KCM WHEEL LOADER 30ZV-2 40ZV-2A 42ZV-2 SHOP MANUAL 93202-00051 (1)

30/40/42ZV-2

93202-00051

SHOP MANUAL - Disassembly & Reassembly

Printed in Japan (k) ( アメリカ用 )

93202-00051

©2017 KCM Corporation All rights reserved.

June 2017

SHOP MANUAL WHEEL LOADER

30ZV-2 40ZV-2A 42ZV-2 Technical Manual -Disassembly & Reassembly

Powered by KUBOTA D1803-M-D1-E3B Engine (30ZV-2) KUBOTA V2403-M-DI-E3B Engine (40ZV-2A, 42ZV-2) Serial No. 30ZV-2A 30K1-5001 and up 40ZV-2A 40K1-5001 and up 42ZV-2A 01037-01793, 05001 and up

93202-00051

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

GENERAL ....................................................................................................................W-1-1

Group 1

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

Group 2

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

Group 3

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

SECTION 2 BODY ...........................................................................................................................W-2-1 Group 1

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

Group 2

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

Group 3

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

Group 4

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

Group 5

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

Group 6

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

Group 7

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

Group 8

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

SECTION 3 TRAVEL SYSTEM........................................................................................................W-3-1 Group 1

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

Group 2

Reduction Gear .........................................................................................................W3-2

Group 3

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

Group 4

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

Group 5

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

Group 6

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

Group 7

Inching Valve .............................................................................................................W3-7

Group 8

Power Steering..........................................................................................................W3-8

Group 9

Steering Cylinder.......................................................................................................W3-9

SECTION 4 FRONT ATTACHMENT................................................................................................W-4-1 Group 1

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

Group 2

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

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

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

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

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

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

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

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

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

W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL HEADLINE NOTATIONS

AND

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

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

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

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

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

x

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

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

x

NOTE: Indicates supplementary technical information or know-how.

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

2

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

this manual.

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

Quantity Length Volume

Weight Force Torque

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

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

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

Quantity

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

Pressure Power Temperature Velocity Flow rate

IN-02

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

Into

Multiply By 2

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

10.197 145.0 1.360 1.341 qCu1.8+32 0.6214 1.0 0.2642 1.0

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

Follow recommended precautions and safe operating practices.

001-E01A-0001

SA-2644

UNDERSTAND SIGNAL WORDS x On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

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

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

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

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

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

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

SA-1223

NOTE indicates an additional explanation for an element of information.

002-E01A-1223

S-1

SAFETY FOLLOW SAFETY INSTRUCTIONS x Carefully read and follow all safety signs on the

machine and all safety messages in operator’s manual. x Safety signs should be installed, maintained and replaced when necessary.

If a safety sign or operator’s manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). x Learn how to operate the machine and its controls correctly and safely. x Allow only trained, qualified, authorized personnel to operate the machine. x Keep your machine in proper working condition.

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

Do not modify any machine parts without authorization.

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

Do not use attachments and/or optional parts or equipment not authorized by KCM. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void KCM Warranty Policy. x The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

SA-003

003-E01B-0003

S-2

SAFETY PREPARE FOR EMERGENCIES

x Be prepared if a fire starts or if an accident occurs.

Keep a first aid kit and fire extinguisher on hand.

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

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

Establish emergency procedure guidelines to cope with fires and accidents.

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

SA-437

004-E01A-0437

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

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

SA-438

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

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

x Operating equipment safely requires the full atten-

tion of the operator. Do not wear radio or music headphones while operating the machine.

005-E01A-0438

S-3

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

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

SA-434

006-E01A-0434

INSPECT MACHINE x Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal injury.

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

SA-435 007-E01A-0435

S-4

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

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

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

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

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

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

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

524-E01A-0000

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

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

Do not use any controls as hand-holds.

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

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

SA-439 008-E01A-0439

S-5

SAFETY ADJUST THE OPERATOR'S SEAT x A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator leading to miss-operations.

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

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

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

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

SA-462

009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT x Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the loader control lever to the LOCK position.

Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.

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

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

NEVER RIDE ATTACHMENT x Never allow anyone to ride attachment or the load.

This is an extremely dangerous practice.

S-6

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

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

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

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

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

SA-237

010-E01A-0237

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

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

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

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

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

SA-398

011-E01A-0398

S-7

SAFETY HANDLE STARTING AIDS SAFELY

Starting fluid:

x Starting fluid is highly flammable.

Keep all sparks and flame away when using it.

Keep starting fluid well away from batteries and cables.

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

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

Do not incinerate or puncture a starting fluid container.

SA-293

036-E01A-0293-3

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

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

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

Do not start engine by shorting across starter terminals.

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

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

SA-431

012-E01B-0431

S-8

SAFETY JUMP-STARTING

x Battery gas can explode, resulting in serious injury.

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

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

Jump-starting is a two-person operation.

Never use a frozen battery.

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

SA-032

S013-E01A-0032

INVESTIGATE JOB SITE BEFOREHAND x When working at the edge of an excavation or on a

road shoulder, the machine could tip over, possibly resulting in serious injury or death.

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

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

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

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

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

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

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

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

SA-447

015-E01B0447

S-9

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

SA-521

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES x For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481 SA-481

S-10

SAFETY KEEP RIDERS OFF MACHINE x Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off the machine.

Only the operator should be on the machine.

Keep riders off.

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

SA-427

014-E01B-0427

DRIVE SAFELY

x Beware of the possibility of slipping and/or turning

over the machine when driving on a slope.

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

Avoid driving over any obstacles.

Drive the machine slowly when driving on rough terrain.

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

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

x Even though the machine is equipped with the

emergency steering system, if the steering function becomes inoperable during drive operation, press the emergency steering check switch on the right console to activate the emergency steering system.

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

019-E07A-0448

S-11

SA-448

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

Be sure to detour around any obstructions.

x Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.

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

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

SA-449

x Driving across the face of a slope or steering on a

slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-450

019-E05B-0515

SA-451

DRIVE SAFELY WITH BUCKET LOADED x If the machine is operated incorrectly while driving

with the bucket loaded, the machine may turn over.

Be sure to follow all of the instructions indicated below.

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

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

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

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

S-12

SA-400

SAFETY DRIVE ON SNOW SAFELY x Beware of the possibility of slipping or turning over

the machine when driving on frozen snow surfaces.

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

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

Be sure to use tire chains when driving on snow.

Avoid applying the brake for quick stops on snow.

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

SA-452

052-E02A-0452

TRAVEL ON PUBLIC ROADS SAFELY x This machine is not allowed to drive on public loads

with the bucket loaded.

Be sure to empty the bucket.

Hold the bucket at mark (A) 300 to 400 mm (12 to 16 in) above the road surface as illustrated. x Even though the machine is equipped with the emergency steering system, if the steering function becomes inoperable during operation, press the emergency steering check switch on the right console to activate the emergency steering system.

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

053-E02A-0453

S-13

SA-453

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

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

Do not park the machine on a grade.

Lower the bucket to the ground.

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

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

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

Pull the lock lever to LOCK position.

Block both tires and lower the bucket to the ground.

Position the machine to prevent rolling.

Park a reasonable distance from other machines.

SA-457

020-E02A-0516

S-14

SA-458

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

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

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

Keep windows, mirrors, and lights in good condition.

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

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

SA-383

021-E02A-0517

SA-312

AVOID POSITIONING ANYONE

BUCKET

OVER

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

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

023-E02A-0518

S-15

SA-518

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

x The danger of tipping is always present when op-

erating on a grade, possibly resulting in serious injury or death.

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

Prepare machine operating area flat.

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

Reduce operating speeds to avoid tipping or slipping.

Avoid changing direction when traveling on grades.

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

Reduce speed as necessary when swinging loads.

SA-463

x Be careful when working on frozen ground.

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

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

026-E01A-0519

SA-519

S-16

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

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

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

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

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

Have them mark all underground utilities.

SA-396

027-E01A-0396

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

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

Always select a level surface for truck loading.

028-E01A-397 SA-397

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

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

29-E01A-0455

SA-455

S-17

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

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

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

In the event of an electrical storm, immediately stop operation, and take the following actions.

If you are around the machine, evacuate to a safe place far away from the machine.

If you are in the cab, stay in the cab until lightning has passed and safety is secured. Close the cab doors and windows. Lower the bucket to the ground, and stop the engine. Put your hands on your lap to avoid contact with any metal surfaces.

Never go out of the cab.

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

S-18

SA-4EK-020

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

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

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

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

Move the load slowly and carefully. Never it suddenly.

Keep all persons well away from the load.

Never move a load over a person’s head.

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

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

SA-132

032-E01A-0132

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

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

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

031-E01A-0432

SA-432

S-19

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

Lower bucket to the ground.

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

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

Turn key switch to OFF to stop engine.

Remove the key from the key switch.

Lower the lock lever to the LOCK position.

Close windows, roof vent, and cab door.

Lock all access doors and compartments.

SA-456

033-E07B-0456

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

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

504-E01A-0034

SA-034

S-20

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

Observe the related regulations and rules for safe transportation.

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

Be sure to use a signal person.

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

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

3. Use a low speed gear.

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

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

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

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

035-E07A-0454

S-21

Less than 15q

SA-454

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

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

Always stop the engine before refueling the machine.

Fill the fuel tank outdoors.

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

Store flammable fluids well away from fire hazards.

Do not incinerate or puncture pressurized containers.

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

Securely tighten the fuel and oil filler caps.

034-E01A-0496

SA-018

SA-019

S-22

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

Keep the work area clean and dry.

Do not spray water or steam inside cab.

Never lubricate or service the machine while it is moving.

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

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

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

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

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

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

7. Remove the key from the switch.

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

9. Lower the lock lever to the LOCK position.

10. Lock bar connects the front and rear frames.

11. Allow the engine to cool.

SA-028

SA-312

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

Never work under a machine raised by the lift arm.

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

Keep all parts in good condition and properly installed.

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

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

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

500-E02C-0520

S-23

SA-134

SA-527

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

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

SA-037

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

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

This tag is available from your authorized dealer.

501-E01A-0287

SS2045102-4

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

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

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

519-E01A-0527 SA-527

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

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

502-E01A-0026

S-24

SA-026

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

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

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

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

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

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

SA-249

521-E02A-0249

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

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

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

503-E03A-0344

SA-344

S-25

SAFETY PREVENT BURNS Hot spraying fluids:

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

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

To avoid possible injury from hot spraying water.

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

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

SA-039

Hot fluids and surfaces:

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

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

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

SA-225

505-E01B-0498

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

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

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

S506-E01A-0019

S-26

SA-019

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

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

Tighten all connections before applying pressure.

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

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

SA-031

507-E03A-0499

SA-292

SA-044

S-27

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

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

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

Do not bend or strike high-pressure lines.

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

Check for Shorts: x Short circuits can cause fires.

Clean and tighten all electrical connections.

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

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

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

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

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

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

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

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

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

508-E02B-0019

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

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

508-E02A-0393

S-28

SA-019

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

Use a fire extinguisher if there is time.

Exit the machine.

518-E01A-0393

SA-393

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

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

509-E01A-0016

SA-016

PRECAUTIONS GRINDING

FOR

WELDING

AND

x Welding may generate gas and/or small fires.

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

Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding. x Grinding on the machine may create fire hazards.

Store flammable objects in a safe place before starting grinding. x After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

523-E01A-0818

S-29

SA-818

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

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

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

SA-030

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

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

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING x

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

Avoid potentially toxic fumes and dust.

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

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

2.

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

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

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

511-E01A-0029

S-30

SA-029

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

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

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

Keep bystanders out of the work site during operation.

Asbestos might be present in imitation parts. Use only genuine KCM/Hitachi Parts.

SA-029

PREVENT BATTERY EXPLOSIONS x Battery gas can explode.

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

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

Do not charge a frozen battery; it may explode.

Warm the battery to 16 qC (60 qF) first.

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

Explosion of the battery may result.

Loose terminals may produce sparks. Securely tighten all terminals.

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

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

512-E01B-0032

S-31

SA-032

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

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

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

Never touch the refrigerant.

SA-405

513-E01A-0405

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

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

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

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

SA-2579

515-E01A-0309

S-32

SAFETY DISPOSE OF WASTE PROPERLY

x Improperly disposing of waste can threaten the en-

vironment and ecology. Potentially harmful waste used with KCM/Hitachi equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids.

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

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

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

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

SA-226

516-E01A-0226

BEFORE RETURNING THE MACHINE TO THE CUSTOMER

x

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

• Worn or damaged parts have been repaired or replaced.

S517-E01A-0435 SA-435

S-33

SAFETY (Blank)

S-34

SECTION 1

GENERAL

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

Group 2 Tightening Tightening Torque................................... W1-2-1 Tightening Bolts and Nuts....................... W1-2-3 Tightening Piping Joint ........................... W1-2-6 Periodic Replacement of Parts ............. W1-2-10

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

W-1-1

30_42ZV-2

(Blank)

W-1-2

30_42ZV-2

GENERAL / Precautions for Disassembling and Assembling DISASSEMBLY AND ASSEMBLY Precautions

Inspect the contact or sliding surfaces of

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

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

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

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

Damage or looseness of parts

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

When Disassembling and Assembling

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

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

Before disassembling, drain gear oil from the reduction gear.

Be sure to provide appropriate containers for draining fluids.

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

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

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

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

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

W1-1-1

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

Measure and record the degree of wear and clearances.

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

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

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

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

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

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

Utilize matching marks when assembling.

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

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

45ZV-2

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

Air Bleed Plug

x Bleed air from HST pump and HST motor

W4FG-01-01-001

Remove air bleed plug on the top of the pump.

Add hydraulic oil into the pump.

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

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

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

W1-1-2

45ZV-2

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

(Never fully stroke the cylinders during initial operation.)

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

Stop the engine. Recheck hydraulic oil level.

W4EK-01-02-011

Replenish oil as necessary.

W1-1-3

45ZV-2

GENERAL / Precautions for Disassembling and Assembling Precautions for Using Floating Seals

1. In general, replace the floating seal with a new one after disassembling.

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

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

(The stepped part should remain.)

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

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

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

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

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

Correct

Twisting of O-Ring

Incorrect

Bending of O-Ring

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

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

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

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

Correct

Incorrect

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

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

W4EK-01-01-003

W1-1-4

45ZV-2

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

Correct Sling Application

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

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

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

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

Incorrect Sling Application

Do not lift acid or alkali chemicals.

Take care not to allow the sling to become wet.

The load may slip.

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

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

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

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

Do not place any object on twisted or bent slings.

(Refer to the right illustration.)

Bent Sling

W4EK-01-01-004

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

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

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

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

W1-1-5

45ZV-2

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

Always visually inspect before using.

Damaged Appearance Broken Sewing Thread

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

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

Scuffing

Fuzz

Broken Sewing Thread Broken Sewing Thread

Broken Sewing Thread

Scoring

Fuzz

Separation of Belt

Scuffing Broken Fuzz Warp

W4EK-01-01-002

W1-1-6

45ZV-2

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

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

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

be

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

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

W1-1-7

45ZV-2

GENERAL / Precautions for Disassembling and Assembling (Blank)

W1-1-8

45ZV-2

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

Bolt Diameter

Q’ty

Tool Wrench Size

Torque N·m (kgf·m, lbf·ft)

1

Front axle mounting nut

20

4

30

418~460 (42.6~46.9, 308~339)

2

Rear axle support mounting bolt

16

4

24

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

3

Wheel rim mounting bolt

18

24

27

375~412 (38.3~42.1, 277~304)

4

Front propeller shaft mounting bolt

12

8

17

113~123 (11.5~12.5, 83~90)

5

Rear propeller shaft mounting bolt

8

8

13

30~36 (3.04~3.72, 22~27)

6

Reduction gear mounting bolt; Bracket

12

6

19

83.4~93.2 (8.5~9.5, 61~69)

7

Reduction gear mounting bolt; Cushion rubber

12

4

19

44.1~53.9 (4.5~5.5, 33~40)

8

Engine mounting bolt; Bracket, Rear

12/10

7/1

19/17

83.4~93.2 (8.5~9.5, 61~69) 49.0~53.9 (5.0~5.5, 36~40)

9

Engine mounting bolt; Bracket, Front

10

17

22

49.0~53.9 (5.0~5.5, 36~40)

10 Engine mounting bolt; Cushion rubber

12

4

19

83.4~93.2 (8.5~9.5, 61~69)

®

LOCTITE #262 is applied to the threaded portion marked

in torque field.

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

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

W1-2-1

42ZV-2

GENERAL / Tightening

Bolt Diameter

Q’ty

Tool Wrench Size

11 Counterweight shaft mounting bolt

24

2 (30ZV-2) 3 (40/42ZV-2)

36

698~768 (71~78, 513~564)

12 Stopper on center pin

12

4

19

77.3~94.4 (7.8~9.6, 56~59)

Retightening Portion

Torque N·m (kgf·m, ft·lb)

13 Plate securing under center pin

12/16

4/1

19/24

77.3~94.4 (7.8~9.6, 56~69) / 188.3~229.5 (19.2~23.4, 139~169)

14 Steering cylinder pin stopper

10

4

17

44.1~53.9 (4.5~5.5, 33~40)

Radiator frame mounting nut 15 (Final nut / Locking nut)

10

4

17

17.7~21.5 (1.8~2.2, 13~16) / 14.7~16.6 (1.5~1.7, 11~12)

16 Cutting edge mounting nut

16

6

24

245.2a294.2 (25~30, 181~217)

W1-2-2

42ZV-2

GENERAL / Tightening TIGHTENING BOLTS AND NUTS CAUTION: Use tools appropriate for the work to be done. Makeshift tools and parts can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury Kinds of Bolts Tighten nuts or bolts correctly to torque specifications when assembling.

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

W4EK-01-02-001

Specified Tightening Torque Hexagon Bolt Bolt Diameter mm (in)

Socket Bolt Wrench Size Socket Bolt Wrench Size N·m (kgf·m, ft·lb) mm (in) mm (in)

N·m (kgf·m, ft·lb) N·m (kgf·m, ft·lb) N·m (kgf·m, ft·lb) 6 (0.2)

3.3 to 4.2 (0.3 to 0.4, 2 to 3)

10

5

8 (0.3)

30 (3.0, 22)

20 (2.0, 14)

10 (1.0, 7)

13

20 (2.0, 14)

6

10 (0.4)

65 (6.5, 47)

50 (5.0, 36)

20 (2.0, 14)

17

50 (5.0, 36)

8

12 (0.5)

110 (11, 80)

90 (9.0, 65)

35 (3.5, 25)

19

90 (9.0, 65)

10

14 (0.6)

180 (18, 130)

140 (14, 101)

55 (5.5, 40)

22

140 (14, 101)

12

16 (0.6)

270 (27, 195)

210 (21, 152)

80 (8.0, 58)

24

210 (21, 152)

14

18 (0.7)

400 (40, 289)

300 (30, 217)

120 (12, 87)

27

300 (30, 217)

14

20 (0.8)

550 (55, 398)

400 (40, 289)

170 (17, 123)

30

400 (40, 289)

17

22 (0.9)

750 (75, 542)

550 (55, 398)

220 (22, 159)

32

24 (0.9)

950 (95, 687)

700 (70, 506)

280 (28, 202)

36

27 (1.1)

1400 (140, 1012) 1050 (105, 759)

400 (40, 289)

41

30 (1.2)

1950 (195, 1410) 1450 (195, 1410) 550 (55, 398)

46

33 (1.3)

2600 (260, 1880) 1950 (195, 1410) 750 (75, 542)

50

36 (1.4)

3200 (320, 2314) 2450 (245, 1772) 950 (95, 687)

55

W1-2-3

30_42ZV-2

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

1. Apply lubricant to nuts and bolts to reduce their friction coefficients when tightening.

(Example: White zinc B dissolved into spindle oil) 2. Torque tolerance is ±10 %.

3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole.

Bolts that are too short cannot develop sufficient tightening force.

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

5. Make sure that nut and bolt threads are clean before installing. Remove dirt or corrosion, if any.

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

Equally Tighten Upper and Lower Alternately

Tighten Diagonally

Tighten From Center and Diagonally

W4EK-01-02-002

W1-2-4

30_42ZV-2

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

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

3. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-Ring.

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

5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tightening of the others, resulting in damage to O-Rings or uneven tightening of bolts.

Do not use impact wrenches for tightening split flange bolts.

W105-01-01-015

Incorrect

W105-01-01-016

Correct

W105-01-01-008

Incorrect

Nut and Bolt Locking

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

Bend along edge sharply

Correct

Do not bend it round

Correct

Incorrect

Bend along edge sharply W105-01-01-009

x Split Pin IMPORTANT: Match the holes in the bolt and nut while tightening, not while loosening.

Do not reuse split pins.

Correct

Correct

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

Do not reuse wires.

W1-2-5

Correct

Incorrect

Loosen

Incorrect

Tighten

30_42ZV-2

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

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

1

4

3

2

5

Union Joint

M202-07-051

Joint Body

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

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

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

Be sure to tighten nut (3) to specifications.

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

Take care not to damage them when connecting/disconnecting.

Type

30° male

30° female

37㼻 30㼻

Male Union Joint

Female Union Joint W105-01-01-017

Wrench Size mm

Wrench Size mm

Tightening Torque

Union Nut (in)

Hose Fittings (in)

N·m (kgf·m, ft·lb)

19

19

59 (6, 43)

22

22

98 (10, 72)

27

27

118 (12, 87)

36

36

235 (24, 174)

41

41

295 (30, 217)

50

50

490 (50, 362)

60

60

670 (68, 492)

70

70

980 (100, 732)

19

17

44 (4.5, 33)

22

19

59 (6, 43)

27

22

118 (12, 87)

36

30, 32

235 (24, 174)

41

36

295 (30, 217)

50

46

490 (50, 362)

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

W1-2-6

30_42ZV-2

GENERAL / Tightening O-Ring Seal Joint O-Ring (6) seats against the end face of adapter (7) to seal pressurized oil.

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

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

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

3. Take care not to damage O-Ring groove (8) on adapter (7) and sealing surface (10) on the hose end.

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

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

Replace O-Ring (6) with a new one and check that O-Ring (6) is correctly seated in O-Ring groove (8), tighten union nut (9).

W1-2-7

7

6

9

8

10

W4EK-01-02-006

Wrench Size mm (in) Union Nut 19 22 27 32 36 41 50

Wrench Size mm (in) Hose Fittings 17 19 22 27 30, 32 36 46

Tightening Torque N·m (kgf·m, ft·lb) 29.5 (3.0, 22) 69 (7.0, 51) 93 (9.5, 69) 137 (14.0, 101) 175 (18.0, 130) 205 (21.0, 152) 205 (21.0, 152)

30_42ZV-2

GENERAL / Tightening Screw Fittings G

R

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

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

(The straight screw is not used in principle.)

30q

Male · Taper Screw

Male · Straight Screw W4EK-01-02-007

Male taper screw Wrench Size mm (in)

Tightening Torque

Hose Fittings

Iron Casting

Steel Structure

19

14.5 (1.5, 11)

34 (3.5, 25)

22

29.5 (3.0, 22)

49 (5.0, 36)

27

49 (5.0, 36)

93 (9.5, 69)

36

69 (7.0, 51)

157 (16, 116)

41

108 (11, 80)

205 (21, 152)

50

157 (16, 116)

320 (33, 239)

60

195 (20, 145)

NOTE: Unit: N·m (kgf·m, ft·lb) Seal Tape Application

Internal Thread

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

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

External Thread

x Application procedure

Clearance

Leave One to Two Pitch Threads Uncovered

Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads with one to two pitch threads left.

Wrap seal tape in the same direction as the threads.

W4EK-01-02-008

Low-Pressure-Hose Clamp Tightening Torque

T-Bolt Type

Worm Gear Type

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

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

W4EK-01-02-009

W1-2-8

30_42ZV-2

GENERAL / Tightening Connecting Hose CAUTION: When replacing hoses, be sure to use only genuine KCM/Hitachi service parts. Using hoses other than genuine KCM/Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine.

Incorrect (Twisted)

Correct

W105-01-01-011

Do not install hoses kinked.

Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting.

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

Incorrect

Take necessary measures to protect hoses from rubbing against each other. If hoses rub against each other, wear to the hoses will result, leading to hose rupture.

Incorrect

Correct

Rubbing Against Each Other

W105-01-01-012

Clamp

Correct Clamp

Rubbing Against Each Other W105-01-01-013

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

Incorrect

Correct

Rubbing Against Each Other

Clamp W105-01-01-014

W1-2-9

30_42ZV-2

GENERAL / Tightening PERIODIC REPLACEMENT OF PARTS 1. Periodic replacement inspection)

of

parts

(1)

(for

In order to assure the safety of operation at all times, the machine user shall perform the daily checks (operational and pre-start checks) and the periodic inspections, those are prescribed in local regulations.

In order to assure the safety, perform the periodic replacement of the following safety parts.

Replacement Part Name

Replacement Intervals

Fuel Tank

Hose

Every 2 years Fuel leakage may cause a fire.

Master cylinder

seals (Rubber parts)

Every 1 year

Wet Type Brake

Piston D-Ring

Brake Piping

Hose

Device Name

Engine

Brake Device

Replacement Reason

If oil leakage occurs while Every 4 years traveling, the braking operation may be impossible.

Every 2 years

Stop Lamp

Switch

As the brake operating indication cannot be informed to Every 2 years other machines, serious hazard may occur.

Steering Piping

Hose

Every 2 years

Steering Device Steering Cylinder Steering Valve

Seals (Rubber parts) Seals (Rubber parts)

If oil leakage occurs, the Every 4 years steering operation may be impossible.

Every 2 years

1. The parts listed below deteriorate as the machine ages and are worn out or fatigued. AS it is difficult to detect these levels from the periodic inspections, these parts should be replaced at regular intervals even if no abnormalities are noticed.

2. In the unlikely event that the part listed below is abnormal, repair or replace the part even if expiration date is not reached.

W1-2-10

30_42ZV-2

GENERAL / Tightening 2. Periodic replacement of parts (2) To ensure safe operation, be sure to conduct periodic inspection of the machine. In order to enhance the safety, the periodic replacement of the following parts closely related to safety aspect is recommended.

The parts listed below deteriorate as the machine ages and are worn out or fatigued by repeated loads.

It may cause serious personal injury or physical damage. The service life of these parts cannot be detected through machine operation or visual inspection. Therefore, these parts should be replaced at regular intervals even if no abnormalities are noticed.

In case any abnormalities are found on a part at any time regardless of its specified replacement interval, immediately replace the part.

Device Name

Replacement Intervals

Pump

Suction Hose Delivery Hose

Every 2 years

Work Device

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

Every 2 years

Seat Belt

Seat Belt

Every 3 years

Hydraulic System

Operator's Cab

Replacement Part Name

NOTE: Be sure to replace seals, such as O-Rings or gaskets, when replacing hoses.

W1-2-11

30_42ZV-2

GENERAL / Tightening (Blank)

W1-2-12

30_42ZV-2

GENERAL / Painting Painting

WE804-01-03-01KC

Painted Surface 1 Front Fender 2 Lamp Bracket 3 Body 4 Cowl Frame 5 Handrail 6 ROPS CANOPY 7 Hood Base 8 Hood (Upper) (*) 9 Hood (Lower) (*) *) Material is resin.

Painting Color Marigold Yellow Marigold Yellow Marigold Yellow HG Beige Deep HG Beige Deep HG Beige Deep HG Beige Deep Marigold Yellow HG Beige Deep

10 11 12 13 14 15 16 17 18

Painted Surface Counterweight Rim Seat Support Operator Frame Step Oil Tank / Fuel Tank Articulation Lock Bar Back Mirror Mounting Part Cab

Painting Color Marigold Yellow Marigold Yellow HG Beige Deep HG Beige Deep Marigold Yellow Marigold Yellow Red HG Beige Deep HG Beige Deep

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

W1-3-1

42ZV-2

GENERAL / Painting (Blank)

W1-3-2

42ZV-2

SECTION 2

BODY

— CONTENTS — Group 1 Canopy

Group 8 Control Valve

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

Removal and Installation of

Removal and Installation of

Control Valve..............................................W2-8-1

Operator Frame......................................... W2-1-5

Disassembly and Assembly of Control Valve............................................W2-8-10

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

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

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

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

Group 6 HST Pump and Main Pump Removal and Installation of HST Pump................................................. W2-6-1 Disassembly and Assembly of HST Pump................................................. W2-6-6 Removal and Installation of Main Pump .............................................. W2-6-10 Disassembly of Main Pump....................... W2-6-14 Assembly of Main Pump ........................... W2-6-16

Group 7 HST Motor Removal and Installation of HST Motor ................................................. W2-7-1 Disassembly and Assembly of HST Motor ................................................. W2-7-7

W-2-1

30_42ZV-2

(Blank)

W-2-2

30_42ZV-2

BODY / Canopy REMOVAL CANOPY

AND

INSTALLATION

OF

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

1

W4EK-02-01-006A

W2-1-1

30_42ZV-2

BODY / Canopy Removal of Canopy 1. Install eyebolts (6) [M12, Pitch 1.75 mm (0.068 in)] (4 used) on the top of ROPS canopy (1).

Lifting Tool

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

1

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

Hold ROPS canopy (1).

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

6

: 24 mm 4. Hoist and remove ROPS canopy (1) from the floor board.

2

3

5

5

WE804-02-01-002

4

W2-1-2

30_42ZV-2

BODY / Canopy Installation of Canopy CAUTION: ROPS Canopy (1) weight: 140 kg (309 lb)

Lifting Tool

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

Hoist and align ROPS canopy (1) with the mounting hole on the floor board (7).

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

1

6

: 24 mm : 188 to 229 N·m (19.2 to 23.4 kgf·m䠈138.7 to 169.0 ft䡡lb)

2

3

5

5

WE804-02-01-002

4

W2-1-3

7

30_42ZV-2

BODY / Canopy (Blank)

W2-1-4

30_42ZV-2

BODY / Canopy REMOVAL AND FLOOR BOARD

INSTALLATION

OF

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

Stop the engine. Lower the bucket onto the ground horizontally.

2. Place a wheel stopper in front of and behind the axle in order to secure the machine.

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

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

Floor Inspection Cover Seat Support Front Console and Surroundings Right Console and Surroundings

1

W4EK-02-01-006A

W2-1-5

30_42ZV-2

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

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

2. Remove screws (3) (2 used) by using a screwdriver.

Remove inspection cover (4) from floor board (5).

1

2

3

5 4

W4EK-02-01-003A

W2-1-6

30_42ZV-2

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

2. Install floor mat (1).

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

1

2

3

5 4

W4EK-02-01-003A

W2-1-7

30_42ZV-2

BODY / Canopy Removal of Seat Support

13

CAUTION: Suspension seat (1) weight: 22 kg (48.5 lb)

1

1. When equipped with a suspension seat (1): ( ) and washers Remove nuts (3), spring washers (4) (5) (4 used for each)) from suspension seat (1).

Remove suspension seat (1) from seat support (6). : 13 mm

reclining → suspension に変えました （次ページも）

2. Remove bolts (8), spring washers (9) and washers (10) (4 used for each) from seat support (6).

6

10 9

5 4

8

: 17 mm

3

3. Remove bolt (14) and nut (15). Remove seat belt (13) from the belt holes on bracket (16) and seat support (6).

12

: 16 mm When equipped with a heater, refer to CAB / Removal and Installation of Heater.

4. Remove set bolts (12) (4 used) from support (11).

Remove support (11) from the floor board.

15

: 19 mm

11

14

16 WE804-02-01-004

W2-1-8

30_42ZV-2

BODY / Canopy Installation of Seat Support 1. Install support (11) to the floor board with set bolt (11) (4 used).

13

1

: 19 mm When the heater is provided, refer to Removal and Installation of Heater.

2. Pass seat belt (13) through the belt hole on seat support (6).

Install seat belt (13) to bracket (16) with bolt (14) and nut (15).

6 10 9

: 16 mm 3. Install seat support (6) to support (11) with bolts (8) (4 used), spring washers (9) (4 used) and washers (10) (4 used).

5 4

8

3

: 17 mm

12

CAUTION: Suspension seat (1) weight: 22 kg (48.5 lb) 4. Install suspension seat (1) to seat support (6) with nuts (3) (4 used), spring washers (4) (4 used) and washers (5) (4 used).

15

: 13 mm

11

14

16 WE804-02-01-004

W2-1-9

30_42ZV-2

BODY / Canopy Removal of Front Console and Surroundings

4 5

CAUTION: Front cover (1), stay (2) and stay (3) weight: Approx. 24 kg (53 lb)

6

1

3

1. Remove bolts (4) (4 used), spring washers (5) (4 used) and washers (6) (4 used).

Remove front cover (1) and stays (2, 3) (2 used) from floor board (7). (Except for the cab machine.)

7

: 24 mm 2. Disconnect all hoses from the power steering.

(Refer to W3-8.)

2

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

WE804-02-01-009

4. Disconnect all hoses from the inching valve.

(Refer to W3-7.)

9 12

7

10

5. Remove return spring (8) of the accelerator pedal from floor board (7).

6. Remove nut (9) and spring washer (10) from rod end (11).

Disconnect engine throttle cable (13) from accelerator pedal link (12).

8

11

: 10 mm

13

W4EK-02-01-010A

7. Disconnect harness (14) of the front console at the connector part (arrow).

Remove steering column mounting bolt (17) (1 used).

Disconnect the ground line. : 17 mm 14

17

Ground

W4EK-02-01-008A

W2-1-10

30_42ZV-2

BODY / Canopy

CAUTION: Front console, steering support (15) and others weight: 42 kg (93 lb) 8. Remove SEMS bolts (16) (5 used).

Attach a nylon sling onto steering support (15).

Hoist and remove the front console and the steering support and surroundings from floor board (7).

15 16 7

: 17 mm

W4EK-02-01-011A

W2-1-11

30_42ZV-2

BODY / Canopy Installation of Front Console and Surroundings CAUTION: Front console, steering support (15) and others weight: 42 kg (93 lb) 15

1. Attach a nylon sling onto steering support (15).

Hoist and align with the mounting hole on floor board (7).

16 7

2. Install the steering support to floor board (7) with SEMS bolts (16) (5 used). : 17 mm

W4EK-02-01-011A

3. Connect harness (14) of the front console at the connector part (arrow).

Install the ground line with steering column mounting bolt (17) (1 used). : 17 mm 14

17 Ground

W4EK-02-01-008A

W2-1-12

30_42ZV-2

BODY / Canopy 4. Connect engine control cable (13) to accelerator pedal link (12) with rod end (11), nut (9) and spring washer (10).

9 12

: 10 mm

7

10

5. Install return spring (8) of the accelerator pedal to floor board (7).

8

6. Connect all hoses to the inching valve. (Refer to W3-7.)

7. Connect all hoses to the master cylinder. (Refer to W3-5.)

11

13

W4EK-02-01-010A

8. Connect all hoses to the power steering. (Refer to W3-8.)

4

CAUTION: Front cover (1), stay (2) and stay (3) weight: Approx. 24 kg (53 lb) 9. Install front cover (1) and stays (2, 3) (2 used) to floor board (7) with bolt (4), spring washers (5) and washers (6) (4 used for each). (Except for the cab machine.)

5 1

6 3

7

: 24 mm

2

WE804-02-01-009

W2-1-13

30_42ZV-2

BODY / Canopy Removal of Right Console and Surroundings

4

1. Remove bolt (1) and washers (2) (7 used).

Remove covers (5, 6) from right console box (3).

2

: 5 mm

1

2. When the heater switch (optional) is provided, disconnect harness (13) at connector part (B).

7

3. Remove the cap part of key switch (12).

Remove bolt (1) and washers (2) (4 used).

Remove covers (4) from right console box (3).

1

5

2

1 2

6

: 5 mm 4. Remove key switch (12) with harness (A) connected from right console box (3).

5. Remove attached bolts (8) and nuts (9) (2 used for each), which are attached to front control lever (7).

Disconnect control cables (10, 11) (2 used) from main front control lever (7).

Attach an identification tag onto control cables (10, 11).

14

12

15 3 16 11

6. Remove bolts (14), spring washers (15) and washers (16) (4 used for each).

Remove right console box (3) from the floor board.

10 A

: 17 mm

B

9

8 13

W4EK-02-01-012A

W2-1-14

30_42ZV-2

BODY / Canopy Installation of Right Console and Surroundings

4

1. Install right console box (3) to the floor board with bolt (14), spring washer (15) and washers (16) (4 used).

2 1

: 17 mm 2. Connect control cables (10, 11) (2 used) with bolts (8) and nuts (9) (2 used for each), which are attached to front control lever (7).

7 1

5

2

1

3. Install key switch (12) to right console box (3).

2

6

4. Install cover (4) to right console box (3) with bolt (1) and washers (2) (4 used). Install the cap part of key switch (12). : 5 mm

14

5. When the heater switch (optional) is provided, connect harness (13) at connector part (B).

12

15 3

6. Install covers (5, 6) to right console box (3) with bolt (1) and washers (2) (7 used).

16 11

: 5 mm

10

9

8 13

W4EK-02-01-012A

W2-1-15

30_42ZV-2

BODY / Canopy Removal of Floor board

11 A

1. Remove bolts (11) and washers (12) (2 used for each). Remove cover (13) from the floor board.

12 13

2 4

CAUTION: Floor board (1) weight: 77 kg (170 lb) 2. Attach a nylon sling onto floor board (1). Hold floor board (1).

3. Remove bolts (2), nuts (3) (2 used for each), washers (4) (4 used) and washers (5) (2 used) from the front side of the floor board mounting hole (2 places) (part A).

8

: 30 mm 4. Remove bolts (6), washers (4) and washers (5) (2 used for each) from the rear side of the floor board mounting hole (2 places) (part B).

8

9

9

10

10 8

8 5

5

4

4

6

3 1

: 30 mm

4

B

2

8

IMPORTANT: Hoist floor board (1) while sliding it forward in order not to come contact with the hood base behind floor board (1).

7 9 10

5. Hoist and remove floor board (1) from rear chassis (7).

DETAIL A

5 4 3

1

6. Remove rubbers (8) (8 used), spacers (9) (4 used) and rubbers (10) (4 used) from the rear chassis (7) mounting hole (4 places).

8 7 5 4 6

9

10

DETAIL B W4EK-02-01-005A

W2-1-16

30_42ZV-2

BODY / Canopy Installation of Floor board CAUTION: Floor board (1) weight: 77 kg (170 lb)

11 A

1. Install rubber (8), spacer (9), rubber (10) and rubber (8) in this order to the rear chassis (7) mounting hole (4 places) with the rubber (8) groove facing to the rear chassis side.

12 13

2 4

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

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

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

8

®

3. Apply LOCTITE #262 onto bolts (6) (2 used).

Install floor board (1) to the rear side (2 places) (part B) of the rear chassis mounting holes with bolts (6) (2 used), washers (4) (2 used) and washers (5) (2 used).

8

9

9

10

10 8

8 5

5

4

4

6

3 1

4

B

2

: 30 mm : 375 to 460 N·m (38.3 to 47 kgf·m, 277 to 340 ft·lb)

8 7

®

4. Apply LOCTITE #262 onto nuts (3) (2 used).

Install floor board (1) to the front side (2 places) (part A) of the rear chassis mounting holes with bolts (2) (2 used), nuts (3) (2 used), washers (4) (4 used) and washers (5) (2 used).

9 10

DETAIL A

5 4 3

1 8

: 30 mm : 375 to 460 N·m (38.3 to 47 kgf·m, 277 to 340 ft·lb)

7

5. Install cover (13) to the floor board with bolts (11) and washers (12) (2 used for each).

5 4 6

9

10 DETAIL B

W4EK-02-01-005A

W2-1-17

30_42ZV-2

BODY / Canopy (Blank)

W2-1-18

30_42ZV-2

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with ring pin (3).

3

1

2

W4EK-02-01-006A

W2-2-1

30_42ZV-2

BODY / Cab Removal 1. Open the engine hood. Disconnect washer hose (2) from washer tank (1).

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

2

1

W4EK-02-02-003A

2. Remove bolts (3) (3 used). Remove cover (4) from the right console. : 5 mm

4

3

W4EK-02-02-004A

3. Disconnect cab harness (5) at the connector part (3 places).

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

Bind up washer hose (2) as washer hose (2) is long.

2

5

W2-2-2

5

W4EK-02-02-006A

30_42ZV-2

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

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

7 6

6. Install eyebolts [M12, Pitch 1.75 mm (0.068 in)] (4 used) on the top of cab (9).

7. Remove bolts (10) (10 used) and washers (11) (10 used), which secure cab (9).

8

: 24 mm

W4EK-02-02-005A

CAUTION: Cab (9) weight: 300 kg (661 lb)

Lifting Tool

IMPORTANT: When hoisting or lowering cab (9), prevent front wiper motor cover (13) (cab side) from touching steering support (14).

13 10

14 W4EK-01-02-017A

11

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

Hoist and remove cab (9) from operator frame (12).

9 10

12

11

11

10

W4EK-02-02-001A

W2-2-3

30_42ZV-2

BODY / Cab Installation

Lifting Tool

CAUTION: Cab (9) weight: 300 kg (661 lb) IMPORTANT: When hoisting or lowering cab (9), prevent front wiper motor cover (13) (cab side) from touching steering support (14).

13 10

14 W4EK-01-02-017A

11

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

Hoist and align cab (9) with the mounting hole on the operator frame (12).

9 12

10 11

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

Install bolt (10) and washer (11) to part A (both sides 2 places) from the bottom of the operator frame.

11

: 24 mm

10

A

W4EK-02-02-001A

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

7 6

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

8

W4EK-02-02-005A

W2-2-4

30_42ZV-2

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

Connect cab harness (5) at the connector part (3 places).

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

2

5

5

W4EK-02-02-006A

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

4

3

W4EK-02-02-004A

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

Secures washer hose (2) with the cable clamp.

2

1

W4EK-02-02-003A

W2-2-5

30_42ZV-2

BODY / Cab Removal of Heater (Optional) 1. Remove the seat and the seat support. (Refer to W2-1-7.)

2. Disconnect hose connectors (2) (2 used) from heater (1).

3. Disconnect heater harness (4) from the connector part.

Remove SEMS bolts (10).

Disconnect the ground wire of heater (1) from the rear chassis.

3

: 17 mm Rear chassis

8

2

1

4 10

Ground Line

W4EK-02-02-018A

4. Fully tighten the cock in valve (5) and turn to the CLOSE position.

5. Loosen hose clamps (6) (2 used).

Disconnect hoses (7) (2 used) from heater (1).

Cap the open ends.

6. Remove SEMS bolts (8) (4 used).

Remove heater (1) from support (9).

9 6 5

7

W4EK-02-02-007A

: 17 mm

W2-2-6

30_42ZV-2

BODY / Cab Installation of Heater (Optional) 1. Install heater (1) to support (9) with SEMS bolts (8) (4 used). : 17 mm 2. Connect hoses (7) (2 used) to heater (1) with hose clamps (6) (2 used).

3

3. Fully loosen the cock in valve (5) and turn to the OPEN position.

4. Connect heater harness (4) at the connector part.

Install the ground line in the heater to the rear chassis with SEMS bolts (10).

8

2

: 17 mm Rear chassis

1

4 9 10

Ground Line

6 5

W4EK-02-02-018A

5. Install defroster hoses (3) (2 used) to heater (1) with hose connectors (2) (2 used).

7

W4EK-02-02-007A

W2-2-7

30_42ZV-2

BODY / Cab (Blank)

W2-2-8

30_42ZV-2

BODY / Counterweight REMOVAL AND COUNTERWEIGHT

INSTALLATION

OF

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

1

W4EK-02-01-006A

W2-3-1

30_42ZV-2

BODY / Counterweight Removal IMPORTANT: If removing counterweight (1) with the engine hood installed, the engine hood may be damaged.

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

2. Remove screws (4) and washers (5) (2 used for each).

Remove bracket (6) from counterweight (1) together with reverse light (2) and reverse alarm (3).

3. Disconnect the harnesses of reverse light (2) and reverse alarm (3) in counterweight (1) at the connector part.

4. Remove screws (7) (2 used for each).

Remove cover (8) (2 used) from counterweight (1) upper surface.

the

WE804-02-03-001

5. Disconnect the harnesses of rear combination lights (9) (2 used) from cover (8) open end at the connector part.

6. Remove bolts (10), spring washers (11) and washers (12) (2 used for each) from cover (8) open end.

Remove rear combination light (9) from counterweight (1).

W2-3-2

30_42ZV-2

BODY / Counterweight CAUTION: Counterweight (1) weight: 30ZV-2: 300 kg (660 lb) 40ZV-2A/42ZV-2: 780 kg (1720 lb)

Lifting Tool

IMPORTANT: When hoisting the counterweight too much, it difficult to remove bolt (13) and the screw part may be damaged.

7. Install a lifting tool to counterweight (1).

Hold counterweight (1).

NOTE: Lifting tool bolt holes (M20, Pitch 1.5 mm, Depth 30 mm) (2 used) are provided in cover (8) open end on the counterweight (1) upper surface.

8. Loosen bolts (13) (3 used).

Remove bolts (13) (3 used) and washers (14) (3 used) from counterweight (1) while finely adjusting the hoist of counterweight (1). : 36 mm

9. Remove counterweight (1) from rear chassis (15).

W2-3-3

42ZV2-W2-03-01

30_42ZV-2

BODY / Counterweight Installation CAUTION: Counterweight (1) weight: 30ZV-2: 300 kg (660 lb) 40ZV-2A/42ZV-2: 780 kg (1720 lb)

Lifting Tool

IMPORTANT: If removing counterweight (1) with the engine hood installed, the engine hood may be damaged.

1. Hoist counterweight (1) by using a lifting tool.

2. Align counterweight (2) with the bolt hole on frame (15).

3. Install counterweight (1) to frame (15) with bolts (13) and washers (14) (3 used for each). : 36 mm : 698 to 768 N·m (71 to 78 kgf·m, 513 to 564 ft·lb)

42ZV2-W2-03-01

W2-3-4

30_42ZV-2

BODY / Counterweight Install rear combination light (9) to counterweight (1) with bolts (10), spring washers (11) and washers (12) (2 used for each) from cover (8) open end.

5. Connect the connectors of rear combination lights (9) (2 used) from cover (8) open end.

6. Install covers (8) (2 used) on the counterweight (1) upper surface with screws (7) (2 used for each).

7. Connect the connector of reverse light (2) and reverse alarm (3).

8. Install bracket (6) to counterweight (1) with screws (4) and washers (5) (2 used for each) together with rear combination light (2) and reverse alarm (3).

42ZV2-W2-03-02

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

W2-3-5

30_42ZV-2

BODY / Counterweight (Blank)

W2-3-6

30_42ZV-2

BODY / Center Hinge DISASSEMBLY AND CENTER HINGE

ASSEMBLY

OF

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

Operation 15

16

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

1. Remove the canopy (or the cab) and the operator frame. (Refer to W2-1 or W2-2.)

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

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

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

W4EK-02-04-002A

5. Remove the connecting parts between the front chassis and the rear chassis.

Propeller Shaft (Refer to W3-4.)

Steering Cylinder (Refer to W3-9.)

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

Control Cable (Refer to W2-8.)

Harness 6. Support front chassis (15) and rear chassis (16) by using the solid support.

W2-4-1

30_42ZV-2

BODY / Center Hinge

1

18

2

19 3 4 5

17

6

16

7

15

8 9

10 11 13 14

12

W4EK-02-04-001A

12345-

Bolt (4 Used) Center Pin Shim 1.0 mm (0.04 in) (2 Used) Shim 0.5 mm (0.02 in) (2 Used) Collar

6 - Oil Seal 7 - Taper Roller Bearing 8 - Taper Roller Bearing 9 - Oil Seal 10 - Collar

11 - Plate 12 - Bolt (4 Used) 13 - Washer 14 - Bolt 15 - Front chassis

16 - Rear chassis 17 - Guide 18 - Bolt 19 - Spring Washer

W2-4-2

30_42ZV-2

BODY / Center Hinge Disassembly of Hinge Pin 1. Remove bolts (18) (2 used) and spring washers (19) (2 used).

Remove guide (17) from front chassis (15).

8. Grind off the crimped part (3 places) of rear chassis (16).

Remove oil seals (6, 9) from rear chassis (16).

9. Remove bearings (7, 8) from pin (2) hole on rear chassis (16).

: 19 mm 2. Remove bolt (14) and washer (13) from center pin (2). : 24 mm 3. Remove SEMS bolts (12) (4 used) from plate (11).

Remove plate (11) from front chassis (15). : 19 mm 4. Remove SEMS bolts (1) (4 used) from center pin (2).

Remove center pin (2) and shims (3, 4) from front chassis (15). : 19 mm 5. Put the pipe from pin (2) hole on front chassis (15) on bearings (7, 8).

Lightly tap and push out collars (5, 10).

Remove collars (5, 10) from front chassis (15).

CAUTION: Front chassis (13) weight (including control valve weight): 30ZV-2: 217 kg (478 lb) 40ZV-2A/42ZV-2: 255 kg (562 lb) 6. Attach a nylon sling onto front chassis (15).

Hoist front chassis (15).

Remove front chassis (15) from rear chassis (16).

7. Remove collars (5, 10) from front chassis (15).

W2-4-3

30_42ZV-2

BODY / Center Hinge

1

18

2

19 3 4 5

17

6

16

7

15

8 9

10 11 13 14

12

W4EK-02-04-001A

12345-

Bolt (4 Used) Center Pin Shim 1.0 mm (0.04 in) (2 Used) Shim 0.5 mm (0.02 in) (2 Used) Collar

6 - Oil Seal 7 - Taper Roller Bearing 8 - Taper Roller Bearing 9 - Oil Seal 10 - Collar

W2-4-4

11 - Plate 12 - Bolt (4 Used) 13 - Washer 14 - Bolt 15 - Front chassis

16 - Rear chassis 17 - Guide 18 - Bolt 19 - Spring Washer

30_42ZV-2

BODY / Center Hinge Assembly of Hinge Pin 1. Apply grease onto bearings (7, 8).

Insert bearings (7, 8) to pin (2) hole on rear chassis (16).

16 D

6, 9

IMPORTANT: Check the direction of oil seals (6, 9).

Install oil seals (6, 9) with the wider rubber side facing upward.

1

3, 4

C

2. Lightly tap and install oil seals (6, 9) to rear chassis (16) so that dimension D in the right figure is 1 mm (0.04 in).

After installing, crimp by using a punch at the places where the circumference of rear chassis (16) is evenly divided into three.

5

6

16 7 2

CAUTION: Front chassis (15) weight (including control valve weight): 30ZV-2: 217 kg (478 lb) 40ZV-2A/42ZV-2: 255 kg (562 lb)

8 9 11

3. Attach a nylon sling onto front chassis (15).

Hoist and align front chassis (15) with the pin (2) holes on front chassis (15) and rear chassis (16).

4. Insert collars (5, 10) to the pin (2) holes on front chassis (15) and rear chassis (16).

1

13, 14

10

W4EK-02-04-004A

5. Insert center pin (2) to the pin (2) holes on front chassis (15) and rear chassis (16).

16

6, 9

5

2

W4EK-02-04-003A

W2-4-5

30_42ZV-2

BODY / Center Hinge

1

18

2

19 3 4 5

17

6

16

7 Tie Down

15

8 9

10 11 13 14

12

W4EK-02-04-001A

W2-4-6

30_42ZV-2

BODY / Center Hinge ®

6. Apply LOCTITE #262 onto sems bolts (12) (4 used).

Install plate (11) to front chassis (15) with SEMS bolts (12) (4 used).

16 D

6, 9

: 19 mm : 77.3 to 94.4 N·m (7.8 to 9.6 kgf·m, 56.4 to 69.4 lbf·ft)

1

3, 4

C

®

7. Apply LOCTITE #262 onto bolt (14).

Secure center pin (2) with bolt (14) and washer (13).

5

6

16

: 24 mm : 188.3 to 229.5 N·m (19.2 to 23.4 kgf·m, 138.8 to 169.2 lbf·ft)

7 2

8. Attach a spring balance to the tie down hole on front chassis (15).

Insert shims (3, 4) to clearance C between front chassis (15) and center pin (2) so that sliding resistance of the center hinge part is 98 N (10 kgf, 22 lbf) or less.

8 9 11 1

®

9. Apply LOCTITE #262 onto SEMS bolts (1) (4 used). Install center pin (2) to front chassis (15) with SEMS bolts (1) (4 used).

13, 14

10

W4EK-02-04-004A

: 19 mm : 77.3 to 94.4 N·m (7.8 to 9.6 kgf·m, 56.4 to 69.4 lbf·ft)

10. Install guide (17) to front chassis (15) with bolts (18) and spring washers (19) (2 used for each). : 19 mm

20

11. Apply grease through grease fitting (20).

M4EJ-07A-006

W2-4-7

30_42ZV-2

BODY / Center Hinge (Blank)

W2-4-8

30_42ZV-2

BODY / Engine Hood REMOVAL AND ENGINE HOOD

INSTALLATION

OF

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

1

W4EK-02-01-006A

W2-5-1

30_42ZV-2

BODY / Engine Hood Removal 5

1. Open hood (1).

4 3

2. Remove bolts (3), spring washers (4) and washers (5) (4 used for each).

Remove hood (1) from hood support (2).

2 3 4

: 17 mm

5 1

W4EK-02-05-002A

3. Remove snap pins (8), yoke pins (9) (2 used for each) and gas damper (7) rod side (2 places) from hood support (2).

6

4. Remove bolts (10), spring washers (11) and washers (12) (4 used for each) from hinge (6).

Remove hinge (6) from hood base (13) together with hood support (2) and gas dampers (7) (2 used).

2

7

7

: 17 mm

8 13

9 12 11 10

W4EK-02-05-003A

W2-5-2

30_42ZV-2

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

6

2

7

: 17 mm

7

2. Install gas lift cylinder (7) rod side (2 places) to hood support (2) with snap pins (8) and yoke pins (9) (2 used for each).

8 13

9 12 11 10

W4EK-02-05-003A

3. Install hood (1) to hood support (2) with bolts (3), spring washers (4) and washers (5) (4 used for each). : 17 mm

5 4 3

2 3 4

4. Close hood (1).

5 1

W4EK-02-05-002A

W2-5-3

30_42ZV-2

BODY / Engine Hood (Blank)

W2-5-4

30_42ZV-2

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

1

W4EK-02-01-006A

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

5. Remove the inspection cover and the seat support from the operator frame. (Refer to W2-1.)

4

6. After installing HST pump, remove plug (with O-Ring) (4).

Fill HST pump with hydraulic oil (0.4 to 0.5 L) (0.10 to 0.13 gal). : 6 mm

W4EK-01-02-012

W2-6-1

30_42ZV-2

BODY / HST Pump and Main Pump

12

Y

11 10 2

1 3 4 9

8

7 6

5

13 13

Y

14

17

16

15

1

W4EK-02-06-001A

12345-

HST Pump Main Pump Split Flange (4 Used) Spring Washer (8 Used) Bolt (8 Used)

6 - O-Ring 7 - Hose 8 - O-Ring 9 - Hose 10 - Hose

11 - Hose 12 - Hose 13 - Hose Clamp (2 Used) 14 - Hose

15 - Washer (2 Used) 16 - Bolt (2 Used) 17 - Connector (Forward and Reverse Solenoid Harness)

W2-6-2

30_42ZV-2

BODY / HST Pump and Main Pump Removal of HST Pump 1. Unplug connector (17) of the forward and reverse selection solenoid harness.

2. Disconnect all hydraulic hoses from main pump (2). (Refer to REMOVAL AND INSTALLATION OF MAIN PUMP.) 3. Remove bolts (5), lock spring washers (4) (4 used for each) and split flanges (3) (2 used for each) from hoses (7, 9).

Disconnect hoses (7, 9) from HST pump (1). Cap the open ends. : 17 mm 4. Remove O-Rings (6, 8) from hoses (7, 9).

5. Disconnect hoses (10, 11) from HST pump (1).

Cap the open ends. : 19 mm 6. Disconnect hose (12) from HST pump (1). Cap the open ends. : 22 mm 7. Loosen hose clamp (13).

Disconnect hose (14) from HST pump (1).

Cap the open ends.

CAUTION: HST pump (1) (with main pump) weight: 36 kg (79 lb) IMPORTANT: When hoisting HST pump, check the position to attach a nylon sling onto the solenoid connector in order not to damage the solenoid connector.

8. Attach a nylon sling to HST pump (1).

Hold HST pump (1).

9. Remove bolts (16) and washers (15) (2 used for each) from HST pump (1).

Hoist and remove HST pump (1) from the engine. : 22 mm

W2-6-3

30_42ZV-2

BODY / HST Pump and Main Pump

12

Y

11 10 2

1 3 4 9

8

7 6

5

13 13

Y

14

17

16

15

1

W4EK-02-06-001A

12345-

HST Pump Main Pump Split Flange (4 Used) Spring Washer (8 Used) Bolt (8 Used)

6 - O-Ring 7 - Hose 8 - O-Ring 9 - Hose 10 - Hose

11 - Hose 12 - Hose 13 - Hose Clamp (2 Used) 14 - Hose

15 - Washer (2 Used) 16 - Bolt (2 Used) 17 - Connector (Forward and Reverse Solenoid Harness)

W2-6-4

30_42ZV-2

BODY / HST Pump and Main Pump Installation of HST Pump CAUTION: HST pump (1) (with main pump) weight: 36 kg (79 lb) IMPORTANT: When hoisting HST pump, check the position to attach a nylon sling onto the solenoid connector in order not to damage the solenoid connector.

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

Hoist and align with the mounting hole on the engine.

Install HST pump (1) to the engine with bolts (16) and washers (15) (2 used for each). : 22 mm : 122 to 149 N·m (12.45 to 15.3 kgf·m, 90.0 to 110.6 lbf·ft) 2. Connect hose (14) to HST pump (1) with clamp (13). : 6 N·m (0.61 kgf·m, 4.41 lbf·ft) 3. Connect hose (12) to HST pump (1). : 22 mm 4. Connect hoses (10, 11) to HST pump (1). : 22 mm 5. Install O-Rings (6, 8) to hoses (7, 9).

Connect hoses (7, 9) to HST pump (1) with split flanges (3) (2 used for each), bolt (5) and spring washers (4) (4 used for each). : 17 mm : 58 to 71 N·m (5.91 to 7.24 kgf·m, 42.7 to 52.3 lbf·ft) 6. Connect all hydraulic hoses to the main pump.

(Refer to REMOVAL AND INSTALLATION OF MAIN PUMP.) 7. Connect the forward and reverse solenoid harness of HST pump (1) at connector (17) part.

W2-6-5

30_42ZV-2

BODY / HST Pump and Main Pump DISASSEMBLY AND ASSEMBLY OF HST PUMP

1

IMPORTANT: Only trained and competent personnel should disassemble and repair the HST pump.

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

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

2

5

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

2

W4EK-02-06-004A

Removal and Installation of High-Pressure and Low-Pressure Relief Valves

2

1. Remove high-pressure relief valves (2) (2 used) from HST pump (1).

2. Remove O-Ring (3) and backup ring (4) from high-pressure relief valve (2).

4

: 32 mm : 160 ± 10 N·m (16.32 ± 1.02 kgf·m, 118.0 ± 7.37 lbf·ft) 3. Remove low-pressure relief valve (5) from HST pump (1).

4. Remove O-Ring (6) and piston ring (7) from low-pressure relief valve (5).

3

W4EK-02-06-005A

5

6

7

: 27 mm : 70 ± 10 N·m (7.14 ± 1.02 kgf·m, 51.6 ± 7.37 lbf·ft) IMPORTANT: Do not disassemble high-pressure relief valve (2) and low-pressure relief valve (5).

Replace with a new one if inoperable.

W4EK-02-06-006A

Install the relief valves in reverse order of removal.

W2-6-6

30_42ZV-2

BODY / HST Pump and Main Pump Removal and Installation of DA Valve

1

1. Remove DA valve (8) from HST pump (1).

8

W4EK-02-06-004A

2. Remove O-Ring (9) from DA valve (8).

Check for any damage on the orifice (arrowed part).

8

9

W4EK-02-06-008A

3. Install O-Ring (9) to DA valve (8).

Install DA valve (8) to HST pump (1). : 27 mm : 50 N·m (5.1 kgf·m, 36.8 lbf·ft)

W2-6-7

30_42ZV-2

BODY / HST Pump and Main Pump Removal and Installation of Solenoid Valve (Forward and Reverse Selection) 1. Remove socket bolts (3) (3 used) and socket bolts (4) (2 used).

Remove solenoid valve (2) from HST pump (1).

3 5

: 5 mm

3

2. Remove gasket (5) and O-Ring (6) from solenoid valve (2).

4

6

1

2

W4EK-02-06-007A

3. Remove solenoids (8, 9) from valve housing (7).

Remove O-Rings (10, 11) from solenoids (8, 9).

8

7

10

9

11

W4EK-02-06-012A

Install the relief valves in reverse order of removal.

W2-6-8

30_42ZV-2

BODY / HST Pump and Main Pump Disassembly of HST Pump Connected Part (Engine Side) 1. Place HST pump on a clean stand with the drive shaft (1) facing upward.

1

NOTE: Protect the spline part of drive shaft (1).

3 4

2

2. Remove retaining ring (3) from housing (2).

3

3. Evenly install tapping screw (5) [Nominal Diameter 3.5 mm (0.14 in) ¯ Length 25 mm (0.98 in)] to the holes (2 places), which are blocked by the rubber of seal ring (4).

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

W4EK-02-06-010A

Assembly of HST Pump Connected Part (Engine Side) 1. Push seal ring (4) to the position where seal ring (4) is sopped.

Install seal ring (4) to housing (2) by using the special tool.

5

4

2. Install retaining ring (3) to housing (2).

W4EK-02-06-011A

W2-6-9

30_42ZV-2

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

5

6

7

8

4

3 10 9

2

8

1

11

W4EK-02-06-017A

1 - HST Pump 2 - Main Pump 3 - Hose

4 - Hose 5 - Tube 6 - Washer (4 Used)

7 - Bolt (4 Used) 8 - Hose Clamp (2 Used) 9 - Tube

W2-6-10

10 - O-Ring 11 - Bolt (2 Used)

30_42ZV-2

BODY / HST Pump and Main Pump Removal of Main Pump 1. Disconnect hoses (3, 4) from main pump (2).

Cap the open ends.

Attach an identification tag onto the disconnected hoses for assembling. : 19 mm࣭22 mm, 22 mm㺃27 mm 2. Remove bolts (7) and spring washers (6) (4 used for each) from tube (5).

Disconnect tube (5) from main pump (2).

Cap the open ends. : 17 mm 3. Remove O-Ring (10) from tube (5).

4. Remove bolts (11) (2 used) from main pump (2).

Remove main pump (2) from HST pump (1).

12

: 17 mm 5. Remove coupling (12) from HST pump (1) connected part.

W4EK-02-06-016A

W2-6-11

30_42ZV-2

BODY / HST Pump and Main Pump

5

6

7

8

4

3 10 9

2

8

1

11

W4EK-02-06-017A

1 - HST Pump 2 - Main Pump 3 - Hose

4 - Hose 5 - Tube 6 - Washer (4 Used)

7 - Bolt (4 Used) 8 - Hose Clamp (2 Used) 9 - Tube

W2-6-12

10 - O-Ring 11 - Bolt (2 Used)

30_42ZV-2

BODY / HST Pump and Main Pump Installation of Main Pump 1. Install coupling (12) to HST pump (1) connected part.

12

2. Install main pump (1) to HST pump (1) with bolts (11) (2 used). : 17 mm 3. Install O-Ring (10) to tube (5).

4. Install tube (5) to main pump (2) with bolts (7) and spring washers (6) (4 used for each).

W4EK-02-06-016A

: 17 mm 5. Connect hoses (3, 4) to main pump (2). : 19 mm㺃22 mm, 22 mm㺃27 mm

W2-6-13

30_42ZV-2

BODY / HST Pump and Main Pump DISASSEMBLY OF MAIN PUMP Rear Pump

1

2

3

4

5

6

7

8

Front Pump

9

10

18

19

20

21

22

23

24

25

25

17

16

15

14

13

12

11

30

29

28

27

26 W4EK-02-06-014A

Rear Pump 1 - Snap Ring 2 - Ring Frame 3 - Parallel Pin 4 - Case 5 - Side Plate 6 - Drive Gear 7 - Side Plate 8 - Plate (6 Used) 9 - Square Ring (2 Used)

10 - O-Ring (2 Used) 11 - O-Ring 12 - O-Ring 13 - Guide (2 Used) 14 - Square Ring (2 Used) 15 - Driven Gear 16 - Fastener Seal 17 - Socket Bolt (4 Used)

Front Pump 18 - Coupling 19 - Snap Ring 20 - Frame 21 - Pin (2 Used) 22 - Housing 23 - Drive Gear 24 - Socket Bolt (4 Used) 25 - Metal (4 Used) 26 - Driven Gear

W2-6-14

27 - Side Plate 28 - Square Ring 29 - Backup Ring 30 - O-Ring

30_42ZV-2

BODY / HST Pump and Main Pump Disassembly of Rear Pump

Disassembly of Front Pump

1. Remove snap ring (1) from drive gear (6).

1. Remove socket bolts (24) (4 used) from housing (22).

Separate housing (22) and frame (20).

2. Remove socket bolts (17) and fastener seal (16) from frame (2).

Separate the rear pump and the front pump. : 8 mm

: 10 mm 2. Remove O-Ring (30) from frame (20).

3. Remove case (4) from frame (2).

4. Remove square rings (9) (2 used), O-Rings (10) (2 used), O-Rings (11, 12) (2 used for each), guides (13) (2 used) and plates (8) (3 used for each) from case (4).

3. Remove side plate (27) from housing (22).

Remove backup ring (29) and square ring (28) from side plate (27).

4. Remove drive gear (23) and driven gear (26) from housing (22).

5. Remove side plates (5, 7) (2 used), drive gear (6) and driven gear (15) from case (4).

6. Remove square ring (14) (2 used) from side plates (5, 7) (2 used).

7. Remove snap ring (19) and coupling (18) from drive shaft (6).

W2-6-15

30_42ZV-2

BODY / HST Pump and Main Pump ASSEMBLY OF MAIN PUMP

Rear Pump

1

2

3

4

5

6

7

8

Front Pump

9

10

18

19

20

21

22

23

24

25

25

17

16

15

14

13

12

11

30

29

28

27

26 W4EK-02-06-014A

Rear Pump 1 - Snap Ring 2 - Ring Frame 3 - Parallel Pin 4 - Case 5 - Side Plate 6 - Drive Gear 7 - Side Plate 8 - Plate (6 Used) 9 - Square Ring (2 Used)

10 - O-Ring (2 Used) 11 - O-Ring 12 - O-Ring 13 - Guide (2 Used) 14 - Square Ring (2 Used) 15 - Driven Gear 16 - Fastener Seal 17 - Socket Bolt (4 Used)

Front Pump 18 - Coupling 19 - Snap Ring 20 - Frame 21 - Pin (2 Used) 22 - Housing 23 - Drive Gear 24 - Socket Bolt (4 Used) 25 - Metal (4 Used) 26 - Driven Gear

W2-6-16

27 - Side Plate 28 - Square Ring 29 - Backup Ring 30 - O-Ring

30_42ZV-2

BODY / HST Pump and Main Pump Assembly of Rear Pump

Assembly of Front Pump

1. Install coupling (18) to drive shaft (6) with snap ring (19).

1. Install drive gear (23) and driven gear (26) to housing (22).

2. Install square ring (14) (2 used) to side plates (5, 7) (2 used).

2. Install square ring (28) and backup ring (29) to side plate (27).

3. Install plate (8) (3 used), guide (13), square ring (9), O-Ring (10) and O-Rings (11, 12) (2 used) to the frame (2) side of case (4).

29

28

27

4. Install side plate (5), drive gear (6) and driven gear (15) to case (4).

5. Install plate (8) (3 used), guide (13), square ring (9), O-Ring (10) and O-Rings (11, 12) (2 used) to the front pump side of case (4).

6. Install case (4) to frame (2) while aligning the pin (3) hole (2 places).

7. Install the rear pump and the front pump with socket bolt (17) and fastener seal (16) while aligning the pin (3) hole (2 places). : 8 mm

W4EK-02-06-018A

IMPORTANT: Install with the concave side of square ring (28) facing to the bottom side of the groove on side plate (27).

3. Install O-Ring (30) to frame (20).

4. Install housing (22) and frame (20) with socket bolts (24) (4 used) while aligning pin (21) (2 places). : 10 mm

W2-6-17

30_42ZV-2

BODY / HST Pump and Main Pump (Blank)

W2-6-18

30_42ZV-2

BODY / HST Motor REMOVAL AND INSTALLATION OF HST MOTOR Operation 1. Park the machine on a level and solid surface.

Stop the engine.

Lower the bucket level to the ground.

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

3

3. Install articulation lock bar (2) to the front chassis (1) pin. Secure with ring pin (3).

W4EK-03-04-001

2

1

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

W4EK-02-01-006A

5. Remove the inspection cover and the seat support from the operator frame. (Refer to W2-1.)

10

6. Remove bolts (5), spring washers (6), washers (7), nuts (8) (2 used for each) and rubber (9) from fuel pump (4).

Remove fuel pump (4) from rear chassis (10) mounting plate.

NOTE: Removal of fuel pump (4) is performed in order not to come in contact with other parts when removing and installing HST motor.

7. After installing HST motor, remove plug (with O-Ring) (11).

Fill HST motor with hydraulic oil (0.4 to 0.5 L) (0.10 to 0.13 gal).

8

9

4

7

6

5

W4EK-02-07-002A

11

: 10 mm

W4EK-02-07-003A

W2-7-1

30_42ZV-2

BODY / HST Motor

7 6 3

4

9

5 8

10

11 12 2

1

13 14

15

1

16

17

W4EK-02-07-001A

12345-

HST Motor O-Ring Bolt (2 Used) Spring Washer (2 Used) Split Flange (2 Used)

6789-

Hose Hose O-Ring Hose

10 - O-Ring 11 - Split Flange (2 Used) 12 - Spring Washer (2 Used) 13 - Bolt (2 Used)

14 - Hose 15 - Socket Bolt 16 - O-Ring 17 - Reduction

W2-7-2

30_42ZV-2

BODY / HST Motor Removal 1. Remove bolts (3), lock spring washers (4) (4 used for each) and split flanges (5) (2 used for each) from hose (6).

Disconnect hose (6) from HST motor (1). Cap the open ends. : 17 mm 2. Remove bolts (13), lock spring washers (12) (4 used for each) and split flanges (11) (2 used for each) from hose (9).

Disconnect hose (9) from HST motor (1).

Cap the open ends. : 17 mm 3. Disconnect hoses (7, 14) from HST motor (1). Cap the open ends. : 17 mm CAUTION: HST Motor (1) weight: 26 kg (57 lb) 4. Attach a nylon sling onto HST motor (1). Hold HST motor (1).

5. Remove socket bolts (15) (4 used) from HST motor (1).

Hoist and remove HST motor (1) from reduction (17). : 10 mm 6. Remove O-Ring (16) from HST motor (1).

W2-7-3

30_42ZV-2

BODY / HST Motor 7 6 3

4

9

5 8

10

11 12 2

1

13 14

15

1

16

17

W4EK-02-07-001A

12345-

HST Motor O-Ring Bolt (2 Used) Spring Washer (2 Used) Split Flange (2 Used)

6789-

Hose Hose O-Ring Hose

10 - O-Ring 11 - Split Flange (2 Used) 12 - Spring Washer (2 Used) 13 - Bolt (2 Used)

W2-7-4

14 - Hose 15 - Socket Bolt 16 - O-Ring 17 - Reduction

30_42ZV-2

BODY / HST Motor Installation 1. Install O-Ring (16) to HST motor (1).

CAUTION: HST motor (1) weight: 26 kg (57 lb) 2. Attach a nylon sling onto HST motor (1).

Hoist and align with the mounting hole on reduction (17).

Install HST pump (1) to reduction (17) with socket bolts (15) (4 used). : 10 mm : 101 to 123 N·m (10.3 to 12.5 kgf·m, 74.4 to 90.4 lbf·ft) 3. Connect hoses (9, 10) to HST motor (1). : 17 mm 4. Connect hose (9) to HST motor (1) with split flanges (11) (2 used) and bolts (13) and lock spring washers (12) (4 used for each). : 17 mm : 58 to 71 N·m (5.91 to 7.24 kgf·m, 42.74 to 52.36 lbf·ft) 5. Connect hose (6) to HST motor (1) with split flanges (5) (2 used) and bolts (3) and lock spring washers (4) (4 used for each). : 17 mm : 58 to 71 N·m (5.91 to 7.24 kgf·m, 42.74 to 52.36 lbf·ft)

W2-7-5

30_42ZV-2

BODY / HST Motor (Blank)

W2-7-6

30_42ZV-2

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

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

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

1

A

2 3 4

5

Disassembly of HST Motor Connected Part (Reduction Side)

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

NOTE: Protect the spline part of drive shaft (1).

2. Remove snap ring (2) from housing (5).

Remove shim (3).

W4EK-02-07-006A

6

3. Evenly install tapping screw (6) [Nominal Diameter 3.5 mm (0.14 in) x Length 25 mm (0.98 in)] to the holes (2 places), which are blocked by the rubber of seal ring (4).

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

IMPORTANT: Identify installing depth (A) of seal ling (4).

W4EK-02-07-011A

Assembly of HST (Reduction Side)

Motor

Connected

Part

1. Check for the installing depth (A) of seal ring (4).

Install seal ring (4) to housing (5).

2. Install shim (3) to housing (5).

Secure with snap ring (2).

W2-7-7

30_42ZV-2

BODY / HST Motor

1

A

3

1 12

2

4 11

5

21

6

7 8 9 10

14

15

12

13

19

18

17

20

16 W4EK-02-07-005A

123456-

Control Part Assembly Socket Bolt (4 Used) Port Plate Assembly O-Ring (3 Used) Spring Collar Spring

7 - Spring Collar 8 - Spring 9 - Spring Collar 10 - Spring 11 - O-Ring

12 - Cover Assembly 13 - Socket Bolt (4 Used) 14 - O-Ring 15 - O-Ring (3 Used) 16 - Plug

W2-7-8

17 - Guide 18 - Orifice 19 - Guide 20 - O-Ring 21 - O-Ring (2 Used)

30_42ZV-2

BODY / HST Motor Disassembly of HD Regulator

Assembly of HD Regulator

1. Remove socket bolts (2) (4 used) from control part assembly (1).

Remove control part assembly (1) from port plate assembly (3).

Remove O-Ring (11) from control part assembly (1).

1. Install O-Ring (20) to plug (16).

Install guide (19), orifice (18) and guide (17) in this order to cover assembly (12).

Remove plug (16).

: 5 mm NOTE: When removing control part assembly (1), pay attention to the reaction force of spring (6, 8 and 10).

CAUTION: Do not disassemble adjusting screw part (A) of the control part assembly (1).

2. Remove O-Rings (4) (3 used) from port plate assembly (3).

Remove O-Ring (21) from check valve part (2 place).

Remove spring collar (5, 7 and 9) and spring (6, 8 and 10) from the control part assembly (1) mounting hole.

3. Remove socket bolts (13) (4 used) from cover assembly (12).

Remove cover assembly (12) from port plate assembly (3). : 6 mm 4. Remove O-Ring (14) from cover assembly (12).

Remove O-Rings (15) (3 used) from port plate assembly (3).

: 6 mm 2. Install O-Ring (14) to cover assembly (12).

Install O-Rings (15) (3 used) to port plate assembly (3).

3. Install cover assembly (12) to port plate assembly (3) with socket bolts (13) (4 used). : 6 mm 4. Install O-Rings (4) (3 used) to port plate assembly (3).

Install O-Rings (21) (2 used) to check valve part (2 place).

Install spring (10), spring collar (9), spring (8), spring collar (7), spring (6) and spring collar (5) in this order to the control part assembly (1) mounting hole.

5. Install O-Ring (11) to control part assembly (1).

Install control part assembly (1) to port plate assembly (3) with socket bolts (2) (4 used). : 5 mm NOTE: When installing control part assembly (1), evenly tighten socket bolts (2) (4 used) while paying attention to the reaction force of spring (6, 8 and 10).

5. Remove plug (16), guide (17), orifice (18) and guide (19) from cover assembly (12).

Remove O-Ring (20) from plug (16). : 6 mm

W2-7-9

30_42ZV-2

BODY / HST Motor

21 23

24 25

34

32

33

29

26 31

22

3

27

28

30

W4EK-02-07-007A

3 - Control Part Assembly 21 - O-Ring (2 Used) 22 - Socket Bolt (8 Used) 23 - Guide (2 Used)

24 - Backup Ring (2 Used) 25 - O-Ring (2 Used) 26 - Piston 27 - Piston Ring (2 Used)

28 - Socket Bolt 29 - Motor Housing 30 - O-Ring 31 - Parallel Pin

32 - Cylinder Block Assembly 33 - Piston (7 Used) 34 - Control Plate

W2-7-10

30_42ZV-2

BODY / HST Motor Removal of Port Plate Assembly

Installation of Port Plate Assembly

1. Put match marks on motor housing (29) and port plate assembly (3).

1. Install piston ring (27) to piston (26).

Install piston (26) to port plate assembly (3) with socket bolt (28).

2. Remove socket bolts (22) (8 used) from port plate assembly (3).

Remove port plate assembly (3) from motor housing (29).

2. Install backup ring (24) and O-Ring (25) to guide (23).

Install guide (23) to check valve part (2 place) of port plate assembly (3).

: 8 mm 3. Remove O-Ring (30) from motor housing (29).

3. Apply grease onto O-Ring (30). Install O-Ring (30) to motor housing (29).

4. Remove guide (23) from check valve part (2 place) of port plate assembly (3).

Remove backup ring (24) and O-Ring (25) from guide (23).

4. Apply grease onto the sliding surface of port plate assembly (3).

Secure control plate (34) while aligning with the cylinder block (32) mounting surface.

5. Remove socket bolts (28) and piston (26) from port plate assembly (3).

Remove piston ring (27) from piston (26).

34

CAUTION: Do not tilt cylinder block (32).

Piston (33) may be removed from cylinder block (32).

3

W4EK-02-07-009A

5. Align match marks with motor housing (29) and port plate assembly (3).

Install port plate assembly (3) to motor housing (29) with socket bolts (22) (8 used). : 8 mm

W2-7-11

30_42ZV-2

BODY / HST Motor (Blank)

W2-7-12

30_42ZV-2

BODY / Control Valve REMOVAL AND CONTROL VALVE

INSTALLATION

OF 5

Preparation WARNING: Never work under a raised bucket.

The front attachment may lower, possibly causing personal injury.

If you must work with the front attachment raised, hold the front attachment securely by using a support or blocks.

4

W4EK-02-08-012A

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

Stop the engine and release the hydraulic pressure.

If you must work with the front attachment raised, set the bucket to the full dump position and hold the lift arm by using support (4).

Set and secure stoppers (5) to the lift cylinder.

3

2

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

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

Secure with ring pin (3).

1

W4EK-02-01-006A

W2-8-1

30_42ZV-2

BODY / Control Valve

17 3

4

5

7

6

18

16

8

15 14 11

9 2

13 12

26 19

10 1

1

26

21

23 20

1

22

24

1

25

W4EK-02-08-001A

1234567-

Control Valve Hose Hose Bolt (2 Used) Plate Clamp (2 Used) Washer (2 Used)

8 - Nut (4 Used) 9 - Hose 10 - Hose 11 - Bolt (2 Used) 12 - Spring Washer (2 Used) 13 - Washer (2 Used) 14 - Nut

15 - Spring Washer 16 - Washer (2 Used) 17 - Bolt 18 - Cover 19 - Cable (2 Used) 20 - Connector 21 - Hose

W2-8-2

22 - Hose 23 - Bolt (3 Used) 24 - Spring Washer (3 Used) 25 - Nut (3 Used) 26 - Front chassis

30_42ZV-2

BODY / Control Valve Removal CAUTION: Bleed air from the hydraulic circuit before doing any work. (Refer to W1-1-3.)

CAUTION: Attach an identification tag onto the disconnected hose and the pipe for assembling.

1. Remove SEMS bolts (28) (4 used).

Remove cover (27) from front chassis (26).

28

: 17 mm

27

2. Remove bolts (4) (2 used), nuts (8) (4 used) and washers (7) (2 used).

Remove clamps (6) (2 used) and plate (5), which secure hydraulic hoses (9, 10).

26

: 17 mm 3. Disconnect the harness of the bucket auto leveler proximity switch at the connector (20) part.

4. Remove bolts (11), lock spring washers (12) and washers (13) (2 used for each), and remove bolt (17), washers (16) (2 used), lock spring washer (15) and nut (14).

Remove cover (18) from front chassis (26).

W4EK-02-08-002A

: 17 mm

W2-8-3

30_42ZV-2

BODY / Control Valve

17 3

4

5

7

6

8

18

16 15 14 11

9 2

13 12

26 19

10 1

1

26

21

23 20

22

1

24

1

25

W4EK-02-08-001A

W2-8-4

30_42ZV-2

BODY / Control Valve 5. Disconnect control cables (19) (2 used) from control valve (1) : 13 mm, 24 mm 6. Disconnect hoses (21, 22) from control valve (1).

Cap the open ends. : 27 mm 7. Disconnect hoses (9, 10) from control valve (1).

Cap the open ends. : 22 mm 8. Disconnect hoses (2, 3) from control valve (1).

Cap the open ends. : 22 mm 9. Remove bolts (23), spring washers (24) and nuts (25) (3 used for each).

Remove control valve (1) from front chassis (26). : 17 mm

W2-8-5

30_42ZV-2

BODY / Control Valve

17 3

4

5

7

6

18

16

8

15 14 11

9 2

13 12

26 19

10 1

1

26

21

23 20

1

22

24

1

25

W4EK-02-08-001A

1234567-

Control Valve Hose Hose Bolt (2 Used) Plate Clamp (2 Used) Washer (2 Used)

8 - Nut (4 Used) 9 - Hose 10 - Hose 11 - Bolt (2 Used) 12 - Spring Washer (2 Used) 13 - Washer (2 Used) 14 - Nut

15 - Spring Washer 16 - Washer (2 Used) 17 - Bolt 18 - Cover 19 - Cable (2 Used) 20 - Connector

W2-8-6

21 - Hose 22 - Hose 23 - Bolt (3 Used) 24 - Spring Washer (3 Used) 25 - Nut (3 Used) 26 - Front chassis

30_42ZV-2

BODY / Control Valve Installation 1. Align control valve (1) with front chassis (26) mounting hole.

Secure control valve (1) with bolts (23) (3 used), spring washers (24) (3 used) and nuts (25) (3 used). : 17 mm 2. Connect hoses (2, 3) to control valve (1). : 22 mm 3. Connect hoses (9, 10) to control valve (1). : 22 mm

Unit : mm (in) [203 (7.99)]

4. Connect hoses (21, 22) to control valve (1).

[6 (0.24)] [190 (7.48)]

: 27 mm

13(0.51) 11 (0.43)

5. Connect control cables (19) (2 used) to control valve (1) so that the dimension is as illustrated in the right. : 13 mm, 24 mm : 79.4 to 97.1 N·m (8.1 to 9.9 kgf·m, 58.5 to 71.6 lbf·ft)

19

1

W4EK-02-08-003A

W2-8-7

30_42ZV-2

BODY / Control Valve

17 3

4

5

7

6

8

18

16 15 14 11

9 2

13 12

26 19

10 1

1

26

21

23 20

22

1

24

1

25

W4EK-02-08-001A

W2-8-8

30_42ZV-2

BODY / Control Valve 6. Install cover (18) to front chassis (26) with bolts (11), lock spring washers (12), washers (13) (2 used for each), bolt (17), lock spring washer (15), washers (16) (2 used) and nut (14). : 17 mm

7. Connect the harness of the bucket auto leveler proximity switch at the connector (20) part.

8. Install clamps (6) (2 used) and plate (5) to hoses (9, 10).

Secure to front chassis (26) with bolts (4), washer (7) (2 used for each) and nuts (8) (4 used).

28 27

: 17 mm

9. Install cover (27) to front chassis (26) with SEMS bolts (28) (4 used).

26

: 17 mm

W4EK-02-08-002A

W2-8-9

30_42ZV-2

BODY / Control Valve DISASSEMBLY AND CONTROL VALVE

ASSEMBLY

5

OF

1

9

8

12

3

15

11

10

14

4

12

13

7

5

6

2

3

W4EK-02-08-004A

1234-

Support Rod (2 Used) Nut (4 Used) Rod

5678-

Nut (2 Used) Inlet Housing O-Ring Bucket Plunger Assembly

9 - Lift Plunger Assembly 10 - Main Relief Valve 11 - O-Ring 12 - Relief Valve

W2-8-10

13 - O-Ring 14 - Anti-Void Valve 15 - O-Ring

30_42ZV-2

BODY / Control Valve Disassembly of Control Valve CAUTION: Attach a spanner onto the hexagonal part of the relief valve case.

1. Remove main relief valve (10) from inlet housing (6).

Remove O-Ring (11) from main relief valve (10).

2. Remove relief valves (12) (2 used) from bucket plunger assembly (8).

Remove O-Ring (13) from relief valve (12).

3. Remove anti-void valve (14) from lift plunger assembly (9).

Remove O-Ring (15) from anti-void valve (14).

4. Remove nuts (3) (2 used) and nut (5) from rods (2) (2 used) and rod (4).

Pull out and separate rods (2) (2 used) and rod (4) from inlet housing (6), bucket plunger assembly (8), lilt plunger assembly (9) and outlet housing (1). : Nut (3): 13 mm Nut (5): 17 mm 5. Remove O-Ring (7) from inlet housing (6).

6. Refer to the disassembly and assembly of bucket plunger assembly (8).

7. Refer to the disassembly and assembly of lift plunger assembly (9).

W2-8-11

30_42ZV-2

BODY / Control Valve

5

1

9

8

12

3

11

15

10

14

4

12

13

7

5

6

2

3

W4EK-02-08-004A

1234-

Support Rod (2 Used) Nut (4 Used) Rod

5678-

Nut (2 Used) Inlet Housing O-Ring Bucket Plunger Assembly

9 - Lift Plunger Assembly 10 - Main Relief Valve 11 - O-Ring 12 - Relief Valve

W2-8-12

13 - O-Ring 14 - Anti-Void Valve 15 - O-Ring

30_42ZV-2

BODY / Control Valve Assembly of Control Valve CAUTION: Attach a spanner onto the hexagonal part of the relief valve case.

1. Install O-Ring (7) to inlet housing (1).

NOTE: Assemble bucket plunger assembly (8) and lilt plunger assembly (9) in advance.

2. Pass rods (2) (2 used) and rod (4) through inlet housing (6), bucket plunger assembly (8), lilt plunger assembly (9) and support (1). Install with nuts (3) (2 used) and nut (5). : Nut (3) 13 mm Nut (5) 17 mm : Nut (3): 19 N·m (1.94 kgf·m, 14.0 lbf·ft) Nut (5): 46 N·m (4.69 kgf·m, 33.9 lbf·ft) 3. Install O-Ring (15) to anti-void valve (14).

Install anti-void valve (14) to lift plunger assembly (9).

4. Install O-Ring (13) to relief valves (12) (2 used).

Install relief valves (12, 2) to bucket plunger assembly (8).

5. Install O-Ring (11) to main relief valve (10).

Install main relief valve (10) to inlet housing (6).

W2-8-13

30_42ZV-2

BODY / Control Valve Disassembly and Assembly of Bucket Plunger Assembly

22 23

21

5 3

4

17

1

10 11 12 19

20

13

18

14

2 4

17

5 15

7 6

16

9 8 9

W4EK-02-08-005A

123456-

Housing Plunger Sleeve O-Ring (2 Used) Wiper Ring (2 Used) O-Ring

7 - Plate 8 - Spring 9 - Spring Seat (2 Used) 10 - Cap Screw 11 - Nut 12 - Plate

13 - Socket Bolt 14 - Coil Tube 15 - Cap 16 - Socket Bolt (2 Used) 17 - O-Ring (2 Used) 18 - Shim [Thickness 0.5 mm (0.02 in)]

W2-8-14

19 - Spring 20 - Poppet 21 - O-Ring 22 - Screw (2 Used) 23 - Seal Plate

30_42ZV-2

BODY / Control Valve Disassembly of Bucket Plunger Assembly 1. Remove O-Rings (21), poppet (20) and spring (19) from housing (1).

2. Remove screws (22) (2 used) and seal plate (23) from housing (1).

3. Remove socket bolts (16) (2 used) from housing (1).

Separate cap (15), coil tube (14) and sleeve (3).

9. Remove plunger (2) from housing (1).

NOTE: For easy removal, rotate and remove plunger (2).

10. Remove wiper rings (5) (2 used) and O-Rings (4) (2 used) from housing (1).

: 5 mm 4. Remove cap (15) and O-Ring (17) from coil tube (14).

5. Remove coil tube (14) and shim (18) from sleeve (3).

6. Remove socket bolts (13), plate (12) and lock nut (11) from cap screw (10). : Socket Bolt (13): 4 mm : Lock Nut (11): 8 mm 7. Remove sleeve (3) from plunger (2).

Remove O-Rings (17, 6) from sleeve (3).

8. Remove cap screw (10) from plunger (2).

Remove spring seats (9), spring (8) and plate (7). : 8 mm

W2-8-15

30_42ZV-2

BODY / Control Valve

16 15 17

14 13

11

12

10

18

17 8 3 9

7 6 5 4

1

19 20

4

5 23 22

2

W4EK-02-08-007A

123456-

Housing Plunger Sleeve O-Ring (2 Used) Wiper Ring (2 Used) O-Ring

7 - Plate 8 - Spring 9 - Spring Seat (2 Used) 10 - Cap Screw 11 - Nut 12 - Plate

13 - Bolt 14 - Coil Tube 15 - Cap 16 - Socket Bolt (2 Used) 17 - O-Ring (2 Used) 18 - Shim [Thickness 0.5 mm (0.02 in)]

W2-8-16

19 - Spring 20 - Poppet 21 - O-Ring 22 - Screw (2 Used) 23 - Seal Plate

30_42ZV-2

BODY / Control Valve Assembly of Bucket Plunger Assembly 1. Install O-Rings (4) (2 used) and wiper rings (5) (2 used) to housing (1).

8. Install sleeve (3), coil tube (14) and cap (15) to housing (1) with socket bolts (16) (2 used). : Socket Bolt (13): 4 mm : 8.8 N·m (0.9 kgf·m, 6.5 lbf·ft)

2. Install plunger (2) to housing (1).

NOTE: For easy removal, rotate and install plunger (2).

9. Install seal plate (23) to housing (1) with screws (22) (2 used).

3. Install plate (7), spring seat (9), spring (8) and spring seat (9) in this order with cap screw to plunger (2).

: 2.7 N·m (0.28 kgf·m, 2.02 lbf·ft)

: 8 mm : 20.1 N·m (2.05 kgf·m, 14.8 lbf·ft) 4. Install O-Rings (6, 17) to sleeve (3).

Install sleeve (3) to plunger (2).

5. Install lock nut (11) and plate (12) to cap screw (10) with socket bolts (13).

Tighten with lock nut (11) so that clearance (A) between lock nut (11) and plate (12) is 0.5 mm. : Lock Nut (11): 8 mm : Socket Bolt (13): 4 mm : 2.6 N·m (0.27 kgf·m, 1.95 lbf·ft) 13

6. Install shim (18) and coil tube (14) to sleeve (3).

7. Install O-Ring (17) and cap (15) to coil tube (14).

12 A

11

W4EK-02-08-009A

W2-8-17

30_42ZV-2

BODY / Control Valve Disassembly and Assembly

Assembly of Lift Plunger

21 3 5 20

10

4 11

2 1

10

9 19

14

18

12 13

17 4

8

6

15 16

7

22

W4EK-02-08-006A

123456-

Housing Plunger Seal Plate O-Ring (2 Used) Wiper Ring Spacer

7 - Cap 8 - Sleeve 9 - Pin 10 - Seat (2 Used) 11 - Spring 12 - Spring

13 - Ball 14 - Ball (4 Used) 15 - Spacer 16 - Snap Ring 17 - O-Ring 18 - Poppet

W2-8-18

19 - Spring 20 - O-Ring 21 - Screw (2 Used) 22 - Bolt (2 Used)

30_42ZV-2

BODY / Control Valve Disassembly of Lift Plunger Assembly 1. Remove O-Rings (20), poppet (18) and spring (19) from housing (1).

9. Remove wiper rings (5) (2 used) and O-Rings (4) (2 used) from housing (1).

2. Remove screws (21) (2 used) and seal plate (3) from housing (1).

3. Remove snap ring (16) and spacer (15) from cap (7).

4. Remove socket bolts (22) (2 used) and cap (7) from cap (7).

Remove sleeve (8) while pushing large steel ball (13) in pin (9). : 4 mm 5. Slowly push back large steel ball (13).

Remove large steel ball (13), small steel balls (14) (4 used) and spring (12) in pin (9).

7 13

NOTE: Do not loose steel ball (13) and steel balls (14) (4 used) as the steel balls may fly out.

6. Remove pin (9) from plunger (2).

Remove spring seats (10) (2 used) and spring (11).

14

8 9

12

7. Remove spacer (6) from plunger (2).

Remove O-Rings (6, 17) from spacer (6).

8. Remove plunger (2) from housing (1).

NOTE: For easy removal, rotate and remove plunger (2).

W2-8-19

W4EK-02-08-011A

30_42ZV-2

BODY / Control Valve

16

15

13

14

8 12 10

7 9

11

22

6 4 17

1

18 19

4 5 3 21 2

W4EK-02-08-010A

123456-

Housing Plunger Seal Plate O-Ring (2 Used) Wiper Ring Spacer

7 - Cap 8 - Sleeve 9 - Pin 10 - Seat (2 Used) 11 - Spring 12 - Spring

13 - Ball 14 - Ball (4 Used) 15 - Spacer 16 - Snap Ring 17 - O-Ring 18 - Poppet

W2-8-20

19 - Spring 20 - O-Ring 21 - Screw (2 Used) 22 - Bolt (2 Used)

30_42ZV-2

BODY / Control Valve Assembly of Lilt Plunger Assembly 1. Install O-Ring (4) and wiper ring (5) to housing (1).

2. Install plunger (2) to housing (1).

NOTE: For easy removal, rotate and install plunger (2).

3. Install O-Rings (6, 7) to spacer (6).

Install spacer (6) to plunger (2).

4. Install spring seat (10), spring (8) and spring seat (10) in this order with pin (9) to plunger (2).

5. Install spring (12) and large steel ball (13) in pin (9).

Insert small steel balls (14) (4 used) to the hole (4 places) on the side of pin (9) while pushing steel ball (13). Install sleeve (8).

6. Install cap (7) and spacer (6) to housing (1) with socket bolts (22) (2 used).

7 13 14

8 9

: 4 mm : 8.8 N·m (0.9 kgf·m, 6.50 lbf·ft)

12

7. Install spacer (15) to cap (7) with snap ring (16).

8. Install seal plate (3) to housing (1) with screws (21) (2 used).

: 2.7 N·m (0.28 kgf·m, 2.02 lbf·ft)

W4EK-02-08-011A

9. Install O-Rings (20), poppet (18) and spring (19) to housing (1).

W2-8-21

30_42ZV-2

BODY / Control Valve (Blank)

W2-8-22

30_42ZV-2

SECTION 3

TRAVEL SYSTEM

— CONTENTNS — Group 1 Tire

Group 6 Parking Brake Solenoid

Removal and Installation of Tire.................. W3-1-1

Removal and Installation of Parking Brake Solenoid .............................W3-6-1

Group 2 Reduction Gear Group 7 Inching Valve

Removal and Installation of Reduction Gear ......................................... W3-2-1

Removal and Installation of

Disassembly and Assembly of

Inching Valve..............................................W3-7-1

Reduction Gear ......................................... W3-2-6

Disassembly and Assembly of

Maintenance Standard .............................. W3-2-22

Inching Valve..............................................W3-7-4

Group 3 Axle

Group 8 Power Steering

Removal and Installation of

Removal and Installation of

Front Axle .................................................. W3-3-1

Orbitrol .......................................................W3-8-1

Removal and Installation of

Disassembly of Orbitrol ...............................W3-8-4

Rear Axle................................................... W3-3-7

Assembly of Orbitrol ....................................W3-8-8

Disassembly and Assembly of Axle ......................................................... W3-3-16

Group 9 Steering Cylinder

Disassembly and Assembly of

Removal and Installation of

Differential Assembly............................... W3-3-18

Steering Cylinder........................................W3-9-1

Disassembly and Assembly of

Disassembly of Steering Cylinder ................W3-9-6

Final Drive ............................................... W3-3-30

Assembly of Steering Cylinder...................W3-9-10

Group 4 Propeller Shaft

Removal and Installation of Propeller Shaft........................................... W3-4-1

Group 5 Master Cylinder Removal and Installation of Master Cylinder ......................................... W3-5-1 Disassembly and Assembly of Master Cylinder ......................................... W3-5-6 Bleeding Air from Brake System ................. W3-5-8

W-3-1

30_42ZV-2

(Blank)

W-3-2

30_42ZV-2

TRAVEL SYSTEM / Tire REMOVAL AND INSTALLATION OF TIRE Removal 1. Secure the front chassis and the rear chassis with the articulation lock bar and the pin.

2. When removing the rear tires, insert wooden block (1) between the rear chassis and the rear axle on both left and right sides in order to prevent the cradle from moving.

1

W4EK-03-01-001

3

3. Loosen wheel bolts (2) (6 used) of tire (3) to be removed about one turn. : 27 mm CAUTION: Machine weight: Canopy

Cab

30ZV-2

3085 kg (6800 lb)

3245 kg (7154 lb)

40ZV-2A

3810 kg (8400 lb)

3970 kg (8752 lb)

42ZV-2

4030 kg (8885 lb)

4195 kg (9248 lb)

2

4. Raise the machine until tire (3) to be removed slightly gets above the shop floor surface.

Support the machine securely by using blocks.

W4EK-03-01-002

CAUTION: Tire (3) and rim weight: 30ZV-2: 50 kg (110 lb) 40ZV-2A, 42ZV-2: 75 kg (165 lb) 5. Attach a lifting tool to tire (3). Hold tire (3).

3

6. Remove wheel bolts (2) (6 used) and washers (4) (6 used).

Remove tire (3) from the axle.

2

4

W4EK-03-01-003

W3-1-1

30_42ZV-2

TRAVEL SYSTEM / Tire Installation CAUTION: Tire (3) and rim weight: 30ZV-2: 50 kg (110 lb) 40ZV-2A, 42ZV-2: 75 kg (165 lb) 1. Hoist and install tire (3) to the axle.Install tire (3) with the air valve side facing outside.

3

2. Install and lightly tighten wheel bolts (2) (6 used) and washers (4) (6 used) to tire (3).

2

4

W4EK-03-01-003

6

3. Lower the machine.

Tighten wheel bolts (2) according to the order as illustrated to the right. : 27 mm : 375 to 412 N m (38.3 to 42.1 kgf m, 277 to 304 lbf·ft)

1

3

2

4 5

2

W4EK-03-01-002

4. Remove wooden block (1) between the rear chassis and the rear axle on both left and right sides.

1

W4EK-03-01-001

W3-1-2

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear REMOVAL AND INSTALLATION REDUCTION GEAR

OF

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

1

W4EK-02-01-006A

W3-2-1

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

5 8

9

6 7

4

3

2

10 1

W4EK-03-02-001

1 - SEMS Bolt (4 Used) 2 - Bracket (Left) 3 - Parking Brake Solenoid

4 - Hose 5 - Master Cylinder 6 - Hose

7 - Reduction Gear 8 - Bracket (Right)

W3-2-2

9 - SEMS Bolt (3 Used) 10 - Rear Chassis

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Removal 1. Remove the main pump. (Refer to W2-6.)

2. Remove the HST motor. (Refer to W2-7.)

3. Remove the propeller shaft. (Refer to W3-4.)

4. Remove the drain plug from reduction gear (7).

Drain transmission oil. : 14 mm NOTE: Prepare a 2 L container in order to collect oil.

Place reduction gear (7) on a waste oil stand.

Remove reduction gear (7) from the chassis.

5. Disconnect hoses (4, 6) from reduction gear (7).

Cap the open ends. : 17 mm, 19 mm CAUTION: Reduction gear (7) weight: 57 kg (126 lb) 6. Attach a nylon sling to reduction gear (7) and place a stand under reduction gear (7).

Hold reduction gear (7).

7. Remove SEMS bolts (1, 9) (3 used for each).

Remove reduction gear (7) from rear chassis mounting brackets (2, 8). : 19 mm 8. Remove reduction gear (7) from the chassis.

W3-2-3

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

5 8

9

6 7

4

3

2

10 1

W4EK-03-02-001

1 - SEMS Bolt (4 Used) 2 - Bracket (Left) 3 - Parking Brake Solenoid

4 - Hose 5 - Master Cylinder 6 - Hose

7 - Reduction Gear 8 - Bracket (Right)

W3-2-4

9 - SEMS Bolt (3 Used) 10 - Rear Chassis

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Installation 1. Place reduction gear (7) on a stand and put it into the chassis.

CAUTION: Reduction gear (7) weight: 57 kg (126 lb) 2. Sling reduction gear (7) onto the rear chassis mounting brackets (2, 8) by using a lifting tool.

3. Apply LOCTITE® #262 onto SEMS bolts (1, 9) (3 used).

Align the mounting holes on reduction gear (7) with the rear chassis mounting bracket holes. : 19 mm : 83.4 to 93.2 N m (8.5 to 9.5 kgf, 61 to 69 lbf·ft) 4. Install reduction gear (7) to rear chassis mounting brackets (2, 8) with SEMS bolts (1, 9) (3 used).

5. Install the propeller shaft. (Refer to W3-4.)

6. Install the HST motor. (Refer to W2-7.)

7. Install the main pump. (Refer to W2-6.)

W3-2-5

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear DISASSEMBLY AND REDUCTION GEAR

ASSEMBLY

OF

46 45 41

43

47

50

44

42 1

43 45

49 50 48 54

51 52 53

7

6 8

W4EK-03-02-013

1 - Case 6 - Cover 7 - Gasket 8 - Set Bolt (14 Used) 41 - Output Gear

42 - Output Shaft 43 - Bearing (2 Used) 44 - Snap Ring 45 - Snap Ring (2 Used) 46 - Flange

47 - Plug 48 - Flange 49 - Spacer 50 - Oil Seal (2 Used)

W3-2-6

51 - O-Ring 52 - Washer 53 - Nut 54 - Air Bleeder

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Disassembly of Output Shaft 1. Remove set bolts (8) (14 used) from cover (6).

Remove cover (6) and gasket (7) from case (1). : 17 mm 2. Remove nut (53) and washer (52) from case (1) front side and flange (48).

Remove O-Ring (51), flange (48) and spacer (49) from output shaft (42). : 36 mm 3. Remove oil seal (50) and snap ring (45) from case (1) front side.

4. Remove plug (47) and flange (46) from case (1) rear side and output shaft (42).

5. Remove oil seal (50) and snap rings (45) (2 places) from case (1) rear side.

IMPORTANT: When removing output shaft (42), hold output gear (41).

6. Remove output shaft (42) from case (1) front side by using a soft hammer.

7. Remove output gear (41) from case (1).

8. Remove bearing (43) from output shaft (42).

9. Remove bearing (43) from case (1) front side.

W3-2-7

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

50

44

47

46

45 43

6

7

8

43 45 49 50

51

42

53

52

48

1

41

5

W4EK-03-02-005

1 - Case 6 - Cover 7 - Gasket 8 - Set Bolt (14 Used) 41 - Output Gear

42 - Output Shaft 43 - Bearing (2 Used) 44 - Snap Ring 45 - Snap Ring (2 Used) 46 - Flange

47 - Plug 48 - Flange 49 - Spacer 50 - Oil Seal (2 Used)

W3-2-8

51 - O-Ring 52 - Washer 53 - Nut

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Assembly of Output Shaft 42

1. Place the output shaft assembly on a stand with case (1) front side (HST motor mounting side) facing down.

50

1

4 mm (0.16 in)

2. Install snap ring (45) and bearing (43) to case (1).

3. Place the longer protuberances surface of output gear (41) boss in case (1) facing to the bearing (43) side.

1

W4EK-03-02-006

7. Apply grease onto the oil seal (50) contact surface of flange (48).

Install spacer (49), flange (48) and O-Ring (51) to output shaft (42).

41

43

NOTE: After installing flange (48), if a warp is found on the oil seal (50) lip part, move flange (48) back and forth in order to correct the warp.

W4EK-03-02-007

4. Install bearing (43) and snap ring (44) to output shaft (42).

5. Engage input gear (5) and output gear (41).

Install output shaft (42) to output gear (41).

6. Apply LOCTITE® #262 onto the outer surface (metal part) of oil seal (50).

Apply grease onto the lip part of oil seal (50).

Position the lip part of oil seal (50) upside.

Install oil seal (50) so that the depth from the case (1) outer surface end is 4 mm (0.16 in).

W3-2-9

8. Apply LOCTITE® #262 onto nut (53). Install washer (52) and nut (53) to flange (48). : 36 mm : 245 N m (25 kgf m, 181 lbf ft) 9. Install gasket (7) and cover (6) to case (1) with set bolts (8) (14 used). : 17 mm : 18.6 N m (1.9 kgf m, 13.7 lbf ft)

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

Parking Brake Assembly

36 Brake Assembly

37

22 15 16 21 21

23

14

1

13 12 4 5 12 13 Input Shaft Assembly

W4EK-03-02-004

1 - Case 4 - Input Shaft 5 - Input Gear 12 - Bearing (2 Used)

13 - Snap Ring (2 Used) 14 - Snap Ring 15 - Retainer

16 - O-Ring 21 - Snap Ring (2 Used) 22 - O-Ring

W3-2-10

23 - Hub Disc 36 - Bolt (4 Used) 37 - Washer (4 Used)

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Disassembly of Input Shaft 1. Place the input shaft assembly on a stand with case (1) front side (HST motor mounting side) facing down.

NOTE: Put match marks on case (1), seal retainer (15), the brake assembly and the parking brake assembly.

2. Remove bolts (36) and washers (37) (4 used for each).

Remove the parking brake assembly and the brake assembly from case (1). : 17 mm 3. Install bolts (36) (2 used) to the pulling out hole (2 places) on seal retainer (15).

Tighten bolts (36) (2 used) evenly.

Remove seal retainer (15) from case (1).

4. Remove O-Rings (16, 22) from seal retainer (15).

5. Remove the input shaft (4) assembly from case (1) front side by using a soft hammer.

6. Remove snap rings (21) (2 used) and disc hub (23) from the input shaft (4) assembly.

7. Remove snap rings (13) (2 used), bearings (12) (2 used) and input gear (5) from the input shaft (4) assembly.

8. Remove snap ring (14) from case (1).

W3-2-11

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

21

23

17

36 37

Parking Brake Assembly

18

Brake Assembly

22 15

16 13 12 5 12

41

4

13

14

1

W4EK-03-02-008

1 - Case 4 - Input Shaft 5 - Input Gear 12 - Bearing (2 Used) 13 - Snap Ring (2 Used)

14 - Snap Ring 15 - Retainer 16 - O-Ring 17 - Brake Disc (30ZV-2: 4 Used) (40ZV-2A/42ZV-2: 5 Used)

18 - Brake Plate (30ZV-2: 5 Used) (40ZV-2A/42ZV-2: 6 Used) 21 - Snap Ring (2 Used) 22 - O-Ring

23 - Disc Hub 36 - Bolt (4 Used) 37 - Washer (4 Used)

W3-2-12

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Installation of Input Shaft 1. Install snap ring (14) to the case (1) front side.

4

2. Install input gear (5) to input shaft (4) with the boss convex side facing to HST motor mounting side (A).

3. Install bearings (12) and snap rings (13) (2 used for each) to input shaft (4).

4. Install the assembled input shaft (4) to case (1).

Engage input gear (5) and output gear (41).

5. Apply grease onto O-Rings (16, 22).

Install O-Rings (16, 22) to seal retainer (15).

Install seal retainer (15) to case (1) while aligning the matching marks.

NOTE: Check that the pulling out hole (A) (2 places) on seal retainer (15) is in horizontal position.

5

A

W4EK-03-02-009

Head

5

6. Install disc hub (23) to the input shaft (4) assembly with snap rings (21) (2 used) with the inner engaged part facing to the brake assembly side.

7. Engage brake disc hubs (17) (30ZV-2: 4 used, 40ZV-2A/42ZV-2: 5 used) and disc hub (23).

8. Install to case (1) with bolts (36) and washers (37) (4 used for each) while aligning the matching marks with seal retainer (15), the brake assembly and the parking brake assembly.

A

A

Tail W4EK-03-02-010

18

17

23

21

4

: 17 mm : 50 N m (5.1 kgf m, 36.8 lbf ft)

W4EK-03-02-011

W3-2-13

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

35 37

39

33 32 30 36 37

39

38

24

37

22

34

27 31

Parking Brake Assembly

Brake Assembly

W4EK-03-02-014

22 - O-Ring 24 - Piston Housing 27 - Pin 30 - Parking Brake Piston

31 - O-Ring (2 Used) 32 - D-Ring 33 - Spring (10 Used)

34 - Cap 35 - Bolt (2 Used) 36 - Bolt (4 Used)

W3-2-14

37 - Washer (7 Used) 38 - Bolt 39 - Plug

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Disassembly of Parking Brake 1. Place on a stand with case (1) front side (HST motor mounting side) facing down.

2. Remove bolts (36) and washers (37) (4 used for each) from cap (34).

Separate the parking brake assembly from the brake assembly.

3. Remove bolts (35) and washers (37) (2 used for each) from cap (34).

Remove cap (34) and springs (33) (10 used) from piston hosing (24).

IMPORTANT: Pay attention to the reaction force of spring (33) when removing cap (34).

Evenly and slowly loosen bolts (35) (2 used).

4. Remove parking brake piston (30) from piston housing (24).

5. Remove D-ring (32) and O-rings (31) (2 used) from parking brake piston (30).

6. Remove O-Ring (22) from piston housing (24).

W3-2-15

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

36, (35)

27

30

37 34 33 32

24

31

Parking Brake Assembly

25 Brake Assembly

W4EK-03-02-008

24 - Piston Housing 25 - Brake Piston 27 - Pin

30 - Parking Brake Piston 31 - O-Ring (2 Used) 32 - D-Ring

33 - Spring (10 Used) 34 - Cap 35 - Bolt (2 Used)

W3-2-16

36 - Bolt (4 Used) 37 - Washer (7 Used)

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Hole (27) on piston (30)

Assembly of Parking Brake 1. Install O-Ring (22) to piston housing (24).

2. Install D-ring (32) and O-rings (31) (2 used) to piston (30).

3. Place springs (33) (10 used) onto the spring (33) mounting hole on cap (34).

4. Align the groove on cap (34) and the pin (27) hole (2 places) on parking brake piston (30) vertically.

Install the spring groove on parking brake piston (30) while aligning springs (33) (10 used).

Groove (34)

W4EK-03-02-016

34

35

36

5. Install pins (27) (2 used) to pin hole (2 places) on piston housing (24).

36

6. Install the parking brake piston (30) assembly on step 4 to piston housing (24) with bolts (35) and washers (37) (2 used for each) while aligning the pin (27) holes (2 used).

IMPORTANT: When installing parking brake piston (30) assembly, evenly and slowly tighten socket bolts (35) (2 used) while paying attention to the reaction force of springs (33) (10 used).

36

35

W4EK-03-02-017

7. Install the piston housing (24) assembly (the parking brake assembly) to the brake assembly with bolts (36) and washers (37) (4 used for each).

W3-2-17

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

26 25 28 29 20

17

36 37

18

19

Parking Brake Assembly

1

23

Brake Assembly

Input Shaft Assembly

W4EK-03-02-015

1 - Case 17 - Brake Disc (30ZV-2: 4 Used) (40ZV-2A/42ZV-2: 5 Used)

18 - Brake Plate (30ZV-2: 5 Used) (40ZV-2A/42ZV-2: 6 Used) 19 - End Plate

20 - Brake Housing 23 - Disc Hub 25 - Brake Piston 26 - D-Ring

28 - Wave Spring 29 - End Plate 36 - Bolt (4 Used) 27 - Washer (4 Used)

W3-2-18

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Disassembly of Brake 1. Place on a stand with case (1) front side (HST motor mounting side) facing downward.

2. Remove bolts (36) and washers (37) (4 used for each) from the parking brake assembly.

Separate the parking brake assembly and the brake assembly from case (1).

3. Remove brake piston (25) from brake housing (20).

NOTE: Brake piston (25) may be stuck on the parking brake assembly.

4. Remove D-ring (26) from brake piston (25).

5. Remove wave spring (28), end plate (29), brake discs (17) (5 used), brake plates (18) (5 used) and end plate (19) from brake housing (20).

W3-2-19

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear

36 37 Parking Brake Assembly

26 25 28

22 Brake Assembly

29 17

18 19

23

W4EK-03-02-008

1 - Case 17 - Brake Disc (30ZV-2: 4 Used) (40ZV-2A/42ZV-2: 5 Used)

18 - Brake Plate (30ZV-2: 5 Used) (40ZV-2A/42ZV-2: 6 Used) 19 - End Plate

20 - Brake Housing 23 - Disc Hub 25 - Brake Piston 26 - D-Ring

28 - Wave Spring 29 - End Plate 36 - Bolt (4 Used) 37 - Washer (4 Used)

W3-2-20

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear Assembly of Brake 1. Install brake housing (20) to case (1) while aligning the matching marks.

Head

NOTE: Check that drill hole (1 place) (A) on the mounting surface of the parking brake assembly is located in the bottom.

IMPORTANT: Soak brake disc (17) in gear oil (reduction oil) before installing.

2. Install end plate (19), brake discs (17) (5 used), brake plates (18) (6 used) to brake housing (20) alternately. In addition, install end plate (29) and wave spring (28).

(A)

Tail W4EK-03-02-018

3. Install D-ring (26) to brake piston (25).

4. Install brake piston (25) to brake housing (20).

5. Apply grease onto O-Ring (22) on the parking brake assembly side.

Align the matching marks on the parking brake assembly with the brake housing (20) assembly and install the brake housing (20) assembly with bolts (36) and washers (37) (4 used for each).

W3-2-21

30_42ZV-2

TRAVEL SYSTEM / Reduction Gear MAINTENANCE STANDARD 1. Backlash between input gear and output gear.

Standard: 0.13 mm to 0.23 mm (0.005 in to 0.009 in) 2. Seal surface outer diameter of oil seal (49) in companion flange front (47) and rear (45).

Standard: 57.95 mm to 58.00 mm (2.281 in to 2.283 in) Wear limit: 0.05 mm (0.002 in) 3. Brake disc (17) thickness (including facing).

Standard: 2.10 mm to 2.25 mm (0.082 in to 0.088 in) Limit dimension: 1.90 mm (0.074 in) 4. Brake Plate (18) Thickness Standard: 1.54 mm to 1.66 mm (0.060 in to 0.065 in) Limit dimension: 1.40 mm (0.055 in) 5. End plate (19) thickness Standard: 3.87 mm to 4.00 mm (0.152 in to 0.157 in) 6. Parking brake spring (32) free length Standard: 45.5 mm (1.791 in) Limit dimension: 43.7 mm (1.720 in)

W3-2-22

30_42ZV-2

TRAVEL SYSTEM / Axle REMOVAL AND FRONT AXLE

INSTALLATION

OF 3

2

Preparation 1. Install articulation lock bar (2) to the front chassis (1) pin.

Secure with ring pin (3).

1

CAUTION: Machine weight: Canopy

Cab

30ZV-2

3085 kg (6800 lb)

3245 kg (7154 lb)

40ZV-2A

3810 kg (8400 lb)

3970 kg (8752 lb)

4195 kg (9248 lb)

W4EK-02-01-006A

42ZV-2

4030 kg (8885 lb)

4

2. Place a hydraulic jack on both sides of front chassis (4).

Raise front chassis (3).

Insert stand (5) under front chassis (4) and set wheel stoppers (6) to the rear wheels.

Lower the bucket end on the ground.

Stop the engine.

3. Drain oil from the axle. (As for the details, refer to MAINTENANCE group, C. Power Train and 2.

Axle Oil section in the Operator's Manual.)

5

6 W4EK-03-03-002

W3-3-1

30_42ZV-2

TRAVEL SYSTEM / Axle Removal of Front Axle 1. Remove the front tires (2 used). (Refer to W3-1.)

Lifting Tool

2. Remove the propeller shaft. (Refer to W3-4.)

CAUTION: Front axle (7) weight: 131 kg (289 lb) 3. Hoist and hold front axle (7) by using a lifting tool.

7

W4EK-03-03-003

3

4. Remove nuts (9) (4 used), washers (8) (8 used) and bolts (10) (4 used) from front axle (7) and front chassis (3).

10

: 30 mm

8

8 9

7

W4EK-03-03-004

W3-3-2

30_42ZV-2

TRAVEL SYSTEM / Axle 5. Remove front axle (7) from front chassis (3).

Place front axle (7) on stand (11).

Remove front axle (7) from the chassis.

11

7

CAUTION: When a front axle (7) will be removed for a prolonged time, place stand (11) to the front axle (7) in a secured position. Stabilize the front chassis (3) in order to secure the machine.

W4EK-03-03-005

W3-3-3

30_42ZV-2

TRAVEL SYSTEM / Axle Installation of Front Axle

1. Place front axle (7) on stand (11).

Push front axle (7) to the mounting position at front chassis (3).

11

7

W4EK-03-03-005

Lifting Tool

CAUTION: Front axle (7) weight: 131 kg (289 lb) 2. Hoist front axle (7) to the mounting part in front chassis (3) by using a lifting tool.

7

W4EK-03-03-003

W3-3-4

30_42ZV-2

TRAVEL SYSTEM / Axle ®

3. Apply LOCTITE #262 onto bolt (10).

Install front axle (7) to front chassis (3) with bolts (10) (4 used), washers (8) (8 used) and nuts (9) (4 used).

3 10

: 30 mm : 418 to 460 N m 㸦42.6 to 46.9 kgf m, 31.4 to 34.6 lbf ft)

8

8 9

7

W4EK-03-03-004

4. Install the propeller shaft. (Refer to W3-4.)

5. Install the front tires. (Refer to W3-1.)

4

CAUTION: Machine weight: Canopy

Cab

30ZV-2

3085 kg (6800 lb)

3245 kg (7154 lb)

40ZV-2A

3810 kg (8400 lb)

3970 kg (8752 lb)

42ZV-2

4030 kg (8885 lb)

4195 kg (9248 lb)

6. Start the engine and check for any oil leaks.

Raise the bucket.

Place a hydraulic jack on both sides of front chassis (4).

Raise front chassis (4).

Remove stand (5) under front chassis (4) and rear wheel stoppers (6).

5

6 W4EK-03-03-002

After completing the work, check the hydraulic oil level. (Refer to the Operator's Manual.)

W3-3-5

30_42ZV-2

TRAVEL SYSTEM / Axle (Blank)

W3-3-6

30_42ZV-2

TRAVEL SYSTEM / Axle REMOVAL AND INSTALLATION OF REAR AXLE

3

2

Preparation 1. Install articulation lock bar (2) to the front chassis (1) pin.

Secure with ring pin (3).

1

CAUTION: Machine weight: Canopy

Cab

30ZV-2

3085 kg (6800 lb)

3245 kg (7154 lb)

40ZV-2A

3810 kg (8400 lb)

3970 kg (8752 lb)

42ZV-2

4030 kg (8885 lb)

4195 kg (9248 lb)

W4EK-02-01-006A

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

3. Place a hydraulic jack on the rear side of rear chassis (5).

Raise rear chassis (5).

Insert stands (6, 7) under rear chassis (5) in order not to apply the machine weight excessively.

Lower the bucket on the ground.

Stop the engine.

5

7

6 W4EK-03-03-007

4. Drain oil from the axle. (As for the details, refer to MAINTENANCE group, C. Power Train and 2.

Axle Oil section in the Operator's Manual.)

W3-3-7

30_42ZV-2

TRAVEL SYSTEM / Axle

2

1

3

3 22

5

4

21 20

6 22 19

7 17

8 9

16

10

15

14 13

12

11

W4EK-03-03-009

123456-

Axle Bracket Bolt (4 Used) Washer (8 Used) Nut (4 Used) Rear Axle Rear chassis

7 - Washer (3 Used) 8 - Bolt (3 Used) 9 - Thrust Cap 10 - SEMS Bolt (6 Used) 11 - Lubrication Hose 12 - Thrust Washer

13 - Thrust Plate 14 - Thrust Washer 15 - Bushing 16 - Snap Ring 17 - Dust Seal

W3-3-8

19 - Lubrication Hose 20 - Bushing 21 - Snap Ring 22 - Dust Seal (2 Used)

30_42ZV-2

TRAVEL SYSTEM / Axle Removal of Rear Axle 1. Remove the engine hood. (Refer to W2-5.)

23

2. Remove bolts (27) (4 used for each), spring washers (26) (4 used for each) and washers (25) (4 used for each) from fenders (24) (2 used).

Remove fenders (24) (2 used) from hood base (23).

24

: 13 mm 3. Remove the rear tires (2 used). (Refer to W3-1.)

25 26

4. Remove the propeller shaft. (Refer to W3-4.)

27

5. Disconnect remote lubrication hoses (11, 19) (2 used).

W4EK-03-03-008

: 11 mm 6. Remove SEMS bolts (10) (6 used).

Remove thrust cap (9) from rear chassis (6). : 19 mm 7. Remove bolts (8) (3 used) and washers (7) (3 used).

Remove thrust washers (12), thrust plate (13) and thrust washers (14) from rear axle (5). : 19 mm

W3-3-9

30_42ZV-2

TRAVEL SYSTEM / Axle

2

1

3

3 22

5

4

21 20

6 22 19

7 17

8 9

16

10

15

14 13

12

11

W4EK-03-03-009

W3-3-10

30_42ZV-2

TRAVEL SYSTEM / Axle CAUTION: Rear axle (5) weight: 126 kg (278 lb) Axle bracket (1) weight: 13 kg (29 lb) Lifting Tool

8. Hoist and hold rear axle (5) and the axle bracket (1) assembly by using a lifting tool.

9. Remove nuts (4) (4 used), washers (3) (8 used) and bolts (2) (4 used) from rear axle bracket (1). : 24 mm

1

10. Remove rear axle (5) and axle bracket (1) assembly from rear chassis (6).

5

W4EK-03-03-010

11. Place rear axle (5) and axle bracket (1) assembly on stand (23).

Remove rear axle (5) and the axle bracket (1) assembly from the machine.

23

1

5

12. Remove dust seal (17) from the rear axle mounting hole.

13. Remove axle bracket (1) from rear axle (5).

14. Remove dust seals (22) (2 used) from the rear axle mounting hole on axle bracket (1).

W3-3-11

W4EK-03-03-011

30_42ZV-2

TRAVEL SYSTEM / Axle

6

7

2

16

15

9

10

3

1

7

3

8

4 22 Lip

21

11

20

5

14

Lip

13

12

Lip

W4EK-03-03-012

123456-

Axle Bracket Bolt (4 Used) Washer (8 Used) Nut (4 Used) Rear Axle Rear chassis

7 - Washer (3 Used) 8 - Bolt (3 Used) 9 - Thrust Cap 10 - SEMS Bolt (6 Used) 11 - Lubrication Hose 12 - Thrust Washer

13 - Thrust Plate 14 - Thrust Washer 15 - Bushing 16 - Snap Ring 17 - Dust Seal

W3-3-12

18 - Dust Seal 19 - Lubrication Hose 20 - Bushing 21 - Snap Ring 22 - Dust Seal

30_42ZV-2

TRAVEL SYSTEM / Axle Installation of Rear Axle 1. Install dust seals (22) (2 used) to axle bracket (1).

Crimp axle bracket (1) side by using a punch at the places where the circumference of axle bracket (1) is evenly divided into three.

IMPORTANT: Install dust seal (17) with the lip side surface facing outside.

2. Install axle bracket (1) to rear axle (5).

3. Install dust seal (17) to the rear axle mounting hole on rear chassis (6).

Crimp the rear chassis side by using a punch at the places where the circumference of the rear chassis is evenly divided into three.

IMPORTANT: Install dust seal (17) with the lip side surface facing outside.

CAUTION: Rear axle (5) weight: 126 kg (278 lb) Axle bracket (1) weight: 13 kg (29 lb)

Lifting Tool

4. Hoist rear axle (5) and the rear axle bracket (1) assembly to the rear chassis (6) mounting part by using a lifting tool.

1

5

W4EK-03-03-010

W3-3-13

30_42ZV-2

TRAVEL SYSTEM / Axle

6

7

2

16

15

9

10

3

1

7

3

8

4 22 Lip

21

11

20

5

Lip

14 Lip

W3-3-14

13

12 W4EK-03-03-012

30_42ZV-2

TRAVEL SYSTEM / Axle 5. Insert rear axle (5) of rear chassis (6) to the rear axle mounting hole. ®

6. Apply LOCTITE #262 onto bolts (2) (4 used).

Install axle bracket (1) to rear chassis (6) with bolts (2) (4 used), washers (3) (8 used) and nuts (4) (4 used). : 24 mm : 188 to 229 N m (19.2 to 23.4 kgf m, 138.7 to 169 lbf ft) ®

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

Install thrust washer (14), thrust plate (13) and thrust washer (12) to rear axle (5) with bolts (8) (3 used) and washer (7). : 19 mm : 101 to 126 N m (10.3 to 12.5 kgf mm, 74.5 to 92.9 lbf ft) IMPORTANT: Fill thrust cap (9) with grease. If grease is insufficient, grease does not enter bushing (15) and squeak may occur.

8. Install thrust cap (9) to rear chassis (6) with SEMS bolts (10) (6 used).

23

24

: 19 mm 9. Connect remote lubrication hoses (11, 19) at the back and front of rear axle (5). : 11 mm

25 26 27

10. Install fenders (24) (2 used) to hood base (23) with bolts (27) (4 used), spring washers (26) (4 used for each) and washers (25) (4 used for each).

W4EK-03-03-008

: 13 mm

W3-3-15

30_42ZV-2

TRAVEL SYSTEM / Axle DISASSEMBLY AND ASSEMBLY OF AXLE

2 1

3 4 5 6

6

5 4

W4EK-03-03-013

1 - Differential Assembly 2 - Final Drive Assembly

3 - Final Drive Assembly 4 - Bolt (22 Used)

5 - Washer (22 Used)

W3-3-16

6 - Pin (4 Used)

30_42ZV-2

TRAVEL SYSTEM / Axle Disassembly of Axle

Assembly of Axle ®

1. Apply LOCTITE FMD-127 onto the mounting surface on differential assembly (1).

CAUTION: Front axle weight: 131 kg (289 lb) Rear axle weight: 126 kg (278 lb)

®

1. Remove bolts (4) and washers (5) (11 used for each) from final drive assemblies (2, 3) (2 used).

Separate the axle into differential assembly (1) and final drive assemblies (2, 3) (2 used). : 19 mm

IMPORTANT: Apply LOCTITE onto the inside of the bolt hole on the final drive assemblies (2, 3) mounting surface side in order not to intermit on the bead width [from 2 to 3 mm (0.07 to 0.12 in)].

2. Align the pin hole on final drive assembly (2) with pin (5) (2 used for each) in differential assembly (1) and install with bolts (4) (11 used). : 19 mm : 98 N m (10 kgf m, 72.3 lbf ft)

W3-3-17

30_42ZV-2

TRAVEL SYSTEM / Axle DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY

OF

5 6

1

4

3

36, 35, 34, 33, 32

41

28 39 42 40 43

2

44 29

30

31

38

37

W4EK-03-03-014

123456-

Differential Case Assembly Pinion Gear Differential Body Cover Flange Bolt (16 Used) Spring Washer (16 Used)

29 - Nut 30 - Washer 31 - O-Ring 32 - Shim [Thickness 1.0 mm (0.039 in)] 33 - Shim [Thickness 0.5 mm (0.019 in)] 34 - Shim [Thickness 0.25 mm (0.009 in)]

W3-3-18

35 - Shim [Thickness 0.2 mm (0.007 in)] 36 - Shim [Thickness 0.1 mm (0.003 in)] 37 - Bolt (6 Used) 38 - Washer (6 Used) 39 - Bearing Cage

40 - Bearing 41 - Bearing 42 - Spacer 43 - Oil Seal 44 - Flange

30_42ZV-2

TRAVEL SYSTEM / Axle Removal of Drive Pinion CAUTION: The differential assembly weight: 45 kg (99 lb) 1. Remove flange bolts (5) and washers (6) (16 used for each) from cover (4).

Remove cover (4) from differential gear body (3). : 13 mm NOTE: Check for the tooth contact and backlash of ring gear (1) in the differential case assembly.

2. Place the differential assembly onto a workbench with the drive pinion (2) side facing upward.

3. Remove nut (29), washer (30) and O-Ring (31) from drive pinion (2).

4. Remove flange (44) from drive pinion (2) by using a gear puller.

44 39

W4EK-03-03-015

37

5. Remove bolt (37) and washer (36) from bearing housing (39).

Install bolt (37) in the jack screw holes (2 places) on bearing housing (39).

Remove bearing housing (39) from differential body (3) while evenly tightening bolt (37).

6. Remove pinion gear (2) from bearing housing (39) with a press.

7. Remove oil seal (43) and the outer bearings (40, 41) from bearing housing (39).

2 39

3

W4EK-03-03-016

8. Remove the inner races of bearings (40, 41) and spacer (42) from pinion gear (2).

W3-3-19

30_42ZV-2

TRAVEL SYSTEM / Axle

3

5, 6

4

1

28

41

38 37

42

39

40

31

43

30

29

2

44

W4EK-03-03-017

123456-

Differential Case Assembly Pinion Gear Differential Body Cover Flange Bolt (16 Used) Spring Washer (16 Used)

29 - Nut 30 - Washer 31 - O-Ring 32 - Shim [Thickness 1.0 mm (0.039 in)] 33 - Shim [Thickness 0.5 mm (0.019 in)] 34 - Shim [Thickness 0.25 mm (0.009 in)]

W3-3-20

35 - Shim [Thickness 0.2 mm (0.007 in)] 36 - Shim [Thickness 0.1 mm (0.003 in)] 37 - Bolt (6 Used) 38 - Washer (6 Used) 39 - Bearing Cage

40 - Bearing 41 - Bearing 42 - Spacer 43 - Oil Seal 44 - Flange

30_42ZV-2

TRAVEL SYSTEM / Axle Installation of Drive Pinion 1. Install the outer races of bearings (40, 41) (2 places) to bearing cage (39).

2. Install the inner race of bearing (41) and spacer (42) to pinion gear (2).

Install the inner race of bearing (40) to pinion gear (2).

3. Install pinion gear (2) onto bearing cage (39).

A

4. Install the inner races of bearing (40) to pinion gear (2) by using special tool (A).

After installing, check if bearing cage (39) rotates smoothly without looseness.

40 39

2

W4EK-03-03-018

5. Apply grease onto the inner surface of oil seal (43) and apply liquid seal onto the outer surface of oil seal (43).

Install oil seal (43) to bearing cage (39).

NOTE: If a warp is found on the seal part of the oil seal (43) inner surface, move flange (44) back and forth several times in order to remove the warp.

W3-3-21

30_42ZV-2

TRAVEL SYSTEM / Axle

3

5, 6

4

1

28

41

38 37

42

39

40

31

43

30

29

2

44

W4EK-03-03-017

W3-3-22

30_42ZV-2

TRAVEL SYSTEM / Axle 6. Apply grease onto the mounting parts of pinion gear (2) and flange (44).

Engage pinion gear (2) and flange (44).

Install O-Ring (31) and washer (30) to flange (44) with nut (29).

Apply LOCTITE #262 or equivalent onto nut (29).

44

: 36 mm : 245.5 N m (25 kgf m, 181 lbf ft) 39

7. Attach a spring balance to the bolt hole on bearing cage (39).

Measure the preload of bearing while holding flange (44) by hand.

If the measured value is 20 N (2 kgf, 4.4 lbf), the preload is normal.

Apply grease onto O-Ring (28).

Install O-Ring (28) to bearing cage (39).

W4EK-03-03-019

Head

8. Install the original quantity of shims (32, 33, 34, 35 and 36) to differential body (3).

Install with bolts (37) with the groove on bearing cage (39) facing as illustrated below.

Tail W4EK-03-03-027

W3-3-23

30_42ZV-2

TRAVEL SYSTEM / Axle

7

9

Differential Case Assembly

20

10

3

11

11

10

12, 13, 14, 15, 16

20

12, 13, 14, 15, 16

9

7

W4EK-03-03-021

3 - Differential Body

10 - Bolt (12 Used)

7 - Gear and Shaft

11 - Spring Washer (12 Used)

9 - Bearing Retainer

12 - Shim [Thickness 1.0 mm (0.039 in)]

13 - Shim [Thickness 0.5 mm (0.019 in)] 14 - Shim [Thickness 0.25 mm (0.009 in)] 15 - Shim [Thickness 0.2 mm (0.007 in)]

W3-3-24

16 - Shim [Thickness 0.1 mm (0.003 in)] 19 - Bolt (6 Used) 20 - Bearing (2 Used)

30_42ZV-2

TRAVEL SYSTEM / Axle Removal of Differential Case Assembly

Installation of Differential Case Assembly

1. Remove gears and shafts (7) (2 used) from the differential case assembly.

1. Install the outer race of bearing (20) to bearing retainer (9).

IMPORTANT: When removing bearing retainer (9), the differential case assembly may be removed from differential body (3).

2. Install the differential case assembly to differential body (3).

Temporary install shims (12, 13, 14, 15 and 16) to bearing retainers (9) (2 used) with bolt (10).

2. Remove bolt (10) and washer (11) from bearing retainers (9) (2 used).

Install bolts (10) (2 used) to the pulling out hole (2 places) on bearing retainer (9).

Remove on bearing retainer (9) from differential body (3) while evenly tightening bolts (10) (2 used).

Remove the other side in the same way. : 13 mm

: 13 mm NOTE: Install the same number of shim (17) (thickness) before disassembling.

3. Adjust shims (12, 13, 14, 15 and 16) in order to remove looseness of the axle direction of the differential case assembly and install with bolt (10). : 13 mm

3. Remove shims (12, 13, 14, 15 and 16) and the outer race of bearing (20) from bearing retainer (9).

4. Remove the differential case assembly from differential body (3).

(Refer to the disassembly and assembly of differential case assembly.)

W3-3-25

NOTE: Shim Thickness: (12) 0.1 mm (0.003 in), (13) 0.2 mm (0.007 in), (14) 0.25 mm (0.009 in), (15) 0.5 mm (0.019 in) and (16) 1.0 mm (0.039 in) 4. Install gears and shafts (7) (2 used) to the differential case assembly.

30_42ZV-2

TRAVEL SYSTEM / Axle

25

23

21

24 24 22

26

27

1 24 19 22 20 24

21

23

20

W4EK-03-03-022

1 - Ring Gear 20 - Bearing (2 Used) 21 - Side Gear (2 Used)

22 - Pinion Gear (4 Used) 23 - Thrust Washer (2 Used)

24 - Thrust Washer (4 Used) 25 - Differential Case (A)

W3-3-26

26 - Differential Case (B) 27 - Spider

30_42ZV-2

TRAVEL SYSTEM / Axle Disassembly of Differential Case Assembly

Installation of Differential Case Assembly

1. Put the matching marks on differential case A (25) and differential case B (26).

1. Install the inner races of bearings (20) (2 used) to differential case A (25) and differential case B (26).

2. Remove bolts (19) (6 used) from ring gear (1).

Remove ring gear (1) from differential case B (26).

2. Install ring gear (1) to differential case B (26) with bolts (19) (6 used).

: 17 mm 3. Separate differential case A (25) and differential case B (26) by using a soft hammer.

4. Remove thrust washers (23) (2 used), thrust washers (24) (2 used), side gears (21) (2 used) and pinion gears (22) (4 used) from spider (27).

5. Remove the inner races of bearings (20) (2 used) from differential case A (25) and differential case B (26).

3. Place differential case B (26) with ring gear (1) side of differential case B (26) facing downward.

4. Install thrust washer (23) and side gear (21) (1 used for each) to differential case B (26).

5. Install pinion gears (22) and thrust washers (24) (4 used for each) to spider (27).

Install spider (27) to side gear (21) on differential case B (26) side.

Install side gear (21) (1 used) and thrust washer (23) (1 used) on differential case B (26). ®

6. Apply LOCTITE #262 onto bolts (19) (12 used).

Install differential case A (25) and differential case B (26) with bolts (19) (6 used for each) while aligning the matching marks. : 17 mm : 54.9 N m (5.6 kgf m, 40.5 lbf ft)

W3-3-27

30_42ZV-2

TRAVEL SYSTEM / Axle Adjustment Procedure After performing the disassembly and assembly of the differential assembly, adjust the tooth contact and backlash of ring gear (1) as followings.

1. Set a dial gauge onto the teeth outer of ring gear (1).

2. Secure flange (44) (drive pinion).

Rotate ring gear (1) forward and backward.

Measure the backlash.

The specification is from 0.09 to 0.13 mm (0.004 to 0.005 in).

If the backlash is not in the specification, adjust the backlash.

3. Increasing or decreasing quantity of right and left shims (12, 13, 14, 15 and 16) in order to adjust the backlash.

At this time, do not change the total number (thickness) of right and left shims.

1

4

W4EK-03-03-020

NOTE: Shim Thickness: (12) 0.1 mm (0.003 in), (13) 0.2 mm (0.007 in), (14) 0.25 mm (0.009 in), (15) 0.5 mm (0.019 in) and (16) 1.0 mm (0.039 in) When the backlash is above the acceptable range: Reduce the shim (thickness) on the ring gear (1) side.

Install the reduced shim to the opposite side.

Ring gear (1) closes to drive pinion (2) side and the tooth contact is increased.

When the backlash is below the acceptable range: Increase the shim on the ring gear (1) side to install.

Ring gear (1) gets away from drive pinion (2) side and the tooth contact is decreased.

W3-3-28

30_42ZV-2

TRAVEL SYSTEM / Axle (Blank)

W3-3-29

30_42ZV-2

TRAVEL SYSTEM / Axle DISASSEMBLY FINAL DRIVE

AND

17

ASSEMBLY

OF

16 1

4 6

3 2 15

15 13, 12, 11, 10, 9

8 7

19 5

W4EK-03-03-023

1 - Axle Tube

6 - Oil Seal (2 Used)

2 - Axle Tube

7 - Retainer Plate (2 Used)

3 - Axle Shaft

8 - Bolt (2 Used)

4 - Bearing (2 Used)

9 - Shim [Thickness 1.0 mm (0.039 in)] 10 - Shim [Thickness 0.5 mm (0.019 in)]

5 - Bearing (2 Used)

11 - Shim [Thickness 0.25 mm (0.009 in)] 12 - Shim [Thickness 0.2 mm (0.007 in)] 13 - Shim [Thickness 0.1 mm (0.003 in)] 15 - Pin (4 Used)

W3-3-30

16 - Ring Gear (2 Used) 17 - Pin (2 Used) 19 - Planet Carrier Assembly (2 Used)

30_42ZV-2

TRAVEL SYSTEM / Axle Disassembly of Axle Housing Assembly 1. Remove bolt (8) from axle shaft (3).

Remove retainer plate (7), shims (9, 10, 11, 12 and 13) and planet carrier assembly (19). : 19 mm 2. Remove axle shaft (3) from axle tube (1) by using a soft hammer.

CAUTION: Axle shaft weight: 12 kg (26 lb) 3. Remove the inner race of bearing (4) from axle shaft (3) by using the pulling out special tool and a press.

4. Remove oil seal (6) from axle shaft (3).

5. Remove the outer race of bearing (4) from axle tube (1).

6. Remove ring gear (16) from axle tube (1) by using a gear puller.

W3-3-31

30_42ZV-2

TRAVEL SYSTEM / Axle

2

15

19A

16 17

8

7

3

5

4

6

9, 10, 11, 12, 13

W4EK-03-03-027A

1 - Axle Tube

5 - Bearing (2 Used)

2 - Axle Tube

6 - Oil Seal (2 Used)

3 - Axle Shaft

7 - Retainer Plate (2 Used)

4 - Bearing (2 Used)

8 - Bolt (2 Used)

9 - Shim [Thickness 1.0 mm (0.039 in)] 10 - Shim [Thickness 0.5 mm (0.019 in)] 11 - Shim [Thickness 0.25 mm (0.009 in)] 12 - Shim [Thickness 0.2 mm (0.007 in)]

W3-3-32

13 - Shim [Thickness 0.1 mm (0.003 in)] 15 - Pin (4 Used) 16 - Ring Gear (2 Used) 17 - Pin (2 Used)

30_42ZV-2

TRAVEL SYSTEM / Axle Assembly of Axle Housing

9. Measure step (Y) between the axle shaft (3) end and planet carrier (19).

The specification is from 1.8 mm to 2.0 mm (0.07 to 0.08 in).

Select the shims so that the total thickness of shims is 0.15 mm to 0.20 mm (0.006 to 0.008 in) shorter than step (Y).

1. Align the pin hole on axle tube (1) and install ring gear (16).

2. Install the inner races of bearings (4, 5) to axle shaft (3).

Install the outer race of bearing (4) to axle tube (1).

NOTE: Shim Thickness: (13) 0.1 mm (0.003 in), (12) 0.2mm (0.007 in), (11) 0.25 mm (0.009 in), (10) 0.5 mm (0.019 in) and (9) 1.0 mm (0.039 in)

3. Install oil seal (6) to axle tube (1).

Remove the sleeve of oil seal (6) and install axle tube (1) to axle shaft (3).

4. Hold axle tube (1) with the axle tube (1) wheel side facing upward.

19

5. Install axle shaft (3) to axle tube (1) by using a soft hammer.

6. Turn over assembled axle tube (1).

Hold assembled axle tube (1) with the differential side facing upward.

Y

3

7. Install the inner race of bearings (5) to axle shaft (3).

8. Temporary install planet carrier (19) to axle shaft (3) in order to adjust the preload of bearing (5).

W4EK-03-03-025

W4EK-03-03-026

W3-3-33

30_42ZV-2

TRAVEL SYSTEM / Axle

2

15

19A

16 17

8

7

3

5

4

6

9, 10, 11, 12, 13

W4EK-03-03-027A

W3-3-34

30_42ZV-2

TRAVEL SYSTEM / Axle 10. Temporary install selected shims (9, 10, 11, 12 and 13) and retainer plate (7) to planet carrier (19A) with bolt (8).

Under this condition, check that the bearing rotation is normal and there is no looseness of planet carrier (19A).

11. Attach a spring balance to the bolt hole on axle tube (1).

Secure axle shaft (3).

Measure the rotational resistance torque of bearings (4, 5) (2 used).

Adjust shims (9, 10, 11, 12 and 13) so that the specification is 3 to 5 kg.

12. After adjusting the rotational resistance torque of bearings (4, 5) (2 used), remove temporary installed planet carrier (19A).

NOTE: Assemble planet carrier (19A) in advance.

13. Install the planet carrier (19) assembly to axle tube (1). ®

14. Apply LOCTITE #262 onto bolt (8).

Install selected shims (9, 10, 11, 12 and 13) and retainer plate (7) to the planet carrier (19) assembly with bolt (8). : 19 mm Assemble the final drive assembly on the opposite side in the same way.

W3-3-35

30_42ZV-2

TRAVEL SYSTEM / Axle

5 4 2 4 5

7

1

3

6

W4EK-03-03-024

1 - Planet Carrier 2 - Planet Gear (3 Used)

3 - Shaft (3 Used) 4 - Needle Bearing (6 Used)

5 - Washer 6 - Snap Ring (3 Used)

W3-3-36

7 - Ball (3 Used)

30_42ZV-2

TRAVEL SYSTEM / Axle Disassembly of Planet Carrier Assembly

Installation of Planet Carrier Assembly

1. Remove snap ring (6) and anti-extraction ball (7) from shafts (3) (3 used).

Remove shaft (3) (3 places) from planet carrier (1).

Remove planet gear (2) and washers (5) (2 used for each).

1. Install needle bearings (4) (2 used) to planet gear (2).

NOTE: When removing shaft (3) (3 places), do not lose anti-extraction ball (7).

2. Install planet gear (2) and washes (5) (2 used) to planet carrier (1) (3 places) with shafts (3) (3 used) while aligning the shaft mounting hole on planet carrier (1).

3. Install ball (7) and O-Ring to shafts (3) (3 used).

2. Remove needle bearings (4) (2 used for each) from planet gear (2).

W3-3-37

30_42ZV-2

TRAVEL SYSTEM / Axle (Blank)

W3-3-38

30_42ZV-2

TRAVEL SYSTEM / Propeller Shaft REMOVAL AND INSTALLATION PROPELLER SHAFT

OF

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with link pin (3).

3

2

1

W4EK-02-01-006A

W3-4-1

30_42ZV-2

TRAVEL SYSTEM / Propeller Shaft Between Front Axle and Reduction Gear

1

3

2

4

5

B

A

2D

6

4D

2B

6

30ZV-2 Front Axle

Reduction Gear

2A

2C 6

2D

2B

2D

6

40ZV-2 A/42ZV-2 Front Axle

Reduction Gear

2C

2A

W4EK-03-04-002

1 - Front Axle 2 - Propeller Shaft 2A - Propeller Shaft 2䠞 - Spline Seal

2C - Grease Fitting 2D - Grease Fitting (2 Used) 3 - Reduction 4 - Propeller Shaft

5 - Rear Axle 6 - Bolt (8 Used) A - Lower Part of Front Chassis (Position of Stand)

B - Lower Part of Rear Chassis (Position of Stand)

W3-4-2

30_42ZV-2

TRAVEL SYSTEM / Propeller Shaft Removal (Between Front Axle and Reduction Gear)

Installation (Between Front Axle and Reduction Gear)

1. Remove grease fitting (2C) from propeller shaft (2).

Position propeller shaft (2) in order to drain the internal grease.

IMPORTANT: Align the flanges of front propeller shaft (2) and rear propeller shaft (4).

Install front propeller shaft (2) and rear propeller shaft (4) with the grease fittings of front propeller shaft (2) and rear propeller shaft (4) facing to the same side.

At this time, lift the machine so that the tires can turn.

IMPORTANT: Do not separate and remove propeller shaft (2).

If separating and removing propeller shaft (2), as spline seal (2B) may be damaged, remove as an assembly.

2. Remove bolts (1) (4 used for each) from both ends of propeller shaft (2).

3. Remove propeller shaft (4) from the machine.

IMPORTANT: 30ZV-2: Install the spline shaft (2B) side facing to front axle (1) side.

40ZV-2A/42ZV-2: Install the spline shaft (2B) side facing to the reduction (3) side. ®

1. Apply LOCTITE #262 onto bolts (6) (8 used).

Install propeller shaft (2) to the flanges of the front axle and the reduction gear with bolts (6) (4 used for each). : 17 mm : 113 to 123 N m (11.5 to 12.5 kgf m, 83.4 to 90.7 lbf ft) 2. Install grease fitting (2C) to propeller shaft (2).

Apply grease through grease fittings (2C, 2D).

W3-4-3

30_42ZV-2

TRAVEL SYSTEM / Propeller Shaft Between Reduction Gear and Rear Axle

3

2

1

A

4

5

B

6

4A

4B

W4EK-03-04-002A

1 - Front Axle 2 - Propeller Shaft 3 - Reduction

4 - Propeller Shaft 4A - Propeller Shaft 4B - Grease Fitting (2 Used)

5 - Rear Axle 6 - Bolt (8 Used) A - Lower Part of Front chassis (Position of Stand)

W3-4-4

B - Lower Part of Rear chassis (Position of Stand)

30_42ZV-2

TRAVEL SYSTEM / Propeller Shaft Removal (Between Reduction Gear and Rear Axle)

Installation (Between Transmission and Rear Axle)

1. Remove bolts (6) (4 used for each) from both ends of propeller shaft (4).

IMPORTANT: Align the flanges of front propeller shaft (2) and rear propeller shaft (4).

Install front propeller shaft (2) and rear propeller shaft (4) with the grease fittings of front propeller shaft (2) and rear propeller shaft (4) facing to the same side.

At this time, lift the machine so that the tires can turn.

2. Remove propeller shaft (4) from the machine.

®

1. Apply LOCTITE #262 onto bolts (6) (8 used).

Install propeller shaft (4) to the flanges of the reduction and the rear axle with bolts (6) (4 used for each). : 13 mm : 30 to 36 N m (3.04 to 3.72 kgf m, 22.1 to 26.5 lbf ft) 2. Apply grease through grease fitting (4B).

W3-4-5

30_42ZV-2

TRAVEL SYSTEM / Propeller Shaft (Blank)

W3-4-6

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder REMOVAL AND INSTALLATION MASTER CYLINDER

OF

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

1

W4EK-02-01-006A

W3-5-1

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder Removal 1. Loosen hose clamp (3).

Disconnect hose (2) from master cylinder (1).

2. Disconnect hose (4) from master cylinder (1).

Cap the open ends. : 7 mm, 19 mm

1 3

2

4

W4EK-03-05-007

3. Remove snap pin (8), washer (7) and pin (5).

Remove yoke (6) from brake pedal (9).

4. Remove nuts (11), spring washers (12) and bolts (10) (2 used for each).

Remove master cylinder (1) from steering support (14).

9

5

6

7

8

: 13 mm 5. Loosen nut (13).

Remove yoke (6) from master cylinder (1).

13

: 13 mm

14 12 11

10 1

W4EK-03-05-008

W3-5-2

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder Installation 1. Temporary install yoke (6) to master cylinder (1).

9

: 13 mm

2. Install master cylinder (1) to steering support (14) with bolts (10), spring washers (12) and nuts (11) (2 used for each).

5

6

: 13 mm : 24.5 to 28.4 N m (2.5 to 2.9 kgf m, 18.0 to 20.6 lbf ft)

7

8

13

3. Install yoke (6) so that dimension A of brake pedal (9) and the master cylinder (1) connected parts is 5 mm. Tighten nut (13). : 13 mm : 23 to 28 N m (2.3 to 2.9 kgf m, 16.9 to 20.6 lbf ft)

14 10

12 11

1

W4EK-03-05-008

4. Connect hose (4) to master cylinder (1). : 17 mm, 19 mm : 24.5 to 28.4 N m (2.5 to 2.9 kgf m, 18.0 to 20.6 lbf ft) 5. Connect hose (2) to master cylinder (1) with hose clamp (3).

1 3

: 3.4 N m (0.35 kgf m, 2.50 lbf ft)

2

4

6. Align yoke (6) with the mounting hole on brake pedal (9) and install yoke (6) with pin (5), washer (7) and snap pin (8).

W4EK-03-05-007

W3-5-3

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder Assembly Standard Pedal Rubber

Adjust dimension A (fully up) with stopper bolt (20) so that dimension A is 192 ± 5 mm (7.56 ± 0.20 in).

9 (Pedal Bottom End)

E

Check for dimensions A, Y and Z after bleeding air from the brake.

Dimension A (free up): 2 ± 5 mm (7.56 ± 0.20 in).

Dimension Y (when the brake begins to be applied.)

10 mm (0.39 in).

Dimension Z (fully applied): 160 mm (6.30 in) or more.

B

Z

A

Y

Reference: Dimension B: 5 mm (0.20 in).

Dimension E:150 mm (5.91 in).

12 Inching Valve Lever

NOTE: There are three holes with the inching valve lever. Connect rod end (12) to the hole at the center.

W4EK-03-05-010

22

Installation and Adjustment of Brake Light Switch Adjust brake light switch (22) mounting positions (G, H).

Tighten attached lock nut (23).

H

: 19 mm : 7.8 to 9.8 N m (0.8 to 1.0 kgf m, 0.03 to 0.04 lbf ft)

20

G

23

Reference: Dimension G: 42 mm (1.65 in) Dimension H: within 10 ~ 15 mm (0.39~ 0.59 in)

W4EK-03-05-011

W3-5-4

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder (Blank)

W3-5-5

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder DISASSEMBLY AND MASTER CYLINDER

ASSEMBLY

OF

4 7 6 5

2 1

8

3 9

W4EK-03-05-009

1 - Cylinder 2 - Piston Assembly 3 - Snap Ring

4 - Filler Union 5 - Clamp

6 - Bleeder Valve 7 - Cap

W3-5-6

8 - Rod 9 - Boot

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder Disassembly

Assembly

1. Remove rod (8) and boot (9) from cylinder (1).

IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

2. Remove snap ring (3) from cylinder (1).

NOTE: When removing snap ring (3), remove piston assembly (2) while pushing rod (8).

3. Remove piston assembly (2) from cylinder (1).

4. Remove clamp (5) from filler union (4).

Remove filler union (4) from cylinder (1).

1. Install bleeder valve (6) to cylinder (1).

2. Apply sealant onto filler union (4).

Connect filler union (4) to cylinder (1) with clamp (5). : 1.95 to 2.94 N m (20 to 30 kgf m, 1.44 to 2.16 lbf ft)

5. Remove bleeder valve (6) from cylinder (1).

3. Install piston assembly (2) to cylinder (1).

4. Install snap ring (3) to cylinder (1).

NOTE: When installing snap ring (3), install piston assembly (2) while pushing with rod (8).

5. Install rod (8) and boot (9) to cylinder (1).

W3-5-7

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder BLEEDING AIR FROM BRAKE SYSTEM When brake oil is drained, or when the removal and installation of the master cylinder or the parking brake solenoid is done, bleed air from the brake system by doing the following procedures.

IMPORTANT: If the brake is applied with air mixed in the brake system, the braking force may be reduced or operational failure may occur.

IMPORTANT: Regarding adding brake oil, use the same type of oil (mineral oil series), listed in MAINTENANCE / Kinds of Grease in the Operator's Manual.

When using other oil (such as vegetable oil series), or brake operation failure or the malfunction will occur.

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

W3-5-8

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder Procedures 2

1

1. Insert transparent vinyl tube (2) to bleeder screw (1).

Put the other one end into the clean container so that brake oil does not spray out.

W4EK-03-05-004

2. Depress the brake pedal (3) several times.

Loosen bleeder screw (1) from half turn to one turn with the pedal depressed.

Drain brake oil and trapped air.

3

3. Tighten bleeder screw (1).

Release brake pedal (3).

4. Repeat step 2 and step 3 until clean brake oil flows in vinyl hose (2) and bubbles disappear completely.

5. When bubbles completely disappear in the hose, tighten bleeder screw (1) with brake pedal (3) depressed.

W4EK-03-05-005

6. After bleeding air, adjust the brake oil level in brake oil tank (4).

When the brake oil level is within MIN to MAX, the amount of brake oil is proper.

4

W4EK-03-05-002

W3-5-9

30_42ZV-2

TRAVEL SYSTEM / Master Cylinder (Blank)

W3-5-10

30_42ZV-2

TRAVEL SYSTEM / Parking Brake Solenoid REMOVAL AND INSTALLATION PARKING BRAKE SOLENOID

OF

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

4. Remove the inspection cover. (Refer to W2-1-6.)

1

W4EK-02-01-006A

W3-6-1

30_42ZV-2

TRAVEL SYSTEM / Parking Brake Solenoid Removal 1. Disconnect connector of the parking brake solenoid (1) harness.

2

2. Disconnect hoses (2, 3 and 4) from parking brake solenoid (1).

Cap the open ends.

3

: 17 mm, 19 mm

4

1

W4EK-03-06-004

1

3. Remove bolts (5) (2 used) and spring washers (6) (2 used).

Remove parking brake solenoid (1) and plate (8) from rear chassis (7).

7 5

6

: 17 mm 4. Remove bolts (10) (2 used) and spring washers (9) (2 used).

Remove parking brake solenoid (1) from plate (8).

10

9 8

: 13 mm

W4EK-03-06-005

W3-6-2

30_42ZV-2

TRAVEL SYSTEM / Parking Brake Solenoid Installation 1

1. Install parking brake solenoid (1) to plate (8) with bolts (10) (2 used) and spring washers (9) (2 used).

7 5

6

: 13 mm : 9.2 to 11.1 N m (0.94 to 1.14 kgf m, 6.79 to 8.19 lbf ft) 10

9

2. Install plate (2) with parking brake solenoid (1) to rear chassis (7) with bolts (5) (2 used) and spring washers (6) (2 used).

8

: 17 mm

W4EK-03-06-005

3. Connect hoses (2, 3 and 4) to parking brake solenoid (1).

2

: 17 mm, 19 mm 3

4. Connect connector of the parking brake solenoid (1) harness.

4

1

W4EK-03-06-004

W3-6-3

30_42ZV-2

TRAVEL SYSTEM / Parking Brake Solenoid (Blank)

W3-6-4

30_42ZV-2

TRAVEL SYSTEM / Inching Valve REMOVAL AND INCHING VALVE

INSTALLATION

OF

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

Stop the engine.

Lower the bucket level to the ground.

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

W4EK-03-04-001

2. Install articulation lock bar (2) to the front chassis (1) pin.

Secure with link pin (3).

3

2

1

W4EK-02-01-006A

W3-7-1

30_42ZV-2

TRAVEL SYSTEM / Inching Valve Removal 1. Remove nut (2) and spring washer (1) from rod end (3). : 13 mm 2. Disconnect hoses (5, 6) (2 places) from inching valve (4). : 22 mm 3. Remove socket bolts (8) (2 used) from inching valve (4).

Remove inching valve (4) from steering support (7). : 6 mm

Y

7 3

1

Y

2

4

8 5 6

W4EK-03-07-001

W3-7-2

30_42ZV-2

TRAVEL SYSTEM / Inching Valve Installation 1. Align the mounting holes on steering support (7) and inching valve (4).

Install with socket bolts (8) (2 places). : 6 mm : 29.8 to 36.5 N m (3.0 to 3.7 kgf m, 21.9 to 26.9 lbf ft) 2. Connect hoses (5, 6) (2 places) to inching valve (4). : 22 mm

Y

3. Align rod end (3) with the mounting hole on inching valve (4).

Install with nut (2) and spring washer (1). : 13 mm : 23 to 28 N m (2.3 to 2.9 kgf m, 16.9 to 20.6 lbf ft)

7 3

1

Y

2

4

8 5

IMPORTANT: After the completion of installation, adjust the inching valve (4) lever position. (Refer to W3-5-5.)

6

W4EK-03-07-001

W3-7-3

30_42ZV-2

TRAVEL SYSTEM / Inching Valve DISASSEMBLY AND INCHING VALVE

10

ASSEMBLY

OF

3

7

2 A

A

9 8

6

5

4

SECTION AA

1

W4EK-03-07-003

1 - Body 2 - Shaft 3 - Spring Pin

4 - Shim 5 - Snap Ring 6 - Plug

7 - O-Ring 8 - O-Ring

W3-7-4

9 - Lever 10 - Socket Bolt

30_42ZV-2

TRAVEL SYSTEM / Inching Valve Disassembly

Assembly

1. Remove socket bolt (10) from lever (9).

Remove lever (9) and spring pin (3) from shaft (2).

1. Install O-ring (8) to body (1).

2. Install O-ring (7) to shaft (2).

: 4 mm 2. Remove snap ring (5) and shim (4) from shaft (2).

Remove shaft (2) from body (1).

3. Install shaft (2) to body (1).

Install shim (4) and snap ring (5) to shaft (2).

4. Install spring pin (3) and lever (9) to shaft (2) with socket bolt (10).

3. Remove O-ring (7) from shaft (2).

4. Remove O-ring (8) from body (1).

: 4 mm

W3-7-5

30_42ZV-2

TRAVEL SYSTEM / Inching Valve (Blank)

W3-7-6

30_42ZV-2

TRAVEL SYSTEM / Power Steering REMOVAL ORBITROL

AND

INSTALLATION

OF

CAUTION: In order to release the hydraulic pressure in the steering hydraulic circuit, stop the engine and turn the steering wheel to the right and the left several times. The steering wheel turns heavily when the hydraulic pressure is released.

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

Stop the engine and release the hydraulic pressure.

Lower the bucket level to the ground.

2. Place a wheel stopper in front of and behind the axle in order to secure the machine.

W4EK-03-04-001

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

Secure with ring pin (3).

3

2

1

W4EK-02-01-006A

W3-8-1

30_42ZV-2

TRAVEL SYSTEM / Power Steering Removal 1. Remove bolt (1), spring washer (2), pipe (3), plate (4), rubbers (5) (2 used) and hoses (6, 13) (2 used) from the operator frame.

2

: 17 mm

3

4

5

1

2. Disconnect hoses (8, 9, 10, 11 and 12) (5 places) ® from Orbitrol (7).

Cap the open ends.

7

6

: 17 and 19 mm 19 and 22 mm 22 and 27 mm

9

13

12

10

8

11

W4EK-03-08-002

3. Remove bolts (19) (6 used) and washers (14) (6 used).

Remove cover (15) from steering support (16). : 5 mm 19

4. Remove SEMS bolts (18) (3 used). ® Remove Orbitrol (7) from steering column (17).

14

15

17 16

: 17 mm

18

7

W4EK-03-08-001

W3-8-2

30_42ZV-2

TRAVEL SYSTEM / Power Steering Installation ®

1. Install Orbitrol (7) to steering column (17) with SEMS bolts (18) (3 used). : 17 mm 19

2. Install cover (15) to steering support (16) with bolts (19) and washers (14) (6 used).

14

15

17 16

: 5 mm

3. Connect hoses (8, 9, 10, 11 and 12) (5 places) to ® Orbitrol (7).

18

: 17 and 19 mm 19 and 22 mm 22 and 27 mm 7

4. Secure hoses (6, 13) (2 used) to the operator frame with bolt (1), spring washer (2), pipe (3), plate (4) and rubbers (5) (2 used).

W4EK-03-08-001

: 17 mm 2

3

4

5

1

7

6

9

13

12

10

8

11

W4EK-03-08-002

W3-8-3

30_42ZV-2

TRAVEL SYSTEM / Power Steering DISASSEMBLY OF ORBITROL

20

5

3

2

1

A

12 15 16 14 8

4

9

8

A

01

02

13

10

11

10

7

6

18

17

SECTION AA

W4EK-03-08-003

01 - Housing 02 - Spool and Sleeve Assembly 1 - Screw (7 Used) 2 - Cap 3 - Rotor

456789-

Spacer Plate Drive Pin Center Spring (4 Used) Flat Spring (2 Used)

10 - Bearing Race (2 Used) 11 - Thrust Needle 12 - O-Ring 13 - Oil Seal 14 - Dust Seal

W3-8-4

15 - Retaining Ring 16 - Bushing 17 - O-Ring (2 Used) 18 - O-Ring 20 - Ball

30_42ZV-2

TRAVEL SYSTEM / Power Steering Disassembly IMPORTANT: Attach a cloth to the open end of a ® vise and hold the Orbitrol lightly. Do not hold it too strong.

IMPORTANT: Wear a pair of protective glasses as retaining ring (15) may fly out from housing (01).

1. Secure housing (01) with the cap (2) side facing upward in a vise.

5. Remove housing (01) from the vise.

Turn over housing (01). Remove ball (20).

Place housing (01) on a clean cloth in order not to damage the finished surface.

Remove retaining ring (15) from housing (01) by using a screwdriver.

2. Remove screws (1) (7 used) from caps (2).

Remove cap (2) from housing (01).

Remove O-ring (17) from cap (2).

3. Remove rotor (3) from housing (01).

Remove spacer (4) and O-ring (17) from rotor (3).

15

NOTE: Do not drop star (3A) in rotor (3) when removing rotor (3).

02

01

4. Remove drive (6) and plate (5) from housing (01).Remove O-ring (18) from housing (01).

17

W4EK-03-08-004

NOTE: Do not drop or lose ball (20). Check the hole position where ball (20) was installed.

1

17 5 18 2 4 3 3A

W4EK-03-08-006

20

W3-8-5

W4EK-03-08-007

30_42ZV-2

TRAVEL SYSTEM / Power Steering

20

A

5

3

2

1

12 15 16 14 8

4

9

8

A

01

02

13

10

11

10

7

6

SECTION AA

18

17

W4EK-03-08-003

W3-8-6

30_42ZV-2

TRAVEL SYSTEM / Power Steering 6. Rotate spool and sleeve assembly (02), and set pin (7) horizontally.

Push spool and sleeve assembly (02) from the cap (2) side.

Remove seal grand bushing (17) from housing (01).

7. Remove oil seal (13) and dust seal (14) from seal grand bushing (16).

IMPORTANT: Wear a pair of protective glasses as center spring (8) and flat spring (9) may fly out.

11. Push spool (02A) in sleeve (02B) forward.

Remove center springs (8) (4 used) and flat springs (9) (2 used) from spool (02A).

NOTE: Do not damage seal grand bushing (16) when removing oil seal (13).

8. Remove bearing races (10) (2 used) and thrust needle (11) from spool and sleeve assembly (02).

8

9

8

9. Remove spool and sleeve assembly (02) from housing (01).

NOTE: Remove spool and sleeve assembly (02) from housing (01) by rotating in order not to get sleeve (02B) caught in housing (01).

10. Remove pin (7) from spool and sleeve assembly (02).

02B

NOTE: Put the matching marks onto spool (02A) and sleeve (02B) by using an oil-based pen before removing pin (7).

02A

W4EK-03-08-010

12. Remove spool (02A) from sleeve (02B) by rotating.

7

13. Remove O-ring (12) from housing (01).

Matching Mark W4EK-03-08-009

W3-8-7

30_42ZV-2

TRAVEL SYSTEM / Power Steering ASSEMBLY OF ORBITROL

20

5

3

2

1

A

12 15 16 14 8

4

9

8

A

01

02

13

10

11

10

7

6

18

17

SECTION AA

W4EK-03-08-003

01 - Housing 02 - Spool and Sleeve Assembly 1 - Screw (7 Used) 2 - Cap 3 - Rotor

456789-

Spacer Plate Drive Pin Center Spring (4 Used) Flat Spring (2 Used)

10 - Bearing Race (2 Used) 11 - Thrust Needle 12 - O-Ring 13 - Oil Seal 14 - Dust Seal

W3-8-8

15 - Retaining Ring 16 - Bushing 17 - O-Ring (2 Used) 18 - O-Ring 20 - Ball

30_42ZV-2

TRAVEL SYSTEM / Power Steering Assembly

8

IMPORTANT: Set the spring grooves on spool (02A) and sleeve (02B) to the same side.

9 8

1. Install spool (02A) to sleeve (02B) by rotating.

Align match marks on spool (02A) and sleeve (02B).

02A ST2497

Spring Groove

02A 02B

02B

W4EK-03-08-011

Matching Mark W4EK-03-08-013

IMPORTANT: Wear a pair of protective glasses as center spring (8) and flat spring (9) may fly out.

2. Align the spring groove positions of spool (02A) and sleeve (02B), and place them on a flat plate.

Set center springs (8) (2 used for each) back-to-back.

Set flat springs (9) (2 used) at the center position and install to the special tool (ST2497).

Install center springs (8) (4 used) and flat springs (9) (2 used) to the spring grooves on spool (02A) and sleeve (02B) by using the special tool (ST 2497).

W3-8-9

3. Insert pin (7) into the holes on spool (02A) and sleeve (02B).

Align both ends of pin (7) with the outer diameter surface of sleeve (02B).

4. Insert spool and sleeve assembly (02) from the cap (2) side of housing (01).

NOTE: When inserting spool and sleeve assembly (02), do not get caught in housing (01).

Rotate pin (7) to the right and the left while holding pin (7) horizontally.

Insert pin (7) until both rear end surfaces of spool and sleeve assembly (02) and housing (01) are located in the same position.

30_42ZV-2

TRAVEL SYSTEM / Power Steering

20

5

3

2

1

A

12 15 16 14 8

4

9

8

A

01

02

13

10

11

10

7

6

SECTION AA

18

17

W4EK-03-08-003

W3-8-10

30_42ZV-2

TRAVEL SYSTEM / Power Steering 5. Install O-rings (12), bearing races (10) (2 used) and thrust needle (11) to housing (01).

IMPORTANT: Wear a pair of protective glasses as retaining ring (15) may fly out from housing (01).

6. Install oil seal (13) and dust seal (14) to seal grand bushing (16).

9. Secure housing (01) in a vise lightly.

7. Insert seal grand bushing (16) into spool (02A) by tapping lightly by using a plastic hammer.

10. Install O-ring (18) to housing (01).

Install ball (20) to housing (01) as illustrated below.

Place plate (5) onto housing (01).

NOTE: Check that seal grand bushing (16) comes in contact with bearing race (10) evenly.

NOTE: Do not drop or lose ball (20).

8. Install retaining ring (15) to housing (01).

NOTE: After installing retaining ring (15), extend the inner diameter of retaining ring (15) by using a screwdriver in order to install retaining ring (15) correctly to the groove on housing (01).

02A

Screwdriver

15

01

16 14

20 W4EK-03-08-007

12

13

10 11 10

W4EK-03-08-014

W3-8-11

30_42ZV-2

TRAVEL SYSTEM / Power Steering

20

5

3

2

1

A

12 15 16 14 8

4

9

8

A

01

02

13

10

11

10

7

6

SECTION AA

18

17

W4EK-03-08-003

W3-8-12

30_42ZV-2

TRAVEL SYSTEM / Power Steering 11. Rotate spool and sleeve assembly (02) and set pin (7) and the port surface of housing (01) in parallel.

Put line B onto the spline side end so that line B is parallel to line C on the yoke part of drive (6).

Insert drive (6).

Assemble the yoke part of drive (6) and pin (7).

Set the line B on the spline side end in drive (6) and the port surface of housing (01) in parallel.

14. Insert spacer (4) into rotor (3).

Install O-ring (17) to cap (2).

Place cap (2) on rotor (3).

15. Install cap (2) to housing (01) with screws (1) (7 used). : 23 N m (2.3 kgf m, 16.9 lbf ft)

Line B

C

6

Yoke Part

W4EK-03-08-015

Port Surface

6 Set pin (7) and port surface in parallel

7

01 Yoke Part W4EK-03-08-016

Concave Part

12. Install O-ring (17) to rotor (3).

13. Face the O-ring (17) side of rotor (3) to the plate (5) side.

Install star (3A) while fitting the splines of star (3A) and drive (6) so that line A connecting the concave parts of star (3A) is parallel to line B on drive (6).

Check that the lines A, B, C and D are in parallel as illustrated in the right.

Fit the bolt holes on rotor (3) while mating drive (6) and star (3A).

3

A

3A B

6 5

7

Bolt Hole

C D

Port Surface W4EK-03-08-017

W3-8-13

30_42ZV-2

TRAVEL SYSTEM / Power Steering (Blank)

W3-8-14

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder REMOVAL AND INSTALLATION STEERING CYLINDER

OF

CAUTION: Bleed air from the cylinder before doing any work. (Refer to W1-1-3.)

CAUTION: In order to release the hydraulic pressure in the steering hydraulic circuit, stop the engine and turn the steering wheel to the right and the left several times. The steering wheel turns heavily when the hydraulic pressure is released.

WARNING:Never work under a raised bucket.

The front attachment may be lowered, possibly causing personal injury or death. If you must work with the front attachment raised, hold the front attachment securely by using the safety supports or blocks.

5

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

Stop the engine and release the hydraulic pressure.

If you must work with the front attachment raised, set the bucket to the full dump position and hold the lift arm by using support (4).

Set and secure stopper (5) to the lift arm cylinder.

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

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

Secure with ring pin (3).

4

W4EK-02-08-012A

3

2

1

W4EK-02-01-006A

W3-9-1

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder

4 3 2

6 5

1 7 8 9 10

12 13 12 13

11

14

15

14

16

W4EK-03-09-001

1234-

Front Chassis Lock Plate Spring Washer (2 Used) Bolt (2 Used)

5678-

Pin Remote Lubrication Hose Bolt (2 Used) Spring Washer (2 Used)

9 - Lock Plate 10 - Pin 11 - Rear Chassis 12 - Shim (2 Used)

13 - Spacer (4 Used) 14 - Steering Cylinder 15 - Hose 16 - Hose

W3-9-2

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder Removal 18

1. Remove SEMS bolts (18) (4 used) from cover (17).

Remove cover (17) from front chassis (1).

17

: 17 mm 1

2. Disconnect hoses (15, 16) from steering cylinder (14).

Cap the open ends. : 19 mm

3. Connect remote lubrication hose (6).

: 11 mm

W4EK-03-09-002

4. Remove bolts (4) (2 used), lock spring washers (3) (2 used) and lock plate (2) from pin (5).

Remove pin (5) from front chassis (1). : 17 mm CAUTION: Cutting hazard. Shims may develop sharp surfaces. Wear gloves while working with shims.

5. Remove bolts (7) (2 used), lock spring washers (8) (2 used) and lock plate (9) from pin (10).

Remove pin (10) from rear chassis (11).

Remove shims (12) (2 used) and spacers (13) (4 used) from steering cylinder (14).

6. Remove steering cylinder (14) from rear chassis (11).

W3-9-3

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder

4 3 2

6 5

1 7 8 9 10

12 13 12 13

11

14

15

14

16

W4EK-03-09-001

1234-

Front Chassis Lock Plate Spring Washer (2 Used) Bolt (2 Used)

5678-

Pin Remote Lubrication Hose Bolt (2 Used) Spring Washer (2 Used)

9 - Lock Plate 10 - Pin 11 - Rear Chassis 12 - Shim (2 Used)

W3-9-4

13 - Spacer (4 Used) 14 - Steering Cylinder 15 - Hose 16 - Hose

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder Installation CAUTION: Cutting hazard. Shims may develop sharp surfaces. Wear gloves while working with shims.

1. Align the pin (5) holes on steering cylinder (14) and the rod side of front chassis (1).

Install shims (12) and spacer (13) (1 used for each) to the upper surface at the rod side of steering cylinder (14).

Install spacer (13) (1 used) to the lower surface at the rod side of steering cylinder (14).

2. Install pin (5) to front chassis (1) with lock plate (2), spring washers (3) (2 used) and bolts (4) (2 used). : 17 mm : 44.1 to 53.9 N m (4.5 to 5.5 kgf m, 32.5 to 39.7 lbf ft) 3. Align the pin (10) holes on steering cylinder (14) and the bottom side of rear chassis (11).

Install shim (12) (1 used) and spacer (13) (1 used for each) to the upper surface at the bottom side of steering cylinder (14).

Install spacer (13) (1 used) to the lower surface at the bottom side of steering cylinder (14).

4. Install pin (5) to rear chassis (11) with lock plate (9), lock spring washer (8) and bolt (7). : 17 mm : 44.1 to 53.9 N m (4.5 to 5.5 kgf m, 32.5 to 39.7 lbf ft) 5. Connect lubrication hose (6). : 11 mm 6. Connect hoses (15, 16) to steering cylinder (14).

7. : 19 mm

18

7. Install cover (17) to front chassis (1) with SEMS bolts (18) (4 used).

1

17

: 17 mm

W4EK-03-09-002

W3-9-5

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder DISASSEMBLY OF STEERING CYLINDER

1

12 13

11

14

5

8

7

4

10

9

12

3 6

2

W4EK-03-09-003

1234-

Cylinder Tube Piston Rod Cylinder Head Bushing

5678-

U-Ring Wiper Ring O-Ring Backup Ring

9 - O-Ring 10 - Piston 11 - Seal Ring Assembly

12 - Slide Ring 13 - Set Screw 14 - Steel Ball

W3-9-6

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder Disassembly

The disassembling procedure starts on the

3. Loosen cylinder head (3) by using a hooked wrench.

Remove piston rod (2) assembly from cylinder tube (1).

premise that the hydraulic piping and the bands securing the piping have been removed.

1. Secure the cylinder on a workbench horizontally.

Drain hydraulic oil from the cylinder.

Cylinder head (3) diameter: 30ZV-2: 73 mm (2.84 in) 40ZV-2A/42ZV-2: 78 mm (3.07 in)

1

W4EK-03-09-004

IMPORTANT: The lock ring forms an integral part with cylinder tube (1).

Do not damage cylinder tube (1) and cylinder head (3) when bending the lock ring.

2. Pull out piston rod (2) about 50 mm (2.0 in) from cylinder tube (1).

Install a protective cover to piston rod (2).

Bend the lock ring in cylinder tube (1) by using a chisel and a hammer.

1

2

3 W4EK-03-09-006

IMPORTANT: Loosen set screw (13) after cutting the crimped part (2 places) by using a hand drill.

Do not lose steel ball (14).

4. Secure piston rod (2) horizontally.

Remove set screw (13) from piston (10).

Remove steel ball (14) from the set screw (13) mounting hole. : 5 mm

3

2

Lock Washer

W4EK-03-09-005

W3-9-7

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder DISASSEMBLY OF STEERING CYLINDER

1

12 13

11

14

5

8

7

4

10

9

12

3 6

2

W4EK-03-09-003

W3-9-8

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder 5. Remove piston (10) from piston rod (2).

10. Remove U-ring (5) from cylinder head (3) by using an awl.

Awl

: 36 mm 6. Remove cylinder head (3) from piston rod (2).

IMPORTANT: Do not damage the seal groove.

7. Place piston (10) on a V-shaped stable stand.

Remove slide rings (12) (2 used) from the both sides of piston (10).

Carefully cut and remove seal ring (11-1) and O-ring (11-2) in the seal ring assembly on the center part of piston (10) by using a hammer and a screwdriver.

5

3

Hammer

W4EK-03-09-008

Screwdriver

11. Remove wiper ring (6) from cylinder head (3).

11-1

Hammer Screwdriver

10

11-2 W4EK-03-09-007

Vise

8. Place cylinder head (3) on the workbench, which is covered with an anti-skid waste cloth.

9. Remove O-ring (9), backup ring (8) and O-ring (7) from the outer surface of cylinder head (3).

3

6 W4EK-03-09-009

IMPORTANT: Do not remove bushing (4) unless necessary.

12. Remove bushing (4) from cylinder head (3).

W3-9-9

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder ASSEMBLY OF STEERING CYLINDER

1

13

11

12

14

5

8

7

4

10

9

12

3 6

2

W4EK-03-09-003

1234-

Cylinder Tube Piston Rod Cylinder Head Bushing

5678-

U-Ring Wiper Ring O-Ring Backup Ring

9 - O-Ring 10 - Piston 11 - Seal Ring Assembly

W3-9-10

12 - Slide Ring 13 - Set Screw 14 - Steel Ball

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder Assembly IMPORTANT: Before assembling, apply hydraulic oil to parts to prevent them from seizing.

Install bushing (4) so as not to make a gap between the bushing (4) end and U-ring (5) mounting surface (D) of cylinder head (3).

4. Install O-ring (9) to the outer surface of cylinder head (3).

Install backup ring (8) and O-ring (7).

6 9

8

1. Install bushing (4) to cylinder head (3).

7

Piston Side

3

5

Piston Side W4EK-03-09-011

5. Install special tool (A) to piston (10).

Install O-ring (11-2) in seal ring assembly (11) to the seal groove on the center of piston (10).

4

6. Place seal ring (11-1) in seal ring assembly (11) onto special tool (A).

Gradually push special tool (B) into special tool (A).

Install seal ring (11-1) to the seal groove on the center of piston (10).

W4EK-03-09-010

IMPORTANT: When installing U-ring (5), install the lip facing to the piston side.

2. Install U-ring (5) to cylinder head (3).

IMPORTANT: When installing wiper ring (6), face the lip outside and evenly contact a screwdriver with the metal ring of wiper ring (6).

Install wiper ring (6) by tapping lightly with a hammer.

If hit hard, the metal ring may be deformed or damaged.

B

3. Install wiper ring (6) to cylinder head (3) by using a screwdriver and a soft hammer.

A

11-1

11-2

10

W4EK-03-09-012

W3-9-11

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder

1

12 13

11

14

8

7

5 4

10

9

12

3 6

2

W4EK-03-09-003

W3-9-12

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder 7. Adjust seal ring (11-1) of extended seal ring assembly (11) by using special compression tool (C).

12. Insert steel ball (14) to the set screw mounting hole on piston (10).

Install set screw (13) to piston (10).

Crimp set screw (13) by using a punch (2 places). : 5 mm : 6.8 N m (0.7 kgf m, 5.01 lbf ft)

C 11-1

10

13. Apply hydraulic oil onto the packing parts.

Secure cylinder tube (1) in a vise horizontally.

Insert piston rod (10) into cylinder tube (1).

11-2

W4EK-03-09-013

IMPORTANT: When installing slide ring (12), do not set the slit positions at the same place.

8. Install slide rings (12) (2 used) to the seal grooves on both sides of piston (10).

9. Secure piston horizontally.

rod

(2)

on

a

workbench

14. Apply hydraulic oil onto the packing parts.

Apply THREEBOND #1901 onto the thread part of cylinder tube (1).

Tighten cylinder head (3) to cylinder tube (1) by using a hooked wrench.

Bend the lock ring to secure it. : : 30ZV-2: 235 N m (24 kgf m, 173.3 lbf ft) 40ZV-2A/42ZV-2: 304 N m (31 kgf m, 224.2 lbf ft)

10. Apply a small amount of hydraulic oil onto the piston rod (2) surface.

Install cylinder head (3) to piston rod (2).

11. Apply hydraulic oil onto the thread part of the piston (10) bore part.

Install piston (10) to piston rod (2). : 36 mm : 30ZV-2: 271 N m (27.6 kgf m, 200 lbf ft) 40ZV-2A/42ZV-2: 323 N m (32.9 kgf m, 238.3 lbf ft)

W3-9-13

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder Special Tools When Assembling and Adjusting Piston Seal Ring When Assembling: Special Tool (A)

Cylinder

Application Model

Special Tool (A) Bolt Diameter mm (in)

30ZV-2

65 (2.56)

40ZV-2A/42ZV-2

70 (2.76)

30ZV-2/40ZV-2A

65 (2.56)

42ZV-2

70 (2.76)

30ZV-2

55 (2.17)

40ZV-2A/42ZV-2

60 (2.36)

Bucket

Lift Arm

Steering

Special Tool (A) Dimension mm (in) L1

L2

D

d1

d2

d3

15.7 (0.62) 20 (0.79) 15.7 (0.62) 20 (0.79) 12.3 (0.48) 15.7 (0.62)

20 (0.79) 25 (0.79) 20 (0.79) 25 (0.79) 20 (0.79) 20 (0.79)

65.5 (2.58) 70.5 (2.78) 65.5 (2.58) 70.5 (2.78) 55.5 (2.19) 60.5 (2.38)

63.3 (2.49) 68.3 (2.69) 63.3 (2.49) 68.3 (2.69) 53.3 (2.10) 58.3 (2.30)

50 (1.97) 50 (1.97) 45 (1.77) 50 (1.97) 35 (1.38) 40 (1.57)

30 (1.18) 30 (1.18) 25 (0.79) 30 (1.18) 15 (0.59) 20 (0.79)

W4EK-03-09-014

W3-9-14

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder When Assembling: Special Tool (B)

Cylinder

Application Model

Special Tool (B) Bolt Diameter mm (in)

30ZV-2

65 (2.56)

40ZV-2A/42ZV-2

70 (2.76)

30ZV-2/40ZV-2A

65 (2.56)

42ZV-2

70 (2.76)

30ZV-2

55 (2.17)

40ZV-2A/42ZV-2

60 (2.36)

Bucket

Lift Arm

Steering

Special Tool (B) Dimension mm (in) D

D1

D2

D3

70 (2.76) 75 (2.95) 70 (2.76) 75 (2.95) 60 (2.36) 65 (2.56)

66 (2.60) 71 (2.80) 66 (2.60) 71 (2.80) 56 (2.20) 61 (2.40)

62 (2.44) 67 (2.64) 62 (2.44) 67 (2.64) 52 (2.05) 57 (2.24)

58 (2.28) 63 (2.48) 58 (2.28) 63 (2.48) 48 (1.89) 53 (2.09)

W4EK-03-09-015

W3-9-15

30_42ZV-2

TRAVEL SYSTEM / Steering Cylinder When Adjusting: Special Tool (C)

Cylinder

Application Model

Special Tool (B) Bolt Diameter mm (in)

30ZV-2

65 (2.56)

40ZV-2A/42ZV-2

70 (2.76)

30ZV-2/40ZV-2A

65 (2.56)

42ZV-2

70 (2.76)

30ZV-2

55 (2.17)

40ZV-2A/42ZV-2

60 (2.36)

Bucket

Lift Arm

Steering

Special Tool (C) Dimension mm (in) D

D1

70 (2.76) 75 (2.95) 70 (2.76) 75 (2.95) 60 (2.36) 65 (2.56)

85 (3.35) 90 (3.54) 85 (3.35) 90 (3.54) 75 (2.95) 80 (3.15)

W4EK-03-09-16KC

W3-9-16

30_42ZV-2

SECTION 4

FRONT ATTACHMENT

CONTENTS Group 1 Front Attachment Removal and Installation of Front Attachment...................................... W4-1-1

Group 2 Cylinder Removal and Installation of Cylinder....... W4-2-1 Disassembly of Lift Cylinder ................. W4-2-10 Assembly of Lift Cylinder ...................... W4-2-14 Disassembly of Bucket Cylinder ........... W4-2-18 Assembly of Bucket Cylinder ................ W4-2-22 Maintenance Standard.......................... W4-2-26

W-4-1

30_42ZV-2

(Blank)

W-4-2

30_42ZV-2

FRONT ATTACHMENT / Front Attachment REMOVAL AND INSTALLATION OF FRONT ATTACHMENT CAUTION: Bleed air from the cylinder before doing any work and after completing the work. (Refer to W1-1-3.)

WARNING: Never work under a raised bucket.

The front attachment may be lowered, possibly causing personal injury or death.If you must work with the front attachment raised, hold the front attachment securely by using the safety supports or blocks.

W4EK-03-04-001

Preparation 3

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

Stop the engine and release the hydraulic pressure.

Lower the bucket level to the ground.

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

2

1

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

Secure with ring pin (3).

4. Disconnect the harness of the bucket auto leveler proximity switch (4).

W4EK-02-01-006A

4

W4-1-1

W4EK-04-01-002

30_42ZV-2

FRONT ATTACHMENT / Front Attachment 8 5 3

9

10

11

12

13

7

6

4 15

2

14

1 19

18

16 17 24

23 22

25 26

20

28

27

21

31

45

49

48

44 1 - Bucket 2 - Bucket Link 3 - Shim (2 Used) 4 - Pin 5 - Washer 6 - Spring Washer 7 - Bolt 8 - Shim (2 Used) 9 - Lever 10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

47

50

46

43

14 - Shim (2 Used) 15 - Bucket Cylinder 16 - Bolt 17 - Spring Washer 18 - Washer 19 - Pin 20 - Shim (2 Used) 21 - Lift Arm 22 - Pin 23 - Washer 24 - Spring Washer 25 - Bolt 26 - Pin

42

41

36 37

40

27 - Washer 28 - Spring Washer 29 - Bolt 30 - Shim 31 - Pin (2 Used) 32 - Washer (2 Used) 33 - Spring Washer (2 Used) 34 - Bolt (2 Used) 35 - Lift Arm Cylinder (2 Used) 36 - Pin (2 Used) 37 - Washer (2 Used) 38 - Spring Washer (2 Used)

W4-1-2

34 33

30

38 39

32

29

35

W4EK-04-01-003

39 - Bolt (2 Used) 40 - Shim (4 Used) 41 - Pin (2 Used) 42 - Washer (2 Used 43 - Spring Washer (2 Used) 44 - Bolt (2 Used) 45 - Shim (4 Used) 46 - Pin (2 Used) 47 - Washer (2 Used) 48 - Spring Washer (2 Used) 49 - Bolt (2 Used) 50 - Front chassis

30_42ZV-2

FRONT ATTACHMENT / Front Attachment Removal CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

1. Operate the front control lever.

Release the remaining pressure in bucket cylinder (15) and lift arm cylinder (35).

15

1

21 35

4

2. Remove bolt (7), lock spring washer (6) and washer (5) from bucket (1).

Remove pin (4) from bucket (1).

Remove shims (3) (2 used) from bucket link (2).

: 19 mm

41

2

W4EK-04-01-004

3. Remove bolt (44), lock spring washer (43) and washer (42) from bucket (1).

Remove pins (41) (2 used) from bucket (1).

Remove shims (40) (4 used) from lift arm (21). : 19 mm CAUTION: Bucket (1) weight: [Bolt-On Cutting Edge] 30ZV-2 (0.4 m3 (0.52 yd3)): 178 kg (392 lb) 40ZV-2A (0.5 m3 (0.65 yd3)): 201 kg (443 lb) 42ZV-2 (0.6 m3 (0.78 yd3)): 216 kg (476 lb) 4. Attach a lifting cable to the holes on the bucket (1) side plates.

Lift bucket (1).

5. Remove bucket (1) from lift arm (21).

W4EK-04-01-005

W4-1-3

30_42ZV-2

FRONT ATTACHMENT / Front Attachment 8

9

10

11

12

13

15

2

14

1 23

24

25

22

21

W4EK-04-01-003

1289-

Bucket Bucket Link Shim (2 Used) Lever

10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

14 - Shim (2 Used) 15 - Bucket Cylinder 21 - Lift Arm 22 - Pin

W4-1-4

23 - Washer 24 - Spring Washer 25 - Bolt

30_42ZV-2

FRONT ATTACHMENT / Front Attachment 6. Attach a nylon sling onto bucket cylinder (15).

Hold bucket cylinder (15).

7. Remove bolt (13), lock spring washer (12) and washer (11) from lever (9).

Remove pin (10) from lever (9).

Remove shims (8) (2 used) from bucket cylinder (15).

15 10

9

: 19 mm 8. Start the engine.

Retract the piston rod of bucket cylinder (15).

Stop the engine.

Tilt bucket cylinder (15) to the operator's seat side.

W4EK-04-01-007

CAUTION: Lever (9) weight: 30ZV-2: 52 kg (115 lb) 40ZV-2A: 61 kg (134 lb) 42ZV-2: 62 kg (137 lb) CAUTION: Bucket link (2) weight: 30ZV-2: 10 kg (22 lb) 40ZV-2A: 12 kg (26 lb) 42ZV-2: 12 kg (26 lb)

Pin Hole (10)

9

9. Install pin (10) to the pin hole on lever (9).

Attach a nylon sling onto pin (10). Hold lever (9).

22

10. Remove bolt (25), lock spring washer (24) and washer (23) from lift arm (21).

Remove pin (22) from lever (9).

Remove shims (14) (2 used) from lever (9).

2

21

: 19 mm

W4EK-04-01-008

11. Remove lever (9) and bucket link (2) from the lift arm.

W4-1-5

30_42ZV-2

FRONT ATTACHMENT / Front Attachment

24

23

25

22

21

31

45

49

48

47

50

46

32

34 33

30

35

21 - Lift Arm 22 - Pin 23 - Washer 24 - Spring Washer 25 - Bolt

30 - Shim 31 - Pin (2 Used) 32 - Washer (2 Used) 33 - Spring Washer (2 Used)

34 - Bolt (2 Used) 35 - Lift Arm Cylinder (2 Used) 45 - Shim (4 Used) 46 - Pin (2 Used)

W4-1-6

W4EK-04-01-003

47 - Washer (2 Used) 48 - Spring Washer (2 Used) 49 - Bolt (2 Used) 50 - Front chassis

30_42ZV-2

FRONT ATTACHMENT / Front Attachment CAUTION: Lift arm (21) weight: 30ZV-2: 157 kg (346 lb) 40ZV-2A: 215 kg (474 lb) 42ZV-2: 225 kg (496 lb) 12. Install pin (22) to the pin hole on lift arm (21).Attach a nylon sling onto pin (22). Hold lever (9).

13. Start the engine.

Raise lift arm (21) until lift arm cylinder (35) is located at horizontal position.

14. Place a stand under lift arm cylinders (35) (2 used).

Stop the engine.

15. Remove bolt (49), spring washer (48) and washer (47) from lift arm cylinder (35).

Remove pins (46) (2 used) from lift arm (21).

Remove shims (45) (4 used) from lift arm (21).

35 22 21

50 31

Stand

: 19 mm 16. Remove bolt (34), spring washer (33) and washer (32) from front chassis (50).

Remove pins (31) (2 used) from lift arm (21).

Remove shims (30) (4 used) from lift arm (21).

W4EK-04-01-011

: 19 mm 17. Attach a nylon sling onto lift arm (21).

Hold lift arm (21).

Remove lift arm (21) from front chassis (50).

W4-1-7

30_42ZV-2

FRONT ATTACHMENT / Front Attachment

24

23

25

22

21

31

45

49

48

47

50

46

32

34 33

30

35

21 - Lift Arm 22 - Pin 23 - Washer 24 - Spring Washer 25 - Bolt

30 - Shim 31 - Pin (2 Used) 32 - Washer (2 Used) 33 - Spring Washer (2 Used)

34 - Bolt (2 Used) 35 - Lift Arm Cylinder (2 Used) 45 - Shim (4 Used) 46 - Pin (2 Used)

W4-1-8

W4EK-04-01-003

47 - Washer (2 Used) 48 - Spring Washer (2 Used) 49 - Bolt (2 Used) 50 - Front chassis

30_42ZV-2

FRONT ATTACHMENT / Front Attachment Installation CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

IMPORTANT: Check for the outer and inner diameters, wear and damage of all pins and bushings before installation. If any damage is found, replace the parts.

IMPORTANT: When installing the pin, apply grease onto the inside of the bushing and the dust seal.

Apply the rust-inhibiting oil onto the inside of the boss.

Taper 15°

IMPORTANT: Install the bushing as illustrated to the right.

W4EK-04-01-010

CAUTION: Lift arm (21) weight: 30ZV-2: 157 kg (346 lb) 40ZV-2A: 215 kg (474 lb) 42ZV-2: 225 kg (496 lb)

指示原稿は214kgだが W4-1-7では215kg

1. Hoist and align pin (22) in lift arm (21) with the pin hole on front chassis (50).

2. Install shims (30) (2 used) to the pin (31) holes (2 used) on lift arm (21). Install pins (31) (2 used) to front chassis (50) with spring washers (33) (2 used), washers (32) (2 used) and bolts (34) (2 used). : 19 mm

35

3. Hoist lift arm (21).

Align the pin (46) holes on lift arm (21) and lift arm cylinder (35).

4. Install shims (45) (4 used) to the pin (46) holes (2 used) on lift arm (21).

Install pins (46) (2 used) to lift arm cylinder (35) with washers (47) (2 used), spring washers (48) (2 used) and bolts (49) (2 used).

22 21

50 31

Stand

W4EK-04-01-011

: 19 mm

W4-1-9

30_42ZV-2

FRONT ATTACHMENT / Front Attachment 8

9

10

11

12

13

15

2

14

1 23

24

25

22

21

W4EK-04-01-003

1289-

Bucket Bucket Link Shim (2 Used) Lever

10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

14 - Shim (2 Used) 15 - Bucket Cylinder 21 - Lift Arm 22 - Pin

W4-1-10

23 - Washer 24 - Spring Washer 25 - Bolt

30_42ZV-2

FRONT ATTACHMENT / Front Attachment CAUTION: Lever (9) weight: 30ZV-2: 52 kg (115 lb) 40ZV-2A: 61 kg (134 lb) 42ZV-2: 62 kg (137 lb)

Pin Hole (10)

CAUTION: Bucket link (2) weight: 30ZV-2: 10 kg (22 lb) 40ZV-2A: 12 kg (26 lb) 42ZV-2: 12 kg (26 lb)

9

21

22

5. Hoist pin (10) in lever (9).

Align the pin (22) holes on lever (9) and lift arm (21).

2

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

6. Install shims (14) (2 used) to pin hole (22) on lever (9).

Install pin (22) to lift arm (21) with washer (23), lock spring washer (24) and bolt (22).

W4EK-04-01-008

15 10

9

: 19 mm 7. Hoist bucket cylinder (15).

Align the pin (10) holes on bucket cylinder (15) and lever (9).

8. Install shims (8) (2 used) to pin (10) hole on bucket cylinder (15).

Install pin (10) to lever (9) with washer (11), lock spring washer (12) and bolt (13).

W4EK-04-01-007

: 19 mm

W4-1-11

30_42ZV-2

FRONT ATTACHMENT / Front Attachment 8 5 3

9

10

11

12

13

7

6

4 15

2

14

1 19

18

16 17 24

23 22

25 26

20

28

27

21

31

45

49

48

44 1 - Bucket 2 - Bucket Link 3 - Shim (2 Used) 4 - Pin 5 - Washer 6 - Spring Washer 7 - Bolt 8 - Shim (2 Used) 9 - Lever 10 - Pin 11 - Washer 12 - Spring Washer 13 - Bolt

47

50

46

43

14 - Shim (2 Used) 15 - Bucket Cylinder 16 - Bolt 17 - Spring Washer 18 - Washer 19 - Pin 20 - Shim (2 Used) 21 - Lift Arm 22 - Pin 23 - Washer 24 - Spring Washer 25 - Bolt 26 - Pin

42

41

36 37

40

27 - Washer 28 - Spring Washer 29 - Bolt 30 - Shim 31 - Pin (2 Used) 32 - Washer (2 Used) 33 - Spring Washer (2 Used) 34 - Bolt (2 Used) 35 - Lift Arm Cylinder (2 Used) 36 - Pin (2 Used) 37 - Washer (2 Used) 38 - Spring Washer (2 Used)

W4-1-12

34 33

30

38 39

32

29

35

W4EK-04-01-003

39 - Bolt (2 Used) 40 - Shim (4 Used) 41 - Pin (2 Used) 42 - Washer (2 Used) 43 - Spring Washer (2 Used) 44 - Bolt (2 Used) 45 - Shim (4 Used) 46 - Pin (2 Used) 47 - Washer (2 Used) 48 - Spring Washer (2 Used) 49 - Bolt (2 Used) 50 - Front chassis

30_42ZV-2

FRONT ATTACHMENT / Front Attachment CAUTION: Bucket (1) weight: [Bolt-On Cutting Edge] 30ZV-2 (0.4 m3 (0.52 yd3)): 178 kg (392 lb) 40ZV-2A (0.5 m3 (0.65 yd3)): 201 kg (443 lb) 42ZV-2 (0.6 m3 (0.78 yd3)): 216 kg (476 lb) 9. Hoist bucket (1).

Align the pin (41) holes on bucket (1) and lift arm (21).

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

10. Install shims (40) (4 used) to the pin (41) holes (2 used) on lift arm (21).

Install pins (41) (2 used) to bucket (1) with washers (42) (2 used), lock spring washers (43) (2 used) and bolts (44) (2 used). : 19 mm 11. Install shims (3) (2 used) to pin (4) hole on bucket link (2).

Install pin (4) to bucket (1) with washer (5), lock spring washer (6) and bolt (7). : 19 mm 12. Apply grease through the grease fitting.

Connect the harness of the bucket auto leveler proximity switch.

W4-1-13

30_42ZV-2

FRONT ATTACHMENT / Front Attachment (Blank)

W4-1-14

30_42ZV-2

FRONT ATTACHMENT / Cylinder REMOVAL CYLINDER

AND

INSTALLATION

OF

CAUTION: Bleed air from the cylinder before doing any work and after completing the work. (Refer to BLEED AIR FROM CYLINDER on W1-1-2.)

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

Stop the engine.

Place the bucket on a stand of about 500 to 800 mm (20 to 32 in) (A) height.

500 mm (1.97 in) 800mm (31.5 in) ~

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

W4EK-04-02-001

W4-2-1

30_42ZV-2

FRONT ATTACHMENT / Cylinder 6

5 2

3

7

4

8

1 11

12

10

9

14

13

W4EK-04-02-002

1234-

Bolt (2 Used) Spring Washer (2 Used) Washer (2 Used) Pin (2 Used)

5678-

Shim (4 Used) Lift Arm Front chassis Lift Cylinder

9 - Bolt (2 Used) 10 - Spring Washer (2 Used) 11 - Washer (2 Used)

W4-2-2

12 - Pin (2 Used) 13 - Hose 14 - Hose

30_42ZV-2

FRONT ATTACHMENT / Cylinder Removal of Lift Cylinder

Installation of Lift Cylinder

CAUTION: Lift cylinder (8) weight: 30ZV-2: 26 kg (57 lb) 40ZV-2A: 28 kg (62 lb) 42ZV-2: 32 kg (71 lb)

CAUTION: Lift cylinder (8) weight: 30ZV-2: 26 kg (57 lb) 40ZV-2A: 28 kg (62 lb) 42ZV-2: 32 kg (71 lb)

1. Attach a nylon sling onto lift cylinders (8) (2 used).

Hold lift cylinders (8) (2 used).

1. Attach a nylon sling onto lift cylinders (8) (2 used).

Hold lift cylinders (8) (2 used).

2. Disconnect hoses (15, 16) (2 each) from lift cylinders (8) (2 used).

Cap the open ends.

2. Align the pin (12) (2 used) holes on the bottom side and on the front chassis.

3. Install pins (12) (2 used) to front chassis (7) with washers (11) (2 used), lock spring washers (10) (2 used) and bolts (9) (2 used).

: 19 mm, 22 mm 3. Remove bolts (1) (2 used), lock spring washers (2) (2 used) and washers (3) (2 used) from pins (4) (2 used).

: 19 mm 4. Connect hoses (15, 16) (2 each) to lift cylinders (8) (2 used).

: 19 mm CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

4. Remove pins (4) (2 used) from lift cylinders (8) (2 used).

5. Remove bolts (9) (2 used), lock spring washers (10) (2 used) and washers (11) (2 used) from pins (12) (2 used).

: 19 mm, 22 mm 5. Start the engine.

Extend the piston rod of lift cylinders (8) (2 used).

Align the pin (4) holes on lift cylinders (8) (2 used) and the lift arm.

Install shims (5) (4 used) to the rod side of lift cylinders (8) (2 used).

6. Install pins (4) (2 used) to lift cylinders (8) (2 used) with washers (3) (2 used), lock spring washers (2) (2 used) and bolts (1) (2 used). : 19 mm

: 19 mm 6. Remove pins (12) (2 used) from front chassis (7).

7. Remove lift cylinders (8) (2 used) and shims (5) (4 used) on the lift cylinder rod side from lift arm (6) and front chassis (7).

W4-2-3

CAUTION: Bleed air from the cylinder after completing the work. (Refer to BLEED AIR FROM HYDRAULIC CIRCUIT on W1-1-3.)

30_42ZV-2

FRONT ATTACHMENT / Cylinder 3

4

5

6

7

8

9

2

1 13

12

11 10

15

14

W4EK-04-02-003

1234-

Hose Hose Shim (2 Used) Lever

5678-

Pin Washer Spring Washer Bolt

9 - Bucket cylinder 10 - Bolt 11 - Spring Washer 12 - Washer

W4-2-4

13 - Pin 14 - Front chassis 15 - Lift Arm

30_42ZV-2

FRONT ATTACHMENT / Cylinder Removal of Bucket Cylinder

Installation of Bucket Cylinder

CAUTION: Bucket cylinder (9) weight: 30ZV-2: 20 kg (44 lb) 40ZV-2A: 25 kg (55 lb) 42ZV-2: 26 kg (57 lb)

CAUTION: Bucket cylinder (9) weight: 30ZV-2: 20 kg (44 lb) 40ZV-2A: 25 kg (55 lb) 42ZV-2: 26 kg (57 lb)

1. Attach a nylon sling onto bucket cylinder (9).

Hold bucket cylinder (9).

1. Attach a nylon sling onto bucket cylinder (9).

Hold bucket cylinder (9).

2. Disconnect hoses (1, 2) (2 each) from bucket cylinder (9).

Cap the open ends.

2. Align the pin (13) holes on bucket cylinder (9) and front chassis (14).

3. Align the pin (13) holes on the bottom side and the front chassis (14) side of bucket cylinder (9).

: 19 mm, 22 mm 3. Remove bolt (8), lock spring washer (7) and washer (6) from pin (5). : 19 mm CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary personal protection, such as protective goggles, face shield, etc., in order to prevent personal injury.

4. Install pin (13) to front chassis (14) with washer (12), spring washer (11) and bolt (10). : 19 mm 5. Connect hoses (1, 2) (2 used) to bucket cylinder (9).

4. Remove pin (5) from lever (4).

5. Remove bolt (10), spring washer (11) and washer (12) from pin (13). : 19 mm 6. Remove pin (13) from front chassis (14).

7. Remove bucket cylinder (9) and shims (3) (2 used) on the bucket cylinder rod side from lever (4) and front chassis (14).

: 19 mm, 22 mm 6. Start the engine.

Extend the piston rod of bucket cylinder (9).

Align the pin (5) holes on bucket cylinder (9) and lever (4).

Install shims (3) (2 used) to the rod side of bucket cylinder (9).

5. Install pin (5) to lever (4) with washer (6), spring washer (7) and bolt (8). : 19 mm CAUTION: Bleed air from the cylinder after completing the work. (Refer to BLEED AIR FROM HYDRAULIC CIRCUIT on W1-1-3.)

W4-2-5

30_42ZV-2

FRONT ATTACHMENT / Cylinder DISASSEMBLY OF LIFT CYLINDER

1

12 11 10

14

13

12 7 8 5 4 9 3 6

2

W4EK-04-02-003

1234-

Cylinder Tube Piston Rod Cylinder Head Bushing

5678-

U-Ring Wiper Ring O-Ring Backup Ring

9 - O-Ring 10 - Piston 11 - Seal Ring Assembly

W4-2-6

12 - Slide Ring 13 - Set Screw 14 - Steel Ball

30_42ZV-2

FRONT ATTACHMENT / Cylinder Disassembly of Lift Cylinder

The disassembling procedure starts on the premise that the hydraulic piping and the bands securing the piping have been removed.

3. Loosen cylinder head (3) by using a hook wrench.

Remove the piston rod (2) assembly from cylinder tube (1).

IMPORTANT: Loosen set screw (13) after cutting the crimped part (2 places) by using a hand drill.

Do not lose steel ball (14).

CAUTION: Lift cylinder weight: 30ZV-2: 26 kg (57 lb) 40ZV-2A: 28 kg (62 lb) 42ZV-2: 32 kg (71 lb) 1. Secure the cylinder on a workbench horizontally.

Drain hydraulic oil from the cylinder.

1

2

3

W4EK-03-09-004

IMPORTANT: The lock ring forms an integral part with cylinder tube (1). Do not damage cylinder tube (1) and cylinder head (3) when bending the lock ring.

W4EK-04-02-005

4. Secure piston rod (2) horizontally.

Remove set screw (13) from piston (10).

Remove steel ball (14) from the set screw (13) mounting hole. : 6 mm

2. Pull out piston rod (2) about 50 mm (2.0 in) from cylinder tube (1).

Install a protective cover to piston rod (2).

Bend the lock ring in cylinder tube (1) by using a chisel and a hammer.

Lock Washer

1 2

3

W4EK-04-02-004

W4-2-7

30_42ZV-2

FRONT ATTACHMENT / Cylinder 5. Remove piston (10) from piston rod (2).

10. Remove U-Ring (5) from cylinder head (3) by using an awl.

: 30ZV-2/40ZV-2A: 50 mm 42ZV-2: 55 mm

Awl

6. Remove cylinder head (3) from piston rod (2).

IMPORTANT: Do not damage the seal groove.

7. Place piston (10) on a V-shaped stable stand.

Remove slide rings (12) (2 used) from the both sides of piston (10).

Cut and remove seal ring (11-1) and O-Ring (11-2) in the seal ring assembly on the center part of piston (10) by using a hammer and a screwdriver.

5 3

W4EK-03-09-008

Hammer Screwdriver

11. Remove wiper ring (6) from cylinder head (3).

Hammer

Screwdriver

11-1 10 V-stand

11-2 W4EK-03-09-007

8. Place cylinder head (3) on the workbench which is covered with an anti-skid waste cloth.

9. Remove O-Ring (9), backup ring (8) and O-Ring (7) from the outer surface of cylinder head (3).

Vise

3

6 W4EK-03-09-009

IMPORTANT: Do not remove bushing (4) unless necessary.

12. Remove bushing (4) from cylinder head (3).

W4-2-8

30_42ZV-2

FRONT ATTACHMENT / Cylinder (Blank)

W4-2-9

30_42ZV-2

FRONT ATTACHMENT / Cylinder ASSEMBLY OF LIFT CYLINDER

1

12 11 10

14

13

12 7 8 5 4 9 3 6 2

W4EK-04-02-006

1234-

Cylinder Tube Piston Rod Cylinder Head Bushing

5678-

U-Ring Wiper Ring O-Ring Backup Ring

9 - O-Ring 10 - Piston 11 - Seal Ring Assembly

W4-2-10

12 - Slide Ring 13 - Set Screw 14 - Steel Ball

30_42ZV-2

FRONT ATTACHMENT / Cylinder Assembly of Lift Cylinder IMPORTANT: Install bushing (4) so as not to make a gap between the bushing (4) end and U-ring (5) mounting surface (D) of cylinder head (3).

4. Install O-Ring (9) to the outer surface of cylinder head (3).

Install backup ring (8) and O-Ring (7).

6

1. Install bushing (4) to cylinder head (3).

9 Piston Side

8 3

9

D

5

Piston Side

4

W4EK-03-09-010

IMPORTANT: When installing U-Ring (5), install the lip facing to the piston side.

2. Install U-Ring (5) to cylinder head (3).

IMPORTANT: When installing wiper ring (6), face the lip outside and evenly contact a screwdriver with the metal ring of wiper ring (6).

Install wiper ring (6) by tapping lightly with a hammer.

If hit hard, the metal ring may be deformed or damaged.

W4EK-03-09-011

5. Install special tool (A) to piston (10).

Install O-Ring (11-2) in seal ring assembly (11) to the seal groove on the center of piston (10).

6. Place seal ring (11-1) in seal ring assembly (11) onto special tool (A).

Gradually push special tool (B) into special tool (A).

Install seal ring (11-1) to the seal groove on the center of piston (10).

B

3. Install wiper ring (6) to cylinder head (3) by using a screwdriver and a soft hammer.

A

10

11-1

11-2

W4EK-03-09-012

W4-2-11

30_42ZV-2

FRONT ATTACHMENT / Cylinder 7. Adjust seal ring (11-1) of extended seal ring assembly (11) by using special tool (C).

C

11-1

10

11-2

12. Insert steel ball (14) to the set screw mounting hole on piston (10).

Install set screw (13) to piston (10).

Crimp set screw (13) by using a punch (2 places). : 6 mm : 16.2 N m (1.65 kgf m, 11.9 lbf ft) 13. Apply hydraulic oil onto the packing parts.

Secure cylinder tube (1) in a vise horizontally.

Insert piston rod (10) into cylinder tube (1).

W4EK-03-09-013

IMPORTANT: When installing slide ring (12), do not set the slit positions at the same place.

8. Install slide rings (12) (2 used) to the seal grooves on both sides of piston (10).

9. Secure piston rod (2) on a workbench horizontally.

10. Apply a small amount of hydraulic oil onto the piston rod (2) surface.

Install cylinder head (3) to piston rod (2).

14. Apply hydraulic oil onto the packing parts.

Apply THREEBOND #1901 onto the thread part of cylinder tube (1).

Tighten cylinder head (3) to cylinder tube (1) by using a hook wrench.

Bend the lock ring to secure it. : 30ZV-2: 343 N m (35 kgf m, 253 lbf ft) 40ZV-2A: 343 N m (35 kgf m, 253 lbf ft) 42ZV-2: 382 N m (39 kgf m, 282 lbf ft)

11. Apply hydraulic oil onto the thread part of the piston (10) bore part.

Install piston (10) to piston rod (2).

30ZV-2/40ZV-2A : 50 mm : 618 N m (63 kgf m, 456 lbf ft) 42ZV-2: : 55 mm : 755 N m (77 kgf m, 557 lbf ft)

W4-2-12

30_42ZV-2

FRONT ATTACHMENT / Cylinder (Blank)

W4-2-13

30_42ZV-2

FRONT ATTACHMENT / Cylinder DISASSEMBLY OF BUCKET CYLINDER

1

12 11 10

14

13

12 7 8 5 4 9 3 6

2

W4EK-04-02-003

1234-

Cylinder Tube Piston Rod Cylinder Head Bushing

5678-

U-Ring Wiper Ring O-Ring Backup Ring

9 - O-Ring 10 - Piston 11 - Seal Ring Assembly

W4-2-14

12 - Slide Ring 13 - Set Screw 14 - Steel Ball

30_42ZV-2

FRONT ATTACHMENT / Cylinder Disassembly of Bucket Cylinder

Lock Washer

The disassembling procedure starts on the premise that the hydraulic piping and the bands securing the piping have been removed.

1

CAUTION: Bucket cylinder weight: 30ZV-2: 20 kg (44 lb) 40ZV-2A: 25 kg (55 lb) 42ZV-2: 26 kg (57 lb)

2

3

1. Secure the cylinder on a workbench horizontally.Drain hydraulic oil from the cylinder.

W4EK-04-02-007

3. Loosen cylinder head (3) by using a hook wrench.

Remove the piston rod (2) assembly from cylinder tube (1).

1

W4EK-03-09-004

IMPORTANT: The lock ring forms an integral part with cylinder tube (1). Do not damage cylinder tube (1) and cylinder head (3) when bending the lock ring.

2. Pull out piston rod (2) about 50 mm (2.0 in) from cylinder tube (1).

Install a protective cover to piston rod (2).

Bend the lock ring in cylinder tube (1) by using a chisel and a hammer.

2 3

W4EK-04-02-008

IMPORTANT: Loosen set screw (13) after cutting the crimped part (2 places) by using a hand drill.Do not lose steel ball (14).

4. Secure piston rod (2) horizontally.

Remove set screw (13) from piston (10).

Remove steel ball (14) from the set screw (13) mounting hole. : 6 mm

W4-2-15

30_42ZV-2

FRONT ATTACHMENT / Cylinder 5. Remove piston (10) from piston rod (2).

10. Remove U-Ring (5) from cylinder head (3) by using an awl.

: 30ZV-2: 50 mm 40ZV-2A /42ZV-2: 55 mm

Awl

6. Remove cylinder head (3) from piston rod (2).

IMPORTANT: Do not damage the seal groove.

5

7. Place piston (10) on a V-shaped stable stand.

Remove slide rings (12) (2 used) from the both sides of piston (10).

Carefully cut and remove seal ring (11-1) and O-Ring (11-2) in the seal ring assembly on the center part of piston (10) by using a hammer and a screwdriver.

3

W4EK-03-09-008

11. Remove wiper ring (6) from cylinder head (3).

Hammer Screwdriver

Hammer

Screwdriver

11-1

V-stand

10

11-2 Vise

W4EK-03-09-007

3

8. Place cylinder head (3) on the workbench which is covered with an anti-skid waste cloth.

9. Remove O-Ring (9), backup ring (8) and O-Ring (7) from the outer surface of cylinder head (3).

6 W4EK-03-09-009

IMPORTANT: Do not remove bushing (4) unless necessary.

12. Remove bushing (4) from cylinder head (3).

W4-2-16

30_42ZV-2

FRONT ATTACHMENT / Cylinder (Blank)

W4-2-17

30_42ZV-2

FRONT ATTACHMENT / Cylinder ASSEMBLY OF BUCKET CYLINDER

1

12 11 10

14

13

12 7 8 5 4 9 3 6 2

W4EK-04-02-006

1234-

Cylinder Tube Piston Rod Cylinder Head Bushing

5678-

U-Ring Wiper Ring O-Ring Backup Ring

9 - O-Ring 10 - Piston 11 - Seal Ring Assembly

W4-2-18

12 - Slide Ring 13 - Set Screw 14 - Steel Ball

30_42ZV-2

FRONT ATTACHMENT / Cylinder Assembly of Bucket Cylinder IMPORTANT: Install bushing (4) not to make a step between the bushing (4) end and U-ring (5) mounting surface (D) of cylinder head (3).

4. Install O-Ring (9) to the outer surface of cylinder head (3).Install backup ring (8) and O-Ring (7).

6 9

1. Install bushing (4) to cylinder head (3).

8

Piston Side

9 3

D

5 4

W4EK-03-09-010

IMPORTANT: When installing U-Ring (5), install the lip facing to the piston side.

2. Install U-Ring (5) to cylinder head (3).

IMPORTANT: When installing wiper ring (6), face the lip outside and evenly contact a screwdriver with the metal ring of wiper ring (6).

Install wiper ring (6) by tapping lightly by with a hammer.

If hit hard, the metal ring may be deformed or damaged.

3. Install wiper ring (6) to cylinder head (3) by using a screwdriver and a soft hammer.

Piston Side

W4EK-03-09-011

5. Install special tool (A) to piston (10).

Install O-Ring (11-2) of seal ring assembly (11) to the seal groove on the center of piston (10).

6. Place seal ring (11-1) of seal ring assembly (11) onto special tool (A).

Gradually push special tool (B) into special tool (A).

Install seal ring (11-1) to the seal groove on the center of piston (10).

B

A

10

11-1

11-2

W4EK-03-09-012

W4-2-19

30_42ZV-2

FRONT ATTACHMENT / Cylinder 7. Adjust seal ring (11-1) of extended seal ring assembly (11) by using special tool (C).

C

11-1

10

11-2

12. Insert steel ball (14) to the set screw mounting hole on piston (10).

Install set screw (13) to piston (10).

Crimp set screw (13) by using a punch (2 places). : 6 mm : 16.2 N m (1.65 kgf m, 11.9 lbf ft) 13. Apply hydraulic oil onto the packing parts.

Secure cylinder tube (1) in a vise horizontally.

Insert piston rod (10) into cylinder tube (1).

W4EK-03-09-013

IMPORTANT: When installing slide ring (12), do not fit the slit positions at the same place.

8. Install slide rings (12) (2 used) to the seal grooves on both sides of piston (10).

9. Secure piston rod (2) on a workbench horizontally.

10. Apply a small amount of hydraulic oil onto the piston rod (2) surface.

Install cylinder head (3) to piston rod (2).

14. Apply hydraulic oil onto the packing parts.

Apply THREEBOND #1901 onto the thread part of cylinder tube (1).

Tighten cylinder head (3) to cylinder tube (1) by using a hook wrench.

Bend the lock ring to secure it. : 30ZV-2: 343 N m (35 kgf m, 253 lbf ft) 40ZV-2A: 382 N m (39 kgf m, 282 lbf ft) 42ZV-2: 382 N m (39 kgf m, 282 lbf ft)

11. Apply hydraulic oil onto the thread part of the piston (10) bore part.

Install piston (10) to piston rod (2).

30ZV-2 : 50 mm : 618 N m (63 kgf m, 456 lbf ft) 40ZV-2A/42ZV-2: : 55 mm : 755 N m (77 kgf m, 557 lbf ft)

W4-2-20

30_42ZV-2

FRONT ATTACHMENT / Cylinder (Blank)

W4-2-21

30_42ZV-2

FRONT ATTACHMENT / Cylinder MAINTENANCE STANDARD Rod Bend and Straightness Dial Gauge Cylinder Rod

V-Shaped Block

(200 ~ 500 mm) (7.87 ~19.69 in)

W4EK-04-02-009

Unit: mm (in) Bend

Straightness

Remedy

0.5 (0.019)

1.0 (0.039)

Replacement

W4-2-22

30_42ZV-2