DOWNLOAD PDF : Kawasaki WHEEL LOADER 45ZV-2 SHOP MANUAL 93204-00100

45ZV-2

93204-00100

SHOP MANUAL - Disassembly & Reassembly

Printed in Japan (k) ( アメリカ用 )

93204-00100

©2010 KCM Corporation All rights reserved.

November 2010

SHOP MANUAL WHEEL LOADER

45ZV-2 Workshop Manual -Disassembly & Reassembly

Powered by KUBOTA V3307-DI-T ENGINE Serial No. 00193 and up

TECHNICAL MANUAL (Workshop Manual) INTRODUCTION......................................................................................................................... IN-01~02 SAFETY ......................................................................................................................................... S-1~34 SECTION 1

GENERAL ..........................................................................................................4FGEW -1

Group 1

Precautions for Disassembling and Assembling ..................................................... W1-1

Group 2

Tightening............................................................................................................... W1-2

Group 3

Painting................................................................................................................... W1-3

SECTION 2

BODY .................................................................................................................4FGEW -2

Group 1

Canopy ................................................................................................................... W2-1

Group 2

Cab......................................................................................................................... W2-2

Group 3

Counterweight ........................................................................................................ W2-3

Group 4

Center Hinge .......................................................................................................... W2-4

Group 5

Engine Hood........................................................................................................... W2-5

Group 6

HST Pump and Main Pump .................................................................................... W2-6

Group 7

HST Motor .............................................................................................................. W2-7

Group 8

Control Valve .......................................................................................................... W2-8

SECTION 3

TRAVEL SYSTEM ..............................................................................................4FGEW -3

Group 1

Tire ......................................................................................................................... W3-1

Group 2

Reduction Device ................................................................................................... W3-2

Group 3

Axle ........................................................................................................................ W3-3

Group 4

Propeller Shaft........................................................................................................ W3-4

Group 5

Master Cylinder ...................................................................................................... W3-5

Group 6

Parking Brake Solenoid .......................................................................................... W3-6

Group 7

Steering Valve......................................................................................................... W3-7

Group 8

Steering Cylinder .................................................................................................... W3-8

Group 9

Priority Valve........................................................................................................... W3-9

SECTION 4

ATTACHMENT....................................................................................................4FGEW -4

Group 1

Front Attachment .................................................................................................... W4-1

Group 2

Cylinder .................................................................................................................. W4-2

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

INTRODUCTION TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

• Be sure to thoroughly read this manual for correct product information and service procedures.

ADDITIONAL REFERENCES • Please refer to the other materials (operator’s manual, parts catalog, etc.) in addition to this manual.

MANUAL COMPOSITION • This manual consists the Technical Manual and the Workshop Manual.

• Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.

PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL HEADLINE NOTATIONS

AND

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed along with the safety alert symbol.

The safety alert symbol is also used to draw attention to component/part weights.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

•

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

•

NOTE: Indicates supplementary technical information or know-how.

UNITS USED • SI Units (International System of Units) are used in

2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)

this manual.

MKSA system of units and English units are also indicated in parentheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L 3 m kg N N N⋅m N⋅m

Into in ft US gal US qt 3 yd lb kgf lbf kgf⋅m lbf⋅ft

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-02

To Convert From MPa MPa kW kW °C km/h -1 min L/min mL/rev

Into

Multiply By 2

kgf/cm psi PS HP °F mph rpm US gpm cc/rev

10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in operator’s manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe operating practices.

001-E01A-0001 SA-688

UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs don’t use any of the designated signal words above after the safety alert symbol has been used on this machine.

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

•

SA-1223

NOTE indicates an additional explanation for an element of information.

002-E01A-1223

S-1

SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in operator’s manual.

• Safety signs should be installed, maintained and replaced when necessary.

• If a safety sign or operator’s manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorized personnel to operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

• Do not modify any machine parts without authorization.

Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Kawasaki Warranty Policy.

• Do not use attachments and/or optional parts or equipment not authorized by Kawasaki. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Kawasaki Warranty Policy.

• The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

SA-003

003-E01B-0003

S-2

SAFETY PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire-extinguisher manual.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

004-E01A-0437

WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask.

SA-438

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

005-E01A-0438

S-3

SAFETY PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

006-E01A-0434

INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.

• In the walk-around inspection be sure to cover all points described in the “INSPECT MACHINE DAILY BEFORE STARTING” section in the operator’s manual.

SA-435 007-E01A-0435

S-4

SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any control such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

• Do not leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.

• Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.

• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.

• Keep all flammable objects and/or explosives away from the machine.

• After using the ashtray, always cover it to extinguish the match and/or tobacco.

• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

524-E01A-0000

USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or dismount a moving machine.

• Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

SA-439 008-E01A-0439

S-5

SAFETY ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to miss-operations.

• The seat should be adjusted whenever changing the operator for the machine.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

• If not, move the seat forward or backward, and check again.

• Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

SA-462

009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT • Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the loader control lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.

• Before leaving the machine, be sure to first lower the front attachment to the ground and then move the loader control lever to the LOCK position. Turn the key switch OFF to stop the engine.

• Before leaving the machine, close all windows, doors, and access covers and lock them up.

S-6

SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware.

If any item is damaged or worn, replace the seat belt or component before operating the machine.

• Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

• We recommend that the seat belt be replaced every three years regardless of its apparent condition.

SA-237

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine.

• Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.

• Use a signal person when moving, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

• Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.

SA-398

011-E01A-0398

S-7

SAFETY HANDLE STARTING AIDS SAFELY Starting fluid:

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and cables.

• Remove container from machine if engine does not need starting fluid.

• To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.

• Do not incinerate or puncture a starting fluid container.

SA-293

036-E01A-0293-3

OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only when seated in the operator's seat.

• NEVER start the engine while standing on the tire or on ground.

• Do not start engine by shorting across starter terminals.

• Before starting the engine, confirm that all control levers are in neutral.

• Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-431

012-E01B-0431

S-8

SAFETY JUMP-STARTING • Battery gas can explode, resulting in serious injury.

• If the engine must be jump-started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.

• The operator must be in the operator’s seat so that the machine will be under control when the engine starts.

Jump-starting is a two-person operation.

• Never use a frozen battery.

• Failure to follow correct jump-starting procedures could result in a battery explosion or a runaway machine.

SA-032

S013-E01A-0032

INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.

• When working on an incline or on a road shoulder, employ a signal person as required.

• Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.

• Beware of the possibility of fire when operating the machine near flammable objects such as dry grass.

SA-447

015-E01B0447

S-9

SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-521

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481 SA-481

S-10

SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.

• Only the operator should be on the machine.

Keep riders off.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-427

014-E01B-0427

DRIVE SAFELY • Beware of the possibility of slipping and/or turning over the machine when driving on a slope.

• When driving on level ground, hold the bucket at mark (A) 300 to 400 mm (12 to 16 in) above the ground as illustrated.

• Avoid driving over any obstacles.

• Drive the machine slowly when driving on rough terrain.

• Avoid quick direction changes. Failure to do so may cause the machine to turn over.

• If the engine stops while driving, the steering function becomes inoperative. Immediately stop the machine by applying the bake to prevent personal accident.

• • Even though the machine is equipped with the emergency steering system, if the steering function becomes inoperable during drive operation, press the emergency steering check switch on the right console to activate the emergency steering system.

Then, immediately park and stop the machine in a safe location.

• 019-E07A-0448

S-11

SA-44

SAFETY DRIVE MACHINE SAFELY (WORK SITE) • Before driving the machine, always confirm that the steering wheel/ forward/reverse lever direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions.

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 300 to 400 mm (approximately 12 to 16 in) (A) above the ground.

• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-449

• Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-450

019-E05B-0515

SA-451

DRIVE SAFELY WITH BUCKET LOADED • If the machine is operated incorrectly while driving with the bucket loaded, the machine may turn over.

Be sure to follow all of the instructions indicated below.

• When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.

• Do not exceed the rated load capacity. Always operate the machine within the rated load capacity.

• Avoid fast starts, stops, and quick turns. Failure to do so may result in personal injury and/or death.

• Avoid rapid drive direction changes which could possibly cause personal injury and/or death.

S-12

SA-400

SAFETY DRIVE ON SNOW SAFELY • Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces.

• The machine may slip more easily than expected on frozen snow surfaces even if the incline is small. Reduce speed when driving. Avoid fast starts, stops and quick turns.

• Road shoulder and/or set-up utilities covered with snow are difficult to locate. Be sure where they are before removing snow.

• Be sure to use tire chains when driving on snow.

• Avoid applying the brake for quick stops on snow.

If a quick stop is required, lower the bucket to the ground.

SA-452

052-E02A-0452

TRAVEL ON PUBLIC ROADS SAFELY • This machine is not allowed to drive on public loads with the bucket loaded.

• Be sure to empty the bucket.

• Hold the bucket at mark (A) 300 to 400 mm (12 to 16 in) above the road surface as illustrated.

• Even though the machine is equipped with the emergency steering system, if the steering function becomes inoperable during operation, press the emergency steering check switch on the right console to activate the emergency steering system.

Then, immediately park and stop the machine in a safe location.

053-E02A-0453

S-13

SA-453

SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollways: • Select level ground when possible to park machine.

• Do not park the machine on a grade.

• Lower the bucket to the ground.

• Place the forward/reverse lever (switch) in neutral, and pull up the park brake switch (lever) in the ON (parking brake) position.

• Run the engine at low idle speed without load for 5 minutes to cool down the engine.

• Stop the engine and remove the key from the key switch.

• Pull the lock lever to LOCK position.

• Block both tires and lower the bucket to the ground.

• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.

020-E02A-0516

S-14

SA-457

SA-458

SAFETY AVOID ACCIDENTS FROM BACKING UP AND TURNING • Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine.

• Keep all personnel away from the machine by sounding the horn and/or using hand signals.

Use extra care to be sure no one is in from the articulation area before turning the machine.

• Keep windows, mirrors, and lights in good condition.

• Reduce travel speed when dust, heavy rain, fog, etc., reduce the visibility.

• In case good visibility is not obtained, use a signal person to guide you.

SA-383

021-E02A-0517

SA-312

AVOID POSITIONING ANYONE

BUCKET

OVER

• Never allow the bucket to pass over co-workers and/or the dump truck operator’s cab. Falling material from the bucket or contact with bucket may cause serious personal accidents and/or damage to the machine.

• Avoid carrying the bucket over the co-workers to ensure safe operation.

023-E02A-0518

S-15

SA-518

SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping: • Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the machine.

• Reduce operating speeds to avoid tipping or slipping.

• Avoid changing direction when traveling on grades.

• NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable.

• Reduce speed as necessary when swinging loads.

SA-463

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become soft and make ground travel unstable.

NEVER UNDERCUT A HIGH BANK • The edges could collapse or a landslide could occur causing serious injury or death.

026-E01A-0519

SA-519

S-16

SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.

• Before digging, check the location of cables, gas lines, and water lines.

• Keep the minimum distance required by law, from cables, gas lines, and water lines.

• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

• Contact your local “diggers hot line” if available in your area, and/or the utility companies directly.

Have them mark all underground utilities.

SA-396

027-E01A-0396

PERFORM TRUCK LOADING SAFELY • Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and/or death.

• Do not lower the bucket with the loader control lever in the FLOAT position. The bucket may free fall, possibly causing personal injury and/or death.

• Always select a level surface for truck loading.

028-E01A-397 SA-397

AVOID POWER LINES Serious injury or death can result from contact with electric lines.

Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length.

29-E01A-0455 SA-455

S-17

SAFETY PRECAUTIONS FOR OPERATION • If the front attachment or any part of the machine comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result.

• Take care to avoid coming in contact with overhead obstacles with the bucket or arm during operation.

PRECAUTIONS FOR LIGHTENING • The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.

• After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

SA-4EK-020

S-18

SAFETY OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.

• When using the machine for craning operations, be sure to comply with all local regulations.

• Do not use damaged chains or frayed cables, sables, slings, or ropes.

• Before craning, position the upper structure with the position of the bucket support located on the chassis at the front.

• Move the load slowly and carefully. Never it suddenly.

• Keep all persons well away from the load.

• Never move a load over a person’s head.

• Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.

• Never attach a sling or chain to the bucket teeth or to the attachment. They may come off, causing the load to fall.

SA-132

032-E01A-0132

PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result.

• Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

• Keep bystanders away from the working area before striking any object.

031-E01A-0432

SA-432

S-19

SAFETY PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface.

• Lower bucket to the ground.

• Place the forward/reverse lever (switch) in neutral, and turn the parking brake switch (lever) in the ON (parking brake) position.

• Run engine at low idle speed without load for 3 minutes.

• Turn key switch to OFF to stop engine.

• Remove the key from the key switch.

• Lower the lock lever to the LOCK position.

• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.

SA-456

033-E07B-0456

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

504-E01A-0034

SA-034

S-20

SAFETY TRANSPORT SAFELY • Be careful because machine may turn over when loading or unloading the machine on or off of a truck or trailer.

• Observe the related regulations and rules for safe transportation.

• Select an appropriate truck or trailer for the machine to be transported.

• Be sure to use a signal person.

• Always follow the following precautions for loading or unloading: 1. Select solid and level ground.

2. Always use a ramp or deck strong enough to support the machine weight.

3. Use a low speed gear.

4. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

5. After loading, install the lock bar to securely hold the articulation mechanism.

6. Chock the front and rear of tires. Securely hold the machine to the truck or trailer deck with heavy chains or wire cables.

Be sure to further follow the details described in the TRANSPORTING section.

035-E07A-0454

S-21

Less than 15°

SA-454

SAFETY HANDLE FLUIDS SAFELY-AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always stop the engine before refueling the machine.

• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flammable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.

• Do not store oily rags; they can ignite and burn spontaneously.

• Securely tighten the fuel and oil filler caps.

SA-018

034-E01A-0496 SA-019

S-22

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work.

• Keep the work area clean and dry.

• Do not spray water or steam inside cab.

• Never lubricate or service the machine while it is moving.

• Keep hands, feet and clothing away from power-driven parts.

Before servicing the machine: 1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for 3 minutes.

5. Turn the key switch to OFF to stop engine.

6. Relieve the pressure in the hydraulic system by moving the control levers several times.

7. Remove the key from the switch.

8. Attach a “Do Not Operate” tag on the control lever.

9. Lower the lock lever to the LOCK position.

10. Lock bar connects the front and rear frames.

11. Allow the engine to cool.

SA-028

SA-312

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.

• Never work under a machine raised by the lift arm.

• Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of operator’s manual.

• Keep all parts in good condition and properly installed.

• Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

• When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.

• Disconnect battery ground cable (-) before making adjustments to electrical systems or before performing welding on the machine.

SA-134

500-E02C-0520 SA-527

S-23

SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.

• Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

501-E01A-0287

SS2045102

SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you work on the machine.

• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

519-E01A-0527 SA-527

STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury.

• To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026

S-24

SA-026

SAFETY SUPPORT MAINTENANCE PROPERLY • Explosive separation of a tire and rim parts can cause serious injury or death.

• Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service.

• Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure.

• When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available.

• Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts.

• Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

SA-249

521-E02A-0249

PREVENT PARTS FROM FLYING • Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and face away from the axle AIR RELEASE PLUG to avoid injury.

• GEAR OIL is hot. Wait for GEAR OIL to cool, and then gradually loosen AIR RELEASE PLUG to release pressure.

503-E03A-0344

SA-344

S-25

SAFETY PREVENT BURNS Hot spraying fluids:

• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.

• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

S506-E01A-0019

S-26

SA-019

SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

• Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031

507-E03A-0499

SA-292

SA-044

S-27

SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires.

• Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

• Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes, or hoses.

Check for Shorts: • Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.

Clean up Flammables: • Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.

Check Key Switch: • If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle.

2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine.

508-E02B-0019

Check Heat Shields: • Damaged or missing heat shields may lead to fires.

• Damaged or missing heat shields must be repaired or replaced before operating the machine.

508-E02A-0393

S-28

SA-019

SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time.

• Use a fire extinguisher if there is time.

• Exit the machine.

518-E01A-0393

SA-393

BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

• If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

509-E01A-0016

SA-016

PRECAUTIONS GRINDING

FOR

WELDING

AND

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding.

• Grinding on the machine may create fire hazards.

Store flammable objects in a safe place before starting grinding.

• After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

523-E01A-0818

S-29

SA-818

SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING •

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.

• Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

2.

If you use solvent or paint stripper, remove stripper with soap and water before welding.

Remove solvent or paint stripper containers and other flammable material from area.

Allow fumes to disperse at least 15 minutes before welding or heating.

511-E01A-0029

S-30

SA-029

SAFETY BEWARE OF ASBESTOS DUST • Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer.

• Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air.

• When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.

• Keep bystanders out of the work site during operation.

• Asbestos might be present in imitation parts. Use only genuine Kawasaki Parts.

SA-029

PREVENT BATTERY EXPLOSIONS • Battery gas can explode.

• Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode.

Warm the battery to 16 °C (60 °F) first.

• Do not continue to use or charge the battery when electrolyte level is lower than specified.

Explosion of the battery may result.

• Loose terminals may produce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking electrolyte specific gravity.

512-E01B-0032

S-31

SA-032

SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn.

• Refer to the instructions described on the container for proper use when handling the refrigerant.

• Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.

• Never touch the refrigerant.

513-E01A-0405

SA-405

HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

• See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine.

515-E01A-0309

S-32

SA-309

SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Kawasaki equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids.

Do not use food or beverage containers that may mislead someone into drinking from them.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

SA-226

516-E01A-0226

BEFORE RETURNING THE MACHINE TO THE CUSTOMER •

After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems.

• Worn or damaged parts have been repaired or replaced.

S517-E01A-0435 SA-435

S-33

SAFETY (Blank)

S-34

SECTION 1

GENERAL ⎯ CONTENTS ⎯ Group 1 Precautions for Disassembling and Assembling Disassembly and Assembly ..................... W1-1-1

Group 2 Tightening Tightening Torque .................................... W1-2-1 Torque Chart............................................ W1-2-3 Piping Joint.............................................. W1-2-8 Periodic Replacement of Parts .............. W1-2-12

Group 3 Painting Painting ................................................... W1-3-1

4FGEW-1-1

45ZV-2

(Blank)

4FGEW-1-2

45ZV-2

GENERAL / Precautions for Disassembling and Assembling DISASSEMBLY AND ASSEMBLY Precautions

• Inspect the contact or sliding surfaces of

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

disassembled parts for abnormal wear, sticking, or other damage.

• Measure and record the degree of wear and clearances.

• Clean the machine

• Inspect the machine Be sure to thoroughly understand all disassembling/ assembling procedures beforehand. It is helpful to avoid incorrect disassembling of components as well as personal injury.

Check and record the items listed below. It is helpful to prevent problems from occurring in the future.

• Model, serial No., hour meter symptoms, failed parts and causes • Clogging of filters, oil quality and quantity, and oil, water or air leaks, if any.

• Damage or looseness of parts

• Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. Thoroughly clean the tools.

When Disassembling and Assembling

• Disassembling • In order to prevent dirt from entering, cap or plug the removed pipes.

• Before disassembling, clean the exterior of the components. Place the components on a work bench.

• Before disassembling, drain gear oil from the reduction gear.

• Be sure to provide appropriate containers for draining fluids.

• Put the matching marks on pieces that are being disassembled in order not to confuse when reassembling.

• Be sure to use the specified special tools, when instructed.

• If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it by force. Find the cause(s), and then take the appropriate measures to remove it.

• Orderly arrange disassembled parts. Mark and tag them as necessary.

• Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.

W1-1-1

• Assembling • Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part.

• Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces.

• Apply a film of grease before installing. Apply new hydraulic oil or gear oil onto the sliding part in order to prevent seizure.

• Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled.

• Be sure that liquid-gasket-applied surfaces are clean and dry.

• If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent.

• Utilize matching marks when assembling.

• Be sure to use the designated tools to assemble bearings, bushings and oil seals.

• Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine.

45ZV-2

GENERAL / Precautions for Disassembling and Assembling Bleed Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of HST pump, HST motor or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. If the cylinder is quickly operated with air trapped in the cylinder tube, damage to the cylinder may result.

Air Bleed Plug

• Bleed air from HST pump and HST motor

W4FG-01-01-001

• Remove air bleed plug on the top of the pump.

Add hydraulic oil into the pump.

• After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed.

• Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out.

• After bleeding air, tighten the plug to the specified torque.

W1-1-2

45ZV-2

GENERAL / Precautions for Disassembling and Assembling • Bleed air from hydraulic circuit inside • After refilling hydraulic oil, start the engine. While operating each cylinder evenly, operate the machine under light loads while extending and retracting 2 to 3 times. Slowly start each operation.

(Never fully stroke the cylinders during initial operation.)

• Reposition the front attachment to check hydraulic oil level. (Lower boom and place bucket level to ground.)

• Stop the engine. Recheck hydraulic oil level.

W4EK-01-02-011

Replenish oil as necessary.

W1-1-3

45ZV-2

GENERAL / Precautions for Disassembling and Assembling Precautions for Using Floating Seals 1. In general, replace the floating seal with a new one after disassembling.

If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with oiled seal ring faces together.

(2) Sliding surface (C) on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear are not allowed.

(The stepped part should remain.)

(3) Replace O-rings (B) with new ones.

2. If incorrectly assembled, oil leakage or damage will occur.

(1) Clean the floating seal and seal mounting bores with cleaning solvent.

Use a wire brush to remove mud, rust or dirt and clean the mounting part.

(After cleaning, thoroughly dry parts with dry compressed air.)

Correct

Twisting of O-Ring

Incorrect

Bending of O-Ring

(2) The mounting part of seal ring (A) or O-ring (B) must be free of dirt or damage.

(Check the bore surface for scuffing or scoring by touching the surface with a finger.)

(3) Make sure no bending and twisting of O-ring (B) after installing on seal ring (A).

Mounting surface (D), O-ring (B) and seal ring sliding surface (C) shall be installed in parallel.

Correct

Incorrect

(4) Mounting surface (D), O-ring (B) and seal ring sliding surface (C) shall be installed in parallel.

IMPORTANT: Wear elastic gloves when doing above work, because salt and sweat will corrode the seal surface.

W4EK-01-01-003

W1-1-4

45ZV-2

GENERAL / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling Correct Sling Application

1. Follow the precautions below to use nylon slings safely.

IMPORTANT: Wear elastic gloves when doing above work, because salt and sweat will corrode the seal surface.

• Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged or cut and the lifted load from slipping or falling.

• Lower the temperature of the lifted load to lower than 100°C (212°F) or less. If unavoidably lifting a load with a temperature of 100 °C (212°F) or more, reduce the load weight.

Incorrect Sling Application

• Do not lift acid or alkali chemicals.

• Take care not to allow the sling to become wet.

The load may slip.

• When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced.

• When lifting a load using a sling, be sure to eliminate any gaps between the sling and load.

(Refer to the right illustration.) Reduce the load weight so that it is less than 80% of the sling breaking force.

• Avoid using twisted, bound, connected, or hitched slings.

• Do not place any object on twisted or bent slings.

Bent Sling

(Refer to the right illustration.)

W4EK-01-01-004

• When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions.

• Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object.

• When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged.

• Store the nylon slings indoors so they will not deteriorate with heat, sunlight, or chemicals.

W1-1-5

45ZV-2

GENERAL / Precautions for Disassembling and Assembling WARNING: If a load is lifted with a damaged nylon sling, death or serious personal injury may result.

Always visually inspect before using.

Damaged Appearance Broken Sewing Thread

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, destroy and discard the sling.

Even if no damage is found, do not use slings older than 7-years.

Scuffing

Fuzz

Broken Sewing Thread Broken Sewing Thread

Broken Sewing Thread

Scoring

Separation of Belt

Scuffing Fuzz Broken Fuzz Warp

W4EK-01-01-002

W1-1-6

45ZV-2

GENERAL / Precautions for Disassembling and Assembling Maintenance Standard Terminology Standard: 1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated as necessary.

Allowable limit: 1. Normal machine performance cannot accomplished after exceeding this limit.

be

2. Repair or adjustment is impossible after exceeding this limit.

Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the Allowable Limit.

W1-1-7

45ZV-2

GENERAL / Precautions for Disassembling and Assembling (Blank)

W1-1-8

45ZV-2

GENERAL / Tightening TIGHTENING TORQUE The bolts and the nuts of the machine: Standard Tightening Torque Chart Retightening Portion

Bolt Diameter

Lock nut 1

Front axle mounting nut

Q’ty

Tool Wrench Size

8 18

Nut

27 8

Torque N·m (kgf·m, lbf·ft)

207 to 253 (21.1 to 25.8, 153 to 187) *259 to 316 (26.4 to 32.2, 191 to 233)

2

Rear axle / reduction gear mounting nut

20

4

30

*491 to 600 (50.0 to 61.2, 362 to 443)

3

Wheel rim mounting nut

22

32

32

494 to 604 (50.4 to 61.6, 365 to 446)

4

Propeller shaft mounting bolt

10

16

17

*58 to 71 (5.9 to 7.2, 43 to 52)

5

HST motor shaft mounting bolt

16

4

24

186 to 227 (19 to 23, 137 to 168)

6

HST pump mounting bolt

18

4

27

265 to 314 (27 to 32, 196 to 232)

Front

12

8

19

7

Engine mounting bolt; Bracket

*83 to 93 (8.5 to 9.5, 61.3 to 68.6)

Rear

14

8

22

*122 to 149 (12.4 to 15.2, 90 to 110)

18

4

27

343 to 412 (34.9 to 42.0, 253 to 304)

8

Engine mounting bolt; Cushion rubber Luck nut

9

Muffler mounting nut;

4 10

Nut 10 Counterweight mounting bolt

17 4

20

4

30

20 to 24 (2.0 to 2.4, 14.8 to 17.7) 44 to 54 (4.5 to 5.5, 32.5 to 40) 423 to 460 (43.1 to 46.9, 312 to 339)

LOCTITE #262 is applied to the treaded portion marked ∗ in torque field. ®

NOTE: 1: Apply lubricant to nuts and bolts to reduce their friction coefficients and increase clamping force when tightening.

(Example: White zinc B dissolved into spindle oil) 2: Make sure bolt and nut threads are clean before installing.

W1-2-1

45ZV-2

GENERAL / Tightening

Bolt Diameter

Q’ty

Tool Wrench Size

Torque N·m (kgf·m, lbf·ft)

Mounting Nut

24

1

36

*155 to 314 (26.0 to 32.0, 188 to 232)

Retainer Lock

12

4

19

*77 to 94 (7.9 to 9.6, 56.8 to 69.4)

Lock

12

1

19

*77 to 94 (7.9 to 9.6, 56.8 to 69.4)

12 Bottom center pin lock

12

1

19

77 to 94 (7.9 to 9.6, 56.8 to 69.4)

13 Loader front pin lock

12

13

19

77 to 94 (7.9 to 9.6, 56.8 to 69.4)

14 Steering cylinder pin lock

12

4

19

77 to 94 (7.9 to 9.6, 56.8 to 69.4)

15 Radiator frame mounting bolt

12/10

4/8

19/17

77 to 94 (7.9 to 9.6, 56.8 to 69.4)/44 to 54 (4.5 to 5.5, 32.5 to 39.9)

16 Cutting edge mounting nut

16

7

24

245 to 300 (24.9 to 30.6, 181 to 221)

17 Canopy mounting bolt

16

6

24

188 to 229 (19.2 to 23.4, 139 to 169)

18 Cab cushion rubber

16

10

24

188 to 229 (19.2 to 23.4, 139 to 169)

Retightening Portion

11 Top center pin

W1-2-2

45ZV-2

GENERAL / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury.

Bolt Types Tighten nuts or bolts correctly to torque specifications.

Make sure to employ correct bolts and tighten them correctly when assembling the machine or components.

SA-040

Specified Tightening Torque Hexagon Wrench

Bolt Dia. (mm) (in)

M4FG-07-73

Standard torque

Wrench Size mm (in)

Allowable torque range

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

kgf⋅m

lbf⋅ft

4 (0.2)

1.27

0.13

0.94

1.18 to 1.37

0.12 to 0.14

0.87 to 1

7 (0.3)

5 (0.2)

2.55

0.26

1.88

2.26 to 2.84

0.23 to 0.29

1.67 to 2.1

8 (0.3)

6 (0.2)

4.31

0.44

3.18

3.92 to 4.71

0.40 to 0.48

2.9 to 3.48

10 (0.4)

8 (0.3)

10.2

1.04

7.53

9.22 to 11.2

0.94 to 1.14

6.8 to 8.27

13 (0.5)

10 (0.4)

19.7

2.01

14.5

17.8 to 21.7

1.81 to 2.21

13.2 to 16

17 (0.7)

12 (0.5)

34.5

3.52

25.5

31.1 to 38.0

3.17 to 3.87

23 to 22.1

19 (0.7)

14 (0.6)

54.3

5.54

40.1

48.9 to 59.7

4.99 to 6.09

36.1 to 44.1

22 (0.9)

16 (0.6)

83.9

8.56

61.9

75.5 to 92.4

7.70 to 9.42

55.7 to 68.2

24 (0.9)

18 (0.7)

116

11.8

85.6

104 to 127

10.6 to 13.0

76.8 to 93.7

27 (1.1)

20 (0.8)

168

17.1

124

151 to 184

15.4 to 18.8

111 to 136

30 (1.2)

22 (0.9)

221

22.5

163

199 to 243

20.3 to 24.8

147 to 179

32 (1.3)

24 (0.9)

280

28.6

207

252 to 309

25.7 to 31.5

186 to 228

36 (1.4)

27 (1.1)

346

35.3

255

312 to 380

31.8 to 38.8

230 to 221

41 (1.6)

30 (1.2)

475

48.4

351

428 to 522

43.6 to 53.2

316 to 385

46 (1.8)

W1-2-3

45ZV-2

GENERAL / Tightening Hexagon Wrench

Bolt Dia. (mm) (in)

M4GB-07-122

Standard torque

Wrench Size mm (in)

Allowable torque range

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

kgf⋅m

lbf⋅ft

4 (0.2)

3.24

0.33

2.39

2.94 to 3.53

0.30 to 0.36

2.17 to 2.61

7 (0.3)

5 (0.2)

6.28

0.64

4.63

5.69 to 6.86

0.58 to 0.70

4.2 to 5.06

8 (0.3)

6 (0.2)

10.9

1.11

8.04

9.80 to 12.0

1.00 to 1.22

7.23 to 8.86

10 (0.4)

8 (0.3)

25.4

2.59

18.7

22.8 to 27.9

2.33 to 2.85

16.8 to 2.1

13 (0.5)

10 (0.4)

49.1

5.01

36.2

44.2 to 54.0

4.51 to 5.51

32.6 to 39.9

17 (0.7)

12 (0.5)

85.8

8.75

63.3

77.2 to 94.4

7.88 to 9.63

57 to 70

19 (0.7)

14 (0.6)

135

13.8

99.6

122 to 149

12.4 to 15.2

90 to 110

22 (0.9)

16 (0.6)

209

21.3

154

188 to 229

19.2 to 23.4

139 to 169

24 (0.9)

18 (0.7)

287

29.3

212

259 to 316

26.4 to 32.2

191 to 233

27 (1.1)

20 (0.8)

418

42.6

308

376 to 460

38.3 to 46.9

277 to 339

30 (1.2)

22 (0.9)

549

56.0

405

494 to 604

50.4 to 61.6

365 to 446

32 (1.3)

24 (0.9)

699

71.3

516

630 to 769

64.2 to 78.4

465 to 568

36 (1.4)

27 (1.1)

862

87.9

636

775 to 948

79.0 to 96.7

572 to 700

41 (1.6)

30 (1.2)

1187

121

876

1069 to 1304

109 to 133

789 to 963

46 (1.8)

W1-2-4

45ZV-2

GENERAL / Tightening Hexagon Wrench

Bolt Dia. (mm) (in)

M4GB-07-123

Standard torque

Wrench Size mm (in)

Allowable torque range

N⋅m

kgf⋅m

lbf⋅ft

N⋅m

kgf⋅m

lbf⋅ft

4 (0.2)

4.22

0.43

3.1

3.82 to 4.61

0.39 to 0.47

2.8 to 3.4

5 (0.2)

9.24

0.84

6.8

7.45 to 9.02

0.76 to 0.92

5.5 to 6.7

8 (0.3)

6 (0.2)

14.2

1.45

10.5

12.8 to 15.7

1.31 to 1.60

9.4 to 11.6

10 (0.4) 13 (0.5)

7 (0.3)

8 (0.3)

33.1

3.38

24.4

29.8 to 36.5

3.04 to 3.72

23 to 27

10 (0.4)

64.2

6.55

47.4

57.9 to 70.7

5.90 to 7.21

42.7 to 52.2

17 (0.7)

12 (0.5)

112

11.4

82.7

101 to 123

10.3 to 12.5

74.5 to 90.8

19 (0.7)

14 (0.6)

177

18.0

131

159 to 194

16.2 to 19.8

117 to 143

22 (0.9)

16 (0.6)

273

27.8

201

245 to 300

25.0 to 30.6

181 to 221

24 (0.9)

18 (0.7)

376

38.3

277

338 to 413

34.5 to 42.1

249 to 305

27 (1.1)

20 (0.8)

545

55.6

402

490 to 600

50.0 to 61.2

362 to 443

30 (1.2)

22 (0.9)

718

73.2

530

646 to 789

65.9 to 80.5

477 to 582

32 (1.3)

24 (0.9)

912

93.0

673

821 to 1000

83.7 to 102

606 to 738

36 (1.4)

27 (1.1)

1128

115

832

1020 to 1245

104 to 127

753 to 919

41 (1.6)

30 (1.2)

1540

157

1137

1383 to 1697

141 to 173

1021 to 1252

46 (1.8)

W1-2-5

45ZV-2

GENERAL / Tightening Specified Tightening Torque Bolt Dia. (mm) (in)

Socket Bolt lbf⋅ft

Wrench Size (mm) (in)

22

6 (0.2)

N⋅m

kgf⋅m

8 (0.3)

29.5

3.0

10 (0.4)

64.0

6.4

47

8 (0.3)

12 (0.5)

108

11

80

10 (0.4)

14 (0.6)

175

18

130

12 (0.5)

16 (0.6)

265

27

195

14 (0.6)

18 (0.7)

390

40

290

14 (0.6)

20 (0.8)

540

55

400

17 (0.7)

6 (0.2)

5 (0.2)

Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

Tighten upper and lower alternately

Tighten diagonally 1

1st to 4th

IMPORTANT: The following items are applied to both fine and coarse pitch threads.

1. Apply lubricant (i.e. white zinc B dissolved into spindle oil) to nuts and bolts to reduce their friction coefficients.

The plated bolts require no lubricant.

2. Torque tolerance is ±10%.

3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of the bolthole. Bolts that are too short cannot develop sufficient tightening force.

4. The torque values given in the chart are for general use only. Do not use these torque values if a different torque value is given for a specific application.

5. Remove rust, dirt, and dust before tightening.

Tighten from center and diagonally 12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

6 4

5 2

2nd to 3rd W105-01-01-003

W1-2-6

45ZV-2

GENERAL / Tightening Service Recommendations for Split Flanges IMPORTANT: 1. Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear.

2. Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place.

3. While lightly and evenly tightening the bolts, check that the flange is installed to the port correctly. Take care not to pinch the O-ring.

4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening.

5. Using an impact wrench often causes tightening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.

Do not use impact wrenches for tightening split flange bolts.

W105-01-01-015

Incorrect

W105-01-01-016

W105-01-01-008

Correct

Incorrect

Nut and Bolt Locking Bend along edge sharply

• Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice.

Correct

Do not bend it round

Correct

Incorrect

Bend along edge sharply

• Split Pin

W105-01-01-009

IMPORTANT: Do not reuse split pins. Match the holes in the bolt and nut while tightening, not while loosening.

Do not reuse split pins.

• Lock Wire IMPORTANT: Apply wire to bolts in the bolt-tightening direction, not in the bolt-loosening direction.

Do not reuse wires.

Correct

Correct

Correct

Incorrect

Loosen

Incorrect

Tighten

W105-01-01-010

W1-2-7

45ZV-2

GENERAL / Tightening PIPING JOINT IMPORTANT: The torque values given in the chart are for general use only.

In case there are some specific points indicating tightening torque, tighten according to its torque value.

1

4

3

5

2

Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressurized oil. Union joints are used to join small-diameter lines.

M202-07-051

Joint Body

IMPORTANT: 1. Do not over-tighten union nut (3).

Excessive force will be applied to metal sealing surfaces (4) and (5), possibly crack adapter (1).

Be sure to tighten union nut (3) to specifications.

2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint.

Take care not to damage them when connecting/disconnecting.

Description

30° male

37° female

37° 30°

Male Union Joint

Female Union Joint W105-01-01-017

Wrench Size mm Wrench Size mm Tightening Torque (in) (in) Union Nut

Joint Body

N·m (kgf·m, lbf·ft)

19 (0.7)

19 (0.7)

59 (6, 44)

22 (0.9)

22 (0.9)

98 (10, 72)

27 (1.1)

27 (1.1)

118 (12, 87)

36 (1.4)

36 (1.4)

235 (24, 173)

41 (1.6)

41 (1.6)

295 (30, 218)

50 (2.0)

50 (2.0)

490 (50, 362)

60 (2.4)

60 (2.4)

670 (68, 494)

70 (2.8)

70 (2.8)

980 (100, 723)

19 (0.7)

17 (0.7)

44 (4.5, 32)

22 (0.9)

19 (0.7)

59 (6, 44)

27 (1.1)

22 (0.9)

118 (12, 87)

36 (1.4)

30 (1.2)、32 (1.3)

235 (24, 173)

41 (1.6)

36 (1.4)

295 (30, 218)

50 (2.0)

46 (1.8)

490 (50, 362)

NOTE: Tightening torque of 37° male coupling without union is similar to tightening torque of 37° female.

W1-2-8

45ZV-2

GENERAL / Tightening 7

O-Ring Seal Joint

6

9

O-ring (6) seats against the end surface of adapter (7) to seal pressurized oil.

IMPORTANT: 1. Be sure to replace O-ring (6) with a new one when reconnecting.

2. Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8).

Tightening union nut (9) with O-ring (6) placed incorrectly will damage O-ring (6), resulting in oil leakage.

3. Take care not to damage O-ring groove (8) of adapter (7) or sealing surface (10) at the hose end.

Damage to O-ring (6) will cause oil leakage.

4. If union nut (9) is loose and oil is leaking, do not re-tighten union nut (9).

Replace O-ring (6) with a new one and check that O-ring (6) is correctly seated in place, then tighten union nut (9).

W1-2-9

8

Wrench Size mm (in) Union Nut 19 (0.7) 22 (0.9) 27 (1.1) 32 (1.3) 36 (1.4) 41 (1.6) 50 (2.0)

10 Hose Fittings

M104-07-033

Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 29.5 (3.0, 21.5) 69 (7.0, 51) 93 (9.5, 69) 137 (14.0, 101) 175 (18.0, 129) 205 (21.0, 151) 205 (21.0, 151)

45ZV-2

GENERAL / Tightening Screw-In Connection PT

30°

Depending on types of screw and sealing, different types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

We use the male tapered thread type mainly except for a measurement.

Male Tapered Thread

PF

Male Straight Thread

W105-01-01-018

Wrench Size mm (in) Joint Body 19 (0.7) 22 (0.9) 27 (1.1) 36 (1.4) 41 (1.6) 50 (2.0) 60 (2.4)

Male Tapered Thread Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) FC material SS material 14.5 (1.5, 10.5) 34 (3.5, 25) 29.5 (3.0, 21.5) 49 (5.0, 36) 49 (5.0, 36) 93 (9.5, 69) 69 (7.0, 51) 157 (16, 116) 108 (11, 80) 205 (21, 151) 157 (16, 116) 320 (33, 235) 195 (20, 144)

Internal Thread

Seal Tape Application Seal tape is used to seal clearances between male and female tapered threads and prevent leaks.

Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.

External Thread

Clearance

W105-01-01-019

• Application Procedure

Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of dirt or damage.

Apply seal tape around threads in the same direction as the threads.

M114-07-041

Low-Pressure-Hose Clamp Tightening Torque T-Bolt Type

Worm Gear Type

M114-07-043

M114-07-042

Low-pressure-hose clamp tightening torque differs depending on the type of clamp.

T-Bolt Type Band Clamp: 4.4 N⋅m (0.4 kgf⋅m, 3.2 lbf⋅ft) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.4 to 5.1 lbf⋅ft)

W1-2-10

45ZV-2

GENERAL / Tightening Connecting Hose

Incorrect (Twisted)

Correct

CAUTION: When replacing hoses, be sure to use only genuine Kawasaki service parts.

Using hoses other than genuine Kawasaki hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine.

W105-01-01-011

Do not install kinked hoses. Application of high pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting.

Utilize print marks on hoses when installing to prevent hose from being kinked.

Incorrect

Correct

Rubbing Against Each Other

W105-01-01-012

Take necessary measures to protect hoses from rubbing against each other.

If hoses rub against each other, wear to the hoses will result, leading to hose rupture.

Incorrect Clamp

Take care so that hoses do not come into contact with moving parts or sharp objects.

Correct Clamp

Rubbing Against Each Other W105-01-01-013

Incorrect

Rubbing Against Each Other

Correct

Clamp W105-01-01-014

W1-2-11

45ZV-2

GENERAL / Tightening PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspections of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards.

It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below.

However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval.

Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary.

Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary.

Device Name Engine

Brake Device

Steering Device

Replacement Intervals

Fuel Tank

Hose

Every 2 years

Master Cylinder

Seals (Rubber parts)

Every 1 year

Wet Type Brake

Piston D-ring

Every 4 years

Brake Piping

Hose

Every 2 years

Stop Light

Switch

Every 2 years

Steering Piping

Hose

Every 2 years

Steering Cylinder

Seals (Rubber parts)

Every 4 years

Steering Valve

Seals (Rubber parts)

Every 2 years

Pump

Suction Hose Delivery Hose

Every 4 years

Work Device

Bucket Cylinder Line Hose Lift Arm Cylinder Line Hose Hydraulic Oil Tank Return Hose Hydraulic Oil Cooler Line Hose

Every 4 years

Seat Belt

Seat Belt

Every 3 years

Hydraulic System

Operator's Cab

Replacement Part Name

NOTE: When replacing hoses, replace O-rings, or gaskets used for them at the same time.

W1-2-12

45ZV-2

GENERAL / Painting Painting

W4FGE-01-03-001

1 2 3 4 5 6 7 8

Painted Surface Front Fender Light Bracket Body Cowl Frame Handrail Steering Cover Steering Support ROPS Canopy

9

Hood Base

10 Hood (Upper) (*) 11 Hood (Lower) (*) (*) Material is resin.

Painting Color HG Beige Deep HG Beige Deep JDM Yellow HG Beige Deep HG Beige Deep HG Beige Deep HG Beige Deep Japan Paint Manufacturers Association YH-65 JDM Yellow JDM Yellow HG Beige Deep

12 13 14 15 16 17 18 19

20 21

Painted Surface Counterweight Rear Fender Rim Seat Support Operator Frame Step Oil Tank / Fuel Tank Articulation Lock Bar

Painting Color JDM Yellow HG Beige Deep JDM Yellow HG Beige Deep HG Beige Deep JDM Yellow JDM Yellow Red

Back Mirror Mounting Part Cab

HG Beige Deep HG Beige Deep

IMPORTANT: When cleaning the front attachment, cylinder, etc. fitted with HN bushing, take care not to pour washing liquid directly on the bushing. The ambient temperature should not exceed 70°C (158°F) when painting and drying.

W1-3-1

45ZV-2

GENERAL / Painting (Blank)

W1-3-2

45ZV-2

SECTION 2

BODY — CONTENTS — Group 1 Canopy

Group 7 HST Motor

Removal and Installation of ROPS Canopy........................................... W2-1-1

Removal and Installation of HST Motor..................................................W2-7-1

Removal and Installation of Floor Plate ................................................. W2-1-5

Disassembly and Assembly of HST Motor..................................................W2-7-7 Removal and Installation of Regulator ...................................................W2-7-8 Disassembly of Regulator .........................W2-7-10

Group 2 Cab Removal and Installation of Cab ................. W2-1-1

Assembly of Regulator ..............................W2-7-12

Group 3 Counterweight Removal and Installation of Counterweight ........................................... W2-3-1

Group 8 Control Valve

Group 4 Center Hinge Disassembly and Assembly of Center Hinge ............................................. W2-4-1

Group 5 Engine Hood Removal and Installation of Engine Hood ............................................. W2-5-1

Group 6 HST Pump and Main Pump Removal and Installation of HST Pump................................................. W2-6-1

Removal and Installation of Control Valve .............................................W2-8-1 Disassembly and Assembly of Control Valve .............................................W2-8-6 Disassembly and Assembly of Bucket Spool Assembly .............................W2-8-8 Disassembly and Assembly of Lift Arm Spool Assembly ..........................W2-8-12 Disassembly and Assembly of Auxiliary (Coupler) Spool Assembly ........W2-8-16

Disassembly and Assembly of HST Pump................................................. W2-6-6 Removal and Installation of Main Pump .............................................. W2-6-10 Disassembly and Assembly of Main Pump .............................................. W2-6-12

4FGEW-2-1

45ZV-2

(Blank)

4FGEW-2-2

45ZV-2

BODY / Canopy REMOVAL AND INSTALLATION OF ROPS CANOPY Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

W4FG-02-01-001

W2-1-1

45ZV-2

BODY / Canopy Removal of ROPS Canopy 1. Install eyebolts (6) [M12, Pitch 1.75 mm (0.07 in)] (4 used) on the top of ROPS canopy (1).

Lifting Tool

CAUTION: ROPS Canopy (1) weight: 140 kg (309 lb)

1

2. Attach a chain onto the eyebolts (6) (4 used) on the top of ROPS canopy (1).

Hold ROPS canopy (1).

3. Remove bolts (2) (6 used), bolts (3) (2 used), nut (4) (2 used) and washers (5) (10 used), which secure ROPS canopy (1).

6

: 24 mm (0.9 in) 4. Hoist and remove ROPS canopy (1) from floor plate (7).

2 5

3 5

7 5 4 W4FGE-02-01-002

W2-1-2

45ZV-2

BODY / Canopy Installation of ROPS Canopy Lifting Tool

CAUTION: ROPS Canopy (1) weight: 140 kg (309 lb) 1. Attach a chain onto the eyebolts (6) on the top of ROPS canopy (1).

Hoist and fit ROPS canopy (1) to the mounting hole of floor plate (7).

Hold ROPS canopy (1).

2. Install ROPS canopy (1) to floor plate (7) with bolts (2) (6 used), bolts (3) (2 used), washers (5) (10 used) and nut (4) (2 used).

1

6

: 24 mm (0.9 in) : 188 to 229 N⋅m (19.2 to 23.4 kgf⋅m, 139 to 169 lbf⋅ft) 2 5

3 5

7 5 4

W2-1-3

W4FGE-02-01-006

45ZV-2

BODY / Canopy (Blank)

W2-1-4

45ZV-2

BODY / Canopy REMOVAL AND FLOOR PLATE

INSTALLATION

OF

Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to the rear chassis pin (1).

Secure with link pin (2).

When removing and installing the floor plate, remove and install the following parts.

• Floor Inspection Cover • Seat Support • Front Console and Surroundings • Right Console and Surroundings W4FG-02-01-001

W2-1-5

45ZV-2

BODY / Canopy Removal of Floor Inspection Cover 1. Remove floor mat (1).

In case of the cab machine, remove floor mat (1) and sponge mat (2).

2. Remove screws (5) (2 used) by using a screwdriver.

Remove inspection cover (4) from floor plate (3).

W4FG-02-01-004

W2-1-6

45ZV-2

BODY / Canopy Installation of Floor Inspection Cover 1. Install inspection cover (4) to floor plate (3) with screws (5) (2 used).

2. Install floor mat (1).

In case of the cab machine, Install sponge mat (2) and floor mat (1).

W4FG-02-01-004

W2-1-7

45ZV-2

BODY / Canopy Removal of Seat Support CAUTION: Standard seat (6) weight: 16 kg (35 lb) Full suspension seat (1) weight: 29 kg (64 lb) 1. Remove bolts (14) (4 used), spring washers (15) (4 used), and washers (16) (4 used) from seat support (2).

Remove standard seat (6) or full suspension seat (1) and seat support (2) from seat support (11). : 17 mm (0.7 in) 2. When equipped with a standard seat (6): Remove bolts (7) (4 used), washers (8) (4 used), spring washers (9) (4 used), and nuts (10) (4 used) from standard seat (6).

Remove standard seat (6) from seat support (2). : 13 mm (0.5 in) When equipped with a full suspension seat (1): Remove bolts (5) (4 used), spring washers (4) (4 used), and washers (3) (4 used) from full suspension seat (1).

Attach a nylon sling onto full suspension seat (1).

Hoist and remove full suspension seat (1). : 13 mm (0.5 in) 3. Remove plugs (13) (2 used) from seat support (11) by using a screwdriver.

4. When equipped with a heater, refer to Removal/ Installation of Heater on W2-2-6 in the CAB section.

5. Remove bolts and washers (12) (4 used) from seat support (11).

Remove seat support (11) from the floor plate.

W4FG-02-01-005

: 19 mm (0.7 in)

W2-1-8

45ZV-2

BODY / Canopy Installation of Seat Support 1. Install seat support (11) to the floor plate with bolts and washers (12) (4 used). : 19 mm (0.7 in) When equipped with a heater is provided, refer to Removal/ Installation of Heater on W2-2-6.

2. Install plugs (13) (2 used) to seat support (11).

CAUTION: Standard seat (6) weight: 16 kg (35 lb) Full suspension seat (1) weight: 29 kg (64 lb) 3. When equipped with a standard seat (6): Install standard seat (6) to seat support (2) with bolts (7) (4 used), washers (8) (4 used), spring washers (9) (4 used), and nuts (10) (4 used). : 13 mm (0.5 in) When equipped with a full suspension seat (1): Install full suspension seat (1) to seat support (2) with washers (3) (4 used), spring washers (4) (4 used), and bolts (5) (4 used). : 13 mm (0.5 in) 4. Install seat support (2) to seat support (11) with bolts (14) (4 used), spring washers (15) (4 used), and washers (16) (4 used). : 17 mm (0.7 in)

W4FG-02-01-005

W2-1-9

45ZV-2

BODY / Canopy Removal of Front Console and Surroundings CAUTION: Front cover (1) and mirror stays (2, 7) weight: Approx. 28 kg (62 lb) 1. Remove bolts (10) (2 used), spring washers (9) (2 used), washers (8) (2 used), bolts (6) (2 used), spring washers (5) (2 used), and washers (4) (2 used).

Remove front cover (1) and mirror stays (2, 7) from floor plate (3). (Except the cab spec. machine)

W4FG-02-01-006

: 24 mm (0.9 in) 2. Disconnect all hoses from the power steering.

(Refer to W3-7.)

3. Disconnect all brake hoses from the master cylinder. (Refer to W3-5.)

4. Disconnect connector (11) of brake angle sensor (12).

5. Remove bolt (16), spring washer (17), washer (18), brackets (19, 21), and spacer (20).

Disconnect harness (14) of the front console from rear chassis (15).

W4FG-02-01-007

6. Disconnect harness (14) of the front console from the connector part.

Remove bolt (13) from rear chassis (15).

Remove harness (14) from the clamp.

W4FG-02-01-008

W2-1-10

45ZV-2

BODY / Canopy 7. Remove nut (28) and spring washer (27).

Disconnect engine throttle cable (23) from accelerator pedal link (22). : 10 mm (0.4 in) 8. Loosen nut (26) of engine control cable (23).

Remove engine throttle cable (23) from the bracket of steering support (24). : 24 mm (0.9 in)

W4FG-02-01-009

CAUTION: Front console, steering support (24), and others weight: Approx. 50 kg (110 lb) 9. Remove bolts and washers (25) (6 used).

Attach a nylon sling onto steering support (24).

Hoist and remove the front console and steering support (24) from floor plate (3). : 17 mm (0.7 in)

W4FG-02-01-010

W2-1-11

45ZV-2

BODY / Canopy Installation of Front Console and Surroundings CAUTION: Front console, steering sppot (24), and others weight: Approx. 50 kg (110 lb) 1. Attach a nylon sling onto steering support (24).

Hoist and fit steering support (24) to the mounting hole of floor plate (3).

2. Install steering support (24) to floor plate (3) with bolts and washers (25) (6 used). : 17 mm (0.7 in)

W4FG-02-01-010

3. Install engine throttle cable (23) to the bracket of steering support (24).

Tighten nut (26) of engine control cable (23). : 24 mm (0.9 in)

4. Connect engine throttle cable (23) to accelerator pedal (22) with nut (28) and spring washer (27). : 10 mm (0.4 in) W4FG-02-01-009

W2-1-12

45ZV-2

BODY / Canopy 5. Install the clamp to harness (14) of the front console. Install harness (14) of the front console to rear chassis (15) with bolt and washer (13).

Connect harness (14) connector of the front console.

6. Install harness (14) of the front console to rear chassis (15) with bolt (16), spring washer (17), washer (18), brackets (19, 21), and spacer (20).

W4FG-02-01-008

7. Connect connector of harness of brake angle sensor (12).

8. Connect all brake hoses to the master cylinder.

(Refer to W3-5.)

9. Connect all hoses to the power steering. (Refer to W3-7.)

W4FG-02-01-007

CAUTION: Front cover (1) and mirror stays (2, 7) weight: Approx. 28 kg (62 lb) 10. Install front cover (1) and mirror stays (2, 7) to floor plate (3) with bolts (10) (2 used), spring washers (9) (2 used), washers (8) (2 used), bolts (6) (2 used), spring washers (5) (2 used), and washers (4) (2 used).

(Except for the cab machine) : 24 mm (0.9 in) W4FGE-02-01-006

W2-1-13

45ZV-2

BODY / Canopy Removal of Right Console and Surroundings 1. Remove bolts (4) (7 used) and washers (5) (7 used).

Remove covers (6, 7) from right console box (8). : 5 mm (0.2 in) 2. Disconnect connector (B) of harness (11) from the ECO mode switch.

3. When a heater switch (optional) is provided, disconnect connector (C) harness (11).

4. Remove the cap part of key switch (7).

Remove bolts (3) (4 used) and washers (2) (4 used).

Remove cover (1) from right console box (8). : 5 mm (0.2 in) 5. Remove key switch (7) with harness connected from right console box (8).

(A)

6. Remove attached bolts (12) (2 used) and nuts (9) (2 used), which are attached to front attachment control lever (7).

Disconnect control cables (9, 10) from front attachment control lever (20).

Attach identification tags onto control cables (10, 11).

7. Remove bolts (16) (4 used), spring washers (15) (4 used) and washers (14) (4 used).

Remove right console box (8) from the floor plate. : 17 mm (0.7 in)

W4FG-02-01-011

W2-1-14

45ZV-2

BODY / Canopy Installation of Right Console and Surroundings 1. Install right console box (8) to the floor plate with bolts (16) (4 used), spring washers (15) (4 used), and washers (14) (4 used). : 17 mm (0.7 in) 2. Connect control cables (9, 10) with bolts (12) (2 used) and nuts (13) (2 used), which are attached to front attachment control lever (7).

3. Install key switch (7) to right console box (8).

4. Install cover (1) to right console box (8) with bolts (3) (4 used) and washers (2) (4 used).

Install the cap part of key switch (7). : 5 mm (0.2 in) 5. When a heater switch (optional) is provided, connect connector (C) of harness (11).

6. Connect connector (B) of harness (11) to eco mode switch.

7. Install covers (6, 17) to right console box (8) with bolts (4) (7 used) and washers (5) (7 used). : 5 mm (0.2 in)

W4FG-02-01-011

W2-1-15

45ZV-2

BODY / Canopy Removal of Floor Plate 1. Remove harness and brake hoses secured onto floor plate (1).

CAUTION: Floor Plate (1) weight: 120 kg (265 lb) 2. Attach a nylon sling onto floor plate (1).

Hold floor plate (1).

3. Remove bolts (8) (4 used), washers (7) (4 used), and washers (6) (4 used) from mounting holes of the floor plate (1). : 30 mm (1.2 in) IMPORTANT: Hoist floor plate (1) while sliding it forward in order not to come contact with the hood base behind floor plate (1).

4. Hoist and remove floor plate (1) from rear chassis (9).

5. Remove rubbers (2) (4 used), rubbers (5) (4 used), spacers (3) (4 used) and rubbers (4) (4 used) from mounting hoses of the rear chassis (9).

View A W4FG-02-01-012

W2-1-16

45ZV-2

BODY / Canopy Installation of Floor Plate CAUTION: Floor plate (1) weight: 120 kg (265 lb) 1. Install rubber (5), spacer (3), rubber (4) and rubber (2) to the rear chassis (9) mounting hole (4 places) in sequence with the rubber (2, 5) groove facing to the rear chassis (9) side.

2. Attach a nylon sling onto floor plate (1).

Hoist and align with the rear chassis mounting hole (4 places).

IMPORTANT: Slide floor plate (1) from the front to rear while aligning with the rear chassis mounting holes in order not to come contact with the hood base behind floor plate (1). ®

3. Apply LOCTITE #262 onto bolts (8) (4 used).

Install floor plate (1) to mounting holes (4 places) of rear chassis (9) with bolts (8) (4 used), washers (7) (4 used) and washers (6) (4 used). : 30 mm (1.2 in) : 375 to 460 N·m (38.3 to 47 kgf·m, 277 to 339 lbf⋅ft) 4. Secure harness and brake hoses onto floor plate (1).

View A W4FG-02-01-012

W2-1-17

45ZV-2

BODY / Canopy (Blank)

W2-1-18

45ZV-2

BODY / Cab REMOVAL AND INSTALLATION OF CAB Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

W4FG-02-01-001

W2-2-1

45ZV-2

BODY / Cab Removal 1. Open the engine hood.

Disconnect washer hose (2) from washer tank (1) (2 places).

Cut the hose clamp, which secures washer hoses (2).

W4FG-02-02-001

2. Remove bolts (3) (3 used).

Remove cover (4) from the right console. : 5 mm (0.2 in)

W4EK-02-02-004

3. Disconnect connectors (3 used) of cab harness (5).

Remove cab harness (5) and washer hoses (2) (2 used) from right console.

Bind up washer hoses (2) (2 used).

W4FG-02-02-002

W2-2-2

45ZV-2

BODY / Cab 4. Disconnect connector (6) of front wiper harness.

5. Cut hose clamp (8), which secures defroster hoses (7) (2 used) to the cab side.

6. Install eyebolts (M12, Pitch 1.75 mm (0.07 in)) (4 used) on the top of cab (9).

7. Remove bolts (10) (10 used) and washers (11) (10 used), which secure cab (9). : 24 mm (0.9 in) W4FG-02-02-003

CAUTION: Cab (9) weight: 300 kg (660 lb) IMPORTANT: When hoisting or lowering cab (9), prevent front wiper motor cover (13) (cab side) from touching steering support (14).

Lifting Tool

W4FG-02-02-005

8. Attach a chain onto the eyebolts on the top of cab (9).

Hoist and remove cab (9) from floor plate (12).

W4FG-02-02-004

W2-2-3

45ZV-2

BODY / Cab Installation CAUTION: Cab (9) weight: 300 kg (660 lb) IMPORTANT: When hoisting or lowering cab (9), prevent front wiper motor cover (13) (cab side) from touching steering support (14).

Lifting Tool

W4FG-02-02-005

1. Attach a chain onto the eyebolts on the top of cab (9).

Hoist and fit cab (9) with the mounting hole on the floor plate.

2. Install cab (9) to the machine with bolts (10) (10 used) and washers (11) (10 used).

At part A, install bolt (10) and washer (11) from the bottom of the floor plate (12). : 24 mm (0.9 in) : 188 to 229 N⋅m (19.2 to 23.4 kgf⋅ft, 139 to 169 lbf⋅ft) A

W4FG-02-02-004

3. Secure defroster hoses (7) (2 used) to the cab side with hose clamp (8).

4. Connect connector (6) of the front wiper harness.

W4FG-02-02-003

W2-2-4

45ZV-2

BODY / Cab 5. Pass cab harness (5) and washer hoses (2) (2 used) through right console.

Plug in connectors (3 used) of cab harness (5).

Pass washer hoses (2) to washer tank (1) in the engine compartment.

W4FG-02-02-002

6. Install cover (4) of the right console with bolts (3) (3 used). : 5 mm (0.2 in)

W4EK-02-02-004

7. Connect washer hose (2) to washer tank (1) (2 places).

Secures washer hose (2) with the hose clamp.

W4FG-02-02-001

W2-2-5

45ZV-2

BODY / Cab Removal of Heater (Optional) 1. Remove the seat and the seat support.

(Refer to W2-1-7.)

2. Disconnect defroster hoses (3) (2 used) and hose connectors (5) (2 used) from heater (1).

3. Disconnect connector (B) of heater harness (4).

Remove bolt (13).

Disconnect ground wire (12) of heater (1) from the rear chassis (11). : 17 mm (0.7 in) 4. Fully tighten the cock in valve (6) and turn to the CLOSED position.

5. Loosen hose clamps (10) (2 used).

Disconnect hoses (9) (2 used) from heater (1).

Cap the open ends.

6. Remove bolts and washers (8) (4 used) from heater support (7).

Remove heater support (7) from the seat support. : 17 mm (0.7 in) 7. Remove bolts and washers (2) (4 used).

Remove heater (1) from heater support (7). : 17 mm (0.7 in)

W4FG-02-02-006

W4FG-02-02-007

W2-2-6

45ZV-2

BODY / Cab Installation of Heater (Optional) 1. Install heater (1) to heater support (7) with bolts and washers (2) (4 used). : 17 mm (0.7 in) 2. Install heater support (7) to the seat support with bolts and washers (8) (4 used). : 17 mm (0.7 in) 3. Connect hoses (9) (2 used) to heater (1) with hose clamps (10) (2 used).

4. Fully open the cock in valve (6) and turn to the OPEN position.

5. Connect connector (B) of heater harness (4).

Connect ground line (12) of heater (1) to the rear chassis with bolt (13). : 17 mm (0.7 in) 6. Install defroster hoses (3) (2 used) to heater (1) with hose connectors (5) (2 used).

W4FG-02-02-006

W4FG-02-02-007

W2-2-7

45ZV-2

BODY / Cab (Blank)

W2-2-8

45ZV-2

BODY / Counterweight REMOVAL AND COUNTERWEIGHT

INSTALLATION

OF

Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel stoppers in front of and behind the wheel in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (2) to rear chassis pin (1).

Secure with link pin (3).

W4FG-02-01-001

W2-3-1

45ZV-2

BODY / Counterweight Removal IMPORTANT: If removing counterweight (17) with the engine hood installed, the engine hood may be damaged.

1. Remove the engine hood. (Refer to W2-5.)

2. Remove bolts (1) (8 used), spring washers (2) (8 used), and washers (3) (8 used).

Remove cover (4, 6) from cover (5). : 17 mm (0.7 in) 3. Remove bolts (7) (2 used) and washers (8) (2 used).

Remove cove (5) from counterweight (17). : 30 mm (1.2 in) 4. Disconnect harnesses of reverse light (20) in counterweight (17).

5. Remove screws (18) (2 used) and washers (19) (2 used).

Remove reverse light (20) from counterweight (17).

W4FGE-02-03-001

6. Remove screws (16) (2 used), spring washers (15) (2 used), and washers (14) (2 used).

Remove cover (13) from rear combination light (12).

7. Disconnect harnesses of rear combination lights (12).

8. Remove bolts (9) (4 used), spring washers (10) (4 used), and washers (11) (4 used).

Remove rear combination light (12) from counterweight (17). : 13 mm (0.5 in) 9. Disconnect harnesses of reverse alarm (22) in counterweight (17).

10. Remove bolts (23) (2 used).

Remove reverse alarm (22) and cover (21) from battery box.

Battery box

: 17 mm (0.7 in) W4FGE-02-03-002

W2-3-2

45ZV-2

BODY / Counterweight CAUTION: Counterweight (17) weight: 560 kg (1230 lb)

Lifting Tool

11. Install eyebolt (M20, Pitch 2.5 mm (0.1 in)) (2 used) on the top of counterweight (17).

Install a lifting tool. Hold counterweight (17).

12. Loosen bolts (24) (4 used). Remove bolts (24) (4 used) and washers (25) (4 used) from counterweight (17) while finely adjusting the hoist of counterweight (17).

Eyebolt

: 30 mm (1.2 in) 13. Remove counterweight (17) from additional weight (26).

CAUTION: Additional weight (26) weight: 131 kg (289 lb)

W4FGE-02-03-003

14. Install eyebolt (M12, Pitch 1.75 mm (0.07 in)) (2 used) on the top of additional weight (26). Install a lifting tool.

Hold additional weight (26).

15. Loosen bolts (30) (4 used). Remove bolts (30) (4 used) and washers (31) (4 used) from additional weight (26) while finely adjusting the hoist of additional weight (26). : 30 mm (1.2 in) CAUTION: Additional weight (27) weight: 131 kg (289 lb) 16. Remove additional weight (26) from additional weight (27).

17. Install eyebolt (M12, Pitch 1.75 mm (0.07 in)) (2 used) on the top of additional weight (27).

Install a lifting tool. Hold additional weight (27).

W4FGE-02-03-004

18. Loosen bolts (29) (4 used). Remove bolts (29) (4 used) and washers (28) (4 used) from additional weight (27) while finely adjusting the hoist of additional weight (27).

19. Remove additional weight (27) from rear chassis (32).

W2-3-3

45ZV-2

BODY / Counterweight Installation CAUTION: Additional weight (27) weight: 131 kg (289 lb) 1. Install eyebolt (M12, Pitch 1.75 mm (0.07 in)) (2 used) on the top of additional weight (27).

Install a lifting tool. Hold additional weight (27).

2. Fit additional weight (27) to the bolt hole of rear chassis (32).

3. Install additional weight (27) to rear chassis (32) with bolts (29) (4 used) and washers (28) (4 used). : 30 mm (1.2 in) : 376 to 460 N·m (38 to 47 kgf·m, 275 to 339 lbf·ft) W4FGE-02-03-004

CAUTION: Additional weight (26) weight: 131 kg (289 lb) Lifting Tool

4. Install eyebolt (M12, Pitch 1.75 mm (0.07 in)) (2 used) on the top of additional weight (26).

Install a lifting tool. Hold additional weight (26).

5. Fit additional weight (26) to the bolt hole of additional weight (27).

Eyebolt

6. Install additional weight (26) to additional weight (27) with bolts (30) (4 used) and washers (31) (4 used). : 30 mm (1.2 in) : 376 to 460 N·m (38 to 47 kgf·m, 275 to 339 lbf·ft) CAUTION: Counterweight (17) weight: 560 kg (1230 lb) 7. Install an eyebolt (M20, Pitch 2.5 mm (0.1 in)) (2 used) on the top of counterweight (17).

Install a lifting tool. Hold counterweight (17).

W4FGE-02-03-003

8. Fit counterweight (17) to the bolt hole of additional weight (26).

9. Install counterweight (17) to additional weight (26) with bolts (24) (4 used) and washers (25) (4 used). : 30 mm (1.2 in) : 423 to 460 N·m (43 to 47 kgf·m, 312 to 339 lbf·ft)

W2-3-4

45ZV-2

BODY / Counterweight 10. Install cover (21) and reverse alarm (22) to battery box with bolts (23) (2 used). : 17 mm (0.7 in) 11. Connect harnesses of reverse alarm (22).

Battery box

W4FGE-02-03-002

12. Install rear combination light (12) to counterweight (17) with bolts (9) (4 used), spring washers (10) (4 used), and washers (11) (4 used). : 13 mm (0.5 in) 13. Connect harnesses of rear combination light (12).

14. Install cover (13) to rear combination light (12) with screws (16) (2 used), spring washers (15) (2 used), and washers (14) (2 used).

15. Install reverse light (20) to counterweight (17) with screws (18) (2 used) and washers (19) (2 used).

16. Connect harnesses of reverse light (20).

17. Install cove (5) to counterweight (17) with bolts (7) (2 used) and washers (8) (2 used). : 30 mm (1.2 in) 18. Install cover (4, 6) to cover (5) with bolts (1) (8 used), spring washers (2) (8 used), and washers (3) (8 used).

W4FGE-02-03-001

: 17 mm (0.7 in) 19. Install the engine hood. (Refer to W2-5.)

W2-3-5

45ZV-2

BODY / Counterweight (Blank)

W2-3-6

45ZV-2

BODY / Articulation Joint DISASSEMBLY AND CENTER HINGE

ASSEMBLY

OF

W4FG-02-04-001

Upper Hinge Pin

Section A

Lower Hinge Pin

Section B W4FG-02-04-002

123456-

Washer Nut Pin Shim Shim Collar

7 - Rear Chassis 8 - Spacer 9 - Retainer 10 - Grease Fitting (2 Used) 11 - Front Chassis 12 - Collar

13 - Bolt 14 - Lock Washer (Spring) 15 - Washer 16 - Bushing 17 - Bolt (4 Used) 18 - Lock Washer (Spring) (4 Used)

W2-4-1

19 - Pin 20 - Retaining Ring 21 - Bushing 22 - Washer 23 - Lock Washer (Spring) 24 - Bolt

45ZV-2

BODY / Articulation Joint

W4FG-02-04-001

Upper Hinge Pin

Section A

Lower Hinge Pin

Section B W4FG-02-04-002

W2-4-2

45ZV-2

BODY / Articulation Joint

CAUTION: The center hinge is required to disassemble for the major maintenance work such as removal of the front chassis from the rear chassis.

Preparation 1. When disassembling the center hinge, set the machine as illustrated to the right.

2. Remove the canopy (or the cab) and the floor plate. (Refer to W2-1 or W2-2.)

3. Remove the front attachment. (Refer to W4-1 or W4-2.)

4. Remove the engine hood. (Refer to W2-5.)

W4FG-02-04-004

5. Remove the counterweight. (Refer to W2-3.)

6. Remove the connecting parts between the front chassis (11) and the rear chassis (7).

• Propeller Shaft (Refer to W3-4.)

• Steering Cylinder (Refer to W3-8.)

• Hydraulic Hose (between steering valve and control valve) (Refer to W2-8.)

• Control Valve (Refer to W2-8.)

• Harness 7. Support front chassis (11) and rear chassis (7) by using solid support stands (25, 26, and 27).

W2-4-3

45ZV-2

BODY / Articulation Joint

W4FG-02-04-001

Upper Hinge Pin

Section A

Lower Hinge Pin

Section B W4FG-02-04-002

1 - Washer 2 - Nut 3 - Pin 4 - Shim 5 - Shim 6 - Collar

7 - Rear Chassis 8 - Spacer 9 - Retainer 10 - Grease Fitting (2 Used) 11 - Front Chassis 12 - Collar

13 - Bolt 14 - Lock Washer (Spring) 15 - Washer 16 - Bushing 17 - Bolt (4 Used) 18 - Lock Washer (Spring) (4 Used)

W2-4-4

19 - Pin 20 - Retaining Ring 21 - Bushing 22 - Washer 23 - Lock Washer (Spring) 24 - Bolt

45ZV-2

BODY / Articulation Joint Disassembly of Center Hinge 1. Remove bolts (28) (2 used), spring washers (29) (2 used) and washers (30) (2 used). Remove pipe (31), collars (32) (2 used), collars (33) (2 used), plate (34), and cables (35) (2 used) from rear chassis (7). : 13 mm (0.5 in) 2. Remove bolt (24), spring washer (23), and washer (22) from pin (19). : 19 mm (0.7 in) 3. Remove nut (2), washer (1), shims (4, 5), and collar (6) from pin (3). : 36 mm (1.4 in) 4. Remove bolt (13), spring washer (14), and washer (15) from pin (3). : 19 mm (0.7 in) 5. Remove pin (3) and collar (12) from front chassis (11) and rear chassis (7).

W4FG-02-04-005

6. Remove pin (19) and retaining ring (20) from front chassis (11).

CAUTION: Front chassis (11) assembly weight: Approx. 660 kg (1460 lb) 7. Attach a nylon sling onto front chassis (11). Hoist front chassis (11). Remove front chassis (11) from rear chassis (7).

8. Remove spacer (8) from front chassis (11).

Remove bolts (17) (4 used), spring washer (18) (4 used), and retainer (9). : 19 mm (0.7 in) 9. Remove bushings (16, 21) from front chassis (11).

W2-4-5

45ZV-2

BODY / Articulation Joint

Tie Down Hole W4FG-02-04-001

Upper Hinge Pin

Section A

Lower Hinge Pin

Section B W4FG-02-04-002

123456-

Washer Nut Pin Shim Shim Collar

7 - Rear Chassis 8 - Spacer 9 - Retainer 10 - Grease Fitting (2 Used) 11 - Front Chassis 12 - Collar

13 - Bolt 14 - Lock Washer (Spring) 15 - Washer 16 - Bushing 17 - Bolt (4 Used) 18 - Lock Washer (Spring) (4 Used)

W2-4-6

19 - Pin 20 - Retaining Ring 21 - Bushing 22 - Washer 23 - Lock Washer (Spring) 24 - Bolt

45ZV-2

BODY / Articulation Joint Assembly of Center Hinge 1. Install bushing (16) to the upper hinge part of front chassis (11).

2. Add grease through grease fitting (10) into the inside of bushing (16) while rotating bushing (16).

3. Install bushing (21) and retaining ring (20) to the lower hinge part of front chassis (11).

4. Add grease through grease fitting (10) into the inside of bushing (21) while rotating bushing (21).

5. Install retainer (9) to the upper hinge part of front chassis (11). ® Apply LOCTITE #262 onto bolts (17) (4 used).

Install retainers (9) (4 used), bolts (17) (4 used), and spring washers (18) (4 used).

Install spacer (8) to retainer (9). : 19 mm (0.7 in) : 77 to 94 N·m (7.9 to 9.6 kgf·m, 57 to 69 lbf·ft)

7. Install pin (3), and collar (6) to the upper hinge part. ® Apply LOCTITE #262 onto nut (2). Install nut (2) and washer (1). : 36 mm (1.4 in) : 255 to 314 N·m (26 to 32 kgf·m, 188 to 232 lbf·ft) 8. Install Plate (15) to the upper hinge part. ® Apply LOCTITE #262 onto bolt (13). Install bolt (13), spring washer (14), and collar (12). : 19 mm (0.7 in) : 77 to 94 N·m (7.9 to 9.6 kgf·m, 57 to 69 lbf·ft) 9. Install pin (19) to rear chassis (7) with bolt (24), spring washer (23), and washer (22). : 19 mm (0.7 in)

CAUTION: Front chassis (11) assembly weight: Approx. 660 kg (1460 lb)

10. Attach a spring balance to the tie down hole on front chassis (11).

Insert shims (4, 5) to clearance between washer (1) and collar (6) so that sliding resistance of the center hinge part is 98 N (10 kg⋅f) or less.

6. Attach a nylon sling onto front chassis (11).

Hoist front chassis (11).

Fit the pin (3, 19) holes of front chassis (11) and rear chassis (7).

W2-4-7

45ZV-2

BODY / Articulation Joint 11. Install plate (34), cables (35) (2 used), collars (32, 33) (2 used for each), and pipe (31) to rear chassis (7) with bolts (28) (2 used), spring washers (29) (2 used), and washers (30) (2 used). : 13 mm (0.5 in) 12. Remove stands (25, 26, and 27).

13. Install the connecting parts between front chassis (11) and rear chassis (7).

• Propeller Shaft (Refer to W3-4.)

• Steering Cylinder (Refer to W3-8.)

• Hydraulic Hose between Steering Valve and Control Valve (Refer to W2-8.)

• Control Cable (Refer to W2-8.)

• Harness 14. Install the counterweight. (Refer to W2-3.)

15. Install the engine hood. (Refer to W2-5.)

16. Install the front attachment. (Refer to W4-2.)

17. Install the canopy or cab and the floor plate.

(Refer to W2-1 or W2-2.)

W4FG-02-04-005

W4FG-02-04-004

W2-4-8

45ZV-2

BODY / Engine Hood REMOVAL AND ENGINE HOOD

INSTALLATION

OF

Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

W4FG-02-01-001

W2-5-1

45ZV-2

BODY / Engine Hood Removal 1. Open hood (1)

2. Remove bolts and washers (3) (4 used).

Remove hood (1) from hood support (2). : 17 mm (0.7 in)

W4FG-02-05-001

3. Remove snap pins (5) (2 used), yoke pins (7) (2 used), washers (6) (2 used), and gas damper (8) rod side (2 places) from hood support (2).

4. Remove bolts (9) (2 used), spring washers (10) (2 used), and washers (11) (2 used) from hinge (12).

Remove hood support (2) from hood base (4). : 17 mm (0.7 in)

W4FG-02-05-002

W2-5-2

45ZV-2

BODY / Engine Hood Installation 1. Install hinge (6) to hood base (13) with bolts (10), spring washers (11) and washers (12) (4 used for each) together with hood support (2) and gas dampers (7) (2 used). : 17 mm (0.7 in)

2. Install gas lift cylinder (8) rod side (2 places) to hood support (2) with snap pins (5) (2 used), yoke pins (7) (2 used), and washers (6) (2 used).

W4FG-02-05-002

3. Install hood (1) to hood support (2) with bolts and washers (3) (4 used). : 17 mm (0.7 in) 4. Close hood (1).

W4FG-02-05-001

W2-5-3

45ZV-2

BODY / Engine Hood (Blank)

W2-5-4

45ZV-2

BODY / HST Pump and Main Pump REMOVAL AND INSTALLATION OF HST PUMP Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

4. Remove the canopy or the cab. (Refer to W2-1 or W2-2.)

5. Remove the floor plate. (Refer to W2-1.)

W4FG-02-01-001

W2-6-1

45ZV-2

BODY / HST Pump and Main Pump

W4FG-02-06-001

1 - Main Pump

5 - O-Ring (2 Used)

2 - HST Pump 3 - Washer (4 Used) 4 - Bolt (4 Used)

6 - Split Flange (4 Used) 7 - Hose 8 - Bolt (8 Used)

9 - Lock Washer (Spring) (8 Used) 10 - Hose 11 - Hose 12 - Hose Clamp

W2-6-2

13 - Hose 14 - Hose 15 - Hose

45ZV-2

BODY / HST Pump and Main Pump Removal of HST Pump 1. Unplug connector of the forward/reverse selection solenoid harness on HST pump (2).

2. Disconnect all hydraulic hoses from main pump (1). (Refer to REMOVAL AND INSTALLATION OF MAIN PUMP.) 3. Remove bolts (8) (8 used), lock spring washers (9) (8 used) and split flanges (6) (4 used) from hoses (7, 10).

Disconnect hoses (7, 10) from HST pump (2). Cap the open ends. : 19 mm (0.7 in) 4. Remove O-rings (5) from hoses (7, 10).

5. Disconnect hoses (14, 15) from HST pump (2).

Cap the open ends. : 22 mm (0.9 in), 27 mm (1.1 in) 6. Disconnect hose (13) from HST pump (2). Cap the open ends. : 36 mm (1.4 in) 7. Loosen hose clamp (12).

Disconnect hose (11) from HST pump (2).

CAUTION: HST pump (2) (with main pump (1)) weight: 66 kg (146 lb) IMPORTANT: Check the nylon sling position in order not to damage the solenoid valve connector when hoisting HST pump.

8. Attach a nylon sling to the HST pump (2).

Hold HST pump (2).

9. Remove bolts (4) (4 used) and washers (3) (4 used) from HST pump (2).

Hoist and remove HST pump (2) from the engine. : 27 mm (1.1 in)

W2-6-3

45ZV-2

BODY / HST Pump and Main Pump

W4FG-02-06-001

1 - Main Pump

5 - O-Ring (2 Used)

2 - HST Pump 3 - Washer (4 Used) 4 - Bolt (4 Used)

6 - Split Flange (4 Used) 7 - Hose 8 - Bolt (8 Used)

9 - Lock Washer (Spring) (8 Used) 10 - Hose 11 - Hose 12 - Hose Clamp

W2-6-4

13 - Hose 14 - Hose 15 - Hose

45ZV-2

BODY / HST Pump and Main Pump Installation of HST Pump CAUTION: HST pump (2) (with main pump (1)) weight: 66 kg (146 lb) IMPORTANT: Check the nylon sling position order not to damage the solenoid valve connector when hoisting HST pump.

7. Connect connector of the forward/reverse selection solenoid harness of HST pump (2).

8. Remove plug (16) with O-ring attached.

Add hydraulic oil (1 L) to HST pump (2). : 6 mm (0.2 in)

1. Attach a nylon sling onto HST pump (2).

Hoist and fit with the mounting hole on the engine.

Install HST pump (2) to the engine with bolts (4) (4 used) and washers (3) (4 used). : 27 mm (1.1 in) : 265 to 314 N·m (27 to 32 kgf·m, 196 to 232 lbf·ft) 2. Connect hose (11) to HST pump (2) with clamp (12).

W4FG-02-06-002

: 6 N·m (0.61 kgf·m, 4.43 lbf·ft) 9. Install the floor plate. (Refer to W2-1.)

3. Connect hose (13) to HST pump (2).

10. Install the canopy or cab. (Refer to W2-1 or W2-2.)

: 36 mm (1.4 in) 4. Connect hoses (14, 15) to HST pump (2). : 22 mm (0.9 in) 5. Install O-rings (5), (2 used) to hoses (7, 10).

Connect hoses (7, 10) to HST pump (2) with split flanges (6) (4 used), bolt (8) (8 used) and spring washers (9) (8 used). : 19 mm (0.7 in) : 77 to 95 N·m (7.85 to 9.69 kgf·m, 57 to 70 lbf·ft) 6. Connect all hydraulic hoses to the main pump (1).

(Refer to REMOVAL AND INSTALLATION OF MAIN PUMP.)

W2-6-5

45ZV-2

BODY / HST Pump and Main Pump DISASSEMBLY AND ASSEMBLY OF HST PUMP IMPORTANT: Only trained and competent personnel should disassemble and repair the HST pump.

The pump must be thoroughly cleaned prior to removal from machine for repair.

Carefully check externally mounted parts of HST pump prior to checking internal pieces.

IMPORTANT: Carefully attach a wrench onto the hexagonal part of the relief valve case to remove it.

Removal and Installation of High-Pressure Relief Valve and Low-Pressure Relief Valve 1. Remove high-pressure relief valves (2) (2 used) from HST pump (3). : 32 mm (1.3 in) : 150 N·m (15.3 kgf·m, 111 lbf·ft)

2. Remove O-ring (4), backup ring (5), and O-ring (6) from high-pressure relief valve (2).

W4FG-02-06-011

3. Remove low-pressure relief valve (1) from HST pump (3). : 27 mm (1.1 in) : 70 N·m (7.14 kgf·m, 52 lbf·ft)

W4FG-02-06-003

4. Remove O-ring (7) from low-pressure relief valve (1).

IMPORTANT: Do not disassemble high-pressure relief valve (2) and low-pressure relief valve (1).

Replace with a new one if inoperable.

Install the parts in reverse order for removal.

W4FG-02-06-004

W2-6-6

45ZV-2

BODY / HST Pump and Main Pump Removal and Installation of DE Pump Solenoid Valve 1. Remove valve housing (9) from HST pump (3).

(Refer to W2-6-8.)

W4FG-02-06-012

2. Remove pump solenoid valve (8) from valve housing (9).

Install the parts in reverse order for removal.

W4FG-02-06-005

W2-6-7

45ZV-2

BODY / HST Pump and Main Pump Removal and Installation of Solenoid Valve (Forward and Reverse Selection) 1. Remove socket bolts (17) (4 used), bolts (14) (2 used) and washers (15) (2 used).

Remove valve housing (9) from HST pump (1). : 5 mm (0.2 in) : 10 mm (0.4 in)

2. Remove O-rings (11, 12, 16) and O-ring (13) (3 used) from valve housing (9).

W4FG-02-06-006

3. Remove solenoid valves (18, 20) from valve housing (9). Remove O-rings (19) (2 used), and O-rings (21) (2 used) from solenoid valves (18, 20).

Install the parts in reverse order of removal.

W4FG-02-06-010

W2-6-8

45ZV-2

BODY / HST Pump and Main Pump Disassembly of HST Pump Connecting Part (Engine Side)

22

1. Place HST pump on a clean stand with the drive shaft (22) facing upward.

NOTE: Protect the spline part of drive shaft (22).

23

24 25

2. Remove retaining ring (24) from housing (23).

24 3. Evenly install tapping screw (26) (3.5 mm (0.1 in), 25 mm (1.0 in) long) to the holes (2 places), which are blocked by the rubber of seal ring (25).

4. Remove seal ring (25) by using a pair of pliers.

W4EK-02-06-010

Assembly of HST Pump Connected Part (Engine Side) 1. Install seal ring (25) to housing (23) with tapping screws (26).

26

2. Install retaining ring (24) to housing (23).

25

W4EK-02-06-011

W2-6-9

45ZV-2

BODY / HST Pump and Main Pump REMOVAL AND INSTALLATION OF MAIN PUMP

W4FG-02-06-007

1 - HST Pump 2 - Main Pump

4 - Lock Washer (Spring) (2 Used) 5 - Washer (2 Used)

3 - Bolt (2 Used)

6 - O-Ring

7 - Bolt (2 Used)

10 - O-Ring

8 - Lock Washer (Spring) (2 Used) 9 - Pipe

11 - Hose

W2-6-10

45ZV-2

BODY / HST Pump and Main Pump Removal of Main Pump

Installation of Main Pump

1. Disconnect hose (11) from main pump (2).

Cap the open ends.

Attach an identification tag onto the disconnected hoses for assembling.

1. Install coupling (12) to the connecting part of HST pump (1).

: 27 mm (1.1 in), 36 mm (1.4 in)

3. Install main pump (2) to HST pump (1) with bolts (3) (2 used), spring washers (4) (2 used), and washers (5) (2 used).

2. Remove bolts (7) (4 used) and spring washers (8) (4 used) from pipe (9).

Remove tube (9) from main pump (2).

Cap the open ends.

2. Install O-ring (6) to HST pump (1).

: 17 mm (0.7 in) 4. Connect O-ring (10) to tube (9).

: 17 mm (0.7 in) 5. Install pipe (9) to main pump (2) with bolts (7) (4 used) and spring washers (8) (4 used).

3. Remove O-ring (10) from tube (9).

4. Remove bolts (3) (2 used), spring washers (4) (2 used), and washers (5) (2 used) from main pump (2).

Remove main pump (2) from HST pump (1).

: 17 mm (0.7 in) 6. Connect hose (11) to main pump (2). : 27 mm (1.1 in), 36 mm (1.4 in)

: 17 mm (0.7 in) 7. Install the operator frame. (Refer to W2-1.)

5. Remove O-ring (6) from HST pump (1).

6. Remove coupling (12) from the connecting part of HST pump (1).

8. Install the canopy or cab. (Refer to W2-1 or W2-2.)

W4FG-02-06-008

W2-6-11

45ZV-2

BODY / HST Pump and Main Pump DISASSEMBLY AND ASSEMBLY OF MAIN PUMP

W4FG-02-06-009

1234-

Cover Case Cover Bolt (4 Used)

5678-

Washer (4 Used) Gear (Driven) Plate (2 Used) Backup Ring (2 Used)

9 - Gasket (2 Used) 10 - Gasket (2 Used) 11 - Bushing (4 Used)

W2-6-12

12 - Gear (Driving) 13 - Retaining Ring 14 - Oil Seal

45ZV-2

BODY / HST Pump and Main Pump Disassembly of Main Pump

Assembly of Main Pump

1. Remove bolts (4) (4 used) and washers (5) (4 used) from cover (3).

Remove cover (3), backup ring (8), gasket (9), gasket (10), and bushings (11) (2 used) from case (2).

IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Install retaining ring (13) and oil seal (14) to cover (1).

: 10 mm (0.4 in) 2. Install backup rings (8) (2 used), gaskets (9) (2 used), gaskets (10) (2 used), and bushings (11) (4 used) to covers (1, 3).

2. Remove plate (7) from case (2).

3. Remove case (2) from cover (1).

3. Install plate (7) and gears (6, 12) to cover (1).

4. Remove gears (6, 12) and plate (7) from cover (1).

5. Remove backup rings (8) (2 used), gaskets (9) (2 used), gaskets (10) (2 used), and bushings (11) (4 used) from covers (1, 3).

IMPORTANT: Install plate (7) with the coated side facing the gear side.

6. Remove retaining ring (13) and oil seal (14) from cover (1).

4. Install body (2) to cover (1).

5. Install plate (7) to case (2).

6. Install cover (3), backup ring (8), gasket (9), gasket (10), and bushings (11) (2 used) to body (2) with bolts (4) (4 used) and washers (5) (4 used). : 10 mm (0.4 in) : 10.9 N·m (1.1 kgf·m, 8 lbf·ft)

W2-6-13

45ZV-2

BODY / HST Pump and Main Pump (Blank)

W2-6-14

45ZV-2

BODY / HST Motor REMOVAL AND INSTALLATION OF HST MOTOR Operation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

4. Remove the canopy or the cab. (Refer to W2-1 or W2-2.)

5. Remove the inspection cover and the seat support from the floor plate. (Refer to W2-1.)

6. Remove the main pump. (Refer to W2-6.)

7. Remove the propeller shaft. (Refer to W3-4.)

W4FG-02-01-001

W2-7-1

45ZV-2

BODY / HST Motor

W4FG-02-07-001

1 - HST Motor 2 - Flange

6 - Lock Washer (Spring) (4 Used) 7 - Bolt (4 Used)

3 - O-Ring 4 - Reduction Gear Case 5 - Washer (4 Used)

8 - Hose 9 - Hose 10 - Hose

11 - Hose Clamp

16 - Bolt (4 Used)

12 - Split Flange (2 Used)

17 - Lock Washer (Spring) (4 Used) 18 - Bolt (4 Used) 19 - Hose

13 - O-Ring (2 Used) 14 - Split Flange (2 Used) 15 - Lock Washer (Spring) (4 Used)

W2-7-2

45ZV-2

BODY / HST Motor Removal 1. Disconnect harnesses.

flange

(2)

of

HST

motor

(1)

2. Remove split flanges (12) (2 used), bolts (18) (4 used), and lock spring washers (17) (4 used) from hose (8).

Disconnect hose (8) from HST motor (1). : 22 mm (0.9 in) 3. Remove split flanges (14) (2 used), bolts (16) (4 used), and lock spring washers (15) (4 used) from hose (9).

Disconnect hose (9) from HST motor (1). Cap the open ends. : 22 mm (0.9 in) 4. Disconnect hose (19) from HST motor (1).

5. Loosen hose clamp (11).

Disconnect hose (10) from HST motor (1).

Cap the open ends.

CAUTION: HST motor (1) weight: 64 kg (141 lb) 6. Attach a nylon sling onto HST motor (1).

Hold HST motor (1).

7. Remove bolts (7) (4 used), lock spring washers (6) (4 used), and washers (5) (4 used) from HST motor (1).

Hoist and remove HST motor (1) from reduction gear (4). : 24 mm (0.9 in) 8. Remove O-ring (3) from HST motor (1).

W2-7-3

45ZV-2

BODY / HST Motor

W4FG-02-07-001

1 - HST Motor 2 - Flange

6 - Lock Washer (Spring) (4 Used) 7 - Bolt (4 Used)

3 - O-Ring 4 - Reduction Gear Case 5 - Washer (4 Used)

8 - Hose 9 - Hose 10 - Hose

11 - Hose Clamp

16 - Bolt (4 Used)

12 - Split Flange (2 Used)

17 - Lock Washer (Spring) (4 Used) 18 - Bolt (4 Used) 19 - Hose

13 - O-Ring (2 Used) 14 - Split Flange (2 Used) 15 - Lock Washer (Spring) (4 Used)

W2-7-4

45ZV-2

BODY / HST Motor Installation 1. Install O-ring (3) to HST motor (1).

8. Install the propeller shaft. (Refer to W3-4.)

9. Install the main pump. (Refer to W2-6.)

CAUTION: HST motor (1) weight: 64 kg (141 lb) 2. Attach a nylon sling onto HST motor (1).

Hoist and fit HST motor (1) to the mounting hole of reduction gear (4).

Install HST motor (1) to reduction (4) with bolts (7) (4 used), spring washers (6) (4 used), and washers (5) (4 used).

10. Add hydraulic oil (1 L) to the HST pump. (Refer to W2-6-5.)

11. Install the inspection cover and the seat support to the floor plate. (Refer to W2-1.)

12. Install the canopy or cab. (Refer to W2-1 or W2-2.)

: 24 mm (0.9 in) : 168 to 227 N⋅m (19 to 23 kgf⋅m, 124 to 168 lbf⋅ft) 3. Connect hose (10) to HST motor (1) with hose clamp (11).

4. Connect hose (19) to HST motor (1).

5. Connect hose (9) to HST motor (1) with split flanges (12) (2 used), bolts (16) (4 used), and spring washers (15) (4 used). : 22 mm (0.9 in) : 122 to 149 N⋅m (12.4 to 15.2 kgf⋅m, 90 to 110 lbf⋅ft) 6. Connect hose (8) to HST motor (1) with split flanges (14) (2 used), bolts (18) (4 used), and spring washers (17) (4 used). : 22 mm (0.9 in) : 122 to 149 N⋅m (12.4 to 15.2 kgf⋅m, 90 to 110 lbf⋅ft) 7. Connect connector (2) of HST motor (1) harness.

W2-7-5

45ZV-2

BODY / HST Motor (Blank)

W2-7-6

45ZV-2

BODY / HST Motor DISASSEMBLY AND ASSEMBLY OF HST MOTOR IMPORTANT: Only trained and competent personnel should disassemble and repair the HST pump.

The pump must be thoroughly cleaned prior to removal from machine for repair.

Carefully check externally mounted parts of HST pump prior to checking internal pieces.

Disassembly of HST Motor Connected Part (Reduction Side) 1. Place HST motor on a clean stand with the drive shaft (1) of HST motor facing upward.

NOTE: Protect the spline part of drive shaft (1).

2. Remove retaining ring (2) from housing (5).

Remove shim (3).

3. Evenly install tapping screw (6) (Nominal Diameter 3.5 mm (0.1 in)¯Length 25 mm (1.0 in)) to the holes (2 places), which are blocked by the rubber of seal ring (4).

Remove seal ring (4) by using a pair of pliers.

W4FG-02-07-006

IMPORTANT: Record installing depth (A) of seal ling (4).

Assembly of HST (Reduction Side)

Motor

Connected

Part

1. Check for the installing depth (A) of seal ring (4).

Install seal ring (4) to housing (5).

2. Install shim (3) to housing (5).

Secure with retaining ring (2).

W4FG-02-07-007

W2-7-7

45ZV-2

BODY / HST Motor REMOVAL AND REGULATOR

INSTALLATION

OF

W4FG-02-07-004

1 - Regulator 2 - Socket Bolt (8 Used)

3 - Housing 4 - Plunger

5 - Cylinder Block 6 - O-Ring

W2-7-8

7 - Valve Plate

45ZV-2

BODY / HST Motor Removal of Regulator

Installation of Regulator

1. Put match marks on housing (3) and regulator (1).

1. Apply grease onto O-ring (6).

Install O-ring (6) to motor housing (3).

2. Remove socket bolts (2) (8 used) from regulator (1).

Remove regulator (1) from housing (3). : 14 mm (0.6 in)

2. Apply grease onto the sliding surface of regulator (1).

Install valve plate (7) to regulator (1) by aligning with the cylinder block (5) mounting surface.

3. Remove O-Ring (6) from motor housing (3).

CAUTION: Do not tilt cylinder block (5).

Plungers (4) may be removed from cylinder block (5).

W4FG-02-07-009

3. Fit the match marks with housing (3) and regulator (3).

Install regulator (1) to housing (3) with socket bolts (2) (8 used). : 8 mm (0.3 in)

W2-7-9

45ZV-2

BODY / HST Motor DISASSEMBLY OF REGULATOR

W4FG-02-07-005

123456-

Housing Socket Bolt (4 Used) Cover O-Ring Socket Bolt O-Ring

7 - Piston 8 - Piston Ring 9 - Spring 10 - Spring 11 - Spring 12 - O-Ring

13 - Square Ring 14 - Collar 15 - Collar 16 - Bushing 17 - Control Part Assembly 18 - Motor Solenoid Valve

W2-7-10

19 - Socket Bolt (4 Used) 20 - Check Valve 21 - Guide 22 - Backup Ring 23 - O-Ring 24 - O-Ring

45ZV-2

BODY / HST Motor Disassembly of Regulator 1. Remove motor solenoid valve (18) from control part assembly (17).

Remove square ring (13) from motor solenoid valve (18).

2. Remove socket bolts (19) (4 used) from control part assembly (17).

Remove control part assembly (17) from housing (1).

Remove O-ring (12) from control part assembly (17). : 6 mm (0.2 in) NOTE: Remove control part assembly (17) with careful attention to the force of springs (9, 10, and 11).

3. Remove O-ring (24) and guide (21) from the check valve part (2 places) of housing (1).

Remove O-ring (23) and backup ring (22) from guide (21).

4. Remove bushing (16), collars (14, 15), and springs (9, 10, 11) from control part assembly (17).

5. Remove socket bolts (2) (4 used) from cover (3).

Remove cover (3) from housing (1).

Remove O-Ring (4) from cover (3). : 10 mm (0.4 in) 6. Remove O-ring (6) from housing (1).

7. Remove socket bolt (5) from piston (7).

Remove piston (7) from housing (1).

Remove piston rings (8) (2 Used) from piston (7). : 12 mm (0.5 in)

W2-7-11

45ZV-2

BODY / HST Motor ASSEMBLY OF REGULATOR

W4FG-02-07-005

123456-

Housing Socket Bolt (4 Used) Cover O-Ring Socket Bolt O-Ring

7 - Piston 8 - Piston Ring 9 - Spring 10 - Spring 11 - Spring 12 - O-Ring

13 - Square Ring 14 - Collar 15 - Collar 16 - Bushing 17 - Control Part Assembly 18 - Motor Solenoid Valve

W2-7-12

19 - Socket Bolt (4 Used) 20 - Check Valve 21 - Guide 22 - Backup Ring 23 - O-Ring 24 - O-Ring

45ZV-2

BODY / HST Motor Assembly of Regulator IMPORTANT: Before assembling, apply hydraulic oil on to parts to prevent them from seizing.

1. Install piston ring (8) (2 Used) to Piston (7).

Install piston (7) to housing (1) with socket bolt (5). : 12 mm (0.5 in) 2. Install O-ring (4) to cover (3).

Install O-ring (6) to housing (1).

Install cover (3) to housing (1) with socket bolts (2) (4 used). : 10 mm (0.4 in) 3. Install backup ring (22) and O-ring (23) to guide (21).

Install guide (21) and O-ring (24) to the check valve part (2 places) of housing (1).

4. Install spring (9), collar (14), spring (10), collar (15), spring (11), and bushing (16) to the mounting hole of control part assembly (17) in sequence.

5. Install O-ring (12) to control part assembly (17).

Install control part assembly (17) to housing (1) with socket bolts (19) (4 used). : 6 mm (0.2 in) NOTE: When installing control part assembly (17),

evenly tighten socket bolts (19) (4 used)

with careful attention to the force of springs (9, 10, and 11).

6. Install square ring (13) to motor solenoid valve (18).

Install motor solenoid valve (18) to control part assembly (17).

W2-7-13

45ZV-2

BODY / HST Motor (Blank)

W2-7-14

45ZV-2

BODY / Control Valve REMOVAL AND CONTROL VALVE

INSTALLATION

OF

Preparation WARNING: Never work under a raised bucket.

The front attachment may lower, possibly causing personal injury.

If you must work with the front attachment raised, hold the front attachment securely by using a support or blocks.

1. Park the machine on a level and solid surface.

Stop the engine and release the hydraulic pressure.

If you must work with the front attachment raised, set the bucket to the full dump position and hold the lift arm by using support (4).

Set and secure stoppers (5) to the lift cylinder.

2. Place wheel stopper in front of and behind the wheel in order to secure the machine.

W4FG-02-08-001

3. Install articulation lock bar (2) to front chassis pin (1).

Secure with ring pin (3).

W4FG-02-01-001

W2-8-1

45ZV-2

BODY / Control Valve

W4FGE-02-08-002

1 - Control Valve 2 - Hose 3 - Hose

7 - Hose 8 - Hose 9 - Bolt (2 Used)

13 - Washer 14 - Cover 15 - Lock Washer (Spring)

4 - Hose

10 - Lock Washer (Spring) (2 Used) 11 - Washer (2 Used) 12 - Bolt

16 - Nut

19 - Bolt (3 Used) 20 - Washer (3 Used) 21 - Lock Washer (Spring) (3 Used) 22 - Nut (3 Used)

17 - Cable (3 Used) 18 - Front chassis

23 - Hose 24 - Hose

5 - Hose 6 - Connector

W2-8-2

45ZV-2

BODY / Control Valve Removal CAUTION: Attach an identification tag onto the disconnected hose and the pipe for assembling.

1. Remove bolts (24) (4 used).

Remove cover (23) from front chassis (18).

24

23

: 17 mm (0.7 in) 2. Disconnect the bucket auto leveler proximity switch connector (6) of harness.

18

3. Remove bolts (9) (2 used), lock spring washers (10) (2 used), washers (11) (2 used), bolt (12), washer (13), lock spring washer (15), and nut (16).

Remove cover (14) from front chassis (18).

W4FG-02-08-003

: 17 mm (0.7 in) 4. Remove control cables (17) (3 used) from control valve (1). : 10 mm (0.4 in), 13 mm (0.5 in), 14 mm (0.6 in), 24 mm (0.9 in) 5. Disconnect hoses (7, 8) from control valve (1).

Cap the open ends. : 27 mm (1.1 in), 36 mm (1.4 in) 6. Disconnect hoses (4, 5, 23, 24) from control valve (1).

Cap the open ends. : 22 mm (0.9 in) 7. Disconnect hoses (2, 3) from control valve (1).

Cap the open ends. : 19 mm (0.7 in), 27 mm (1.1 in) 8. Remove bolts (19) (3 used), washers (20) (3 used), lock spring washers (21) (3 used), and nuts (22) (3 used).

Remove control valve (1) from front chassis (18). : 17 mm (0.7 in)

W2-8-3

45ZV-2

BODY / Control Valve

W4FGE-02-08-002

1 - Control Valve 2 - Hose 3 - Hose

7 - Hose 8 - Hose 9 - Bolt (2 Used)

13 - Washer 14 - Cover 15 - Lock Washer (Spring)

4 - Hose

10 - Lock Washer (Spring) (2 Used) 11 - Washer (2 Used) 12 - Bolt

16 - Nut

19 - Bolt (3 Used) 20 - Washer (3 Used) 21 - Lock Washer (Spring) (3 Used) 22 - Nut (3 Used)

17 - Cable (3 Used) 18 - Front chassis

23 - Hose 24 - Hose

5 - Hose 6 - Connector

W2-8-4

45ZV-2

BODY / Control Valve Installation 1. Fit control valve (1) with front chassis (18) mounting hole.

Secure control valve (1) with bolts (19) (3 used), washers (20) (3 Used), lock spring washers (21) (3 used), and nuts (22) (3 used). : 17 mm (0.7 in)

8. Install cover (23) to front chassis (18) with bolts (24) (4 used). : 17 mm (0.7 in) 24

23

2. Connect hoses (2, 3) to control valve (1).

18

: 19 mm (0.7 in), 22 mm (0.9 in) 3. Connect hoses (4, 5, 23, 24) to control valve (1). : 22 mm (0.9 in) 4. Connect hoses (7, 8) to control valve (1).

W4FG-02-08-003

: 27 mm (1.1 in), 36 mm (1.4 in) 5. Connect control cables (17) (3 used) to control valve (1) so that the dimension is as illustrated in the right. : 10 mm (0.4 in), 13 mm (0.5 in), 14 mm (0.6 in), 24 mm (0.9 in) : 79.4 to 97.1 N·m (8.1 to 9.9 kgf·m, 59 to 72 lbf·ft)

1

(6)

(203) (190) 11 13

17

W4FGE-02-08-004

6. Install cover (14) to front chassis (18) with bolts (9), (2 Used) lock spring washers (10) (2 Used), washers (11) (2 used), bolt (12), washer (16), lock spring washer (15), and nut (16). : 17 mm (0.7 in) 7. Connect the bucket auto leveler proximity switch connector (6) of harness.

W2-8-5

45ZV-2

BODY / Control Valve DISASSEMBLY AND CONTROL VALVE

ASSEMBLY

OF

W4FGE-02-08-005

1234-

Support Rod (2 Used) Nut (4 Used) Rod

5678-

Nut (2 Used) Inlet Housing O-Ring Bucket Spool Assembly

9 - Lift Arm Spool Assembly 10 - Main Relief Valve 11 - O-Ring 12 - Overload Relief Valve (4 Used)

W2-8-6

13 - O-Ring (4 Used) 14 - Make-Up Valve 15 - O-Ring 16 - Auxiliary (Coupler) Spool Assembly

45ZV-2

BODY / Control Valve Disassembly of Control Valve

Assembly of Control Valve

IMPORTANT: Apply a spanner correctly to the hexagonal part of the relief valve case.

1. Remove main relief valve (10) from inlet housing (6).

Remove O-Ring (11) from main relief valve (10).

2. Remove overload relief valves (12) (2 used) from bucket spool assembly (8).

Remove O-Rings (13) (2 used) from overload relief valve (12).

3. Remove make-up valve (14) from lift arm spool assembly (9).

4. Remove overload relief valves (12) (2 used) from auxiliary (coupler) spool assembly (16).

Remove O-Rings (13) (2 used) from overload relief valve (12).

5. Remove nuts (3) (2 used) from rods (2) (2 used).

Remove nut (5) from rod (4).

Pull out and separate rods (2) (2 used) and rod (4) from inlet housing (6), bucket spool assembly (8), lilt arm spool assembly (9), auxiliary (coupler) spool assembly (16) and support (1). : Nut (3): 13 mm (0.5 in) Nut (5): 17 mm (0.7 in)

IMPORTANT: Before assembling, apply hydraulic oil to parts to prevent them from seizing.

IMPORTANT: Apply a spanner correctly to the hexagonal part of the relief valve case.

IMPORTANT: Use correct torque value to assemble, or spools will not perform as designed.

1. Install O-Ring (7) to inlet housing (1).

NOTE: Assemble bucket spool assembly (8), auxiliary (coupler) spool assembly and lilt arm spool assembly (9) in advance.

(Refer to W2-8-8, W2-8-12, W2-8-16) 2. Install rods (2) (2 used) and rod (4) through inlet housing (6), bucket spool assembly (8), lilt arm spool assembly (9), auxiliary (coupler) spool assembly (16) and support (1).

Install with nuts (3) (4 used) and nuts (5) (2 used). : Nut (3) 13 mm (0.5 in) : 19 N·m (1.9 kgf·m, 14 lbf·ft) : Nut (5) 17 mm (0.7 in) : 46 N·m (4.7 kgf·m, 34 lbf·ft) 3. Install O-Rings (13) (2 used) to overload relief valves (12) (2 used).

Install overload relief valves (12) (2 used) to auxiliary (coupler) spool assembly (16).

6. Remove O-Ring (7) from inlet housing (6).

4. Install O-Ring (15) to make-up valve (14).

Install make-up valve (14) to lift arm spool assembly (9).

5. Install O-Rings (13) (2 used) to overload relief valves (12) (2 used).

Install overload relief valves (12) (2 used) to bucket spool assembly (8).

6. Install O-Ring (11) to main relief valve (10).

Install main relief valve (10) to inlet housing (6).

W2-8-7

45ZV-2

BODY / Control Valve Disassembly and Assembly of Bucket Spool Assembly

W4EK-02-08-005

123456-

Housing Spool Sleeve O-Ring (2 Used) Wiper Ring (2 Used) O-Ring

7 - Plate 8 - Spring 9 - Spring Seat (2 Used) 10 - Cap Screw 11 - Nut 12 - Plate

13 - Socket Bolt 14 - Coil Tube 15 - Cap 16 - Socket Bolt (2 Used) 17 - O-Ring 18 - Shim (Thickness 0.5 mm (0.02 in))

W2-8-8

19 - Spring 20 - Poppet (Load Check) 21 - O-Ring 22 - Screw (2 Used) 23 - Seal Plate

45ZV-2

BODY / Control Valve Disassembly of Bucket Spool Assembly 1. Remove O-Rings (21), poppet (20) and spring (19) from housing (1).

2. Remove screws (22) (2 used) and seal plate (23) from housing (1).

3. Remove socket bolts (16) (2 used) from housing (1).

Separate cap (15), coil tube (14) and sleeve (3).

9. Remove spool (2) from housing (1).

NOTE: For easy removal, rotate and remove spool (2).

10. Remove wiper rings (5) (2 used) and O-Rings (4) (2 used) from housing (1).

: 5 mm (0.2 in) 4. Remove cap (15) and O-Ring (17) from coil tube (14).

5. Remove coil tube (14) and shim (18) from sleeve (3).

6. Remove socket bolt (13), plate (12) and nut (11) from cap screw (10). : Socket Bolt (13): 4 mm (0.2 in) : Nut (11): 8 mm (0.3 in) 7. Remove sleeve (3) from spool (2).

Remove O-Rings (17, 6) from sleeve (3).

8. Remove cap screw (10) from spool (2).

Remove spring seats (9) (2 used), spring (8) and plate (7). : 8 mm (0.3 in)

W2-8-9

45ZV-2

BODY / Control Valve

W4FG-02-08-006

123456-

Housing Spool Sleeve O-Ring (2 Used) Wiper Ring (2 Used) O-Ring

7 - Plate 8 - Spring 9 - Spring Seat (2 Used) 10 - Cap Screw 11 - Nut 12 - Plate

13 - Socket Bolt 14 - Coil Tube 15 - Cap 16 - Socket Bolt (2 Used) 17 - O-Ring (2 Used) 18 - Shim (Thickness 0.5 mm (0.02 in))

W2-8-10

19 - Spring 20 - Poppet 21 - O-Ring 22 - Screw (2 Used) 23 - Seal Plate

45ZV-2

BODY / Control Valve Assembly of Bucket Spool Assembly IMPORTANT: Before assembling, apply hydraulic oil to parts to prevent them from seizing.

1. Install O-Rings (4) (2 used) and wiper rings (5) (2 used) to housing (1).

2. Install spool (2) to housing (1).

NOTE: For easy removal, rotate and install spool (2).

3. Install plate (7), spring seat (9), spring (8), and spring seat (9) to spool (2) with cap screw (10) in sequence.

W4FG-02-08-005

: 8 mm (0.3 in) : 20.1 N·m (2.05 kgf·m, 14.8 lbf·ft) 4. Install O-Rings (6, 17) to sleeve (3).

Install sleeve (3) to spool (2).

5. Install nut (11) and plate (12) to cap screw (10) with socket bolt (13). Tighten with nut (11) so that clearance (A) between nut (11) and plate (12) is 0.5 mm (0.02 in). : Nut (11): 8 mm (0.3 in) : Socket Bolt (13): 4 mm (0.2 in) : 2.6 N·m (0.27 kgf·m, 1.92 lbf·ft) 6. Install shim (18) and coil tube (14) to sleeve (3).

7. Install O-Ring (17) and cap (15) to coil tube (14).

8. Install sleeve (3), coil tube (14) and cap (15) to housing (1) with socket bolts (16) (2 used).

W4EK-02-08-009

: Socket Bolt (13): 4 mm (0.2 in) : 8.8 N·m (0.9 kgf·m) 9. Install seal plate (23) to housing (1) with screws (22) (2 used). : 2.7 N·m

(0.28 kgf·m)

10. Install O-ring (21), poppet (20), and spring (19) to housing (1).

W2-8-11

45ZV-2

BODY / Control Valve Disassembly and Assembly of Lift Arm Spool Assembly

W4EK-02-08-006

123456-

Housing Spool Seal Plate O-Ring (2 Used) Wiper Ring Spacer

7 - Cap 8 - Sleeve 9 - Pin 10 - Seat (2 Used) 11 - Spring 12 - Spring

13 - Steel Ball 14 - Steel Ball (4 Used) 15 - Spacer 16 - Retaining Ring 17 - O-Ring 18 - Poppet

W2-8-12

19 - Spring 20 - O-Ring 21 - Screw (2 Used) 22 - Socket Bolt (2 Used)

45ZV-2

BODY / Control Valve Disassembly of Lift Plunger Assembly 1. Remove O-Rings (20), poppet (18) and spring (19) from housing (1).

Screwdriver (-)

2. Remove screws (21) (2 used) and seal plate (3) from housing (1).

3. Remove retaining ring (16) and spacer (15) from cap (7).

4. Remove socket bolts (22) (2 used) from cap (7).

Remove cap (7) from housing (1).

Remove sleeve (8) while pushing large steel ball (13) in pin (9) with screwdriver (-). : 4 mm (0.2 in) 5. Slowly push back large steel ball (13).

Remove large steel ball (13), small steel balls (14) (4 used) and spring (12) from pin (9).

W4EK-02-08-011

NOTE: Do not loose steel ball (13) and steel balls (14) (4 used) as the steel balls may fly out.

6. Remove pin (9) from spool (2).

Remove spring seats (10) (2 used) and spring (11).

7. Remove spacer (6) from spool (2).

Remove O-Rings (4, 17) from spacer (6).

8. Remove spool (2) from housing (1).

NOTE: For easy removal, rotate and remove spool (2).

9. Remove wiper ring (5) and O-Ring (4) from housing (1).

W2-8-13

45ZV-2

BODY / Control Valve

W4FG-02-08-007

123456-

Housing Spool Seal Plate O-Ring (2 Used) Wiper Ring Spacer

7 - Cap 8 - Sleeve 9 - Pin 10 - Spring Seat (2 Used) 11 - Spring 12 - Spring

13 - Steel Ball 14 - Steel Ball (4 Used) 15 - Spacer 16 - Retaining Ring 17 - O-Ring 18 - Poppet (Load Check)

W2-8-14

19 - Spring 20 - O-Ring 21 - Screw (2 Used) 22 - Socket Bolt (2 Used)

45ZV-2

BODY / Control Valve Assembly of Lilt Arm Spool Assembly IMPORTANT: Before assembling, apply hydraulic oil to parts to prevent them from seizing.

1. Install O-Ring (4) and wiper ring (5) to housing (1).

Screwdriver (-)

2. Install spool (2) to housing (1).

NOTE: For easy removal, rotate and install spool (2).

3. Install O-Rings (4, 17) to spacer (6).

Install spacer (6) to spool (2).

4. Install spring seat (10), spring (11) and spring seat (10) in sequence with pin (9) to spool (2).

5. Install spring (12) and large steel ball (13) to pin (9).

Insert small steel balls (14) (4 used) to the hole (4 places) on the side of pin (9) while pushing steel ball (13) with screwdriver (-).

Install sleeve (8).

W4EK-02-08-011

6. Install cap (7) and spacer (6) to housing (1) with socket bolts (22) (2 used). : 4 mm (0.2 in) : 8.8 N·m (0.9 kgf·m, 6.5 lbf·ft) 7. Install spacer (15) to cap (7) with retaining ring (16).

8. Install seal plate (3) to housing (1) with screws (21) (2 used).

W4FG-02-08-005

: 2.7 N·m (0.28 kgf·m, 2.0 lbf·ft) 9. Install O-Ring (20), poppet (18) and spring (19) to housing (1).

W2-8-15

45ZV-2

BODY / Control Valve Disassembly and Assembly of Auxiliary (Coupler) Spool Assembly

W4FGE-02-08-007

1 - Housing 2 - Spool 3 - Seal Plate ４- O-Ring (1 Used) 5 - Wiper Ring (2 Used) 6 - Spacer

7 - Cap 8 - Sleeve 9 - Pin 10 - Spring Seat (2 Used) 11 - Spring 12 - Spring

13 - Steel Ball 14 - Steel Ball (4 Used) 15 - Spacer 16 - Retaining Ring 17 - O-Ring 18 - Poppet

W2-8-16

19 - Spring 20 - O-Ring 21 - Screw (2 Used) 22 – Socket Bolt (2 Used)

45ZV-2

BODY / Control Valve Disassembly Assembly

of

Auxiliary

(Coupler)

Spool Screwdriver (-)

1. Remove O-Rings (20), poppet (18) and spring (19) from housing (1).

2. Remove screws (21) (2 used) and seal plate (3) from housing (1).

3. Remove retaining ring (16) and spacer (15) from cap (7).

4. Remove socket bolts (22) (2 used) from cap (7).

Remove cap (7).

Remove sleeve (8) while pushing large steel ball (13) in pin (9) with screwdriver (-). : 4 mm (0.2 in) W4EK-02-08-011

5. Slowly push back large steel ball (13).

Remove large steel ball (13), small steel balls (14) (4 used) and spring (12) from pin (9).

NOTE: Do not loose steel ball (13) and steel balls (14) (4 used) as the steel balls may fly out.

6. Remove pin (9) from spool (2).

Remove spring seats (10) (2 used) and spring (11).

7. Remove spacer (6) from spool (2).

Remove wiper ring (5) and O-Rings (17) from spacer (6).

8. Remove spool (2) from housing (1).

NOTE: For easy removal, rotate and remove spool (2).

9. Remove wiper ring (5) and O-Ring (4) from housing (1).

W2-8-17

45ZV-2

BODY / Control Valve

W4FGE-02-08-006

1 - Housing 2 - Spool 3 - Seal Plate ４- O-Ring (2 Used) 5 - Wiper Ring (2 Used) 6 - Spacer

7 - Cap 8 - Sleeve 9 - Pin 10 - Spring Seat (2 Used) 11 - Spring 12 - Spring

13 - Steel Ball 14 - Steel Ball (4 Used) 15 - Spacer 16 - Retaining Ring 17 - O-Ring 18 - Poppet

W2-8-18

19 - Spring 20 - O-Ring 21 - Screw (2 Used) 22 - Socket Bolt (2 Used)

45ZV-2

BODY / Control Valve Assembly of Auxiliary (Coupler) Spool Assembly IMPORTANT: Before assembling, apply hydraulic oil to parts to prevent them from seizing.

1. Install O-Ring (4) and wiper ring (5) to housing (1).

Screwdriver (-)

2. Install spool (2) to housing (1).

NOTE: For easy removal, rotate and install spool (2).

3. Install O-Ring (4,17) to spacer (6).

Install spacer (6) to spool (2).

4. Install spring seat (10), spring (11) and spring seat (10) in sequence with pin (9) to spool (2).

5. Install spring (12) and large steel ball (13) to pin (9).

Insert small steel balls (14) (4 used) to the hole (4 places) on the side of pin (9) while pushing steel ball (13) with screwdriver (-). Install sleeve (8).

W4EK-02-08-011

6. Install cap (7) and spacer (6) to housing (1) with socket bolts (22) (2 used). : 4 mm (0.2 in) : 8.8 N·m (0.9 kgf·m, 6.5 lbf·ft) 7. Install spacer (15) to cap (7) with retaining ring (16).

8. Install seal plate (3) to housing (1) with screws (21) (2 used).

W4FG-02-08-005

: 2.7 N·m (0.28 kgf·m, 2.0 lbf·ft) 9. Install O-Ring (20), poppet (18) and spring (19) to housing (1).

W2-8-19

45ZV-2

BODY / Control Valve (Blank)

W2-8-20

45ZV-2

SECTION 3

TRAVEL SYSTEM — CONTENTNS — Group 1 Tire

Group 8 Steering Cylinder Removal and Installation of Steering Cylinder .......................................W3-8-1

Removal and Installation of Tire.................. W3-1-1

Group 2 Reduction Device

Disassembly of Steering Cylinder................W3-8-6 Assembly of Steering Cylinder ..................W3-8-10

Removal and Installation of Reduction Device ...................................... W3-2-1

Group 9 Priority Valve Group 3 Axle Removal and Installation of Front Axle .................................................. W3-3-1 Removal and Installation of Rear Axle................................................... W3-3-7

Removal and Installation of Priority Valve ..............................................W3-9-1

Group 4 Propeller Shaft Removal and Installation of Propeller Shaft........................................... W3-4-1

Group 5 Master Cylinder Removal and Installation of Master Cylinder ......................................... W3-5-1 Disassembly and Assembly of Master Cylinder ......................................... W3-5-6 Bleeding Air from Brake System ................. W3-5-8

Group 6 Parking Brake Solenoid Removal and Installation of Parking Brake Solenoid............................. W3-6-1

Group 7 Steering Valve Removal and Installation of Steering Valve ........................................... W3-7-1 Disassembly of Steering Valve.................... W3-7-6 Assembly of Steering Valve ...................... W3-7-10

4FGEW-3-1

45ZV-2

(Blank)

4FGEW-3-2

TRAVEL SYSTEM / Tire REMOVAL AND INSTALLATION OF TIRE Removal 1. Install articulation lock bar (3) to rear chassis pin (1). Secure with link pin (2).

W4FG-02-01-001

2. When removing the rear tires, insert wooden block (4) between the rear chassis and the rear axle on both left and right sides in order to prevent the cradle from moving.

W4FG-03-01-001

3. Loosen wheel nuts (6) (8 used) of tire (5) to be removed about one turn. : 32 mm CAUTION: Machine weight: Canopy machine: 4820 kg (10630 lb) Cab machine: 5040 kg (11110 lb) 4. Raise the machine until tire (5) to be removed slightly gets above the shop floor surface.

Support the machine securely by using blocks.

CAUTION: Tire (5) and rim weight: 105 kg (231 lb) 5. Attach a lifting tool to tire (5). Hold tire (5).

6. Remove wheel nuts (6) (8 used).

Remove tire (5) from the axle.

W3-1-1

W4FG-03-01-002

TRAVEL SYSTEM / Tire Installation CAUTION: Tire (5) and rim weight: 105 kg (231 lb) 1. Hoist and install tire (5) to the axle.

Install tire (5) with the air valve side facing outside.

2. Install and lightly tighten wheel nuts (6) (8 used) to tire (5).

W4FG-03-01-002

3. Lower the machine.

Tighten wheel nuts (6) according to the order as illustrated to the right. : 32 mm : 494 to 604 N⋅m (50.4 to 61.6 kgf⋅m, 365 to 446 lbf⋅ft)

M4FG-07-032

4. Remove wooden block (4) between the rear chassis and the rear axle on both left and right sides.

W4FG-03-01-001

W3-1-2

TRAVEL SYSTEM / Reduction Device REMOVAL AND INSTALLATION REDUCTION DEVICE

OF

The reduction device and the rear axle are united into one part.

Remove the reduction device and the rear axle from the rear chassis. (Refer to W3-3-7.)

As for assembly and disassembly of reduction device, refer to Reduction Device Service Manual.

W3-2-1

45ZV-2

TRAVEL SYSTEM / Reduction Device (Blank)

W3-2-2

45ZV-2

TRAVEL SYSTEM / Axle REMOVAL AND FRONT AXLE

INSTALLATION

OF

Preparation 1. Install articulation lock bar (3) to the rear chassis pin (1).

Secure with ring pin (2).

2. Drain oil from the axle. (Refer to the Operator's Manual.)

CAUTION: Machine weight: Canopy machine: 4820 kg (10630 lb) Cab machine: 5040 kg (11110 lb)

W4FG-02-01-001

3. Place a hydraulic jack on both sides of front chassis (4).

Raise front chassis (4).

Insert stand (6) under front chassis (4) and set wheel stoppers (5) to the rear wheels.

Lower the bucket end on the ground.

Stop the engine.

As for assembly and disassembly of front axle, refer to Axle Service Manual.

W4FG-03-03-001

W3-3-1

45ZV-2

TRAVEL SYSTEM / Axle Removal of Front Axle 1. Remove the front tires (2 used). (Refer to W3-1.)

Lifting Tool

2. Remove the propeller shaft. (Refer to W3-4.)

CAUTION: Front axle (7) weight: 235 kg (518 lb) 3. Hoist and hold front axle (7) by using a lifting tool.

W4FG-03-03-002

4. Remove U-bolts (8) (4 used), washers (9) (8 used), and nuts (10) (16 used) from front axle (7). : 27 mm (1.1 in)

W4FG-03-03-003

W3-3-2

45ZV-2

TRAVEL SYSTEM / Axle 5. Remove front axle (7) from front chassis (4).

Place front axle (7) on stand (11).

Pull front axle (7) and stand (11) out.

CAUTION: When a front axle (7) will be removed for a prolonged time, place stand (11) to the front axle (7) in a secured position. Stabilize the front chassis (4) in order to secure the machine.

W4FG-03-03-004

W3-3-3

45ZV-2

TRAVEL SYSTEM / Axle Installation of Front Axle 1. Place front axle (7) on stand (11).

Push front axle (7) to the mounting position at front chassis (4).

W4FG-03-03-004

Lifting Tool

CAUTION: Front axle (7) weight: 235 kg (518 lb) 2. Hoist front axle (7) to the mounting part in front chassis (4) by using a lifting tool.

W4FG-03-03-002

W3-3-4

45ZV-2

TRAVEL SYSTEM / Axle ®

3. Apply LOCTITE #262 onto nut (10) (8 used).

Install front axle (7) to front chassis (4) with U-bolts (8) (4 used), washers (9) (8 used), and nuts (10) (16 used).

6.

: 27 mm (1.1 in) : Nut (10): 265 to 320 N⋅m (26.5 to 32 kgf⋅m, 190 to 235 lbf⋅ft) Stopper nut (10): 210 to 260 N⋅m (21 to 26 kgf⋅m, 153 to 185 lbf⋅ft)

4. Install the propeller shaft. (Refer to W3-4.)

W4FG-03-03-003

5. Install the front tires. (Refer to W3-1.)

CAUTION: Machine weight: Canopy machine: 4820 kg (10630 lb) Cab machine: 5040 kg (11110 lb) 6. Start the engine.

Raise the bucket.

Place a hydraulic jack on both sides of front chassis (4).

Raise front chassis (4).

Remove stand (6) under front chassis (4) and rear wheel stoppers (5).

After completing the work, add the axle oil to the specified level. (Refer to the Operator's Manual.)

W4FG-03-03-001

W3-3-5

45ZV-2

TRAVEL SYSTEM / Axle (Blank)

W3-3-6

45ZV-2

TRAVEL SYSTEM / Axle REMOVAL AND INSTALLATION OF REAR AXLE Preparation 1. Install articulation lock bar (3) to the front chassis pin (1).

Secure with ring pin (2).

W4FG-02-01-001

2. Remove the counterweight. (Refer to W2-3.)

3. Drain oil from the axle and the reduction device.

(Refer to the Operator's Manual.)

CAUTION: Machine weight: Canopy machine: 4820 kg (10630 lb) Cab machine: 5040 kg (11110 lb) 4. Place a hydraulic jack on the rear side of rear chassis (4).

Raise rear chassis (4).

Insert stands (5, 6) under rear chassis (4) in order not to apply the machine weight excessively.

Lower the bucket on the ground.

Stop the engine.

As for assembly and disassembly of rear axle, refer to Axle Service Manual.

W4FG-03-03-005

W3-3-7

45ZV-2

TRAVEL SYSTEM / Axle Removal of Rear Axle 1. Remove the rear tires (2 used). (Refer to W3-1.)

2. Remove the propeller shaft. (Refer to W3-4.)

3. Disconnect remote lubrication hoses (19, 20). : 11 mm (0.4 in) CAUTION: Rear axle (4) and reduction device (1) weight: 270 kg (600 lb) 4. Place a hydraulic jack under reduction device (12) and support reduction device (12).

W4FG-03-03-006

5. Hoist and hold rear axle (15) and reduction device (12).

Lifting Tool

6. Remove bolts (17) (4 used), washers (18) (4 used), washers (14) (4 used), and nuts (13) (4 used) from rear axle (15) and reduction device (12). : 19 mm (0.7 in)

W4FG-03-03-007

W3-3-8

45ZV-2

TRAVEL SYSTEM / Axle 7. Remove the assembly of rear axle (15) and reduction device (12) from rear chassis (16).

Place the assembly of rear axle (15) and reduction device (12) on stand (11).

Pull the assembly of rear axle (15), reduction device (12), and stand (11) out.

8. Remove reduction device (12) from rear axle (15).

Refer to Reduction Device Service Manual.

W4FG-03-03-008

W3-3-9

45ZV-2

TRAVEL SYSTEM / Axle Installation of Rear Axle CAUTION: Rear axle (15) and reduction device (12) weight: 270 kg (600 lb) 1. Place rear axle (15) on stand (11).

Install reduction device (12). (Refer to Reduction Device Service Manual.

2. Push rear axle (15) to the mounting position in rear chassis (16).

3. Place a hydraulic jack under reduction device (12) and support reduction device (12).

W4FG-03-03-008

4. Hoist the assembly of rear axle (15) and reduction device (12) up to the mounting position in rear chassis (16) by using a lifting tool.

W4FG-03-03-007

W3-3-10

45ZV-2

TRAVEL SYSTEM / Axle 5. Install rear axle (15) to rear chassis (16) with bolts (17) (4 used), washers (18) (4 used), washers (14) (4 used), and nuts (13) (4 used). : 30 mm (1.2 in) : 500 to 610 N⋅m ( 50 to 61 kgf⋅m, 360 to 440 lbf⋅ft) 6. Connect remote lubrication piping (19, 20) to rear axle (15) and reduction device (12). : 17 mm (0.7 in) : 40 N⋅m ( 4 kgf⋅m, 28.5 lbf⋅ft) 7. Install the propeller shaft. (Refer to W3-4.)

8. Install the rear tires. (Refer to W3-1.)

CAUTION: Machine weight: Canopy machine: 4820 kg (10630 lb) Cab machine: 5040 kg (11110 lb) 9. Start the engine.

Raise the bucket.

Place a hydraulic jack on both sides of rear chassis (16).

Raise rear chassis (16).

Remove stands (5, 6).

After completing the work, add the axle oil and the transmission oil to the specified level. (Refer to the Operator's Manual.)

W4FG-03-03-006

10. Install the counterweight. (Refer to W2-3.)

W4FG-03-03-005

W3-3-11

45ZV-2

TRAVEL SYSTEM / Axle (Blank)

W3-3-12

45ZV-2

TRAVEL SYSTEM / Propeller Shaft REMOVAL AND INSTALLATION PROPELLER SHAFT

OF

Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

W4FG-02-01-001

W3-4-1

45ZV-2

TRAVEL SYSTEM / Propeller Shaft Propeller Shaft

Front Axle

Reduction Gear

W4FG-03-04-001

1 - Front Axle 2 - Propeller Shaft 2A - Spline Seal 2B - Grease Fitting

2C - Grease Fitting 2D - Grease Fitting 3 - Reduction Gear 4 - Rear Axle

5 - Bolt (8 Used) 6 - Nut (8 Used) 7 - Nut (8 Used)

W3-4-2

8 - Bolt (8 Used) 9 - Washer (8 Used) 10 - Washer (8 Used)

45ZV-2

TRAVEL SYSTEM / Propeller Shaft Removal

Installation

1. Remove grease fitting (2C) from propeller shaft (2). Position propeller shaft (2) in order to drain the internal grease.

IMPORTANT: Install propeller shaft (2) with the spline shaft (2A) side facing to the front axle (1) side.

IMPORTANT: Never reuse driveline bolts. Replace them with new ones.

IMPORTANT: Do not separate and remove propeller shaft (2).

If separating and removing propeller shaft (2), as spline seal (2A) may be damaged, remove as an assembly.

CAUTION: Propeller shaft (2) weight: 24 kg (53 lb) ®

2. Remove bolts (5) (8 used) bolts (8) (8 used), washers (9) (8 used), washers (10) (8 used), nut (6) (8 used), and nuts (7) (8 used) from propeller shaft (2). : 17 mm (0.7 in) CAUTION: Propeller shaft (2) weight: 24 kg (53 lb)

1. Apply LOCTITE #262 onto bolts (5) (8 used) and bolts (8) (8 used).

Install propeller shaft (2) to front axle (1) and the flange of reduction gear (3) with bolts (5) (8 used), bolts (8) (8 used), washers (9) (8 used), washers (10) (8 used), nuts (6) (8 used), and nuts (7) (8 used). : 17 mm (0.7 in) : 58 to 71 N⋅m (5.9 to 7.2 kgf⋅m, 43 to 52 lbf⋅ft)

3. Remove propeller shaft (2) from the machine.

2. Install grease fitting (2C) to propeller shaft (2).

Add grease through grease fittings (2B, 2C, and 2D).

W3-4-3

45ZV-2

TRAVEL SYSTEM / Propeller Shaft (Blank)

W3-4-4

45ZV-2

TRAVEL SYSTEM / Master Cylinder REMOVAL AND INSTALLATION MASTER CYLINDER

OF

Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with ring pin (2).

W4FG-02-01-001

W3-5-1

45ZV-2

TRAVEL SYSTEM / Master Cylinder Removal 1. Loosen hose clamp (2).

Disconnect hose (2) from master cylinder (1).

2. Disconnect hose (4) from master cylinder (1).

Cap the open ends. : 7 mm (0.3 in), 19 mm (0.7 in)

W4FG-03-05-001

3. Remove pin (13), washer (12) and pin (10).

Remove yoke (11) from brake pedal (14).

4. Remove nuts (6) (2 used), spring washers (7) (2 used) and bolts (8) (2 used).

Remove master cylinder (1) from steering support (5). : 17 mm (0.7 in) 5. Loosen nut (9). Remove yoke (11) from master cylinder (1). : 17 mm (0.7 in)

W4FG-03-05-002

W3-5-2

45ZV-2

TRAVEL SYSTEM / Master Cylinder Installation 1. Install nut (9) and yoke (11) to master cylinder (1). : 17 mm (0.7 in) : 23 to 28 N⋅m (2.3 to 2.9 kgf⋅m, 17 to 21 lbf⋅ft) 2. Install master cylinder (1) to steering support (5) with bolts (8) (2 used), spring washers (7) (2 used) and nuts (6) (2 used). : 17 mm (0.7 in) : 44 to 54 N⋅m (4.5 to 5.5 kgf⋅m, 32 to 40 lbf⋅ft)

W4FG-03-05-002

3. Connect hose (4) to master cylinder (1). : 17 mm (0.7 in), 19 mm (0.7 in) : 44 N⋅m (4.5 kgf⋅m, 32 lbf⋅ft) 4. Connect hose (3) to master cylinder (1) with hose clamp (2). : 3.4 N⋅m (0.35 kgf⋅m, 2.51 lbf⋅ft) 5. Fit yoke (11) with the mounting hole on brake pedal (14) and install yoke (11) with pin (10), washer (12) and snap pin (13).

6. After completing the work, adjust the parts (Refer to Installation Standard on W3-5-4.)

W4FG-03-05-001

W3-5-3

45ZV-2

TRAVEL SYSTEM / Master Cylinder Assembly Standard Adjust dimension A (fully up) with stopper bolt (3) so that dimension A is 182±5 mm (7.1±0.2 in).

Reference: Dimension B: 0 mm (0 in) Dimension E: 160 mm (6.3 in)

Pedal Bottom End

Check for dimensions A, Y and Z after bleeding air from the brake.

Dimension A (fully up): 182±5 mm (7.1±0.2 in) Dimension Y (when the brake begins to be applied): +2 +0.08 18 0 mm (0.7 0 in) Dimension Z (fully applied): Between 160 mm (6.3 in) and 105 mm (4.1 in)

W4FG-03-05-003

Brake Angle Sensor

Installation and Adjustment of Brake Light Switch

W4FG-03-05-004

Adjust brake light switch (1) mounting positions (G, H).

Tighten attached lock nut (2). : 19 mm (0.7 in) : 7.8 to 9.8 N⋅m (0.8 to 1.0 kgf⋅m, 5.8 to 7.2 lbf⋅ft) Reference: Dimension G: 46 mm (1.8 in) Dimension H: Within 10 to 15 mm (0.6 in) W4FG-03-05-005

W3-5-4

45ZV-2

TRAVEL SYSTEM / Master Cylinder (Blank)

W3-5-5

45ZV-2

TRAVEL SYSTEM / Master Cylinder DISASSEMBLY AND MASTER CYLINDER

ASSEMBLY

OF

W4FG-03-05-006

1 - Filler Union 2 - O-Ring 3 - Clamp

4 - Cylinder 5 - Spring 6 - Piston Assembly

7 - Retaining Ring 8 - Rod

W3-5-6

9 - Boot 10 - Stop Plate

45ZV-2

TRAVEL SYSTEM / Master Cylinder Disassembly

Assembly

1. Remove rod (8) and boot (9) from cylinder (4).

IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

2. Remove snap ring (7) from cylinder (4).

NOTE: When removing retaining ring (7), remove piston assembly (6) while pushing piston assembly (6) with rod (8).

1. Install O-ring (2) to cylinder (4).

3. Remove stop plate (10) from cylinder (4).

2. Connect filler union (1) to cylinder (4) with clamp (3). : 1.95 to 2.94 N⋅m (0.2 to 0.3 kgf⋅m, 1.43 to 2.17 lbf⋅ft)

4. Remove piston assembly (6) and spring (5) from cylinder (1).

3. Install spring (5) and piston assembly (6) to cylinder (4).

5. Remove clamp (3) from filler union (1). Remove filler union (1) from cylinder (4).

4. Install stop plate (10) to cylinder (4).

5. Install retaining ring (7) to cylinder (4).

6. Remove O-ring (2) from cylinder (4).

NOTE: When installing retaining ring (7), install piston assembly (6) by pushing with rod (8).

6. Install rod (8) and boot (9) to cylinder (1).

W3-5-7

45ZV-2

TRAVEL SYSTEM / Master Cylinder BLEEDING AIR FROM BRAKE SYSTEM When brake oil is drained, or when the removal and installation of the master cylinder or the parking brake solenoid is done, bleed air from the brake system by doing the following procedures.

IMPORTANT: If the brake is applied with air mixed in the brake system, the braking force may be reduced or operational failure may occur.

IMPORTANT: Regarding adding brake oil, use the same type of oil (mineral oil series), listed in MAINTENANCE / Kinds of Grease in the Operator's Manual.

When using other oil (such as vegetable oil series), brake operation failure or the malfunction will occur.

Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place a wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1). Secure with ring pin (2).

W4FG-02-01-001

W3-5-8

45ZV-2

TRAVEL SYSTEM / Master Cylinder Procedures 1. Insert transparent vinyl tube (2) to bleeder screw (1).

Put the other one end into the clean container so that brake oil does not spray out.

W4FG-03-05-007

2. Depress the brake pedal (3) several times and hold down.

Loosen bleeder screw (1) from half turn to one turn with the pedal (3) depressed.

Drain brake oil and trapped air.

3. Tighten bleeder screw (1).

Release brake pedal (3).

4. Repeat step 2 and step 3 until clean brake oil flows in vinyl hose (2) and bubbles disappear completely.

W4FG-03-05-008

5. When bubbles completely disappear in the hose, tighten bleeder screw (1) with brake pedal (3) depressed.

6. After bleeding air, adjust the brake oil level in brake oil tank (4).

When the brake oil level is within MIN to MAX, the amount of brake oil is proper.

W4FG-03-05-009

W3-5-9

45ZV-2

TRAVEL SYSTEM / Master Cylinder (Blank)

W3-5-10

45ZV-2

TRAVEL SYSTEM / Parking Brake Solenoid REMOVAL AND INSTALLATION PARKING BRAKE SOLENOID

OF

Preparation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

4. Remove the inspection cover. (Refer to W2-1-6.)

W4FG-02-01-001

W3-6-1

45ZV-2

TRAVEL SYSTEM / Parking Brake Solenoid Removal 1. Disconnect connector of the parking brake solenoid (1) harness.

2. Disconnect hoses (2, 3 and 4) from parking brake solenoid (1).

Cap the open ends. : 17 mm (0.7 in), 19 mm (0.7 in) W4FG-03-06-001

3. Remove bolts (9) (2 used), spring washers (8) (2 used), and washers (7) (2 used).

Remove parking brake solenoid (1) and plate (6) from rear chassis (5). : 17 mm (0.7 in)

4. Remove bolts (11) (2 used) and spring washers (10) (2 used).

Remove parking brake solenoid (1) from plate (6). : 10 mm (0.4 in)

W4FG-03-06-002

W3-6-2

45ZV-2

TRAVEL SYSTEM / Parking Brake Solenoid Installation 1. Install parking brake solenoid (1) to plate (6) with bolts (11) (2 used) and spring washers (10) (2 used). : 10 mm (0.4 in) : 9.2 to 11.1 N⋅m (0.94 to 1.14 kgf⋅m, 6.79 to 8.19 lbf⋅ft)

2. Install plate (6) with parking brake solenoid (1) to rear chassis (5) with bolts (9) (2 used), spring washers (8) (2 used) and washers (7) (2 used). : 17 mm (0.7 in)

W4FG-03-06-002

3. Connect hoses (2, 3 and 4) to parking brake solenoid (1). : 17 mm (0.7 in), 19 mm (0.7 in)

4. Connect connector of the parking brake solenoid (1) harness.

5. Install the inspection cover. (Refer to W2-1-7.)

W4FG-03-06-001

W3-6-3

45ZV-2

TRAVEL SYSTEM / Parking Brake Solenoid (Blank)

W3-6-4

45ZV-2

TRAVEL SYSTEM / Steering Valve REMOVAL AND STEERING VALVE

INSTALLATION

OF

CAUTION: In order to release the hydraulic pressure in the steering hydraulic circuit, stop the engine and turn the steering wheel to the right and the left several times. The steering wheel turns heavily when the hydraulic pressure is released.

Preparation 1. Park the machine on a level and solid surface.

Operate the steering cylinder to the stroke end and lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

W4FG-02-01-001

W3-7-1

45ZV-2

TRAVEL SYSTEM / Steering Valve Removal 1. In case of the canopy machine: Remove the front cover and the mirror stay. (Refer to W2-1-10) In case of the cab machine: Remove nuts (4) (2 used), lock spring washers (3) (2 used), washers (2) (2 used), bolts (6) (4 used), spring washers (7) (4 used), and washers (8) (4 used) from cab (5).

Remove cover (1) from cab (5). : 17 mm (0.7 in)

2. Disconnect hose (12) from steering valve (9).

Cap the open ends.

W4FG-03-07-001

: 12 mm (0.5 in), 19 mm (0.7 in)

3. Disconnect hoses (10, 14) from steering valve (9).

Cap the open ends. : 22 mm (0.9 in), 27 mm (1.1 in)

4. Disconnect hoses (11, 13) from steering valve (9).

Cap the open ends. : 22 mm (0.9 in), 27 mm (1.1 in)

W4FG-03-07-002

W3-7-2

45ZV-2

TRAVEL SYSTEM / Steering Valve 5. Remove screws (19) (4 used) and washers (18) (4 used) by using a screwdriver.

Remove cover (17) from steering support (15).

6. Remove bolts (20) (4 used).

Remove steering valve (9) from steering column (16) and the ground wire. : 17 mm (0.7 in) NOTE: The ground wire is connected to position A with bolt (20).

A

W4FG-03-07-003

W3-7-3

45ZV-2

TRAVEL SYSTEM / Steering Valve Installation 1. Install steering valve (9) to steering column (16) and the ground wire with bolts (20) (4 used). : 17 mm (0.7 in) NOTE: Connect the ground wire to position A with bolt (20).

A

2. Install cover (17) to steering support (15) with bolts (19) (4 used) and washers (18) (4 used).

W4FG-03-07-003

3. Connect hoses (11, 13) to steering valve (9). : 22 mm (0.9 in), 27 mm (1.1 in)

4. Connect hoses (10, 14) to steering valve (9). : 22 mm (0.9 in), 27 mm (1.1 in)

5. Connect hose (12) to steering valve (9). : 12 mm (0.5 in), 19 mm (0.7 in)

W4FG-03-07-002

W3-7-4

45ZV-2

TRAVEL SYSTEM / Steering Valve 6. In case of the canopy machine: Install the front cover and the mirror stay. (Refer to W2-1-12) In case of the cab machine: Install cover (1) to cab (5) with nuts (4) (2 used), lock spring washers (3) (2 used), washers (2) (2 used), bolts (6) (4 used), lock spring washers (7) (4 used), and washers (8) (4 used). : 17 mm (0.7 in)

W4FG-03-07-001

W3-7-5

45ZV-2

TRAVEL SYSTEM / Steering Valve DISASSEMBLY OF STEERING VALVE

Section A-A

W4FG-03-07-004

123456-

Housing Spool/Sleeve Assembly O-Ring Ball Plate Rotor

7 - Cap 8 - Screw (7 Used) 9 - Spacer 10 - O-Ring (2 Used) 11 - O-Ring

12 - Drive 13 - Pin 14 - Bearing Race (2 Used) 15 - Thrust Needle 16 - Oil Seal

W3-7-6

17 - Flat Spring (2 Used) 18 - Center Spring (4 Used) 19 - Dust Seal 20 - Bushing 21 - Retaining Ring

45ZV-2

TRAVEL SYSTEM / Steering Valve Disassembly IMPORTANT: Attach a cloth to the open end of a vise and clamp housing (1) lightly.

Do not clamp it too strongly.

IMPORTANT: Wear a pair of protective glasses as retaining ring (21) may fly out from housing (1).

1. Secure housing (1) with the cap (7) side facing upward in a vise.

Carefully make match marks at all joints with a centering pinch.

5. Remove housing (1) from the vise. Turn over housing (1). Remove ball (4). Place housing (1) on a clean cloth in order not to damage the finished surface.

Remove retaining ring (21) from housing (1).

2. Remove screws (8) (7 used) from caps (7).

Remove cap (7) from housing (1).

Remove O-ring (10) from cap (7).

3. Remove rotor (6) from housing (1).

Remove spacer (9) and O-ring (10) from rotor (6).

NOTE: Do not drop star (6A) in rotor (6) when removing rotor (6).

4. Remove drive (12) and plate (5) from housing (1).

Remove O-ring (11) from housing (1).

W4FG-03-07-005

W4FG-03-07-006

W4FG-03-07-008

W3-7-7

45ZV-2

TRAVEL SYSTEM / Steering Valve

Port Surface

Port Surface

Section A-A

W4FG-03-07-004

123456-

Housing Spool/Sleeve Assembly O-Ring Ball Plate Rotor

7 - Cap 8 - Screw (7 Used) 9 - Spacer 10 - O-Ring (2 Used) 11 - O-Ring

12 - Drive 13 - Pin 14 - Bearing Race (2 Used) 15 - Thrust Needle 16 - Oil Seal

W3-7-8

17 - Flat Spring (2 Used) 18 - Center Spring (4 Used) 19 - Dust Seal 20 - Bushing 21 - Retaining Ring

45ZV-2

TRAVEL SYSTEM / Steering Valve 6. Rotate spool and sleeve assembly (02), and set pin (13) and the port surface of housing (1) in parallel.

Push spool and sleeve assembly (2) from the cap (7) side.

Remove bushing (20) from housing (1).

IMPORTANT: Wear a pair of protective glasses as center spring (18) and flat spring (17) may fly out.

11. Push spool (2A) in sleeve (2B) forward.

Remove center springs (18) (4 used) and flat springs (17) (2 used) from spool (2A).

7. Remove oil seal (16) and dust seal (19) from bushing (20).

NOTE: Do not damage bushing removing oil seal (16).

(20)

when

8. Remove bearing races (14) (2 used) and thrust needle (15) from spool and sleeve assembly (2).

9. Remove spool and sleeve assembly (2) from housing (1).

NOTE: Remove spool and sleeve assembly (2) from housing (1) by rotating in order not to get sleeve (2B) caught in housing (1).

10. Remove pin (13) from spool and sleeve assembly (2).

NOTE: Put matching marks onto spool (2A) and sleeve (2B) by using an oil-based pen before removing pin (7).

W4FG-03-07-009

12. Remove spool (2A) from sleeve (2B) by rotating them.

13. Remove O-ring (3) from housing (1).

W4FG-03-07-010

Matching Mark

W3-7-9

45ZV-2

TRAVEL SYSTEM / Steering Valve ASSEMBLY OF STEERING VALVE

Section A-A

W4FG-03-07-004

123456-

Housing Spool/Sleeve Assembly O-Ring Ball Plate Rotor

7 - Cap 8 - Screw (7 Used) 9 - Spacer 10 - O-Ring (2 Used) 11 - O-Ring

12 - Drive 13 - Pin 14 - Bearing Race (2 Used) 15 - Thrust Needle 16 - Oil Seal

W3-7-10

17 - Flat Spring (2 Used) 18 - Center Spring (4 Used) 19 - Dust Seal 20 - Bushing 21 - Retaining Ring

45ZV-2

TRAVEL SYSTEM / Steering Valve Assembly IMPORTANT: Before assembling, apply hydraulic oil to parts to prevent them from seizing.

IMPORTANT: Set spring grooves on spool (2A) and sleeve (2B) to the same side.

1. Install spool (2A) to sleeve (2B) by rotating.

Align the matching marks on spool (2A) and sleeve (2B).

Spring Groove

W4FG-03-07-012

W4FG-03-07-011

3. Insert pin (13) into the holes on spool (2A) and sleeve (2B).

Fit both ends of pin (13) with the outer diameter surface of sleeve (2B).

Matching Mark

4. Insert spool and sleeve assembly (2) from the cap (2) side of housing (1).

IMPORTANT: Wear a pair of protective glasses as center spring (18) and flat spring (17) may fly out.

2. Fit the spring groove positions of spool (2A) and sleeve (2B), and place them on a flat plate.

Set center springs (18) (2 used for each) back-to-back.

Set flat springs (17) (2 used) at the center position and install to the special tool (ST2497).

Install center springs (18) (4 used) and flat springs (17) (2 used) to the spring grooves on spool (2A) and sleeve (2B) by using the special tool (ST 2497).

W3-7-11

NOTE: When inserting spool and sleeve assembly (2), do not get it caught in housing (1).

Rotate pin (13) to the right and the left while holding pin (13) horizontally.

Insert pin (13) until both rear end surfaces of spool and sleeve assembly (2) and housing (1) are located at the same position.

45ZV-2

TRAVEL SYSTEM / Steering Valve 5. Install O-rings (3), bearing races (14) (2 used) and thrust needle (15) to housing (1).

6. Install oil seal (16) and dust seal (19) to bushing (20).

7. Insert bushing (20) into spool (2A) by tapping lightly by using a plastic hammer.

9. Secure housing (1) in a vise lightly.

10. Install O-ring (11) to housing (1).

Install ball (4) to housing (1) as illustrated below.

Place plate (5) onto housing (1).

NOTE: Do not drop or lose ball (4).

NOTE: Check that bushing (20) comes in contact with bearing race (14) evenly.

IMPORTANT: Wear a pair of protective glasses as retaining ring (21) may fly out from housing (1).

8. Install retaining ring (21) to housing (1).

NOTE: After installing retaining ring (21), extend the inner diameter of retaining ring (21) by using a screwdriver in order to install retaining ring (21) correctly to the groove on housing (1).

W4FG-03-07-006

Screwdriver

W4FG-03-07-007

W4FG-03-07-004

W3-7-12

45ZV-2

TRAVEL SYSTEM / Steering Valve 11. Rotate spool and sleeve assembly (2) and set pin (13) and the port surface of housing (1) in parallel.

Put line B onto the spline side end so that line B is parallel to line C on the yoke part of drive (12).

Insert drive (12).

Assemble the yoke part of drive (12) and pin (13).

Set the line B on the spline side end in drive (12) and the port surface of housing (1) in parallel.

14. Insert spacer (9) into rotor (6).

Install O-ring (10) to cap (7). Place cap (7) on rotor (6).

15. Install cap (7) to housing (1) with screws (8) (7 used). : 23 N⋅m (2.3 kgf⋅m, 15 lbf⋅ft)

Line B

Yoke Part

W4FG-03-07-013 W4FG-03-07-008

Port Surface Concave Part Bolt Hole Set pin (7) and port surface in parallel

Yoke Part

W4FG-03-07-014

12. Install O-ring (10) to rotor (6).

13. Face the O-ring (10) side of rotor (6) to the plate (5) side. Install star (6A) while fitting the splines of star (6A) and drive (6) so that line A connecting the concave parts of star (6A) is parallel to line B on drive (12).

Check that the lines A, B, C and D are in parallel as illustrated in the right.

Fit the bolt holes on rotor (6) while mating drive (12) and star (6A).

W3-7-13

Port Surface

W4FG-03-07-015

45ZV-2

TRAVEL SYSTEM / Steering Valve (Blank)

W3-7-14

45ZV-2

TRAVEL SYSTEM / Steering Cylinder REMOVAL AND INSTALLATION STEERING CYLINDER

OF

CAUTION: In order to release the hydraulic pressure in the steering hydraulic circuit, stop the engine and turn the steering wheel to the right and the left several times. The steering wheel turns heavily when the hydraulic pressure is released.

WARNING: Never work under a raised bucket.

The front attachment may be lowered, possibly causing personal injury or death. If you must work with the front attachment raised, hold the front attachment securely by using the safety supports or blocks.

Preparation 1. Park the machine on a level and solid surface.

Stop the engine and release the hydraulic pressure.

If you must work with the front attachment raised, set the bucket to the full dump position and hold the lift arm by using support (4).

Set and secure stopper (5) to the lift arm cylinder.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4FG-02-08-001

3. Install articulation lock bar (3) to the rear chassis pin (1).

Secure with link pin (2).

W4FG-02-01-001

W3-8-1

45ZV-2

TRAVEL SYSTEM / Steering Cylinder

W4FG-03-08-001

1 - Front Chassis 2 - Bolt (2 Used) 3 - Lock Washer (Spring) (2 Used) 4 - Washer (2 Used) 5 - Pin (2 Used)

6 - Shim (2 Used) 7 - Shim (2 Used) 8 - Remote Lubrication Hose

11 - Shim (2 Used) 12 - Shim (2 Used) 13 - Pin (2 Used)

16 - Bolt (2 Used) 17 - Hose 18 - Hose

9 - Steering Cylinder 10 - Remote Lubrication piping

14 - Washer (2 Used) 15 - Lock Washer (Spring) (2 Used)

19 - Hose (2 Used) 20 - Steering Cylinder

W3-8-2

45ZV-2

TRAVEL SYSTEM / Steering Cylinder Removal 22

1. Remove bolts (2) (4 used) from cover (21).

Remove cover (21) from front chassis (1).

21

: 17 mm (0.7 in) 2. Disconnect hoses (17, 18) from steering cylinder (9).

Disconnect hoses (19) (2 used) from steering cylinder (9, 20).

Cap the open ends.

1

: 19 mm (0.7 in), 22 mm (0.9 in) W4FG-03-08-015

3. Disconnect remote lubrication piping (8, 10). : 17 mm (0.7 in) 4. Remove bolts (16) (2 used), lock spring washers (15) (2 used) and washers (14) (2 used) from pins (13) (2 used).

Remove pin (13) from front chassis (1). : 17 mm (0.7 in)

CAUTION: Cutting hazard.

Shims may develop sharp surfaces. Wear gloves while working with shims.

5. Remove bolts (2) (2 used), lock spring washers (3) (2 used) and washers (4) (2 used) from pins (5) (2 used).

Remove pins (5) (2 used) from the rear chassis.

Remove shims (6, 7, 11, 12) (2 used for each). : 17 mm (0.7 in) 6. Remove steering cylinders (9, 20) from front chassis (1) and the rear chassis.

W3-8-3

45ZV-2

TRAVEL SYSTEM / Steering Cylinder

W4FG-03-08-001

1 - Front chassis 2 - Bolt (2 Used) 3 - Lock Washer (Spring) (2 Used) 4 - Washer (2 Used) 5 - Pin (2 Used)

6 - Shim (2 Used) 7 - Shim (2 Used) 8 - Remote Lubrication Hose

11 - Shim (2 Used) 12 - Shim (2 Used) 13 - Pin (2 Used)

16 - Bolt (2 Used) 17 - Hose 18 - Hose

9 - Steering Cylinder 10 - Remote Lubrication piping

14 - Washer (2 Used) 15 - Lock Washer (Spring) (2 Used)

19 - Hose (2 Used) 20 - Steering Cylinder

W3-8-4

45ZV-2

TRAVEL SYSTEM / Steering Cylinder Installation 1. Fit the pin (13) holes on steering cylinders (9, 20) and the rod side of front chassis (1).

Install shims (12) (2 used) to the upper surface at the rod side of steering cylinders (9, 20).

Install shims (11) (2 used) to the lower surface at the rod side of steering cylinders (9, 20).

2. Install pins (13) (2 used) to front chassis (1) with bolts (16) (2 used), spring washers (15) (2 used) and washers (14) (2 used). : 17 mm (0.7 in) : 77.5 to 94.1 N⋅m (7.9to 9.6 kgf⋅m, 57.2 to 69.4 lbf⋅ft)

CAUTION: Cutting hazard.

Shims may develop sharp surfaces. Wear gloves while working with shims.

3. Fit the pin (5) holes on steering cylinders (9, 20) and the bottom side of rear chassis.

Install shims (6) (2used) to the upper surface at the bottom side of steering cylinders (9, 20).

Install shims (7) (2 used) to the lower surface at the bottom side of steering cylinders (9, 20).

4. Install pins (5) (2 used) to the rear chassis with bolts (2) (2 used), lock spring washers (3) (2 used) and washers (4) (2 used). : 17 mm (0.7 in) : 77.5 to 94.1 N⋅m (7.9to 9.6 kgf⋅m, 57.2 to 69.4 lbf⋅ft) 5. Connect lubrication pipings (8, 10). : 17 mm (0.7 in) 6. Connect hoses (17, 18) to steering cylinder (9).

Connect hoses (19) (2 used) to steering cylinders (9, 20).

22

21

: 19 mm (0.7 in), 22 mm (0.9 in) 1

7. Install cover (21) to front chassis (1) with bolts (22) (4 used). : 17 mm (0.7 in)

W4FG-03-08-015

W3-8-5

45ZV-2

TRAVEL SYSTEM / Steering Cylinder DISASSEMBLY OF STEERING CYLINDER

W4FG-03-08-002

1234-

Cylinder Tube Slide Ring Seal Ring Assembly Set Screw

5678-

Steel Ball Piston Slide Ring O-Ring

9 - Backup Ring 10 - Bushing 11 - U-Ring 12 - Backup Ring

W3-8-6

13 - O-Ring 14 - Cylinder Head 15 - Wiper Ring 16 - Piston Rod

45ZV-2

TRAVEL SYSTEM / Steering Cylinder Disassembly

• The disassembling procedure starts on the premise that the hydraulic piping and the bands securing the piping have been removed.

6. Loosen cylinder head (14) by using a hook wrench.

Remove piston rod (16) from cylinder tube (1). : Cylinder head (14): 58 mm (2.3 in)

1. Secure the cylinder on a workbench horizontally.

Drain hydraulic oil from the cylinder.

W4FG-03-08-014 W4EK-03-09-004

IMPORTANT: The lock ring forms an integral part with cylinder tube (1).

Do not damage cylinder tube (1) and cylinder head (14) when bending the lock ring.

2. Pull out piston rod (16) about 50 mm (2.0 in) from cylinder tube (1). Install a protective cover to piston rod (16).

Bend the lock ring in cylinder tube (1) by using a chisel and a hammer.

Lock Ring

IMPORTANT: Loosen set screw (4) after cutting the crimped part (2 places) by using a hand drill.

Do not lose steel ball (5).

4. Secure piston rod (16) horizontally. Remove set screw (4) from piston (6).

Remove steel ball (5) from the set screw (4) mounting hole. : 5 mm (0.2 in)

W4FG-03-08-007

W3-8-7

45ZV-2

TRAVEL SYSTEM / Steering Cylinder

W4FG-03-08-002

1234-

Cylinder Tube Slide Ring Seal Ring Assembly Set Screw

5678-

Steel Ball Piston Slide Ring O-Ring

9 - Backup Ring 10 - Bushing 11 - U-Ring 12 - Backup Ring

W3-8-8

13 - O-Ring 14 - Cylinder Head 15 - Wiper Ring 16 - Piston Rod

45ZV-2

TRAVEL SYSTEM / Steering Cylinder 5. Remove piston (6) from piston rod (16).

10. Remove U-ring (5) from cylinder head (14) by using an awl.

: 27 mm (1.1 in)

Awl

6. Remove cylinder head (14) from piston rod (16).

IMPORTANT: Do not damage the seal groove.

7. Place piston (6) on a V-shaped stable stand.

Remove slide rings (2, 7) from the both sides of piston (6).

Carefully cut and remove seal ring (3-1) and O-ring (3-2) in the seal ring assembly on the center part of piston (6) by using a hammer and a screwdriver.

Hammer

W4FG-03-08-003

Screwdriver

11. Remove wiper ring (15) from cylinder head (14).

Hammer Screwdriver

W4FG-03-08-008

8. Place cylinder head (14) on the workbench, which is covered with an anti-skid waste cloth.

9. Remove O-ring (13), backup ring (9) and O-ring (8) from the outer surface of cylinder head (14).

Vise

W4FG-03-08-004

IMPORTANT: Do not remove bushing (10) unless necessary.

12. Remove bushing (10) from cylinder head (14).

W3-8-9

45ZV-2

TRAVEL SYSTEM / Steering Cylinder ASSEMBLY OF STEERING CYLINDER

W4FG-03-08-002

1234-

Cylinder Tube Slide Ring Seal Ring Assembly Set Screw

5678-

Steel Ball Piston Slide Ring O-Ring

9 - Backup Ring 10 - Bushing 11 - U-Ring 12 - Backup Ring

W3-8-10

13 - O-Ring 14 - Cylinder Head 15 - Wiper Ring 16 - Piston Rod

45ZV-2

TRAVEL SYSTEM / Steering Cylinder Assembly IMPORTANT: Before assembling, apply hydraulic oil to parts to prevent them from seizing.

4. Install O-ring (13) to the outer surface of cylinder head (14).

Install backup ring (9) and O-ring (8).

1. Install bushing (10) to cylinder head (14).

Piston Side

Piston Side

W4FG-03-08-005

IMPORTANT: When installing U-ring (11), install the lip facing to the piston side.

2. Install U-ring (11) and backup ring (12) to cylinder head (14).

IMPORTANT: When installing wiper ring (15), face the lip outside and evenly contact a screwdriver with the metal ring of wiper ring (15).

Install wiper ring (15) by tapping lightly with a hammer.

If hit hard, the metal ring may be deformed or damaged.

W4FG-03-08-006

5. Install special tool (A) to piston (6).

Install O-ring (3-2) in seal ring assembly (3) to the seal groove on the center of piston (6).

6. Place seal ring (3-1) in seal ring assembly (3) onto special tool (A).

Gradually push special tool (B) into special tool (A).

Install seal ring (3-1) to the seal groove over O-ring (3-2) on the center of piston (6).

3. Install wiper ring (15) to cylinder head (14) by using a screwdriver and a soft hammer.

W4FG-03-08-009

W3-8-11

45ZV-2

TRAVEL SYSTEM / Steering Cylinder

W4FG-03-08-002

1234-

Cylinder Tube Slide Ring Seal Ring Assembly Set Screw

5678-

Steel Ball Piston Slide Ring O-Ring

9 - Backup Ring 10 - Bushing 11 - U-Ring 12 - Backup Ring

W3-8-12

13 - O-Ring 14 - Cylinder Head 15 - Wiper Ring 16 - Piston Rod

45ZV-2

TRAVEL SYSTEM / Steering Cylinder 7. Adjust seal ring (3-1) of extended seal ring assembly (3) by using special compression tool (C).

12. Insert steel ball (5) to the set screw mounting hole on piston (6). Install set screw (4) to piston (6).

Crimp set screw (4) by using a punch (2 places). : 5 mm (0.2 in) : 6.8 N⋅m (0.7 kgf⋅m, 5.0 lbf⋅ft) 13. Apply hydraulic oil onto the packing parts.

Secure cylinder tube (1) in a vise horizontally.

Insert piston rod (16) into cylinder tube (1).

W4FG-03-08-010

IMPORTANT: When installing slide rings (2, 7), do not set the slit positions at the same place. For illustration, refer to page W3-8-12.

14. Apply hydraulic oil onto the packing parts.

Apply Molybdenum disulfide sticking prevention lubricant onto the thread part of cylinder tube (1).

Tighten cylinder head (14) to cylinder tube (1) by using a hook wrench. Bend the lock ring to secure it. : 235 N⋅m (23.9 kgf⋅m, 173 lbf⋅ft)

8. Install slide rings (2, 7) to the seal grooves on both sides of piston (6).

9. Secure piston horizontally.

rod

(16)

on

a

workbench

10. Apply a small amount of hydraulic oil onto the piston rod (16) surface.

Install cylinder head (14) to piston rod (16).

11. Apply hydraulic oil onto the thread part of the piston (6) bore part.

Install piston (6) to piston rod (16). : 27 mm (1.1 in) : 184 N⋅m (18.8 kgf⋅m, 136 lbf⋅ft)

W3-8-13

45ZV-2

TRAVEL SYSTEM / Steering Cylinder Special Tools When Assembling and Adjusting Piston Seal Ring When Assembling: Special Tool (A)

Cylinder

Special Tool (A) Bolt Diameter

Bucket

80 (3.2)

Lift Arm

85 (3.3)

Steering

45 (1.8)

Special Tool (A) Dimension (mm) (in) L1 12.3 (0.5) 12.3 (0.5) 14.7 (0.6)

L2 20 (0.8) 20 (0.8) 20 (0.8)

D

d1

80.5 (3.2) 85.5 (3.4) 45.5 (1.8)

78.3 (3.1) 83.3 (3.3) 43 (1.7)

d2

d3

60 (2.4)

40 (1.6)

65 (2.6)

45 (1.8)

20 (0.8)

5 (0.2)

No Burrs

Paper

Paper

Paper

W4FG-03-08-011

W3-8-14

45ZV-2

TRAVEL SYSTEM / Steering Cylinder When Assembling: Special Tool (B)

Cylinder

Special Tool (B) Bolt Diameter

Special Tool (B) Dimension (mm) (in) D

d1

d2

d3

80 (3.2)

85 (3.3)

81 (3.2)

77 (3.0)

73 (2.9)

Lift Arm

85 (3.3)

90 (3.5)

86 (3.4)

82 (3.2)

78 (3.1)

Steering

45 (1.8)

50 (2.0)

46 (1.8)

42 (1.7)

38 (1.5)

Slot

Bucket

W4FG-03-08-012

W3-8-15

45ZV-2

TRAVEL SYSTEM / Steering Cylinder When Adjusting: Special Tool (C)

Cylinder

Special Tool (C) Bolt Diameter

Special Tool (C) Dimension (mm) (in) D

D1

Bucket

80 (3.2)

70 (2.8)

95 (3.7)

Lift Arm

85 (3.3)

85 (3.3)

100 (3.9)

Steering

45 (1.8)

45 (1.8)

60 (2.4)

W4FG-03-08-013

W3-8-16

45ZV-2

TRAVEL SYSTEM / Priority Valve REMOVAL AND PRIORITY VALVE

INSTALLATION

OF

CAUTION: In order to release the hydraulic pressure in the steering hydraulic circuit, stop the engine and turn the steering wheel to the right and the left several times. The steering wheel turns heavily when doing this exercise to release hydraulic fluid.

Preparation 1. Park the machine on a level and solid surface.

Operate the steering cylinder to the stroke end and lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

3. Install articulate lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

W4FG-02-01-001

4. Remove the inspection cover. (Refer to W2-1-6.)

W3-9-1

45ZV-2

TRAVEL SYSTEM / Priority Valve

W4FG-03-09-001

1 - Bolt (2 Used) 2 - Lock Washer (Spring) (2 Used) 3 - Priority Valve

4 - Bracket 5 - Hose

6 - Hose 7 - Hose

W3-9-2

8 - Hose 9 - Hose

45ZV-2

TRAVEL SYSTEM / Priority Valve Removal

Installation

CAUTION: Attach identification tags onto the disconnected hoses and the pipes for assembling.

1. Disconnect hoses (6, 9) from priority valve (3).

Cap the open ends. : 27 mm (1.1 in), 36 mm (1.4 in)

1. Fit priority valve (3) to the mounting holes of bracket (4).

Install priority valve (3) with bolts (1) (2 used) and spring washers (2) (2 used). : 13 mm (0.5 in)

2. Connect hoses (7, 8) to priority valve (3). : 17 mm (0.7 in), 19 mm (0.7 in)

2. Disconnect hose (5) from priority valve (3).

Cap the open ends.

3. Connect hose (5) to priority valve (3).

: 19 mm (0.7 in), 27 mm (1.1 in)

: 19 mm (0.7 in), 27 mm (1.1 in) 3. Disconnect hoses (7, 8) from priority valve (3).

Cap the open ends. : 17 mm (0.7 in), 19 mm (0.7 in)

4. Connect hoses (6, 9) to priority valve (3). : 27 mm (1.1 in), 36 mm (1.4 in)

4. Remove bolts (1) (2 used) and spring washers (2) (2 used).

Remove priority valve (3) from bracket (4). : 13 mm (0.5 in)

W3-9-3

45ZV-2

TRAVEL SYSTEM / Priority Valve (Blank)

W3-9-4

45ZV-2

SECTION 4

ATTACHMENT ⎯ CONTENTS ⎯ Group 1 Front Attachment Removal and Installation of Front Attachment...................................... W4-1-1

Group 2 Cylinder Removal and Installation of Cylinder ....... W4-2-1 Disassembly of Lift Arm Cylinder ............. W4-2-6 Assembly of Lift Arm Cylinder ................ W4-2-10 Disassembly of Bucket Cylinder ............ W4-2-14 Assembly of Bucket Cylinder ................. W4-2-18 Maintenance Standard........................... W4-2-22

4FGEW-4-1

45ZV-2

(Blank)

4FGEW-4-2

45ZV-2

ATTACHMENT / Front Attachment REMOVAL AND INSTALLATION OF FRONT ATTACHMENT WARING: Never work under a raised bucket.

The front attachment may lower, possibly causing personal injury or death. If you must work with the front attachment raised, hold the front attachment securely by using the safety supports or blocks.

Preparation 1. Park the machine on a level and solid surface.

Lower the bucket level to the ground.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

W4EK-03-04-001

3. Install articulation lock bar (3) to rear chassis pin (1).

Secure with link pin (2).

W4FG-02-01-001

4. Disconnect connector (4) of the bucket auto leveler proximity switch.

W4FG-04-01-001

W4-1-1

45ZV-2

ATTACHMENT / Front Attachment

W4FG-04-01-002

1234-

Bucket Bucket Link Shim (4 Used) Pin

10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

5678-

Washer Spring Washer Bolt Lever

14 - Shim (2 Used) 15 - Bucket Cylinder 16 - Bolt 17 - Lock Washer (Spring)

9 - Shim (4 Used)

18 - Washer

19 - Pin 20 - Lift Arm 21 - Bolt (2 Used) 22 - Lock Washer (Spring) (2 Used) 23 - Washer (2 Used) 24 - Pin (2 Used) 25 - Front chassis 26 - Bolt (2 Used) 27 - Lock Washer (Spring) (2 Used)

W4-1-2

28 - Washer (2 Used) 29 - Pin (2 Used) 30 - Shim (4 Used) 31 - Lift Arm Cylinder (2 Used) 32 - Shim (4 Used) 33 - Pin (2 Used) 34 - Washer (2 Used) 35 - Lock Washer (Spring) (2 Used) 36 - Bolt (2 Used)

45ZV-2

ATTACHMENT / Front Attachment Removal 1. Operate the front control lever.

Release the remaining pressure in bucket cylinder (15) and lift arm cylinder (31).

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

2. Remove bolt (7), lock spring washer (6) and washer (5) from bucket (1).

Remove pin (4) from bucket (1).

Remove shims (3) (4 used) from bucket link (2). : 19 mm (0.7 in) 3. Remove bolts (36) (2 used) lock spring washers (35) (2 used) and washers (34) (2 used) from bucket (1).

Remove pins (33) (2 used) from bucket (1).

Remove shims (32) (4 used) from lift arm (20).

W4FG-04-01-003

: 19 mm (0.7 in) CAUTION: Bucket (1) weight: Approx. 310 kg (683 lb) 4. Attach a lifting cable to the holes on the bucket (1) side plates.

Lift bucket (1).

5. Remove bucket (1) from lift arm (20).

W4EK-04-01-005

W4-1-3

45ZV-2

ATTACHMENT / Front Attachment

W4FG-04-01-002

1234-

Bucket Bucket Link Shim (4 Used) Pin

10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

5678-

Washer Spring Washer Bolt Lever

14 - Shim (2 Used) 15 - Bucket Cylinder 16 - Bolt 17 - Lock Washer (Spring)

9-

Shim (4 Used)

18 - Washer

19 - Pin 20 - Lift Arm 21 - Bolt (2 Used) 22 - Lock Washer (Spring) (2 Used) 23 - Washer (2 Used) 24 - Pin (2 Used) 25 - Front chassis 26 - Bolt (2 Used) 27 - Lock Washer (Spring) (2 Used)

W4-1-4

28 - Washer (2 Used) 29 - Pin (2 Used) 30 - Shim (4 Used) 31 - Lift Arm Cylinder (2 Used) 32 - Shim (4 Used) 33 - Pin (2 Used) 34 - Washer (2 Used) 35 - Lock Washer (Spring) (2 Used) 36 - Bolt (2 Used)

45ZV-2

ATTACHMENT / Front Attachment 6. Attach a nylon sling onto bucket cylinder (15).

Hold bucket cylinder (15).

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

7. Remove bolt (13), lock spring washer (12) and washer (11) from lever (8).

Remove pin (10) from lever (8).

Remove shims (9) (2 used) from bucket cylinder (15). : 19 mm (0.7 in) 8. Start the engine.

Retract the piston rod of bucket cylinder (15).

Stop the engine.

Tilt bucket cylinder (15) to the operator's seat side.

CAUTION: Lever (8) weight: 73 kg (161 lb) W4FG-04-01-004

Bucket link (2) weight: 19 kg (42 lb) 9. Install pin (10) to the pin hole on lever (8) with bolt (13), lock spring washer (12), and washer (11).

Attach a nylon sling onto pin (10). Hold lever (8).

10. Remove bolt (16), lock spring washer (17) and washer (18) from lift arm (20).

Remove pin (19) from lever (8).

Remove shims (14) (2 used) from lever (8).

Pin (10) Hole

: 19 mm (0.7 in) 11. Remove lever (8) and bucket link (2) from lift arm (20).

W4FG-04-01-005

W4-1-5

45ZV-2

ATTACHMENT / Front Attachment

W4FG-04-01-002

1234-

Bucket Bucket Link Shim (4 Used) Pin

10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

5678-

Washer Spring Washer Bolt Lever

14 - Shim (2 Used) 15 - Bucket Cylinder 16 - Bolt 17 - Lock Washer (Spring)

9-

Shim (4 Used)

18 - Washer

19 - Pin 20 - Lift Arm 21 - Bolt (2 Used) 22 - Lock Washer (Spring) (2 Used) 23 - Washer (2 Used) 24 - Pin (2 Used) 25 - Front chassis 26 - Bolt (2 Used) 27 - Lock Washer (Spring) (2 Used)

W4-1-6

28 - Washer (2 Used) 29 - Pin (2 Used) 30 - Shim (4 Used) 31 - Lift Arm Cylinder (2 Used) 32 - Shim (4 Used) 33 - Pin (2 Used) 34 - Washer (2 Used) 35 - Lock Washer (Spring) (2 Used) 36 - Bolt (2 Used)

45ZV-2

ATTACHMENT / Front Attachment CAUTION: Lift arm (20) weight: 300 kg (661 lb) 12. Install pin (19) to the pin hole on lift arm (20) with bolt (16), lock spring washer (17), and washer (18).

Attach a nylon sling onto pin (19).

Hold lift arm (20).

13. Start the engine.

Raise lift arm (20) until lift arm cylinder (31) is located at horizontal position.

14. Place a stand under lift arm cylinders (31) (2 used).

Stop the engine.

15. Operate the front control lever.

Release the remaining pressure in lift arm cylinder (31).

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

Stand

W4FG-04-01-006

16. Remove bolts (26) (2 used), lock spring washers (27) (2 used) and washers (28) (2 used) from lift arm cylinders (31) (2 used).

Remove pins (29) (2 used) from lift arm (20).

Remove shims (30) (2 used) from lift arm (20). : 19 mm (0.7 in) 17. Start the engine.

Retract the piston rod of lift arm cylinder (31).

Stop the engine.

18. Remove bolts (21) (2 used), lock spring washers (22) (2 used) and washers (32) (2 used) from front chassis (25).

Remove pins (24) (2 used) from lift arm (21).

Remove shims (30) (2 used) from lift arm (20). : 19 mm (0.7 in) 19. Attach a nylon sling onto lift arm (20).

Hold lift arm (21).

Remove lift arm (21) from front chassis (25).

W4-1-7

45ZV-2

ATTACHMENT / Front Attachment

W4FG-04-01-002

1234-

Bucket Bucket Link Shim (4 Used) Pin

10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

5678-

Washer Spring Washer Bolt Lever

14 - Shim (2 Used) 15 - Bucket Cylinder 16 - Bolt 17 - Lock Washer (Spring)

9-

Shim (4 Used)

18 - Washer

19 - Pin 20 - Lift Arm 21 - Bolt (2 Used) 22 - Lock Washer (Spring) (2 Used) 23 - Washer (2 Used) 24 - Pin (2 Used) 25 - Front chassis 26 - Bolt (2 Used) 27 - Lock Washer (Spring) (2 Used)

W4-1-8

28 - Washer (2 Used) 29 - Pin (2 Used) 30 - Shim (4 Used) 31 - Lift Arm Cylinder (2 Used) 32 - Shim (4 Used) 33 - Pin (2 Used) 34 - Washer (2 Used) 35 - Lock Washer (Spring) (2 Used) 36 - Bolt (2 Used)

45ZV-2

ATTACHMENT / Front Attachment Installation IMPORTANT: Check for the outer and inner diameters, wear and damage of all pins and bushings before installation. If any damage is found, replace the parts.

Taper 15°

IMPORTANT: When installing the pin, apply grease onto the inside of the bushing and the dust seal. Apply rust-inhibiting oil to the inside of the boss.

IMPORTANT: Install the bushing as illustrated to the right.

W4EK-04-01-010

CAUTION: Lift arm (21) weight: 300 kg (661 lb) 1. Hoist and fit pin (19) in lift arm (20) with the pin hole on front chassis (25).

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

2. Install pins (24) (2 used) to front chassis (25) with spring washers (22) (2 used), washers (23) (2 used) and bolts (21) (2 used). : 19 mm (0.7 in) 3. Start the engine.

Extend the piston rod of lift arm cylinder (31).

Stop the engine.

4. Hoist lift arm (21).

Fit the pin (29) holes on lift arm (20) and lift arm cylinder (31).

5. Install shims (30) (4 used) to the pin (29) holes (2 places) on lift arm (20).

Install pins (29) (2 used) to lift arm cylinder (31) (2 used) with washers (28) (2 used), lock spring washers (27) (2 used) and bolts (26) (2 used).

Stand

W4FG-04-01-006

: 19 mm (0.7 in)

W4-1-9

45ZV-2

ATTACHMENT / Front Attachment

W4FG-04-01-002

1234-

Bucket Bucket Link Shim (4 Used) Pin

10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

5678-

Washer Spring Washer Bolt Lever

14 - Shim (2 Used) 15 - Bucket Cylinder 16 - Bolt 17 - Lock Washer (Spring)

9-

Shim (4 Used)

18 - Washer

19 - Pin 20 - Lift Arm 21 - Bolt (2 Used) 22 - Lock Washer (Spring) (2 Used) 23 - Washer (2 Used) 24 - Pin (2 Used) 25 - Front chassis 26 - Bolt (2 Used) 27 - Lock Washer (Spring) (2 Used)

W4-1-10

28 - Washer (2 Used) 29 - Pin (2 Used) 30 - Shim (4 Used) 31 - Lift Arm Cylinder (2 Used) 32 - Shim (4 Used) 33 - Pin (2 Used) 34 - Washer (2 Used) 35 - Lock Washer (Spring) (2 Used) 36 - Bolt (2 Used)

45ZV-2

ATTACHMENT / Front Attachment CAUTION: Lever (8) weight: 73 kg (161 lb) Bucket link (2) weight: 19 kg (42 lb)

Pin (10) Hole

5. Hoist lever (8).

Fit pin (19) to hole on lever (8) and lift arm (20).

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

6. Install shims (14) (2 used) to pin (19) hole on lever (8).

Install pin (19) to lift arm (20) with washer (18), lock spring washer (17) and bolt (16). : 19 mm (0.7 in) 7. Start the engine.

Extend the piston rod of bucket cylinder (15).

Stop the engine.

W4FG-04-01-007

8. Operate the front control lever.

Release the remaining pressure in bucket cylinder (15).

9. Hoist bucket cylinder (15).

Fit pin (10) to hole on bucket cylinder (15) and lever (8).

10. Install shims (9) (2 used) to pin (10) hole on bucket cylinder (15).

Install pin (10) to lever (8) with washer (11), lock spring washer (12) and bolt (13). : 19 mm (0.7 in)

W4FG-04-01-004

W4-1-11

45ZV-2

ATTACHMENT / Front Attachment

W4FG-04-01-002

1234-

Bucket Bucket Link Shim (4 Used) Pin

10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

5678-

Washer Spring Washer Bolt Lever

14 - Shim (2 Used) 15 - Bucket Cylinder 16 - Bolt 17 - Lock Washer (Spring)

9-

Shim (4 Used)

18 - Washer

19 - Pin 20 - Lift Arm 21 - Bolt (2 Used) 22 - Lock Washer (Spring) (2 Used) 23 - Washer (2 Used) 24 - Pin (2 Used) 25 - Front chassis 26 - Bolt (2 Used) 27 - Lock Washer (Spring) (2 Used)

W4-1-12

28 - Washer (2 Used) 29 - Pin (2 Used) 30 - Shim (4 Used) 31 - Lift Arm Cylinder (2 Used) 32 - Shim (4 Used) 33 - Pin (2 Used) 34 - Washer (2 Used) 35 - Lock Washer (Spring) (2 Used) 36 - Bolt (2 Used)

45ZV-2

ATTACHMENT / Front Attachment CAUTION: Bucket (1) weight: Approx. 310 kg (680 lb) 9. Hoist bucket (1).

Fit pins (33) to holes on bucket (1) and lift arm (20).

W4EK-04-01-005

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

10. Install shims (32) (4 used) to the pin (33) holes (2 used) on lift arm (20).

Install pins (33) (2 used) to bucket (1) with washers (34) (2 used), lock spring washers (35) (2 used) and bolts (36) (2 used). : 19 mm (0.7 in) 11. Install shims (3) (4 used) to pin (4) hole on bucket link (2).

Install pin (4) to bucket (1) with washer (5), lock spring washer (6) and bolt (7). : 19 mm (0.7 in) 12. Add grease through the grease fittings.

W4FG-04-01-003

W4-1-13

45ZV-2

ATTACHMENT / Front Attachment (Blank)

W4-1-14

45ZV-2

ATTACHMENT / Cylinder REMOVAL CYLINDER

AND

INSTALLATION

OF

Preparation 1. Park the machine on a solid and level surface.

Stop the engine.

Place the bucket on a stand of about 500 to 800 mm (20 to 32 in) (A) height.

2. Place wheel chocks in front of and behind the wheels in order to secure the machine.

3. Operate the front control lever.

Release the remaining pressure in bucket cylinder and lift arm cylinders.

W4-2-1

W4FG-04-02-001

45ZV-2

ATTACHMENT / Cylinder

W4FG-04-02-002

1 - Lift Arm 2 - Front Chassis 3 - Shim (4 Used) 4 - Pin (2 Used)

5 - Washer (2 Used) 6 - Lock Washer (Spring) (2 Used) 7 - Bolt (2 Used) 8 - Lift Arm Cylinder (2 Used)

9 - Shim (4 Used) 10 - Pin (2 Used)

13 - Bolt (2 Used) 14 - Hose (2 Used)

11 - Washer (2 Used) 12 - Lock Washer (Spring) (2 Used)

15 - Hose (2 Used)

W4-2-2

45ZV-2

ATTACHMENT / Cylinder Removal of Lift Arm Cylinder

Installation of Lift Arm Cylinder

CAUTION: Lift cylinder (8) weight: 37 kg (82 lb)

CAUTION: Lift cylinder (8) weight: 37 kg (82 lb)

1. Attach a nylon sling onto lift arm cylinder (8). Hold lift arm cylinder (8).

1. Attach a nylon sling onto lift arm cylinder (8). Hold lift arm cylinder (8).

2. Disconnect hoses (14, 15) from lift arm cylinder (8). Cap the open ends.

2. Fit the pin (4) hole on the bottom side of lift cylinder (8) and on the front chassis.

: 27 mm (1.1 in)

3. Install pin (4) to front chassis (2) with washer (5), lock spring washer (6) and bolt (7).

3. Remove bolt (13), lock spring washer (12) and washer (11) from pin (10). : 19 mm (0.7 in)

: 19 mm (0.7 in) 4. Connect hoses (14, 15) to lift arm cylinder (8).

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

: 27 mm (1.1 in)

4. Remove pin (10) from lift arm cylinder (8).

5. Start the engine.

Extend the piston rod of lift arm cylinder (8).

Fit the pin (10) hole on lift arm cylinder (8) and the lift arm.

Install shims (9) (2 used) to the rod side of lift arm cylinder (8).

5. Remove bolt (7), lock spring washer (6) and washer (5) from pin (4).

6. Install pin (10) to lift arm cylinder (8) with washer (11), lock spring washer (12) and bolt (13).

: 19 mm (0.7 in)

: 19 mm (0.7 in)

6. Remove pin (12) from front chassis (2).

7. Install another cylinder in the same way.

7. Remove lift arm cylinder (8) and shims (9) (2 used) on the lift arm cylinder rod side from lift arm (1) and front chassis (2).

8. Remove another cylinder in the same way.

W4-2-3

CAUTION: Bleed air from the cylinder after completing the work. (Refer to BLEED AIR FROM HYDRAULIC CIRCUIT on W1-1-3.)

45ZV-2

ATTACHMENT / Cylinder

W4FG-04-02-003

1234-

Bucket Cylinder Hose Hose Lever

5678-

Shim (2 Used) Pin Bolt Lock Washer (Spring)

9 - Washer 10 - Bolt 11 - Lock Washer (Spring) 12 - Washer

W4-2-4

13 - Pin 14 - Front Chassis 15 - Shim (2 Used) 16 - Lift Arm

45ZV-2

ATTACHMENT / Cylinder Removal of Bucket Cylinder

Installation of Bucket Cylinder

CAUTION: Bucket cylinder (1) weight: 30 kg (66 lb)

CAUTION: Bucket cylinder (1) weight: 30 kg (66 lb)

1. Attach a nylon sling onto bucket cylinder (1).

Hold bucket cylinder (1).

1. Attach a nylon sling onto bucket cylinder (1).

Hold bucket cylinder (1).

2. Disconnect hoses (2, 3) from bucket cylinder (1).

Cap the open ends.

2. Fit the pin (13) holes on bucket cylinder (1) bottom side and the front chassis (14).

: 19 mm (0.7 in), 22 mm (0.9 in) 3. Remove bolt (7), lock spring washer (8) and washer (9) from pin (6). : 19 mm (0.7 in) CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

3. Install pin (13) to front chassis (14) with washer (12), lock spring washer (11) and bolt (10). : 19 mm (0.7 in) 4. Connect hoses (2, 3) to bucket cylinder (9). : 19 mm (0.7 in), 22 mm (0.9 in)

4. Remove pin (6) from lever (4).

5. Remove bolt (10), spring washer (11) and washer (12) from pin (13). : 19 mm (0.7 in) 6. Remove pin (13) from front chassis (14).

7. Remove bucket cylinder (1) shims (5) (2 used) on the bucket cylinder rod side, and shims (2 used) on bucket cylinder bottom side from bell crank (4) and front chassis (14).

5. Start the engine.

Extend the piston rod of bucket cylinder (1).

Fit the pin (6) holes on bucket cylinder (1) and lever (4).

Install shims (5) (2 used) to bucket cylinder (1) rod side.

6. Install pin (6) to lever (4) with washer (9), lock spring washer (8) and bolt (7). : 19 mm (0.7 in) CAUTION: Bleed air from the cylinder after completing the work. (Refer to BLEED AIR FROM HYDRAULIC CIRCUIT on W1-1-3.)

W4-2-5

45ZV-2

ATTACHMENT / Cylinder DISASSEMBLY OF LIFT ARM CYLINDER

W4FG-04-02-004

1234-

Cylinder Tube Slide Ring Seal Ring Assembly Set Screw

5678-

Steel Ball Piston Slide Ring O-ring

9 - Backup Ring 10 - U-Ring 11 - Bushing 12 - O-Ring

W4-2-6

13 - Cylinder Head 14 - Wiper Ring 15 - Piston Rod

45ZV-2

ATTACHMENT / Cylinder Disassembly of Lift Arm Cylinder

• The disassembling procedure starts on the premise that the hydraulic piping and the bands securing the piping have been removed.

3. Loosen cylinder head (13) by using a hook wrench.

Remove the piston rod (15) from cylinder tube (1).

Cylinder head (13) diameter: 105 mm (4.1 in)

CAUTION: Lift Arm cylinder weight: 37 kg (82 lb) 1. Secure the cylinder on a workbench horizontally.

Drain hydraulic oil from the cylinder.

W4FG-04-02-012

W4EK-03-09-004

IMPORTANT: The lock ring forms an integral part with cylinder tube (1). Do not damage cylinder tube (1) and cylinder head (13) when bending the lock ring.

2. Pull out piston rod (15) about 50 mm (2.0 in) from cylinder tube (1).

Install a protective cover to piston rod (15).

Bend the lock ring in cylinder tube (1) by using a chisel and a hammer.

Lock Washer

IMPORTANT: Loosen set screw (4) after cutting the crimped part (2 places) by using a hand drill.

Do not lose steel ball (5).

4. Secure piston rod (15) horizontally.

Remove set screw (4) from piston (6).

Remove steel ball (5) from the set screw (4) mounting hole. : 6 mm (0.2 in)

W4FG-04-02-009

W4-2-7

45ZV-2

ATTACHMENT / Cylinder 5. Remove piston (6) from piston rod (15).

10. Remove U-Ring (10) from cylinder head (13) by using an awl.

: 60 mm (2.3 in) Awl

6. Remove cylinder head (13) from piston rod (15).

IMPORTANT: Do not damage the seal groove.

7. Place piston (6) on a V-shaped stable stand.

Remove slide rings (2, 7) from the both sides of piston (6).

Carefully cut and remove seal ring (3-1) and O-Ring (3-2) in the seal ring assembly on the center part of piston (6) by using a hammer and a screwdriver.

W4FG-04-02-010

Hammer

11. Remove wiper ring (14) from cylinder head (13).

Screwdriver

Hammer

Screwdriver

Vise W4FG-03-08-008

8. Place cylinder head (13) on the workbench which is covered with an anti-skid waste cloth.

9. Remove O-ring (12), backup ring (9) and O-ring (8) from the outer surface of cylinder head (13).

W4FG-04-02-011

IMPORTANT: Do not remove bushing (11) unless necessary.

12. Remove bushing (11) from cylinder head (13).

W4-2-8

45ZV-2

ATTACHMENT / Cylinder (Blank)

W4-2-9

45ZV-2

ATTACHMENT / Cylinder ASSEMBLY OF LIFT ARM CYLINDER

W4FG-04-02-004

1234-

Cylinder Tube Slide Ring Seal Ring Assembly Set Screw

5678-

Steel Ball Piston Slide Ring O-Ring

9 - Backup Ring 10 - U-Ring 11 - Bushing 12 - O-Ring

W4-2-10

13 - Cylinder Head 14 - Wiper Ring 15 - Piston Rod

45ZV-2

ATTACHMENT / Cylinder Assembly of Lift Arm Cylinder IMPORTANT: Install bushing (11) so as not to make a gap between the bushing (11) end and U-ring (10) mounting surface (D) of cylinder head (13).

4. Install O-ring (12) to the outer surface of cylinder head (13).

Install backup ring (9) and O-ring (8).

1. Install bushing (11) to cylinder head (13).

Piston Side

D

Piston Side

W4FG-04-02-013

IMPORTANT: When installing U-ring (10), install the lip facing to the piston side.

2. Install U-ring (10) to cylinder head (13).

IMPORTANT: When installing wiper ring (14), face the lip outside and evenly contact a screwdriver with the metal ring of wiper ring (14).

Install wiper ring (14) by tapping lightly with a hammer.

If hit hard, the metal ring may be deformed or damaged.

W4FG-04-02-014

5. Install special tool (A) to piston (6).

Install O-ring (3-2) in seal ring assembly (3) to the seal groove on the center of piston (6).

6. Place seal ring (3-1) of seal ring assembly (3 onto special tool (A).

Gradually push special tool (B) into special tool (A).

Install seal ring (3-1) to the seal groove at 3-2 on the center of piston (6).

3. Install wiper ring (14) to cylinder head (13) by using a screwdriver and a soft hammer.

W4FG-03-08-009

W4-2-11

45ZV-2

ATTACHMENT / Cylinder 7. Adjust seal ring (3-1) of extended seal ring assembly (3) by using special tool (C).

W4FG-03-08-010

IMPORTANT: When installing slide rings (2, 7), do not fit the slit positions at the same place.

8. Install slide rings (2, 7) to the seal grooves on both sides of piston (6).

9. Secure piston horizontally.

rod

(15)

on

a

workbench

10. Apply a small amount of hydraulic oil onto the piston rod (15) surface.

Install cylinder head (13) to piston rod (15).

11. Apply hydraulic oil onto the thread part of the piston (6) bore part.

Install piston (6) to piston rod (2). : 60 mm (2.3 in) : 1291 N⋅m (132 kgf⋅m, 950 lbf⋅ft) 12. Insert steel ball (5) to the set screw mounting hole on piston (6).

Install set screw (4) to piston (6).

Crimp set screw (4) by using a punch (2 places). : 6 mm (0.2 in) : 16.2 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft) 13. Apply hydraulic oil onto the packing parts.

Secure cylinder tube (1) in a vise horizontally.

Insert piston rod (15) into cylinder tube (1).

14. Apply hydraulic oil onto the packing parts.

Apply Molybdenum disulfide sticking prevention lubricant to the thread part of cylinder tube (1).

Tighten cylinder head (13) to cylinder tube (1) by using a hook wrench.

Bend the lock ring to secure it. : 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)

W4-2-12

45ZV-2

ATTACHMENT / Cylinder (Blank)

W4-2-13

45ZV-2

ATTACHMENT / Cylinder DISASSEMBLY OF BUCKET CYLINDER

W4FG-04-02-005

1234-

Cylinder Tube Slide Ring Seal Ring Assembly Set Screw

5678-

Steel Ball Piston Slide Ring O-Ring

9 - Backup Ring 10 - U-Ring 11 - Bushing 12 - O-Ring

W4-2-14

13 - Cylinder Head 14 - Wiper Ring 15 - Piston Rod

45ZV-2

ATTACHMENT / Cylinder Disassembly of Bucket Cylinder

• The disassembling procedure starts on the premise that the hydraulic piping and the bands securing the piping have been removed.

CAUTION: Bucket cylinder weight: 30 kg (66 lb) 1. Secure the cylinder on a workbench horizontally.

Drain hydraulic oil from the cylinder.

Lock Washer W4FG-04-02-006

3. Loosen cylinder head (13) by using a hook wrench.

Remove the piston rod (15) from cylinder tube (1).

Cylinder head (13) diameter: 97 mm (3.8 in)

W4EK-03-09-004

IMPORTANT: The lock ring forms an integral part with cylinder tube (1). Do not damage cylinder tube (1) and cylinder head (13) when bending the lock ring.

2. Pull out piston rod (15) about 50 mm (2.0 in) from cylinder tube (1).

Install a protective cover to piston rod (15).

Bend the lock ring in cylinder tube (1) by using a chisel and a hammer.

W4FG-04-02-007

IMPORTANT: Loosen set screw (4) after cutting the crimped part (2 places) by using a hand drill. Do not lose steel ball (5).

4. Secure piston rod (15) horizontally.

Remove set screw (4) from piston (6).

Remove steel ball (5) from the set screw (4) mounting hole. : 6 mm (0.2 in)

W4-2-15

45ZV-2

ATTACHMENT / Cylinder 5. Remove piston (6) from piston rod (15).

10. Remove U-ring (10) from cylinder head (13) by using an awl.

: 55 mm (2.2 in) Awl

6. Remove cylinder head (13) from piston rod (15).

IMPORTANT: Do not damage the seal groove.

7. Place piston (6) on a V-shaped stable stand.

Remove slide rings (2, 7) from the both sides of piston (6).

Carefully cut and remove seal ring (3-1) and O-ring (3-2) in the seal ring assembly on the center part of piston (6) by using a hammer and a screwdriver.

W4FG-04-02-010

Hammer

11. Remove wiper ring (14) from cylinder head (13).

Screwdriver

Hammer

Screwdriver

Vise W4FG-03-08-008

8. Place cylinder head (13) on the workbench which is covered with an anti-skid waste cloth.

9. Remove O-ring (12), backup ring (9) and O-ring (8) from the outer surface of cylinder head (13).

W4FG-04-02-011

IMPORTANT: Do not remove bushing (11) unless necessary.

12. Remove bushing (11) from cylinder head (13).

W4-2-16

45ZV-2

ATTACHMENT / Cylinder (Blank)

W4-2-17

45ZV-2

ATTACHMENT / Cylinder ASSEMBLY OF BUCKET CYLINDER

W4FG-04-02-005

1.

2.

3.

4.

Cylinder Tube Slide Ring Seal Ring Assembly Set Screw

5.

6.

7.

8.

Steel Ball Piston Slide Ring O-Ring

9 - Backup Ring 10 - U-Ring 11 - Bushing 12 - O-Ring

W4-2-18

13 - Cylinder Head 14 - Wiper Ring 15 - Piston Rod

45ZV-2

ATTACHMENT / Cylinder Assembly of Bucket Cylinder IMPORTANT: Install bushing (11) not to make a step between the bushing (11) end and U-ring (10) mounting surface (D) of cylinder head (13).

4. Install O-ring (12) to the outer surface of cylinder head (13).

Install backup ring (9) and O-ring (8).

1. Install bushing (11) to cylinder head (13).

Piston Side

D

Piston Side

W4FG-04-02-013

IMPORTANT: When installing U-ring (10), install the lip facing to the piston side.

2. Install U-ring (10) to cylinder head (13).

IMPORTANT: When installing wiper ring (14), face the lip outside and evenly contact a screwdriver with the metal ring of wiper ring (14).

Install wiper ring (14) by tapping lightly with a hammer.

If hit hard, the metal ring may be deformed or damaged.

W4FG-04-02-014

5. Install special tool (A) to piston (6).

Install O-ring (3-2) of seal ring assembly (3) to the seal groove on the center of piston (6).

6. Place seal ring (3-1) of seal ring assembly (3) onto special tool (A).

Gradually push special tool (B) into special tool (A).

Install seal ring (3-1) to the seal groove at 3-2 on the center of piston (6).

3. Install wiper ring (14) to cylinder head (13) by using a screwdriver and a soft hammer.

W4FG-03-08-009

W4-2-19

45ZV-2

ATTACHMENT / Cylinder 7. Adjust seal ring (3-1) of extended seal ring assembly (3) by using special tool (C).

W4FG-03-08-010

IMPORTANT: When installing slide rings (2, 7), do not fit the slit positions at the same place.

8. Install slide rings (2, 7) to the seal grooves on both sides of piston (6).

9. Secure piston horizontally.

rod

(15)

on

a

workbench

10. Apply a small amount of hydraulic oil onto the piston rod (15) surface. Install cylinder head (13) to piston rod (15).

11. Apply hydraulic oil onto the thread part of the piston (6) bore part.

Install piston (6) to piston rod (2). : 55 mm (2.2 in) : 1110 N⋅m (113 kgf⋅m, 820 lbf⋅ft) 12. Insert steel ball (5) to the set screw mounting hole on piston (6).

Install set screw (4) to piston (6).

Crimp set screw (4) by using a punch (2 places). : 6 mm (0.7 in) : 16.2 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft) 13. Apply hydraulic oil onto the packing parts.

Secure cylinder tube (1) in a vise horizontally.

Insert piston rod (15) into cylinder tube (1).

14. Apply hydraulic oil onto the packing parts.

Apply Molybdenum disulfide sticking prevention lubricant to the thread part of cylinder tube (1).

Tighten cylinder head (13) to cylinder tube (1) by using a hook wrench.

Bend the lock ring to secure it. : 450 N⋅m (46 kgf⋅m, 330 lbf⋅ft)

W4-2-20

45ZV-2

ATTACHMENT / Cylinder (Blank)

W4-2-21

45ZV-2

ATTACHMENT / Cylinder MAINTENANCE STANDARD Rod Bend and Straightness Dial Gauge Cylinder Rod

V-Shaped Block

(200 to 500 mm) (9.9 to 19.7 in)

Bend

Straightness

Remedy

0.5 (0.02)

1.0 (0.04)

Replacement

W4EK-04-02-009

Unit: mm (in)

W4-2-22

45ZV-2