Kawasaki 85ZIV-2 WHEEL LOADER SHOP MANUAL AAA-S85N3E14-00Z (1)

AAA-S85N3E14-00Z

(93211-00131)

WHEEL LOADER SHOP MANUAL

85ZIV-2

Powered by NISSAN PE6T44 Engine.

SERIAL NUMBERS 85N3-9001 and up.

Disassembly& Reassembly Service standard

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

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

Disasembly & Reassembly Service Standard Note: ① For General Information and Functions and Structure, refer to the 85ZⅣ -2 Shop Manual AAA-S85N3E00-00Z (93211-00111). ② For Troubleshooting and Measurement for Performance Check, refer to the 85ZⅣ -2 Shop Manual AAA-S85N3E01-00Z (93211-00121).

The purpose of this manual is to provide information on the product and the correct maintenance and repair methods.

Please read this manual to ensure correct troubleshooting and good repair service.

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

（1）

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

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

（2）

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

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

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

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

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

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

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

（3）

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

Symbol

Item Reference

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

Shows the weight of a part or unit. The weight

Weight

should be considered in selecting wire rope or cable for slinging work or determining the working posture.

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

Coating

l

Oil or water supply

Drainage

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

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

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

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.

（4）

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

Bolt size Type

Nominal dimension

Nominal dia.

Pitch

M8

8

(C) 1.25

9

26

38

(C) 1.5

19

53

76

(F) 1.25

20

55

80

(C) 1.75

32

90

132

(F) 1.25

34

96

142

(C) 2.0

51

142

206

(F) 1.5

54

152

221

(C) 2.0

76

216

314

(F) 1.5

80

226

330

(C) 2.5

103

299

436

(F) 1.5

113

324

476

(C) 2.5

147

417

608

(F) 1.5

162

451

662

(C) 2.5

196

559

814

(F) 1.5

211

598

878

(C) 3.0

255

721

1,030

(F) 2.0

270

770

1,128

(C) 3.0

373

1,030

1,520

(F) 2.0

397

1,128

1,618

(C) 3.5

510

1,422

2,109

(F) 2.0

549

1,569

2,256

(C) 3.5

686

1,912

2,844

M10 M12 M14 M16

Metric thread

Unified thread

(N・m)

Bolt strength

10 12 14 16

4.6 (4T)

8.8 (8T)

10.9T (11T)

M18

18

M20

20

M22

22

M24

24

M27

27

M30

30

M33

33

(F) 2.0

736

2,059

3,040

5/16

05

18 UNC

9

25

35

3/8

06

16 UNC

16

44

65

7/16

07

14 UNC

25

71

103

1/2

08

13 UNC

36

103

147

9/16

09

12 UNC

52

147

216

5/8

10

11 UNC

72

201

294

3/4

12

10 UNC

127

358

525

7/8

14

9 UNC

196

554

809

1

16

16 UNC

309

868

1,275

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

（5）

(kgf・m) Bolt size Type

Nominal dia.

Pitch

4.6 (4T)

8.8 (8T)

10.9T (11T)

M8

8

(C) 1.25

0.9

2.7

3.9

M10

10

(C) 1.5

1.9

5.4

7.8

(F) 1.25

2.0

5.6

8.2

M12

12

(C) 1.75

3.3

9.2

13.5

(F) 1.25

3.5

9.8

14.5

M14

14

(C) 2.0

5.2

14.5

21.0

(F) 1.5

5.5

15.5

22.5

M16

16

(C) 2.0

7.8

22.0

32.0

(F) 1.5

8.2

23.0

33.7

(C) 2.5

10.5

30.5

44.5

(F) 1.5

11.5

33.0

48.5

(C) 2.5

15.0

42.5

62.0

(F) 1.5

16.5

46.0

67.5

(C) 2.5

20.0

57.0

83.0

(F) 1.5

21.5

61.0

89.5

(C) 3.0

26.0

73.5

105.0

(F) 2.0

27.5

78.5

115.0

(C) 3.0

38.0

105.0

155.0

(F) 2.0

40.5

115.0

165.0

(C) 3.5

52.0

145.0

215.0

(F) 2.0

56.0

160.0

230.0

(C) 3.5

70.0

195.0

290.0

(F) 2.0

75.0

210.0

310.0

M18 Metric thread

M20 M22 M24

Unified thread

Bolt strength

Nominal dimension

18 20 22 24

M27

27

M30

30

M33

33

5/16

05

18 UNC

0.9

2.5

3.6

3/8

06

16 UNC

1.6

4.5

6.6

7/16

07

14 UNC

2.6

7.2

10.5

1/2

08

13 UNC

3.7

10.5

15.0

9/16

09

12 UNC

5.3

15.0

22.0

5/8

10

11 UNC

7.3

20.5

30.0

3/4

12

10 UNC

13.0

36.5

53.5

7/8

14

9 UNC

20.0

56.5

82.5

1

16

16 UNC

31.5

88.5

130.0

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

（6）

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

Metric thread 4〜8T

3. Thread pitch

Coarse pitch thread(C)

(N・m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

M5

0.8

28

49

M6

1

49

84

M8

1.25

106

206

M10

1.5

206

382

M12

1.75

363

677

M16

2

-

1,657

M20

2.5

-

3,187

M24

3

−

5,521

(kgf・m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

M5

0.8

0.4

0.7

M6

1

0.7

1.2

M8

1.25

1.5

2.9

M10

1.5

2.9

5.4

M12

1.75

5.1

9.6

M16

2

-

23.5

M20

2.5

-

45.0

M24

3

−

78.0

（7）

Hose Band Tightening Torque

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

Hose band

Tightening torque

Tightening torque

(N・m)

(kgf・cm)

1.6

16

4

40

Tightening torque (N・m)

Tightening torque (kgf・cm)

1.6

16

4

40

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

16.5

HH022W

7.9

18.5

HH022W

9.5

20.5

HH022W

12.7

24.5

HH027W

15.9

29.9

HH031W

19.0

30.0

HH031W

25.4

38.0

HH044W

31.8

45.8

HH052W

38.1

52.1

HH057W

50.8

67.8

HH071W

60.5

76.0

HH082W

75.5

93.0

HH095W

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

Hose band

6

16.5

HH022W

8

18.5

HH022W

9

20.5

HH022W

9

22.0

HH023W

12

24.5

HH027W

12

26.0

HH027W

15

29.0

HH031W

15

30.5

HH031W

19

32.0

HH038W

19

34.0

HH038W

25

39.5

HH044W

25

41.5

HH044W

32

46.0

HH052W

32

48.0

HH052W

38

54.0

HH057W

50

70.5

HH076W

50

73.0

HH076W

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

Hose band Center of pipe protrusion 10〜20mm

（8）

Pipe

Liquid Gasket and Screw Lock Agent

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

Liquid Gasket Code

Manufacturer

Product name

ＡＡ０１

Loctite

Plastic Gasket 568

ＡＡ０２

Loctite

Hydraulic sealant

ＡＡ０３

Three Bond

Three Bond 1215

Code

Manufacturer

Product name

ＡＢ０１

Loctite

Loctite 262

ＡＢ０２

Three Bond

Three Bond 1327

ＡＢ０３

Three Bond

Three Bond 1374

Screw Lock Agent

・ Cautions regarding parts removal

・ Cautions regarding reassembly

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

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

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

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

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

Note: A piece of hardened lock agent may be peeled off and remain in the component.

The remaining piece may cause malfunction during operation.

To bond a plane or to fit a shaft: Remove the hardened lock agent using a wire brush or the like, and polish the surface using sand paper.

Use of a loctite primer like Locquic Primer T cleans threads and speeds curing time.

Antiseize Agent Code

Manufacturer

ＡＣ０１

Loctite

Product name Loctite 767 (Paste or spray)

（9）

Cautions Regarding Welding Repair Service

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

Cautions: 1) Remove the ground terminal from the battery.

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

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

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

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

Example 1:

Section to be welded Do not ground this section.

Electric current may flow through the cylinders.

Ground this section. (correct grounding)

Example 2:

Do not ground this section.

Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

（ 10 ）

Cautions Regarding Welding Repair Service

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

Be sure to mask these units and parts before welding.

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

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

Hydraulic cylinder

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

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

1m or more

Scrap material, etc.

Section to be welded

1

1m or more

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

Section to be welded Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

（ 11 ）

Weight of Main Components

Part name

Approx.

Weight (kg)

Bucket

1440

Boom

1250

" Z " -Lever

360

Link (Bucket to Lever)

70

Item Unit name

Remarks

GSN bucketStandard

305

Including air cleaner and condenser

265

Excluding air cleaner and condenser

Hydraulic tank

150

Excluding oil

Fuel tank

150

Excluding fuel

Deck

65

Including hand rail

Cab

560

Rops

Floor board

340

Including ope. board, instrument panel and control box

Front chassis

1680

Bare chassis

Rear chassis

1360

Bare chassis

Counterweight

1100

Standard

Engine

860

Excluding oil

Radiator

200

Excluding water and oil

Transmission

880

Excluding oil

Second propeller shaft

55

Third propeller shaft

10

Air cleaner

18

Exhaust silencer (Muffler)

23

Front axle assembly

1300

Excluding tires and oil

Rear axle assembly

1700

Excluding tires and oil (Including axle support)

Differential

178

Multiple control valve

54

Steering valve

22

Hydraulic

Gear pump

33

system

Boom cylinder

200/pc

Excluding oil

Bucket cylinder

215

Excluding oil

Steering cylinder

38/pc

Excluding oil

Tire

510/pc

With rim (23.5-25-16PR); No Hydro Inflation

Air conditioner unit

40

Battery

40/pc

Engine room assembly

Chassis

Power line

Other

(In cab portion)

（ 12 ）

Applying and Storing Articulation Stopper 1.Applying articulation stopper

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

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

Using a 17mm wrench remove bolt (1) from the articulation stopper on the front chassis.

１

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

２

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

Stay out of the articulation area while aligning the holes.

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

３

LOCKED POSITION

３

2.Storing articulation stopper

２

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

STORED POSITION

（ 13 ）

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

CHASSIS GROUP 14 Removing and Reinstalling Deck ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-2 Removing and Reinstalling Fuel Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-3 Removing and Reinstalling Hydraulic Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-4 Removing and Reinstalling Engine Room ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-5 Removing and Reinstalling Cab ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-8 Removing and Reinstalling Floor Board ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-11 Removing and Reinstalling Boom ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-13 Removing and Reinstalling Bushing ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-16 Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-18 Removing and Reinstalling Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-19

14-1

Removing and Reinstalling Deck

85ZIV-2

CHASSIS 14

Removing and Reinstalling Deck 1.Removing Deck

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

Note: The illustration shows the parts on the left side.

On the right side, the parts are located at the same points.

1)Apply a sling to the hand rail (1) and the deck, remove the bolt (2)(3)(4).

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

１ ５

４

２

３

2)While considering the balance, remove the deck (5) together with the hand rail.

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

14-2

８５Ｗ１４００１

Removing and Reinstalling Fuel Tank

85ZIV-2

CHASSIS 14

Removing and Reinstalling Fuel Tank 1.Removing fuel tank

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

Before starting work: a)Drain fuel from the fuel tank. (Fuel tank capacity: 300 l) b)Remove the deck by referring to "Removing and Reinstalling Deck".

４

2) Temporarily sling the fuel tank (3) to remove the bolts (4).

３

１

1)Remove the cover (1) and disconnect the level sensor electrical line coupler (2). ２

: Fuel tank : 150kg (empty) Torque for assembly: : Retainer bolt (4) : 427N・m (43.5kgf ・m)

８０Ｋ１４００１

3)Slightly pull out the fuel tank (3) to disconnect the suction/return hose (5). Plug the fuel line to prevent leakage and dirt entry. Be careful not to damage the fitting on the tank.

５

３ ８０Ｋ１４００２

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

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

14-3

Removing and Reinstalling Hydraulic Tank

85ZIV-2

CHASSIS 14

Removing and Reinstalling Hydraulic Tank 1.Removing hydraulic tank

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

１

２

Rear chassis ８５Ｋ１４００１

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

(Hydraulic tank capacity. : 130 l) b)Remove the deck by referring to "Removing and Reinstalling Deck". c) Clean the area around the tank.

３

５

1)Remove the transmission line filter (1) bracket bolt (2). Fix the transmission line filter with a strap to prevent contact with the tank during removal.

４

2)Disconnect the electrical line (4) and the vinyl tube (3) for the window washer liquid tank (option).

８５Ｋ１４００２

3)Disconnect the hoses (5). ・Plug or cover the hoses and fittings to prevent leakage and dirt entry. ７

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

６

: Hydraulic tank : 150kg (empty) Torque for assembly: : Retainer bolt (7) : 231N・m (23.5kgf ・m) ８５Ｋ１４００３

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

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

14-4

Removing and Reinstalling Engine Room

85ZIV-2

CHASSIS 14

Removing and Reinstalling Engine Room 1.Removing engine room

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

Before starting work: a)Recover/recycle freon refrigerant on machines with optional air conditioner, if required.

Note: If the quick coupler is attached, no recovery/recycling will be needed. b)Remove the right and left decks together with the hand rail. １

1)Remove the side covers (2) from both the right and left.

２ ８０Ｋ１４００５

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

３

８５Ｋ１４００４

3)Remove the hose (5) between the radiator and subtank.

５ ８５Ｋ１４００５

14-5

Removing and Reinstalling Engine Room

85ZIV-2

CHASSIS 14

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

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

６

８５Ｋ１４００６

5)Remove the bands (8) from the brake oil tank (7).

Clamp the brake oil tank (7) to the air master or the like. The brake oil in the tank does not have to be drained.

Note: During installation, use a new nylon tie strap of similar size and type.

８ ７

８０Ｋ１４００９

6)Remove the clamp from the rear axle breather tube (9). Also remove the clamp from the electric line (10).

１０

９

８５Ｋ１４００７

7)Disconnect the hose (11) from the condenser.

１１

Ｃｏｎｄｅｎｓｅ ｒ ８５Ｗ１４１０１

14-6

Removing and Reinstalling Engine Room

85ZIV-2

8)Open the radiator grill and disconnect the electrical line coupler (12). Remove all the bolts (13) from the engine room.

Lift the engine room together with the screen board.

Torque for assembly: : Retainer bolt : (M12) 98N・m (10.0kgf ・m) (M16) 216N・m (22.0kgf ・m) : Engine room : 305kg (Including air cleaner and condenser) Note: Slowly lift the engine room while checking that there are no obstacles.

CHASSIS 14

１３

１２ ８５Ｋ１４０２４

Ｍ１６ Ｍ１２ Ｍ１６

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

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

14-7

８５Ｗ１４０１０

Removing and Reinstalling Cab

85ZIV-2

CHASSIS 14

Removing and Reinstalling Cab 1.Removing Cab

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket 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.

1) The cover (1) for the outer filter is located at the right rear side of the cab.

Turn the rings counterclockwise and then remove the cover (1) .

Remove the outer filter (2) from the cab.

２

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

１ ６５Ｋ１４０５０

2)Remove the cover (3).

３

６５Ｋ１４０５１

3)Disconnect the vinyl tube (4) for window washer liquid. ４

６５Ｋ１４０５２

14-8

Removing and Reinstalling Cab

85ZIV-2

CHASSIS 14

4)Disconnect the electrical line coupler (5) and the ground cable (6). ５

６

６５Ｋ１４０５３

5)Remove the nut (7) and the lever (8). Then remove the cover (9).

７

Torque for assembly: : Nut (7) : 34N・m (3.5kgf ・m)

８

９ ６５Ｋ１４０５４

6)Remove the pin (11) for the arm (10). Tilt the steering shaft (12) backward.

１２ １０

１１

６５Ｋ１４０１４

7)Remove the bolt (13).

Front Right/Left 2pcs each Rear Right/Left 3pcs each Torque for assembly : : Bolt : 721N・m (73.5kgf ・m)

Ｃａｂ

Ｆ ｌ ｏｏｒ ｂｏａ ｒ ｄ １３

14-9

６５Ｖ１４００２

Removing and Reinstalling Cab

85ZIV-2

8)Remove the bolts (14) and the seal washer (15).

Install the eye bolt (M16 × 2.0) on the cab.

Lift the cab slowly.

CHASSIS 14

Ｃａｂ

１４ １５

: Cab 560kg

６５Ｖ１４００３

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

3.Cautions regarding reassembly 1)Check the movement of the wiper and adjust the moving angle if necessary.

2) Tune the clock and the radio.

14-10

Removing and Reinstalling Floor Board

85ZIV-2

CHASSIS 14

Removing and Reinstalling Floor Board 1.Removing and Floor Board

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

Before starting work: a)Remove the deck from both the right and left sides of the machine. b)Remove the cab. c) Disconnect the hose and the electrical coupler between the floor board and the chassis. d)Disconnect the pipes from the air conditioner lines at the self seal couplings.

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

Prepare a can for the oil.

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

２

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

１

６５Ｋ１４０１７

2)Disconnect the accelerator control cable (3) from the engine.

Throttle lever

３

８５Ｗ１４０１１

14-11

Removing and Reinstalling Floor Board

85ZIV-2

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

Install the eye bolt (M16 × 2.0) to the floor board at 4 places.

Attach sling then gradually lift the floor board while checking that there are no obstacles and that all the pipes, cables, pins etc. are disconnected. : ncluding ope. board, air conditioner, seat etc.

CHASSIS 14

４ ５

340kg

Torque for assembly : : Nut (5) : 417N・m (42.5kgf ・m)

８５Ｗ１４０１２

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

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

14-12

Removing and Reinstalling Boom

85ZIV-2

CHASSIS 14

Removing and Reinstalling Boom 1.Removing boom

WARNING

WARNING

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

Hitting the parts quenched such as bearing, shaft, pin and tooth by a steel-hammer could cause a breakage resulting in injury or death. ・ Keep persons away from working area. ・ Use a support plate in case a steel hammer is used. ・ Use a copper-hammer or a plastic hammer. ・ Always wear protection goggles.

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

１

３

: Bucket : 1,440kg Note: There are shims in the pin sections.

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

２

６５Ｋ１４０２２

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

５

: Link : 70kg

６

４ ６５Ｋ１４０２３

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

８

: Bucket cylinder : 215kg ５ ７

６５Ｋ１４０２４

14-13

Removing and Reinstalling Boom

85ZIV-2

CHASSIS 14

4) Lift the bucket cylinder (7) on the rod side. Apply a cable from the cab hoisting point to the bucket cylinder, and then temporarily turn up the cylinder.

CAUTION ・ To temporarily turn up the bucket cylinder, check that the cylinder angle is 90 °or less. Further tilting may cause the cylinder to overturn onto the cab. ・ You have to work on the machine to turn up the bucket cylinder. Carefully check your step on the machine.

７ ６５Ｋ１４０２５

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

: Lever : 360kg

９

６５Ｋ１４０２６

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

１０ １２

CAUTION Stop the engine when the boom is approximately 30cm above the stand (A). Set the boom lever to the boom down position to lower the boom onto the stand (A).

Open the hydraulic oil tank to release the internal pressure.

Ａ

１１

６５Ｋ１４０２７

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

14-14

Removing and Reinstalling Boom

85ZIV-2

8) Temporarily sling the cross pipe of the boom (10).

Remove the pin (13) from the boom on both the right and left side of the boom then slowly lift the boom (10) to remove it from the machine.

CHASSIS 14

１０

: Boom : 1,250kg Note: The pin sections are adjusted (to 1.2mm or less clearance) using liners. Do not lose the liners during the service work.

１３

６５Ｋ１４０２８

CAUTION Loss of control of the boom structure during removal or installation may 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.

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

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

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

14-15

Removing and Reinstalling Bushing

85ZIV-2

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

2.Reinstalling dust seal

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

Use tool and install the seal.

14-16

CHASSIS 14

Removing and Reinstalling Bushing

85ZIV-2

CHASSIS 14

3.Removing bushing Use a hydraulic jack (A), adapter (1) and (2). Remove two bushings at once.

Ａ Pulling direction

Adapter (1) material SS41

Diameter(mm) φA φC

φB

20

A

Bushing outside dia.-2

B

Bushing inside dia.-1

C

Jack rod dia. + 2

１

２

20

Adapter (2) material SS41

φAφB

30

30

Dimension(mm) 30

A

Bushing outside dia. + 20

B

Bushing outside dia. + 5

L

Bushing length×2

L Inspection hole

4.Reinstalling bushing Put clean grease on the bushings then use a hydraulic jack (A) and adapter (1). Install them from each side.

Make sure to prepare the space for dust seal.

Ａ

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

１

14-17

Center Pin

85ZIV-2

CHASSIS 14

Center Pin Upper center pin

Shim adjustment

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

Lower center pin

Rear

Front

Spherical plain bearing outer ring split position

Direction of grease nipple 20 °

14-18

Split shim

Removing and Reinstalling Center Pin

85ZIV-2

CHASSIS 14

Removing and Reinstalling Center Pin 1.Removing center pin

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

1)Disconnect the second propeller shaft (1) from the intermediate joint section.

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

１ ８５Ｋ１４０１０

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

3)Disconnect the brake hose (4), and disconnect the electrical line (5) from the clamp.

４ ５ ６

:Brake oil : Approx. 3 l Note: Wrap the steering cylinder rods to prevent accidental damage to the chrome rods.

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

２ ３

８５Ｋ１４０１１

4)Disconnect the high-pressure hoses (6). :Hydraulic oil : Approx. 3 l Note: Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

14-19

Removing and Reinstalling Center Pin

85ZIV-2

CHASSIS 14

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

Torque for assembly: : Castle nut : 260N・m (26.5kgf ・m) Retainer bolt (10) : 216N・m (22.0kgf・m) With lubrication oil (Engine oil or gear oil)

９

１０ ８

Steering valve

７ Castle nut ８５Ｋ１４０１２

6)Remove the clamp (12) from the pilot line hoses (11) to loosen the hoses.

Note: Normally there is enough slack to allow center pin group replacement. However, if the chassis must be completely separated mark, disconnect, and cover the hoses.

１１

１２

８５Ｋ１４０１３

7)Remove the upper center pin retainer bolt (13).

Torque for assembly: : Retainer bolt : 476N・m (48.5kgf ・m)

１３

８５Ｋ１４０１４

8)Screw the M12 (P1.75) bolt of approximately 70mm length into the center of the bushing (14) to push out the bushing. This bolt is used as a jack screw. １４

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

70 ８５Ｋ１４０２５

14-20

Removing and Reinstalling Center Pin

85ZIV-2

CHASSIS 14

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

１５

Jack ８５Ｋ１４０１５

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

１６

８５Ｋ１４０１６

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

１７ Jack

８５Ｋ１４０１７

12)While supporting the bottom of the fuel tank (18) using a garage jack, push the lower center pin (19) out using another jack to remove the pin. １９

１８

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

Garage jack ８５Ｗ１４０１４

14-21

Removing and Reinstalling Center Pin

85ZIV-2

CHASSIS 14

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

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 height adjustment is necessary.

Note: The chassis separation distance should be limited with the pilot line hose length.

Bar ９０Ｋ１４０２２

14)To disassemble the front chassis upper center pin, remove the ring (20), and then remove the bolt (22) from the plate (21).

Torque for assembly: : Retainer bolt : 216N・m (22kgf ・m)

２２

２０ Front

２１

８５Ｋ１４０２０

22.5 °

Grease port

２４

15)Remove the shim (23).

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

Thickness of shim (mm) : 0.1, 0.2, 0.3, 0.5, and 1.0 ２３ ８５Ｋ１４０２１

16)Check the dust seal (25) for distortion and scratches. If the dust seal is extremely distorted or scratched, replace it.

Note: Direction of dust seal (Top)

２５

(Bottom)

８５Ｋ１４０１９

８５Ｋ１４０２２

14-22

Removing and Reinstalling Center Pin

85ZIV-2

17)Check and replace the dust seal (26) of the lower center pin in the same way as described above.

To reinstall the spherical plain bearing (27), be sure to check the direction. For the bearing direction, refer to page 15-4.

CHASSIS 14

２７ ２６

８５Ｋ１４０２３

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

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

14-23

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

15-1

Linkage

85ZIV-2

CHASSIS 15

Linkage 1. Bucket -Boom

2. Boom-Lever

3. Boom-Boom cylinder

φ７０ φ１３０

4. Front chassis-Boom

φ９０

6. Lever-Link

5. Bucket-Link

φ９０ φ９０

φ１００

8. Bucket cylinder-Front chassis

7. Lever-Bucket cylinder

φ１００

9. Boom cylinderFront chassis

φ９０

φ１００

10. Front chassis-Steering cylinder

11. Steering cylinder-Rear chassis

φ５０

φ５０

８ ７

４

９

２

５ １０

３ ６

１１

１

15-2

Linkage Pin Standard Clearance Values

85ZIV-2

CHASSIS 15

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

Item

Solution

Pin standard dimension

Standard clearance

Tolerance

※

1

Joint section between bucket and boom

φ 70

0.104〜0.213

1.0

Replacement

※

2

Joint section between boom and lever

φ 130

0.153〜0.293

1.0

Replacement

3

Joint section between boom and boom cylinder

φ 90

0.117〜0.237

1.0

Replacement

※

4

Joint section between front chassis and boom

φ 100

0.117〜0.242

1.0

Replacement

※

5

Joint section between bucket and link

φ 90

0.117〜0.237

1.0

Replacement

※

6

Joint section betwen lever and link

φ 90

0.117〜0.237

1.0

Replacement

※

7

Joint section between lever and bucket cylinder

φ 100

0.117〜0.242

1.0

Replacement

※

8

φ 100

0.117〜0.242

1.0

Replacement

φ 90

0.117〜0.237

1.0

Replacement

φ 50

0.085〜0.178

1.0

Replacement

φ 50

0.085〜0.178

1.0

Replacement

9

※

10

※

11

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

Liner clearance adjustment ※

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

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

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

15-3

Center Pin

85ZIV-2

CHASSIS 15

Center Pin Upper Adjusting shim (#5) The clearance between the front chassis and bearing cover (#3) is 0.75mm before shim adjustment.

Adjust the shim so that the clearance is 0.1 ± 0.05mm .

〔Upper center pin〕

3 5

14 φ 85

Rear chassis Front chassis

12

Installing bearing cover (#3) Install the bearing cover so that the grease nipple mounting hole is positioned at the specified angle as shown in the right figure.

Front

3 22.5 °

Grease hole

〔Lower center pin〕

Lower Installing bearing outer ring (#9) Install the bearing outer ring so that the split is perpendicular to the front-rear line of the machine.

Rear chassis

9 φ 85

Torque for assembly: : Retainer bolt #12・ ・476N・m (48.5kgf・m) #14・ ・216N・m (22.0kgf・m)

Front chassis

Front

Rear

9 Grease nipple mounting direction

Split of outer ring 20 °

15-4

Bucket

85ZIV-2

CHASSIS 15

Bucket

(Tooth mouting section)

5

2

52

17.5 Tooth

(Wear edge mounting section)

6

Edge (Wear plate mounting section) 32

7 17.5

Center : 28 Side : 32 32

Wear edge

17.5

Wear plate

: 5. Tooth mounting bolt 834N・m (85.0kgf・m) 6.Wear edge mounting bolt 834N ・m (85.0kgf ・ m) 7.Wear plate mounting bolt

834N ・m (85.0kgf ・

m)

15-5

Bucket Positioner and Boom Kick-Out

85ZIV-2

CHASSIS 15

Bucket Positioner and Boom Kick-Out (Optional) Kick-out adjusting plate

6

Positioner

5

3

A

A

（Ｐｏｓ ｉ ｔ ｉ ｏｎｅ ｒ）

（Ｋ ｉ ｃｋ ‐ ｏｕ ｔ） 3 2 Connector

５．Ｂｕｃｋｅ ｔ ａｎｇ ｌ ｅ ａｄ ｊ ｕｓ ｔｍｅｎ ｔ 3 4 4 1

7°

Proximity switch

12° Cross section A-A

Unit : mm No.

Item

Judgment standard

Solution

1

Clearance of bucket positioner switch

5±2

Adjustment

2

Clearance of boom kick-out switch

5±2

Adjustment

3

Adjusting plate mounting bolt tightening torque

98N・m (10.0kgf・m)

Tightening

4

Switch mounting nut tightening torque

20N・m (2.0kgf・m)

Tightening

5

Bucket positioner adjustable angle

-7 ° 〜12 °

Adjustment

6

Boom kick-out adjustable angle

0〜43 °

Adjustment

15-6

Bucket Positioner and Boom Kick-Out

85ZIV-2

CHASSIS 15

Kick-out angle adjustment

0〜43 °

８５Ｅ１５００１

15-7

POWER GROUP 24 Power Line Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-2 Radiator Mount Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-3 Removing and Reinstalling Radiator ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-4 Removing and Reinstalling Engine ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-7 Removing and Reinstalling Propeller Shaft ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-9 Removing and Reinstalling Air Cleaner ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-11 Removing and Reinstalling Muffler ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-13 Front Axle Assembly Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-14 Removing and Reinstalling Front Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-15 Rear Axle Assembly Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-18 Axle Support Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-19 Removing and Reinstalling Rear Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-20 Disassembling and Reassembling Planetary Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-24 Floating Seal ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-31 Removing and Reinstalling Differential ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-36 Special Jigs for Disassembling Axle ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-38 Disassembling and Reassembling Internal Gear Hub ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-41 Front Differential Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-44 Rear Differential Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-45 Disassembling and Reassembling Differential Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-46 Disassembling and Reassembling Spider Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-56

24-1

Power Line Tightening Torque

85ZIV-2

POWER 24

Power Line Tightening Torque RADIATOR MOUNT

ENGINE

T3 L 1

T2 L 1 T4 L 1 T1 L 3

T3 L 1 T2 L 1

T1 L 3 REAR DIFFERENTIAL

FRONT DIFFERENTIAL

T5 L 2

T4 L 1 3RD PROPELLER SHAFT TRANSMISSION

T5 L 2

T2 L 1

T5 L 2 2ND PROPELLER SHAFT

T4 L 1 T2 L 1

: Bolt tightening torque T1 : 53N・m (5.4kgf・m) T2 : 417N・m (42.5kgf・m) T3 : 152N・m (15.5kgf・m) T4 : 231N・m (23.5kgf・m) T5 : 142N・m (14.5kgf・m)

L1 : Screw lock agent(Loctite 262)application L2 : Screw lock agent(Three Bond 1327)application L3 : Lubricate with engine oil or gear oil.

24-2

８５Ｅ２４００１

Radiator Mount Tightening Torque

85ZIV-2

POWER 24

Radiator Mount Tightening Torque

T2 L 1 RADIATOR

ENGINE

T1 L 2 T2 L 1

８５Ｗ２４１０２

: Bolt tightening torque T1 : 49N・m (5.0kgf・m) T2 : 231N・m (23.5kgf・m)

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

24-3

Removing and Reinstalling Radiator

85ZIV-2

POWER 24

Removing and Reinstalling Radiator 1.Removing radiator

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

Before starting work: ・Remove engine room (Refer to Section14).

1)Remove the lower cover from the bottom of the radiator. Remove the drain plug (1) to drain the coolant, also open the drain cock on the engine side to drain the coolant from the engine.

１

: Lower cover : 27kg : Capacity for coolant in system : 66 l

８５Ｋ２４００３

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

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

２

８５Ｋ２４００４

24-4

Removing and Reinstalling Radiator

85ZIV-2

POWER 24

3)Remove the fan guard (3).

３

８０Ｋ２４００５

4)Remove the right and left covers (4)(rear side).

４ ８５Ｋ２４００６

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

７ ６ ８ ５ ８０Ｋ２４００７

6)Remove the right and left stay (9).

Torque for assembly: : Retainer bolt : 231N・m (23.5kgf・m) : Screw lock agent (Loctite 262) applidation ９

８５Ｋ２４００７

24-5

Removing and Reinstalling Radiator

85ZIV-2

POWER 24

7) Temporariy sling the radiator (6). Remove the right and left retainer bolts (7), and then lift the radiator.

６

: Radiator : 200kg Torque for assembly: : Retainer bolt : 49N・m (5.0kgf・m) : Lubricate with engine oil or gear oil ７

８５Ｋ２４００８

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

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

Clearances

８５Ｗ２４１０３

24-6

Removing and Reinstalling Engine

85ZIV-2

POWER 24

Removing and Reinstalling Engine 1.Removing engine

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

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

Note: After removing the cooling fan, the engine may be removed without removing radiator. c) Collect the air conditioner refrigerant (option) using the proper recovery method. d)Drain engine oil : Engine oil : Approx. 39 l

側 １

1)Disconnect the negative side of the battery cable.

Then remove the positive cable.

６５Ｋ２４０１３

２

2)Disconnect the wire for the each sensor, preheat, alternator, airconditioner and engine stop motor.

3)Disconnect the fuel hose, and then remove the heater hose and cooler hose. Disconnect the pipe from the aircompressor, and then remove the drain hose.

２

８５Ｋ２４００９

4)Disconnect the accel control cable.

5) Temporarily sling the engine, then remove the bolt (2) both the right and lett. : Engine assembly : Approx. 900kg Torque for assembly: : Retainer bolt (2) : 417N・m (42.5kgf ・m) : Retainer bolt (2) : Screw lock agent (Loctite 262) application

24-7

Removing and Reinstalling Engine

85ZIV-2

POWER 24

6)Slowly lift the engine while checking that there are no obstacles and that all the pipes, cables, pins etc. are disconnected, and then remove the bot (3). ３

Note: Place a support, like a wooden block, under the transmission case.

Torque for assembly: : Retainer bolt (3) : 53N・m (5.4kgf ・m) (Lubricate with engine oil or gear oil) ８５Ｋ２４０１０

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

Note: Lift the engine approximately 100mm.

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

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

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

3.Cautions regarding engine reinstallation ①There is an O-ring in the housing between the engine and torque converter. Be sure to replace the O-ring with a new one.

When the ring gear interlocking is hard, open the flywheel cover and slowly rotate the transmission ring gear. ②Refill the engine with the proper quantity and type engine oil. ③Refill the radiator with premixed coolant (approx 50% water / 50% antifreeze). ④After reinstalling the engine, completely bleed the fuel line of air. ⑤Set the starter key to ON, and then check the monitor lamps of electrical equipment. ⑥Operate the engine at the idling speed for 5 minutes. After that, check the amount of the coolant. ⑦While gradually increasing the engine speed, check operation of the electrical equipment.

24-8

Removing and Reinstalling Prop. Shaft

85ZIV-2

POWER 24

Removing and Reinstalling Propeller Shaft 1.Removing second propeller shaft

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

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

Torque for assembly: : Retainer bolt : 142N・m (14.5kgf・m) : Screw lock agent (Loctite 262) application 2)Disconnect the grease pipe, and remove the bolt (4) from the pillow unit (5).

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

５ ４

１

３

２

８５Ｗ２４０１４

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

Torque for assembly: : Retainer bolt : 142N・m (14.5kgf・m) : Screw lock agent (Loctite 262) application : Second propeller shaft : 50kg Note: If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner.

Keep the flame away from the seals of the coupling.

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

2.Removing third propeller shaft 1)Remove the bolt (6).

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

６ ８５Ｗ２４０１５

24-9

Removing and Reinstalling Prop. Shaft

85ZIV-2

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

Note: During reinstallation, align the direction of the flange yokes on the second and third propeller shaft sides of the transmission. (Refer to Section 23) 〔 Difference in the yoke phase (direction) will cause the propeller shaft damage.〕

24-10

POWER 24

Removing and Reinstalling Air Cleaner

85ZIV-2

POWER 24

Removing and Reinstalling Air Cleaner 1.Removing air cleaner

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks 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)Remove the cap nut (1), and then remove the cover (2).

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

１ ３

４ ５

２

６

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

3)Remove the wing nut (5), and then remove the inner element (6). ８５Ｗ２４０１６

4)Disconnect the air duct (7).

Disconnect the indicator wire coupler (8).

８

７

８５Ｗ２４０１７

5)Remove the cover (10) from the top of the engine room (9).

１０

９ ７０Ｋ２４００９

24-11

Removing and Reinstalling Air Cleaner

85ZIV-2

POWER 24

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

７０Ｋ２４０１０

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

１３

７０Ｋ２４０１１

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

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

Carefully reinstall the air duct.

24-12

Removing and Reinstalling Muffler

85ZIV-2

POWER 24

Removing and Reinstalling Muffler 1.Removing muffler

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

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

２

１ ７ ４

1)Remove the clamp (1) and then remove the exhaust pipe (2). After that, remove the Engine room.

６

３

７

Torque for assembly: : Clamp tighten bolt : 29N・m (3.0kgf ・m) ８５Ｋ２４０１３

2)Remove the clamp (4) of the exhaust pipe (3), and then remove the retainer bolt (5), and the exhaust pipe.

Torque for assembly: : Retainer bolt : 53N・m (5.4kgf・m) Note: After disconnection, cover the pipe and the turbocharger side with vinyl, plugs or the like to protect the turbocharger from dust and dirt.

3)Remove the drain pipe (6), After that, remove the muffler retainer bolt (7), and then lift the muffler. : Muffler : 23kg Torque for assembly: : Retainer bolt (7) : 53N・m (5.4kgf ・m)

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

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

24-13

５

Front Axle Assembly Tightening Torque

85ZIV-2

POWER 24

Front Axle Assembly Tightening Torque

T3・L 1

T8・L 3 Floating seal B

L2

T5・L 1 T2

T1・L 1

A

T4 T7

８５Ｅ２４００２

T6・L 1

: Bolt tightening torque T1: 216N・m (22.0kgf ・m) T2: 33N・m (3.4kgf ・m) T3: 132N・m (13.5kgf ・m) T4: 86N・m (8.8kgf ・m) T5: 53N・m (5.4kgf ・m) T6: 89.7N・m (9.15kgf ・m) T7: 892N・m (91.0kgf ・m) T8: 1373N・m (140.0kgf ・m)

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

Note : 1. Axle nut tightening procedure 1)Tighten the axle nut (A) with 1765N ・ m (180kgf ・ m) tightening torque to install the taper roller bearing.

2)Loosen the axle nut (A).

3)Tighten the axle nut (A) again with 1765N ・m (180kgf・m) tightening torque.

4)Turn the wheel hub 2 〜3 turns back and forth, and measure the preload applied to section (B). Preload of section (B) : 226 〜 265N (23 〜 27kgf) This is "breakaway" force. The force required to start the wheel turning.

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

24-14

Removing and Reinstalling Front Axle

85ZIV-2

POWER 24

Removing and Reinstalling Front Axle Assembly 1.Removing front axle assembly Boom lock collar

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.

Stand Stand

1) Lift the front wheel using the bucket, and then place a stand under the front chassis to support the chassis. １

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

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

Reassembly : Clean the nylon breather tube before reinstalling.

７０Ｋ２４０１９

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

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

２

７０Ｋ２４０２０

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

３

: 1 Tire : 650kg Torque for assembly: : Retainer bolt : 892N・m (91.0kgf・m)

７０Ｋ２４０２１

24-15

Removing and Reinstalling Front Axle

85ZIV-2

POWER 24

6)Disconnect the right and left brake pipes (4). : Brake oil : 0.2 l

４ ７０Ｋ２４０２２

7) Temporarily sling the axle assembly (5), and then remove eight retainer bolts (6). : Axle assembly : 1,300kg Torque for assembly: : Retainer bolt : 1373N・m (140kgf ・m) Note: During reassembly be sure both mating surfaces are clean and free of paint.

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

24-16

５

６ ７０Ｋ２４０２３

Removing and Reinstalling Front Axle

85ZIV-2

POWER 24

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

After reinstallation, completely bleed air in the automatic adjuster valve first and then the service brake.

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

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

Finally the spider and the cover may fall off.

Spider ９０Ｗ５４００２

Socket bolt

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

Fill the brake oil tank. Slightly loosen the air bleeder nipple, and then press the brake pedal several times.

When the oil flows from the air bleeder nipple, close the nipple.

After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple. Repeat this until there is no air in the oil. When the oil level in the reservoir lowers, add oil to the tank.

Completely bleed each wheel of air.

24-17

Rear Axle Assembly Tightening Torque

85ZIV-2

POWER 24

Rear Axle Assembly Tightening Torque Floating seal

B L2

T5・L 1

T2 T3・L 1 A

T1・L 1

T4 T7

T6・L 1

: Bolt tightening torque T1: 216N・m (22.0kgf ・m) T2: 33N・m (3.4kgf ・m) T3: 132N・m (13.5kgf ・m) T4: 86N・m (8.8kgf ・m) T5: 53N・m (5.4kgf ・m) T6: 89.7N・m (9.15kgf ・m) T7: 892N・m (91.0kgf ・m) T8: 1373N・m (140.0kgf ・m)

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

８５Ｅ２４００３

Note : 1. Axle nut tightening procedure 1)Tighten the axle nut (A) with 1765N ・ m (180kgf ・ m) tightening torque to install the taper roller bearing.

2)Loosen the axle nut (A).

3)Tighten the axle nut (A) again with 1765N ・m (180kgf・m) tightening torque.

4)Turn the wheel hub 2 〜3 turns back and forth, and measure the preload applied to section (B). Preload of section (B) : 226 〜 265N (23 〜 27kgf) This is "breakaway" force. The force required to start the wheel turning.

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

24-18

Axle Support Tightening Torque

85ZIV-2

POWER 24

Axle Support Tightening Torque

T10・L 1

T9・

FRONT

８５Ｅ２４００４

: Bolt tightening torque T9 : 687N・m (70.0kgf ・m) T10 : 441N・m (45.0kgf ・m)

L1 : Screw lock agent (Three Bond 1327) application L3 : With lubricating oil (Engine oil or gear oil)

24-19

Removing and Reinstalling Rear Axle Assy

85ZIV-2

POWER 24

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

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

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

Ａ

８０Ｋ２４０２９

2) Lift the boom, and then roll the bucket back to level.

Check that the rear wheels are off the ground.

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

Ｂ

８０Ｋ２４０３０

3)Remove the lower cover, and insert the wooden blocks into the swing stopper section to prevent the axle from swinging .

Wooden blocks

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.

: Lower cover : 28kg ８０Ｋ２４０３１

24-20

Removing and Reinstalling Rear Axle Assy

85ZIV-2

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

POWER 24

１

: Tire of 1 wheel : 650kg (without hydroinflation) Torque for assembly: : Retainer bolt : 892N・m (91.0kgf・m)

８０Ｋ２４０３２

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

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

２

Rear differential

３

6)Disconnect the air breather tube (4).

Note: Remove and clean the tube reinstalling.

(4)

3rd propeller shaft ８０Ｋ２４０３３

before ４

Rear axle

８０Ｋ２４０３４

7)Disconnect the front and rear grease pipes.

8)Disconnect the hose (6) from the brake oil inlet side of the auto adjuster valve (5).

５

: Brake oil : approx. 3 l Note: Cover and plug the hose and fittings on the auto adjuster valve to prevent dirt entry.

８５Ｋ２４０２５

24-21

６

Removing and Reinstalling Rear Axle Assy

85ZIV-2

POWER 24

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

Lower the rear axle (7) on the carrier and then pull out the rear axle on the carrier.

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

８

CAUTION

７

８０Ｋ２４０３６

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.

Torque for assembly: : Retainer bolt : 687N・m (70.0kgf・m) : Rear axle : 1,700kg Note: Be careful not to bend or damage the oil pipes.

10)Remove the snap ring (9) and temporarily sling the rear axle support (10).

１０

: Axle support : 88.0kg 11)Remove the packing (11) and the O-ring (12).

９

１１

１２ １５ １４

12)Remove the bushing (13), O-ring (14) and the packing (15) from the swing shaft. １３

８０Ｋ２４０３７

Breather

13)Sling the rear axle support (16) and remove the bolt (17). Remove the plate (18), packing (19), wear ring (20) and the O-ring (21).

Torque for assembly: : Retainer bolt : 441N・m (45.0kgf・m) : Axle support : 108kg

１６ ２４ ２１ Grease piping

１７ １８

２５ ２３

２２

１９ ２０ ２６

24-22

８０Ｋ２４０３８

Removing and Reinstalling Rear Axle Assy

85ZIV-2

POWER 24

14)Remove the rear axle rear support (16) from the rear axle. Remove the packing (22) and the wear ring (23).

Breather

１６ ２４ ２１ Grease piping

15)Remove the bushing (24), ring (25) and the O-ring (26).

１７ １８

２５ ２３

２２

１９ ２０

２６

８５Ｗ２４０３３

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

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

Ｆｒｏｎ ｔ ｓｕｐｐｏｒ ｔ

Axle support

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

８

２

９

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

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

Bushing

７ ３１

１ ５６

Swing shaft ８５Ｗ２４０２２

Ｒｅａｒ ｓｕｐｐｏｒ ｔ

Axle support

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

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

１３ Bushing

１２

１１

３ ４ ５

１０

Swing shaft

６

24-23

７７． １

４． ５

８５Ｗ２４０２３

Disassembling Reassembling Planetary Assembly85ZIV-2 Disassembling andand Reassembling Planetary Assembly

POWER 24

Disassembling and Reassembling Planetary Assembly 1.Disassembling planetary Notes: ・Front axle is shown. To raise the rear axle off the ground follow the steps of "Removing and Reinstalling Rear Axle Assy". ・Drawings of the required jigs are shown page 24-38〜40.

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

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

2) Lift the boom until it is horizontal. Place a stand (B) under the boom to support it.

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

Stand Stand

１

: Tire of 1 wheel : 650kg Torque for assembly: : Retainer bolt : 892N・m (91.0kgf・m)

Ｂ

Ａ

７０Ｖ２４０２２

4)Remove the drain plug (2) from the differential section to drain oil. : Gear oil : Approx. 43 l

２ ７０Ｋ２４０３７

24-24

Disassembling Reassembling Planetary Assembly85ZIV-2 Disassembling andand Reassembling Planetary Assembly

POWER 24

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

Wheel hub section : 16 l for left side, 16 l for right side Differential section : 43 l 〔48 l for rear〕 Total oil amount for front axle : 75 l Total oil amount for rear axle : 80 l

３ ４

6)Remove the cover (5).

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

７０Ｋ２４０３８

５

７０Ｋ２４０３９

7) Temporarily sling the spider using the hoisting tool (A) and (E). Remove four spider retainer bolts (6) to remove the spider assembly (7).

Torque for assembly: : Retainer bolt : 86N・m (8.8kgf・m) : Spider assembly : 95kg

Ａ Ｅ

７

６

７０Ｖ２４０１８

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

９ ８

１０

9)Remove the friction plates (10).

７０Ｖ２４０１９

24-25

Disassembling Reassembling Planetary Assembly85ZIV-2 Disassembling andand Reassembling Planetary Assembly

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

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

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

POWER 24

１１ １２

７０Ｋ２４０４２

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

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

１５ １４

１６

１３

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

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

７０Ｋ２４０４３

Turnbuckle

Ｅ

３ ７０Ｋ２４０４４

13)Remove the axle nut (17).

Torque for assembly: : Nut : 1,765N・m (180kgf ・m) Note: Axle nut width across flat: 120mm

１７

８５Ｗ２４０２４

24-26

Disassembling Reassembling Planetary Assembly85ZIV-2 Disassembling andand Reassembling Planetary Assembly

POWER 24

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

Ｂ ８５Ｗ２４０２５

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

And remove the hub (18).

Ｃ

１８

８５Ｋ２４０２９

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

Then remove the wheel hub (3).

Ｄ

Ｅ

３

７０Ｋ２４０４８

17)Remove the oil seal (19). Also remove the sleeve from the axle.

Note: Disassemble the other wheels as described above.

１９

８５Ｋ２４０３０

24-27

Disassembling Reassembling Planetary Assembly85ZIV-2 Disassembling andand Reassembling Planetary Assembly

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

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

24-28

POWER 24

Disassembling Reassembling Planetary Assembly85ZIV-2 Disassembling andand Reassembling Planetary Assembly

POWER 24

3.Cautions regarding reassembly 1)Reinstall the internal gear hub assembly (18).

Note: Before reinstallation, 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.

１８

Spring pin ８５Ｋ２４０３７

Example LF

2) Tighten the axle nut (17) so that the preload of the tire mounting hole section is 226 to 265N (23 to 27kgf).

Note: This is the force to start the wheel hub moving or "breakaway" force.

１７ ８５Ｗ２４０２６

3)Disconnect the brake pipe (19) and elbow (20).

Attach the jig (G) for brake oil leakage test.

Jig (G) Shut off valve

Air supply PT 1/4

２０

Air pressure gauge

１９ ８５Ｗ２４０２７

4)Use the jig (B) to hold the brake piston not to come out.

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

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

Jig (B)

８５Ｗ２４０２８

24-29

Disassembling Reassembling Planetary Assembly85ZIV-2 Disassembling andand Reassembling Planetary Assembly

5) To reassemble the steel plates and friction plates, observe the following items. Note that the plates should be assembled to make possible the plate wear measurement after reassembling. ① Insert the steel plate having 4-teeth sections first.

Then install a friction plate. ② Insert the steel plate having two 2-teeth sections so that the spring pin is positioned at the midpoint between the 2-teeth sections. ③ Align the cooling holes of two friction plates with each other.

POWER 24

Spring pin Friction plate Align the black teeth with each other Cooling holes

Steel plate

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

Wheel hub Spider "TOP" mark (at top)

Brake oil line

Drain plug (at bottom)

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

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

24-30

Floating Seal

85ZIV-2

Floating Seal Construction Floating seal location Ｆ ｌ ｏａ ｔ ｉ ｎｇ ｓｅａ ｌ Ｗｈｅｅ ｌ ｈｕｂ Ａｘ ｌ ｅ ｈｏｕｓ ｉ ｎｇ

Ｒ ｉ ｎｇ

Ｓｅａ ｌｃ ｒ ｏｓｓ ｓｅｃ ｔ ｉ ｏｎ

Ｏ‐ ｒ ｉ ｎｇ

Ｓｅａ ｌＲ ｉ ｎｇ

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

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

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

24-31

POWER 24

Floating Seal

85ZIV-2

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

Ｒ ｉ ｎｇ

Ｒｅｍｏｖｅ ｏ ｉ ｌ

Ｐｕ ｔｔ ｈ ｉ ｎ ｇｅａｒ ｏ ｉ ｌ （Ｄｏ ｎｏ ｔ ｕｓｅ ｇｒｅａｓｅ）

Ｄｏ ｎｏ ｔｔ ｏｕｃｈ ｂｙ ｈａｎｄ （Ｉ ｔ ｍａｙ ｃａｕｓｅ ｒ ｕｓ ｔ ｉ ｎｇ）

24-32

POWER 24

Floating Seal

85ZIV-2

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

POWER 24

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

Ｇｕ ｉ ｄｅ ｊ ｉ ｇ

(2)In case jig is used

１

２

Ｂｅ ｆ ｏ ｒ ｅｉ ｎｓ ｔ ａ ｌ ｌ ａ ｔ ｉ ｏｎ

３

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

４

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

Ｇｕ ｉ ｄｅ ｊ ｉ ｇ

Ｉ ｎｓ ｔ ａ ｌ ｌ ａｔ ｉ ｏｎ

Ａｆ ｔ ｅ ｒｉ ｎｓ ｔ ａ ｌ ｌ ａ ｔ ｉ ｏｎ

24-33

Floating Seal

85ZIV-2

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

24-34

POWER 24

５

Ｃ

１０±０． ３ ７±０．

１０±０．

Ｒ０． ３

）

３

Ｒ０． ２〜Ｒ０．

24-35

２．

１３

２０

３

Ｃ

Ｒ０． ２〜Ｒ０．

Ｆｏｒ ｗｈｅｅ ｌ ｈｕｂ

１． ２．

１３ ３

３Ｃ

（ Φ２３０

１．

Φ１９０

85ZIV-2

Φ２６０

３

（ ３Ｃ

Φ２２０

１５ ３

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

２０

Φ２４２±０． １ Φ２３５±０． １

１０±０． ３ Φ２１４． Φ２７０

Ｆｏｒ ｗｈｅｅ ｌ ｈｕｂ

Φ２５８ Φ２４６． ２０−０．１

２．

（ ）

Φ２４７． Φ２６０

１． ３０ Φ２２６−０． −０． ３５ Φ２０９． ４±０． １

８±０．

２５ Φ２５６−０． −０． ３ Φ２４１±０． １

１５

Φ２３０

３

Φ１９０

Φ２２４． Φ２１４． Φ２０９． Φ２０１． １±０．

Φ２４０

Φ２３５

１ Φ２１４＋０． ＋０． ０５

２．

Φ２６０

２５ Φ２２３＋０． ＋０． ３

Φ２０９． ４±０．

１．

Φ２２０

Φ２５８ Φ２４６． Φ２４２±０． １ Φ２３５±０． １

Φ２７０

５

Φ２６５

１ Φ２４７． ２＋０． ＋０． ０５

Φ２４１． ８±０．

２５ Φ２５３＋０． ＋０． ３

Floating Seal POWER 24

4.Jigs (1)70ZIV-2〜80ZIV-2

Ｆｏｒ ｒ ｉ ｎｇ （ ）

２０ １１±０． ２

３ ３

１０±０．

Ｃ １０． ４±０．

Ｒ０． ３ Ｒ０． ２〜Ｒ０． ５

(2)85ZⅣ -2〜90ZⅣ -2

Ｆｏｒ ｒ ｉ ｎｇ ）

２０ １０． ９±０． ２

３ ３

１２±０．

１０±０．

Ｃ

１２±０． １

Ｒ０． ３

Ｒ０． ３

Ｒ０． ２〜Ｒ０． ５

Removing and Reinstalling Differential

85ZIV-2

POWER 24

Removing and Reinstalling Differential 1. Removing differential Before starting work: a)Drain oil from the axle assembly. b)Remove the axle from the machine. c) Place the axle assembly on workbenches. d)For the rear axle, remove the axle supports. For axle support removal, refer to the steps of "Removing and Reinstalling Rear Axle Assembly". : Axle assembly Front : 1,300kg Rear : 1,700kg

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

Torque for assembly: : Retainer bolt : 86N・m (8.8kgf・m) : Spider assembly : 95kg

Ａ １

ＴＯＰ

２

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

３

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

Torque for assembly: : Front differential retainer bolts : 132N ・ m (13.5kgf ・ m) : Rear differential retainer bolts : 314N ・ m (32.0kgf ・ m) : Screw lock agent (Loctite 262) application

４

５

24-36

Removing and Reinstalling Differential

85ZIV-2

Note: Spacers are inserted in eight "・" mark sections of the front differential.

POWER 24

Spacers

Spacers in "・" mark sections

4) Temporarily sling the differential (4), and insert bolts into the remover tap (Jack Screw) holes (6) to slightly lift the differential. : Differential : 178kg Note: Be careful to sling the differential so that it is balanced and is lifted straight up. ４

６ ７０Ｖ２４０３２

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

７

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

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

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

Also check the differential for oil leakage.

24-37

Special Jigs for Disassembling Axle

85ZIV-2

POWER 24

Special Jigs for Disassembling Axle (A) Spider hoisting tool

(Material: SS41)

46

6-mm dia.round steel 4 10

C2

12 3 75

3 65

6

t6

t6

6

105

10

22

46

t6

65

(B) Internal gear hub puller

(Material: SS41)

30

30

t12 M16

4

2

130

12

90

180 260 330

８５Ｗ２４０３５

24-38

Special Jigs for Disassembling Axle

85ZIV-2

POWER 24

(C) Internal gear hub hoisting tool

(Material: SS41) φ 13-mm drilled

75

35

t12

35

235 107

345

25

①

452

35

13

155

288

②

35 t9

31

27.5

35 90 A-A

A

A

24-39

27.5

25

15

3 15

7

10

t9

15

310

215

Special Jigs for Disassembling Axle

85ZIV-2

(D) Wheel hub hoisting tool

POWER 24

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

(Material: SS41)

10

4

4

3

20

t6

3

10

t6

3

25 ※

55

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

3

4

20

t6

60

(E) Eye bolt

M24 × 2

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

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

30

24-40

Internal Gear Hub

85ZIV-2

POWER 24

Disassembling and Reassembling Internal Gear Hub 1. Disassembling internal gear hub 1) Turn up the internal gear hub (1), and then remove the two O-rings (2). １

２

2)Remove the taper roller bearing (3).

Removal method: For easy removal, heat the inner race using a gas burner with slow flame. ３

3)Remove eight bolts (5) from the brake piston (4).

Torque for assembly: : Locknut : 33N・m (3.4kgf ・m)

５

４

4)Remove the return spring (6).

６ ５

24-41

Internal Gear Hub

85ZIV-2

POWER 24

5) Insert two remover bolts (2) into the brake piston (1) to remove the piston.

２ １

6)Remove the brake piston O-rings (3) (4). ３

４

7) There is a snap ring (7) that connects the internal gear (5) to the internal gear hub (6). Shift the snap ring to the inside using a round bar or the like.

５

６

8)Sling the internal gear (5) to remove it.

５

７

24-42

Internal Gear Hub

85ZIV-2

POWER 24

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

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

1)When reassembling the internal gear (10) and the brake piston (1) to the internal gear hub, align the oil groove of the internal gear hub with that of the brake piston and the spring pin (12).

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

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

１

１０

Oil groove

１２ ８５Ｗ２４０２９

2)Before reinstallation of the taper roller bearing (3), be sure to heat the bearing to 120 ℃ (248 ° F) to 150 ℃ (302 ° F) in oil.

3)Apply grease to the O-rings.

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

３

９０Ｋ２４００７

24-43

Front Differential Tightening Torque

85ZIV-2

POWER 24

Front Differential Tightening Torque

7

〜

Shim (T=0.07) (T=0.50) 〜

(T=16.70) (T=16.98)

８５Ｗ２４０３０

: Bolt tightening torque T1 : 883N・m (90.0kgf・m) T2 : 515N・m (52.5kgf・m ) T3 : 331N・m (33.7kgf・m) T4 : 314N・m (32.0kgf・m) T5 : 235N・m (24.0kgf・m) T6 : 52.5N・m (5.35kgf・m) T7 : 132N・m (13.5kgf・m)

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

Preload of section A : 57 to 66N (5.8 to 6.7kgf) Use spacer B to adjust the preload.

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

Adjust the backlash by nut F .

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

24-44

Rear Differential Tightening Torque

85ZIV-2

POWER 24

Rear Differential Tightening Torque

7

〜

Shim (T=0.07) (T=0.50) 〜

(T=16.70) (T=16.98)

８５Ｗ２４０３１

: Bolt tightening torque T1 : 883N・m (90.0kgf ・m) T2 : 515N・m (52.5kgf ・m) T3 : 331N・m (33.7kgf ・m) T4 : 314N・m (32.0kgf ・m) T5 : 235N・m (24.0kgf ・m) T6 : 52.5N・m (5.35kgf ・m) T7 : 314N・m (32.0kgf ・m)

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

Preload of section : 57 to 66N (5.8 to 6.7kgf) Use spacer B to adjust the preload.

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

Use nut F to adjust the backlash.

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

24-45

Differential Assy

85ZIV-2

POWER 24

Disassembling and Reassembling Differential Assembly 1. Disassembling differential assembly Before starting work: a)Fix the differential assembly onto the disassembly workbench. b) Insert a straight-end screwdriver or the like into the clearance between the pinion and the bevel gear to prevent the gear from rotation. Loosen the nut.

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

Adjust nut

Shim

Bevel gear Nut

Pinion

Adjust nut

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

1

2

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

3

4

1 ７０Ｖ３４０３４

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

5 6

24-46

Differential Assy

85ZIV-2

POWER 24

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

７

８ Ｍａ ｔ ｃｈ ｍａｒｋ ７０Ｋ２４０６４

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

１０ ９ ７０Ｋ２４０６５

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

１２

１３ １１ ７０Ｋ２４０６６

7)Remove the side gear (14).

１４ ７０Ｋ２４０６７

24-47

Differential Assy

85ZIV-2

POWER 24

8)Remove the thrust washer (15). １５

７０Ｋ２４０６８

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

１７

１６ ７０Ｋ２４０６９

10)Remove the bolts (18) to remove the pinion (19). At the same time, remove the shim.

１９

１８

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

Note: Nut width across flat:57.1mm.

２０

24-48

２１

Differential Assy

85ZIV-2

POWER 24

12)Remove the flange yoke (22).

２２

７０Ｖ２４０３５

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

２３

２４

14)Remove the taper roller bearing (25).

２５

15)Remove the spacer (26). ２６

24-49

Differential Assy

85ZIV-2

POWER 24

2. Reassembling differential assembly IMPORTANT ・ Clean and check all the parts. If a part is worn or damaged, replace it. ・ Be sure to replace O-rings and seals with new ones.

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

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

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

２４ ２６

２０

２５ ２７

２３

Ａ

２８

２２ ７０Ｖ２４０３６

Pinion

Bearing

Pinion

: Standard preload * : 57 to 66N (5.8 to 6.7kgf) If the preload is out of the above range, replace the spacer (26) to adjust the preload to the specified range. * Preload is the force required to start the cage moving-breakaway force.

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

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

24-50

Stake at 3 points

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

２９ ２４

Differential Assy

85ZIV-2

POWER 24

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

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

(Nut width across flat : 57.1mm)

22 20

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

21

Shim

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

18

31

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

30

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

15 14 32

７０Ｋ２４０７３

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

12 13 11

24-51

Differential Assy

85ZIV-2

POWER 24

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

9 10

７０Ｋ２４０７４

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

8

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

7

Match mark

9) Tighten the bolts (17) in the bevel gear (16). : Retainer bolt : 331N・m (33.7kgf・m) : Screw lock agent (Three Bond 1327) application 17 15

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

24-52

6

Differential Assy

85ZIV-2

POWER 24

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

(For both the right and left sides)

3

4

Adjust nut

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

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

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

13)Tighten the bolts (3) of the bearing cap (4). : Retainer bolt : 515N・m (52.5kgf・m) : Screw lock agent (Three Bond 1327) application 14)Mount the lock plate (2), and then tighten the bolts (34) to fix the lock plate. : Retainer bolts : 52.5N・m (5.35kgf・m) : Screw lock agent (Three Bond 1327) application

24-53

1

16

33

2

34 3 4

Differential Assy

85ZIV-2

POWER 24

② Adjusting tooth contact After adjusting the backlash to the standard value, check that manual rotation of the gear is possible. After that, paint blue or red on the tooth surface of ring gear, and check the tooth contact. To adjust the tooth contact, adjust the thickness of the shim between the pinion and cage, and turn the adjustment nut.

Tooth contact

A

Adjusting method

Correct

Loosen the bearing adjuster on the rear side of 2

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

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

Check again the backlash and tooth contact.

2

C

Do the reverse adjusting as B.

Decrease the thickness of shim at the part of D

2

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

Check again the backlash and tooth contact.

1

E

2

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

1

24-54

Differential Assy

85ZIV-2

POWER 24

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

Tooth contact position and length(rate) 10 1

Pattern A

5 TOP

4

HEEL 4〜5

Pitch line TOE

10

BOTTOM 10 2

Pattern B

4 TOP

4

Pitch line

HEEL 4〜5

10

TOE BOTTOM 10 3 Pattern C

4 TOP

3

TOE Pitch line

HEEL 4〜5

10

BOTTOM

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

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

24-55

Spider Assy

85ZIV-2

POWER 24

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

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

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

１ ３

④

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

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

５ ６

４

７

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

８

９

24-56

Spider Assy

85ZIV-2

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

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

24-57

POWER 24

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

25-1

Propeller Shaft Service Standard

85ZIV-2

POWER 25

Propeller Shaft Service Standard

Third propeller shaft

①

①

Second propeller shaft

①

② Measurement of circumferential play

勝

匠

③ Measurement of transverse play

mm No.

Item

Tolerance

Solution

1

Spider bearing play

Second, third propeller shaft

0.25

Replacement

2

Spline circumferential play

Second propeller shaft

0.8

Replacement

3

Spline transverse play

Second propeller shaft

1.0

Replacement

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

25-2

Axle and Differential Service Standard

85ZIV-2

POWER 25

Axle and Differential Service Standard Axle group

4

5

2・3

1・3

4

5

mm Judgment standard No.

Item

Solution Standard dimension

Tolerance

1

Backlash between sun gear and planetary gear

0.12〜0.60

←

Replacement

2

Backlash between planetary gear and internal gear

0.14〜0.73

←

Replacement

3

Tooth contact of gear

No abnormality

Replacement

4

Axle support wear

Dia.: 1.0 / Radius: 0.5 (stepped)

Replacement

5

Bushing and wear ring wear

No oil groove

Replacement

25-3

Axle and Differential Service Standard

85ZIV-2

POWER 25

Differential

①

② ③

④

mm Judgment standard No.

Item

Solution Standard valve

Tolerance

1

Backlash between ring gear and drive pinion

0.26〜0.38

←

Adjustment

2

Backlash between side gear and pinion gear

0.23〜0.58

←

Adjustment

3

Clearance between pinion gear and spider

0.098〜0.126

←

Replacement

4

Runout of ring gear rear surface (when assembled)

0.076

←

Adjustment or replacement

5

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

6

Tooth contact

No abnormality

Replacement

25-4

TORQUE CONVERTER AND TRANSMISSION GROUP 34 Removing and Reinstalling Transmission Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-2 Bolt Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-09 Disassembling and Reassembling Torque Converter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-10 Disassembling and Reassembling Transmission Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-17 Disassembling and Reassembling Forward/Reverse Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-30 Disassembling and Reassembling 1st/3rd Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-34 Disassembling and Reassembling 2nd Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-38 Disassembling and Reassembling 4th Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-41 Control Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-45 Removing and Reinstalling Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-46 Disassembling and Reassembling Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-48

34-1

Removing and Reinstalling T / M Assy

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Removing and Reinstalling Transmission Assembly 1.Removing transmission assembly

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

Before starting work: a)Remove the cab and the floor board. b)Remove the engine room. c) Consider the type of failure and if the T/C oil cooler must also be removed for cleaning or replacement. ・If a small amount of contamination is found in the transmission strainer and filter the cooler does not need removal. ・If a large amount of contamination is found the cooler must be removed.

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

１

８５Ｋ３４００１

: Transmission oil : 38 l 2)Disconnect the bolts (3) from the third propeller shaft (2) on the transmission side.

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

Keep the flame away from the seals of the coupling.

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

Tightening torque for assembly : Bolt : 80N・m (8.2kgf ・m) : Screw lock agent application (Three Bond 1327) 3)Remove the bolt (5) from the second propeller shaft on the transmission side only. Disconnect the electric wire (6) (7) from the speed meter sensor and speed sensor.

Tightening torque for assembly : Bolt : 142N・m (14.5kgf ・m) : Screw lock agent application (Three Bond 1327) Note: The speed sensor (7) is for the machines S/N 85N3 - 9001〜9050.

２ ４ ３ ５ ８５Ｋ３４００２

６ ７

l ８５Ｋ３４００３

34-2

Removing and Reinstalling T / M Assy

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

IMPORTANT When the transmission is lifted, the parking brake cylinder will come in contact with the chassis. To prevent this, remove the parking brake cylinder before lifting the transmission.

８

4)Release the parking brake and disconnect the link of the cylinder. If the machine has no air, feed air into the air hose (8) from the outside.

Note: If there is no air source, apply a rope or cable to the link, and then pull it down using a bar to compress the spring of the cylinder. After that, remove the pin.

８５Ｗ３４００１

5)Remove the split pin (9), and then remove the pin (10).

6)Remove the bolts (12) from the cylinder mounting bracket (11). Disconnect the air source, and then remove the cylinder (13).

１３ １１ １２ ９

１０

８５Ｋ３４００５

7)Disconnect the hose (14) from the transmission level gauge.

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

１４ ８５Ｋ３４００６

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

１６

１６

8)Disconnect all the hoses and pipes (16) from the steering valve (15).

Note: After removing the hoses, cover the hoses with vinyl, and cover the valve with caps or the like to protect them from dust and dirt.

34-3

１６ １６

１５

１６

８５Ｋ３４００７

Removing and Reinstalling T / M Assy

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

9)Remove the split pin (17), and then remove the castle nut (18) to remove the pin (19). After that, swing the steering link out of the way.

Remove the bolts (22), and then remove the steering valve with the bracket as a unit.

Tightening torque for assembly : Bolt : 216N・m (22.0kgf ・m) : Steering valve : 30kg (including bracket)

１８

１７

２１ ２２ ２０ １９ ８５Ｋ３４００８

10)Remove all the connected hoses (24) from the gear pump assembly (23).

Remove the suction hose (25) from the pump assembly (23).

Note: After removing the hoses, cover the hoses with vinyl, and cover the pump ports with the caps or the like to protect them from dust and dirt.

２５ ２６

２３

２４

11)Remove four bolts (26) from the gear pump (23).

Tightening torque for assembly : Bolt : 147N・m (15.0kgf ・m)

２４ ８５Ｋ３４００９

12)Temporarily sling the gear pump (23) and remove it from the spline section. ２５

: Gear pump assembly : 33kg Note: Be sure to replace the gasket of the gear pump flange with a new one.

２６

２３

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

２４

８５Ｗ３４００２

13)Disconnect the electric wires from torque converter oil temperature switch sensors (27). Disconnect the main clutch pressure outlet hose (28).

２７ ２８

８５Ｋ３４０１０

34-4

Removing and Reinstalling T / M Assy

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

14)There are two hoses (29) between the line filter and the transmission. There are two hoses (30) between the torque converter and the cooler.

Disconnect the hoses (29)(30).

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

２９

３０ ８５Ｋ３４０１１

15)Remove all the electric wire couplers (32) from the control valve (31).

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

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

For reassembly refer to the connection illustration "Reinstalling control valve".

３２

３１

８５Ｋ３４０１２

IMPORTANT When the transmission assembly is lifted, it will come in contact with the hose of the steering cylinder. To prevent this, remove the hose support before lifting the transmission assembly.

３４

３３

３４

16)Remove the clamp (34) from the steering hoses (33), and then remove the hose support (35). ３５ ３５

８５Ｋ３４０１３

17)Temporarily sling the transmission assembly (37), and then remove 12 bolts (38) from the engine flywheel housing.

Tightening torque for assembly : Bolt : 55N・m (5.6kgf ・m) : Transmission assembly : 880kg

３８

３７

８５Ｗ３４００３

34-5

Removing and Reinstalling T / M Assy

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

18)Remove the bolts (39) (both sides).

Tightening torque for assembly : Bolt : 216N・m (22.0kgf ・m) ３９

８５Ｗ３４００４

Note: The joint section between the engine and the transmission consists of the pilot boss and the gear coupling as shown in the figure. The pilot boss is inserted for centering, and the gear coupling is used for power transmission. To separate the transmission from the engine, remove the bolts from the engine flywheel housing, and then pull the transmission straight out approximately 50mm to the front.

Engine flywheel housing

Flywheel Pull 50 cm to separate transmission Transmission

Pilot boss Ring gear

Engine-transmission joint section

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

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

Wooden block

８５Ｋ３４０１６

20)Slowly lift the transmission assembly (40) while avoiding contact with other parts. ４０

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

８５Ｗ３４００５

34-6

Removing and Reinstalling T / M Assy

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

１

８５Ｋ３４０１８

② Rotate the engine flywheel to align the ring gear.

８５Ｋ３４０１９

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

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

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

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

2)Check each section for oil leakage.

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

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

34-7

Removing and Reinstalling T / M Assy

DATE:

85ZIV-2

HOURS:

TORQUE CONVERTER AND TRANSMISSION 34

MACHINE MODEL & SERIAL NO. :

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO. :

AMBIENT TEMP:

COMPONENT SERIAL NO. :

CHECKLIST TO BE COMPLETED BEFORE START-UP □ TRANSMISSION COOLER CLEANED

□ TRANSMISSION PIPING CLEANED

□ IN-LINE PRESSURE FILTER REPLACED

□ TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

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

CLUTCH PRESSURE AT IDLE F1

2

Pa (kgf/cm )

N1

Pa (kgf/cm2)

R1

Pa (kgf/cm2)

F2

Pa (kgf/cm2)

N2

Pa (kgf/cm2)

R2

Pa (kgf/cm2)

F3

Pa (kgf/cm2)

N3

Pa (kgf/cm2)

R3

Pa (kgf/cm2)

F4

Pa (kgf/cm2)

N4

Pa (kgf/cm2)

R4

Pa (kgf/cm2)

F1

2

Pa (kgf/cm )

N1

Pa (kgf/cm2)

R1

Pa (kgf/cm2)

F2

Pa (kgf/cm2)

N2

Pa (kgf/cm2)

R2

Pa (kgf/cm2)

F3

Pa (kgf/cm2)

N3

Pa (kgf/cm2)

R3

Pa (kgf/cm2)

F4

Pa (kgf/cm2)

N4

Pa (kgf/cm2)

R4

Pa (kgf/cm2)

CLUTCH PRESSURE AT HIGH IDLE

COMMENTS:

Serviceman's Signature

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

34-8

Bolt Tightening Torque

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Bolt Tightening Torque

T2

T2 L1

T1 T2 L1

T3 L 1 T5

T4 ８５ＺＡ３２０１

T2

T1 : 29N・m (3kgf・m) T2 : 53N・m (5.4kgf・m) T3 : 235N・m (24kgf・m) T4 : 392N・m (40kgf・m)(Molybdenum disulfide grease / MOS2 application) T5 : 98N・m (10kg・m) L1 : Screw lock agent application (Loctite 262)

34-9

Torque Converter

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and Reassembling Torque Converter 1.Disassembling torque converter Before starting work: a)Clean the transmission assembly. b)Drain oil from the transmission.

２

1)Remove the bolts (1), and then remove the cover (2).

１ ８５Ｋ３４０２０

2)Removing the front cover from the pump impeller.

Remove the bolts (3). (Number of bolts : 24) Tightening torque for assembly : Bolt : 29N・m (3kgf・m)

３ ８５Ｋ３４０２１

3)Remove the front cover (4).

After removing the front cover, remove the ball bearing (5).

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

４ ５

８５Ｋ３４０２２

Shim

4)Remove the turbine impeller assembly (8).

８

８５Ｗ３４０１

34-10

Torque Converter

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

5)Remove the thrust washers (9), thrust bearing (10), and spacer (11).

１０

９ １１

８５Ｗ３４０２

6)Remove the snap ring (12) and the stator (13).

１３

１２

８５Ｗ３４０３

7)Remove the collar (14), thrust washer (15), thrust bearing (16) and shim (17). １５ １７

１６

１４

８５Ｗ３４０４

8)Remove the pump impeller assembly (18). １８

８５Ｗ３５０５

34-11

Disassembling and Reassembling Torque Converter 85ZIV-2

9) Remove the seal ring (19), bolts (20), and then stator shaft (21).

TORQUE CONVERTER AND TRANSMISSION 34

１９

２０ ２１

８５Ｗ３４００６

10)Remove the seal ring (22).

11)Separate torque converter transmission housing.

housing

from 25

23

12)Turn the torque converter housing over.

13)Remove the turbine shaft (24).

22 24

14)Remove the snap ring (23) and the turbine shaft bearing (25).

34-12

３４−０１３ ８５ＺⅣ

85ZIV-2

Torque Converter

TORQUE CONVERTER AND TRANSMISSION 34

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

1) Turn the torque converter housing over.

2) Install the spring (3) and washer (4) to the bolt (2).

１

４

５

3) Install the bolt (2) to the housing.

IMPORTANT ① Adjust the clearance between the housing (1) and the bolt (2) to 35.2 mm. ２

３

２

３ ４

４

８５Ｋ３４０２８

35.2

８５Ｗ３４００７

4) Install the nut (5) onto the bolt (2).

Tightening torque for assembly : Nut : 50N・m (5.1kgf・m) : Screw lock agent application (Loctite 262)

34-13

85ZIV-2

Torque Converter

TORQUE CONVERTER AND TRANSMISSION 34

5) Install the turbine bearing (25) and the snap ring (23).

２１

6) Install the turbine shaft (24) . ２５２３

２０

7)Connect the torque converter housing to the transmission housing.

8)Attach the seal ring (22). : Apply grease to the seal ring, and then insert into the groove.

２２ ８５Ｗ３４００８

２４

9) Tighten the bolts (20) to fix the stator shaft (21). : Bolt : 53N・m (5.4kgf ・m) : Screw lock agent application (Loctite 262)

１８ ７

IMPORTANT Adjusting thrust clearance ① Temporarily assemble the pump impeller (18) on the PTO drive gear, stator, bearing washers etc. and the turbine impeller (8). ② Measure the distance from the ball bearing (7) to the mounting face of the pump impeller assembly. Regard the obtained distance as dimension A.

８ ８５Ｗ３４００９

IMPORTANT ③ Measure the distance from the mounting face of the front cover (6) to the end face of the bearing receiver. Regard the obtained distance as dimension B. ④ Adjust the difference between distance B and distance A (thrust clearance) to 0.2 to 0.4 mm using a shim as shown in the figure below. ⑤ After shim adjustment, remove the ball bearing (step (2) above), and then sequentially attach the shim and then the ball bearing to the front cover.

６

８５Ｗ３４０１０

A

B-A = 0.2〜0.4mm Front cover B Ball bearing

Adjusting shim ３４−０１５ ８５ＺⅣ

34-14

85ZIV-2

Torque Converter

10)Install the pump impeller assembly (18), and then attach the shim (17), thrust bearing (16), thrust washer (15), and collar (14).

TORQUE CONVERTER AND TRANSMISSION 34

１８

１４ １５ １６ １７

８５Ｗ３４０４

11)Install the stator (13), and attach the snap ring (12).

１３

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

Correctly install the stator (13).

１２

８５Ｗ３４０３

12)Attach the spacer (11), thrust washer (9), and thrust bearing (10).

１０

９ １１

８５Ｗ３４０２

13)Install the turbine impeller assembly (8).

８

８５Ｗ３４０１

34-15

85ZIV-2

Torque Converter

TORQUE CONVERTER AND TRANSMISSION 34

14)Install the front cover, and then tighten the bolts (3) to connect the front cover to the pump impeller assembly.

Number of bolts : 24 : Bolt : 29N・m (3kgf・m)

３ ８５Ｗ３４０１１

15)Install the cover (2), and then tighten the bolts (1). : Bolt : 39N・m (4.0kgf ・m) Note: At the completion of reassembly, manually turn the front cover to check that it rotates smoothly.

２

１ ８５Ｗ３４０１２

34-16

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

1)Remove the bolts (1).

2) Lift the control valve assy (2), and remove it. : Control valve assembly : 20kg ２

１ ８５Ｗ３４０６

3)Remove the bolt (3), and remove the back drum (4). ４

３

８５Ｗ３４０７

4)Remove the nut (5), then remove the flange yoke (6). ６

５

８５Ｗ３４０８

34-17

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

5)Remove the bolt (7), and then remove the brake assembly (8). ８

７ ８５Ｗ３４０９

6)Remove the bolt (10) and then remove the drive cover assembly (11).

１０

１１ １０

7)Remove the bolts (9).

Lift the cover assy (12) to remove it.

８５Ｗ３４１０

９ １２

８５Ｗ３４１１

8)Remove the gear (13).

１３

８５Ｋ３４０４６

34-18

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

9)Remove the bolt (14).

１４ ８５Ｋ３４０４７

10) Remove the output shaft (15).

１５

８５Ｋ３４０５０

11)Remove the 4th speed clutch pack assembly (16). １６

８５Ｋ３４０５１

12)Remove the 1st speed clutch pack assembly (17).

Note: Pull out the 1st speed clutch pack assembly. It is tight due to the ball bearing between the housing and the shaft. １７

８５Ｋ３４０５２

34-19

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

13)Remove the bolt (18). １８

８５Ｋ３４０５３

14) Lift the housing (19) slowly. １９

８５Ｋ３４０５４

15)Remove the 3rd and the forward speed clutch pack assembly (20).

２０

８５Ｋ３４０５５

16)Remove the 2nd and the reverse speed clutch pack assembly (21).

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.

２１

８５Ｋ３４０５６

34-20

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

17)Remove the turbine shaft assembly (22).

２２

８５Ｋ３４０５７

18)Remove the bolt (23), plate (24) and gear (25).

２４ ２５ ２３

８５Ｋ３４０５８

19)Remove the bolt (26) and then remove the shaft (27). ２７

２６

８５Ｋ３４０５９

20)Remove the bolt (28) and then remove the charge pump assembly (29).

２９

２８

34-21

８５Ｋ３４０６０

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

２９

３０

1) Install the torque converter gear pump (29) with the bolt (28).

Note: ・Check the thrust clearance (0.5 to 1.0mm) at the pump shaft (30) (PTO shaft). Tap the shaft with a soft hammer to check the thrust clearance, if necessary. : Bolt : 53N・m (5.4kgf ・m) ２８

８５Ｗ３４０１３

2) Install the shaft (27) with the bolt (26). : Bolt : 53N・m (5.4kgf ・m) ２７

２６

８５Ｗ３４０１４

3) Install the gear (25) onto the shaft (27).

Install the plate (24) and tighten the bolt (23).

２３

: Bolt : 53N・m (5.4kgf ・m) ２５

２４

８５Ｗ３４０１５

34-22

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4) Install the turbine shaft assembly (22).

２２

８５Ｗ３４０１６

5) Install the 2nd and the reverse speed clutch pack assembly (21).

２１

８５Ｗ３４０１７

6) Install the bearing (31) into the housing .

３１

８５Ｗ３４０１８

7) Install the 3rd and the forward speed clutch assembly (20).

２０

８５Ｗ３４０１９

34-23

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

8) Install the housing (19) on to the T/C housing. １９

８５Ｗ３４０２０

9) Tighten the bolt (18). : Bolt : 53N・m (5.4kgf ・m)

１８

８５Ｗ３４０２１

10)Install the 1st speed clutch pack assembly (17) and the 4th speed clutch pack assembly (16).

１６

１７

８５Ｗ３４０２２

11)Install the small end bearing (32) on the output shaft (15) and install the snap ring .

Note: Before installation of the ball bearing (32), be sure to heat the bearing to 100 ℃ in oil.

１５

３２

８５Ｗ３４０２３

34-24

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

12)Install the output shaft (15) into the housing (19).

１５

１９

８５Ｗ３４０２４

13)Tighten the bolt (14). : Bolt : 53N・m (5.4kgf ・m)

１４

８５Ｗ３４０２５

14)Install the gear (34) onto the output shaft (15).

３４ ８５Ｗ３４０２６

１５

15)Measure and record the clearance between the 1st speed clutch pack gear (17) and the 4th speed clutch pack gear (16) .

１６

Note: The clearance between them should be no less than 0.5 〜1.0mm.

１７ ８５Ｗ３４０２７

34-25

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

16)Measure the distance from the bearing of the 4th speed clutch pack (16) to the mounting face (including gasket) of the housing.

Regard the obtained distance as dimension A.

１６

８５Ｗ３４０２８

17)Measure the distance from the bearing of the 1st speed clutch pack (17) to the mounting face (including gasket) of the housing.

Regard the obtained distance as dimension A ′.

１７ ８５Ｗ３４０２９

18)Measure the distance from the mounting face of the cover (12) to the end face of the bearing receiver for the 4th speed clutch pack .

Regard the obtained distance as dimension B.

１２

８５Ｗ３４０３０

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

Regard the obtained distance as dimension B ′.

１２

８５Ｗ３４０３１

34-26

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

20)Adjust the difference between the distance B and the distance A (thrust clearance) to 0.5 〜 1.0mm using a shim (35).

B-A=0.5〜1.0mm

３５ ８５Ｗ３４０３２

21)Adjust the difference between the distance B' and the distance A' (thrust clearance) to 0.5 〜 1.0mm using a shim (36).

B'-A' = 0.5〜1.0mm

３６

８５Ｗ３４０３３

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

C

C

22)Install the cover (12) onto the housing . １２

８５Ｗ３４０３４

34-27

85ZIV-2

Transmission

TORQUE CONVERTER AND TRANSMISSION 34

23)Install the ball bearing (37) and gear (38) onto the output shaft. ３７ ３８

３７ ３８

８５ＺＡ３４０３

８５Ｗ３４０３５

24)Install the drive cover assembly (11) and tighten the bolt (10).

１１

: Bolt : 53N・m (5.4kgf ・m)

１０ ８５Ｗ３４０３６

25)Tighten the bolts (9). Install the brake assembly (8) and tighten the bolt (7). : Bolt (9) : 53N・m (5.4kgf・m) : Bolt (7) : 235N・m (24kgf ・m)

８

９ ７ ８５Ｗ３４０３７

26)Install the brake drum (4) and tighten the bolt (3).

Install the flange yoke (6) and tighten the nut (5).

５

６

: Bolt : 98N・m (10kgf ・m) :Nut : 392N・m (40kgf ・m)

４ ３

８５Ｗ３４０３８

34-28

Transmission

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

27)Install the control valve assembly (2) and tighten the bolts (1). : Bolt (1) : 39N・m (4.0kgf・m) : Bolt (T6) : 20N・m (2.0kgf・m)

２

８５Ｗ３４０３９

Ｔ６

１

８５Ｗ３４０４０

34-29

Forward / Reverse Clutch Pack

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

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

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

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

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

２

３

１

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

４ ５ ６ ７ ６５Ａ３４００１

34-30

Forward / Reverse Clutch Pack

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

Note: Number of friction plates: 7 Number of steel plates: 6

８

９

６５Ａ３４００２

4)Slightly depress the ring (11). Remove the snap ring (10) and the ring (11).

１１ １０

８５Ｗ３４０５３

5)Remove 20 springs (12), and then feed compressed air to the clutch oil port at the end of the shaft (14) to remove the piston (13).

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

１４ １２ １５

１３

１６ １７ ９０Ｗ３４０６０

6)Remove the ring (15) from the piston (13).

7)Remove the piston ring (16) (17) from the shaft assy.

34-31

Forward / Reverse Clutch Pack

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

1) Install the piston (13), and 20 springs (12). If necessary gently and evenly tap the piston into place using a plastic hammer or driver.

１２ １３

８５Ｅ３４００１

2) Insert the ring (11), and snap ring (10).

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

１１ １０

８５Ｅ３４００２

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

Note: Number of friction plates: 7 Number of steel plates: 6 After installing the piston, be sure to insert the friction plate first.

８

９

34-32

８５Ｅ３４００３

Forward / Reverse Clutch Pack

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

4) Insert the backing plate (7) and the snap ring (6).

４ ５ ６ ７ ８５Ｅ３４００４

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

Note:

Depth micrometer Straight edge

Air line

Piston stroke Forward

3.3±0.5mm

Reverse

3.3±0.5mm

Backing plate

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

6) Insert the thrust washer (5).

Note: When inserting the thrust washer (5), put the notch side up.

7) Install the gear (1), and then insert two needle bearings (4) and the thrust washer (3).

Note: When inserting the thrust washer (3), put the notch side down.

８５Ｗ３４０４１

４

３ １ ５

８５Ｅ３４００５

8) Install the ball bearing (2) and snap ring (18).

Note: To assemble the forward clutch pack, install the roller bearing inner race. １８ ２

８５Ｅ３４００６

34-33

1st / 3rd Speed Clutch Pack

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

The different points are described for each procedure.

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

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

Spacer

１ ８５Ｋ３４０９９

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

７

６

２

３

４

3rd speed

５

８

１０

1st speed ９

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

１２ １１

Shaft assy

８５Ｋ３４１００

34-34

85ZIV-2

1st / 3rd Speed Clutch Pack

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

Note: Friction plates

Steel plates

1st speed

9

8

3rd speed

5

4

TORQUE CONVERTER AND TRANSMISSION 34

１４

１３

5)Remove the snap ring (15) and ring (16). １６

８５Ｗ３４０４２

１５

6)Remove 20 springs (17), and then feed compressed air to the oil port to remove the piston (18).

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

１８

１７ Shaft assy

８５Ｗ３４０４３

34-35

85ZIV-2

1st / 3rd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

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

1) Install the piston (1), and insert 20 springs (2).

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

８５Ｗ３４０４４

2) Install the ring (3), and snap ring (4).

Note: When inserting the snap ring into the groove, use a screwdriver or the like to press the snap ring fully into the groove. ４ ３

８５Ｗ３４０４５

3)Alternately insert the friction plates (5) and steel plates (6).

Note: Friction plates

Steel plates

1st speed

9

8

3rd speed

5

4

５

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

６ ８５Ｗ３４０４６

34-36

85ZIV-2

1st / 3rd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

4) Insert the backing plate (7) and the snap ring (8).

８ ７ ８５Ｗ３４０４７

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

Note: Piston stroke 1st speed

3.5±0.5mm

3rd speed

2.1±0.5mm

If the piston stroke value is beyond the above range, replace the parts, or check that the parts are not warped and are correctly reassembled. ８５Ｋ３４１０７

6)〔3rd speed〕Insert the thrust washer (9).

Note: Put the notch side up. 〔1st speed〕Insert the thrust washer (10), thrust bearing (11), and then thrust washer (12) as shown below.

９

１２ １１ １０ ８５Ｗ３４０４８

7)〔3rd speed〕Align and install the gear (13). After that, sequentially press in the two needle bearings (14), install thrust washer (15), and the ball bearing (16).

Nore: When installing the thrust washer, put the notch side down. 〔1st speed〕Install the gear (13).

After that, sequentially press in the two needle bearings (14), install thrust washer (17), thrust bearing (18), thrust washer (19), and then ball bearing (20).

34-37

２０ １６

１９ １８ １７

１５ 3rd speed

１４

1st speed

１３

85ZIV-2

2nd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and Reassembling 2nd Speed Clutch Pack 1.Disassembling 2nd speed clutch pack 1)Remove the spacer (1) and the gear (2). After that, remove the snap ring (3) and backing plate (4).

４

３

２

１

８５Ｗ３４２３

2)Remove the friction plates (5) and steel plates (6).

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

５

６

８５Ｗ３４２４

3)Remove the thrust washer (7), thrust bearing (9) and thrust washer (8). Store the thrust washers for possible reuse. ９

８ ７

８５Ｗ３４２５

4)Depress the plate (11) and remove the snap ring (10), and plate (11).

5)Remove 20 springs (12).

１２ １０ １１

８５Ｗ３４０５７

34-38

2nd Speed Clutch Pack

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

6)Apply compressed air to the clutch oil port at the end of the shaft to remove the piston (13).

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

１３

８５Ｗ３４０５８

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

1)Reinstall the piston (1), and insert 20 springs (2).

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

１ ２

８５Ｗ３４２８

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

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

６

７ ５ ３ ４ ８５Ｗ３４０５９

34-39

85ZIV-2 Disassembling and Reassembling 2nd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

4)Alternately insert the friction plates (7) and steel plates (8).

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

７

８

８５Ｗ３４０６０

5) Insert the backing plate (9) and the snap ring (10).

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

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

Piston stroke: 2.1±0.5mm : 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.

１０

１２

９

１１ ８５Ｗ３４０６１

7) Install the gear (11), and insert the spacer (12).

８５Ｋ３４１０７

34-40

85ZIV-2

4th Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and Reassembling 4th Speed Clutch Pack 1.Disassembling 4th speed clutch pack 1)Using a puller remove the ball bearing (1). １

８５Ｗ３４２９

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

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

Remove the needle bearing (4) and the thrust washer (5).

５

４ ３

２

８５Ｗ３４０６２

3)Remove the snap ring (6) and the backing plate (7). ６

７

８５Ｗ３４０６３

4)Remove the friction plates (8) and steel plates (9).

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

８

９

８５Ｗ３４０６４

34-41

4th Speed Clutch Pack

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

5)Depress the ring (11) and remove the snap ring (10), and ring (11).

１１

１０

８５Ｗ３４０６５

6)Remove 20 springs (12), and then blow air to the clutch oil port at the end of the shaft to remove the piston (13).

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

１３ １２

８５Ｗ３４０６６

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

1)Reinstall the piston (1), and insert 20 springs (2).

１ ２

８５Ｗ３４０６７

34-42

4th Speed Clutch Pack

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

Note: When inserting the snap ring into the groove, use a screwdriver or the like to press the snap ring fully into the groove. ４

３

８５Ｗ３４０６８

3)Alternately insert the friction plates (5) and steel plates (6).

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

５

６

８５Ｗ３４０６９

4) Insert the backing plate (7) and the snap ring (8). ８

７

８５Ｗ３４０７０

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

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

Piston stroke: 2.1±0.5mm : If the piston stroke value is beyond the above range, replace the parts, or check that the parts not warped and are correctly reassembled.

Depth micrometer Straight edge

Air line

Backing plate ８５Ｗ３４０４１

34-43

85ZIV-2

4th Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

6) Insert the thrust washer (12) and press in the needle bearing (10).

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

7)Align and install the gear (11). After that, press in the needle bearing (10) and insert the thrust washer (9).

１０

１２

９ １１

１２ １０ ８５Ｗ３４０７１

１１

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

8) Install the ball bearing (13).

１３

８５Ｗ３４０７２

Caution When installing the gear (32400 - 21230) to the shaft, follow the procedure below. ① Assemble the gear onto the clutch drum with the bolts. ② Heat them up to 190 ℃ . ③ Insert the shaft into the clutch drum and gear.

Ｃ ｌ ｕ ｔ ｃｈ ｄｒｕｍ

Ｓｈａ ｆ ｔ

Ｂｏ ｌ ｔ

34-44

Ｇｅａｒ （３２４００‐２１２３０）

85ZIV-2

Control Valve Tightening Torque

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Tightening Torque

T1 T1

T4

T2

T3

８５ＺＡ３２１０

T1: 20N・m (2.0kgf ・m) T2: 39N・m (5.4kgf ・m) T3: 10N・m (1.0kgf ・m)(Solenoid valve nut) T4: 34N・m (3.5kgf ・m)(Solenoid valve body)

34-45

Removing and Reinstalling Control Valve

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

Removing and Reinstalling Control Valve 1.Removing control valve

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

１

８５Ｋ３４１２６

1)Remove the cover (1) (option).

2)Disconnect all the electric wire couplers (2) and the bracket (3) also disconnect the hose (4) for checking the clutch pressure.

Note: Put match marks on the electric wire couplers.

２ ４

３ ８５Ｗ３４０４９

3) Temporarily sling the control valve (5), and then remove the valve bolts (6).

Note: Do not remove two trimmer bolts (7).

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

６

５

７

８５Ｗ３４０５０

4) Lower the control valve to remove it.

Be sure to replace the gasket .

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

: Control valve : 20kg

34-46

Removing and Reinstalling Control Valve

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

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

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

BrL BrW BrR BrB BrY BrG BrGy Electrical Wiring

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

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

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

7)Check oil leakage.

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

34-47

Control valve

Transmission Control Valve

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

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

1)Remove the nut (1) using special tool (A).

Note: Nut width across flat : 30mm Special tool (A) is described on the next page.

For other valves, follow the same procedure.

Tightening torque for assembly : Bolt : 10N・m (1.0kgf ・m)

１

８５Ｋ３４１２９

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

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

３

８５Ｋ３４１３０

２

3)Remove the valve (4) using a 17mm wrench.

Tightening torque for assembly : Valve : 34N・m (3.5kgf・m) Ａ

４ ８５Ｋ３４１３１

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

Note: Do not remove the trimmer body (7) unless absolutely necessary. ５

６ ７

８５Ｋ３４１３２

34-48

Transmission Control Valve

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 34

5)Remove the regulator valve (8), trimmer plug (9), springs (10), spring retainer (11), and plug (12). １２

１１ ８

１０ ９

2.Special tool(A) ８５Ｋ３４１３３

Material : SS41 North American dealer tool number : KL03-102-1 75 65 60 15

φ 30

φ 23

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

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

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

Check free lengths and if necessary replace them.

3)Check the operation of the solenoid valves.

(Also the movement by pressing the manual plunger. The plunger should move freely and smoothly in both directions (spring return).)

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

5)Check coil resistance.

Resistance : Approx. 26 Ω

34-49

φ 7 Drill

.1 -0 .2 -0 7 1

5 φ 40

30

+ 0.2 + 0.1

C1

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

35-1

Transmission Assembly

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Transmission Assembly

12

13

8 4

16

5 17 18

14

14 18 5 15 17

16

9 11 10

85ZA3201

35-2

Control Valve

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Control Valve

1

2

6

7

3

８５ＺＡ３２０９

35-3

Control Valve

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

mm , N (kgf) Judgement criteria REF.

ITEM Allowable limit

0.030〜0.061

0.09

Replace

0.016〜0.045

0.07

Replace

0.025〜0.066

0.09

Replace

Standard value

Allowable limit

Control valve regulator valve〜valve body

1

2

Correction

Standard clearance

Clearance

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

3

ITEM

4

T/C inlet valve spring Clutch return spring

5 Spring

(The same spring for all clutches)T/C

Free length

Installed length

Installed load

Free length

Installed load

44.6

35.2

100 (10.2)

43.6

90 (9.2)

Replace

24.4

21

32 (3.3)

23.7

29 (3.0)

Replace

6

Control valve regulator spring

89

89

0

87.5

0

Replace

7

Control valve trimmer spring

81.4

69

49 (5)

80

44 (4.5)

Replace

Judgement criteria ITEM Standard value

Allowable limit

8

Charge pump shaft dia.

41.93〜42.0

41.8

Replace

9

Rear yoke shaft dia.

79.92〜80.0

79.8

Front yoke shaft dia.

79.92〜80.0

79.8

11

Speedometer driven gear shaft dia.

11.95〜12.0

11.8

Replace oil Replace seal when disassembling Replace and reassembling Replace

W

3.0 ± 0.05

2.8

12

Torque converter inlet H

3.25 ± 0.05

3.05

W

3.8 ± 0.05

3.6

H

4.75 ± 0.05

4.55

Clutch shaft

W

3.8 ± 0.05

3.6

(The same for all clutches)

H

4.75 ± 0.05

4.55

15

Piston outer dia. (F,R)

H

4.3 ± 0.1

4.1

Replace

16

Piston outer dia. (1〜4 speed)

H

4.3 ± 0.1

4.1

Replace

17

Piston inner dia.

H

4.0 ± 0.1

3.8

Replace

Thrust washer thickness

2.9〜3.1

2.7

Replace

Gear backlash

0.2〜0.3

0.5

Replace

10

Oil seal

Seal ring

13

Torque converter outlet W

14

18

H

35-4

Replace

Replace

Replace

Gear Pump

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Gear Pump 2 4

1

3

Gear pump specifications

1

Theoretical discharge

64.5cm3/rev

Maximum operation pressure Maximum operation speed (pump speed)

2.0MPa (20kgf/cm2)

Actual discharge

Approx.120 l/min.

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

2400min-1

2

Unit : mm No.

Item

Standard value

Solution

1

Top clearance between gear and housing

0.08〜0.11

Replacement

2

Side clearance between gear and housing

0.03〜0.073

Replacement

3

Backlash between gears

0.2〜0.3

Replacement

4

Tightening torque for pump fixing bolt

59N・m (6.0kgf・m)

Tightening

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

35-5

Clutch Plate Thickness / Piston Stroke

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

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

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

Steel plate

Return spring

7

8

20

Reverse clutch

7

8

20

1st speed clutch

9

8

20

2nd speed clutch

5

4

20

3rd speed clutch

5

4

20

4th speed clutch

5

4

20

Outer dia.

φ 192

φ 203.2

Inner dia.

φ 124.5

φ 133.5

When new

3.3 ± 0.1

2.6 ± 0.1

Wear limit

3.1

2.4

Dimension

Friction plate

Forward clutch

(mm)

Thickness

T1

Name of clutch

T2 L1 T2 L1 T5

T3 L 1 T6 T4

Piston stroke

(mm) Judgement criteria Correction

Standard value

Allowable limit

Forward clutch

3.3 ± 0.5

5.0

Replace

Reverse clutch

3.3 ± 0.5

5.0

Replace

1st speed clutch

3.5 ± 0.5

5.0

Replace

2nd speed clutch

2.1 ± 0.5

5.0

Replace

3rd speed clutch

2.1 ± 0.5

5.0

Replace

4th speed clutch

2.1 ± 0.5

5.0

Replace

Clutch

T6 85ZA3201

Bolt tightening torque T1 :29N・m (3.0kgf・m) T2 :59N・m (6.0kgf・m) T3 :157N・m (16.0kgf・m) T4 :392N・m (40.0kgf・m) (Molydenum disulfide grease/MOS 2 application ) T5 :98N・m (10kgf・m) T6 :53N・m (5.4kgf・m) L 1: Screw lock agent application (Loctite 262 )

35-6

Oil Pressure

85ZIV-2

TORQUE CONVERTER AND TRANSMISSION 35

Oil Pressure

2

7

1 7

3

4

8

6 3

5 4

9

6

85ZA3501

Standard Value

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

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

Measuring port location

Measuring port

Engine revolution (min-1)

size

800 (Low idle)

2350 (High idle)

Shift lever position

Torque converter inlet pressure

PF1/2

0.03〜0.54 (0.3〜5.5)

0.2〜0.54 (2.0〜5.5)

All speed range

2

Main oil pressure

PT1/8

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

All speed range

3

Forward clutch oil pressure Reverse clutch oil pressure 1st speed clutch oil pressure 2nd speed clutch oil pressure 3rd speed clutch oil pressure

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

Forward

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

Reverse

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

1st speed

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

2nd speed

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

3rd speed

4th speed clutch oil pressure Transmission lubrication oil pressure

PF1/4

1.27 ± 0.2 (13 ± 2)

1.47 ± 0.2 (15 ± 2)

4th speed

PT1/4

0.01〜0.1 (0.1〜1.0)

0.05〜0.25 (0.5〜2.5)

All speed range

4 5 6 7 8 9

Clutch oil pressure

1

35-7

HYDRAULIC GROUP 44 Hydraulic Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-2 Removing and Reinstalling Gear Pump Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-3 Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-5 Removing and Reinstalling Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-6 Disassembling and Reassembling Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-8 Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-12 Removing and Reinstalling Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-13 Disassembling and Reassembling Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-16 Boom Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-24 Removing and Reinstalling Boom Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-25 Bucket Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-27 Removing and Reinstalling Bucket Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-28 Steering Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-31 Removing and Reinstalling Steering Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-32 Hydraulic Cylinder Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-34 Disassembling and Reassembling Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-35 Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-40 Pilot Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-41 Removing and Reinstalling Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-42 Disassembling and Reassembling Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-44

44-1

Hydraulic Pump

85ZIV-2

HYDRAULIC 44

Hydraulic Pump Tightening torque

T1

T2

T2

８５Ｋ４４００１

: Bolt tightening torque T1 : 196N・m (20.0kgf ・m) T2 : 73N・m (7.4kgf ・m)

44-2

Removing and Reinstalling Gear Pump Assy

85ZIV-2

HYDRAULIC 44

Removing and Reinstalling Gear Pump Assembly 1.Removing gear pump assembly

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 bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Disconnect the negative side of the cable from the battery.

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

３

４ ３

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

Note: Cover or plug the hoses as they are removed.

This prevents dirt entry into the hoses during repair.

１

2)Remove the gear pump retainer bolts (4).

Torque for assembly: : Bolt : 245N・m (25.0kgf ・m) ２

3) Temporarily sling the gear pump (1), and remove the spline section.

２

２ ８５Ｗ４４００１

44-3

Removing and Reinstalling Gear Pump Assy

85ZIV-2

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

Replace all gaskets, O-rings, and seals during reinstallation.

Cautions regarding reinstallation IMPORTANT 1) Be sure to remove all caps, plugs, tape, etc. from the pump and pour new oil from the outlet and inlet ports into the pump to form an oil film inside the pump.

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

3) Check the oil level of the hydraulic tank.

4) Close the cap of the hydraulic tank, and remove the plugs of the pump suction pipe. Pour hydraulic oil into the plug port until the oil overflows from the port (approx. 4 l).

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

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

6)Move each cylinder almost full stroke 5-6 times. Do not fully extend or retract any cylinder during this period.

7) Confirm that there is no abnormal heat, noise, or abnormal operation of the system during this break-in period.

8) Inspect the hydraulic oil sight gauge and confirm that there are no bubbles in the hydraulic oil. Bubbles may indicate a suction side air leak that must be corrected to prevent premature pump failure.

44-4

HYDRAULIC 44

Steering Valve

85ZIV-2

HYDRAULIC 44

Steering Valve

T5 T7 L 1

4 14 T2

13 T6 T4 6 7

T5 4

9

8 T1

8 T4

5

10 5 11

L1

11

12 12

T7 2 13

10 15 1 T2

T1 3 T3

: Tightening torque

: 22kg

T1 : 137N ・ m (14.0kgf ・

1. Steering plunger 2. Flow control plunger

m)

3. Main relief valve T2 : 93N・m (9.5kgf・m)

4. Overload relief valves

T3 : 74N・m (7.5kgf・m)

5. Check valves

T4 : 42N・m (4.3kgf・m)

6. Cap

T5 : 83N・m (8.5kgf・m)

7. Screw

T6 : 64N・m (6.5kgf・m)

8. Spring seats

T7 : 10N・m (1.0kgf・m)

9. Spring

L1 : Loctite No. 271

10. Plate

44-5

Removing and Reinstalling Steering Valve

85ZIV-2

HYDRAULIC 44

Removing and Reinstalling Steering Valve 1.Removing steering valve

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

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

1)Disconnect the hoses (2)(3) from the steering valve (1). : Hydraulic oil : Approx. 1 l Torque for assembly: : Bolts on hose flange : 53N・m (5.4kgf ・m) Note: Cover the disconnected hoses and the valve with vinyl, plugs or caps to protect them from dust and dirt.

２ １

2)Remove the split pin (4), castle nut (5), and pin (6).

After that, disconnect the steering link (7) from the steering valve.

２

８５Ｋ４４００５

１

Torque for assembly: : Castle nut : 255N・m (26.0kgf ・m) ３

８５Ｗ４４０１０

８

3)Remove the steering valve retainer bolt (8), and then remove the steering valve. ５

Torque for assembly: : Bolt : 88N・m (9.0kgf ・m) : Steering valve : 22kg

４

７ ６ ８５Ｋ４４００７

44-6

Removing and Reinstalling Steering Valve

85ZIV-2

HYDRAULIC 44

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

At the completion of reinstallation, check operation of the steering valve by following the procedure below:

WARNING Entering the articulation area while engine is running could cause serious injury or death.

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

1)Start the engine and confirm that the drop arm comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise.

2)Check around the valve for oil leakage.

Drop arm Drop arm stopper bolts

3)Measure various values for performance check.

Measure the time required for full steering.

Measure the relief valve setting pressure.

(Refer to Section 03-Measurement for Performance Check) ８５ＺⅣ０３−００９

44-7

Disassembling and Reassembling STV

85ZIV-2

HYDRAULIC 44

Disassembling and Reassembling Steering Valve 1.Disassembling steering valve

１

Before starting work: a)Clean the valve body.

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

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

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

３

２

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

５

４

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

６

44-8

Disassembling and Reassembling STV

85ZIV-2

HYDRAULIC 44

5)Slowly pull out the plunger assembly.

Note: Always handle the plunger with extreme care.

Even a small nick, dent or scratch can ruin the plunger which requires replacement of the entire valve.

１

6)Remove the front and rear wipers (2) and seals (3).

２ ３

7)Gently clamp the two flats of the plunger assembly using wooden blocks in a vice, and then loosen the screw (4).

Remove the spring seat (5), spring (6), plate (7), spring (8), poppet (9), O-ring (10), backup ring (11), and plug (12) from the plunger (13). : Screw (4), (12) : 10N・m (1.0kgf ・m) (Loctite No. 271) Note: a)Cover the spool to protect it from being scratched. b)A thread adhesive is applied to the threaded section of the spool end. To disassemble the spool, heat the adhesive of the threaded section using an industrial drier (heat gun) or the equivalent. Do not heat the threaded section to 200 ° C(390 ° F )or more. If it is overheated, replace the spring with a new one. c) All seals should be replaced with new ones because they were heated.

8)Remove the plug (14).

５ １０ ５ ６ ７ ９ ８

１３

１２

１４

44-9

４

１１

１０

８

９ ８０ＺⅣ４４０３

Disassembling and Reassembling STV

85ZIV-2

HYDRAULIC 44

9)Remove the main relief valve (1).

１

10)Disassemble the main relief valve (1).

１

11)Pull out the spring (2) and the flow control valve (3) from the inside of the valve.

Note: Be sure to reinstall the same number of shims (4) and in the same location upon reassembly.

１

２

３ ４

44-10

Disassembling and Reassembling STV

85ZIV-2

HYDRAULIC 44

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

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

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

Plate

Valve body

Seal

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

Wiper

Ball joint

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

Rod

Foreign matter gets caught.

Steering valve

Adj. Screw Orifice clogged.

58mm

Spring is broken.

Poppet has worn out.

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

44-11

Multiple Control Valve

85ZIV-2

HYDRAULIC 44

Multiple Control Valve ⑬T

2

T6

⑭⑫

T3

⑮

T2

T8

T1 T5

⑪

T4

②

T5

⑬T ⑭ 2

T5

⑫ ④

⑫

⑤

③ ①

⑪

⑫④

T1

④

⑦ T7

⑥

④

⑨

⑬T

2

⑧ T7

⑩

⑬T

2

1. Valve housing

11. Caps

21. O-rings

2. Spool (Bucket)

12. O-rings

22. Plug assembly

3. Spool (Boom)

13. Socket head bolts

23. Plug

4. Spring seats

14. Spacers

24. Plugs

5. Spring (Bucket)

15. Cover

25. Main relief valve

6. Spring (Boom)

16. O-ring

26. Overload relief valves with

7. Spool end (Bucket)

17. Socket head bolts

8. Spool end (Boom)

18. Plugs

27. Make-up valve

9. Cap (Bucket)

19. Springs

28. Cap

10. Cap (Boom)

20. Poppets

29. Plug (for test port)

Tightening torque

make-up function

: Multiple control valve : 54kg

T1 : 98N ・ m (10.0kgf ・ m) T2 : 42N ・ m (4.3kgf ・m) T3 : 132N ・m (13.5kgf ・m) T4 : 157N ・m (16.0kgf ・m) T5 : 83N ・ m (8.5kgf ・m) T6 : 103N ・m (10.5kgf ・m) T7 : 12N ・ m (1.2kgf ・m) T8 : 23N ・ m (2.3kgf ・m)

44-12

Removing and Reinstalling MCV

85ZIV-2

HYDRAULIC 44

Removing and Reinstalling Multiple Control Valve 1.Removing multiple control valve Boom lock collar

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

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Raise the boom until it is horizontal, and then place a stand (A) under the boom to support it. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Use a step, ladder, or work platform, and do not stand on the machine.

Stand

８５Ｗ４４００２

1)Remove the cover (1).

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

A

１

A

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

８５Ｋ４４０１１

２

２ ８５Ｋ４４０１２

3) There are several pipes (4) above the multiple control valve (3). Disconnect all the pipes (4) and the block (5).

４ ５

３

８５Ｋ４４０１３

44-13

Removing and Reinstalling MCV

85ZIV-2

HYDRAULIC 44

4)Disconnect the inlet hose (6) and the return hose (7).

Remove the pipe (8) from the multiple control valve (3).

９ ９ ８

: Approximately 5 l of hydraulic oil will be drained from the disconnected hoses. Place a container to receive the drained oil.

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

６

３

７

８５Ｋ４４０１４

5)Remove the bolts (9) from the pipe brackets of the right and left bucket cylinders.

6)Remove the bolts (10) from the pipe brackets of the right and left boom cylinders.

Note: This allows the piping over the valve to be moved away from the valve.

7)Remove the retainer bolts (11) from the multiple control valve, and then remove the multiple control valve.

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

44-14

１０

１１

１０ １１ ８５Ｋ４４０１５

Removing and Reinstalling MCV

85ZIV-2

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

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

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

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

c) Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to Section 03. d)Operate the bucket and the boom, and check that they operate correctly. e)Check each section for oil leakage. f) Add hydraulic oil to the tank until the oil level rises to the specified point.

44-15

HYDRAULIC 44

Disassembling and Reassembling MCV

85ZIV-2

HYDRAULIC 44

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

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

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

Hexagon width across flat: 38mm

１

2)Remove the overload relief valves (2).

Hexagon width across flat: 32mm

２

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

Hexagon width across flat: 32mm

３

44-16

Disassembling and Reassembling MCV

85ZIV-2

HYDRAULIC 44

4)Remove the socket head bolt (1) from the bucket side of the cap.

Hexagon hole width across flat: 8mm

１

5)Remove the cap (2) with the O-ring of the flange as a unit.

２

6)Remove the socket head bolt (3) from the boom side of the cap.

Hexagon hole width across flat: 8mm

３

7)Remove the cap (4) with the O-ring of the flange as a unit.

４

44-17

Disassembling and Reassembling MCV

85ZIV-2

HYDRAULIC 44

8)Pull out the spool assembly (1) from the bucket side.

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

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

１

9)Pull out the spool assembly (2) from the boom side in the same way.

２

10)Remove the socket head bolts (3), and then remove the cap (4). Also remove the O-ring from the cap.

Hexagon hole width across flat: 8mm

４

３

７

11)Remove the socket head bolts (5), and then remove the cover (6). Also remove the O-ring (7) from the mating face.

Hexagon hole width across flat: 12mm

６

５

44-18

Disassembling and Reassembling MCV

85ZIV-2

HYDRAULIC 44

12)Remove out the plug (1), and then remove the spring (2) and the poppet (3).

Also remove the O-ring from the plug.

Hexagon hole width across flat: 19mm

１ ２

３

13)Remove the hexagon bolt, and then remove the cap kit (4).

Hexagon bolt width across flat: 14mm ４

14)Remove the plug assembly (5), and remove the O-ring.

Hexagon hole width across flat: 17mm

５

15)Gently clamp the spool assembly using wooden blocks in a vice. After that loosen the spool end (6) to remove it.

Hexagon bolt width across flat: 22mm 16)Remove the spring seats (7) and the spring (8) from each spool (there are two spools).

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

44-19

６

７ ８

７ Adhesive Apply heat

Spool

Disassembling and Reassembling MCV

85ZIV-2

HYDRAULIC 44

2.Reassembling multiple control valve Note: ・ Clean and check all the parts. If a part is defective, replace or repair it. ・ Replace all the O-rings with new ones. ・ Apply a thin coat of hydraulic oil or grease to each part before reassembly. ・ Apply the specified torque to tighten each main part.

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

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

３ １ ２ １ Spool

2)Reinsert the plug assembly (4).

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

４

3)Reinstall the cap kit (5).

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

44-20

５

Disassembling and Reassembling MCV

85ZIV-2

HYDRAULIC 44

4)Sequentially insert the poppet (1) and then the spring (2) into the housing seat section. After that, attach a new O-ring (3) to the plug (4), and then reinstall the plug.

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

４ ３

２ １

5)Attach a new O-ring to the groove of the cover (5), and then reinstall the cover on the valve housing.

Tighten the socket head bolts (6).

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

６ ５

6) Insert the O-rings to the caps (7), and then reinstall the caps on the valve housing. Tighten the socket head bolts (8).

Hexagon hole width across flat: 8mm : Bolt : 42N・m (4.3kgf ・m) ７ ７

８

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

Spool

: Apply hydraulic oil to the spool.

44-21

Disassembling and Reassembling MCV

85ZIV-2

HYDRAULIC 44

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

Spool

9) Insert a new O-ring to the cap (1), and then reinstall the cap on the spool of the bucket side.

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

１

10)Tighten the socket head bolts (2). : Bolt : 42N・m (4.3kgf ・m)

２

11)Attach a new O-ring to the cap (3), and then install the cap on the spool of the boom side.

３

44-22

Disassembling and Reassembling MCV

85ZIV-2

HYDRAULIC 44

12)Tighten the socket head bolts (1). : Bolt : 42N・m (4.3kgf ・m)

１

13)Reinstall the make-up valve (2).

Hexagon nut width across flat: 32mm : Make-up valve : 83N・m (8.5kgf ・m) ２

14)Reinstall the right and left overload relief valves (3).

Hexagon nut width across flat: 32mm : Overload relief valve : 83N・m (8.5kgf ・m) Note: If the overload relief valves or main relief valve have been disassembled back the adjusting screws out and readjust after start up.

３

15)Reinstall the main relief valve (4).

Hexagon nut width across flat: 38mm : Main relief valve 103N・m (10.5kgf ・m)

４

44-23

Boom Cylinder

85ZIV-2

HYDRAULIC 44

Boom Cylinder 22 6

6 22

11

1 12 15

13

14 20

7

18 3

19 16 17 4 2 21 23

5

8

9 ８５Ｅ４４００１

1. Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 7. Piston nut 8. Stop ring 9. Bolt 11. Wear ring 12. Square ring

13. Slipper ring 14. O-ring 15. Wear ring 16. O-ring 17. Backup ring 18. U-packing 19. Backup ring 20. Buffer ring 21. Scraper ring 22. Dust seal 23. Stop ring : Boom cylinder : 200kg For torque values refer to "Hydraulic cylinder tightening torque".

44-24

Removing and Reinstalling Boom Cylinder

85ZIV-2

HYDRAULIC 44

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

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

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Raise the boom until it is horizontal, and then place a stand (A) under the boom to support it. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Use a step, ladder, or work platform, and do not stand on the machine.

Stand (A) ６５Ｋ４４０５２

a)Clean the area around the cylinder and piping.

Note: Relieving residual pressure from pipe 1. Raise the boom.

When the boom is approximately 30cm above stand (A), stop the engine.

2. Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure.

3. Open the cap of the hydraulic tank to relieve the residual pressure.

１

８５Ｋ４４０１６

1) Temporarily sling the boom cylinder (1). : Boom cylinder : 200kg

２

2)Disconnect the hoses (2) (3).

３ ８５Ｋ４４０１７

: Drain oil : Approx. 10 l Cover the disconnected hoses with vinyl, plugs, or caps to protect them from dust, water, and dirt. ５

3)Remove the lock bolt (4) and the pin (5). : Bolt : 265N・m (27.0kgf ・m)

８５Ｋ４４０１８

44-25

４

Removing and Reinstalling Boom Cylinder

85ZIV-2

HYDRAULIC 44

4)Place a container to receive oil from the oil port on the bottom side of the cylinder. After that, push in the rod (6). : Hydraulic oil (each for right and left sides) : Approx.10 l

６ ８５Ｋ４４０１９

5)Remove the lock bolts from the retainer pins on the bottom side, and then attach the remover bolt (8) to the pins (7) to remove them. : Removal bolts : M16 × P2 : Lock bolt : 265N・m (27.0kgf ・m)

７

８ ８５Ｋ４４０２０

6)Sling the boom cylinder, and lower it onto the ground. After that, remove the pipe (9) from the cylinder.

For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

2.Reinstalling boom cylinder To reinstall the boom cylinder, follow the above removal procedure in the reversed direction.

Note: Be sure the pins accept grease after installation.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or backup ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100mm before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-26

９ ８５Ｋ４４０２１

Bucket Cylinder

85ZIV-2

HYDRAULIC 44

Bucket Cylinder

11 2 12 24

22

15

22

3

16

6

17 20 6

18

6

19 4 22

21

6 22

5 23

13 14

10 9

1. Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 7. Piston nut 8. Stop ring 9. Bolt 10. Spring washer 11. Wear ring 12. Seal set

1

7

8

13. Plug 14. O-ring 15. O-ring 16. O-ring 17. Backup ring 18. U-packing 19. Backup ring 20. Buffer ring 21. Scraper ring 22. Dust seal 23. Stop ring 24. Wear ring : Bucket cylinder : 215kg For torque values refer to "Hydraulic cylinder tightening torque".

44-27

Removing and Reinstalling Bucket Cyl.

85ZIV-2

HYDRAULIC 44

Removing and Reinstalling Bucket Cylinder 1.Removing bucket cylinder

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

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Place the boom and bucket on the ground. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Use a step, and do not stand on the machine.

Bucket cylinder

Note: Relieving residual pressure from pipe 1. Lower the boom and bucket to the ground.

2. Stop the engine and move the bucket and boom levers back and forth.

3. Open the cap of the hydraulic tank to relieve the residual pressure.

1)Clean the area around the cylinder and piping.

８５Ｋ４４０２３

2)Remove the coupler of the bucket positioner switch (1), and then remove the bracket (2). : Tightening torque : 59N・m (6.0kgf ・m) ２

3)Remove the rod (3). : Tightening torque : 34N・m (3.5kgf ・m) １ ３

８５Ｋ４４０２４

4)Remove the hose (4), (5). : Drain : Approx. 10 l

４

Cover the disconnected hoses and the cylinder with vinyl, cap or plugs to protect them from dust, water and dirt.

８５Ｋ４４０２５

44-28

５

Removing and Reinstalling Bucket Cyl.

85ZIV-2

HYDRAULIC 44

4) Temporarily sling the bucket cylinder (1). After that, remove the lock bolt (2), and then remove the pin (3).

１ ３

: Bucket cylinder : 215kg : Lock bolt : 265N・m (27.0kgf ・m) ２

８５Ｋ４４０２６

5)Disconnect the grease pipe. After that, remove the lock bolt (4), and then remove the pin (5).

５

: Lock bolt : 265N・m (27.0kgf ・m)

４

８５Ｋ４４０２７

6)Slowly lift up the bucket cylinder (1) and remove the shim.

１ Shim

８５Ｋ４４０２８

7)Push in the cylinder rod to drain some of the residual oil. : Drain oil : Approx. 10 l 8) Lower the bucket cylinder onto the ground, and then disconnect the oil pipe (6).

For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

６ ８５Ｋ４４０２９

44-29

Removing and Reinstalling Bucket Cyl.

85ZIV-2

2.Reinstalling bucket cylinder To reinstall the bucket cylinder, follow the above removal procedure in the reversed direction.

Note: Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation

WARNING During service work, do not stand on the machine.

Standing on tire, boom or linkage could cause accidents and serious injury or death. Use a step, ladder, or work platform and do not stand on the machine.

①Bleed the cylinder of air.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100mm before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

②Adjust the bucket positioner so that the clearance between the switch and the rod is 5±2mm .

44-30

HYDRAULIC 44

Steering Cylinder

85ZIV-2

HYDRAULIC 44

Steering Cylinder

2

13

12 14 6

15 16 20 19

12

3

21 17

6

18

6 11 12

1

7

6 12

4

9

5

8

10

８５Ｅ４４００２

1. Cylinder tube 2. Rod 3. Piston 4. Rod cover 5. Bushing 6. Bushing 7. Scraper ring 8. Piston nut 9. Lock ring 10. Stop ring

11. O-ring 12. Dust seal 13. Wear ring 14. Square ring 15. Slipper ring 16. O-ring 17. O-ring 18. Backup ring 19. U-packing 20. Buffer ring 21. Backup ring : Steering cylinder : 38kg For torque values refer to "Hydraulic cylinder tightening torque".

44-31

Removing and Reinstalling Steering Cyl.

85ZIV-2

HYDRAULIC 44

Removing and Reinstalling Steering Cylinder 1.Removing steering cylinder (Right cylinder shown)

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Place the boom and bucket on the ground. ・ Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line. ・ Open the cap of the hydraulic tank to relieve the internal pressure from the tank. ・ Place a "DO NOT START!" tag on the steering wheel.

１ ２

1)Clean the area around the cylinder to be removed.

2)Disconnect the hoses (1) (2). : Cover the disconnected hoses with vinyl, caps, or plugs to protect them from dust, water, and dirt.

８５Ｋ４４０３０

3) There is a pin (5) at the between the front chassis (3) and the steering cylinder (4). Remove the pin (5), and then push the rod into the cylinder to shorten the length of the cylinder.

６ ９

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

Approx. 2 l 4)Disconnect the grease pipe (6).

５ ４ ３

８ ４

７ ８ ８５Ｋ４４０３１

5)Remove three pin lock bolts (7) and one pin lock plate (8).

6) Tap the pin (9) from the bottom side to remove it from the top side.

44-32

Removing and Reinstalling Steering Cyl.

85ZIV-2

7)Remove the steering cylinder assembly (4). Note that two persons are needed to remove and lift the assembly. : Steering cylinder : 38kg Note: Remove the left steering cylinder in the same way as described above.

For detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

2.Reinstalling steering cylinder To reinstall the steering cylinder, follow the above removal procedure in the reversed direction.

Note: Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation ①When reinstall the pins

WARNING Articulation area is a crush zone. Moving the machine with a person in this area could cause injury or death.

When turning the steering wheel while engine is running, do not enter the articulation area of the machine.

If a person is in the articulation area, do not start the engine.

②Bleed the cylinder of air

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or backup ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100mm before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

44-33

HYDRAULIC 44

Hydraulic Cylinder Tightening Torque

85ZIV-2

HYDRAULIC 44

Hydraulic Cylinder Tightening Torque Boom cylinder

T1

８５Ｋ４４０７２

T2

Bucket cylinder

T4

T3

８５Ｋ４４０７３

Steering cylinder

T5

T1 : 4,756N・m (485kgf ・m) T2 : 843N・m (86kgf ・m) T3 : 5,394〜5884N・m (550〜600kgf・m) T4 : 736〜883N・m (75〜90kgf ・m) T5 : 1,079〜1,275N・m (110〜130kgf・m) T6 : 1,569〜1765N・m (160〜180kgf・m)

T6

Cylinder

８５Ｋ４４０７４

Piston nut width across flat (S)

Boom

90(M62)

Bucket

110(M76)

Steering

55(M36)

44-34

s

Disassembling and Reassembling Hyd. Cyl.

85ZIV-2

HYDRAULIC 44

Disassembling and Reassembling Hydraulic Cylinder 1.Disassembling hydraulic cylinder Note: The bucket cylinder disassembling procedure is described below. For other cylinders, follow the same procedure.

1) Install the bottom side of the cylinder to the repair stand.

Repair stand

2)Put the match marks on the rod cover (1) and the cylinder tube (2).

Remove the rod cover bolt (3).

Match mark

３

: Bolt : 736〜883N・m (75〜90kgf ・m)

２ １

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

４

９０ＺⅣ４４０８

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

Repair stand

４

Wooden block

44-35

Disassembling and Reassembling Hyd. Cyl.

85ZIV-2

HYDRAULIC 44

5)Remove the stop ring (5) and put match marks on the rod and the piston nut for alignment with the stop ring holes.

５

４

Match mark

６

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

Note: Refer to "Hydraulic Cylinder Tightening Torque" for the tightening torque and the size of the piston nuts.

６ Ｃ

Hydraulic jack

Hydraulic cylinder

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

７

４

８５ＺⅣ４４−０４２

8)Remove the wear ring (8), the backup ring (20), the square ring (9), the slipper ring (10), the O-ring (11) and the wear ring (12).

(There is no wear ring (12) for steering cylinder.)

８ ９

１０ １２

８

１０ ９

２０ １０２０ １２ ８ ９

１１ (Boom cylinder)

１１ (Bucket cylinder)

44-36

１１ (Steering cylinder)

Disassembling and Reassembling Hyd. Cyl.

85ZIV-2

HYDRAULIC 44

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

４

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

１

１７ １６

１８

１５

１４

１３ ８５Ｗ４４００５

2.Reinstalling cylinder １

To reinstall the cylinders, follow the above removal procedure in the reversed direction. １６

１７

１５

１４

44-37

１３

Disassembling and Reassembling Hyd. Cyl.

85ZIV-2

HYDRAULIC 44

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

CAUTION Hot oil can cause injury or burns.

Avoid contact with hot oil.

1)Put the slipper ring (10) into hot oil to heat the ring to 120 to 150 ℃ .

(This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston.

Therefore, heat the slipper ring to expand its inner diameter for easy attachment.) : Attach the slipper ring while taking care not to extremely expand it. : After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

2)Before installing the backup ring (2) and the O-ring (3), heat the backup ring.

(This is because the inner diameter of the backup ring is smaller than the outer diameter of the rod cover. To easily attach the backup ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.)

Be careful not to extremely expand the backup ring.

After installation, wait until the backup ring is cooled, and then insert the rod cover into the cylinder tube.

3)Reinstall the rod cover of the steering cylinder, screw the rod cover using a spanner wrench.

Screw in and tighten the set screw. : 1,569N・m (160kgf・m)

44-38

１０

２

３

Disassembling and Reassembling Hyd. Cyl.

85ZIV-2

HYDRAULIC 44

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

１

Caulking

１３

６５Ｋ４４０６７

１

１３

Caulking

44-39

７０Ｖ４４００５

Pilot Valve

85ZIV-2

HYDRAULIC 44

Pilot Valve For bucket control

Neutral

1 Dump

Roll back

For bucket control

For boom control

8 2

3

T

To tank port

4 5 6

From pump port

7

P

８５Ｗ４２１１

To MCV oil packs

８５Ｗ４２１８

View from the rear

For boom control

Raise

Neutral

Down

1. Lever 2. Disc 3. Push rod 4. Spring seat 5. Spring for secondary pressure 6. Return spring 7. Spool 8. Detent magnet solenoid

Float

To tank port ８５Ｗ４２１９

44-40

Pilot Valve Tightening Torque

85ZIV-2

HYDRAULIC 44

Pilot Valve Tightening Torque : Tightening torque T1 : 29N・m (3.0kgf・m) T2 : 36N・m (3.7kgf・m) T3 : 17N・m (1.7kgf・m) T4 : 29N・m (3.0kgf・m) T5 : 29N・m (3.0kgf・m) T6 : 17N・m (1.7kgf・m) T7 : 42N・m (4.3kgf・m) T8 : 12N・m (1.2kgf・m)

For boom control Front

For bucket control

T3

: Pilot valve 9.5kg : L1 : Screw lock agent (Three Bond1327)

T3

T5

T5 T6 L1

T6 L1

T7

T8

T7

T8

T7

T7

T4

T4 T4 T4

T2 ９０Ｋ４４０９０

T1

T1

44-41

application

Removing and Reinstalling Pilot Valve

85ZIV-2

HYDRAULIC 44

Removing and Reinstalling Pilot Valve 1.Removing pilot valve

WARNING

１

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

Control box

Cover mount

８５Ｗ４４００６

1)Open the cab door (the right hand side).

Remove the cover (1) from the control box.

２

2)Disconnect the electrical line (2) of PUS switch.

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

３

８５Ｋ４４０３３

4)Remove the knob (4) and then separate the PUS switch (5).

４

４

５ ８５Ｋ４４０３４

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

７ ８５Ｋ４４０３５

44-42

Removing and Reinstalling Pilot Valve

85ZIV-2

HYDRAULIC 44

6)Disconnect the hoses (11) from the pilot valve. : Drain oil : Approx. 1 l Note: Before disconnecting the electrical coupler and hoses, be sure to put match marks on them.

After disconnection, cover the discon- nected hoses with vinyl, caps, or plugs to protect them from dust and dirt.

１１ １１

８５Ｋ４４０３６

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

１２ Adapter

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

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

１３

１４

: Adapter : 36N・m (3.7kgf ・m) : Nut : 28N・m (2.9kgf・m) : Pilot valve : 9.5kg

１４ １５ １６ ８５Ｗ４４００７

2.Reinstalling pilot valve To reinstall the pilot valve, follow the removal procedure in the reversed direction.

Note: After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage.

If the oil level is too low, add hydraulic oil to the tank.

44-43

Nut

Disassembling and Reassembling P / V

85ZIV-2

HYDRAULIC 44

Disassembling and Reassembling Pilot Valve 1.Disassembling pilot valve Note: ・Put plug on each port then clean the outer surface of the vlave. ・Place the removed parts, in order, on a clean paper or cloth. ・Carefully disassemble the pilot valve so that the parts are not scratched.

1)Clamp the pilot valve in a vise.

Pull up the boot (1) to remove it from the cover (2).

For boom control Front For bucket control

７０Ｋ４４０４５

2) Loosen the lock nut for the solenoid (3) and then remove the solenoid from the cover (2).

Torque for assembly : : Solenoid : 42N・m (4.3kgf ・m) Note: Before removing the solenoid (3), measure the distance "A".

A

Lock nut

１

３ ４

２

７０Ｋ４４０４６

７０ＺⅣ４２０７

Carefully store the ball (4).

44-44

Disassembling and Reassembling P / V

85ZIV-2

HYDRAULIC 44

3)Remove the socket bolt (5).

Torque for assembly: : Bolt : 29N・m (3.0kgf ・m)

５ ６ ７

4)Remove the lever (6) from the disc (7).

７０Ｋ４４０４７

5) Loosen the socket bolt (8).

８

Torque for assembly: : Retainer bolt : 17N・m (1.7kgf・m) : Screw lock agent (Three Bont 1327) application 6)Remove the cam shaft (9).

Note: ・Temporarily install the socket bolt (5) into the disc. ・Pull the cam shaft to the direction shown.

９ ７０Ｋ４４０４８

7)Pull up the socket bolt (5) with the disc (7) and remove it.

１０

７

8)Put match mark on the cover (2) and the case assembly.

Remove the socket bolt (10). ２

７０Ｋ４４０４９

9)Remove the cover (2) from the case assembly. ２

７０Ｋ４４０５０

44-45

Disassembling and Reassembling P / V

85ZIV-2

10)Remove the plug (11) together with the push rod (12).

Note: ・Carefully store the spring and spring seat in the push rod. ・Carefully remove the plug so that the parts are not scratched. ・In case the plug(11)does not come out, use the screw driver to remove it.

HYDRAULIC 44

１１ １２ １３ １４

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

７０Ｋ４４０５１

11)Remove the springs (15) (16) from the case assembly (14).

１６

１４

１５

７０Ｋ４４０５２

Note: When installing, carefully install the spool assembly so that the end of the spool does not hit the hole corner in the case assembly.

Carefully install into the case

７０ＺＡ４４０９

12)Clamp the case assembly (14) in the vise up side down.

Remove the socket bolt (17), then remove the plate (18) from the case assembly.

Torque for assembly: : Bolt : 29N・m (3.0kgf ・m)

１７ １８

１４ ７０Ｋ４４０５３

44-46

Disassembling and Reassembling P / V

85ZIV-2

HYDRAULIC 44

13)Remove the spring (19) and the spring seat (20) from the push rod (12).

Note: The spring (19) and the spring seat (20) are used in the following position.

Boom down/Float・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・70Z Ⅳ〜115Z Ⅳ Boom raise・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・70Z Ⅳ〜85Z Ⅳ Roll back・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・70Z Ⅳ〜85Z Ⅳ Dump・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・70Z Ⅳ〜85Z Ⅳ

１１

１２

１９

14)Remove the push rod (12) from the plug (11).

２０ ７０Ｋ４４０５４

15)Push down the spring seat (23), and then remove the plane washer (24).

Note: ・Carefully remove the plane washer so that the spool is not scratched. ・Do not push the spring seat (23) down more than 4mm.

２４ ２３

２５ ２６

16)Remove the spring seat (23), spring (25), plane washer (24) and the shim from the spool (22).

Note: Shim for adjusting secondary pressure.

Some spool need shim, but others may not need it.

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

Note: ・Clean and check all the parts. If a part is defective, replace or repair the part. ・Replace all the O-rings and seals with new ones. ・Apply the specified torque to tighten each main parts. ・Apply a thin coat of hydraulic oil or grease to each part before reassembly. ・Measure the resistance of each coil magnet assembly. The resistance should be 238Ω ±10 at normal room temperature (20 ° C). If measured in extremely low temperatures the resistance will be less. At operating temperature the resistance will be higher.

Cautions regarding reassembling : Install the plane washer (24) so that the plane washer sharp edge side comes to the top position.

Note: Do not push the spring seat (23) down more than 4mm.

44-47

２２ ７０Ｋ４４０５５

２４

２３

Sharp edge side

７０ＺＡ４４０８

HYDRAULIC GROUP 45 Steering Linkage ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-2 Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-4 Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-5 Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-6

45-1

Steering Linkage

85ZIV-2

HYDRAULIC 45

Steering Linkage (Standard dimensions)

2

243

18.5

1 5

7

32

Center of center pin

3

Drop arm

4

Left-turn position

387.5 16.2°

13.5 °

58

45-2

6

Steering Linkage

85ZIV-2

HYDRAULIC 45

Tightening torque No.

Unit : N・m (kgf・m) I

t

e

m

Standard value

1

Steering valve retainer bolt

88 (9.0)

2

Link bracket retainer bolt

216 (22.0)

3

Ball joint retainer nut

255 (26.0)

4

Ball joint lock nut

162 (16.5)

5

Steering valve bracket retainer bolt

216 (22.0)

6

Overload relief valve

83 (8.5)

7

Main relief valve

74 (7.5)

45-3

Solution

Tightening

Multiple Control Valve

85ZIV-2

HYDRAULIC 45

Multiple Control Valve

6 1

8

2 2

3 5 9 7

4

Tightening torque No.

Unit : N・m (kgf・m) I

t

e

m

Standard value

1

Main relief valve

103 (10.5)

2

Overload relief valve

83 (8.5)

3

Make-up valve

83 (8.5)

4

Check valve retainer plug

132 (13.5)

5

Cap retainer bolt

42 (4.3)

6

Cover retainer bolt

157 (16.0)

7

Cap kit retainer bolt

42 (4.3)

8

Plug

98 (10.0)

9

Multiple control valve retainer bolt

90 (9.2)

45-4

Solution

Tightening

Hydraulic Cylinder

85ZIV-2

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder ４

８５Ｋ４５００２

２

１

(Note) The cylinder shown in the above figure is the boom cylinder.

３

Steering cylinder

４

８５Ｋ４５００３

(Note) The cylinder shown in the above figure is the steering cylinder.

Unit : mm Judgment standard No.

Item

Boom cylinder

1

Bucket cylinder

Steering cylinder

No.

2

Standard dimension of rod dia. φ 80

φ 100

φ 50

Standard value

Standard

Limit Bushing Clearance

Rod

Bushing

clearance

-0.030 〜

+0.195 〜

0.090 〜

-0.076

+0.060

0.271

-0.036 〜

+0.195 〜

0.096 〜

-0.090

+0.060

0.285

-0.025 〜

+0.110 〜

0.025 〜

-0.064

0

0.174

Item Piston nut tightening torque (N・m) (kgf・m) Piston nut width across flat (mm)

3

Rod cover bolt tightening torque (N・m) (kgf・m)

4

Piston stroke (mm)

Solution

+0.295

0.371

Replacement

+0.295

0.385

Replacement

+0.210

0.274

Replacement

Boom cylinder

Bucket cylinder

Steering cylinder

M62 × 2 (3,923〜4,217) (400〜430)

M76 × 2 (5,394〜5,884) (550〜600)

M36 × 1.5 (1,079〜1,275) (110〜130)

90

110

55

M24 (736〜883) (75〜90)

M24 (736〜883) (75〜90)

(Rod cover) (1,569〜1765) (160〜180)

814

538

440

45-5

Pilot Valve

85ZIV-2

HYDRAULIC 45

Pilot Valve

212-1

７０Ｖ４５００２

Judgement standard No.

Item Wear 1mm

212-1

Push rod

Solution

(φ7)

45-6

Standard value

Allowable limit

36mm

35mm

Replacement

BRAKE GROUP 54 Brake Valve Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-2 Removing and Reinstalling Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-3 Disassembling and Reassembling Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-4 Air Master Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-6 Removing and Reinstalling Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-7 Disassembling and Reassembling Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-8 Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-14 Removing and Reinstalling Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-15 Auto-Adjuster Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-16 Disassembling and Reassembling Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-17 Removing and Reinstalling Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-18 Air Cylinder for Parking ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-19 Removing and Reinstalling Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-20 Disassembly and Reassembly of Air Cyilnder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-21 Removing and Reinstalling Parking Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-23

54-1

Brake Valve Assembly

85ZIV-2

BRAKE 54

Brake Valve Assembly

16

: Torque T1 : 12N・m (1.2kgf・m) T2 : 6N・m (0.6kgf ・m) T3 : 34N・m (3.5kgf・m) L2 15 13

L1 : Liquid gasket application (Loctite gasket 568) L2 : Anti-seize compound

12 14

11

T1

1. Diaphragm 2. Cover 3. nlet / exhaust valve assembly 4. Body 5. Piston 6. Relay piston assembly 7. Valve assembly 8. Body 9. Upper piston assembly 10. Spring seat 11. Boot 12. Plunger 13. Roller 14. Spring 15. Pin 16. Pedal

T2

5

T3 10

L1

7 9 4

T3

L1

T2 3 8

2

6

1

54-2

Removing and Reinstalling Brake Valve

85ZIV-2

BRAKE 54

Removing and Reinstalling Brake Valve 1.Removing brake valve

WARNING ２

Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. ・ Drain the air pressure from the air tank.

１

Before starting work, clean the area around the brake valve.

1)Disconnect the air pipes (1), the tee (2), and then disconnect the air hose (3).

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

2)One person should support the brake valve under the machine, and another person should enter the cab. The person in the cab should remove three connection bolts (5) from the brake pedal (4), and the person under the machine should remove the brake valve. Remove the pedal assembly (4) from the top side.

３ ６５Ｋ５４００１

５ ４

６５Ｋ５４００２

2.Reinstalling brake valve To reinstall the brake valve, follow the above removal procedure in the reversed direction Note: After reinstallation, check all the pipe- joints for air leakage.

To check or adjust the brake valve, refer to Section 53.

54-3

Disassembling and Reassembling Brake / V

85ZIV-2

BRAKE 54

Disassembling and Reassembling Brake Valve 1.Disassembling brake valve

２

Before starting work: a)Clean the outer surface of the valve.

１

1)Remove the diaphragm (1) and the cover (2).

2)Remove the inlet exhaust valve assembly (3). ３

１

２

3)Disassemble the inlet exhaust valve assembly (3).

３

4)Remove the retainer ring (4), spring seat (5), O-rings (6) (7), retainer (8), valve spring (9), and inlet exhaust valve (10). Also remove the body retainer bolt (11).

１１ ６

４

５

８ １０

７

９ ６５Ｋ５４０１９

54-4

Disassembling and Reassembling Brake / V

85ZIV-2

BRAKE 54

5)Separate the body into two sections (1) (2).

１

6) Loosen and remove the nut (3), and then remove the spring set (4), piston assemblies (5) (6), rubber spring (7), and piston return springs (8) (9).

８

To reassemble the brake valve, follow the above disassembly procedure in the reversed direction.

3.Cautions regarding reassembly 1)Clean and check the disassembled parts. If a part is defective, replace it.

Note: All the rubber parts should be replaced annually. Certain cleaners and solvents can damage rubber parts, use only approved cleaners and solvents.

2)Apply lithium-based grease to all the sliding surfaces of the body, O-rings, and O-ring grooves.

3)After reassembly, reinstall the brake valve on the machine, and check that no air is leaking. Also check operation of the brake valve referring to "Checking Brake Valve" in Section 53.

54-5

５ ４

６

2.Reassembling brake valve

２

９

７

３

Air Master Tightening Torque

85ZIV-2

BRAKE 54

Air Master Tightening Torque

T4

T3

T2 T1

T5

:Torque T1 : 55N ・ m (5.6kgf ・m) (width across flat: 30mm) T2 : 147N ・m (15.0kgf ・m) (width across flat: 100mm) T3 : 10N ・ m (1.0kgf ・m) T4 : 44N ・ m (4.5kgf ・m) T5 : 137N ・m (14.0kgf ・m)

54-6

Removing and Reinstalling Air Master

85ZIV-2

BRAKE 54

Removing and Reinstalling Air Master 1.Removing air master

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. ・ Use a stepladder or the like to reach a high position of the machine. ・ Drain the air pressure from the air tank.

１

８５Ｋ５４００１

1)Remove the cover (1).

２

2)Disconnect the air hose (2).

８５ＺⅣ５４０１

3)Disconnect the brake hoses (3) (4).

Note: The brake oil will be drained. Place a container to catch the drained oil. : Brake oil 0.4 l

4)Disconnect the stroke indicator connector (5), and remove the retainer nuts (7) from the air master (6).

Remove the air master.

２ ３

６

７ ４ ８５ＺⅣ５４０１

2.Reinstalling air master

AIR MASTER

To reinstall the air master, follow the above removal procedure in the reversed direction.

Note: After reinstallation, completely bleed the brake line of air, and check performance of the air master.

To bleed the brake line of air, refer to Section 24.

To check performance of the air master, refer to Section 53. ５ ８５ＺⅣ５４０２

54-7

Disassembling and Reassembling Air / M

85ZIV-2

BRAKE 54

Disassembling and Reassembling Air Master 1.Disassembling air master IMPORTANT ・ Clean the outer surface of the air master. ・ Put match marks on the parts before disassembly. ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

1)Securely clamp the air master in a vise.

2

2) Feed low-pressure air (approx. 98KPa (1kgf/cm )) into the air cylinder from the air inlet port, and operate the hydraulic pistion in full stroke mode (continue operation in full stroke mode).

Note: This may discharge some remaining brake oil.

3) Loosen the locknut (1).

Nut width across flat: 100mm

１

Air inlet port

4) Loosen the cylinder (2), and remove it. ２

5)Slide the retainer ring (3) to remove the straight pin (4). After that, separate the push rod (5) from the piston (6).

５

３

４

６

6)Bleed the air cylinder of air.

Slide ③ in the "

４ Remove the straight pin

３

54-8

"direction

Disassembling and Reassembling Air / M

85ZIV-2

BRAKE 54

7)Remove the snap ring (2) from the piston (1). After that, remove, in order, the spring seat (3), spring (4), and valve (5).

After that, remove the piston cup (6).

Note: The piston(1)should be replaced as an assembly, therefore further disassembly is not needed.

１

５

４

３

２

６

8)Remove the breather (7) and the switch (8), and rod (22).

７

２２ ８

9) The spring of the air cylinder has a high force of 25kg. Therfore, press the spring using a press, and then remove the bolts (9), washers (10), and nuts (11).

Press

１１ ９ １０

WARNING The inner spring may spring out causing injury. To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the bolts (9). When reducing the pressure of the press, be sure to slowly reduce it.

10)Separate the cover into two sections, and then remove the spring (12).

11)Loosen and remove the nut (13), and then remove the spring washer (14), piston (15), and rod (16).

After that, remove, in order, the washer (17), piston seal (19), piston ring (20), and O-ring (21).

Note: To loosen the nut (13), cover the shaded area of the rod (area A in the right figure)with a copper sheet or the like for protection, and then clamp the shaded area using a vice. Do not clamp over the area having a pin sliding hole.

１２

１８１５ １９１３

A １６１７

２０ １４２１

Pin sliding hole Two chamfered flats Enlarged area A

54-9

Disassembling and Reassembling Air / M

85ZIV-2

BRAKE 54

12)Remove the snap ring (2) from the end cover (1), and then remove, in order, the support ring (3), seal (4), seat ring (5), and seal (6).

13)After that, remove the snap ring (7) on the opposite side, and then remove the seat ring (8) and the seal (9).

７

９ ２

４

６

８

2.Reassembling air master Notes: ・Clean the metal parts using approved brake cleaning solvent, and then blow the compressed air to dry them. ・After cleaning, check the parts for damage and wear.

If a part is defective, replace it with a new one. ・Replace all the O-rings and seals with new ones. ・Measure the clearance between the hydraulic cylinder and the piston by cheking of inner diameter of cylinder and outer diameter of piston. If the clearance is too large and exceeds the following limit value, replace the hydraulic cylinder and the piston as an assembly.

Clearance between hydraulic cylinder and piston (mm)

１

Standard value for assembly

Limit

0.025〜0.126

0.15

３

５

・ Use brake oil (engine oil SAE 5W). ・ Use lithium grease.

1)Reinstall, in order, the O-ring (2), washer (3), piston (4), and spring washer (5) on the rod (1), and then tighten the nut (6). : Nut 137N・m (14.0kgf・m) Note: To tighten the nut, cover the shaded area of the rod(area a in the right figure )with a copper sheet or the like for protection, and then clamp the shaded area using a vice.

Do not clamp over the area having a pin sliding hole.

１

８

２

６

2)Apply a thin coating of lithium grease to the piston ring (7) and the piston seal (8), and then insert them into the piston.

Ａ

３ ４

７

Pin sliding hole

54-10

５

Disassembling and Reassembling Air / M

85ZIV-2

3)Apply a coating of brake oil to the seal (2), seat ring (3), seal (4), and support ring (5), and then sequentially install them to the end cover (1) in the above order. After that, install the snap ring (6).

4)Apply a coating of brake oil to the seal (7) and the seal ring (8), and then install them to the opposite side of the end cover. After that, install the snap ring (9).

BRAKE 54

１ ６

４

５

７

２

９

８

３

5)Apply a thin coating of lithium grease to the O-ring (10), and then install the O-ring to the end cover (1). １０

１

6)Apply lithium grease to the inside of the cover, and then insert the air piston assembly (11), already reassembled, and the spring (12) into the cover. １２

WARNING

１１

Cover

Be careful! The spring could spring out. To reassemble, fix the cylinder assembly so that it is not inclined. ・ Press the spring using a press until it loses the spring force, and then start the work.

7)Reinstall the end cover (1) on the cover already reassembled at step 6) above. While applying pressure to the end cover using a press, insert the bolts (13), washers (14), and nuts (15), and then tighten the bolts. : Bolt 44N・m (4.5kgf ・m)

54-11

Press

１３ １４１５

１

Disassembling and Reassembling Air / M

85ZIV-2

BRAKE 54

8)Apply a coating of brake oil to the valve (2), spring (3), and spring seat (4), and then insert them into the piston (1). In addition, install the snap ring (5) to the piston.

After that, reinstall the piston cup (6).

１

２

４

３

６

9) Feed low-pressure air of approximately 1kg/cm2 into the air cylinder (already reassembled at step 7 above) from the air inlet. Operate the air piston in full stroke mode until the push rod (7) is protruded from the end cover.

Note: Keep the air pressure applied.

End cover

Air inlet port

７

10)Just like the disassembly procedure, slide the retainer ring (8) to insert the straight pin (9) into the piston (1), and then push the straight pin through the push rod (7).

７ ８ ９ １

Slide (8) in the " "direction

９ Insert the straight pin

11)Install an O-ring (11) to the cylinder (10), and then apply a coating of brake oil to the inside of the cylinder and the O-ring.

12)Screw the locknut (12) all the way on the threaded area of the cylinder (10). １０

54-12

１１ １２

５

85ZIV-2

13)Screw the threaded area of the cylinder (1) all the way into the end cover (2).

Note: Align the plug with the breather so that it (distance from center line A-A)is 20mm or less(see the figure).

14)After completion of the alignment, tighten the locknut (3).

BRAKE 54

Air breather Breather Plug

A

Plug

A

20 20

Disassembling and Reassembling Air / M

２

１ ３

: Nut 147N・m (15.0kgf・m) Nut width across flat 100mm

A-A

15)Install the rod (6) in the end cover (2), and tighten the switch (4) to the end cover (2) until its end fits in the groove of the rod (6).

５

: Switch 55N・m (5.6kgf ・m) 16)Reinstall the breather (5), and tighten it.

Note: After reassembling the air master, reinstall it on the machine referring to Section 54.

２ １

４ ６

54-13

Auto-Adjuster Valve

85ZIV-2

BRAKE 54

Auto-Adjuster Valve 8

15

16

1

2

18

19

Brake piston port

4

3 9

Air master port

17

6

5

7

10

11

12 10 14 13

1. Cylinder 2. Piston 3. O-ring 4. Valve body 5. Valve 6. Spring 7. O-ring 8. Body 9. O-ring 10. Spring washer

11. Bolt 12. Plain washer 13. Plate 14. Bolt 15. Air bleeder screw 16. Cap 17. Washer 18. Screw 19. O-ring

54-14

Removing and Reinstalling Auto-Adjuster Valve

85ZIV-2

BRAKE 54

Removing and Reinstalling Auto-Adjuster Valve 1.Removing auto-adjuster valve (The illustration show the rear wheels).

1)Disconnect the hose (1) and the pipes (2).

Oil will be drained from the hose. Place a container to catch the drained oil. : Brake oil 0.4 l １ ２ ９０Ｋ５４００２

2)Remove four retainer auto-adjuster valve (3).

bolts

(4)

from

the ３

: Bolt (4)

29〜35N・m (3.0〜3.6kgf ・m)

3)Remove the auto-adjuster valve (4).

４

９０Ｋ５４００３

2.Reinstalling auto-adjuster valve To reinstall the auto-adjuster valve, follow the above removal procedure in the reversed direction.

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

For the detailed procedure of air bleeding, refer to Section 24.

54-15

Auto-Adjuster Valve Tightening Torque

85ZIV-2

BRAKE 54

Auto-Adjuster Valve Tightening Torque 11 10 T4

4 7 5

1

6 3

17

16

14 T2

T1

10

2 T3 18

15 T3

9

19 12

8

: Torque T1 : 39N・m (4.0kgf・m) T2 : 54N・m (5.5kgf・m) T3 : 10N・m (1.0kgf・m) T4 : 15N・m (1.5kgf・m)

54-16

13

T2

Disassembling and Reassembling Autovalve

85ZIV-2

BRAKE 54

Disassembling and Reassembling Auto-Adjuster Valve 1.Disassembling auto-adjuster valve (The disassembly procedure described below is for the left-side of the valve. ) IMPORTANT ・ Clean the outer surface of the auto-adjuster . ・ Put match marks on the parts before disassembly. ・ Place the removed parts according to the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

1)Remove the bolts (1).

Torque for assembly : Retainer bolt 54N・m (5.5kgf・m) 10

2)Separate the cylinder (2) into two sections.

Remove and clean the plug (10). Remove and inspect the plug (11) and replace the O-ring. : Plug (10) 15N・m (1.5kgf・m) Plug (11) 10N・m (1.0kgf・m)

1

6 3

8 2

11 5

3)Pull out the piston (3) from the cylinder (2).

4

7

4)Gently clamp the two opposite flats of the piston (3) using a vice. Loosen the valve body (4), and then remove the valve (6), spring (7), washer (8), O-rings (5)(9).

2.Reassembling auto-adjuster valve To reassemble the auto-adjuster valve, follow the above disassembly procedure in the reversed direction.

Note: Be sure to replace all the O-rings with new ones, and apply a coat of brake oil to them before reassembly. Inspect the parts for scoring or other damage. Replace as necessary.

54-17

9

８５Ｗ５４００１

Removing and Reinstalling Service Brake

85ZIV-2

BRAKE 54

Removing and Reinstalling Service Brake Removing and reinstalling service brake Refer to the power group 24 for removing and reinstalling service brake.

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

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

Finally the spider and the cover may fall off.

Spider ９０Ｗ５４００２

Socket bolt

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

Fill the brake oil tank. Slightly loosen the air bleeder nipple, and then press the brake pedal several times.

When the oil flows from the air bleeder nipple, close the nipple.

After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple. Repeat this until there is no air in the oil. When the oil level in the reservoir lowers, add oil to the tank.

Completely bleed each wheel of air.

54-18

Air Cylinder for Parking

85ZIV-2

BRAKE 54

Air Cylinder for Parking 14

4 10 8 3

2

7 13 11 5 9 6

12 15

1

1. Cylinder tube 2. Piston rod 3. Rod cover 4. Rod cap 5. Piston 6. U-nut 7. Spring 8. Wear ring 9. U-packing 10. Dust seal

11. O-ring 12. O-ring 13. Filter 14. Set screw 15. Retainer bolt : Air cylinder

54-19

8.0kg

Removing and Reinstalling Cylinder

85ZIV-2

BRAKE 54

Removing and Reinstalling Cylinder 1.Removing air cylinder

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ When removing the air cylinder, the machine may move.

To prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

６

５

1) If there is an air source, release the parking brake, and then remove the split pin (1) and the pin (2).

Note: If there is no air source, apply a cable to the link, and then pull it down using a bar to overcome the spring force, and then remove the pin.

３ ４

１ ２

2)Release the air pressure. Disconnect the air hose.

3) Loosen the locknut (3) to remove the joint (4).

Remove the retainer bolts (5) to remove the air cylinder (6). : Retainer bolts 49〜59N・m (5.0〜6.0kgf・m) : Air cylinder 8kg

2.Reinstalling air cylinder To reinstall the air cylinder, follow the above removal procedure in the reversed direction.

Note: To insert the connection pin to connect the air cylinder to the parking brake, observe the following items: ①Start the engine to build air pressure in the air tank. ②Release the parking brake. ③Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the air cylinder and the parking brake. After that, insert the connection pin into the joint hole.

To check performance of the parking brake, refer to Section 53.

54-20

８５Ｗ５４００２

Disassembly and Reassembly of Cylinder

85ZIV-2

BRAKE 54

Disassembly and Reassembly of Air Cylinder 1.Disassembling air cylinder

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

1) Removal of the set screw of rod cap Note: Since the set screw is locked by punching, cut off the punched area with 15 to 20mm dia. drill.

Since it is necessary to install the set screw at the same position during reassembly, mark the positioning match- mark on the rod cap and cylinder tube.

2) Initial loosening of rod cap Using the threaded hole of the rod cap, unscrew the rod cap approx. 1/8 turn alone.

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

Component parts of air cylinder １

1. Cylinder tube 2. Rod Cap 3. Spring 4. Piston 5. Piston rod 6. Rod cover

２ ３

５ ４

54-21

６

Disassembly and Reassembly of Cylinder

85ZIV-2

BRAKE 54

2.Reassembling air cylinder To reassemble the air cylinder, follow the disassembly procedure in the reversed direction.

CAUTION When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined.

Tighten the rod cap to the position where the matchmark was marked before disassembly, screw in the screw, and punch it for locking.

Adjustment procedure of air cylinder linkage.

1

4

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ When removing the air cylinder, the machine may move.

To prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

A 2

4

3 A 2

1)Release parking brake (OFF).

2)Measure dimension "A" if it is 84mm.

3

3) If not, remove pin (5), split pin (6), and washer (7) and loosen lock nut (2).

And adjust the linkage length by turning link 3 so that dimension "A" is 84mm.

5, 6, 7

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

5)Confirm the parking brake performance referring to Section 53.

Parking brake "OFF" position.

1. Air cylinder 2. Lock nut 3. Link 4. Bracket 5. Pin 6. Split pin 7. Washer

54-22

Removing and Reinstalling Parking Brake

85ZIV-2

BRAKE 54

Removing and Reinstalling Parking Brake 1.Removing parking brake

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

Note:Drain the transmission oil. Drain the oil into a suitable container. 38 l 1)Release the parking brake, and then disconnect the second propeller shaft (1) at the transmission end.

Torque for reassembly : Retainer bolt 142N・m (14.5kgf・m) : Screw lock agent application (Three bond 1327)

１

８５Ｗ５４００４

2)Remove the nut (2), and then remove the washer, O-ring, and backup ring.

Torque for reassembly : Nut 392N・m (40.0kgf・m) : Application of anti-seize compound ２

８０Ｋ５４００４

3)Remove the flange yoke (3) with the brake drum (4).

Torque for reassembly : Retainer bolt 98N・m (10.0kgf ・m)

３

４

８０Ｋ５４００５

54-23

Removing and Reinstalling Parking Brake

85ZIV-2

BRAKE 54

4)Separate the air cylinder and the parking brake at the ball joint (5) part.

５

８５Ｗ５４００３

5)Remove the bolt (6) and then remove the brake assembly (7).

Torque for reassembly : Bolt 216N・m (22.0kgf ・m) : Screw lock agent application(Loctite 262)

７

６

８０Ｋ５４００７

6)Remove the spring (9) and then remove the plate (10).

１０ ９

９

６５Ｖ５４００１

7)Remove the shoe hold pins (11) by turning 90 degree.

8)Remove the brake shoes (12).

１２

１１

６５Ｖ５４００２

54-24

Removing and Reinstalling Parking Brake

85ZIV-2

BRAKE 54

9)Remove the spring (13) and the adjust screw (14).

１３

１４

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

Note: To adjust the parking brake, refer to Section 53.

To check performance of the parking brake, refer to Section 53.

54-25

６５Ｖ５４００３

BRAKE GROUP 55 Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-2 Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-4 Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-5 Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-6 Parking Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-7

55-1

Brake Valve

85ZIV-2

BRAKE 55

Brake Valve

17 7

6

9 2

5

1

17

8 10 11 13

4

12

14

15 16

3

No.

Item

Standard value

Solution

1

Mounting plate retainer bolt tightening torque

12N・m (1.2kgf・m)

Tightening

2

Rubber spring setting nut tightening torque

6N・m (0.6kgf・m)

Tightening

3

Lower body retainer bolt tightening torque

6N・m (0.6kgf・m)

Tightening

4

Plug tightening torque

34N・m (3.5kgf・m)

Tightening

55-2

Brake Valve

85ZIV-2

BRAKE 55

Unit : mm No. 5

6

7

Item Pedal pin hole dia

Nominal

Service standard

Wear limit

10

10.25

10

9.85

Inner dia.

10

10.1

Outer dia.

23.2

23

Inner dia. of pin bushing

10

10.25

Inner dia. of plunger bushing

26.5

26.65

Outer dia. of pin (pins for both roller and mounting plate)

Note

Roller

Mounting plate 8

9

Outer dia. of plunger

26.5

26.16

10

Free height of rubber spring

14

12

11

12

13

14

15

16

17

Spring

Free length mm

71.4

(piston return)

Load N (kgf)

113 (11.5)

Spring

Free length mm

41.3

(upper valve)

Load N (kgf)

44 (4.5)

Spring

Free length mm

35.6

(inner valve)

Load N (kgf)

28 (2.8)

Spring

Free length mm

41.0

(outer stem)

Load N (kgf)

39 (4.0)

Spring

Free length mm

39.5

(relay piston)

Load N (kgf)

46 (4.7)

Spring

Free length mm

16.5

(lower valve)

Load N (kgf)

29 (3.0)

Spring

Free angle

131deg

(pedal return)

Set angle

115deg

55-3

When the length is 14.6mm

When the length is 14.3mm

When the length is 16.0mm

When the length is 16.0mm

When the length is 12.1mm

When the length is 10.2mm

When the pedal is returned

Air Master

85ZIV-2

BRAKE 55

Air Master 3

1

5 2 6 4

8 7

Unit : mm No.

1

Item

Clearance between cylinder and piston

Judgment standard

Solution

Standard dimension

Standard clearance

Allowable clearance

68

0.025〜0.126

0.15

Replacement

2

Stroke of hydraulic cylinder

84.5

-

3

Stroke of air cylinder

85.5

-

4

Stroke to overstroke switch

59 ± 3

-

5

Air piston retainer nut tightening torque

137N・m (14.0kgf・m)

Tightening

6

Locknut tightening torque (100mm Nut Size)

147N・m (15.0kgf・m)

Tightening

7

Overstroke switch tightening torque

55N・m (5.6kgf・m)

Tightening

8

Air cylinder retainer bolt tightening torque

44N・m (4.5kgf・m)

Tightening

55-4

Auto-Adjuster Valve

85ZIV-2

BRAKE 55

Auto-Adjuster Valve

5 4

7 1

Wet brake piston port

6 Air master port

2

3

Unit : mm No.

Item

Judgment standard Tolerance

Standard 1

2

Clearance between

Standard

Allowable

Hole

clearance

clearance

φ 55

-0.100 〜 0.146

+ 0.08 〜 0

0.100 〜 0.226

0.264

φ 14

-0.032 〜 -0.059

+0.043 〜 0

0.032 〜 0.102

0.110

dimension

Shaft

cylinder and piston

Clearance between check valve and body

Solution

Replacement

Standard dimension Item

Replacement

Allowable load

Free length

Installation length

Installation load N (kgf)

Installation load N (kgf)

23.5

20

90 (9.2)

90 ± 13 (9.2 ± 1.3)

3

Spring

4

Retainer bolt tightening torque

54N・m (5.5kgf・m)

5

Air bleeder screw tightening torque

10N・m (1.0kgf・m)

Remedy

Replacement

Tightening 6

Valve body tightening torque

39N・m (4.0kgf・m)

7

Plug tightening torque

15N・m (1.5kgf・m)

55-5

Service Brake

85ZIV-2

BRAKE 55

Service Brake

2,6

3

4

5 7

1 6

Unit : mm No.

1

Item

Thickness of steel plate

Judgement standard Standard dimension

Tolerance

Solution Wear limit

5.0

+0 〜 -0.2

4.4 Replacement

2

Thickness of friction plate

7.0

±0.1

5.7

3

Thickness of brake disc when measured by calipers (with brake applied)

29.0

+0.3 〜 -0.5

25.1

4

Piston seal contact face

-0.210 〜 -0.299

-

5

Piston seal contact face

0 〜 +0.081

-

6

Distortion of steel and friction plate

7

Return spring

(Manufacturing dimension) 355 (Manufacturing dimension) 310

-

-

-

0.30

Free length

Installation length

Installation load N (kgf)

54

49

287 (29.3)

55-6

Replacement

Parking Brake

85ZIV-2

BRAKE 55

Parking Brake

2

5

1 3

Clearance

Spring (4) released

4

Unit : mm No.

Item

Judgment standard Standard dimension

1

Solution

Wear limit

Wear of lining

Replacement 6.15

2.95

2

Deflection of drum

0.38 or more

Replacement

3

Lining inspection

Grease or oil on the lining

Replacement

4

Expansion of adjuster spring

5

There is clearance between the spring and the coil when the spring is released

Expansion of return spring

55-7

Replacement

ELECTRICAL GROUP 64 Removing and Reinstalling Wiper Motor ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-2 Removing and Reinstalling Controller ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-6 Removing and Reinstalling Fuse ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-7

64-1

Removing and Reinstalling Wiper Motor

85ZIV-2

ELECTRICAL 64

Removing and Reinstalling Wiper Motor 1.Removing front wiper motor 1)Remove the cover (1).

１

６５Ｋ６４００７

2)Remove the nut (2) and then remove the wiper arm (3).

２

３

3)Remove the nut (4) and the bolt (5).

After that, remove the wiper arm (3).

６５Ｋ６４００８

４

５ ３

６５Ｋ６４００９

4)Remove the cover (6) and the cover (7). ６， ７

６５Ｋ６４０１０

64-2

Removing and Reinstalling Wiper Motor

85ZIV-2

5)Remove the defroster hose (8).

ELECTRICAL 64

９

6)Disconnect the electrical line coupler (9) from the wiper motor.

８

６５Ｋ６４０１１

7)Remove the motor retainer bolt (10), and remove the ground cable (11).

8)Disconnect the coupler (12) for the relay. １３

9)Remove the wiper motor (13).

１１ １０ １２ ６５Ｋ６４０１２

2.Reinstalling front wiper motor To reinstall the front wiper motor, follow the above removal procedure in the reversed direction.

Note :When reinstalling the wiper arm, adjust the operation angle by the nut (2).

64-3

Removing and Reinstalling Wiper Motor

85ZIV-2

ELECTRICAL 64

1.Removing rear wiper motor 1)Remove the cover (1).

１

2)Remove the nut (2), and then remove the wiper arm (3). ３

２

3)Remove the nut (4) and then remove the wiper arm (3). ４

３

６５Ｖ６４００１

4)Remove the cover (5). ５

６５Ｋ６４０１６

64-4

Removing and Reinstalling Wiper Motor

85ZIV-2

ELECTRICAL 64

5)Disconnect the coupler (6) for the wiper motor (8).

７

6)Remove the motor retainer bolts (7).

7)Remove the wiper motor (8). ６ ８ ６５Ｋ６４０１７

2.Reinstalling rear wiper motor To reinstall the rear wiper motor, follow the above removal procedure in the reversed direction.

Note: When reinstalling the wiper arm, adjust the operation angle by the nut(2).

64-5

Removing and Reinstalling Controller

85ZIV-2

ELECTRICAL 64

Removing and Reinstalling Controller 1.Removing controller

１

WARNING Before you remove the controller, be sure to stop the engine, and remove the starter key. In addition, hang a "DO NOT START THE ENGINE!" tag on the instrument panel.

２

1)Remove the catch (1), and then remove the cover (2).

６５Ｋ６４０１８

2)Disconnect the electrical coupler (3).

３

６５Ｖ６４００２

3)Remove the bolt (4) 4pcs, and then remove the controller (5).

５

４

2.Reinstalling controller To reinstall the controller, follow the above removal procedure in the reversed direction.

Note: After reinstallation, set the starter key to the ON position, and check the function of the LED indicator.In addition, run the machine, and check operation of the machine.

Note: The following items may have caused the controller to fail.

Test and correct any problems before installing a new controller. ①Short in the output circuit (Refer to Section 63) ②Defective diode allowing voltage surges.

Identify and test each diode using procedures on Section 63.

64-6

６５Ｖ６４００３

Removing and Reinstalling Fuse

85ZIV-2

ELECTRICAL 64

Removing and Reinstalling Fuse 1.Removing fuse from inside of control box

CAUTION Before removing a fuse, be sure to turn off the starter key.

1)Remove the catch (1), then open the cover (2). ●

１

２

６５Ｖ６４００４

2)Remove the cover (3) (4), then remove the fuses (5) (6).

5A

LIGHTING HEAD LIGHT

2 PERSONS CAB F. WIPER (RH)(OPTION)

5A

R. WORK LIGHT

RADIO

3A

SPARE

CIGARETTE LIGHTER

SPARE

10A 10A

SPARE

PARKING BRAKE CONTROLLER BUZZER MONITOR

SPARE R. WINDOW HEATING

5A

4 WAY FLASHER HORN

SPARE

5A

PREHEAT

AIRCON (OPTION)

5A

SAFETY RELAY

NEUTRAL RELAY

5A

BATTERY RELAY

5A

SPARE

E/G STOP MOTOR

5A

AIRCON (OPTION)

20A 20A 20A

AIRCON (OPTION)

5A

SPARE

15A 15A 20A 15A 15A

F. WORK LIGHT

10A 10A 10A

BACK LAMP STOP LAMP TURN SIGNAL

F. WIPER

5A

5A

BOOM KICKOUT BUCKET POSITIONER

R. WIPER

20A 10A 10A 15A 10A

2 PERSONS CAB F. WIPER (LH)(OPTION)

2.Reinstalling fuse from inside of control box To install the fuse, follow the above removal procedure in the reversed direction.

64-7

３

４

６ ５

６５Ｋ６４０２２

OPERATOR STATION GROUP 74

Air Conditioner .............................................................................................74-2

74-1

85ZIV _ 2

Air conditioner

OPERATOR STATION 74

Air Conditioner Air conditioner mount

Cover unit

Air damper unit

Air conditioner unit

Seat stand

Floor board

74-2

85ZIV _ 2

Air conditioner

OPERATOR STATION 74

Removing and installing of air conditioner Removing the air conditioner

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on level ground, and apply the parking brake.

• Lower the bucket to the ground, and block the tires.

• Pull out the engine key, and attach a tag indicating that startup is prohibited.

Before starting the work, •Recover the gas using a gas recovery unit.

•Remove the seat and the seat stand.

•Disconnect the air conditioner piping at the self-sealing coupling.

２ ３ １

1) Remove the covers (1) to (5).

４

５

2) Disconnect the wiring (7) of the air conditioner (6) and the wiring (9) of the air damper (8) at each coupler.

９

８ ６

７

74-3

Air conditioner

85ZIV _ 2

OPERATOR STATION 74

3) Disconnect the refrigerant piping (10) and the heater hose (11).

10

11

4) Remove the air conditioner mounting bolts (12) and the air damper mounting bolts (13). Then, remove the air conditioner (6) and the air damper (8).

８ ６

13

12

Installing the air conditioner 1) Install the air conditioner in the reverse order of the removing procedure.

Reference After installing the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-4

85ZIV _ 2

Air conditioner

OPERATOR STATION 74

Condenser mount Receiver dryer

Condenser unit

Condenser unit 1. Core 2. Fan shroud 3. Bracket 4. Bracket 5. Fan 6. Motor 7. Bolt 8. Resistor 9. Cable

7 6

2

8

5 1

9

4

74-5

3

85ZIV _ 2

Air conditioner

OPERATOR STATION 74

Removing and installing of condensers Removing the condensers

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on level ground, and apply the parking brake.

• Lower the bucket to the ground, and block the tires.

• Pull out the engine key, and attach a tag indicating that startup is prohibited. １

Before starting the work, •Recover the gas using a gas recovery unit.

•Remove the air cleaner, etc. which may hinder removal 1) Disconnect the condenser hose (1).

2) Disconnect the condenser wiring at the coupler (2).

Remove the condenser mounting nut (3), and remove the condensers. ２

３

Installing the condensers 1) Install the condensers in the reverse order of the removal procedure.

Reference After installing the condensers, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-6

85ZIV _ 2

Air conditioner

OPERATOR STATION 74

Compressor mount

７ ６ T2

１ ５

４

２

３ T1

85K74001

1. Compressor 2. Bracket 3. Idler pulley shaft 4. Tension pulley 5. V belt 6. Compressor mounting bolt 7. Adjustment bolt

: Tightening torque T1 : 31N·m (3.2kgf·m) T2 : 29N·m (3.0kgf·m)

74-7

85ZIV _ 2

Air conditioner

OPERATOR STATION 74

Removing and installing of compressor Removing the compressor

WARNING Unexpected movements of the machine may cause serious accidents.

• Park the machine on level ground, and lower the bucket, etc. to the ground • Block the tires, and apply the parking brake.

• In the starter key area, put up an indication that startup is prohibited. ５

Before starting the work, •Recover the gas using a gas recovery unit.

２

３

４

６

1) Loosen the tension pulley (1) lock nut and the lock bolt (2). Turn the adjustment bolt (3) to make the V belt (4) slack, then remove the V belt from the compressor.

Tightening torque during assembly : Pulley (1) lock nut ....................31N·m (3.2kgf·m) 2) Disconnect the compressor wiring and the cooler piping (5). Remove the compressor mounting nut (6), and remove the compressor (7).

Tightening torque during assembly : Nut (6)..........28N·m (2.9kgf·m)

Installing the compressor 1) Install the compressor in the reverse order of the removing procedure.

Reference •After installing the compressor, adjust the tension of the V belt.

•Charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leak.

•The quantity of the compressor lubricating oil (NDO1L2) is 180 cm3. Never use or mix any other oil.

74-8

１

７

85K74002

OPERATOR STATION GROUP 75

Air Conditioner .............................................................................................75-2

75-1

85ZIV _ 2

Air conditioner

OPERATION 75

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

Criteria

Action

Refrigerant

Charge quantity

Inspection/ Air bubbles should not be seen through sight glass. adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Compressor

Operating status

Belt tension pulley

Operating status

V belt

Damage and tension

Magnetic clutch should operate. Abnormal sounds Inspection/ adjustment/ should not be detected. replacement Abnormal sounds and backlash should not be Inspection/ detected. replacement Damages should not be detected.

Adjustment/ Tension should be proper. replacement

Blower motor and fan

Operating status

Abnormal sounds or vibration should not be detected.

Control mechanism

Operating status

Inspection/ replacement Each part should operate in accordance with switch Inspection/ operations. replacement Air quantity should not be so small as to hinder air Cleaning/ conditioning. replacement

Air filter for inside/outside air Blockage Each mounting area and piping

Clean

Looseness, gas leak and Looseness, gas leak and damage should not be damages detected.

Tightening/charge

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

Nut type

Connection area

Pipe size or bolt size

Tightening torque N·m (kgf·m)

Condenserexpansion valve

ø8 piping

15 (1.50)

Compressorcondenser

D1/2 piping

25 (2.50)

Evaporatorcompressor

D5/8 piping

34 (3.50)

Receiver

M6 bolt in receiver (4T) Any M6 bolt (6T) other than above

Special control region

Bolt size

Tightening torque N·m (kgf·m)

Head bolt of magnetic clutch

M6

13 (1.35)

Mounting bolt for servo motor for inside/outside air selection

M5

0.5 (0.05)

Fixing nut of blower motor and condenser fan

M6

5 (0.55)

Fixing bolt of blower motor and condenser motor

M5

3 (0.30)

7 (0.70)

Block joint Evaporatorcompressor

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

12 (1.20)

75-2

85ZIV _ 2

Air conditioner

OPERATOR STATION 75

3. Compressor

A

4 1

A

3

2

A-A 85ZA7204

Crank pulley 85ZA7202

No.

Item

Standard value

Remedy

8~10mm 98N (10kgf)

Adjustment

1

V-Belt tension

2

Tension pulley mounting nut tightening torque

31N·m (3.2kgf·m)

Tightening

3

Compressor mounting bolt tightening torque

29N·m (3.0kgf·m)

Tightening

4

Compressor lubricating oil amount

180cm3

Adjustment

✽

✽✽

✽ Refer to the section 72 for V-belt tension adjustment ✽✽ -Refer to the section 72 for adjustment of compressor lubrication oil quantity -Compressor lubricating oil······ND-OIL8 (Never mix any other oil)

75-3

85Z Ⅳ -2 Disassembly & Reassembly, Service Standard AAA-S85N3E14-001 AAA-S85N3E14-00Z

① 2000.1.31

K

② 2000.12.15

KAWASAKI HEAVY INDUSTRIES, LTD. Rolling Stock, Construction Machinery & Crushing Plant Company Construction Machinery Division Tokyo Head Office

W.T.C. Bldg., 2-4-1 Hamamatsu-cho Minato-ku, Tokyo 105-6116

Kobe Head Office

Kobe Crystal Tower, 1-1-3 Higashi Kawasaki-cho Chuo-ku, Kobe, Hyogo 650-0044

Banshu Works

2680 Oka Inami-cho Kako-gun, Hyogo 675-1113

All rights reserved. No copy allowed without written consent.