DOWNLOAD PDF :Kawasaki Wheel Loader 90ZIV-2 CUMMINS M11-C Engine Shop Manual AAA-S90C3V14-012

AAA-S90C3V14-012 (93213-00091)

WHEEL LOADER SHOP MANUAL

90 Z

Powered by CUMMINS M11-C Engine.

SERIAL NUMBERS 90C3-5501 and up.

Disassembly & Reassembly Service Standard

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

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

Disassembly & Reassembly Service Standard Note: ① For Genaral Information and Functions and Structure, refer to the 90ZⅣ -2 Shop Manual AAA-S90C3V00-012 (93213-00071) ② For Troubleshooting and Measurement for Performance Check, refer to the 90ZⅣ -2 Shop Manual AAA-S90C3V01-012 (93213-00081). ③ For the engine, refer to the engine Shop Manual provided by the engine manufacturer.

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

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

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

（1）

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

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

（2）

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

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

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

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

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

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

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

（3）

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

Symbol

Item Reference

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

Shows the weight of a part or unit. The weight

Weight

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

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

Coating

l

Oil or water supply

Drainage

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

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

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

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

The message shows the preventive measures.

（4）

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

Bolt size Type

Nominal dimension

Nominal dia.

Pitch

M8

8

(C) 1.25

9

26

38

(C) 1.5

19

53

76

(F) 1.25

20

55

80

(C) 1.75

32

90

132

(F) 1.25

34

96

142

(C) 2.0

51

142

206

(F) 1.5

54

152

221

(C) 2.0

76

216

314

(F) 1.5

80

226

330

(C) 2.5

103

299

436

(F) 1.5

113

324

476

(C) 2.5

147

417

608

(F) 1.5

162

451

662

(C) 2.5

196

559

814

(F) 1.5

211

598

878

(C) 3.0

255

721

1,030

(F) 2.0

270

770

1,128

(C) 3.0

373

1,030

1,520

(F) 2.0

397

1,128

1,618

(C) 3.5

510

1,422

2,109

(F) 2.0

549

1,569

2,256

(C) 3.5

686

1,912

2,844

M10 M12 M14 M16

Metric thread

Unified thread

(N-m)

Bolt strength

10 12 14 16

4.6 (4T)

8.8 (8T)

10.9T (11T)

M18

18

M20

20

M22

22

M24

24

M27

27

M30

30

M33

33

(F) 2.0

736

2,059

3,040

5/16

05

18 UNC

9

25

35

3/8

06

16 UNC

16

44

65

7/16

07

14 UNC

25

71

103

1/2

08

13 UNC

36

103

147

9/16

09

12 UNC

52

147

216

5/8

10

11 UNC

72

201

294

3/4

12

10 UNC

127

358

525

7/8

14

9 UNC

196

554

809

1

16

16 UNC

309

868

1,275

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

（5）

(kgf-m) Bolt size Type

Nominal dia.

Pitch

4.6 (4T)

8.8 (8T)

10.9T (11T)

M8

8

(C) 1.25

0.9

2.7

3.9

M10

10

(C) 1.5

1.9

5.4

7.8

(F) 1.25

2.0

5.6

8.2

M12

12

(C) 1.75

3.3

9.2

13.5

(F) 1.25

3.5

9.8

14.5

M14

14

(C) 2.0

5.2

14.5

21.0

(F) 1.5

5.5

15.5

22.5

M16

16

(C) 2.0

7.8

22.0

32.0

(F) 1.5

8.2

23.0

33.7

(C) 2.5

10.5

30.5

44.5

(F) 1.5

11.5

33.0

48.5

(C) 2.5

15.0

42.5

62.0

(F) 1.5

16.5

46.0

67.5

(C) 2.5

20.0

57.0

83.0

(F) 1.5

21.5

61.0

89.5

(C) 3.0

26.0

73.5

105.0

(F) 2.0

27.5

78.5

115.0

(C) 3.0

38.0

105.0

155.0

(F) 2.0

40.5

115.0

165.0

(C) 3.5

52.0

145.0

215.0

(F) 2.0

56.0

160.0

230.0

(C) 3.5

70.0

195.0

290.0

(F) 2.0

75.0

210.0

310.0

M18 Metric thread

M20 M22 M24

Unified thread

Bolt strength

Nominal dimension

18 20 22 24

M27

27

M30

30

M33

33

5/16

05

18 UNC

0.9

2.5

3.6

3/8

06

16 UNC

1.6

4.5

6.6

7/16

07

14 UNC

2.6

7.2

10.5

1/2

08

13 UNC

3.7

10.5

15.0

9/16

09

12 UNC

5.3

15.0

22.0

5/8

10

11 UNC

7.3

20.5

30.0

3/4

12

10 UNC

13.0

36.5

53.5

7/8

14

9 UNC

20.0

56.5

82.5

1

16

16 UNC

31.5

88.5

130.0

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

（6）

(lb-ft.)

Bolt size Type

Nominal dia.

Pitch

4.6 (4T)

8.8 (8T)

10.9T (11T)

M8

8

(C) 1.25

6.5

19.5

28

M10

10

(C) 1.5

13.7

39

56

(F) 1.25

14.5

40

59

M12

12

(C) 1.75

23

66

97

(F) 1.25

25

70

105

M14

14

(C) 2.0

37

105

150

(F) 1.5

39

110

160

M16

16

(C) 2.0

56

160

230

(F) 1.5

59

165

245

(C) 2.5

76

220

320

(F) 1.5

83

235

350

(C) 2.5

105

305

450

(F) 1.5

120

330

490

(C) 2.5

145

410

600

(F) 1.5

155

440

650

(C) 3.0

190

530

760

(F) 2.0

200

565

830

(C) 3.0

275

760

1120

(F) 2.0

295

830

1190

(C) 3.5

375

1050

1550

(F) 2.0

405

1160

1660

(C) 3.5

505

1410

2100

(F) 2.0

540

1520

2240

M18 Metric thread

M20 M22 M24

Unified thread

Bolt strength

Nominal dimension

18 20 22 24

M27

27

M30

30

M33

33

5/16

05

18 UNC

6.5

18.0

26

3/8

06

16 UNC

11.5

32

47

7/16

07

14 UNC

18.8

52

76

1/2

08

13 UNC

26

76

105

9/16

09

12 UNC

38

110

160

5/8

10

11 UNC

52

150

215

3/4

12

10 UNC

94

265

385

7/8

14

9 UNC

145

410

595

1

16

16 UNC

225

640

940

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

（7）

Flanged Hexagon Bolt Tightening Torque 1.Bolt Type

Metric thread

2.Bolt strength

4〜8T

3.Thread pitch

Coarse pitch thread(C)

(N-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

M5

0.8

4

7

M6

1

7

12

M8

1.25

15

28

M10

1.5

28

53

M12

1.75

50

94

M16

2

−

231

M20

2.5

−

441

M24

3

−

765

4.8 (4T)

8.8 (8T)

(kgf-m) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

M5

0.8

0.4

0.7

M6

1

0.7

1.2

M8

1.25

1.5

2.9

M10

1.5

2.9

5.4

M12

1.75

5.1

9.6

M16

2 2.5

− −

23.5

M20 M24

3

−

78.0

45.0

(lb-ft) Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

4.8 (4T)

8.8 (8T)

M5

0.8

2.9

5.0

M6

1

5.0

8.6

M8

1.25

10.8

20.9

M10

1.5

20.9

38.9

M12

1.75

36.7

69.1

M16

2

−

169.2

M20

2.5

−

324.0

M24

3

−

561.6

（8）

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

Hose band

Tightening torque

Tightening torque

Tightening torque

(N-m)

(kgf-cm)

(lb-ft)

1.6

16

1.2

4

40

2.9

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

1.6

16

1.2

4

40

2.9

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

16.5

HH022W

7.9

18.5

HH022W

9.5

20.5

HH022W

12.7

24.5

HH027W

15.9

29.9

HH031W

19.0

30.0

HH031W

25.4

38.0

HH044W

31.8

45.8

HH052W

38.1

52.1

HH057W

50.8

67.8

HH071W

60.5

76.0

HH082W

75.5

93.0

HH095W

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

Hose band

6

16.5

HH022W

8

18.5

HH022W

9

20.5

HH022W

9

22.0

HH023W

12

24.5

HH027W

12

26.0

HH027W

15

29.0

HH031W

15

30.5

HH031W

19

32.0

HH038W

19

34.0

HH038W

25

39.5

HH044W

25

41.5

HH044W

32

46.0

HH052W

32

48.0

HH052W

38

54.0

HH057W

50

70.5

HH076W

50

73.0

HH076W

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

Hose band Center of pipe protrusion 10〜20mm

（9）

Pipe

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

Liquid Gasket Code

Manufacturer

Product name

ＡＡ０１

Loctite

Plastic Gasket 568

ＡＡ０２

Loctite

Hydraulic sealant

ＡＡ０３

Three Bond

Three Bond 1215

Code

Manufacturer

Product name

ＡＢ０１

Loctite

Loctite 262

ＡＢ０２

Three Bond

Three Bond 1327

ＡＢ０３

Three Bond

Three Bond 1374

Screw Lock Agent

・ Cautions regarding parts removal

・ Cautions regarding reassembly

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

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

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

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

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

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

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

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

Antiseize Agent Code

Manufacturer

ＡＣ０１

Loctite

Product name Loctite 767 (Paste or spray)

（ 10 ）

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

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

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

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

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

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

Example 1:

Section to be welded Do not ground this section.

Electric current may flow through the cylinders.

Ground this section. (correct grounding)

Example 2:

Do not ground this section.

Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

（ 11 ）

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

Be sure to mask these units and parts before welding.

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

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

Hydraulic cylinder

Plated section (Mask this section.)

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.)

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

1m or more

Scrap material, etc.

Section to be welded

1

1m or more

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

Section to be welded Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

（ 12 ）

Weight of Main Components With CUMMINS engine

Part name

Approx.

Weight (kg)

Approx.

Weight (lb)

Bucket

2010

4420

GSN bucket

Boom

1520

3350

Standard

" Z " -Lever

213/pc

470/pc

Link (Bucket to Lever)

38/pc

84/pc

Engine room assembly

305

670

Including air cleaner and condenser

Hydraulic tank

172

380

Excluding oil

Fuel tank

163

360

Excluding fuel

Deck

57

125

Including hand rail

ROPS cab

560

1230

Floor board

340

750

Including air conditioner unit and seat

Front chassis

1920

4200

Bare chassis

Rear chassis

1670

3670

Bare chassis

Counterweight

1530/420

3370/920

Outer / Inner

Engine

1000

2200

Excluding oil

Radiator

240

530

Excluding water and oil

Transmission

880

1940

Excluding oil

Second propeller shaft

85

190

Third propeller shaft

13

30

Air cleaner

18

40

Exhaust silencer (Muffler)

23

50

Front axle assembly

1350

2970

Excluding tires and oil

Rear axle assembly

1700

3750

Excluding tires and oil (Including axle support)

Differential

178

390

Multiple control valve

91

200

Steering valve

24

55

Hydraulic

Gear pump

47

105

system

Boom cylinder

228/pc

500

Excluding oil

Bucket cylinder

133/pc

290

Excluding oil

Steering cylinder

39/pc

85/pc

Excluding oil

Tire

650/pc

1450/pc

With rim (26.5-25-20PR); No Hydro Inflation

Air conditioner unit

83

185/pc

(In cab portion)

Battery

40/pc

90/pc

Item Unit name

Chassis

Remarks

Power line

Other

（ 13 ）

Excluding precleaner

Applying and Storing Articulation Stopper 1.Applying articulation stopper WARNING Unexpected movement of the machine could cause serious injury or death. There is a possibility that a service man could be crushed in the articulation area if the machine unexpectedly turns during repair work. To prevent such an accident, be sure to apply the articulation stopper before starting work.

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

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

1

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

WARNING

2

3

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

Stay out of the articulation area while aligning the holes.

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

LOCKED POSITION

3

1 2

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

STORED POSITION

（ 14 ）

Chassis Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-1 Power Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-1 Torque Converter & Transmission Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-1 Hydraulic Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-1 Brake Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-1 Electrical Group ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-1

CHASSIS GROUP 14 Disassembly and Reassembly Removing and Reinstalling Deck ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-2 Removing and Reinstalling Fuel Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-3 Removing and Reinstalling Hydraulic Tank ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-4 Removing and Reinstalling Engine Room ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-6 Removing and Reinstalling Cab ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-9 Removing and Reinstalling Floor Board ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-12 Removing and Reinstalling Boom ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-14 Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-17 Removing and Reinstalling Center Pin ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 14-18

14-1

Removing and Reinstalling Deck

90Z Ⅳ -2

CHASSIS 14

Removing and Reinstalling Deck 1.Removing deck WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting deck removal: ・ Position the machine on level ground, and apply the parking brake. ・ Lower the bucket onto the ground, and block the tires with chocks, etc. to prevent them from moving. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

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

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

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

1 5 4

Torque for assembly: : Bolt : 90N-m (9.2kgf-m) (66 lb-ft) : Deck (with hand rail) : 65kg (143 lb)

2

3

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

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

14-2

85W14001

Removing and Reinstalling Fuel Tank

90Z Ⅳ -2

CHASSIS 14

Removing and Reinstalling Fuel Tank 1.Removing fuel tank WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting fuel tank removal: ・ Position the machine on level ground, and apply the parking brake. ・ Lower the bucket onto the ground, and block the tires with chocks, etc. to prevent them from moving. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

Before starting work: a)Drain fuel from the fuel tank. (Fuel tank capacity: 310 l (82 gal.)) b)Remove the deck by referring to page 4.

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

1

3

2

90K14001

2) Temporarily sling the fuel tank (2) to remove the bolts (3). : Fuel tank : 163kg (360 lbs) (empty) Torque for assembly: : Retainer bolt (3) : 441N-m (45.0kgf-m) (326 lb-ft)

4

2

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

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

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

14-3

90K14002

Removing and Reinstalling Hydraulic Tank

90Z Ⅳ -2

CHASSIS 14

Removing and Reinstalling Hydraulic Tank 1.Removing hydraulic tank WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting hydraulic tank removal: ・ Position the machine on level ground, and apply the parking brake. ・ Lower the bucket onto the ground, and block the tires with chocks, etc. to prevent them from moving. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

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

(Hydraulic tank capacity. : 175 l (46 gal.)) b)Remove the deck by referring to page 4. c) Clean the area around the tank.

2 1

1)Disconnect the hose (1) and remove the transmission line filter (2) bracket bolt (3). Fix the transmission line filter with a strap to prevent contact with the tank during removal.

3

Rear chassis 90W14001

2)Disconnect the electrical line (5) and the vinyl tube (4) for the window washer liquid tank (option).

4

3)Disconnect the hoses (6). ・Plug or cover the hoses and fittings to prevent leakage and dirt entry.

5 6

90K14003

4) Temporarily sling the hydraulic tank (7), and remove the bolts (8). : Hydraulic tank : 172kg (380 lbs) (empty) Torque for assembly: : Retainer bolt (9) : 441N-m (45.0kgf-m) (326 lb-ft)

8 7 90W14002

14-4

Removing and Reinstalling Hydraulic Tank

90Z Ⅳ -2

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

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

14-5

CHASSIS 14

Removing and Reinstalling Engine Room

90Z Ⅳ -2

CHASSIS 14

Removing and Reinstalling Engine Room 1.Removing engine room WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting engine room removal: ・ Position the machine on level ground, and apply the parking brake. ・ Lower the bucket onto the ground, and block the tires with chocks, etc. to prevent them from moving. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

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

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

2 1

1)Remove the right and left decks (1) together with the hand rail (2).

85W14002

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

3

85W14003

3)Remove the exhaust pipe (4).

4

85W14004

14-6

Removing and Reinstalling Engine Room

90Z Ⅳ -2

CHASSIS 14

5

CAUTION Spray from hot coolant can cause burns.

Prevent injury by relieving pressure in the radiator and work on the system only when cool.

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

85W14005

8

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

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

6

85W14006

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

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

8

7)Remove and cap (engine side) the ether line. Cut the nylon tie strap from the clamp.

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

7

85W14007

9

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

Rear axle 85W14008

14-7

Removing and Reinstalling Engine Room

90Z Ⅳ -2

CHASSIS 14

9)Disconnect the hose (10) from the condenser (option).

Note: Before hose disconnection, be sure to recover/recycle the refrigerant on machine with optional airconditioner if required.

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

10

North American units have a single condenser unit.

Condenser 85K14009

10)Open the radiator grill and disconnect the electrical line coupler (11). Remove all the bolts (12) from the engine room.

12

Torque for assembly: :Retainer bolt : (M12)

98N-m (10.0kgf-m) (72 lb-ft) (M16) 216N-m (22.0kgf-m) (159 lb-ft) 11 85W14013

Note: (M12)Retainer bolts : Qty : 6 (M16)Retainer bolts : Qty : 10 11)Lift the engine room together with the air cleaner. :Engine room : 305kg (670 lbs) (Including air cleaner and condenser) Note: Slowly lift the engine room while checking that there are no obstacles.

M16 M12 M16

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

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

14-8

85W14010

Removing and Reinstalling Cab

90Z Ⅳ -2

CHASSIS 14

Removing and Reinstalling Cab 1.Removing cab WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket onto the ground, and apply the parking brake. ・ Remove the engine key, and hang a "DO NOT START ENGINE!" tag on the steering wheel.

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

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

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

Remove the outer filter (2) from the cab.

2

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

1 65K14050

2)Remove the cover (3).

3

65K14051

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

4

65K14052

14-9

Removing and Reinstalling Cab

90Z Ⅳ -2

CHASSIS 14

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

5

6

65K14053

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

7

Torque for assembly: :Nut (7) : 34N-m (3.5kgf-m)(25 lb-ft)

8

9 65K14054

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

12 10

11

65K14014

7)Remove the bolt (13).

Front Right/Left 2pcs each Rear Right/Left 3pcs each Torque for assembly : :Bolt : 721N-m (73.5kgf-m)(532 lb-ft)

Cab

Floor board 13

14-10

65V14002

Removing and Reinstalling Cab

90Z Ⅳ -2

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

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

Lift the cab slowly.

CHASSIS 14

Cab

14 15

: Cab 560kg (1,230 lb)

65V14003

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

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

2) Tune the clock and the radio.

14-11

Removing and Reinstalling Floor Board

90Z Ⅳ -2

CHASSIS 14

Removing and Reinstalling Floor Board 1.Removing floor board WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket onto the ground, and release the residual pressure from the hydraulic oil tank and lines. ・ Drain the air in the air tank. side of the battery. ・ Disconnect the side of the battery. ・ Disconnect the

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

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

Prepare a can for the oil.

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

1

1)Put match marks on the hoses (1), and then disconnect them from the steering pilot valve (2).

2

: Hydraulic oil : Approx. 0.5 l (0.2 Gal.) Note: Cover the disconnected hoses with vinyl, plugs, or caps to protect them from dust, water, and dirt.

Match mark

90W14003

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

Throttle lever

3

85W14011

14-12

90Z Ⅳ -2

Removing and Reinstalling Floor Board

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

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

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

CHASSIS 14

4 5

340kg (750 lb)

Torque for assembly : : Nut (5) : 417N-m (42.5kgf-m)(307 lb-ft)

90W14004

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

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

14-13

Removing and Reinstalling Boom

90Z Ⅳ -2

CHASSIS 14

Removing and Reinstalling Boom 1.Removing boom WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. ・ Position the machine on level ground, and block the tires with chocks, etc. to prevent them from moving. ・ Lower the bucket onto the ground, and release the residual pressure from the hydraulic oil tank and lines. ・ Apply the parking brake and remove the starter key.

1)Remove the connection pin (3) from the bucket (1) and the link (2).

Note : There are shims in the pin sections.

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

2

3 1

90K14006

2)Remove the connection pin (5) from the boom (4) and bucket (1) to remove the bucket. :Bucket : 2,010kg (4,420 lbs)

5

4 1 90K14007

3) Temporarily sling the link (2), and then remove the connection pin (6) from the lever (5) and link (2). :Link (for 1 pc) : 38kg (84 lbs)

6

5

2 90K14008

14-14

Removing and Reinstalling Boom

90Z Ⅳ -2

CHASSIS 14

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

4)Remove the grease pipe (7) from the lever (5).

CAUTION

7

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

Always use a stepladder for this work.

5

90K14009

5) Temporarily sling the bucket cylinder (8), and then remove the connection pin (9) from the lever (5) and bucket cylinder (8).

8

: Bucket cylinder : 133kg (290 lbs)

9

5 90K14010

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

Lower the bucket cylinder rod (10) on the machine.

10

90K14011

7) Temporarily sling the lever (5), and then remove the lever pin (11).

5

8)Remove the lever (5).

11

: Lever (for 1 pc) : 213kg (470 lbs)

90K14012

14-15

Removing and Reinstalling Boom

90Z Ⅳ -2

CHASSIS 14

9)Remove the grease hose (13) from the pin (12).

13

10)Place a wooden piece between the boom cylinder (14) and the hydraulic pipe (15), and then remove the pin (12).

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

12 15

14

Wooden block

11)Temporarily sling the cross pipe of the boom (4), and then remove the pins (16) from the boom on both the right and left side of the boom.

90K14013

4

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

16

: Boom : 1,520kg (3,350 lbs)

90K14014

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

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

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

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

14-16

90Z Ⅳ -2

Center Pin

CHASSIS 14

Center Pin Upper center pin

Shim adjustment

T1

T1: 216N-m (22.0kgf-m) (159 lb-ft) T2: 461N-m (47.0kgf-m) (340 lb-ft) Shim adjustment: Adjust the clearance to 0.1±0.05mm (0.0039±0.0020 in.) using the shim.

After that, tighten the T1 bolt.

Shim

T2 ９０ＺⅣ１４０１

Lower center pin

Rear

Front

Spherical plain bearing outer ring split position

Direction of grease nipple 22.5 °

９０ＺⅣ１４０２

14-17

Removing and Reinstalling Center Pin

90Z Ⅳ -2

CHASSIS 14

Removing and Reinstalling Center Pin 1.Removing center pin WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Be sure to observe the following items before starting center pin removal: ・ Place the machine on level and paved ground. ・ Lower the bucket onto the ground, and block the front tires with chocks, etc to prevent them from moving. ・ Apply the stopper to the rear wheel oscillation section to prevent the machine from oscillation. ・ Release the residual pressure from the hydraulic line, and also release the internal pressure from the hydraulic tank. ・ Cover the steering cylinder rod to prevent it from being scratched.

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

Torque for assembly: : Bolts : 142N-m (14.5kgf-m) (105 lb-ft) Use three bond 1327

2 1

90W14005

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

5

3)Disconnect the brake hose (5), and disconnect the electrical line (6) from the clamp.

6 7

:Brake oil : Approx. 3 l (0.8 gal.)

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

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

3 4

90W14006

4)Disconnect the high-pressure hoses (7). :Hydraulic oil : Approx. 3 l (0.8 gal.)

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

14-18

Removing and Reinstalling Center Pin

90Z Ⅳ -2

CHASSIS 14

5)Remove the pilot line hoses (8) at the rear chassis bracket part.

Rear chassis bracket

8

90W14007

6)Remove the upper center pin retainer bolt (9).

Torque for assembly: : Retainer bolt : 476N-m (48.5kgf-m) (351 lb-ft)

9

90W14008

7)Screw the M12 (P1.75) bolt of approximately 70mm length into the center of the bushing (10) to push out the bushing. This bolt is used as a jack screw.

10

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

70

90W14009

8)Before disconnecting the front chassis (11) from the rear chassis, be sure to support the front chassis using the jack and blocks so that the front chassis will not be fall backward.

11

Jack 90W14010

14-19

Removing and Reinstalling Center Pin

90Z Ⅳ -2

CHASSIS 14

9)Before disconnecting the front chassis from the rear chassis, be sure to sling the rear chassis using a crane (apply the rope to the hook (12)) so that the rear chassis will not fall backward.

12

90W14011

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

Jack

90W14012

11)While supporting the bottom of the fuel tank (13) using a garage jack, remove the lock bolt from the lower center pin (14), and then push the lower center pin (14) out using another jack to remove the pin.

14

13

Jack

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

Garage jack 90W14013

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

Note: While turning the rear tires, check that the garage jack under the fuel tank shifts backward together with the rear chassis.

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

Bar 90W14014

14-20

90Z Ⅳ -2

Removing and Reinstalling Center Pin

CHASSIS 14

13)Remove the ring (15).

17

14)Remove the bolts (17) from the plate (16).

Torque for assembly: : Retainer bolt : 216N-m (22.0kgf-m) (159 lb-ft)

Front

15 16 22.5 °

90W14015

Grease port

19

15)Remove the shim (18).

Note: If the taper roller bearing (19) is replaced, be sure to adjust the clearance using the shim.

For shim adjustment, refer to page 19 or 28.

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

18 90W14016

16)Check the dust seal (20) for distortion and scratches. If the dust seal is extremely distorted or scratched, replace it.

Note: Direction of dust seal.

(Top)

20

(Bottom)

８５Ｋ１４０１９

90W14017

17)If the spherical bearing (22) is replaced, be sure to adjust the direction of outer ring split.

For the bearing direction, refer to page 19 or 28.

22

21

90W14018

14-21

Removing and Reinstalling Center Pin

90Z Ⅳ -2

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

3.Cautions regarding reassembly ① Check the dust seal for distortion and scratches.

If the dust seal is extremely distorted or scratched, replace it. ② Grease the center pins and check the pins for abnormal noise. ③ Completely bleed the brake of air.

For air bleeding, refer to Section 24. ④ No oil leakage should be found in any part.

14-22

CHASSIS 14

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

15-1

90Z Ⅳ -2

Linkage

CHASSIS 15

Linkage 1. Bucket-Boom

2. Boom-Lever

3. Boom-Boom cylinder

4. Front chassis-Boom

5. Bucket-Rod

6. Lever-Rod

7. Lever-Bucket cylinder

8. Bucket cylinder -Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

7

11. Steering cylinder Rear chassis

3

8

4

2

10

5

1

6

9

15-2

11

９０ＺⅣ１２０２

Linkage Pin Standard Clearance Values

90Z Ⅳ -2

CHASSIS 15

Linkage Pin Standard Clearance Values Unit : mm (in.)

Judgment standard No.

Item

Solution

Pin standard dimension

Standard clearance

Tolerance

1

Joint section between bucket and boom

φ 70 ( φ 2.7559)

0.104〜0.213 (0.0041〜0.0083)

1.0 (0.0393)

Replacement

2

Joint section between boom and lever

φ 100 ( φ 3.9370)

0.117〜0.242 (0.0046〜0.0095)

1.0 (0.0393)

Replacement

3

Joint section between boom and boom cylinder

φ 90 ( φ 3.5433)

0.117〜0.237 (0.0046〜0.0093)

1.0 (0.0393)

Replacement

4

Joint section between front chassis and boom

φ 110 ( φ 4.3307)

0.119〜0.244 (0.0046〜0.0096)

1.0 (0.0393)

Replacement

※

5

Joint section between bucket and link

φ 60 ( φ 2.3622)

0.098〜0.202 (0.0038〜0.0079)

1.0 (0.0393)

Replacement

※

6

Joint section betwen lever and link

φ 60 ( φ 2.3622)

0.098〜0.202 (0.0038〜0.0079)

1.0 (0.0393)

Replacement

7

Joint section between lever and bucket cylinder

φ 80 ( φ 3.1496)

0.101〜0.217 (0.0039〜0.0085)

1.0 (0.0393)

Replacement

φ 80 ( φ 3.1496)

0.101〜0.217 (0.0039〜0.0085)

1.0 (0.0393)

Replacement

φ 90 ( φ 3.5433)

0.117〜0.237 (0.0046〜0.0093)

1.0 (0.0393)

Replacement

φ 50 ( φ 1.9685)

0.085〜0.178 (0.0033〜0.0070)

1.0 (0.0393)

Replacement

φ 50 ( φ 1.9685)

0.085〜0.178 (0.0033〜0.0070)

1.0 (0.0393)

Replacement

※

8

9

※

10

※

11

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

Liner clearance adjustment ※

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

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

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

15-3

Center Pin

90Z Ⅳ -2

CHASSIS 15

Center Pin Upper Adjusting shim (#5)

〔Upper center pin〕

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

Adjust the shim so that the clearance is 0.1±0.05mm (0.0039±0.0020 in.).

3 14

5 φ85

Rear chassis

Front chassis

12

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

Front

3 22.5 ° Grease hole

Lower Installing bearing outer ring (#9)

〔Lower center pin〕

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

Rear chassis

9 φ85

Torque for assembly: : Retainer bolt #12・ ・476N-m (48.5kgf-m) (351 lb-ft) #14・ ・216N-m (22.0kgf-m) (159 lb-ft)

Front chassis

Front

Rear

9 Split of outer ring

Grease nipple mounting direction 22.5 °

15-4

90Z Ⅳ -2

Bucket

CHASSIS 15

Bucket

(Tooth mounting section)

5

2

63

27 Tooth

(Wear edge mounting section)

6

Edge

(Wear plate mounting section)

38

7 22.5

Center : 32 Side: 36 32

Wear edge

17.5

Wear plate

:kg-m Tooth mounting bolt Wear edge mounting bolt Wear plate mounting bolt

1314N-m (134kgf-m) (969 lb-ft) 1314N-m (134kgf-m) (969 lb-ft) 834N-m (85.0kgf-m) (615 lb-ft)

15-5

90Z Ⅳ -2

Bucket Positioner and Boom Kick-Out

CHASSIS 15

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

6 5

3

A

A

(Bucket positioner)

(Boom kick-out) 3 2

Connector

3 4

4 1

Proximity switch ８０ＺⅣ１５０３

Section A-A

Unit : mm No.

Item

Judgment standard

Solution

1

Clearance of bucket positioner switch

5 ± 2 (0.196±0.078 in.)

Adjustment

2

Clearance of boom kick-out switch

5 ± 2 (0.196±0.078 in.)

Adjustment

3

Adjusting plate mounting bolt tightening torque

98N-m (10.0 kgf-m) (72 lb-ft)

Tightening

4

Switch mounting nut tightening torque

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

Tightening

5

Bucket positioner adjustable angle

-7 ° 〜12 °

Adjustment

6

Boom kick-out adjustable angle

0〜43 °

Adjustment

15-6

Bucket Positioner and Boom Kick-Out

90Z Ⅳ -2

CHASSIS 15

Bucket positioner adjustable angle

-7° 12°

Boom kick-out adjustable angle

９０Ｗ１５００１

15-7

POWER GROUP 24 Disassembly and Reassembly Power Line Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-2 Radiator Mount Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-3 Removing and Reinstalling Radiator ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-4 Removing and Reinstalling Radiator Lower Tank (Bolt on type) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-7 Removing and Reinstalling Engine ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-8 Removing and Reinstalling Propeller Shaft ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-11 Removing and Reinstalling Air Cleaner ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-13 Removing and Reinstalling Muffler ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-15 Front Axle Assembly Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-16 Removing and Reinstalling Front Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-18 Rear Axle Assembly Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-21 Axle Support Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-23 Removing and Reinstalling Rear Axle Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-24 Disassembling and Reassembling Planetary Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-28 Floating Seal ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-35 Removing and Reinstalling Differential ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-38 Special Jigs for Disassembling Axle ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-40 Disassembling and Reassembling Internal Gear Hub ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-44 Front Differential Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-47 Rear Differential Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-48 Disassembling and Reassembling Differential Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-49 Disassembling and Reassembling Spider Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 24-59

24-1

90Z Ⅳ -2

Power Line Tightening Torque

POWER 24

Power Line Tightening Torque

T4 L1 T3 L2

T3 L 2 L1 T4

T5 L 1

T1 L 2

T6 L 1

T1 L 2

T5 L 1

T5 L 1

T3 L2

T5 L 1 T4 L 1

T4 L 1

:Bolt tightening torque T1 :53N-m (5.4kgf-m) (39 lb-ft) T3 :417N-m (42.5kgf-m) (307 lb-ft) T4 :216N-m (22.0kgf-m) (159 lb-ft) T5 :142N-m (14.5kgf-m) (105 lb-ft) T6 :441N-m (45.0kgf-m) (326 lb-ft)

T4 L 1 90W24001

Note: Always replace drive shaft bolts with new bolts − Never reuse.

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

24-2

90Z Ⅳ -2

Radiator Mount Tightening Torque

POWER 24

Radiator Mount Tightening Torque 2

2

4

4

C

7

1

1

3

3

2 Radiator

Thermostat open (when hot) close (when cool)

C

7

Hydraulic oil cooler

A B

A

B

6 5 5

Viewed from rear Torque converter oil cooler

99

6

９０ＺⅣ ＵＳ２２０3

9

９０ＺＡ ２２−００４

② ① 8

①

A-A

B-B

C-C ９０ＺⅣＵＳ２２０４

Torque for assembly:

①230N-m (23.5kgf-m) (170 lb-ft) With liquid adhesive Loctite 262 ② 49N-m (5.0kgf-m) (36 lb-ft) With lubrication oil (engine oil or gear oil)

24-3

1. Radiator assembly (three piece type) 2. Fan guard Coolant inlet 3. Stay (Bracket) 4. Coolant inlet hose 5. Coolant outlet hose 6. Coolant bypass hose 7. Thermostat 8. Rubber cushion 9. Coolant drain plug

Removing and Reinstalling Radiator

90Z Ⅳ -2

POWER 24

Removing and Reinstalling Radiator 1.Removing radiator WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

1

85K24003

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

4

1)Remove the drain plug (1) to drain the coolant.

2

: Capacity for coolant in system : 66 l (17.5 Gal.)

5

2)Disconnect the coolant hose (2)(3)(4)(5) from the radiator.

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

Engine

3

85W24003

3)Remove the fan guard (6).

6

85W24004

24-4

Removing and Reinstalling Radiator

90Z Ⅳ -2

POWER 24

4)Remove the plates (8) for both L&R side.

Torque for assembly: : Retainer bolt (7) : 230N-m (23.5kgf-m) (170 lb-ft) : Screw lock agent (Loctite 262) application 8

7 85W24005

5)Disconnect the hydraulic oil cooler hose (9) (R.H side). : Hydraulic oil : Approx. 2 l (0.53 Gal.) Note: Cover the disconnected hoses with vinyl to protect the hoses from dust and dirt.

9

Radiator

6)Disconnect the hydraulic oil cooler hose (10) (L.H side).

10 85W24006

7) Temporarily sling the radiator (11). Remove the right and left retainer bolts (12), and then lift the radiator.

11 12

: Radiator : 240kg (530 lbs) Torque for assembly: : Retainer bolt : 49N-m (5.0kgf-m) (36 lb-ft) : With lubricating oil (Engine oil, gear oil etc.)

85W24007

8) Lift the radiator approx. 10cm, and then disconnect the transmission cooler hoses (13).

Radiator

11

: Transmission oil : 2 l (0.53 Gal.) 9)Remove the radiator (11) by lifting.

13

: Radiator : 240kg (530 lbs)

85W24008

24-5

Removing and Reinstalling Radiator

90Z Ⅳ -2

POWER 24

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

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

Clearance

80K24010

24-6

Ⅳ -2 Removing and Reinstalling Radiator Lower Tank (Bolt 90Z on type)

POWER 24

Removing and Reinstalling Radiator Lower Tank (Bolt on type) 1.Removing radiator lower tank

Radiator setting position

Before starting work: Put the radiator upside down as illustrated.

Note: In order not to damage the filler, put the radiator on the block.

Lower tank

Block

Filler

1)Remove the bolt (M10 44pcs) connecting the lower tank.

2)Remove the lower tank.

The lower tank, packing and the patches are come off at the same time.

Note: In case the packing is not come off without any damage from the radiator core side, no removal necessary.

Lower tank

Nut welded Packing

Patch (short) Female thread (5 pcs) Bolt hole

Patch (long)

2.Reinstalling radiator lower tank 1)Put the lower tank on the radiator core. : Liquid adhesive (Three Bond 1374) application Put Three Bond 1374 on the both sides of the packing.

2) Tighten the bolt. ●: Put plane washer under the bolt head : No nut necessary other: Use spring washer and nut : 25〜29N-m (2.5〜3kgf-m) (18〜22 lb-ft)

24-7

Removing and Reinstalling Engine

90Z Ⅳ -2

POWER 24

Removing and Reinstalling Engine 1.Removing engine WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

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

Note: After removing the cooling fan, the engine may be removed without removing radiator. c) Collect the air conditioner refrigerant (option) using the proper recovery method. d)Drain engine oil : Engine oil : Approx. 39 l (10 Gal.)

1

1)Disconnect the negative side of the battery cable.

Then remove the positive cable.

65K24013

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

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

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

Throttle lever

3

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

85W14011

4)Remove the fan guard (3).

3

85W24004

24-8

Removing and Reinstalling Engine

90Z Ⅳ -2

POWER 24

5)Remove the engine oil drain hose.

6)Temporarily sling the engine and remove engine assembly mounting bolts (4).

Torque for assembly: :Retainer bolt : 417N-m (42.5kgf-m) (307 lb-ft) :Engine assy : Approx. 1,000kg (2,200 lbs) (Excluding oil)

4

7)Remove the bolts (5) from the housing between the engine flywheel and transmission.

Torque for assembly: :Retainer bolt : 53N-m (5.4kgf-m) (39 lb-ft)

90W24002

5

85W24010

8)Remove the four bracket mounting bolts (6) (both sides) on the flywheel side.

Torque for assembly: :Retainer bolt : 216N-m (22.0kgf-m) (159 lb-ft) :Screw lock agent (Loctite 262) application 7

9)Remove the two block mounting bolts (7) (both sides).

Torque for assembly: :Retainer bolt : 417N-m (42.5kgf-m) (307 lb-ft)

6 85W24011

10)Loosen the four bracket mounting bolts (8) (both sides) on the transmission side.

Note: Take care not to loosen too much.

8

Torque for assembly: :Retainer bolt : 216N-m (22.0kgf-m) (159 lb-ft) :Screw lock agent (Loctite 262) application

85W24012

24-9

Removing and Reinstalling Engine

90Z Ⅳ -2

POWER 24

11)Lift the engine assembly a little, and place a support, like a wooden block, under the torque converter case (between the case and the axle support). Then, slowly lower the engine assembly to rest the torque converter on the support.

Support

85Z Ⅳ US2404

12)Slide the engine assembly toward the back of the machine to disengage the flywheel ring gear.

13)After confirming that the ring gear has been disengaged, remove the engine assembly by lifting it slowly while avoiding any obstructions.

2.Cautions regarding engine reinstallation ①There is an O-ring (9) in the housing between the engine and torque converter. Be sure to replace the O-ring with a new one. ②Refill the engine with the proper quantity and type engine oil. ③Refill the radiator with premixed coolant (approx 50% water / 50% antifreeze). ④After reinstalling the engine, completely bleed the fuel line of air. ⑤Set the starter key to ON, and then check the monitor lamps of electrical equipment. ⑥Operate the engine at the idling speed for 5 minutes. After that, check the amount of the coolant. ⑦While gradually increasing the engine speed, check operation of the electrical equipment.

24-10

9

85W24013

Removing and Reinstalling Prop. Shaft

90Z Ⅳ -2

POWER 24

Removing and Reinstalling Propeller Shaft 1.Removing second propeller shaft WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

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

Torque for assembly: : Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent (Loctite 262) application 2)Disconnect the grease pipe, and remove the bolt (4) from the pillow unit (5).

Torque for assembly: : Retainer bolt : 441N-m (45.0kgf-m) (326 lb-ft)

5 4

1

3

2

85W24014

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

Torque for assembly: : Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent (Loctite 262) application : Second propeller shaft : 85kg (187 lbs) Note: If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner.

Keep the flame away from the seals of the coupling.

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

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

Torque for assembly: : Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent (Loctite 262) application : Third propeller shaft : 13kg (28 lbs)

6 85W24015

24-11

Removing and Reinstalling Propeller Shaft

90Z Ⅳ -2

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

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

24-12

POWER 24

Removing and Reinstalling Air Cleaner

90Z Ⅳ -2

POWER 24

Removing and Reinstalling Air Cleaner 1.Removing air cleaner WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel, or disconnect the negative side of the battery.

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

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

1 3

4 5

2

6

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

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

85W24016

4)Disconnect the air duct (7).

Disconnect the indicator wire coupler (8).

8

7

85W24017

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

10

9 70K24009

24-13

Removing and Reinstalling Air Cleaner

90Z Ⅳ -2

POWER 24

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

12 11

70K24010

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

13

70K24011

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

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

Carefully reinstall the air duct.

24-14

Removing and Reinstalling Muffler

90Z Ⅳ -2

POWER 24

Removing and Reinstalling Muffler 1.Removing muffler CAUTION You may get burned if you remove the muffler before the engine is cold enough. To prevent such an incident, be sure to stop the engine, and open the side covers. Start the muffler removal work when the engine is cold enough.

1)Remove the clamp (1) and then remove the exhaust pipe (2).

2)Remove the engine room by referring to Section 14. : Engine room : 305kg (670 lbs)

2

1

85W24034

3)Remove four bolts (5) and U-clamp (4), and then remove the muffler (3).

5

3

: Muffler : 23kg (50 lbs)

5

4 85W24018

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

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

24-15

90Z Ⅳ -2

Front Axle Assembly Tightening Torque

POWER 24

Front Axle Assembly Tightening Torque (S/N 90C3-5501〜5600)

B

T1 L 3

T4 L 1

T5

T7 T6 L 1 T5 T3 L 1

T5

A

T8 T2

T9 L 1 85W24019

: Bolt tightening torque T1 : 1,373N-m (140.0kgf-m) (1,013 lb-ft) T2 : 892N-m (91.0kgf-m) (658 lb-ft) T3 : 216N-m (22.0kgf-m) (159 lb-ft) T4 : 132N-m (13.5kgf-m) (98 lb-ft) T5 : 78N-m (8.0kgf-m) (58 lb-ft) T6 : 54N-m (5.5kgf-m) (40 lb-ft) T7 : 34N-m (3.5kgf-m) (25 lb-ft) T8 : 86N-m (8.8kgf-m) (64 lb-ft) T9 : 90N-m (9.2kgf-m) (67 lb-ft)

A while measuring the preload applied to Note: Tighten ◯ section ◯ B. Preload of section ◯ B :226〜265N (23〜27kgf) (50〜59 lbs)* *This is "breakaway" force. The force required to start the wheel turning.

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

24-16

Front Axle Assembly Tightening Torque

90Z Ⅳ -2

POWER 24

Front Axle Assembly Tightening Torque (S/N 90C3-5601〜) T3 ・L1 Floating seal

T8 ・L3 B

T5 ・L 1 T2

A T1 ・L1

T4 T7

T6 ・L 1

Bolt tightening torque T1: 221N-m (22.5kgf-m) (163 Ib-ft) T2: 33N-m (3.4kgf-m) (25 Ib-ft) T3: 132N-m (13.5kgf-m) (98 Ib-ft) T4: 86N-m (8.8kgf-m) (64 Ib-ft) T5: 53N-m (5.4kgf-m) (39 Ib-ft) T6: 90N-m (9.2kgf-m) (67 Ib-ft) T7: 892N-m (91.0kgf-m) (658 Ib-ft) T8: 1373N-m (140.0kgf-m) (1010 Ib-ft)

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

Note : 1. Axle nut tightening procedure 1)Tighten the axle nut (A) with 1765N-m (180kgf-m)(1,300 Ib-ft) tightening torque to install the taper roller bearing.

2)Loosen the axle nut (A).

3)Tighten the axle nut (A) again with 1765N-m (180kgf-m)(1,300 Ib-ft) tightening torque.

4)Turn the wheel hub 2 〜3 turns back and forth, and measure the preload applied to section (B). Preload of section (B) : 226〜265N (23〜27kgf) (50〜59 Ibs) This is "breakaway" force. The force required to start the wheel turning.

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

24-17

Removing and Reinstalling Front Axle

90Z Ⅳ -2

POWER 24

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

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

Stand Stand

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

1

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

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

Reassembly : Clean the nylon breather tube before reinstalling.

70K24019

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

Torque for assembly: : Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent (Three Bond 1327) application

2

70K24020

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

3

: 1 Tire : 650kg (1,450 lbs) Torque for assembly: : Retainer bolt : 892-m (91.0kgf-m) (658 lb-ft)

70K24021

24-18

Removing and Reinstalling Front Axle

90Z Ⅳ -2

POWER 24

6)Disconnect the right and left brake pipes (1). : Brake oil : 0.2 l (0.05 gal.)

4 70K24022

7) Temporarily sling the axle assembly (5), and then remove eight retainer bolts (6). : Axle assembly : 1,350kg (2,970 lbs) Torque for assembly: : Retainer bolt : 1,373N-m (140kgf-m) (1,013 lb-ft) Note: During reassembly be sure both surfaces are clean and free of paint.

5

mating

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

24-19

6 70K24023

Removing and Reinstalling Front Axle

90Z Ⅳ -2

POWER 24

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

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

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

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

Finally the spider and the cover may fall off.

Spider ９０Ｗ５４００２

Socket bolt

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

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

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

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

Completely bleed each wheel of air.

24-20

90Z Ⅳ -2

Rear Axle Assembly Tightening Torque

POWER 24

Rear Axle Assembly Tightening Torque (S/N 90C3-5501〜5600)

Axle support group

(B)

T5 T5

T6 L1

T7

T5 Rear differential

(A)

T4 L1

T3 L 1

T5

T8

T9 L 1

Tire & disk wheel group

T2

85W24020

:Bolt tightening torque T2 :892N-m (91.0kgf-m) (658 lb-ft) T3 :216N-m (22.0kgf-m) (159 lb-ft) T4 :314N-m (32.0kgf-m) (232 lb-ft) T5 :78N-m (8.0kgf-m) (58 lb-ft) T6 :54N-m (5.5kgf-m) (40 lb-ft) T7 :34N-m (3.5kgf-m) (25 lb-ft) T8 :86N-m (8.8kgf-m) (64 lb-ft) T9 :90N-m (9.2kgf-m) (67 lb-ft)

Note: Tighten (A) while measuring the preload applied to section (B) .

Preload of section (B) : 226〜265N (23〜27kgf) (50〜59 lbs)* *This is "breakaway" force. The force required to start the wheel turning.

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

24-21

90Z Ⅳ -2

Rear Axle Assembly Tightening Torque

POWER 24

Rear Axle Assembly Tightening Torque (S/N 90C3-5601〜)

Axle support group

B T5 T5 T5 T6 L 1

Rear differential

T7 T4 L 1 A T3 L 1

T9

L1

8 T5 T

Tire & disk wheel group

: Bolt tightening torque T2 : 892N-m (91.0kgf-m) (658 lb-ft) T3 : 221N-m (22.5kgf-m) (163 lb-ft) T4 : 314N-m (32.0kgf-m) (232 lb-ft) T5 : 78N-m (8.0kgf-m) (58 lb-ft) T6 : 53N-m (5.4kgf-m) (39 lb-ft) T7 : 33N-m (3.4kgf-m) (25 lb-ft) T8 : 86N-m (8.8kgf-m) (64 lb-ft) T9 : 90N-m (9.2kgf-m) (67 lb-ft)

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

T2

Note : 1. Axle nut tightening procedure 1)Tighten the axle nut (A) with 1765N-m (180kgf-m)(1,300 Ib-ft) tightening torque to install the taper roller bearing.

2)Loosen the axle nut (A).

3)Tighten the axle nut (A) again with 1765N-m (180kgf-m)(1,300 Ib-ft) tightening torque.

4)Turn the wheel hub 2 〜3 turns back and forth, and measure the preload applied to section (B). Preload of section (B) : 226〜265N (23〜27kgf) (50〜59 Ibs) This is "breakaway" force. The force required to start the wheel turning.

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

24-22

Axle Support Tightening Torque

90Z Ⅳ -2

POWER 24

Axle Support Tightening Torque

T2 L1

T1 L2

FRONT

85W24021

:Bolt tightening torque T1 :686N-m (70.0kgf-m) (506 lb-ft) T2 :441N-m (45.0kgf-m) (326 lb-ft)

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

24-23

Removing and Reinstalling Rear Axle Assy

90Z Ⅳ -2

POWER 24

Removing and Reinstalling Rear Axle Assembly 1.Removing rear axle assembly WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. ・ Apply the articulation stopper. ・ Block the front wheels with chocks or the like to prevent the wheels from moving.

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

A

80K24029

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

Check that the rear wheels are off the ground.

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

B

80K24030

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

Wooden blocks

WARNING The axle will not be balanced when a tire is removed. If wooden blocks are not inserted, your fingers or body may be caught in the machine.

: Lower cover : 28kg (62 lbs) 80K24031

24-24

90Z Ⅳ -2

Removing and Reinstalling Rear Axle Assy

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

POWER 24

1

: Tire of 1 wheel : 650kg (1,450 lbs) (without hydroinflation) Torque for assembly: : Retainer bolt : 892N-m (91.0kgf-m) (658 lb-ft)

80K24032

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

Torque for assembly: : Retainer bolt : 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent (Loctite 262) application : Third propeller shaft : 13kg (30 lbs)

2

Rear differential

3

6)Disconnect the air breather tube (4).

Note: Remove and clean the tube reinstalling.

(4)

3rd propeller shaft 80K24033

before 4

Rear axle

80K24034

7)Disconnect the front and rear grease pipes.

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

5

: Brake oil : approx. 3 l (0.79 gal.)

Note: Cover and plug the hose and fittings on the auto adjuster valve to prevent dirt entry.

85K24025

24-25

6

Removing and Reinstalling Rear Axle Assy

90Z Ⅳ -2

POWER 24

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

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

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

8

CAUTION

7

80K24036

The axle assembly could fall off the carrier causing injury.

Before pulling out the rear axle, carefully position the axle onto the carrier using a strap so that the axle will not fall from the carrier.

Torque for assembly: : Retainer bolt : 686N-m (70.0kgf-m) (506 lb-ft) : Rear axle : 1,700kg (3,740 lbs) Note: Be careful not to bend or damage the oil pipes.

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

10

: Axle support : 88.0kg-m (194 lb-ft) 11)Remove the packing (11) and the O-ring (12).

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

11

12

9 15 14

13

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

Torque for assembly: : Retainer bolt : 441N-m (45.0kgf-m) (326 lb-ft) : Axle support : 108kg (238 lbs)

80K24037

Breather

16 24 21 Grease piping

17

25 23

18

22

19 20 26

24-26

80K24038

Removing and Reinstalling Rear Axle Assy

90Z Ⅳ -2

POWER 24

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

Breather

16 24 21 Grease piping

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

17

25 23

18

22

19 20

26

85W24033

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

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

Front support

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

8

Bushing

2

9

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

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

Axle support

1 7 31

56

Swing shaft 85W24022

Rear support

Axle support

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

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

13 Bushing

12

11

3 4 5

10

Swing shaft

6

24-27

77.1

4.5

85W24023

Disassembling and Reassembling Planetary Assembly

90Z Ⅳ -2

POWER 24

Disassembling and Reassembling Planetary Assembly 1.Disassembling planetary Notes:

・ Front axle is shown. To raise the rear axle off the ground follow the steps of "Removing and Reinstalling Rear Axle Assy".

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

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

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

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

Stand Stand

1

:Tire of 1 wheel: 650kg (1,450 lbs) Torque for assembly: :Retainer bolt : 892N-m (91.0kgf-m) (658 lb-ft)

B

A

70V24022

4)Remove the drain plug (2) from the differential section to drain oil. :Gear oil : Approx. 43 l (11.5 Gal.)

2 70K24037

24-28

Disassembling and Reassembling Planetary Assembly

90Z Ⅳ -2

POWER 24

5)Turn the drain plug (4) to the bottom of the wheel hub (3) to drain oil. :Gear oil : Approx. 32 l (8.4 Gal.) Note: To replace the oil, refer to the oil amount described below.

Wheel hub section : 16 l (4.2 Gal.)for left side, 16 l (4.2 Gal.)for right side Differential section : 43 l (11.5 Gal.) 〔48 l (12.7 Gal.)for rear〕 Total oil amount for front axle : 75 l (20.0 Gal.) Total oil amount for rear axle : 80 l (21.1 Gal.)

3 4

6)Remove the cover (5).

Torque for assembly: :Retainer bolt : 90N-m (9.2kgf-m) (67 lb-ft) :Screw lock agent (Three Bond 1327) application

70K24038

5

70K24039

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

Torque for assembly: :Retainer bolt : 86N-m (8.8kgf-m) (64 lb-ft) :Spider assembly : 95kg (209 lbs)

A E

7

6

70V24018

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

9 8

10

9)Remove the friction plates (10).

70V24019

24-29

Disassembling and Reassembling Planetary Assembly

90Z Ⅳ -2

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

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

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

POWER 24

11 12

70K24042

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

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

15 14

16

13

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

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

70K24043

Turnbuckle

E

3 70K24044

13)Remove the axle nut (17).

Torque for assembly: :Nut : 1,765N-m (180kgf-m) (1,300 lb-ft) Note: Axle nut width across flat:120mm

17

85W24024

24-30

Disassembling and Reassembling Planetary Assembly

90Z Ⅳ -2

POWER 24

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

18

B 85W24025

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

And remove the hub (18).

C

18

85K24029

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

Then remove the wheel hub (3).

D

E

3

70K24048

17)Remove the oil seal (19). Also remove the sleeve from the axle. (S/N 90C3 - 5501〜5600) Note: Disassemble the other wheels as described above.

19

85K24030

24-31

Disassembling and Reassembling Planetary Assembly

90Z Ⅳ -2

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

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

24-32

POWER 24

Disassembling and Reassembling Planetary Assembly

90Z Ⅳ -2

POWER 24

3.Cautions regarding reassembly 1)To insert the oil seal into the wheel hub, use the wheel hub oil seal press-in jig (F).

2)Pack grease into the clearance between the oil seal and sleeve.

Note: Refer to "Floating Seal" for the machines S/N 90C3 - 5601 and up.

Oil seal

Packed grease

Sleeve

3)Reinstall the internal gear hub assembly (18).

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

(S/N 90C3 - 5501〜5600)

18

Spring pin 85K24037

Example LF

4)Tighten the axle nut (17) so that the preload of the tire mounting hole section is 226 to 265N (23 to 27kgf) (50 to 59 lbs).

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

17 85W24026

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

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

Jig (G) Shut off valve

Air supply PT 1/4

Air pressure gauge

20

19 85W24027

24-33

Disassembling and Reassembling Planetary Assembly

90Z Ⅳ -2

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

2 Apply 588kPa (6kgf/cm ) (85 psi) air pressure for approxi- mately 1 minute. Shut off the valve.

Check that the pressure does not fall.

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

POWER 24

Jig (B)

８５Ｗ２４０２８

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

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

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

Steel plate

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

Wheel hub Spider "TOP" mark (at top)

Brake oil line

Drain plug (at bottom)

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

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

24-34

90Z Ⅳ -2

Floating Seal

POWER 24

Floating Seal (S/N 90C3-5601〜) Construction Floating seal location Assembling procedure 1.Checking before seal installation (1)Checking seal ・Check the seal ring for distortion and scratches. ・Check the O-ring for scratches.

Floating seal Wheel hub Axle housing

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

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

Ring Ring

Remove oil

Seal cross section

Put thin gear oil (Do not use grease)

O-ring

Seal Ring

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

Do not touch by hand (It may cause rusting)

24-35

90Z Ⅳ -2

Floating Seal

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

POWER 24

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

Guide jig

(2)In case jig is used

1

2

Before installation

3

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

4

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

Guide jig

Installation jig

After installation

24-36

Floating Seal

90Z Ⅳ -2

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

24-37

POWER 24

Removing and Reinstalling Differential

90Z Ⅳ -2

POWER 24

Removing and Reinstalling Differential 1.Removing differential Before starting work: a)Drain oil from the axle assembly. b)Remove the axle from the machine. c) Place the axle assembly on workbenches. d)For the rear axle, remove the axle supports. For axle support removal, refer to the steps of "Removing and Reinstalling Rear Axle Assembly". : Axle assembly Front : 1,300kg (2,870 lbs) Rear : 1,700kg (3,750 lbs)

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

Torque for assembly: : Retainer bolt : 86N-m (8.8kgf-m) (64 lb-ft) : Spider assembly : 95kg (209 lbs)

A 1

TOP

2

2)Pull out the right and left axle shafts (3) 30cm (1.18 in.).

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

Torque for assembly: : Front differential retainer bolts : 132N-m (13.5kgf-m) (98 lb-ft) : Rear differential retainer bolts : 314N-m (32.0kgf-m) (232 lb-ft) : Screw lock agent (Loctite 262) application

3

4

5

24-38

Removing and Reinstalling Differential

90Z Ⅳ -2

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

POWER 24

Spacers

Spacers in " " mark sections

4) Temporarily sling the differential (4), and insert bolts into the remover tap (Jack Screw) holes (6) to slightly lift the differential. : Differential : 178kg (390 lbs) Note: Be careful to sling the differential so that it is balanced and is lifted straight up.

4

6 70V24032

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

7

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

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

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

Also check the differential for oil leakage.

24-39

90Z Ⅳ -2

Special Jigs for Disassembling Axle

POWER 24

Special Jigs for Disassembling Axle (A) Spider hoisting tool

(Material: SS41)

46

6-mm dia.round steel 4 10

C2

12 3 75

3 65

6

t6

t6

6

105

10

22

46

t6

65

(B) Internal gear hub puller

(Material: SS41)

30

30

t12 M16

4

2

130

12

90

180 260 330

８５Ｗ２４０３５

24-40

90Z Ⅳ -2

Special Jigs for Disassembling Axle

POWER 24

(C) Internal gear hub hoisting tool

(Material: SS41) φ 13-mm drilled

75

35

t12

35

235 107

345

25

①

452

35

13

155

288

②

35 t9

31

27.5

35 90 A-A

A

A

24-41

27.5

25

15

3 15

7

10

t9

15

310

215

90Z Ⅳ -2

Special Jigs for Disassembling Axle

(D) Wheel hub hoisting tool

POWER 24

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

(Material: SS41)

10

4

4

3

20

t6

t6

3

3

10

25 ※

55

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

3

4

20

t6

60

(E) Eye bolt

M24 × 2

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

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

30

(F) Wheel hub oil seal press-in jig

(Material: SS41) 20

30

4

13

φ 30

φ 238 φ 230

7

Welded 5

24-42

5

C

10 ± 0.3

-0.25

10 ± 0.3 10 ± 0.3

R0.3

)

3

R0.2〜R0.5

24-43

2.

13

C

R0.2〜R0.5

For wheel hub

1.

20 13 3

3C

(

3

2. (

Φ 230

90Z Ⅳ -2

Φ 260

3C

Φ 190

1.

Φ 220

7 ± 0.2

3

Φ 224.8 0 Φ 214.6-0.1 Φ 209.6± 0.1 Φ 201.1 ± 0.1

20

Φ 242 ± 0.1 Φ 235 ± 0.1

15

( )

Φ 214.8+0.1 +0.05 Φ 270

For wheel hub

Φ 258 Φ 246.20-0.1

2.

-0.30

8 ± 0.2

Φ 226-0.35 Φ 209.4 ± 0.1

3

Φ 230

15

(

Φ 247.2+0.1 +0.05 Φ 260

3 Φ 190

Φ 224.8 0 Φ 214.6-0.1 Φ 209.6+0.1 Φ 201.1 ± 0.1

Φ 240

Φ 235

Φ 214+0.1 +0.05

2.

Φ 256-0.3 Φ 241 ± 0.1

Φ 223+0.25 +0.3 Φ 209.4 ± 0.1

1.

Φ 260

1.

Φ 220

Φ 258 Φ 246.20-0.1 Φ 242 ± 0.1 Φ 235 ± 0.1

Φ 270

5

Φ 265

+0.1

Φ 247.2+0.05

Φ 241.8 ± 0.1

Φ 253+0.25 +0.3

Special Jigs for Disassembling Axle POWER 24

(K) Floating seal jig (1)70ZIV-2〜80ZIV-2

For ring )

20 11 ± 0.2

3 3

10 ± 0.3

C 10.4 ± 0.3

R0.3 R0.2〜R0.5

(2)85ZⅣ -2〜90ZⅣ -2

For ring )

20 10.9 ± 0.2

3 3

12 ± 0.1

10 ± 0.3

C

12 ± 0.1

R0.3

R0.3

R0.2〜R0.5

Internal Gear Hub

90Z Ⅳ -2

POWER 24

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

1

2

2)Remove the taper roller bearing (3).

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

3

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

Torque for assembly: : Locknut : 33N-m (3.4kgf-m) (25 lb-ft)

5

4

4)Remove the return spring (6).

6 5

24-44

Internal Gear Hub

90Z Ⅳ -2

POWER 24

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

2 1

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

3

4

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

5

6

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

5

7

24-45

90Z Ⅳ -2

Internal Gear Hub

POWER 24

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

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

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

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

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

1

Oil groove

12

10 85W24029

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

3)Apply grease to the O-rings.

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

3

90K24007

24-46

90Z Ⅳ -2

Front Differential Tightening Torque

POWER 24

Front Differential Tightening Torque

7

〜

Shim (T=0.07) (T=0.50) 〜

(T=16.70) (T=16.98)

８５Ｗ２４０３０

: Bolt tightening torque T1 : 883N-m (90.0kgf-m) (651 lb-ft) T2 : 515N-m (52.5kgf-m) (380 lb-ft) T3 : 331N-m (33.7kgf-m) (244 lb-ft) T4 : 314N-m (32.0kgf-m) (232 lb-ft) T5 : 235N-m (24.0kgf-m) (174 lb-ft) T6 : 53N-m (5.35kgf-m) (39 lb-ft) T7 : 132N-m (13.5kgf-m) (98 lb-ft)

T1 , measure the preload of section Note: 1) To tighten ◯ ◯ A. Preload of section ◯ A : 57 to 66N (5.8 to 6.7kgf) (13 to 15 lbs) Use spacer ◯ B to adjust the preload.

2)Use shim ◯ E to adjust the tooth contact of spiral bevel gears ◯ C◯ D. Adjust the backlash by nut ◯ F.

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

24-47

90Z Ⅳ -2

Rear Differential Tightening Torque

POWER 24

Rear Differential Tightening Torque

7

〜

Shim (T=0.07) (T=0.50) 〜

(T=16.70) (T=16.98)

８５Ｗ２４０３１

: Bolt tightening torque T1 : 883N-m (90.0kgf-m) (651 lb-ft) T2 : 515N-m (52.5kgf-m) (380 lb-ft) T3 : 331N-m (33.7kgf-m) (244 lb-ft) T4 : 314N-m (32.0kgf-m) (232 lb-ft) T5 : 235N-m (24.0kgf-m) (174 lb-ft) T6 : 53N-m (5.35kgf-m) (39 lb-ft) T7 : 314N-m (32.0kgf-m) (232 lb-ft)

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

Preload of section : 57 to 66N (5.8 to 6.7kgf) (13 to 15 lbs) Use spacer ◯ B to adjust the preload.

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

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

24-48

Differential Assy

90Z Ⅳ -2

POWER 24

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

Torque for assembly: :Nut (A) : 883N-m (90kgf-m) (651 lb-ft) Note: Nut width across flat: 57.1mm

Adjust nut

Shim

Bevel gear Nut (A)

Pinion

Adjust nut

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

1

2

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

3

4

1 ７０Ｖ３４０３４

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

5 6

24-49

Differential Assy

90Z Ⅳ -2

POWER 24

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

7

8 Match mark 70K24064

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

10 9 70K24065

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

12

13 11 70K24066

7)Remove the side gear (14).

14 70K24067

24-50

Differential Assy

90Z Ⅳ -2

POWER 24

8)Remove the thrust washer (15).

15

70K24068

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

17

16 70K24069

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

19

18

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

Note: Nut width across flat:57.1mm.

20

24-51

21

Differential Assy

90Z Ⅳ -2

POWER 24

12)Remove the flange yoke (22).

22

70V24035

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

23

24

14)Remove the taper roller bearing (25).

25

15)Remove the spacer (26).

26

24-52

90Z Ⅳ -2

Differential Assy

POWER 24

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

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

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

Note: Do not install the oil seal and O-ring of the nut. : Nut : 883N-m (90kgf-m) (651 lb-ft) ⑤Measure the preload at section (A) (bolt hole).

24 26

20

25 27

23

A

28

22 70V24036

Pinion

Bearing

Pinion

: Standard preload * : 57 to 66 N (5.8 to 6.7kgf) (13〜15 lbs) If the preload is out of the above range, replace the spacer (26) to adjust the preload to the specified range. * Preload is the force required to start the cage moving-breakaway force.

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

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

24-53

Stake at 3 points

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

29 24

Differential Assy

90Z Ⅳ -2

POWER 24

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

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

(Nut width across flat : 57.1mm)

22 20

: Nut : 883N-m (90kgf-m) (651 lb-ft) : Liquid gasket (Three Bond 1215) application

21

Shim

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

18

31

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

30

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

15 14 32

70K24073

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

12 13 11

24-54

Differential Assy

90Z Ⅳ -2

POWER 24

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

9 10

70K24074

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

8

: Retainer bolt : 235N-m (24.0kgf-m) (174 lb-ft) : Screw lock agent (Three Bond 1327) application

7

Match mark

9) Tighten the bolts (17) in the bevel gear (16). : Retainer bolt : 331N-m (33.7kgf-m) (244 lb-ft) : Screw lock agent (Three Bond 1327) application 17 15

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

24-55

6

Differential Assy

90Z Ⅳ -2

POWER 24

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

(For both the right and left sides)

3

4

Adjust nut

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

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

Standard backlash : 0.26 to 0.38mm (0.0102〜0.0149 ″) ・ Tighten the adjustment nut (33) on the bevel gear side or loosen the adjustment nut (1) on the opposite side to reduce the backlash. ・ Loosen the adjustment nut (33) on the bevel gear side or tighten the adjustment nut (1) on the opposite side to increase the backlash.

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

24-56

1

16

33

2

34 3 4

90Z Ⅳ -2

Differential Assy

POWER 24

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

Tooth contact

A

Adjusting method

Correct

Loosen the bearing adjuster on the rear side of 2

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

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

Check again the backlash and tooth contact.

2

C

Do the reverse adjusting as B.

Decrease the thickness of shim at the part of D

2

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

Check again the backlash and tooth contact.

1

E

2

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

1

24-57

90Z Ⅳ -2

Differential Assy

POWER 24

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

Tooth contact position and length(rate) 10 1

Pattern A

5 TOP

4

HEEL 4〜5

Pitch line TOE

10

BOTTOM 10 2

Pattern B

4 TOP

4

Pitch line

HEEL 4〜5

10

TOE BOTTOM 10 3 Pattern C

4 TOP

3

TOE Pitch line

HEEL 4〜5

10

BOTTOM

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

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

24-58

Spider Assy

90Z Ⅳ -2

POWER 24

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

Torque for assembly: : Lock bolts : 216N-m (22.0kgf-m) (159 lb-ft) : Screw lock agent (Three bond 1327) application 2 1

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

1 3

④

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

Bearing (5) : width 20mm (0.787 in.)

Bearing (6) : width 25mm (0.984 in.)

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

5 6

4

7

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

8

9

24-59

Spider Assy

90Z Ⅳ -2

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

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

24-60

POWER 24

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

25-1

90Z Ⅳ -2

Propeller Shaft Service Standard

POWER 25

Propeller Shaft Service Standard

1

Third propeller shaft

1

Second propeller shaft 1

2 Measurement of circumferential play

a

b

3 Measurement of transverse play

mm (inch) No.

Item

Tolerance

Solution

1

Spider bearing play

Second, third propeller shaft

0.25 (0.0098)

Replacement

2

Spline circumferential play

Second propeller shaft

0.8 (0.0315)

Replacement

3

Spline transverse play

Second propeller shaft

1.0 (0.0394)

Replacement

Note: Bolt tightening torque a:69N-m (7.0kgf-m) (51 lb-ft) b:156N-m (15.0kgf-m) (109 lb-ft)

25-2

Axle and Differential Service Standard

90Z Ⅳ -2

POWER 25

Axle and Differential Service Standard Axle group

4

5

2・3

1・3

4

5 90Z Ⅳ 2404

mm (inch) Judgment standard No.

Item

Solution Standard dimension

Tolerance

1

Backlash between sun gear and planetary gear

0.12〜0.60 (0.0047〜0.0236)

←

Replacement

2

Backlash between planetary gear and internal gear

0.14〜0.73 (0.0055〜0.0287)

←

Replacement

3

Tooth contact of gear

No abnormality

Replacement

4

Axle support wear

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

Replacement

5

Bushing and wear ring wear

No oil groove

Replacement

25-3

Axle and Differential Service Standard

90Z Ⅳ -2

POWER 25

Differential

①

② ③

④

mm (inch) Judgment standard No.

Item

Solution Standard valve

Tolerance

1

Backlash between ring gear and drive pinion

0.26〜0.38 (0.0102〜0.0149)

←

Adjustment

2

Backlash between side gear and pinion gear

0.23〜0.58 (0.0090〜0.0228)

←

Adjustment

3

Clearance between pinion gear and spider

0.098〜0.126 (0.0038〜0.0049)

←

Replacement

4

Runout of ring gear rear surface (when assembled)

0.076 (0.0029)

←

Adjustment or replacement

5

Tooth surface wear (each gear)

Abnormal wear or missing

Replacement

6

Tooth contact

No abnormality

Replacement

25-4

TORQUE CONVERTER AND TRANSMISSION GROUP 34 Transmission Assembly Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-2 Removing and Reinstalling Transmission Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-3 Bolt Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-10 Disassembling and Reassembling Torque Converter ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-11 Disassembling and Reassembling Transmission Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-18 Disassembling and Reassembling Forward/Reverse Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-31 Disassembling and Reassembling 1st/3rd Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-39 Disassembling and Reassembling 2nd Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-43 Disassembling and Reassembling 4th Speed Clutch Pack ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-46 Control Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-50 Removing and Reinstalling Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-51 Disassembling and Reassembling Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 34-53

34-1

Transmission Assembly Tightening Torque

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

Transmission Assembly Tightening Torque

T4 L 1 T3 L 2

L 1 T4

T5 L 1

T1 L 2

T6 L 1

1 L2 T1

T5 L 1

T5 L 1

T3 L2

T5 L 1 T4 L 1

T4 L 1

T4 L 1 90W34001

: Bolt tightening torque T1 : 53N-m (5.4kgf-m) (39 lb-ft) T3 : 417N-m (42.5kgf-m) (307 lb-ft) T4 : 216N-m (22.0kgf-m) (159 lb-ft) T5 : 142N-m (14.5kgf-m) (105 lb-ft) T6 : 441N-m (45.0kgf-m) (326 lb-ft)

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

34-2

Removing and Reinstalling T / M Assy

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

Removing and Reinstalling Transmission Assembly 1.Removing transmission assembly WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground. Lower the bucket onto the ground, and then block the tires with chocks to prevent wheels from moving. ・ Disconnect the ground cable from the negative side of the battery.

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

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

1

85K34001

: Transmission oil : 38 l (10 gal.)

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

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

Keep the flame away from the seals of the coupling.

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

Tightening torque for assembly : Bolt : 142N-m (14.5kgf-m)(105 lb-ft) : Screw lock agent application (Three Bond 1327) 3)Remove the bolt (5) from the second propeller shaft on the transmission side only. Disconnect the electric wire (6) (7) from the speed meter sensor and speed sensor.

Tightening torque for assembly : Bolt : 142N-m (14.5kgf-m)(105 lb-ft) : Screw lock agent application (Three Bond 1327) Note: The speed sensor (6) is for the machines S/N 90C3 - 5501〜5800.

2 4 3 5 85K34002

6 7

85K34003

34-3

Removing and Reinstalling T / M Assy

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

8

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

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

90W34002

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

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

13 11 12 9

10

85K34005

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

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

14 85K34006

34-4

Removing and Reinstalling T / M Assy

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

IMPORTANT

16

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

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

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

15 17

90W34003

9) Temporarily sling the steering valve. Remove the bolts (17), and then remove the steering valve with the bracket as a unit.

Tightening torque for assembly : Bolt : 216N-m (22.0kgf-m) (159 lb-ft) : Steering valve : 30kg (66 lbs) (including bracket)

10)Remove all the connected hoses (19) from the gear pump assembly (18), and then remove the pump assembly (18).

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

Refer to the Section 44 "Hydraulic Group" for the reinstallation.

Tightening torque for assembly : Bolt : 147N-m (15.0kgf-m) (109 lb-ft) : Gear pump : 47kg (103 lbs)

19

18

90W34004

11)Disconnect the electrical wire for the torque converter temperature switch sensor (20).

Disconnect the main clutch pressure outlet hose (21).

Note: After removing the hoses, cover the hoses with vinyl to protect from dust and dirt.

20 21

90W34005

34-5

Removing and Reinstalling T / M Assy

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

12)There are two hoses (22) between torque converter and the cooler. There are two hoses (23) between the line filter and the transmission. Disconnect the hoses (22)(23).

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

22

23 90W34006

13)Remove all the electric wire couplers (25) from the control valve (24).

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

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

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

25

24

90W34007

14)Temporarily sling the transmission assembly (25), and then remove 12 bolts (26) from the engine flywheel housing.

Tightening torque for assembly : Bolt : 53N-m (5.4kgf-m) (39 lb-ft) : Transmission assembly : 880kg (1,940 lbs)

26

25

90W34008

15)Remove the bolts (27) (both sides).

Tightening torque for assembly : Bolt : 22.0kg-m (159 lb-ft) 27

85Z Ⅳ US 3401

34-6

Removing and Reinstalling T / M Assy

90Z Ⅳ -2

Note: The joint section between the engine and the transmission consists of the pilot boss and the gear coupling as shown in the figure. The pilot boss is inserted for centering, and the gear coupling is used for power transmission. To separate the transmission from the engine, remove the bolts from the engine flywheel housing, and then pull the transmission straight out approximately 50mm(2 in.)to the front.

TORQUE CONVERTER AND TRANSMISSION 34

Engine flywheel housing

Flywheel Pull 50 cm to separate transmission

Pilot boss Ring gear

Transmission

Engine-transmission joint section

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

Note: Lift the transmission approximately 100mm(4 in.), and then insert a wooden piece of 200mm(8 in.) into the clearance between the bottom of the engine flywheel housing and the rear axle housing. Lower the transmission to make a slight clearance between the engine and the transmission.Repeat the above procedure 2 to 3 times while pulling the transmission away from the engine to separate them.

Chocks

Block here 34-008-1 85Z Ⅳ

Wooden block

85K34016

17)Slowly lift the transmission assembly (28) while avoiding contact with other parts.

28

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

90W34009

34-7

Removing and Reinstalling T / M Assy

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

3.Cautions for installation ① Be sure to replace the O-ring (2) with new one.

2

90W34010

② Rotate the engine flywheel to align the ring gear. ③ After reinstallation, check operation of the transmission assembly by the following procedure.

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

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

85K34019

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

2)Check each section for oil leakage.

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

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

34-8

90Z Ⅳ -2

Removing and Reinstalling T / M Assy

DATE:

HOURS:

TORQUE CONVERTER AND TRANSMISSION 34

MACHINE MODEL & SERIAL NO. :

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO. :

AMBIENT TEMP:

COMPONENT SERIAL NO. :

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

□ TRANSMISSION PIPING CLEANED

□ IN-LINE PRESSURE FILTER REPLACED

□ TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

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

CLUTCH PRESSURE AT IDLE F1

kg/cm

2

N1

kg/cm2

R1

kg/cm2

F2

kg/cm2

N2

kg/cm2

R2

kg/cm2

F3

kg/cm2

N3

kg/cm2

R3

kg/cm2

F4

kg/cm2

N4

kg/cm2

R4

kg/cm2

F1

kg/cm

2

N1

kg/cm2

R1

kg/cm2

F2

kg/cm2

N2

kg/cm2

R2

kg/cm2

F3

kg/cm2

N3

kg/cm2

R3

kg/cm2

F4

kg/cm2

N4

kg/cm2

R4

kg/cm2

CLUTCH PRESSURE AT HIGH IDLE

COMMENTS:

Serviceman's Signature

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

34-9

90Z Ⅳ -2

Bolt Tightening Torque

TORQUE CONVERTER AND TRANSMISSION 34

Bolt Tightening Torque

T2

T2 L1

T1 T2 L1

T3 L 1 T5

T4 85ZA3201

T2

T1 : 29N-m (3kgf-m)(22 lb-ft) T2 : 53N-m (5.4kgf-m)(39 lb-ft) T3 : 235N-m (24kgf-m)(174 lb-ft) T4 : 392N-m (40kgf-m)(289 lb-ft)(Molybdenum disulfide grease / MOS2 application) T5 : 98N-m (10kgf-m)(72 lb-ft) L1 : Screw lock agent application (Loctite 262)

10

Torque Converter

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

2

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

1 85K34020

2)Removing the front cover from the pump impeller.

Remove the bolts (3). (Number of bolts : 24) Tightening torque for assembly : Bolt : 29N-m (3kgf-m) (22 lb-ft)

3 85K34021

3)Remove the front cover (4).

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

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

4 5

Shim

85K34022

4)Remove the turbine impeller assembly (8).

8

85W3401

11

Torque Converter

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

10

9 11

85W3402

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

13

12

85W3403

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

15 17

16

14

85W3404

8)Remove the pump impeller assembly (18).

18

85W3505

12

90Z Ⅳ -2

Torque Converter

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

TORQUE CONVERTER AND TRANSMISSION 34

19

20 21

85W34006

10)Remove the seal ring (22).

11)Separate torque converter transmission housing.

housing

from 25

23

12)Turn the torque converter housing over.

13)Remove the turbine shaft (24).

22 24

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

34-013 85Z Ⅳ

13

90Z Ⅳ -2

Torque Converter

TORQUE CONVERTER AND TRANSMISSION 34

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

1) Turn the torque converter housing over.

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

1

4

5

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

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

2

3

2

3

4

4

85K34028

35.2

85W34007

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

Tightening torque for assembly : Nut : 50N-m (5.1kgf-m)(37 lb-ft) : Screw lock agent application (Loctite 262)

14

90Z Ⅳ -2

Torque Converter

TORQUE CONVERTER AND TRANSMISSION 34

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

21

6) Install the turbine shaft (24) .

25 23

20

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

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

22 85W34008

24

9) Tighten the bolts (20) to fix the stator shaft (21). : Bolt : 53N-m (5.4kgf-m) (39 lb-ft) : Screw lock agent application (Loctite 262)

18 7

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

8 85W34009

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

6

85W34010

A

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

Adjusting shim 34-015 85Z Ⅳ

15

90Z Ⅳ -2

Torque Converter

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

TORQUE CONVERTER AND TRANSMISSION 34

18

16 17

15

14

85W3404

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

13

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

Correctly install the stator (13).

12

85W3403

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

10

9 11

85W3402

13)Install the turbine impeller assembly (8).

8

85W3401

16

Torque Converter

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

Number of bolts : 24 : Bolt : 29N-m (3kgf-m) (22 lb-ft)

3 85W34011

15)Install the cover (2), and then tighten the bolts (1). : Bolt : 39N-m (4.0kgf-m) (29 lb-ft) Note: At the completion of reassembly, manually turn the front cover to check that it rotates smoothly.

2

1 85W34012

17

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

1)Remove the bolts (1).

2) Lift the control valve assy (2), and remove it. : Control valve assembly : 20kg (44 lb) 2

1 85W3406

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

4

3

85W3407

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

6

5

85W3408

18

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

8

7 85W3409

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

10

11 10

7)Remove the bolts (9).

Lift the cover assy (12) to remove it.

85W3410

9 12

85W3411

8)Remove the gear (13).

13

85K34046

19

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

9)Remove the bolt (14).

14 85K34047

10) Remove the output shaft (15).

15

85K34050

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

16

85K34051

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

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

17

85K34052

20

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

13)Remove the bolt (18).

18

85K34053

14) Lift the housing (19) slowly.

19

85K34054

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

20

85K34055

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

Note: Pull out the 2nd and the reverse speed clutch pack assembly. It is tight due to the ball bearing between the housing and the shaft.

21

85K34056

21

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

17)Remove the turbine shaft assembly (22).

22

85K34057

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

24 25 23

85K34058

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

27

26

85K34059

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

29

28

22

85K34060

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

2.Reassembling transmission assembly Note:

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

29

30

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

Note: ・Check the thrust clearance (0.5 to 1.0mm) at the pump shaft (30) (PTO shaft).

Tap the shaft with a soft hammer to check the thrust clearance, if necessary. : Bolt : 53N-m (5.4kgf-m)(39 lb-ft) 28

85W34013

2) Install the shaft (27) with the bolt (26). : Bolt : 53N-m (5.4kgf-m)(39 lb-ft) 27

26

85W34014

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

Install the plate (24) and tighten the bolt (23). : Bolt : 53N-m (5.4kgf-m)(39 lb-ft)

23

25

24

85W34015

23

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

4) Install the turbine shaft assembly (22).

22

85W34016

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

21

85W34017

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

31

85W34018

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

20

85W34019

24

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

19

85W34020

9) Tighten the bolt (18). : Bolt : 53N-m (5.4kgf-m)(39 lb-ft)

18

85W34021

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

16

17

85W34022

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

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

15

32

85W34023

25

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

15

19

85W34024

13)Tighten the bolt (14). : Bolt : 53N-m (5.4kgf-m)(39 lb-ft)

14

85W34025

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

34 85W34026

15

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

16

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

17 85W34027

26

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

Regard the obtained distance as dimension A.

16

85W34028

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

Regard the obtained distance as dimension A ′ .

17 85W34029

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

Regard the obtained distance as dimension B.

12

85W34030

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

Regard the obtained distance as dimension B ′.

12

85W34031

27

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

B − A=0.5〜1.0mm

35 85W34032

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

B' − A' = 0.5〜1.0mm

36

85W34033

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

C

C

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

12

85W34034

28

90Z Ⅳ -2

Transmission

TORQUE CONVERTER AND TRANSMISSION 34

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

37 38

37 38

85ZA3403

85W34035

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

11

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

10

85W34036

25)Tighten the bolts (9). Install the brake assembly (8) and tighten the bolt (7). : Bolt (9) : 53N-m (5.4kgf-m)(39 lb-ft) : Bolt (7) : 235N-m (24kgf-m)(174 lb-ft)

8

9 7 85W34037

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

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

5

6

: Bolt : 98N-m (10kgf-m)(72 lb-ft) :Nut : 392N-m (40kgf-m)(289 lb-ft)

4 3

85W34038

29

Transmission

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

27)Install the control valve assembly (2) and tighten the bolts (1). :Bolt (1) : 39N-m (4.0kgf-m)(29 lb-ft) :Bolt (T6) : 20N-m (2.0kgf-m)(14 lb-ft)

2

85W34039

T6

1

85W34040

30

Forward / Reverse Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and Reassembling Forward /Reverse Clutch Pack (S/N 90C3-5501〜5700) 1.Disassembling forward/reverse clutch pack (The disassembling procedure for the reverse clutch pack is described below.)

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

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

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

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

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

For inspection and wear standard refer to "Service standard".

2 1 85K34092

2

3

1

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

5

4

6 7 85W34051

31

Forward / Reverse Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

Note: Number of friction plates: 7 Number of steel plates: 8

8 9

85W34052

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

11

10

85W34053

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

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

12 13

85W34054

32

Forward / Reverse Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

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

12 13

85W34054

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

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

11

10

85W34053

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

Note: Number of friction plates: 7 Number of steel plates: 8 After installing the piston, be sure to insert the friction plate first.

8 9

33

85W34052

Forward / Reverse Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

5

4

6 7 85W34051

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

Note:

Depth micrometer Straight edge

Piston stroke Forward

3.3±0.5mm

Reverse

3.3±0.5mm

Air line

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

Backing plate 85W34041

6) Insert the thrust washer (5).

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

4

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

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

3 1 5

85W34055

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

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

2

85W34056

34

Forward / Reverse Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

Disassembling and Reassembling Forward /Reverse Clutch Pack (S/N 90C3-5701〜) 1.Disassembling forward/reverse clutch pack (The disassembling procedure for the reverse clutch pack is described below.)

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

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

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

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

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

For inspection and wear standard refer to "Service standard".

2 1 85K34092

2

3

1

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

4 5 6 7 65A34001

35

Forward / Reverse Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

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

8

9

65A34002

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

11

10

85W34053

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

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

14 12 15

13

16 17 90W34060

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

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

36

Forward / Reverse Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

1) Install the piston (1), and 20 springs (2). If necessary gently and evenly tap the piston into place using a plastic hammer or driver.

2 1

90W34061

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

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

3

4

90W34062

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

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

5

6

37

65A34003

Forward / Reverse Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

11 9 8 7 65A34004

5)Using a straight edge and depth micrometer apply pressure (approx. 0.6MPa 〔 6kgf/cm2〕〔 85psi 〕 ) to the clutch oil port at the end of the shaft, and then measure and record the piston stroke.

Note:

Depth micrometer Straight edge

Air line

Piston stroke Forward

3.3±0.5mm

Reverse

3.3±0.5mm

Backing plate

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

85W34041

6) Insert the thrust washer (9).

Note: When inserting the thrust washer (9), put the notch side up.

11

7) Install the gear (10), and then insert two needle bearings (11) and the thrust washer (12).

Note: When inserting the thrust washer (12), put the notch side down.

12 10 9

90W34065

8) Install the ball bearing (13) and snap ring (14).

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

14 13

90W34066

38

1st / 3rd Speed Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

The different points are described for each procedure.

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

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

Spacer

1 85K34099

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

7

6

2

3

4

3rd speed

8

1st speed

5 10

9

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

12 11

Shaft assy

85K34100

39

90Z Ⅳ -2

1st / 3rd Speed Clutch Pack

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

Note: Friction plates

Steel plates

1st speed

9

8

3rd speed

5

4

TORQUE CONVERTER AND TRANSMISSION 34

14

13

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

15

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

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

16

85W34042

18

17 Shaft assy

85W34043

40

90Z Ⅳ -2

1st / 3rd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

2 1

85W34044

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

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

4 3

85W34045

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

Note: Friction plates

Steel plates

1st speed

9

8

3rd speed

5

4 5

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

6 85W34046

41

90Z Ⅳ -2

1st / 3rd Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

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

8 7 85W34047

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

Note: Piston stroke 1st speed

3.5±0.5mm

3rd speed

2.1±0.5mm

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

85K34107

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

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

9

12 11 10

85W34048

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

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

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

20 16

19 18 17

15 3rd speed

14

1st speed

13

42

2nd Speed Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

4

3

2

1

85W3423

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

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

5

6

85W3424

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

9

8 7

85W3425

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

5)Remove 20 springs (12).

12 10

11

85W34057

43

2nd Speed Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

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

13

85W34058

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

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

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

1 2

85W3428

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

6

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

7 5 3 4 85W34059

44

2nd Speed Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

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

7

8

85W34060

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

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

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

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

10

12

9

11 85W34061

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

85K34107

45

4th Speed Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

1

85W3429

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

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

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

5

4

3 2

85W34062

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

6

7

85W34063

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

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

8

9

85W34064

46

4th Speed Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

11

10

85W34065

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

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

13 12

85W34066

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

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

1 2

85W34067

47

4th Speed Clutch Pack

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

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

4

3

85W34068

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

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

5

6

85W34069

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

8

7

85W34070

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

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

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

Depth mictometer Straight edge

Air line

Backing plate 85W34041

48

90Z Ⅳ -2

4th Speed Clutch Pack

TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

１０

１２

９ １１

１２ １０ ８５Ｗ３４０７１

１１

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

8)Install the ball bearing (13).

１３

８５Ｗ３４０７２

Caution When installing the gear (32400-21230) to the shaft, follow the procedure below.

1 Assemble the gear onto the clutch drum with the bolts.

2 Heat them up to 190 ℃ .

3 Insert the shaft into the cluth drum and gear.

Clutch drum

Shaft

Gear Bolt

49

(32400-21230)

90Z Ⅳ -2

Control Valve Tightening Torque

TORQUE CONVERTER AND TRANSMISSION 34

Control Valve Tightening Torque

T1 T1

T4

T2

T3

85ZA3210

T1: 20N-m (2.0kgf-m)(14 lb-ft) T2: 39N-m (4.0kgf-m)(29 lb-ft) T3: 10N-m (1.0kgf-m)(7 lb-ft) (Solenoid valve nut) T4: 32N-m (3.5kgf-m)(24 lb-ft) (Solenoid valve body)

50

Removing and Reinstalling Control Valve

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

Removing and Reinstalling Control Valve 1.Removing control valve WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then lower the bucket onto the ground. ・ Apply the parking brake, and block the tires with chocks to prevent wheels from moving. ・ Remove the starter key, and hang a "DO NOT START !" tag on the steering wheel.

1

85K34126

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

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

Note: Put match marks on the electric wire couplers.

2 4

3 85W34049

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

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

Tightening torque for assembly : Bolt : 39N-m (4.0kgf-m)(29 lb-ft)

6

5

7

85W34050

4) Lower the control valve to remove it.

Be sure to replace the gasket .

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

: Control valve : 20kg(44 lbs)

51

Removing and Reinstalling Control Valve

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

BrL

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

BrW BrR

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

BrB BrY

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

BrG BrGy

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

Electrical Wiring

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

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

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

7)Check oil leakage.

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

52

Control valve

Transmission Control Valve

90Z Ⅳ -2

TORQUE CONVERTER AND TRANSMISSION 34

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

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

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

For other valves, follow the same procedure.

Tightening torque for assembly : Bolt : 10N-m (1.0kgf-m)(7 lb-ft)

1

85K34129

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

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

3

85K34130

2

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

Tightening torque for assembly : Valve : 34N-m (3.5kgf-m)(24 lb-ft)

A

4 85K34131

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

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

5

6 7

85K34132

53

90Z Ⅳ -2

Transmission Control Valve

TORQUE CONVERTER AND TRANSMISSION 34

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

12

11 8

10 9

2.Special tool(A) 85K34133

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

φ 30

φ 23

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

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

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

Check free lengths and if necessary replace them.

3)Check the operation of the solenoid valves.

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

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

5)Check coil resistance.

Resistance : Approx. 26 Ω

54

φ 7 Drill

.1 -0 .2 -0 7 1

5 φ 40

30

+ 0.2 + 0.1

C1

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

35-1

90Z Ⅳ -2

Transmission Assembly

TORQUE CONVERTER AND TRANSMISSION 35

Transmission Assembly

12

13

8 4

16

5 17 18

14

14 18 5 15 17

16

9 11 10

85ZA3201

35-2

90Z Ⅳ -2

Control Valve

TORQUE CONVERTER AND TRANSMISSION 35

Control Valve

1

2

6

7

3

８５ＺＡ３２０９

35-3

90Z Ⅳ -2

Control Valve

TORQUE CONVERTER AND TRANSMISSION 35

mm (in.), kg (lbs) Judgement criteria REF.

ITEM

Solution

Standard clearance Control valve regulator valve〜valve body

1

2

Clearance

Control valve trimmer plug〜valve body

3

ITEM 4

6 7

0.016〜0.045

0.07

(0.0006〜0.0017)

(0.0027)

Replace

Replace

0.025〜0.066

0.09

(0.0010〜0.0026)

(0.0035)

Standard value

Allowable limit

Replace

Installed length

Installed load

Free length

Installed load

44.6 35.2 (1.7559) (1.3853)

10.2 (23 )

43.6 (1.7165)

9.2 (20 )

Clutch return spring Spring

0.09 (0.0035)

Free length

T/C inlet valve spring

5

0.030〜0.061 (0.0011〜0.0024)

Control valve regulator valve〜 seal retainer

Allowable limit

24.4

3.3

23.7

3.0

(The same spring for all clutches)T/C

(0.9606) (0.8267)

(7)

(0.9330)

(6)

Control valve regulator spring

89 89 (3.5039) (3.5039) 81.4 69 (3.2047) (2.7165)

0

87.5 (3.4448) 80 (3.1496)

0

Replace

4.5 (10 )

Replace

Control valve trimmer spring

21

Replace

5 (11 )

Replace

Judgement criteria ITEM Standard value

Allowable limit

41.93〜42.0 (1.6507〜1.6535) 79.92〜80.0 (3.1464〜3.1496) 79.92〜80.0 (3.1464〜3.1496) 11.95〜12.0 (0.4704〜0.4724)

41.8 (1.6456) 79.8 (3.1417) 79.8 (3.1417) 11.8 (0.4645)

3.0 ± 0.05 (0.1181 ± 0.0019) 3.25 ± 0.05 (0.1279 ± 0.0019) 3.8 ± 0.05 (0.1496 ± 0.0019) 4.75 ± 0.05 (0.1870 ± 0.0019) 3.8 ± 0.05 (0.1496 ± 0.0019) 4.75 ± 0.05 (0.1870 ± 0.0019) 4.3 ± 0.1 (0.1693 ± 0.0019) 4.3 ± 0.1 (0.1693 ± 0.0019) 4.0 ± 0.1 (0.1574 ± 0.0019)

2.8 (0.1102) 3.05 (0.1200) 3.6 (0.1417) 4.55 (0.1791) 3.6 (0.1417) 4.55 (0.1791) 4.1 (0.1614) 4.1 (0.1614) 3.8 (0.1496)

Thrust washer thickness

2.9〜3.1 (0.1141〜0.1220)

2.7 (0.1063)

Replace

Gear backlash

0.2〜0.3 (0.0078〜0.0118)

0.5 (0.0196)

Replace

8

Charge pump shaft dia.

9

Rear yoke shaft dia.

10

Oil seal

11

Front yoke shaft dia.

Speedometer driven gear shaft dia.

W 12

Torque converter inlet H

13

Seal ring

W Torque converter outlet H Clutch shaft

W

(The same for all clutches)

H

15

Piston outer dia. (F,R)

H

16

Piston outer dia. (1〜4 speed)

H

17

Piston inner dia.

H

W

14 H

18

35-4

Replace Replace oil Replace seal when disassembling Replace and reassembling Replace

Replace

Replace

Replace Replace Replace Replace

90Z Ⅳ -2

Gear Pump

TORQUE CONVERTER AND TRANSMISSION 35

Gear Pump 2 4

1

Gear pump specifications

3

Theoretical discharge

64.5cc/rev

Maximum operation pressure Maximum operation speed (pump speed)

2MPa (20kgf/cm2)(284psi)

Actual discharge

1

2400min-1 Approx.120 l/min.

Conditions : Pump speed: 2200min-1 Oil temperature: 80 to 100 ℃ Oil viscosity: 40CST (SAE10W) Discharge pressure: 1.4 to 1.6MPa (14 to 16kgf/cm2) (199 to 228psi)

2

Unit : mm No.

Item

Standard value

Solution

1

Top clearance between gear and housing

0.08〜0.11

Replacement

2

Side clearance between gear and housing

0.03〜0.073

Replacement

3

Backlash between gears

0.2〜0.3

Replacement

4

Tightening torque for pump fixing bolt

59N-m (6.0kgf-m)(43 lb-ft)

Tightening

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

35-5

90Z Ⅳ -2

Clutch Plate Thickness / Piston Stroke

TORQUE CONVERTER AND TRANSMISSION 35

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

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

Steel plate

Return spring

7

8

20

Reverse clutch

7

8

20

1st speed clutch

9

8

20

2nd speed clutch

5

4

20

3rd speed clutch

5

4

20

4th speed clutch

5

4

20

Outer dia.

φ 192

φ 203.2

Inner dia.

φ 123.8

φ 133

When new

3.3 ± 0.1

2.6 ± 0.1

Wear limit

3.1

2.4

Dimension

Friction plate

Forward clutch

(mm) (in.)

Thickness

T1

Name of clutch

T2 L1 T2 L1 T5

T3 L 1 T6 T4

Piston stroke

(mm) Judgement criteria Solution

Standard value

Allowable limit

Forward clutch

3.3 ± 0.5

5.0

Replace

Reverse clutch

3.3 ± 0.5

5.0

Replace

1st speed clutch

3.5 ± 0.5

5.0

Replace

2nd speed clutch

2.1 ± 0.5

5.0

Replace

3rd speed clutch

2.1 ± 0.5

5.0

Replace

4th speed clutch

2.1 ± 0.5

5.0

Replace

Clutch

T6 85ZA3201

Bolt tightening torque T1 :29N-m (3.0kgf-m) (22 lb-ft) T2 :59N-m (6.0kgf-m) (43 lb-ft) T3 :157N-m (16.0kgf-m) (116 lb-ft) T4 :392N-m (40.0kgf-m) (289 lb-ft) (Molydenum disulfide grease/MOS 2 application ) T5 :98N-m (10kgf-m) (72 lb-ft) T6 :53N-m (5.4kgf-m) (39 lb-ft) L 1: Screw lock agent application (Loctite 262 )

35-6

90Z Ⅳ -2

Oil Pressure

TORQUE CONVERTER AND TRANSMISSION 35

Oil Pressure

2

7

1 7

3

4

8

6 3

5 4

9

6

85ZA3501

Standard Value

(Oil temperature 50〜80 ° C (120〜180 °F)) 2

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

Measuring port location

Measuring port

Engine revolution (rpm)

size

800 (Low idle)

Shift lever position

2350 (High idle)

Torque converter inlet

PF1/2

0.03〜0.5(0.3〜5.5)(4.3〜78) 0.2〜0.5(2.0〜5.5)(28〜78)

All speed range

2

Main oil pressure

PT1/8

1.3 ± 0.2(13 ± 2)(185 ± 28) 1.5 ± 0.2(15 ± 2)(213 ± 28)

All speed range

3

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

PF1/4

1.3 ± 0.2(13 ± 2)(185 ± 28) 1.5 ± 0.2(15 ± 2)(213 ± 28)

Forward

PF1/4

1.3 ± 0.2(13 ± 2)(185 ± 28) 1.5 ± 0.2(15 ± 2)(213 ± 28)

Reverse

PF1/4

1.3 ± 0.2(13 ± 2)(185 ± 28) 1.5 ± 0.2(15 ± 2)(213 ± 28)

1st speed

PF1/4

1.3 ± 0.2(13 ± 2)(185 ± 28) 1.5 ± 0.2(15 ± 2)(213 ± 28)

2nd speed

7

3rd speed clutch oil pressure

PF1/4

1.3 ± 0.2(13 ± 2)(185 ± 28) 1.5 ± 0.2(15 ± 2)(213 ± 28)

3rd speed

8

4th speed clutch oil pressure Transmission lubrication oil pressure

PF1/4

1.3 ± 0.2(13 ± 2)(185 ± 28) 1.5 ± 0.2(15 ± 2)(213 ± 28)

4th speed

PT1/4

0.01〜0.1(0.1〜1.0)(1.4〜14) 0.05〜0.2(0.5〜2.5)(7〜36)

All speed range

4 5 6

9

Clutch oil pressure

1

35-7

HYDRAULIC GROUP 44 Disassembly and Reassembly Hydraulic Pump ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-3 Removing and Reinstalling Gear Pump Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-4 Steering Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-6 Steering Pilot Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-7 Removing and Reinstalling Steering Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-8 Disassembling and Reassembling Steering Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-10 Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-18 Removing and Reinstalling Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-19 Disassembling and Reassembling Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-21 Stop Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-26 Removing and Reinstalling Stop Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-27 Disassembling and Reassembling Stop Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-29 Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-30 Removing and Reinstalling Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-31 Disassembling and Reassembling Multiple Control Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-33 Boom Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-36 Removing and Reinstalling Boom Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-37 Bucket Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-39 Removing and Reinstalling Bucket Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-40 Steering Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-43 Removing and Reinstalling Steering Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-44 Hydraulic Cylinder Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-46 Disassembling and Reassembling Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-48 Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-53

44-1

Pilot Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-54 Removing and Reinstalling Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-55 Disassembling and Reassembling Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-57 Pilot Relief Valve Unit ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 44-61

44-2

90Z Ⅳ -2

Hydraulic Pump

HYDRAULIC 44

Hydraulic Pump Triple pump

80V42002

Triple pump specifications

KAWASAKI MACHINE

90ZⅣ

KAWASAKI PART NUMBER

44093-61190

JSB PART NUMBER

2104871

JOHN S. BARNES MODEL NUMBER

F3-G302020W-4EJ32CJ19CJ-EJ9AJ-34861L

Measurement conditions: Oil temperature 50 ℃〜80 ℃ Hydraulic oil ISO VG46

44-3

DISPLACEMENT in3/REV (mL/REV) FRONT CENTER PUMP PUMP

REAR PUMP

6.30 (104)

1.79 (29)

3.77 (62)

MIN. RATED SPEED RATED PRESS AT RATED SPEED P.S.I. PRESSURE (min-1) (bar) (min-1) 2500

3300 (228)

600

Removing and Reinstalling Gear Pump Assy

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Gear Pump Assembly 1.Removing gear pump assembly WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Disconnect the negative side of the cable from the battery. ・ Release the residual pressure from the hydraulic line.

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

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

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

2)Remove the gear pump retainer bolts.

Torque for assembly: : Bolt : 245N-m (25.0kgf-m) (181 lb-ft)

3

2

1

90W44001

3)Remove the gear pump (1).

44-4

Removing and Reinstalling Gear Pump Assy

90Z Ⅳ -2

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

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

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

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

3) Check the oil level of the hydraulic tank.

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

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

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

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

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

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

44-5

HYDRAULIC 44

90Z Ⅳ -2

Steering Pilot Valve

HYDRAULIC 44

Steering Pilot Valve

※ 6 11

13

※

※

※

※

1

10

※ 5

18 21

19 ※

※ ※

2

※

22

23

7

4

26

９０ＺⅣ４４０１

1. Screw 2. End plate 4. Rotor assembly 5. Spacer 6.Wear plate 7. Shaft 10.Pin 11.Spring kit

13.Bearing kit 18.Seal retainer 19.Retainer ring 21.Retainer 22.Ball 23.Check valve 26.Screw

44-6

Steering Pilot Valve Tightening Torque

90Z Ⅳ -2

HYDRAULIC 44

Steering Pilot Valve Tightening Torque

T2

T1 L1 90Z Ⅳ 4402

Tightening torque T1 : 12N-m (1.2kgf-m) (9 lb-ft) T2 : 28N-m (2.9kgf-m) (21 lb-ft)

: 7.0kg (15 lbs)

L1 : With liquid adhesive (Loctite 262 or equivalent)

44-7

Removing and Reinstalling Steering P/V

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Steering Pilot Valve 1.Removing steering pilot valve WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Apply the articulation stopper. ・ Before starting work, be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel. ・ Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right. ・ Relieve the internal pressure from the hydraulic tank.

1)Remove the lock lever (1) and the cover (2).

1

90K44006

2)Remove the plate (3).

2

2

3

3)Remove the sound suppression sheet (4).

4 90K44007

44-8

Removing and Reinstalling Steering P/V

90Z Ⅳ -2

HYDRAULIC 44

4)Put match marks on the hoses (6), and then disconnect them from the steering pilot valve (5).

6 5

5)Remove the bolt (7), and then remove the steering pilot valve.

Torque for assembly: : Bolt : 29N-m (3.0kgf-m) (22 lb-ft) : Steering pilot valve : 7kg (15 lbs) Note: One person should support the steering pilot valve under the machine. The person in the cab should remove the retainer bolt.This work should be done by two persons.

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

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

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

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

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

2)Check around the valve for oil leakage.

44-9

7

Disassembling and Reassembling Steering

90Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Steering Pilot Valve 1.Disassembling steering pilot valve Before starting work: a)Clean the steering pilot valve. b)Clamp the steering pilot valve in a vise.

Copper

90ZA44-017-1

(Disassembling rotor) 1)Remove the bolt (1), end plate (2) and O-ring (3).

1 2

3

90Z Ⅳ 4403

2)Remove the rotor assembly (4), spacer (5) and O-ring (6).

6

4

5

90Z Ⅳ 4404

3)Remove the drive shaft (8), plate (9) and O-ring (10).

10

8

9 90ZA44-018-1

44-10

Disassembling and Reassembling Steering

90Z Ⅳ -2

HYDRAULIC 44

(Disassembling valve) Take care not to damage the finished surface.

4)Remove the retainer ring (11) by a screw driver.

11 90ZA44-018-2

5)Remove the seal retainer (12) by pressing the spool and sleeve from behind with your fingers.

12

90ZA44-018-3

6)Remove the X-ring seal (13) and dust seal (14) from the seal retainer (12).

14

12

13

90ZA44-018-4

7)Remove the races (15) and needle bearing (16) from the spool (17) and sleeve (18).

15 16 15

17

18 90ZA44-019-1

44-11

90Z Ⅳ -2

Disassembling and Reassembling Steering

HYDRAULIC 44

8)Pull the spool and sleeve assembly (18) out slowly, turning it clockwise and counter-clockwise from the housing (19).

Note: Take care so that the spool and sleeve do not damage the housing.

18 19 90ZA44-019-2

9)Pull the pin (20) from the spool and sleeve assembly.

20

90ZA44-019-3

10)Push the spool slightly out of the sleeve, and remove the centering springs (21). Pull the spool from the sleeve while slowly turning the spool clockwise and counter-clockwise.

21

Push out

Sleeve Spool 90Z Ⅳ 4410

21 90ZA44-019-4

44-12

Disassembling and Reassembling Steering

90Z Ⅳ -2

HYDRAULIC 44

11)Remove the O-ring (22) from the housing.

22

O-ring I.D 9.3φ

23

24

26

O-ring 25 I.D 7.6φ

80

13)Pull out the check valve (24) with the puller (B).

10φ

B 50

14)Tap gently on the housing to take out the ball (25) and the retainer (26).

30

10φ

(Disassembling emergency check valve) Note: Liquid adhesive is applied to the set screw.

12)Remove the set screw (23) from the housing.

90ZA44-020-1

10

Thread 10-24UNC

4.8φ

44-13

90ZA44-020-2

Disassembling and Reassembling Steering

90Z Ⅳ -2

HYDRAULIC 44

2.Reassembling steering pilot valve Before starting work: a)Clean and inspect each part. If necessary replace it with new one. b)Apply grease to the O-rings.

(There is no need to grease the X-ring seal.)

Note: Make sure that the end of the check valve with the hole in it is facing downward when inserting the valve into the housing.

1)Insert the retainer (26) and ball (25), put O-rings on the check valve (24), and then press the check valve into the housing.

Apply Loctite 262 or equivalent to the screw (23), and then tighten the screw. :Screw : 12N-m (1.2kgf-m) (9 lb-ft) :With liquid adhesive (Loctite 262 or equivalent) Note: Confirm that the screw is tightened to the extent that the screw head is slightly below the edge of the housing.

23 O-ring I.D 9.3φ O-ring I.D 7.6φ

24 25 26

90ZA44-021-1

2)Assemble the spool (17) and sleeve (18) so that the spring grooves in them are lined up.

Note: Align the match-marks on the spool and sleeve.

18

Spring groove

Spring groove

Match mark

17

90ZA44-021-2

Spring insertion jig

3)Install the springs (21) through the spring grooves in the sleeve and spool (18) using a spring insertion jig.

Note: Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

21

18 90ZA44-021-3

44-14

Disassembling and Reassembling Steering

90Z Ⅳ -2

HYDRAULIC 44

4)Insert the pin (20) in the holes in the spool (17) and sleeve (18) until the end of the pin is flush with the surface of the sleeve.

18

17

20

5)Insert the spool and sleeve assembly (18) from the back of the housing (19).

Note: ① Take care not to tilt the assembly and cause damage during insertion. ② Insert the assembly until the back end of the assembly is flush with the back end of the housing. ③ Confirm that the assembly can be turned easily in the housing.

18 19 90ZA44-022-2

6)Install the O-ring (22), races (15) and needle bearing (16).

16 15

22

90ZA44-022-3

7)Insert the dust seal (13) and the X-ring seal (14) in the seal retainer (12).

13

44-15

12

14

Disassembling and Reassembling Steering

90Z Ⅳ -2

HYDRAULIC 44

8)Insert the seal retainer (12) onto the spool, and then t a p it gently into position with a plastic-faced hammer. Then install the retainer ring (11).

11 12

90ZA44-023-1

Note: Be sure the position and direction of the seals.

Dust seal

Screw driver

Retainer ring Seal retainer X-ring seal O-ring

90ZA44-023-2

9)Put on the O-ring (10), then align the bolt holes in the plate (9) with those in the housing.

9

10

90ZA44-023-3

10)Insert the drive shaft (8) to mate its yoke with the pin (20).

Port face

8 Pin parallel with port face

20 90ZA44-023-4

44-16

Disassembling and Reassembling Steering

90Z Ⅳ -2

HYDRAULIC 44

11)Put the O-ring (6) in the rotor assembly (4).

4

6

90ZA44-024-1

12)Holding the rotor assembly with the O-ring side facing the plate, install the assembly so that the grooves in the star-shaped bore mesh with the drive shaft.

Note: ① Align the bolt holes in the rotor assembly with those in the housing without disengaging the drive shaft from the rotor assembly's star-shaped bore. ② Confirm that lines A, B, C and D are all parallel.

Grooves in rotor bore

A B

Drive shaft

C

Pin

D

Port face

90ZA44-024-2

13)Install the spacer (5), O-ring (6) and end cap (2). :Provisional tightening torque : 15N-m (1.5kgf-m)(11 lb-ft) Tightening torque : 28N-m (2.9kgf-m)(21 lb-ft)

5

6

2

1

Note: Provisionally tighten the bolt (1), then tighten them securely in the order shown at the right.

90ZA44-024-3

90ZA44-024-4

44-17

90Z Ⅳ -2

Steering Valve

HYDRAULIC 44

Steering Valve

4

T6

T3

T1

T7

9 7 6

4

10

T1

5 T2 L 1

T4

1 2 T2 L 1 T6

8

3 5 T3

6 9

7

T4

T5 90ZA44-025

Tightening torque T1 : 88N-m (9.0kgf-m) (65 lb-ft) T2 : 10N-m (1.0kgf-m) (7 lb-ft) T3 : 53N-m (5.4kgf-m) (39 lb-ft) T4 : 137N-m (14.0kgf-m) (101 lb-ft) T5 : 78N-m (8.0kgf-m) (58 lb-ft) T6 : 98N-m (10.0kgf-m) (72 lb-ft) T7 : 69N-m (7.0kgf-m) (51 lb-ft) L1 : With liquid adhesive (Loctite 262 or equivalent)

1. Steering plunger 2. Flow control plunger 3.Main relief valve 4. Overload relief valve 5. Cap 6. Poppet 7. Stopper 8. Plug 9. Spring seat 10.Valve body

: 24kg (53 lbs)

44-18

Removing and Reinstalling Steering Valve

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Steering Valve 1.Removing steering valve WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Relieve the internal pressure from the hydraulic tank. ・ Oil spilled on the parking brake shoe section may cause malfunction. To prevent such a problem, cover the shoe section with vinyl before valve removal.

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

1)Disconnect the hoses (1)(2) from the steering valve.

2)Remove the pipe (3).

1

: Hydraulic oil : Approx. 1 l (0.3 gal.)

2

3

90K44034

3)Remove the hoses (4)(5)(6)(7)(8)(9).

8

7

9 6 4 5

90K44035

4)Remove the bolt (11) and then remove the steering valve (10).

Torque for assembly: : Bolt : 88N-m (9.0kgf-m) (65 lb-ft) : Steering valve : 24kg (53 lbs) Note: Cover the disconnected hoses and the valve with vinyl, plugs or caps to protect them from dust and dirt.

11

10

90K44036

44-19

Removing and Reinstalling Steering Valve

90Z Ⅳ -2

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

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

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

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

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

2)Check around the valve for oil leakage.

3)Measure various values for performance check.

Measure the time required for full steering.

Measure the relief valve setting pressure.

(Refer to the Section 03 - Measurement for Performance Check).

44-20

HYDRAULIC 44

Disassembling and Reassembling STV

90Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Steering Valve 1.Disassembling steering valve Before starting work: a)Clean the valve body.

1

1)Remove the right and left overload relief valves (1). : Torque for assembly : 88N-m (9.0kgf-m) (65 lb-ft)

2)Remove the main relief valve (2).

Torque for assembly: : Main relief valve : 78N-m (8.0kgf-m) (58 lb-ft) Note: The orifice is behind the main relief valve.Do not loose the orifice during the service work.

3

2

3)Remove the retainer bolt (5) from the cap (4).

Torque for assembly: : Retainer bolt : 53N-m (5.4kgf-m) (39 lb-ft)

4

5

4)Remove the cap (4). Also remove the O-ring from the cap.

4

44-21

Disassembling and Reassembling STV

90Z Ⅳ -2

HYDRAULIC 44

5)Remove the spring (6).

6

6)Remove the spring seat (7).

Note: To disassemble other side of the cap part, follow the above removal procedure.

7

7)Pull out the steering plunger (8) slowly.

Note: Carefully pull out the plunger so that it is not forced out or distorted.

Handle the plunger with extreme care, even a small nick, dent, or scratch can ruin the plunger which requires replacement of the entire valve.

8

8)Remove the plug (9).

Torque for assembly: : Plug : 137N-m (14.0kgf-m) (101 lb-ft)

9

44-22

Disassembling and Reassembling STV

90Z Ⅳ -2

HYDRAULIC 44

9)Remove the filter (10) at the bottom of the plug to prevent it from being lost, and remove the spring (11).

9

11

10

10)Remove the plug (12).

Torque for assembly: : Plug : 137N-m (14.0kgf-m) (101 lb-ft)

12

11)Slowly pull out the flow control plunger (13).

Note: Carefully pull out the plunger so that it is not forced out or distorted.

Handle the plunger with extreme care.

44-23

13

90Z Ⅳ -2

Disassembling and Reassembling STV

HYDRAULIC 44

12)Disassemble the steering plunger Clamp the steering plunger in a vise using the block for clamping plunger, and remove the cap screw (14)(both sides).

Torque for assembly: : Cap screw : 10N-m (1.0kgf-m) (7 lb-ft) : With liquid adhesive (Loctite 262 or equivalent)

30〜40

14

2〜4

Block for clamping plunger (Hard wood)

70〜100

φ25

10〜20

φ20

With hex. socket or hex. head

5 4.7 -0.30

For disassembling/assembling cap screw

９０ＺＡ４４−０３１

13)Remove the poppet (15) and the spring (16) from the plunger (both sides).

16

15

14)Main relief valve disassembly Loosen the lock nut (17) and remove the adjuster (18), spring (19), poppet (20), O-ring (21) and back up ring (22).

Note: Replace O-ring and back-up ring with new ones.

Do not disassemble the pilot seat (23) crimped to the plug (9).

18

17 21

9

21 19

20

23 22 21

90ZA44-032

44-24

Disassembling and Reassembling STV

90Z Ⅳ -2

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

Cautions regarding reassembly: Before starting work: a)Clean and check all the parts. Replace all O-rings and seals. b)Before reassembly, apply a coating of hydraulic oil to all the parts. c) Be sure to apply the specified torque to tighten each part.

44-25

HYDRAULIC 44

90Z Ⅳ -2

Stop Valve

HYDRAULIC 44

Stop Valve

4

14

14

2

3

5

6

15

10 11

3

5

13

7

12

8

9

10

11

12

13

6

2 1 15

4

16

９０ＺＡ４４−０３３

1. Bolt 2. Boot 3. Flange 4. Bolt 5.Wiper 6. U-packing

13. O-ring 14. Adapter 15. Spool 16. Body

7. Poppet 8. Spring 9.O-ring 10.Washer 11. Screw 12. Spring

44-26

Removing and Reinstalling Stop Valve

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Stop Valve 1.Removing stop valve WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death.

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Remove the engine key, and hang a "DO NOT START ENGINE !" tag on the steering wheel.

(The illustration shows the machine right hand side.)

1)Remove the hoses (1)(2)(3)(4) from the stop valve.

3

6

5

2

2)Remove the bolt (5) and then remove the stop valve (6).

1

4

90K44052

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

44-27

90Z Ⅳ -2

Removing and Reinstalling Stop Valve

HYDRAULIC 44

3.Cautions regarding reinstalling: Adjust the stop valve as shown below before installing it.

1)Confirm the proper position of the stop valve assembly (on each side).

31.7〜36.3mm (1.25〜1.43 in.)

Stop valve (installed on rear chassis)

Stopper (installed on front chassis)

3mm (0.12 in.)

Stopper actuation position ９０ＺⅣ

2)When the chassis stopper clearance is 11.8 〜 23.5mm (0.46〜0.93 in.), confirm that the stop valve is forced in 3mm (0.12 in.) when the stopper bolt length is 31.7〜36.3mm (1.25〜1.43 in.) as shown.

3)Check each section for oil leakage.

44-28

Disassembling&Reassembling Stop Valve

90Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Stop Valve 1.Disassembling stop valve Before starting work: a)Clean the stop valve assembly.

1)Remove the boot (1).

2

1

2) Loosen the adapter (2).

WARNING The inner spring may spring out causing injury.

Do not point the spring toward your face.

90K44053

3)Remove the spring (3).

4)Remove the spool assembly (4).

2 3 4 90K44054

5)Clamp the spool assembly (4) at the bottom side in a vise and remove the screw (5) using a screw driver.

6)Remove the washer (6), spring (7) and poppet (8) and the O-ring (9) from the spool assembly (4).

8

7 5

4 9

6

Two flats

90K44055

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

44-29

90Z Ⅳ -2

Multiple Control Valve

HYDRAULIC 44

Multiple Control Valve T5 T4

T3

Overload relief valve with make-up function

T8 L 1 T

2

T6

T7 T7

T1 T10 Make-up valve

T9

T6

T7

T11

Bucket spool

T9 Main relief valve Boom spool

T6

T1

T6 90ZA44-038

Tightening torque T1 : 196N-m (20.0kgf-m) (145 lb-ft) T2 : 284N-m (29.0kgf-m) (210 lb-ft) T3 : 226N-m (23.0kgf-m) (166 lb-ft) T4 : 39N-m (4.0kgf-m) (29 lb-ft) T5 : 245N-m (25.0kgf-m) (181 lb-ft) T6 : 54N-m (5.5kgf-m) (40 lb-ft) T7 : 74N-m (7.5kgf-m) (54 lb-ft) T8 : 39N-m (4.0kgf-m) (29 lb-ft) T9 : 128N-m (13.0kgf-m) (94 lb-ft) T10 : 10N-m (1.0kgf-m) (7 lb-ft) T11 : 29N-m (3.0kgf-m) (22 lb-ft)

: 91kg (200 lbs)

L1 : Screw lock agent application (Three Bond 1327)

44-30

Removing and Reinstalling MCV

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Multiple Control Valve 1.Removing multiple control valve WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death.

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Lift the boom until it is horizontal, and then place a stand (A) to support the bottom of the boom.

Stand (A)

85K44038

1)Remove the nut (1) and then remove the cover (2).

1

2 90K44056

2)Disconnect the boom cylinder hose (3).

3)Remove the pipe clamp (4) for the oil pipe .

4 3 90K44057

4)Remove the boom cylinder oil pipe (5).

Remove the oil pipe (6)(7)(8). Clamp them on the front chassis.

7 6 5

: Hydralulic oil : Approx. 5 l (1.32 gal.)

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

5

90K44058

44-31

8

6

Removing and Reinstalling MCV

90Z Ⅳ -2

5)Put match marks on the pilot line hoses (9), and then disconnect them.

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

HYDRAULIC 44

9

9 90K44059

6)Remove the bolts (11) for the control valve (10).

Use a hoist to remove the control valve.

Torque for assembly: : Bolt : 98N-m (10.0kgf-m) (72 lb-ft) : Multiple control valve : 91kg (200 lbs)

10 11

90K44060

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

Cautions regarding reinstallation: a)Replace all the O-rings with new ones. b)Wash the multiple control valve mounting area.

WARNING Unexpected movement of the machine may cause serious injury or death.

To prevent such an accident, be sure to stop the engine before you start working under the machine. In addition, block the tires with chocks to prevent the wheels from moving. While working under the machine, carefully keep contact with the person in the cab by giving signals to each other.

c) Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the Section 03. d)Operate the bucket and the boom, and check that they operate correctly. e)Check each section for oil leakage. f ) Add hydraulic oil to the tank until the oil level rises to the specified point.

44-32

Disassembling and Reassembling MCV

90Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Multiple Control Valve 1.Disassembling multiple control valve IMPORTANT ・ Place the removed parts, in order, on a clean paper or cloth. ・ Do not disassemble any section unless disassembly is absolutely necessary for repair or adjustment. ・ As a rule, the main relief valve or overload relief valve once disassembled should be replaced as an assembly.

Therefore, do not disassemble these valves, unless absolutely necessary.

a)Clean the valve body 1)Bucket spool disassembling Remove the socket head bolt (1) and the cover (2).

Hexagon hole width across flat: 8mm (5/16 in.)

Torque for assembly: : Bolt : 54N-m (5.5kgf-m) (40 lb-ft)

2 1

2)Pull out the spool assembly from the bucket side.

Note: Carefully pull out the spool so that it is not forced out or distorted.

Handle the spool with extreme care, even a small nick, dent, or scratch can ruin the spool which requires replacement of the entire valve.

3)Clamp the spool (3) in a vise using copper plates and then loosen the bolt (4).

Hexagon hole width across flat: 12mm (1/2 in.)

Torque for assembly: : Bolt : 39N-m (4.0kgf-m) (29 lb-ft) : Screw lock agent application (Three Bond 1327)

4

3

44-33

Disassembling and Reassembling MCV

90Z Ⅳ -2

HYDRAULIC 44

4)Remove the bolt (4), spring retainer (5), outer spring (6), inner spring (7), stopper (8) and spring retainer (9).

6 4

5 9 8

7

5)Boom spool disassembling To disassemble the boom spool, follow the bucket spool disassembling procedure.

6)Remove the overload relief valves (10).

Hexagon width across flat: 34mm (1 11/32 in.)

Torque for assembly: : Overload relief valve : 74N-m (7.5kgf-m) (54 lb-ft) Note: The overload relief valve should be replaced as an assembly.

Therefore, please do not disassemble it, unless absolutely necessary.

１０

7)Remove the main relief valve (11).

Hexagon width across flat: 41mm (1 5/8 in.)

Torque for assembly: : Main relief valve : 128N-m (13.0kgf-m) (94 lb-ft) Note: The main relief valve should be replaced as an assembly.

Therefore, please do not disassemble it, unless absolutely necessary.

11

44-34

Disassembling and Reassembling MCV

90Z Ⅳ -2

HYDRAULIC 44

8)Remove the plug (12), and then remove the spring (13) and the poppet (14).

Hexagon hole width across flat: 14mm (9/16 in.)

Torque for assembly: : Plug : 226N-m (23.0kgf-m) (166 lb-ft)

14 12

13

9)Remove the make up valve (15) from the body.

Hexagon width across flat: 34mm (1 11/32 in.)

Torque for assembly: : Make up valve : 128N-m (13.0kgf-m) (94 lb-ft)

15

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

Cautions regarding reassembling: ・ Clean and check all the parts. If a part is defective, replace or repair it. ・ Replace all the O-rings with new ones. ・ Apply a thin coat of hydraulic oil or grease to each part before reassembly. ・ Apply the specified torque to tighten each main part.

44-35

90Z Ⅳ -2

Boom Cylinder

HYDRAULIC 44

Boom Cylinder

11

12 2

13 15 14 16 3

17 22

20 18

6

19 4 6 21

22

5

1

23

8 7 9

９０Ｗ４４００２

1.Cylinder tube 2.Rod 3.Piston 4.Rod cover 5.Bushing 6.Bushing 7.Piston nut 8.Stop ring 9.Bolt 11.Wear ring 12.Square ring

13.Slipper ring 14.O-ring 15.Wear ring 16.O-ring 17.Back-up ring 18.U-packing 19.Back-up ring 20.Buffer ring 21.Scraper ring 22.Dust seal 23.Stop ring

: Boom cylinder : 228kg (500 lbs) For torque values refer to "Hydraulic cylinder tightening torque".

44-36

Removing and Reinstalling Boom Cylinder

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Boom Cylinder 1.Removing boom cylinder (The illustration shows the left side of the machine.)

WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death.

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Raise the boom until it is horizontal, and then place a stand (A) under the boom to support it. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Use a stepladder or work platform, and do not stand on the machine.

Stand (A)

85K44038

3

a)Clean the area around the cylinder and piping.

Note: Relieving residual pressure from pipe 1. Raise the boom.

When the boom is approximately 30cm (1 foot) above stand (A), stop the engine.

2. Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure.

3. Open the cap of the hydraulic tank to relieve the residual pressure.

2 1

90K44067

1) Temporarily sling the boom cylinder (1).

Disconnect the grease hose (2) from the pin (3), and then remove the pin (3).

4 5

: Boom cylinder : 228kg (500 lbs) 2)Disconnect the hose (4) and pipe holder (5).

90K44068

: Drain oil : Approx. 10 l (2.6 gal.)

3)Remove the oil pipe (6), and then push the rod into the cylinder to shorten the length of the cylinder.

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

6

90K44069

44-37

Removing and Reinstalling Boom Cylinder

90Z Ⅳ -2

HYDRAULIC 44

4)Remove the lock bolt (8) for the pin (7).

8 7

90K44070

5) Insert jack bolts (9) to the pin (7), and then remove the pin (7).

9 7

90K44071

6)Sling the boom cylinder (1), and lower it onto the ground.

For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

1

2.Reinstalling boom cylinder To reinstall the boom cylinder, follow the above removal procedure in the reversed direction.

Note: Be sure the pins accept grease after installation.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100mm (4.0 in.) before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-38

90K44072

90Z Ⅳ -2

Bucket Cylinder

HYDRAULIC 44

Bucket Cylinder

22

6 22

1

11

12 13

8 15

7 14 16 17

3

20 18 19 4

21

2

5 23

10 9

22

22 6 ９０ＺⅣ４４０６

1.Cylinder tube 2.Rod 3.Piston 4.Rod cover 5.Bushing 6.Bushing 7.Piston nut 8.Stop ring 9.Bolt 10.Spring washer 11.Wear ring 12.Square ring

13.Slipper ring 14.O-ring 15.Wear ring 16.O-ring 17.Back-up ring 18.U-packing 19.Back-up ring 20.Buffer ring 21.Scraper ring 22.Dust seal 23.Stop ring : Bucket cylinder : 133kg (292 lbs) For torque values refer to "Hydraulic cylinder tightening torque".

44-39

Removing and Reinstalling Bucket Cyl.

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Bucket Cylinder 1.Removing bucket cylinder WARNING Unexpected movement of the machine, bucket, or boom during service work could cause serious injury or death.

To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Place the boom and bucket on the ground. ・ Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out. ・ Use a step, and do not stand on the machine.

a)Clean the area around the cylinder and piping.

Note: Relieving residual pressure from pipe 1. Lower the boom and bucket to the ground.

2. Stop the engine and move the bucket and boom levers back and forth.

3. Open the cap of the hydraulic tank to relieve the residual pressure.

1)Remove the coupler of the bucket positioner switch (1).

1

90K44074

2) Temporarily sling the bucket cylinder.

After that, remove the pin (2).

2

: Bucket cylinder : 133kg (292 lbs)

90K44075

44-40

Removing and Reinstalling Bucket Cyl.

90Z Ⅳ -2

HYDRAULIC 44

3) Lift the bucket cylinder (3) and disconnect the bucket cylinder from the lever.

Remove the rod (4) .

3

4

90K44076

4)Start the engine and shorten the cylinder rod.

Stop the engine and disconnect the hose (5)(6).

6

: Drain : Approx. 1 l (0.26 gal.)

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

5

90K44077

5)Remove the bucket positioner bracket (7).

7

90K44078

6)Disconnect the grease pipe and then remove the pin (8).

8

7)Slowly lift up the bucket cylinder.

Lower the bucket cylinder onto the ground.

For a detailed description of cylinder disassembly and reassembly, refer to "Disassembling and reassembling hydraulic cylinder".

90K44079

44-41

Removing and Reinstalling Bucket Cyl.

90Z Ⅳ -2

2.Reinstalling bucket cylinder To reinstall the bucket cylinder, follow the above removal procedure in the reversed direction.

Note: Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation WARNING During service work, do not stand on the machine.

Standing on tire, boom or linkage may cause accidents and serious injury or death. Use a step, ladder, or work platform and do not stand on the machine.

①Bleed the cylinder of air.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100mm before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

②Adjust the bucket positioner so that the clearance between the switch and the rod is 5±2mm (0.12 〜 0.27 in.).

44-42

HYDRAULIC 44

90Z Ⅳ -2

Steering Cylinder

HYDRAULIC 44

Steering Cylinder 2

13

17 11 12 15

10 17

9 8 7 17 6 3

5 4

1

16

14

17

90K44080

1.Cylinder tube 2. Rod 3. Rod cover 4. Snap ring 5. Dust seal 6. O-ring 7. Bushing 8. Packing 9. Back-up ring

10.O-ring 11. Piston 12. Piston ring 13.Wear ring 14. Piston nut 15. Bushing 16. Bushing 17.Dust seal

: Steering cylinder : 41kg (90 lbs) For torque values refer to "Hydraulic cylinder tightening torque".

44-43

Removing and Reinstalling Steering Cyl.

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Steering Cylinder 1.Removing steering cylinder WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent wheels from moving. ・ Place the boom and bucket on the ground. ・ Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line. ・ Open the cap of the hydraulic tank to relieve the internal pressure from the tank. ・ Place a "DO NOT START!" tag on the steering wheel.

a)Clean the area around the cylinder to be removed.

2

1)Disconnect the hoses (1) (2).

1

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

90K44081

2) There is a pin (5) at the between the front chassis (3) and the steering cylinder (4). Remove the pin (5), and then push the rod into the cylinder to shorten the length of the cylinder.

5

: Oil will be drained from the oil port of the cylinder. Place a container at the oil port to catch the drained oil.

Approx. 2 l (0.53 gal.)

4 3 90K44082

3)Disconnect the grease pipe (6) and remove the pin (7).

6 7

4)Remove the steering cylinder assembly. : Steering cylinder : 41kg (90 lbs) For detailed description of cylinder disassembly and reassembly, refer to "Disassebling and reassembling hydraulic cylinder".

4

44-44

90K44083

Removing and Reinstalling Steering Cyl.

90Z Ⅳ -2

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

Note : Be sure the pins accept grease after installation.

3.Cautions regarding reinstallation ①When reinstall the pins

IMPORTANT Insert shims so that the clearance between the chassis and the cylinder is 1.2mm or less. Place approximately the same number of shims under the cylinder as on top of the cylinder.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area can cause injury or death.

When turning the steering wheel while engine is running, do not enter the articulation area of the machine.

If a person is in the articulation area, do not start the engine.

②Bleed the cylinder of air

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or backup ring may be seized.

Air bleeding procedure a)While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note: Stop the piston about 100mm (4.0 in.) before both stroke ends. b)After that, operate the cylinder piston to both stroke ends for 4 to 5 times. c)Add hydraulic oil to the tank, and check the cylinder for oil leakage.

44-45

HYDRAULIC 44

90Z Ⅳ -2

Hydraulic Cylinder Tightening Torque

HYDRAULIC 44

Hydraulic Cylinder Tightening Torque (S/N 90C3-5501〜5700) Boom cylinder

T1

T2 90K44092-1

Bucket cylinder

T3

T4

90K44092-2

Steering cylinder

T5

T6 90K44092-3

T1 : 4,217N-m 430kg-m (3,100 lb-ft) T2 : 843N-m (86kgf-m) (622 lb-ft) T3 : 2,648N-m (270kgf-m) (1,950 lb-ft) T4 : 686N-m (70kgf-m) (506 lb-ft) T5 : 1,177N-m (120kgf-m) (868 lb-ft) T6 : 863N-m (88kgf-m) (637 lb-ft)

Cylinder

Piston nut width across flat (S)

Boom

90mm (3.54 in.)

Bucket

80mm (3.14 in.)

Steering

55mm (2.16 in.)

44-46

s

90Z Ⅳ -2

Hydraulic Cylinder Tightening Torque

HYDRAULIC 44

Hydraulic Cylinder Tightening Torque (S/N 90C3-5701〜) Boom cylinder 23 ・ 20

22

15 14 16

12 ・ 13 21

2 1

11 ・ 8 7 10

6

9 17 5

3

4

９０Ｋ４２０２０−１

18

: Tightening torque #16 ・・・・・ 4756N-m(485kgf-m)(3510Ib-ft) #18 ・・・・・ 843N-m(86kgf-m)(622Ib-ft)

Bucket cylinder 22

23 ・ 20

15 13 12 21 1 3 2 8 7 10 11 4 6 9 17 5

14

16 28・29 Gauge port PF1/4(Right side)

18

20・23

６５Ａ４２０３２

: Tightening torque #16 ・・・・・ 2354〜2648N-m(240〜270kgf-m) (1740〜1950Ib-ft) #18 ・・・・・ 588〜686N-m(60〜70kgf-m) (434〜506Ib-ft)

Steering cylinder 23 ・ 20

16

15

24

1

2

3

11 9 ・ 27 11 5 4 10 17

23 ・ 20

９０Ｋ４２０２０−３

: Tightening torque #4 ・・・・・・ 1961〜2157N-m(200〜220kgf-m) (1450〜1592Ib-ft) #16 ・・・・・ 1079〜1275N-m(110〜130kgf-m) (796〜941Ib-ft) 44-47

1. Piston 2. Piston rod 3. Cylinder tube 4. Rod cover 5. Dust seal 6. Backup ring 7. U-packing 8. Buffer ring 9. Bushing 10. Backup ring 11. O-ring 12. Slipper ring 13. Square ring 14. O-ring 15. Wear ring 16. Piston nut 17. Stop ring 18. Bolt 19. Backup ring 20. Dust seal 21. Wear ring 22. Stop ring 23. Bushing 24. Piston ring 25. Bolt 26. Washer 27. Seal ring 28. O-ring 29 Plug

Disassembling and Reassembling Hyd. Cyl.

90Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Hydraulic Cylinder 1.Disassembling hydraulic cylinder Note: The bucket cylinder disassembling procedure is described below. For other cylinders, follow the same procedure.

1) Install the bottom side of the cylinder to the repair stand.

Repair stand

2)Put the match marks on the rod cover (1) and the cylinder tube (2).

Remove the rod cover bolt (3).

Match mark

3

: Bolt : 686N-m (70.0kgf-m) (506 lb-ft) (Bucket cylinder)

2 1

3)Remove the piston rod assembly (4) from the cylinder tube.

4

: Hydraulic oil will be drained, so place a container to receive the drain oil.

90Z Ⅳ 4408

4)Remove the cylinder tube from the repair stand and install the rod assembly (4) to the repair stand and support the rod as shown in the figure.

Repair stand

4

Wooden block

44-48

Disassembling and Reassembling Hyd. Cyl.

90Z Ⅳ -2

HYDRAULIC 44

5)Remove the stop ring (5) and put match marks on the rod and the piston nut for alignment with the stop ring holes.

5

4

Match mark

6

6)Use a hydraulic jack or hydraulic cylinder to loosen the piston nut (6).

Note: Refer to "Hydraulic Cylinder Tightening Torque" for the tightening torque and the size of the piston nuts.

6 C

Hydraulic jack

Hydraulic cylinder

7)Remove the piston nut (6), and then remove the piston (7) from the piston rod (4).

6

8)Remove the wear ring (8), the square ring (9), the slipper ring (10), the O-ring (11) and the wear ring (12).

(There is no wear ring (12) for steering cylinder.)

8

7

9

10

4

12

10 9

11 (Boom and bucket cylinder)

44-49

8

11 (Steering cylinder)

Disassembling and Reassembling Hyd. Cyl.

90Z Ⅳ -2

HYDRAULIC 44

9)Remove the rod cover (1) from the piston rod (4).

1

4

10)Remove the scraper ring (13), backup ring (14), U-packing (15), buffer ring (18), backup ring (16) and the O-ring (17) from the rod cover (1).

Note: Ring (18) is not for steering cylinder. Two back-up rings are installed behind the U-packing (15) for steering cylinder.

17

1

16

18

15

14

13

For boom and bucket cylinder

2.Reassembling hydraulic cylinder 1

To reassemble the cylinders, follow the above removal procedure in the reversed direction.

16

17

15

14

44-50

13

Disassembling and Reassembling Hyd. Cyl.

90Z Ⅳ -2

HYDRAULIC 44

3.Cautions regarding reassembling Before starting work: a)Be sure to replace all the seals and packings. b)Clean and check all the parts. If a part is damaged, replace it. c) Before reassembling the parts, apply a coat of hydraulic oil to the parts.

CAUTION Hot oil can cause injury or burns.

Avoid contact with hot oil.

1)Put the slipper ring (10) into hot oil to heat the ring to 120 to 150 ℃ .

(This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston.

Therefore, heat the slipper ring to expand its inner diameter for easy attachment.) : Attach the slipper ring while taking care not to extremely expand it. : After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

2)Before installing the backup ring (2) and the O-ring (3), heat the backup ring.

(This is because the inner diameter of the backup ring is smaller than the outer diameter of the rod cover. To easily attach the backup ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.)

Be careful not to extremely expand the backup ring.

After installation, wait until the backup ring is cooled, and then insert the rod cover into the cylinder tube.

3)Reinstall the rod cover of the steering cylinder, screw the rod cover using a spanner wrench.

Screw in and tighten the set screw. : 863N-m (88kgf-m) (637 lb-ft)

44-51

10

2

3

Disassembling and Reassembling Hyd. Cyl.

90Z Ⅳ -2

HYDRAULIC 44

4)Caulk the rod cover (1) at 4 points to prevent the scraper ring (13) coming out.

1

Caulking

13 65K44067

1

13

Caulking 70V44005

44-52

90Z Ⅳ -2

Pilot Valve

HYDRAULIC 44

Pilot Valve For bucket control

Neutral

1 Dump

Roll back

For bucket control

For boom control

8 2

3

T

To tank port

4 5 6

From pump port

7

P

８５Ｗ４２１１

To MCV oil packs

８５Ｗ４２１８

View from the rear

For boom control

Raise

Neutral

Down

1. Lever 2. Disc 3. Push rod 4. Spring seat 5. Spring for secondary pressure 6. Return spring 7. Spool 8. Detent magnet solenoid

Float

To tank port ８５Ｗ４２１９

44-53

90Z Ⅳ -2

Pilot Valve Tightening Torque

HYDRAULIC 44

Pilot Valve Tightening Torque : Tightening torque T1 : 29N-m (3.0kgf-m) (22 lb-ft) T2 : 36N-m (3.7kgf-m) (27 lb-ft) T3 : 17N-m (1.7kgf-m) (12 lb-ft) T4 : 29N-m (3.0kgf-m) (22 lb-ft) T5 : 29N-m (3.0kgf-m) (22 lb-ft) T6 : 17N-m (1.7kgf-m) (12 lb-ft) T7 : 42N-m (4.3kgf-m) (31 lb-ft) T8 : 12N-m (1.2kgf-m) (9 lb-ft)

For boom control Front

For bucket control

T3

: Pilot valve 9.5kg (21 lbs) : L1 : Screw lock agent (Three Bond1327)

T3

T5

T5 T6 L1

T6 L1

T7

T8

T7

T8

T7

T7

T4

T4 T4 T4

T2 ９０Ｋ４４０９０

T1

T1

44-54

application

Removing and Reinstalling Pilot Valve

90Z Ⅳ -2

HYDRAULIC 44

Removing and Reinstalling Pilot Valve 1.Removing pilot valve WARNING

1

Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. In addition, apply the parking brake. ・ Lower the bucket onto the ground, and then relieve the internal pressure from the line. ・ Relieve the internal pressure from the hydraulic tank.

Control box

Cover mount

85W44006

1)Open the cab door (the right hand side).

Remove the cover (1) from the control box.

2

2)Disconnect the electrical line (2) of QUAD (PUS) switch.

3)Disconnect the electrical line coupler (3) from the pilot valve.

3

85K44033

4)Remove the knob (4) and then separate the QUAD (PUS) switch (5).

4

4

5 85K44034

5)Remove the boot (6) and the covers (7)(8)(9)(10).

10 8 9 6

7 85K44035

44-55

Removing and Reinstalling Pilot Valve

90Z Ⅳ -2

HYDRAULIC 44

6)Disconnect the hoses (11) from the pilot valve. : Drain oil : Approx. 1 l (0.3 gal.)

Note: Before disconnecting the electrical coupler and hoses, be sure to put match marks on them.

After disconnection, cover the discon- nected hoses with vinyl, caps, or plugs to protect them from dust and dirt.

11 11

85K44036

7)Disconnect the arm (12) and the rod (13) at the ball joint part.

12 Adapter

13

8)Disconnect the rod (13) and the lever (14) at the ball joint part.

9)Remove the bolt (15) (4 pcs) and pull up the pilot valve to remove it.

14 14 15

: Adapter : 36N-m (3.7kgf-m) (27 lb-ft) : Nut : 28N-m (2.9kgf-m) (21 lb-ft)

16 85W44007

: Pilot valve : 9.5kg (21 lbs)

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

Note: After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage.

If the oil level is too low, add hydraulic oil to the tank.

44-56

Nut

Disassembling and Reassembling P / V

90Z Ⅳ -2

HYDRAULIC 44

Disassembling and Reassembling Pilot Valve 1.Disassembling pilot valve Note: ・Put plug on each port then clean the outer surface of the vlave. ・Place the removed parts, in order, on a clean paper or cloth. ・Carefully disassemble the pilot valve so that the parts are not scratched.

1)Clamp the pilot valve in a vise.

Pull up the boot (1) to remove it from the cover (2).

For boom control Front For bucket control

70K44045

2) Loosen the lock nut for the solenoid (3) and then remove the solenoid from the cover (2).

Torque for assembly : : Solenoid : 42N-m (4.3kgf-m) (31 lb-ft) Note: Before removing the solenoid (3), measure the distance "A".

A

Lock nut

1

3 4

2

70K44046

70Z Ⅳ 4207

Carefully store the ball (4).

44-57

Disassembling and Reassembling P / V

90Z Ⅳ -2

HYDRAULIC 44

3)Remove the socket bolt (5).

Torque for assembly: : Bolt : 29N-m (3.0kgf-m) (22 lb-ft)

5 6 7

4)Remove the lever (6) from the disc (7).

70K44047

5) Loosen the socket bolt (8).

8

Torque for assembly: : Retainer bolt : 17N-m (1.7kgf-m) (12 lb-ft) : Screw lock agent (Three Bont 1327) application 6)Remove the cam shaft (9).

Note: ・Temporarily install the socket bolt (5) into the disc. ・Pull the cam shaft to the direction shown.

9 70K44048

7)Pull up the socket bolt (5) with the disc (7) and remove it.

8)Put match mark on the cover (2) and the case assembly.

Remove the socket bolt (10).

10

7

2

70K44049

9)Remove the cover (2) from the case assembly.

2

70K44050

44-58

Disassembling and Reassembling P / V

90Z Ⅳ -2

10)Remove the plug (11) together with the push rod (12).

Note: ・Carefully store the spring and spring seat in the push rod. ・Carefully remove the plug so that the parts are not scratched. ・In case the plug(11)does not come out, use the screw driver to remove it.

HYDRAULIC 44

11 12 13 14

CAUTION Be careful! The spring inside the case assembly may spring out and hit your face. Do not point the plug assembly toward your face.

70K44051

11)Remove the springs (15) (16) from the case assembly (14).

16

14

15

70K44052

Note: When installing, carefully install the spool assembly so that the end of the spool does not hit the hole corner in the case assembly.

Carefully install into the case

70ZA4409

12)Clamp the case assembly (14) in the vise up side down.

Remove the socket bolt (17), then remove the plate (18) from the case assembly.

Torque for assembly: : Bolt : 29N-m (3.0kgf-m) (22 lb-ft)

17 18

14 70K44053

44-59

Disassembling and Reassembling Pilot Valve

90Z Ⅳ -2

HYDRAULIC 44

13)Remove the spring (19) and the spring seat (20) from the push rod (12).

Note: The spring (19) and the spring seat (20) are used in the following position.

Boom down/Float 70Z Ⅳ〜115Z Ⅳ Boom raise 70Z Ⅳ〜85Z Ⅳ Roll back 70Z Ⅳ〜85Z Ⅳ Dump 70Z Ⅳ〜85Z Ⅳ

11

12

19

14)Remove the push rod (12) from the plug (11).

20 70K44054

15)Push down the spring seat (23), and then remove the plane washer (24).

Note: ・ Carefully remove the plane washer so that the spool is not scratched. ・ Do not push the spring seat (23) down more than 4mm.

24 23

25 26

16)Remove the spring seat (23), spring (25), plane washer (24) and the shim from the spool (22).

Note: Shim for adjusting secondary pressure.

Some spool need shim, but others may not need it.

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

Note: ・ Clean and check all the parts. If a part is defective, replace or repair the part. ・ Replace all the O-rings and seals with new ones. ・ Apply the specified torque to tighten each main parts. ・ Apply a thin coat of hydraulic oil or grease to each part before reassembly. ・ Measure the resistance of each coil magnet assembly. The resistance should be 238Ω±10 at normal room temperature (20 ° C). If measured in extremely low temperatures the resistance will be less.

At operating temperature the resistance will be higher.

Cautions regarding reassembling : Install the plane washer (24) so that the plane washer sharp edge side comes to the top position.

Note: Do not push the spring seat (23) down more than 4mm.

44-60

22 70K44055

24

23

Sharp edge side

70ZA4408

90Z Ⅳ -2

Pilot Relief Valve Unit

HYDRAULIC 44

Pilot Relief Valve Unit 1.Removing pilot relief valve unit WARNING Unexpected movement of the machine may cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and lower the bucket onto the ground. ・ Block the tires with chocks to prevent the wheels from moving. ・ Relief the internal pressure from the hydraulic tank. ・ Place a "DO NOT START!" tag on the steering wheel.

1)Put match marks on the hoses (1), then disconnect them. : Cover the disconnected hoses with vinyl, caps, or plugs to protect them from dust, water, and dirt.

2

2)Remove the bolt and the relief valve (2).

1

2.Reinstalling pilot relief valve unit To reinstall the pilot relief valve unit, follow the above removal procedure in the reversed direction.

Caution regarding reinstallation: ①When reassembling the pilot relief valve unit, after the completion of reinstallation, be sure to check the pressure.

Refer to Section 03 for the pressure check procedure.

Refer to Section 03 for the standard measurement valve. ②Start the engine and check that the boom properly works. ③Check for oil leakage.

44-61

90W44003

HYDRAULIC GROUP 45 Service Standard Steering Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-2 Hydraulic Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-3 Pilot Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 45-4

45-1

90Z Ⅳ -2

Steering Valve

HYDRAULIC 45

Steering Valve

2

1

Tightening torque No. 1

Unit : N-m (kgf-m) (lb-ft) Item

Standard value

Steering valve retainer bolt

Remedy

88 (9.0) (65) Tightening

2

Steering valve bracket retainer bolt

216 (22.0) (159)

45-2

90Z Ⅳ -2

Hydraulic Cylinder

HYDRAULIC 45

Hydraulic Cylinder Boom cylinder 2 4

1

(Note)The cylinder shown in the above figure is the boom cylinder

3

90K45002

Steering cylinder 2

1

4

3

(Note)The cylinder shown in the above figure is the steering cylinder

90K45001

Unit : mm (in.)

Judgment standard No.

Item

clearance

φ 90

-0.036 (-0.0014)

+0.195 (+0.0076)

0.096 (0.0037)

-0.090 (-0.0035)

+0.060 (+0.0023)

0.285 (0.0112)

-0.030 (-0.0011)

+0.190 (+0.0074)

0.090 (0.0035)

-0.076 (-0.0030) -0.025 (-0.0010)

+0.060 (+0.0023) +0.110 (+0.0043)

0.266 (0.0104) 0.025 (0.0010)

-0.064 (-0.0025)

0 (0)

0.174 (0.0068)

2

N-m (kgf-m) (lb-ft) Piston nut width across flat mm (in.)

3 4

〜

Piston nut tightening torque

Boom cylinder

〜

Item

〜

( φ 1.9685)

〜

φ 50

Steering cylinder

Limit

Standard

〜

( φ 2.9527)

〜

φ 75

〜

( φ 3.5433)

Bucket cylinder

No.

Bushing

〜

1

Rod

Standard value

〜

Boom cylinder

Standard dimension of rod dia.

Solution

Bushing

Clearance

+0.295 (+0.0116)

0.385 (0.0151)

Replacement

+0.290 (+0.0114)

0.366 (0.0144)

Replacement

+0.210 (+0.0082)

0.274 (0.0107)

Replacement

Bucket cylinder

Steering cylinder

M62 × 2

M52 × 2

M36 × 1.5

4,217 (430) (3,110)

2,648 (270) (1,950)

1,177 (120) (868)

90 (3.54)

80 (3.14)

55 (2.16)

M24

M22

(Rod cover)

N-m (kgf-m) (lb-ft)

843 (86) (622)

686 (70) (506)

863 (88) (637)

Piston stroke mm

850 (2 ft 9 in.)

619 (2 ft)

450 (1 ft 6 in.)

Rod cover bolt tightening torque

45-3

90Z Ⅳ -2

Pilot Valve

HYDRAULIC 45

Pilot Valve

212-1

７０Ｖ４５００２

Judgement standard No.

Item Wear 1mm

212-1

Push rod

Solution

(φ7)

45-4

Standard value

Allowable limit

36mm

35mm

Replacement

BRAKE GROUP 54 Disassembly and Reassembly Brake Valve Assembly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-2 Removing and Reinstalling Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-3 Disassembling and Reassembling Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-4 Air Master Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-6 Removing and Reinstalling Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-7 Disassembling and Reassembling Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-8 Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-14 Removing and Reinstalling Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-15 Auto-Adjuster Valve Tightening Torque ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-16 Disassembling and Reassembling Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-17 Removing and Reinstalling Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-18 Air Cylinder for Parking ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-19 Removing and Reinstalling Cylinder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-20 Disassembly and Reassembly of Air Cyilnder ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-21 Removing and Reinstalling Parking Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 54-23

54-1

90Z Ⅳ -2

Brake Valve Assembly

BRAKE 54

Brake Valve Assembly

16

: Torque T1 : 12N-m (1.2kgf-m) (9 lb-ft) T2 : 6N-m (0.6kgf-m) (4 lb-ft) T3 : 34N-m (3.5kgf-m) (25 lb-ft) L2 15 13

L1 : Liquid gasket application (Loctite gasket 568) L2 : Anti-seize compound

12 14

11

T1

1. Diaphragm 2. Cover 3. Inlet / exhaust valve assembly 4. Body 5. Piston 6. Relay piston assembly 7. Valve assembly 8. Body 9. Upper piston assembly 10. Spring seat 11. Boot 12. Plunger 13. Roller 14. Spring 15. Pin 16. Pedal

T2

5

T3 10

L1

7 9 4

T3

L1

T2 3 8

2

6

1

54-2

Removing and Reinstalling Brake Valve

90Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Brake Valve 1.Removing brake valve WARNING 2

Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. ・ Drain the air pressure from the air tank.

1

Before starting work, clean the area around the brake valve.

1)Disconnect the air pipes (1), the tee (2), and then disconnect the air hose (3).

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

2)One person should support the brake valve under the machine, and another person should enter the cab. The person in the cab should remove three connection bolts (5) from the brake pedal (4), and the person under the machine should remove the brake valve. Remove the pedal assembly (4) from the top side.

3 90W54001

5 4

65K54002

2.Reinstalling brake valve To reinstall the brake valve, follow the above removal procedure in the reversed direction Note : After reinstallation, check all the pipe- joints for air leakage.

To check or adjust the brake valve, refer to Section 53.

54-3

Disassembling and Reassembling Brake / V

90Z Ⅳ -2

BRAKE 54

Disassembling and Reassembling Brake Valve 1.Disassembling brake valve

2

Before starting work: a)Clean the outer surface of the valve.

1

1)Remove the diaphragm (1) and the cover (2).

2)Remove the inlet exhaust valve assembly (3).

3

1

2

3)Disassemble the inlet exhaust valve assembly (3).

3

4)Remove the retainer ring (4), spring seat (5), O-rings (6) (7), retainer (8), valve spring (9), and inlet exhaust valve (10). Also remove the body retainer bolt (11).

11 6

4

5

8

7

10

9 65K54019

54-4

Disassembling and Reassembling Brake / V

90Z Ⅳ -2

BRAKE 54

5)Separate the body into two sections (1) (2).

1

6) Loosen and remove the nut (3), and then remove the spring set (4), piston assemblies (5) (6), rubber spring (7), and piston return springs (8) (9).

8

To reassemble the brake valve, follow the above disassembly procedure in the reversed direction.

3.Cautions regarding reassembly 1)Clean and check the disassembled parts. If a part is defective, replace it.

Note : All the rubber parts should be replaced annually. Certain cleaners and solvents can damage rubber parts, use only approved cleaners and solvents.

2)Apply lithium-based grease to all the sliding surfaces of the body, O-rings, and O-ring grooves.

3)After reassembly, reinstall the brake valve on the machine, and check that no air is leaking. Also check operation of the brake valve referring to "Checking Brake Valve" in Section 53.

54-5

5 4

6

2.Reassembling brake valve

2

9

7

3

Air Master Tightening Torque

90Z Ⅳ -2

BRAKE 54

Air Master Tightening Torque

A

T4

T3

T2 T1

A

T5

:Torque T1 : 55N-m (5.6kgf-m) (41 lb-ft) (width across flat: 30mm) T2 : 147N-m (15.0kgf-m) (109 lb-ft) (width across flat: 100mm) T3 : 10N-m (1.0kgf-m) (7 lb-ft) T4 : 44N-m (4.5kgf-m) (33 lb-ft) T5 : 137N-m (14.0kgf-m) (101 lb-ft)

54-6

Removing and Reinstalling Air Master

90Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Air Master 1.Removing air master WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ Park the machine on level ground, and then block the tires with chocks to prevent wheels from moving. ・ Use a stepladder or the like to reach a high position of the machine. ・ Drain the air pressure from the air tank.

1

85K54001

1)Remove the cover (1).

2

2)Disconnect the air hose (2).

85Z Ⅳ 5401

3)Disconnect the brake hoses (3) (4).

Note : The brake oil will be drained. container to catch the drained oil. : Brake oil 0.4 l (0.1 gal.)

2

Place a

3 6

4)Disconnect the stroke indicator connector (5), and remove the retainer nuts (7) from the air master (6).

Remove the air master.

7 4 85Z Ⅳ 5401

2.Reinstalling air master

AIR MASTER

To reinstall the air master, follow the above removal procedure in the reversed direction.

Note : After reinstallation, completely bleed the brake line of air, and check performance of the air master.

To bleed the brake line of air, refer to Section 24.

To check performance of the air master, refer to Section 53.

5 85Z Ⅳ 5402

54-7

Disassembling and Reassembling Air / M

90Z Ⅳ -2

BRAKE 54

Disassembling and Reassembling Air Master 1.Disassembling air master IMPORTANT ・ Clean the outer surface of the air master. ・ Put match marks on the parts before disassembly. ・ Sequentially place the removed parts in the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

1)Securely clamp the air master in a vise.

2

2) Feed low-pressure air (approx. 98kPa (1kgf/cm ) (14psi)) into the air cylinder from the air inlet port, and operate the hydraulic pistion in full stroke mode (continue operation in full stroke mode).

Note : This may discharge some remaining brake oil.

3) Loosen the locknut (1).

Nut width across flat: 100mm

1

Air inlet port

2

4) Loosen the cylinder (2), and remove it.

5)Slide the retainer ring (3) to remove the straight pin (4). After that, separate the push rod (5) from the piston (6).

5

3

4

6

6)Bleed the air cylinder of air.

Slide ③ in the "

4 Remove the straight pin

3

54-8

"direction

Disassembling and Reassembling Air / M

90Z Ⅳ -2

BRAKE 54

7)Remove the snap ring (2) from the piston (1). After that, remove, in order, the spring seat (3), spring (4), and valve (5).

After that, remove the piston cup (6).

Note : The piston(1)should be replaced as an assembly, therefore further disassembly is not needed.

1

5

4

3

2

6

8)Remove the breather (7) and the switch (8), and rod (22).

7

22 8

9) The spring of the air cylinder has a high force of 25kg. Therfore, press the spring using a press, and then remove the bolts (9), washers (10), and nuts (11).

Press

9

10 11

WARNING The inner spring may spring out causing injury. To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the bolts (9). When reducing the pressure of the press, be sure to slowly reduce it.

10)Separate the cover into two sections, and then remove the spring (12).

12

11)Loosen and remove the nut (13), and then remove the spring washer (14), piston (15), and rod (16).

After that, remove, in order, the washer (17), piston seal (19), piston ring (20), and O-ring (21).

Note : To loosen the nut (13), cover the shaded area of the rod (area A in the right figure)with a copper sheet or the like for protection, and then clamp the shaded area using a vice. Do not clamp over the area having a pin sliding hole.

18 15

A 16 17

19 13

20 14 21

Pin sliding hole Two chamfered flats Enlarged area A

9

90Z Ⅳ -2

Disassembling and Reassembling Air / M

BRAKE 54

12)Remove the snap ring (2) from the end cover (1), and then remove, in order, the support ring (3), seal (4), seat ring (5), and seal (6).

1

2

4

6

8

2.Reassembling air master

Standard value for assembly

Limit

0.025〜0.126

0.15

5

3

Notes: ・Clean the metal parts using approved brake cleaning solvent, and then blow the compressed air to dry them. ・After cleaning, check the parts for damage and wear.

If a part is defective, replace it with a new one. ・Replace all the O-rings and seals with new ones. ・Measure the clearance between the hydraulic cylinder and the piston by cheking of inner diameter of cylinder and outer diameter of piston. If the clearance is too large and exceeds the following limit value, replace the hydraulic cylinder and the piston as an assembly.

Clearance between hydraulic cylinder and piston (mm)

7

9

13)After that, remove the snap ring (7) on the opposite side, and then remove the seat ring (8) and the seal (9).

・ Use brake oil (engine oil SAE 5W or Mobil Delvac1). ・ Use lithium grease.

1)Reinstall, in order, the O-ring (2), washer (3), piston (4), and spring washer (5) on the rod (1), and then tighten the nut (6). : Nut 137N-m (14.0kgf-m) (101 lb-ft) Note : To tighten the nut, cover the shaded area of the rod(area a in the right figure )with a copper sheet or the like for protection, and then clamp the shaded area using a vice.

Do not clamp over the area having a pin sliding hole.

1

8

2

6

2)Apply a thin coating of lithium grease to the piston ring (7) and the piston seal (8), and then insert them into the piston.

A

3 4

7

Pin sliding hole

10

5

Disassembling and Reassembling Air / M

90Z Ⅳ -2

3)Apply a coating of brake oil to the seal (2), seat ring (3), seal (4), and support ring (5), and then sequentially install them to the end cover (1) in the above order. After that, install the snap ring (6).

BRAKE 54

1 6

4

4)Apply a coating of brake oil to the seal (7) and the seal ring (8), and then install them to the opposite side of the end cover. After that, install the snap ring (9).

7

2

8

3

5

9

5)Apply a thin coating of lithium grease to the O-ring (10), and then install the O-ring to the end cover (1).

10

1

6)Apply lithium grease to the inside of the cover, and then insert the air piston assembly (11), already reassembled, and the spring (12) into the cover.

12

WARNING

Cover

11

Be careful! The spring could spring out. To reassemble, fix the cylinder assembly so that it is not inclined. ・ Press the spring using a press until it loses the spring force, and then start the work.

7)Reinstall the end cover (1) on the cover already reassembled at step 6) above. While applying pressure to the end cover using a press, insert the bolts (13), washers (14), and nuts (15), and then tighten the bolts. : Bolt 44N-m (4.5kgf-m) (33 lb-ft)

Press

13

11

14 15

1

Disassembling and Reassembling Air / M

90Z Ⅳ -2

BRAKE 54

8)Apply a coating of brake oil to the valve (2), spring (3), and spring seat (4), and then insert them into the piston (1). In addition, install the snap ring (5) to the piston.

After that, reinstall the piston cup (6).

1

2

4

3

6

9) Feed low-pressure air of approximately 1kg/cm2 into the air cylinder (already reassembled at step 7 above) from the air inlet. Operate the air piston in full stroke mode until the push rod (7) is protruded from the end cover.

Note : Keep the air pressure applied.

End cover

Air inlet port

7

10)Just like the disassembly procedure, slide the retainer ring (8) to insert the straight pin (9) into the piston (1), and then push the straight pin through the push rod (7).

7

8 9

1

Slide (8) in the " "direction

9 Insert the straight pin

11)Install an O-ring (11) to the cylinder (10), and then apply a coating of brake oil to the inside of the cylinder and the O-ring.

12)Screw the locknut (12) all the way on the threaded area of the cylinder (10).

10

12

11

12

5

Disassembling and Reassembling Air / M

90Z Ⅳ -2

13)Screw the threaded area of the cylinder (1) all the way into the end cover (2).

Note : Align the plug with the breather so that it (distance from center line A-A)is 20mm or less(see the figure).

BRAKE 54

Air breather Breather Plug

A

20 20

14)After completion of the alignment, tighten the locknut (3).

A

Plug

2

1

: Nut 147N-m (15.0kgf-m) (109 lb-ft) Nut width across flat 100mm

3

A-A

15)Install the rod (6) in the end cover (2), and tighten the switch (4) to the end cover (2) until its end fits in the groove of the rod (6).

5

:Switch 55N-m (5.6kgf-m) (41 lb-ft) 2

16)Reinstall the breather (5), and tighten it.

Note : After reassembling the air master, reinstall it on the machine referring to Section 54.

1

4 6

13

90Z Ⅳ -2

Auto-Adjuster Valve

BRAKE 54

Auto-Adjuster Valve 8

15

16

1

2

18

19

Brake piston port

4

3 9

Air master port

17

6

5

7

10

11

12 10 14 13

1.Cylinder 2.Piston 3.O-ring 4.Valve body 5.Valve 6.Spring 7.O-ring 8.Body 9.O-ring 10.Spring washer

11.Bolt 12.Plain washer 13.Plate 14.Bolt 15.Air bleeder screw 16.Cap 17.Washer 18.Screw 19.O-ring

14

Removing and Reinstalling Auto-Adjuster Valve

90Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Auto-Adjuster Valve 1.Removing auto-adjuster valve (The illustration show the rear wheels).

1)Disconnect the hose (1) and the pipes (2).

Oil will be drained from the hose. Place a container to catch the drained oil. : Brake oil 0.4 l (0.1 gal.)

1 2 90K54002

2)Remove four retainer auto-adjuster valve (3).

bolts

(4)

from

the 3

: Bolt (4)

29〜35N-m (3.0〜3.6kgf-m) (22〜26 lb-ft)

3)Remove the auto-adjuster valve (4).

4

90K54003

2.Reinstalling auto-adjuster valve To reinstall the auto-adjuster valve, follow the above removal procedure in the reversed direction.

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

For the detailed procedure of air bleeding, refer to Section 24.

15

90Z Ⅳ -2

Auto-Adjuster Valve Tightening Torque

BRAKE 54

Auto-Adjuster Valve Tightening Torque 11 10 T4

4 7 5

1

6 3

17

16

14 T2

T1

10

2 T3 18

15 T3

9

19 12

8

:Torque T1 : 39N-m (4.0kgf-m) (29 lb-ft) T2 : 54N-m (5.5kgf-m) (40 lb-ft) T3 : 10N-m (1.0kgf-m) (7 lb-ft) T4 : 15N-m (1.5kgf-m) (11 lb-ft)

16

13

T2

Disassembling and Reassembling Autovalve

90Z Ⅳ -2

BRAKE 54

Disassembling and Reassembling Auto-Adjuster Valve 1.Disassembling auto-adjuster valve (The disassembly procedure described below is for the left-side of the valve. )

IMPORTANT ・ Clean the outer surface of the auto-adjuster . ・ Put match marks on the parts before disassembly. ・ Place the removed parts according to the disassembly order. ・ Carefully remove each part so that it is not scratched or dented.

1)Remove the bolts (1).

Torque for assembly : Retainer bolt 54N-m (5.5kgf-m) (39 lb-ft) 10

2)Separate the cylinder (2) into two sections.

Remove and clean the plug (10). Remove and inspect the plug (11) and replace the O-ring. : Plug (10) 15N-m (1.5kgf-m) (11 lb-ft) Plug (11) 10N-m (1.0kgf-m) (7 lb-ft)

1

6 3

8 2

11 5

3)Pull out the piston (3) from the cylinder (2).

4

7

4)Gently clamp the two opposite flats of the piston (3) using a vice. Loosen the valve body (4), and then remove the valve (6), spring (7), washer (8), O-rings (5)(9).

9

2.Reassembling auto-adjuster valve To reassemble the auto-adjuster valve, follow the above disassembly procedure in the reversed direction.

Note : Be sure to replace all the O-rings with new ones, and apply a coat of brake oil to them before reassembly. Inspect the parts for scoring or other damage. Replace as necessary.

17

85W54001

Removing and Reinstalling Service Brake

90Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Service Brake Removing and reinstalling service brake Refer to the power group 24 for removing and reinstalling service brake.

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

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

Finally the spider and the cover may fall off.

Spider ９０Ｗ５４００２

Socket bolt

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

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

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

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

Completely bleed each wheel of air.

18

90Z Ⅳ -2

Air Cylinder for Parking

BRAKE 54

Air Cylinder for Parking 14

4 10 8 3

2

7 13 11 5 9 6

12 15

1

1.Cylinder tube 2.Piston rod 3.Rod cover 4.Rod cap 5.Piston 6.U-nut 7.Spring 8.Wear ring 9.U-packing 10.Dust seal

11.O-ring 12.O-ring 13. Filter 14.Set screw 15.Retainer bolt : Air cylinder

19

8.0kg (18 lbs)

Removing and Reinstalling Cylinder

90Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Cylinder 1.Removing air cylinder WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ When removing the air cylinder, the machine may move.

To prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

6

5

1) If there is an air source, release the parking brake, and then remove the split pin (1) and the pin (2).

Note : If there is no air source, apply a cable to the link, and then pull it down using a bar to overcome the spring force, and then remove the pin.

3 4

1 2

2)Release the air pressure. Disconnect the air hose.

3) Loosen the locknut (3) to remove the joint (4).

Remove the retainer bolts (5) to remove the air cylinder (6).

85W54002

49〜59N-m (5.0〜6.0kgf-m) (36〜43 lb-ft) 8kg (18 lbs)

: Retainer bolts : Air cylinder

2.Reinstalling air cylinder To reinstall the air cylinder, follow the above removal procedure in the reversed direction.

Note : To insert the connection pin to connect the air cylinder to the parking brake, observe the following items: ①Start the engine to build air pressure in the air tank. ②Release the parking brake. ③Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the air cylinder and the parking brake. After that, insert the connection pin into the joint hole.

To check performance of the parking brake, refer to Section 53.

20

Disassembly and Reassembly of Cylinder

90Z Ⅳ -2

BRAKE 54

Disassembly and Reassembly of Air Cylinder 1.Disassembling air cylinder WARNING The inner spring could spring out causing injury. To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the rod cap. When reducing the pressure of the press, be sure to slowly reduce it.

1) Removal of the set screw of rod cap Note : Since the set screw is locked by punching, cut off the punched area with 15 to 20mm dia. drill.

Since it is necessary to install the set screw at the same position during reassembly, mark the positioning match- mark on the rod cap and cylinder tube.

2) Initial loosening of rod cap Using the threaded hole of the rod cap, unscrew the rod cap approx. 1/8 turn alone.

3) Removal of rod cap Using the press, press down the rod cover with the pipe (outer dia. : 50mm or less, inner dia. : 30mm or more, length: 80mm), and it will be allowed to loosen the rod cap with hand. So, remove the rod cap.

Component parts of air cylinder 1

1. Cylinder tube 2. Rod Cap 3. Spring 4. Piston 5. Piston rod 6. Rod cover

2 3

5 4

21

6

Disassembly and Reassembly of Cylinder

90Z Ⅳ -2

BRAKE 54

2.Reassembling air cylinder To reassemble the air cylinder, follow the disassembly procedure in the reversed direction.

CAUTION When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined.

Tighten the rod cap to the position where the matchmark was marked before disassembly, screw in the screw, and punch it for locking.

Adjustment procedure of air cylinder linkage.

1

4

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: ・ When removing the air cylinder, the machine may move.

To prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

A 2

4

3 A 2

1)Release parking brake (OFF).

2)Measure dimension "A" if it is 84mm.

3

3) If not, remove pin (5), split pin (6), and washer (7) and loosen lock nut (2).

And adjust the linkage length by turning link 3 so that dimension "A" is 84mm.

5, 6, 7

4) Tighten lock nut (2) and reinstall pin (5), split pin (6) and washer (7).

5)Confirm the parking brake performance referring to page 53-002.

Parking brake "OFF" position.

1. Air cylinder 2. Lock nut 3. Link 4. Bracket 5. Pin 6. Split pin 7. Washer

22

Removing and Reinstalling Parking Brake

90Z Ⅳ -2

BRAKE 54

Removing and Reinstalling Parking Brake 1.Removing parking brake WARNING Unexpected movement of the machine could cause injury or death. To prevent such and accident, observe the following items: ・ When removing the parking brake, the machine may move. So, to prevent the machine from moving, park the machine on level ground, and lower the bucket onto the ground. ・ In addition, block the tires with chocks to prevent wheels from moving.

Note : Drain the transmission oil. Drain the oil into a suitable container. 38 l (10 gal.)

1)Release the parking brake, and then disconnect the second propeller shaft (1) at the transmission end.

Torque for reassembly : Retainer bolt 142N-m (14.5kgf-m) (105 lb-ft) : Screw lock agent application (Three bond 1327)

1

85W54004

2)Remove the nut (2), and then remove the washer, O-ring, and backup ring.

Torque for reassembly : Nut 392N-m (40.0kgf-m) (289 lb-ft) : Application of anti-seize compound 2

80K54004

3)Remove the flange yoke (3) with the brake drum (4).

Torque for reassembly : Retainer bolt 98N-m (10.0kgf-m) (72 lb-ft)

3

4

80K54005

23

Removing and Reinstalling Parking Brake

90Z Ⅳ -2

BRAKE 54

4)Separate the air cylinder and the parking brake at the ball joint (5) part.

5

85W54003

5)Remove the bolt (6) and then remove the brake assembly (7).

Torque for reassembly : Bolt 216N-m (22.0kgf-m)(159 lb-ft) : Screw lock agent application(Loctite 262)

7

6

80K54007

6)Remove the spring (9) and then remove the plate (10).

10 9

9

65V54001

7)Remove the shoe hold pins (11) by turning 90 degree.

12

11

8)Remove the brake shoes (12).

65V54002

24

Removing and Reinstalling Parking Brake

90Z Ⅳ -2

BRAKE 54

9)Remove the spring (13) and the adjust screw (14).

13

14

2.Reinstalling parking brake To reinstall the parking brake, follow the above removal procedure in the reversed direction.

Note : To adjust the parking brake, refer to Section 53.

To check performance of the parking brake, refer to Section 53.

25

65V54003

BRAKE GROUP 55 Service Standard Brake Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-2 Air Master ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-4 Auto-Adjuster Valve ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-5 Service Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-6 Parking Brake ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 55-7

55-1

90Z Ⅳ -2

Brake Valve

BRAKE 55

Brake Valve

17 7

6

9 2

5

1

17

8 10 11 13

4

12

14

15 16

3

No.

Item

Standard value

Solution

1

Mounting plate retainer bolt tightening torque

12N-m (1.2kgf-m) (9 lb-ft)

Tightening

2

Rubber spring setting nut tightening torque

6N-m (0.6kgf-m) (4 lb-ft)

Tightening

3

Lower body retainer bolt tightening torque

6N-m (0.6kgf-m) (4 lb-ft)

Tightening

4

Plug tightening torque

34N-m (3.5kgf-m) (25 lb-ft)

Tightening

55-2

90Z Ⅳ -2

Brake Valve

BRAKE 55

Unit : mm(in.)

No. 5

6

7

Item Pedal pin hole dia

Nominal

Service standard

Wear limit

10 (0.393)

10.25 (0.403)

10 (0.393)

9.85 (0.387)

Inner dia.

10 (0.393)

10.1 (0.397)

Outer dia.

23.2 (0.913)

23 (0.905)

Inner dia. of pin bushing

10 (0.393)

10.25 (0.403)

Inner dia. of plunger bushing

26.5 (1.043)

26.65 (1.049)

Outer dia. of pin (pins for both roller and mounting plate)

Note

Roller

Mounting plate 8

9

Outer dia. of plunger

26.5 (1.043)

26.16 (1.029)

10

Free height of rubber spring

14 (0.551)

12 (0.472)

11

12

13

14

15

16

17

Spring

Free length mm(in.)

71.4 (2.811)

(piston return)

Load N (kgf) (lbf)

113 (11.5) (25)

Spring

Free length mm(in.)

41.3 (1.626)

(upper valve)

Load N (kgf) (lbf)

44 (4.5) (10)

Spring

Free length mm(in.)

35.6 (1.402)

(inner valve)

Load N (kgf) (lbf)

27 (2.8) (6)

Spring

Free length mm(in.)

41.0 (1.614)

(outer stem)

Load N (kgf) (lbf)

39 (4.0) (9)

Spring

Free length mm(in.)

39.5 (1.555)

(relay piston)

Load N (kgf) (lbf)

46 (4.7) (10)

Spring

Free length mm(in.)

16.5 (0.649)

(lower valve)

Load N (kgf) (lbf)

29 (3.0) (7)

Spring

Free angle

131deg

(pedal return)

Set angle

115deg

55-3

When the length is 14.6mm (0.574 in.)

When the length is 14.3mm (0.562 in.)

When the length is 16.0mm (0.629 in.)

When the length is 16.0mm (0.629 in.)

When the length is 12.1mm (0.476 in.)

When the length is 10.2mm (0.401 in.)

When the pedal is returned

90Z Ⅳ -2

Air Master

BRAKE 55

Air Master 3

1

5 2 6 4

8 7

Unit : mm (in.)

No.

Item

Judgment standard

Solution

Standard dimension

Standard clearance

Allowable clearance

68 (2.6771)

0.025〜0.126 (0.0010〜0.0050)

0.15 (0.0059)

1

Clearance between cylinder and piston

2

Stroke of hydraulic cylinder

84.5 (3.3267)

-

3

Stroke of air cylinder

85.5 (3.3661)

-

4

Stroke to overstroke switch

59 ± 3 (2.3228 ± 0.1181)

-

5

Air piston retainer nut tightening torque

137N-m (14.0kgf-m) (101 lb-ft)

Tightening

6

Locknut tightening torque (100mm Nut Size)

147N-m (15.0kgf-m) (109 lb-ft)

Tightening

7

Overstroke switch tightening torque

55N-m (5.6kgf-m) (41 lb-ft)

Tightening

8

Air cylinder retainer bolt tightening torque

44N-m (4.5kgf-m) (33 lb-ft)

Tightening

55-4

Replacement

90Z Ⅳ -2

Auto-Adjuster Valve

BRAKE 55

Auto-Adjuster Valve

5 4

7 1

Wet brake piston port

6 Air master port

2

3

Unit : mm (in.)

No.

Item

Judgment standard Tolerance

Standard 1

2

Clearance between cylinder and piston

Clearance between check valve and body

Standard

Allowable

Hole

clearance

clearance

φ 55 (2.1653)

-0.100 (0.0039) 〜 0.146 (0.0057)

+ 0.08 (0.0031) 〜 0 (0)

0.100 (0.0039) 〜 0.226 (0.0089)

0.264 (0.0104)

φ 14 (0.5511)

-0.032 (-0.0012) 〜 -0.059 (-0.0023)

+0.043 (0.0017) 〜 0 (0)

0.032 (0.0012) 〜 0.102 (0.0040)

0.110 (0.0043)

dimension

Shaft

Standard dimension Item

Solution

Replacement

Replacement

Allowable load

Free length

Installation length

Installation load (kg)

Installation load (kg)

23.5 (0.9252)

20 (0.7874)

9.2 (20 lbs)

9.2 ± 1.3 (20 ± 2.8 lbs)

3

Spring

4

Retainer bolt tightening torque

54N-m (5.5kgf-m) (40 lb-ft)

5

Air bleeder screw tightening torque

10N-m (1.0kgf-m) (7 lb-ft)

Remedy

Replacement

Tightening 6

Valve body tightening torque

39N-m (4.0kgf-m) (29 lb-ft)

7

Plug tightening torque

15N-m (1.5kgf-m) (11 lb-ft)

55-5

90Z Ⅳ -2

Service Brake

BRAKE 55

Service Brake

2,6

3

4

5 7

1 6

Unit : mm (in.)

No.

1

Item

Thickness of steel plate

Judgement standard

Solution

Standard dimension

Tolerance

Wear limit

5.0 (0.1968)

+0 (+0) 〜 -0.2 (-0.0078)

4.4 (0.1732) Replacement

2

Thickness of friction plate

7.0 (0.2756)

±0.1 (±0.0118)

5.7 (0.2244)

3

Thickness of brake disc when measured by calipers (with brake applied)

29.0 (1.1417)

+0.3 (+0.0118) 〜 -0.5 (-0.0196)

25.1 (0.9881)

4

Piston seal contact face

-0.210 (-0.0082) 〜 -0.299 (-0.0117)

-

5

Piston seal contact face

(Manufacturing dimension) 355 (13.9763) (Manufacturing dimension) 310 (12.2047)

0 (0) 〜 +0.081(+0.0319)

-

6

Distortion of steel and friction plate

-

-

0.30 (0.0118)

Free length 7

Return spring

Installation length

Installation load (kg)

54 (2.1260)

49 (1.9291)

29.3 (64 lbs)

55-6

-

Replacement

90Z Ⅳ -2

Parking Brake

BRAKE 55

Parking Brake

2

5

1 3

Clearance

Spring (4) released

4

Unit : mm (in.)

No.

Item

Judgment standard Standard dimension

1

Solution

Wear limit

Wear of lining

Replacement 6.15 (0.2421)

2.95 (0.1161)

2

Deflection of drum

0.38 (0.0149) or more

Replacement

3

Lining inspection

Grease or oil on the lining

Replacement

4

Expansion of adjuster spring

5

There is clearance between the spring and the coil when the spring is released

Expansion of return spring

55-7

Replacement

ELECTRICAL GROUP 64 Disassembly and Reassembly Removing and Reinstalling Wiper Motor ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-2 Removing and Reinstalling Controller ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-6 Removing and Reinstalling Fuse ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 64-7

64-1

Removing and Reinstalling Wiper Motor

90Z Ⅳ -2

ELECTRICAL 64

Removing and Reinstalling Wiper Motor 1.Removing front wiper motor 1)Remove the cover (1).

1

65K64007

2)Remove the nut (2) and then remove the wiper arm (3).

2

3

65K64008

3)Remove the nut (4) and the bolt (5).

After that, remove the wiper arm (3).

4

5 3

65K64009

4)Remove the cover (6) and the cover (7).

6, 7

65K64010

64-2

Removing and Reinstalling Wiper Motor

90Z Ⅳ -2

5)Remove the defroster hose (8).

ELECTRICAL 64

9

6)Disconnect the electrical line coupler (9) from the wiper motor.

8

65K64011

7)Remove the motor retainer bolt (10), and remove the ground cable (11).

8)Disconnect the coupler (12) for the relay.

13

9)Remove the wiper motor (13).

11 10 12 65K64012

2.Reinstalling front wiper motor To reinstall the front wiper motor, follow the above removal procedure in the reversed direction.

Note :When reinstalling the wiper arm, adjust the operation angle by the nut (2).

64-3

Removing and Reinstalling Wiper Motor

90Z Ⅳ -2

ELECTRICAL 64

1.Removing rear wiper motor 1)Remove the cover (1).

1

2)Remove the nut (2), and then remove the wiper arm (3).

3

2

3)Remove the nut (4) and then remove the wiper arm (3).

4

3

65V64001

4)Remove the cover (5).

5

65K64016

64-4

Removing and Reinstalling Wiper Motor

90Z Ⅳ -2

ELECTRICAL 64

5)Disconnect the coupler (6) for the wiper motor (8).

7

6)Remove the motor retainer bolts (7).

7)Remove the wiper motor (8).

6 8 65K64017

2.Reinstalling rear wiper motor To reinstall the rear wiper motor, follow the above removal procedure in the reversed direction.

Note : When reinstalling the wiper arm, adjust the operation angle by the nut(2).

64-5

Removing and Reinstalling Controller

90Z Ⅳ -2

ELECTRICAL 64

Removing and Reinstalling Controller 1.Removing controller 1

WARNING Before you remove the controller, be sure to stop the engine, and remove the starter key. In addition, hang a "DO NOT START THE ENGINE!" tag on the instrument panel.

2

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

65K64018

2)Disconnect the electrical coupler (3).

3

65V64002

3)Remove the bolt (4) 4pcs, and then remove the controller (5).

5

4

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

Note : After reinstallation, set the starter key to the ON position, and check the function of the LED indicator.In addition, run the machine, and check operation of the machine.

Note : The following items may have caused the controller to fail. Test and correct any problems before installing a new controller. ① Short in the output circuit (Refer to Section 63) ② Defective diode allowing voltage surges.

Identify and test each diode using procedures on Section 63.

64-6

65V64003

90Z Ⅳ -2

Removing and Reinstalling Fuse

ELECTRICAL 64

Removing and Reinstalling Fuse 1.Removing fuse from inside of control box.

CAUTION Before removing a fuse, be sure to turn off the starter key.

1)Remove the catch (1), then open the cover (2). ●

1

2

65V64004

2)Remove the cover (3) (4), then remove the fuses (5) (6).

5A

LIGHTING HEAD LIGHT

SPARE

5A

R. WORK LIGHT

F. WORK LIGHT

10A 10A 10A

BACK LAMP STOP LAMP TURN SIGNAL

SPARE

3A

COLD STARTER

F. WIPER SPARE

FUEL VALVE

5A

NEUTRAL RELAY

5A

BATTERY RELAY

5A

AIRCON (OPTION)

5A

AIRCON (OPTION)

RADIO

20A 20A 20A

AIRCON (OPTION)

15A 15A 15A 15A 15A

SPARE

SPARE

5A

SPARE

4 WAY FLASHER HORN ROOM LAMP

5A

SPARE

5A

SPARE

10A 10A

R. WORK LIGHT (CAB)

PARKING BRAKE CONTROLLER BUZZER MONITOR

5A

5A

BOOM KICKOUT BUCKET POSITIONER

R. WIPER

20A 10A 10A 15A 10A

SPARE

SPARE SPARE

2.Reinstalling fuse To install the fuse, follow the above removal procedure in the reversed direction.

64-7

3

4

6 5

65K64022

90Z Ⅳ -2 Disassembly & Reassembly, Service Standard AAA-S90C3V14-979 AAA-S90C3V14-012

① 1997.9

K

② 2001.2

KAWASAKI HEAVY INDUSTRIES, LTD. Rolling Stock, Construction Machinery & Crushing Plant Company Construction Machinery Division Tokyo Head Office

W.T.C. Bldg., 2-4-1 Hamamatsu-cho Minato-ku, Tokyo 105-6116

Kobe Head Office

Kobe Crystal Tower, 1-1-3 Higashi Kawasaki-cho Chuo-ku, Kobe, Hyogo 650-0044

Banshu Works

2680 Oka Inami-cho Kako-gun, Hyogo 675-1113

All rights reserved. No copy allowed without written consent.