kgf-m) (69 lb-ft) T3: 74 N-m (7.5 kgf-m) (54 lb-ft) T4: 49 N-m (5.0 kgf-m) (36 lb-ft) L1: Screw lock agent (Loctite® 262) L2: With lubrication oil (Engine oil or gear oil)

24-4 80ZV-2 Disassembly & Reassembly Power Group Radiator (S/N 9101~)

T4 L2 T1 L1

Fan guard

Radiator

T3 L1

T2 L2 Fan

Fan motor

T2 L2 T2 L2

Rear chassis K80V2J24023

: T1: 230 N-m (23.5 kgf-m) (170 lb-ft) T2: 94 N-m (9.5 kgf-m) (69 lb-ft) T3: 74 N-m (7.5 kgf-m) (54 lb-ft) T4: 49 N-m (5.0 kgf-m) (36 lb-ft) L1: Screw lock agent (Loctite® 262) L2: With lubrication oil (Engine oil or gear oil)

24-5 80ZV-2 Disassembly & Reassembly Power Group Radiator

Radiator removing and installing Radiator removing

2

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

- Apply the articulation stopper.

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

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

1

Rear chassis

80V2E24003

2. Temporarily sling radiator guard (2), and remove bolt (1) to remove radiator guard (2). : Bolt (1): 230 N-m (23.5 kgf-m) (170 lb-ft) : Radiator guard: 84 kg (185 lbs)

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

(S/N 9001~9100)

3 4 5

Radiator

Engine

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

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

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

6

7 Drain line

(S/N 9101~)

3

80V2E24004

6

1. Drain the coolant from the engine and the radiator. : Coolant: 63 L (16.7 gal) Engine

4 5

Radiator

7 Drain line

K80V2J24001

3. Disconnect coolant hoses (3)~(7) from the radiator.

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

24-6 80ZV-2 Disassembly & Reassembly Power Group Radiator

(S/N 9001~9100)

T/C oil cooler (Bottom of radiator)

Air cooler

8 12

9

13 Engine

Transmission 80V2E24005

4. Disconnect air cooler hoses (8)(9) from the air cooler.

80V2E24007

(S/N 9101~)

T/C oil cooler

Radiator

12

: Hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft) Note - Cover the disconnected hoses and air cooler openings with caps, plugs, or vinyl to protect them from dust and dirt.

- During reassembly, carefully inspect and clean the hoses and air cooler of any contamination as it will go directly into the engine causing extensive engine damage.

13

Transmission

K80V2J24004

6. Disconnect hoses (12)(13) from the torque converter oil cooler.

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

Oil cooler

10 11

80V2E24006

5. Remove hoses (10)(11) from the hydraulic oil cooler.

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

24-7 80ZV-2 Disassembly & Reassembly Power Group Radiator

Rear chassis

14

Radiator installing

15

For reinstallation, follow the above procedure in reverse order.

16

80V2E24008

Radiator installation cautions

Clearance

7. Temporarily sling radiator (14).

Remove the right and left retainer bolts (15)(16), and then lift the radiator. : Radiator: 380 kg (840 lbs) : Bolt (15): 49 N-m (5.0 kgf-m) (36 lb-ft) : With lubricating oil (Engine oil or gear oil) : Bolt (16): 230 N-m (23.5 kgf-m) (170 lb-ft) : Screw lock agent (Loctite® 262) application

K90V2J24009

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

24-8 80ZV-2 Disassembly & Reassembly Power Group Fan

Fan Fan removing and installing

(S/N 9001~9100) 1

Fan removing

4

3

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

2 85V2E24008

(S/N 9101~)

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

2

1 3

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

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

K80V2J24024

1. Remove bolts (1)(2) and remove fan guards (3).

Take the fan guards out of the machine.

Note Removing the radiator grill may help the following work.

2. Disconnect the coolant hose at the top middle of radiator (4) and either left or right air cooler hose (5). : Air cooler hose band: : 5.7 N-m (0.58 kgf-m) (4.2 lb-ft) Note Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

24-9 80ZV-2 Disassembly & Reassembly Power Group Fan

Fan installing 5 9

Radiator

See the details below.

7 6

For reinstallation, follow the above procedure in reverse order.

Fan installation cautions

Base bracket

F80V2E24009

Clearance

3. Remove bolts (6) and release fan motor bracket (7) from the base bracket. Slide it to the engine side to make clearance between the fan. : Bolt (6): 94 N-m (9.55 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil) K90V2J24009

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

Refer to "Fan Motor" page 44-61 to remove and/or disassemble the fan motor.

Fan motor

8

9

90V2E24008

4. Remove retainer bolts (8) for fan (9). : Bolt (8): 94 N-m (9.55 kgf-m) (69 lb-ft) : With lubrication oil (Engine oil or gear oil) 5. Sling fan (9) and take it out from the top opening. : Fan: 17 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.

24-10 80ZV-2 Disassembly & Reassembly Power Group Engine

Engine Engine removing and installing Engine removing 1

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

- Apply the articulation stopper.

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

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

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

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

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

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

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

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

- Drain engine oil : Engine oil: Approx. 33 L (8.7 gal)

+ Battery K80V2J24010

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

Then remove the positive cable.

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

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

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

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

3. Remove the engine oil drain hose.

24-11 80ZV-2 Disassembly & Reassembly Power Group Engine

4 1mm

1mm

Bracket

3 Lock nut Bracket

3

Rear chassis 80ZV24011

6. Remove bolts (3)(4) (both sides).

80ZV24009

4. Temporarily sling the engine and the transmission assembly. : Engine and transmission assembly: 1,300 kg (2,850 lbs)

: Bolt (4): 417 N-m (42.5 kgf-m) (307 lb-ft) : Screw lock agent (Loctite® 262) application Note When installing bolt (3) to the rear chassis, adjust it with the lock nut so that the clearance between bolt (3) and the bracket becomes 1 mm (0.4 in) as shown above.

7. Disconnect the 2nd propeller shaft and the 3rd propeller shaft from the transmission assembly.

2

8. Carefully lift the engine and the transmission assembly while checking that there are no obstacles around them. : Engine and transmission assembly: 1,300 kg (2,850 lbs)

Engine

80V2E24010

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

9. Remove the engine and the transmission assembly from the rear chassis.

Place them on the stand.

24-12 80ZV-2 Disassembly & Reassembly Power Group Engine

Engine installation cautions 5

7

6 80ZV24012

10. Sling the engine assembly and remove bolts (5) from the housing between the engine flywheel and the transmission. : Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft) : Engine assembly: 695 kg (1,530 lbs) 11. Move the engine assembly backward to disengage the flywheel ring gear.

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

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

80ZV24079

- There is an O-ring (6) in the housing between the engine and the torque converter.

Be sure to replace the O-ring with a new one, and apply liquid gasket. : Liquid gasket (Three Bond 1215) application - Make sure that bushing (7) is installed.

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

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

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

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

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

After that, check the amount of the coolant.

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

24-13 80ZV-2 Disassembly & Reassembly Power Group Propeller Shaft

Propeller Shaft Propeller shaft removing and installing Second propeller shaft removing

3 5

4

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

- Apply the articulation stopper.

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

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

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

1

2

80V2E24011

1. Remove bolt (2) from the transmission side of propeller shaft (1). : Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application 2. Disconnect the grease pipe, and remove bolt (3) from pillow unit (4). : Bolt (3): 441 N-m (45.0 kgf-m) (325 lb-ft) : Screw lock agent (Loctite® 262) application 3. Remove bolt (5) to disconnect the propeller shaft from the front differential.

Support the shaft by cable or garage jack. Take out the second propeller shaft to the front. : Bolt (5): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application : Second propeller shaft: 50 kg (110 lbs) Note If the retainer bolt is too tight due to the screw lock agent, heat the bolt head to about 235ºC (450ºF) using slow flame of a gas burner.

Keep the flame away from the seals of the coupling.

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

24-14 80ZV-2 Disassembly & Reassembly Power Group Propeller Shaft

Third propeller shaft removing

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

Transmission Rear differential

Propeller shaft installation cautions Engine Transmission

3rd propeller shaft

6

K80ZV24015E

1. Remove bolt (6). : Bolt (6): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application

2nd propeller shaft

3rd propeller shaft 80V2E24012

2. Remove the third propeller shaft. : Third propeller shaft: 15 kg (35 lbs)

During reinstallation, align the direction of the flange yokes on the second and third propeller shaft sides of the transmission. (Refer to 80ZV-2 Shop Manual, Function and Structure, Section 22.)

[Difference in the yoke phase (direction) will cause the propeller shaft damage and "knocking" during a turn.]

24-15 80ZV-2 Disassembly & Reassembly Power Group Air Cleaner

Air Cleaner Air cleaner removing and installing

4

3

2

1

Air cleaner removing

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

- Apply the articulation stopper.

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

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

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

5 95V2E24011

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

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

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

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

8

Engine

7

85ZV24014

2. Disconnect air duct (7).

Disconnect indicator wire coupler (8).

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

24-16 80ZV-2 Disassembly & Reassembly Power Group Air Cleaner

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

10

9

Air cleaner installation cautions 2~3 mm (1/8 in) 5 mm (1/4 in) or less 80V2E24013

Fix the bands avoiding the beading

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

Air duct

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

K85V2U24005

Screen board

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.

11

80ZV24018

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

5. Take out air cleaner case (11) from the opening.

Note Cover the open pipes with caps, plugs or vinyl.

24-17 80ZV-2 Disassembly & Reassembly Power Group Muffler

Muffler Muffler removing and installing

(S/N 9001~9100)

6

Muffler removing 3

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

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

4 5

5

85V2E24016

(S/N 9101~)

6

Drain pipe

2

3

1 Engine roof

5 5

Muffler

4

1. Remove bolt (1) and then remove exhaust pipe (2). : Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft) 2. Remove the engine roof by referring to "Engine Room" page 14-8. : Engine roof: 32 kg (70 lbs)

K80V2E24001

85V2E24015

3. Remove the drain pipe.

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

5. Remove four bolts (5) to remove muffler (6). : Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft) : Muffler: 23 kg (50 lbs)

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

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

24-18 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front Axle Assembly Front axle assembly tightening torque

T4 L1

T2 L2

Front differential

T7

T7

A B

T8 L1

T3 L1

T7

T6 T1

T5 L1

80V2E24017

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

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

24-19 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Axle nut tightening procedure 1. Tighten axle nut (A) with 1,177 N-m (120 kgf-m) (868 lb-ft) tightening torque to install the taper roller bearing.

2. Loosen axle nut (A).

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

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

Preload at housing (B): 206~245 N (21~25 kgf) (46~55 lbf) Note This is "breakaway" force, which is required to start the wheel turning.

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

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

24-20 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly removing and installing

3

Front axle assembly removing

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

- Apply the parking brake and the articulation stopper.

90ZV24033

3. Remove right and left wheel and tire assemblies (3). : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) : 1 tire: 520 kg (1,150 lbs)

Stand

1 Stand 85ZV24018

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

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

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

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

Front axle 80V2E24018

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

Note When assembling, clean the nylon breather tube before installing it.

24-21 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

2

5

6 80ZV24022

5. Remove second propeller shaft retainer bolt (2). : Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application

90ZV24035

7. Temporarily sling axle assembly (5), and then remove eight retainer bolts (6). : Bolt (6): 721 N-m (73.5 kgf-m) (532 lb-ft) : Axle assembly: 960 kg (2,110 lbs) Note During reassembly be sure both mating surfaces are clean and free of paint.

4

4 Front axle

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

Front axle assembly installing 80ZV24023

6. Disconnect brake pipes (4).

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

For reinstallation, follow the above procedure in reverse order.

24-22 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly installation cautions

Service brake air bleeding procedure

After reinstallation, completely bleed air in the service and parking brake lines.

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

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

Air bleeder nipple

Spider Socket bolt 90ZV24036

CAUTION Before air bleeding in the brake oil line, be sure that the wheel and tire assemblies are installed on the wheel hub. If fail to do, the bolts (4 pcs) temporarily tighten the spider and the wheel hub may be broken by the brake piston.

Finally the spider and the cover may fall off.

Vinyl tube 70ZV52019

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

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

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

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

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

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

24-23 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle disassembling and assembling

1

Front axle disassembling

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

- Apply the articulation stopper.

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

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

90ZV24052

3. Remove wheel and tire assembly (1) from the side to be disassembled (example: left side). : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft) : Tire of 1 wheel: 520 kg (1,150 lbs)

Stand Stand

2

Differential section 90ZV24053

85ZV24018

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

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

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

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

4. Remove drain plug (2) from the differential section to drain oil. : Gear oil: Approx. 32 L (8.5 gal)

24-24 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

A 7 6

TOP

3 4

90ZV24054

90ZV24056

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

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

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

: Gear oil: Approx. 22 L (5.8 gal) Note To replace the oil, refer to the oil amount described below.

: Bolt (6): 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 75 kg (165 lbs)

: Wheel hub section: 11 L (2.9 gal) for left side, 11 L (2.9 gal) for right side

9

Differential section (front): 32 L (8.4 gal) Total oil amount for front axle: 54 L (14.3.5 gal)

8

Reference Differential section (rear): 37 L (9.8 gal) Total oil amount for rear axle: 59 L (15.6 gal) 10

80V2E24020

8. Remove snap ring (8), and then remove sun gear (9).

TOP

9. Remove friction plate (10).

5

90ZV24055

6. Remove cover (5). : Retainer bolt: 90 N-m (9.2 kgf-m) (67 lb-ft) : Screw lock agent (Three Bond 1327) application

24-25 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Turnbuckle

E 11

12

3 80V2E24021

90ZV24060

10. Remove steel plate (separation disc) (11) and disc gear (12).

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

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

Refer to the 80ZV-2 Shop Manual, Function and Structure, Section 52 and "Service Brake" page 55-4 for additional information.

13

16

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

15 17

14

80V2E24022

80V2E24023

11. Remove axle shaft (13) and wear ring (14).

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

13. Remove axle nut (17).

Refer to "Axle nut tightening procedure" page 2419.

: Bolt (15): 53 N-m (5.4 kgf-m) (39 lb-ft) : Screw lock agent (Three Bond 1327) application Note When reassembling axle shaft (13) into the axle housing, applying the principle of leverage, insert axle shaft (13) making sure the toothing between the side gear of the differential and shaft (13).

: Nut (17): 1,177 N-m (120 kgf-m) (868 lb-ft) Note Axle nut width across flat: 120 mm (4.72 in)

24-26 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

D

Extension

E 3

Jig (B)

18

19

Wooden block 80ZV24027

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

Wooden block

80ZV24029

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

Then remove wheel hub (3).

17. Remove taper roller bearing (19).

18

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

C

Front axle assembling Wooden block

80ZV24028

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

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

24-27 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly cautions

Ring

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

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

Remove oil

Floating seal installation 1. Checking before floating seal installation Put thin gear oil (Do not use grease)

Bearing

O-ring Wheel hub

O-ring Axle housing

Do not touch (It may cause rusting) 90ZV24066

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

Seal ring

Ring

90ZV24065

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

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

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

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

- Install the O-ring on the seal ring.

- Put thin gear oil on the O-ring.

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

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

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

24-28 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly (b) In case jig (F) is used

1

Guide jig

2 3

4

70ZV24095J

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

95ZVE24011

Guide jig

Installation jig

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

- Put thin gear oil on the O-ring.

- Insert the floating seal into the guide jig.

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

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

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

After installation 95ZVE24010

3. Caution before operation - After assembling, turn the wheel hub 2~3 turns by hands.

- Check if it turns lightly by hands. If it is tight to turn the wheel hub, the O-ring may be twisted. In this case it is necessary to disassemble the floating seal.

24-29 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Internal gear hub installation

Axle nut tightening

Spring pin

18

80ZV24032

Internal gear hub assembly Brake oil holes at 2 locations

80ZV24033

Example LF

Brake oil holes

17

80V2E24024

1. Tighten axle nut (17) with 1,177 N-m (120 kgf-m) (868 lb-ft) tightening torque to install the taper roller bearing and, after that, once loosen axle nut (17).

2. Again tighten axle nut (17) so that the preload of the tire mounting hole section becomes 206~245 N (21~25 kgf) (46~55 lbf).

Axle housing extension

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

Refer to "Axle nut tightening procedure" page 24-19.

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

24-30 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Brake adjustment

Jig (F)

80ZV24036

Brake oil inlet port 90ZV24074

2. Use jig (F) to hold the brake piston not to come out.

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

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

Shut off valve

Air supply PT 1/4

A

Air pressure gauge

Brake piston Jig (H) 90ZV24071

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

Wheel hub

80V2E24025

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

A......100.25~101.40 mm (3.95~3.99 in) Note Dimension A should be equal at the top and bottom sides.

24-31 80ZV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Wheel hub Spider "TOP" mark (at top)

Brake oil line

Drain plug (at bottom) 90ZV24077

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

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

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

24-32 80ZV-2 Disassembly & Reassembly Power Group Internal Gear Hub

Internal Gear Hub Internal gear hub disassembling and assembling

4

F

Internal gear hub disassembling

B 1 80V2E24029

2

80ZV24037

3. Place the jig B at the end face of the internal gear hub. Install the jig F to the remover bolt hole for brake piston (4).

Remove brake piston (4) by tightening the center remover bolt.

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

1

5 6

3

80ZV24040

4. Remove brake piston O-rings (5)(6).

80ZV24038

2. Remove taper roller bearing (3).

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

24-33 80ZV-2 Disassembly & Reassembly Power Group Internal Gear Hub

Internal gear hub assembling 8

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

7

1 80ZV24078

5. There is snap ring (7) that connects internal gear (8) to internal gear hub (1). Shift snap ring (7) to inside using a round bar or the like.

8

1 80ZV24042

6. Sling internal gear (8) to remove it. : Internal gear: 27 kg (60 lbs)

24-34 80ZV-2 Disassembly & Reassembly Power Group Internal Gear Hub

Internal gear hub assembly cautions

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

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

9

3

Be certain these plugs are tight.

80ZV24038

Oil holes

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

8

Example LF

- Apply grease to the O-rings.

1 80ZV24080

F

- When reassembling internal gear (8) to internal gear hub (1), align the oil holes of internal gear hub (1) with that of spring pin (9).

Note To reinstall the internal gear hub (1) on the axle, the brake oil path should be aligned to these oil grooves. In addition, the oil grooves are used for alignment of spring pin (9).

Moreover, spring pin (9) is used for the target to measure the brake disc wear.

- Check that the snap ring is properly inserted into the groove of internal gear (8).

Bolt

80ZV24046

- When reassembling the piston, temporarily install the piston and then tighten the bolt evenly using jig (F).

Confirm that the piston is fully retracted.

Refer to "Service Brake" page 54-25.

24-35 80ZV-2 Disassembly & Reassembly Power Group Spider Assembly

Spider Assembly Spider assembly disassembling and assembling

5 6

Spider assembly disassembling

4

7 70ZV24044J

2

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

1 90ZV24136

1. Remove lock bolts (1) and then plate (2). : Lock bolt (1): 216 N-m (22.0 kgf-m) (159 lb-ft) : Screw lock agent (Three Bond 1327) application

Note - Install the bearings so that bearing (5) locates outside (cover side) and bearing (6) inside (brake backing plate side).

Bearing (5) width: 20 mm (0.787 in) Bearing (6) width: 25 mm (0.984 in)

9

1 3

8 4 80V2E24019

90ZV24137

2. Insert lock bolt (1) into planetary pin (3), and remove the pin. Remove planetary gear (4) with the wear rings and the bearings (5)(6) as a unit.

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

24-36 80ZV-2 Disassembly & Reassembly Power Group Spider Assembly

Spider assembly assembling

Spider assembly assembly cautions

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

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

Before starting work: - Clean all the parts.

- Check the brake backing plate, pins, bearings, planetary gears, wear ring, for distortion and wear.

- Replace the O-ring and defective parts with new ones.

- Inspect the internal bores of the spider for wear.

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

1 3

4

90ZV24137

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

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

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

24-37 80ZV-2 Disassembly & Reassembly Power Group Special Tool

Special Tool Special tool for axle (A) Spider hoisting tool mm (in) (Material: SS41)

2)

(1.

4(0.2) C2(0.08)

R

8( 0.

3)

3(0.1)

75(3.0)

R

12 (0.5)

65(2.6) 10 (0.4)

t6(0.2)

3(0.1)

6

t6

t6

6

(0.2)

(0.2)

(0.2)

(0.2)

22(0.9)

C2 (0.08)

m ril 5m )d ø2 . 0 in (1

46(1.8)

105(4.1)

30

R (0 10 .4 )

10 (0.4)

46(1.8)

ø6 mm (0.2 in) dia. round steel

C 2(0.08)

led

C 2(0.08)

65(2.6) 90ZV24085

(B) Internal gear hub puller mm (in)

(Material: SS41)

30 (1.2) 30 (1.2)

t12 (0.5) 2 x 12 (0.5)

80 (3.1)

160 (6.3) 230 (9.1)

80ZV24047

24-38 80ZV-2 Disassembly & Reassembly Power Group Special Tool (C) Internal gear hub hoisting tool mm (in) (Material: SS41) 75 (3.0)

ø13 mm (0.5 in) drilled

35(1.4)

t12 (0.5)

R

15

20 R .8) (0

107 (4.2)

235 (9.3) 345 (14)

0 R2 .8) (0

13 35

5 R1 .6) (0

259 (10.2)

215 (8.5)

15

7 (0.3)

15 (0.6) 25 (1.0)

3 15 (0.1) (0.6)

5 R1 .6) (0

0 R1 .4) (0

A

.4)

(0.4)

A

t9(0.4)

0(2

38.7 (1.52)

R6

t9

10 (0.4)

35 (1.4)

(0.6)

281 (11)

0 R2 .8) (0

423 (16.7)

35 (1.4)

155 (6.1) (1.4) (0.5)

25 (1.0)

)

.6

(0

27.5 (1.1)

35 (1.4) 90 (3.5)

27.5 (1.1)

A-A 80ZV24048

24-39 80ZV-2 Disassembly & Reassembly Power Group Special Tool (D) Wheel hub hoisting tool mm (in)

(Material: SS41)

10(0.4)

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

4(0.2)

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

t6 (0.2)

3(0.1)

ril le d

45(1.8)

3 (0.1)

10 (0.4)

C2 (0.08)

t6 (0.2)

3 (0.1)

*

3 (0.1)

4(0.2)

2 (1 5-m .0 m ) d

t6(0.2) 20(0.8)

55(2.2)

20(0.8)

R 5(

4(0.2)

25(1.0)

0.

2)

R (0 20 .8 )

C 2(0.08)

C2 (0.08)

C2 (0.08) 60(2.4)

90ZV24088

(E) Eye bolt

M24x2

30(1.2)

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

90ZV24089

24-40 80ZV-2 Disassembly & Reassembly Power Group Special Tool (F) Brake piston puller mm (in)

(Material: SS41)

30 (1.2) 30 (1.2)

t12 (0.5) M16x2

4x 12 (0.5)

156 (6.1)

80 (3.1) 160 (6.3) 312 (12.3) 355 (14)

80ZV24049

(G) Floating seal jig 1. For wheel hub [ P/N for tool set: 99202-01790 ]

mm (in)

2.

1.

15(0.6)

230(9.1)

3(0.1)

190(7.5)

+0

224.8(8.9)

240(9.5)

214.6 +00.1 (8.4 0.004) +0.1 209.6 +0 (8.2–0.004) 201.1–0.1(7.9–0.004)

10–0.3 (0.4–0.01)

235(9.3)

+0.004

214 +0.1 +0.05 (8.4 +0.002 )

+0.010

223 +0.25 +0.3 (8.8 +0.012 )

209.4–0.1(8.2–0.004) C

)

20(0.8) 8–0.2 (0.31–0.008)

3(0.1)

5(0.2)

(

10–0.3 (0.4–0.01) R0.3 (0.01) R0.2~R0.5 (0.008~0.02)

80V2E24040

24-41 80ZV-2 Disassembly & Reassembly Power Group Special Tool 2. For ring [ P/N for tool set: 99202-01760 ]

2.

1.

13(0.5) 3C

(

mm (in)

)

20(0.8) 11–0.2 (0.43–0.008)

3(0.1)

3(0.1)

230(9.1)

+0

224.8(8.9)

190(7.5)

10–0.3 (0.4–0.01)

214.6 +00.1 (8.4 0.004) +0.1 209.6 +0 (8.2–0.004) 201.1–0.1(7.9–0.004)

0.012 214.8 0.1 0.05 (8.9 0.014 ) 270(10.6)

0.012 226 0.30 0.35 (8.9 0.014 ) 209.4–0.1(8.2–0.004)

3(0.1)

10.4–0.3 (0.41–0.01)

C R0.3 (0.01) R0.2~R0.5 (0.008~0.02)

80V2E24041

24-42 80ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear Axle Assembly Rear axle assembly tightening torque

T6

T6 T6 T2 L1

A

T7 L1

B

T3 L1

T6

T5

T1

T4 L1 80V2E24026

: T1: 892 N-m (91.0 kgf-m) (658 lb-ft) T2: 314 N-m (32.0 kgf-m) (232 lb-ft) T3: 216 N-m (22.0 kgf-m) (159 lb-ft) T4: 90 N-m (9.2 kgf-m) (67 lb-ft) T5: 86 N-m (8.8 kgf-m) (64 lb-ft) T6: 78 N-m (8.0 kgf-m) (58 lb-ft) T7: 53 N-m (5.4 kgf-m) (39 lb-ft)

L1: Screw lock agent (Three Bond 1327) application

24-43 80ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Axle nut tightening procedure 1. Tighten axle nut (A) with 1,177 N-m (120 kgf-m) (868 lb-ft) tightening torque to install the taper roller bearing.

2. Loosen axle nut (A).

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

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

Preload at housing (B): 206~245 N (21~25 kgf) (46~55 lbf) Note This is "breakaway" force, which is required to start the wheel turning.

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

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

24-44 80ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear axle assembly removing and installing Rear axle assembly removing

WARNING

1

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.

80V2E24027

3. Remove lower cover (1). : Lower cover: 23 kg (50 lbs)

2

A

90ZV24039

3

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

80V2E24028

4. Remove lower partition plates (2)(3). : Partition plate (2): 21 kg (45 lbs) Partition plates in sets (3): 5 kg (11 lbs)

B

90ZV24040

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

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

24-45 80ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Wooden blocks Transmission Rear differential

6

5

90ZV24041

80V2E24030

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

7. Remove retainer bolts (6) to remove third propeller shaft (5).

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

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

: Bolt (6): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application : Third propeller shaft: 15 kg (35 lbs) Note - Replace propeller shaft retainer bolts (6) with new ones. Do not reuse them when reassembling.

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

4

Breather nipple

7

90V2E24023

6. Remove right and left wheel and tire assemblies (4).

Rear axle 80V2E24031

: Tire of 1 wheel: 520 kg (1,150 lbs) (without hydro-inflation) : Retainer bolt: 892 N-m (91.0 kgf-m) (658 lb-ft)

8. Disconnect air breather tube (7).

Note - Before disconnecting the tube, press the oil filler cap of the hydraulic tank to release the tank pressure.

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

- Remove and clean tube (7) before reinstalling.

24-46 80ZV-2 Disassembly & Reassembly Power Group Rear Axle Assembly 12. Lower rear axle assembly (9) evenly on the carrier, and then, pull out the rear axle.

CAUTION

Rear axle

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

5 80V2E24032

9. Disconnect the front and rear grease pipes.

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

Note Cover and plug the hose and fittings to prevent dirt entry.

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

Refer to "Service brake air bleeding procedure" page 24-22 for air bleeding in the service brake.

Rear axle disassembling and assembling

10

For disassembling and reassembling the rear axle assembly, refer to "Front axle disassembling and assembling" page 24-23.

9

90V2E24027

11. Temporarily sling rear axle assembly (9), and remove right and left retainer bolts (10) from the rear axle support. : Bolt (10): 721 N-m (73.5 kgf-m) (532 lb-ft) : Rear axle assembly (including axle supports): 1,120 kg (2,460 lbs) Note - The rear support is locked by not only the bolts but also dowel pins. Carefully remove or reinstall the support while checking the dowel pins.

- Be careful not to bend or damage the oil pipes.

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

24-47 80ZV-2 Disassembly & Reassembly Power Group Axle Support

Axle Support Axle support tightening torque

Rear axle assy

8 (S/N ~9023) 8 (S/N 9024~)

5

9 (S/N ~9023) 8

5 11 4 12 7

1

(S/N 9024~) 8

3 7

14

13

10

13

2 6

K80V2U22001

: T1: 721 N-m (73.5 kgf-m) (532 lb-ft) T2: 314 N-m (32.0 kgf-m) (232 lb-ft) T3: 53 N-m (5.4 kgf-m) (39 lb-ft) L1: Screw lock agent (Three Bond 1327) application L2: With lubricating oil (Engine oil or gear oil)

24-48 80ZV-2 Disassembly & Reassembly Power Group Axle Support

Axle support disassembling and assembling

8

Rear support

10 11 13

Axle support disassembling

6

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

7

12 9

Rear axle Front support

K80V2E24003

4

4. Remove bolt (6).

3 2 Rear axle

1

: Bolt (6): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application 5. Remove plate (7) and wear ring (8).

5 K80V2E24002

6. Remove bolt (9). Remove plate (10) and wear ring (11).

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

: Bolt (9): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application 7. Remove the rear support from the rear axle assembly.

: Axle support (front): 66 kg (145 lbs) : Axle support (rear): 81 kg (179 lbs) 3. Remove packing (4) and bushing (5) from the front support.

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

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

24-49 80ZV-2 Disassembly & Reassembly Power Group Axle Support

Axle support assembly cautions

IMPORTANT

Bushing installation [Front support]

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

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

5 Front Grease Swing shaft 80ZV24067

[Rear support]

13 Rear Grease Swing shaft

80ZV24068

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

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

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

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

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

24-50 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential Assembly Differential assembly removing and installing Differential assembly removing [ Front axle assembly ]

30 cm (1 ft)

3 85ZV24057J 80V2E24036

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

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

- Remove the axle from the machine.

- Place the axle assembly on work benches. : Axle assembly (Front): 960 kg (2,110 lbs) : Axle assembly (Rear): 1,120 kg (2,460 lbs) - For the rear axle, remove the axle supports.

Refer to "Rear axle assembly removing and installing" page 24-44.

4

5 A

Spider assembly

90ZV24081

2

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

TOP

: Bolt (5) (Front): 132 N-m (13.5 kgf-m) (98 lb-ft) (Rear): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application

1 Cover bolt 90ZV24079

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

Remove the cover bolts and cover (1). Remove retainer bolts (2) to remove the spider assembly. : Cover bolt: 90 N-m (9.2 kgf-m) (67 lb-ft) : Bolt (2): 86 N-m (8.8 kgf-m) (64 lb-ft) : Spider assembly: 75 kg (165 lbs)

24-51 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

mark sections: Spacers are installed.

7

80ZV24070

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

90ZV24084

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

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

4

Differential assembly installation cautions

6 90ZV24083

4. Temporarily sling differential (4), and insert bolts into remover tap (Jack Screw) holes (6) to slightly lift the differential. : Differential: 165 kg (365 lbs) Note Carefully sling the differential so that it is balanced and is lifted straight up.

- After reinstallation, refill with the specified oil until the oil level reaches the level check plug.

- Refill the oil in each planetary assy.

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

- Check the differential for oil leakage.

24-52 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assembly disassembling and assembling Front differential tightening torque

T4 L1

F

Torque proportional differential

T5 L1

Limited slip differential (option)

T2 L1

F

D T7 L1

C

Shim

E

T6 L1

A

~

(T=0.07) (T=0.50)

F

B (T=16.70)

~

T3 L1

T1 L2

(T=16.98)

T4 L1

K80V2U24003

: T1: 883 N-m (90.0 kgf-m) (651 lb-ft) T2: 515 N-m (52.5 kgf-m) (380 lb-ft) T3: 330 N-m (33.7 kgf-m) (244 lb-ft) T4: 314 N-m (32.0 kgf-m) (232 lb-ft) T5: 235 N-m (24.0 kgf-m) (174 lb-ft) T6: 132 N-m (13.5 kgf-m) (98 lb-ft) T7: 53 N-m (5.35 kgf-m) (39 lb-ft) L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three Bond 1215)

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

Preload at flange (A): 57~66 N (5.8~6.7 kgf) (13~15 lbf) Use spacer (B) to adjust the preload.

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

Adjust the backlash by nut (F).

24-53 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Rear differential tightening torque

T2 L1

T6 L1

F

T3 L1 Limited slip differential (opt)

D

T4 L1

C T5 L1

F T4 L1 Torque proportional differential

E Shim

~

(T=0.07) (T=0.50)

A

(T=16.70)

~

T1 L2

B

(T=16.98)

T4 L1

K80V2U24004

: T1: 883 N-m (90.0 kgf-m) (651 lb-ft) T2: 515 N-m (52.5 kgf-m) (380 lb-ft) T3: 330 N-m (33.7 kgf-m) (244 lb-ft) T4: 314 N-m (32.0 kgf-m) (232 lb-ft) T5: 235 N-m (24.0 kgf-m) (174 lb-ft) T6: 53 N-m (5.35 kgf-m) (39 lb-ft)

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

Preload at flange (A): 57~66 N (5.8~6.7 kgf) (13~15 lbf) Use spacer (B) to adjust the preload.

L1: Screw lock agent (Three Bond 1327) application L2: Liquid gasket (Three Bond 1215 or a locally procured Room Temperature Vulcanizer (RTV) that does not contain acetic acid.)

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

Use nut (F) to adjust the backlash.

24-54 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assembly disassembling Adjust nut

3

Shim

3 Nut (A)

4

Bevel gear

Pinion

2

Adjust nut

90ZV24103

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

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

- Insert a straight-end screwdriver or the like into the clearance between the pinion and the bevel gear to prevent the gear from rotating.

Loosen pinion nut (A). : Nut (A): 883 N-m (90 kgf-m) (651 lb-ft) : Nut width across flat: 57.1 mm (2.25 in)

90V2E24038

: Bolt (3): 515 N-m (52.5 kgf-m) (380 lb-ft) : Screw lock agent (Three Bond 1327) application

5

6

90ZV24150

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

1

: Differential: 100 kg (220 lbs)

2 90V2E24037

1. Remove right and left lock plates (1) from adjustment nut (2). : Bolt: 53 N-m (5.35 kgf-m) (39 lb-ft) : Screw lock agent (Three Bond 1327) application

24-55 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

7 8

Clutch assy

Matchmark 90ZV24107

90V2E24039

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

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

: Retainer bolt (8, Torque proportional diff.): 235 N-m (24.0 kgf-m) (174 lb-ft) : Retainer bolt (8, Limited slip diff.): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application

12

11 13

90ZV24109

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

10

9 90ZV24108

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

14

90ZV24110

7. Remove side gear (14).

24-56 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

17 15

16 90ZV24111

90ZV24112

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

8. Remove thrust washer (15).

: Bolt (17): 330 N-m (33.7 kgf-m) (244 lb-ft) : Screw lock agent (Three Bond 1327) application Trunnion

Clutch assy 90V2E24039

19

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

18 90ZV24113

10. Remove bolts (18) to remove pinion (19). At the same time, remove the shim. : Bolt (18): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application Note The rear differential assembly has the trunnion installed with bolts (18) as shown.

24-57 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

20

21

25

90ZV24114

90ZV24117

14. Remove taper roller bearing (25).

11. Remove nut (20) and O-ring (21). : Nut: 883 N-m (90.0 kgf-m) (651 lb-ft) : Screw lock agent (Three Bond 1327) application

26

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

22 90ZV24118

15. Remove spacer (26).

90ZV24115

12. Remove flange yoke (22).

23

24 90ZV24116

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

24-58 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assembly assembling

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

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

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

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

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

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

26

24

0

A

90ZV24119

20

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

25 27

23

28

: Standard preload∗: 57~66 N (5.8~6.7 kgf) (13~15 lbf)

A 22 90ZV24120

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

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

Pinion

Bearing

Pinion Stake at 3 points

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

Note There are 15 types of spacers (16.70~16.98 mm) (0.66~0.67 in) in increments of 0.02 mm (0.0008 in).

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

90ZV24121

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

24-59 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Rear

Front Shim

Shim

18

18

Check direction of the lips

29 31

24

Apply liquid gasket (AA03) to these surfaces

31

30

30

Trunnion

90ZV24122

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

80V2E24039

4. Install O-ring (30) and the shims (the one(s) removed during disassembly) to the cage.

Insert the cage into differential case (31), and tighten retainer bolt (18).

Note Install the trunnion to the rear differential assembly.

22

: Bolt (18): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application Torque proportional diff.

Limited slip diff.

20 14

21

15 90ZV24123

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

(Nut width across flat: 57.1 mm) : Nut (20): 883 N-m (90.0 kgf-m) (651 lb-ft) : Liquid gasket (Three Bond 1215) application

32

90V2E24042

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

Note Different part is assembled according to the differential type.

24-60 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

12

11

8

13 7

Matchmark

90ZV24145

90ZV24147

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

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

Torque proportional diff.

: Retainer bolt (8, Torque proportional diff.): 235 N-m (24.0 kgf-m) (174 lb-ft) : Retainer bolt (8, Limited slip diff.): 314 N-m (32.0 kgf-m) (232 lb-ft) : Screw lock agent (Three Bond 1327) application

Limited slip diff.

9

10

16 17

90V2E24043

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

Note Different part is assembled according to the differential type.

90ZV24148

9. Tighten bolts (17) in bevel gear (16). : Bolt (17): 330 N-m (33.7 kgf-m) (244 lb-ft) : Screw lock agent (Three Bond 1327) application

24-61 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

1 6 A

16

90ZV24149

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

33

80ZV24077

12. Adjust the backlash as follows: (a) Tighten adjustment nut (33) on the bevel gear side until the backlash is "0". Then back off the adjustment nut 2 to 3 notches. (b) Tighten opposite side adjustment nut (1). After you feel that the nut is tight, turn it one more notch.

3

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

4

(d) Adjust the backlash.

Adjust nut

90ZV24131

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

(For both the right and left sides)

Standard backlash: 0.26~0.38 mm (0.0102~0.0149 in) - Tighten adjustment nut (33) on the bevel gear side or loosen adjustment nut (1) on the opposite side to reduce the backlash.

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

24-62 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

34

3

2 4

90ZV24133

13. Tighten bolts (3) of bearing cap (4). : Bolt (3): 515 N-m (52.5 kgf-m) (380 lb-ft) : Screw lock agent (Three Bond 1327) application 14. Mount lock plate (2), and then tighten bolts (34) to fix the lock plate. : Bolt (34): 53 N-m (5.35 kgf-m) (39 lb-ft) : Screw lock agent (Three Bond 1327) application

24-63 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly

Adjusting tooth contact Tooth contact

Possible cause

Adjusting method

A

Correct

B

Ring gear is too close to the drive pinion

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

C

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

D

Drive pinion is too close to the ring gear.

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

Check again the backlash and tooth contact.

2

2

2

1

E

Drive pinion is too far from the ring gear.

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

Check again the backlash and tooth contact.

2

1

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

24-64 80ZV-2 Disassembly & Reassembly Power Group Differential Assembly Three types of tooth contact shown below are acceptable as best tooth contact.

Tooth contact position and length (rate) 10 1

Pattern A

5 TOP

4

HEEL 4~5

Pitch line TOE

10

BOTTOM 10 2

Pattern B

4 TOP

4

HEEL

Pitch line

4~5

10

TOE BOTTOM 10 3

Pattern C

4

TOP TOE

3

HEEL 4~5

10

Pitch line BOTTOM

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

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

25-1 80ZV-2 Service Standard Power Group

80ZV-2 Service Standard Power Group Propeller Shaft Service Standard ............................ 25-2 Axle and Differential Service Standard.................... 25-3

25-2 80ZV-2 Service Standard Power Group Propeller Shaft Service Standard

Propeller Shaft Service Standard 1

1. Bearing play

Third propeller shaft

1 c

a

2 Measurement of circumferential play

b 4

3 Measurement of transverse play

Second propeller shaft

K80V2E25001

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

7.34 ± 3 (0.29 ± 0.12)

—

Note Bolt tightening torque a: 69 N-m (7.0 kgf-m) (51 lb-ft) b: 155 N-m (15.8 kgf-m) (114 lb-ft) c: 17.2 N-m (1.75 kgf-m) (12.7 lb-ft)

25-3 80ZV-2 Service Standard Power Group Axle and Differential Service Standard

Axle and Differential Service Standard Axle group

6 5 4

2, 3

1, 3

4 5

7

80V2E25002

Unit: mm (in) Judgment standard No.

Item

Solution Standard dimension

Tolerance

1

Backlash between sun gear and planetary gear

0.12~0.60 (0.0047~0.0236)

←

Replacement

2

Backlash between planetary gear and internal gear

0.14~0.73 (0.0055~0.0287)

←

Replacement

3

Tooth contact of gear

4

Replacement

No abnormality Front

(11.4567 +0.0032 ) ø 291 +0.081 0 0

Rear

Replacement

ø 176 +0.063 (6.9291 +0.0025 ) 0 0

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

Axle support wear

5

Bushing and wear ring wear

Oil groove 1.0 (0.0394)

No oil groove

Replacement

6

Trunnion wear

0 0 ø 280 -0.081 (11.0236 -0.0032 )

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

Replacement

7

Sleeve wear

0 0 ø 165 -0.100 (6.4961 -0.0039 )

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

Replacement

25-4 80ZV-2 Service Standard Power Group Axle and Differential Service Standard

Differential

2 3

1 4 5, 6 5, 6

K80V2E25002

Unit: mm (in) Judgment standard No.

Item

Solution Standard valve

Tolerance

1

Backlash between ring gear and drive pinion

0.26~0.38 (0.0102~0.0149)

←

Adjustment

2

Backlash between side gear and pinion gear

0.23~0.58 (0.0090~0.0228)

←

Adjustment

3

Clearance between pinion gear and spider

0.098~0.126 (0.0038~0.0049)

←

Replacement

4

Runout of ring gear rear surface (when assembled)

0.076 (0.0029)

←

Adjustment or replacement

5

Tooth surface wear (each gear)

6

Tooth contact

Abnormal wear or missing

Replacement

No abnormality

Replacement

34-1 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group

80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly....... 34-2 Torque Converter Assembly .................................... 34-12 Transmission Assembly .......................................... 34-20 Transmission Forward/Reverse Clutch Pack .......... 34-33 Transmission 1st/3rd Speed Clutch Pack................ 34-36 Transmission 2nd Speed Clutch Pack..................... 34-38 Transmission 4th Speed Clutch Pack...................... 34-40 Control Valve Assembly .......................................... 34-43

34-2 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque Converter and Transmission Assembly Torque converter and transmission assembly tightening torque T1 L1 T5 L1

Rear chassis Engine

T6 L3

T7 L3

Rear differential 3rd propeller shaft

T4 L2

T2 L1

T1 L1

T4 L2

2nd propeller shaft

Transmission

T3 L1 T4 L2

Front differential

: T1: 441 N-m (45 kgf-m) (325 lb-ft) T2: 417 N-m (42.5 kgf-m) (307 lb-ft) T3: 230 N-m (23.5 kgf-m) (170 lb-ft) T4: 142 N-m (14.5 kgf-m) (105 lb-ft) T5: 94 N-m (9.6 kgf-m) (69 lb-ft) T6: 67 N-m (6.8 kgf-m) (49 lb-ft) T7: 53 N-m (5.4 kgf-m) (39 lb-ft)

80V2E24001

L1: Screw lock agent (Loctite® 262) L2: Screw lock agent (Three Bond 1327) L3: With lubrication oil (Engine oil or gear oil) Note Always replace drive shaft bolts with new ones - never reuse them.

34-3 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

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

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

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

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

1

80ZV34002

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

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

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

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

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

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

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

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

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

- Lines to cooler must be also replaced.

: Transmission oil: 35 L (9.2 gal) 3

2

4

5

R80V2E34002

2. Disconnect bolts (3) from third propeller shaft (2) on the transmission side.

Remove bolt (5) from second propeller shaft (4) on the transmission side only. : Bolt (3)(5): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application Note - If the retainer bolts are too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner.

- Keep the flame away from the seals of the coupling.

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

34-4 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

12 10

6 11 9

8

80ZV34004

3. Disconnect electric wire (6) from the speed meter sensor and speed sensor.

90ZV34005

5. Remove split pin (8), and then remove pin (9).

6. Remove bolts (11) from actuator mounting bracket (10). Disconnect the oil source, and then remove actuator (12). : Actuator (with bracket): 10 kg (22 lbs)

7

Unloader valve

Valve assembly

Valve assembly

Actuator 80V2E34001

4. Release the parking brake and disconnect the link of the actuator. If the machine has low accumulator oil pressure, feed oil into hose (7) from an external source.

Note If there is no oil source, apply a rope or cable to the link, and then pull it down using a bar to compress the spring of the actuator. After that, remove the pin.

Bracket Accumulator Rear chassis 80V2E34002

7. Disconnect all the hoses and the pipes from the unloader valve, the valve assembly and the accumulator. Remove the bracket. : Bracket (with valves and accumulators): : 62 kg (137 lbs) Note Cover or plug the disconnected hoses, pipes and fittings to protect them from dust and dirt.

34-5 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Oil pump

13

Transmission

14

15

16

80ZV34006

R80V2E34003

8. Disconnect hose (13) from the transmission level gauge.

10. Disconnect hoses and pipes (14)(15)(16) from the oil pump.

Note Cover or plug the disconnected hose and fitting to protect them from dust and dirt.

Note Cover the disconnected hoses and the pump ports with caps to protect them from dust and dirt.

Stop valve

17

Bracket

18 Steering valve

Rear chassis

19

Transmission

80V2E34003

R80V2E34004

9. Disconnect all the hoses and the pipes from the steering valve and the stop valves. Remove the bracket with the valves.

11. Remove suction pipes (17)(18), and then remove pump assembly (19).

: Bracket (with valves): 40 kg (88 lbs) Note Cover or plug the disconnected hose and fitting to protect them from dust and dirt.

: Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) : Gear pump: 50 kg (110 lbs) Note Cover the disconnected hoses and the pump ports with caps to protect them from dust and dirt.

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

34-6 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

24

21 20

23

80V2E34004

12. Disconnect the electrical wire for torque converter temperature switch sensor (20).

Disconnect main clutch pressure outlet hose (21).

Note Cover or plug the disconnected hose and fitting to protect them from dust and dirt.

80V2E34006

14. Disconnect hoses (23)(24).

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

22

Multiple control valve

Multiple control valve

25

80V2E34007

80V2E34005

13. Put matchmarks on hoses (22) in the pilot line, and then, disconnect them.

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

15. Remove return pipe (25).

Note Cover or plug the disconnected pipe and port to protect them from dust and dirt.

34-7 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly Note Cover or plug the disconnected hoses and fittings to protect them from dust and dirt.

26 27 30

Multiple control valve 80V2E34008

31

16. Temporarily sling the multiple control valve, and remove bracket (27) from the rear chassis.

80ZV34016

: Bolt (26): 94 N-m (9.6 kgf-m) (69 lb-ft) : Bracket (with multiple control valve): 72 kg (159 lbs)

18. Remove all electric wire couplers (31) from control valve (30).

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

For reassembly, refer to the connection illustration on "Control valve installation cautions" page 34-45.

(S/N 9001~9100)

29

33 28 32

R80V2E34005

(S/N 9101~)

29 R80V2E34006

28

19. Temporarily attach a sling to transmission assembly (32), and then, remove 12 each of bolts (33) from the engine flywheel housing.

R80V2J34034

17. Disconnect the two hoses (28) between the torque converter and the cooler.

Disconnect the two hoses (29) between the line filter and the transmission.

: Bolt (33): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) : Transmission assembly: 610 kg (1,345 lbs)

34-8 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

34 1mm

1mm

Bracket

35 Rear chassis

Lock nut

Bracket

35

Wooden piece

80ZV34086

80V2E34009

20. Remove bolts (34)(35) (both sides). : Bolt (34): 417 N-m (42.5 kgf-m) (307 lb-ft) : Screw lock agent (Loctite® 262) application Note When installing bolt (35) to the rear chassis, adjust it with the lock nut so that the clearance between bolt (35) and the bracket becomes 1 mm (0 04 in).

Wooden piece Engine flywheel housing R80V2E34018

Flywheel

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

Pilot boss Pull to separate transmission Transmission

Ring

Ring gear

Engine-transmission joint section

80ZV34019

Note The joint section between the engine and the transmission consists of the pilot boss and the gear coupling as shown in the figure. The pilot boss is inserted for centering, and the gear coupling is used for power transmission.

To separate the transmission from the engine, remove the bolts from the engine flywheel housing, and then, pull the transmission straight out to the front.

Note Lift the transmission approximately 100 mm (4 in), and then, insert a wooden piece of 200 mm (8 in) into the clearance between the bottom of the engine flywheel housing and the rear axle housing. Lower the transmission to make a slight clearance between the engine and the transmission.

Repeat this procedure 2 to 3 times while pulling the transmission away from the engine to separate them.

34-9 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Transmission assembly installation cautions 36

Joint between the torque converter and the engine

1

80V2E34024

22. Slowly lift transmission assembly (36) while avoiding contact with other parts.

80ZV34023

Torque converter and transmission assembly installing - Be sure to replace O-ring (1) with new one.

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

Transmission side

Engine side Flywheel

O-ring (1)

Ring gear Ring 80V2E34000R

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

- Rotate the engine flywheel to align the ring gear.

34-10 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

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

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

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

1. 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.

34-11 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

DATE:

HOURS:

MACHINE MODEL & SERIAL NO.:

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO.:

AMBIENT TEMP:

COMPONENT SERIAL NO.:

CHECKLIST TO BE COMPLETED BEFORE START-UP TRANSMISSION COOLER CLEANED

TRANSMISSION PIPING CLEANED

IN-LINE PRESSURE FILTER REPLACED

TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

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

F1

MPa (kgf/cm ) (psi)

N1

MPa (kgf/cm2) (psi)

R1

MPa (kgf/cm2) (psi)

F2

MPa (kgf/cm2) (psi)

N2

MPa (kgf/cm2) (psi)

R2

MPa (kgf/cm2) (psi)

F3

MPa (kgf/cm2) (psi)

N3

MPa (kgf/cm2) (psi)

R3

MPa (kgf/cm2) (psi)

F4

MPa (kgf/cm2) (psi)

N4

MPa (kgf/cm2) (psi)

R4

MPa (kgf/cm2) (psi)

CLUTCH PRESSURE AT HIGH IDLE 2

F1

MPa (kgf/cm ) (psi)

N1

MPa (kgf/cm2) (psi)

R1

MPa (kgf/cm2) (psi)

F2

MPa (kgf/cm2) (psi)

N2

MPa (kgf/cm2) (psi)

R2

MPa (kgf/cm2) (psi)

F3

MPa (kgf/cm2) (psi)

N3

MPa (kgf/cm2) (psi)

R3

MPa (kgf/cm2) (psi)

F4

MPa (kgf/cm2) (psi)

N4

MPa (kgf/cm2) (psi)

R4

MPa (kgf/cm2) (psi)

COMMENTS:

Serviceman’s Signature

KCM CORPORATION Copy as required. Make attachments if needed.

34-12 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque Converter Assembly Torque converter assembly bolt tightening torque

T2 L 3

T2 L 3

T1 L 3 R80V2E34007

: T1: 29 N-m (3 kgf-m) (22 lb-ft) T2: 59 N-m (6 kgf-m) (43 lb-ft) L3: With lubrication oil (Engine oil or gear oil)

34-13 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque converter assembly disassembling and assembling Torque converter assembly disassembling 7

Before starting work: - Clean the torque converter assembly.

- Drain oil from the transmission and the torque converter.

8

Shim

4 1

80ZV34028

2

3

4. Remove front cover (7).

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

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

5

80ZV34026

1. Remove control valve (2) from transmission housing (1).

Note For disassembling control valve, refer to page 34-46.

2. Remove hose (3), and then, remove bolts (4) and cover (5).

9

Note Cover or plug the disconnected hose and fitting to protect them from dust and dirt.

R80V2E34008

5. Remove turbine impeller assembly (9).

6

80ZV34027

3. To remove the front cover from the pump impeller, remove bolts (6). (Number of bolts: 18)

34-14 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

11

23

10

12

19

18

20 24

22

21 17

R80V2E34009

R80V2E34012

6. Remove thrust bearing (10), thrust washer (11), and sleeve (12).

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

13

25

14

26 R80V2E34010

27 R80V2E34013

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

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

15 ∗: Remover bolt installation position

16

Torque converter housing

R80V2E34011

Transmission housing

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

R80V2E34029

11. Attach sling to the torque converter housing.

Separate the torque converter housing from the transmission housing.

34-15 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

(T/M S/N: CT180E01-0141~)

30

31

29 28

Torque converter housing K80V2E34001

12. Remove seal ring (28).

13. Turn over the torque converter housing.

14. Remove snap ring (29) and turbine shaft bearing (30).

15. Remove turbine shaft (31).

Torque converter housing

36

32

35 34 33 80V2E34025

16. Remove nut (32) from bolt (33).

17. Remove bolt (33) from the torque converter housing.

18. Remove spring (34) and washers (35)(36) from bolt (33).

34-16 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque converter assembly assembling 25

(T/M S/N: CT180E01-0141~)

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

- Before reassembly, apply transmission oil to the parts.

26

30

29

28

27

1. Turn over the torque converter housing.

Torque converter housing

31 Torque converter housing

K80V2E34002

5. Install turbine shaft bearing (30).

36

32

6. Install turbine shaft (31) and snap ring (29).

7. Connect the torque converter housing to the transmission housing.

35 34

8. Attach seal ring (28).

33 80V2E34025

: Apply grease to seal ring (28), and then insert it into the groove.

9. Tighten bolts (26) to fix stator shaft (27), and then install seal ring (25).

: Bolt: 59 N-m (6 kgf-m) (43 lb-ft) : With lubrication oil (Engine oil or gear oil)

15

20

24

22

19

18 16

21 17

2. Install spring (34) and washer (35) to bolt (33).

23

3. Install bolt (33) to the housing.

IMPORTANT Adjust the clearance between the torque converter housing and bolt (33) to 38.3 mm.

4. Install washer (36) and nut (32) onto bolt (33). : Screw lock agent (Three Bond 1327) application

R80V2E34019

10. Install needle bearing (22) and snap rings (21)(24) into gear (23).

Install plate (16) to pump impeller (17), and then, attach spacer (20), thrust bearing (19), and thrust washer (18) in order. : Bolt: 59 N-m (6 kgf-m) (43 lb-ft) : With lubrication oil (Engine oil or gear oil)

34-17 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

13 14

9

R80V2E34010

R80V2E34008

13. Install turbine impeller assembly (9).

11. Install stator (14), and attach snap ring (13).

IMPORTANT If stator (14) is installed upside down, the stator will not function properly. Carefully install stator (14) in correction direction.

IMPORTANT Adjust the thrust clearance here as follows.

17 11

8

10

12

9

80ZV34039 R80V2E34009

12. Attach sleeve (12), thrust washer (11), and thrust bearing (10).

(a) Measure the distance from ball bearing (8) to the mounting face of pump impeller assembly (17).

Regard the obtained distance as dimension A.

34-18 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly (d) After shim adjustment, remove the ball bearing, and then sequentially attach the shim and then the ball bearing to the front cover.

6 7

80ZV34040

(b) Measure the distance from the mounting face of front cover (7) to the end face of the bearing receiver.

Regard the obtained distance as dimension B. B – A = 0.2~0.4 mm (0.008~0.016 in)

A Front cover

80ZV34027

14. Install the front cover, and then tighten bolts (6) to connect the front cover to the pump impeller assembly.

Number of bolts (6): 18

B

: Bolt (6): 29 N-m (3 kgf-m) (22 lb-ft) : With lubrication oil (Engine oil or gear oil) Ball bearing

5

4

F80V2E34010

Front cover

Wooden block

80ZV34043

Ball bearing

15. Install cover (5), and then tighten bolts (4).

Adjusting shim 90ZV34032

(c) Adjust the difference between distance B and distance A (thrust clearance) to 0.2~0.4 mm (0.008~0.016 in) using a shim as shown in the figure above.

: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) Note At the completion of reassembly, manually turn the front cover to check that it rotates smoothly.

34-19 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter Assembly

Torque converter housing

Transmission housing 80ZV34044

16. Install the torque converter housing on to the transmission housing. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

1

2

3

80ZV34045

17. Install control valve (2).

Connect hose (3) between the torque converter housing and transmission housing (1).

34-20 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission Assembly Transmission assembly bolt tightening torque

T2 L 3

T7 L 3 T6 L 3

T7 L 3

T1 L 3 T5 L 1 T2 L 3

T3 L 1

T4 L 2 T6 L 3 T6 L 3

K80V2U34001

34-21 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly : T1: 29 N-m (3 kgf-m) (22 lb-ft) T2: 59 N-m (6 kgf-m) (43 lb-ft) T3: 216 N-m (22 kgf-m) (159 lb-ft) T4: 392 N-m (40 kgf-m) (289 lb-ft) T5: 94 N-m (9.6 kgf-m) (69 lb-ft) T6: 53 N-m (5.4 kgf-m) (39 lb-ft) T7: 50 N-m (5.1 kgf-m) (37 lb-ft) L1: Screw lock agent (Loctite® 262) application L2: Molybdenum disulfide grease / MOS2 application L3: With lubrication oil (Engine oil or gear oil)

34-22 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission assembly disassembling and assembling 4

Transmission assembly disassembling Before starting work: - Clean the transmission assembly.

- Remove the coupling yoke, the oil seal and the snap ring of the ball bearing for the third propeller shaft.

Unless removed, they will fall off.

- Place the transmission assembly so that the parking brake side is up.

- For disassembling and reassembling for the parking brake, refer to "Parking Brake" page 54-31.

3

90ZV34039

3. Remove bolt (3), and remove brake drum (4).

Snap ring

6

5 Coupling yoke Oil seal T/M S/N: CT180E01-0380~

K80V2E34003

90ZV34040

4. Remove nut (5), then remove flange yoke (6).

2

8 Strainer

1 R80V2E34021

7

1. Disconnect hose (1) and the strainer.

2. Remove control valve (2). : Control valve assembly: 20 kg (44 lb) Note Refer to "Control valve removing and installing" page 34-44 to remove control valve assy (2).

90ZV34041

5. Remove bolt (7), and then remove brake assembly (8).

34-23 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

14

9

Gasket

10

9 90ZV34042

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

80V2E34013

9. Remove gear (14).

11

75 mm (3 in)

Ball bearing

Torque converter

15 80V2E34027

80V2E34011

10. Remove bolt (15).

7. Hit in output shaft (11) (approx. 75 mm (3 in)), after that, remove output shaft (11) with the ball bearing.

12

13

16

17

12

80V2E34014

80V2E34012

8. Remove bolts (12), and then, remove cover (13).

11. Remove bearing (16), and then, remove 4th speed clutch pack assembly (17).

34-24 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

18

21

Ball bearing

80V2E34015

12. Remove 1st speed clutch pack assembly (18).

Note Pull out the 1st speed clutch pack assembly. It is tight due to the ball bearing between the housing and the shaft.

80ZV34052

15. Remove 3rd and forward speed clutch pack assembly (21).

22

19

80ZV34053

16. Remove 2nd and reverse speed clutch pack assembly (22).

90ZV34119

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

13. Remove bolt (19).

20

90ZV34120

14. Lift transmission housing (20) slowly.

34-25 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

(T/M S/N: CT180E01-0141~)

31 23 24 25 27 26

30 90ZV34125

19. Remove bolt (30), and then, remove charge pump assembly (31).

K80V2E34004

17. Remove bolt (23), plate (24), gear (25), snap ring (26) and bearing (27).

28 29

80ZV34055

18. Remove bolt (28) and then remove shaft (29).

34-26 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission assembly assembling Note - For clutch pack disassembly and reassembly, refer to the "disassembling and assembling" section of each clutch pack.

- Clean and check all the parts. If a part is damaged, replace it with a new one. Refer to Section 35 for wear limits.

- When assembling, apply transmission oil to the parts.

- Replace all the seals and packings with new ones.

- When installing each clutch pack assembly, manually turn the gears to check that the gears are engaged properly.

28 29

80ZV34055

31

32

2. Install shaft (29) with bolt (28). : Bolt: 59 N-m (6 kgf-m) (43 lb-ft) (T/M S/N: CT180E01-0141~)

23 24 25 30 90ZV34126

1. Install torque converter gear pump (31) with bolt (30).

27 26

: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) Note Check the thrust clearance (0.5~0.9 mm) (0.020~0.035 in) at pump shaft (32) (PTO shaft). Tap the shaft with a soft hammer to check the thrust clearance, if necessary.

K80V2E34004

3. Install gear (25), bearing (27) and snap ring (26) onto shaft (29).

Install plate (24) and tighten bolt (23). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

34-27 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

19

22

90ZV34127

4. Install 2nd and reverse speed clutch pack assembly (22).

90ZV34119

7. Tighten bolt (19). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

21 17

18

80ZV34052 90ZV34132

5. Install 3rd and forward speed clutch assembly (21).

8. Install 1st speed clutch pack assembly (18) and 4th speed clutch pack assembly (17).

20 18

16

17

Gasket 85V2E34033

6. Install transmission housing (20) onto the T/C housing.

80V2E34017

9. Install bearing (16) onto 1st speed clutch pack assembly (18).

34-28 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

11

34

Snap ring

15 R80V2E34022

10. Install small end bearing (34) on output shaft (11) and install the snap ring.

85ZV34015

13. Tighten bolt (15). : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

11 20

14

Snap ring R80V2J34022

11

11. Install output shaft (11) into housing (20).

14. Install gear (14) onto output shaft (11).

Note Support output shaft (11) from the bottom side to prevent it from falling down.

12. Install the snap ring.

90ZV34137

34-29 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

17

18

18 90ZV34138

90ZV34140

15. Measure and record the clearance between 1st speed clutch pack gear (18) and 4th speed clutch pack gear (17).

17. Measure the distance from the bearing of 1st speed clutch pack (18) to the mounting face (including the gasket) of the housing.

Regard the obtained distance as dimension A'.

Note The clearance between them should be 0.5~1.0 mm (0.02~0.04 in).

13

17 R80V2J34027

90ZV34139

16. Measure the distance from the bearing of 4th speed clutch pack (17) to the mounting face (including the gasket) of the housing.

Regard the obtained distance as dimension A.

18. Measure the distance from the mounting face of cover (13) to the end face of the bearing receiver for the 4th speed clutch pack.

Regard the obtained distance as dimension B.

34-30 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

36

13

R80V2J34028

19. Measure the distance from the mounting face of cover (13) to the end face of the bearing receiver for the 1st speed clutch pack.

Regard the obtained distance as dimension B'.

R80V2J34030

36

35

35 Clutch shaft cover

R80V2J34033

R80V2J34029

20. Adjust the difference between the distance B and the distance A (thrust clearance) to 0.5~1.0 mm using shim (35).

B – A = 0.5~1.0 mm (0.02~0.04 in)

21. Adjust the difference between the distance B' and the distance A' (thrust clearance) to 0.5~1.0 mm using shim (36).

B' – A' = 0.5~1.0 mm (0.02~0.04 in) Remove clutch shaft covers.

C

C

R80V2E34024

Note Insert the shim into the section C so that the difference between the distance A (A') and the distance B (B') is adjusted to a clearance of 0.5~1.0 mm (0.02~0.04 in).

34-31 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Clutch shaft cover

10

O-ring

Gasket

13

9

R80V2J34032

22. Install cover (13) onto the transmission housing.

90ZV34143

24. Install drive cover assembly (10) and tighten bolt (9). : Bolt (9): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil)

38

37

8

12 80V2E34019

7

90ZV34144

25. Tighten bolts (12). Install brake assembly (8) and tighten bolt (7).

37 38

: Bolt (12): 53 N-m (5.4 kgf-m) (39 lb-ft) : With lubrication oil (Engine oil or gear oil) : Bolt (7): 216 N-m (22 kgf-m) (159 lb-ft) : Screw lock agent (Loctite® 262) application 90ZV34057

23. Install ball bearing (37) and gear (38) onto the output shaft.

34-32 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

5

6

4 3

85W34038

26. Install brake drum (4) and tighten bolt (3). : Bolt (3): 94 N-m (9.6 kgf-m) (69 lb-ft) : Screw lock agent (Loctite® 262) application Install the flange yoke (6) and tighten nut (5). : Nut (5): 392 N-m (40 kgf-m) (289 lb-ft) : Molybdenum disulfide grease / MOS2 application

2

1 80V2E34020

27. Install control valve assembly (2) and hose (1).

Note Refer to "Control valve removing and installing" page 34-44 to reinstall control valve assy (2).

34-33 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Forward/Reverse Clutch Pack

Transmission Forward/Reverse Clutch Pack Forward/reverse clutch pack disassembling and assembling Forward/reverse clutch pack disassembling Note The disassembling procedure for the reverse clutch pack is described below.

The structure of the forward clutch pack is the same as that of the reverse clutch pack. Therefore, to disassemble or reassemble the forward clutch pack, follow the reverse clutch pack procedure.

3 2 90ZV34059

3

(T/M S/N: CT180E01-0141~)

4

2

K80V2E34005

& 8 -!"

1. Remove snap ring (1).

2. Attach the bearing puller to gear (2), and then remove the gear with bearing (3) as a unit.

There is thrust washer (4) between gear (2) and the ball bearing. Remove thrust washer (4).

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

For inspection and wear standard refer to "Service standard".

34-34 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Forward/Reverse Clutch Pack

11 12 13 5 6 7 8 80ZV34061

80ZV34063

3. Remove two needle bearings (5) and thrust washer (6). After that, remove snap ring (7) and backing plate (8).

5. Slightly depress ring (12). Remove snap ring (11), ring (12) and plate (13).

Note When reassembling, install thrust washers (4)(6) so that the notch faces to gear (2).

16 14 15 17 18 19 9 R80V2E34025

10

6. Remove 20 springs (14), and then, turn over the clutch and tap the shaft on a wooden block to remove piston (15).

80ZV34062

4. Alternately remove friction plates (9) and steel plates (10).

Note - Number of friction plates: 8 Number of steel plates: 7 - After reinstalling piston (15), be sure to insert friction plate (9) first.

Note When reassembling, install piston (15) into place using a plastic hammer or a driver.

7. Remove U-ring (17) from piston (15).

8. Remove piston ring (18)(19) from shaft assy (16).

34-35 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Forward/Reverse Clutch Pack

Forward/reverse clutch pack assembling

Forward/reverse clutch pack assembly cautions

For reassembling, follow the above procedure in reverse order.

Note - Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings.

- To assemble the forward/reverse clutch pack, be sure to apply transmission oil.

- Be sure the residual pressure prevention orifices are not plugged. Pass a small wire through the orifices.

Depth micrometer Straight edge

Air line

Backing plate 85W34041

After assembling clutch pack.

- Using a straight edge and depth micrometer apply pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Piston stroke Forward

3.8 ± 0.3 mm (0.15 ± 0.01 in)

Reverse

4.3 ± 0.3 mm (0.17 ± 0.01 in)

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

34-36 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 1st/3rd Speed Clutch Pack

Transmission 1st/3rd Speed Clutch Pack Transmission 1st/3rd speed clutch pack disassembling and assembling

3

Transmission 1st/3rd speed clutch pack disassembling

4

Note This disassembling and reassembling procedures for the 1st and 3rd clutch packs are basically the same.

The different points are described for each procedure.

5

6 K80V2E34008

3. Remove thrust washer (3), and then, remove rear gear (4).

Using an internal or blind hole puller, remove needle bearings (5) and thrust washer (6).

1

Note When reassembling, install thrust washers (3)(6) so that the notch faces to gear (4).

K80V2E34006

1. Remove snap ring (1) to the 1st speed clutch pack.

8 7

Spacer

Shaft assembly

K80V2E34009

4. Remove snap ring (7) and backing plate (8).

2

K80V2E34007

2. Remove ball bearing (2) using a puller.

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

34-37 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 1st/3rd Speed Clutch Pack

Transmission 1st/3rd speed clutch pack assembling

10

For reassembling, follow the above procedure in reverse order.

9

Shaft assembly

11

12

13

15 K80V2E34010

Note - Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings.

- To assemble the 1st/3rd speed clutch pack, be sure to apply transmission oil.

- Be sure the residual pressure prevention orifices are not plugged. Pass a small wire through the orifices.

5. Alternately remove friction plates (9) and steel plate (10).

Note After reinstalling piston (15), be sure to insert friction plate (9) first.

Number of friction plate (9)

Number of steel plate (10)

1st speed

10

9

3rd speed

5

4

Transmission 1st/3rd speed clutch pack assembly cautions

6. Remove snap ring (11) and rings (12)(13).

17 16 15

85K34107

14

Shaft assembly

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.

K80V2E34011

Piston stroke

7. Remove 16 springs (14), and then, turn over the clutch and tap the shaft on a wooden block to remove piston (15).

Note When reassembling, install piston (15) into place using a plastic hammer or a driver.

8. Remove U-ring (16) from piston (15).

9. Remove piston ring (17) from the shaft assembly.

1st speed

+0.02 3.8 +0.15 -1.0 mm (0.15 -0.04 in)

3rd speed

3.0 ± 1.0 mm (0.12 ± 0.04 in)

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

34-38 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 2nd Speed Clutch Pack

Transmission 2nd Speed Clutch Pack Transmission 2nd speed clutch pack disassembling and assembling Transmission 2nd speed clutch pack disassembling 7

3 8

2 6

80ZV34071

1

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

80ZV34069

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

11 10 9

4

80ZV34072

4. Depress plate (10) and remove snap ring (9), and plate (10).

5

5. Remove 16 springs (11).

80ZV34070

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

Note - Number of friction plates: 5 Number of steel plates: 4 - After reinstalling piston (12), be sure to insert friction plate (4) first.

34-39 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 2nd Speed Clutch Pack

Transmission 2nd speed clutch pack assembly cautions 14 13 12

Shaft assembly 80ZV34073

6. Turn over the clutch and tap the shaft on a wooden block to remove piston (13).

7. Remove U-ring (14) from piston (13).

8. Remove piston ring (15) from the shaft assembly.

Transmission 2nd speed clutch pack assembling

85K34107

After assembling clutch pack - Using a straight edge and depth micrometer, apply pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Piston stroke 2nd speed

For reassembling, follow the above procedure in reverse order.

Note - Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings.

- To reassemble the 2nd speed clutch pack, be sure to apply transmission oil.

3.0 ± 1.0 mm (0.12 ± 0.04 in)

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

34-40 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 4th Speed Clutch Pack

Transmission 4th Speed Clutch Pack Transmission 4th speed clutch pack disassembling and assembling

7 6

Transmission 4th speed clutch pack disassembling

80ZV34076

3. Remove snap ring (6) and backing plate (7).

1

8

80ZV34074

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

9

5 80ZV34077

4

4. Remove friction plates (8) and steel plates (9).

2 3

80ZV34075

2. Remove thrust washer (2) and gear (3). Use an internal or blind hole puller to remove needle bearing (4) from inside the gear.

Remove needle bearing (4) and thrust washer (5).

Note When reassembling, install thrust washers (2)(5) so that notch faces to gear (3).

Note - Number of friction plates: 5 Number of steel plate: 4 - After reinstalling piston (14), be sure to insert friction plate (8) first.

34-41 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 4th Speed Clutch Pack

Transmission 4th speed clutch pack assembling For reassembling, follow the above procedure in reverse order.

12 11 10

80ZV34078

5. Depress ring (11) and remove snap ring (10), ring (11) and plate (12).

15

16

17

14 13

Shaft assembly

80ZV34079

6. Remove 16 springs (13), and then turn over the clutch and tap the shaft on a wooden block to remove piston (14).

Note When reassembling, install piston (14) into place using a plastic hammer or a driver.

7. Remove U-ring (15) from piston (14).

8. Remove piston ring (16)(17) from the shaft assembly.

Note - Clean and check all the parts. If a part is damaged, replace it with a new one. Be sure to use new piston rings and seal rings.

- To reassemble the 4th speed clutch pack, be sure to apply transmission oil.

34-42 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission 4th Speed Clutch Pack

Transmission 4th speed clutch pack assembly cautions

Depth micrometer Straight edge

Air line

Shaft

Backing plate Gear

85W34041

2. After assembling clutch pack.

Clutch drum 90ZV34114

1. When installing the gear to the shaft, follow the procedure below.

- Assemble the gear onto the clutch drum with the bolts.

- Heat them up to 190ºC (374ºF).

- Insert the shaft into the clutch drum and gear. : Bolt: 86 N-m (8.8 kgf-m) (64 lb-ft) : With lubrication oil (Engine oil or gear oil)

- Using a straight edge and depth micrometer, apply pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Piston stroke 4th speed

2.95 ± 1.0 mm (0.12 ± 0.04 in)

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

34-43 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control Valve Assembly Control valve tightening torque

T1 T4

T1

T2

T3

80ZV34089

: T1: 20 N-m (2.0 kgf-m) (14 lb-ft) T2: 39 N-m (4.0 kgf-m) (29 lb-ft) T3: 10 N-m (1.0 kgf-m) (7 lb-ft) (Solenoid valve nut) T4: 34 N-m (3.5 kgf-m) (24 lb-ft) (Solenoid valve body)

34-44 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve removing and installing

5 4

Control valve removing

WARNING

6

3

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

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

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

5

R80V2E34016

2. Attach sling to control valve (3), and then, remove valve bolts (4)(5). : Bolt (4): 39 N-m (4.0 kgf-m) (29 lb-ft) : Bolt (5): 20 N-m (2.0 kgf-m) (14 lb-ft) : With lubrication oil (Engine oil or gear oil) Note Do not remove two trimmer bolts (6).

1

3. Lower the control valve to remove it.

Be sure to replace the gasket.

2

IMPORTANT 1 R80V2E34015

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

Note Put matchmarks on the electric wire couplers.

After removing or while reinstalling the control valve, take care not to allow any foreign material into the main body or the control valve. Carefully remove or reinstall the control valve and the gasket. : Control valve: 20 kg (44 lbs)

34-45 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve installation cautions

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

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

LP

Control valve

TR

LW 4

LR LY

1 (h) Adjust the transmission oil level to the specified point with the dipstick.

R 3

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

(g) Check oil leakage.

F

LG

(f)

2

LBr LO

80ZV34087

(a) Be sure to replace all the O-rings and gaskets with new ones. (b) Sequentially tighten the bolts in the order from the center to the outside. Apply equal (specified) torque to all the bolts. (c) Align the matchmarks of the electric wire couplers, and then connect the couplers while checking that the electric wires are not tangled with each other. (d) Install the cover while checking that the emergency operation bolts are positioned over the center of the solenoid valves. (e) During installation, be careful not to damage the gasket.

34-46 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve disassembling and assembling Control valve disassembling Note Clean the control valve.

4 R80V2E34028

3. Remove valve (4) using a 17 mm wrench. : Valve: 34 N-m (3.5 kgf-m) (24 lb-ft) 1

R80V2E34026

5

1. Remove nut (1).

7

: Nut: 10 N-m (1.0 kgf-m) (7 lb-ft)

6

Note Nut width across flat: 30 mm For other valves, follow the same procedure.

90ZV34109

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

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

3

2

R80V2E34027

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

Note For other solenoid valves, follow the same procedure.

34-47 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve assembly cautions 12 8

11 10 9

90ZV34110

5. Remove regulator valve (8), trimmer plug (9), springs (10), spring retainer (11), and plug (12).

Control valve assembling To reassemble the control valve, follow the disassembling procedure in reverse order.

- Before you insert the regulator valve, apply transmission oil to the valve. After insertion, check that the valve operates smoothly.

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

Check free lengths and if necessary replace them.

- Check the operation of the solenoid valves.

(Also check movement by pressing the manual plunger. The plunger should move freely and smoothly in both directions (spring return).)

- Replace all seals, O-rings and gaskets.

- Check coil resistance.

Resistance: Approx. 27 Ω

34-48 80ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group

MEMO

35-1 80ZV-2 Service Standard Torque Converter and Transmission Group

80ZV-2 Service Standard Torque Converter and Transmission Group Transmission Assembly .......................................... 35-2 Control Valve ........................................................... 35-3 Gear Pump .............................................................. 35-5 Clutch Plate Thickness/Piston Stroke ..................... 35-6 Clutch Oil Pressure ................................................. 35-8

35-2 80ZV-2 Service Standard Torque Converter and Transmission Group Transmission Assembly

Transmission Assembly 13

12

8

4 5

16

18

14

17

17

14 18 5

16

15

9 10

11

Note Numbers correspond to the REF. number on page 35-4.

80V2E35001

35-3 80ZV-2 Service Standard Torque Converter and Transmission Group Control Valve

Control Valve

1

3

7

6

2 90ZV35002

Note Numbers correspond to the REF. number on page 35-4.

35-4 80ZV-2 Service Standard Torque Converter and Transmission Group Control Valve

mm (in), kg (lbs) Judgement criteria REF.

ITEM

1 2

Clearance

3

Solution Standard clearance

Allowable limit

Control valve regulator valve ~ valve body

0.030~0.061 (0.0011~0.0024)

0.09 (0.0035)

Replacement

Control valve regulator valve ~ seal retainer

0.016~0.045 (0.0006~0.0017)

0.07 (0.0027)

Replacement

Control valve trimmer plug ~ valve body

0.025~0.066 (0.0010~0.0026)

0.09 (0.0035)

Replacement

Standard value

Allowable limit

ITEM Free length

Installed length

Installed load

Free length

Installed load

4

T/C inlet valve spring

44.6 (1.7559)

35.2 (1.3853)

10.2 (23)

43.6 (1.7165)

9.2 (20)

Replacement

5

Clutch return spring (The same spring for all clutches) T/C

24.4 (0.9606)

21 (0.8267)

3.3 (7)

23.7 (0.9330)

3.0 (6)

Replacement

6

Control valve regulator spring

89 (3.5039)

89 (3.5039)

0

87.5 (3.4448)

0

Replacement

7

Control valve trimmer spring

81.4 (3.2047)

69 (2.7165)

5 (11)

80 (3.1496)

4.5 (10)

Replacement

Spring

Judgement criteria ITEM Standard value

Allowable limit

41.93~42.0 (1.6507~1.6535)

41.8 (1.6456)

Rear yoke shaft diameter

74.92~75.0 (2.9496~2.9528)

74.8 (2.9449)

10

Front yoke shaft diameter

79.92~80.0 (3.1464~3.1496)

79.8 (3.1417)

11

Speedometer driven gear shaft diameter

11.95~12.0 (0.4704~0.4724)

11.8 (0.4645)

W

0 0 2.8 -0.1 (0.1102 -0.0039 )

2.5 (0.0984)

H

2.5±0.05 (0.0984±0.0019)

2.3 (0.0905)

W

2.8±0.1 (0.1102±0.0039)

2.5 (0.0984)

H

2.2±0.05 (0.0866±0.0019)

2.0 (0.0787)

W

0 0 3.89 -0.1 (0.1532 -0.0039 )

3.69 (0.1453)

H

4.35±0.1 (0.1713±0.0039)

4.15 (0.1634)

8

Charge pump shaft diameter

9 Oil seal

12

13

Torque converter inlet

Seal ring

14

W

Torque converter outlet

Clutch shaft (The same for all clutches)

H

Replacement Replace oil seal when disassembling and reassembling

Replacement Replacement Replacement

Replacement

Replacement

Replacement

15

Piston outer dia. (F, R)

H

4.3±0.1 (0.1693±0.0039)

4.1 (0.1614)

Replacement

16

Piston outer dia. (1~4 speed)

H

4.3±0.1 (0.1693±0.0039)

4.1 (0.1614)

Replacement

17

Piston inner diameter

H

4.25+0.015 (0.1673+0.0006 ) 0 0

4.05 (0.1595)

Replacement

Thrust washer thickness

2.9~3.1 (0.1141~0.1220)

2.7 (0.1063)

Replacement

Gear backlash

0.2~0.3 (0.0078~0.0118)

0.5 (0.0196)

Replacement

18

35-5 80ZV-2 Service Standard Torque Converter and Transmission Group Gear Pump

Gear Pump Gear pump specifications

1 4

Theoretical

64.5 cm3/rev (3.9 in3/rev)

Maximum operation pressure

2 MPa (20 kgf/cm2) (284 psi)

Maximum operation speed

2,400 min-1 (rpm)

2 Actual discharge

Approx. 120 L/min (31.7 gpm) Conditions: Pump speed 2,200 min-1 Oil temp. 80~100°C (176~212°F) Oil viscosity 40CST (SAE10W) Discharge pressure 1.4~1.6 MPa (14~16 kgf/cm2) (199~228 psi)

3

2

1

90ZV35003

Unit: mm (in) No.

Item

Standard value

Solution

1

Top clearance between gear and housing

0.08~0.11 (0.003~0.004)

Replacement

2

Side clearance between gear and housing

0.03~0.073 (0.001~0.003)

Replacement

3

Backlash between gears

0.2~0.3 (0.008~0.012)

Replacement

4

Tightening torque for pump fixing bolt

59 N-m (6.0 kgf-m) (43 lb-ft)

Tightening

Note When measuring the side clearance of item 2 above, remove the gasket.

35-6 80ZV-2 Service Standard Torque Converter and Transmission Group Clutch Plate Thickness/Piston Stroke

Clutch Plate Thickness/Piston Stroke

T2 L 3

T7 L 3 T2 L 3

T7 L 3

T1 L 3 T2 L 3 T5 L 1

T3 L 1

T4 L 2 T6 L 3 T6 L 3

K80V2E35001

: T1: 29 N-m (3.0 kgf-m) (22 lb-ft) T2: 59 N-m (6.0 kgf-m) (43 lb-ft) T3: 216 N-m (22.0 kgf-m) (159 lb-ft) T4: 392 N-m (40.0 kgf-m) (289 lb-ft) T5: 94 N-m (9.6 kgf-m) (69 lb-ft) T6: 53 N-m (5.4 kgf-m) (39 lb-ft) T7: 50 N-m (5.1 kgf-m) (37 lb-ft)

L1: Screw lock agent (Loctite® 262) application L2: Molybdenum disulfide grease / MOS2 application L3: With lubrication oil (Engine oil or gear oil)

35-7 80ZV-2 Service Standard Torque Converter and Transmission Group Clutch Plate Thickness/Piston Stroke

Clutch plate Number of clutch plates

Name of clutch

Friction plate

Steel plate

Return spring

Forward clutch

8

7

20

Reverse clutch

8

7

20

1st speed clutch

10

9

16

2nd speed clutch

5

4

16

3rd speed clutch

5

4

16

4th speed clutch

5

4

16

Outer dia.

ø167 (6.57 in)

ø182 (7.17 in)

—

Inner dia.

ø104.8 (4.13 in)

ø116 (4.57 in)

—

When new

2.0±0.1 (0.08±0.004 in)

1.8±0.1 (0.07±0.004 in)

—

Wear limit

1.8 (0.07 in)

1.6 (0.06 in)

—

Thickness

Dimension (mm) (in)

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

Piston stroke mm (in) Clutch

Standard value

Forward clutch

3.8±0.3 (0.15±0.01)

Reverse clutch

4.3±0.3 (0.17±0.01)

1st speed clutch

3.8 +0.5 -1.0

(0.15 +0.02 -0.04 )

2nd speed clutch

3.0±1.0 (0.12±0.04)

3rd speed clutch

3.0±1.0 (0.12±0.04)

4th speed clutch

2.95±1.0 (0.12±0.04)

35-8 80ZV-2 Service Standard Torque Converter and Transmission Group Clutch Oil Pressure

Clutch Oil Pressure

1

8 8 2 4 9 3 7 4

5

6 5

6

80ZV35007

Clutch oil pressure standard value (Oil temperature 50~80ºC (120~180ºF)) Oil pressure MPa (kgf/cm2) (psi) No.

Measuring port location

Measuring port size

Engine revolution (rpm) 800 (Low idle)

2,350 (High idle)

Shift lever position

Torque converter inlet

PT3/4

0.03~0.5 (0.3~5.5) (4.3~78)

0.2~0.5 (2.0~5.5) (28~78)

All speed range

2

Main oil pressure

PT1/8

1.3±0.2 (13±2) (185±28)

1.5±0.2 (15±2) (213±28)

All speed range

3

Forward clutch oil pressure

PT1/4

1.3±0.2 (13±2) (185±28)

1.5±0.2 (15±2) (213±28)

Forward

Reverse clutch oil pressure

PT1/4

1.3±0.2 (13±2) (185±28)

1.5±0.2 (15±2) (213±28)

Reverse

1st speed clutch oil pressure

PT1/4

1.3±0.2 (13±2) (185±28)

1.5±0.2 (15±2) (213±28)

1st speed

2nd speed clutch oil pressure

PT1/4

1.3±0.2 (13±2) (185±28)

1.5±0.2 (15±2) (213±28)

2nd speed

3rd speed clutch oil pressure

PT1/4

1.3±0.2 (13±2) (185±28)

1.5±0.2 (15±2) (213±28)

3rd speed

8

4th speed clutch oil pressure

PT1/4

1.3±0.2 (13±2) (185±28)

1.5±0.2 (15±2) (213±28)

4th speed

9

Transmission lubrication oil pressure

PT1/2

0.01~0.1 (0.1~1.0) (1.4~14)

0.05~0.2 (0.5~2.5) (7~36)

All speed range

4 5 6 7

Clutch oil pressure

1

44-1 80ZV-2 Disassembly & Reassembly Hydraulic Group

80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning ............................................................................. 44-2 Hydraulic Parts Disassembly and Assembly Cautions ............................................................................. 44-3 Hydraulic Pump Assembly ...................................... 44-4 Hydraulic Cylinder ................................................... 44-8 Pilot Valve (S/N 9001~9205) ................................... 44-21 Pilot Valve (S/N 9206~) ........................................... 44-32 Multiple Control Valve.............................................. 44-42 Orbitrol® ................................................................... 44-48 Steering Valve ......................................................... 44-58 Stop Valve ............................................................... 44-63 Fan Motor ................................................................ 44-67

44-2 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning

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

Understand the following items well and work safely.

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

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

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

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

- Use signals as agreed upon before starting work.

- Do not enter the hazardous area.

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

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

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

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

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

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

- Apply the specified torque to tighten each part.

44-3 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Disassembly and Assembly Cautions

Hydraulic Parts Disassembly and Assembly Cautions Hydraulic parts may be very delicate. When disassembling or reassembling, handle with care.

Understand the following well to perform disassembly and reassembly work.

Hydraulic parts disassembly cautions - Completely drain hydraulic oil from parts. Clean unit before disassembly. Plug each open ports.

- Work in a well ventilated area.

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

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

- Because hydraulic parts may be delicate, do not drop or scratch them.

- When disassembling, do not hit or pry the parts by force. The parts may be burred and scored, which may cause oil leakage or poor performance.

- Do not disassemble adjusting screws unless needed.

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

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

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

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

- Replace O-rings and seals with new ones.

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

- Apply the specified torque to tighten parts.

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

44-4 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic Pump Assembly Hydraulic pump assembly removing and installing

Transmission

Hydraulic pump assembly removing

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

So, when entering the area, stop the engine and place "DO NOT START" or "DO NOT OPERATE" tag on 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: - Remove the cab and the floor board by referring to Section 14.

- Clean the area around the hydraulic pump.

3

1

2 2 80V2E44001

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

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

2. Remove the hydraulic pump retainer bolts. : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft) 3. Remove hydraulic pump (1). : Hydraulic pump: 35 kg (76 lbs)

Hydraulic pump assembly installing To reinstall the hydraulic pump assembly, follow the above removal procedure in reverse order.

Replace all gaskets and O-rings during reinstallation.

44-5 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic pump installation cautions

IMPORTANT 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.

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

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

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

- Check the oil level of the hydraulic tank.

- Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe. Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 L).

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

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

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

- Confirm that there is no abnormal noise or operation, and be sure that there is no excessive heat.

Inspect the hydraulic oil at the sight gauge to be sure that there are no bubbles which may indicate air being drawn in at the suction side of the pump.

If there are any bubbles, correct the cause prior to using the machine, as this may contribute to premature pump failure.

44-6 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Hydraulic pump assembly disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

IMPORTANT - Handle pumps carefully.

- In case hydraulic system breaks down, do not disassemble the pump first.

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

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

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

Do not disassemble the pump except when necessary to replace oil seals and O-rings between the double and triple pumps which are able to be separated.

Hydraulic pump assembly cross section and tightening torque

T2

T1

80V2E44002

: T1: 177 N-m (18 kgf-m) (130 lb-ft) T2: 275 N-m (28 kgf-m) (203 lb-ft)

44-7 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Pump Assembly

Oil seal replacement procedure There are two kinds of the pump drive gear shaft unit.

One has one oil seal only, and the other has an additional dust seal or oil seal outside.

[Example 1] Oil seal

Snap ring

In case of example 2 1. After removing the outer oil seal, remove the snap ring and the inner oil seal.

2. When removing the oil seals, remove any scores on the front cover and the drive gear shaft.

3. Cover the drive gear shaft with vinyl electrical tape to protect the splines.

Drive gear shaft

4. Apply a thin coat of grease to the oil seal and the lip unit.

5. Install the seal straight.

Front cover

90ZV44048

[Example 2]

Front cover

Drive gear shaft

Oil seal

Oil seal

Snap ring 90ZV44049

44-8 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder removing and installing Boom cylinder removing (The illustration shows the left side of the machine.)

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block 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.

1

K80ZV44001

1. Attach sling to boom cylinder (1). : Boom cylinder: 140 kg (310 lbs)

Before starting work: - Clean the area around the cylinder and piping.

3

2

80V2E44003

2. Disconnect hoses (2)(3).

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

Stand (A)

85ZV44003

Relieving residual pressure from pipe (a) Raise the boom. When the boom is approximately 30 cm (1 foot) above stand (A), stop the engine. (b) Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. (c) First press down on the hydraulic tank cap to vent residual pressure, then open the cap of the hydraulic tank. Leave hydraulic tank cap loosely on top of tank opening.

44-9 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

1

5

4 9 K80ZV44002

3. Remove lock bolt (4) and pin (5). : Bolt (4): 265 N-m (27.0 kgf-m) (195 lb-ft)

80ZV44024J

6. Sling boom cylinder (1), and lower it onto the ground.

After that, remove pipe (9) from the cylinder.

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

For the detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-15.

Boom cylinder installing

6

85ZV44014

4. Place a container to receive the oil from the oil port on the cylinder bottom side. Then, push in rod (6).

8 7

80ZV44005

5. Remove lock bolts (7), and then, remove pin (8). : Lock bolt: 265 N-m (27.0 kgf-m) (195 lb-ft)

To reinstall the boom cylinder, follow the above removal procedure in reverse order.

44-10 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Boom cylinder installation cautions Be sure the pins accept grease after installation.

Bucket cylinder removing and installing Bucket cylinder removing

Cylinder air bleeding procedure

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note Stop the piston about 100 mm (4.0 in) before stroking fully. (b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

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

- Place the boom and the bucket onto the ground.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Use a step, and do not stand on the machine.

Before starting work: - Clean the area around the cylinder and piping.

Relieving residual pressure from pipe (a) Lower the boom and the bucket onto the ground. (b) Stop the engine and move the bucket and boom levers back and forth. (c) Open the cap of the hydraulic tank to relieve the residual pressure.

Bucket cylinder

1

2 3

80ZV44007

1. Remove the coupler of bucket leveler switch (1), and then, remove bracket (2).

2. Remove rod (3).

44-11 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

9

Grease pipe

5 4 Bucket cylinder

8

Bucket cylinder

80ZV44025J

80ZV44010

5. Disconnect the grease pipe and then remove lock bolt (8) and pin (9).

3. Attach sling to the bucket cylinder.

After that, remove lock bolt (4) and pin (5). : Lock bolt: 265 N-m (27.0 kgf-m) (195 lb-ft) : Bucket cylinder: 200 kg (440 lbs)

: Lock bolt: 265 N-m (27.0 kgf-m) (195 lb-ft) 6. Slowly lift up the bucket cylinder. Lower the bucket cylinder onto the ground.

7

For the detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-15.

Bucket cylinder

Bucket cylinder installing 6 Cylinder rod

80ZV44009

4. Start the engine and shorten the cylinder rod.

Stop the engine and disconnect hoses (6)(7).

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

To reinstall the bucket cylinder, follow the above removal procedure in reverse order.

44-12 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder installation cautions

WARNING During service work, do not stand on the machine.

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

- Be sure the pins accept grease after installation.

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

Refer to "Attachment Leveler" page 15-7.

Cylinder air bleeding procedure

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note Stop the piston about 100 mm (4.0 in) before stroking fully. (b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-13 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder removing and installing

5 3 6

Steering cylinder removing

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

- Place the boom and the attachment onto the ground.

- Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line.

- Press cap downward to vent, then open the cap of the hydraulic tank to relieve the internal pressure from the tank.

- Place a "DO NOT START!" tag on the steering wheel or the operator's seat.

4

80ZV44012

2. There is pin (6) at the link between front chassis (3) and steering cylinder (4).

Remove lock bolt (5) and pin (6), and then push the rod into the cylinder to shorten the length of the cylinder. : Oil will be drained from the oil port of the cylinder. Place a container at the oil port to catch the drained oil.

7

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

8 9

1

4 80ZV44013

2

3. Disconnect grease pipe (7).

Steering cylinder 80ZV44011

1. Disconnect hoses (1)(2).

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

4. Remove pin lock bolts (8).

5. Tap pin (9) from the bottom side to remove it from the top side.

44-14 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder 6. Remove steering cylinder assembly (4).

Note that two persons are needed to remove and lift the assembly. : Steering cylinder: 25 kg (55 lbs) Note For detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-15.

Cylinder air bleeding procedure

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Steering cylinder installing

Note Stop the piston about 100 mm (4.0 in) before stroking fully.

To reinstall the steering cylinder, follow the above removal procedure in reverse order.

(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.

Steering cylinder installation cautions Pin installation Be sure the pins accept grease after installation.

IMPORTANT Insert shims so that the clearance between the chassis and the cylinder is 1.2 mm (0.047 in) or less.

Place approximately the same number of shims under the cylinder as on top of the cylinder. Refer to "Linkage Pin Standard Clearance Values" page 15-3.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area can cause injury or death.

When turning the steering wheel while engine is running, do not enter the articulation area of the machine.

If a person is in the articulation area, do not start the engine.

44-15 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Hydraulic cylinder cross section and tightening torque Boom cylinder

T1

T2 80ZV44001J

Piston nut width across flats: 90 mm (3.54 in) Thread size: M58 x 2

: T1: 3,923 N-m (400 kgf-m) (2,894 lb-ft) T2: 471 N-m (48 kgf-m) (347 lb-ft) Bucket cylinder

T3

T4 80ZV44002J

: T3: 4,903 N-m (500 kgf-m) (3,618 lb-ft) T4: 686 N-m (70 kgf-m) (506 lb-ft)

Piston nut width across flats: 100 mm (3.94 in) Thread size: M68 x 2

44-16 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder Steering cylinder

T5

T6

80V2E44004

: T5: 930 N-m (94.8 kgf-m) (686 lb-ft) T6: 300 N-m (30.6 kgf-m) (221 lb-ft) Piston nut width across flats: 46 mm (1.81 in) Thread size: M30 x 2

44-17 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling Note The bucket cylinder disassembling procedure is described below. For other cylinders, follow the same procedure.

4

95ZV44006

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

Repair stand 95ZV44004

1. Install the bottom side of the cylinder to the repair stand.

Repair stand

4 Matchmark

3

Wooden block 95ZV44007

2 1 95ZV44005

2. Put the matchmarks on rod cover (1) and cylinder tube (2). Remove rod cover bolt (3). : Bolt (3): (Boom cylinder) 471 N-m (48.0 kgf-m) (347 lb-ft) (Bucket cylinder) 686 N-m (70.0 kgf-m) (506 lb-ft) Rod cover (1): (Steering cylinder) 300 N-m (30.6kgf-m) (221 lb-ft)

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

44-18 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

5

4

Matchmark

7

6

4

6 95ZV44008

95ZV44010

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

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

21

6 8

10 21 12

8

22

8

9

C

Hydraulic jack

11 (Bucket cylinder)

(Steering cylinder)

Hydraulic cylinder

80V2E44005 95ZV44009

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

Piston nut width across flats mm (in)

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

Boom cylinder

90 (3.54)

3,923 (40) (2,894)

Bucket cylinder

110 (4.33)

4,903 (500) (3,618)

Steering cylinder

46 (1.81)

930 (94.8) (686)

8

9

10

12

11 (Boom cylinder) 85ZV44029

8. Remove wear ring (8), back-up ring (21), square ring (9), slipper ring (10), O-ring (11), wear ring (12) and piston packing (22).

(There is no wear ring (12) for steering cylinder.)

44-19 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder assembling To reassembling the hydraulic cylinders, follow the above removal procedure in reverse order.

1

Hydraulic cylinder assembly cautions 4

95ZV44013

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

1 20 16 17

CAUTION

1

19

20 16 17

18

13

Before starting work: - Be sure to replace all the seals and packings.

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

- Before reassembling the parts, apply a coat of hydraulic oil to the parts.

19

Hot oil can cause injury or burns.

Avoid contact with hot oil.

15

18

14

Slipper ring installation

(Bucket cylinder)

(Boom cylinder)

10

K80V2E44001

18 20 19 17 16

21 13

95ZV44016

Put slipper ring (10) into hot oil to heat the ring to 120~150ºC (250~300ºF).

(Steering cylinder)

80V2E44006

10. Remove dust seal (13), stop ring (14), scraper ring (15), back-up ring (16), U-packing (17), buffer ring (18), back-up ring (19) O-rings (20)(21) from rod cover (1).

Note - This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston.

Therefore, heat the slipper ring to expand its inner diameter for easy attachment.

- Attach the slipper ring while taking care not to damage the ring by over expansion.

- After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

44-20 80ZV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder Rod cover installation

Back-up ring installation

2

3 95ZV44017

K65V2E44013

Before installing back-up ring (2) and O-ring (3), heat the back-up ring.

Install the rod cover of the steering cylinder, screw the rod cover using a spanner wrench.

Screw in and tighten the set screw.

Stake the set screw.

Note This is because the inner diameter of the back-up ring is smaller than the outer diameter of the rod cover. To easily attach the back-up ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.

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.

: 1,569 N-m (160 kgf-m) (1,158 lb-ft)

44-21 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

Pilot Valve (S/N 9001~9205) Pilot valve removing and installing

Downshift button

Pilot valve

Pilot valve removing 2

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

- Lower the attachment onto the ground, and then relieve the internal pressure from the line.

- Relieve the internal pressure from the hydraulic tank.

3

95ZVE44039

2. Disconnect electrical line (2) of the Downshift button.

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

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

Control box

4

A

4

A

1 Cover mount

5

95ZVE44038

1. Open the cab door (the right hand side).

Remove cover (1) from the control box.

Pilot valve 95ZVE44040

4. Remove knob (4), and then, separate Downshift button (5).

44-22 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

10

8

12

9 6

12

Adapter 2

13 14

Adapter 1

13

14 7 15 95ZVE44041

5. Remove boot (6) and covers (7)~(10).

95ZVE44042

7. Loosen nut (14) and disconnect vinyl tube (12) and rod (13).

Pilot valve

8. Remove nut (15) (4 pcs) and pull up the pilot valve to remove it. : Adapter 1: 29.4 N-m (3.0 kgf-m) (21.7 lb-ft) Adapter 2: 49.0 N-m (5.0 kgf-m) (38.0 lb-ft) : Pilot valve: 6.5 kg (14.3 lbs)

11 11

Pilot valve installing 95ZVE44043

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

To reinstall the pilot valve, follow the removal procedure in reverse order.

: Drain oil: Approx. 1 L (0.3 gal) Note Before disconnecting the hoses, be sure to put matchmarks on them.

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

Pilot valve installation cautions After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage.

If the oil level is too low, add hydraulic oil to the tank.

44-23 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

Pilot valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve cross section and tightening torque

T7 L1

T7 L1 T4

T4

T4

T4

T6

A

T6

B

T port:

T8 L1 T5

T

T3

T1

T

T3

T3

T

P port:

P

T3

T3

P

T3 Port 1

Port 2

Cross section A-A

P

T3

T2 A

Port 3

Port 4

Port 1, 2

B Port 3, 4

Cross section B-B 95ZVE44037

: T1: 49.0 N-m (5.0 kgf-m) (36.0 lb-ft) T2: 29.5 N-m (3.0 kgf-m) (22.0 lb-ft) T3: 20.5 N-m (2.1 kgf-m) (15.2 lb-ft) T4: 17.0 N-m (1.7 kgf-m) (12.3 lb-ft) T5: 14.5 N-m (1.5 kgf-m) (10.7 lb-ft) T6: 9.0 N-m (0.9 kgf-m) (6.5 lb-ft) T7: 7.0 N-m (0.7 kgf-m) (5.1 lb-ft) T8: 1.5 N-m (0.15 kgf-m) (1.1 lb-ft)

L1: Screw lock agent (Loctite® 241) application : Pilot valve: 6.5 kg (14.5 lbs)

44-24 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

Pilot valve disassembling (S/N 9001~9205) 2

(Illustrated on the boom side. Disassemble the bucket side in the same manner.)

1

3

4

1

5

4. Put match-marks on cover assembly (2) and case assembly (5). Then, remove the cover from the case assembly.

2 [Cross section view]

95ZVE44005

95ZVE44007

7 6

1. Plug all ports of the pilot valve and rinse it with illuminating kerosene.

5

2. Clamp the pilot valve in a vise.

Pull up boot (1) to remove it from cover (2).

95ZVE44004

7 4 3

95ZVE44006

3. Loosen socket bolts (3), which look deeper, with a hexagon (Allen) wrench.

6

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft) 95ZVE44003

Note Do not loosen bolt (4) here, which is later loosened in step 18.

5. Remove plug (6) by carefully pushing it up with a screwdriver while pressing push rod (7) with a cloth.

Note Carefully remove plug (6), as plug (6) and push rod (7) may spring out by the force of return spring inside.

44-25 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

8 6

7

11 5

12

10

9

95ZVE44011

95ZVE44010

6. Remove push rod (7), plug (6), reducing valve parts as an assembly, and return spring (8) from case assembly (5).

8. Remove spool (11), secondary pressure spring (10) and plane washer (12) if assembled.

Note Put a match-mark on plug (6) and case assembly (5).

Note Plane washer (12) is used for the preset adjustment of spring (10), and may be of a different thickness or not used depending on the spool assembly. Make sure to keep the disassembled parts per each port.

15

Slide

9 95ZVE44009

14

7. To disassemble the reducing valve assembly, push spring seat (9) to compress secondary pressure spring (10), and slide spring seat (9) so that spool (11) is released from the bigger hole of the spring seat.

Note - Do not damage the spool surface.

- Do not push spring seat (9) 6 mm (0.24 in) or more.

13

6

7 95ZVE44008

9. Pull out spring (13) and spring seat (14) from push rod (7).

Note Only the port 1 and port 3 have spring (13) and spring seat (14). Make sure to keep the disassembled parts per each port.

Refer to page 44-23 for the port location.

44-26 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

17

5

18

7

15

6

Port 1&2

20

Port 3&4

95ZVE44013

95ZVE44015

10. Remove push rod (7) from plug (6). Remove O-ring (15) from plug (6).

12. Put match-marks on case assembly (5) and plate (20). Remove socket bolt (17) and nut (18) using the hexagon (Allen) wrench, and separate case assembly (5) and plate (20).

16

: Socket bolt (17): 20.5 N-m (2.10 kgf-m) (15.2 lb-ft)

19 6 95ZVE44014

11. Remove seal (16) from plug (6) using a small screwdriver.

Note Take care not to damage the internal surface of plug (6).

20 95ZVE44012

13. Remove O-ring (19) from plate (20).

Note Take care not to damage O-ring (19).

44-27 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

24 21

5

95ZVE44019

95ZVE44017

14. Remove O-rings (21) from case assembly (5).

17. Remove O-ring (24) from case assembly (5).

Note Take care not to damage O-ring (21).

Note Take care not to damage O-ring (24).

22 26 26

23

2

27

25 22 5

95ZVE44018

95ZVE44016

15. Clamp case assembly (5) in a vise. Loosen and remove socket bolts (22) on port plate (23).

18. Clamp center plate (25) in a vise. Remove socket bolts (26) in the shallow pits with a hexagon (Allen) wrench.

: Socket bolt (20): 20.5 N-m (2.10 kgf-m) (15.2 lb-ft) 16. Remove port plate (23) from case assembly (5).

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft)

44-28 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

2

27

28 25

27 95ZVE44023

19. Remove cover (2) and detent casing (27) from center plate (25).

Be advised that fixing discs (29) on outer springs (28) may be stuck to detent casing (27) with grease, and could be dropped.

95ZVE44021

21. Remove detent casing (27) from cover (2).

Note The push rod may be fall off the detent bush without the steel ball.

29 27

28

25

30 95ZVE44022

95ZVE44020

20. Remove outer springs (28) and fixing discs (29) on center plate (25).

22. Remove solenoid coil (30) from detent casing (27).

Note While removing solenoid coil (30), do not pull the electrical harness.

44-29 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

32 31 31

34

95ZVE44028

23. Remove lever (31) by loosening socket bolt (32) with a hexagon (Allen) wrench.

95ZVE44026

26. Clamp lever (31) in a vise, and remove nuts (34). : Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)

: Socket bolt (32): 6.9 N-m (0.7 kgf-m) (5.1 lb-ft)

35 (with pre-detent)

Note Loctite® 241 is applied requiring bigger torque to loosen the bolt.

37

35 (without pre-detent)

31

2

33

F95ZVE44025

2

95ZVE44027

24. Remove cam shaft (33).

25. Take out lever (31) from cover (2).

2

Tool

95ZVE44024

27. Remove assembled detent bush (35), push rod (37), etc. from cover (2) using the tool.

44-30 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

[Tool]

(Material: SS400)

37

40

38

Center hole (ø2 or less)

39

30 35

2

45 115V2E44021

95ZVE44030

30. [For the port with pre-detent] Hold detent ring (38) and press to compress spring (39), and then take out balls (40).

2

Note Be sure to keep balls (40) (4 pcs.).

31. Pull out push rod (37).

36

39 35 95ZVE44032

28. Remove O-rings (36) from cover (2).

Note Take care not to damage O-rings (36).

38

95ZVE44029

35

32. Remove detent ring (38) and spring (39) from detent bush (35).

37 95ZVE44031

29. [For the port without pre-detent] Remove push rod (37) from detent bush (35). Put a match-mark on them beforehand.

44-31 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9001~9205)

41

Push rod (37)

Detent bush (35)

Scraper (41) Scraper (41)

A

35

Detail of A 95ZVE44033

95ZVE44035

33. Remove scraper (41) from detent bush (35).

- Insert scraper (41) in correct direction.

Note Be sure not to damage scraper (41) or the internal surface of detent bush (35).

- Do not push push rod (37) too much with the set screw while adjusting the position of the lever (31). It may cause bumping at Neutral position, resulting in unexpected movement at starting the engine.

Pilot valve assembling Push rod (7)

To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

Pilot valve assembly cautions Plug (6)

- Clean and check all the parts. If any part is defective, replace or repair it.

Seal (16) 95ZVE44034

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

- Install seal (16) in plug (6) in correct direction.

- Apply the specified torque to tighten each main part.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Measure the resistance of each coil magnet assembly. The resistance should be 62 Ω at normal room temperature [(20ºC) (70ºF)]. If measured in extremely low temperatures the resistance will be less, and at operating temperature the resistance will be higher.

- Be aware that the assembled parts, such as the push rod, spring, etc. are different depending on the ports. Use the correct parts.

44-32 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

Pilot Valve (S/N 9206~) Pilot valve removing and installing

Downshift button

Pilot valve

Pilot valve removing 2

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

- Lower the attachment onto the ground, and then relieve the internal pressure from the line.

- Relieve the internal pressure from the hydraulic tank.

3

95ZVE44039

2. Disconnect electrical line (2) of the Downshift button.

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

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

Control box

4

A

4

A

1 Cover mount

5

95ZVE44038

1. Open the cab door (the right hand side).

Remove cover (1) from the control box.

Pilot valve 95ZVE44040

4. Remove knob (4), and then, separate Downshift button (5).

44-33 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

10

8

12

9 6

12

Adapter 2

13 14

Adapter 1

13

14 7 15 95ZVE44041

5. Remove boot (6) and covers (7)~(10).

95ZVE44042

7. Loosen nut (14) and disconnect vinyl tube (12) and rod (13).

Pilot valve

8. Remove nut (15) (4 pcs) and pull up the pilot valve to remove it. : Adapter 1: 29.4 N-m (3.0 kgf-m) (21.7 lb-ft) Adapter 2: 49.0 N-m (5.0 kgf-m) (38.0 lb-ft) : Pilot valve: 6.5 kg (14.3 lbs)

11 11

Pilot valve installing 95ZVE44043

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

To reinstall the pilot valve, follow the removal procedure in reverse order.

: Drain oil: Approx. 1 L (0.3 gal) Note Before disconnecting the hoses, be sure to put matchmarks on them.

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

Pilot valve installation cautions After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage.

If the oil level is too low, add hydraulic oil to the tank.

44-34 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

Pilot valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve cross section and tightening torque A T4

B

T4

T2 L1

T2 L1

T3 T3

T6 T5

P T 2

4

A Port 1

Port 2

Cross section A-A

Port 3

Port 4

Port 1, 2

B Port 3, 4

Cross section B-B K85Z544001

: T1: 1.6 N-m (0.16 kgf-m) (1.2 lb-ft) T2: 7.9 N-m (0.8 kgf-m) (5.8 lb-ft) T3: 9.8 N-m (1.0 kgf-m) (7.2 lb-ft) T4: 17.7 N-m (1.8 kgf-m) (13 lb-ft) T5: 53.9 N-m (5.5 kgf-m) (40 lb-ft) T6: 31.4 N-m (3.2 kgf-m) (23 lb-ft) Port 1~4 (adapter: 31.4 N-m (3.2 kgf-m) (23 lb-ft)

L1: Screw lock agent (Loctite® 241) application : Pilot valve: 6.5 kg (14.5 lbs)

44-35 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

Pilot valve disassembling (S/N 9206~) 2

(Illustrated on the boom side. Disassemble the bucket side in the same manner.)

1

3

4 5

1

K90Z544010

4. Put match-marks on cover assembly (2) and case assembly (5). Then, remove the cover from the case assembly.

2 [Cross section view]

95ZVE44007

1. Plug all ports of the pilot valve and rinse it with illuminating kerosene.

7 6 5

2. Clamp the pilot valve in a vise.

Pull up boot (1) to remove it from cover (2).

K90Z544011

7 4 3

95ZVE44006

3. Loosen socket bolts (3), which look deeper, with a hexagon (Allen) wrench.

6

: Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft) K90Z544012

Note Do not loosen bolt (4) here, which is later loosened in step 18.

5. Remove plug (6) by carefully pushing it up with a screwdriver while pressing push rod (7) with a cloth.

Note Carefully remove plug (6) as plug (6) and push rod (7) may spring out by the force of return spring inside.

44-36 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

6 7

5 8

11

12

10

9

K90Z544013

95ZVE44010

6. Remove push rod (7), plug (6), reducing valve parts as an assembly, and return spring (8) from case assembly (5).

8. Remove spool (11), secondary pressure spring (10) and plane washer (12) if assembled.

Note Put a match-mark on plug (6) and case assembly (5).

Note Plane washer (12) is used for the preset adjustment of spring (10), and may be of a different thickness or not used depending on the spool assembly. Make sure to keep the disassembled parts per each port.

15

Slide

9 95ZVE44009

14

7. To disassemble the reducing valve assembly, push spring seat (9) to compress secondary pressure spring (10), and slide spring seat (9) so that spool (11) is released from the bigger hole of the spring seat.

Note - Do not damage the spool surface.

- Do not push spring seat (9) 6 mm (0.24 in) or more.

13

6

7 95ZVE44008

9. Pull out spring (13) and spring seat (14) from push rod (7).

Note Only the port 1 and port 3 have spring (13) and spring seat (14). Make sure to keep the disassembled parts per each port.

Refer to page 44-23 for the port location.

44-37 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

26 26

2

27

25

7

15

6

95ZVE44013

95ZVE44016

10. Remove push rod (7) from plug (6). Remove O-ring (15) from plug (6).

12. Clamp center plate (25) in a vise. Remove socket bolts (26) in the shallow pits with a hexagon (Allen) wrench. : Socket bolt (3): 8.8 N-m (0.90 kgf-m) (6.5 lb-ft)

16

27

28 25

6 95ZVE44014

11. Remove seal (16) from plug (6) using a small screwdriver.

95ZVE44023

Note Take care not to damage the internal surface of plug (6).

Note Item numbers (17) through (24) are intentionally omitted in the following steps.

13. Remove cover (2) and detent casing (27) from center plate (25).

Be advised that fixing discs (29) on outer springs (28) may be stuck to detent casing (27) with grease, and could be dropped.

44-38 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

29 27

28

25

30 95ZVE44022

95ZVE44020

14. Remove outer springs (28) and fixing discs (29) on center plate (25).

16. Remove solenoid coil (30) from detent casing (27).

Note While removing solenoid coil (30), do not pull the electrical harness.

2

32

31 27 95ZVE44021

15. Remove detent casing (27) from cover (2).

95ZVE44028

Note The push rod may be fall off the detent bush without the steel ball.

17. Remove lever (31) by loosening socket bolt (32) with a hexagon (Allen) wrench. : Socket bolt (32): 6.9 N-m (0.7 kgf-m) (5.1 lb-ft) Note Loctite® 241 is applied requiring bigger torque to loosen the bolt.

44-39 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

35 (with pre-detent) 31 37

35 (without pre-detent)

33

2 2

95ZVE44027

F95ZVE44025

18. Remove cam shaft (33).

19. Take out lever (31) from cover (2).

31 Tool

2

95ZVE44024

34

21. Remove assembled detent bush (35), push rod (37), etc. from cover (2) using the tool.

95ZVE44026

20. Clamp lever (31) in a vise, and remove nuts (34). : Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)

[Tool]

(Material: SS400) Center hole (ø2 or less)

30 35

2

45 115V2E44021

44-40 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

2

37

40

38

39

36 95ZVE44032

95ZVE44030

24. [For the port with pre-detent] Hold detent ring (38) and press to compress spring (39), and then take out balls (40).

22. Remove O-rings (36) from cover (2).

Note Take care not to damage O-rings (36).

Note Be sure to keep balls (40) (4 pcs.).

25. Pull out push rod (37).

35 39 35

37 95ZVE44031

38

23. [For the port without pre-detent] Remove push rod (37) from detent bush (35). Put a match-mark on them beforehand.

95ZVE44029

26. Remove detent ring (38) and spring (39) from detent bush (35).

44-41 80ZV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve (S/N 9206~)

41

Push rod (37)

Detent bush (35)

Scraper (41) Scraper (41)

A

35

Detail of A 95ZVE44033

95ZVE44035

27. Remove scraper (41) from detent bush (35).

- Insert scraper (41) in correct direction.

Note Be sure not to damage scraper (41) or the internal surface of detent bush (35).

- Do not push push rod (37) too much with the set screw while adjusting the position of the lever (31). It may cause bumping at Neutral position, resulting in unexpected movement at starting the engine.

Pilot valve assembling Push rod (7)

To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

Pilot valve assembly cautions Plug (6)

- Clean and check all the parts. If any part is defective, replace or repair it.

Seal (16) 95ZVE44034

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

- Install seal (16) in plug (6) in correct direction.

- Apply the specified torque to tighten each main part.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Measure the resistance of each coil magnet assembly. The resistance should be 62 Ω at normal room temperature [(20ºC) (70ºF)]. If measured in extremely low temperatures the resistance will be less, and at operating temperature the resistance will be higher.

- Be aware that the assembled parts, such as the push rod, spring, etc. are different depending on the ports. Use the correct parts.

44-42 80ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple Control Valve Multiple control valve removing and installing

3

Multiple control valve removing

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

- Lower the attachment onto the ground.

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

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

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

2

80V2E44008

2. Put matchmarks on hoses (2)(3) and disconnect them.

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

1 Multiple control valve

4

80V2E44009

Multiple control valve 80V2E44007

1. Put matchmarks on hoses (1) of the pilot line, and then, disconnect them.

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

3. Remove return hose (4) from the multiple control valve.

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

44-43 80ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve installation cautions

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

To prevent such an accident, be sure to stop the engine before you start working. In addition, block tires with chocks to prevent wheels from moving.

While working, carefully keep contact with the person in the cab by giving signals to each other.

5

Multiple control valve 80V2E44010

- Replace all the O-rings with new ones.

4. Sling the multiple control valve, and remove bracket (5) from the rear chassis. : Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) : Multiple control valve: 72 kg (159 lbs)

Multiple control valve installing To reinstall the multiple control valve, follow the above removal procedure in reverse order.

- Wash the multiple control valve mounting area.

- Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the Section 03.

- Operate the bucket and the boom, and check that they operate correctly.

- Check each section for oil leakage.

- Add hydraulic oil to the tank until the oil level rises to the specified point.

44-44 80ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Multiple control valve cross section and tightening torque T7 T8

T3 T3

Main relief valve

T2 T6 T1

T3

Bucket spool

T3 Make-up valve

T6 Overload relief valve with make-up function

T2

T4 L1

Boom spool

T4

: T1: 180 N-m (18.4 kgf-m) (133 lb-ft) T2: 39 N-m (4.0 kgf-m) (29 lb-ft) T3: 78 N-m (8.0 kgf-m) (58 lb-ft) T4: 18 N-m (1.8 kgf-m) (13 lb-ft) T5: 34 N-m (3.5 kgf-m) (25 lb-ft) T6: 410 N-m (41.8 kgf-m) (302 lb-ft) T7: 260 N-m (26.5 kgf-m) (192 lb-ft) T8: 65 N-m (6.6 kgf-m) (48 lb-ft)

L1 T5 85ZV44022

L1: Screw lock agent (Loctite® 262) application : 55 kg (125 lbs)

44-45 80ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling

3

1

70ZV44011J

70ZV44009J

3. Remove make-up valve (3). : Valve (3): 78 N-m (8.0 kgf-m) (58 lb-ft) : Hexagon width across flat: 32 mm (1.26 in)

1. Remove main relief valve (1). : Valve (1): 78 N-m (8.0 kgf-m) (58 lb-ft) : Hexagon width across flat: 30 mm (1.18 in)

4

6

5

2

7

70ZV44010J

2. Remove right and left overload relief valve (2). : Valve (2): 78 N-m (8.0 kgf-m) (58 lb-ft) : Hexagon width across flat: 32 mm (1.26 in)

70ZV44012J

4. Remove socket head bolt (4)(5) from the bucket and boom side of the cap. Then remove cap (6)(7). : Bolt (4)(5): 34 N-m (3.5 kgf-m) (25 lb-ft) : Hexagon width across flat: 6 mm (0.24 in)

44-46 80ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

15

8

14

9

70ZV44013J

85ZV44023

5. Slowly pull out spool (8) from the bucket side, and spool (9) from the boom side as an assembly.

7. Remove four socket head bolts (14), and remove cover (15). Also remove the O-ring from the mating face.

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

: Bolt (14): 180 N-m (18.4 kgf-m) (133 lb-ft) : Hexagon width across flat: 12 mm (0.47 in)

16

11

19 13

17 18

12 10

70ZV44014J

70ZV44016J

6. Remove socket head bolt (10)(11) to remove cap (12)(13). Also remove the O-ring of the flange from the cap.

8. Remove plug (16) from the bucket side to remove spring (17) and poppet (18). Also remove plug (19) from the boom side.

Remove the O-ring from the plug.

: Bolt (10)(11): 34 N-m (3.5 kgf-m) (25 lb-ft) : Hexagon width across flat: 6 mm (0.24 in)

: Plug (16)(19): 260 N-m (26.5 kgf-m) (192 lb-ft) : Hexagon width across flat: 12 mm (0.47 in)

44-47 80ZV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

22 20

23

24 25 23

Spool 70ZV44017J

85ZV44024

9. Remove the hexagon bolts and remove cap kit (20).

11. Set the spool assembly in a rise and then loosen bolt (22) to remove.

: Bolt: 65 N-m (6.6 kgf-m) (48 lb-ft) : Hexagon width across flat: 8 mm (0.31 in)

: Bolt (22): 18 N-m (1.8 kgf-m) (13 lb-ft) : Screw lock agent (Loctite® 262) application : Hexagon width across flat: 10 mm (0.39 in) 12. 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.

21

Multiple control valve assembling 70ZV44018J

To reassemble the multiple control valve, follow the above removal procedure in reverse order.

10. Remove plug assembly (21) and remove the Oring.

Multiple control valve assembly cautions : Plug (21): 410 N-m (41.8 kgf-m) (302 lb-ft) : Hexagon width across flat: 17 mm (0.67 in)

- 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.

44-48 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® Orbitrol® removing and installing Orbitrol® removing

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

- Block tires with chocks to prevent wheels from moving.

- Apply the articulation stopper.

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

- Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right.

- Relieve the internal pressure from the hydraulic tank.

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

1

85V2E44008

1. Remove cover (1).

2 85V2E44009

2. Remove floor mat (2).

3

4 85V2E44010

3. Put matchmarks on hoses (3), and then disconnect them from Orbitrol® (4).

44-49 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® installation cautions At the completion of reinstallation, check operation of the Orbitrol® by following the procedure below:

WARNING 5

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.

85V2E44011

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

Orbitrol® installing To reinstall the Orbitrol®, follow the above removal procedure in reverse order.

1. Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise.

2. Check around the Orbitrol® for oil leakage.

44-50 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Orbitrol® cross section and tightening torque

T1

90ZV44053

: T1: 23 N-m (2.3 kgf-m) (17 lb-ft)

: 7 kg (15 lbs)

44-51 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® disassembling 4

(Disassembling rotor) 5

7 6 Copper plate 97ZV44048

3. Remove rotor assembly (4), spacer (5) and O-ring (6).

95ZV44025

®

1. Set the Orbitrol in a vise so that the rotor side comes to the top position.

Use a copper plates on a vise and do not tighten the vise too strong.

Note Keep rotor (7) in rotor assembly (4).

8

1

9 10 2 97ZV44049

3

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

97ZV44047

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

44-52 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (Disassembling valve)

14

13 15

11

97ZV44052

97ZV44050

5. Remove the housing from the vise and put it on a clean cloth not to damage the finished surface.

Remove retainer ring (11) by a screw driver.

7. Remove Y-packing seal (14) and dust seal (15) from seal retainer (13).

Note Take care not to damage seal retainer (13).

16

12

17 16

18 19 97ZV44051

97ZV44053

6. Rotate the spool and sleeve so that the pin can be in a horizontal position.

Remove seal retainer (12) by pressing the spool and sleeve from behind with your fingers.

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

44-53 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

24

22

22 23

19

23

20 97ZV44054

97ZV44056

9. Pull out spool and sleeve assembly (19) slowly from housing (20) while turning the assembly clockwise and counterclockwise.

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

Note Take care so that the spool and sleeve do not damage the housing.

26 27 19

21 25 97ZV44057

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

97ZV44055

13. Remove adapter (26) to take out ball (27).

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

Note Do not disassemble, unless absolutely necessary.

44-54 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Orbitrol® assembling

24

26 27

19 20 97ZV44060

25 97ZV44058

1. Assemble ball (27) and adapter (26) in housing (20).

3. Install springs (24) through the spring grooves in the sleeve and spool (19) using a spring insertion jig.

Note Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

Spring groove

22 Spring groove

22 23 23 Matchmark

95ZV44026

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

Note Align the matchmarks on the spool and sleeve.

21

97ZV44061

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

44-55 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

13

14

15

19 20

97ZV44062

97ZV44052

5. Insert spool and sleeve assembly (19) from the back of housing (20).

7. Insert dust seal (15) and Y-packing seal (14) in seal retainer (13).

Note - Take care not to tilt the assembly and cause damage during insertion.

- Insert the assembly until the back end of the assembly is flush with the back end of the housing.

- Confirm that the assembly can be turned easily in the housing.

17

11

13

23

16

97ZV44064

25

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

Screw driver 97ZV44063

Dust seal Retainer ring

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

Seal retainer Y-packing seal O-ring

80V2E44019

Note Be sure the position and direction of the seals.

44-56 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

Grooves in rotor bore

A

9 B Drive shaft

C

10

D

Pin 97ZV44066

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

Port face

8 Pin parallel with port face

21 95ZV44028

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

4

6

97ZV44068

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

Port face

95ZV44029

12. Holding the rotor assembly with the O-ring side facing the plate, install the assembly so that the grooves in the star-shaped bore mesh with the drive shaft.

Note - Align the bolt holes in the rotor assembly with those in the housing without disengaging the drive shaft from the rotor assembly's star -shaped bore.

- Confirm that lines A, B, C and D are all parallel.

44-57 80ZV-2 Disassembly & Reassembly Hydraulic Group Orbitrol®

5

1 2 3

97ZV44070

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

Tightening order

95ZV44030

Note Temporarily tighten bolt (1), then tighten them fully and securely in the order shown above.

44-58 80ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering Valve Steering valve removing and installing

7

6 8

9 10

Steering valve removing

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

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

- Relieve the internal pressure from the hydraulic tank.

- Oil spilled on the parking brake shoe section may cause malfunction. To prevent such a problem, cover the shoe section with plastic before valve removal.

5

Steering valve

80V2E44012

2. Remove hoses (5)~(9) and block (10).

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

Steering valve

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

11

Steering valve

3 4

2

80ZV44020

1

3. Remove bolt (11), and then, remove the steering valve.

80V2E44011

1. Disconnect hoses (1)~(4) from the steering valve.

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

: Bolt (11): 49 N-m (5.0 kgf-m) (36 lb-ft) : Steering valve: 25 kg (55 lbs) Note Cover the disconnected hoses and the valve with plastic, plugs or caps to protect them from dust and dirt.

44-59 80ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve installing

Steering valve installation cautions

To reinstall the steering valve, follow the above removal procedure in reverse order.

At the completion of reinstallation, check operation of the steering valve by following the procedure below:

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

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

1. Start the engine and confirm that the stop valve comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise.

2. Check around the valve for oil leakage.

3. Measure various values for performance check.

Measure the time required for full steering.

Measure the relief valve setting pressure.

(Refer to the Section 03 - Measurement for Performance Check).

44-60 80ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Steering valve cross section and tightening torque

T3 T2

T1

T5

Flow control spool

T2

T6

Steering spool

T7

T4

T7

T3 90ZV44040

: T1: 255 N-m (26.0 kgf-m) (188 lb-ft) T2: 79 N-m (8.0 kgf-m) (58 lb-ft) T3: 62 N-m (6.3 kgf-m) (46 lb-ft)

T4: 60 N-m (6.1 kgf-m) (44 lb-ft) T5: 353 N-m (36 kgf-m) (260 lb-ft) T6: 130 N-m (13.3 kgf-m) (96 lb-ft) T7: 108 N-m (11 kgf-m) (80 lb-ft)

44-61 80ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve disassembling

1

6 5 1

4 90ZV44009J

90ZV44007J

1. Remove right and left overload relief valves (1).

Width across flat: 32 mm (1.26 in) : 79 N-m (8.0 kgf-m) (59 lb-ft)

3. Remove spring (4) and spring seat (5) to pull out steering spool (6).

Note Carefully pull out the steering spool so that it is not damaged. Put matchmark to make sure the direction of the steering spool.

7 2

3

90ZV44010J

90ZV44008J

2. Remove bolt (2). Remove end cover (3).

Hexagon hole width across flat: 8 mm (0.315 in) : 62 N-m (6.3 kgf-m) (46 lb-ft)

4. Slightly loosen plug (7).

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

44-62 80ZV-2 Disassembly & Reassembly Hydraulic Group Steering Valve

Steering valve assembling 7

To reassemble the steering valve, follow the above disassembly procedure in reverse order.

11 9

10

8 90ZV44011J

5. Remove relief valve (8) and plug (9). Pull out spring (10) and flow control spool (11) from the casing.

Note - Carefully remove plug (9). It may spring out by the spring force.

- Carefully pull out flow control spool (11) so that the casing and flow control spool are not scratched.

Width across flat: Relief valve (8): 19 mm (0.748 in) Plug (9): 41 mm (1.614 in) : (8)(9): 108 N-m (11 kgf-m) (80 lb-ft) 6. Remove plug (7) loosened at step 4.

44-63 80ZV-2 Disassembly & Reassembly Hydraulic Group Stop Valve

Stop Valve Stop valve removing and installing

6 3

1

Stop valve removing

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

- Relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

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

7

4

2

5

80ZV44021

(The illustration shows the machine right hand side.)

1. Remove hoses (1)~(5) from the stop valve.

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

2. Remove bolt (6) and then remove stop valve (7).

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

44-64 80ZV-2 Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve installation cautions The stop valve works when the spool is pushed in 3 mm (0.118 in).

Adjust the stopper bolt by using the following procedure.

Stop valve (rear chassis) (LH, RH)

Stopper (bolt)

Reference dimension 33.8~38.7 mm (1.33~1.52 in) Stopper (bolt) length 90ZVE43005

38º 36º~

Front chassis

Rear chassis Reference dimension 13.7~27.5 mm (0.54~1.08 in) 90ZVE43006

- Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension "13.7~27.5 mm (0.54~1.08 in)" shown in the table below.

Reference dimension Articulation angle (º)

- When adjustment is completed, tighten the lock nut of the stopper (bolt). : 90 N-m (9.2 kgf-m) (67 lb-ft)

Front chassis

Clearance between machine body and stopper

- After adjustment, turn the steering wheel slowly at a rate of 5 seconds or more per turn, and confirm the clearance between the machine body and the stopper.

38

37

36

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

13.7 (0.54)

20.6 (0.81)

27.5 (1.08)

Stopper (bolt) length (mm) (in)

33.8 (1.33)

36.2 (1.42)

38.7 (1.52)

∗The target value should be the articulation angle "37º".

44-65 80ZV-2 Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Stop valve cross section and tightening torque

(S/N ~9250)

T1

T2

T3 K92V244001

: T1: 206 N-m (21 kgf-m) (152 lb-ft) T2: 5 N-m (0.5 kgf-m) (3.6 lb-ft) T3: 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)

44-66 80ZV-2 Disassembly & Reassembly Hydraulic Group Stop Valve

Stop valve disassembling 12 10

13

11

2

1

A B

9 85V2E44017

97ZV44079

1. Remove boot (1) and plug (2).

4. Remove screw (9) to remove flange (10), dust seal (11), spacer (12) and U-packing (13). : Screw (9): 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)

WARNING The inner spring may spring out causing injury.

Do not point the spring toward your face. : Plug (2): 206 N-m (21 kgf-m) (152 lb-ft)

7

6

5

8 3

4

85V2E44016

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

3. Clamp spool assembly (4) at the bottom side in a vise and remove plug (5) using a screw driver.

Remove washer (6), spring (7) and check valve (8) from the spool. : Plug (5): 5 N-m (0.5 kgf-m) (3.6 lb-ft)

Stop valve assembling To reassemble the stop valve, follow the above procedure in reverse order.

44-67 80ZV-2 Disassembly & Reassembly Hydraulic Group Fan Motor

Fan Motor Fan motor removing and installing

(S/N 9001~9100)

Partition plates

Fan motor removing

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

- Relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

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

Partition plates

F80V2E44014

(S/N 9101~)

Partition plates

2

Partition plates K80V2E44003

3. Remove the partition plates.

1 Sub tank 80V2E44013

1. Remove hose (1) of the sub tank.

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

2. Remove roof (2) from the engine room.

44-68 80ZV-2 Disassembly & Reassembly Hydraulic Group Fan Motor

(S/N 9001~9100)

5

6

4 3 3

7

8 80V2E44016

80V2E44015

(S/N 9101~)

6. Remove hoses (6)~(8) from the fan motor. Use a drain pan to catch all escaping oil.

5

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

4 3

9

3 K80V2E44004

4. Remove fan guards (3) from the radiator assembly.

5. Remove hoses (4) of the air cooler and hoses (5) from the radiator.

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

80V2E44017

7. Attach a sling to the fan motor assembly.

Remove retainer bolts (9). : Bolt (9): 94 N-m (9.6 kgf-m) (69 lb-ft) : With lubrication oil (engine oil or gear oil)

44-69 80ZV-2 Disassembly & Reassembly Hydraulic Group Fan Motor

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

10

Flange installation procedure

Plate

11 80V2E44018

8. Attach sling to the fan motor.

Remove bolts (10)(11), and then, remove the fan motor. : Bolt (10): 73.5 N-m (7.5 kgf-m) (54 lb-ft) : Screw lock agent (Loctite® 262) application

Bolt

Plane washer

Shaft Flange

K80V2E44002

: Bolt (11): 94 N-m (9.6 kgf-m) (69 lb-ft) : With lubrication oil (engine oil or gear oil)

1. Verify that position of the motor is correct, with the solenoid positioned to the top.

: Fan motor: 15 kg (33 lbs)

2. Thoroughly clean and remove all oil from tapered shaft of motor.

3. Thoroughly clean and remove all oil from tapered bore of flange.

4. Install flange and tighten the bolt with the specified torque. : Bolt: 73.5 N-m (7.5 kgf-m) (54 lb-ft)

44-70 80ZV-2 Disassembly & Reassembly Hydraulic Group Fan Motor

Fan motor installation cautions - Do not reuse the flange, and always replace with a new one when the fan motor is replaced.

Clearance

85V2E44024

- Be sure that the right and left clearance between the fan and the radiator guard must be equal.

45-1 80ZV-2 Service Standard Hydraulic Group

80ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder ................................................... 45-2 Pilot Valve................................................................ 45-4 Steering Valve ......................................................... 45-6

45-2 80ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder

3

2

1 80ZV45002

Steering cylinder

2

1

3

80V2E45001

Unit: mm (in) Judgment standard No.

Item

Boom cylinder

1

Bucket cylinder

Steering cylinder

Standard dimension of rod dia.

Standard value Rod

Bushing

Standard clearance

ø75 (ø2.9527)

-0.030 (-0.0011) ~ -0.076 (-0.0030)

+0.190 (+0.0075) ~ +0.060 (+0.0023)

ø90 (ø3.5433)

-0.036 (-0.0014) ~ -0.090 (-0.0035)

ø45 (ø1.7716)

-0.025 (-0.0010) ~ -0.046 (-0.0018)

Limit

Solution

Bushing

Clearance

0.090 (0.0035) ~ 0.266 (0.0104)

+0.290 (+0.0114)

0.366 (0.0144)

Replacement

+0.195 (+0.0076) ~ +0.060 (+0.0023)

0.090 (0.0035) ~ 0.285 (0.0112)

+0.295 (+0.0116)

0.385 (0.0151)

Replacement

+0.105 (+0.0041) ~ 0 (0)

0.030 (0.0012) ~ 0.151 (0.0059)

+0.205 (+0.0080)

0.251 (0.0099)

Replacement

45-3 80ZV-2 Service Standard Hydraulic Group Hydraulic Cylinder

No.

Item Piston nut tightening torque

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

Piston nut width across flat

mm (in)

2

3

Rod cover bolt tightening torque

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

Boom cylinder

Bucket cylinder

Steering cylinder

M58 x 2 3,923 (400) (2,894)

M68 x 2 4,903 (500) (3,618)

M30 x 2 930 (94.8) (686)

90 (3.54)

100 (3.94)

46 (1.81)

M22 471 (48) (347)

M22 686 (70) (506)

(Rod cover) 300 (30.6) (221)

45-4 80ZV-2 Service Standard Hydraulic Group Pilot Valve

Pilot Valve (S/N 9001~9205)

(S/N 9206~)

1

1

3

3

2

2

92V2E45001

45-5 80ZV-2 Service Standard Hydraulic Group Pilot Valve

Judgment standard No.

Item

Solution Standard valve

Allowable limit

87.7 mm (3.452 in)

86.7 mm (3.413 in)

Replacement

36 mm (1.417 in)

35 mm (1.378 in)

Replacement

ø8 mm (0.315 in)

ø7.5 mm (0.295 in)

Replacement with detent solenoid sub

Wear 1 mm (0.0394 in) 1

Push rod 85V2E45003

Wear 1 mm (0.0394 in) 2

Push rod 85V2E45003

3

Bush

85V2E45002

45-6 80ZV-2 Service Standard Hydraulic Group Steering Valve

Steering Valve

1

2

80ZV45001

Tightening torque Unit: N-m (kgf-m) (lb-ft) No.

Item

1

Steering valve retainer bolt

2

Steering valve bracket retainer bolt

Standard value

Solution

49 (5) (36) Tightening 230 (23.5) (170)

54-1 80ZV-2 Disassembly & Reassembly Brake Group

80ZV-2 Disassembly & Reassembly Brake Group Unloader Valve ........................................................ 54-2 Manifold Valve Assembly ........................................ 54-8 Accumulator ............................................................ 54-11 Brake Valve ............................................................. 54-17 Service Brake .......................................................... 54-25 Parking Brake Actuator ........................................... 54-26 Parking Brake.......................................................... 54-31

54-2 80ZV-2 Disassembly & Reassembly Brake Group Unloader Valve

Unloader Valve Unloader valve removing and installing Unloader valve removing

WARNING

1

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

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

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

3

Unloader valve

2 80V2E54001

1. Remove hoses (1)(2)(3) from the unloader valve.

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

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

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

- Prepare a container to catch drained oil.

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

Unloader valve

5

4

80V2E54002

2. Remove hoses (4)(5) from the unloader valve.

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

54-3 80ZV-2 Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve installing

6 Unloader valve

To reinstall the unloader valve, follow the above removal procedure in reverse order.

Unloader valve installation cautions - Replace all O-rings and seals during reinstallation.

Brackets

80V2E54003

- After reinstallation, completely bleed the brake line of air, and check performance of the unloader valve.

3. Remove bolts (6) and then remove the unloader valve.

- To bleed the brake line of air, refer to "Service brake air bleeding procedure" page 24-22.

: Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) : Unloader valve: 4 kg (8.8 lbs)

- To check performance of the unloader valve, refer to 80ZV-2 Shop Manual, Function and Structure, Section 53.

54-4 80ZV-2 Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Unloader valve cross section and tightening torque (S/N 9001~9039)

T1

T8 T7 T6

T4

T3

T2 L1

T5

97ZV54002

54-5 80ZV-2 Disassembly & Reassembly Brake Group Unloader Valve : T1: 137 N-m (14 kgf-m) (101 lb-ft) T2: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T3: 14.7 N-m (1.5 kgf-m) (11 lb-ft) T4: 58.8 N-m (6 kgf-m) (43 lb-ft) T5: 98.1 N-m (10 kgf-m) (72 lb-ft) T6: 118 N-m (12 kgf-m) (87 lb-ft) T7: 16.7 N-m (1.7 kgf-m) (12 lb-ft) T8: 78.5 N-m (8 kgf-m) (58 lb-ft)

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

L1: Screw lock agent (Loctite® 262) application

54-6 80ZV-2 Disassembly & Reassembly Brake Group Unloader Valve (S/N 9040~)

T1

T7

T6

T4

T3

T2 L1

T5

K95V2E54014

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

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

L1: Screw lock agent (Loctite® 262) application

54-7 80ZV-2 Disassembly & Reassembly Brake Group Unloader Valve

Unloader valve disassembling

1

3 2

(S/N (S/N 9040~) 9049~) Pressure governor assembly

(FM) K95V2E54015

Remove plug (1), then pull out spool (2) and spring (3).

Note Carefully remove plug (1). It may spring out by the spring force. : 137 N-m (14 kgf-m) (101 lb-ft) Note Do not disassemble the pressure governor assembly and the pressure switch assembly unless it is necessary. Because, readjustment of accumulator pressure and setting of shims are required.

Unloader valve assembling To reassemble the unloader valve, follow the above disassembly procedure in reverse order.

54-8 80ZV-2 Disassembly & Reassembly Brake Group Manifold Valve Assembly

Manifold Valve Assembly Valve assembly removing and installing

2 1 3

Valve assembly removing Valve 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.

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

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

4

5

6

Unloader valve 80V2E54004

2. Remove hoses (1)~(6) from the valve assembly.

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

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

7

8

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

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

- Prepare a container to catch drained oil.

Valve assembly

80V2E54005

3. Remove hoses (7)(8) from the valve assembly.

1. Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line.

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

54-9 80ZV-2 Disassembly & Reassembly Brake Group Manifold Valve Assembly

Valve assembly disassembling and assembling

9 Valve assembly

IMPORTANT

Bracket

Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

80V2E54006

4. Remove bolt (9) and then remove the valve assembly. : Bolt (9): 53 N-m (5.4 kgf-m) (39 lb-ft) : Valve assembly: 10 kg (22 lbs)

Valve assembly installing To reinstall the valve assembly, follow the above removal procedure in reverse order.

Valve assembly installation cautions - Replace all O-rings and seals during reinstallation.

- After reinstallation, completely bleed the brake line of air, and check performance of the valve assembly.

To bleed the brake line from air, refer to "Service brake air bleeding procedure" page 24-22.

- To check performance of the valve assembly, refer to 80ZV-2 Shop Manual, Function & Structure, Section 53.

54-10 80ZV-2 Disassembly & Reassembly Brake Group Manifold Valve Assembly

Valve assembly cross section and tightening torque

T1

T1

T5

T1

(T) T4

(P)

(TA) (Parking)

(PI) (ACCR)

(ACCF)

ACF (PA) (Z1) (Z2)

(Z)

T2

High pressure test ports

(PPI)

T3

85V2E54007

: T1: 50 N-m (5.1 kgf-m) (37 lb-ft) T2: 23.5 N-m (2.4 kgf-m) (17 lb-ft) T3: 38 N-m (3.9 kgf-m) (28 lb-ft) T4: 11 N-m (1.1 kgf-m) (8 lb-ft) T5: 8 N-m (0.8 kgf-m) (5.8 lb-ft)

CAUTION High pressure test ports contain accumulator pressure [11.8 MPa (1,706 psi)] that can escape from these 2 plugs.

Completely depress brake pedal 15~20 times to relieve all pressure before removing plugs.

54-11 80ZV-2 Disassembly & Reassembly Brake Group Accumulator

Accumulator Accumulator removing and installing

1. Repeatedly depress the brake pedal till you feel the pedal becomes light. That will release oil pressure in brake line.

Accumulator removing 2

4

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

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

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

1

Accumulator

3 Rear chassis 80V2E54007

2. Remove hoses (1)~(4) from the accumulator.

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

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

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

- Prepare a container to catch drained oil.

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

54-12 80ZV-2 Disassembly & Reassembly Brake Group Accumulator

Accumulator installing To reinstall the accumulator, follow the above removal procedure in reverse order.

Replace all O-rings and seals during reinstallation.

Accumulator installation cautions Accumulator

5

- After reinstallation, completely bleed the brake line of air, and check performance of the accumulator. To bleed the brake line of air, refer to "Service brake air bleeding procedure" page 24-22.

- To check performance of the accumulator, refer to 80ZV-2 Shop Manual, Function and Structure, Section 53.

Bracket

6 Rear chassis

80V2E54008

3. Remove bolts (5), nut (6) and then remove the accumulator. : Bolt (5): 94 N-m (9.6 kgf-m) (69 lb-ft) : Accumulator: 17 kg (42 lbs)/pc

54-13 80ZV-2 Disassembly & Reassembly Brake Group Accumulator

Accumulator disassembling and assembling

7 2

4

1

3 13

IMPORTANT

10

Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

12 11

5,6

Accumulator disassembling

8,9 97ZV54007

WARNING Disassembly without breathing the inner gas could cause serious injury or death by explosion. To prevent such an accident, observe the following item: - Carefully handle the accumulator that has the high pressure.

- Before disassembly, completely reduce the gas pressure lower to the atmospheric pressure.

- Do not drill and weld the body.

- Do not use over the specified pressure.

- Use Nitrogen gas for charge.

Gas cap (3)

95ZV54002

IMPORTANT - Take care not to scratch the cylinder to prevent gas leak.

- Carefully remove each part so that it is not scratched or dented.

1. Loosen bolt (13) to remove gas valve guard (12).

2. Remove the cap of gas valve (10) and install the charging valve to gas valve (10), then bleed the gas completely from the accumulator.

3. Insert three pins into gas cap (3). Remove the gas cap by using a long bar.

Pin hole: ø11.4 (0.4 in)

54-14 80ZV-2 Disassembly & Reassembly Brake Group Accumulator

Accumulator assembling 7 2

4

1

3 13 10

12 11

5,6

8,9 97ZV54007

Hydraulic cap (2)

95ZV54003

4. Insert three bolts into hydraulic cap (2) and remove it by using a long bar.

Screw size: 1/2-20UNF-2B 5. Push out piston (4) toward the hydraulic end by using a bar.

To reassemble the accumulator, follow the above disassembly procedure in reverse order.

After reassembly, carry out the gas charging.

54-15 80ZV-2 Disassembly & Reassembly Brake Group Accumulator

Nitrogen gas charging

Nitrogen gas charging procedure

WARNING

Nitrogen gas charging tools

Improper gas pressure can cause serious injury or death. To prevent such an accident, observe the following item: - Before measuring the gas pressure or charging the gas, stop the engine and release the oil pressure in the line by depressing the brake pedal until there is no brake pressure.

1 2

1-1

1-3

1-2 3

4 2

1-1

Accumulator Charging valve installation

1-2 95ZV54004

1. Charging valve assembly 1-1 Handle (for adjusting screw) 1-2 Handle (for bleeder plug) 1-3 Valve body 2. Pressure gauge (4,903 kPa (50 kgf/cm2) (1,000 psi)) 3. Hose assembly 4. Nitrogen (N2) gas cylinder

1-3 115ZVE54016

1. Turn handle (1-1) counterclockwise until it stops turning.

2. Turn handle (1-2) counterclockwise to open.

3. Remove the gas valve guard cap and then install charging valve assembly (1) to the gas valve.

4. Install pressure gauge (2) to the charging valve assembly and connect hose (3) to nitrogen gas cylinder (4).

5. Slightly open the valve of the nitrogen gas cylinder.

Turn handle (1-2) clockwise to close after confirming the gas comes out from handle (1-2) part.

6. Slowly turn handle (1-1) clockwise to open the piston of the gas valve.

7. Open the valve of the nitrogen gas cylinder more and put a charge into the accumulator.

Note Close the valve of the nitrogen gas cylinder when checking the gas pressure on the gauge to read the gauge needle at the stable condition.

54-16 80ZV-2 Disassembly & Reassembly Brake Group Accumulator [Charging pressure: 2.9 MPa (30 kgf/cm2) (427 psi) at 20ºC (68ºF)] Note Gas pressure is variable with temperature.

Use the following formula for the correct nitrogen charging pressure.

If the pressure on the gauge is too high, slowly turn the handle (1-2) counterclockwise.

PX = 30 (kgf/cm2) x {273 + t (ºC)} / {273 + 20 (ºC)} PX: Charging gas pressure t: Ambient temperature 30: Standard gas pressure 8. Turn handle (1-1) counterclockwise to return the piston of the gas valve. Then turn handle (1-2) counterclockwise to bleed the gas from the charging assembly and the hose.

9. After removing pressure gauge (2), remove the charging assembly from the accumulator.

Note - Apply soapy water to the gas valve on the accumulator to check for gas leakage.

- Recheck the gas pressure once within a week after the charging.

- Check the gas pressure at every 2,000 operation hours.

- A little gas is lost each time of the checking, so add the gas to compensate for the loss.

54-17 80ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake Valve Brake valve removing and installing Brake valve removing

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

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

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

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

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

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

Brake valve

80V2E54009

1. Remove all hoses and pipes shown on the above illustration.

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

Brake valve

(S/N 9251~)

(S/N 9101~)

K80V2E54001

2. Remove all adapters and fittings shown on the above illustration.

Cover

Cover K90V2E54001

- Remove the cover.

54-18 80ZV-2 Disassembly & Reassembly Brake Group Brake Valve

1

1

Brake valve installing To reinstall the brake valve, follow the above removal procedure in reverse order.

Brake valve installation cautions

80V2E54011

3. Remove bolt (1) and then remove the brake valve. : Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

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 80ZV-2 Shop Manual, Function and Structure, Section 53.

54-19 80ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Brake valve cross section and tightening torque (main valve)

T1

T2

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)

80V2E54012

54-20 80ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake valve disassembling 12 13 15

16

15

14

11

9

Pedal cover

10

8 7 85V2E54017

85V2E54015

3. Remove nut (7), washer (8) and bolt (9) to remove plate (10).

1. Remove the pedal covers.

: Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)

3

4. Pull out pin (11), pedal pin (12), L-shape pin (13) and washer (14), and then, remove collar (15) and roller (16) from the right pedal.

6

2

1 19

18 17

20 Shaft assembly

Shaft assembly

5

4 85V2E54016

2. Pull out pin (1). Remove washer (2), right pedal (3), mounting plate (4), pedal collar (5) and spring (6) from the shaft assembly.

21 85V2E54018

5. Remove nut (17), washer (18) and bolt (19). : Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft) 6. Pull out the shaft assembly and remove left pedal (20) and pedal collar (21).

54-21 80ZV-2 Disassembly & Reassembly Brake Group Brake Valve

23 24

26

27

26

25

38

22 34

37

36

35

85V2E54019

80V2E54013

7. Pull out pin (22), pedal pin (23), L-shape pin (24) and washer (25), and then, remove collar (26) and roller (27).

10. Loosen bolt (34) and remove spring washer (35) and mounting plate (36). : Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)

32

31

30

29

28

11. Remove dust cover (37) and seat (38).

33

Joint 85V2E54020

8. Remove ring (28) and pull out boot (29).

9. Remove ring (30) for the joint, and remove pin (31) by using a pressing machine or equivalent to separate shaft assembly (32)(33).

54-22 80ZV-2 Disassembly & Reassembly Brake Group Brake Valve

45

44 50

46 49 47

48

Cover

Body 1

Body 2 70V2E54011

41

13. Place the Body 1 and Body 2 on a workbench upside down. Remove C-ring (44), and then, remove plug (45) and spring (46).

42

14. Slowly pull out spool (47) from the Body 1 and remove plunger (49). Also pull out spool (48) from the Body 2 and remove plunger (50).

40

Cover

Body 2

43

51 Body 1 80V2E54015

39

80V2E54014

12. Loosen bolt (39), and separate the brake valve into the Body 1, Body 2 and the Cover. Remove springs (40)(41)(43) and spring seat (42). : Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)

15. Place the cover on a workbench upside down.

Slowly pull out spool input (51) together with the spring and the spring case.

54-23 80ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake valve assembling 52

To reassemble the brake valve, follow the above disassembly procedure in reverse order.

53

54

51

80V2E54016

16. Loosen bolt (52) mounted in spool input (51), and remove retainer (53) and spring seat (54). : Bolt: 8.83 N-m (0.9 kgf-m) (6.5 lb-ft) Note When fixing spool input (51) in a vise to loosen bolt (52), make sure to protect the spool input with a cloth, etc. to avoid the damage on the surface of the spool.

56

55

Installation tool 40 mm (1.57 in)

57 New seal

22 mm (0.87 in)

Cover

Reassembly process 80V2E54017

17. Place the cover on a workbench. Remove C-ring (55), plate (56) and oil seal (57).

Note Do not reuse the oil seal; replace it with a new one when reassembling.

54-24 80ZV-2 Disassembly & Reassembly Brake Group Brake Valve

Brake valve assembly cautions

Brake pedal adjustment

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

- Apply the specified torque to tighten each main parts.

0.5 mm (0.02 in) or less

- Clean and check all the parts. If a part is defective, replace or repair the part.

27

Adjusting screw

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

Nut

38

3.0~3.5 mm

Adjusting screw

16

(0.118~0.138 in)

Left pedal

58

Right pedal

Nut 80V2E54018

- Adjust the left pedal using the adjusting screws on the right and left pedals so that the opening between seat (38) and roller (27) for the left pedal becomes 0.5 mm (0.02 in) or less when the pedal is not depressed. Tighten the nut when adjusted.

Tightening torque: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft) - Adjust the right pedal using the bolt so that the opening between bolt (58) and roller (16) for the right pedal becomes 3.0~3.5 mm (0.118~0.138 in) when fully depressing the left pedal. Tighten the nut when adjusted.

Tightening torque: 58.8 N-m (6.0 kgf-m) (43.4 lb-ft)

54-25 80ZV-2 Disassembly & Reassembly Brake Group Service Brake

Service Brake Service brake disassembling and assembling

1. Loosen the axle housing air bleeder nipple.

Refer to "Front axle disassembling and assembling" page 24-23 for the procedures.

When replacing only the brake discs without removing the brake piston, loosen the air bleeder nipple first. Push back the brake piston, and then, install the brake discs.

If the brake piston is not pushed back, the brake may drag and the brake discs may seize.

After installing the tires, check that manual rotation of the tires is possible.

Service brake installation cautions

WARNING

A B

Wheel hub

Socket bolt

Brake piston Spider

85V2E54029 80ZVE53004

WARNING Before air bleeding in the brake oil line, be sure that the wheel and tire assemblies are installed on the wheel hub. If fail to do, the bolts (4 pcs) temporarily tighten the spider and the wheel hub may be broken by the brake piston. Finally the spider and the cover may fall off and it could cause serious injury or death.

2. After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face.

A: 100.25~101.40 mm (3.95~3.99 in)

IMPORTANT The wheel bearings must be adjusted correctly to get an accurate measurement for dimension A. The dimensions should be equal at top and bottom.

Reference Piston stroke B: 1.55~3.40 mm (0.061~0.134 in) 3. After finishing the installation work, bleed air completely from the brake line.

54-26 80ZV-2 Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking Brake Actuator Parking brake actuator removing and installing

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.

Parking brake actuator removing

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: - When removing the parking brake actuator, the machine may move. To prevent the machine from moving, park the machine on level ground, and lower the attachment onto the ground.

- In addition, block the tires with chocks to prevent the wheels from moving.

2. Release the residual air pressure in hydraulic tank.

Disconnect oil hose (3).

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

3. Loosen locknut (4) to remove joint (5).

Remove retainer bolts (6) to remove parking brake actuator (7). : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) : Parking brake actuator: 8 kg (18 lbs)

3

Parking brake actuator installing To reinstall the parking brake actuator, follow the above removal procedure in reverse order.

7

6

Transmission

4

Brake assembly

5 1

2

80V2E54019

Note To insert the connection pin to connect the parking brake actuator to the parking brake, observe the following items: - Start the engine to build oil pressure in the accumulator.

- Release the parking brake.

- Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the parking 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 80ZV-2 Shop Manual, Function and Structure, Section 53.

54-27 80ZV-2 Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking brake actuator adjustment procedure

Parking brake actuator adjusting

1. Release parking brake (OFF).

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 the machine on level ground.

- Lower the attachment onto the ground.

- Apply the articulation stopper.

2. Measure dimension "A" if it is 87 mm (3.43 in).

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 87 mm (3.43 in).

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

4

5. Confirm the parking brake performance.

(Refer to 80ZV-2 Shop Manual, Function & Structure, Section 53.)

1 A

2

4

3

A 2 3 5,6,7

Parking brake "OFF" position 80ZV54013

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

54-28 80ZV-2 Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking brake actuator disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Parking brake actuator cross section and tightening torque

90ZV54019

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

54-29 80ZV-2 Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking brake actuator disassembling

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.

90ZV54007J

3. Removal of rod cap Using the press, press down the rod cover with the pipe (outer dia.: 50 mm (2.0 in) or less, inner dia.: 30 mm (1.2 in) or more, length: 80 mm (3.15 in)), and it will be allowed to loosen the rod cap with hand. So, remove the rod cap.

Matchmark

90ZV54016

4. Slowly pull up the press until the spring loses the spring force.

1. Removal of the set screw of rod cap 3

Note Since the set screw is locked by punching, cut off the punched area with 15~20 mm (0.6~0.8 in) 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.

4

1 2

90ZV54008J

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

90ZV54006J

2. Initial loosening of rod cap Using the threaded hole of the rod cap, unscrew the rod cap approx. 1/8 turn alone.

54-30 80ZV-2 Disassembly & Reassembly Brake Group Parking Brake Actuator

Parking brake actuator assembling 3 5 4

Matchmark 90ZV54017

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 a drill 15~20 mm (0.6~0.8 in) in diameter.

- During reassembling, align the matchmarks and install the set screw at the same position.

90ZV54011J

To reassemble the parking brake actuator, follow the disassembly procedure in reverse order.

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.

8 4 9 10

7

6

1

90ZV54010J

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).

54-31 80ZV-2 Disassembly & Reassembly Brake Group Parking Brake

Parking Brake Parking brake removing and installing / disassembling and assembling Parking brake removing and disassembling

WARNING When removing the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park the machine on level ground.

- Lower the attachment onto the ground.

- Apply the articulation stopper.

4

5

80ZV54014

1. Drain the transmission oil.

3. Remove bolts (5) of propeller shaft (4). : Bolt (5): 142 N-m (14.5 kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application

2

1

7

3

90ZV54012J

8 9

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

6

80V2E54020

4. Remove bolt (6) of the brake adjustment hole, and then, remove brake drum (7).

Remove nut (8) and flange yoke (9). : Bolt (6): 94 N-m (9.6 kgf-m) (69 lb-ft) Nut (8): 392 N-m (40 kgf-m) (2,891 lb-ft) : Bolt (6): Screw lock agent (Loctite® 262) : Nut (8): Molybdenum disulfide grease/ MOS2 application

54-32 80ZV-2 Disassembly & Reassembly Brake Group Parking Brake

11

15

10

97K54012

5. Remove right and left springs (10) using pliers.

Remove plate (11).

13

Upper guide

Side guide

16

97ZV54026

7. Remove spring (15), and then remove adjusting screw (16).

Note Measure the wear of the brake shoes. If the shoes are extremely worn, replace them.

Refer to Section 53 or Section 55 “80ZV-2 Service Standard Brake Group” for the inspection standards.

Parking brake installing and assembling 12 14

95ZV54029

6. Pull out the upper guides to the front to open brake shoes (12), and then remove shoes (12) from the side guides.

Note If it is necessary to remove back plate (13), remove bolt (14). : Bolt (14): 216 N-m (22 kgf-m) (159 lb-ft) : Screw lock agent (Loctite® 262) application

To reinstall and reassemble the parking brake, follow the above removal and disassembly procedure in reverse order.

Note To adjust and check performance of the parking brake, refer to the 80ZV-2 Shop Manual, Function and Structure, Section 53.

55-1 80ZV-2 Service Standard Brake Group

80ZV-2 Service Standard Brake Group Brake Valve ............................................................. 55-2 Service Brake .......................................................... 55-4 Parking Brake.......................................................... 55-5

55-2 80ZV-2 Service Standard Brake Group Brake Valve

Brake Valve

1 7 6

5

2 3

4 2 3

80V2E55001

55-3 80ZV-2 Service Standard Brake Group Brake Valve

Unit: mm (in) Judgment standard No.

Item

Standard dimension

Tolerance

Solution

Shaft

Hole

Standard clearance

Allowable clearance

1

Clearance between spool input and cover

ø22.4 (0.8819)

-0.020 ~ -0.053 (-0.0008~ -0.0020)

+0.033~0 (+0.0013~0)

0.020~0.086 (0.0008~0.0034)

0.096 (0.0038)

Replacement

2

Clearance between spool and body 1, 2

ø18 (0.7086)

—

—

0.005~0.012 (0.0002~0.0005)

0.014 (0.0006)

Assembly replacement

3

Clearance between plunger and spool

ø12 (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 Standard dimension No.

Item

Tolerance limit Solution

Free length mm (in)

Installation length mm (in)

Installation load N (kgf) (lb)

Free length mm (in)

Installation load N (kgf) (lb)

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

56.4 (2.2205)

48.8 (1.9212)

110 (11.2) (24.7)

—

94 (9.6) (21)

7

Return spring

81 (3.1890)

55 (2.1653)

118 (12) (26.5)

—

100 (10.2) (22.5)

Replacement

55-4 80ZV-2 Service Standard Brake Group Service Brake

Service Brake

3

1

4

Slide caliper

3

2 Backing plate

1 (Steel plate) 2 (Friction plate)

80ZV55001

Unit: mm (in) Judgment standard No.

1

Item

Solution Standard dimension

Tolerance

Wear limit

Thickness

4.9 (0.1929)

±0.1 (±0.0039)

4.4 (0.1732)

Distortion

0.30 (0.0118) or less

—

0.30 (0.0118) and more

Steel plate

2

Thickness of friction plate

7.2 (0.2682)

±0.15 (±0.0059)

5.9 (0.2322)

3

Thickness of brake disc when measured by calipers (with brake applied)

17.2 (0.6772)

±0.2 (±0.0078)

15.1 (0.5944)

Outer dia.

Piston seal contact face

(Manufacturing dimension) 355 (13.9763)

-0.220 (-0.0086)~ -0.290 (-0.0114)

—

4

Inner dia.

(Manufacturing dimension) 285 (11.2205)

+0.05 (+0.0019)~ +0.15 (+0.0059)

—

Replacement

—

55-5 80ZV-2 Service Standard Brake Group Parking Brake

Parking Brake

2

5

1 3

Clearance

Spring (4) released

4

95ZV55002

Unit: mm (in) No. 1

Item

Judgment standard Standard dimension

Wear limit

6.15 (0.2421)

2.95 (0.1161)

Solution

Wear of lining

2

Deflection of drum

0.38 (0.0149) or more

3

Lining inspection

Grease or oil on the lining

4

Expansion of adjuster spring

5

Expansion of return spring

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

55-6 80ZV-2 Service Standard Brake Group

MEMO

74-1 80ZV-2 Disassembly & Reassembly Operator Station Group

80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner ........................................................ 74-2

74-2 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air Conditioner Air conditioner removing and installing Air conditioner removing

IMPORTANT In case that it is necessary to replace the air conditioner parts, be sure to set the air conditioner mode as below before removing the air conditioner unit from the machine.

Temperature control: Max cool Ventilation mode: Foot Air intake control: Inside air circulation Before starting work: - Remover the seat in the cab.

- Collect the air conditioner refrigerant using the proper recovery method.

- Remove the floor mat in the cab.

1

4

2 1 4 2 3

3 View from operator’s seat

95ZVE74001

74-3 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Cab

7 12

11 8

5

6

95ZVE74002

95ZVE74005

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

1. Remove box (1)(2).

2. Remove cover (3) and plate (4).

3. Remove cover (5)(6)(7) from the cab.

Air conditioner installing 4. Remove duct (8).

To reinstall the air conditioner, follow the above removal procedure in reverse order.

Reference After reinstalling the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

Air conditioner unit

9

95ZVE74003

Air conditioner unit

10 95ZVE74004

5. Disconnect refrigerant piping (9) and heater hose (10).

74-4 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air conditioner disassembling and assembling Air conditioner tightening torque [Cooling unit]

T2 T6 T4

T3

T2

T2

T6

T3

T6

T4

T4 T5

T6 T4

T2 T1 T5

T6

T5

97ZV74002

: T1: 5.4 N-m (0.55 kgf-m) (4 lb-ft) T2: 1.9 N-m (0.19 kgf-m) (1.4 lb-ft) T3: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T4: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft) T5: 1.9 N-m (0.19 kgf-m) (1.4 lb-ft) T6: 2.5 N-m (0.25 kgf-m) (1.8 lb-ft)

74-5 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner [Heater and accessories]

[Air distributor (hood & defroster selection box)]

T3

T1

T3 T2 T2

T2

T4 T1

97ZV74003

: T1: 4.0 N-m (0.4 kgf-m) (2.9 lb-ft) T2: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft) T3: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T4: 5.4 N-m (0.55 kgf-m) (4 lb-ft)

95V2U74001

: T1: 3.7 N-m (0.38 kgf-m) (2.7 lb-ft) T2: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft) T3: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft)

74-6 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner [Air compressor (with magnetic clutch)]

T1

T2

T1

97ZV74005

: T1: 4.9 N-m (0.5 kgf-m) (3.6 lb-ft) T2: 18 N-m (1.8 kgf-m) (13 lb-ft) [Condenser unit]

T1

T1

T1

T2

T1

95V2U74002

: T1: 12 N-m (1.2 kgf-m) (8.7 lb-ft) T2: 5.4 N-m (0.55 kgf-m) (4 lb-ft)

74-7 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air conditioner disassembling

5

[Blower assy]

3

4

Air conditioner unit assy

Blower assy

5

5

95V2U74005

3. Remove motor cooling pipe (3) from motor assy (4) and the blower case.

95V2U74003

4. Remove bolt (5) (3 pcs), and then remove motor assy (4) from the blower case.

1

2

5. Remove the packing from motor assy (4). This packing is reusable.

95V2U74004

1. Remove tapping screw (1) that fixes blower assy (2) to the air conditioner unit assy.

2. Pull blower assy (2) upward to separate it from the air conditioner unit assy.

74-8 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Screw driver Lever

8 9

6

7

Long-nose pliers

8

95V2U74006

6. Remove clamp (6) using a screw driver.

7. Carefully push the link shaft end using long-nose pliers and remove link shaft (7) from the lever.

Note Be careful not to break the link shaft claw.

8. Remove tapping screw (8) (3 pcs) and remove servo motor (9).

11

10

95V2U74007

9. Remove bolt (10) and then remove relay (11).

74-9 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner [Air conditioner unit assy] 6

Air conditioner unit assy

5

4

7 95V2U74010

95V2U74008

3

1

4. Remove tapping screw (4) and then remove plate (5).

5. Remove lever (6) and lever (7) respectively.

2

8

9 95V2U74009

1. Remove tapping screw (1) that fixes blower assy (2) to the air conditioner unit assy.

95V2U74011

2. Pull blower assy (2) upward to separate it from the air conditioner unit assy.

6. Remove clamp (8) using a screw driver. Then remove link shaft (9).

3. Remove thermistor assy (3) from the case.

10

10

95V2U74012

7. Remove tapping screw (10) (11 pcs) and separate the cooler case.

74-10 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

143.5 5 (5.6 in)

Packing 95V2U74013

Note When reassembling, make sure that the packing is placed in the case groove.

236 – 5 (9.3 in)

0

80 – 15 (3.1 in)

16

+10

Thermistor

95V2U74016

10. Remove clamp (16) (2 pcs) and remove the thermistor from the evaporator.

Note When reassembling, place clamps (16) in the positions as shown. Incorrect positioning of the thermistor may cause frost or temperature control malfunction.

13 11

18 17

14

21

12

95V2U74014

8. Loosen joints (11)(12) and remove evaporator (13). : Joint (11): 32 N-m (3.3 kgf-m) (24 lb-ft) : Joint (12): 13 N-m (1.3 kgf-m) (9.4 lb-ft)

19 20 95V2U74017

11. Remove tapping screw (17) and remove clamp 1 (18).

14

15

12. Remove tapping screw (19) and remove clamp 2 (20).

13. Pull heater core (21) upward and remove it.

95V2U74015

9. Remove bolt (15) (2 pcs) and then remove expansion valve (14).

74-11 80ZV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

27

22 28

27

95V2U74018

14. Remove the thermo sensor connector from the bracket and remove thermo sensor (22).

95V2U74021

18. Remove tapping screw (27) and remove servo motor (28).

24 29 30 24

24

24 25

31 32

23

95V2U74019

15. Remove clamp (23) by using a screw driver.

16. Remove tapping screw (24) and remove servo motor (25).

95V2U74022

19. Remove tapping screw (29) (2 pcs) and remove IC assy (30).

20. Remove pressure switch (31) from tube (32).

Air conditioner assembling To reassemble the air conditioner, follow the above procedure in reverse order.

26

95V2U74020

17. Remove plate (26).

74-12 80ZV-2 Disassembly & Reassembly Operator Station Group

MEMO

75-1 80ZV-2 Service Standard Operator Station Group

80ZV-2 Service Standard Operator Station Group Air Conditioner ........................................................ 75-2

75-2 80ZV-2 Service Standard Operator Station Group Air Conditioner

Air Conditioner Periodical Inspection/Servicing Inspection/maintenance item

Criteria

Solution

Refrigerant

Charge quantity

Air bubbles should not be seen through sight glass.

Inspection/adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Clean

Compressor

Operating status

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

Inspection/ adjustment/ replacement

Belt tension pulley

Operating status

Abnormal sounds and backlash should not be detected.

Inspection/ replacement

V belt

Damage and tension

Damages should not be detected.

Replacement

Blower motor and fan

Operating status

Abnormal sounds or vibration should not be detected.

Inspection/ replacement

Control mechanism

Operating status

Each part should operate in accordance with switch operations.

Inspection/ replacement

Air filter for inside/outside air

Clogging

Air quantity should not be so small as to hinder air conCleaning/replacement ditioning.

Each mounting area and piping

Looseness, gas leak and damages

Looseness, gas leak and damages should not be detected.

Tightening/charge

Tightening Torque Tightening torque for hose and pipes

Connection type

Connection area

Condenserexpansion valve Nut type

Pipe size or bolt size

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

ø8 piping

15 (1.50) (11)

Compressorcondenser

D1/2 piping

25 (2.50) (18)

Evaporatorcompressor

D5/8 piping

34 (3.50) (25)

Receiver Block joint Evaporatorcompressor

M6 bolt in receiver (4T) Any M6 bolt (6T) other than above

7 (0.70) (5.1) 12 (1.20) (8.7)

Tightening torque for screws and bolts in special control regions

Special control area

Head bolt of magnetic clutch

Bolt size

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

M6

18 (1.8) (13)

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

0.8 (0.08) (0.6)

Fixing nut of blower motor and condenser fan

M6

5.4 (0.55) (4.0)

Fixing bolt of blower motor and condenser motor

M5

4 (0.4) (2.9)

INDEX A Accumulator ....................................................................54-11 Accumulator assembling .................................................54-14 Accumulator disassembling ............................................54-13 Accumulator disassembling and assembling ..................54-13 Accumulator installation cautions ...................................54-12 Accumulator installing .....................................................54-12 Accumulator removing ....................................................54-11 Accumulator removing and installing ..............................54-11 Air Cleaner ......................................................................24-15 Air cleaner installation cautions ......................................24-16 Air cleaner installing ........................................................24-16 Air cleaner removing .......................................................24-15 Air cleaner removing and installing .................................24-15 Air Conditioner ........................................................ 74-2, 75-2 Air conditioner assembling ..............................................74-11 Air conditioner disassembling ...........................................74-7 Air conditioner disassembling and assembling .................74-4 Air conditioner installing ....................................................74-3 Air conditioner removing ...................................................74-2 Air conditioner removing and installing .............................74-2 Air conditioner tightening torque .......................................74-4 Applying and Storing Articulation Stopper ......................00-15 Applying articulation stopper ...........................................00-15 Attachment Leveler ...........................................................15-7 Attachment leveler ............................................................15-8 Attachment leveler adjustable angle .................................15-8 Axle and Differential Service Standard .............................25-3 Axle group .........................................................................25-3 Axle nut tightening ..........................................................24-29 Axle nut tightening procedure ............................. 24-19, 24-43 Axle Support ...................................................................24-47 Axle support assembling .................................................24-48 Axle support assembly cautions .....................................24-49 Axle support disassembling ............................................24-48 Axle support disassembling and assembling ..................24-48 Axle support tightening torque ........................................24-47

B Bearing cover installing .....................................................15-5 Bearing installation cautions ...........................................00-13 Bearing operation test after installation ..........................00-14 Bearing removal cautions ...............................................00-14 Bolt Tightening Torque .....................................................00-4 Boom ..............................................................................14-17 Boom cylinder installation cautions .................................44-10 Boom cylinder installing ....................................................44-9 Boom cylinder removing ...................................................44-8 Boom cylinder removing and installing .............................44-8 Boom installation cautions ..............................................14-19 Boom installing ...............................................................14-19 Boom removing ...............................................................14-17 Boom removing and installing .........................................14-17 Brake adjustment ............................................................24-30 Brake Valve .......................................................... 54-17, 55-2 Brake valve assembling ..................................................54-23

Brake valve assembly cautions ...................................... 54-24 Brake valve cross section and tightening torque (main valve) ................................................................ 54-19 Brake valve disassembling ............................................. 54-20 Brake valve disassembling and assembling ................... 54-19 Brake valve installation cautions .................................... 54-18 Brake valve installing ...................................................... 54-18 Brake valve removing ..................................................... 54-17 Brake valve removing and installing ............................... 54-17 Bucket cylinder installation cautions ............................... 44-12 Bucket cylinder installing ................................................ 44-11 Bucket cylinder removing ............................................... 44-10 Bucket cylinder removing and installing ......................... 44-10

C Cab ................................................................................. 14-12 Cab installing .................................................................. 14-13 Cab removing ................................................................. 14-12 Cab removing and installing ........................................... 14-12 Cautions Regarding Handling of Bearing ....................... 00-13 Cautions regarding parts removal .................................... 00-9 Cautions regarding reassembly ........................................ 00-9 Cautions Regarding Welding Repair Service ................. 00-11 Center Pin ............................................................. 14-20, 15-5 Center pin installation cautions ...................................... 14-25 Center pin installing ........................................................ 14-25 Center pin removing ....................................................... 14-22 Center pin removing and installing ................................. 14-22 Center pin shim adjustment ................................... 14-20, 15-5 Clutch Oil Pressure .......................................................... 35-8 Clutch oil pressure standard value ................................... 35-8 Clutch plate ...................................................................... 35-7 Clutch Plate Thickness/Piston Stroke .............................. 35-6 Control Valve .................................................................... 35-3 Control valve assembling ............................................... 34-47 Control Valve Assembly ................................................. 34-43 Control valve assembly cautions .................................... 34-47 Control valve disassembling ........................................... 34-46 Control valve disassembling and assembling ................ 34-46 Control valve installation cautions .................................. 34-45 Control valve removing ................................................... 34-44 Control valve removing and installing ............................. 34-44 Control valve tightening torque ....................................... 34-43

D Deck ................................................................................. 14-2 Deck installing .................................................................. 14-3 Deck removing ................................................................. 14-2 Deck removing and installing ........................................... 14-2 Differential ........................................................................ 25-4 Differential Assembly ...................................................... 24-50 Differential assembly assembling ................................... 24-58 Differential assembly disassembling .............................. 24-54 Differential assembly disassembling and assembling ................................... 24-52 Differential assembly installation cautions ...................... 24-51

Differential assembly installing ....................................... 24-51 Differential assembly removing ...................................... 24-50 Differential assembly removing and installing ................ 24-50

E Engine ............................................................................ 24-10 Engine installation cautions ............................................ 24-12 Engine installing ............................................................. 24-12 Engine removing ............................................................ 24-10 Engine removing and installing ...................................... 24-10 Engine Room ................................................................... 14-8 Engine room installation cautions .................................. 14-11 Engine room installing .................................................... 14-10 Engine room removing ..................................................... 14-8 Engine room removing and installing ............................... 14-8

F Fan ................................................................................... 24-8 Fan installation cautions ................................................... 24-9 Fan installing .................................................................... 24-9 Fan Motor ....................................................................... 44-67 Fan motor installation cautions ...................................... 44-70 Fan motor installing ........................................................ 44-69 Fan motor removing ....................................................... 44-67 Fan motor removing and installing ................................. 44-67 Fan removing ................................................................... 24-8 Fan removing and installing ............................................. 24-8 Floating seal installation ........................... 24-19, 24-27, 24-43 Floor Board .................................................................... 14-14 Floor board installation cautions .................................... 14-16 Floor board installing ...................................................... 14-16 Floor board removing ..................................................... 14-14 Floor board removing and installing ............................... 14-14 Forward/reverse clutch pack assembling ....................... 34-35 Forward/reverse clutch pack assembly cautions ........... 34-35 Forward/reverse clutch pack disassembling .................. 34-33 Forward/reverse clutch pack disassembling and assembling ................................... 34-33 Front axle assembling .................................................... 24-26 Front Axle Assembly ...................................................... 24-18 Front axle assembly cautions ......................................... 24-27 Front axle assembly installation cautions ....................... 24-22 Front axle assembly installing ........................................ 24-21 Front axle assembly removing ....................................... 24-20 Front axle assembly removing and installing ................. 24-20 Front axle assembly tightening torque ........................... 24-18 Front axle disassembling ............................................... 24-23 Front axle disassembling and assembling ..................... 24-23 Front differential tightening torque ................................. 24-52 Fuel Tank ......................................................................... 14-4 Fuel tank installation cautions .......................................... 14-4 Fuel tank installing ........................................................... 14-4 Fuel tank removing ........................................................... 14-4 Fuel tank removing and installing ..................................... 14-4

G Gear Pump ....................................................................... 35-5 Gear pump specifications ................................................. 35-5

H Hose Band Tightening Torque ..........................................00-8 How to wind a seal tape .................................................00-10 Hydraulic Cylinder ...................................................44-8, 45-2 Hydraulic cylinder assembling ........................................44-19 Hydraulic cylinder assembly cautions .............................44-19 Hydraulic cylinder cross section and tightening torque ....................................................................................44-15 Hydraulic cylinder disassembling ...................................44-17 Hydraulic cylinder disassembling and assembling ......... 44-15 Hydraulic parts assembly cautions ...................................44-3 Hydraulic Parts Disassembly and Assembly Cautions ..... 44-3 Hydraulic parts disassembly cautions ..............................44-3 Hydraulic Parts Removal and Installation Warning ..........44-2 Hydraulic Pump Assembly ................................................44-4 Hydraulic pump assembly cross section and tightening torque ..............................44-6 Hydraulic pump assembly disassembling and assembling .....................................44-6 Hydraulic pump assembly installing ................................. 44-4 Hydraulic pump assembly removing ................................. 44-4 Hydraulic pump assembly removing and installing ........... 44-4 Hydraulic pump installation cautions ................................44-5 Hydraulic Tank ..................................................................14-5 Hydraulic tank installation cautions ..................................14-7 Hydraulic tank installing ....................................................14-7 Hydraulic tank removing ...................................................14-5 Hydraulic tank removing and installing .............................14-5

I Interference fits for a bearing .......................................... 00-13 Internal Gear Hub ........................................................... 24-32 Internal gear hub assembling .........................................24-33 Internal gear hub assembly cautions ..............................24-34 Internal gear hub disassembling ..................................... 24-32 Internal gear hub disassembling and assembling ..........24-32 Internal gear hub installation .......................................... 24-29

J Joint between the torque converter and the engine .........34-9

L Liner clearance adjustment ..............................................15-4 Linkage .............................................................................15-2 Linkage Pin Standard Clearance Values ..........................15-3 Liquid Gasket and Screw Lock Agent ...............................00-9 Lower center pin .............................................................14-21 Lower center pin bearing outer ring installing ...................15-6

M Manifold Valve Assembly .................................................54-8 Muffler .............................................................................24-17 Muffler installation cautions ............................................24-17 Muffler installing ..............................................................24-17 Muffler removing .............................................................24-17 Muffler removing and installing .......................................24-17 Multiple Control Valve .....................................................44-42 Multiple control valve assembling ...................................44-47

Multiple control valve assembly cautions ........................44-47 Multiple control valve cross section and tightening torque .............................44-44 Multiple control valve disassembling ..............................44-45 Multiple control valve disassembling and assembling ....................................................................................44-44 Multiple control valve installation cautions ......................44-43 Multiple control valve installing .......................................44-43 Multiple control valve removing ......................................44-42 Multiple control valve removing and installing ................44-42

N Nitrogen gas charging .....................................................54-15 Nitrogen gas charging procedure ...................................54-15

O Oil seal replacement procedure ........................................44-7 Orbitrol® ..........................................................................44-48 Orbitrol® assembling .......................................................44-54 Orbitrol® cross section and tightening torque .................44-50 Orbitrol® disassembling ..................................................44-51 Orbitrol® disassembling and assembling ........................44-50 Orbitrol® installation cautions ..........................................44-49 Orbitrol® installing ...........................................................44-49 Orbitrol® removing ..........................................................44-48 Orbitrol® removing and installing ....................................44-48

P Parking Brake ....................................................... 54-31, 55-5 Parking Brake Actuator ...................................................54-26 Parking brake actuator adjusting ....................................54-27 Parking brake actuator assembling ................................54-30 Parking brake actuator cross section and tightening torque .............................54-28 Parking brake actuator disassembling ............................54-29 Parking brake actuator disassembling and assembling ...................................54-28 Parking brake actuator installing .....................................54-26 Parking brake actuator removing ....................................54-26 Parking brake actuator removing and installing ..............54-26 Parking brake installing and assembling ........................54-32 Parking brake removing and disassembling ...................54-31 Parking brake removing and installing / disassembling and assembling ...................................54-31 Partition Plate .................................................................14-26 Partition plate installing ...................................................14-27 Partition plate removing ..................................................14-26 Partition plate removing and installing ............................14-26 Periodical Inspection/Servicing .........................................75-2 Pilot Valve .........................................................................45-4 Pilot Valve (S/N 9001~9205) ..........................................44-21 Pilot Valve (S/N 9206~) ..................................................44-32 Pilot valve assembling ........................................ 44-31, 44-41 Pilot valve assembly cautions ............................. 44-31, 44-41 Pilot valve cross section and tightening torque ........................................................................ 44-23, 44-34 Pilot valve disassembling (S/N 9001~9205) ...................44-24 Pilot valve disassembling (S/N 9206~) ...........................44-35 Pilot valve disassembling and assembling ......... 44-23, 44-34

Pilot valve installation cautions ............................ 44-22, 44-33 Pilot valve installing ............................................. 44-22, 44-33 Pilot valve removing ............................................ 44-21, 44-32 Pilot valve removing and installing ...................... 44-21, 44-32 Piston stroke ..................................................................... 35-7 Power Line ....................................................................... 24-2 Power line tightening torque ............................................. 24-2 Propeller Shaft ................................................................ 24-13 Propeller shaft installation cautions ................................ 24-14 Propeller shaft installing ................................................. 24-14 Propeller shaft removing and installing .......................... 24-13 Propeller Shaft Service Standard ..................................... 25-2

R Radiator ............................................................................ 24-3 Radiator installation cautions ........................................... 24-7 Radiator installing ............................................................. 24-7 Radiator removing ............................................................ 24-5 Radiator removing and installing ...................................... 24-5 Radiator tightening torque ................................................ 24-3 Rear Axle Assembly ....................................................... 24-42 Rear axle assembly installing ......................................... 24-46 Rear axle assembly removing ........................................ 24-44 Rear axle assembly removing and installing .................. 24-44 Rear axle assembly tightening torque ............................ 24-42 Rear axle disassembling and assembling ...................... 24-46 Rear differential tightening torque .................................. 24-53

S Screw lock agent application procedure ......................... 00-10 Second propeller shaft removing .................................... 24-13 Service Brake ........................................................ 54-25, 55-4 Service brake air bleeding procedure ............................. 24-22 Service brake disassembling and assembling ............... 54-25 Service brake installation cautions ................................. 54-25 Special Tool .................................................................... 24-37 Special tool for axle ........................................................ 24-37 Spider Assembly ............................................................ 24-35 Spider assembly assembling .......................................... 24-36 Spider assembly assembly cautions .............................. 24-36 Spider assembly disassembling ..................................... 24-35 Spider assembly disassembling and assembling ........... 24-35 Steering cylinder installation cautions ............................ 44-14 Steering cylinder installing .............................................. 44-14 Steering cylinder removing ............................................. 44-13 Steering cylinder removing and installing ....................... 44-13 Steering Valve ....................................................... 44-58, 45-6 Steering valve assembling ............................................. 44-62 Steering valve cross section and tightening torque ........ 44-60 Steering valve disassembling ......................................... 44-61 Steering valve disassembling and assembling ............... 44-60 Steering valve installing .................................................. 44-59 Steering valve removing ................................................. 44-58 Steering valve removing and installing ........................... 44-58 Stop Valve ...................................................................... 44-63 Stop valve assembling ................................................... 44-66 Stop valve cross section and tightening torque .............. 44-65 Stop valve disassembling ............................................... 44-66 Stop valve disassembling and assembling ..................... 44-65

Stop valve installation cautions ...................................... 44-64 Stop valve installing ....................................................... 44-63 Stop valve removing ....................................................... 44-63 Stop valve removing and installing ................................. 44-63 Storing articulation stopper ............................................ 00-15 Symbols ........................................................................... 00-2

T Third propeller shaft removing ....................................... 24-14 Tightening torque for hose and pipes ............................... 75-2 Tightening torque for screws and bolts in special control regions .............................................. 75-2 Torque Converter and Transmission Assembly ............... 34-2 Torque converter and transmission assembly installing ...................................................................................... 34-9 Torque converter and transmission assembly removing ...................................................................................... 34-3 Torque converter and transmission assembly removing and installing ................................................. 34-3 Torque converter and transmission assembly tightening torque ........................................................... 34-2 Torque Converter Assembly .......................................... 34-12 Torque converter assembly assembling ........................ 34-16 Torque converter assembly bolt tightening torque ......... 34-12 Torque converter assembly disassembling .................... 34-13 Torque converter assembly disassembling and assembling ................................... 34-13 Transmission 1st/3rd speed clutch pack assembling .................................................................................... 34-37 Transmission 1st/3rd speed clutch pack assembly cautions ...................................................... 34-37 Transmission 1st/3rd speed clutch pack disassembling ............................................................. 34-36 Transmission 1st/3rd speed clutch pack disassembling and assembling ................................... 34-36 Transmission 2nd Speed Clutch Pack ........................... 34-38 Transmission 2nd speed clutch pack assembling .......... 34-39 Transmission 2nd speed clutch pack assembly cautions ...................................................... 34-39 Transmission 2nd speed clutch pack disassembling ............................................................. 34-38 Transmission 2nd speed clutch pack disassembling and assembling ................................... 34-38 Transmission 4th Speed Clutch Pack ............................ 34-40 Transmission 4th speed clutch pack assembling ........... 34-41 Transmission 4th speed clutch pack assembly cautions ...................................................... 34-42 Transmission 4th speed clutch pack disassembling .................................................................................... 34-40 Transmission 4th speed clutch pack disassembling and assembling ................................... 34-40 Transmission Assembly ........................................ 34-20, 35-2 Transmission assembly assembling .............................. 34-26 Transmission assembly bolt tightening torque ............... 34-20 Transmission assembly disassembling .......................... 34-22 Transmission assembly disassembling and assembling ................................... 34-22 Transmission assembly installation cautions ................... 34-9 Transmission assembly operation check ....................... 34-10 Transmission Forward/Reverse Clutch Pack ................. 34-33

U Unloader Valve .................................................................54-2 Unloader valve assembling ..............................................54-7 Unloader valve cross section and tightening torque .........54-4 Unloader valve disassembling ..........................................54-7 Unloader valve disassembling and assembling ................ 54-4 Unloader valve installation cautions ................................. 54-3 Unloader valve installing ...................................................54-3 Unloader valve removing .................................................. 54-2 Unloader valve removing and installing ............................ 54-2 Upper center pin .............................................................14-20

V Valve assembly cross section and tightening torque ......54-10 Valve assembly disassembling and assembling ..............54-9 Valve assembly installation cautions ................................54-9 Valve assembly installing .................................................54-9 Valve assembly removing .................................................54-8 Valve assembly removing and installing ...........................54-8

W Weight of Main Components ............................................ 00-3

MEMO

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