KCM Wheel Loader 70ZIV-2 Disassembly & reassembly Workshop Manual

70ZIV-2

93208-00661

SHOP MANUAL Disassembly & Reassembly Service Standard

Printed in Japan (k) ( 輸出一般用 )

93208-00661

©2019 Hitachi Construction Machinery Co., Ltd. All rights reserved.

April 2019

SHOP MANUAL WHEEL LOADER

70ZIV-2 General Information Disassembly & Reassembly Service Standard

Powered by ISUZU A-6BG1T Engine Serial No. 70J1-1001 and up 70J1-7101 and up

93208-00661 April 2019

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

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

Disassembly & Reassembly Service Standard Note: For Troubleshooting and Measurement for Performance Check, refer to the 70ZIV-2 Shop Manual (9320800053).

For General Information and Function & Structure, refer to the 70ZIV-2 Shop Manual (93208-00651).

For the engine, refer to the engine Shop Manual provided by the engine manufacturer.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- Avoid the use of flammable solvents and cleaners.

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

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

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

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

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

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

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

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

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

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

CONTENTS 70ZIV-2 General Information ................................................................................................................................. 00-1 Symbols ............................................................................................................................................................ 00-2 Weight of Main Components ............................................................................................................................. 00-3 Bolt Tightening Torque ...................................................................................................................................... 00-4 Hose Band Tightening Torque ........................................................................................................................... 00-8 Liquid Gasket and Screw Lock Agent ............................................................................................................... 00-9 Cautions regarding parts removal ............................................................................................................... 00-9 Cautions regarding reassembly .................................................................................................................. 00-9 Screw lock agent application procedure ................................................................................................... 00-10 How to wind a seal tape ............................................................................................................................ 00-10 Cautions Regarding Welding Repair Service ...................................................................................................00-11 Applying and Storing Articulation Stopper ....................................................................................................... 00-13 Applying articulation stopper ..................................................................................................................... 00-13 Storing articulation stopper ....................................................................................................................... 00-13

70ZIV-2 Disassembly & Reassembly Chassis Group ........................................................................................... 14-1 Deck .................................................................................................................................................................. 14-2 Deck removing and installing ...................................................................................................................... 14-2 Fuel Tank .......................................................................................................................................................... 14-3 Fuel tank removing and installing ............................................................................................................... 14-3 Hydraulic Tank .................................................................................................................................................. 14-4 Hydraulic tank removing and installing ....................................................................................................... 14-4 Hydraulic tank return filter removing and installing ..................................................................................... 14-6 Hydraulic tank breather valve disassembling and assembling ................................................................... 14-7 Engine Room .................................................................................................................................................... 14-9 Engine room removing and installing .......................................................................................................... 14-9 Cab ................................................................................................................................................................. 14-12 Cab removing and installing ...................................................................................................................... 14-12 Floor Board ..................................................................................................................................................... 14-14 Floor board removing and installing .......................................................................................................... 14-14 Boom ............................................................................................................................................................... 14-16 Boom removing and installing ................................................................................................................... 14-16 Dust Seal ........................................................................................................................................................ 14-19 Dust seal removing and installing ............................................................................................................. 14-19

Bushing ........................................................................................................................................................... 14-20 Bushing removing and installing ............................................................................................................... 14-20 Center Pin ....................................................................................................................................................... 14-21 Upper center pin ........................................................................................................................................ 14-21 Lower center pin ........................................................................................................................................ 14-22 Center pin removing and installing ............................................................................................................ 14-23

70ZIV-2 Service Standard Chassis Group ............................................................................................................ 15-1 Linkage .............................................................................................................................................................. 15-2 Linkage Pin Standard Clearance Values ........................................................................................................... 15-3 Liner clearance adjustment ......................................................................................................................... 15-4 Center Pin ......................................................................................................................................................... 15-5 Center pin shim adjustment ........................................................................................................................ 15-5 Grease nipple installing ............................................................................................................................... 15-5 Lower center pin bearing outer ring installing ............................................................................................. 15-6 Bucket ............................................................................................................................................................... 15-7 Bucket Positioner and Boom Kick-Out (Option) ................................................................................................ 15-8 Bucket positioner ......................................................................................................................................... 15-9 Boom kick-out (option) .............................................................................................................................. 15-10

70ZIV-2 Disassembly & Reassembly Power Group .............................................................................................. 24-1 Power Line ........................................................................................................................................................ 24-2 Power line tightening torque ........................................................................................................................ 24-2 Radiator ............................................................................................................................................................. 24-3 Radiator tightening torque ........................................................................................................................... 24-3 Radiator removing and installing ................................................................................................................. 24-4 Engine ............................................................................................................................................................... 24-7 Engine removing and installing ................................................................................................................... 24-7 Propeller Shaft .................................................................................................................................................. 24-9 Propeller shaft removing and installing ....................................................................................................... 24-9 Air Cleaner ...................................................................................................................................................... 24-11 Air cleaner removing and installing ........................................................................................................... 24-11 Muffler ............................................................................................................................................................. 24-13 Muffler removing and installing ................................................................................................................. 24-13

Front Axle Assembly ....................................................................................................................................... 24-14 Front axle assembly tightening torque ...................................................................................................... 24-14 Front axle assembly removing and installing ............................................................................................ 24-16 Planetary assy disassembling and assembling ........................................................................................ 24-19 Floating Seal (S/N 1201~, 7201~) .................................................................................................................. 24-25 Floating seal installation ............................................................................................................................ 24-25 Floating seal assembling .......................................................................................................................... 24-26 Internal Gear Hub ........................................................................................................................................... 24-27 Internal gear hub disassembling and assembling ..................................................................................... 24-27 Spider Assembly ............................................................................................................................................. 24-29 Spider assy disassembling and assembling ............................................................................................. 24-29 Special Tool ..................................................................................................................................................... 24-31 Special tool for axle ................................................................................................................................... 24-31 Rear Axle Assembly ........................................................................................................................................ 24-36 Rear axle assembly tightening torque ....................................................................................................... 24-36 Rear axle assembly removing and installing ............................................................................................. 24-38 Axle Support ................................................................................................................................................... 24-41 Axle support tightening torque .................................................................................................................. 24-41 Axle support disassembling and assembling ............................................................................................ 24-43 Differential Assembly ...................................................................................................................................... 24-47 Differential assembly removing and installing ........................................................................................... 24-47 Differential assembly disassembling and assembling ............................................................................... 24-49 Front Differential ............................................................................................................................................. 24-62 Front differential removing and installing .................................................................................................. 24-62

70ZIV-2 Service Standard Power Group ............................................................................................................... 25-1 Propeller Shaft Service Standard ...................................................................................................................... 25-2 Axle and Differential Service Standard .............................................................................................................. 25-3 Axle group ................................................................................................................................................... 25-3 Differential ................................................................................................................................................... 25-4

70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group .............................................. 34-1 Torque Converter and Transmission Assembly ................................................................................................. 34-2 Torque converter and transmission assembly tightening torque ................................................................. 34-2 Torque converter and transmission assembly removing and installing ....................................................... 34-3 Transmission assembly bolt tightening torque ............................................................................................ 34-8 Transmission Assembly .................................................................................................................................. 34-10 Transmission assembly disassembling and assembling ........................................................................... 34-10 Torque Converter ............................................................................................................................................ 34-16 Torque converter assembly disassembling and assembling ..................................................................... 34-16 Transmission Clutch Pack ............................................................................................................................... 34-18 Forward/reverse clutch pack disassembling and assembling ................................................................... 34-18 Control Valve Assembly .................................................................................................................................. 34-23 Control valve removing and installing ....................................................................................................... 34-23 Control valve disassembling and assembling ........................................................................................... 34-26

70ZIV-2 Service Standard Torque Converter and Transmission Group ............................................................... 35-1 Torque Converter and Transmission Assembly ................................................................................................. 35-2

70ZIV-2 Disassembly & Reassembly Hydraulic Group ......................................................................................... 44-1 Hydraulic Parts Removal and Installation Warning ........................................................................................... 44-2 Hydraulic Parts Disassembly and Assembly Cautions ...................................................................................... 44-3 Hydraulic parts disassembly cautions ......................................................................................................... 44-3 Hydraulic parts assembly cautions .............................................................................................................. 44-3 Gear Pump ........................................................................................................................................................ 44-4 Gear pump tightening torque ...................................................................................................................... 44-5 Gear pump assembly removing and installing ............................................................................................ 44-6 Gear pump assembly disassembling and assembling ................................................................................ 44-8 Steering Valve (S/N ~2200, ~8250) ................................................................................................................. 44-12 Steering valve removing and installing ...................................................................................................... 44-13 Steering valve disassembling and assembling ......................................................................................... 44-15 Multiple Control Valve ...................................................................................................................................... 44-18 Multiple control valve removing and installing ........................................................................................... 44-18 Multiple control valve disassembling and assembling (S/N ~1481) .......................................................... 44-20 Multiple control valve disassembling and assembling (S/N 1482~) .......................................................... 44-29

Hydraulic Cylinder ........................................................................................................................................... 44-33 Boom cylinder removing and installing ..................................................................................................... 44-33 Bucket cylinder removing and installing .................................................................................................... 44-35 Steering cylinder removing and installing .................................................................................................. 44-37 Hydraulic cylinder disassembling and assembling .................................................................................... 44-39 Pilot Valve ....................................................................................................................................................... 44-51 Pilot valve removing and installing ............................................................................................................ 44-53 Pilot valve disassembling and assembling ................................................................................................ 44-55 Orbitrol® (S/N 2201~, 8251~) .......................................................................................................................... 44-60 Orbitrol® removing and installing ............................................................................................................... 44-60 Orbitrol® disassembling and assembling .................................................................................................. 44-62 Priority Valve (S/N 2201~, 8251~) ................................................................................................................... 44-72 Priority valve removing and installing ........................................................................................................ 44-72 Priority valve disassembling and assembling ........................................................................................... 44-73 Accumulator (S/N 2201~, 8251~) ................................................................................................................... 44-74 Accumulator removing and installing ........................................................................................................ 44-74

70ZIV-2 Service Standard Hydraulic Group .......................................................................................................... 45-1 Steering Linkage (S/N ~2200, ~8250) ............................................................................................................... 45-2 Steering linkage tightening torque .............................................................................................................. 45-3 Gear Pump ........................................................................................................................................................ 45-4 Hydraulic Cylinder ............................................................................................................................................. 45-5 Pilot Valve ......................................................................................................................................................... 45-6

70ZIV-2 Disassembly & Reassembly Brake Group .............................................................................................. 54-1 Brake Valve Assembly ...................................................................................................................................... 54-2 Brake valve removing and installing ........................................................................................................... 54-2 Brake valve disassembling and assembling ............................................................................................... 54-3 Air Master Assembly ......................................................................................................................................... 54-6 Air master removing and installing .............................................................................................................. 54-6 Air master disassembling and assembling .................................................................................................. 54-7 Service Brake ...................................................................................................................................................54-11 Service brake disassembling and assembling ...........................................................................................54-11

Air Cylinder for Parking Brake ......................................................................................................................... 54-12 Parking brake air cylinder removing and installing .................................................................................... 54-12 Parking brake air cylinder disassembling and assembling ........................................................................ 54-14 Parking Brake .................................................................................................................................................. 54-17 Parking brake removing and installing ...................................................................................................... 54-17 Air Tank ........................................................................................................................................................... 54-19 Air tank removing and installing ................................................................................................................ 54-19

70ZIV-2 Service Standard Brake Group ................................................................................................................ 55-1 Brake Valve ....................................................................................................................................................... 55-2 Air Master .......................................................................................................................................................... 55-4 Service Brake .................................................................................................................................................... 55-5 Parking Brake .................................................................................................................................................... 55-6

70ZIV-2 Disassembly & Reassembly Electrical Group ......................................................................................... 64-1 Wiper Motor ....................................................................................................................................................... 64-2 Front wiper motor removing and installing .................................................................................................. 64-2 Rear wiper motor removing and installing ................................................................................................... 64-4 Controller ........................................................................................................................................................... 64-5 Controller removing and installing ............................................................................................................... 64-5 Fuse Box ........................................................................................................................................................... 64-6 Fuse box removing and installing ................................................................................................................ 64-6

70ZIV-2 Disassembly & Reassembly Operator Station Group .............................................................................. 74-1 Air Conditioner .................................................................................................................................................. 74-2 Air conditioner removing and installing ....................................................................................................... 74-3 A/C condenser removing and installing ....................................................................................................... 74-5 A/C compressor removing and installing ..................................................................................................... 74-6

70ZIV-2 Service Standard Operator Station Group ............................................................................................... 75-1 Air Conditioner .................................................................................................................................................. 75-2 Periodical inspection/servicing .................................................................................................................... 75-2 Tightening torque ........................................................................................................................................ 75-2 Compressor adjustment standard ............................................................................................................... 75-3

00-1 70ZIV-2 General Information

70ZIV-2 General Information Symbols .................................................................. 00-2 Weight of Main Components ................................... 00-3 Bolt Tightening Torque ............................................ 00-4 Hose Band Tightening Torque................................. 00-8 Liquid Gasket and Screw Lock Agent ..................... 00-9 Cautions Regarding Welding Repair Service .......... 00-11 Applying and Storing Articulation Stopper ............... 00-13

00-2 70ZIV-2 General Information Symbols

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

Symbol

Item

Description

Reference

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

Weight

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

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

Coating

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

Oil or water supply

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

Drainage

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

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

The message shows the preventive measures.

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

E/G T/C T/M SOL SW F A/M B R

........... Engine ........... Torque converter ........... Transmission ........... Solenoid valve ........... Switch ........... Front or Forward ........... Auto/Manual ........... Battery ........... Rear or Reverse

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

3rd ............3rd speed 4th ............4th speed M/C ............Machine min-1 ............RPM

00-3 70ZIV-2 General Information Weight of Main Components

Weight of Main Components

Part name

Approx. weight (kg)

Bucket

1,065

2,340

Boom

810

1,780

Item Unit name

"Z" -Lever

255/pc

565/pc

Link (Bucket to Lever)

45/pc

95/pc

Engine room assembly

260

570

145

320

Excluding oil

155

340

Excluding fuel

Floor board

150

330

Cab (ROPS)

560

1,230

Deck

45

100

Front chassis

1,130

2,490

Rear chassis

1,010

2,220

Counter weight

670

1,480

Radiator assembly

515

1,130

(S/N ~2550)

130

290

(S/N 2551~)

90

200

With handrail

Excluding oil Excluding water and oil

Transmission

515

1,130

Excluding oil

Cooling unit (S/N 2551~)

7.5

16.5

Torque converter oil cooler

Second propeller shaft

50

110

Third propeller shaft

7

15

Air cleaner

7

15

Muffler

7

15

Front axle assembly

840

1,850

Excluding tires and oil

Rear axle assembly

940

2,070

Excluding tires and oil (Including axle support)

Differential

130

290

Multiple control valve

55

120

Steering valve

35

80

®

Orbitrol (S/N 2201~, 8251~)

Other

GSN bucket

Fuel tank

Engine

Hydraulic system

Remarks

Hydraulic tank Chassis

Power line

Approx. weight (lb)

Gear pump

(S/N ~1200, ~7200) (S/N 1201~, 7201~)

7

15

45

100

30

66

Boom cylinder

145/pc

320/pc

Excluding oil

Bucket cylinder

140/pc

310/pc

Excluding oil

Steering cylinder

25/pc

55/pc

Excluding oil With rim (20.5-25-16PR)

Tire

275/pc

610/pc

Battery

35/pc

80/pc

Air conditioner unit

40

88

In CAB

00-4 70ZIV-2 General Information Bolt Tightening Torque

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

Nominal dia.

Pitch

M8

8

(C) 1.25

26

38

(C) 1.5

53

76

(F) 1.25

55

80

(C) 1.75

90

132

M10

M12

M14

Metric thread

Unified thread

Bolt strength

Nominal dimension

10

12

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27

27

M30

30

M33

33

5/16

05

8.8 (8T)

10.9 (11T)

(F) 1.25

96

142

(C) 2.0

142

206

(F) 1.5

152

221

(C) 2.0

216

314

(F) 1.5

226

330

(C) 2.5

299

436

(F) 1.5

324

476

(C) 2.5

417

608

(F) 1.5

451

662

(C) 2.5

559

814

(F) 1.5

598

878

(C) 3.0

721

1,030

(F) 2.0

770

1,128

(C) 3.0

1,030

1,520

(F) 2.0

1,128

1,618

(C) 3.5

1,422

2,109

(F) 2.0

1,569

2,256

(C) 3.5

1,912

2,844

(F) 2.0

2,059

3,040

18 UNC

25

35

3/8

06

16 UNC

44

65

7/16

07

14 UNC

71

103

1/2

08

13 UNC

103

147

9/16

09

12 UNC

147

216

5/8

10

11 UNC

201

294

3/4

12

10 UNC

358

525

7/8

14

9 UNC

554

809

1

16

8 UNC

868

1,275

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

00-5 70ZIV-2 General Information Bolt Tightening Torque

(kgf-m) Bolt size Type

Metric thread

Nominal dia.

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

2.7

3.9

(C) 1.5

5.4

7.8

(F) 1.25

5.6

8.2

(C) 1.75

9.2

13.5

(F) 1.25

9.8

14.5

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

24

27

30

(C) 2.0

14.5

21.0

(F) 1.5

15.5

22.5

(C) 2.0

22.0

32.0

(F) 1.5

23.0

33.7

(C) 2.5

30.5

44.5

(F) 1.5

33.0

48.5

(C) 2.5

42.5

62.0

(F) 1.5

46.0

67.5

(C) 2.5

57.0

83.0

(F) 1.5

61.0

89.5

(C) 3.0

73.5

105.0

(F) 2.0

78.5

115.0

(C) 3.0

105.0

155.0

(F) 2.0

115.0

165.0

(C) 3.5

145.0

215.0

(F) 2.0

160.0

230.0

(C) 3.5

195.0

290.0

M33

33

(F) 2.0

210.0

310.0

5/16

05

18 UNC

2.5

3.6

3/8

06

16 UNC

4.5

6.6

7/16

07

14 UNC

7.2

10.5

1/2

08

13 UNC

10.5

15.0

9/16

09

12 UNC

15.0

22.0

5/8

10

11 UNC

20.5

30.0

3/4

12

10 UNC

36.5

53.5

7/8

14

9 UNC

56.5

82.5

1

16

8 UNC

88.5

130.0

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

00-6 70ZIV-2 General Information Bolt Tightening Torque

(lb-ft) Bolt size Type

Metric thread

Nominal dia.

Pitch

8.8 (8T)

M8

8

(C) 1.25

19.5

28

(C) 1.5

39

56

(F) 1.25

40

59

(C) 1.75

66

97

(F) 1.25

70

105

(C) 2.0

105

150

(F) 1.5

110

160

(C) 2.0

160

230

(F) 1.5

165

245

(C) 2.5

220

320

(F) 1.5

235

350

(C) 2.5

305

450

(F) 1.5

330

490

(C) 2.5

410

600

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

24

27

30

M33

33

5/16

05

10.9 (11T)

(F) 1.5

440

650

(C) 3.0

530

760

(F) 2.0

565

830

(C) 3.0

760

1,120

(F) 2.0

830

1,190

(C) 3.5

1,050

1,550

(F) 2.0

1,160

1,660

(C) 3.5

1,410

2,100

(F) 2.0

1,520

2,240

18 UNC

18.0

26

3/8

06

16 UNC

32

47

7/16

07

14 UNC

52

76

1/2

08

13 UNC

76

105

9/16

09

12 UNC

110

160

5/8

10

11 UNC

150

215

3/4

12

10 UNC

265

385

7/8

14

9 UNC

410

595

1

16

8 UNC

640

940

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

00-7 70ZIV-2 General Information Bolt Tightening Torque

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

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

7

M6

1

12

M8

1.25

28

M10

1.5

53

M12

1.75

94

M16

2

231

M20

2.5

441

M24

3

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

0.7

M6

1

1.2

M8

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

2

23.5

M20

2.5

45.0

M24

3

78.0 (lb-ft)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

5.0

M6

1

8.6

M8

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

2

169.2

M20

2.5

324.0

M24

3

561.6

00-8 70ZIV-2 General Information Hose Band Tightening Torque

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

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

16

1.2

4

40

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

16

1.2

4

40

2.9

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

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

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

16.5

8

18.5

9

20.5

9

22.0

12

24.5

12

26.0

15

29.0

15

30.5

19

32.0

19

34.0

25

39.5

25

41.5

32

46.0

32

48.0

38

54.0

50

70.5

50

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

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

Hose

Pipe

Hose band Center of pipe protrusion

10~20 mm

70ZV00003

00-9 70ZIV-2 General Information Liquid Gasket and Screw Lock Agent

Liquid Gasket and Screw Lock Agent To reassemble the disassembled parts, be sure to use the specified liquid gasket or screw lock agent or the equivalent according to the following lists: Code AA01 Liquid gasket

Screw lock agent

Manufacturer

Product name

®

Plastic Gasket 568

®

Loctite

AA02

Loctite

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

®

®

AB01

Loctite

Loctite 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

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

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

To bond a plane or to fit a shaft

Cautions regarding parts removal

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

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

Antiseize Agent

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

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

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

Code

Manufacturer

Product name

AC01

Loctite®

Loctite® 767 (Paste or spray)

00-10 70ZIV-2 General Information Liquid Gasket and Screw Lock Agent

Screw lock agent application procedure

How to wind a seal tape

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

Seal tape

Leave 1~2 screw

Screw lock agent

65ZV00004a

65ZV00002

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

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

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

00-11 70ZIV-2 General Information Cautions Regarding Welding Repair Service

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

Cautions 1. Turn the starter switch OFF. 2. Remove the battery terminals both positive and negative sides from the battery.

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

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

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

Example 1

Section to be welded Do not ground this section.

Electric current may flow through the cylinders.

Ground this section. (correct grounding)

35C00002

Example 2

Do not ground this section.

Electric current may flow through the cylinders.

Section to be welded

Ground this section. (correct grounding)

35C00006

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

Be sure to mask these units and parts before welding.

00-12 70ZIV-2 General Information Cautions Regarding Welding Repair Service

Hydraulic cylinder Heat-resistant cloth

Plated section (Mask this section.)

Pin section with pin temporarily inserted

Remove and if necessary wrap Chassis

Pin

35A00005

Plated section (Mask this section.)

35C00003

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

Note The weld spattered on the plated sections causes corrosion.

Scrap material, etc.

1m or more

Section to be welded

Hydraulic hose Nylon tube Harness

Section to be welded

1m or more 35C00004

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

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

00-13 70ZIV-2 General Information Applying and Storing Articulation Stopper

Applying and Storing Articulation Stopper Applying articulation stopper 2

3

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

IL14-1(90ZV-D&R)

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

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

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

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

Stay out of the articulation area while aligning the holes.

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

1

Storing articulation stopper

IL12-1(70ZV-D&R)

2

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

3

Stored position

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

IL12-3(70ZV-D&R)

00-14 70ZIV-2 General Information

MEMO

14-1 70ZIV-2 Disassembly & Reassembly Chassis Group

70ZIV-2 Disassembly & Reassembly Chassis Group Deck ........................................................................ 14-2 Fuel Tank................................................................. 14-3 Hydraulic Tank......................................................... 14-4 Engine Room .......................................................... 14-9 Cab.......................................................................... 14-12 Floor Board ............................................................. 14-14 Boom ....................................................................... 14-16 Dust Seal................................................................. 14-19 Bushing ................................................................... 14-20 Center Pin ............................................................... 14-21

14-2 70ZIV-2 Disassembly & Reassembly Chassis Group Deck

Deck Deck removing and installing

Deck installing

Deck removing

For reinstallation, follow the above procedure in reverse order.

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

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

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

1. Apply a sling to handrail (1) and remove bolts (2)(3)(4).

2. Remove deck (5) with the handrail considering the balance. : Deck (5) including handrail: 50 kg

14-3 70ZIV-2 Disassembly & Reassembly Chassis Group Fuel Tank

Fuel Tank Fuel tank removing and installing Fuel tank removing

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

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

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

Before starting work: - Drain fuel from the fuel tank.

(Fuel tank capacity: 220 L) - Remove the engine room.

- Remove the radiator. (Refer to Section 22)

2. Disconnect level sensor electrical line coupler (3).

Put matchmarks on fuel hoses (4) and disconnect them.

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

3. Fix eye bolt (5) (M16) to the fuel tank and attach sling fuel tank. Then remove bolt (6) and slowly lower the fuel tank. : Bolt (6): 417 N-m (42.5 kgf-m) : Fuel tank: 145 kg (when empty)

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

Fuel tank installation cautions 1. Disconnect engine oil drain hose clamp (1) and radiator drain hose (2).

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

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

14-4 70ZIV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic Tank Hydraulic tank removing and installing

Hydraulic tank

Hydraulic tank removing

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

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

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

2. Remove hose (2) from the hydraulic tank.

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

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

(Hydraulic tank capacity: 130 L) - Remove the deck.

- Clean the area around the tank.

From hydraulic tank

3. Disconnect hoses (3)(4) from the hydraulic tank.

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

1. Disconnect vinyl tube (1) for the optional window washer liquid tank, when installed.

14-5 70ZIV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic tank installing Accumulator assy

For reinstallation, follow the above procedure in reverse order.

6

5

K70ZIV1407

4. Temporarily attach sling to hydraulic tank (5) and remove bolts (6).

Carefully remove the tank. : Hydraulic tank: 145 kg (when empty) : Bolt (6): 216 N-m (22.0 kgf-m) Note The accumulators are mounted on the hydraulic tank as shown on machines S/N 2201/8251 and thereafter.

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

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

14-6 70ZIV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic tank return filter removing and installing Hydraulic tank return filter removing

WARNING Unexpected movement of the machine could cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Position the machine on level ground, and apply the parking brake.

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

- Let the hydraulic oil become cool.

- Release the internal pressure from the piping and the hydraulic tank.

Releasing the residual pressure from piping (a) Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm above the ground. (b) Tilt down the bucket until it comes in contact with the ground, and then lower the boom. (c) Move the bucket and boom levers back and forth fully to relive the pressure. (d) Press the tank cap to release the residual pressure from the tank.

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

1 2 3 4 5

6

(S/N 1214~1269) (S/N 7208~7236) 65K44005a

1. Remove bolt (1) of cover (2).

Using these bolts as remover, remove cover (2).

2. Remove O-ring (3), spring (4), relief valve (5) and return filter (6).

Note Remove the hose and packing on machines S/Ns 1214~1269, 7208~7236.

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

Hydraulic tank return filter installation cautions Be sure to replace the O-ring with new one.

14-7 70ZIV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic tank breather valve disassembling and assembling Hydraulic tank breather valve disassembling

2 3 4 5

(S/N ~2550)

(S/N 2551~) Breather valve

Breather valve

6

65K44007

2. Remove bolts (2) and then remove body (3) and packing (4).

3. Remove filter (6) by removing stop ring (5).

K70ZIV1401

Note The breather valve is changed as shown on machines S/N 2551 and thereafter.

Note - After removing the parts, cover the tank port with vinyl to protect it from dust and dirt.

- Stop ring (5) is attached on machines S/N 1001~1495, 7101~7316 only.

1 10 9 Starter keyhole

8

7 65K44008 K70ZIV1401

Before starting work: - Insert the starter key and turn the key 180º counterclockwise to unlock the cap key. (S/N 1001~1600, 7101~7350 only)

1. Remove cap (1) by turning it counterclockwise while pressing.

4. Remove stop ring (7), then remove valve assembly (8).

5. Remove filter element (10) and spring (9) from cover (1).

Note Do not disassemble valve assembly (8) further since the valve is being setting 1 kPa (0.01 kgf/cm2) for the inlet pressure and 78 kPa (0.8 kgf/cm2) for the exhaust pressure.

14-8 70ZIV-2 Disassembly & Reassembly Chassis Group Hydraulic Tank

Hydraulic tank breather valve assembling Nut

To reassemble the breather valve, follow the above procedure in reverse order.

Filter element

K70ZIV1408

Note The breather valve on machines S/N 2551 and thereafter is configured as shown. : Nut: 7.06 N-m (0.72 kgf-m) : With lubricating oil (engine oil or gear oil)

14-9 70ZIV-2 Disassembly & Reassembly Chassis Group Engine Room

Engine Room Engine room removing and installing Engine room removing

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

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

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

2. Remove exhaust pipe (3).

4

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

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

- Remove the deck with the handrail both the right and left side.

65K14007

3. Disconnect sub tank hose (4) for the radiator.

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

1. Remove screen board covers (1) on both right and left sides.

14-10 70ZIV-2 Disassembly & Reassembly Chassis Group Engine Room

4. Disconnect hose (5) between the air cleaner and engine at the engine side.

6. Disconnect electrical line coupler (8) for the condenser and the brake oil tank level sensor.

Remove the clamp for rear axle breather tube (9).

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

11

10

65K14010

7. Disconnect hose (11) from the optional air conditioner condenser, if equipped.

5. Remove band (7) of brake oil tank (6).

Temporarily clamp the brake oil tank to the line filter.

Note You don’t have to drain the brake oil tank.

Note - Before hose disconnection, be sure to recover/recycle the refrigerant.

- When the optional quick coupler is attached, no recovery/recycling will be needed.

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

14-11 70ZIV-2 Disassembly & Reassembly Chassis Group Engine Room 10. Slowly lift the engine room together with the air cleaner while checking that there are no obstacles. : Engine room: 260 kg (Including air cleaner and condenser)

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

8. Open the radiator grill.

Disconnect electrical line coupler (12).

Remove bolts (13).

Engine room installation cautions After reinstallation, be sure to check the air conditioner for refrigerant leakage.

Also check that the air cleaner rubber hose connection band is properly positioned and tightened with proper torque.

: Bolt (M12): 98 N-m (10.0 kgf-m) : Bolt (M16): 216 N-m (22.0 kgf-m)

M16 (S/N 1244~)

M12 (S/N 1244~) (S/N 1244~)

M16

70K14007a

9. Remove hose band (14).

Remove bolt (13). : Bolt (M12)(4 each): 98 N-m (10.0 kgf-m) : Bolt (M16)(10 each): 216 N-m (22.0 kgf-m)

14-12 70ZIV-2 Disassembly & Reassembly Chassis Group Cab

Cab Cab removing and installing Cab removing

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

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

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

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

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

65ZV14014J

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

2. Remove cover (3).

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

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

Remove outer filter (2) from the cab.

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

14-13 70ZIV-2 Disassembly & Reassembly Chassis Group Cab

Cab

Floor board

13 65V14002

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

7. Remove bolt (13). : Bolt (13): 721 N-m (73.5 kgf-m) 14 15

65V14003

5. Remove nut (7) and lever (8).

Then remove cover (9).

8. Remove bolt (14) and seal washer (15).

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

Attach sling and remove the cab.

: Nut (7): 34 N-m (3.5 kgf-m)

: Cab: 560 kg 12

10

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

11

65K14014

6. Remove pin (11) for arm (10).

Move steering shaft (12) backward.

Cab installation cautions - Check the movement of the wiper and adjust the moving angle, if necessary.

- Tune the clock and the radio.

14-14 70ZIV-2 Disassembly & Reassembly Chassis Group Floor Board

Floor Board Floor board removing and installing Floor board removing

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

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

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

- Disconnect the (-) side of the battery.

- Disconnect the (+) side of the battery.

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

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

- Remove the cab.

- Disconnect the hoses and the electrical couplers between the floor board and the chassis.

- Disconnect the pipes from the optional air conditioner at the self seal couplings, when equipped.

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

Note - Before disconnecting the electrical couplers, hoses and pipes between the floor board and the chassis, put match marks on them to help during reassembly.

- Prepare a drain pan for the oil.

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

2. Put matchmarks on hoses (3)(4) and disconnect them. : Hydraulic oil: Approx. 0.5 L Note Cover the disconnected hoses with vinyl to protect them from dust and dirt.

14-15 70ZIV-2 Disassembly & Reassembly Chassis Group Floor Board

8 9

65K14021

WARNING Spray from hot coolant could cause burns. Prevent injury by relieving pressure in the radiator. Work on the system only when cool.

3. Remove clamp (5) and then disconnect heater hoses (option) (6) at the intermediate joints.

Plug the hose ends to prevent the coolant from running out.

5. Remove floor board retaining nut (9).

Install the eye bolt (M16 × 2.0) to floor board (8) at 4 places.

Attach sling then gradually lift floor board (8) while checking that there are no obstacles and that all the pipes, cables, pins, etc. are disconnected. : Floor board: 340 kg (including ope. board, air conditioner, seat, etc.) : Nut (9): 417 N-m (42.5 kgf-m)

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

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

4. Disconnect accelerator control cable (7) from the engine.

14-16 70ZIV-2 Disassembly & Reassembly Chassis Group Boom

Boom Boom removing and installing

1

Boom removing 3

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

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

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

- Apply the parking brake and remove the starter key.

2

65ZV14020J

1. Remove pins (2)(3) to remove bucket (1). : Bucket: 1,065 kg

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

- Keep persons away from working area.

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

- Use a copper-hammer or a plastic hammer.

- Always wear protection goggles.

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

5

6

4 70V2E14026

2. Remove connection pin (6) from rod (4) and lever (5). : Link: 42 kg

14-17 70ZIV-2 Disassembly & Reassembly Chassis Group Boom

8 5

5 9 7

70ZV14003J

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

65ZV14024J

5. Attach sling to lever (5), and then remove lever pin (9). : Lever: 225 kg

: Bucket cylinder: 140 kg 10

CAUTION

12

Before removing the connecting pin, hold the lever with a rope not to tilt the end of the lever.

A

11

65ZV14025J

7 70ZV14004J

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

CAUTION - To temporarily turn up the bucket cylinder, check that the cylinder angle is 90º or less. Further tilting may cause the cylinder to overturn onto the cab.

- You have to work on the machine to turn up the bucket cylinder. Carefully check your step on the machine.

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

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

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

Open the hydraulic oil tank to release the internal pressure.

14-18 70ZIV-2 Disassembly & Reassembly Chassis Group Boom

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

10

Boom installation cautions 13

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

70ZV14005J

7. Attach sling to torque tube of boom (10), and then remove pins (13) from the boom on both the right and left side of the boom.

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

8. Slowly lift boom (10) to remove it from the machine. : Boom: 810 kg

WARNING Losing control of the boom structure during removal or installation could result in injury or death.

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

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

14-19 70ZIV-2 Disassembly & Reassembly Chassis Group Dust Seal

Dust Seal Dust seal removing and installing

Dust seal installing

Dust seal removing

K70ZIV1403.tif

Use tool and install the seal.

CAUTION K70ZIV1402.tif

Remove the seal using a screw driver as illustrated.

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

14-20 70ZIV-2 Disassembly & Reassembly Chassis Group Bushing

Bushing Bushing removing and installing

Bushing installing

Bushing removing

New bushing Pulling direction

K70ZIV1406.tif

K70ZIV1404.tif

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

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

Make sure to prepare the space for dust seal.

CAUTION Adapter (1)

Adapter (2)

Inspection hole

K70ZIV1405.tif

Adapter specifications Adapter (1) Material

SS41

Adapter (2) SS41

Dimension (A) Bushing outer diameter Bushing outer diameter - 2 (mm) + 20 Dimension (B) Bushing inner diameter Bushing inner diameter - 1 (mm) +5 Dimension (C) Jack rod diameter +2 (mm) Length (L) (mm)

—

— Bushing length x 2

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

14-21 70ZIV-2 Disassembly & Reassembly Chassis Group Center Pin

Center Pin Upper center pin 1

8

4

10

3 5

11

6

T1

Front chassis

2 12 9

Rear chassis

Upper 70ZA1208

Split shim T2 L1 70ZIV1401

: T1: Bolt (10): 216 N-m (22.0 kgf-m) T2: Bolt (9): 422 N-m (43.0 kgf-m) L1: Bolt (9): With lubrication oil (Engine oil or gear oil)

Center pin shim adjustment Adjust the clearance to 0.1±0.05 mm using the shim.

After that, tighten bolt (T1).

14-22 70ZIV-2 Disassembly & Reassembly Chassis Group Center Pin

Lower center pin (S/N ~1204)

7

2

5 6

4

3 Front chassis

Rear chassis

1

Lower

70ZA1209

70ZIV1402

[Lower]

3

Front

Rear

Split of outer bearing 20

Grease nipple installation direction

70ZV15004

14-23 70ZIV-2 Disassembly & Reassembly Chassis Group Center Pin

Center pin removing and installing

2

4

Center pin removing

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

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

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

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

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

3

70ZV14008J

2. Disconnect brake hose (2) and high pressure hoses (3), and disconnect electrical line (4) from the coupler. : Brake oil: Approx. 3 L : Hydraulic oil: Approx. 5 L Note Plug or cover the disconnected hoses to protect them from dust and dirt.

5

1

6

70ZV14007J 70ZV14009J

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

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

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

3. Remove right and left steering cylinder retainer pins (5) and shims (6).

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

14-24 70ZIV-2 Disassembly & Reassembly Chassis Group Center Pin

7

14 10 8

12

Jack screw 70K14017a

Remover bolt: M12 (Pitch 1.75), totally threaded Steering valve

M12 x 1.75

9 11 70

70K14015 65ZV14011

4. The upper center pin will come in contact with the steering rod (7) as the upper center pin is removed.

To smoothly remove the upper center pin, remove steering rod (7), arm (8), steering rod (9) and bracket (10).

6. Screw the M12 (Pitch 1.75) bolt of approximately 70 mm length into the center of bushing (14) to push out the bushing. This bolt is used as a jack screw.

: Castle nut (11): 191 N-m (19.5 kgf-m) : Bolt (12): 216 N-m (22.0 kgf-m) : With lubrication oil (Engine oil or gear oil) 15

Jack

13 70K14018

70ZV14011J

5. Remove upper center pin retainer bolt (13). : Bolt (13): 422 N-m (43.0 kgf-m)

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

14-25 70ZIV-2 Disassembly & Reassembly Chassis Group Center Pin

16

18

70K14021

70K14019

8. Before disconnecting the front chassis from the rear chassis, be sure to sling the rear chassis using a crane (apply sling to pin (16)) so that the rear chassis will not fall backward.

10. Support the bottom of hydraulic tank (18) using a rolling floor jack.

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

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

- Use the signals as agreed upon before starting work.

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

19

70K14022

11. Remove the lock bolt from the lower center pin.

Push out lower center pin (19) using another jack to remove the pin.

WARNING 17

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

Jack 70K14020

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

14-26 70ZIV-2 Disassembly & Reassembly Chassis Group Center Pin

24

23 Bar 70ZV14018

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

Note While turning the rear tires, check that the rolling floor jack under the hydraulic tank is rolling backward together with the rear chassis.

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

70K14024

14. Remove shim (23).

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

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

24

20 70K14025

22

21 70K14023

13. Remove ring (20) and remove bolts (22) from plate (21). : Bolt (22): 216 N-m (22.0 kgf-m)

15. Replace dust seals (24) in the upper center pin and the lower center pin with new ones.

14-27 70ZIV-2 Disassembly & Reassembly Chassis Group Center Pin

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

Center pin

Center pin installation cautions

70ZV14024

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

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

- Check each section for oil leakage.

- No oil leakage should be found in any part.

- Be sure to completely bleed the brake of air.

For air bleeding procedure, refer to the "Service brake air bleeding procedure" page 24-18.

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

25

70K14026

16. Check and replace dust seal (25) of the lower center pin in the same way as step 15.

14-28 70ZIV-2 Disassembly & Reassembly Chassis Group

MEMO

15-1 70ZIV-2 Service Standard Chassis Group

70ZIV-2 Service Standard Chassis Group Linkage.................................................................... 15-2 Linkage Pin Standard Clearance Values ................. 15-3 Center Pin ............................................................... 15-5 Bucket ..................................................................... 15-7 Bucket Positioner and Boom Kick-Out (Option) ...... 15-8

15-2 70ZIV-2 Service Standard Chassis Group Linkage

Linkage mm (in) 1. Attachment - Boom

2. Boom - Lever

3. Boom - Boom cylinder

4. Front chassis - Boom

5. Attachment - Link

6. Lever - Link

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

8

4

7 9 2

5 10

11

3

6 1

70V2E12001

15-3 70ZIV-2 Service Standard Chassis Group Linkage Pin Standard Clearance Values

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

Item

Solution

Pin standard dimension

Standard clearance

Tolerance

1

Joint section between attachment and boom

ø70 (ø2.7559)

0.100~0.250 (0.0039~0.0098)

1.0 (0.0393)

Replacement

2

Joint section between boom and lever

ø110 (ø4.3307)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

3

Joint section between boom and boom cylinder

ø80 (ø3.1496)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

4

Joint section between front chassis and boom

ø90 (ø3.5433)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

*

5

Joint section between attachment and link

ø80 (ø3.1496)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

*

6

Joint section between lever and link

ø80 (ø3.1496)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

7

Joint section between lever and bucket cylinder

ø90 (ø3.5433)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

8

Joint section between bucket cylinder and front chassis

ø90 (ø3.5433)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

9

Joint section between boom cylinder and front chassis

ø80 (ø3.1496)

0.120~0.295 (0.0047~0.0116)

1.0 (0.0393)

Replacement

*

10

Joint section between front chassis and steering cylinder

ø45 (ø1.7716)

0.080~0.205 (0.0031~0.0080)

1.0 (0.0393)

Replacement

*

11

Joint section between steering cylinder and rear chassis

ø45 (ø1.7716)

0.080~0.205 (0.0031~0.0080)

1.0 (0.0393)

Replacement

*

15-4 70ZIV-2 Service Standard Chassis Group Linkage Pin Standard Clearance Values

Liner clearance adjustment

70ZV15001

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

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

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

15-5 70ZIV-2 Service Standard Chassis Group Center Pin

Center Pin Center pin shim adjustment

[Upper]

1

8

Grease nipple installing

4 3

10

3

Front

5

11

Front chassis

6

22.5

Grease nipple installation direction

70ZV15003

Front chassis

2 12 9

Rear chassis

Upper 70ZA1208

The clearance between the front chassis and bearing cover (3) is 0.75±0.5 mm (0.0295±0.0197 in) before shim adjustment.

Add shims so that the clearance is 0.1±0.05 mm (0.0039±0.0020 in). : Bolt (10): 216 N-m (22.0 kgf-m) (159 lb-ft) Bolt (9): 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubrication oil (engine oil or gear oil))

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

15-6 70ZIV-2 Service Standard Chassis Group Center Pin

Lower center pin bearing outer ring installing [Lower]

7

2

3

5 6 Front

4

Rear

Split of outer bearing

3

20

Front chassis Grease nipple installation direction Rear chassis

1

Lower

70ZV15004

Install bearing outer ring (3) so that the split is perpendicular to the front-rear line of the machine.

70ZA1209

15-7 70ZIV-2 Service Standard Chassis Group Bucket

Bucket (Tooth mounting section)

Tooth

: Tooth mounting bolt (5): 834N-m (85.0 kgf-m)

(Wear edge mounting section)

(Wear plate mounting section)

Edge

Center 28 Side 32

Wear edge

: Wear edge mounting bolt (6): 834N-m (85.0 kgf-m)

Wear plate (option)

: Wear plate mounting bolt (7): 834N-m (85.0 kgf-m)

15-8 70ZIV-2 Service Standard Chassis Group Bucket Positioner and Boom Kick-Out (Option)

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

Bucket positioner

15-9 70ZIV-2 Service Standard Chassis Group Bucket Positioner and Boom Kick-Out (Option)

Bucket positioner

Adjusting plate

3 Indicator lamp

5 Proximity switch

5 2

2.5

3

4 1

K70ZIV1501

Bucket positioner adjustable angle

-7º Adjusting distance (5): 6 mm

0 46 mm

+15º 134 mm K90ZV15001

No.

Item

Judgment standard

Solution

5±2 mm

Adjustment

1

Clearance of bucket positioner switch

3

Adjusting plate mounting bolt tightening torque

94 N-m (9.6 kgf-m)

Tightening

4

Switch mounting nut tightening torque

20 N-m (2.0 kgf-m)

Tightening

5

Bucket positioner adjustable angle (distance (5))

-7º ~ +15º (6 ~ 134 mm)

Adjustment

15-10 70ZIV-2 Service Standard Chassis Group Bucket Positioner and Boom Kick-Out (Option)

Boom kick-out (option) Boom highest position

Adjusting plate

Connector

Proximity switch

Direction of indicator lamp

Boom kick-out hoist angle

6

15-11 70ZIV-2 Service Standard Chassis Group Bucket Positioner and Boom Kick-Out (Option)

No.

Item

Judgment standard

Solution

5 ± 1 mm

Adjustment

2

Clearance of boom kick-out switch

3

Adjusting plate mounting bolt tightening torque

53 N-m (5.4 kgf-m)

Tightening

4

Switch mounting nut tightening torque

20 N-m (2.0 kgf-m)

Tightening

6

Boom kick-out adjustable angle

8 ~ 43º

Adjustment

15-12 70ZIV-2 Service Standard Chassis Group

MEMO

24-1 70ZIV-2 Disassembly & Reassembly Power Group

70ZIV-2 Disassembly & Reassembly Power Group Power Line .............................................................. 24-2 Radiator................................................................... 24-3 Engine ..................................................................... 24-7 Propeller Shaft......................................................... 24-9 Air Cleaner .............................................................. 24-11 Muffler ..................................................................... 24-13 Front Axle Assembly ............................................... 24-14 Floating Seal (S/N 1201~, 7201~)........................... 24-25 Internal Gear Hub.................................................... 24-27 Spider Assembly ..................................................... 24-29 Special Tool ............................................................. 24-31 Rear Axle Assembly ................................................ 24-36 Axle Support............................................................ 24-41 Differential Assembly............................................... 24-47 Front Differential...................................................... 24-62

24-2 70ZIV-2 Disassembly & Reassembly Power Group Power Line

Power Line Power line tightening torque Radiator assy

T2 L3

Engine

T3 L1

T2 L3

T2 L3

T1 L3

T4 L1

Oil pump

T3 L1

Rear differential

Transmission

3rd propeller shaft (S/N 1973~, 7772~) (S/N ~1023, ~7107) T4 L2 (S/N 1024~, 7108~) T7 L2

T6 L2

(S/N 1001~1023, 7101~7107)

3rd propeller shaft (S/N 1001~1972, 7101~7771)

T2 L3

T5 L2 T5 L2 (S/N 1001~1023, 7101~7107) 2nd propeller shaft

T4 L1

T6 L2

Front differential 70K24001

: T1: 53 N-m (5.4 kgf-m) T2: 417 N-m (42.5 kgf-m) T3: 55 N-m (5.6 kgf-m) T4: 230 N-m (23.5 kgf-m) T5: 142 N-m (14.5 kgf-m) T6: 80 N-m (8.2 kgf-m) T7: 441 N-m (45 kgf-m)

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

24-3 70ZIV-2 Disassembly & Reassembly Power Group Radiator

Radiator Radiator tightening torque

(S/N 1001~1600) (S/N 7101~7350)

Radiator assy

T1 L2

T1 L2

Fan guard

T2 L1

Engine

70N24004

: T1: 94 N-m (9.5 kgf-m) T2: 90 N-m (9.2 kgf-m) L1: Screw lock agent (Loctite® 262) L2: With lubrication oil (Engine oil or gear oil)

24-4 70ZIV-2 Disassembly & Reassembly Power Group Radiator

Radiator removing and installing Radiator removing

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

- Apply the articulation stopper.

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

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

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

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

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

3. Remove plate (3) for both right and left sides.

1. Remove drain plug (1) to drain the coolant. : Coolant in system: 35 L

: Retainer bolt (a): 94 N-m (9.6 kgf-m) : With lubrication oil (Engine oil or gear oil) : Retainer bolt (b): 90 N-m (9.2 kgf-m) : Screw lock agent (Loctite® 262)

24-5 70ZIV-2 Disassembly & Reassembly Power Group Radiator

4. Disconnect coolant hose (4) and remove fan guard (5).

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

6. Disconnect hoses (8)(9) from the hydraulic oil cooler. : Hydraulic oil: 2 L

5. Remove covers (6)(7).

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

24-6 70ZIV-2 Disassembly & Reassembly Power Group Radiator

7. Temporarily sling radiator (10).

Remove the right and left retainer bolts (11). : Bolt (11): 94 N-m (9.6 kgf-m) : With lubrication oil (Engine oil or gear oil)

9. Disconnect transmission cooler hose (13) and radiator drain hose (14).

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

10. Lift the radiator to remove it from the rear chassis. : Radiator: 135 kg

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

8. Lift the radiator about 10 cm and disconnect transmission cooler hose (12).

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

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

24-7 70ZIV-2 Disassembly & Reassembly Power Group Engine

Engine Engine removing and installing Engine removing

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

- Apply the articulation stopper.

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

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

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

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

- Remove the fan and radiator, if necessary.

Note After removing the cooling fan, the engine maybe removed without removing the radiator.

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

3. Disconnect the fuel hose, and then remove the heater hose and cooler hose. Disconnect the pipe from the air compressor, and then remove the drain hose.

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

4. Disconnect the accelerator control cable.

2

Engine

2

70K24004

5. Temporarily sling the engine and the transmission, and then remove engine assembly mounting bolts (2). : Bolt (2): 417 N-m (42.5 kgf-m) : With lubricating oil (Engine oil or gear oil)

Negative side

1. Disconnect the negative side of the battery cable.

Then remove the positive cable.

2. Remove the wiring from the alternator, each sensor, preheat, air conditioner and engine stop motor.

: Engine assy: Approx. 600 kg (excluding oil)

24-8 70ZIV-2 Disassembly & Reassembly Power Group Engine

Engine installing O-ring

3

For reinstallation, follow the above procedure in reverse order.

Engine installation cautions

70K24005

6. Slowly lift the engine while checking that there are no obstacles and that all the pipes, cables, pins, etc. are disconnected, and then remove bolt (3). : Bolt (3): 53 N-m (5.3 kgf-m) : With lubricating oil (Engine oil or gear oil) Note - Place a support, like a wooden block, under the transmission case.

- There is an O-ring in the housing between the engine and torque converter. Be sure to replace the O-ring with a new one. When the ring gear interlocking is hard, open the flywheel cover and slowly rotate the transmission ring gear.

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

Note Lift the engine approximately 100 mm.

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

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

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

Refill the radiator with the properly premixed coolant.

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

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

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

After that, check the amount of the coolant.

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

24-9 70ZIV-2 Disassembly & Reassembly Power Group Propeller Shaft

Propeller Shaft Propeller shaft removing and installing Second propeller shaft removing

5 4 6 2

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

- Apply the articulation stopper.

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

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

1 2nd propeller shaft Front differential 70V24011

1. Remove bolt (2) from the transmission side of second propeller shaft (1). : Bolt (2): 142 N-m (14.5 kgf-m) : Screw lock agent (Three Bond 1327) 2. Disconnect the grease pipe, and remove bolt (5) from pillow unit bearing (4). : Bolt (5) with washer (S/N ~1023): 230 N-m (23.5 kgf-m) : Bolt (5) (S/N 1024~): 441 N-m (45.0 kgf-m) : Screw lock agent (Three Bond 1327) 3. Remove bolt (6) to disconnect the propeller shaft from the front differential.

Support the shaft by cable or garage jack. Take out the second propeller shaft to the front. : Bolt (6): 142 N-m (14.5 kgf-m) : Screw lock agent (Three Bond 1327) : Second propeller shaft: 50 kg Note - If the retainer bolt is too tight due to the screw lock agent, heat the bolt head to about 235ºC using slow flame of a gas burner.

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

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

24-10 70ZIV-2 Disassembly & Reassembly Power Group Propeller Shaft

Third propeller shaft removing

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

(S/N ~1972, ~7771)

Propeller shaft installation cautions

Rear differential

7

70V24012

- During reinstallation, align the direction of the flange yokes on the second and third propeller shaft sides of the transmission. (Refer to Section 22.)

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

- Adjust the shafts so that the grease nipples on them come to the same direction.

(S/N 1973~, 7772~)

Rear differential

7

70V24012a

1. Remove bolt (7). : Bolt (7): 80 N-m (8.2 kgf-m) : Screw lock agent (Three Bond 1327) 2. Remove the third propeller shaft. : Third propeller shaft: 7.6 kg

24-11 70ZIV-2 Disassembly & Reassembly Power Group Air Cleaner

Air Cleaner Air cleaner removing and installing

5 1 6

Air cleaner removing 3

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

- Apply the articulation stopper.

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

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

4 2

70K24007

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

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

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

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

4. Remove the rubber valve on the bottom of the air cleaner case, and inspect it for any damage.

Replace it if necessary.

5. Disconnect air duct (7).

Disconnect indicator wire coupler (8).

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

24-12 70ZIV-2 Disassembly & Reassembly Power Group Air Cleaner

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

Air cleaner installation cautions If the bands of the air duct are not properly positioned or tightened, the duct will draw in dust that will cause an engine problem. Carefully reinstall the air duct.

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

7. While supporting air cleaner case (11) with your hand, remove band retainer nuts (12).

Lower the air cleaner case.

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

24-13 70ZIV-2 Disassembly & Reassembly Power Group Muffler

Muffler Muffler removing and installing

4 (S/N ~1204, ~7200)

Muffler removing

(S/N ~1600, ~7350)

6

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

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

7 5

8

Engine

70K24014a

2. Disconnect drain pipe (3), remove band (4) and nut (5). : Nut (5): 55 N-m (5.6 kgf-m) 3. Remove nuts (7)(8), and then remove muffler (6). : Nut (7): 53 N-m (5.4 kgf-m) : Nut (8): 10 N-m (1.0 kgf-m) : Muffler: 7 kg 1. Remove clamp (1), and then remove exhaust pipe (2).

Note After disconnection, cover the pipe and the turbocharger side with vinyl, plugs or the like to protect the turbocharger from dust and dirt.

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

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

24-14 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front Axle Assembly Front axle assembly tightening torque

T2 L1

T1 L3 (S/N ~1200, ~7200)

Front differential

B T7 L1

(S/N 1601~1919)

T7 L2 (S/N 7351~7615) (S/N 1201~, 7201~)

T6 L1

A

T4 L1

T5

T3

T4 L1

(S/N ~1009)

70V24014a

: T1: 687 N-m (70.0 kgf-m) (S/N ~1684, ~7417) T1: 721 N-m (73.5 kgf-m) (S/N 1685~, 7418~) T2: 132 N-m (13.5 kgf-m) T3: 892 N-m (91.0 kgf-m) T4: 90 N-m (9.2 kgf-m) T5: 86 N-m (8.8 kgf-m) T6: 53 N-m (5.4 kgf-m) T7: 10 N-m (1.0 kgf-m)

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

24-15 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

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

2. Loosen axle nut (A).

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

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

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

24-16 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly removing and installing 1

Front axle assembly removing

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

- Apply the parking brake and the articulation stopper.

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

70ZV24018J

3. Disconnect air bleeder tube (1) from the upper part of the axle housing. Install plastic caps on hose and fitting.

Note Clean the nylon breather tube before reinstalling.

2

Stand Stand 70ZV24017

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

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

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

Release the accumulator pressure, by slowly and fully depressing and releasing the brake pedal many times until it feels light.

70ZV24019J

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

24-17 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

3

5

6 90ZV24033

5. Remove right and left wheel and tire assemblies (3). : Retainer bolt: 892 N-m (91.0 kgf-m) : 1 tire: 275 kg

90ZV24035

7. Temporarily sling axle assembly (5), and then remove retainer bolts (6). : Bolt (6): 687 N-m (70.0 kgf-m) (S/N ~1684, ~7417) 721 N-m (73.5 kgf-m) (S/N 1685~, 7418~) : Axle assembly: 840 kg Note During reassembly be sure both mating surfaces are clean and free of paint.

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

4

70ZV24021J

6. Disconnect brake pipes (4). : Brake oil: 3 L Note Install plastic caps to avoid the dirt from entering the fittings or pipes.

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

24-18 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Front axle assembly installation cautions

Service brake air bleeding procedure

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

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

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

Air bleeder nipple

Spider Socket bolt 90ZV24036

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

Finally the spider and the cover may fall off.

Vinyl tube 70ZV52019

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

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

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

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

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

Repeat this for all wheels until there is no air in the oil. : Air bleeder nipple: 10 N-m (0.9 kgf-m)

24-19 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Planetary assy disassembling and assembling

1

Planetary assy disassembling

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

- Apply the articulation stopper.

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

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

90ZV24052

3. Remove the wheel and tire assembly (1) from the side to be disassembled (example: left side). : Retainer bolt: 892 N-m (91.0 kgf-m) : Tire: 275 kg / each

Differential section

Stand Stand

2 70ZV24025J

70ZV24017

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

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

4. Remove drain plug (2) from the differential section to drain oil. : Gear oil: Approx. 30 L

24-20 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

3 4

90ZV24054

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

6. Temporarily sling the spider using hoisting tool (A). and (E).

Remove four spider retainer bolts (6) to remove spider assembly (7). : Bolt (6): 86 N-m (8.8 kgf-m) : Spider assembly: 60 kg

Wheel hub section: 10 L for left side, 10 L for right side Differential section (front): 30 L Total oil amount for front axle: 50 L Reference Differential section (rear): 34 L Total oil amount for rear axle: 52 L

TOP

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

8. Remove friction plate (10).

5

90ZV24055

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

24-21 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Turnbuckle

E

3 90ZV24060

9. Remove steel plate (11) and disc gear (12).

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

Refer to Section 52 and for additional information.

11. Turn wheel hub (3) until the drain plug is positioned on the top.

Connect the turnbuckle to eye bolt (E) to lock the wheel hub, and then place a wooden block under the wheel hub to support it.

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

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

Remove retainer bolts (15), and then remove lock plate (16). : Bolt (15): 53 N-m (5.4 kgf-m) : Screw lock agent (Three Bond 1327) Note When reassembling axle shaft (13) into the axle housing, applying the principle of leverage, insert axle shaft (13) making sure the toothing between the side gear of the differential and shaft (13).

12. Remove axle nut (17). : Nut (17): 1,177 N-m (120 kgf-m) Axle nut width across flat: 120 mm

24-22 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

D

Extension

E 3

Jig (B)

18

19

Wooden block 80ZV24027

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

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

Wooden block

80ZV24029

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

Then remove wheel hub (3).

16. Remove taper roller bearing (19).

Also remove the sleeve from the axle on machines S/N 1001~1200, 7101~7200.

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

24-23 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Planetary assy assembling

Internal gear hub installation

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

Internal gear Brake oil holes Brake oil holes at 2 locations

Planetary assy assembly cautions

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

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

Oil seal installation (S/N ~1200, ~7200)

Oil seal

Grease

Axle housing extension

Before reinstalling the internal gear hub assembly, align the brake oil holes of the axle housing extension with that of the internal gear hub assembly.

Axle nut tightening

Sleeve

Use wheel hub oil seal press-in jig (F) to insert the oil seal into the wheel hub.

Fill the clearance between the oil seal and sleeve with grease.

17

80V2E24024

1. Tighten axle nut (17) with 1,177 N-m (120 kgf-m) tightening torque to install the taper roller bearing, and then loosen axle nut (17).

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

Note This is the force to start the wheel hub moving or "breakaway" force. Before measuring the preload, turn the wheel hub 2~3 turns back and forth.

24-24 70ZIV-2 Disassembly & Reassembly Power Group Front Axle Assembly

Brake adjustment Wheel hub Spider "TOP" mark (at top)

Brake oil line

Drain plug (at bottom) 90ZV24077

Brake oil inlet port 90ZV24074

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

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

Shut off valve

Air supply PT 1/4

Air pressure gauge

Jig (G) 90ZV24071

1. Disconnect the brake pipe and the elbow from the brake oil inlet port on the axle housing, and attach jig (G) to the port.

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

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

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

24-25 70ZIV-2 Disassembly & Reassembly Power Group Floating Seal (S/N 1201~, 7201~)

Floating Seal (S/N 1201~, 7201~) Floating seal installation

Ring

1. Checking before floating seal installation.

Bearing

O-ring Wheel hub

O-ring Axle housing

Remove oil

Put thin gear oil (Do not use grease)

Seal ring

Ring

90ZV24065

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

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

Do not touch (It may cause rusting) 90ZV24066

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

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

24-26 70ZIV-2 Disassembly & Reassembly Power Group Floating Seal (S/N 1201~, 7201~)

Floating seal assembling Guide jig

1. In case no jig is used - Install the O-ring on the seal ring.

- Put thin gear oil on the O-ring.

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

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

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

Before installation

95ZVE24011

2. In case jig is used

1

2 3 Guide jig

Installation jig

4

70ZV24095J

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

-

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

Put thin gear oil on the O-ring.

Insert the floating seal into the guide jig.

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

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

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

After installation 95ZVE24010

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

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

24-27 70ZIV-2 Disassembly & Reassembly Power Group Internal Gear Hub

Internal Gear Hub Internal gear hub disassembling and assembling

1

Internal gear hub disassembling

1

3 70ZV24038J

2. Temporarily sling internal gear (1) to remove gear (3).

2 A

: Internal gear: 25 kg 70ZV24020

4

Screwdriver Bend slightly

70ZV24039J 70ZV24019

3. Remove O-rings (4).

1. Put the internal gear hub assembly on a platform or a level place.

There is snap ring (A) that connects internal gear (1) to internal gear hub (2).

Shift the snap ring to the inside using a screwdriver or the like.

24-28 70ZIV-2 Disassembly & Reassembly Power Group Internal Gear Hub

Internal gear hub assembly cautions

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

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

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

5 70ZV24040J

4. Remove taper roller bearing (5).

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

5. Remove the brake piston from the internal gear hub.

5

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

70ZV24041J

- Before reinstallation of taper roller bearing (5), be sure to heat the bearing to 120~150ºC in oil.

- Apply grease to the O-rings.

- For disassembling and reassembling the brake piston, refer to Section 54.

24-29 70ZIV-2 Disassembly & Reassembly Power Group Spider Assembly

Spider Assembly Spider assy disassembling and assembling

5 6

Spider assy disassembling

4

7 70ZV24044J

2

1 90ZV24136

1. Remove lock bolts (1), and then remove plate (2). : Lock bolt (1): 90 N-m (9.2 kgf-m) : Screw lock agent (Three Bond 1327)

3. Remove thrust washers (7) and bearing (5)(6) from planetary gear (4).

Note - Install the bearings so that bearing (5) comes outside (cover side) and bearing (6) inside (brake retainer side).

Bearing (5) width: 20 mm Bearing (6) width: 25 mm

: Spider assy: 95 kg 9 1 3

4 8 80V2E24019 90ZV24137

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

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

24-30 70ZIV-2 Disassembly & Reassembly Power Group Spider Assembly

Spider assy assembling

Spider assy assembly cautions

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

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

Before starting work: - Clean all the parts.

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

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

- Inspect the internal bores of the spider for wear.

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

1 3

4

90ZV24137

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

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

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

24-31 70ZIV-2 Disassembly & Reassembly Power Group Special Tool

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

R

8( 0.

3)

R (0 10 .4 )

30

3(0.1)

75(3.0)

R

12 (0.5)

65(2.6) 10 (0.4)

t6(0.2)

3(0.1)

6

t6

t6

6

(0.2)

(0.2)

(0.2)

(0.2)

C2 (0.08)

m ril 5m )d ø2 . 0 i n (1

46(1.8)

22(0.9)

105(4.1)

2)

(1.

4(0.2) C2(0.08)

10 (0.4)

46(1.8)

ø6 mm (0.2 in) dia. round steel

C 2(0.08)

led

C 2(0.08)

65(2.6) 90ZV24085

(B) Internal gear hub puller & Brake piston remover mm (in)

(Material: SS41)

25(1)

25(1)

t12(0.5) M12x1.75

156(6.1)

4x 12(0.5)

80(3.1) 160(6.3) 312(12.3) 345(13.6)

70ZV24021

24-32 70ZIV-2 Disassembly & Reassembly Power Group Special Tool (C) Internal gear hub hoisting tool mm (in)

(Material: SS41)

75(3.0) 75 (3.0)

t12(0.5)

35(1.4) 35(1.4)

ø13 mm (0.5 in) drilled

20 R .8) t12 (0.5) 0 15

(

13 35

R

15 R

35

155 (6.1)

270(10.6) 288 (11.3)

35 (1.4)

215(8.5) 215 (8.5)

t9

56 (2.2)

A

(0.6)

15

(0.6)

A A

15 5 R .6) R1 .6) (0 (0 10 0 R .4) R1 .4) (0 (0

A

t9(0.4)

.4)

(0.4)

t9(0.4) 3 15 7 3 15 7 (0.1) (0.6) (0.3) (0.1) (0.6) (0.3)

(0.4)

35 (1.4)

(2 .4) 60 0(2 R

56(2.2)

R6

t9

27.5 (1.1)

27.5 (1.1)

35(1.4) 90(3.5) 35 (1.4)

A 90 - A(3.5) A-A

27.5 (1.1)

15 10 15 (0.6)10 (0.4) (0.6) (0.4) 25 25 (1.0) (1.0)

35 (1.4)

15

292(11.5) 310 (12.2)

20 0 R .8) R2 .8) (0 (0

434(17) 452 (17.8)

)

.6

(0

155(6.1) 13 (1.4) (0.5) (1.4) (0.5)

25 (1.0) 25 (1.0)

(

20 R .8) 0 35 ( (1.4)

20 0 R .8) R2 .8) (0 (0 15 5 R .6) R1 .6) (0 (0

107(4.2) 107 (4.2)

235(9.3) 345(14) 235 (9.3) 345 (14)

)

6 0.

27.5 (1.1) 90ZV24087 70ZV24036

24-33 70ZIV-2 Disassembly & Reassembly Power Group Special Tool (D) Wheel hub hoisting tool mm (in)

(Material: SS41)

10(0.4)

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

4(0.2)

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

3(0.1)

t6 (0.2)

3 (0.1)

*

25(1.0)

4(0.2)

t6(0.2)

C2 (0.08)

t6 (0.2)

2 (1 5-m .0 m ) dr ille d

45(1.8)

3 (0.1)

10 (0.4)

20(0.8)

55(2.2)

20(0.8)

R 5(

4(0.2)

3 (0.1)

0.

2)

R (0 20 .8 )

C 2(0.08)

C2 (0.08)

C2 (0.08) 60(2.4)

90ZV24088

(E) Eye bolt mm (in) M24x2

30(1.2)

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

90ZV24089

24-34 70ZIV-2 Disassembly & Reassembly Power Group Special Tool (F) Wheel hub oil seal press-in tool mm (in)

(Material: SS41)

30 C2

30

5 Welded

R

7

20

13

R

C1

4

230 238 70ZIV2404

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

mm (in)

2.

1.

15(0.6)

230(9.1)

3(0.1)

190(7.5)

240(9.5)

224.8(8.9) +0 214.6 +00.1 (8.4 0.004) +0.1 209.6 +0 (8.2–0.004) 201.1–0.1(7.9–0.004)

10–0.3 (0.4–0.01)

235(9.3)

+0.004

214 +0.1 +0.05 (8.4 +0.002 )

+0.010

223 +0.25 +0.3 (8.8 +0.012 )

209.4–0.1(8.2–0.004) C

)

20(0.8) 8–0.2 (0.31–0.008)

3(0.1)

5(0.2)

(

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

80V2E24040

24-35 70ZIV-2 Disassembly & Reassembly Power Group Special Tool 2. For ring [ P/N for tool set: 99202-01760 ]

mm (in)

2.

1.

13(0.5) 3C

(

)

20(0.8) 11–0.2 (0.43–0.008)

3(0.1)

3(0.1)

230(9.1)

190(7.5)

10–0.3 (0.4–0.01)

224.8(8.9) +0 214.6 +00.1 (8.4 0.004) +0.1 209.6 +0 (8.2–0.004) 201.1–0.1(7.9–0.004)

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

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

3(0.1)

10.4–0.3 (0.41–0.01)

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

80V2E24041

24-36 70ZIV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear Axle Assembly Rear axle assembly tightening torque

T4 L1 (S/N ~1200, ~7200)

B

T5 T4 L1

A T6 L1 (S/N ~1009)

T1 (S/N ~1919, ~7615)

C

T7 L1 (S/N 1601~1919)

T7 L2 (S/N 7351~7615) (S/N 1201~, 7201~)

C Rear differential T2 L1 70N24002a

: T2: 314 N-m (32.0 kgf-m) T3: 892 N-m (91.0 kgf-m) T4: 90 N-m (9.2 kgf-m) T5: 86 N-m (8.8 kgf-m) T6: 53 N-m (5.4 kgf-m) T7: 10 N-m (1.0 kgf-m)

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

24-37 70ZIV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

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

2. Loosen axle nut (A).

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

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

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

24-38 70ZIV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

Rear axle assembly removing and installing Rear axle assembly removing

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

- Apply the articulation stopper.

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

B 70ZV24054J

2. Lift the boom, and then roll the attachment back to level. Check that the rear wheels are off the ground. Place stand (B) under the counter weight to support it.

Wooden blocks

Block

70ZV24024

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

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

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

A

70ZV24053J

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

24-39 70ZIV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

1

70ZV24056J

4. Remove right and left wheel and tire assemblies (1). : Tire of 1 wheel: 275 kg : Retainer bolt: 892 N-m (91.0 kgf-m)

6. Disconnect air bleeder hose (3).

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

- Release the accumulator pressure by slowly and fully depressing and releasing the brake pedal many times until it feels light.

- Remove and clean hose (3) before reinstalling.

- Install plastic cap on the breather fitting.

5. Remove retainer bolts to remove third propeller shaft (2). : Bolt (2): 80 N-m (8.2 kgf-m) : Screw lock agent (Loctite® 262) : Third propeller shaft: 10 kg (25 lbs) Note Replace propeller shaft retainer bolts (2) with new ones.

Do not reuse them when reassembling.

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

7. Disconnect front and rear grease pipes (4) and brake hose (5). : Brake oil: Approx. 3 L Note Cover and plug the hose and fittings to prevent dirt entry.

24-40 70ZIV-2 Disassembly & Reassembly Power Group Rear Axle Assembly

CAUTION Wooden block

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

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

Refer to "Service brake air bleeding procedure" page 24-18 for air bleeding in the service brake.

Rear axle disassembling and assembling For disassembling and reassembling the rear axle assembly, refer to the front axle disassembling and reassembling procedures.

8. Temporarily sling rear axle (6), and remove right and left retainer bolts (7) from the rear axle front support.

Remove right and left retainer bolts (8) from the rear axle rear support. : Bolt (7)(8): 687 N-m (70.0 kgf-m) (S/N ~1684, ~7417) 721 N-m (73.5 kgf-m) (S/N 1685~, 7418~) : Rear axle: 940 kg 9. Lower rear axle assembly (6) on the carrier, and then pull out the rear axle.

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

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

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

24-41 70ZIV-2 Disassembly & Reassembly Power Group Axle Support

Axle Support Axle support tightening torque (S/N 1001~1919, 7101~7615) (S/N ~1841, ~7582)

Rear axle assembly

(S/N 1842~, 7583~)

T3 L1

T1 L2

FRONT

T2 L1

Front axle support

T1 L2

Rear axle support

70N24003a

: T1: 687 N-m (70.0 kgf-m) (S/N ~1684, ~7417) T1: 721 N-m (73.5 kgf-m) (S/N 1685~, 7418~) T2: 231 N-m (23.5 kgf-m) (S/N ~1919, ~7615) T2: 314 N-m (32.0 kgf-m) (S/N 1920~, 7616~) T3: 53 N-m (5.4 kgf-m) (39 lb-ft)

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

24-42 70ZIV-2 Disassembly & Reassembly Power Group Axle Support (S/N 1920~, 7616~)

Rear axle assembly (S/N ~1935) (S/N ~7881)

T1 L2

(S/N ~1935) (S/N ~7881) Front axle support

T3 L1

T2 L1

FRONT

T1 L2

T2 L1

Rear axle support

K70ZIV2401

: T1: 721 N-m (73.5 kgf-m) T2: 314 N-m (32.0 kgf-m) T3: 53 N-m (5.4 kgf-m)

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

24-43 70ZIV-2 Disassembly & Reassembly Power Group Axle Support

Axle support disassembling and assembling

4. Remove bushing (7), O-ring (8) and packing (9).

Remove ring (10) (S/N 1842~, 7583~ only).

Breather (A)

Axle support disassembling (S/N 1001~1919, 7101~7615)

16 19

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

12

11 13 17

15 14

18

(S/N 1001~1841) (S/N 7101~7582)

1 20

6

Rear axle assy

5

9

Snap ring

21 70K24033

5. Temporarily sling rear axle support (11) and remove bolt (12).

8

: Bolt (12): 231 N-m (23.5 kgf-m) : Screw lock agent (Three Bond 1327) 7 FRONT

70V24017

(S/N 1842~1919) (S/N 7583~7615)

5

7. Remove and clean breather fitting (A).

6

4

Note When the fitting is reinstalled, apply Liquid gasket AA03 (Three Bond 1215) on the threads.

Lubricate after reassembly to be sure grease comes out of the breather.

3

7 FRONT

2

6. Remove plate (13), packing (14), wear ring (15), and O-ring (16) from rear axle support (11).

1

10

Rear axle assy

8. Remove rear axle support (11) from the rear axle assembly.

9 8 70V24017a

1. Temporarily sling front axle support (1) and remove by sliding it off the rear axle assembly. : Axle support (front) (1): 50 kg 2. (S/N 1001~1841, 7101~7582) Remove snap ring (9).

(S/N 1842~1919, 7583~7615) Remove bolt (2), plate (3) and ring (4). : Bolt (2): 53 N-m (5.4 kgf-m) (40 lb-ft) 3. Remove packing (5) and O-ring (6).

: Axle support (rear) (11): 51 kg 9. Remove packing (17) and wear ring (18).

10. Remove bushing (19), ring (20), and O-ring (21) from the rear axle support.

24-44 70ZIV-2 Disassembly & Reassembly Power Group Axle Support

Axle support disassembling (S/N 1920~, 7616~)

8

Rear support

10

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

12

6 7

Rear axle

9 11

Front support

13 70V2E24039

3 2

5. Temporarily sling the rear axle rear support.

Remove bolt (6).

Remove plate (7) and wear ring (8). Remove bolt (9), plate (10) and wear ring (11).

1 5

4 70ZIV2406

1. Remove bolt (1) and attach sling to the rear axle front support. : Bolt (1): 53 N-m (5.4 kgf-m) : Screw lock agent (Three Bond 1327) : Axle support (front): 55 kg

: Bolt (6)(9): 314 N-m (32.0 kgf-m) : Screw lock agent (Three Bond 1327) : Axle support (rear): 60 kg 6. Remove the rear axle rear support from the rear axle.

7. Remove bushing (12) and packing (13) from the rear support.

2. Remove ring (2). Remove the rear axle front support from the rear axle.

3. Remove packing (3) from ring (2).

Axle support assembling

4. Remove bushing (4) and packing (5) from the front support.

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

Axle support assembly cautions

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

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

24-45 70ZIV-2 Disassembly & Reassembly Power Group Axle Support

Bushing installation Front support (S/N 1920~, 7616~)

Front support (S/N ~1919, ~7615)

Axle support Axle support

5

2 Bushing

1

3

Swing shaft Front Swing shaft

4

1. Before installing, put the bushing into hot water to heat it to 80ºC.

70ZV24029

1. Before installing, put bushing (2) into dry ice.

2. Install lip seal packing (1) on the axle support.

2. Install packing (1) and O-ring (2) on the swing shaft.

3. Install the heated bushing onto the swing shaft as shown in the illustration.

4. Carefully install the axle support onto the swing shaft.

CAUTION When installing the bushing onto the differential swing shaft, make sure no oil is left on the inner surface of the bushing or the swing shaft surface. If oil is left on them, the bushing may turn alone causing the bushing wear.

Avoid damage to lip seal packings (1)(8).

5. After installing the axle support, install O-ring (7), packing (8) and snap ring (9).

3. Install cooled bushing (2) to the front axle support as shown in the illustration.

After installing, be sure to press bushing (2) until stopped by the stopper of the axle support.

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

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

4. Carefully install the axle support onto the swing shaft.

Avoid damage to lip seal packings (1)(4).

5. Install ring (3) and lip seal packing (4).

6. Tighten bolts (5). : Bolt: 53 N-m (5.4 kgf-m) : Screw lock agent (Three Bond 1327)

24-46 70ZIV-2 Disassembly & Reassembly Power Group Axle Support Rear support (S/N ~1919, ~7615) Axle support

Rear support (S/N 1920~, 7616~) [Rear support]

Rear

Axle support

Bushing

6 7 8 Swing shaft

13

12

10

11 70ZV24030

1. Before installing, put the bushing into hot water to heat it to 80ºC. 2. Install packing (3), wear ring (4), ring (5), O-ring (6) on the swing shaft.

3. Install the heated bushing onto the swing shaft as shown in the illustration.

4. Carefully install the axle support onto the swing shaft.

CAUTION When installing the bushing onto the differential swing shaft, make sure no oil is left on the inner surface of the bushing or the swing shaft surface. If oil is left on them, the bushing may turn alone causing the bushing wear.

Avoid damage to lip seal packings (3)(13).

5. After installing the axle support, install O-ring (10), wear ring (11), and then install packing (13) to plate (12).

1. Before installing, put bushing (10) into dry ice.

2. Install cooled bushing (10) to the rear axle support as shown in the illustration.

After installing, be sure to press bushing (10) until stopped by the stopper of the axle support.

Note The side with a groove on bushing (10) should come to the rear side.

3. Install lip seal packing (11) onto the axle support and install snap ring (12).

4. Carefully install the axle support onto the swing shaft. Avoid damage to packing (11).

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

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

Note When installing the axle support, fill enough grease between the packing and the axle support as shown in the illustration (shaded area).

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

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

24-47 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential Assembly Differential assembly removing and installing

A

Spider assembly

2

Differential assembly removing

TOP

1 Cover bolt 90ZV24079

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

Remove the cover bolts and cover (1).

Remove retainer bolts (2) to remove the spider assembly.

70ZV24067J

: Bolt (2): 86 N-m (8.8 kgf-m) : Spider assembly: 60 kg (132 lbs)

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

3

- Remove the axle from the machine.

Note Refer to "Front Differential" page 24-62 when removing the front differential without removing the front axle from the machine.

- For the rear axle, remove the axle supports.

Refer to "Rear axle assembly removing and installing" page 24-38.

70ZV24069J

- Place the axle assembly on work benches. : Axle assembly (Front): 840 kg : Axle assembly (Rear): 940 kg

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

24-48 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

4

7 5 90ZV24084

90ZV24081

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

3. Remove bolts (5) from differential (4). : Front differential retainer bolts: 132 N-m (13.5 kgf-m) Rear differential retainer bolts: 314 N-m (32.0 kgf-m) : Screw lock agent (Three Bond 1327)

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

Differential assembly installation cautions

4

6 90ZV24083

4. Temporarily sling differential (4), and insert bolts into remover tap (Jack Screw) holes (6) to slightly lift the differential. : Differential: 130 kg Note Carefully sling the differential so that it is balanced and is lifted straight up.

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

- Refill the oil in each planetary assy.

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

- Check the differential for oil leakage.

24-49 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assembly disassembling and assembling Front differential tightening torque T2 L1

T5 L1

T3 L1

T7 L1 F

C

E

D

F

T6 L1

Shim (T=0.07~ 0.50)

B (T=16.70~16.98)

A

T1 L1 T4 L1 L2

: T1: 883 N-m (90.0 kgf-m) T2: 515 N-m (52.5 kgf-m) T3: 231 N-m (23.5 kgf-m) T4: 314 N-m (32.0 kgf-m) T5: 132 N-m (13.5 kgf-m) T6: 330 N-m (33.7 kgf-m) T7: 55 N-m (5.6 kgf-m)

L1: Screw lock agent (Three Bond 1327) L2: Liquid gasket (Three Bond 1215, or a locally procured RTV that does not contain acetic acid.) : Differential: 130 kg

70V24033

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

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

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

Adjust the backlash by nut (F).

24-50 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

Rear differential tightening torque (S/N 1001~1919, 7101~7615) T6 L1 D

T3 L1

F T2 L1

T7 L1

C A

T5 L1

E

Shim (T=0.07~0.50)

F B T1 L1

L2

T4 L1

(T=16.70~16.98) 70V24021

: T1: 883 N-m (90.0 kgf-m) T2: 515 N-m (52.5 kgf-m) T3: 230 N-m (23.5 kgf-m) T4: 314 N-m (32.0 kgf-m) T5: 132 N-m (13.5 kgf-m) T6: 330 N-m (33.7 kgf-m) T7: 55 N-m (5.6 kgf-m) L1: Screw lock agent (Three Bond 1327) L2: Liquid gasket (Three Bond 1215, or a locally procured RTV that does not contain acetic acid.) : Differential: 130 kg

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

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

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

Adjust the backlash by nut (F).

24-51 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

Rear differential tightening torque (S/N 1920~, 7616~) T6 L1 T3 L1

D

F

T2 L1

T7 L1

C A (T=0.07~0.50) E Shim

T5 L1

B (T=16.70~ 16.98)

F

L2 T4 L1

T1 L1 70V24021a

: T1: 883 N-m (90.0 kgf-m) T2: 515 N-m (52.5 kgf-m) T3: 230 N-m (23.5 kgf-m) T4: 314 N-m (32.0 kgf-m) T5: 132 N-m (13.5 kgf-m) T6: 330 N-m (33.7 kgf-m) T7: 55 N-m (5.6 kgf-m) L1: Screw lock agent (Three Bond 1327) L2: Liquid gasket (Three Bond 1215, or a locally procured RTV that does not contain acetic acid.) : Differential: 130 kg

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

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

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

Adjust the backlash by nut (F).

24-52 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assembly disassembling

Adjust nut

3

Shim

3 Nut

4

Bevel gear

Pinion

2

Adjust nut 70ZV24031

90V2E24038

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

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

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

Loosen the pinion nut.

: Bolt (3, L.H with bushing): 230 N-m (23.5 kgf-m) : Bolt (3, R.H without bushing): 515 N-m (52.5 kgf-m) : Screw lock agent (Three Bond 1327)

5

: Pinion nut: 883 N-m (90 kgf-m) : Nut width across flat: 57.1 mm 6

90ZV24150

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

1 2 90V2E24037

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

24-53 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

12

7 8

Matchmark

11 90ZV24107

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

13

90ZV24109

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

: Bolt (8): 132 N-m (13.5 kgf-m) : Screw lock agent (Three Bond 1327)

14

90ZV24110

10

7. Remove side gear (14).

9 90ZV24108

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

15

90ZV24111

8. Remove thrust washer (15).

24-54 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

20

17

21

16 90ZV24112

9. Turn the differential upside down.

Remove bolts (17) from bevel gear (16) to separate the gear.

90ZV24114

11. Remove nut (20) and O-ring (21). : Nut (20): 883 N-m (90.0 kgf-m) : Nut width across flat: 57.1 mm : Screw lock agent (Three Bond 1327)

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

22

19

18

90ZV24115 90ZV24113

12. Remove flange yoke (22).

10. Remove bolts (18) to remove pinion (19).

At the same time, remove the shim.

23

: Bolt (18): 314 N-m (32.0 kgf-m) : Screw lock agent (Three Bond 1327) Note The rear differential assembly (S/N 1920~, 7616~) has the trunnion installed with bolts (18) as shown.

24 90ZV24116

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

24-55 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

25

90ZV24117

14. Remove taper roller bearing (25).

26

90ZV24118

15. Remove spacer (26).

24-56 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

Differential assy assembling

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

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

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

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

: Nut (20): 883 N-m (90.0 kgf-m)

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

26

24

0

A

90ZV24119

20

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

25 27

23

28

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

A

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

22 90ZV24120

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

Pinion

Bearing

Pinion

(f)

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

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

Stake at 3 points

90ZV24121

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

24-57 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

Front

Rear Shim

Shim

18

18 Check direction of the lips

29

24

Apply liquid gasket (AA03) to these surfaces 90ZV24122

2. Install oil seal (29) to cage (24).

Note Before installing oil seal (29), be sure to apply grease to the lip, and also apply liquid gasket to the outside of the seal.

30 31

30 31

70V2E24043

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

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

Note Install the trunnion to the rear differential assembly. : Bolt (18): 314 N-m (32.0 kgf-m) : Screw lock agent (Three Bond 1327)

22

20

21 90ZV24123

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

Apply liquid gasket to nut (20), and then tighten the nut. : Nut (20): 883 N-m (90.0 kgf-m) : Nut width across flat: 57.1 mm : Liquid gasket (Three Bond 1215)

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

24-58 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

12

16

11

17

13

90ZV24145

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

90ZV24148

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

6

90ZV24149

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

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

8

7

3

Matchmark

4

90ZV24147

Adjust nut

8. Align differential cage (7) with the matchmark, and then tighten bolts (8). : Retainer bolt (8): 132 N-m (13.5 kgf-m) : Screw lock agent (Three Bond 1327)

90ZV24131

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

(For both the right and left sides)

24-59 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

1

34

3

2 4

Dial gauge (A)

16

33

70ZV24032

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

Read the backlash value indicated on the dial gauge. (d) Adjust the backlash.

Standard backlash: 0.25~0.33 mm - Tighten adjustment nut (33) on the bevel gear side or loosen adjustment nut (1) on the opposite side to reduce the backlash.

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

90ZV24133

13. Tighten bolts (3) of bearing cap (4). : Bolt (3, Bevel gear side): 231 N-m (23.5 kgf-m) : Bolt (3, Opposite side (without bushing)): 515 N-m (52.5 kgf-m) : Screw lock agent (Three Bond 1327) 14. Mount lock plate (2), and then tighten bolts (34) to fix the lock plate. : Bolt (34): 53 N-m (5.35 kgf-m) : Screw lock agent (Three Bond 1327)

24-60 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly

Adjusting tooth contact Tooth contact

Possible cause

Adjusting method

A

Correct

B

Ring gear is too close to the drive pinion

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

C

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

D

Drive pinion is too close to the ring gear.

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

Check again the backlash and tooth contact.

2

2

2

1

E

Drive pinion is too far from the ring gear.

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

Check again the backlash and tooth contact.

2

1

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

24-61 70ZIV-2 Disassembly & Reassembly Power Group Differential Assembly Three types of tooth contact shown below are acceptable as the best tooth contact.

Tooth contact position and length (rate)

10 1

Pattern A

5 TOP

4

HEEL

4~5

Pitch line TOE

10

BOTTOM

10 2 Pattern B

4 TOP

4 HEEL

Pitch line

4~5

10

TOE BOTTOM

10 3 Pattern C

4 TOP

TOE

3 HEEL

4~5

10

Pitch line BOTTOM

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

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

24-62 70ZIV-2 Disassembly & Reassembly Power Group Front Differential

Front Differential Front differential removing and installing (Without removing the front axle assembly)

WARNING

Differential section

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

- Apply the articulation stopper.

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

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

2 70ZV24025J

3. Remove drain plug (2) from the differential section to drain oil. : Gear oil: Approx. 30 L

Stand Stand 70ZV24017

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

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

4. Remove grease pipe (3) and bolts (4).

24-63 70ZIV-2 Disassembly & Reassembly Power Group Front Differential

5 6

7

70K24058

5. Disconnect brake pipe (5) and remove bolts (7).

Then disconnect 2nd propeller shaft (6) from the differential. : Bolt (7): 132 N-m (13.5 kgf-m) : Screw lock agent (Three Bond 1327)

7. Holding sun gear (A), pull out left axle shaft (9) about 300 mm.

Note If shaft (9) is pulled out with sun gear (A), the plate and the disc also come out.

To prevent it, holding the sun gear.

8. Pull out the right axle shaft about 300 mm.

8

70K24059

11

6. Remove cover (8).

70K24061

9. Remove all the bolts from the differential except bolt (11) to prevent the differential falls down.

24-64 70ZIV-2 Disassembly & Reassembly Power Group Front Differential

Front differential removing and installing tool Thickness: t15 mm Material: SS41

Jack

10. Attach a special jig (12) installed on a jack to the differential by using bolts (13).

11. Remove bolt (11).

12. Remove the differential assy (1) from the axle housing.

25-1 70ZIV-2 Service Standard Power Group

70ZIV-2 Service Standard Power Group Propeller Shaft Service Standard ............................ 25-2 Axle and Differential Service Standard.................... 25-3

25-2 70ZIV-2 Service Standard Power Group Propeller Shaft Service Standard

Propeller Shaft Service Standard

1 Bearing play

Third propeller shaft

2: Circumferential play

6 4

5

Second propeller shaft

3: Transverse play

70ZV25001

Unit: mm (in) No.

Item

Tolerance

Solution

Second, third propeller shaft

0.25

Replacement

1

Spider bearing play

2

Spline circumferential play

Second propeller shaft

0.8

Replacement

3

Spline transverse play

Second propeller shaft

1.0

Replacement

4

Bolt tightening torque

69 N-m (7.0 kgf-m)

Tightening

5

Bolt tightening torque

155 N-m (15.8 kgf-m)

Tightening

6

Clearance

7.34 ± 3

—

25-3 70ZIV-2 Service Standard Power Group Axle and Differential Service Standard

Axle and Differential Service Standard Axle group

2,3

4

1,3

4

70ZV25002J

Unit: mm Judgment standard No.

Item

Solution Standard dimension

Tolerance

1

Backlash between sun gear and planetary gear

0.196~0.564

0.196~0.564

Replacement

2

Backlash between planetary gear and internal gear

0.216~0.604

0.216~0.604

Replacement

3

Tooth contact of gear

4

Bushing and wear ring wear

Replacement

No abnormality Oil groove 1.0

No oil groove

Replacement

25-4 70ZIV-2 Service Standard Power Group Axle and Differential Service Standard

Differential 1

2

3

4

5, 6 5, 6

K70V2E25003

Unit: mm Judgment standard No.

Item

Solution Standard valve

Tolerance

1

Backlash between ring gear and drive pinion

0.25~0.33

0.25~0.33

Adjustment

2

Backlash between side gear and pinion gear

0.23~0.45

0.23~0.45

Adjustment

3

Clearance between pinion gear and spider

0.102~0.153

0.102~0.153

Replacement

4

Runout of ring gear rear surface (when assembled)

0.076

0.076

Adjustment or replacement

5

Tooth surface wear (each gear)

6

Tooth contact

Abnormal wear or missing

Replacement

No abnormality

Replacement

34-1 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group

70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly....... 34-2 Transmission Assembly .......................................... 34-10 Torque Converter .................................................... 34-16 Transmission Clutch Pack ....................................... 34-18 Control Valve Assembly .......................................... 34-23

34-2 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque Converter and Transmission Assembly Torque converter and transmission assembly tightening torque Radiator assy

T2 L3

Engine

T3 L1

T2 L3

T2 L3

T1 L3

T4 L1

Oil pump

T3 L1

Rear differential

Transmission

3rd propeller shaft (S/N 1973~, 7772~) (S/N ~1023, ~7107) T4 L2 (S/N 1024~, 7108~) T7 L2

T6 L2

(S/N 1001~1023, 7101~7107)

3rd propeller shaft (S/N 1001~1972, 7101~7771)

T2 L3

T5 L2 T5 L2 (S/N 1001~1023, 7101~7107) 2nd propeller shaft

T4 L1

T6 L2

Front differential 70K24001

: T1: 53 N-m (5.4 kgf-m) T2: 417 N-m (42.5 kgf-m) T3: 55 N-m (5.6 kgf-m) T4: 230 N-m (23.5 kgf-m) T5: 142 N-m (14.5 kgf-m) T6: 80 N-m (8.2 kgf-m) T7: 441 N-m (45 kgf-m)

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

34-3 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

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

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

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

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

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

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

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

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

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

- Remove the steering valve (Refer to Section 44).

- Remove the air cylinder and bracket for the parking brake (Refer to Section 54).

: Transmission oil: 22 L 2. Disconnect hose (2) for the transmission oil level gauge.

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

3. Remove multiple control valve return pipe (3).

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

34-4 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Hydraulic pump

4. Remove pipe (4) and hoses (5) (at the hidden end in the above illustration).

6. Disconnect hoses (9)(10) between the torque converter and the oil cooler.

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

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

Remove bolts (6) and remove the hydraulic pump assembly. : Bolt (6): 142 N-m (14.5 kgf-m) : Pump: 45 kg Note Be sure to replace the gasket of the hydraulic pump flange with a new one.

7. Disconnect speed meter sensor coupler (11), the electric wire coupler for speed sensor (auto shift) (13) and clutch pressure measuring hose (12).

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

- Speed meter sensor coupler (11) is for the machine S/Ns 1001~1600, 7101~7350.

5. Disconnect hose (7) between the torque converter pump and the line filter.

Disconnect hose (8) between the line filter and the control valve.

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

34-5 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

8. Disconnect electric wire coupler (14) for the solenoid valve on the control valve.

10. Disconnect bolts (15) from the third propeller shaft on the transmission side. : Bolt: 80 N-m (8.2 kgf-m) : Screw lock agent (Three Bond 1327) Note - If the retainer bolt is too tight due to the screw lock agent, heat the bolt head using slow flame of a gas burner.

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

- Do not reuse the bolt once heated.

9. Remove bolts (14) from the second propeller shaft on the transmission side only. : Bolt: 142 N-m (14.5 kgf-m) : Screw lock agent (Three Bond 1327)

11. Temporarily sling the transmission assembly and then remove bolts (16). : Bolt (16): 417 N-m (42.5 kgf-m) : With lubrication oil (Engine oil or gear oil) : Transmission assembly: 515 kg

34-6 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque converter and transmission assembly installing To reinstall the torque converter and transmission assembly, follow the above removal procedure in reverse order.

Transmission assembly installation cautions Rotate the engine flywheel to align the ring gear.

12. Insert wooden pieces (17) into the clearance between the bottom of the engine flywheel housing and the rear axle housing.

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

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

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

13. Remove 12 bolts (18) connecting the transmission housing and the engine flywheel. : Bolt (18): 53 N-m (5.4 kgf-m) : With lubrication oil (Engine oil or gear oil) 14. Pull the transmission assembly straight out approximately 30 mm to the front then slowly lift it.

CAUTION Slowly lift the transmission assembly while checking that there are no obstacles.

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

2. Check each section for oil leakage.

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

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

34-7 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

DATE:

HOURS:

MACHINE MODEL & SERIAL NO.:

CUSTOMER:

DEALER:

DEALER LOCATION:

MACHINE LOCATION:

TIRE SIZE:

BRAND & SPECIFICATION OF OIL:

COMPONENT TYPE & MODEL NO.:

AMBIENT TEMP:

COMPONENT SERIAL NO.:

CHECKLIST TO BE COMPLETED BEFORE START-UP TRANSMISSION COOLER CLEANED

TRANSMISSION PIPING CLEANED

IN-LINE PRESSURE FILTER REPLACED

TRANSMISSION LINKAGE CHECKED

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

DIAGNOSTIC DATA TEST TO BE PERFORMED

INITIAL TEST

RETEST

HIGH IDLE RPM LOW IDLE RPM T/C STALL RPM HYDRAULIC STALL RPM FULL STALL RPM CREEP WITH BRAKE (F1) RPM CREEP WITH BRAKE (R2) RPM CLUTCH PRESSURE AT LOW IDLE 2

F1

MPa (kgf/cm ) (psi)

N1

MPa (kgf/cm2) (psi)

R1

MPa (kgf/cm2) (psi)

F2

MPa (kgf/cm2) (psi)

N2

MPa (kgf/cm2) (psi)

R2

MPa (kgf/cm2) (psi)

F3

MPa (kgf/cm2) (psi)

N3

MPa (kgf/cm2) (psi)

R3

MPa (kgf/cm2) (psi)

F4

MPa (kgf/cm2) (psi)

N4

MPa (kgf/cm2) (psi)

R4

MPa (kgf/cm2) (psi)

CLUTCH PRESSURE AT HIGH IDLE 2

F1

MPa (kgf/cm ) (psi)

N1

MPa (kgf/cm2) (psi)

R1

MPa (kgf/cm2) (psi)

F2

MPa (kgf/cm2) (psi)

N2

MPa (kgf/cm2) (psi)

R2

MPa (kgf/cm2) (psi)

F3

MPa (kgf/cm2) (psi)

N3

MPa (kgf/cm2) (psi)

R3

MPa (kgf/cm2) (psi)

F4

MPa (kgf/cm2) (psi)

N4

MPa (kgf/cm2) (psi)

R4

MPa (kgf/cm2) (psi)

COMMENTS:

Serviceman’s Signature

Copy as required. Make attachments if needed.

34-8 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Transmission assembly bolt tightening torque 9

T8

11 10

2

3

1 T1 12

7

15

14

6 13 52T 52T

T5

53T

R

F

Hydraulic pump installation

T1

T6

24 23 28T

17

4

21

28T

29T

19

37T

5 57T

20

1ST

2ND

43T

22

T3 8

31

20T

16

Idler shaft

32T 51T

T1

43T

48T

18

37T

32 23T

30 34

35

33T

4TH

3RD 36T

26

25 T4 29 33 27 28 37

T2 T4 T1 T7

T1

36 70ZA3206a

34-9 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter and Transmission Assembly 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Pump impeller Turbine impeller Stator Turbine shaft Stator shaft (Fixed) Ring gear Drive cover P.T.O. drive gear T/C pump drive gear Hydraulic pump drive gear T/C pump Reverse clutch Reverse clutch gear Forward clutch Forward clutch gear Counter gear A 2nd speed clutch 2nd speed clutch gear 1st speed clutch 1st speed clutch gear

Transmission type: CT160A01 (S/N ~70J1-1972, ~70J1-7771) CT160A02 (S/N 70J1-1973~, 70J1-7772~)

: T1: 68.6 N-m (7.0 kgf-m) T2: 108 N-m (11.0 kgf-m) T3: 26.0 N-m (2.65 kgf-m) T4: 255 N-m (26.0 kgf-m) T5: 53 N-m (5.4 kgf-m) T6: 66 N-m (6.7 kgf-m) T7: 28 N-m (2.85 kgf-m) T8: 46 N-m (4.7 kgf-m) Control valve assy: 34.3 N-m (3.5 kgf-m) Solenoid body (F, R, 1st, 2nd): 32.3 N-m (3.3 kgf-m) Solenoid body (3rd, 4th): 33 N-m (3.4 kgf-m)

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

Counter gear B Counter shaft A Idle shaft Idle gear 4th speed clutch 4th speed clutch gear 3rd speed clutch 3rd speed clutch gear Counter gear C Counter shaft B Counter gear D Counter gear E Output shaft Output shaft gear Parking brake Speed sensor drive (S/N 1001~1600, 7101~7350) Suction strainer

34-10 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission Assembly Transmission assembly disassembling and assembling Transmission assembly disassembling Before starting work: - Clean the transmission assembly.

- Remove the torque converter assembly.

Suction pipe

3. Remove pump retainer bolt (3), and remove the pump. : Bolt (3): 46 N-m (4.7 kgf-m) 4. Remove the retainer bolt and remove the suction pipe. : Bolt: 38 N-m (3.9 kgf-m)

1. Remove the bolt and disconnect pipe (1).

Remove the strainer inside. : Bolt: 68.6 N-m (7.0 kgf-m) 2. Remove suction hose (2).

5. Remove retainer bolt (4) for the transmission housing.

: Hose band: 43 N-m (4.4 kgf-m) : Bolt (4): 68.6 N-m (7.0 kgf-m) Note Cover the disconnected pipe and hose with vinyl to protect the hose from dust and dirt.

Use a jacking bolt (M10x1.5) to separate the torque converter housing and the transmission housing.

34-11 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

PTO gear pump

T/M oil pump

6. Remove snap ring (5) for hydraulic pump drive gear (6).

8. Remove snap ring (10) from the torque converter charge pump side, then remove adapter (11).

9. Remove bolt (13) then remove gear (12), shaft (14), bearing (15) and snap ring (16) as an assembly. : Bolt (13): 73.6 N-m (7.5 kgf-m) : Screw lock agent (Loctite® 262)

7. Remove snap ring (7) from the hydraulic pump side.

Remove shaft (8) with bearings (9) as an assembly.

Note When removing shaft (8), support pump drive gear (6) by hand.

10. Remove plug (17) for the clutch oil regulator valve, then remove springs (19)(20) and piston (21).

Also remove plug (18) for the torque converter inlet pressure regulator valve, then remove spring (22) and piston (23). : Plug (17)(18): 73 N-m (7.4 kgf-m)

34-12 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

11. Remove plug (24) for the torque converter outlet pressure regulator valve, then remove spring (25) and piston (26).

13. Remove bolt (29) and plate (30) from the torque converter housing. : Bolt (29): 25.5 N-m (2.6 kgf-m)

: Plug (24): 73 N-m (7.4 kgf-m)

31

Stopper Stopper 65K34038

12. Remove cover (27) for the 1st speed pressure detection valve and cover (28) for the 2nd speed pressure detection valve.

14. Remove forward/reverse clutch pack (31) using a 16mm eye bolt.

Special tool

: Bolt for covers: 15.7 N-m (1.6 kgf-m) 32

33

CAUTION The spring and stopper for the 1st speed pressure detection valve and the 2nd speed pressure detection valve are not the same.

Carefully install them when assembling.

65K34039

15. Remove 1st/2nd speed clutch pack (32) and 3rd/ 4th speed clutch pack (33) at the same time using a special tool.

34-13 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly Special tool for removing speed range clutch (Tool No. KL03-200-1 for North American dealer) 1

7

3

5

2

1

4

6

1. Plate 15 20

250 7

13

R

28

R

7 50

25

24 65

24

180

35.4

35.4

150 280 135 95 6

9

2. Lock 10 39

7 R

13

10

7 R

31

250 135 95 6

13 70ZV34004

1.

2.

3.

4.

5.

6.

7.

Plate Lock Eye bolt Nut (M12) Bolt (M6) Nut (M6) Split pin

34-14 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

3rd propeller shaft

37

41 34 65K34017

36

38

18. Remove speedometer drive gear (41).

35 2nd propeller shaft

65K34015

16. Remove bolt (34), then remove drum (35) and flange (36).

Remove bolt (37) and brake assy (38). : Bolt (34)(37): 255 N-m (26 kgf-m) : Screw lock agent (Loctite® 262)

42

Bolt

40

65K34018

Socket bolt

19. Remove shroud (42) in the housing. : Bolt for shroud: 25 N-m (2.5 kgf-m) : Screw lock agent (Loctite® 262)

39

65K34016a

17. Remove bolt (39).

Using a jack bolt (M10x1.5), remove meter drive case (40).

43

: Bolt (39): 68.6 N-m (7.0 kgf-m) : Socket bolt: 15.7 N-m (1.6 kgf-m)

65K34040

20. Remove output shaft (43) using a 16mm eye bolt.

34-15 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Assembly

Transmission assy assembly cautions (a) When installing oil seal apply grease to inner lip and liquid gasket (AA03) to outside seal.

44

(b) When installing O-ring, apply lithium grease to Oring.

45 Bolt Abutment joint

Overlap

65V34004

Remove snap ring (44) and the bolt for idle gear shaft (45).

Remove idle gear shaft (45) from the housing. : Bolt: 68.6 N-m (7.0 kgf-m) Note When removing the shaft, support the gear by hand.

Tightening torque for assembly

Transmission assembly assembling To reassemble the transmission assembly, follow the above procedure in reverse order.

- Clean and check all the parts. If a part is damaged, replace it with a new one. Refer to Section 35 for wear limits.

- When assembling, apply transmission oil to the parts.

- Replace all the seals and packings with new ones.

Seal ring

When installed

(c) When installing seal ring to the shaft, install it as shown in the figure.

Do not open the abutment joint wider before installing.

Apply grease to the shaft before installing seal ring.

IMPORTANT Make sure to rotate the shaft by hand during assembly and after assembly.

If it is hard to rotate the shaft by hand, disassemble and check the cause.

34-16 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter

Torque Converter Torque converter assembly disassembling and assembling Torque converter assembly disassembling Before starting work: - Clean the transmission assembly.

- Prepare a can for oil.

Stator shaft

3. Remove snap ring (3) and lock nut (4) and then remove stator (5). : Lock nut (7): 66 N-m (6.7 kgf-m)

IMPORTANT 1. Remove 2 each of plug (1) from drive cover and drain oil from the transmission and the torque converter.

If stator (5) is installed upside down, the stator will not properly function.

Correctly install stator (5) as shown in the figure.

: Plug (1): 10 N-m (1.0 kgf-m) : Transmission oil: 0.5 L 2. Remove bolt (2).

Using a jacking bolt (M10x1.5), remove the drive cover.

Stator shaft

: Bolt (2): 31 N-m (3.1 kgf-m)

4. Remove pump impeller assy (6) from the stator shaft. Then remove gear (7) and bearings (8) from the pump impeller assy.

34-17 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Torque Converter

Torque converter assembly assembling Stator shaft

To reassemble the torque converter assembly, follow the procedure in the reversed direction.

Before starting work: - Clean and check all the parts. If a part is worn or damaged, replace it with a new one.

- Before reassembly, apply transmission oil to the parts.

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

- Install new bearing if replacement is needed.

5. Remove stator shaft retainer bolt (9), then remove the stator shaft retainer shaft. : Bolt (9): 53 N-m (5.4 kgf-m)

After reassembling, make sure to rotate the drive cover by hand.

34-18 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Clutch Pack

Transmission Clutch Pack The disassembling procedure for the forward/reverse clutch pack is described below.

For the other clutch pack, refer to the following procedure.

Forward/reverse clutch pack disassembling and assembling Forward/reverse clutch pack disassembling 9

7

6

5

8 T/C side

10

8 65K34021

2. Remove snap ring (5), then remove plate (6), back plate (7), friction disc (clutch plate) (8), separation disc (steel plate) (9), and plate (10).

1 3

9

2

4 65K34020

1. Remove seal ring (1) from the turbine shaft.

Remove bearing (2), washer (3) and gear (4) with bearings.

11 11

12

13

65K34022

3. Pressing washer (11) using a special tool, then remove snap ring (12).

Remove washer (11) and spring (13).

34-19 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Clutch Pack Special tool to remove snap ring For forward/reverse clutch pack

For other speed clutch pack

(mm)

100 80 0.5 85

5

65

370

60

360

72 0.5

60 5

65

40 79 0.5

40 92 0.5

65ZV34031J

4. Feed air and remove clutch piston (14).

14

IMPORTANT Do not remove the clutch drum from the shaft.

65V34005

34-20 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Clutch Pack

Air inlet port

WARNING

Forward/reverse clutch pack assembling

If the air pressure is applied suddenly, the piston may jump out from the clutch. Feed air slowly.

15

65K34030

5. Remove seal rings (15) from the shaft and the piston.

6. Follow the same steps for the forward clutch assembling.

For reassembling, follow the above procedure in reverse order.

34-21 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Clutch Pack

Clutch pack assembly cautions Thrust washer press-fit for 1st speed clutch Clutch pack assembling direction 1st speed clutch Thrust washer press-fit

Be careful of the direction when assembling the indicated parts in each clutch pack.

Transmission output gear Output gear

1st speed clutch cross section

Boss side

This thrust washer is press-fitted to the shaft. Carefully remove it when disassembling.

Forward/Reverse clutch pack Back plate (convex part faces to outside) Washer Washer

Grooved side Grooved side

34-22 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Transmission Clutch Pack 1st/2nd speed clutch pack Back plate

Thrust washer (inner diameter Ø52)

Washer

Chamfered side Grooved side

Thrust washer (inner diameter Ø50)

3rd/4th speed clutch pack Back plate Washer Washer

Chamfered side

Grooved side

Grooved side

34-23 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control Valve Assembly Control valve removing and installing Control valve removing

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

- Apply the parking brake, and block the tires with chocks to prevent the wheels from moving.

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

2. Put match mark on each coupler and remove electric wiring coupler (1) for each solenoid valve.

Control valve mount

Bolt

Cover

K70ZIV3401

1. Remove the cover for the control valve. : Bolt: 37 N-m (3.8 kgf-m) Note The cover is fixed with the valve block using this bolt.

3. Remove main clutch pressure measuring hose (2).

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

34-24 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve for 3rd & 4th

Control valve for F, R, 1st & 2nd

4. Remove bolts (5)(6) and the control valve. : Bolt (5)(6): 34.3 N-m (3.5 kgf-m) : Control valve (F, R, 1st, 2nd): 15 kg : Control valve (3rd, 4th): 5 kg

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

5. If necessary, remove sub plate (7) and plate (8). : Bolt (9): 25.5 N-m (2.6 kgf-m) : Bolt (10): 29 N-m (2.85 kgf-m)

34-25 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve installation For reinstallation, follow the removing procedure in reverse order.

Control valve installation cautions - Be sure to replace all the O-rings and gaskets with new ones.

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

- Align the matchmarks of the electric wire couplers, and then connect the couplers while checking that the electric wires are not tangled with each other.

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

- During installation, be careful not to damage the gasket.

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

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

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

- Check oil leakage.

- Adjust the transmission oil level to the specified point with the dipstick.

34-26 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve disassembling and assembling Control valve disassembling Note Clean the control valve.

1

[ Tool A ]

Heat treated (HB 212~253) and press fit.

65K34027

1. Remove nut (1). : Nut: 9.8 N-m (1.0 kgf-m)

(Tool number for North America: KL03-102-2)

2. Remove solenoid valve (2) using tool (A). : Solenoid valve: 29.4 N-m (3.0 kgf-m) Valve width across flat: 30 mm

34-27 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Control valve assembling To reassemble the control valve, follow the disassembling procedure in reverse order.

Control valve assembly cautions - Before you insert the regulator valve, apply transmission oil to the valve. After insertion, check that the valve operates smoothly.

- Check the operation of the solenoid valves.

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

- Replace all seals, O-rings and gaskets.

3. Remove covers (3)(4) by removing bolts (a).

Remove the spools and springs. : Bolt for covers (a): 9.8 N-m (1.0 kgf-m)

CAUTION When removing the cover, the spring may jump out.

Slowly loosen the bolt for the cover.

IMPORTANT Do not loosen set screw and nut (5) when disassembling the control valve unless necessary.

If fail to do, screw adjustment is necessary. Misadjustment may cause shift shock or clutch plate slipping. Refer to the procedure described in the following “Control valve assembly cautions”.

4. Follow the same steps for the 3rd/4th speed control valve.

34-28 70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group Control Valve Assembly

Screw adjustment procedure If the adjusting screw is loosen, follow the procedure below to re-adjust it.

See the enlarged figure below.

65V34006

3

A

1 2

65V34007

(a) Loosen nut (1). : Nut (1): 10.8 N-m (1.1 kgf-m) (b) Loosen set screw (2) until it comes out 20 mm (A). (c) Screw in set screw (2) until the tip of the screw contacts to spring retainer (3). (d) From this position, turn the screw clockwise 5 turns. (e) Tighten nut (1) to lock set screw (2). (f)

After the adjustment, confirm that "A" is 12 mm.

35-1 70ZIV-2 Service Standard Torque Converter and Transmission Group

70ZIV-2 Service Standard Torque Converter and Transmission Group Torque Converter and Transmission Assembly....... 35-2

35-2 70ZIV-2 Service Standard Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Torque Converter and Transmission Assembly Piston or spool-housing clearance Standard value (A - B) (mm)

Allowable limit (mm)

Clearance between clutch oil regulator piston and housing

0.015~0.049

0.070

Clearance between torque converter oil inlet regulator piston and housing

0.020~0.071

0.090

Clearance between torque converter oil outlet regulator piston and housing

0.020~0.061

0.080

Clearance between accumulator (1st,2nd) piston and housing

0.020~0.062

0.080

Clearance between pressure detection valve (1st,2nd) spool and housing

0.020~0.059

0.080

Clearance between control valve detection valve spool and body

0.020~0.058

0.080

Clearance between control valve 1st,2nd speed shift spool and body

0.020~0.062

0.080

Clearance between control valve accumulator piston and body

0.020~0.075

0.095

Clearance between control valve 3rd, 4th speed shift spool and body

0.020~0.061

0.080

Item

A: Housing inner diameter B: Piston outer diameter (spool)

Spring free length and installed load Item

Standard value C mm

Clutch oil regulator spring (S)

C mm Clutch oil regulator spring (L)

C mm

C mm Torque converter oil outlet regulator spring

C mm

C mm Pressure detection valve (1st) spring D

C mm Pressure detection valve (2nd) spring (S)

294 (30)

265 (27.0)

99.75

97.5 75.0

287 (29.26)

89.1 71.0

49 (5)

45 (4.5)

111

105.3 52.8

201 (20.5)

181 (18.5)

50.5

49.7 42.9

104 (10.6)

93 (9.5)

134.8

127.9

D mm E N (kgf)

258 (26.3)

91.2

D mm E N (kgf)

95.9 72.0

D mm E N (kgf)

C: Free length (reference) D: Installed length E: Installed load

282 (28.8)

98.58

D mm E N (kgf)

Accumulator (1st) spring

314 (32)

D mm E N (kgf)

106.5 94.0

D mm E N (kgf)

Torque converter oil inlet regulator spring

107.96

D mm E N (kgf)

Allowable limit

77.8 191 (19.5)

173 (17.6) (Continued)

35-3 70ZIV-2 Service Standard Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Item

Standard value C mm

Pressure detection valve (2nd) spring (L)

C mm Pressure detection valve (2nd) spool spring

C mm

C mm 1,2,3,4 speed clutch return spring

C mm

C mm Control valve accumulator spring (M)

C: Free length (reference) D: Installed length E: Installed load

C mm Control valve accumulator spring (L)

C mm

C mm Control valve pressure detection valve spool spring (S)

C mm Control valve

1765 (180)

1324 (135)

60.32

59.5 30.5

1451 (148.0)

C mm 3/4 speed control valve detent spring

588 (60.0)

530 (54.0)

132.44

130.65 99.0

881 (89.8)

793 (80.82)

100.31

98.95 64.0

245 (25.0)

221 (22.5)

43.19

42.6 30.2

134 (13.7)

121 (12.33)

44.56

43.96 30.2

62 (6.3)

56 (5.67)

43.13

42.6 38.0

62 (6.3)

56 (5.67)

40.47

D mm E N (kgf)

125.84 99.0

D mm E N (kgf)

1306 (133.2)

127.57

D mm E N (kgf)

62.4 32

D mm E N (kgf)

93 (9.5)

72.5

D mm E N (kgf)

Control valve pressure detection valve spool spring (L)

104 (10.6)

D mm E N (kgf)

49.7 42.9

D mm E N (kgf)

181 (18.5)

50.5

D mm E N (kgf)

Control valve accumulator spring (S)

201 (20.5)

D mm E N (kgf)

105.3 52.8

D mm E N (kgf)

F/R clutch return spring

111

D mm E N (kgf)

Allowable limit

40.0 22.0

29 (3.0)

26 (2.7)

Standard value

Allowable limit

F Ø mm

—

129

G Ø mm

129.9~130.00

129.22

F Ø mm

—

80

G Ø mm

79.92~80.00

79.80

F Ø mm

—

9.7

G Ø mm

9.96 ~10.00

9.91

Oil seal lip and shaft diameter Item Torque converter impeller hub seal

Output flange seal

F: Inner diameter G: Outer diameter

Speedometer driven gear seal

35-4 70ZIV-2 Service Standard Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Seal ring (Piston ring) Item I mm J mm

Stator shaft ring

I

I: Width J: Thickness

2.9 76.20

L mm

2.44~2.49

2.65

I mm

2.36~2.41

2.16

3.25~3.55

3.05

92.00~92.03

92.15

L mm

2.51~2.58

2.70

I mm

2.87~2.92

2.67

K Ø mm

70ZA3507

J mm

F/R Clutch Piston ring (S)

3.0~3.2

2.8

80.00~80.04

80.15

L mm

3.10~3.15

3.30

I mm

2.35~2.40

2.15

K Ø mm

J mm

F/R Clutch Shaft seal ring

2.0~2.2

1.8

55.20~55.25

55.45

L mm

2.50~2.51

2.65

I mm

2.82~2.92

2.62

K Ø mm

K: Seal contact face diameter 1,2,3,4 speed clutch Piston ring (L) L: Groove width

1,2,3,4 speed clutch Piston ring (S)

1,2,3,4 speed clutch Shaft seal ring

2.10

3.1~3.3

J mm

F/R Clutch Piston ring (L)

Allowable limit

2.30~2.35 76.00~76.03

K Ø mm

J

Standard value

J mm

3.85~4.15

3.65

155.08~155.13

155.33

L mm

3.025~3.125

3.175

I mm

2.28~2.33

2.08

K Ø mm

J mm

3.4~3.6

3.2

70.00~70.05

70.15

L mm

2.49~2.50

2.65

I mm

2.93~2.98

2.73

K Ø mm

J mm K Ø mm L mm

1.6~1.8

1.4

40.20~40.25

40.35

3.07~3.15

3.30

Standard value

Allowable limit

Clutch thrust washer Item

M

M: Thickness 70ZA3509

1st clutch (a)

M mm

3.92~4.00

3.57

1st clutch (b)

M mm

3.92~4.00

3.57

1st clutch (c)

M mm

1.92~2.00

1.75

35-5 70ZIV-2 Service Standard Torque Converter and Transmission Group Torque Converter and Transmission Assembly

Clutch plate, Steel plate, Clutch clearance Item

N: Clutch plate thickness O: Steel plate thickness P: Clutch clearance

Standard value

Allowable limit

F/R clutch Clutch plate

N mm

2.9~3.1

2.5

F/R clutch Steel plate

O mm

1.92~2.08

1.80

F/R clutch Clutch clearance

P mm

2.8~3.2

4.0

1,2,3,4 speed clutch Clutch plate

N mm

2.6~2.8

2.3

1,2,3,4 speed clutch Steel plate

O mm

1.92~2.08

1.80

1,2 speed clutch Clutch clearance

P mm

2.2~2.6

4.5

3 speed clutch Clutch clearance

P mm

2.3~2.5

4.5

4 speed clutch Clutch clearance

P mm

1.7~1.9

4.5

Standard value

Allowable limit

Clutch conical plate Item

Q: Free height

F/R clutch Conical drive plate

Q mm

3.35~3.65

3.15

F/R clutch Conical plate

Q mm

6.10~6.30

5.75

1,2,3,4 speed clutch Conical plate

Q mm

4.15~4.45

3.85

35-6 70ZIV-2 Service Standard Torque Converter and Transmission Group

MEMO

44-1 70ZIV-2 Disassembly & Reassembly Hydraulic Group

70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning ........44-2 Hydraulic Parts Disassembly and Assembly Cautions...44-3 Gear Pump .....................................................................44-4 Steering Valve (S/N ~2200, ~8250)................................44-12 Multiple Control Valve.....................................................44-18 Hydraulic Cylinder ..........................................................44-33 Pilot Valve.......................................................................44-51 Orbitrol® (S/N 2201~, 8251~) .........................................44-60 Priority Valve (S/N 2201~, 8251~)..................................44-72 Accumulator (S/N 2201~, 8251~)...................................44-74

44-2 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Removal and Installation Warning

Hydraulic Parts Removal and Installation Warning Disassembly and reassembly work of hydraulic parts greatly depends on the working area and working condition (soon after operation or not).

Understand the following items well and work safely.

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

- Apply the parking brake and block tires with chocks to prevent wheels from moving.

- Be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

- Relieve the internal pressure from the hydraulic line and hydraulic tank.

- Use signals as agreed upon before starting work.

- Do not enter the hazardous area.

- When removing a heavy load over 20 kg (44 lbs), use a crane or a lift device.

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

- While working with the boom raised, put safety blocks or supports to prevent it from dropping suddenly.

- The temperature at each part may be high soon after the engine is stopped. Be careful not to get burned.

- When removing pipes, place a container to catch the drained oil.

IMPORTANT - Cover the disconnected hoses and pipes with plastic caps or plugs to protect them from dust, water and dirt.

- Apply the specified torque to tighten each part.

44-3 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Parts Disassembly and Assembly Cautions

Hydraulic Parts Disassembly and Assembly Cautions Hydraulic parts may be very delicate. When disassembling or reassembling, handle with care.

Understand the following well to perform disassembly and reassembly work.

Hydraulic parts disassembly cautions - Completely drain hydraulic oil from parts. Clean unit before disassembly. Plug each open ports.

- Work in a well ventilated area.

- Before disassembling, put a matchmark on each alignment point.

- When clamping the part in a vice, use a copper plate so as not to damage it.

- Because hydraulic parts may be delicate, do not drop or scratch them.

- When disassembling, do not hit or pry the parts by force. The parts may be burred and scored, which may cause oil leakage or poor performance.

- Do not disassemble adjusting screws unless needed.

- When work is stopped, protect removed parts from dirt and debris.

- Preserve disassembled parts with oil. After cleaning, do not dry with compressed air. It may cause rust due to condensation.

- Carefully place removed parts in the order it was removed so as to see how they came apart.

Hydraulic parts assembly cautions - Check the surface and inside of the parts for burrs, scores, dirt, or rust.

- Replace O-rings and seals with new ones.

- Before reassembly, apply a thin coat of hydraulic oil or grease to the O-rings and seals.

- Apply the specified torque to tighten parts.

- After reassembly, plug the ports so as not to allow foreign material to enter.

44-4 70ZIV-2 Disassembly & Reassembly Hydraulic Group Gear Pump

Gear Pump Triple pump

Center (for loading)

Rear (for loading)

Front (for steering)

1.

2.

3.

4.

5.

6.

7.

Oil seals Driven gear Drive gear Pressure plates Plate seal Coupling Coupling

: Gear pump: 44 kg

44-5 70ZIV-2 Disassembly & Reassembly Hydraulic Group Gear Pump

Gear pump tightening torque

: T1: 34 N-m (3.5 kgf-m) T2: 69 N-m (7.0 kgf-m) T3: 118 N-m (12.0 kgf-m)

44-6 70ZIV-2 Disassembly & Reassembly Hydraulic Group Gear Pump

Gear pump assembly removing and installing Gear pump assembly removing

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving.

- Disconnect the negative side of the battery cable.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

Before starting work: - Remove the deck by referring to Section 14.

- Clean the area around the hydraulic pump.

3. Disconnect gear pump (1) from the torque converter using a bar, and then remove gear pump (1). : Gear pump: 44 kg

Gear pump assembly installing To reinstall the gear pump assembly, follow the above removal procedure in reverse order.

Replace all gaskets and O-rings during reinstallation.

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

Note Cover the disconnected hoses with plastic, plugs or caps to protect from dust and dirt.

2. Remove gear pump retainer bolts (4). : Bolt: 245 N-m (25.0 kgf-m)

44-7 70ZIV-2 Disassembly & Reassembly Hydraulic Group Gear Pump

Gear pump installation cautions When replacing gear pump or when draining hydraulic oil for extended periods, it is important to prime the hydraulic system properly. Air will be in the lines that go to and come from the pump. After a pump has been installed, or when the hydraulic oil has been drained for extended time periods, air will not purge easily from the lines, and this could lead to pump damage.

WARNING Oil injection hazard!

Hydraulic oil can penetrate skin. When performing this procedure: - Release all trapped circuit pressure prior to starting any procedure involving hydraulic oil.

- Wear protective gloves.

- Wear eye and face protection.

- Stay clear of areas where air may be purged.

- Route oil into a receiving canister [such as a 5 gallon bucket] by use of an additional hose.

- Rotate pump at a low RPM.

Oil filling port

IMPORTANT - Fill the inlet port of the hydraulic pump with clean hydraulic oil and rotate the pump shaft by hand prior to installing the pump. It should rotate smoothly.

Prior to installing pump and plumbing to pump, remove all caps, plugs, and covers from pump and piping.

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

- Check the oil level of the hydraulic tank.

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

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

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

- Actuate cylinders 5 to10 times to almost full stroke, but do not fully extend or retract any of the cylinders at this time.

- Confirm that there is no abnormal noise or operation, and be sure that there is no excessive heat.

Inspect the hydraulic oil at the sight gauge to be sure that there are no bubbles which may indicate air being drawn in at the suction side of the pump.

If there are any bubbles, correct the cause prior to using the machine, as this may contribute to premature pump failure.

44-8 70ZIV-2 Disassembly & Reassembly Hydraulic Group Gear Pump

Gear pump assembly disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

IMPORTANT - Handle pumps carefully.

- In case hydraulic system breaks down, do not disassemble the pump first.

Check the whole hydraulic circuit and find its cause. Confirm the cause, then repair.

- When the pump is broken down, not only fix or replace it but also inspect the failure cause to prevent recurrence.

If a pump must be repaired, be sure no pieces of damaged pump material has scatted through hydraulic system. New parts must be "broken in" and performance must be checked.

Do not disassemble the pump except when necessary to replace oil seals and O-rings between the double and triple pumps which are able to be separated.

44-9 70ZIV-2 Disassembly & Reassembly Hydraulic Group Gear Pump

Gear pump disassembling

Matchmark

1. Clean the pump and put match marks on the connecting sections of the pump.

2. Remove bolts (1)(2) to separate the pump sections.

- Front pump (3) - Center pump (4) - Rear pump (5) : Bolt (1)(2): 34 N-m (3.5 kgf-m)

44-10 70ZIV-2 Disassembly & Reassembly Hydraulic Group Gear Pump

1. Disassembling front pump Front cover

Rear cover

1. Remove coupling (6), and then remove retainer bolts (7). : Bolt (7): 118 N-m (12.0 kgf-m)

4. Remove dust seal (14) from the mounting flange using screw driver or the like and remove snap ring (15) and oil seal (16).

Note Do not remove the oil seal unless absolutely necessary (unless it was damaged).

2. Remove the rear cover.

2. Disassembling center pump

3. Put matchmarks and remove bearing box (8), wear plate (9), drive shaft (10), driven shaft (11), wear plate (12) and bearing box (13) in order.

Note - Before removing the gears, put matchmarks on both sides ends of the gears using oil stone or the like.

When reassembling the gears, align the matchmarks so that the gears will be smoothly engaged.

- Correctly insert the wear plate so that the inlet and outlet sides of the plate are properly positioned when assembling.

1. Remove bolt (17) and front cover (18).

Remove bolt (19) and rear cover (20). : Bolt (17)(19): 69 N-m (7.0 kgf-m) 2. Put matchmarks and remove bearing box (21), wear plate (22), drive shaft (23), driven shaft (24), wear plate (25) and bearing box (26) in order.

Note Before removing the gears, put matchmarks on both sides ends of the gears using oil stone or the like. When reassembling the gears, align the matchmarks so that the gears will be smoothly engaged.

44-11 70ZIV-2 Disassembly & Reassembly Hydraulic Group Gear Pump

3. Disassembling rear pump

Gear pump assembling To reassemble the gear pump assembly, follow the above procedure in reverse order.

Gear pump assembly cautions - Replace the O-ring with new one.

1. Remove coupling (27), bolts (28) and front cover (29).

Remove bolt (30) and rear cover (31). : Bolt (28)(30): 69 N-m (7.0 kgf-m) 2. Put matchmarks and remove bearing box (32), wear plate (33), drive shaft (34), driven shaft (35), wear plate (36) and bering box (37) in order.

Note Before removing gears, put match marks on both sides ends of the gears using oil stone or the like. When reassembling the gears, align the match marks so that the gears will be smoothly engaged.

- Assemble the center pump and the rear pump to the front pump so that the matchmarks (1)(2) are aligned.

- Pour hydraulic oil into the oil port until the oil overflows from the port and turn the drive shaft by hand.

44-12 70ZIV-2 Disassembly & Reassembly Hydraulic Group Steering Valve (S/N ~2200, ~8250)

Steering Valve (S/N ~2200, ~8250)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Steering plunger Flow control plunger Main relief valve Overload relief valve Check valve Cover Cap Spring guide Spring Retainer Wiper Oil seal O-ring Valve body

: T1: 59 N-m (6.0 kgf-m) T2: 25 N-m (2.5 kgf-m) T3: 63 N-m (6.4 kgf-m) T4: 98 N-m (10.0 kgf-m) : 35kg

44-13 70ZIV-2 Disassembly & Reassembly Hydraulic Group Steering Valve (S/N ~2200, ~8250)

Steering valve removing and installing Steering valve removing

WARNING Unexpected movement of the machine, attachment, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground.

- Apply the parking brake. In addition, block the tires with chocks to prevent the wheels from moving.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Spilled oil on the parking brake shoe section may cause malfunction. To prevent such a problem, cover the shoe section with vinyl before removing the valve.

1. Remove pipe (3) from the steering valve. : Hydraulic oil: 1 L Note Cover the disconnected pipe with vinyl, plugs or caps to protect them from dust and dirt.

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

1. Remove hoses (4)(5).

Note Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

1. Disconnect hoses (2) from steering valve (1).

Note Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

44-14 70ZIV-2 Disassembly & Reassembly Hydraulic Group Steering Valve (S/N ~2200, ~8250)

Steering valve installing To reinstall the steering valve, follow the above procedure in reversed order.

Steering valve installation cautions

WARNING

1. Remove split pin (6), castle nut (7) and pin (8).

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

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

: Castle nut (7): 255 N-m (26.0 kgf-m) 2. Remove steering valve retainer bolt (9), and then remove the valve. : Bolt (9): 88 N-m (9.0 kgf-m) : Steering valve: 35 kg

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

Drop arm stopper bolt

(a) Start the engine and confirm that the drop arm comes in contact with the stoppers by turning the steering wheel clockwise and counterclockwise. (b) Check around the valve for oil leakage. (c) Measure various values for performance check.

Measure the time required for full steering.

Measure the relief valve setting pressure.

(Refer to the Section 03 Measurement for Performance Check).

44-15 70ZIV-2 Disassembly & Reassembly Hydraulic Group Steering Valve (S/N ~2200, ~8250)

Steering valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

4

5

6

Steering valve disassembling

70ZIV44022

Before starting work: - Clean the valve body.

1 23

23 1

3. Remove bolts (4) and cover (5).

70ZIV44020

: Bolt (4): 25 N-m (2.5 kgf-m) 1. Remove plugs (1) and overload relief valves (23).

4. Remove plunger assembly (6).

: Plug (1): 63 N-m (6.4 kgf-m)

7 8 8 7 3

Plunger

Plunger assembly

2

70ZIV44023 70ZIV44021

5. Remove front and rear wipers (7) and seals (8).

2. Remove bolts (2) and plate (3). : Bolt (2): 25 N-m (2.5 kgf-m)

44-16 70ZIV-2 Disassembly & Reassembly Hydraulic Group Steering Valve (S/N ~2200, ~8250)

Shim

12 9 10

14 13

11

20 22 21

10

16

15 13 14 Plunger Spring

17

19

Plunger assembly

Sleeve

70ZIV44024

6. Gently clamp the two flats of the plunger assembly using wooden blocks in a vice, and then loosen screws (9) and (17).

Remove spring seat (10), spring (11), plate (12), spring (13), poppet (14), O-ring (15) and back-up ring (16) from plunger (18).

70ZIV44025

7. Remove cap (19) and the spring. : Cap (19): 98 N-m (10.0 kgf-m) 8. Remove cap (20) and flow control plunger (21). : Cap (20): 98 N-m (10.0 kgf-m)

: Screw (9)(17): 59 N-m (6.0 kgf-m) : Screw lock agent (Loctite® 262) Note - Cover the spool to protect it from being scratched.

- A thread adhesive is applied to the threaded section of the spool end. To disassemble the spool, heat the adhesive of the threaded section using an industrial drier (heat gun) or the equivalent. Do not heat the threaded section to 200ºC or more. If overheated, replace the spring with a new one.

- All seals should be replaced with new ones because they were heated.

9. Remove main relief valve (22). : Valve (22): 63 N-m (6.4 kgf-m)

Steering valve assembling To reassemble the steering valve, follow the above disassembly procedure in reverse order.

Before starting work: - Clean and check all the parts. Replace all O-rings and seals.

- Before reassembly, apply a coating of hydraulic oil to all the parts.

- Be sure to apply the specified torque to tighten each part.

44-17 70ZIV-2 Disassembly & Reassembly Hydraulic Group Steering Valve (S/N ~2200, ~8250)

Steering valve assembly cautions

Main Relief and Overload Inspection [Example of defective valve] Foreign matters

Valve body

Plate

Adjusting screw Clogged orifice Broken spring Adjusting screw Worn-out poppet

Seal

Wiper Adjusting screw

Attach the seal and wiper to the valve body as shown above.

Note Carefully insert the plunger so that the seals are not scratched or cut.

Ball joint

Rod

Steering valve

To insert the ball joint, adjust the distance as shown above.

During disassembly and inspection of the main relief valve and overload relief valves be sure to check the pilot valve, valve seat, and orifices as shown above.

44-18 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple Control Valve Multiple control valve removing and installing Multiple control valve removing

WARNING Unexpected movement of the machine, attachment, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground.

- Apply the parking brake. In addition, block the tires with chocks to prevent the wheels from moving.

- Remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

Before starting work: - If possible carefully clean the area around the multiple control valve, dirt or water entering the hydraulic system can cause many future problems.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

1. Put match marks on hoses (1) of the pilot line, and then disconnect them.

Note Cover the disconnected hose with plastic, cap or plug to protect them from dust, water and dirt.

Releasing residual pressure from pipe Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm above the ground.

Tilt down the bucket until it comes in contact with the ground, and then lower the boom.

Press the hydraulic tank breather valve cap or open the tank cap.

2. Put match marks on hoses (2)(3) then disconnect them. : Hydraulic oil: Approx. 5 L Note Cover the disconnected hoses with plastic, cap or plug to protect them from dust, water and dirt.

44-19 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve installation cautions

WARNING Unexpected movement of the machine may cause serious injury or death.

To prevent such an accident, be sure to stop the engine before you start working. In addition, block tires with chocks to prevent wheels from moving.

While working, carefully keep contact with the person in the cab by giving signals to each other.

- Replace all the O-rings with new ones.

3. Remove return pipe (4).

- Wash the multiple control valve mounting area.

- Attach the pressure gauge, and then start the engine. Measure the pressure, and adjust it to the specified value. For a detailed description of pressure adjustment, refer to the 70ZIV-2 Shop Manual Function & Structure, Section 03.

- Operate the bucket and the boom, and check that they operate correctly.

- Check each section for oil leakage.

- Add hydraulic oil to the tank until the oil level rises to the specified point.

4. Use a hoist and strap to support control valve (6) and remove control valve (6) by removing bolts (5). : Bolt: 90 N-m (9.2 kgf-m) : Multiple control valve: 55 kg

Multiple control valve installing To reinstall the multiple control valve, follow the above removal procedure in reverse order.

44-20 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling and assembling (S/N ~1481) Multiple control valve cross section and tightening torque

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Valve housing Spool (Bucket) Spool (Boom) Spring seat Spring (Bucket) Spring (Boom) Spool end (Bucket) Spool end (Boom) Cap (Bucket) Cap (Boom) : T1: 98 N-m (10.0 kgf-m) T2: 42 N-m (4.3 kgf-m) T3: 132 N-m (13.5 kgf-m) T4: 157 N-m (16.0 kgf-m) T5: 83 N-m (8.5 kgf-m) T6: 103 N-m (10.5 kgf-m) T7: 12 N-m (1.2 kgf-m) : 55 kg

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Cap O-ring Socket head bolt O-ring Cover O-ring Socket head bolt Plug Spring Poppet

21.

22.

23.

24.

25.

26.

O-ring Plug assembly Plug Plug Main relief valve Overload relief valve (with make-up function) 27. Make-up valve 28. Cap

IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

44-21 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling (S/N ~1481)

3. Remove make-up valve (3).

1. Remove main relief valve (1). : Valve (1): 103 N-m (10.5 kgf-m) Hexagon width across flat: 38 mm

2. Remove right and left overload relief valve (2). : Valve (2): 83 N-m (8.5 kgf-m) Hexagon width across flat: 32 mm

: Valve (3): 83 N-m (8.5 kgf-m) Hexagon width across flat: 32 mm

4. Remove socket head bolt (4) from the bucket side of the cap. : Bolt (4): 42 N-m (4.3 kgf-m) Hexagon width across flat: 8 mm

44-22 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

5. Remove cap (5) with the O-ring of the flange as a unit.

8. Slowly pull out spool (8) from the bucket side, and spool (9) from the boom side as an assembly.

6. Remove socket head bolt (6) from the boom side of the cap. : Bolt (6): 42 N-m (4.3 kgf-m) Hexagon width across flat: 8 mm

7. Remove cap (7) with the O-ring of the flange as a unit.

Note Carefully pull out the spool so that it is not forced out or distorted. Handle the spool with extreme care. Even a small nick, dent, or scratch could ruin the spool, resulting in replacement of the entire valve.

44-23 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

9. Remove socket head bolt (10) to remove cap (11).

Also remove the O-ring of the flange from the cap. : Bolt (10): 42 N-m (4.3 kgf-m) Hexagon width across flat: 8 mm

10. Remove socket head bolt (12) to remove cover (13). Also remove O-ring (14) of the flange from the cap. : Bolt (12): 157 N-m (16.0 kgf-m) Hexagon width across flat: 12 mm

11. Remove plugs (15), and remove spring (16) and poppet (17) inside.

Also remove the O-ring from the plug. : Plug (15): 132 N-m (13.5 kgf-m) Hexagon width across flat: 19 mm

12. Remove the hexagon bolts and remove cap kit (18). : Bolt: 42 N-m (4.3 kgf-m) Hexagon width across flat: 14 mm

44-24 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

20

21

22

21 Adhesive Heat

Spool K70ZIV4417

13. Remove plug assembly (19) and remove the Oring. : Plug (19): 98 N-m (10.0 kgf-m) Hexagon width across flat: 17 mm

14. Gently clamp the spool assembly using wooden blocks in a vice.

After that loosen spool end (20) to remove it. : Spool end (20): 12 N-m (1.2 kgf-m) Hexagon width across flat: 22 mm 15. Remove spring seat (21) and spring (22) from each spool (there are two spools).

Note - Cover the spool to protect it from being scratched.

- A thread adhesive is applied to the threaded section of the spool end.

To disassemble the spool, heat the adhesive of the threaded section using an industrial drier (heat gun) or the equivalent.

Do not heat the threaded section to 200ºC or more.

If it is overheated, replace the spring with a new one.

44-25 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve assembling (S/N ~1481)

Spool

3. Reinstall cap kit (5).

1. Attach spring seats (1) and spring (2) to the spool, and then tighten bolt head at spool end (3). : Spool end (3): 12 N-m (1.2 kgf-m) Hexagon width across flat: 22 mm Thread lock agent (Loctite® 262)

: Bolt: 42 N-m (4.3 kgf-m) Hexagon width across flat: 14 mm Note Carefully tighten the bolts so that the O-ring of the flange is not caught and damaged.

Note Carefully clean all threads of any oil film using a non-oil based solvent or locquic primer.

4. Sequentially insert poppet (6) and then spring (7) into the housing seat section. After that, attach a new O-ring (8) to plug (9), and then reinstall the plug.

2. Reinsert plug assembly (4). : Plug (4): 98 N-m (10.0 kgf-m) Hexagon width across flat: 17 mm

: Plug (9): 132 N-m (13.5 kgf-m) Hexagon width across flat: 19 mm Note Excessive torque on these plugs can cause the body to crack or the poppets to stick.

44-26 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Spool

5. Attach a new O-ring to the groove of the cover (10), and then reinstall the cover on the valve housing.

Tighten socket head bolts (11).

7. Slowly and carefully insert the spool assembly of the bucket side into the valve housing.

Apply hydraulic oil to the spool.

: Bolt (11): 157 N-m (16.0 kgf-m) Hexagon width across flat: 12 mm Note Before reinstalling the cover, be sure to check the mating faces of the valve housing and the cover for foreign material or sharp pointed material.

Spool

8. Slowly and carefully insert the spool assembly of the boom side into the valve housing in the same way.

Apply hydraulic oil to the spool.

6. Insert the O-rings to caps (12), and then reinstall the caps on the valve housing.

Tighten socket head bolts (13). : Bolt (13): 42 N-m (4.3 kgf-m) Hexagon width across flat: 8 mm

44-27 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

9. Insert a new O-ring to cap (14), and then reinstall the cap on the spool of the bucket side.

Do not confuse the spools or caps since they are similar but different.

10. Tighten socket head bolts (15). : Bolt (15): 42 N-m (4.3 kgf-m) Hexagon width across flat: 8 mm

11. Attach a new O-ring to cap (16), and then install the cap on the spool of the boom side.

12. Tighten socket head bolts (17). : Bolt (17): 42 N-m (4.3 kgf-m) Hexagon width across flat: 8 mm

13. Reinstall make-up valve (18). : Valve (18): 83 N-m (8.5 kgf-m) Hexagon width across flat: 32 mm

44-28 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve assembly cautions - Clean and check all the parts. If a part is defective, replace or repair it.

- Replace all the O-rings with new ones.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Apply the specified torque to tighten each main part.

14. Reinstall the right and left overload relief valves (19). : Valve (19): 83 N-m (8.5 kgf-m) Hexagon width across flat: 32 mm Note If the overload relief valves or main relief valve have been disassembled back the adjusting screws out and readjust after start up.

15. Reinstall the main relief valve (20). : Valve (20): 103 N-m (10.5 kgf-m) Hexagon width across flat: 38 mm

44-29 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling and assembling (S/N 1482~)

Overload relief valve with make-up function

Lock T9 nut

T7 T8

T3

Lock nut T9

T3

Main relief valve

T2 T6 T1

T3

Bucket spool

Lock nut T9

T3 Make-up valve

Lock nut T 9

T6 Overload relief valve with make-up function

T2

T4 L1

T4

Boom spool

L1 T5

70ZV44001a

: T1: 180 N-m (18.4 kgf-m) T2: 39 N-m (4.0 kgf-m) T3: 78 N-m (8.0 kgf-m) T4: 18 N-m (1.8 kgf-m) T5: 34 N-m (3.5 kgf-m) T6: 410 N-m (41.8 kgf-m) T7: 260 N-m (26.5 kgf-m) T8: 65 N-m (6.6 kgf-m) T9: 31 N-m (3.2 kgf-m) (Lock nut)

L1: Screw lock agent (Loctite® 262) application : 55 kg

IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

44-30 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

Multiple control valve disassembling (S/N 1482~)

IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

3

70ZV44011J

3. Loosen the lock nut and remove make-up valve (3).

1

: Lock nut: 31 N-m (3.2 kgf-m) : Valve: 78 N-m (8.0 kgf-m) Hexagon width across flat: 32 mm

70ZV44009J

1. Loosen the lock nut and remove main relief valve (1).

4

6

5

: Lock nut: 31 N-m (3.2 kgf-m) : Valve: 78 N-m (8.0 kgf-m) Hexagon width across flat: 30 mm

7

70ZV44012J

4. Remove socket head bolt (4)(5) from the bucket and boom side of the cap. Then remove cap (6)(7). : Bolt (4)(5): 34 N-m (3.5 kgf-m) Hexagon width across flat: 6 mm

2

70ZV44010J

2. Loosen the lock nut and remove right and left overload relief valves (2). : Lock nut: 31 N-m (3.2 kgf-m) : Valve: 78 N-m (8.0 kgf-m) Hexagon width across flat: 32 mm

44-31 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

15

8

O-ring

14

9

70ZV44013J

5. Slowly pull out spool (8) from the bucket side, and spool (9) from the boom side as an assembly.

85ZV44023

7. Remove four socket head bolts (14), and remove cover (15). Also remove the O-ring from the mating face.

Note Carefully pull out the spool so that it is not forced out or distorted.

: Bolt (14): 180 N-m (18.4 kgf-m) Hexagon width across flat: 12 mm

16

11

19 13

17 18

12 10

70ZV44014J

6. Remove socket head bolt (10)(11) to remove caps (12)(13). Also remove the O-ring of the flange from the cap. : Bolt (10)(11): 34 N-m (3.5 kgf-m) Hexagon width across flat: 6 mm

70ZV44016J

8. Remove plug (16) from the bucket side to remove spring (17) and poppet (18). Also remove plug (19) from the boom side.

Remove the O-ring from the plug. : Plug (16)(19): 260 N-m (26.5 kgf-m) Hexagon width across flat: 12 mm

44-32 70ZIV-2 Disassembly & Reassembly Hydraulic Group Multiple Control Valve

22 20

23

24 25 23

Spool 70ZV44017J

9. Remove the hexagon bolts and remove cap (20). : Bolt (20): 65 N-m (6.6 kgf-m) Hexagon width across flat: 8 mm

85ZV44024

11. Set the spool assembly in a rise, and then loosen bolt (22) to remove. : Bolt (22): 18 N-m (1.8 kgf-m) Hexagon width across flat: 10 mm : Screw lock agent (Loctite® 262) application 12. Remove spring seat (23), spring (24), stopper (25) from each spool (there are two spools).

21

Note Cover the spool to protect it from being scratched.

Multiple control valve assembling 70ZV44018J

To reassemble the multiple control valve, follow the above procedure in reverse order.

10. Remove plug assembly (21) and remove the Oring. : Plug (21): 410 N-m (41.8 kgf-m) Hexagon width across flat: 17 mm

Multiple control valve assembly cautions - Clean and check all the parts. If a part is defective, replace or repair it.

- Replace all the O-rings with new ones.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Apply the specified torque to tighten each main part.

44-33 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder removing and installing Boom cylinder removing (The illustration shows the left side of the machine.)

WARNING Unexpected movement of the machine, attachment, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving.

- Raise the boom until it is horizontal, and then place stand (A) under the boom to support it.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Use a stepladder or work platform, and do not stand on the machine.

Before starting work: - Clean the area around the cylinder and piping.

1. Attach sling to boom cylinder (1). : Boom cylinder: 145 kg 2. Disconnect hoses (2) (3). : Oil: Approx. 10 L Note Cover the disconnected hoses and pipes with plastic, plugs, or caps to protect them from dust, water and dirt.

Stand

85ZV44003

3. Remove lock bolt (4) and pin (5).

Relieving residual pressure from pipe (a) Raise the boom. When the boom is approximately 30 cm above the stand, stop the engine. (b) Tilt the bucket all the way down, and then lower the boom onto the stand. Move the bucket and boom levers back and forth to fully relieve the pressure. (c) First press down on the hydraulic tank cap to vent residual pressure, then open the cap of the hydraulic tank. Leave hydraulic tank cap loosely on top of tank opening.

4. Remove lock bolt (6) on the bottom side and remove retainer pin (7) 5. Sling boom cylinder (1) and lower it onto the ground.

For the detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-39.

44-34 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Boom cylinder installing To reinstall the boom cylinder, follow the above removal procedure in reverse order.

Boom cylinder installation cautions Be sure the pins accept grease after installation.

Cylinder air bleeding procedure

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note Stop the piston about 100 mm before stroking fully. (b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-35 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder removing and installing Bucket cylinder removing

WARNING Unexpected movement of machine, bucket, or boom during service work could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block tires with chocks to prevent wheels from moving.

- Place the boom and the bucket onto the ground.

- Relieve the internal pressure from the loading line, and also relieve the internal pressure from the hydraulic tank to prevent the oil from spouting out.

- Use a step, and do not stand on the machine.

2. Disconnect hoses (4)(5).

Note Cover the disconnected hose and the cylinder with plastic, caps or plugs to protect them from dust, water and dirt.

Before starting work: - Clean the area around the cylinder and piping.

Relieving residual pressure from pipe (a) Lower the boom and the bucket onto the ground. (b) Stop the engine and move the bucket and boom levers back and forth. (c) Open the cap of the hydraulic tank to relieve the residual pressure.

3. Attach sling to bucket cylinder (6).

After that, remove lock bolt (7) and pin (8). : Bucket cylinder: 141 kg

1. Remove the coupler of bucket positioner switch (1), and then remove bracket (2).

Remove rod (3) for the bucket positioner.

44-36 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder installation cautions

WARNING During service work, do not stand on the machine.

Standing on tire, boom or linkage may cause accidents and serious injury or death. Use a stepladder, ladder, or work platform, and do not stand on the machine.

- Be sure the pins accept grease after installation.

4. Disconnect grease pipe (9).

- Adjust the bucket leveler so that the clearance between the switch and the rod is 5±2 mm.

Refer to "Bucket positioner" page 15-9.

Cylinder air bleeding procedure

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

5. Remove lock bolt (10) and pin (11).

6. Slowly lift up bucket cylinder (6) and remove the shim.

Lower the bucket cylinder onto the ground.

For the detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-39.

Bucket cylinder installing To reinstall the bucket cylinder, follow the above removal procedure in reverse order.

Note Stop the piston about 100 mm before stroking fully. (b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-37 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder removing and installing Steering cylinder removing

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and apply the parking brake. In addition, block the tires with chocks to prevent the wheels from moving.

- Place the boom and the attachment onto the ground.

- Stop the engine, and turn the steering wheel clockwise and counterclockwise to relieve the pressure from the line.

- Press cap downward to vent, then open the cap of the hydraulic tank to relieve the internal pressure from the tank.

- Place a "DO NOT START!" tag on the steering wheel or the operator's seat.

2. There is a pin (5) between front chassis (3) and steering cylinder (4).

Remove pin (5), and then push rod (6) into the cylinder to shorten the length of the cylinder. : Approx. 2 L Oil will be drained from the oil port of the cylinder.

Place a container at the oil port to catch the drained oil.

Before starting work: - Clean the area around the cylinder to be removed.

3. Disconnect grease pipe (6).

1. Disconnect hoses (1)(2).

Note Cover the disconnected hoses with plastic, caps, or plugs to protect them from dust, water, and dirt.

44-38 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder installation cautions Pin installation Be sure the pins accept grease after installation.

IMPORTANT Insert shims so that the clearance between the chassis and the cylinder is 1.2 mm or less.

Place approximately the same number of shims under the cylinder as on top of the cylinder. Refer to "Linkage Pin Standard Clearance Values" page 15-3.

4. Remove bolt (7) and pin (8).

5. Remove steering cylinder assembly (4).

Note that two persons are needed to remove and lift the assembly. : Steering cylinder: 26 kg Note For detailed description of cylinder disassembly and reassembly, refer to "Hydraulic cylinder disassembling and assembling" page 44-39.

WARNING Articulation area is a crush zone. Moving the machine with a person in this area can cause injury or death.

When turning the steering wheel while engine is running, do not enter the articulation area of the machine.

If a person is in the articulation area, do not start the engine.

Cylinder air bleeding procedure

Steering cylinder installing To reinstall the steering cylinder, follow the above removal procedure in reverse order.

IMPORTANT After repairing or replacing a cylinder, be sure to bleed the cylinder of air, or the piston seal or back-up ring may be seized. (a) While operating the engine at low-idling speed, operate the cylinder piston for 4 to 5 strokes.

Note Stop the piston about 100 mm before stroking fully. (b) After that, stroke the cylinder piston fully to both ends 4 to 5 times. (c) Add hydraulic oil to the tank, and check the cylinder and its piping for oil leakage.

44-39 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Hydraulic cylinder cross section and tightening torque Boom cylinder

T1

T2

70N44005

(S/N 1001~1056, 7101~7128) T1: 2,648 N-m (270 kgf-m) T2: 588 N-m (60 kgf-m) (S/N 1057~1200, 7129~7200) T1: 2,648 N-m (270 kgf-m) T2: 471 N-m (48 kgf-m) (S/N 1201~, 7201~) T1: 3,040 N-m (310 kgf-m) T2: 471 N-m (48 kgf-m) T1: Piston nut width across flats: 80 mm

: Boom cylinder: 145 kg

44-40 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

22 6

(S/N ~1200, ~7200)

8 7

6 22 1

12

7 13 15

11

14 20 3

18 16

19

17 4

5 23 (S/N 1227~, 7224~) 25

21 2 (S/N ~1056, ~7128)

9 9

10

70N44003a

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Cylinder tube Rod Piston Rod cover Bushing Bushing Piston nut Stop ring Bolt Spring washer Wear ring Square ring Slipper ring O-ring Wear ring

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

O-ring Back-up ring U-packing Back-up ring Buffer ring Scraper ring Dust seal Stop ring — Stop ring

44-41 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder (S/N ~1964, ~7775)

T2

T1

70N44006

T1: Piston nut width across flats: 90 mm T1: 4,217 N-m (430 kgf-m) T2: 880 N-m (90 kgf-m)

: Bucket cylinder: 141 kg

(S/N ~1226, ~7223)

22

6

1

22 3 12

25

13

24

8

14

(S/N 1048~, 7126~)

7

16

11

15

17 18 19 4

20

5 23

2

21

22

10 9

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cylinder tube Rod Piston Rod cover Bushing Bushing Piston nut Stop ring Bolt

26 (S/N 1048~, 7126~)

10.

11.

12.

13.

14.

15.

16.

17.

18.

Spring washer Wear ring Square ring Slipper ring Wear ring O-ring O-ring Back-up ring Buffer ring

6

22 70K44027a

19.

20.

21.

22.

23.

24.

25.

26.

U-packing Back-up ring Scraper ring Dust seal Stop ring Plug O-ring Plug

44-42 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Bucket cylinder (S/N 1965~, 7776~)

T1

T2 70N44006a

(S/N 1965~2550, 7776~) T1: 5,900±300 N-m (602±31 kgf-m) T2: 880±90 N-m (90±9 kgf-m)

(S/N 2551~) T1: 5,900±300 N-m (602±31 kgf-m) T2: 500±65 N-m (56±6.6 kgf-m) (S/N 2551~)

: Bucket cylinder: 135 kg

880±90 N-m (90±9 kgf-m)

500±65 N-m (56±6.6 kgf-m)

Cylinder bolt (20) tightening torque K70V2J42023

Note Number of cylinder fixing bolt (T2) has increased on S/N 70J1-2551 and thereafter.

44-43 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

22 6

1

11

22 3 24

8

25

25

24

14 15

7

17 23 5 18 19 20 4 22

2 6

21

22 9

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cylinder tube Rod Piston Rod cover Bushing Bushing Piston nut — Bolt

K70ZIV4403

10.

11.

12.

13.

14.

15.

16.

17.

18.

— Wear ring — — Wear ring O-ring — Back-up ring Buffer ring

19.

20.

21.

22.

23.

24.

25.

U-packing Back-up ring Scraper ring Dust seal Stop ring Plug O-ring

44-44 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder (S/N 1001~1972, 7101~7771)

T1

T2 70N44007

T1: Piston nut width across flats: 50 mm T1: 1,471 N-m (150 kgf-m) T2: 1,569 N-m (160 kgf-m)

: Steering cylinder: 26 kg

(S/N ~1226, ~7223)

11 1

6 11 1

3 13 14 16

15

17

8 (S/N 1227~, 7224~)

10

18

20

(S/N ~1226, ~7223)

21 (S/N 1048~, 7126~)

22

19 (S/N ~1047, ~7125)

9

12

2

7

11

5

6

11 70N44004a

1.

2.

3.

4.

5.

6.

7.

8.

9.

Cylinder tube Rod Piston Rod cover Bushing Bushing Scraper ring Piston nut Stop ring

10.

11.

12.

13.

14.

15.

16.

17.

18.

O-ring Dust seal Wear ring Square ring Slipper ring O-ring O-ring Back-up ring U-packing

19.

20.

21.

22.

Back-up ring Back-up ring Buffer ring Screw

44-45 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Steering cylinder (S/N 1973~, 7772~)

T2

T1

70N44007

T1: 930±50 N-m (95±5 kgf-m) T2: 300±30 N-m (31±3 kgf-m) (S/N 1973~1982, 7772~7852)

11 6 11 1 3 7

12

12

8 9 5 16 17 18 4 13

2

14 15

11 6

11 K70ZIV4404

1.

2.

3.

4.

5.

6.

7.

8.

Cylinder tube Rod Piston Rod cover (case) Bushing Bushing Packing Piston nut

9.

10.

11.

12.

13.

14.

15.

16.

Clip — Dust seal Wear ring Packing Back-up ring Dust seal O-ring

17. Back-up ring 18. O-ring 19. Buffer ring

44-46 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder (S/N 1983~, 7853~)

11

6 11 3

1 7

12 12 8

16

9

17 13 18

14

4 2 5 9 15

11 6

11 K70ZIV4405

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Cylinder tube Rod Piston Rod cover (case) Bushing Bushing Packing Piston nut Clip — Dust seal Wear ring Packing Back-up ring Dust seal O-ring Back-up ring O-ring Buffer ring

: Steering cylinder: 24 kg

44-47 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder disassembling Note The boom cylinder disassembling procedure is described below. For other cylinders, follow the same procedure.

4

95ZV44006

3. Remove piston rod assembly (4) from the cylinder tube. : Hydraulic oil will be drained, so place a container to receive the drain oil.

Repair stand 95ZV44004

1. Install the bottom side of the cylinder to the repair stand.

Repair stand

4 Matchmark

3

Wooden block 95ZV44007

2 1 95ZV44005

2. Put the matchmarks on rod cover (1) and cylinder tube (2). Remove rod cover bolt (3). : Bolt (3): (Boom cylinder) 471 N-m (48.0 kgf-m) (Bucket cylinder) (S/N ~2550) 880 N-m (90 kgf-m) (Bucket cylinder) (S/N 2551~) 500 N-m (56 kgf-m) : Rod cover (1): (Steering cylinder) (S/N ~1972, ~7771) 1,569 N-m (160 kgf-m) (Steering cylinder) (S/N 1973~, 7772~) 300 N-m (31kgf-m)

4. Remove the cylinder tube from the repair stand and install rod assembly (4) to the repair stand and support the rod as shown in the figure.

44-48 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

5

4

Matchmark

7

6

4

6

95ZV44008

5. Remove stop ring (5) and put matchmarks on rod (4) and piston nut (6) for alignment with the stop ring holes.

95ZV44010

7. Remove piston nut (6), and then remove piston (7) from piston rod (4).

8. Remove wear ring (8), square ring (9), slipper ring (10), O-ring (11), wear ring (12) and piston packing (19).

(There is no square ring (9), slipper ring (10) and Oring (11) for the bucket cylinder and the steering cylinder.)

6 C

Note Refer to "Boom cylinder" page 44-39 through "Steering cylinder (S/N 1973~, 7772~)" page 44-45 for each parts.

Hydraulic jack

Hydraulic cylinder 95ZV44009

1

6. Use a hydraulic jack or hydraulic cylinder to loosen piston nut (6).

Piston nut width across flats

Tightening torque

80 mm

(S/N ~1200, ~7200) 2,648 N-m (270 kgf-m) (S/N 1201~, 7201~) 3,040 N-m (310) kgf-m)

Bucket cylinder

90 mm

(S/N ~1964, ~7775) 4,217 N-m (430 kgf-m) (S/N 1965~, 7776~) 5,900 N-m (602 kgf-m)

Steering cylinder

50 mm

(S/N ~1972, ~7771) 1,471 N-m (150 kgf-m) (S/N 1973~, 7772~) 930 N-m (95 kgf-m)

Boom cylinder

4

95ZV44013

9. Remove rod cover (1) from piston rod (4).

10. Remove scraper ring (13), back-up ring (14), Upacking (15), buffer ring (18), back-up ring (16), Oring (17), stop ring (20) and dust seal (21) from rod cover (1).

Note Refer to "Boom cylinder" page 44-39 through "Steering cylinder (S/N 1973~, 7772~)" page 44-45 for each parts.

44-49 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Hydraulic cylinder assembling

Hydraulic cylinder assembly cautions

To reassembling the hydraulic cylinders, follow the above removal procedure in reverse order.

Before starting work: - Be sure to replace all the seals and packings.

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

- Before reassembling the parts, apply a coat of hydraulic oil to the parts.

CAUTION Hot oil can cause injury or burns.

Avoid contact with hot oil.

Slipper ring installation

Piston nut

Slipper ring

Example of boom cylinder

K70ZIV4406

Put the slipper ring into hot oil to heat the ring to 120~150ºC. Note - This is because the inner diameter of the slipper ring is smaller than the outer diameter of the piston.

Therefore, heat the slipper ring to expand its inner diameter for easy attachment.

- Attach the slipper ring while taking care not to damage the ring by over expansion.

- After attaching the slipper ring, cool the slipper ring so that it is contracted to the original size.

44-50 70ZIV-2 Disassembly & Reassembly Hydraulic Group Hydraulic Cylinder

Back-up ring installation

Rod cover installation

2

3 95ZV44017

Before installing back-up ring (2) and O-ring (3), heat the back-up ring.

Note This is because the inner diameter of the back-up ring is smaller than the outer diameter of the rod cover. To easily attach the back-up ring to the rod cover, heat the ring to soften it. The soft ring can be easily expanded.

K65V2E44013

When installing the rod cover of the steering cylinder, screw the rod cover using a spanner wrench.

Screw in and tighten the set screw.

Stake the set screw. : 1,569 N-m (160 kgf-m) (S/N ~1972, ~7771) 300 N-m (31 kgf-m) (S/N 1973~, 7772~)

Be careful not to over expand the back-up ring. After installation, wait until the back-up ring is cooled, and then insert the rod cover into the cylinder tube.

Caulking

Caulking

Caulk rod cover (1) at four points to prevent scraper ring (13) from coming out.

44-51 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot Valve For bucket control

For bucket control

Neutral

1

Roll back (Detent)

Dump

For boom control

8 2

T 3 To tank port

4 5

P

6 From pump port

7

To / from MCV oil packs

Bucket spool in MCV

Boom spool in MCV

View from the rear side 80ZV42017

1.

2.

3.

4.

5.

6.

7.

8.

Lever Disc Push rod Spring seat Spring for secondary pressure Return spring Spool Detent magnet solenoid

44-52 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

For boom control

Raise (Detent)

Neutral

Down Float (Detent)

To tank port

95ZV42012

44-53 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve removing and installing

PUS switch

Pilot valve

Pilot valve removing 6

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and then block tires with chocks to prevent wheels from moving.

- Apply the parking brake.

- Lower the attachment onto the ground, and then relieve the internal pressure from the line.

- Relieve the internal pressure from the hydraulic tank.

7

70N44008

3. Separate the PUS switch.

Disconnect electrical line (6) of the PUS switch.

4. Disconnect electrical line (7) from the pilot valve.

Cover mount

Note Before disconnecting the electrical couplers, be sure to put matchmarks on them.

Pilot valve

Control box

1. Open the cab door (the right hand side).

Remove cover (1) from the control box.

Pilot valve

5. Disconnect hoses (8)(9)(10) from the pilot valve. : Drain oil: Approx. 1 L Note Before disconnecting the hoses, be sure to put matchmarks on them.

Cover the disconnected hoses with plastic, caps, or plugs to protect them from dust and dirt.

2. Remove the knobs, boot (2), and covers (3)(4)(5).

44-54 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve installing To reinstall the pilot valve, follow the removal procedure in reverse order.

Pilot valve

Pilot valve installation cautions After reinstallation, check operation of the pilot valve. In addition, check the pilot valve for oil leakage.

If the oil level is too low, add hydraulic oil to the tank.

6. Loosen nut (11) and disconnect the rod from the pilot valve.

Remove bolt (12) (4 pcs) and pull up the pilot valve to remove it. : Bolt (12): 28 N-m (2.9 kgf-m) : Pilot valve: 9.5 kg

44-55 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Pilot valve tightening torque For boom FRONT

Bucket side

Boom side

For bucket

T1

T1 T3 L1

T3 L1

T3

T5

T4

T5

T4

T3

T4

T1

T1

T4

T1

T1

: T1: 29 N-m (3.0 kgf-m) T2: 36 N-m (3.7 kgf-m) T3: 17 N-m (1.7 kgf-m) T4: 42 N-m (4.3 kgf-m) T5: 12 N-m (1.2 kgf-m) : L1: Screw lock agent (Three Bond 1327)

T2

T1

T1

: Pilot valve: 9.5 kg

95ZV44021

44-56 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve disassembling

3. Loosen the lock nut for solenoid (3), and then remove solenoid from cover (2).

IMPORTANT

: Solenoid: 42 N-m (4.3 kgf-m)

- Place the removed parts, in order, on a clean paper or cloth.

- Carefully disassemble the pilot valve so that the parts are not scratched.

(Illustrated on the boom side. Disassemble the bucket side in the same manner.)

4. Be sure to carefully store ball (4).

5 6 7

1. Plug all ports of the pilot valve and rinse it with illuminating kerosene.

1 97ZV44024

3

4

5. Loosen socket bolt (5).

Put a matchmark on lever (6) and disc (7) and remove lever (6) from disc (7).

2

: Bolt (5): 29 N-m (3.0 kgf-m)

97ZV44023

8

2. Clamp the pilot valve in a vise.

Pull up boot (1) to remove it from cover (2).

A Lock nut

9 97ZV44025

6. Loosen socket bolt (8).

Remove cam shaft (9).

95ZV44076

Note Before removing solenoid (3), measure the distance (A) between solenoid (3) and cover (2).

: Bolt (8): 17 N-m (1.7 kgf-m) : Screw lock agent (Three Bond 1327) Note In case the cam shaft cannot be pulled out, use the hexagon wrench to push it out.

44-57 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

11 12 7

10 13 14

2

97ZV44026

97ZV44028

7. Temporarily tighten socket bolt (5).

Put matchmark on disc (7) and cover (2).

Pull up socket bolt (5) with disc (7) to remove it.

10. Put matchmark on plug (11), push rod (12) and case assembly (14).

Remove plug (11) together with push rod (12).

8. Loosen socket bolt (10).

Note - Carefully store the spring and spring seat in the push rod.

- Carefully remove plug (11) as it may spring out by the spring force. Be careful so that the parts are not damaged.

- In case plug (11) does not come out, use a screwdriver to remove it.

: Bolt (10): 12 N-m (1.2 kgf-m) Note In case the spring force for the return spring is strong, alternately loosen the socket bolts so that cover (2) can be level.

2

11. Put matchmark on reducing valve assembly and case assembly. Remove reducing valve assembly (13) from case assembly (14).

A

A

11

12 97ZV44027

19

9. Put matchmark on cover (2) and the case assembly.

Remove cover (2) from the case assembly.

20 97ZV44032

12. Disassemble plug (11).

- Remove spring (19) and spring seat (20) from push rod (12), when mounted.

- Remove push rod (12) from plug (11).

Note Keep the disassembled parts per each port.

44-58 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

24 23

Carefully install the spool into the case.

25 26

22 97ZV44033

95ZV44022

Note When installing, carefully install the spool assembly so that the end of the spool does not hit the hole corner in the case assembly.

13. Disassemble reducing valve (13).

- Push down spring seat (23).

- Remove plain washer (24).

- Remove spring (25) and shim (26), if any, from spool (22).

17

Note - Carefully remove plain washer so that the spool is not damaged.

- Do not push down spring seat (23) 4 mm or more.

- Shim is for the secondary pressure adjustment.

16

18

14 97ZV44031

14

15. Clamp case assembly (14) in a vise up side down.

Put matchmark on plate (18) and case assembly (14).

Loosen socket bolt (17) and remove plate (18) from the case assembly.

15

97ZV44029

: Bolt (17): 29 N-m (3.0 kgf-m) 14. Put matchmark on return springs (15)(16) and case assembly (14).

Remove return springs (15)(16) from case assembly (14).

44-59 70ZIV-2 Disassembly & Reassembly Hydraulic Group Pilot Valve

Pilot valve assembling To reassemble the pilot valve, follow the above disassembly procedure in reverse order.

Pilot valve assembly cautions - Clean and check all the parts. If any part is defective, replace or repair it.

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

- Apply the specified torque to tighten each main part.

- Apply a thin coat of hydraulic oil or grease to each part before reassembly.

- Measure the resistance of each coil magnet assembly. The resistance should be 138 Ω at normal room temperature (20ºC). If measured in extremely low temperatures the resistance will be less, and at operating temperature the resistance will be higher.

24

Sharp edge side

22 95ZV44023

- Install plain washer (24) so that the plain washer sharp edge side comes to the top.

- Do not push spring seat (23) 4 mm or more.

44-60 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

Orbitrol® (S/N 2201~, 8251~) Orbitrol® removing and installing Orbitrol® removing

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and lower the attachment onto the ground.

- Block tires with chocks to prevent wheels from moving.

- Apply the articulation stopper.

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

- Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right.

- Relieve the internal pressure from the hydraulic tank.

Note This work should be done by two persons. One person should support the Orbitrol® under the machine. The person in the cab should remove the retainer bolt.

1 2 K70IV2EX44001

1. Remove cover (1).

2. Remove floor mat (2).

3

Orbitrol®

K70IV2EX44002

3. Put matchmarks on hoses (3), and then disconnect them from Orbitrol® (4).

44-61 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

Orbitrol® installation cautions At the completion of reinstallation, check operation of the Orbitrol® by following the procedure below:

WARNING 4

Orbitrol®

5

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

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

K70IV2EX44003

4. Remove bolts (4) (5), and then remove the Orbitrol®. : Bolt (4)(5): 53 N-m (5.4 kgf-m) : Orbitrol®: 7.3 kg

Orbitrol® installing To reinstall the Orbitrol®, follow the above removal procedure in reverse order.

Start the engine and check around the Orbitrol® for oil leakage.

44-62 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

Orbitrol® disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Orbitrol® cross section and tightening torque

Centering springs

Push spool

O-ring Plate

Check value Sleeve

O-ring

T1

Make-up valve Ball

Needle bearing Housing Seal unit

O-ring

Spacer

End cap

Overload relief valve

Rotor assembly Retainer

Drive shaft

70V2E44014

: T1: 28 N-m (2.9 kgf-m)

: 7.3 kg

44-63 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

Orbitrol® disassembling [ Disassembling rotor ] 1 Make matchmarks before disassembling unit.

A

25 (1 m m in)

Housing 70V2E44015

Copper plate

1 60ZV44123

5 ®

1. Set the Orbitrol in a vise so that the rotor side comes to the top position.

Use a copper plates on a vise and do not tighten the vise too strong.

1

3 4

70V2E44016

2. Remove seven bolts (1), end cap (3), O-ring (4) and spacer (5).

Note The make-up valve installed in the housing is tightened with bolts (A).

When removing the bolts, take care not to drop the make-up valve.

44-64 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

7 14

13

12

6

8

60ZV44081

16 15

70V2E44017

5. Remove the housing from the vise.

Remove adapter screw (12), Spring pin (14) and ball (13) of the emergency check valve by a screw driver.

Also remove pin (15) and ball (16) of the make-up valve.

3. Remove rotor assembly (6) and O-ring (7).

Note Keep star (8) in rotor assembly (6).

10 9 11 60ZV44082

4. Remove drive shaft (9), spacer plate (10) and Oring (11).

44-65 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~) [ Disassembling valve ] 18

19

20

60ZV44086

17 60ZV44084

8. Remove Y-packing seal (19) and dust seal (20) from seal retainer (18).

6. Remove retainer ring (17) with a screw driver.

Note Carefully remove the retainer ring so that it does not spring out.

Note Take care not to damage seal retainer (18).

21

23

18

22 60ZV44087

60ZV44085

7. Place the housing horizontally on clean cloth.

Rotate the spool and sleeve so that the pin can be in a horizontal position. Remove seal retainer (18) by pressing the spool and sleeve from behind with your fingers.

9. Remove races (21), needle bearing (22), and Oring (23).

44-66 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

27 Housing

26

25 Spool / sleeve assembly

60ZV44090

60ZV44088

10. Pull the spool and sleeve assembly out slowly, turning it clockwise and counterclockwise from the housing.

12. Push spool (25) slightly out of sleeve (26), and remove centering springs (27).

Note Take care so that the spool and sleeve assembly do not damage the housing.

26

26

Spool / sleeve assembly

25

25 60ZV44091

24

13. Pull spool (25) from sleeve (26) while slowly turning the spool clockwise and counterclockwise.

Matchmark 60ZV44089

11. Pull out pin (24) from the spool and sleeve assembly.

Note Before pulling out pin (24), put matchmarks on spool (25) and sleeve (26) for reassembly.

29

30

31

28 27

Overload relief valve units 70V2E44018

14. Remove plug (27) to remove O-ring (28) from the plug using a hexagon (allen) wrench (width across flat: 5 mm).

Take out spring (29), poppet (30) and seat (31) (2 places).

44-67 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

Orbitrol® assembling [ Reassembling valve ]

32

Spring groove

26

Spring groove

25

60ZV44093

Note Inlet check valve (32) built in port P is connected with the housing and cannot be removed.

Matchmark 60ZV44094

1. Assemble spool (25) and sleeve (26) so that the spring grooves in them are lined up. Use light oil for assembly of parts Note - Confirm that the spool can be turned easily in the sleeve.

- Align the matchmarks on the spool and sleeve.

25 27

26 60ZV44095

2. Install centering springs (27) through the spring grooves in spool (25) and sleeve (26) using a spring insertion jig.

Note Assemble two sets of 2 springs each, back to back, with the flat plate in between the sets, and install with the notches at the ends facing downward.

44-68 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

26 21

22

23 25 24

Matchmark 60ZV44098

60ZV44096

3. Insert pin (24) in the holes in spool (25) and sleeve (26) until the end of the pin is flush with the surface of the sleeve.

5. Install O-ring (23), races (21), and needle bearing (22).

18

19

20

Housing

Spool / sleeve assembly 60ZV44086 60ZV44097

4. Insert the spool and sleeve assembly squarely inward from the back of housing.

Note - Take care not to tilt the assembly and cause damage during insertion.

- Insert the assembly until the back end of the assembly is flush with the back end of the housing.

- Confirm that the assembly can be turned easily in the housing.

6. Insert dust seal (20) and Y-packing seal (19) in seal retainer (18).

17

18 25

60ZV44099

7. Insert seal retainer (18) onto spool (25), and then tap it gently into position with a plastic-faced hammer. Then install retainer ring (17).

44-69 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~) [ Reassembling rotor ] Screw driver Dust seal Retainer ring 25 (1 m m in)

Seal retainer Y-packing seal O-ring Housing

Plate 80V2E44019

Note Be sure that the position and direction of the seals are placed correctly.

Overload relief valve units

27 28 29

60ZV44102

9. Set the Orbitrol® in a vise so that the rotor side comes to the top position.

Use a copper plates on a vise and do not tighten the vise too strong.

30 31

10 Housing

15

11

12 14

16

13

70V2E44019

8. Insert O-ring (28) in plug (27). Apply grease to ball holder (30) and install ball (31).

Insert ball holder (30) and spring (29) into the housing, and then insert plug (27) using the hexagon wrench (width across flat: 5 mm).

70V2E44020

10. Insert ball (16) and pin (15) of the make-up valve to the housing.

Insert ball (13) and spring pin (14) of the emergency check valve and tighten adapter screw (12) by a screw driver.

Then install O-ring (11) to the housing and put on spacer plate (10).

Align the bolt holes in the plate with those in the housing.

44-70 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

A

Grooves in rotor bore Port face

B 9

Drive shaft

C

Parallelize with port face

D

Pin

Port face

24

11. Insert drive shaft (9) to mate its yoke with pin (24).

Rotate the spool and sleeve so that the pin (24) can be parallel with the port face.

Note Put a matchmark on the end face of the drive shaft parallel with the pin.

95ZV44029

13. Holding the rotor assembly with the O-ring side facing the spacer plate, install the assembly so that the grooves in the star-shaped bore mesh with the drive shaft.

Note - Align the bolt holes in the rotor assembly with those in the housing without disengaging the drive shaft from the rotor assembly's star-shaped bore.

- Confirm that lines A, B, C and D are all parallel.

6 1 4 1

7

2 60ZV44105

3

12. Put O-ring (7) in rotor assembly (6).

K70V2J44022

14. Install spacer (4), O-ring (3) and end cap (2).

Provisionally tighten bolt (1). : Provisional tightening torque: 15 N-m (1.5 kgf-m) Tightening torque: 28 N-m (2.9 kgf-m)

44-71 70ZIV-2 Disassembly & Reassembly Hydraulic Group Orbitrol® (S/N 2201~, 8251~)

6

4

1

2 3

7 5 60ZV44112

15. Evenly tighten the seven bolts in the order shown above.

44-72 70ZIV-2 Disassembly & Reassembly Hydraulic Group Priority Valve (S/N 2201~, 8251~)

Priority Valve (S/N 2201~, 8251~) Priority valve removing and installing

8 5

Priority valve removing

6

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and lower the attachment onto the ground.

- Block tires with chocks to prevent wheels from moving.

- Apply the articulation stopper.

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

- Relieve the internal pressure from the steering hydraulic line by turning the steering wheel left and right.

- Relieve the internal pressure from the hydraulic tank.

7

1 K70IV2EX44005

2. Disconnect hoses (5)(6) to the Orbitrol® and drain hose (7).

Note - Approximately 1 L of hydraulic oil will be drained from the disconnected hoses. Place a container to receive the drained oil.

- Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

3. Loosen bolt (8) to remove priority valve (1).

Before starting work: - Release residual pressure in the loading and steering lines.

: Priority valve: Approx. 6 kg

Priority valve installing 2

To reinstall the priority valve, follow the above removal procedure in reverse order.

3 1 4 K70IV2EX44004

1. Disconnect hoses (2)(3) from the pump, hose (4) to the multiple control valve.

Note Cover the disconnected hoses with vinyl, plugs or caps to protect them from dust and dirt.

44-73 70ZIV-2 Disassembly & Reassembly Hydraulic Group Priority Valve (S/N 2201~, 8251~)

Priority valve disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

Priority valve cross section and tightening torque

T2

T2 2

T1

1

3

70V2E44023

:(S/N ~2429) T1: 25 N-m (2.5 kgf-m) T2: 54 N-m (5.5 kgf-m) :(S/N 2430~) T1: 21 N-m (2.1 kgf-m) T2: 44 N-m (4.5 kgf-m)

Priority valve disassembly cautions Carefully remove plug (1) or (2). It may spring out by the spring force. Alternately loosen plug (1)(2) to reduce the spring force and remove them.

44-74 70ZIV-2 Disassembly & Reassembly Hydraulic Group Accumulator (S/N 2201~, 8251~)

Accumulator (S/N 2201~, 8251~) Accumulator removing and installing Accumulator removing 2

WARNING Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items: - Park the machine on level ground, and lower the attachment onto the ground.

- Block tires with chocks to prevent wheels from moving.

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

1 Accumulator

Before starting work: - Press the hydraulic oil tank cap, and relieve the internal pressure from the hydraulic tank.

4

3

K70IV2EX44006

1. Remove cover (1) from the hydraulic oil tank.

2. Remove hose (2).

3. Remove nut (3) and then remove band (4).

4. Remove accumulator. : Accumulator: 2.7 kg/pc

Accumulator installing To reinstall the accumulator, follow the above removal procedure in reverse order.

Accumulator installation cautions - Replace all O-rings and seals during reinstallation.

- After reinstallation, completely bleed the brake line of air, and check performance of the accumulator.

45-1 70ZIV-2 Service Standard Hydraulic Group

70ZIV-2 Service Standard Hydraulic Group Steering Linkage (S/N ~2200, ~8250) ..................... 45-2 Gear Pump .............................................................. 45-4 Hydraulic Cylinder ................................................... 45-5 Pilot Valve................................................................ 45-6

45-2 70ZIV-2 Service Standard Hydraulic Group Steering Linkage (S/N ~2200, ~8250)

Steering Linkage (S/N ~2200, ~8250)

Center of center pin

Drop arm Left-turn position

45-3 70ZIV-2 Service Standard Hydraulic Group Steering Linkage (S/N ~2200, ~8250)

Steering linkage tightening torque No.

Item

Standard value

1

Steering valve retainer bolt tightening torque

52.5 N-m (5.35 kgf-m)

2

Link bracket retainer bolt tightening torque

216 N-m (22.0 kgf-m)

3

Ball joint retainer nut tightening torque

191 N-m (19.5 kgf-m)

4

Ball joint lock nut tightening torque

113 N-m (11.5 kgf-m)

5

Steering valve bracket retainer bolt tightening torque

216 N-m (22.0 kgf-m)

6

Overload relief valve tightening torque

7

Main relief valve tightening torque

83 N-m (8.5 kgf-m) 103 N-m (10.5 kgf-m)

Solution

Tightening

45-4 70ZIV-2 Service Standard Hydraulic Group Gear Pump

Gear Pump

Front (for steering)

No.

Item

Center (for loading)

Rear (for loading)

Standard value

Solution

1

Deviation of the gear width

0.01 mm or less

Replacement of pump assy

2

Deviation of the drive and the driven shaft outer diameter

0.01 mm or less

Replacement of pump assy

3

Deviation of the inner diameter of the bushing

0.02 mm or less

Replacement of pump assy

4

Roughness of the pressure plate surface

0.02 mm or less

Replacement of pump assy

5

Pump connection bolt tightening torque

34 N-m (3.5 kgf-m)

Tightening

6

Pump connection bolt tightening torque

34 N-m (3.5 kgf-m)

Tightening

45-5 70ZIV-2 Service Standard Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Boom cylinder

Steering cylinder

Unit: mm Judgment standard No.

1

Item

Standard value

Standard rod diameter

Rod

Boom cylinder

ø75

Bucket cylinder Steering cylinder

No.

Solution

Bushing

Bushing

Clearance

-0.030~-0.076

+0.195~+0.060

0.090~0.271

+0.295

0.371

Replacement

ø80

-0.030~-0.076

+0.190~+0.060

0.090~0.266

+0.290

0.366

Replacement

ø45

-0.025~-0.064

+0.105~0

0.025~0.169

+0.205

0.269

Replacement

Item

Piston nut tightening torque 2 Piston nut size (mm) Piston nut width across flat (mm)

Rod cover bolt tightening torque

Boom cylinder (S/N ~1200, ~7200) 2,648 N-m (270 kgf-m) (S/N 1201~, 7201~) 3,040 N-m (310 kgf-m)

Bucket cylinder (S/N ~1964, ~7775) 4,217 N-m (430 kgf-m) (S/N 1965~, 7776~) 5,900 N-m (602 kgf-m)

Steering cylinder (S/N ~1972, ~7771) 1,471 N-m (150 kgf-m) (S/N 1973~, 7772~) 930 N-m (95 kgf-m)

M52 x 2

M62 x 2

M33 x 3

80

90

50

471 N-m (48 kgf-m)

3

4

Limit

Standard clearance

(S/N 1001~2550, 7101~) 880 N-m (90 kgf-m) (S/N 2551~) 500 N-m (56 kgf-m)

(S/N ~1972, ~7771) 1,569 N-m (160 kgf-m) (S/N 1973~, 7772~) 300 N-m (31 kgf-m)

Bolt size (mm)

M20

M24

(Rod cover)

Piston stroke (mm)

754

502

380

45-6 70ZIV-2 Service Standard Hydraulic Group Pilot Valve

Pilot Valve

2

97ZV45002a

Judgment standard No.

Item

Solution Standard valve

Allowable limit

36 mm

35 mm

Wear 1 mm 2

Push rod 85V2E45003

Ø 7 mm

Replacement

54-1 70ZIV-2 Disassembly & Reassembly Brake Group

70ZIV-2 Disassembly & Reassembly Brake Group Brake Valve Assembly............................................. 54-2 Air Master Assembly ............................................... 54-6 Service Brake .......................................................... 54-11 Air Cylinder for Parking Brake ................................. 54-12 Parking Brake.......................................................... 54-17 Air Tank ................................................................... 54-19

54-2 70ZIV-2 Disassembly & Reassembly Brake Group Brake Valve Assembly

Brake Valve Assembly Brake valve removing and installing Brake valve removing

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

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

- Relieve the air pressure from the air tank.

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

- Clean the area around the brake valve.

3. The person in the cab should remove three connection bolts (5) from brake pedal (4), and the person under the machine should remove the brake valve.

Remove pedal assembly (4) from the top side.

Brake valve installing To reinstall the brake valve, follow the above removal procedure in reverse order.

Brake valve installation cautions After reinstallation, completely bleed the brake line of air, and check all the pipe-joints for oil leakage.

To check or adjust the brake valve, refer to the 70ZIV-2 Shop Manual, Function & Structure, Section 53.

1. Disconnect air pipes (1), tee (2), and then disconnect air hose (3).

Note Cover the disconnected hoses and pipes with plastic, plugs or caps to protect them from dust and dirt.

2. One person should support the brake valve under the machine, and another person should enter the cab.

54-3 70ZIV-2 Disassembly & Reassembly Brake Group Brake Valve Assembly

Brake valve disassembling and assembling Brake valve cross section and tightening torque (main valve)

: T1: 12 N-m (1.2 kgf-m) T2: 6 N-m (0.6 kgf-m) T3: 34 N-m (3.5 kgf-m) : L1: Liquid gasket (Loctite® gasket 568) L2: Anti-seize compound

1. Diaphragm 2. Cover 3. Inlet / exhaust valve assembly 4. Body 5. Piston 6. Relay piston assembly 7. Valve assembly 8. Body 9. Upper piston assembly 10. Spring seat 11. Boot 12. Plunger 13. Roller 14. .Spring 15. Pin 16. Pedal

54-4 70ZIV-2 Disassembly & Reassembly Brake Group Brake Valve Assembly

Brake valve disassembling Before starting work: - Clean the outer surface of the valve.

4. Remove retainer ring (4), spring seat (5), O-rings (6)(7), retainer (8), valve spring (9), and inlet exhaust valve (10).

Also remove body retainer bolt (11).

1. Remove diaphragm (1) and cover (2).

5. Separate the body into two sections (12)(13).

2. Remove inlet exhaust valve assembly (3).

3. Disassemble inlet exhaust valve assembly (3).

6. Loosen and remove nut (14), and then remove spring set (15), piston assemblies (16)(17), rubber spring (18), and piston return springs (19)(20).

54-5 70ZIV-2 Disassembly & Reassembly Brake Group Brake Valve Assembly

Brake valve assembling To reassemble the brake valve, follow the above disassembly procedure in reverse order.

Brake valve assembly cautions - Clean and check all the parts. If a part is defective, replace or repair the part.

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

- Apply lithium-based grease to all the sliding surfaces of the body, O-rings, and O-ring grooves.

Note Certain cleaners and solvents can damage rubber parts, use only approved cleaners and solvents.

- Apply the specified torque to tighten each main parts.

- After reassembly, reinstall the brake valve on the machine, and check that no air is leaking.

Also check operation of the brake valve referring to "Checking Brake Valve" in Section 53.

54-6 70ZIV-2 Disassembly & Reassembly Brake Group Air Master Assembly

Air Master Assembly Air master removing and installing Air master removing

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

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

- Relieve the air pressure from the air tank.

Before starting work: - Remove the left side deck (refer to Section 14).

1. Disconnect air hoses (1) and brake hose (2).

Note - Cover the disconnected hoses and pipes with plastic, plugs or caps to protect them from dust and dirt.

- The brake oil will be drained. Place a container to catch the drained oil. : Brake oil: 1.5 L

2. Disconnect stroke indicator connectors (4), and remove brake pipe (3).

3. Remove bolts (5) and then remove air master (6).

Air master installing To reinstall the air master, follow the above removal procedure in reverse order.

Replace all O-rings and seals during reinstallation.

Note - After reinstallation, completely bleed the brake line of air, and check performance of the air master.

- To bleed the brake line of air, refer to the 70ZIV-2 Shop Manual, Function and Structure, Section 53.

54-7 70ZIV-2 Disassembly & Reassembly Brake Group Air Master Assembly

Air master disassembling and assembling Air master tightening torque

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Pressure plate Non-pressure plate Diaphragm Return spring Push rod assembly Clamp ring Bolt Nut Push nut Nut Spring nut Nut Cylinder Return spring O-ring ST seal SKY seal O-ring Piston Valve assembly

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

Gasket Piston stopper plate C-ring Spring guide Gasket Stroke indicator Bolt Ball Bleeder screw Cap

: T1: 20 N-m (2.0 kgf-m) T2: 64 N-m (6.5 kgf-m) T3: 88 N-m (9.0 kgf-m) T4: 10 N-m (1.0 kgf-m) T5: 29 N-m (3.0 kgf-m) L1: Screw lock agent (Three Bond 1327) application

54-8 70ZIV-2 Disassembly & Reassembly Brake Group Air Master Assembly

Air master disassembling

IMPORTANT - Clean the outer surface of the air master.

- Put match marks on the parts before disassembly.

- Sequentially place the removed parts in the disassembly order.

- Carefully remove each part so that it is not scratched or dented.

3. Remove bleeder screw (8) and then remove the ball. : Bleeder screw (8): 10 N-m (1.0 kgf-m)

Press machine

1. Put match marks on the air master body to show the direction of the fittings (1)(2)(3) for reassembling.

Snap ring

4. Disassemble the cylinder.

Press the spring as shown, and remove the snap ring.

WARNING

2. Remove stroke indicator (4) and nut (5), and then separate chamber (6) and cylinder (7). : Nut (5): 88 N-m (9.0 kgf-m) : Stroke indicator (4): 29 N-m (3.0 kgf-m) : Screw lock agent (Three Bond 1327)

The inner spring may spring out causing injury.

To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the snap ring.

When reducing the pressure of the press, be sure to reduce it slowly.

CAUTION When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined.

54-9 70ZIV-2 Disassembly & Reassembly Brake Group Air Master Assembly

Press machine

Match mark

5. Remove snap ring (9) and piston (10).

8. Press the spring as shown, and disassemble the chamber.

Put match marks on the section and remove bolts (14), and then remove clamp (15). : Bolt (14): 20 N-m (2.0 kgf-m)

WARNING The inner spring may spring out causing injury.

To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the bolts.

When reducing the pressure of the press, be sure to reduce it slowly.

6. Remove piston stopper plate (11) and return spring (12).

9. Slowly reduce the pressure of the press and then remove the inner parts.

7. Do not disassemble valve assembly (13) in piston (10).

54-10 70ZIV-2 Disassembly & Reassembly Brake Group Air Master Assembly

Air master assembly cautions - Clean the metal parts using approved brake cleaning solvent, and then blow the compressed air to dry them.

- After cleaning, check the parts for damage and wear.

If a part is defective, replace it with a new one.

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

- Use brake oil (engine oil SAE 5W or equivalent).

- Use lithium grease.

10. Remove pressure plate (16), diaphragm (17), push rod (18) and return spring (19).

Air master assembling To reassemble the air master, follow the above disassembly procedure in reverse order.

54-11 70ZIV-2 Disassembly & Reassembly Brake Group Service Brake

Service Brake Service brake disassembling and assembling Refer to "Planetary assy disassembling and assembling" page 24-19 for the procedures.

Service brake installation cautions Air bleeding procedure - After reinstalling tires, check that manual rotation of the tires is possible.

- Check the wheels for oil leakage.

Socket bolt

(a) Connect a vinyl tube to the air bleeder nipple, and place an oil can to receive the oil. (b) Fill the brake oil tank. (c) Slightly loosen the air bleeder nipple, and then press the brake pedal several times. When the oil flows from the air bleeder nipple, close the nipple. (d) After that, each time you press the pedal, open the air bleeder nipple to slightly discharge oil, and then immediately close the nipple. (e) Repeat this until there is no air in the oil. (f) Completely bleed each wheel of air.

Note When the oil level in the reservoir is low, add oil to the tank.

Spider

95ZV54024

WARNING Before air bleeding in the brake oil line, be sure that the wheel and tire assemblies are installed on the wheel hub. If fail to do, the bolts (4 pcs) temporarily tighten the spider and the wheel hub may be broken by the brake piston. Finally the spider and the cover may fall off and it could cause serious injury or death.

Brake disc installation cautions

CAUTION When only the friction plates or the steel plates are to be replaced, if the brake piston and brake stroke adjusting mechanism are installed as they are, the brake may drag and the brake discs may seize.

After reinstalling tires, check that manual rotation of the tires is possible.

54-12 70ZIV-2 Disassembly & Reassembly Brake Group Air Cylinder for Parking Brake

Air Cylinder for Parking Brake Parking brake air cylinder removing and installing

From brake line

Parking brake air cylinder removing

WARNING Unexpected movement of the machine could cause serious injury or death. To prevent such an accident, observe the following items: - When removing the parking brake air cylinder, the machine may move. To prevent the machine from moving, park the machine on level ground, and lower the attachment onto the ground.

- Block the tires with chocks to prevent the wheels from moving.

Air cylinder

Brake assy

1. If there is an oil source, release the parking brake, and then remove split pin (1) and pin (2).

Note If there is no oil source, apply a cable to the link, and pull it down using a bar to overcome the spring force, and then remove the pin.

2. Release the residual air pressure. Disconnect the air hose.

Note Cover the disconnected hoses with plastic, plugs or caps to protect them from dust and dirt.

3. Loosen lock nut (3) to remove joint (4).

Remove retainer bolts (5) to remove parking brake air cylinder (6). : Bolt (5): 59 N-m (6.0 kgf-m) : Parking brake air cylinder: 8 kg

54-13 70ZIV-2 Disassembly & Reassembly Brake Group Air Cylinder for Parking Brake

Parking brake air cylinder installing To reinstall the parking brake air cylinder, follow the above removal procedure in reverse order.

Parking brake air cylinder installation cautions To insert the connection pin to connect the parking brake air cylinder to the parking brake, observe the following items: - Start the engine to build oil pressure in the accumulator.

- Release the parking brake.

- Slightly raise the parking brake lever by hand, and adjust the position of the joint hole between the parking brake air cylinder and the parking brake. After that, insert the connection pin into the joint hole.

To check performance of the parking brake, refer to the 70ZIV-2 Shop Manual, Function & Structure, Section 53.

54-14 70ZIV-2 Disassembly & Reassembly Brake Group Air Cylinder for Parking Brake

Parking brake air cylinder disassembling and assembling IMPORTANT Before disassembly or reassembly, read and understand the aforementioned "Hydraulic Parts Disassembly and Assembly Cautions" page 44-3.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Cylinder tube Piston rod Rod cover Rod cap Piston U-nut Spring Bushing U-packing Dust seal O-ring O-ring Filter Set screw Retainer bolt

: Air cylinder: 8.0 kg

54-15 70ZIV-2 Disassembly & Reassembly Brake Group Air Cylinder for Parking Brake

Parking brake air cylinder disassembling

WARNING The inner spring may spring out causing injury.

To prevent this, be sure to press the spring using a press until the spring loses the spring force, and then remove the rod cap.

When reducing the pressure of the press, be sure to reduce it slowly.

3. Press down the rod cover with a pipe (outer diameter: 50 mm or less, inner diameter: 30 mm or more, length: 80 mm).

Loosen the rod cap with hand and remove the rod cap. : Piston nut: 245 N-m (25.0 kgf-m)

1. Put a matchmark on the rod cap and cylinder tube.

Cut off the punched area of the set screw with a drill of 15~20 mm diameter, and remove the rod cap.

Note - Set screw is locked by punching.

- Be sure to install the set screw at the same position during reassembly.

4. Disassemble the cylinder. < Component parts > 1. Cylinder tube 2. Rod Cap 3. Spring 4. Piston 5. Piston rod 6. Rod cover 7. Piston nut

2. Using the threaded hole of the rod cap, slightly loosen the rod cap about 1/8 turn.

54-16 70ZIV-2 Disassembly & Reassembly Brake Group Air Cylinder for Parking Brake

Parking brake air cylinder assembling

Air cylinder linkage adjustment

To reassemble the air cylinder, follow the above disassembly procedure in reverse order.

Parking brake air cylinder assembly cautions - Tighten the rod cap to the position until the matchmarks are aligned, tighten the screw, and punch it for locking.

CAUTION When compressing the spring with the press, press the center of the cylinder with the press to prevent the cylinder from being inclined.

95ZV54027

1.

2.

3.

4.

5.

6.

7.

Air cylinder Lock nut Link Bracket Pin Split pin Washer

1. Release parking brake (OFF).

2. Measure dimension "A".

3. If the dimension “A” is not 97 mm, remove pin (5), split pin (6), and washer (7) and loosen lock nut (2).

And adjust the linkage length by turning link (3) so that dimension "A" becomes 97 mm.

4. Tighten lock nut (2) and reinstall pin (5), split pin (6) and washer (7).

5. Confirm the parking brake performance referring to Section 53.

54-17 70ZIV-2 Disassembly & Reassembly Brake Group Parking Brake

Parking Brake Parking brake removing and installing Parking brake removing and disassembling

IMPORTANT When removing the parking brake, the machine may move and it could cause serious injury or death. To prevent such an accident, observe the following item: - Park the machine on level ground.

- Lower the attachment onto the ground.

- Apply the articulation stopper.

- Block the tires with chocks to prevent the wheels from moving.

1. Drain the transmission oil.

3. Release the parking brake, and then remove connection pin (2) from the air cylinder.

: Transmission oil: 20 L

2. Disconnect second propeller shaft (1) at the transmission end. : Bolt: 137 N-m (14.0 kgf-m) : Screw lock agent (Three Bond 1327)

4. Remove retainer bolt (3) and remove lock plate (4) and the O-ring.

Remove flange yoke (5). : Bolt (3): 29 N-m (3.0 kgf-m)

54-18 70ZIV-2 Disassembly & Reassembly Brake Group Parking Brake

12

11

65V54002

9. Remove shoe hold pins (11) by turning 90 degree.

Remove brake shoes (12).

5. Remove brake drum (6).

13

14

6. Remove retainer bolt (7) and remove brake assembly (8). : Bolt (7): 157 N-m (16.0 kgf-m) : Screw lock agent (Three Bond 1327) 10 9

65V54003

10. Remove spring (13), and then remove adjusting screw (14).

Note Measure the wear of the brake shoes. If the shoes are extremely worn, replace them.

Refer to Section 53 or Section 55 inspection standards.

9

Parking brake installing and assembling To reinstall and reassemble the parking brake, follow the above removal and disassembly procedure in reverse order.

65V54001

7. Remove spring (9) using pliers.

8. Remove plate (10).

Note To adjust and check performance of the parking brake, refer to the 70ZIV-2 Shop Manual, Function & Structure, Section 53.

54-19 70ZIV-2 Disassembly & Reassembly Brake Group Air Tank

Air Tank Air tank removing and installing Air tank removing

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

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

- Relieve the air pressure from the air tank.

Before starting work: - Remove the left side deck (refer to Section 14).

1. Remove cover (1).

3. Temporarily sling cover (3), and remove retainer bolts (4) and then remove cover (3).

4. Disconnect wire (5) for the wet air tank and piping (6).

5. Remove retainer bolts (7) and then remove wet air tank (8).

2. Disconnect wire (2) for drain.

54-20 70ZIV-2 Disassembly & Reassembly Brake Group Air Tank

6. Disconnect pipes (9) from dry air tank (10).

7. Remove the retainer bolts, and then remove dry air tank (10).

Air tank installing To reinstall the air tank, follow the above removal procedure in reverse order.

55-1 70ZIV-2 Service Standard Brake Group

70ZIV-2 Service Standard Brake Group Brake Valve ............................................................. 55-2 Air Master ................................................................ 55-4 Service Brake .......................................................... 55-5 Parking Brake.......................................................... 55-6

55-2 70ZIV-2 Service Standard Brake Group Brake Valve

Brake Valve

No.

Item

Standard value

1

Mounting plate retainer bolt tightening torque

12 N-m (1.2 kgf-m)

2

Rubber spring setting nut tightening torque

6 N-m (0.6 kgf-m)

3

Lower body retainer bolt tightening torque

6 N-m (0.6 kgf-m)

4

Plug tightening torque

34 N-m (3.5 kgf-m)

Solution

Tightening

55-3 70ZIV-2 Service Standard Brake Group Brake Valve

Unit: mm No.

Item

Nominal

5

Pedal pin hole diameter

10

10.25

6

Outer diameter of pin (pins for both roller and mounting plate)

10

9.85

Inner diameter

10

10.1

Outer diameter

23.2

23

Inner diameter or pin bushing

10

10.25

Inner diameter or plunger bushing

26.5

26.65

7

8

Service standard

Wear limit

Roller

Mounting plate

9

Outer diameter or plunger

26.5

26.16

10

Free height of rubber spring

14

12

11

12

13

14

15

16

17

Note

Spring (Piston return)

Spring (Upper valve)

Spring (Inner valve)

Spring (Outer stem)

Spring (Relay piston)

Spring (Lower valve)

Spring (Pedal return)

Free length

71.4

Load

113 N (11.5 kgf)

Free length

41.3

Load

44 N (4.5 kgf)

Free length

35.6

Load

28 N (2.8 kgf)

Free length

41.0

Load

39 N (4.0 kgf)

Free length

39.5

Load

46 N (4.7 kgf)

Free length

16.5

Load

29 N (3.0 kgf)

Free angle

131º

Load

115º

When spring is 14.6 mm long

When spring is 14.3 mm long

When spring is 16.0 mm long

When spring is 16.0 mm long

When spring is 12.1 mm long

When spring is 16.0 mm long

When the pedal is returned

55-4 70ZIV-2 Service Standard Brake Group Air Master

Air Master

No.

Item

Standard value

Solution

1.0 mm

Replacement

45 ± 1.5 mm

—

40 mm

—

1

Clearance between push nut and piston

2

Stroke of air chamber push rod

3

Stroke to overstroke switch

4

Hydraulic cylinder retainer nut tightening torque

88 N-m (9.0 kgf-m)

—

5

Clamp ring retainer nut tightening torque

20 N-m (2.0 kgf-m)

Tightening

6

Locknut tightening torque

64 N-m (6.5 kgf-m)

Tightening

7

Overstroke switch tightening torque

29 N-m (3.0 kgf-m)

Tightening

8

Air bleeder nipple tightening torque

10 N-m (1.0 kgf-m)

Tightening

55-5 70ZIV-2 Service Standard Brake Group Service Brake

Service Brake

Unit: mm Judgment standard No.

1

Item

Solution Standard dimension

Tolerance

Wear limit

Thickness

5.0

+0 - 0.2

4.4

Distortion

0.3 or less

0.3

—

Steel plate

Replacement 2

Thickness of friction plate

7.4

± 0.1

5.9

3

Thickness of brake disc when measured by calipers (with brake applied)

17.4

± 0.2

15.1

Outer diameter

355

- 0.22 ~ - 0.29

—

4

Piston Inner diameter

285

0.05 ~ 0.15

—

—

55-6 70ZIV-2 Service Standard Brake Group Parking Brake

Parking Brake

2

5

1 3

Clearance

Spring (4) released

4

95ZV55002

No.

1

Item

Judgment standard

Solution

Standard dimension

Wear limit

5.45

4.0

Wear of lining (mm)

2

Deflection of drum (mm)

3

Lining inspection

4

Expansion of adjuster spring

5

Expansion of return spring

0.38 or more Replacement Grease or oil on the lining There is clearance between the coils when the spring is released.

64-1 70ZIV-2 Disassembly & Reassembly Electrical Group

70ZIV-2 Disassembly & Reassembly Electrical Group Wiper Motor............................................................. 64-2 Controller................................................................. 64-5 Fuse Box ................................................................. 64-6

64-2 70ZIV-2 Disassembly & Reassembly Electrical Group Wiper Motor

Wiper Motor Front wiper motor removing and installing Front wiper motor removing

3. Remove nut (4) and bolt (5).

After that, remove wiper arm (3).

1. Remove cover (1).

4. Remove cover (6) and cover (7).

2. Remove nut (2) and then remove wiper arm (3).

5. Remove defroster hose (8).

Disconnect electrical line coupler (9) from the wiper motor.

64-3 70ZIV-2 Disassembly & Reassembly Electrical Group Wiper Motor

Front wiper motor installing To reinstall the front wiper motor, follow the above removal procedure in reverse order.

Note When reinstalling the wiper arm, adjust the operation angle by nut (2).

6. Remove motor retainer bolt (10), and remove ground cable (11).

7. Disconnect coupler (12) for the relay.

8. Remove wiper motor (13).

64-4 70ZIV-2 Disassembly & Reassembly Electrical Group Wiper Motor

Rear wiper motor removing and installing Rear wiper motor removing

4. Remove cover (5).

1. Remove cover (1).

5. Disconnect coupler (6) for wiper motor (8).

6. Remove motor retainer bolts (7).

7. Remove wiper motor (8).

2. Remove nut (2), and then remove wiper arm (3).

Rear wiper motor installing To reinstall the rear wiper motor, follow the above removal procedure in reverse order.

Note When reinstalling the wiper arm, adjust the operation angle by nut (2).

3. Remove nut (4) and then remove wiper arm (3).

64-5 70ZIV-2 Disassembly & Reassembly Electrical Group Controller

Controller Controller removing and installing Controller removing

WARNING Before removing the controller, be sure to stop the engine, remove the engine key, and hang a "DO NOT START!" tag on the steering wheel.

3. Remove bolt (4) (4 pcs), and then remove controller (5).

Controller installing To reinstall the controller, follow the above removal procedure in reverse order.

1. Remove catch (1), and then remove cover (2).

Controller installation cautions - After reinstallation, set the starter key to the ON position, and check the function of the LED indicator.

- Run the machine, and check operation of the machine.

- The following items may have caused the controller to fail. Test and correct any problems before installing a new controller.

2. Disconnect electrical coupler (3).

1. Shortcircuit in the output circuit 2. Defective diode allowing voltage surges.

Identify and test each diode by referring to the procedures written in the 70ZIV-2 Shop Manual Function & Structure, Section 63,

64-6 70ZIV-2 Disassembly & Reassembly Electrical Group Fuse Box

Fuse Box Fuse box removing and installing Fuse box removing (inside control box)

WARNING Before removing a fuse box, be sure to turn off the starter key or disconnect the negative side of the battery.

1. Remove catch (1), and then open cover (2).

2. Remove covers (3)(4), and remove the fuse boxes (5)(6).

Fuse No.

Fuse capacity (A)

1

20A

Lighting Head light

2

10A

Rear working light

3

10A

Boom kickout Bucket leveler

4

15A

Back lamp Stop lamp

5

10A

Parking brake Controller

6

5A

Buzzer Monitor

7

15A

Spare

8

15A

Spare

9

15A

Spare

10

15A

Turn signal Horn

11

15A

Preheat

12

5A

Spare

13

5A

Engine stop motor

14

5A

Neutral relay

15

5A

Battery relay

Fuse No.

Fuse capacity (A)

16

5A

2 persons cab front wiper (LH) (option)

17

5A

2 persons cab front wiper (RH) (option)

Protective circuit

Spare 20A Spare 15A Spare 10A Spare 5A

Protective circuit

18

5A

Rear wiper

19

10A

Front wiper

20

10A

Cigar lighter

21

10A

Front working light

22

3A

Radio

23

10A

Spare

24

10A

Spare

25

5A

Spare

26

5A

Spare

27

5A

Air conditioner (option)

28

20A

Air conditioner (option)

29

20A

Air conditioner (option)

30

20A

Spare

Spare 20A Spare 15A Spare 10A Spare 5A

Fuse box installing (inside control box) To reinstall the fuse box, follow the above removal procedure in reverse order.

74-1 70ZIV-2 Disassembly & Reassembly Operator Station Group

70ZIV-2 Disassembly & Reassembly Operator Station Group Air Conditioner ........................................................ 74-2

74-2 70ZIV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air Conditioner Cover unit

Air damper unit

Air conditioner unit

Floor board

74-3 70ZIV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air conditioner removing and installing Air conditioner removing

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

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

- Be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

1. Remove covers (1) ~ (5).

Before starting work: - Remove the floor mat in the cab.

- Remover the seat and the seat stand in the cab.

- Collect the air conditioner refrigerant using the proper recovery method.

- Disconnect the air conditioner pipes at the self-sealing coupling.

2. Disconnect wiring (7) of air conditioner (6) and wiring (9) of air damper (8) at each coupler.

Air conditioner

3. Disconnect refrigerant piping (10) and heater hose (11).

74-4 70ZIV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

Air conditioner installing To reinstall the air conditioner, follow the above removal procedure in reverse order.

Reference After reinstalling the air conditioner, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

4. Remove air conditioner mounting bolts (12) and air damper mounting bolts (13).

Remove air conditioner (6) and air damper (8).

74-5 70ZIV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

A/C condenser removing and installing A/C condenser removing

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

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

- Be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

Condenser

1. Disconnect condenser hose (1).

Receiver dryer Condenser

Before starting work: - Collect the air conditioner refrigerant using the proper recovery method.

- Remove the air cleaner, etc. for easier removal.

2. Disconnect the condenser wiring at coupler (2).

Remove condenser mounting nut (3), and remove the condensers.

A/C condenser installing To reinstall the condenser, follow the above removal procedure in reverse order.

Reference After reinstalling the condenser, charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leaks.

74-6 70ZIV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

A/C compressor removing and installing

Engine

1.

2.

3.

4.

5.

6.

7.

8.

Compressor Bracket Idler pulley shaft Tension pulley V belt Compressor mounting bolt Compressor mounting nut Adjustment bolt : T1: 31 N-m (3.2 kgf-m) T2: 29 N-m (3.0 kgf-m)

A/C compressor removing

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

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

- Be sure to remove the engine key, and hang a "DO NOT START!" tag on the steering wheel or the operator's seat.

Before starting work: - Collect the air conditioner refrigerant using the proper recovery method.

74-7 70ZIV-2 Disassembly & Reassembly Operator Station Group Air Conditioner

A/C condenser installing To reinstall the compressor, follow the above removal procedure in reverse order.

A/C condenser installation cautions

Engine

- After installing the compressor, adjust the tension of the V-belt. Refer to the 70ZIV-2 Shop Manual, Function and Structure, Section 72 for the adjustment procedure.

1. Loosen tension pulley (1) lock nut and lock bolt (2). : Pulley (1) lock nut: 31 N-m (3.2 kgf-m) 2. Turn adjustment bolt (3) to make V-belt (4) slack, then remove the V-belt from the compressor.

3. Disconnect the compressor wiring and the cooler piping (5).

4. Remove compressor mounting nut (6), and remove compressor (7). : Nut (6): 28 N-m (2.9 kgf-m)

Belt tension at A: 637 ± 98 N (65 ± 10 kgf) - Charge the refrigerant, confirm the operation, confirm the gas pressure, then check for gas leak.

- The quantity of the compressor lubricating oil (NDO1L2) is 180 cm3. Never use or mix any other oil.

74-8 70ZIV-2 Disassembly & Reassembly Operator Station Group

MEMO

75-1 70ZIV-2 Service Standard Operator Station Group

70ZIV-2 Service Standard Operator Station Group Air Conditioner ........................................................ 75-2

75-2 70ZIV-2 Service Standard Operator Station Group Air Conditioner

Air Conditioner Periodical inspection/servicing Inspection/maintenance item

Criteria

Solution

Refrigerant

Charge quantity

Air bubbles should not be seen through sight glass.

Inspection/adjustment

Condenser

Blockage in fins

Blockage should not be detected.

Clean

Compressor

Operating status

Magnetic clutch should operate. Abnormal sounds should not be detected.

Inspection/ adjustment/ replacement

Belt tension pulley

Operating status

Abnormal sounds and backlash should not be detected.

Inspection/ replacement

V belt

Damage and tension

Damages should not be detected.

Replacement

Blower motor and fan

Operating status

Abnormal sounds or vibration should not be detected.

Inspection/ replacement

Control mechanism

Operating status

Each part should operate in accordance with switch operations.

Inspection/ replacement

Air filter for inside/outside air

Clogging

Air quantity should not be so small as to hinder air conCleaning/replacement ditioning.

Each mounting area and piping

Looseness, gas leak and damages

Looseness, gas leak and damages should not be detected.

Tightening/charge

Tightening torque Tightening torque for hose and pipes Connection type

Connection area

Condenserexpansion valve Nut type

Compressorcondenser Evaporatorcompressor

Pipe size or bolt size

Tightening torque N-m (kgf-m)

ø8 piping

15 (1.50)

D1/2 piping

D5/8 piping

Receiver

M6 bolt in receiver (4T)

Evaporatorcompressor

Any M6 bolt (6T) other than above

Block joint

25 (2.50) 34 (3.50) 7 (0.70) 12 (1.20)

Tightening torque for screws and bolts in special control regions

Bolt size

Tightening torque N-m (kgf-m)

Head bolt of magnetic clutch

M6

13 (1.35)

Mounting bolt for servo motor for inside/outside air selection

M5

0.5 (0.05)

Fixing nut of blower motor and condenser fan

M6

5 (0.55)

Fixing bolt of blower motor and condenser motor

M5

3 (0.30)

Special control area

75-3 70ZIV-2 Service Standard Operator Station Group Air Conditioner

Compressor adjustment standard

Fan pulley

Crank pulley

No.

Item

Standard value

Solution

637±98 N (65±10 kgf)

Adjustment

1

V-Belt tension

2

Tension pulley mounting nut tightening torque

31 N-m (3.2 kgf-m)

Tightening

3

Compressor mounting bolt tightening torque

29 N-m (3.0 kgf-m)

Tightening

4

Compressor lubricating oil amount

180 cm3

Adjustment

Note - Use a tension gauge to measure the belt tension.

- Refer to Section 72 in the 70ZIV-2 Shop Manual, Function and Structure for the adjustment.

- Use ND-OIL8 or equivalent to lubricate the compressor. Never mix any other oil.

75-4 70ZIV-2 Service Standard Operator Station Group

MEMO

INDEX A A/C compressor removing ................................................74-6 A/C compressor removing and installing ..........................74-6 A/C condenser installation cautions ..................................74-7 A/C condenser installing ......................................... 74-5, 74-7 A/C condenser removing ..................................................74-5 A/C condensor removing and installing ............................74-5 Accumulator (S/N 2201~, 8251~) ...................................44-74 Accumulator installation cautions ...................................44-74 Accumulator installing .....................................................44-74 Accumulator removing ....................................................44-74 Accumulator removing and installing ..............................44-74 Air Cleaner ......................................................................24-11 Air cleaner installation cautions ......................................24-12 Air cleaner installing ........................................................24-12 Air cleaner removing .......................................................24-11 Air cleaner removing and installing .................................24-11 Air Conditioner ........................................................ 74-2, 75-2 Air conditioner installing ....................................................74-4 Air conditioner removing ...................................................74-3 Air conditioner removing and installing .............................74-3 Air Cylinder for Parking Brake ........................................54-12 Air Master .........................................................................55-4 Air master assembling ....................................................54-10 Air Master Assembly .........................................................54-6 Air master assembly cautions .........................................54-10 Air master disassembling ..................................................54-8 Air master disassembling and assembling .......................54-7 Air master installing ..........................................................54-6 Air master removing ..........................................................54-6 Air master removing and installing ....................................54-6 Air master tightening torque ..............................................54-7 Air Tank ..........................................................................54-19 Air tank installing .............................................................54-20 Air tank removing ............................................................54-19 Air tank removing and installing ......................................54-19 Applying and Storing Articulation Stopper ......................00-13 Applying articulation stopper ...........................................00-13 Axle and Differential Service Standard .............................25-3 Axle group .........................................................................25-3 Axle nut tightening procedure ............................. 24-15, 24-37 Axle Support ...................................................................24-41 Axle support assembling .................................................24-44 Axle support assembly cautions .....................................24-44 Axle support disassembling (S/N 1001~1919, 7101~7615) .....................................24-43 Axle support disassembling (S/N 1920~, 7616~) ...........24-44 Axle support disassembling and assembling ..................24-43 Axle support tightening torque ........................................24-41

B Bolt Tightening Torque .....................................................00-4 Boom ..............................................................................14-16 Boom cylinder installation cautions .................................44-34 Boom cylinder installing ..................................................44-34 Boom cylinder removing .................................................44-33

Boom cylinder removing and installing ........................... 44-33 Boom installation cautions .............................................. 14-18 Boom installing ............................................................... 14-18 Boom kick-out (option) ................................................... 15-10 Boom kick-out hoist angle .............................................. 15-10 Boom removing .............................................................. 14-16 Boom removing and installing ........................................ 14-16 Brake disc installation cautions ...................................... 54-11 Brake Valve ...................................................................... 55-2 Brake valve assembling ................................................... 54-5 Brake Valve Assembly ..................................................... 54-2 Brake valve assembly cautions ........................................ 54-5 Brake valve cross section and tightening torque (main valve) .................................................................. 54-3 Brake valve disassembling ............................................... 54-4 Brake valve disassembling and assembling ..................... 54-3 Brake valve installation cautions ...................................... 54-2 Brake valve installing ........................................................ 54-2 Brake valve removing ....................................................... 54-2 Brake valve removing and installing ................................. 54-2 Bucket .............................................................................. 15-7 Bucket cylinder installation cautions ............................... 44-36 Bucket cylinder installing ................................................ 44-36 Bucket cylinder removing ............................................... 44-35 Bucket cylinder removing and installing ......................... 44-35 Bucket positioner .............................................................. 15-9 Bucket positioner adjustable angle ................................... 15-9 Bucket Positioner and Boom Kick-Out (Option) ............... 15-8 Bushing .......................................................................... 14-20 Bushing installing ........................................................... 14-20 Bushing removing ........................................................... 14-20 Bushing removing and installing ..................................... 14-20

C Cab ................................................................................. 14-12 Cab installation cautions ................................................ 14-13 Cab installing .................................................................. 14-13 Cab removing ................................................................. 14-12 Cab removing and installing ........................................... 14-12 Cautions regarding parts removal .................................... 00-9 Cautions regarding reassembly ........................................ 00-9 Cautions Regarding Welding Repair Service ................. 00-11 Center Pin ............................................................. 14-21, 15-5 Center pin installation cautions ...................................... 14-27 Center pin installing ........................................................ 14-27 Center pin removing ....................................................... 14-23 Center pin removing and installing ................................. 14-23 Center pin shim adjustment ................................... 14-21, 15-5 Clutch pack assembly cautions ...................................... 34-21 Compressor adjustment standard .................................... 75-3 Control valve assembling ............................................... 34-27 Control Valve Assembly ................................................. 34-23 Control valve assembly cautions .................................... 34-27 Control valve disassembling ........................................... 34-26 Control valve disassembling and assembling ................ 34-26 Control valve installation ................................................ 34-25

Control valve installation cautions .................................. 34-25 Control valve removing .................................................. 34-23 Control valve removing and installing ............................ 34-23 Controller installation cautions ......................................... 64-5 Controller installing ........................................................... 64-5 Controller removing .......................................................... 64-5 Controller removing and installing .................................... 64-5

D Deck ................................................................................. 14-2 Deck installing .................................................................. 14-2 Deck removing ................................................................. 14-2 Deck removing and installing ........................................... 14-2 Differential ........................................................................ 25-4 Differential Assembly ..................................................... 24-47 Differential assembly disassembling .............................. 24-52 Differential assembly disassembling and assembling .................................................................................... 24-49 Differential assembly installation cautions ..................... 24-48 Differential assembly installing ....................................... 24-48 Differential assembly removing ...................................... 24-47 Differential assembly removing and installing ................ 24-47 Differential assy assembling .......................................... 24-56 Dust Seal ........................................................................ 14-19 Dust seal installing ......................................................... 14-19 Dust seal removing ........................................................ 14-19 Dust seal removing and installing .................................. 14-19

E Engine .............................................................................. 24-7 Engine installation cautions .............................................. 24-8 Engine installing ............................................................... 24-8 Engine removing .............................................................. 24-7 Engine removing and installing ........................................ 24-7 Engine Room ................................................................... 14-9 Engine room installation cautions .................................. 14-11 Engine room installing .................................................... 14-11 Engine room removing ..................................................... 14-9 Engine room removing and installing ............................... 14-9

F Floating Seal (S/N 1201~, 7201~) .................................. 24-25 Floating seal assembling ................................................ 24-26 Floating seal installation ................................................. 24-25 Floor Board .................................................................... 14-14 Floor board installation cautions .................................... 14-15 Floor board installing ...................................................... 14-15 Floor board removing ..................................................... 14-14 Floor board removing and installing ............................... 14-14 Forward/reverse clutch pack assembling ....................... 34-20 Forward/reverse clutch pack disassembling .................. 34-18 Forward/reverse clutch pack disassembling and assembling ................................... 34-18 Front Axle Assembly ...................................................... 24-14 Front axle assembly installation cautions ....................... 24-18 Front axle assembly installing ........................................ 24-17 Front axle assembly removing ....................................... 24-16 Front axle assembly removing and installing ................. 24-16 Front axle assembly tightening torque ........................... 24-14

Front Differential .............................................................24-62 Front differential removing and installing ........................24-62 Front differential tightening torque ..................................24-49 Front wiper motor installing ..............................................64-3 Front wiper motor removing ..............................................64-2 Front wiper motor removing and installing ........................64-2 Fuel Tank ..........................................................................14-3 Fuel tank installation cautions ..........................................14-3 Fuel tank installing ............................................................14-3 Fuel tank removing ...........................................................14-3 Fuel tank removing and installing .....................................14-3 Fuse Box ..........................................................................64-6 Fuse box installing (inside control box) ............................ 64-6 Fuse box removing (inside control box) ............................ 64-6 Fuse box removing and installing .....................................64-6

G Gear Pump .......................................................................44-4 Gear pump assembling ..................................................44-11 Gear pump assembly cautions .......................................44-11 Gear pump assembly disassembling and assembling ......................................................................................44-8 Gear pump assembly installing ........................................44-6 Gear pump assembly removing ........................................44-6 Gear pump assembly removing and installing ..................44-6 Gear pump disassembling ................................................44-9 Gear pump installation cautions ....................................... 44-7 Gear pump tightening torque ............................................ 44-5 Grease nipple installing ....................................................15-5

H Hose Band Tightening Torque ..........................................00-8 How to wind a seal tape .................................................00-10 Hydraulic Cylinder .................................................44-33, 45-5 Hydraulic cylinder assembling ........................................44-49 Hydraulic cylinder assembly cautions .............................44-49 Hydraulic cylinder cross section and tightening torque ....................................................................................44-39 Hydraulic cylinder disassembling ...................................44-47 Hydraulic cylinder disassembling and assembling ......... 44-39 Hydraulic parts assembly cautions ...................................44-3 Hydraulic Parts Disassembly and Assembly Cautions ......................................................................................44-3 Hydraulic parts disassembly cautions ..............................44-3 Hydraulic Parts Removal and Installation Warning ..........44-2 Hydraulic Tank ..................................................................14-4 Hydraulic tank breather valve assembling ........................14-8 Hydraulic tank breather valve disassembling ...................14-7 Hydraulic tank breather valve disassembling and assembling .....................................14-7 Hydraulic tank installation cautions ..................................14-5 Hydraulic tank installing ....................................................14-5 Hydraulic tank removing ...................................................14-4 Hydraulic tank removing and installing .............................14-4 Hydraulic tank return filter installation cautions ................ 14-6 Hydraulic tank return filter installing ..................................14-6 Hydraulic tank return filter removing ................................. 14-6 Hydraulic tank return filter removing and installing ........... 14-6

I Internal Gear Hub ...........................................................24-27 Internal gear hub assembling .........................................24-28 Internal gear hub assembly cautions ..............................24-28 Internal gear hub disassembling .....................................24-27 Internal gear hub disassembling and assembling ...........24-27

L Liner clearance adjustment ...............................................15-4 Linkage .............................................................................15-2 Linkage Pin Standard Clearance Values ..........................15-3 Liquid Gasket and Screw Lock Agent ...............................00-9 Lower center pin .............................................................14-22 Lower center pin bearing outer ring installing ...................15-6

M Muffler .............................................................................24-13 Muffler installation cautions ............................................24-13 Muffler installing ..............................................................24-13 Muffler removing .............................................................24-13 Muffler removing and installing .......................................24-13 Multiple Control Valve .....................................................44-18 Multiple control valve assembling ...................................44-32 Multiple control valve assembling (S/N ~1481) ...............44-25 Multiple control valve assembly cautions ............ 44-28, 44-32 Multiple control valve cross section and tightening torque .............................44-20 Multiple control valve disassembling (S/N ~1481) ..........44-21 Multiple control valve disassembling (S/N 1482~) ..........44-30 Multiple control valve disassembling and assembling (S/N ~1481) ...............44-20 Multiple control valve disassembling and assembling (S/N 1482~) ...............44-29 Multiple control valve installation cautions ......................44-19 Multiple control valve installing .......................................44-19 Multiple control valve removing ......................................44-18 Multiple control valve removing and installing ................44-18

O Orbitrol® (S/N 2201~, 8251~) ...................................................44-60 Orbitrol® assembling .......................................................44-67 Orbitrol® cross section and tightening torque .................44-62 Orbitrol® disassembling ..................................................44-63 Orbitrol® disassembling and assembling ........................44-62 Orbitrol® installation cautions ..........................................44-61 Orbitrol® installing ...........................................................44-61 Orbitrol® removing ..........................................................44-60 Orbitrol® removing and installing ....................................44-60

P Parking Brake ....................................................... 54-17, 55-6 Parking brake air cylinder assembling ............................54-16 Parking brake air cylinder assembly cautions .................54-16 Parking brake air cylinder disassembling .......................54-15 Parking brake air cylinder disassembling and assembling ...................................54-14 Parking brake air cylinder installation cautions ...............54-13 Parking brake air cylinder installing ................................54-13

Parking brake air cylinder removing ............................... 54-12 Parking brake air cylinder removing and installing ......... 54-12 Parking brake installing and assembling ........................ 54-18 Parking brake removing and disassembling ................... 54-17 Parking brake removing and installing ........................... 54-17 Periodical Inspection/Servicing ........................................ 75-2 Pilot Valve ............................................................. 44-51, 45-6 Pilot valve assembling .................................................... 44-59 Pilot valve assembly cautions ........................................ 44-59 Pilot valve cross section and tightening torque .............. 44-55 Pilot valve disassembling ............................................... 44-56 Pilot valve disassembling and assembling ..................... 44-55 Pilot valve installation cautions ....................................... 44-54 Pilot valve installing ........................................................ 44-54 Pilot valve removing ....................................................... 44-53 Pilot valve removing and installing ................................. 44-53 Planetary assy assembling ............................................. 24-23 Planetary assy assembly cautions ................................. 24-23 Planetary assy disassembling ........................................ 24-19 Planetary assy disassembling and assembling .............. 24-19 Power Line ....................................................................... 24-2 Power line tightening torque ............................................. 24-2 Priority Valve (S/N 2201~, 8251~) .................................. 44-72 Priority valve cross section and tightening torque .......... 44-73 Priority valve disassembling and assembling ................. 44-73 Priority valve disassembly cautions ................................ 44-73 Priority valve installing .................................................... 44-72 Priority valve removing ................................................... 44-72 Priority valve removing and installing ............................. 44-72 Propeller Shaft .................................................................. 24-9 Propeller shaft installation cautions ................................ 24-10 Propeller shaft installing ................................................. 24-10 Propeller shaft removing and installing ............................ 24-9 Propeller Shaft Service Standard ..................................... 25-2

R Radiator ............................................................................ 24-3 Radiator installation cautions ........................................... 24-6 Radiator installing ............................................................. 24-6 Radiator removing ............................................................ 24-4 Radiator removing and installing ...................................... 24-4 Radiator tightening torque ................................................ 24-3 Rear Axle Assembly ....................................................... 24-36 Rear axle assembly installing ......................................... 24-40 Rear axle assembly removing ........................................ 24-38 Rear axle assembly removing and installing .................. 24-38 Rear axle assembly tightening torque ............................ 24-36 Rear axle disassembling and assembling ...................... 24-40 Rear differential tightening torque (S/N 1001~1919, 7101~7615) .................................... 24-50 Rear differential tightening torque (S/N 1920~, 7616~) .................................................................................... 24-51 Rear wiper motor installing ............................................... 64-4 Rear wiper motor removing .............................................. 64-4 Rear wiper motor removing and installing ........................ 64-4

S

U

Screw lock agent application procedure ........................ 00-10 Second propeller shaft removing ..................................... 24-9 Service Brake ........................................................ 54-11, 55-5 Service brake air bleeding procedure ............................ 24-18 Service brake disassembling and assembling ............... 54-11 Service brake installation cautions ................................. 54-11 Special Tool ................................................................... 24-31 Special tool for axle ........................................................ 24-31 Spider Assembly ............................................................ 24-29 Spider assy assembling ................................................. 24-30 Spider assy assembly cautions ...................................... 24-30 Spider assy disassembling ............................................. 24-29 Spider assy disassembling and assembling .................. 24-29 Steering cylinder installation cautions ............................ 44-38 Steering cylinder installing ............................................. 44-38 Steering cylinder removing ............................................. 44-37 Steering cylinder removing and installing ....................... 44-37 Steering Linkage (S/N ~2200, ~8250) .............................. 45-2 Steering Valve (S/N ~2200, ~8250) ............................... 44-12 Steering valve assembling ............................................. 44-16 Steering valve assembly cautions .................................. 44-17 Steering valve disassembling ......................................... 44-15 Steering valve disassembling and assembling .............. 44-15 Steering valve installation cautions ................................ 44-14 Steering valve installing ................................................. 44-14 Steering valve removing ................................................. 44-13 Steering valve removing and installing ........................... 44-13 Storing articulation stopper ............................................ 00-13 Symbols ........................................................................... 00-2

Upper center pin .............................................................14-21

T Third propeller shaft removing ....................................... 24-10 Tightening torque for hose and pipes ............................... 75-2 Tightening torque for screws and bolts in special control regions .............................................. 75-2 Torque Converter ........................................................... 34-16 Torque Converter and Transmission Assembly ...... 34-2, 35-2 Torque converter and transmission assembly installing ........................................................................ 34-6 Torque converter and transmission assembly removing ....................................................................... 34-3 Torque converter and transmission assembly removing and installing ................................................. 34-3 Torque converter and transmission assembly tightening torque ........................................................... 34-2 Torque converter assembly assembling ........................ 34-17 Torque converter assembly disassembling .................... 34-16 Torque converter assembly disassembling and assembling ................................... 34-16 Transmission Assembly ................................................. 34-10 Transmission assembly assembling .............................. 34-15 Transmission assembly bolt tightening torque ................. 34-8 Transmission assembly disassembling .......................... 34-10 Transmission assembly disassembling and assembling ................................... 34-10 Transmission assembly installation cautions ................... 34-6 Transmission assy assembling ...................................... 34-15

W Weight of Main Components ............................................ 00-3 Wiper Motor ......................................................................64-2

MEMO

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes