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Kawasaki WHEEL LOADER 135ZV-2 SHOP MANUAL 93217-00210 – PDF DOWNLOAD
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Kawasaki WHEEL LOADER 135ZV-2 SHOP MANUAL 93217-00210 – PDF DOWNLOAD
Disassembly & Reassembly Service Standard
Powered by CUMMINS QST30-C ENGINE
Serial No. 13C1-9501~
Serial No. 13C1-9501~
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Description
Kawasaki WHEEL LOADER 135ZV-2 SHOP MANUAL 93217-00210 – PDF DOWNLOAD
FILE DETAILS:
Kawasaki WHEEL LOADER 135ZV-2 SHOP MANUAL 93217-00210 – PDF DOWNLOAD
Language :English
Pages :346
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Kawasaki WHEEL LOADER 135ZV-2 SHOP MANUAL 93217-00210 – PDF DOWNLOAD
Disassembly & Reassembly Service Standard
Powered by CUMMINS QST30-C ENGINE
Serial No. 13C1-9501~
Serial No. 13C1-9501~
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
- 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 meth- ods. 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.
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.
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 move- ment.
prevent move- ment.
– Remove the cable from the battery before starting the service work, and attach a “DO NOT
OPERATE!” tag to the operation board.
OPERATE!” tag to the operation board.
IMPORTANT
If a battery terminal is removed from a machine in less than 30 seconds after the
key is put into the “OFF” position, it can corrupt the ECM program, which can disable
the engine. Always wait 1 full minute to be sure to be past this “write to memory
function” prior to removing battery terminals.
If a battery terminal is removed from a machine in less than 30 seconds after the
key is put into the “OFF” position, it can corrupt the ECM program, which can disable
the engine. Always wait 1 full minute to be sure to be past this “write to memory
function” prior to removing battery terminals.
– 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.
You may get burned.
– Contact tire manufacturer’s local dealer for tire ser- vicing and changing.
– Always store the tools in good condition, and use them properly.
– Keep the work area clean. Clean up spills immedi- ately.
– 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.
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.
certified through an EPA approved testing program.
– Be sure to release the internal pressure before you remove a pipe, such as the hydraulic
oil, air, or engine coolant pipe.
oil, air, or engine coolant pipe.
– Be sure to apply the articulation stopper before start- ing work.
– While supporting the bottom of the chassis using a jack, be sure to support the chassis using
the blocks.
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 ade- quate cribbing under the unit to prevent unexpected dropping.
stand or ade- quate cribbing under the unit to prevent unexpected dropping.
– Do not start to work in an enclosed area if adequate ventilation is not provided.
TABLE OF CONTENTS:
Kawasaki WHEEL LOADER 135ZV-2 SHOP MANUAL 93217-00210 – PDF DOWNLOAD
Disassembly & Reassembly Service Standard
Powered by CUMMINS QST30-C ENGINE
Serial No. 13C1-9501~
Serial No. 13C1-9501~
Foreword 2
Safety precautions 3
Safety Symbols 4
CONTENTS 6
00 General Information 12
Symbols 13
Weight of Main Components 14
Bolt Tightening Torque 15
Hose Band Tightening Torque 19
Liquid Gasket and Screw Lock Agent 20
Cautions regarding parts removal 20
Cautions regarding reassembly 20
Screw lock agent application procedure 21
How to wind a seal tape 21
Cautions Regarding Welding Repair Service 22
Cautions Regarding Handling of Bearing 24
Bearing installation cautions 24
Interference fits for a bearing 24
Bearing operation test after installation 25
Bearing removal cautions 25
Applying and Storing Articulation Stopper 26
Applying articulation stopper 26
Storing articulation stopper 26
14 Disassembly & Reassembly Chassis Group 28
Deck 29
Deck removing and installing 29
Deck removing 29
Deck installing 30
Fuel Tank 31
Fuel tank removing and installing 31
Fuel tank removing 31
Fuel tank installing 32
Fuel tank installation cautions 32
Hydraulic Tank 33
Hydraulic tank removing and installing 33
Hydraulic tank removing 33
Hydraulic tank installing 34
Hydraulic tank installation cautions 34
Engine Room 35
Engine room removing and installing 35
Engine room removing 35
Engine room installing 38
Engine room installation cautions 38
ROPS 39
ROPS removing and installing 39
ROPS removing 39
ROPS installing 39
Cab 40
Cab removing and installing 40
Cab removing 40
Cab installing 41
Cab installation cautions 41
Floor Board 42
Floor board removing and installing 42
Floor board removing 42
Floor board installing 45
Floor board installation cautions 45
Boom 46
Boom removing and installing 46
Boom removing 46
Boom installing 48
Boom installation cautions 48
Center Pin 49
Upper center pin 49
Center pin shim adjustment 49
Lower center pin 50
Center pin removing and installing 51
Center pin removing 51
Center pin installing 55
Center pin installation cautions 55
15 Service Standard Chassis Group 56
Linkage 57
Linkage Pin Standard Clearance Values 58
Liner clearance adjustment 58
Shim adjustment 59
Linkage 1: Bucket ~ Boom 59
Linkage 5: Bucket ~ Link 60
Center Pin 61
Center pin shim adjustment 61
Bearing cover installing 61
Lower center pin bearing outer ring installing 62
Attachment Leveler 63
Attachment leveler 64
Attachment leveler adjustable angle 64
24 Disassembly & Reassembly Power Group 66
Power Line 67
Power line tightening torque 67
Radiator 68
Radiator tightening torque 68
Radiator removing and installing 69
Radiator removing 69
Radiator installing 71
Torque Converter Oil Cooler 72
Torque converter oil cooler removing and installing 72
Torque converter oil cooler removing 72
Torque converter oil cooler installing 73
Fan 74
Fan removing and installing 74
Fan removing 74
Fan installing 75
Fan installation cautions 75
Engine 76
Engine removing and installing 76
Engine removing 76
Engine installing 78
Engine installation cautions 78
Propeller Shaft 79
Propeller shaft removing and installing 79
Second propeller shaft removing 80
First propeller shaft removing 80
Third propeller shaft removing 80
Propeller shaft installing 81
Propeller shaft installation cautions 81
Air Cleaner 82
Air cleaner removing and installing 82
Air cleaner removing 82
Air cleaner installing 83
Air cleaner installation cautions 83
Muffler 84
Muffler removing and installing 84
Muffler removing 84
Muffler installing 84
Muffler installation cautions 84
Front Axle Assembly 85
Front axle assembly tightening torque 85
Axle tightening procedure 86
Front axle assembly removing and installing 87
Front axle assembly removing 87
Front axle assembly installing 88
Front axle assembly installation cautions 88
Service brake air bleeding procedure 89
Front axle disassembling and assembling 90
Front axle disassembling 90
Front axle assembling 93
Front axle assembly cautions 94
Floating seal installation 94
Internal gear hub installation 96
Spider Assembly 98
Spider assembly disassembling and assembling 98
Spider assembly disassembling 98
Spider assembly assembling 98
Spider assy assembly cautions 98
Special Tool 99
Special tool for axle 99
Rear Axle Assembly103
Rear axle assembly tightening torque103
Axle tightening procedure104
Rear axle assembly removing and installing105
Rear axle assembly removing105
Rear axle assembly installing108
Rear axle disassembling and assembling108
Axle Support109
Axle support tightening torque109
Axle support disassembling and assembling110
Axle support disassembling110
Axle support assembling110
Axle support assembly cautions111
Bushing installation111
Differential Assembly112
Differential assembly removing and installing112
Differential assembly removing112
Differential assembly installing114
Differential assembly installation cautions114
Differential assembly disassembling and assembling115
Front differential tightening torque115
Rear differential tightening torque116
Differential assembly disassembling117
Differential assembly assembling119
Differential assy assembly cautions120
25 Service Standard Power Group126
Propeller Shaft Service Standard127
Axle and Differential Service Standard128
Axle group128
Differential129
34 Disassembly & Reassembly Torque Converter and Transmission Group130
Torque Converter and Transmission Assembly131
Torque converter and transmission assembly tightening torque131
Torque Converter Assembly132
Torque converter removing and installing132
Torque converter removing132
Torque converter installing134
Torque converter installation cautions134
Torque converter assembly bolt tightening torque135
Torque converter assembly disassembling and assembling136
Torque converter assembly disassembling136
Torque converter assembly assembling139
Torque converter assembly cautions140
Transmission Assembly142
Transmission removing and installing142
Transmission removing142
Transmission assembly installing145
Transmission assembly installation cautions145
Transmission assembly bolt tightening torque147
Transmission assembly disassembling and assembling148
Transmission assembly disassembling148
Transmission assembly assembling151
Transmission assy assembly cautions156
Clutch Assembly157
Clutch assembly disassembling and assembling157
Clutch assembly disassembling157
Clutch assembly assembling163
Clutch Spider Assembly171
Forward and 3rd clutch spiders disassembling and assembling171
Forward and 3rd clutch spiders disassembling171
Forward and 3rd clutch spiders assembling172
Forward and 3rd clutch spiders assembly cautions172
2nd Clutch Spider173
2nd clutch spider disassembling and assembling173
2nd clutch spider disassembling173
2nd clutch spider assembling174
2nd clutch spider assembly cautions174
Reverse Clutch Spider175
Reverse clutch spider disassembling and assembling175
Reverse clutch spider disassembling175
Reverse clutch spider assembling176
Reverse clutch spider assembly cautions176
1st Clutch Assembly177
1st clutch assembly disassembling and assembling177
1st clutch assembly disassembling177
1st clutch assembly assembling178
Input Gear Box Assembly180
Input gear box disassembling and assembling180
Input gear box disassembling180
Input gear box assembling181
Input gear box assembly cautions181
Control Valve Assembly182
Control valve removing and installing182
Control valve removing182
Control valve assembly installing184
Control valve installation cautions184
Control valve disassembling and assembling185
Control valve disassembling185
Control valve assembling185
Control valve assembly cautions186
Special Tool187
35 Service Standard Torque Converter and Transmission Group190
Transmission Assembly191
Transmission191
Torque converter192
Torque Converter Gear Pump195
Gear pump specifications196
Clutch Train and Number of Teeth197
Clutch specifications198
Clutch Oil Pressure199
44 Disassembly & Reassembly Hydraulic Group200
Hydraulic Parts Removal and Installation Warning201
Hydraulic Parts Disassembly and Assembly Cautions202
Hydraulic parts disassembly cautions202
Hydraulic parts assembly cautions202
Hydraulic Pump203
Hydraulic pump removing and installing203
Hydraulic pump removing203
Hydraulic steering pump removing205
Hydraulic loading pump removing206
Hydraulic pilot (triple) pump removing207
Hydraulic pump installing207
Hydraulic pump installation cautions208
Hydraulic pump assembly disassembling and assembling209
Hydraulic pump disassembly tools209
Hydraulic steering/loading pump disassembling211
Hydraulic steering pump assembling213
Hydraulic steering pump assembly cautions214
Regulator disassembling and assembling215
Regulator disassembling216
Regulator assembling219
Hydraulic pilot (triple) pump disassembling and assembling222
Oil seal replacement procedure222
Pilot Valve (for Loading)223
Pilot valve (for loading) removing and installing223
Pilot valve (for loading) removing223
Pilot valve (for loading) installing224
Pilot valve (for loading) installation cautions224
Pilot valve (for loading) disassembling and assembling225
Pilot valve (for loading) cross section and tightening torque225
Pilot valve (for loading) disassembling226
Pilot valve (for loading) assembling231
Pilot valve (for loading) assembly cautions231
Pilot Valve (for Steering)232
Pilot valve (for steering) removing and installing232
Pilot valve (for steering) removing232
Pilot valve (for steering) installing233
Pilot valve (for steering) installation cautions233
Pilot valve (for steering) disassembling and assembling234
Pilot valve (for steering) cross section and tightening torque234
Pilot valve (for steering) disassembling235
Pilot valve (for steering) assembling236
Pilot valve (for steering) assembly cautions237
Steering Valve238
Steering valve removing and installing238
Steering valve removing238
Steering valve installing240
Steering valve installation cautions240
Steering valve disassembling and assembling241
Steering valve cross section and tightening torque241
Steering valve disassembling242
Steering valve assembling244
Steering valve assembly cautions244
Multiple Control Valve245
Multiple control valve removing and installing245
Multiple control valve removing245
Multiple control valve installing247
Multiple control valve installation cautions247
Multiple control valve disassembling and assembling248
Multiple control valve cross section and tightening torque248
Multiple control valve disassembling250
Multiple control valve assembling252
Multiple control valve assembly cautions252
Stop Valve253
Stop valve removing and installing253
Stop valve removing253
Stop valve installing253
Stop valve installation cautions254
Stop valve disassembling and assembling255
Stop valve cross section and tightening torque255
Stop valve disassembling256
Stop valve assembling256
Hydraulic Cylinder257
Hydraulic cylinder removing and installing257
Boom cylinder removing and installing257
Boom cylinder removing257
Boom cylinder installing259
Boom cylinder installation cautions259
Bucket cylinder removing and installing260
Bucket cylinder removing260
Bucket cylinder installing261
Bucket cylinder installation cautions261
Steering cylinder removing and installing262
Steering cylinder removing262
Steering cylinder installing263
Steering cylinder installation cautions263
Hydraulic cylinder disassembling and assembling265
Hydraulic cylinder disassembling268
Hydraulic cylinder assembling270
Hydraulic cylinder assembly cautions271
Special tool for hydraulic cylinder disassembling272
45 Service Standard Hydraulic Group274
Hydraulic Cylinder275
54 Disassembly & Reassembly Brake Group278
Brake Valve279
Brake valve removing and installing279
Brake valve removing279
Brake valve installing280
Brake valve installation cautions280
Brake valve disassembling and assembling281
Brake valve cross section and tightening torque281
Brake valve disassembling282
Brake valve assembling285
Brake valve assembly cautions286
Unloader Valve287
Unloader valve removing and installing287
Unloader valve removing287
Unloader valve installing288
Unloader valve installation cautions288
Unloader valve disassembling and assembling289
Unloader valve cross section and tightening torque289
Unloader valve disassembling290
Unloader valve assembling290
Manifold Valve Assembly291
Valve assembly removing and installing291
Valve assembly removing291
Valve assembly installing292
Valve assembly installation cautions292
Valve assembly disassembling and assembling293
Valve assembly cross section and tightening torque293
Accumulator294
Accumulator removing and installing294
Accumulator removing294
Accumulator installing295
Accumulator installation cautions295
Accumulator disassembling and assembling296
Accumulator tightening torque296
Accumulator disassembling296
Accumulator assembling298
Jig for accumulator assembly300
Nitrogen gas charging302
Nitrogen gas charging procedure302
Service Brake304
Service brake disassembling and assembling304
Service brake disassembling304
Service brake installation305
Service brake installation cautions305
Parking Brake308
Parking brake removing and installing308
Parking brake disassembling and assembling309
Parking brake bolt tightening torque309
Parking brake disassembling310
Parking brake assembling312
55 Service Standard Brake Group314
Brake Valve315
Service Brake317
Parking Brake318
74 Disassembly & Reassembly Operator Station Group320
Air Conditioner321
Air conditioner removing and installing321
Air conditioner removing321
Air conditioner installing322
Air conditioner disassembling and assembling323
Air conditioner tightening torque323
Air conditioner disassembling326
Air conditioner assembling330
75 Service Standard Operator Station Group332
Air Conditioner333
Periodical Inspection/Servicing333
Tightening Torque333
Tightening torque for hose and pipes333
Tightening torque for screws and bolts in special control regions333
INDEX334
Maintenance Log339
Notes343
Safety precautions 3
Safety Symbols 4
CONTENTS 6
00 General Information 12
Symbols 13
Weight of Main Components 14
Bolt Tightening Torque 15
Hose Band Tightening Torque 19
Liquid Gasket and Screw Lock Agent 20
Cautions regarding parts removal 20
Cautions regarding reassembly 20
Screw lock agent application procedure 21
How to wind a seal tape 21
Cautions Regarding Welding Repair Service 22
Cautions Regarding Handling of Bearing 24
Bearing installation cautions 24
Interference fits for a bearing 24
Bearing operation test after installation 25
Bearing removal cautions 25
Applying and Storing Articulation Stopper 26
Applying articulation stopper 26
Storing articulation stopper 26
14 Disassembly & Reassembly Chassis Group 28
Deck 29
Deck removing and installing 29
Deck removing 29
Deck installing 30
Fuel Tank 31
Fuel tank removing and installing 31
Fuel tank removing 31
Fuel tank installing 32
Fuel tank installation cautions 32
Hydraulic Tank 33
Hydraulic tank removing and installing 33
Hydraulic tank removing 33
Hydraulic tank installing 34
Hydraulic tank installation cautions 34
Engine Room 35
Engine room removing and installing 35
Engine room removing 35
Engine room installing 38
Engine room installation cautions 38
ROPS 39
ROPS removing and installing 39
ROPS removing 39
ROPS installing 39
Cab 40
Cab removing and installing 40
Cab removing 40
Cab installing 41
Cab installation cautions 41
Floor Board 42
Floor board removing and installing 42
Floor board removing 42
Floor board installing 45
Floor board installation cautions 45
Boom 46
Boom removing and installing 46
Boom removing 46
Boom installing 48
Boom installation cautions 48
Center Pin 49
Upper center pin 49
Center pin shim adjustment 49
Lower center pin 50
Center pin removing and installing 51
Center pin removing 51
Center pin installing 55
Center pin installation cautions 55
15 Service Standard Chassis Group 56
Linkage 57
Linkage Pin Standard Clearance Values 58
Liner clearance adjustment 58
Shim adjustment 59
Linkage 1: Bucket ~ Boom 59
Linkage 5: Bucket ~ Link 60
Center Pin 61
Center pin shim adjustment 61
Bearing cover installing 61
Lower center pin bearing outer ring installing 62
Attachment Leveler 63
Attachment leveler 64
Attachment leveler adjustable angle 64
24 Disassembly & Reassembly Power Group 66
Power Line 67
Power line tightening torque 67
Radiator 68
Radiator tightening torque 68
Radiator removing and installing 69
Radiator removing 69
Radiator installing 71
Torque Converter Oil Cooler 72
Torque converter oil cooler removing and installing 72
Torque converter oil cooler removing 72
Torque converter oil cooler installing 73
Fan 74
Fan removing and installing 74
Fan removing 74
Fan installing 75
Fan installation cautions 75
Engine 76
Engine removing and installing 76
Engine removing 76
Engine installing 78
Engine installation cautions 78
Propeller Shaft 79
Propeller shaft removing and installing 79
Second propeller shaft removing 80
First propeller shaft removing 80
Third propeller shaft removing 80
Propeller shaft installing 81
Propeller shaft installation cautions 81
Air Cleaner 82
Air cleaner removing and installing 82
Air cleaner removing 82
Air cleaner installing 83
Air cleaner installation cautions 83
Muffler 84
Muffler removing and installing 84
Muffler removing 84
Muffler installing 84
Muffler installation cautions 84
Front Axle Assembly 85
Front axle assembly tightening torque 85
Axle tightening procedure 86
Front axle assembly removing and installing 87
Front axle assembly removing 87
Front axle assembly installing 88
Front axle assembly installation cautions 88
Service brake air bleeding procedure 89
Front axle disassembling and assembling 90
Front axle disassembling 90
Front axle assembling 93
Front axle assembly cautions 94
Floating seal installation 94
Internal gear hub installation 96
Spider Assembly 98
Spider assembly disassembling and assembling 98
Spider assembly disassembling 98
Spider assembly assembling 98
Spider assy assembly cautions 98
Special Tool 99
Special tool for axle 99
Rear Axle Assembly103
Rear axle assembly tightening torque103
Axle tightening procedure104
Rear axle assembly removing and installing105
Rear axle assembly removing105
Rear axle assembly installing108
Rear axle disassembling and assembling108
Axle Support109
Axle support tightening torque109
Axle support disassembling and assembling110
Axle support disassembling110
Axle support assembling110
Axle support assembly cautions111
Bushing installation111
Differential Assembly112
Differential assembly removing and installing112
Differential assembly removing112
Differential assembly installing114
Differential assembly installation cautions114
Differential assembly disassembling and assembling115
Front differential tightening torque115
Rear differential tightening torque116
Differential assembly disassembling117
Differential assembly assembling119
Differential assy assembly cautions120
25 Service Standard Power Group126
Propeller Shaft Service Standard127
Axle and Differential Service Standard128
Axle group128
Differential129
34 Disassembly & Reassembly Torque Converter and Transmission Group130
Torque Converter and Transmission Assembly131
Torque converter and transmission assembly tightening torque131
Torque Converter Assembly132
Torque converter removing and installing132
Torque converter removing132
Torque converter installing134
Torque converter installation cautions134
Torque converter assembly bolt tightening torque135
Torque converter assembly disassembling and assembling136
Torque converter assembly disassembling136
Torque converter assembly assembling139
Torque converter assembly cautions140
Transmission Assembly142
Transmission removing and installing142
Transmission removing142
Transmission assembly installing145
Transmission assembly installation cautions145
Transmission assembly bolt tightening torque147
Transmission assembly disassembling and assembling148
Transmission assembly disassembling148
Transmission assembly assembling151
Transmission assy assembly cautions156
Clutch Assembly157
Clutch assembly disassembling and assembling157
Clutch assembly disassembling157
Clutch assembly assembling163
Clutch Spider Assembly171
Forward and 3rd clutch spiders disassembling and assembling171
Forward and 3rd clutch spiders disassembling171
Forward and 3rd clutch spiders assembling172
Forward and 3rd clutch spiders assembly cautions172
2nd Clutch Spider173
2nd clutch spider disassembling and assembling173
2nd clutch spider disassembling173
2nd clutch spider assembling174
2nd clutch spider assembly cautions174
Reverse Clutch Spider175
Reverse clutch spider disassembling and assembling175
Reverse clutch spider disassembling175
Reverse clutch spider assembling176
Reverse clutch spider assembly cautions176
1st Clutch Assembly177
1st clutch assembly disassembling and assembling177
1st clutch assembly disassembling177
1st clutch assembly assembling178
Input Gear Box Assembly180
Input gear box disassembling and assembling180
Input gear box disassembling180
Input gear box assembling181
Input gear box assembly cautions181
Control Valve Assembly182
Control valve removing and installing182
Control valve removing182
Control valve assembly installing184
Control valve installation cautions184
Control valve disassembling and assembling185
Control valve disassembling185
Control valve assembling185
Control valve assembly cautions186
Special Tool187
35 Service Standard Torque Converter and Transmission Group190
Transmission Assembly191
Transmission191
Torque converter192
Torque Converter Gear Pump195
Gear pump specifications196
Clutch Train and Number of Teeth197
Clutch specifications198
Clutch Oil Pressure199
44 Disassembly & Reassembly Hydraulic Group200
Hydraulic Parts Removal and Installation Warning201
Hydraulic Parts Disassembly and Assembly Cautions202
Hydraulic parts disassembly cautions202
Hydraulic parts assembly cautions202
Hydraulic Pump203
Hydraulic pump removing and installing203
Hydraulic pump removing203
Hydraulic steering pump removing205
Hydraulic loading pump removing206
Hydraulic pilot (triple) pump removing207
Hydraulic pump installing207
Hydraulic pump installation cautions208
Hydraulic pump assembly disassembling and assembling209
Hydraulic pump disassembly tools209
Hydraulic steering/loading pump disassembling211
Hydraulic steering pump assembling213
Hydraulic steering pump assembly cautions214
Regulator disassembling and assembling215
Regulator disassembling216
Regulator assembling219
Hydraulic pilot (triple) pump disassembling and assembling222
Oil seal replacement procedure222
Pilot Valve (for Loading)223
Pilot valve (for loading) removing and installing223
Pilot valve (for loading) removing223
Pilot valve (for loading) installing224
Pilot valve (for loading) installation cautions224
Pilot valve (for loading) disassembling and assembling225
Pilot valve (for loading) cross section and tightening torque225
Pilot valve (for loading) disassembling226
Pilot valve (for loading) assembling231
Pilot valve (for loading) assembly cautions231
Pilot Valve (for Steering)232
Pilot valve (for steering) removing and installing232
Pilot valve (for steering) removing232
Pilot valve (for steering) installing233
Pilot valve (for steering) installation cautions233
Pilot valve (for steering) disassembling and assembling234
Pilot valve (for steering) cross section and tightening torque234
Pilot valve (for steering) disassembling235
Pilot valve (for steering) assembling236
Pilot valve (for steering) assembly cautions237
Steering Valve238
Steering valve removing and installing238
Steering valve removing238
Steering valve installing240
Steering valve installation cautions240
Steering valve disassembling and assembling241
Steering valve cross section and tightening torque241
Steering valve disassembling242
Steering valve assembling244
Steering valve assembly cautions244
Multiple Control Valve245
Multiple control valve removing and installing245
Multiple control valve removing245
Multiple control valve installing247
Multiple control valve installation cautions247
Multiple control valve disassembling and assembling248
Multiple control valve cross section and tightening torque248
Multiple control valve disassembling250
Multiple control valve assembling252
Multiple control valve assembly cautions252
Stop Valve253
Stop valve removing and installing253
Stop valve removing253
Stop valve installing253
Stop valve installation cautions254
Stop valve disassembling and assembling255
Stop valve cross section and tightening torque255
Stop valve disassembling256
Stop valve assembling256
Hydraulic Cylinder257
Hydraulic cylinder removing and installing257
Boom cylinder removing and installing257
Boom cylinder removing257
Boom cylinder installing259
Boom cylinder installation cautions259
Bucket cylinder removing and installing260
Bucket cylinder removing260
Bucket cylinder installing261
Bucket cylinder installation cautions261
Steering cylinder removing and installing262
Steering cylinder removing262
Steering cylinder installing263
Steering cylinder installation cautions263
Hydraulic cylinder disassembling and assembling265
Hydraulic cylinder disassembling268
Hydraulic cylinder assembling270
Hydraulic cylinder assembly cautions271
Special tool for hydraulic cylinder disassembling272
45 Service Standard Hydraulic Group274
Hydraulic Cylinder275
54 Disassembly & Reassembly Brake Group278
Brake Valve279
Brake valve removing and installing279
Brake valve removing279
Brake valve installing280
Brake valve installation cautions280
Brake valve disassembling and assembling281
Brake valve cross section and tightening torque281
Brake valve disassembling282
Brake valve assembling285
Brake valve assembly cautions286
Unloader Valve287
Unloader valve removing and installing287
Unloader valve removing287
Unloader valve installing288
Unloader valve installation cautions288
Unloader valve disassembling and assembling289
Unloader valve cross section and tightening torque289
Unloader valve disassembling290
Unloader valve assembling290
Manifold Valve Assembly291
Valve assembly removing and installing291
Valve assembly removing291
Valve assembly installing292
Valve assembly installation cautions292
Valve assembly disassembling and assembling293
Valve assembly cross section and tightening torque293
Accumulator294
Accumulator removing and installing294
Accumulator removing294
Accumulator installing295
Accumulator installation cautions295
Accumulator disassembling and assembling296
Accumulator tightening torque296
Accumulator disassembling296
Accumulator assembling298
Jig for accumulator assembly300
Nitrogen gas charging302
Nitrogen gas charging procedure302
Service Brake304
Service brake disassembling and assembling304
Service brake disassembling304
Service brake installation305
Service brake installation cautions305
Parking Brake308
Parking brake removing and installing308
Parking brake disassembling and assembling309
Parking brake bolt tightening torque309
Parking brake disassembling310
Parking brake assembling312
55 Service Standard Brake Group314
Brake Valve315
Service Brake317
Parking Brake318
74 Disassembly & Reassembly Operator Station Group320
Air Conditioner321
Air conditioner removing and installing321
Air conditioner removing321
Air conditioner installing322
Air conditioner disassembling and assembling323
Air conditioner tightening torque323
Air conditioner disassembling326
Air conditioner assembling330
75 Service Standard Operator Station Group332
Air Conditioner333
Periodical Inspection/Servicing333
Tightening Torque333
Tightening torque for hose and pipes333
Tightening torque for screws and bolts in special control regions333
INDEX334
Maintenance Log339
Notes343
S.M 4/2/2025
