90ZV-2 (EU-D&R) CD 9001up CLINT

93213-00471
August 2011
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 - To remove a heavy unit (20 kg (40 lbs) or more), be
safety. To ensure safety, observe the general cautions sure to use a crane or other lifting device.
described below.
- Just after stopping operation, be careful not to
- This manual is intended for properly trained and directly touch a hot component. You may get burned.
equipped service technicians.
- Contact tire manufacturer's local dealer for tire ser-
- Any work on the machine must be performed by the vicing and changing.
trained personnel only.
- Always store the tools in good condition, and use
- Carefully read this manual to thoroughly understand them properly.
the operation method before you operate or repair
the machine. - Keep the work area clean. Clean up spills immedi-
ately.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles. - Avoid the use of flammable solvents and cleaners.
- Place the machine on level and solid ground, and - When working outdoors keep work areas, ladders,
place chocks against the wheels to prevent move- steps, decks and work platforms clear of snow, ice,
ment. and mud.
- Remove the cable from the battery before starting - Use safe work platforms to reach higher areas of the
the service work, and attach a "DO NOT OPER- machine.
ATE!" tag to the steering wheel.
- Any technician that operates a refrigerant recovery
and recycling machine must first be certified through
IMPORTANT an EPA approved testing program.
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.
- 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 start-

ing 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 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.
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.
MEMO
CONTENTS
90ZV-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
Cautions Regarding Handling of Bearing ........................................................................................................ 00-13
Bearing installation cautions ..................................................................................................................... 00-13
Interference fits for a bearing .................................................................................................................... 00-13
Bearing removal cautions ......................................................................................................................... 00-14
Applying and Storing Articulation Stopper ....................................................................................................... 00-15
Applying articulation stopper ..................................................................................................................... 00-15
Storing articulation stopper ....................................................................................................................... 00-16
90ZV-2 Disassembly & Reassembly Chassis Group ............................................................................................ 14-1
Deck .................................................................................................................................................................. 14-2
Deck removing and installing ...................................................................................................................... 14-2
Fuel Tank .......................................................................................................................................................... 14-4
Fuel tank removing and installing ............................................................................................................... 14-4
Hydraulic Tank .................................................................................................................................................. 14-5
Hydraulic tank removing and installing ....................................................................................................... 14-5
Engine Room .................................................................................................................................................... 14-8
Engine room removing and installing .......................................................................................................... 14-8
Cab ................................................................................................................................................................. 14-12
Cab removing and installing ...................................................................................................................... 14-12
Floor Board ..................................................................................................................................................... 14-14
Floor board removing and installing .......................................................................................................... 14-14
Boom ............................................................................................................................................................... 14-17
Boom removing and installing ................................................................................................................... 14-17
Center Pin ....................................................................................................................................................... 14-20
Upper center pin ........................................................................................................................................ 14-20
Lower center pin ........................................................................................................................................ 14-21
Center pin removing and installing ............................................................................................................ 14-22
Partition Plate .................................................................................................................................................. 14-26
Partition plate removing and installing ...................................................................................................... 14-26
90ZV-2 Service Standard Chassis Group ............................................................................................................. 15-1
Linkage .............................................................................................................................................................. 15-2
Linkage Pin Standard Clearance Values ........................................................................................................... 15-3
Liner clearance adjustment ......................................................................................................................... 15-3
Center Pin ......................................................................................................................................................... 15-4
Center pin shim adjustment ........................................................................................................................ 15-4
Bearing cover installing ............................................................................................................................... 15-4
Lower center pin bearing outer ring installing ............................................................................................. 15-5
Attachment Leveler ........................................................................................................................................... 15-6
Attachment leveler ...................................................................................................................................... 15-7
Attachment leveler adjustable angle ........................................................................................................... 15-7
90ZV-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 ................................................................................................................. 24-5
Fan .................................................................................................................................................................... 24-9
Fan removing and installing ........................................................................................................................ 24-9
Engine ............................................................................................................................................................. 24-11
Engine removing and installing ................................................................................................................. 24-11
Propeller Shaft ................................................................................................................................................ 24-14
Propeller shaft removing and installing ..................................................................................................... 24-14
Air Cleaner ...................................................................................................................................................... 24-16
Air cleaner removing and installing ........................................................................................................... 24-16
Muffler ............................................................................................................................................................. 24-18
Muffler removing and installing ................................................................................................................. 24-18
Front Axle Assembly ....................................................................................................................................... 24-20
Front axle assembly tightening torque ...................................................................................................... 24-20
Front axle assembly removing and installing ............................................................................................ 24-22
Front axle disassembling and assembling ................................................................................................ 24-26
Front axle assembly cautions ................................................................................................................... 24-30
Internal Gear Hub ........................................................................................................................................... 24-35
Internal gear hub disassembling and assembling ..................................................................................... 24-35
Internal gear hub assembly cautions ........................................................................................................ 24-37
Spider Assembly ............................................................................................................................................. 24-38
Spider assembly disassembling and assembling ...................................................................................... 24-38
Special Tool ..................................................................................................................................................... 24-40
Special tool for axle ................................................................................................................................... 24-40
Rear Axle Assembly ........................................................................................................................................ 24-44
Rear axle assembly tightening torque ....................................................................................................... 24-44
Rear axle assembly removing and installing ............................................................................................. 24-46
Rear axle disassembling and assembling ................................................................................................. 24-48
Axle Support ................................................................................................................................................... 24-49
Axle support tightening torque .................................................................................................................. 24-49
Axle support disassembling and assembling ............................................................................................ 24-50
Differential Assembly ...................................................................................................................................... 24-52
Differential assembly removing and installing ........................................................................................... 24-52
90ZV-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
90ZV-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
Torque Converter Assembly .............................................................................................................................34-11
Torque converter assembly bolt tightening torque .....................................................................................34-11
Torque converter assembly disassembling and assembling ..................................................................... 34-12
Transmission Assembly .................................................................................................................................. 34-19
Transmission assembly bolt tightening torque .......................................................................................... 34-19
Transmission assembly disassembling and assembling ........................................................................... 34-20
Transmission Forward/Reverse Clutch Pack .................................................................................................. 34-31
Forward/reverse clutch pack disassembling and assembling ................................................................... 34-31
Transmission 1st/3rd Speed Clutch Pack ........................................................................................................ 34-34
Transmission 1st/3rd speed clutch pack disassembling and assembling ................................................. 34-34
Transmission 2nd Speed Clutch Pack ............................................................................................................. 34-36
Transmission 2nd speed clutch pack disassembling and assembling ...................................................... 34-36
Transmission 4th Speed Clutch Pack .............................................................................................................. 34-38
Transmission 4th speed clutch pack disassembling and assembling ....................................................... 34-38
Control Valve Assembly .................................................................................................................................. 34-41
Control valve tightening torque ................................................................................................................. 34-41
Control valve removing and installing ....................................................................................................... 34-42
Control valve disassembling and assembling ........................................................................................... 34-44
90ZV-2 Service Standard Torque Converter and Transmission Group ................................................................ 35-1
Transmission Assembly .................................................................................................................................... 35-2
Control Valve ..................................................................................................................................................... 35-3
Gear Pump ........................................................................................................................................................ 35-5
Gear pump specifications ............................................................................................................................ 35-5
Clutch Plate Thickness/Piston Stroke ............................................................................................................... 35-6
Clutch plate ................................................................................................................................................. 35-7
Piston stroke ............................................................................................................................................... 35-7
Clutch Oil Pressure ........................................................................................................................................... 35-8
Clutch oil pressure standard value .............................................................................................................. 35-8
90ZV-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
Hydraulic Pump Assembly ................................................................................................................................ 44-4
Hydraulic pump assembly removing and installing ..................................................................................... 44-4
Hydraulic Cylinder ........................................................................................................................................... 44-15
Boom cylinder removing and installing ..................................................................................................... 44-15
Bucket cylinder removing and installing .................................................................................................... 44-17
Steering cylinder removing and installing .................................................................................................. 44-20
Hydraulic cylinder disassembling and assembling .................................................................................... 44-22
Pilot Valve (S/N 9001~9352) ........................................................................................................................... 44-28
Pilot valve removing and installing ............................................................................................................ 44-28
Pilot Valve (S/N 9353~) ................................................................................................................................... 44-41
Pilot valve removing and installing ............................................................................................................ 44-41
Multiple Control Valve ..................................................................................................................................... 44-51
Multiple control valve removing and installing ........................................................................................... 44-51
Orbitrol® .......................................................................................................................................................... 44-57
Orbitrol® removing and installing ............................................................................................................... 44-57

Steering Valve ................................................................................................................................................. 44-67
Steering valve removing and installing ...................................................................................................... 44-67
Stop Valve ....................................................................................................................................................... 44-72
Stop valve removing and installing ............................................................................................................ 44-72
Stop valve disassembling and assembling ............................................................................................... 44-74
Fan Motor ........................................................................................................................................................ 44-76
Fan motor removing and installing ............................................................................................................ 44-76
90ZV-2 Service Standard Hydraulic Group ........................................................................................................... 45-1
Hydraulic Cylinder ............................................................................................................................................. 45-2
Pilot Valve ......................................................................................................................................................... 45-4
Steering Valve ................................................................................................................................................... 45-6
90ZV-2 Disassembly & Reassembly Brake Group ............................................................................................... 54-1
Unloader Valve .................................................................................................................................................. 54-2
Unloader valve removing and installing ...................................................................................................... 54-2
Manifold Valve Assembly .................................................................................................................................. 54-8
Valve assembly removing and installing ..................................................................................................... 54-8
Valve assembly disassembling and assembling ......................................................................................... 54-9
Accumulator .....................................................................................................................................................54-11
Accumulator removing and installing .........................................................................................................54-11
Accumulator disassembling and assembling ............................................................................................ 54-13
Nitrogen gas charging ............................................................................................................................... 54-15
Brake Valve ..................................................................................................................................................... 54-17
Brake valve removing and installing .......................................................................................................... 54-17
Service Brake .................................................................................................................................................. 54-24
Service brake disassembling and assembling .......................................................................................... 54-24
Parking Brake Actuator ................................................................................................................................... 54-25
Parking brake actuator removing and installing ........................................................................................ 54-25
Parking brake actuator adjusting ............................................................................................................... 54-26
Parking brake actuator disassembling and assembling ............................................................................ 54-27
Parking Brake .................................................................................................................................................. 54-30
Parking brake removing and installing / disassembling and assembling .................................................. 54-30
Parking brake (for front) removing and installing ...................................................................................... 54-32
Parking brake (for front) disassembling and assembling .......................................................................... 54-35
90ZV-2 Service Standard Brake Group ................................................................................................................. 55-1
Brake Valve ....................................................................................................................................................... 55-2
Service Brake .................................................................................................................................................... 55-4
Parking Brake .................................................................................................................................................... 55-5
90ZV-2 Disassembly & Reassembly Operator Station Group ............................................................................... 74-1
Air Conditioner .................................................................................................................................................. 74-2
Air conditioner removing and installing ....................................................................................................... 74-2
Air conditioner disassembling and assembling ........................................................................................... 74-4
90ZV-2 Service Standard Operator Station Group ................................................................................................ 75-1
Air Conditioner .................................................................................................................................................. 75-2
Periodical Inspection/Servicing ................................................................................................................... 75-2
Tightening Torque ....................................................................................................................................... 75-2
00-1
90ZV-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
Cautions Regarding Handling of Bearing ................ 00-13
Applying and Storing Articulation Stopper ............... 00-15
00-2
Symbols
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Symbol Item Description
Shows the condition or procedure that will be useful

Reference
or efficient in doing service work.
Shows the weight of a part or unit. The weight

should be considered in selecting wire rope or cable
Weight
for slinging work or determining the working pos-
ture.
Tightening Shows the tightening torque of a section that should

torque be carefully tightened during assembly work.
Shows the type of coating or adhesive and the coat-

Coating
ing section.
Oil or
Shows the oil or water supply port and the refill
water
amount.
supply
Shows the oil or water drain port and the drain

Drainage
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 per-
formance 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 follow-
ing abbreviation list.
E/G ........... Engine RH ........... Right hand side 3rd ............3rd speed
T/C ........... Torque converter LH ........... Left hand side 4th ............4th speed
T/M ........... Transmission H ........... High M/C ............Machine
SOL ........... Solenoid valve L ........... Low min-1 ............RPM
SW ........... Switch GND ........... Ground ELS ............Efficient loading system
F ........... Front or Forward OPT ........... Option MODM ........Machine operation diag-
A/M ........... Auto/Manual Assy ........... Assembly nostic module
B ........... Battery 1st ........... 1st speed MCU............Machine control unit
R ........... Rear or Reverse 2nd ........... 2nd speed
00-3
Weight of Main Components
Weight of Main Components
Item Approx. Approx.

Remarks
Unit name Part name weight (kg) weight (lb)
Bucket 2,070 4,565 GSC bucket
Boom 1,675 3,695
Lever 223/pc 495
Link (Bucket to Lever) 37/pc 85
Hinge pin 36/pc 80
Screen board 115 255
Roof 25 55
Engine room access panel 26 60
Radiator guard 88 195
Chassis
Hydraulic tank 173 385 Excluding oil
Fuel tank 184 410 Excluding fuel
Left side 63 140 With handrail
Deck
Right side 67 150 With handrail
Cab (ROPS) 500 1,105
Floor board 230 510
Front chassis 1,890 4,170
Rear chassis 1,760 3,880
Counter weight 1,880 4,145
Engine 940 2,075 Excluding oil
Transmission 910 2,010 Excluding oil
Second propeller shaft 72 160
Third propeller shaft 13 30
Radiator (S/N 9001~9200) 365 805
Excluding water and oil
assembly (S/N 9201~) 230 510
Air cooler 23 50
Power line
Air cleaner 25 55
Muffler 23 50
Front axle assembly 1,230 2,715 Excluding tires and oil
Rear axle assembly 1,470 3,245 Excluding tires and oil (Including axle support)
Axle support (Front) 90 200
Axle support (Rear) 110 245
Differential 185 410
Multiple control valve 91 205
Steering valve 23 50
Valve assembly 8 20 For brake
Valve assembly 16 35 For efficient loading system
Hydraulic Hydraulic pump 46 105
system Accumulator assembly 48 110 Two accumulators and bracket
Fan motor 15 35
Boom cylinder 207/pc 460/pc
Bucket cylinder 130/pc 290/pc
Steering cylinder 42/pc 95/pc
Tire 670/pc 1,480/pc With rim (26.5R25 )
Other
Battery 36/pc 80/pc
00-4
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 Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 26 38
(C) 1.5 53 76
M10 10
(F) 1.25 55 80
(C) 1.75 90 132
M12 12
(F) 1.25 96 142
(C) 2.0 142 206
M14 14
(F) 1.5 152 221
(C) 2.0 216 314
M16 16
(F) 1.5 226 330
(C) 2.5 299 436
M18 18
(F) 1.5 324 476
Metric thread (C) 2.5 417 608
M20 20
(F) 1.5 451 662
(C) 2.5 559 814
M22 22
(F) 1.5 598 878
(C) 3.0 721 1,030
M24 24
(F) 2.0 770 1,128
(C) 3.0 1,030 1,520
M27 27
(F) 2.0 1,128 1,618
(C) 3.5 1,422 2,109
M30 30
(F) 2.0 1,569 2,256
(C) 3.5 1,912 2,844
M33 33
(F) 2.0 2,059 3,040
5/16 05 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
Unified thread 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
(kgf-m)
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 2.7 3.9
(C) 1.5 5.4 7.8
M10 10
(F) 1.25 5.6 8.2
(C) 1.75 9.2 13.5
M12 12
(F) 1.25 9.8 14.5
(C) 2.0 14.5 21.0
M14 14
(F) 1.5 15.5 22.5
(C) 2.0 22.0 32.0
M16 16
(F) 1.5 23.0 33.7
(C) 2.5 30.5 44.5
M18 18
(F) 1.5 33.0 48.5
Metric thread (C) 2.5 42.5 62.0
M20 20
(F) 1.5 46.0 67.5
(C) 2.5 57.0 83.0
M22 22
(F) 1.5 61.0 89.5
(C) 3.0 73.5 105.0
M24 24
(F) 2.0 78.5 115.0
(C) 3.0 105.0 155.0
M27 27
(F) 2.0 115.0 165.0
(C) 3.5 145.0 215.0
M30 30
(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
Unified thread 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
00-6
(lb-ft)
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 19.5 28
(C) 1.5 39 56
M10 10
(F) 1.25 40 59
(C) 1.75 66 97
M12 12
(F) 1.25 70 105
(C) 2.0 105 150
M14 14
(F) 1.5 110 160
(C) 2.0 160 230
M16 16
(F) 1.5 165 245
(C) 2.5 220 320
M18 18
(F) 1.5 235 350
Metric thread (C) 2.5 305 450
M20 20
(F) 1.5 330 490
(C) 2.5 410 600
M22 22
(F) 1.5 440 650
(C) 3.0 530 760
M24 24
(F) 2.0 565 830
(C) 3.0 760 1,120
M27 27
(F) 2.0 830 1,190
(C) 3.5 1,050 1,550
M30 30
(F) 2.0 1,160 1,660
(C) 3.5 1,410 2,100
M33 33
(F) 2.0 1,520 2,240
5/16 05 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
Unified thread 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
00-7
Flanged hexagon bolt
1. Bolt type: Metric thread
2. Bolt strength: 8.8 (8T)
3. Thread pitch: Coarse pitch thread (C)
(N-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 7
M6 1 12
M8 1.25 28
M10 1.5 53
Metric thread
M12 1.75 94
M16 2 231
M20 2.5 441
M24 3 765
(kgf-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 0.7
M6 1 1.2
M8 1.25 2.9
M10 1.5 5.4
Metric thread
M12 1.75 9.6
M16 2 23.5
M20 2.5 45.0
M24 3 78.0
(lb-ft)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 5.0
M6 1 8.6
M8 1.25 20.9
M10 1.5 38.9
Metric thread
M12 1.75 69.1
M16 2 169.2
M20 2.5 324.0
M24 3 561.6
00-8
Hose Band Tightening Torque
Hose Band Tightening Torque
Low pressure hose

(heat resisting hose) Tightening torque Tightening torque Tightening torque
Hose band
(N-m) (kgf-cm) (lb-ft)
Inner dia. (mm) Outer dia. (mm)
6.3 16.5
7.9 18.5 69002-02200 1.6 16 1.2
9.5 20.5
12.7 24.5 69002-02700
15.9 29.9
69002-03100
19.0 30.0
25.4 38.0 69002-04400
31.8 45.8 69002-05200 4 40 2.9
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 Tightening torque Tightening torque Tightening torque

Hose band
Inner dia. (mm) Outer dia. (mm) (N-m) (kgf-cm) (lb-ft)
6 16.5
8 18.5 69002-02200 1.6 16 1.2
9 20.5
9 22.0 69002-02300
12 24.5
69002-02700
12 26.0
15 29.0
69002-03100
15 30.5
19 32.0
69002-03800
19 34.0
4 40 2.9
25 39.5
69002-04400
25 41.5
32 46.0
69002-05200
32 48.0
38 54.0 69002-05700
50 70.5
69002-07600
50 73.0
Fix the band 2~3 mm (1/8 in)

To connect the hose to the pipe, tighten the hose band avoiding the beading.
at the following position: Pipe
Hose
Hose band
K50V200002
00-9
Liquid Gasket and Screw Lock Agent

To reassemble the disassembled parts, be sure to use Cautions regarding reassembly
the specified liquid gasket or screw lock agent or the
equivalent according to the following lists: To reassemble a screw
Code Manufacturer Product name Completely remove the hardened lock agent from the
AA01 Loctite ®
Plastic Gasket 568 screw and the threaded hole before reassembling the
Liquid
screw.
®
AA02 Loctite Hydraulic sealant
Gasket
AA03 Three Bond Three Bond 1215 Note
AB01 Loctite ® ®
Loctite 262 A piece of hardened lock agent may be peeled off and
remain in the component. The remaining piece may
Screw Lock
AB02 Three Bond Three Bond 1327 cause malfunction during fastener installation.
Agent
AB03 Three Bond Three Bond 1374
To bond a plane or to fit a shaft
Remove the hardened lock agent using a wire brush or

the like, and polish the surface using sand paper. Use of
Cautions regarding parts removal 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 Antiseize Agent
using a general tool, such as a wrench or puller.
Code Manufacturer Product name
If it is difficult to remove the screw or shaft, heat the bolt Loctite® 767
to soften the agent (200~250°C) using a soldering iron AC01 Loctite®
(Paste or spray)
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.
00-10
Screw lock agent application pro- How to wind a seal tape

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

threads.
Seal tape
Screw lock agent Leave 1~2 screw
65ZV00004a
As the screw is tightened by turning clockwise, seal

tape must be wound up clockwise direction as shown
65ZV00002 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
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 pos-
sible damage.
Cautions
1. Turn the starter switch OFF. 4. Ground the welder near the section to be welded.
5. To ground the welder, check that the electric cur-

IMPORTANT rent will not flow through the cylinders.
If a battery terminal is removed from a machine in Cylinder head covers for some models have a low
less than 30 seconds after the key is put into the conductive metal that will cause spark if the welding
“OFF” position, it can corrupt the ECM program, current flows. The spark may damage the cylinder
which can disable the engine. Always wait 1 full rod.
function” prior to removing battery terminals. 6. Calibrate throttle pedal to ECM.
(a) Turn the starter switch to "ON".

2. Remove the battery terminals both positive and
(b) Fully depress and release the throttle pedal
negative sides from the battery.
three times.
(c) Turn the starter switch to "OFF".
3. Disconnect the connector for MCU (machine con-
troller), ECM (engine controller) and air conditioner.
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 Section to be welded Ground this section.
through the cylinders. (correct grounding)
35C00006
00-12
7. The weld spattered on the hydraulic cylinders and

on the plated sections of pins will damage the cylin-
ders and pins. There are other parts that may be
damaged by the spatter; hydraulic units, har- Heat-resistant
cloth
nesses, hydraulic hoses, and nylon tubes.
Be sure to mask these units and parts before weld- Section to
ing. Hydraulic hose be welded
Nylon tube Remove
Harness and if
necessary
Hydraulic cylinder wrap
Chassis
35A00005
Plated section (Mask this section.)

(c) Hydraulic hoses, nylon tubes, or harnesses are
easily damaged by the heat during welding. To pro-
tect them from the heat, remove them from the sec-
Pin section with pin tion to be welded to make enough clearance.
temporarily inserted
Pin
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 corro-
sion.
Scrap material, etc.

1m or more
Section to
be welded
1m or more
35C00004
(b) Cover the hydraulic units, electrical units, har-

nesses, hydraulic hoses, nylon tubes, etc. with
heat-resistant cloth (glass wool or canvas) or scrap
material to protect them from spatter.
00-13
Cautions Regarding Handling of Bearing
Bearing installation cautions Force
IMPORTANT
Unwrap a new bearing just before installing it.
Metal pad
K65V2J00002
If the interference is rather small, put an appropriate tool

on the bearing inner ring and press the tool, not directly
the bearing, with a pressing machine or a hammer to fit
the bearing on the shaft, while applying equal pressure
K65V2J00004
onto the inner race circumference.
When installing a bearing to a shaft or a housing, it is When installing the bearing on a shaft and also in a
important to insert the bearing by equally applying pres- housing at the same time, put an appropriate metal pad
sure on the bearing ring circumference. both on the inner and outer rings as shown in the above
Do not partially apply pressure on the bearing ring, as it figure (right), and press the bearing using the tool so
may cause unstable and entangled bearing operation. that equal pressure is applied onto the inner and outer
Do not apply pressure from the side, as it will apply load races.
via the rolling element, making indentations on the bear-
ing ring.
CAUTION
Do not hit the bearing directly with a hammer, etc. to
prevent indentation and crack. Be sure to hold the bearing straight up before and
while pressing it.
Interference fits for a bearing Heating to remove the interference
To assemble a bearing on a shaft, for example, it is usu- If the interference is large enough, heat the bearing
ally assembling an oversize shaft into an undersized before installation. The bearing expands when heated,
hole. The method is called “interference fit” or “press fit”. thus the interference can be temporarily removed,
which makes interference fitting easier.
Note
“Interference” here means the difference between the To heat the bearing, put it in heated clean oil below
bearing inner ring bore and the shaft outer diameter. 120ºC (248ºF). (This method is not applicable to bear-
ings including grease.)
There are two basic methods for assembly, sometimes

used in combination: Force, and changing the size of
the parts by heating.
00-14
Bearing operation test after installation Bearing removal cautions

Manually turn the shaft or housing after installing a
bearing. Pressing
Bearing puller machine
Verify that there is no abnormal noise, chattering, vibra-
tion, or unusual load. If any abnormality is observed,
stop rotating and check the bearing.
Bearing removal tool

K65V2J00003
When removing bearing unit, use an appropriate tools

as shown above.
Make sure to apply load only to the bearing ring to pull

out the bearing, and DO NOT apply any load to the roll-
ing element.
If any load is applied when removing the bearing unit
because of its installation conditions, the bearing must
not be reused.
00-15
Applying and Storing Articulation Stopper
Applying articulation stopper
2 3
Locked position
IL14-3(90ZV-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 seri- WARNING
ous injury or death. There is a possibility that a ser- To align the pin with the pin hole, start the engine and
vice man could be crushed in the articulation area if slightly turn the steering wheel. Be careful! Your body
the machine unexpectedly turns during repair work. or finger could be crushed in the machine when the
To prevent such an accident, be sure to apply the machine turns.
articulation stopper before starting work. 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
IL14-2(90ZV-D&R)
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.
00-16
Storing articulation stopper
1
3 2
Stored position
IL14-4(90ZV-D&R)
Store rod (2) and pin (3) as shown.

14-1
90ZV-2 Disassembly & Reassembly Chassis Group
90ZV-2 Disassembly & Reassembly

Chassis Group
Deck ........................................................................ 14-2

Fuel Tank................................................................. 14-4
Hydraulic Tank......................................................... 14-5
Engine Room .......................................................... 14-8
Cab.......................................................................... 14-12
Floor Board ............................................................. 14-14
Boom ....................................................................... 14-17
Center Pin ............................................................... 14-20
Partition Plate .......................................................... 14-26
14-2
Deck
Deck
Deck removing and installing

Window washer
liquid tank
Deck 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 deck 5 6
removal:
- Position the machine on level ground, and apply
the parking brake. 90V2E14002
- Lower the attachment onto the ground, and block
the tires with chocks, etc. to prevent them from
moving. 2. Remove bolt (5) to remove the window washer liq-
- Remove the engine key, and hang a "DO NOT uid tank from deck (6).
START ENGINE!" tag on the steering wheel.
7 8
Screen board
3
Screen
board 6
9
4 1
Hydraulic 9
tank
K90V2J14003
2
Fuel tank K90V2J14001 3. Apply a sling to handrail (7) and deck (6), then
remove bolts (8)(9).
1. Apply a sling to handrail (1) and deck (4), then : Deck (6) (with handrails): 68 kg (150 lbs)
remove bolts (2)(3).
4. While considering the balance, remove decks (4)(6)
: Deck (4) (with handrails): 65 kg (145 lbs) together with the handrails.
14-3
Deck
10
11
Fuel tank
90V2E14004
5. Remove bolt (10) to remove ladder (11).
: Ladder: 9 kg (20 lbs)
12
13
12
14
Hydraulic tank
K90Z514001
6. Remove bolt (12) to remove steps (13)(14) from the

hydraulic tank.
: Step (13): 7 kg (14.5 lbs)

Step (14): 2.5 kg (5 lbs)
Deck installing
For reinstallation, follow the above procedure in reverse

order.
14-4
Fuel Tank
Fuel Tank
Fuel tank removing and installing

4
Fuel tank removing
WARNING 2
observe the following items before starting fuel tank Fuel tank
removal:
- Position the machine on level ground, and apply
the parking brake. 90V2E14006
moving. 4. Slightly pull out the fuel tank to disconnect suction/
- Remove the engine key, and hang a "DO NOT return hoses (4). Plug the fuel line to prevent dirt
START ENGINE!" tag on the steering wheel. entry. Be careful not to damage the fitting on the
tank.
Before starting work: Note
- Drain fuel from the fuel tank. Cover the disconnected hoses with vinyl to protect the
(Fuel tank capacity: 370 L (95 gal)) hoses from dust and dirt.
- Remove the deck and the ladder.
1
Fuel tank installing

order.
Rear
2
chassis
Fuel tank installation cautions
After reinstallation, be sure to completely bleed air in the

fuel line.
3 90V2E14005
1. Disconnect level sensor electrical line coupler (1).
2. Temporarily sling fuel tank (2).
: Fuel tank: 185 kg (410 lbs) (when empty)
3. Remove retainer bolt (3).
: Bolt (3): 441 N-m (45.0 kgf-m) (326 lb-ft)

14-5
Hydraulic Tank
Hydraulic Tank
Hydraulic tank removing and (S/N 9001~9450) (S/N 9451~)
installing
Breather valve Breather valve
Hydraulic tank removing
WARNING
observe the following items before starting hydraulic
tank removal:
- Position the machine on level ground, and apply K90V2E14006
the parking brake.
1
moving.
- Remove the engine key, and hang a "DO NOT
Before starting work: 2

- Drain hydraulic oil from the hydraulic tank. Hydraulic
(Hydraulic tank capacity: 165 L (44 gal)) tank
- Remove the deck.
- Clean the area around the tank.
90V2E14007
1. Disconnect hoses (1)(2) from the oil cooler.
Note
Cover the disconnected hoses with vinyl to protect the
hoses from dust and dirt.
14-6
Hydraulic Tank
3 5
6
7
Hydraulic
tank
90V2E14008 90V2E14010
2. Disconnect brake line hose (3). 4. Disconnect hose (5) to the pilot valve.
Disconnect hose (6) to the fan motor.
Note Disconnect hose (7) to the unloader valve, and
Cover the disconnected hoses with vinyl to protect the hose (8) to the combination valve.
Note
Pump unit (option)
4
90V2E14009
3. When the optional emergency steering system is

90V2E14011
applicable, remove bolt (4) to remove the pump unit
from the hydraulic tank.
5. Disconnect hose (9) to the oil pump.
Note
14-7
Hydraulic Tank
12
Rear chassis
Hydraulic
tank
10
12
11
90V2E14012
6. Disconnect oil level sensor (10) and temperature

sensor (11) couplers.
7. Temporarily sling the hydraulic tank, and remove

bolts (12).
: Hydraulic tank:
175 kg (385 lbs) (when empty)
Hydraulic tank installing

order.
Hydraulic tank installation cautions
After reinstallation, be sure to check the pipes for leak-

age, 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.
14-8
Engine Room
Engine Room
Engine room removing and install-

ing
3
Engine room removing
WARNING
observe the following items before starting engine
room removal:
- Position the machine on level ground, and apply 90ZV14009
the parking brake.
2. Remove covers (3) at both right and left sides.
moving.
5
- Recover/recycle refrigerant on machine with optional
air conditioner, if required.
Note Engine roof

If the quick coupler is attached, no recovery/recycling
will be needed.
Muffler
K90V2U14012
2
3. Remove bolt (4) and exhaust pipe (5).
1
: Bolt (4): 53 N-m (5.4 kgf-m) (39 lb-ft)
90ZV14008
1. Remove right and left decks (1) together with hand-

rail (2).
14-9
Engine Room
7 11 10
6 Condenser
Engine
Receiver
tank
90V2E14014 90ZV14013
4. Disconnect hoses (6)(7) from the condenser and 6. Remove hose (10) between the air cleaner and tur-
the receiver tank. bocharger at the turbocharger side.
Disconnect indicator wire coupler (11).
Note
- Before disconnecting the hoses, be sure to recover/ Note
recycle the refrigerant. Cover the hose and port of the turbocharger to protect
(If the quick coupler is attached, no recovery/recy- the turbocharger from dust and dirt.
cling will be needed.)
- Cover the disconnected hoses with vinyl to protect
the hoses from dust and dirt.
12
12
Engine access
panel
90V2E14016
9
7. Remove wires (12) for the engine access panel.
90V2E14015
5. Remove bolts (6)(7) to remove the partition plates

from the screen board.
14-10
Engine Room
14 13
18
Screen board
Screen board
18 Rear chassis
Radiator guard 90V2E14017 90V2E14019
8. Remove nut (13) for engine roof (14) and lift the 10. Remove screen board retainer bolt (18) and lift the
roof. screen board.
: Nut (13): 53 N-m (5.4 kgf-m) (39 lb-ft) Note

: Engine roof: 30 kg (66 lbs) Slowly lift the screen board while checking that there
are no obstacles.
15
17 : Bolt (18): 230 N-m (23.5 kgf-m) (169 lb-ft)
15 : Screen board
(with condenser and air cleaner)
135 kg (300 lbs)
Engine room installing

16 16
order.
90V2E14018
9. Remove round bar (15) of engine access panel

(16). Sling engine access panel (16), and remove
bolt (17) to remove the panel.
: Engine access panel: 30 kg (60 lbs)

14-11
Engine Room
Engine room installation cautions
- After reinstallation, be sure to check the air condi-

tioner for refrigerant leakage.
Air cleaner
A
B Engine
A
K90V2E14007
[Hose band A]
2~3 mm (1/8 in)
5 mm (1/4 in) or less
Fix the bands

avoiding the beading
Air hose
50±5 mm (2±1/5 in)
K85V2U24005
[Hose band B]
2~3 mm (1/8 in)
Fix the bands

Air hose
(Air cleaner or Engine)

Insertion amount:
35 mm (1 1/2 in)
K90Z524004
- Check that the air cleaner rubber hose connection

band is properly positioned and tightened with
proper torque.
14-12
Cab
Cab
Cab removing and installing

Cab removing
3
WARNING
an accident resulting in injury or death.
- Position the machine on level ground, and block
moving.
- Lower the attachment onto the ground, and apply 65ZV14013J
the parking brake.
START ENGINE!" tag on the steering wheel. 2. Cover (3) for the filter is located at the right rear
side of the cab. Turn the rings counterclockwise
and then remove cover (3).
Before starting work:
- Remove the decks on both right and left side.
- Disconnect the electrical line couplers.
Filter
65ZV14014J
95V2E14013 3. Remove the filter from the cab.
Note
1. Remove covers (1) and (2). When installing the filter into the cab, be sure to align
the air flow arrow on the filter to point toward the cab.
14-13
Cab
95ZV14016
4. Remove cover (4).
5 6
7
85V2E14023
6. Remove bolts (7)(8).

95ZV14017
: Bolt (7): 721 N-m (73.5 kgf-m) (532 lb-ft)
5. Remove bolt (5). Tilt steering shaft (6) backward.
7. Remove bolt (9) and install the eye bolt (M16 x 2.0)
instead.
Attach sling and remove the cab.
: Cab: 500 kg (1,100 lbs)
Note
When tightening bolt (9) with the washer, make sure
that the rubber-coated side of the washer faces down to
the cab.
Cab installing

order.
14-14
Floor Board
Floor Board
Floor board removing and install-

ing
Floor board removing
WARNING
moving.
- Lower the attachment onto the ground, and
release the residual pressure from the hydraulic 1
tank and lines.
- Disconnect the (-) side of the battery.
- Disconnect the (+) side of the battery. 1
1
IMPORTANT 1
90V2E14021
1. Disconnect air duct hose (1) by releasing the hose
Before starting work: band.
- Remove the decks on both right and left sides of the
machine. Note
- Remove the cab. Cover the disconnected hoses with vinyl to protect them
- Collect the air conditioner refrigerant (option) using from dust and dirt.
the proper recovery method.
Note
- Before disconnecting the electrical couplers, hoses
and pipes, put match marks on them.
- Prepare a can for the oil.
- Cover the disconnected hoses and pipes with vinyl
to protect them from dust and dirt.
14-15
Floor Board
To pilot valve
Control box
2
3 To pilot
valve
Brake valve Hydraulic Combination

4 90V2E14022 tank valve
10
9
2. Disconnect brake line hoses (2)~(4) from the brake
valve.
Rear chassis K90V2U14011
Note
Cover the disconnected hoses and pipes with vinyl to 4. Disconnect pilot hydraulic line hose (8) from the
protect them from dust and dirt. pilot valve at the port located on the hydraulic tank.
Disconnect pilot hydraulic line hose (9) from the
multiple control valve at the chassis side.
Air conditioner
Disconnect hose (10) to the combination valve.
7 Note
Cover the disconnected hoses with vinyl to protect them
6 from dust and dirt.
Floor board
K80V2J14014
Operation stand
3. Disconnect hose (5)~(7) from the air conditioner

unit. Orbitrol® 11
Note
Cover the disconnected hoses and pipes with vinyl to 11
protect them from dust and dirt. 11 90V2E14024
5. Put matchmarks and disconnect pilot hydraulic line

hose (11) from the Orbitrol®.
Note
Cover the disconnected hoses with vinyl to protect them
from dust and dirt.
14-16
Floor Board
Floor board installing

12
order.
13
Floor board installation cautions
After reinstallation, start the engine, and then check the

refrigerant, and oil lines for leakage.
Check operation of the electrical equipment.
Rubber
cushion
Floor board
K90V2J14024
6. Remove elastic plug (12) and floor board retaining

nut (13). Temporarily sling then gradually lift the
floor board while checking that there are no obsta-
cles and that all pipes, cables, pins, etc. are discon-
nected.
: Nut (13): 441 N-m (45.0 kgf-m) (324 lb-ft)

: Floor board assy including ope. stand,
control box, etc.: 350 kg (770 lbs)
Reference
: Bolt for the rubber cushion:
90 N-m (9.2 kgf-m) (67 lb-ft)
14-17
Boom
Boom
Boom removing and installing

2
3
Boom removing 1
WARNING
moving.
- Lower the attachment onto the ground, and 5 4 90ZV14016
release the residual pressure from the hydraulic
tank and lines.
- Apply the parking brake and remove the starter 1. Remove pin (3) connecting bucket (1) and link (2).
key.
Note
There are shims in the pin sections. Carefully store the
WARNING removed shims, and correctly reinsert the shims when
reinstalling the bucket.
Hitting the parts quenched such as bearing, shaft, pin
and tooth by a steel-hammer could cause a breakage
2. Remove connection pin (5) from boom (4) and
resulting in injury or death.
bucket (1) to remove the bucket.
- Keep persons away from working area.
- Use a support plate in case a steel hammer is
: Bucket: 1,500 kg (3,300 lbs)
used.
- Use a copper-hammer or a plastic hammer.
- Always wear protection goggles.
90ZV14017
3. Temporarily sling link (2), and then remove connec-

tion pin (6) from lever (7) and link (2).
: Link (for 1 pc): 40 kg (90 lbs)

14-18
Boom
11
8
7
90ZV14018 90ZV14038
(The illustrations show the parts on the right side. On 6. Start the engine and shorten bucket cylinder rod
the left side, the parts are located at the same points.) (11). Stop the engine.
Lower bucket cylinder rod (11) on the machine.
4. Remove grease pipe (8) from lever (7).
CAUTION
You have to work at a high position to remove the
grease pipe.
Always use a stepladder for this work.
12
7
9 90ZV14020
10 7. Temporarily sling lever (7), and then remove lever

pin (12).
7 8. Remove lever (7).
90ZV14019 : Lever (for 1 pc): 220 kg (485 lbs)
5. Temporarily sling the bucket cylinder (9), and then

remove the connection pin (10) from the lever (7)
and bucket cylinder (9).
: Bucket cylinder: 115 kg (250 lbs)

14-19
Boom
14 CAUTION
13
Loss of control of the boom structure during removal
or installation could result in injury or machine dam-
16
15 age.
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.
Wooden
block 90ZV14039
Boom installing
9. Remove grease hose (14) from pin (13).
10. Place a wooden piece between boom cylinder (15) order.
and hydraulic pipe (16), and then remove pin (13).
Note
Placing a wooden piece between the boom cylinder and Boom installation cautions
the hydraulic pipe helps to reinstall the pin to the boom
easily.
After reinstallation, grease the boom, and then operate
it.
During operation, check the boom for abnormal noise.
17
90ZV14040
11. Temporarily sling the cross pipe of boom (4), and

then remove pins (17) from the boom on both the
right and left side of the boom.
12. Slowly lift boom (4) to remove it from the machine.
: Boom: 1,675 kg (3,695 lbs)

14-20
Center Pin
Center Pin
Upper center pin :

T1: 230 N-m (23.5 kgf-m) (169 lb-ft)
T2: 422 N-m (43.0 kgf-m) (311 lb-ft)
T1
L1: With lubrication oil (Engine oil or gear oil)
Bearing cover
Center pin shim adjustment
Shim
adjustment
Adjust the clearance to 0.1±0.05 mm (0.0039±0.0020
Front chassis in) using the shim. After that, tighten bolt (T1).
Rear chassis
T2 L1
90V2E14027
T1
Shim
T2 L1
90V2E14028
14-21
Center Pin
Lower center pin
Front chassis
Bearing outer
ring
Rear chassis
90V2E14029
85V2E14032
14-22
Center Pin
Center pin removing and installing

Center pin removing
3
WARNING Rear
chassis
Unexpected movement of the machine could cause 4
Front
observe the following items before starting center pin chassis
removal:
Steering cylinder
- Place the machine on level and paved ground.
- Lower the attachment onto the ground, and block 90ZV14026
the front tires with chocks, etc. to prevent them
from moving.
- Apply the stopper to the rear wheel oscillation sec- 2. Remove right and left steering cylinder retainer pins
tion to prevent the machine from oscillation. (3) and shims (4).
- Release the residual pressure from the hydraulic
line, and also release the internal pressure from Note
the hydraulic tank. Wrap the steering cylinder rods to prevent accidental
- Cover the steering cylinder rod to prevent it from damage to the chrome rods.
being scratched.
3. Disconnect the hose. Disconnect the electrical line
from the couplers.
Note
Transmission Cover the disconnected hoses with vinyl to protect the
K90V2E14008
1. Remove bolt (1) and disconnect second propeller 5

shaft (2).
: Bolt (1): 142 N-m (14.5 kgf-m) (105 lb-ft) 90ZV14027
: Screw lock agent application

(Three Bond 1327) 4. Remove the upper center pin retainer bolt (5).
Note : Bolt (5): 422 N-m (43.0 kgf-m) (311 lb-ft)
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 cou-
pling. Do not reuse the bolts, always replace with new
ones.
14-23
Center Pin
Jack screw
90ZV14029 90ZV14031
7. Before disconnecting the front chassis from the

rear chassis, be sure to sling the rear chassis using
Remover bolt: M12 (Pitch 1.75), totally threaded a crane (apply the rope to hook (8)) so that the rear
chassis will not fall backward.
M12 x 1.75
WARNING
When using a crane, insufficient signal and sling
70 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
65ZV14011 improper sling.
- Use the signals as agreed upon before starting
work.
5. Screw the M12 (Pitch 1.75) bolt of approximately
- Stay out of the working area while using a crane.
70 mm (2.76 in) length into the center of bushing
(6) to push out the bushing. This bolt is used as a
jack screw.
By Jack
Jack 90ZV14032
90ZV14030
8. Push out upper center pin (9) using a jack or
"Porto-power".
6. Before disconnecting front chassis (7) from the rear
chassis, be sure to support the front chassis using
the jack and blocks so that the front chassis will not
fall backward.
14-24
Center Pin
10
By Jack 12
90ZV14033
11
9. While supporting the bottom of the fuel tank using a
garage jack, remove the lock bolt from the lower
center pin (10), and then push out the lower center 13
pin (10) using another jack to remove the pin.
WARNING
14
Chassis separation is dangerous work. To ensure
your safety, be careful in doing this work.
90ZV14035
Front
Bar
90W14014
Grease nipple
installation direction
10. Slowly turn the rear tires both the right and the left 90ZV15002
sides using a bar to separate the rear chassis.
Note 11. Remove ring (11).

While turning the rear tires, check that the garage jack
under the fuel tank shifts backward together with the 12. Remove bolts (12) from bearing cover (13).
rear chassis. In addition, adjust the height using the rear
crane whenever the height adjustment is necessary. : Bolt (12): 230 N-m (23.5 kgf-m) (169 lb-ft)
14-25
Center Pin
WARNING
When the chassis is separated, unless the support Bearing outer ring
for the chassis is sufficient, it could cause an accident
resulting in injury or death. Front Rear
To prevent such an accident, observe the following
items:
- Make sure the blocks, support and jack are placed
in the right position to properly support the chassis.
Split of outer bearing
13. Remove shim (14). Grease nipple installation direction 90ZV14037
Note
If the taper roller bearing is replaced, be sure to adjust 15. When the spherical bearing for the lower center pin
the clearance using shims. is replaced, install the bearing outer ring so that the
Thickness of shim: 0.1, 0.2, 0.3, 0.5, and 1.0 mm split is perpendicular to the front - rear line of the
(0.004, 0.008, 0.012, 0.020 and 0.040 in) machine.
14. Replace the dust seals in the upper center pin and
the lower center pin with new ones.
Center pin installing

order.
(Top) (Bottom)
Center pin installation cautions
- After reinstallation, grease the center pins, and oper-

ate them. During operation, check the pins for abnor-
mal noise and looseness.
90ZV14036
- Be sure to completely bleed the brake of air.
For air bleeding procedure, refer to the Section 24.
- Check each section for oil leakage.
Note - No oil leakage should be found in any part.
Take care of the correct direction of dust seals as shown
above.
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.
14-26
Partition Plate
Partition Plate
Partition plate removing and

installing 6 7
8
Partition plate removing

3
5
WARNING 2
observe the following items before starting center pin
removal: 10 1
4 9
- Place the machine on level and paved ground.
the front tires with chocks, etc. to prevent them
from moving.
- Apply the stopper to the rear wheel oscillation sec-
tion to prevent the machine from oscillation. Fan motor bracket
- Release the residual pressure from the hydraulic
line, and also release the internal pressure from
the hydraulic tank.
- Apply the parking brake, remove the starter key,
and hang a "DO NOT START ENGINE!" tag on the
steering wheel.
90V2E14030
Note
The partition plates should be removed prior to other
parts and/or units around, and there is very limited 1. Remove bolt (1) and nut (2) to remove partition
space for the partition plates to take them out. When plate (3).
removing the partition plates, take care so that the plate : Partition plate (3): 4.5 kg (9.5 lbs)
does not damage the fan motor, engine, etc.
2. Remove bolt (4) and nut (5) to remove partition
plate (6).
: Partition plate (6): 4.5 kg (9.5 lbs)
3. Remove nut (7) to remove partition plate (8).

4. Remove bolt (9) to remove partition plate (10).

Partition plate installing
For reinstallation, follow the above procedures in

reverse order.
15-1
90ZV-2 Service Standard Chassis Group
90ZV-2 Service Standard

Chassis Group
Linkage.................................................................... 15-2
Linkage Pin Standard Clearance Values ................. 15-3
Center Pin ............................................................... 15-4
Attachment Leveler ................................................. 15-6
15-2
Linkage
Linkage
1. Attachment - Boom 2. Boom - Lever 3. Boom - Boom cylinder mm (in)
4. Front chassis - Boom 5. Attachment - Link 6. Lever - Link
7. Lever - Bucket cylinder 8. Bucket cylinder - 9. Boom cylinder -

Front chassis Front chassis
10. Front chassis - 11. Steering cylinder -

Steering cylinder Rear chassis
8 4
7 3
5
10 11
6 9
1 90ZV12002
15-3
Linkage Pin Standard Clearance Values
Linkage Pin Standard Clearance Values
Unit: mm (in)
Judgment standard
No. Item Solution

Pin standard
Standard clearance Tolerance
dimension
ø90 0.117~0.237 1.0

* 1 Joint section between attachment and boom
(ø3.5433) (0.0046~0.0093) (0.0393)
Replacement
ø100 0.117~0.242 1.0

2 Joint section between boom and lever Replacement
(ø3.9370) (0.0046~0.0095) (0.0393)
ø90 0.117~0.237 1.0

3 Joint section between boom and boom cylinder Replacement
(ø3.5433) (0.0046~0.0093) (0.0393)
ø110 0.119~0.244 1.0

4 Joint section between front chassis and boom Replacement
(ø4.3307) (0.0046~0.0096) (0.0393)
ø60 0.098~0.202 1.0

* 5 Joint section between attachment and link
(ø2.3622) (0.0038~0.0079) (0.0393)
Replacement
ø60 0.098~0.202 1.0

* 6 Joint section between lever and link
(ø2.3622) (0.0038~0.0079) (0.0393)
Replacement
ø80 0.101~0.217 1.0

7 Joint section between lever and bucket cylinder Replacement
(ø3.1496) (0.0039~0.0085) (0.0393)
ø80 0.101~0.217 1.0

8 Joint section between bucket cylinder and front chassis Replacement
(ø3.1496) (0.0039~0.0085) (0.0393)
ø90 0.117~0.237 1.0

9 Joint section between boom cylinder and front chassis Replacement
(ø3.5433) (0.0046~0.0093) (0.0393)
ø50 0.085~0.178 1.0

* 10 Joint section between front chassis and steering cylinder
(ø1.9685) (0.0033~0.0070) (0.0393)
Replacement
ø50 0.085~0.178 1.0

* 11 Joint section between steering cylinder and rear chassis
(ø1.9685) (0.0033~0.0070) (0.0393)
Replacement
Liner clearance adjustment 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.
95ZV12005
Wear then occurs on the liners and reduces wear on the
chassis. Excessive vertical free play in the steering cyl-
inders can result in loud knocking noises when the
steering wheel is turned.
15-4
Center Pin
Center Pin
Center pin shim adjustment Bearing cover installing
T1
Front
Bearing cover
Shim
adjustment
Front chassis
Grease nipple
installation direction
90ZV15002
Rear chassis
T2 L1 Install the bearing cover so that the grease nipple

mounting hole is positioned at the specified angle as
90V2E14027
shown in the right figure.
The clearance between the front chassis and bearing

cover 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).
:
T1: 230 N-m (23.5 kgf-m) (169 lb-ft)
T2: 422 N-m (43.0 kgf-m) (311 lb-ft)

15-5
Center Pin
Lower center pin bearing outer

ring installing
Front chassis
Bearing outer
ring
Rear chassis
90V2E14029
Bearing outer ring
Front Rear
Split of outer bearing
Grease nipple installation direction 90ZV14037
Install the bearing outer ring so that the split is perpen-

dicular to the front-rear line of the machine.
15-6
Attachment Leveler
Attachment Leveler
Attachment leveler
90V2E15002
15-7
Attachment Leveler
Attachment leveler
Adjusting plate Angle

5 Direction of indicator lamp
Indicator lamp
Proximity switch
2
4
Angle
2.5 mm
5 2
3
1
92V2E15001
Attachment leveler adjustable angle
-7º 0 +10º
Adjusting length: 6 mm (0.236 in) 58 mm (2.283 in) 134 mm (5.275 in)
K90ZV15001
No. Item Judgment standard Solution
1 Clearance of attachment leveler switch 5±2 mm (0.196±0.078 in) Adjustment
2 Adjusting plate mounting bolt tightening torque 94 N-m (9.6 kgf-m) (69 lb-ft) Tightening
3 Switch mounting nut tightening torque 20 N-m (2.0 kgf-m) (14 lb-ft) Tightening
4 Angle mounting bolt tightening torque 53 N-m (5.4 kgf-m) (39 lb-ft) Tightening
5 Attachment leveler adjustable angle (distance ∗) -7º~+10º (6~134 mm) (0.236~5.275 in) Adjustment
15-8
MEMO
24-1
90ZV-2 Disassembly & Reassembly Power Group

Power Group
Power Line .............................................................. 24-2

Radiator................................................................... 24-3
Fan .......................................................................... 24-9
Engine ..................................................................... 24-11
Propeller Shaft......................................................... 24-14
Air Cleaner .............................................................. 24-16
Muffler ..................................................................... 24-18
Front Axle Assembly ............................................... 24-20
Internal Gear Hub.................................................... 24-35
Spider Assembly ..................................................... 24-38
Special Tool ............................................................. 24-40
Rear Axle Assembly ................................................ 24-44
Axle Support............................................................ 24-49
Differential Assembly............................................... 24-52
24-2
Power Line
Power Line
Power line tightening torque
T1 L1 Engine
T3 L1
T6 L3
T3 L1
Rear chassis
T1 L1
T5 L3
Transmission
Rear differential
T4 L2
T2 L1 3rd propeller shaft
Front differential T4 L2
T4 L2
2nd propeller shaft
K90V2J24001
:
T1: 441 N-m (45 kgf-m) (325 lb-ft) L1: Screw lock agent (Loctite® 262)
T2: 417 N-m (42.5 kgf-m) (307 lb-ft) L2: Screw lock agent (Three Bond 1327)
T3: 230 N-m (23.5 kgf-m) (170 lb-ft) L3: With lubrication oil (Engine oil or gear oil)
T4: 142 N-m (14.5 kgf-m) (105 lb-ft)
T5: 67 N-m (6.8 kgf-m) (49 lb-ft)
T6: 53 N-m (5.4 kgf-m) (39 lb-ft) Always replace drive shaft bolts with new ones - never
reuse them.
24-3
Radiator
Radiator
Radiator tightening torque

(S/N 9001~9200)
T4 L2
T1 L1
Fan guard
Radiator
Fan motor T2 L2
T2 L2 T3 L1
Rear chassis
T2 L2
Fan
T2
90V2E24002
:
T1: 230 N-m (23.5 kgf-m) (170 lb-ft)
T2: 94 N-m (9.5 kgf-m) (69 lb-ft)
T3: 74 N-m (7.5 kgf-m) (54 lb-ft)
T4: 49 N-m (5.0 kgf-m) (36 lb-ft)
L1: Screw lock agent (Loctite® 262)

24-4
Radiator
(S/N 9201~)
T4 L2
T1 L1
Fan guard
Radiator
T2 L2
T2 L2 T3 L1
Fan motor
Fan
T2 L2
T2
Rear chassis
K90V2J24002
:
T1: 230 N-m (23.5 kgf-m) (170 lb-ft)
T2: 94 N-m (9.5 kgf-m) (69 lb-ft)
T3: 74 N-m (7.5 kgf-m) (54 lb-ft)
T4: 49 N-m (5.0 kgf-m) (36 lb-ft)
L1: Screw lock agent (Loctite® 262)

24-5
Radiator
Radiator removing and installing

2
Radiator removing
WARNING
an accident resulting in injury or death. To prevent
1
such an accident, observe the following items:
- Park the machine on level ground. Rear chassis
- Apply the articulation stopper.
- Block the front wheels with chocks or the like to 90ZV24003
prevent the wheels from moving.
- Before starting work, be sure to remove the engine
key, and hang a "DO NOT START!" tag on the 1. Remove bolt (1).
steering wheel, or disconnect the negative side of
the battery. : Bolt (1): 230 N-m (23.5 kgf-m) (170 lb-ft)
2. Sling radiator guard (2), and then remove it.

IMPORTANT
: Radiator guard: 90 kg (200 lbs)
3. Drain the coolant from the engine and the radiator.
: Coolant: 63 L (16.7 gal)
<S/N 9001~9200>
Note:
Before starting work: Oil/air coolers are not shown.
- Remove the engine roof (Refer to Section 14).
- Remove the partition plates (Refer to Section 14).
- Remove the fan guard (Refer to "Fan" pages within
this section). For easier work, release or remove the 8
duct and the fan.
7
Radiator
4
3
Engine
Drain line
K90V2U24002
24-6
Radiator
<S/N 9201~> Radiator 5

3
Air cooler
9
Sub tank
10
6
Engine
K90V2U24003
5. Disconnect air cooler hoses (9)(10) from the air

cooler.
Engine
: Hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft)
7
Note
- Cover the disconnected hoses and air cooler open-
ings with caps, plugs, or vinyl to protect them from
dust and dirt.
8 - During reassembly, carefully inspect and clean the
hoses and air cooler of any contamination as it will
K90V2E24001
go directly into the engine causing extensive engine
damage.
4. Disconnect coolant hoses (3)~(8) from the radiator.
Fuel cooler
Note 13
11
To E/G
From
fuel tank
12
K90Z524013
6. Remove hoses (11)(12) from the fuel cooler.

Remove bolt (13) and then remove the fuel cooler.
: Bolt (13): 53 N-m (5.4 kgf-m) (39 lb-ft)

: Fuel: 1.5 L (0.4 gal)
Note
24-7
Radiator
<S/N 9001~9200>
Radiator Radiator
Transmission
17
13
Oil cooler
14
11 T/C oil cooler
(bottom unit)
16
14
15
12
(FM) (FM)
K90Z524007 90ZV24007
7. Remove hoses (14)(15) from the hydraulic cooler. T/C oil cooler
<S/N 9201~>
: Hydraulic oil: 3 L (0.8 gal)
16
13
Transmission
Note
17 Radiator
14
(FM)
K90V2J24007
8. Disconnect hose (16)(17) from the torque converter

oil cooler.
: Torque converter oil: 3 L (0.8 gal)
Note
24-8
Radiator
<S/N 9001~9200> Radiator installing

16
Rear chassis
order.
15
17 Radiator installation cautions
K90V2U24004
Clearance
<S/N 9201~>
19
18
K90V2J24009
20
Reinstall the radiator while checking that the right and
left clearances between the fan and the radiator guard
K90V2E24005
are equal at both sides.
9. Temporarily sling radiator (18).

Remove the right and left retainer bolts (19)(20),
and then lift the radiator.
: Radiator:
365 kg (805 lbs) (S/N 9001~9200)
230 kg (510 lbs) (S/N 9201~)
: Bolt (16): 49 N-m (5.0 kgf-m) (36 lb-ft)
: With lubricating oil (Engine oil or gear oil)
: Bolt (17): 230 N-m (23.5 kgf-m) (170 lb-ft)
: Screw lock agent (Loctite® 262) application
24-9
Fan
Fan
Fan removing and installing <S/N 9001~9200>

4
Fan removing 3
2
WARNING
If a person starts the engine without informing the
service man who is repairing the machine, an acci- 1
dent resulting in injury or death could occur. To pre-
vent such an accident:
key, and hang a "DO NOT START!" tag on the 90V2E24006
the battery.
<S/N 9201~>
4
IMPORTANT
3
less than 30 seconds after the key is put into the 2
1
- Remove the engine roof (Refer to Section 14). K90V2E24006
- Remove the partition plates (Refer to Section 14).

1. Remove bolts (1)(2) and remove fan guards (3).
Take the fan guards out of the machine.
Note
Removing the radiator grill may help the following work.
2. Disconnect the coolant hose at the top middle of

radiator (4) and either left or right air cooler hose
(5).
Note
The hoses from the water tank should be disconnected
on machines S/N 9201 and thereafter.
24-10
Fan
Fan installing
5
9
See the
Radiator order.
details below.
7
6
Fan installation cautions
8
K90V2J24011
Clearance
3. Remove bolts (6) and release fan motor bracket (7)

from the base bracket (8). Slide it to the engine side
to make clearance between the fan.
: Bolt (6): 94 N-m (9.55 kgf-m) (69 lb-ft)

: With lubrication oil (Engine oil or gear oil)
K90V2J24009
Reinstall the fan while checking that the right and left
Fan motor
clearances between the fan and the radiator shroud are
equal at both sides.
10 Refer to "Fan Motor" page 44-76 to remove and/or dis-
assemble the fan motor.
K90V2J24012
4. Remove retainer bolts (10) for fan (9).
: Bolt (10): 94 N-m (9.55 kgf-m) (69 lb-ft)

5. Sling fan (9) and take it out from the top opening.
: Fan: 17 kg (38 lbs)
Note
Carefully remove the fan while checking that the fan will
not damage the radiator fins. Inspect the fan and
replace it if there are any signs of damage or cracks.
Fan blade breakage can cause extensive damage.
24-11
Engine
Engine
Engine removing and installing

Engine removing
WARNING 1
such an accident, observe the following items: -
- Park the machine on level ground.
- Apply the articulation stopper. +
Battery
- Block the front wheels with chocks or the like to K90V2J24033
key, and hang a "DO NOT START!" tag on the IMPORTANT
steering wheel.
Before starting work: which can disable the engine. Always wait 1 full
- Remove the engine room (Refer to Section 14). minute to be sure to be past this “write to memory
- Remove the partition plates (Refer to Section 14). function” prior to removing battery terminals.
- Remove the floor board with the cab (Refer to Sec-
tion 14).
- Remove the fan guard and the fan (Refer to "Fan" 1. Disconnect the negative side of battery cable (1).
pages in this section). Then remove the positive cable.
- Collect the air conditioner refrigerant (option) using
the proper recovery method. 2. Remove the wires from the alternator, starter motor
- Drain engine oil and the oil pressure switch.
: Engine oil: Approx. 37 L (10 gal) Remove the connector for the engine pressure
switch, tachometer and the coolant temperature
gauge.
Disconnect the heater hose and the fuel hose also
disconnect the air conditioner lines from the com-
pressor.
3. Remove the engine oil drain hose.

24-12
Engine
90ZV24141
6. Remove two block mounting bolts (3) (both sides).
: Bolt (3): 441 N-m (45 kgf-m) (325 lb-ft)

7. Disconnect the 2nd propeller shaft and the 3rd pro-

peller shaft from the transmission assembly.
8. Carefully lift the engine and the transmission

assembly while checking that there are no obsta-
cles around them.
90ZV24140
: Engine and transmission assembly:

4. Temporarily sling the engine and the transmission 1,850 kg (4,070 lbs)
assembly.
9. Remove the engine and the transmission assembly
: Engine and transmission assembly: from the rear chassis.
1,850 kg (4,070 lbs) Place them on the stand.
Engine
K90V2J24015
5. Remove engine assembly mounting bolts (2).
: Bolt (2): 441 N-m (45 kgf-m) (325 lb-ft)

24-13
Engine
Engine installing

4 order.
Engine installation cautions
8
5 90ZV24017
10. Remove four bracket mounting bolts (4) (both

sides) on the flywheel side.
Loosen four bracket mounting bolts (5) (both sides)
7
on the transmission side.
: Bolt (4)(5): 230 N-m (23.5 kgf-m) (170 lb-ft)

90ZV24019
Note
Take care not to loosen bolt (5) too much.
- There is O-ring (7) in the housing between the
engine and torque converter. Be sure to replace the
O-ring with a new one, and apply liquid gasket.
: Liquid gasket (Three Bond 1215) application
6
- Make sure that bushing (8) is installed.
- Refill the engine with the proper quantity and type

engine oil.
- After reinstalling the engine, completely bleed the

fuel line of air.
90ZV24016
- Calibrate throttle pedal to ECM.
(a) Turn the starter switch to “ON”.
(b) Fully depress and release the throttle pedal three
11. Sling the engine assembly and remove bolts (6) times.
from the housing between the engine flywheel and (c) Turn the starter switch to “OFF”.
transmission.
- Set the starter key to ON, and then check the moni-
: Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) tor lamps of electrical equipment.
: Engine assembly: 950 kg (2,100 lbs)
- Operate the engine at the idling speed for 5 minutes.
12. Move the engine assembly back side to disengage After that, check the amount of the coolant.
the flywheel ring gear.
- While gradually increasing the engine speed, check
13. After confirming that the ring gear is disengaged, operation of the electrical equipment.
remove the engine assembly by lifting it slowly.
24-14
Propeller Shaft
Propeller Shaft
Propeller shaft removing and

installing
4 1
Second propeller shaft removing
5
3
WARNING
Unexpected movement of the machine could cause 2
- Apply the articulation stopper. K90V2E24007
- Block the front wheels with chocks or the like to
1. Remove bolt (2) from the transmission side of pro-
peller shaft (1).
key, and hang a "DO NOT START!" tag on the
: Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft)
the battery.
(Three Bond 1327)
IMPORTANT 2. Disconnect the grease pipe, and remove bolt (4)
If a battery terminal is removed from a machine in from pillow unit (5).
“OFF” position, it can corrupt the ECM program, : Bolt (4): 417 N-m (42.5 kgf-m) (307 lb-ft)
which can disable the engine. Always wait 1 full : Screw lock agent (Loctite® 262) application
function” prior to removing battery terminals. 3. Remove bolt (3) to disconnect the propeller shaft
from the front differential. Support the shaft by
cable or garage jack. Take out the second propeller
shaft to the front.
: Bolt (3): 142 N-m (14.5 kgf-m) (105 lb-ft)

(Three Bond 1327)
: Second propeller shaft: 75 kg (165 lbs)
Note
If the retainer bolt is too tight due to the screw lock
burner.
Keep the flame away from the seals of the coupling.
Do not reuse the bolts, always replace with new ones.
24-15
Propeller Shaft
Third propeller shaft removing Propeller shaft installation cautions
Rear differential
Transmission
Transmission Engine
3rd propeller shaft
6
2nd propeller shaft 3rd propeller shaft
K90V2U24005 90V2E24009
1. Remove bolt (6). During reinstallation, align the direction of the flange
yokes on the second and third propeller shaft sides of
: Bolt (6): 142 N-m (14.5 kgf-m) (105 lb-ft) the transmission. (Refer to Section 22)
: Screw lock agent application [Difference in the yoke phase (direction) will cause the
(Three Bond 1327) propeller shaft damage and "knocking" during a turn.]
2. Remove the third propeller shaft.
: Third propeller shaft: 15 kg (35 lbs)
Propeller shaft installing

order.
24-16
Air Cleaner
Air Cleaner
Air cleaner removing and installing

5
Air cleaner removing 1
6
3
WARNING
4
an accident resulting in injury or death. To prevent 2
- Block the front wheels with chocks or the like to 90ZV24022
key, and hang a "DO NOT START!" tag on the 1. Release wing nut (1), and then, remove cover (2).
the battery. 2. Release wing nut (3), and then, remove outer ele-
ment (4).
IMPORTANT 3. Release wing nut (5), and then, remove inner ele-
ment (6).
less than 30 seconds after the key is put into the 4. Remove the rubber valve on the bottom of the air
“OFF” position, it can corrupt the ECM program, cleaner case, and inspect it for any damage.
which can disable the engine. Always wait 1 full Replace it if necessary.
function” prior to removing battery terminals. Note
Removing inside elements reduces the weight and
makes air cleaner case removal work easier.
A K90Z524003
5. Disconnect indicator wire coupler (8).

Disconnect air duct (7) by loosening hose bands
(A)(B).
Inspect duct (7) and replace it if there is any dam-
age or wear.
24-17
Air Cleaner
Air cleaner installing

Precleaner
(option)
order.
9
10
Air cleaner installation cautions
[Hose band A]
2~3 mm (1/8 in)
5 mm (1/4 in) or less
90V2E24010
Fix the bands
6. Remove cover (10) from the top of screen board
Air hose
(9).
Note
The precleaner is an optional unit.
50±5 mm (2±1/5 in)
12
K85V2U24005
[Hose band B]
2~3 mm (1/8 in)
Screen board
Fix the bands
11 avoiding the beading
Air hose
90ZV24025
(Air cleaner or Engine)

7. While supporting air cleaner case (11) with your Insertion amount:
hand, remove band retainer nuts (12), and then 35 mm (1 1/2 in)
K90Z524004
lower the air cleaner case.
Note
If the bands of the air duct are not properly positioned or
tightened, the duct will draw in dust that will cause an
engine problem. Carefully reinstall the air duct.
13
90ZV24026
8. Take out air cleaner case (13) from the opening.

24-18
Muffler
Muffler
Muffler removing and installing

4
Muffler removing
CAUTION
You may get burned if you remove the muffler before
the engine is cold enough. To prevent such an inci- 3
dent, be sure to stop the engine, and open the 5
access panels.
Start the muffler removal work when the engine is
cold enough. K90V2U24007
3. Remove U-clamp (3) and remove exhaust pipe (4).

Also disconnect drain pipe (5).
2 (S/N 9001~9200)
1
7 6
6
Engine roof
Muffler
K90V2U24006
1. Remove bolt (1) and then remove exhaust pipe (2).

90V2E24013
: Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft)

(S/N 9201~)
2. Remove the engine roof by referring to Section 14. 7 6
: Engine roof: 25 kg (55 lbs)

6
K90Z524015
4. Remove retainer bolt (6) for muffler (7), and lift it for
removing.
: Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft)

: Muffler: 23 kg (50 lbs)
24-19
Muffler
Muffler installing

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

and vibration.
24-20
Front Axle Assembly
Front Axle Assembly
Front axle assembly tightening torque
T2 L2 T4 L1
Floating seal
Front differential
T7
T9
T7
T7
B
A T8 L1
T3 L1
T7
T1
T6
T5 L1
90V2E24015
:
T1: 892 N-m (91.0 kgf-m) (658 lb-ft) L1: Screw lock agent (Three Bond 1327) application
T3: 216 N-m (22 kgf-m) (159 lb-ft)
T4: 132 N-m (13.5 kgf-m) (98 lb-ft)
T5: 90 N-m (9.2 kgf-m) (67 lb-ft)
T6: 86 N-m (8.8 kgf-m) (64 lb-ft)
T7: 78 N-m (8.0 kgf-m) (58 lb-ft)
T8: 53 N-m (5.4 kgf-m) (39 lb-ft)
T9: 33 N-m (3.4 kgf-m) (25 lb-ft)
24-21
Front Axle Assembly
Axle nut tightening procedure Floating seal installing
1. Tighten axle nut (A) with 1,765 N-m (180 kgf-m) Use jig to install the floating seal to the axle assembly.
(1,300 lb-ft) tightening torque to install the taper
roller bearing. Refer to Front axle assembly, "Front axle assembly cau-
tions" page 24-30 for details.
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):

226~265 N (23~27 kgf) (50~59 lbf)
Note
This is "breakaway" force, which is required to start the
wheel turning.
A
Axle housing extension
K90Z524005
Reference
The distance (B) between axle nut (A) surface and the
axle housing extension edge falls in the range of
1.34~2.46 mm (0.053~0.097 in).
24-22
Front Axle Assembly
Front axle assembly removing and

installing 3
Front axle assembly removing
WARNING
- Apply the parking brake and the articulation stop- 90ZV24033
per.
3. Remove right and left wheel and tire assemblies
(3).
Boom lock collar : 1 tire: 670 kg (1,480 lbs)
: Retainer bolt:
892 N-m (91.0 kgf-m) (658 lb-ft)
Stand 1
Stand
90ZV24030
Front axle
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.
90ZV24031
Lift the boom until it is horizontal. Place a stand
under the boom to support it or install a boom cylin-
der lock collar. 4. Disconnect air breather tube (1) from the upper part
of the axle housing.
2. Press the hydraulic tank oil filler cap to release the
trapped tank pressure. Note
Release the accumulator pressure, by slowly and Clean the nylon breather tube before reinstalling.
fully depressing and releasing the brake pedal at
least 40 times.
24-23
Front Axle Assembly
6
K90V2E24008 90ZV24035
5. Remove second propeller shaft retainer bolt (2). 7. Temporarily sling axle assembly (5), and then
remove eight retainer bolts (6).
: Bolt (2): 142 N-m (14.5 kgf-m) (105 lb-ft)
: Screw lock agent application : Bolt (6): 721 N-m (73.5 kgf-m) (532 lb-ft)
(Three Bond 1327) : Axle assembly: 1,230 kg (2,720 lbs)
Note
During reassembly be sure both mating surfaces are
clean and free of paint.
Bracket
90ZV24142
Disc brake
6. Disconnect brake pipes (4).
90V2E24016
Note
Cover the disconnected pipes with plastic caps or vinyl
to avoid the dirt from entering the pipes or fittings. 8. Remove four bolts (7) for the disc brake bracket
and remove the bracket with the whole disc brake
caliper.
9. Place axle assembly (5) on a carrier or garage jack

with special carrier to smoothly pull out the assem-
bly.
Front axle assembly installing

order.
24-24
Front Axle Assembly
Front axle assembly installation cautions
After reinstallation, completely bleed air in the service

and parking brake lines.
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.
24-25
Front Axle Assembly
Air bleeding procedure

4. Slightly loosen the air bleeder nipple, and then
press the brake pedal several times. When the oil
Service brake air bleeding procedure flows from the air bleeder nipple, close the nipple.
After that, each time you press the pedal, open the
IMPORTANT air bleeder nipple to slightly discharge oil, and then
immediately close the nipple.
Before bleeding the service brake, it is important to Repeat this until there is no air in the oil. Com-
remove all air from the brake valve manifold block, pletely bleed each wheel of air.
and all related valves.
These include the reducing valve and park brake : Air bleeder nipple:
valve. Failure to do this correctly will result in unsatis- : 9 N-m (0.9 kgf-m) (6.5 lb-ft)
factory brake modulation.
1. Start and run the engine to build brake accumulator Secondary parking brake air bleeding proce-
pressure. Shut "off" the engine. Rebuild brake dure
accumulator pressure as often as needed.
Front
Valve assembly
Parking disc brake

Solenoid valve
Front differential
release knob
Rear chassis Air bleeder nipple

90V2E24050
Installation position 90Z552002
1. Start and run the engine to build brake accumulator

2. Turn the parking brake solenoid valve release knob pressure. Shut "off" the engine.
counterclockwise, then back to neutral five times at
5-second interval between each turn. Position this 2. Connect a clean vinyl tube to the air bleeder nipple,
back to the normal position when finished. and place an oil can to receive the oil, or route to
hydraulic tank.
3. Slightly loosen the air bleeder nipple, and then

Air bleeder nipple
push and pull the parking brake switch several
times. When the oil flows from the air bleeder nip-
ple, close the nipple.
4. After that, each time you push the parking brake

switch, open the air bleeder nipple to slightly dis-
charge oil, and then immediately close the nipple.
Vinyl tube
5. Repeat this until there is no air in the oil.
70ZV52019
Note
Refer to 90ZV-2 Shop Manual Function & Structure,
3. Connect a clean vinyl tube to the air bleeder nipple, Section 52 for the detailed procedures.
and place an oil can to receive the oil, or route to
hydraulic tank.
24-26
Front Axle Assembly
Front axle disassembling and

assembling 1
Front axle disassembling
WARNING
Unexpected movement of the machine or compo-
nents could cause an accident resulting in injury or
death. To prevent such an accident, observe the fol-
lowing items:
- Park the machine on level ground, and then apply 90ZV24052
the parking brake.
3. Remove wheel and tire assembly (1) from the side
- Block the rear wheels with chocks or the like to
to be disassembled (example: left side).
: Tire of 1 wheel: 670 kg (1,480 lbs)
Boom lock collar : Retainer bolt:

892 N-m (91.0 kgf-m) (658 lb-ft)
Stand
Stand
90ZV24030

2 Differential section
90ZV24053
attachment. Place a stand under the front chassis
to support it. Check that the tires are off the ground.
Lift the boom until it is horizontal. Place a stand 4. Remove drain plug (2) from the differential section
under the boom to support it or install a boom cylin- to drain oil.
der lock collar.
: Gear oil: Approx. 42 L (11.1 gal)
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 at
least 40 times.
24-27
Front Axle Assembly
A
7
6
TOP
3
4
90ZV24054 90ZV24056
5. Turn drain plug (4) to the bottom of wheel hub (3) to 7. Temporarily sling the spider using hoisting tool (A).
drain oil. Remove four spider retainer bolts (6) to remove spi-
der assembly (7).
: Gear oil: Approx. 32 L (8.4 gal)
: Bolt (6): 86 N-m (8.8 kgf-m) (64 lb-ft)
Note : Spider assembly: 100 kg (220 lbs)
To replace the oil, refer to the oil amount described
below. Note
The brake backing plate is fixed behind the spider
: Wheel hub section: assembly. Do not forget the brake backing plate when
16 L (4.2 gal) for left side, reinstalling the spider assembly.
16 L (4.2 gal) for right side
Differential section (front): 42 L (11.1 gal)

Total oil amount for front axle: 74 L (19.5 gal)
9
Reference
Differential section (rear): 48 L (12.7 gal) 8
Total oil amount for rear axle: 80 L (21.1 gal)
TOP
10
90ZV24057
8. Remove snap ring (8), and then remove sun gear

(9).
5 9. Remove friction plate (10) and the steel plate (sep-

aration disc) behind.
90ZV24055
Note
Friction plate (10) is changed from S/N 9074~.
6. Remove cover (5).
: Retainer bolt: 90 N-m (9.2 kgf-m) (67 lb-ft)

(Three Bond 1327)
24-28
Front Axle Assembly
Turnbuckle
11
E
10
12
90V2E24017 90ZV24060
10. Remove another set of friction plate (10) and steel 12. Turn wheel hub (3) until the drain plug is positioned
plate (11), and disc gear (12). on the top. Connect the turnbuckle to eye bolt (E) to
lock the wheel hub, and then place a wooden block
Note under the wheel hub to support it.
Clean the brake plates, and then check the plates for
distortion, discoloration and wear. Note
Refer to the following section 55 (Brake Group) and Be sure to lock the wheel hub, or the hub will drop when
90ZV-2 Shop Manual Function & Structure, Section 52 the axle nut is removed and the internal gear hub is
for additional information. removed.
13 16
15
17
14
90ZV24059 90ZV24061
11. Remove axle shaft (13) and wear ring (14). 13. Remove axle nut (17).
Remove retainer bolts (15), and then remove lock
plate (16). Refer to "Axle nut tightening procedure" page 24-
21.
: Bolt (15): 53 N-m (5.4 kgf-m) (39 lb-ft)
: Screw lock agent application : Nut (17):
(Three Bond 1327) 1,765 N-m (180 kgf-m) (1,300 lb-ft)
Width across flat: 120 mm (4.72 in)
Note
When reassembling axle shaft (13) into the axle hous-
ing, applying the principle of leverage, insert axle shaft
(13) while making sure the toothing between the side
gear of the differential and shaft (13).
24-29
Front Axle Assembly
Extension D
E
3
19
Jig (B)
18
Wooden block Wooden block

K90ZV24062 K90ZV24064
14. Pull out internal gear hub (18) to the extension end 16. Install wheel hub hoisting tools (D) and (E) and
face using internal gear hub puller (B). remove the turn buckle.
Then remove wheel hub (3).
17. Remove taper roller bearing (19).
18 Note
For easy removal, heat the inner race using a gas
burner with slow flame.
Front axle assembling
Wooden block To reassemble the front axle, follow the above proce-
K90ZV24063
dure in reverse order.
15. Sling internal gear hub (18) using internal gear hub
hoisting tool (C), and remove hub (18).
24-30
Front Axle Assembly
Front axle assembly cautions

Ring
IMPORTANT
- Replace all the O-rings and seals with new ones.
- Clean and check all the parts. If a part is damaged,
replace it.
Remove oil
Floating seal installing
1. Checking before floating seal installation

Put thin gear oil
Bearing (Do not use grease)
O-ring
Wheel hub
O-ring
Axle
housing
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.
Seal ring Ring

Note
90ZV24065
The rotating ring and the fixing ring are exactly the
same. They can be used on either side.
(a) Checking seal
- Check the seal ring for distortion and scratches.
- Check the O-ring for scratches. 2. Assemble the floating seal as follows.
(b) Check the wheel hub and the ring for burr. If any (a) In case no jig is used.
remove it by sand paper etc.
- 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 sub-
assembly)
- Check if the seal ring is correctly positioned or the O-
ring is not twisted.
- Clean the surface and put thin gear oil on it.
- Install the ring, bearing and the wheel hub to the axle
housing.
24-31
Front Axle Assembly
(b) In case jig (F) is used
Guide jig
1 2
3
70ZV24095J
Before installation
1. Wheel hub 95ZVE24011
2. Guide jig
3. Installation jig
4. Floating seal
Guide jig Installation jig
- 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 hous-
ing.
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.
24-32
Front Axle Assembly
Internal gear hub installing Axle nut tightening
Spring pin
18
17
90ZV24072 90ZV24073
Internal gear hub assembly

1. Tighten axle nut (17) with 1,765 N-m (180 kgf-m)
roller bearing and, after that, once loosen axle nut
Brake oil
holes at 2 Brake oil holes (17).
locations
2. Again tighten axle nut (17) so that the preload of
the tire mounting hole section becomes 226~265 N
(23~27 kgf) (50~59 lbf).
Note
This is the force to start the wheel hub moving or
Axle housing
Example LF extension
"breakaway" force. Measure the minimum pulling force
90ZV24070 to rotate the wheel hub using a spring scale.
Before reinstalling internal gear hub assembly (18),

align the brake oil hole of the axle housing extension
with that of the internal gear hub assembly. Note that
the spring pin is positioned at the top when the brake
holes are properly aligned.
24-33
Front Axle Assembly
Brake adjustment
Bolt Bolt
90ZV24075
Brake oil
inlet port
90ZV24074 2. Install 4 bolts to hold the brake piston not to come
out. Apply 588 kPa (6 kgf/cm2) (85 psi) air pressure
for approximately 1 minute. Shut off the valve.
Check that the pressure does not fall.
Jig (G) Note

Shut off valve If the pressure falls, air is leaking from the brake piston
O-rings or internal gear hub O-rings. Disassemble the
internal gear hub again to repair the leakage.
Air supply
PT 1/4 A
Air pressure gauge
Brake piston
90ZV24071
1. Attach jig (G) to the brake oil inlet port on the axle
housing. Wheel hub
90V2E24018
3. Adjust the piston position so that the distance A

from the piston end face to the wheel hub end face
falls within the following range.
A......133.35~134.85 mm (5.25~5.31 in)
Note
Dimension A should be equal at the top and bottom
sides.
24-34
Front Axle Assembly
Spring pin
Friction plate Align the
black teeth
with each
other
Cooling
holes
Steel plate
90ZV24076
4. To reassemble the steel plates and friction plates,

observe the following items. Note that the plates
should be assembled to make possible the plate
wear measurement after reassembling.
(a) Insert the steel plate having 4-teeth sections first.

Then install a friction plate.
(b) Insert the steel plate having two 2-teeth sections so
that the spring pin is positioned at the midpoint
between the 2-teeth sections.
(c) Align the cooling holes of two friction plates with
each other.
Wheel hub
Spider "TOP" mark Brake oil line

(at top)
Drain plug
(at bottom)
90ZV24077
5. Check that the wheel hub drain plug is at the bot-

tom when the spider "TOP" mark is at top.
6. After reinstalling the tires, be sure to completely

bleed the brake of air.
Note
After reinstalling tires, check that manual rotation of the
tires is possible. Also check the wheels for oil leakage.
24-35
Internal Gear Hub
Internal Gear Hub
Internal gear hub disassembling

Washer 6
and assembling
Internal gear hub disassembling 5
Lock nut
4
90V2E24019
2
3. Remove eight bolts (5) and return spring (6) from
brake piston (4).
: Locknut: 33 N-m (3.4 kgf-m) (25 lb-ft)

90ZV24092
Note
1. Turn up internal gear hub (1), and then remove two Washers and bolts (5) are changed from S/N 9074~.
O-rings (2).
11 Example LF
90ZV24095
90ZV24093
4. Insert two remover bolts (11) into brake piston (4) to

2. Remove taper roller bearing (3). remove the piston.
Note
For easy removal, heat the inner race using a gas
burner with slow flame.
24-36
Internal Gear Hub
Internal gear hub assembling

12
To reassemble the internal gear hub, follow the proce-
dure described in reverse order.
13
90ZV24096
5. Remove brake piston O-rings (12)(13).
14
90ZV24097
6. There is snap ring (15) that connects internal gear

(14) to internal gear hub (1). Shift the snap ring to
the inside using a round bar or the like.
14
15
90ZV24098
7. Sling internal gear (14) to remove it.
: Internal gear: 38 kg (83 lbs)

24-37
Internal Gear Hub
Internal gear hub assembly cau-

tions
IMPORTANT
- Replace all the O-rings with new ones. 3
replace it with a new one.
16
Be certain these 90ZV24100
plugs are tight.
- Before reinstallation of taper roller bearing (3), be

Oil holes sure to heat the bearing to 90ºC (194ºF) to 120ºC
Oil groove (248ºF) in oil.
- Apply grease to the O-rings.

14
- Check that the snap ring is properly inserted into the
Hub groove of the internal gear.
Example LF 4
90ZV24099
- When reassembling internal gear (14) and brake pis-

ton (4) to the internal gear hub, align the oil holes of
the internal gear hub with that of the brake piston oil
groove and spring pin (16).
Bolt
Note
To reinstall the internal gear hub on the axle, the brake Bolt
oil path should be aligned to these oil grooves. In addi-
tion, the oil grooves are used for alignment of the spring
pin.
Example LF
Moreover, the aligned grooves are used for external
85ZV24025
measurement of brake disc wear.
- When reassembling the piston, temporarily install

the piston and then tighten the bolt evenly. Confirm
that the piston is fully retracted. (Refer to Section
54.)
24-38
Spider Assembly
Spider Assembly
Spider assembly disassembling 5

and assembling
Spider assembly disassembling
(S/N 9019~)
(S/N 9001~9018)
6 6
K115V24026
2 3. Remove wear rings (6) and bearing (5) from plane-

tary gear (4).
1
90ZV24136
7
1. Remove lock bolts (1) and then plate (2).
: Lock bolt (1):

216 N-m (22.0 kgf-m) (159 lb-ft)
(Three Bond 1327)
1 90ZV24139
3
4. Turn spider (8) upside down. Using a plastic ham-

mer, tap brake backing plate (7) off the spider.
4
Spider assembly assembling
90ZV24137 To reassemble the spider assembly, follow the above

procedure in reverse order.
2. Insert lock bolt (1) into planetary pin (3), and Before starting work:
remove the pin. Remove planetary gear (4) with the - Clean all the parts.
wear rings and the bearings as a unit. - Check the brake backing plate, pins, bearings, plan-
etary 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.
24-39
Spider Assembly
Spider assy assembly cautions
- To reinstall the brake backing plate, check that there

is no clearance between the spider and the brake
backing plate.
- The brake backing plate may only be installed as it

was removed. It may not be flipped over due to the
roll pin hole design.
1
3
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.
24-40
Special Tool
Special Tool
Special tool for axle

(A) Spider hoisting tool
mm (in)
(Material: SS41)
ø6 mm (0.2 in) dia. round steel
2)
(1.
46(1.8)
4(0.2) 30
R
C2(0.08)
(0.4)
10
(0 10
)
R
.4
3)
0.
12
8(
(0.5) 3(0.1)
R
75(3.0)
3(0.1)
65(2.6)
10 6 t6 t6 6
(0.4) (0.2) (0.2) (0.2) (0.2)
105(4.1)
t6(0.2)
C2 m ril led
(0.08) 5m )d
ø2 .0 in
(1
46(1.8)
22(0.9)
C 2(0.08) C 2(0.08)
65(2.6)
90ZV24085
(B) Internal gear hub puller

mm (in) (Material: SS41)
t12(0.5)
30(1.2)
2x 12(0.5)
30(1.2)
90(3.5)
180(7.1)
C 5(0.2)
206(8.1)
90ZV24086
24-41
Special Tool
(C) Internal gear hub hoisting tool

75(3.0)
ø13 mm (0.5 in) drilled
t12(0.5)
35(1.4)
20
R .8)
(0
15
)
.6
R
235(9.3) (0 35
345(14) (1.4)
107(4.2)
25 155(6.1)
(1.0)
R1 .6)
(1.4) (0.5)
(0
5
13
35
R2 .8)
(0
0
434(17)
R2 .8)
(0
0
270(10.6)
215(8.5)
292(11.5)
35
(1.4)
t9(0.4)
R6
0(2
t9 56(2.2)
(0.4)
(0.3)
10
7
.4)
(0.4)
(1.0)
(0.1) (0.6)
25
(0.6)
15
15
R1 .4)
A
(0
0
27.5 35(1.4) 27.5

3
R1 .6)
(1.1) (1.1)
(0
(0.6)
90(3.5)
15
A A-A
90ZV24087
24-42
Special Tool
(D) Wheel hub hoisting tool

Cut the threaded area off the M10 eye bolt before use.
65
15
50
10
12 6 6 12
R
15
20
80
10
25
31
35 12 75
90V2E24040
(E) Eye bolt
M30 x 2
Cut the threaded area off the M10 eye bolt before use.
40
90V2E24044
24-43
Special Tool
(F) Floating seal jig
1. For wheel hub [ P/N for tool set: 99202-01850 ]

mm (in)
1. 2. ( )
15(0.6) 20(0.8)
7±0.2
3(0.1) (0.28±0.008) 3(0.1)
–0.1(9.7 –0.004 )
Ø258(10.2)
Ø242±0.1(9.5±0.004)
Ø235±0.1(9.3±0.004)
+0.05 (9.7 +0.002 )
+0.004
Ø241.8±0.1(9.5±0.004)
+0.3 (10.8 +0.012 )
+0
+0.010
Ø265(10.4)
Ø270(10.6)
Ø24.6 +0
Ø247.2 +0.1
Ø220(8.7)
Ø260(10.2)
Ø253 +0.25
10±0.3
5(0.2) (0.4±0.01) 12±0.3
(0.5±0.004)
R0.3
C (0.01)
R0.2~R0.5
(0.008~0.02)
90V2E24048
2. For ring [ P/N for tool set: 99202-01820 ]

mm (in)
1. 2. ( )
13(0.5)
20(0.8)
3(0.1) 10.9±0.2
3C (0.43±0.008)
3(0.1)
3(0.1)
Ø241±0.1(9.5±0.004)
–0.3 (10.1 –0.012 )
Ø260(10.2)
–0.010
0.05 (9.7 +0.002 )

+0.004
–0.1 (9.7 –0.004 )
Ø242±0.1(9.5±0.004)
Ø258(10.2)
Ø235±0.1(9.3±0.004)
Ø260(10.2)
Ø220(8.7)
+0
Ø256 –0.26
Ø247.2 ++0.1
Ø246 +0
10±0.3
(0.4±0.01)
12±0.1
(0.5±0.004)
C
R0.3
(0.01)
R0.2~R0.5
(0.008~0.02)
90V2E24049
24-44
Rear Axle Assembly
Rear Axle Assembly
Rear axle assembly tightening torque
T6
T8
T6
T6
T2 L1
B
A T7 L1
T3 L1
T4 L1 T6 T5
T1
90V2E24020
:
T2: 314 N-m (32.0 kgf-m) (232 lb-ft)
T3: 216 N-m (22.0 kgf-m) (159 lb-ft)
T4: 90 N-m (9.2 kgf-m) (67 lb-ft)
T5: 86 N-m (8.8 kgf-m) (64 lb-ft)
T6: 78 N-m (8.0 kgf-m) (58 lb-ft)
T7: 53 N-m (5.4 kgf-m) (39 lb-ft)
T8: 33 N-m (3.4 kgf-m) (25 lb-ft)
24-45
Rear Axle Assembly
Axle nut tightening procedure Floating seal installing
1. Tighten axle nut (A) with 1,765 N-m (180 kgf-m) Use jig to install the floating seal to the axle assembly.
roller bearing. Refer to Front axle assembly, "Front axle assembly cau-
tions" page 24-30 for details.
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):

226~265 N (23~27 kgf) (50~59 lbf)
Note
This is "breakaway" force, which is required to start the
wheel turning.
24-46
Rear Axle Assembly
Rear axle assembly removing and

installing Rear chassis
Rear axle assembly removing
WARNING
Unexpected movement of the machine may cause an 1
accident resulting in injury or death. To prevent such
an accident, observe the following items:
- Apply the articulation stopper. 90V2E24021
- Block the front wheels with chocks or the like to
3. Remove lower cover (1).
: Lower cover: 23 kg (51 lbs)
90ZV24039
3
90V2E24022
attachment. Place stand (A) under the rear chassis 4. Remove lower partition plates (2)(3).
(behind the center pin) to support the chassis.
: Partition plate (2): 8 kg (17.5 lbs)
Partition plate (3): 12.5 kg (27 lbs)
90ZV24040
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.
24-47
Rear Axle Assembly
Rear axle
Transmission
Wooden blocks
90ZV24041 K90V2E24002
5. Insert wooden blocks into the swing stopper section 7. Remove retainer bolts (6) to remove third propeller
to prevent the axle from swinging. Block both sides. shaft (5).
: Bolt (6): 142 N-m (14.5 kgf-m) (105 lb-ft)

WARNING : Screw lock agent application
The axle will not be balanced when a tire is removed. (Three Bond 1327)
If wooden blocks are not inserted, your fingers or : Third propeller shaft: 15 kg (35 lbs)
body may be caught in the machine.
Note
Replace propeller shaft retainer bolts (6) with new ones.
4 Do not reuse them when reassembling.
Clean all threads with a thread lock primer to assure a
fast strong bond.
Breather fitting
90V2E24023
Rear axle
6. Remove right and left wheel and tire assemblies

(4).
K90V2E24003
: Tire of 1 wheel:
670 kg (1,480 lbs) (without hydro-inflation)
: Retainer bolt: 8. Disconnect air breather tube (7).
892 N-m (91.0 kgf-m) (658 lb-ft)
Note
Before disconnecting the tube, remove the cap of the
hydraulic tank to vent tank pressure. Release the accu-
mulator pressure by slowly and fully depressing and
releasing the brake pedal at least 40 times. Remove
and clean tube (7) before reinstalling.
24-48
Rear Axle Assembly
12. Lower rear axle assembly (9) evenly on the carrier,

and then, pull out the rear axle.
8 CAUTION
The axle assembly could fall off the carrier causing
injury. Before pulling out the rear axle, carefully posi-
tion the axle onto the carrier using a strap so that the
axle will not fall from the carrier.
Rear axle
K90V2E24004
Rear axle assembly installing
9. Disconnect the front and rear grease pipes. For reinstallation, follow the above procedure in reverse
order.
10. Disconnect hose (8) from the brake oil inlet side. Refer to "Air bleeding procedure" page 24-25 for air
bleeding in the service brake.
Note
Cover and plug the disconnected pipes, hoses and fit-
tings to protect them from dust and dirt.
Rear axle disassembling and

10 assembling
For disassembling and reassembling the rear axle
assembly, refer to "Front axle disassembling and
assembling" page 24-26.
9
90V2E24027
11. Temporarily sling rear axle assembly (9), and

remove right and left retainer bolts (10) from the
rear axle support.
: Bolt (10): 721 N-m (73.5 kgf-m) (532 lb-ft)

: Rear axle assembly
(including axle supports):
1,470 kg (3,240 lbs)
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.
24-49
Axle Support
Axle Support
Axle support tightening torque
T1 L2 (S/N ~9042)
(S/N ~9042)
Front
T3 L1 T2 L1
T1 L2
K90V2E24009
:
T1: 721 N-m (73.5 kgf-m) (532 lb-ft)
T2: 608 N-m (62.0 kgf-m) (449 lb-ft)
T3: 53 N-m (5.4 kgf-m) (39 lb-ft)
L1: Screw lock agent (Three Bond 1327) application

L2: With lubricating oil (Engine oil or gear oil)
24-50
Axle Support
Axle support disassembling and

8
assembling Rear support 10
11 6
Axle support disassembling 13
Before starting work 7

12
- Remove the rear axle assembly from the rear chas- 9
sis.
Front support Rear axle

4 90V2E24032
4. Remove bolt (6).

3
2 Rear axle : Bolt (6): 608 N-m (62.0 kgf-m) (449 lb-ft)
(Three Bond 1327)
1 5. Remove plate (7) and wear ring (8).

5
90V2E24031
6. Remove bolt (9). Remove plate (10) and wear ring
(11).
1. Remove bolt (1).
: Bolt (9): 608 N-m (62.0 kgf-m) (449 lb-ft)
: Bolt (1): 53 N-m (5.4 kgf-m) (40 lb-ft) : Screw lock agent application
(Three Bond 1327)
2. Remove ring (2), packing (3) and front support from
the rear axle assembly. 7. Remove the rear support from the rear axle assem-
bly.
: Axle support (front): 90 kg (200 lbs)
: Axle support (rear): 110 kg (243 lbs)
3. Remove packing (4) and bushing (5) from the front
support. 8. Remove packing (12) and bushing (13) front the
rear support.
Axle support assembling
To reassemble the axle support, follow the above proce-

24-51
Axle Support
Axle support assembly cautions Bushing installing
IMPORTANT Front support

replace it.
Front
Grease Swing shaft

85ZVE24009
Rear support
13
Rear
Grease Swing shaft

85ZVE24010
Before installing, put bushing (5)(13) into dry ice then

install it on to the axle support.
CAUTION
When installing the bushing onto the differential
swing shaft, make sure no oil is left on the inner sur-
face of the bushing or the swing shaft surface.
If oil is left on them, the bushing may turn alone caus-
ing the bushing wear.
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.
24-52
Differential Assembly
Differential assembly removing

A
and installing Spider assembly
2
Differential assembly removing
TOP
[ Front axle assembly ]
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.
90V2E24033
: Cover bolt: 90 N-m (9.2 kgf-m) (67 lb-ft)
: Bolt (2): 86 N-m (8.8 kgf-m) (64 lb-ft)
Before starting work: : Spider assembly: 100 kg (220 lbs)
- Drain oil from the axle assembly.
- Remove the axle from the machine.
- Place the axle assembly on work benches.
: Axle assembly (Front): 1,230 kg (2,720 lbs)
: Axle assembly (Rear): 1,470 kg (3,250 lbs)
- For the front axle, remove the parking brake.
Refer to "Front axle assembly removing and install- 30 cm (1 foot)
ing" page 24-22.
- For the rear axle, remove the axle supports.
Refer to "Rear axle assembly removing and install-
ing" page 24-46.
3
85ZV24057J
2. Pull out right and left axle shafts (3) 30 cm (1 ft).

24-53
5 6
90ZV24081 90ZV24083
3. Remove bolts (5) from differential (4). 4. Temporarily sling differential (4), and insert bolts
into remover tap (Jack Screw) holes (6) to slightly
: Bolt (5) lift the differential.
(Front): 132 N-m (13.5 kgf-m) (98 lb-ft)
(Rear): 314 N-m (32.0 kgf-m) (232 lb-ft) : Differential: 190 kg (420 lbs)
(Three Bond 1327) Note
Be careful to sling the differential so that it is balanced
and is lifted straight up.
mark sections:
Spacers are installed.
7
90ZV24082
90ZV24084
Note
Spacers are inserted in eight asterisk "∗" mark sections
of the front differential. 5. Lift the differential using the sling, and then remove
O-ring (7).
24-54
Differential assembly installing

order.
Differential assembly installation cautions
- After reinstallation, refill with the specified oil until the

oil level reaches the level check plug. Also 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.

24-55
Differential assembly disassembling and assembling

Front differential tightening torque
Torque
proportional
F differential
T5 L1
T6 L1
Limited slip
T2 L1
differential
(opt)
T4 L1 F
F T3 L1
T7 L1
A
Shim E
(T=0.07)
~
(T=0.50) L2
T1 L2
B
T4 L1 (T=14.70)
~
(T=14.98)
90V2E24035
: Note
T1: 883 N-m (90.0 kgf-m) (651 lb-ft) - To tighten nut (T1), measure the preload at the bolt
T2: 515 N-m (52.5 kgf-m) (380 lb-ft) screw hole in flange (A).
T3: 330 N-m (33.7 kgf-m) (244 lb-ft)
T4: 314 N-m (32.0 kgf-m) (232 lb-ft) Preload at flange (A):
T5: 235 N-m (24.0 kgf-m) (174 lb-ft) 62~71 N (6.3~7.2 kgf) (14~16 lbf)
T6: 53 N-m (5.35 kgf-m) (39 lb-ft)
T7: 132 N-m (13.5 kgf-m) (98 lb-ft) Use spacer (B) to adjust the preload.
- Use shim (E) to adjust the tooth contact of spiral

L1: Screw lock agent (Three Bond 1327) application bevel gears (C) and (D).
L2: Liquid gasket (Three Bond 1215) Adjust the backlash by nut (F).
24-56
Rear differential tightening torque
Limited slip T2 L1
differential
(opt)
T3 L1
T6 L1
F T4 L1
Torque
proportional
differential
C T5 L1
T4 L1
E
Shim
(T=0.07~0.50)
A
T1 L2 B
(T=14.70~14.98)
T4 L1
K90V2U24015
: Note
T1: 883 N-m (90.0 kgf-m) (651 lb-ft) - To tighten nut (T1), measure the preload at the bolt
T2: 515 N-m (52.5 kgf-m) (380 lb-ft) screw hold in flange (A).
T3: 330 N-m (33.7 kgf-m) (244 lb-ft)
T4: 314 N-m (32.0 kgf-m) (232 lb-ft) Preload at flange (A):
T5: 235 N-m (24.0 kgf-m) (174 lb-ft) 62~71 N (6.3~7.2 kgf) (14~16 lbf)
T6: 53 N-m (5.35 kgf-m) (39 lb-ft)
Use spacer (B) to adjust the preload.
L1: Screw lock agent (Three Bond 1327) application - Use shim (E) to adjust the tooth contact of spiral
L2: Liquid gasket (Three Bond 1215) bevel gears (C) and (D).
Use nut (F) to adjust the backlash.
24-57
Differential assembly disassembling 3
Adjust nut
Shim 3
Nut (A)
Bevel gear 4
Pinion
2 90V2E24038
Adjust nut 90ZV24103 2. Remove bolts (3), bearing cap (4), and adjustment
nut (2).
- Fix the differential assembly onto the disassembly : Bolt (3): 515 N-m (52.5 kgf-m) (380 lb-ft)
workbench. : Screw lock agent application
- Insert a straight-end screwdriver or the like into the (Three Bond 1327)
clearance between the pinion and the bevel gear to
prevent the gear from rotation. Loosen nut (A). 5
: Nut (A): 883 N-m (90 kgf-m) (651 lb-ft)

6
Note
Nut width across flat: 57.1 mm (2.25 in)
90ZV24150
3. Remove bearing outer race (5). Lift differential cage

assembly (6) to remove it.
: Differential: 120 kg (265 lbs)

1
2
90V2E24037
1. Remove right and left lock plates (1) from adjust-

ment nut (2).
: Bolt: 53 N-m (5.35 kgf-m) (39 lb-ft)

(Three Bond 1327)
24-58
7
8
Matchmark Clutch assy

90ZV24107 90V2E24039
4. Put a matchmark on the alignment point of differen- Note

tial cage (7). Remove bolts (8), and then separate For the limited slip differential, remove the clutch assy,
the differential cage. which is assembled instead of thrust washer (9).
: Retainer bolt (8, Torque proportional diff.)

235 N-m (24.0 kgf-m) (174 lb-ft) 12
: Retainer bolt (8, Limited slip diff.)
314 N-m (32.0 kgf-m) (232 lb-ft)
(Three Bond 1327)
11
13 90ZV24109
6. Remove spider (11) with pinion gears (12) and

10 thrust washers (13) as a unit.
9
90ZV24108
5. Remove thrust washer (9) and side gear (10).
14
90ZV24110
7. Remove side gear (14).

24-59
Trunnion
15
19
18
90ZV24111 90ZV24113
8. Remove thrust washer (15). 10. Remove bolts (18) to remove pinion (19). At the
same time, remove the shim.
: Bolt (18): 314 N-m (32.0 kgf-m) (232 lb-ft)

(Three Bond 1327)
Note
The rear differential assembly has the trunnion installed
with bolts (18) as shown.
20
Clutch assy
90V2E24039
21
Note
For the limited slip differential, remove the clutch assy,
which is assembled instead of thrust washer (15).
17
90ZV24114
11. Remove nut (20) and O-ring (21).
: Nut: 883 N-m (90.0 kgf-m) (651 lb-ft)

(Three Bond 1327)
16 Note
90ZV24112 Nut width across flat: 57.1 mm (2.25 in)
9. Turn the differential upside down. Remove bolts

(17) from bevel gear (16) to separate the gear.
: Bolt (17): 330 N-m (33.7 kgf-m) (244 lb-ft)

(Three Bond 1327)
24-60
26
22
90ZV24115 90ZV24118
12. Remove flange yoke (22). 15. Remove spacer (26).
23
24
90ZV24116
13. Remove pinion (23) from cage (24).
25
90ZV24117
14. Remove taper roller bearing (25).

24-61
Differential assembly assembling (d) Install yoke (22) on pinion (23) and tighten nut (20).
Note
IMPORTANT Do not install the oil seal and O-ring of the nut.
- Clean and check all the parts. If a part is worn or
damaged, replace it. : Nut: 883 N-m (90.0 kgf-m) (651 lb-ft)
- Be sure to replace O-rings and seals with new
ones.
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 A : Standard preload∗:
22 62~71 N (6.3~7.2 kgf) (14~16 lbf)
90ZV24120
∗Preload here is the force required to start the cage

(a) Install new roller bearing (27) on pinion (23) if moving-breakaway force (not a rolling force).
replacement is needed.
(f) If the preload is out of the above range, replace
spacer ring (26) to adjust the preload to the speci-
fied range.
Pinion Bearing
Note
There are 15 types of spacers (14.70~14.98 mm)
(0.58~0.59 in) in increments of 0.02 mm (0.0008 in).
Pinion
Thicker spacers reduce preload; thinner spacers
Stake at increase preload.
3 points
(g) Remove nut (20) and flange yoke (22).
90ZV24121
Note
After attachment, stake the bearing at three points as
shown in the above 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).

24-62
Front Rear
Shim Shim
18 18
Check direction
of the lips
29
31 31
Apply liquid
gasket (AA03) to
these surfaces 30
24 30 Trunnion
90ZV24122 K90V2U24016
2. Install oil seal (29) to cage (24). 4. Install O-ring (30) and the shims (the one(s)
removed during disassembly) to the cage. Insert
: the cage into differential case (31), and tighten
Before installing oil seal, be sure to apply grease to retainer bolt (18).
the lip and liquid gasket the outside of the seal.
Note
Install the trunnion to the rear differential assembly.
: Bolt (18): 314 N-m (32.0 kgf-m) (232 lb-ft)

22 : Screw lock agent application
(Three Bond 1327)
Torque proportional diff. Limited slip diff.

20
14
21
15
90ZV24123
3. Install flange yoke (22), and then O-ring (21). Apply 32

liquid gasket to nut (20), and then tighten the nut.
(Nut width across flat: 57.1 mm)
90V2E24042
: Nut (20): 883 N-m (90.0 kgf-m) (651 lb-ft)
: Liquid gasket (Three Bond 1215)
application 5. Install wear ring or clutch assy (15) and side gear
(14) to differential cage (32).
Note
Different part is assembled according to the differential
type.
24-63
11 8
12
13
7
Matchmark
90ZV24145 90ZV24147
6. Attach spider (11) with side gears (12) and thrust 8. Align differential cage (7) with the matchmark, and
washers (13) as a unit. then tighten bolts (8).
: Retainer bolt (8, Torque proportional diff.):

Torque proportional diff. Limited slip diff. 235 N-m (24.0 kgf-m) (174 lb-ft)
: Retainer bolt (8, Limited slip diff.):
9
314 N-m (32.0 kgf-m) (232 lb-ft)
10 (Three Bond 1327)
16
17
90V2E24043
7. Install side gear (10) and wear ring or clutch assy

(9).
Note
Different part is assembled according to the differential
90ZV24148
type.
9. Tighten bolts (17) in bevel gear (16).
: Bolt (17): 330 N-m (33.7 kgf-m) (244 lb-ft)

(Three Bond 1327)
24-64
(b) Tighten opposite side adjustment nut (1). After you

feel that the nut is tight, turn it one more notch.
6
(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:
0.26~0.38 mm (0.0102~0.0149 in)
90ZV24149
- Tighten adjustment nut (33) on the bevel gear side

or loosen adjustment nut (1) on the opposite side to
10. Install differential cage assembly (6) in the carrier
reduce the backlash.
assembly.
- Loosen adjustment nut (33) on the bevel gear side or
tighten adjustment nut (1) on the opposite side to
3
increase the backlash.
4 34
3
2
4
Adjust nut
90ZV24131
11. Reinstall bearing cap (4), and then temporarily

tighten bolts (3). Reinstall the adjustment nut. 90ZV24133
(For both the right and left sides)
13. Tighten bolts (3) of bearing cap (4).
1
: Bolt (3): 515 N-m (52.5 kgf-m) (380 lb-ft)
(Three Bond 1327)
A
14. Mount lock plate (2), and then tighten bolts (34) to
fix the lock plate.
: Bolt (34): 53 N-m (5.35 kgf-m) (39 lb-ft)

16
(Three Bond 1327)
33 90ZV24132
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 adjust-
ment nut 2 to 3 notches.
24-65
Adjusting tooth contact:
Tooth contact Possible cause Adjusting method
A Correct
Loosen the bearing adjuster on the rear

side of ring gear, and tighten the adjuster of 2
Ring gear is too close to the tooth side at the same quantity as
B
drive pinion loosening, so that the ring gear is far apart
from the drive pinion. Check again the
backlash and tooth contact.
2
Ring gear is too far from the
C Do the reverse adjusting as B.
drive pinion
Increase the thickness of shim at the part

of bearing cage being installed and makes 2
Drive pinion is too close to the
D drive pinion apart from the ring gear.
ring gear.
Check again the backlash and tooth
contact.
1
Decrease the thickness of shim reverse as

2
D, and makes drive pinion approach the
Drive pinion is too far from the
E ring gear.
ring gear.
Check again the backlash and tooth
contact.
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.
24-66
Three types of tooth contact shown below are

acceptable as best tooth contact.
Tooth contact position and length (rate)
10
1 5 4
Pattern TOP HEEL
A
Pitch line 4~5 10
TOE
BOTTOM
10
2 4 4
Pattern TOP HEEL
B Pitch line 4~5 10
TOE
BOTTOM
10
3 4 3
Pattern TOP HEEL
C TOE 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 pin-
ion as a unit.
Note
Single sale of the bevel gear or the drive pinion is not
possible.
25-1
90ZV-2 Service Standard Power Group

Power Group
Propeller Shaft Service Standard ............................ 25-2

Axle and Differential Service Standard.................... 25-3
25-2
Propeller Shaft Service Standard
Propeller Shaft Service Standard
Third propeller shaft
1
a
2 Measurement of circumferential play
b
3 Measurement of transverse play
4
Second propeller shaft
F90ZV25001
Unit: mm (in)
No. Item Tolerance Solution
Second, third
1 Spider bearing play 0.25 (0.0098) Replacement
propeller shaft
Second propeller
2 Spline circumferential play 0.8 (0.0315) Replacement
shaft
Second propeller
3 Spline transverse play 1.0 (0.0394) Replacement
shaft
4 Clearance 17.64±3 (0.69±0.12) —
a: 77 N-m (7.9 kgf-m) (57 lb-ft)

b: 162 N-m (16.5 kgf-m) (119 lb-ft)
25-3
Axle and Differential Service Standard
Axle group
6
5
4
2, 3
1, 3
7 5
90V2E25001
Unit: mm (in)
Judgment standard
No. Item Solution
Standard dimension Tolerance
0.12~0.60
1 Backlash between sun gear and planetary gear ← Replacement
(0.0047~0.0236)
0.14~0.73
2 Backlash between planetary gear and internal gear ← Replacement
(0.0055~0.0287)
3 Tooth contact of gear No abnormality Replacement
Front ø 311 +0.081

0 (12.2241 +0.0032
0 ) Dia.: 1.0 (0.0393)/
4 Axle support wear Radius: 0.5 (0.0196) Replacement
Rear ø 206 +0.072 (8.110 +0.0028 ) (stepped)
0 0
5 Bushing and wear ring wear Oil groove 1.0 (0.0394) No oil groove Replacement
Dia.: 1.0 (0.0393)/

0 0
6 Trunnion wear ø 300 -0.081 (11.8110 -0.0032 ) Radius: 0.5 (0.0196) Replacement
(stepped)
Dia.: 1.0 (0.0393)/
0 0
7 Sleeve wear ø 195 -0.115 (7.6772 -0.0045 ) Radius: 0.5 (0.0196) Replacement
(stepped)
25-4
Differential
5.6
5.6
85ZV25004J
Unit: mm (in)
Judgment standard
No. Item Solution
Standard valve Tolerance
0.26~0.38
1 Backlash between ring gear and drive pinion ← Adjustment
(0.0102~0.0149)
0.23~0.58
2 Backlash between side gear and pinion gear ← Adjustment
(0.0090~0.0228)
0.098~0.126
3 Clearance between pinion gear and spider ← Replacement
(0.0038~0.0049)
0.076 Adjustment or
4 Runout of ring gear rear surface (when assembled) ←
(0.0029) replacement
5 Tooth surface wear (each gear) Abnormal wear or missing Replacement
6 Tooth contact No abnormality Replacement

34-1
90ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group

Torque Converter and Transmission Group
Torque Converter and Transmission Assembly....... 34-2

Torque Converter Assembly .................................... 34-11
Transmission Assembly .......................................... 34-19
Transmission Forward/Reverse Clutch Pack .......... 34-31
Transmission 1st/3rd Speed Clutch Pack................ 34-34
Transmission 2nd Speed Clutch Pack..................... 34-36
Transmission 4th Speed Clutch Pack...................... 34-38
Control Valve Assembly .......................................... 34-41
34-2
Torque Converter and Transmission Assembly
Torque converter and transmission assembly tightening torque
T1 L1 Engine
T3 L1
T6 L3
T3 L1
Rear chassis
T1 L1
T5 L3
Transmission
Rear differential
T4 L2
T2 L1 3rd propeller shaft
Front differential T4 L2
T4 L2
2nd propeller shaft
K90V2J24001
:
T1: 441 N-m (45 kgf-m) (325 lb-ft) L1: Screw lock agent (Loctite® 262)
T2: 417 N-m (42.5 kgf-m) (307 lb-ft) L2: Screw lock agent (Three Bond 1327)
T4: 142 N-m (14.5 kgf-m) (105 lb-ft)
T5: 67 N-m (6.8 kgf-m) (49 lb-ft)
T6: 53 N-m (5.4 kgf-m) (39 lb-ft) Always replace drive shaft bolts with new ones - never
reuse them.
34-3
Torque converter and transmission assembly removing and installing

Torque converter and transmission assem-
bly removing
WARNING
Unexpected movement of machine could cause an
accident resulting in injury or death. To prevent such 1
- Lower the attachment onto the ground, and then
block the tires with chocks to prevent wheels from
moving.
90ZV34001
- Disconnect the ground cable from the negative
side of the battery.
1. Remove drain plug (1) to drain the transmission oil.
IMPORTANT : Transmission oil: 38 L (10 gal)

“OFF” position, it can corrupt the ECM program, 2

- Stop the engine. Depress the brake pedal many
times until there is no brake pressure.
- Press the hydraulic tank cap, and relieve the internal
5
pressure from the hydraulic tank. 4
- Remove the cab and the floor board (Refer to Sec- K90V2E34001
tion 14).
- Remove the engine room (Refer to Section 14).
- Consider the type of failure and if the T/C oil cooler 2. Disconnect bolts (3) from third propeller shaft (2) on
must also be removed for cleaning or replacement. the transmission side.
- If a small amount of contamination is found in the
transmission strainer and filter the cooler does not : Bolt (3): 142 N-m (14.5 kgf-m) (105 lb-ft)
need removal. : Screw lock agent application
- If a large amount of contamination is found the (Three Bond 1327)
cooler must be removed and thoroughly cleaned or
replaced. Note
- Lines to cooler must also be replaced. If the retainer bolts are too tight due to the screw lock
burner.
Keep the flame away from the seals of the coupling.
Do not reuse the bolts, always replace with new ones.
34-4
12
6
10
11
9 8
90ZV34003 90ZV34005
3. Remove bolt (5) from second propeller shaft (4) on 5. Remove split pin (8), and then remove pin (9).
the transmission side only.
Disconnect electric wire (6) from the speed meter 6. Remove bolts (11) from actuator mounting bracket
sensor and speed sensor. (10). Disconnect the oil source, and then remove
actuator (12).
: Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft)
(Three Bond 1327) Accumulator
Unloader valve
(S/N ~9200)
7
Bracket
Bracket
90V2E34002
Manifold valve assy
Parking brake actuator
(Oil cylinder) 7. Disconnect all the hoses and the pipes from the
K90V2E34002
accumulator and unloader valve. Remove the
bracket.
4. Release the parking brake and disconnect the link Install plastic caps or plugs to prevent dirt entry into
of the actuator. If the machine has low accumulator valve and hoses.
oil pressure, feed oil into hose (7) from an external
source.
Note
If there is no oil source, apply a rope or cable to the link,
and then pull it down using a bar to compress the spring
of the actuator. After that, remove the pin.
34-5
ELS valve
13
Rear chassis
Bracket
90ZV34006 90V2E34003
8. Disconnect hose (13) from the transmission level 10. Disconnect all the hoses and the pipes from the
gauge. ELS valve and remove the bracket.
Install plastic caps or plugs to prevent dirt entry into
Note valve and hoses.
After removing the hose, plug or cover the disconnected
part with clean vinyl to protect from dust and dirt.
Transmission
Oil pump
Steering valve
16
15
14 90V2E34004
90ZV34112
11. Disconnect hoses and pipes (14)(15)(16) from the
oil pump.
9. Disconnect all the hoses and the pipes from the
steering valve and remove the steering valve with Note
the bracket. After removing the hoses, cover the hoses with plastic
Install plastic caps or plugs to prevent dirt entry into caps, and cover the pump ports with caps to protect
valve and hoses. them from dust and dirt.
34-6
Gasket <S/N 9001~9200>

Transmission
23
17
22
19 23
18
90V2E34005 90V2E34007
12. Remove suction hoses (17)(18), and then remove <S/N 9201~>
pump assembly (19).
: Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft)

: Gear pump: 55 kg (120 lbs) 23
Note
After removing the hoses, cover the hoses with plastic
caps, and cover the pump ports with the caps to protect
them from dust and dirt.
Refer to "Hydraulic pump assembly installing" page 44-
22
4 for the reinstallation.
23 90V2J34011
14. There are two hoses (22) between torque converter

20 and the cooler. There are two hoses (23) between
the line filter and the transmission. Disconnect
hoses (22)(23).
Note
After removing the hose, cover the fitting section with
plastic caps or plugs to protect the fitting section from
21 dust and dirt.
90V2E34006
13. Disconnect the electrical wire for torque converter

temperature switch sensor (20).
Disconnect main clutch pressure outlet hose (21).
Note
After removing the hoses, cover the hoses with plastic
caps to protect from dust and dirt.
34-7
24
30
29
25
28
90ZV34011 90ZV34013
15. Remove all electric wire couplers (25) from control 17. Loosen bolts (28) (10 mm (0.4 in)) (both sides).
valve (24). Remove bolts (29)(30) (both sides).
Note : Bolt (28): 441 N-m (45 kgf-m) (325 lb-ft)

Before disconnecting the couplers, be sure to put Bolt (29): 230 N-m (23.5 kgf-m) (170 lb-ft)
matchmarks on the couplers. : Screw lock agent (Loctite® 262) application
For reassembly, refer to the connection illustration on
"Control valve installation cautions" page 34-43. Engine flywheel housing
Flywheel
27
Pilot boss
Pull to
separate Ring
26 transmission
Ring gear
Transmission
Engine-transmission joint section 90ZV34014
90ZV34012
Note
The joint section between the engine and the transmis-
16. Attach sling to transmission assembly (26), and sion consists of the pilot boss and the gear coupling as
then remove 12 bolts (27) from the engine flywheel shown in the figure.
housing. The pilot boss is inserted for centering, and the gear
coupling is used for power transmission.
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft) To separate the transmission from the engine, remove
: With lubrication oil (Engine oil or gear oil) the bolts from the engine flywheel housing, and then
: Transmission assembly: 880 kg (1,940 lbs) pull the transmission straight out to the front.
34-8
31
Wooden piece
90ZV34015 90ZV34016
19. Slowly lift transmission assembly (31) while avoid-

ing contact with other parts.
Torque converter and transmission assem-

Wooden bly installing
piece
To reinstall the torque converter and transmission
assembly, follow the above removal procedure in the
reverse direction.
85V2E34024
18. Separate the transmission assembly from the

engine, and then put the engine on the rear axle
housing.
Note
Lift the transmission approximately 100 mm (4 in), and
then insert a wooden piece of 200 mm (8 in) into the
clearance between the bottom of the engine flywheel
housing and the rear axle housing. Lower the transmis-
sion to make a slight clearance between the engine and
the transmission. Repeat the above procedure 2 to 3
times while pulling the transmission away from the
engine to separate them.
34-9
Transmission assembly installation cau- Transmission assembly operation check

tions
After reinstallation, check operation of the transmission
assembly by the following procedure.
Joint between the torque converter and the
engine WARNING
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
1
communicate with the person in the operator seat
using signals as agreed upon before hand.
1. At the completion of reinstallation, start the engine,

and check that the shift lever properly functions at
all the positions.
90ZV34017 2. Check each section for oil leakage.
- Be sure to replace the O-ring (1) with new one. 3. Adjust the transmission oil level to the specified
- Be sure pilot boss bushing (ring) is installed. point with the level gauge.
4. Perform the start-up tests as shown on the

attached sheet.
Transmission side Engine side
Flywheel
O-ring (1)
Ring gear
Ring
90V2E34008
- Rotate the engine flywheel to align the ring gear.

34-10
DATE: HOURS: MACHINE MODEL & SERIAL NO.:
CUSTOMER: DEALER:
DEALER LOCATION: MACHINE LOCATION:
TIRE SIZE: BRAND & SPECIFICATION OF OIL: AMBIENT TEMP:
COMPONENT TYPE & MODEL NO.: 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)
CLUTCH PRESSURE AT HIGH IDLE

2
F1 MPa (kgf/cm ) (psi) N1 MPa (kgf/cm2) (psi) R1 MPa (kgf/cm2) (psi)
COMMENTS:
Serviceman’s Signature
KCM CORPORATION
Copy as required. Make attachments if needed.
34-11
Torque Converter Assembly
Torque converter assembly bolt tightening torque
T2 L 3
T2 L 3 T1 L 3
90V2E34009
:
T1: 29 N-m (3 kgf-m) (22 lb-ft)
T2: 59 N-m (6 kgf-m) (43 lb-ft)

34-12
Torque converter assembly disas-

sembling and assembling
Torque converter assembly disassembling 4

5
- Clean the torque converter assembly.
- Drain oil from the transmission and the torque con-
verter. Shim
90ZV34020
2 3. Remove front cover (4).

Hose
After removing the front cover, remove ball bearing
(5).
Note
If a shim is attached, remove the shim from the bearing
and store it for reassembly.
1
90ZV34019
1. Remove bolts (1), cover (2) and then remove the

hose.
Gasket
8
85V2E34012
4. Remove turbine impeller assembly (8).
3
85K34021
2. Removing the front cover from the pump impeller.

Remove bolts (3). (Number of bolts: 24)
10
11
9
85V2E34013
5. Remove thrust washers (9), thrust bearing (10),

and ring (11).
34-13
21
19
13
20
12
85V2E34014 85V2E34017
6. Remove snap ring (12) and stator (13). 9. Remove seal ring (19), bolts (20), and then stator
shaft (21).
∗: Remover bolt installation position

15
17
14
16
Torque converter housing

85V2E34015 Transmission housing
K85V2E34010
7. Remove collar (14), thrust washer (15), thrust bear-

ing (16) and ring (17). 10. Attach sling to torque converter housing.
Separate torque converter housing from transmis-
sion housing.
18
85V2E34016
8. Remove pump impeller assembly (18).

34-14
Torque converter assembly assembling
22
IMPORTANT
24 23 - Clean and check all the parts. If a part is damaged,
replace it with a new one.
25
- Before reassembly, apply transmission oil to the
parts.
1. Turn over the torque converter housing.

K85V2E34011
30
26
11. Remove seal ring (22).
29
12. Turn over the torque converter housing. 28
27
13. Remove snap ring (23) and turbine shaft (24).
14. Remove turbine shaft bearing (25).

30
K85V2E34012
26
29
28
27
27 28 29 30 26

K85V2E34012
35.2
15. Remove nut (26) from bolt (27).
90ZV34147
16. Remove bolt (27) to the torque converter housing.
17. Remove spring (28) and washers (29)(30) from bolt 2. Install spring (28) and washer (29) to bolt (27).
(27).
3. Install bolt (27) to the housing.
IMPORTANT
Adjust the clearance between torque converter hous-
ing and bolt (27) to 35.2 mm.
4. Install washer (30) and nut (26) onto bolt (27).
: Screw lock agent (Three Bond 1327)

application
34-15
21
IMPORTANT
19 Adjust the thrust clearance here as follows.
20
23
25
18 5
22
24
K85V2E34013
5. Install turbine shaft bearing (25).

8
6. Install turbine shaft (24) and snap ring (23).

90ZV34116
7. Connect the torque converter housing to the trans-

mission housing. (a) Temporarily assemble pump impeller (18) on the
PTO drive gear, stator, bearing washers etc. and
8. Attach seal ring (22). turbine impeller (8).
: Apply grease to the seal ring, (b) Measure the distance from ball bearing (5) to the
and then insert into the groove. mounting face of the pump impeller assembly.
Regard the obtained distance as dimension A.
9. Tighten bolts (20) to fix stator shaft (21), and then
install the seal ring (19).
: Bolt: 59 N-m (6 kgf-m) (43 lb-ft)

90ZV34117
(c) Measure the distance from the mounting face of

front cover (4) to the end face of the bearing
receiver. Regard the obtained distance as dimen-
sion B.
34-16
B – A = 0.2~0.4 mm A Front
(0.008~0.016 in) cover
18
14
15
16
Ball 17
bearing
F90V2E34010 85V2E34020
10. Install pump impeller assembly (18), and then

attach ring (17), thrust bearing (16), thrust washer
(15), and collar (14).
Front cover
Ball bearing
Adjusting shim
90ZV34032
(d) Adjust the difference between distance B and dis- 13

tance A (thrust clearance) to 0.2~0.4 mm
(0.008~0.016 in) using a shim as shown in the fig-
ure above.
12
85V2E34014
(e) After shim adjustment, remove the ball bearing,
and then sequentially attach the shim and then the
ball bearing to the front cover. 11. Install stator (13), and attach snap ring (12).
10
11
9
85V2E34013
12. Attach ring (11), thrust washer (9), and thrust bear-
ing (10).
34-17
2
Hose
8 1
85V2E34012 90ZV34019
13. Install turbine impeller assembly (8). 15. Install cover (2), and then tighten bolts (1).
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)
Note
Gasket At the completion of reassembly, manually turn the front
cover to check that it rotates smoothly.
Gasket
3
85K34021
14. Install the front cover, and then tighten bolts (3) to
connect the front cover to the pump impeller
assembly.
Transmission housing
K85V2E34014
Number of bolts (3): 24
: Bolt: 29 N-m (3 kgf-m) (22 lb-ft) 16. Install the torque converter housing on to the trans-
: With lubrication oil (Engine oil or gear oil) mission housing.
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

34-18
Hose
90ZV34036
17. Connect the hose between the torque converter

housing and transmission housing.
34-19
Transmission Assembly
Transmission assembly bolt tightening torque
T2 L 3
T6 L 3 T7 L 3
T7 L 3
T2 L 3 T1 L 3
T5 L 1
T3 L 1
T/M S/N CT270E01-0937~
T4 L 2 T6 L 3
T6 L 3
K90V2E34003
:
T1: 29 N-m (3 kgf-m) (22 lb-ft) L1: Screw lock agent (Loctite® 262) application
T2: 59 N-m (6 kgf-m) (43 lb-ft) L2: Molybdenum disulfide grease /
T3: 216 N-m (22.0 kgf-m) (159 lb-ft) MOS2 application
T4: 392 N-m (40 kgf-m) (289 lb-ft) L3: With lubrication oil (Engine oil or gear oil)
T5: 94 N-m (9.6 kgf-m) (69 lb-ft)
T6: 53 N-m (5.4 kgf-m) (39 lb-ft)
T7: 86 N-m (8.8 kgf-m) (64 lb-ft)
34-20
Transmission assembly disas- Gasket

sembling and assembling 2
Transmission assembly disassembling

- Clean the transmission assembly.
- Remove the coupling yoke, the sleeve and the snap
ring of ball bearing for the third propeller shaft.
Unless removed, they will fall off.
- Place the transmission assembly so that the parking 1
brake side is up. 90ZV34038
- For disassembling and reassembling for the parking

brake, refer to "Brake Group 54".
2. Remove bolts (1).
Lift the control valve assy (2), and remove it.
Snap
ring : Control valve assembly: 20 kg (44 lb)
Coupling Note
yoke
Refer to "Control valve removing and installing" page
34-42 to remove control valve assy (2).
Sleeve
Oil seal
(T/M S/N: CT270E01-0411~) (T/M S/N: CT270E01-0411~)
K90V2E34004
Hose
3 90ZV34039
3. Remove bolt (3), and remove the brake drum (4).
6
90ZV34037
1. Disconnect the hose.
90ZV34040
4. Remove nut (5), then remove flange yoke (6).

34-21
12 13 12
4
2
3
7
F
90ZV34041 85ZV34013
5. Remove bolt (7), and then remove brake assembly 8. Remove bolts (12), cover (13).
(8).
14
4
Gasket
10
3
R
F
85ZV34014
9
90ZV34042
9. Remove gear (14).

6. Remove bolt (9) and then remove drive cover
assembly (10).
11 Ball bearing
1
71 mm
15
85ZV34015
2
3
R
90ZV34043
10. Remove bolt (15).
7. Hit in output shaft (11) (approx. 71 mm (2.8 in))

after that remove output shaft (11) with the ball
bearing.
34-22
16 17
20
90ZV34044 90ZV34120
11. Remove bearing (16), after that remove 4th speed 14. Lift transmission housing (20) slowly.
clutch pack assembly (17).
21
18
Ball bearing
90ZV34121
90ZV34045
15. Remove the 3rd and the forward speed clutch pack
12. Remove the 1st speed clutch pack assembly (18). assembly (21).
Note
Pull out the 1st speed clutch pack assembly. It is tight
due to the ball bearing between the housing and the
22
shaft.
19
90ZV34122
16. Remove the 2nd and the reverse speed clutch pack
assembly (22).
90ZV34119
Note
Pull out the 2nd and the reverse speed clutch pack
13. Remove bolt (19). assembly. It is tight due to the ball bearing between the
housing and the shaft.
34-23
31
23
24
25
26
30
27 90ZV34125
19. Remove bolt (30) and then remove charge pump

assembly (31).
K85V2E34017
17. Remove bolt (23), plate (24), snap ring (25), bear-
ing (26) and gear (27).
28
29
K85V2E34018
18. Remove bolt (28) and then remove shaft (29).

34-24
Transmission assembly assembling
Note
- For clutch pack disassembly and reassembly refer to 28
"Disassembly and reassembling clutch pack".
- Clean and check all the parts. If a part is damaged, 29
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.
- When installing each clutch pack assembly, manu-
ally turn the gears to check that the gears are
engaged properly.
31 32 K85V2E34018
2. Install shaft (29) with bolt (28).
30
90ZV34126
23
1. Install torque converter gear pump (31) with bolt 24
(30). 25
26
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)
27
Note
Check the thrust clearance (0.5~0.9 mm) (0.020~0.035
in) at pump shaft (32) (PTO shaft). Tap the shaft with a
soft hammer to check the thrust clearance, if necessary.
K85V2E34017
3. Install bearing (26) and snap ring (25) to gear (27).

Install gear (27) to shaft (29) and then install plate
(24) and tighten bolt (23).
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

34-25
19
22
90ZV34127 90ZV34119
4. Install the 2nd and the reverse speed clutch pack 7. Tighten bolt (19).
assembly (22).
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)
21
17
18
90ZV34129
90ZV34132
5. Install the 3rd and the forward speed clutch assem-

bly (21). 8. Install the 1st speed clutch pack assembly (18) and
4th speed clutch pack assembly (17).
20
18 16
Gasket
85V2E34033
90ZV34133
6. Install transmission housing (20) on to the T/C

housing. 9. Install bearing (16) on to the 1st speed clutch pack
assembly (18).
34-26
11
34
14
90ZV34134 11 90ZV34137
10. Install small end bearing (34) on output shaft (11) 13. Install gear (14) onto output shaft (11).
and install the snap ring.
17
11
20
18
90ZV34138
90ZV34135
14. Measure and record the clearance between the 1st

11. Install the output shaft (11) into the housing (20). speed clutch pack gear (18) and the 4th speed
clutch pack gear (17).
Note
Support output shaft (11) from the bottom side to avoid Note
it fell down. The clearance between them should be no less than
0.5~1.0 mm (0.02~0.04 in).
15
85ZV34015
12. Tighten bolt (15).
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

34-27
13
17
90ZV34139 K85V2E34001
15. Measure the distance from the bearing of the 4th 17. Measure the distance from the mounting face of
speed clutch pack (17) to the mounting face cover (13) to the end face of the bearing receiver
(including the gasket) of the housing. for the 4th speed clutch pack.
Regard the obtained distance as dimension A. Regard the obtained distance as dimension B.
13
18
90ZV34140 K85V2E34002
16. Measure the distance from the bearing of the 1st 18. Measure the distance from the mounting face of
speed clutch pack (18) to the mounting face cover (13) to the end face of the bearing receiver
(including the gasket) of the housing. for the 1st speed clutch pack.
Regard the obtained distance as dimension A'. Regard the obtained distance as dimension B'.
34-28
C C
35
K85V2E34003 K85V2E34006
19. Adjust the difference between the distance B and Note

the distance A (thrust clearance) to 0.5~1.0 mm Insert the shim into the section C so that the difference
using shim (35). between the distance A (A') and the distance B (B') is
B – A = 0.5~1.0 mm (0.02~0.04 in) adjusted to a clearance of 0.5~1.0 mm (0.02~0.04 in).
Clutch shaft
cover
36 O-ring O-ring
13
Gasket
K85V2E34004 K85V2E34007
21. Install cover (13) onto the transmission housing

and then install clutch shaft covers.
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

36
Clutch shaft cover
K85V2E34005
20. Adjust the difference between the distance B' and

the distance A' (thrust clearance) to 0.5~1.0 mm
using shim (36).
B' – A' = 0.5~1.0 mm (0.02~0.04 in)
Remove clutch shaft covers.
34-29
38
37
8
Gasket
12
K85V2E34008 90ZV34144
22. Install ball bearing (37) and gear (38) onto the out- 24. Tighten bolts (12). Install brake assembly (8) and
put shaft. tighten bolt (7).
: Bolt (12): 53 N-m (5.4 kgf-m) (39 lb-ft)

10 : With lubrication oil (Engine oil or gear oil)
: Bolt (7): 216 N-m (22 kgf-m) (159 lb-ft)
6
9
90ZV34143
4
23. Install drive cover assembly (10) and tighten bolt 3

(9).
85W34038
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)
25. Install brake drum (4) and tighten bolt (3).
: Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft)

Install the flange yoke (6) and tighten nut (5).
: Nut: 392 N-m (40 kgf-m) (289 lb-ft)

: Molybdenum disulfide grease /
MOS2 application
34-30
Gasket
85V2E34026
85V2E34027
26. Install control valve assembly (2) and tighten bolts

(1).
Note
Refer to "Control valve removing and installing" page
34-42 to reinstall control valve assy (2).
34-31
Transmission Forward/Reverse Clutch Pack
Forward/reverse clutch pack dis-

assembling and assembling
Forward/reverse clutch pack disassem-
bling
Note
The disassembling procedure for the reverse clutch
3
pack is described below.
The structure of the forward clutch pack is the same as 2
to that of the reverse clutch pack. Therefore, to disas-
semble or reassemble the forward clutch pack, follow 90ZV34059
the reverse clutch pack procedure.
1 3
K90V2E34005
90ZV34058
2. Attach the bearing puller to gear (2), and then

1. Remove snap ring (1). remove the gear with bearing (3) as a unit. There is
thrust washer (4) between gear (2) and the ball
Note bearing. Remove thrust washer (4).
Forward clutch snap ring (1) is addition from T/M S/N
CT270E01-0937~. Note
To disassemble the forward clutch pack, remove the
roller bearing inner race.
For inspection and wear standard refer to "Service stan-
dard".
34-32
11
12
5
6
7
8
85ZV34033J 85ZV34035J
3. Remove two needle bearings (5) and thrust washer 5. Slightly depress ring (12). Remove snap ring (11)
(6). After that remove snap ring (7) and backing and ring (12).
plate (8).
Note
When reassembling, install thrust washers (4)(6) so that
the notch faces gear (2).
13
14
15
17 16
18
9 85V2E34028
6. Remove 20 springs (13), and then turn clutch over

and tap shaft on a wooden block to remove piston
(14).
10 85ZV34034J
7. Remove ring (15) from piston (14).

4. Alternately remove friction plates (9) and steel
plates (10). 8. Remove piston ring (16)(17) from shaft assy (18).
Note
- Number of friction plates: 7
Number of steel plates: 6
- After reinstalling piston (14), be sure to insert friction
plate (9) first.
34-33
Forward/reverse clutch pack assembling Forward/reverse clutch pack assembly

cautions
For reassembling follow the above procedure in reverse
order.
Depth micrometer
Note
Straight edge
replace it with a new one. Be sure to use new piston
rings and seal rings.
- To assemble the forward/reverse clutch pack, be Air line
sure to apply transmission oil.
- Be sure the residual pressure prevention orifices are
not plugged. Pass a small wire through the orifices.
Backing plate
85W34041
After assembling clutch pack.

- Using a straight edge and depth micrometer apply
pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the
clutch oil port at the end of the shaft, and then mea-
sure and record the piston stroke.
Piston stroke
Forward 3.3±0.5 mm (0.13±0.02 in)
Reverse 3.3±0.5 mm (0.13±0.02 in)
Note
If the piston stroke value is beyond the above range,
replace the parts, or check that the parts are not warped
and are correctly reassembled.
34-34
Transmission 1st/3rd Speed Clutch Pack
Transmission 1st/3rd speed clutch

pack disassembling and assem- 7 6
bling 2
Transmission 1st/3rd speed clutch pack

disassembling 3 4 8
Note (3rd speed) (1st speed)

This disassembling and reassembling procedures for 5
the 1st and 3rd clutch packs are basically the same. 10 9
The different points are described for each procedure.
90ZV34071
2. [3rd speed]
- Remove thrust washer (2), and then remove rear
gear (3).
- Using internal or blind hole puller remove needle
bearings (4) and thrust washer (5).
Spacer
Note
When reassembling install thrust washers (2)(5) so that
the notch faces to gear (3).
1
[1st speed]
85K34099 - Remove thrust washers (6) and thrust bearing (7).
- Using internal or blind hole puller remove needle
bearings (8), thrust washers (9), and thrust bearing
1. Remove ball bearing (1) using a puller.
(10).
Note
Use a spacer over the shaft to protect the shaft and
inner bearing from damage.
12
11 Shaft assembly
90ZV34072
3. Remove snap ring (11) and backing plate (12).

34-35

14
assembling

order.
13 Note
- To assemble the 1st/3rd speed clutch pack, be sure
16 to apply transmission oil.
15 90ZV34073
- Be sure the residual pressure prevention orifices are
not plugged. Pass a small wire through the orifices.
4. Alternately remove friction plates (13) and steel
plate (14).
Note Transmission 1st/3rd speed clutch pack

After reinstalling piston (18), be sure to insert friction assembly cautions
plate (13) first.
Friction plates Steel plates

1st speed 9 8
3rd speed 5 4
5. Remove snap ring (15) and ring (16).
19 20
18
85K34107
17
Shaft assembly pressure (approx. 0.6 MPa [6 kgf/cm2] [85 psi]) to the
90ZV34074
Piston stroke
6. Remove 20 springs (17), and then turn over the 1st speed 3.5±0.5 mm (0.14±0.02 in)
clutch and tap the shaft on a wooden block to 3rd speed 2.1±0.5 mm (0.08±0.02 in)
remove piston (18).
Note
7. Remove U-ring (19) from piston (18).
8. Remove piston ring (20) from the shaft assembly.
34-36
Transmission 2nd Speed Clutch Pack
Transmission 2nd speed clutch

pack disassembling and assem-
bling
Transmission 2nd speed clutch pack disas-
sembling
9
4
8
3
7 90ZV34084
3. Remove thrust washer (7), thrust bearing (9) and

thrust washer (8). Store the thrust washers for pos-
sible reuse.
1 2
90ZV34082
1. Remove spacer (1) and gear (2). After that, remove

snap ring (3) and backing plate (4). 12
11
10
5
90ZV34085
6
4. Depress plate (11) and remove snap ring (10), and
plate (11).
5. Remove 20 springs (12).
90ZV34083
2. Remove friction plates (5) and steel plates (6).
Note
Number of steel plates: 4
plate (5) first.
34-37
Transmission 2nd speed clutch pack

assembly cautions
14 15
13
Shaft assembly
90ZV34086
6. Turn over clutch the and tap the shaft on a wooden

block to remove piston (13). 85K34107

8. Remove piston ring (15) from the shaft assembly.
Transmission 2nd speed clutch pack
assembling Piston stroke
2nd speed 2.1±0.5 mm (0.08±0.02 in)
order. Note
Note replace the parts, or check that the parts are not warped
- Clean and check all the parts. If a part is damaged, and are correctly reassembled.
- To reassemble the 2nd speed clutch pack, be sure
to apply transmission oil.
34-38
Transmission 4th Speed Clutch Pack
Transmission 4th speed clutch

pack disassembling and assem- 7
bling 6
Transmission 4th speed clutch pack disas-

sembling
90ZV34093
1 3. Remove snap ring (6) and backing plate (7).
90ZV34091
1. Using a puller remove ball bearing (1). 9
5
90ZV34094
4
2
4. Remove friction plates (8) and steel plates (9).
3
Note
Number of steel plate: 4
90ZV34092 plate (8) first.
2. Remove thrust washer (2) and gear (3). Use an

internal or blind hole puller to remove needle bear-
ing (4) from inside the gear.
Remove needle bearing (4) and thrust washer (5).
Note
When reassembling install thrust washers (2)(5) so that
notch faces to gear (3).
34-39
Transmission 4th speed clutch pack

assembling

order.
Note
11 - Clean and check all the parts. If a part is damaged,
10
- To reassemble the 4th speed clutch pack, be sure to
apply transmission oil.
90ZV34095
5. Depress ring (11) and remove snap ring (10), and

ring (11). Transmission 4th speed clutch pack
assembly cautions
16
15
14
13
12
Shaft
Shaft assembly
Gear
90ZV34096
Clutch drum
90ZV34114
6. Remove 20 springs (12), and then turn over the
clutch and tap the shaft on a wooden block to
1. When installing the gear to the shaft, follow the pro-
remove piston (13).
cedure below.
- Assemble the gear onto the clutch drum with the
bolts.
8. Remove piston ring (15)(16) from the shaft assem-
- Heat them up to 190ºC (374ºF).
bly.
- Insert the shaft into the clutch drum and gear.
: Bolt: 86 N-m (8.8 kgf-m) (64 lb-ft)

34-40
Depth micrometer
Straight edge
Air line
Backing plate
85W34041
2. After assembling clutch pack.

Piston stroke
4th speed 2.1±0.5 mm (0.08±0.02 in)
Note
34-41
Control Valve Assembly
Control valve tightening torque
T1 T1
T4
T2
T3.
90ZV34104
: Bolt tightening torque

T1: 20 N-m (2.0 kgf-m) (14 lb-ft)
T2: 39 N-m (4.0 kgf-m) (29 lb-ft)
T3: 10 N-m (1.0 kgf-m) (7 lb-ft)
(Solenoid valve nut)
T4: 34 N-m (3.5 kgf-m) (24 lb-ft)
(Solenoid valve body)
34-42
Control valve removing and

installing
4
Control valve removing
WARNING 3 5

- Park the machine on level ground, and then lower
the attachment onto the ground. 85V2E34023
- Apply the parking brake, and block the tires with
chocks to prevent wheels from moving.
2. Attach sling to control valve (3), and then remove
- Remove the starter key, and hang a "DO NOT
valve bolts (4).
START!" tag on the steering wheel.
: Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft)
Note
Do not remove two trimmer bolts (5).
3. Lower the control valve to remove it.

2 Be sure to replace the gasket.
IMPORTANT
After removing or while reinstalling the control valve,
1 take care not to allow foreign material into the main
90V2E34012 body or the control valve. Carefully remove or rein-
stall the control valve and gasket.
1. Disconnect all electric wire couplers (1) also dis-
connect hose (2) for checking the clutch pressure. : Control valve: 20 kg (44 lbs)
Note
Put matchmarks on the electric wire couplers.
34-43
Control valve installation cautions

WARNING
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.
LP Control valve
TR (f) At the completion of installation, start the engine,

LO and check that the shift lever properly functions at
all the positions.
LR 3
(g) Check oil leakage.
F
LBr R
(h) Adjust the transmission oil level to the specified
LY 2 point with the dipstick.
4 1
LG
LW
K92V2U34001
(a) Be sure to replace all the O-rings and gaskets with

new ones.
(b) Sequentially tighten the bolts in the order from the

center to the outside. Apply equal (specified) torque
to all the bolts.
(c) 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.
(d) Install the cover while checking that the emergency

operation bolts are positioned over the center of the
solenoid valves.
(e) During installation, be careful not to damage the

gasket.
34-44
Control valve disassembling and

assembling
Control valve disassembling
Note
Clean the control valve.
85V2E34031
3. Remove valve (4) using a 17 mm wrench.
: Valve: 34 N-m (3.5 kgf-m) (24 lb-ft)

1
85V2E34029
5
1. Remove nut (1) using special tool (A). 7
: Nut: 10 N-m (1.0 kgf-m) (7 lb-ft) 6
Note
Nut width across flat: 30 mm
Special tool (A) is described on the next page.
For other valves, follow the same procedure. 90ZV34109
4. Remove plugs (5)(6), and then remove the parts

from the inside.
Note
Do not remove trimmer body (7) unless absolutely nec-
essary.
2 85V2E34030
2. Remove O-ring (2), and then remove coil (3).
Note
For other solenoid valves, follow the same procedure.
34-45
Control valve assembling
To reassemble the control valve, follow the disassem-

12
8
bling procedure in reverse order.
11
10
9
Control valve assembly cautions
- Before you insert the regulator valve, apply transmis-

sion oil to the valve. After insertion, check that the
90ZV34110
valve operates smoothly.
- Placing shims under the springs to increase pres-

5. Remove regulator valve (8), trimmer plug (9), sure or change modulation is not recommended.
springs (10), spring retainer (11), and plug (12). Check free lengths and if necessary replace them.
- 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.
- Check coil resistance.

Resistance: Approx. 27 Ω
34-46
MEMO
35-1
90ZV-2 Service Standard Torque Converter and Transmission Group

Torque Converter and Transmission Group
Transmission Assembly .......................................... 35-2

Control Valve ........................................................... 35-3
Gear Pump .............................................................. 35-5
Clutch Plate Thickness/Piston Stroke ..................... 35-6
Clutch Oil Pressure ................................................. 35-8
35-2
13 12
5 16 4
18
14
17
17
14
18
15
16 5
T/M S/N CT270E01-0937~
9
Note
10 11 Numbers correspond to the REF. number
on page 35-4.
K90V2E35001
35-3
Control Valve
Control Valve
3 7 6 2
90ZV35002
Note
Numbers correspond to the REF. number on page 35-4.
35-4
Control Valve
mm (in), kg (lbs)
Judgement criteria
REF. ITEM Solution
Standard clearance Allowable limit
Control valve regulator valve ~ valve 0.030~0.061 0.09
1 Replacement
body (0.0011~0.0024) (0.0035)
Control valve regulator valve ~ seal 0.016~0.045 0.07
2 Clearance Replacement
retainer (0.0006~0.0017) (0.0027)
Control valve trimmer plug ~ valve 0.025~0.066 0.09
3 Replacement
body (0.0010~0.0026) (0.0035)
Standard value Allowable limit
ITEM
Installed Installed Installed
Free length Free length
length load load
44.6 35.2 10.2 43.6 9.2
4 T/C inlet valve spring Replacement
(1.7559) (1.3853) (23) (1.7165) (20)
Clutch return spring 24.4 21 3.3 23.7 3.0
5 Replacement
(The same spring for all clutches) T/C (0.9606) (0.8267) (7) (0.9330) (6)
Spring
89 89 87.5
6 Control valve regulator spring 0 0 Replacement
(3.5039) (3.5039) (3.4448)
81.4 69 5 80 4.5
7 Control valve trimmer spring Replacement
(3.2047) (2.7165) (11) (3.1496) (10)
Judgement criteria
ITEM
Standard value Allowable limit
41.93~42.0 41.8
8 Charge pump shaft dia. Replacement
(1.6507~1.6535) (1.6456)
Replace oil
79.92~80.0 79.8 seal when
9 Rear yoke shaft dia. Replacement
(3.1464~3.1496) (3.1417) disassem-
Oil seal
79.92~80.0 79.8 bling and
10 Front yoke shaft dia. reassem- Replacement
(3.1464~3.1496) (3.1417)
bling
11.95~12.0 11.8
11 Speedometer driven gear shaft dia. Replacement
(0.4704~0.4724) (0.4645)
0 0 2.85
W 3.05 -0.1 (0.1200 -0.0039 )
(0.1122)
12 Torque converter inlet Replacement
2.9±0.1 2.7
H
(0.1142±0.0039) (0.1063)
0 0 3.79
W 3.99 -0.1 (0.1570 -0.0039 )
(0.1492)
13 Seal ring Torque converter outlet Replacement
4.6±0.1 4.4
H
(0.1811±0.0039) (0.1732)
0 0 3.69
W 3.89 -0.1 (0.1532 -0.0039 )
Clutch shaft (0.1453)
14 W Replacement
(The same for all clutches) 4.35±0.1 4.15
H
H (0.1713±0.0039) (0.1634)
4.75±0.1 4.55
15 Piston outer dia. (F, R) H Replacement
(0.1870±0.0039) (0.1791)
4.75±0.1 4.55
16 Piston outer dia. (1~4 speed) H Replacement
(0.1870±0.0039) (0.1791)
4.7
17 Piston inner dia. H 4.9 +0.015
0 (0.1929 +0.0006
0 ) Replacement
(0.1850)
2.9~3.1 2.7
18 Thrust washer thickness Replacement
(0.1141~0.1220) (0.1063)
0.2~0.3 0.5
Gear backlash Replacement
(0.0078~0.0118) (0.0196)
35-5
Gear Pump
Gear Pump
Gear pump specifications
Theoretical 64.5 cm3/rev (3.9 in3/rev)
Maximum operation
2 MPa (20 kgf/cm2) (284 psi)
1 pressure
Maximum operation
4 2,400 min-1 (rpm)
speed
Approx. 120 L/min (31.7 gpm)
Conditions:
Pump speed 2,200 min-1
2 Oil temp. 80~100°C (176~212°F)
Actual discharge
Oil viscosity 40CST (SAE10W)
Discharge pressure 1.4~1.6 MPa
(14~16 kgf/cm2)
(199~228 psi)
90ZV35003
Unit: mm (in)
No. Item Standard value Solution
1 Top clearance between gear and housing 0.08~0.11 (0.003~0.004) Replacement
2 Side clearance between gear and housing 0.03~0.073 (0.001~0.003) Replacement
3 Backlash between gears 0.2~0.3 (0.008~0.012) Replacement
4 Tightening torque for pump fixing bolt 59 N-m (6.0 kgf-m) (43 lb-ft) Tightening
Note
When measuring the side clearance of item 2 above, remove the gasket.
35-6
Clutch Plate Thickness/Piston Stroke
T2 L 3
T6 L 3 T7 L 3
T7 L 3
T2 L 3 T1 L 3
T5 L 1
T3 L 1
T/M S/N CT270E01-0937~
T4 L 2 T6 L 3
T6 L 3
K90V2E34003
:
T1: 29 N-m (3.0 kgf-m) (22 lb-ft) L1: Screw lock agent (Loctite® 262) application
T2: 59 N-m (6.0 kgf-m) (43 lb-ft) L2: Molybdenum disulfide grease /
T3: 216 N-m (22.0 kgf-m) (159 lb-ft) MOS2 application
T5: 94 N-m (9.6 kgf-m) (69 lb-ft)
T6: 53 N-m (5.4 kgf-m) (39 lb-ft)
T7: 86 N-m (8.8 kgf-m) (64 lb-ft)
35-7
Clutch plate
Number of clutch plates
Note
All the friction plates, steel plates, and return springs are
interchangeable for each clutch.
Name of clutch Friction plate Steel plate Return spring
Forward clutch 7 6 20
Reverse clutch 7 6 20
1st speed clutch 9 8 20
2nd speed clutch 5 4 20
3rd speed clutch 5 4 20
4th speed clutch 5 4 20
Outer dia. ø192 (7.55 in) ø203.2 (7.99 in) —
Inner dia. ø123.8 (4.87 in) ø133.5 (5.25 in) —

Dimension
(mm) (in)
When new 3.3±0.1 (0.13±0.004 in) 2.6±0.1 (0.10±0.004 in) —
Thick-
ness Wear limit 3.1 (0.12 in) 2.4 (0.09 in) —
Piston stroke
mm (in)
Clutch Standard value
Forward clutch 3.3±0.5 (0.13±0.02)
Reverse clutch 3.3±0.5 (0.13±0.02)
1st speed clutch 3.5±0.5 (0.14±0.02)
2nd speed clutch 2.1±0.5 (0.08±0.02)
3rd speed clutch 2.1±0.5 (0.08±0.02)
4th speed clutch 2.1±0.5 (0.08±0.02)

35-8
Clutch Oil Pressure
Clutch Oil Pressure
1
7
7
3
2
4 8
3 6
5
4
9
6
90ZV35005
Clutch oil pressure standard value

(Oil temperature 50~80ºC (120~180ºF))
Oil pressure MPa (kgf/cm2) (psi)

Measuring port
No. Measuring port location Engine revolution (rpm) Shift lever position
size
800 (Low idle) 2,350 (High idle)
1 Torque converter inlet PT3/4 0.03~0.5 (0.3~5.5) (4.3~78) 0.2~0.5 (2.0~5.5) (28~78) All speed range
2 Main oil pressure PT1/8 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) All speed range
3 Forward clutch oil pressure PF1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) Forward
Clutch oil pressure
4 Reverse clutch oil pressure PF1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) Reverse
5 1st speed clutch oil pressure PF1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) 1st speed
6 2nd speed clutch oil pressure PF1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) 2nd speed
7 3rd speed clutch oil pressure PF1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) 3rd speed
8 4th speed clutch oil pressure PF1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) 4th speed
9 Transmission lubrication oil pressure PT1/2 0.01~0.1 (0.1~1.0) (1.4~14) 0.05~0.2 (0.5~2.5) (7~36) All speed range
44-1
90ZV-2 Disassembly & Reassembly Hydraulic Group

Hydraulic Group
Hydraulic Parts Removal and Installation Warning

............................................................................. 44-2
Hydraulic Parts Disassembly and Assembly Cautions
............................................................................. 44-3
Hydraulic Pump Assembly ...................................... 44-4
Hydraulic Cylinder ................................................... 44-15
Pilot Valve (S/N 9001~9352) ................................... 44-28
Pilot Valve (S/N 9353~) ........................................... 44-41
Multiple Control Valve.............................................. 44-51
Orbitrol® ................................................................... 44-57
Steering Valve ......................................................... 44-67
Stop Valve ............................................................... 44-72
Fan Motor ................................................................ 44-76
44-2

Disassembly and reassembly work of hydraulic parts
greatly depends on the working area and working condi-
tion (soon after operation or not).
Understand the following items well and work safely.
WARNING
Unexpected movement of machine could cause seri-
ous 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
- 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 sud-
denly.
- 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 plas-
tic caps or plugs to protect them from dust, water
and dirt.
- Apply the specified torque to tighten each part.
44-3

Hydraulic parts may be very delicate. When disassem- Hydraulic parts disassembly cau-
bling or reassembling, handle with care.
Understand the following well to perform disassembly tions
and reassembly work.
- 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 the 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
Hydraulic Pump Assembly
Hydraulic pump assembly remov- 2. Remove the hydraulic pump retainer bolts.
ing and installing : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft)
Hydraulic pump assembly removing 3. Remove hydraulic pump (1).
: Hydraulic pump: 46 kg (105 lbs)

DANGER
Entering the articulation area while engine is running
may cause serious injury or death.
So, when entering the area, stop the engine and Hydraulic pump assembly installing
place "DO NOT START" or "DO NOT OPERATE" tag
on steering wheel. To reinstall the hydraulic pump assembly, follow the
above removal procedure in reverse order.
CAUTION
Removing hoses and plugs without bleeding residual
pressure could cause injuries or burns from hot oil Hydraulic pump installation cautions
under pressure.
Before removing hoses and plugs, relieve residual - Replace all gaskets and O-rings during reinstallation.
pressure. Relieve internal pressure from hydraulic
tank to prevent oil from spraying. - When replacing hydraulic pumps or when draining
hydraulic oil for extended periods, it is important to
Before starting work: prime the hydraulic system properly.
- Remove the cab and the floor board by referring to Air will be in the lines that go to and come from the
Section 14. pump. After a pump has been installed, or when the
- Clean the area around the hydraulic pump. hydraulic oil has been drained for extended time
periods, air will not purge easily from the lines, and
this could lead to pump damage.
Transmission
WARNING
Oil injection hazard!
Hydraulic oil can penetrate skin. When performing
this procedure:
- Release all trapped circuit pressure prior to start-
ing any procedure involving hydraulic oil.
- Wear protective gloves.
1 - Wear eye and face protection.
- Stay clear of areas where air may be purged.
3 2 - Route oil into a receiving canister [such as a 5 gal-
90V2E44001 lon bucket] by use of an additional hose.
- Rotate pump at a low RPM.
1. Disconnect outlet hose (2) and suction hose (3)
from hydraulic pump (1).
Note
Cover the hoses with plastic, plugs or caps to protect
from dust and dirt.
44-5
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 hydraulic 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 dur-
ing 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 cylin-
ders at this time.
- Confirm that there is no abnormal noise or opera-
tion, 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 pre-
mature pump failure.
44-6
Hydraulic pump assembly disassembling and assembling
IMPORTANT WARNING
Before disassembly or reassembly, read and under- Do not attempt to disassemble the pump assembly
stand the aforementioned "Hydraulic Parts Disas- unless otherwise required, as it should significantly
sembly and Assembly Cautions" page 44-3. affect the pump performance or may cause second-
ary problems.
IMPORTANT
- Handle pumps carefully.
- In case hydraulic system breaks down, do not dis-
assemble 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 pre-
vent recurrence.
Hydraulic pump assembly cross section and tightening torque
T1
Damper T2
K90V2E44002

T1: 177 N-m (18 kgf-m) (130 lb-ft)
T2: 275 N-m (28 kgf-m) (203 lb-ft)
44-7
Oil seal replacement procedure [Example 2]
There are two kinds of the pump drive gear shaft unit.
One has one oil seal only, and the other has an addi-
tional dust seal or oil seal outside.
Replace the oil seals and O-rings between the double
Front cover
and triple pumps which are allowed to be separated.
[Example 1]
Oil seal Snap ring
Drive gear shaft
Oil seal
Drive gear shaft
Oil seal Snap ring
90ZV44049
In case of Example 2
Front cover 1. After removing the outer oil seal, remove the snap
ring and the inner oil seal.
2. When removing the oil seals, remove any scores

90ZV44048 on the front cover and the drive gear shaft.
3. Cover the drive gear shaft with vinyl electrical tape

to protect the splines.
4. Apply a thin coat of grease to the oil seal and the lip
unit.
5. Install the seal straight.

44-8
Hydraulic pump disassembling
IMPORTANT
- If a pump must be repaired, be sure no pieces of
damaged pump material has scattered through
hydraulic system. 4
- New parts must be "broken in" and performance 3
must be checked.
- Put appropriate matchmarks and/or place the dis- 5
assembled parts and units in disassembled order
to help and assure correct reassembling of them.
K90V2U44002
- Take great care not to damage the mating face and
sliding surface of each part.
- Clean the pump surface and power input shaft 2. Remove cover (3).
while disassembling. Prevent foreign materials
entering into the pump inside. 3. Remove seal kit (4)(5) from cover (3).
Plate
2
8
1
6
K90V2U44003
O-ring
K90V2U44001
4. Put a matchmark and remove wear plate (6) on the

1. Place the hydraulic pump assembly on a firm and cover side.
flat workbench so the bracket comes bottom side
as shown. Note
Remove cover fixing bolt (1). For easier removal of wear plate (6), slightly move up
drive gear (7) or driven gear (8).
: Bolt (1): 274.6 N-m
(28.0 kgf-m) (202.5 lb-ft) CAUTION
Note Wear plate (6) is an asymmetric part. If it is installed
- It is recommended to fix the pump onto the bottom incorrectly, it may cause serious pump damage.
using the bracket mounting bolts. Be sure to put a matchmark for correct installation.
- If you remove the plate on the third pump intake port,
remove bolt (2). Remove the plate before removing 5. Put matchmarks at the shaft end of drive gear (7)
bolt (1). and driven gear (8), and pull out them to remove.
: Bolt (2): 67 N-m (6.8 kgf-m) (49 lb-ft)

44-9
12, 13
5 8
10
9 10 1 3
4 2
7 6
11
Nut removing order
15
Pin 14
K90V2U44004 K90V2U44006
6. Put a matchmark and slowly separate gear case (9) 9. Remove nut (14) and washer (15) from carrier (10).
and carrier (10). Remove nut (14) diagonally as shown above.
Wear plate (11) in gear case (9) on the carrier side
should remain there. Be careful not to drop it out of : Nut (14): 176.5 N-m (18.0 kgf-m) (130 lb-ft)
the case.
Note 10
There is a locating pin on gear case (9). 16
18
7. Remove seal kit (12)(13) from carrier (10).
10
17
K90V2U44007
11
10. Put a matchmark and slowly separate carrier (10)
and gear case (16).

K90V2U44005
8. Put a matchmark and remove wear plate (11) from

gear case (9).
CAUTION
Wear plate (11) is an asymmetric part. If it is installed
incorrectly, it may cause serious pump damage.
Be sure to put a matchmark for correct installation.
44-10
22
16
23
19 Pin
K90V2U44008 K90V2U44010
12. Put a matchmark and remove wear plate (19). 14. Put a matchmark and slowly separate gear case
(16) and carrier (22).
Wear plate (23) in gear case (16) on the carrier side
CAUTION should remain there. Be careful not to drop it out of
Wear plate (19) is an asymmetric part. If it is installed the case.
Be sure to put a matchmark for correct installation. Note
There is a locating pin on gear case (16).
15. Remove wear plate (23) from gear case (16).
16
20
22
25
21
K90V2U44009
24
13. Put matchmarks at the shaft end of drive gear (20) K90V2U44011
and driven gear (21), and pull out them to remove.
44-11
26 22 26
22
29
28 31
32
27
K90V2U44012 K90V2U44014
17. Put a matchmark and slowly separate carrier (22) 20. Put matchmarks at the shaft end of drive gear (31)
and gear case (26). and driven gear (32), and pull out them to remove.
Note
33
There are sleeves (27) installed in carrier (22) to protect
stud bolts.
26 26
30
26
31 34
32
K90V2U44015
21. Put a matchmark and slowly separate gear case

(26) and bracket (33).
Wear plate (34) in gear case (26) on the bracket
30
side should remain there. Be careful not to drop it
K90V2U44013
out of the case.
19. Put a matchmark and remove wear plate (30) on 22. Remove wear plate (34) from gear case (26).
the cover side.
Note
CAUTION
For easier removal of wear plate (30), slightly move up Wear plate (34) is an asymmetric part. If it is installed
drive gear (31) or driven gear (32). incorrectly, it may cause serious pump damage.
CAUTION
Wear plate (30) is an asymmetric part. If it is installed
44-12
33
33
35
36
39
K90V2U44016
38 K90V2U44018
23. Remove seal kit (35)(36) from bracket (33). 25. Remove snap ring (38) using plier.
Insert a screwdriver from the bearing hole for the
drive gear, and push out oil seal (39) from its back
33 side by hitting the screwdriver with a hammer, etc.
Note
Take care not to scratch the parts around when inserting
and hitting the screwdriver.
37 Hydraulic pump assembling
To reassemble the hydraulic pump assembly, follow the

K90V2U44017
above disassembling procedure in reverse order.
24. Remove stud bolts (37) from bracket (33).
: Bolt (37): 78.5 N-m (8.0 kgf-m) (58 lb-ft) Hydraulic pump assembly cautions
- Clean each part carefully and avoid foreign material

from entering the pump. Especially, clean the bolts
and bolt holes carefully so that no dirt or oil remain.
- Fit in the oil seals at appropriate positions without

kink or bend.
- Apply grease on the sliding surfaces when installing

gears.
44-13
Stud bolt installation Seal kit installation
Install stud bolts (37) to bracket (33) so that the cham-

fered side of stud bolt (37) is screwed into bracket (33). 33
Screw stud bolt (37) fully to the end of threaded portion.
: Bolt (37): 78.5 N-m (8.0 kgf-m) (58 lb-ft)
35
Oil seal installation
36
33 K90V2U44016
When installing seal kit (35)(36) to bracket (33), insert

back-up ring (35) in the groove while wrapping it over
the bush, then, insert seal (36) into the groove.
Incorrect installation of the seals may cause damage to

39
the seal or the pump. Make sure to fit in the seals at
appropriate positions without kink or bend.
38 K90V2U44018
Note
Install the seal kits to the carriers (10)(22) in the same
Apply grease on the external surface for easier installa-
manner.
tion. This also prevent oil seal (39) from being torn.
Prepare and set a supporting tool (steel pipe) to oil seal
(39), and press in or hit the tool with a hammer.
Fix oil seal (39) using snap ring (38). Gear case installation
Tool specifications
Outer diameter: Oil seal outer diameter - 2 mm (0.08 in) 22
Inner diameter: Input axis + 5 mm (0.20 in)
Length: 100 mm (3.94 in) or longer
16
23
Pin
K90V2U44010
Gear cases (9)(16)(26) have locating pin.

For easier installation, install the wear plate into the
gear case before installing the gear case. If you install
the wear plate after installing the gear case, be careful
the wear plate and the gear plate do not get stuck.
44-14
Wear plate installation Sleeve installation
26 22
Intake side
22
29
28
Wear plate (11) (23) (34) 27

K95V2U44013 K90V2U44012
When installing sleeve (27) into carrier (22), press the

sleeve lightly with your fingers and insert it into the
sleeve hole of the carrier.
Install seal kit (28)(29) to carrier (22), and install carrier
(22) to gear case (26). Be advised that the side with
sleeves (27) should come to the pump rear side when
Intake side installing carrier (22).
If sleeve (27) comes out while installing carrier (22),
push it in after installing carrier (22).
Wear plate (6) (19) (30)

K95V2U44014
The wear plates are asymmetric parts. If they are

installed incorrectly, it may cause serious pump dam-
age. Be sure to put matchmarks before removing them
for correct installation.
Drive gear installation
Before installing drive gear (31) to gear case (26), apply

grease to the lip of oil seal (39) to avoid being damaged
by drive gear (31).
44-15
Hydraulic Cylinder
Hydraulic Cylinder
Boom cylinder removing and

installing
Boom cylinder removing
3
(The illustration shows the left side of the machine.)
WARNING
Unexpected movement of machine, bucket, or boom
2
during service work could cause serious injury or
1
lowing items:
- Park the machine on level ground, and apply the 90ZV44006
parking brake. In addition, block the tires with
1. Attach sling to boom cylinder (1).
- Raise the boom until it is horizontal, and then place
Disconnect grease hose (2) from pin (3), and then
stand (A) under the boom to support it.
remove pin (3).
- Relieve the internal pressure from the loading line,
and also relieve the internal pressure from the
: Boom cylinder: 207 kg (460 lbs)
hydraulic tank to prevent the oil from spouting out.
- Use a stepladder or work platform, and do not
stand on the machine.
Clean the area around the cylinder and piping.
Relieving residual pressure from pipe 4

5
90ZV44007
2. Disconnect hose (4) and pipe holder (5).
Stand (A) Note

Cover the disconnected hoses with plastic, plugs, or
caps to protect them from dust, water and dirt.
90ZV44005
(a) Raise the boom. When the boom is approximately

30 cm (1 foot) above stand (A), 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 hydrau-
lic tank. Leave hydraulic tank cap loosely on top of
tank opening.
44-16
Hydraulic Cylinder
90ZV44008 90ZV44011
3. Remove oil pipe (6), and then push the rod into the 6. Sling boom cylinder (1), and lower it onto the
cylinder to shorten the length of the cylinder. ground.
Note For the detailed description of cylinder disassembly

Cover the disconnected pipes with plastic, plugs, or and reassembly, refer to "Hydraulic cylinder disas-
caps to protect them from dust, water and dirt. sembling and assembling" page 44-22.
Boom cylinder installing
To reinstall the boom cylinder, follow the above removal

8 Boom cylinder installation cautions
7 90V2E44002
Be sure the pins accept grease after installation.
4. Remove lock bolt (8) for pin (7). 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.
Cylinder air bleeding procedure
(a) While operating the engine at low-idling speed,

operate the cylinder piston for 4 to 5 strokes.
9
Note
7
Stop the piston about 100 mm (4.0 in) before stroking
fully.
90ZV44010
(b) After that, stroke the cylinder piston fully to both
ends 4 to 5 times.
5. Insert jack bolts (9) to pin (7), and then remove pin
(7). (c) Add hydraulic oil to the tank, and check the cylinder
and its piping for oil leakage.
44-17
Hydraulic Cylinder
Bucket cylinder removing and

installing
Bucket cylinder removing
1
WARNING
lowing items:
- Park the machine on level ground, and apply the 90ZV44014
1. Remove the coupler of bucket leveler switch (1).
- Place the boom and the attachment onto the
ground.
and also relieve the internal pressure from the 2
- Use a step, and do not stand on the machine.
Clean the area around the cylinder and piping.

3
Relieving residual pressure from pipe
(a) Lower the boom and the attachment onto the
ground.
(b) Stop the engine and move the attachment and
boom levers back and forth. 90V2E44003
(c) Open the cap of the hydraulic tank to relieve the
residual pressure.
2. Attach sling to bucket cylinder (3).
After that, remove pin (2).
: Bucket cylinder: 130 kg (290 lbs)
90ZV44015
3. Lift bucket cylinder (3) and disconnect the bucket

cylinder from the lever. Remove rod (4).
44-18
Hydraulic Cylinder
8
6
90ZV44016 90V2E44004
4. Start the engine and shorten the cylinder rod. Stop 6. Disconnect the grease pipe and then remove pin
the engine and disconnect hose (5)(6). (8).
Note 7. Slowly lift up bucket cylinder (3). Lower the bucket

Cover the disconnected hose and the cylinder with plas- cylinder onto the ground.
tic, caps or plugs to protect them from dust, water and
dirt. For the detailed description of cylinder disassembly
and reassembly, refer to "Hydraulic cylinder disas-
sembling and assembling" page 44-22.
Bucket cylinder installing
To reinstall the bucket cylinder, follow the above

removal procedure in reverse order.
7
90ZV44017
5. Remove bucket positioner bracket (7).

44-19
Hydraulic Cylinder
Bucket cylinder installation cautions
- Be sure the pins accept grease after installation.
- Adjust the bucket leveler so that the clearance

between the switch and the rod is 5±2 mm
(0.196±0.078 in).
Refer to "Attachment Leveler" page 15-6.
IMPORTANT
ring may be seized.

Note
fully.

ends 4 to 5 times.
(c) Add hydraulic oil to the tank, and check the cylinder
44-20
Hydraulic Cylinder
Steering cylinder removing and

installing
5
Steering cylinder removing
WARNING
3
observe the following items: 4
- Park the machine on level ground, and apply the
parking brake. In addition, block the tires with 90ZV44020
- Place the boom and the attachment onto the
2. There is pin (5) at the link between front chassis (3)
ground.
and steering cylinder (4). Remove pin (5), and then
- Stop the engine, and turn the steering wheel clock-
push the rod into the cylinder to shorten the length
wise and counterclockwise to relieve the pressure
of the cylinder.
from the line.
- Press the cap of the hydraulic tank downward to
: Oil will be drained from the oil port of the
vent, then open the cap to relieve the internal pres-
cylinder. Place a container at the oil port
sure from the tank.
to catch the drained oil.
- Place a "DO NOT START!" tag on the steering
wheel or the operator's seat.
6
- Clean the area around the cylinder to be removed. 7
4
90V2E44006
3. Disconnect grease pipe (6) and remove pin (7).
4. Remove the steering cylinder assembly.

2
90V2E44005
: Steering cylinder: 42 kg (95 lbs)
1. Disconnect hoses (1)(2). For detailed description of cylinder disassembly

and reassembly, refer to "Hydraulic cylinder disas-
Note sembling and assembling" page 44-22.
Cover the disconnected hoses with plastic, caps, or
plugs to protect them from dust, water, and dirt.
44-21
Hydraulic Cylinder
Steering cylinder installing Steering cylinder installation cautions
To reinstall the steering cylinder, follow the above 1. When reinstalling the pins
Be sure the pins accept grease after installation.
IMPORTANT
Insert shims so that the clearance between the chas-
sis and the cylinder is 1.2 mm (0.047 in) 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.
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 run-
ning, do not enter the articulation area of the
machine.
If a person is in the articulation area, do not start the
engine.
2. Bleed the cylinder of air
IMPORTANT
ring may be seized.

Note
fully.

ends 4 to 5 times.
(c) Add hydraulic oil to the tank, and check the cylinder
44-22
Hydraulic Cylinder
Hydraulic cylinder disassembling and assembling

Hydraulic cylinder cross section and tightening torque
IMPORTANT
Before disassembly or reassembly, read and under-
stand the aforementioned "Hydraulic Parts Disas-
sembly and Assembly Cautions" page 44-3.
Boom cylinder
T1 T2
90ZV44002J
: Piston nut width across flats: 90 mm (3.54 in)

T1: 4,756 N-m (485 kgf-m) (3,509 lb-ft) Thread size: M62 x 2
T2: 843 N-m (86 kgf-m) (622 lb-ft)
Bucket cylinder
T3 T4
90V2E44007

T3: 4,600±230 N-m (469±23.5 kgf-m) (3,393±170 lb-ft) Thread size: M56 x 2
T4: 880±90 N-m (89.7±9.2 kgf-m) (649±67 lb-ft)
44-23
Hydraulic Cylinder
Steering cylinder
T6
T5
90ZV44004J

T5: 1,275 N-m (130 kgf-m) (941 lb-ft) Thread size: M36 x 1.5
T6: 2,157 N-m (220 kgf-m) (1,592 lb-ft)
44-24
Hydraulic Cylinder
Hydraulic cylinder disassembling
Note
The bucket cylinder disassembling procedure is 4
described below. For other cylinders, follow the same
procedure.
95ZV44006
3. Remove piston rod assembly (4) from the cylinder

tube.
: Hydraulic oil will be drained, so place a

Repair stand
container to receive the drain oil.
95ZV44004
1. Install the bottom side of the cylinder to the repair

stand. Repair stand
4
Matchmark
3
Wooden block
95ZV44007
2
4. Remove the cylinder tube from the repair stand and
1 install rod assembly (4) to the repair stand and sup-
95ZV44005 port the rod as shown in the figure.
2. Put the matchmarks on rod cover (1) and cylinder

tube (2). Remove rod cover bolt (3).
: Bolt (3):
843 N-m (86.0 kgf-m) (622 lb-ft)
(Boom cylinder)
880 N-m (89.7 kgf-m) (649 lb-ft)
(Bucket cylinder)
Rod cover (1):

2,157 N-m (220.0 kgf-m) (1,592 lb-ft)
(Steering cylinder)
44-25
Hydraulic Cylinder
5
4
Matchmark 6 7 4
6
K90V2E44003 95ZV44010
5. Remove stop ring (5) and put matchmarks on rod 7. Remove piston nut (6), and then remove piston (7)
(4) and piston nut (6) for alignment with the stop from piston rod (4).
ring holes. (Stop ring is attached to steering cylin-
der only.)
8 9 10 8 10
12
6 9
Hydraulic jack 11 11
(Boom cylinder) (Steering cylinder)

90V2E44017
Hydraulic cylinder
95ZV44009
6. Use a hydraulic jack or hydraulic cylinder to loosen

8 21 8
piston nut (6).
Piston nut width

Tightening torque
across flats
N-m (kgf-m) (lb-ft)
mm (in)
Boom cylinder 90 (3.54) 4,756 (485) (3,509)
Bucket cylinder 85 (3.34) 4,600 (469) (3,393)
(Bucket cylinder)
Steering cylinder 55 (2.17) 1,275 (130) (941)
90V2E44008
8. Remove wear ring (8), square ring (9), slipper ring

(10), O-ring (11), wear ring (12) and piston packing
(21).
(There is no wear ring (12) for steering cylinder.)
44-26
Hydraulic Cylinder
Hydraulic cylinder assembling
To reassembling the hydraulic cylinders, follow the

1
95ZV44013
9. Remove rod cover (1) from piston rod (4).
1 1
19 19
20 20
16 16
17 17
15
18 13 18 14
(Steering cylinder) (Boom cylinder)

90V2E44018
9 10 20 19 18 17 16 13
(Bucket cylinder)
90V2E44009
10. Remove dust seal (13), stop ring (14), scraper ring
(15), back-up ring (16), U-packing (17), buffer ring
(18), back-up ring (19) and O-ring (20) from rod
cover (1).
44-27
Hydraulic Cylinder
Hydraulic cylinder assembly cautions Backup ring

- Be sure to replace all the seals and packings.
2
replace it.
- Before reassembling the parts, apply a coat of
hydraulic oil to the parts.
Ring installation
CAUTION 3
Hot oil can cause injury or burns. 95ZV44017
Avoid contact with hot oil.
Before installing back-up ring (2) and O-ring (3), heat
Slipper ring 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 eas-
10
ily attach the back-up ring to the rod cover, heat the ring
to soften it. The soft ring can be easily expanded.
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.
Rod cover installation

95ZV44016
Put slipper ring (10) into hot oil to heat the ring to
120~150ºC (250~300ºF).
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. K65V2E44013
After attaching the slipper ring, cool the slipper ring so
that it is contracted to the original size.
Reinstall 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.
: 2,157 N-m (220 kgf-m) (1,592 lb-ft)

44-28
Pilot Valve (S/N 9001~9352)
Pilot valve removing and installing Downshift

button Pilot valve
Pilot valve removing
2
WARNING
- Park the machine on level ground, and then block 3
the tires with chocks to prevent wheels from mov-
ing. In addition, apply the parking brake. 95ZVE44039
relieve the internal pressure from the line.
- Relieve the internal pressure from the hydraulic 2. Disconnect electrical line (2) of the Downshift but-
tank. ton.
3. Disconnect electrical line coupler (3) from the pilot

valve.
Control box Note

Before disconnecting the electrical couplers, be sure to
put matchmarks on them.
4
A
4
1 A
Cover mount 95ZVE44038 5
1. Open the cab door (the right hand side).

Remove cover (1) from the control box.
Pilot valve
95ZVE44040
4. Remove knob (4), and then, separate Downshift

button (5).
44-29
10
8
9 12 Adapter 2
6 12
13
14 Adapter 1
13
14
7
15
95ZVE44041 95ZVE44042
5. Remove boot (6) and covers (7)~(10). 7. Loosen nut (14) and disconnect vinyl tube (12) and
rod (13).
Pilot valve
8. Remove nut (15) (4 pcs) and pull up the pilot valve
to remove it.
: Adapter 1: 29.4 N-m (3.0 kgf-m) (21.7 lb-ft)

Adapter 2: 49.0 N-m (5.0 kgf-m) (38.0 lb-ft)
: Pilot valve: 6.5 kg (14.3 lbs)

11
11
Pilot valve installing

95ZVE44043
To reinstall the pilot valve, follow the removal procedure

6. Disconnect hoses (11) from the pilot valve. in reversed direction.
: Drain oil: Approx. 1 L (0.3 gal)
Note Pilot valve installation cautions

Before disconnecting the hoses, be sure to put
matchmarks on them. After reinstallation, check operation of the pilot valve. In
Cover the disconnected hoses with plastic, caps, or addition, check the pilot valve for oil leakage.
plugs to protect them from dust and dirt. If the oil level is too low, add hydraulic oil to the tank.
44-30
Pilot valve disassembling and assembling
IMPORTANT
Pilot valve cross section and tightening torque
(S/N 9001~9350)
T7 L1 T7 L1
T4 T4 T4 T4
T6 T6 A B
T port:
T8 L1
T5 T T1
T
T3 T3
T3 T
P port:
T3 P T3 P
P
T2
T3 T3
A B
Port 1, 2 Port 3, 4
Port 1 Port 2 Port 3 Port 4
Cross section A-A Cross section B-B

95ZVE44037
:
T1: 49.0 N-m (5.0 kgf-m) (36.0 lb-ft)
T2: 29.5 N-m (3.0 kgf-m) (22.0 lb-ft)
T3: 20.5 N-m (2.1 kgf-m) (15.2 lb-ft)
T4: 17.0 N-m (1.7 kgf-m) (12.3 lb-ft)
T5: 14.5 N-m (1.5 kgf-m) (10.7 lb-ft)
T6: 9.0 N-m (0.9 kgf-m) (6.5 lb-ft)
T7: 7.0 N-m (0.7 kgf-m) (5.1 lb-ft)
T8: 1.5 N-m (0.15 kgf-m) (1.1 lb-ft)
L1: Screw lock agent (Loctite® 241) application

44-31
(S/N 9351~9352)
T7 L1 T7 L1
T4 T4 T4 T4
T6 T6 A B
T8 L1
T5 T T1
T
T3 T3
T3 T
T3 P T3 P
P
T2
T3 T3
A B
Port 1, 2 Port 3, 4
Cross section A-A Cross section B-B

K95V2E44013
:
T1: 49.0 N-m (5.0 kgf-m) (36.0 lb-ft)
T2: 29.5 N-m (3.0 kgf-m) (22.0 lb-ft)
T3: 20.5 N-m (2.1 kgf-m) (15.2 lb-ft)
T4: 17.0 N-m (1.7 kgf-m) (12.3 lb-ft)
T5: 14.5 N-m (1.5 kgf-m) (10.7 lb-ft)
T6: 9.0 N-m (0.9 kgf-m) (6.5 lb-ft)
T7: 7.0 N-m (0.7 kgf-m) (5.1 lb-ft)
T8: 1.5 N-m (0.15 kgf-m) (1.1 lb-ft)

44-32
Pilot valve disassembling (S/N 9001~9352)

2
(Illustrated on the boom side. Disassemble the bucket

side in the same manner.)
1
3 4
1 5 95ZVE44005
4. Put match-marks on cover assembly (2) and case

2 assembly (5). Then, remove the cover from the
case assembly.
[Cross section view] 95ZVE44007
7 6
1. Plug all ports of the pilot valve and rinse it with illu- 5
minating kerosene.
2. Clamp the pilot valve in a vise.

Pull up boot (1) to remove it from cover (2).
95ZVE44004
7
4
3 95ZVE44006
3. Loosen socket bolts (3), which look deeper, with a

hexagon (Allen) wrench. 6
: Socket bolt (3):

8.8 N-m (0.90 kgf-m) (6.5 lb-ft)
95ZVE44003
Note
Do not loosen bolt (4) here, which is later loosened in 5. Remove plug (6) by carefully pushing it up with a
step 18. screwdriver while pressing push rod (7) with a
cloth.
Note
Carefully remove plug (6) as plug (6) and push rod (7)
may spring out by the force of return spring inside.
44-33
8
6
11 12 10 9
5 95ZVE44011 95ZVE44010
6. Remove push rod (7), plug (6), reducing valve parts 8. Remove spool (11), secondary pressure spring (10)
as an assembly, and return spring (8) from case and plane washer (12) if assembled.
assembly (5).
Note
Note Plane washer (12) is used for the preset adjustment of
Put a match-mark on plug (6) and case assembly (5). spring (10), and may be of a different thickness or not
used depending on the spool assembly. Make sure to
keep the disassembled parts per each port.
Slide 15
9
95ZVE44009
14 13 6 7
95ZVE44008
7. To disassemble the reducing valve assembly, push
spring seat (9) to compress secondary pressure
spring (10), and slide spring seat (9) so that spool 9. Pull out spring (13) and spring seat (14) from push
(11) is released from the bigger hole of the spring rod (7). (S/N 9001~9350 only)
seat.
Note
Note Only the port 1 and port 3 have spring (13) and spring
- Do not damage the spool surface. seat (14). Make sure to keep the disassembled parts
- Do not push spring seat (9) 6 mm (0.24 in) or more. per each port.
Refer to page 44-30 for the port location.
44-34
17 5
18
20
Port 1&2 Port 3&4
7 15 6 95ZVE44013 95ZVE44015
10. Remove push rod (7) from plug (6). Remove O-ring 12. Put match-marks on case assembly (5) and plate
(15) from plug (6). (20). Remove socket bolt (17) and nut (18) using
the hexagon (Allen) wrench, and separate case
assembly (5) and plate (20).
16
: Socket bolt (17):
20.5 N-m (2.10 kgf-m) (15.2 lb-ft)
19
95ZVE44014
11. Remove seal (16) from plug (6) using a small

screwdriver. 20
95ZVE44012
Note
Take care not to damage the internal surface of plug (6).
13. Remove O-ring (19) from plate (20).
Note
Take care not to damage O-ring (19).
44-35
24
21
95ZVE44019 95ZVE44017
14. Remove O-rings (21) from case assembly (5). 17. Remove O-ring (24) from case assembly (5).
Note Note
Take care not to damage O-ring (21). Take care not to damage O-ring (24).
22
26
23 26
2
27
25
22
5 95ZVE44018 95ZVE44016
15. Clamp case assembly (5) in a vise. Loosen and 18. Clamp center plate (25) in a vise. Remove socket
remove socket bolts (22) on port plate (23). bolts (26) in the shallow pits with a hexagon (Allen)
wrench.
: Socket bolt (20):
20.5 N-m (2.10 kgf-m) (15.2 lb-ft) : Socket bolt (3):
8.8 N-m (0.90 kgf-m) (6.5 lb-ft)
16. Remove port plate (23) from case assembly (5).
44-36
27 2
28
25
27
95ZVE44023 95ZVE44021
19. Remove cover (2) and detent casing (27) from cen- 21. Remove detent casing (27) from cover (2).
ter plate (25).
Be advised that fixing discs (29) on outer springs Note
(28) may be stuck to detent casing (27) with The push rod may be fall off the detent bush without the
grease, and could be dropped. steel ball.
29
27
28 25
30
95ZVE44022 95ZVE44020
20. Remove outer springs (28) and fixing discs (29) on 22. Remove solenoid coil (30) from detent casing (27).
center plate (25).
Note
While removing solenoid coil (30), do not pull the electri-
cal harness.
44-37
32
31
31
34
95ZVE44028 95ZVE44026
23. Remove lever (31) by loosening socket bolt (32) 26. Clamp lever (31) in a vise, and remove nuts (34).
with a hexagon (Allen) wrench.
: Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)
: Socket bolt (32):
6.9 N-m (0.7 kgf-m) (5.1 lb-ft)
Note
Loctite® 241 is applied requiring bigger torque to loosen
the bolt.
31
33
2 95ZVE44027
24. Remove cam shaft (33).
25. Take out lever (31) from cover (2).

44-38
35 (with pre-detent)
2
37
35 (without pre-detent)
36
2
F95ZVE44025 95ZVE44032
28. Remove O-rings (36) from cover (2).
Note
Take care not to damage O-rings (36).
Tool 35
2
95ZVE44024
27. Remove assembled detent bush (35), push rod

(37), etc. from cover (2) using the tool.
37
95ZVE44031
[Tool] (Material: SS400)
29. [For the port without pre-detent]

Center hole (ø2 or less)
Remove push rod (37) from detent bush (35). Put a
match-mark on them beforehand.
30
35 2
45
115V2E44021
44-39
37 40 38 41
39
35
95ZVE44030 95ZVE44033
30. [For the port with pre-detent] 33. Remove scraper (41) from detent bush (35).
Hold detent ring (38) and press to compress spring
(39), and then take out balls (40). Note
Be sure not to damage scraper (41) or the internal sur-
Note face of detent bush (35).
Be sure to keep balls (40) (4 pcs.).
31. Pull out push rod (37).
39
35
38
95ZVE44029
32. Remove detent ring (38) and spring (39) from

detent bush (35).
44-40
Pilot valve assembling
To reassemble the pilot valve, follow the above disas-

Push rod (7)
sembly procedure in reverse order.
Pilot valve assembly cautions

Plug (6)
- Clean and check all the parts. If any part is defective,
Seal (16)
replace or repair it.
95ZVE44034
- Apply the specified torque to tighten each main part. - Install seal (16) in plug (6) in correct direction.
- Apply a thin coat of hydraulic oil or grease to each

part before reassembly.
- Measure the resistance of each coil magnet assem-

bly. The resistance should be 62 Ω at normal room
temperature [(20ºC) (70ºF)]. If measured in
extremely low temperatures the resistance will be
less, and at operating temperature the resistance will
be higher.
- Be aware that the assembled parts, such as the

push rod, spring, etc. are different depending on the
ports. Use the correct parts.
Push rod (37)

Detent
bush (35)
Scraper (41)
A Scraper (41)
Detail of A
95ZVE44035
- Insert scraper (41) in correct direction.
- Do not push push rod (37) too much with the set
screw while adjusting the position of the lever (31). It
may cause bumping at Neutral position, resulting in
unexpected movement at starting the engine.
44-41
Pilot Valve (S/N 9353~)
Pilot valve removing and installing Downshift

button Pilot valve
Pilot valve removing
2
WARNING
- Park the machine on level ground, and then block 3
the tires with chocks to prevent wheels from mov-
ing. In addition, apply the parking brake. 95ZVE44039
relieve the internal pressure from the line.
- Relieve the internal pressure from the hydraulic 2. Disconnect electrical line (2) of the Downshift but-
tank. ton.
3. Disconnect electrical line coupler (3) from the pilot

valve.
Control box Note

Before disconnecting the electrical couplers, be sure to
put matchmarks on them.
4
A
4
1 A
Cover mount 95ZVE44038 5
1. Open the cab door (the right hand side).

Remove cover (1) from the control box.
Pilot valve
95ZVE44040
4. Remove knob (4), and then, separate Downshift

button (5).
44-42
10
8
9 12 Adapter 2
6 12
13
14 Adapter 1
13
14
7
15
95ZVE44041 95ZVE44042
5. Remove boot (6) and covers (7)~(10). 7. Loosen nut (14) and disconnect vinyl tube (12) and
rod (13).
Pilot valve
8. Remove nut (15) (4 pcs) and pull up the pilot valve
to remove it.
: Adapter 1: 29.4 N-m (3.0 kgf-m) (21.7 lb-ft)

Adapter 2: 49.0 N-m (5.0 kgf-m) (38.0 lb-ft)

11
11
Pilot valve installing

95ZVE44043
To reinstall the pilot valve, follow the removal procedure

6. Disconnect hoses (11) from the pilot valve. in reversed direction.
: Drain oil: Approx. 1 L (0.3 gal)
Note Pilot valve installation cautions

Before disconnecting the hoses, be sure to put
matchmarks on them. After reinstallation, check operation of the pilot valve. In
Cover the disconnected hoses with plastic, caps, or addition, check the pilot valve for oil leakage.
plugs to protect them from dust and dirt. If the oil level is too low, add hydraulic oil to the tank.
44-43
A B
T5 L1
T3
T3
T5 L1 T3
T4
T1
T
P T
P
2 4
A B
T2
Cross section A-A Cross section B-B Port 1, 2 Port 3, 4
K90Z544002
:
T1: 49.0 N-m (5.0 kgf-m) (36.0 lb-ft)
T2: 29.5 N-m (3.0 kgf-m) (22.0 lb-ft)
T3: 17.0 N-m (1.7 kgf-m) (12.3 lb-ft)
T4: 9.0 N-m (0.9 kgf-m) (6.5 lb-ft)
T5: 7.0 N-m (0.7 kgf-m) (5.1 lb-ft)
: Port 1~4 (adapter)

29.5 N-m (3.0 kgf-m) (22.0 lb-ft)

44-44
Pilot valve disassembling (S/N 9353~)

2
(Illustrated on the boom side. Disassemble the bucket
side in the same manner.)
1
3 4
1
K90Z544010
4. Put match-marks on cover assembly (2) and case

2 assembly (5). Then, remove the cover from the
case assembly.
[Cross section view] 95ZVE44007
7
1. Plug all ports of the pilot valve and rinse it with illu-
minating kerosene. 6
5
2. Clamp the pilot valve in a vise.

Pull up boot (1) to remove it from cover (2).
K90Z544011
3 95ZVE44006
3. Loosen socket bolts (3), which look deeper, with a

hexagon (Allen) wrench.
6
: Socket bolt (3):
8.8 N-m (0.90 kgf-m) (6.5 lb-ft)
K90Z544012
Note
Do not loosen bolt (4) here, which is later loosened in 5. Remove plug (6) by carefully pushing it up with a
step 18. screwdriver while pressing push rod (7) with a
cloth.
Note
Carefully remove plug (6) as plug (6) and push rod (7)
may spring out by the force of return spring inside.
44-45
6
7
11 12 10 9
K90Z544013 95ZVE44010
6. Remove push rod (7), plug (6), reducing valve parts 8. Remove spool (11), secondary pressure spring (10)
as an assembly, and return spring (8) from case and plane washer (12) if assembled.
assembly (5).
Note
Note Plane washer (12) is used for the preset adjustment of
Put a match-mark on plug (6) and case assembly (5). spring (10), and may be of a different thickness or not
used depending on the spool assembly. Make sure to
keep the disassembled parts per each port.
Slide
9
95ZVE44009
7 15 6 95ZVE44013
7. To disassemble the reducing valve assembly, push
spring seat (9) to compress secondary pressure
spring (10), and slide spring seat (9) so that spool 9. Remove push rod (7) from plug (6). Remove O-ring
(11) is released from the bigger hole of the spring (15) from plug (6).
seat.
Note
- Do not damage the spool surface.
- Do not push spring seat (9) 6 mm (0.24 in) or more.
44-46
27
16
28
25
95ZVE44014 95ZVE44023
10. Remove seal (16) from plug (6) using a small 12. Remove cover (2) and detent casing (27) from cen-
screwdriver. ter plate (25).
Be advised that fixing discs (29) on outer springs
Note (28) may be stuck to detent casing (27) with
Take care not to damage the internal surface of plug (6). grease, and could be dropped.
Note 29
Item numbers (17) through (24) are intentionally omitted
in the following steps.
28 25
26
26
2
27
95ZVE44022
25
13. Remove outer springs (28) and fixing discs (29) on
center plate (25).
95ZVE44016
11. Clamp center plate (25) in a vise. Remove socket

bolts (26) in the shallow pits with a hexagon (Allen)
wrench.
: Socket bolt (3):

8.8 N-m (0.90 kgf-m) (6.5 lb-ft)
44-47
2
32
31
27
95ZVE44021 95ZVE44028
14. Remove detent casing (27) from cover (2). 16. Remove lever (31) by loosening socket bolt (32)
with a hexagon (Allen) wrench.
Note
The push rod may be fall off the detent bush without the : Socket bolt (32):
steel ball. 6.9 N-m (0.7 kgf-m) (5.1 lb-ft)
Note
27 Loctite® 241 is applied requiring bigger torque to loosen
the bolt.
31
33
30
95ZVE44020
15. Remove solenoid coil (30) from detent casing (27).

2 95ZVE44027
Note
While removing solenoid coil (30), do not pull the electri-
cal harness. 17. Remove cam shaft (33).
18. Take out lever (31) from cover (2).

44-48
[Tool] (Material: SS400)
Center hole (ø2 or less)
31
30
34 35 2
45
95ZVE44026 115V2E44021
19. Clamp lever (31) in a vise, and remove nuts (34).

2
: Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)
35 (with pre-detent)
37
35 (without pre-detent)
36
95ZVE44032
2 21. Remove O-rings (36) from cover (2).

F95ZVE44025
Note
Take care not to damage O-rings (36).
35
2 Tool
95ZVE44024 37
95ZVE44031
20. Remove assembled detent bush (35), push rod

(37), etc. from cover (2) using the tool. 22. [For the port without pre-detent]
Remove push rod (37) from detent bush (35). Put a
match-mark on them beforehand.
44-49
37 40 38 41
39
35
95ZVE44030 95ZVE44033
23. [For the port with pre-detent] 26. Remove scraper (41) from detent bush (35).
Hold detent ring (38) and press to compress spring
(39), and then take out balls (40). Note
Be sure not to damage scraper (41) or the internal sur-
Note face of detent bush (35).
Be sure to keep balls (40) (4 pcs.).
24. Pull out push rod (37).
39
35
38
95ZVE44029
25. Remove detent ring (38) and spring (39) from

detent bush (35).
44-50
Pilot valve assembling
To reassemble the pilot valve, follow the above disas-

Push rod (7)
Pilot valve assembly cautions

Plug (6)
- Clean and check all the parts. If any part is defective,
Seal (16)
95ZVE44034
- Apply the specified torque to tighten each main part. - Install seal (16) in plug (6) in correct direction.

- Measure the resistance of each coil magnet assem-

bly. The resistance should be 62 Ω at normal room
temperature [(20ºC) (70ºF)]. If measured in
extremely low temperatures the resistance will be
less, and at operating temperature the resistance will
be higher.
- Be aware that the assembled parts, such as the

push rod, spring, etc. are different depending on the
ports. Use the correct parts.
Push rod (37)

Detent
bush (35)
Scraper (41)
A Scraper (41)
Detail of A
95ZVE44035
- Insert scraper (41) in correct direction.
- Do not push push rod (37) too much with the set
screw while adjusting the position of the lever (31). It
may cause bumping at Neutral position, resulting in
unexpected movement at starting the engine.
44-51
Multiple Control Valve
Multiple control valve removing

and installing
Multiple control valve
Multiple control valve removing
WARNING
Unexpected movement of machine, bucket, or boom 4
death. To prevent such an accident, observe the fol- 3
lowing items:
- Park the machine on level ground, and apply the 90V2E44011
2. Disconnect boom cylinder hose (3).
Remove pipe clamp (4) for the oil pipe.
and also relieve the internal pressure from the
- Lift the boom until it is horizontal, and then place 6 7
stand (A) to support the bottom of the boom.
8 6
5
90V2E44012
Stand
3. Remove boom cylinder oil pipe (5).

Remove oil pipe (6)(7)(8). Clamp them on the front
90ZV44028
chassis.
Note
Cover the disconnected hoses with plastic, caps or
plugs to protect them from dust, water and dirt.
2
90V2E44010
1. Remove nut (1) and then remove cover (2).

44-52
9
Multiple control valve installing
To reinstall the multiple control valve, follow the above

10
Multiple control valve installation cautions
1. Replace all the O-rings with new ones.

9
90V2E44013
2. Wash the multiple control valve mounting area.
4. Put matchmarks on pilot line hoses (9), and then WARNING

disconnect them. Unexpected movement of machine may cause seri-
ous injury or death.
Note To prevent such an accident, be sure to stop the
Cover the disconnected hoses with plastic, caps or engine before you start working. In addition, block
plugs to protect them from dust, water and dirt. 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.
10
3. Attach the pressure gauge, and then start the
engine. Measure the pressure, and adjust it to the
specified value. For a detailed description of pres-
11 sure adjustment, refer to the Section 03.
4. Operate the bucket and the boom, and check that

they operate correctly.
5. Check each section for oil leakage.

90ZV44033
6. Add hydraulic oil to the tank until the oil level rises
to the specified point.
5. Remove bolts (11) for multiple control valve (10).
Use a hoist to remove the multiple control valve.
: Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft)

: Multiple control valve: 95 kg (210 lbs)
44-53
Multiple control valve disassembling and assembling
IMPORTANT
Multiple control valve cross section and tightening torque

T4
T2
Overload relief valve
with make-up function
T3 L1
T5
T1
Make-up valve
T4
T5
Boom spool
T7
T5
T3
Overload relief T6
valve with make-
T4
up function Main relief valve
T4 Bucket spool
T1
K90Z544004
:
T2: 226 N-m (23.0 kgf-m) (166 lb-ft)
T3: 39 N-m (4.0 kgf-m) (29 lb-ft) : 95 kg (210 lbs)
T4: 60 N-m (6.1 kgf-m) (44 lb-ft)
T5: 74 N-m (7.5 kgf-m) (54 lb-ft)
T6: 130 N-m (13.3 kgf-m) (96 lb-ft)
T7: 29 N-m (3.0 kgf-m) (22 lb-ft)
44-54
Multiple control valve disassembling
3
2 97ZV44038
1
97ZV44036 3. Set spool (3) in a vise using copper plates and then
loosen bolt (4).
1. Bucket spool disassembling
Remove two socket head bolts (1) and cover (2). Hexagon hole width across flat: 12 mm (0.47 in)
: Bolt: 39 N-m (4.0 kgf-m) (29 lb-ft)
Hexagon hole width across flat: 8 mm (0.31 in) : Screw lock agent application
: Bolt: 54 N-m (5.5 kgf-m) (40 lb-ft) (Three Bond 1327)
4 5
9
7
8 97ZV44039
97ZV44037
2. Pull out the spool assembly from the bucket side. 4. Remove bolt (4), spring retainer (5), outer spring
(6), inner spring (7), stopper (8) and spring retainer
Note (9).
Carefully pull out the spool so that it is not forced out or
distorted. Handle the spool with extreme care, even a
small nick, dent, or scratch can ruin the spool which
requires replacement of the entire valve.
44-55
97ZV44040 11 97ZV44042
5. Boom spool disassembling 7. Remove main relief valve (11).

To disassemble the boom spool, follow the bucket
spool disassembling procedure. Hexagon width across flat: 41 mm (1.61 in)
: Main relief valve:
127 N-m (13.0 kgf-m) (94 lb-ft)
Note
The main relief valve should be replaced as an assem-
bly. Therefore, please do not disassemble it, unless
absolutely necessary.
10
97ZV44041
6. Remove two overload relief valves (10).
Hexagon width across flat: 34 mm (1.34 in)

: Overload relief valve: 13
74 N-m (7.5 kgf-m) (54 lb-ft) 12
14 97ZV44043
Note
The overload relief valve should be replaced as an 8. Remove plug (12), and then remove spring (13)
assembly. Therefore, please do not disassemble it, and poppet (14).
unless absolutely necessary.
Hexagon hole width across flat: 14 mm (0.55 in)
: Plug: 226 N-m (23.0 kgf-m) (166 lb-ft)
44-56
Multiple control valve assembling
To reassemble the multiple control valve, follow the

15
Multiple control valve assembly cautions
- Clean and check all the parts. If a part is defective,

90ZV44052
- Replace all the O-rings with new ones.
9. Remove make up valve (15) from the body. - Apply the specified torque to tighten each main part.
: Main up valve:
127 N-m (13.0 kgf-m) (94 lb-ft)
44-57
Orbitrol®
Orbitrol®
Orbitrol® removing and installing

Orbitrol® removing
WARNING
1
- Park the machine on level ground, and lower the
attachment onto the ground.
- Block the tires with chocks to prevent wheels from 85V2E44008
moving.
- Before starting work, be sure to remove the engine 1. Remove cover (1).
steering wheel or the operator's seat.
- Relieve the internal pressure from the steering
hydraulic line by turning the steering wheel left and
right.
tank.
85V2E44009
2. Remove floor mat (2).

44-58
Orbitrol®
Orbitrol® installing
3
To reinstall the Orbitrol®, follow the above removal pro-
cedure in reverse order.
Orbitrol® installation cautions
At the completion of reinstallation, check operation of

4 the Orbitrol® by following the procedure below:
85V2E44010
WARNING
3. Put matchmarks on hoses (3), and then disconnect Entering the articulation area while engine is running
them from Orbitrol® (4). may cause serious injury or death.
So, when entering the area, stop the engine and
Note place "DO NOT START" or "DO NOT OPERATE" tag
Cover the disconnected hoses with plastic, caps or on steering wheel or the operator's seat.
plugs to protect them from dust, water and dirt.
1. Start the engine and confirm that the stop valve
comes in contact with the stoppers by turning the
steering wheel clockwise and counterclockwise.
2. Check around the Orbitrol® for oil leakage.
85V2E44011
4. Remove bolt (5), and then remove the Orbitrol®.
: Bolt: 29 N-m (3.0 kgf-m) (22 lb-ft)

: Orbitrol®: 7 kg (15 lbs)
Note
One person should support the Orbitrol® under the
machine. The person in the cab should remove the
retainer bolt. This work should be done by two persons.
44-59
Orbitrol®
Orbitrol® disassembling and assembling
IMPORTANT
Orbitrol® cross section and tightening torque
T1
90ZV44053
: Bolt tightening torque : 7 kg (15 lbs)

T1: 23 N-m (2.3 kgf-m) (17 lb-ft)
44-60
Orbitrol®
Orbitrol® disassembling
4
[Disassembling rotor]
5
Copper plate
97ZV44048
3. Remove rotor assembly (4), spacer (5) and O-ring

(6).
95ZV44025
Note
Keep star (7) in rotor assembly (4).
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 strongly.
8
1
10
2
97ZV44049
3
4. Remove drive shaft (8), plate (9) and O-ring (10).
97ZV44047
2. Remove bolt (1), end plate (2) and O-ring (3).

44-61
Orbitrol®
[Disassembling valve]
13 14
15
11 97ZV44052
97ZV44050
3. Remove Y-packing seal (14) and dust seal (15)
from seal retainer (13).
1. Remove the housing from the vise and put it on a
clean cloth not to damage the finished surface. Note
Remove retainer ring (11) by a screw driver. Take care not to damage seal retainer (13).
16
12 17
16
18
19
97ZV44051 97ZV44053
2. Rotate the spool and sleeve so that the pin can be 4. Remove races (16) and needle bearing (17) from
in a horizontal position. spool (18) and sleeve (19).
Remove seal retainer (12) by pressing the spool
and sleeve from behind with your fingers.
44-62
Orbitrol®
24
22
22
19 23
20 23
97ZV44054 97ZV44056
5. Pull spool and sleeve assembly (19) out slowly, 7. Push spool (23) slightly out of sleeve (22), and
turning it clockwise and counterclockwise from remove centering springs (24). Pull the spool from
housing (20). the sleeve while slowly turning the spool clockwise
and counterclockwise.
Note
Take care so that the spool and sleeve do not damage
the housing.
26
27
19
21
25
97ZV44057
8. Remove O-ring (25) from the housing.

97ZV44055
9. Remove adapter (26) to take out ball (27).

6. Pull out pin (21) from the spool and sleeve assem-
bly (19). Note
Do not disassemble, unless absolutely necessary.
44-63
Orbitrol®
Orbitrol® assembling
24
26
27
19
20
97ZV44060
25
97ZV44058 3. Install springs (24) through the spring grooves in
the sleeve and spool (19) using a spring insertion
1. Assemble ball (27) and adapter (26) in housing jig.
(20).
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.
Spring groove
22
Spring groove 22
23
23
Matchmark
21
95ZV44026
2. Assemble spool (23) and sleeve (22) so that the

spring grooves in them are lined up. 97ZV44061
Note
Align the matchmarks on the spool and sleeve. 4. Insert pin (21) in the holes in spool (23) and sleeve
(22) until the end of the pin is flush with the surface
of the sleeve.
44-64
Orbitrol®
13 14
15
19
20
97ZV44062 97ZV44052
5. Insert spool and sleeve assembly (19) from the 7. Insert dust seal (15) and Y-packing seal (14) in seal
back of housing (20). retainer (13).
Note
- Take care not to tilt the assembly and cause damage
during insertion.
11
- Insert the assembly until the back end of the assem-
bly is flush with the back end of the housing.
- Confirm that the assembly can be turned easily in 13
the housing.
17 23
16
97ZV44064
25
8. Insert seal retainer (13) onto spool (23), and then
tap it gently into position with a plastic-faced ham-
mer. Then install retainer ring (11).
Screw driver
97ZV44063
Dust seal
Retainer ring
6. Install O-ring (25), races (16) and needle bearing Seal retainer
(17).
Y-packing seal
O-ring
90V2E44019
Note
Be sure the position and direction of the seals.
44-65
Orbitrol®
Grooves in rotor bore A

9
B
Drive shaft
C
10 D
Pin
97ZV44066
Port face 95ZV44029
9. Put on O-ring (10), then align the bolt holes in plate 12. Holding the rotor assembly with the O-ring side fac-
(9) with those in the housing. ing the plate, install the assembly so that the
grooves in the star-shaped bore mesh with the
drive shaft.
Port face
Note
- Align the bolt holes in the rotor assembly with those
8
in the housing without disengaging the drive shaft
Pin parallel
with port face
from the rotor assembly's star -shaped bore.
- Confirm that lines A, B, C and D are all parallel.
21 5
95ZV44028
1
10. Insert drive shaft (8) to mate its yoke with pin (21).
2
4 97ZV44070
13. Install spacer (5), O-ring (3) and end cap (2).
6 : Provisional tightening torque:

15 N-m (1.5 kgf-m) (11 lb-ft)
Tightening torque:
23 N-m (2.3 kgf-m) (17 lb-ft)
97ZV44068
11. Put O-ring (6) in rotor assembly (4).

44-66
Orbitrol®
Tightening order
95ZV44030
Note
Provisionally tighten bolt (1), then tighten them securely
in the order shown above.
44-67
Steering Valve
Steering Valve
Steering valve removing and

installing 10
6
Steering valve removing 9
7
WARNING 8
observe the following items: Steering valve
- Park the machine on level ground, and lower the
5
attachment onto the ground. 90ZV44038
- Block the tires with chocks to prevent wheels from
moving.
2. Remove hoses (5)~(10).
tank.
- Oil spilled on the parking brake shoe section may
cause malfunction. To prevent such a problem,
11
cover the shoe section with plastic before valve
removal.
Steering valve

- Remove the seat and seat bracket in the cab.
90ZV44039
2
4
3. Remove bolt (11) and then remove the steering
valve.
: Bolt: 49 N-m (5.0 kgf-m) (36 lb-ft)

: Steering valve: 25 kg (55 lbs)
Steering valve Note

1
Cover the disconnected hoses and the valve with plas-
90V2E44014
tic, plugs or caps to protect them from dust and dirt.
1. Disconnect hoses (1)~(4) from the steering valve.

44-68
Steering Valve
Steering valve installing
To reinstall the steering valve, follow the above removal

Steering valve installation cautions
At the completion of reinstallation, check operation of

the steering valve by following the procedure below:
WARNING
Entering the articulation area while engine is running
may cause serious injury or death.
So, when entering the area, stop the engine and
place "DO NOT START" or "DO NOT OPERATE" tag
on steering wheel or the operator's seat.
1. Start the engine and confirm that the stop valve

comes in contact with the stoppers by turning the
steering wheel clockwise and counterclockwise.
2. Check around the valve for oil leakage.
3. Measure various values for performance check.

Measure the time required for full steering.
Measure the relief valve setting pressure.
(Refer to the Section 03 - Measurement for Perfor-
mance Check).
44-69
Steering Valve
Steering valve disassembling and assembling
IMPORTANT
Steering valve cross section and tightening torque
T3
T2
T1
T5
Flow control spool

T2
T6
Steering spool
T7
T4
T7
T3
90ZV44040
: Bolt tightening torque T4: 60 N-m (6.1 kgf-m) (44 lb-ft)

T1: 255 N-m (26.0 kgf-m) (188 lb-ft) T5: 353 N-m (36 kgf-m) (260 lb-ft)
44-70
Steering Valve
Steering valve disassembling
6
5
1 4
90ZV44009J
90ZV44007J 3. Remove spring (4) and spring seat (5) to pull out
steering spool (6).
1. Remove right and left overload relief valves (1).
Note
: Valve (1): 79 N-m (8.0 kgf-m) (59 lb-ft) Carefully pull out the steering spool so that it is not dam-
Width across flat: 32 mm (1.26 in) aged. Put matchmark to make sure the direction of the
steering spool.
7
2
90ZV44008J
90ZV44010J
2. Remove bolt (2). Remove end cover (3).

4. Slightly loosen plug (7).
: Bolt (2): 62 N-m (6.3 kgf-m) (46 lb-ft)
Hexagon hole width across flat: : Plug (7): 353 N-m (36 kgf-m) (260 lb-ft)
8 mm (0.315 in) Width across flat: 14 mm (0.551 in)
Note
Carefully loosen plug (7). It may spring out by the spring
force.
44-71
Steering Valve
Steering valve assembling

7
To reassemble the steering valve, follow the above dis-
assembly procedure in reverse order.
11
9 10
8
90ZV44011J
5. Remove relief valve (8) and plug (9). Pull out spring
(10) and flow control spool (11) from the casing.
Note
- Carefully remove plug (9). It may spring out by the
spring force.
- Carefully pull out flow control spool (11) so that the
casing and flow control spool are not scratched.
Width across flat:

Relief valve (8): 19 mm (0.748 in)
Plug (9): 41 mm (1.614 in)
: (8)(9): 108 N-m (11 kgf-m) (80 lb-ft)
6. Remove plug (7) loosened on paragraph 4.

44-72
Stop Valve
Stop Valve
Stop valve removing and installing

Stop valve removing
3
WARNING
during service work could cause serious injury or 6
lowing items:
- Park the machine on level ground, and apply the 2
4
tank to prevent the oil from spouting out. 5
90V2E44015
(The illustration shows the machine right hand side.)
1. Remove hoses (1)~(4) from the stop valve.
Note
Cover the disconnected hoses with vinyl, caps or plugs
to protect them from dust and dirt.
2. Remove bolt (5), and then, remove stop valve (6).
Stop valve installing

order.
44-73
Stop Valve
Stop valve installation cautions - After adjustment, turn the steering wheel slowly at a
rate of 5 seconds or more per turn, and confirm the
The stop valve works when the spool is pushed in 3 mm clearance between the machine body and the stop-
(0.118 in). per.
Adjust the stopper bolt by using the following procedure.
- When adjustment is completed, tighten the lock nut
of the stopper (bolt).
Stop valve
(rear chassis)
Stopper (bolt) : 90 N-m (9.2 kgf-m) (67 lb-ft)
(LH, RH)
Front chassis
Reference dimension
31.7~36.3 mm
(1.25~1.43 in)
Stopper (bolt) length

90ZVE43005
Front chassis
8º 3
36º~
Rear chassis
Reference dimension
11.8~23.6 mm (0.46~0.93 in)
Clearance between machine body and stopper 90ZVE43006
- Adjust the stopper (bolt) length so that the clearance

between the machine body and the stopper
becomes the reference dimension "11.8~23.6 mm
(0.46~0.93 in)" shown in the following table.
Reference dimension
Articulation angle (º) 38 37 36

Clearance between machine 11.8 17.6 23.6
body and stopper (mm) (in) (0.46) (0.69) (0.93)
31.7 34.0 36.3
Stopper (bolt) length (mm) (in)
(1.25) (1.34) (1.43)
∗The target value should be the articulation angle "37º".

44-74
Stop Valve
Stop valve disassembling and

assembling
IMPORTANT
Stop valve cross section and tightening

torque
(S/N 9374~)
T1
T2
T3
K92V244001

T1: 206 N-m (21 kgf-m) (152 lb-ft)
T2: 5 N-m (0.5 kgf-m) (3.6 lb-ft)
T3: 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)
44-75
Stop Valve
Stop valve disassembling

13
12
11
10
1 2
85V2E44017
97ZV44079 4. Remove screw (9) to remove flange (10), dust seal

(11), spacer (12) and U-packing (13).
1. Remove boot (1) and plug (2).
: Screw (9): 0.4 N-m (0.04 kgf-m) (0.3 lb-ft)
WARNING
The inner spring may spring out causing injury.
Do not point the spring toward your face. Stop valve assembling
: Plug (2): 206 N-m (21 kgf-m) (152 lb-ft) To reassemble the stop valve, follow the above proce-
5
6
7
8
85V2E44016
2. Remove spring (3) and pull out spool assembly (4).
3. Clamp spool assembly (4) at the bottom side in a

vise and remove plug (5) using a screw driver.
Remove washer (6), spring (7) and check valve (8)
from the spool.
: Plug (5): 5 N-m (0.5 kgf-m) (3.6 lb-ft)

44-76
Fan Motor
Fan Motor
Fan motor removing and installing (S/N 9001~9200)
5
Fan motor removing
4
WARNING 4

death. To prevent such an accident, observe the fol- 3
lowing items:
- Park the machine on level ground, and apply the
parking brake. In addition, block the tires with 3 90V2E44022
tank to prevent the oil from spouting out. (S/N 9201~)
4
3
5
3 K90V2E44004
1 3. Remove fan guard (3) from the radiator assembly.
4. Remove hoses (4) of the air cooler.

90V2E44020
: Air cooler hose band:
: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft)
1. Remove roof (1) from the engine room.
5. Remove hoses (5) from the radiator.
2
Note
2 Cover the disconnected hoses with plastic, plugs or
caps to protect them from dust and dirt.
2
90V2E44021
2. Remove partition plates (2).

44-77
Fan Motor
Fan motor
10
7 7
K90V2E44001 90V2E44027
6. Remove hoses (6)(7) from the fan motor. 8. Remove retainer bolts (9) for fan (10).
Use a drain pan to catch all escaping oil.
: Bolt (9): 94 N-m (9.6 kgf-m) (69 lb-ft)
Note : With lubrication oil (engine oil or gear oil)
Cover the disconnected hoses with plastic, plugs or
caps to protect them from dust and dirt. 9. Sling fan (10) and take it out from the top opening.
: Fan: 17 kg (38 lbs)
8 Note
Carefully remove the fan while checking that the fan will
not damage the radiator fins. Inspect the fan and
replace it if there are any signs of damage or cracks.
Fan blade breakage can cause extensive damage.
90V2E44024
11
7. Remove bolts (8) and release the fan motor bracket
from the base bracket. Slide it to the engine side to
make clearance between the fan.
: Bolt (8): 94 N-m (9.6 kgf-m) (69 lb-ft)

12
: With lubrication oil (engine oil or gear oil)
90V2E44028
10. Attach sling to the fan motor.

Remove bolts (11)(12), and then remove the fan
motor.
: Bolt (11): 73.5 N-m (7.5 kgf-m) (54 lb-ft)

: Bolt (12): 94 N-m (9.6 kgf-m) (69 lb-ft)

: With lubrication oil (engine oil or gear oil)
: Fan motor: 15 kg (33 lbs)
44-78
Fan Motor
Fan motor installing

order.
Fan motor installation cautions
- Do not reuse the flange, and always replace with a

new one when the fan motor is replaced.
Clearance
90V2E44026
- Be sure that the right and left clearance between the

fan and the radiator guard must be equal.
45-1
90ZV-2 Service Standard Hydraulic Group

Hydraulic Group
Hydraulic Cylinder ................................................... 45-2

Pilot Valve................................................................ 45-4
Steering Valve ......................................................... 45-6
45-2
Hydraulic Cylinder
Hydraulic Cylinder
Boom cylinder
2 1
90ZV45001
Steering cylinder
2 1
90ZV45002
Unit: mm (in)
Judgment standard
No. Item Standard Standard value Limit Solution
Standard
dimension of
Rod Bushing clearance Bushing Clearance
rod dia.
-0.036 +0.195 0.096
(-0.0014) (+0.0076) (0.0037)
ø90 +0.295 0.385
Boom cylinder ~ ~ ~ Replacement
(ø3.5433) (+0.0116) (0.0151)
-0.090 +0.060 0.285
(-0.0035) (+0.0023) (0.0112)
-0.030 +0.190 0.090
(-0.0011) (+0.0074) (0.0035)
ø75 +0.290 0.366
1 Bucket cylinder ~ ~ ~ Replacement
(ø2.9527) (+0.0114) (0.0144)
-0.076 +0.060 0.266
(-0.0030) (+0.0023) (0.0104)
-0.025 +0.110 0.025
(-0.0010) (+0.0043) (0.0010)
ø50 +0.210 0.274
Steering cylinder ~ ~ ~ Replacement
(ø1.9685) (+0.0082) (0.0107)
-0.064 0 0.174
(-0.0025) (0) (0.0068)
45-3
Hydraulic Cylinder
No. Item Boom cylinder Bucket cylinder Steering cylinder

M62 x 2 M56 x 2 M36 x 1.5
Piston nut tightening torque N-m (kgf-m) (lb-ft)
2 4,756 (485) (3,509) 4,600 (469) (3,393) 1,275 (130) (941)
Piston nut width across flat mm (in) 90 (3.54) 85 (3.34) 55 (2.17)
M24 M24 (Rod cover)
3 Rod cover bolt tightening torque N-m (kgf-m) (lb-ft)
843 (86) (622) 880 (89.7) (649) 2,157 (220) (1,592)
45-4
Pilot Valve
Pilot Valve
(S/N 9001~9352) (S/N 9353~)
1 1
3 3
2 2
92V2E45001
45-5
Pilot Valve
Judgment standard
No. Item Solution
Standard valve Allowable limit
Wear
1 mm (0.0394 in)
87.7 mm 86.7 mm
1 Push rod Replacement
(3.452 in) (3.413 in)
85V2E45003
Wear
1 mm (0.0394 in)
36 mm 35 mm
2 Push rod Replacement
(1.417 in) (1.378 in)
85V2E45003
Replacement with
ø8 mm ø7.5 mm
3 Bush detent solenoid sub
(0.315 in) (0.295 in)
85V2E45002
45-6
Steering Valve
Steering Valve
90ZV45001J
Tightening torque
Unit: N-m (kgf-m) (lb-ft)
No. Item Standard value Solution
1 Steering valve retainer bolt 94 (9.6) (69)
Tightening
2 Steering valve bracket retainer bolt 230 (23.5) (170)
54-1
90ZV-2 Disassembly & Reassembly Brake Group

Brake Group
Unloader Valve ........................................................ 54-2

Manifold Valve Assembly ........................................ 54-8
Accumulator ............................................................ 54-11
Brake Valve ............................................................. 54-17
Service Brake .......................................................... 54-24
Parking Brake Actuator ........................................... 54-25
Parking Brake.......................................................... 54-30
54-2
Unloader Valve
Unloader Valve
Unloader valve removing and installing

Unloader valve removing
1
WARNING
- Block the front wheels with chocks to prevent
wheels from moving. 2
Unloader valve
key, and hang a "DO NOT START!" tag on the 3 90V2E54001
steering wheel or the operator's seat, or discon-
nect the negative side of the battery.
1. Remove hoses (1)~(3) from the unloader valve.
IMPORTANT Note
If a battery terminal is removed from a machine in Cover the disconnected hoses with plastic, plugs or
less than 30 seconds after the key is put into the caps to protect them from dust and dirt.
function” prior to removing battery terminals. Unloader valve
4
- Press the hydraulic tank cap, and relieve the internal 5
pressure from the hydraulic tank.
- Prepare a container to catch drained oil.
90V2E54002
2. Remove hoses (4)(5) from the unloader valve.
Note
Cover the disconnected hoses with plastic, plugs or
caps to protect them from dust and dirt.
54-3
Unloader Valve
Unloader valve installing

Unloader valve
To reinstall the unloader valve, follow the above
Replace all O-rings and seals during reinstallation.
Unloader valve installation cautions

Bracket - After reinstallation, completely bleed the brake line
90V2E54003
of air, and check performance of the unloader valve.
To bleed the brake line of air, refer to "Air bleeding
procedure" page 24-25.
3. Remove bolts (6) and then remove unloader valve.
- To check performance of the unloader valve, refer to
: Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft) 90ZV-2 Shop Manual, Function and Structure, Sec-
: Unloader valve: 4 kg (8.8 lbs) tion 53.
54-4
Unloader Valve
Unloader valve disassembling and assembling
IMPORTANT
Unloader valve cross section and tightening torque

(S/N 9001~9070)
T1
T8
T7
T6 T4
T3
T2 L1
T5
97ZV54002
54-5
Unloader Valve
:
T1: 137 N-m (14 kgf-m) (101 lb-ft) Width across flats 17 mm (0.669 in)
T2: 14.7 N-m (1.5 kgf-m) (11 lb-ft) Width across flats 5 mm (0.197 in)
T4: 58.8 N-m (6 kgf-m) (43 lb-ft) Width across flats 8 mm (0.315 in)

54-6
Unloader Valve
(S/N 9071~)
T1
T7
T6
T4
T3
T2 L1
T5
K95V2E54014
:

54-7
Unloader Valve
Unloader valve disassembling
(S/N
(S/N 9071~)
9049~)
Pressure governor assembly
(FM)
K95V2E54015
Remove plug (1), then pull out spool (2) and spring (3). Unloader valve assembling
Note To reassemble the unloader valve, follow the above dis-
Carefully remove plug (1). It may spring out by the assembly procedure in reverse order.
spring force.
: 137 N-m (14 kgf-m) (101 lb-ft)
Note
Do not disassemble the pressure governor assembly
and the pressure switch assembly unless it is neces-
sary. Because, readjustment of accumulator pressure
and setting of shims are required.
54-8
Manifold Valve Assembly
Valve assembly removing and

installing 2 3
Valve assembly removing

4
WARNING 5
1
- Park the machine on level ground. 6
- Block the front wheels with chocks to prevent 90V2E54004
wheels from moving.
2. Remove hoses (1)~(6) from the valve assembly.
7
IMPORTANT
less than 30 seconds after the key is put into the 8
“OFF” position, it can corrupt the ECM program, 10
9
90V2E54005
times until there is no brake pressure. 3. Remove hoses (7)~(10) from the valve assembly.
- Press the hydraulic tank cap, and relieve the internal
- Prepare a container to catch drained oil. 12
11
1. Repeatedly depress the brake pedal till you feel the

pedal becomes light. That will release oil pressure
in brake line.
K90V2E54002
4. Remove hoses (11)(12) from the manifold valve

assembly.
54-9
Valve assembly Valve assembly disassembling

13
11
and assembling
IMPORTANT
Rear chassis
(FM)
90V2E54006
5. Remove bolt (13), and then, remove the valve

assembly.
: Bolt (13): 53 N-m (5.4 kgf-m) (39 lb-ft)

: Valve assembly: 10 kg (22 lbs)
Valve assembly installing
To reinstall the valve assembly, follow the above

Replace all O-rings and seals during reinstallation.
Note
After reinstallation, completely bleed the brake line of
air, and check performance of the valve assembly.
To bleed the brake line from air, refer to "Air bleeding
procedure" page 24-25.
To check performance of the valve assembly, refer to
90ZV-2 Shop Manual, Function & Structure, Section 53.
54-10
Valve assembly cross section and tightening torque
T1 T1 T4
T1
(T)
(P) T3
(TA)
(PI) (Parking)
(ACCR) (ACCF) ACF
(PA)
(Z1)
(Z2)
(Z) (PPI)
T2
High pressure
test ports
K90Z554003
:
T1: 50 N-m (5.1 kgf-m) (37 lb-ft)
CAUTION
T2: 38 N-m (3.9 kgf-m) (28 lb-ft) High pressure test ports contain accumulator pres-
T3: 11 N-m (1.1 kgf-m) (8 lb-ft) sure [11.8 MPa (1,706 psi)] that can escape from
T4: 10 N-m (1.0 kgf-m) (7.4 lb-ft) these 2 plugs.
Completely depress brake pedal 15~20 times to
relieve all pressure before removing plugs.
54-11
Accumulator
Accumulator
Accumulator removing and install- Accumulator

ing
Accumulator removing
(S/N 9031~)
WARNING
Unexpected movement of machine could cause an 1
an accident, observe the following items: 2
1
- Block the front wheels with chocks to prevent K90V2E54003
wheels from moving.
2. Remove hoses (1)(2) from the accumulator.
4
IMPORTANT
“OFF” position, it can corrupt the ECM program, Accumulator 5
6
3
90V2E54008
times until there is no brake pressure. 3. Remove bolts (3)(4)(5), nut (6) and then remove
- Press the hydraulic tank cap, and relieve the internal the accumulator.
- Prepare a container to catch drained oil. : Bolt (3)(5): 53 N-m (5.4 kgf-m) (39 lb-ft)
Bolt (4): 94 N-m (9.6 kgf-m) (69 lb-ft)
: Accumulator: 19 kg (42 lbs)/pc
1. Repeatedly depress the brake pedal till you feel the
pedal becomes light. That will release oil pressure
in brake line.
54-12
Accumulator
Accumulator installing Accumulator installation cautions
To reinstall the accumulator, follow the above removal - After reinstallation, completely bleed the brake line of
procedure in reverse order. air, and check performance of the accumulator. To
Replace all O-rings and seals during reinstallation. bleed the brake line of air, refer to "Air bleeding pro-
cedure" page 24-25.
- To check performance of the accumulator, refer to

90ZV-2 Shop Manual, Function and Structure, Sec-
tion 53.
54-13
Accumulator
Accumulator disassembling and

7
assembling 2 4 1 3
13
IMPORTANT 10

stand the aforementioned "Hydraulic Parts Disas- 12
sembly and Assembly Cautions" page 44-3. 11
5,6 8,9
Accumulator disassembling 97ZV54007
WARNING 1. Loosen bolt (13) to remove gas valve guard (12).

Disassembly without breathing the inner gas could
cause serious injury or death by explosion. To pre- 2. Remove the cap of gas valve (10) and install the
vent such an accident, observe the following item: charging valve to gas valve (10), then bleed the gas
- Carefully handle the accumulator that has the high completely from the accumulator.
pressure.
- Before disassembly, completely reduce the gas
pressure lower to the atmospheric pressure.
- Do not drill and weld the body.
- Do not use over the specified pressure.
- Use Nitrogen gas for charge.
Gas cap (3)
IMPORTANT
- Take care not to scratch the cylinder to prevent
gas leak.
- Carefully remove each part so that it is not
scratched or dented. 95ZV54002
3. Insert three pins into gas cap (3). Remove the gas
cap by using a long bar.
Pin hole: ø11.4 (0.4 in)

54-14
Accumulator
Accumulator assembling
7
2 4 1 3
To reassemble the accumulator, follow the above disas-
13 sembly procedure in reverse order.
10
After reassembly, carry out the gas charging by refer-
ring to the following procedure.
12
11
5,6 8,9
97ZV54007
Hydraulic cap
95ZV54003
4. Insert three bolts into hydraulic cap (2) and remove

it by using a long bar.
Screw size: 1/2-20UNF-2B
5. Push out piston (4) toward the hydraulic end by

using a bar.
54-15
Accumulator
Nitrogen gas charging Nitrogen gas charging procedure
Nitrogen gas charging tools WARNING

Improper gas pressure can cause serious injury or
1 death. To prevent such an accident, observe the fol-
2 1-1 lowing item:
1-3 1-2
- Before measuring the gas pressure or charging the
gas, stop the engine and release the oil pressure
3
in the line by depressing the brake pedal until there
is no brake pressure.
2 1-1
Accumulator
Charging valve installation 1-2
95ZV54004
1. Charging valve assembly

1-1 Handle (for adjusting screw)
1-2 Handle (for bleeder plug)
1-3 Valve body
2. Pressure gauge (4,903 kPa (50 kgf/cm2) (1,000 1-3
psi))
115ZVE54016
3. Hose assembly
4. Nitrogen (N2) gas cylinder
1. Turn handle (1-1) counterclockwise until it stops
turning.
2. Turn handle (1-2) counterclockwise to open.
3. Remove the gas valve guard cap and then install

charging valve assembly (1) to the gas valve.
4. Install pressure gauge (2) to the charging valve

assembly and connect hose (3) to nitrogen gas cyl-
inder (4).
5. Slightly open the valve of the nitrogen gas cylinder.

Turn handle (1-2) clockwise to close after confirm-
ing the gas comes out from handle (1-2) part.
6. Slowly turn handle (1-1) clockwise to open the pis-

ton of the gas valve.
7. Open the valve of the nitrogen gas cylinder more

and put a charge into the accumulator.
Note
Close the valve of the nitrogen gas cylinder when
checking the gas pressure on the gauge to read the
gauge needle at the stable condition.
54-16
Accumulator
[Charging pressure: 2.9 MPa (30 kgf/cm2) (427 psi) at

20ºC (68ºF)]
Note
Gas pressure is variable with temperature.
Use the following formula for the correct nitrogen charg-
ing pressure.
If the pressure on the gauge is too high, slowly turn the
handle (1-2) counterclockwise.
PX = 30 (kgf/cm2) x {273 + t (ºC)} / {273 + 20 (ºC)}
PX: Charging gas pressure
t: Ambient temperature
30: Standard gas pressure
8. Turn handle (1-1) counterclockwise to return the

piston of the gas valve. Then turn handle (1-2)
counterclockwise to bleed the gas from the charg-
ing assembly and the hose.
9. After removing pressure gauge (2), remove the

charging assembly from the accumulator.
Note
- Apply soapy water to the gas valve on the accumula-
tor to check for gas leakage.
- Recheck the gas pressure once within a week after
the charging.
- Check the gas pressure at every 2,000 operation
hours.
- A little gas is lost each time of the checking, so add
the gas to compensate for the loss.
54-17
Brake Valve
Brake Valve
Brake valve removing and install-

ing Brake valve
Brake valve removing
WARNING
- Block the front wheels with chocks to prevent K90V2E54004
wheels from moving.
1. Remove all hoses and pipes shown on the above
illustration.
Brake valve
IMPORTANT
If a battery terminal is removed from a machine in (S/N 9451~)
function” prior to removing battery terminals. (S/N 9109~)

K85V2E54001
- Press the hydraulic tank cap, and relieve the internal 2. Remove all adapters and fittings shown on the
pressure from the hydraulic tank. above illustration.
Cover
Cover
K90V2E54001
- Remove the cover.

54-18
Brake Valve
Brake valve installing

1 1
To reinstall the brake valve, follow the above removal
Brake valve installation cautions
After reinstallation, completely bleed the brake line of

air, and check all the pipe-joints for oil leakage.
85V2E54013
To check or adjust the brake valve, refer to 90ZV-2
Shop Manual, Function and Structure, Section 53.
3. Remove bolt (1) and then remove the brake valve.
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

54-19
Brake Valve
Brake valve disassembling and assembling
IMPORTANT
Brake valve cross section and tightening torque (main valve)
T1
T2
T4
T3
T2
85V2E54014
:
T1: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)
T2: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)
T3: 8.83 N-m (0.9 kgf-m) (6.5 lb-ft)
T4: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft)
54-20
Brake Valve
Brake valve disassembling

4. Pull out pin (11), pedal pin (12), L-shape pin (13)
and washer (14), and then, remove collar (15) and
roller (16) from the right pedal.
Pedal cover
19 18 17
20
Shaft assembly
85V2E54015
21
1. Remove the pedal covers. 85V2E54018
3 6 5. Remove nut (17), washer (18) and bolt (19).
: Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)
2 1 6. Pull out the shaft assembly and remove left pedal

(20) and pedal collar (21).
23 24 26 27 26 25 22
Shaft assembly 5 4
85V2E54016
2. Pull out pin (1). Remove washer (2), right pedal (3),
mounting plate (4), pedal collar (5) and spring (6)
from the shaft assembly.
12 13 15 16 15 14 11
85V2E54019
9
7. Pull out pin (22), pedal pin (23), L-shape pin (24)
and washer (25), and then, remove collar (26) and
roller (27).
10 8 7
85V2E54017
3. Remove nut (7), washer (8) and bolt (9) to remove

plate (10).
: Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)

54-21
Brake Valve
32 31 29 28 33
Cover
30 Joint
85V2E54020
8. Remove ring (28) and pull out boot (29).

40
9. Remove ring (30) for the joint, and remove pin (31)
by using a pressing machine or equivalent to sepa-
rate shaft assembly (32)(33).
38
37 Body 2
34 36
35
41
Body 1
85V2E54021
39
10. Loosen bolt (34) and remove spring washer (35)

and mounting plate (36).
: Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft) 85V2E54022
11. Remove dust cover (37) and seat (38).

12. Loosen bolt (39), and separate the brake valve into
the Body 1, Body 2 and the Cover. Remove springs
(40)(41).
: Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)

54-22
Brake Valve
43
42 50
3.5mm
48
44
Pin hole
47 46
45
51
52
53
Body 1 Body 2
85V2E54023 85V2E54025
13. Place the Body 1 and Body 2 on a workbench 16. While pushing down case (50) by 3.5 mm or more
upside down. Remove C-ring (42), and then, using a pressing machine or equivalent, insert an
remove plug (43) and spring (44). appropriate available thin rod into the pinhole (of 1
mm diameter) in another case (51) to push up ring
14. Slowly pull out spool (45) from the Body 1 and (52) to remove.
remove plunger (47). Also pull out spool (46) from Then, release case (50) to remove it. Remove
the Body 2 and remove plunger (48). spring (53) inside case (51).
Note
Be advised that the spring inside the covers may jump
out when disassembling.
Cover
56 54
51 55
49 57
85V2E54024 49
15. Place the Cover on a workbench upside down.

Slowly pull out spool input (49) together with the
85V2E54026
spring and the spring case.
17. Loosen bolt (54) mounted in spool input (49), and

remove retainer (55), spring (56), case (51) and
spring seat (57).
: Bolt: 8.83 N-m (0.9 kgf-m) (6.5 lb-ft)
Note
When fixing spool input (49) in a vise to loosen bolt (54),
make sure to protect the spool input with a cloth, etc. to
avoid the damage on the surface of the spool.
54-23
Brake Valve
Brake valve assembly cautions

59 58 Installation tool
60
New seal
0.5 mm (0.02 in)

27
or less
Adjusting screw
Cover Reassembly process
85V2E54027
38 Nut
18. Place cover (14) on a workbench. Remove C-ring

(58), plate (59) and oil seal (60).
Left pedal
(0.067~0.079 in)
1.7~2.0 mm
Note
Do not reuse the oil seal; replace it with a new one 16
Adjusting screw
when reassembling.
Brake valve assembling 61
To reassemble the brake valve, follow the above disas- Right pedal Nut
85V2E54028
Note
- Clean and check all the parts. If a part is defective, - Adjust the left pedal using the adjusting screws on
replace or repair the part. the right and left pedals so that the opening between
- Replace all the O-rings and seals with new ones. seat (38) and roller (27) for the left pedal becomes
- Apply the specified torque to tighten each main 0.5 mm (0.02 in) or less when the pedal is not
parts. depressed. Tighten the nut when adjusted.
part before reassembly. Tightening torque: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft)
- Adjust the right pedal using the bolt so that the open-
ing between bolt (61) and roller (16) for the right
pedal becomes 1.7~2.0 mm (0.067~0.079 in) when
fully depressing the left pedal. Tighten the nut when
adjusted.
Tightening torque: 58.8 N-m (6.0 kgf-m) (43.4 lb-ft)

54-24
Service Brake
Service Brake
Service brake disassembling and Service brake installation cautions

assembling
Refer to "Front axle disassembling and assembling"
page 24-26 for the procedures.
Spider
Socket bolt
90ZV24036
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.
A
B
Wheel hub
Brake piston
90ZV54013
1. Loosen the axle housing air bleeder nipple.
2. After pushing back the piston, confirm dimension A

from the piston end face to the wheel hub end face.
A: 133.35~134.85 mm (5.250~5.309 in)
Note
Piston stroke B: 1.18~1.83 mm (0.046~0.072 in)
3. After finishing the installation work, bleed air com-

pletely from the brake line.
54-25
Parking Brake Actuator
Parking brake actuator removing Note

If there is no oil source, apply a cable to the link, and
and installing then pull it down using a bar to overcome the spring
force, and then remove the pin.
Parking brake actuator removing
2. Release the residual air pressure in hydraulic tank.
Disconnect oil hose (3).
WARNING
Unexpected movement of machine could cause seri- 3. Loosen locknut (4) to remove joint (5).
ous injury or death. To prevent such an accident, Remove retainer bolts (6) to remove parking brake
observe the following items: actuator (7).
- When removing the parking brake actuator, the
machine may move. To prevent the machine from : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft)
moving, park the machine on level ground, and : Parking brake actuator: 8 kg (18 lbs)
lower the bucket onto the ground.
- In addition, block tires with chocks to prevent
wheels from moving.
Parking brake actuator installing
To reinstall the parking brake actuator, follow the above

3 Note
To insert the connection pin to connect the parking
brake actuator to the parking brake, observe the follow-
7 ing items:
- Start the engine to build oil pressure in the accumu-
lator.
6 - Release the parking brake.
Transmission - Slightly raise the parking brake lever by hand, and
adjust the position of the joint hole between the park-
4 ing brake actuator and the parking brake. After that,
Brake assembly
5 insert the connection pin into the joint hole.
To check performance of the parking brake, refer to
1
90ZV-2 Shop Manual, Function and Structure, Sec-
tion 53.
2
90ZV54014
1. If there is an oil source, release the parking brake,

and then remove split pin (1) and pin (2).
54-26
Parking brake actuator adjusting Parking brake "OFF" position
Parking brake actuator adjustment proce-

dure 4
WARNING
1
When remove the parking brake, the machine may A
move and it could cause serious injury or death. To
prevent such an accident, observe the following item: 2
- Lower the attachment onto the ground. 3 4
2
3
5,6,7
90ZV54015
1. Parking brake actuator 5. Pin

2. Lock nut 6. Split pin
3. Link 7. Washer
4. Bracket
1. Release parking brake (OFF).
2. Measure dimension "A" if it is 85 mm (3 11/32 in).
3. If not, remove pin (5), split pin (6), and washer (7)
and loosen lock nut (2).
And adjust the linkage length by turning link (3) so
that dimension "A" is 85 mm (3 11/32 in).
4. Tighten lock nut (2) and reinstall pin (5), split pin (6)
and washer (7).
5. Confirm the parking brake performance.

(Refer to 90ZV-2 Shop Manual, Function & Struc-
ture, Section 53.)
54-27
Parking brake actuator disassem-

bling and assembling
IMPORTANT
Parking brake actuator cross section and

tightening torque
90ZV54019
No specified torque
When disassembling, put matchmarks on the rod cover
cap and piston. During reassembling, align the match-
marks and install the set screw.
54-28
Parking brake actuator disassembling
WARNING
The inner spring could spring out causing serious
injury. To prevent this, be sure to press the spring
using a press until the spring loses the spring force,
and then remove the rod cap. When reducing the
pressure of the press, be sure to slowly reduce it.
90ZV54007J
3. Removal of rod cap
Using the press, press down the rod cover with the
pipe (outer dia.: 50 mm (2.0 in) or less, inner dia.:
30 mm (1.2 in) or more, length: 80 mm (3.15 in)),
Matchmark and it will be allowed to loosen the rod cap with
hand. So, remove the rod cap.
90ZV54016
4. Slowly pull up the press until the spring loses the
spring force.
1. Removal of the set screw of rod cap

3
Note
Since the set screw is locked by punching, cut off the 4
punched area with 15~20 mm (0.6~0.8 in) dia. drill.
Since it is necessary to install the set screw at the same
position during reassembly, mark the positioning match-
mark on the rod cap and cylinder tube.
2
90ZV54008J
5. Pull out rod cover (1), spring (2), piston rod (3) and
piston (4) from the cylinder tube.
90ZV54006J
2. Initial loosening of rod cap
Using the threaded hole of the rod cap, unscrew

the rod cap approx. 1/8 turn alone.
54-29
Parking brake actuator assembling

3
5
4
Matchmark
90ZV54017
6. Put matchmarks on piston (4) and rod. 90ZV54011J
Remove set screw (5) to pull out piston (4).

To reassemble the parking brake actuator, follow the
Note disassembly procedure in reverse order.
- Since the set screw is locked by punching, cut off the
punched area with a drill 15~20 mm (0.6~0.8 in) in
diameter.
- During reassembling, align the matchmarks and
Parking brake actuator assembly cautions
install the set screw at the same position.
CAUTION
8
When compressing the spring with the press, press
the center of the cylinder with the press to prevent the
4
cylinder from being inclined.
9
10 6 Tighten the rod cap to the position where the match-

7
1 mark was marked before disassembly, screw in the
screw, and punch it for locking.
90ZV54010J
7. Remove dust seal (6) and bushing (7) from rod

cover (1). Remove wear ring (8), U-packing (9) and
O-ring (10) from piston (4).
54-30
Parking Brake
Parking Brake
Parking brake removing and installing /

disassembling and assembling
Parking brake removing and disassem-
bling
4
WARNING
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:
5
- Lower the attachment onto the ground.
K90V2E54005
1. Drain the transmission oil.
3. Remove bolts (5) of propeller shaft (4).
: Bolt (5): 142 N-m (14.5 kgf-m) (105 lb-ft)

2 : Screw lock agent application
(Three Bond 1327)
3 7
90ZV54012J
8
2. Release the parking brake, and then remove pin (3) 9
to disconnect link (1) and lever (2).
6 90V2E54009
4. Remove bolt (6) of brake adjustment hole and then

remove brake drum (7).
Remove nut (8) and flange yoke (9).
: Bolt (6): 94 N-m (9.6 kgf-m) (69 lb-ft)

Nut (8): 392 N-m (40 kgf-m) (2,891 lb-ft)
(Three Bond 1327)
: Nut (8): Molybdenum disulfide grease/
MOS2 application
54-31
Parking Brake
11
15
10 97K54012 16 97ZV54026
5. Remove right and left springs (10) using pliers. 7. Remove spring (15), and then remove adjusting
Remove plate (11). screw (16).
Note
Upper guide
13 Measure the wear of the brake shoes. If the shoes are
extremely worn, replace them.
Refer to Section 53 or Section 55 “90ZV-2 Service Stan-
dard Brake Group” for the inspection standards.
Side
guide
Parking brake installing and assembling
12
To reinstall and reassemble the parking brake, follow
the above removal and disassembly procedure in
14 95ZV54029
reverse order.
6. Pull out the upper guides to the front to open brake Note
shoes (12), and then remove shoes (12) from the To adjust and check performance of the parking brake,
side guides. refer to the 90ZV-2 Shop Manual, Function and Struc-
ture, Section 53.
Note
If it is necessary to remove back plate (13), remove bolt
(14).
: Bolt (14): 216 N-m (22 kgf-m) (159 lb-ft)

54-32
Parking Brake
Parking brake (for front) removing

and installing
Parking brake (for front) removing
WARNING
1
- Block the front wheels with chocks to prevent
wheels from moving.
3
- Stop the engine and set the parking brake switch to
the "OFF" position to discharge the oil pressure in
the line.
- Prepare a container to catch the drained oil.
2
90V2E54011
1. Disconnect hose (1) and remove adapter (2).
Note
Cover the disconnected hoses with clean plastic to pro-
tect them from dust and dirt.
2. Attach sling to disc brake assembly (3), and then

remove four bolts (4).
: Bolt (4): 451 N-m (46.0 kgf-m) (333 lb-ft)

: With lubricating oil
: Disc brake assembly: 35 kg (77 lbs)
3. Place disc brake assembly (3) on a carrier.

54-33
Parking Brake
Front differential Parking brake installation cautions
Bracket 6
Brake oil 1
Brake disc 2 8
7
3
6 4
5
18 5 1 11 14 20 19
7 22 9
6
Brake oil
13
8 7
16
3 10
4 12 21
90V2E54012 17 15
13
Note Brake disc 95ZV54034
If it is necessary to remove the brake disc and the

bracket: - Brake pad assemblies (5) should be free, not
pressed against disc.
: Bolt (5): 132 N-m (13.5 kgf-m) ( 98 lb-ft) If not free, remove brake pad assemblies (5) by
Bolt (6): 765 N-m (78.0 kgf-m) (565 lb-ft) referring to "Brake pad assemblies replacement pro-
: Bolt (5)(6): With lubricating oil cedure" page 54-34.
Use a pry bar to push pistons (10) back into torque
plate assembly (1).
Reinstall brake pad assemblies (5).
Parking brake (for front) installing
- If torque pins (4) of installed brake heads contact the
For reinstallation, follow the above procedure in reverse disc, loosen bolts (3) and move pins away from disc,
order. within limits of the O.D. groove in the pin. Make sure
bolt (3) fully engages groove in pin (4) and bolt tight-
ening torque is 51 N-m (5.2kgf-m) (38 lb-ft).
- After reinstall the disc brake assembly, complete

bleed air in the line as the following procedure.
54-34
Parking Brake
Air bleeding procedure

Brake oil 1 6
2 8
(a) Connect a vinyl tube to the air bleeder nipple, and
place an oil can to receive the oil.
(b) Apply parking brake to build-up pressure in the disc
brake head and slightly loosen air bleeder valve (2) 7
to slightly discharge oil. 3
(c) When the oil flows from the air bleeder nipple, close
4
the nipple.
(d) Repeat this until there is no air in the oil.
- Confirm the performance of the parking brake.

Refer to 90ZV-2 Shop Manual Function & Structure,
Section 53 for the checking procedure. 18 5 1 11 14 20 19
7 22 9
6
Brake pad assemblies replacement proce- Brake oil

dure
13
8 7
WARNING 16
10
Unexpected movement of machine could cause an 12 21
17 15
an accident, observe the following items: Brake disc 95ZV54034
- Block the front wheels with chocks to prevent 1. Connect a vinyl tube to air bleeder (2).
wheels from moving. Open the bleeder.
2. Loosen bolts (3) and slide pins (4) back from the
center or the brake head. Remove brake pad
- Stop the engine.
assemblies (5) down from the brake head.
3. Using a wrench, rotate a 1/4 x 7/8 x 7 inch steel bar

between the disc and piston (10) face to retract the
pistons into the piston bores of torque plate assem-
bly (1).
4. Install new brake pad assemblies (5) by placing a

friction material next to the disc and rotating into the
position in the brake head.
5. Lubricate O.D. of pins (4) with a good anti-seize

compound and install in torque plate assembly (1).
Push the pins toward the disc.
6. Temporarily tighten bolts (3) until they seat in pin (4)

grooves. This can be checked by limited axial
movement of the pins as the bolts are being seated
in the grooves.
After bolts (3) are seated in the grooves, tighten
them firmly.
: Bolt (3): 51 N-m (5.2kgf-m) (38 lb-ft)

54-35
Parking Brake
Parking brake (for front) disassembling and assembling
IMPORTANT
Parking brake (for front) cross section and tightening torque
1 6 18 5 1 11 14 20 19
8 2
7 22 9
4 6
3
13
8 7
16
10
12 21
17 15
13
95ZV54035
1. Torque plate assembly (+) : Valve (2): 25 N-m (2.6 kgf-m) (19 lb-ft)
2. Bleeder valve Bolt (3): 51 N-m (5.2 kgf-m) (38 lb-ft)
3. Bolt Bolt (6): 54 N-m (5.5 kgf-m) (40 lb-ft)
4. Pin
5. Pad assembly
6. Bolt
7. Washer
8. Cap, inlet
9. Packing (∗)
10. Piston
11. Boot (∗)
12. Packing (∗)
13. Nut
14. Spring
15. Washer
16. Retaining ring
17. Sleeve, adjuster
18. Guide, adjuster
19. Guide, adjuster
20. Packing (∗)
21. Ring, back-up (∗)
22. Ring, back-up (∗)
Note
(+): Impossible to repair or replace the part
(∗): Available only as the parts kit contains all of them.
54-36
Parking Brake
Parking brake (for front) disassembling

6. Replace all rubber parts (9) (11) (12) (20) (21) and
(22), using the kit specified in applicable parts cata-
Brake oil 1 6 log.
2 8
7. Clean, degrease, repair or replace damaged or

excessively worn parts, as required.
7
8. Inspect brake pad assemblies (5) for excessive
3
wear.
4 Replace if lining is worn to wear limit. Refer to Sec-
tion 55 for the wear limit.
9. Inspect pistons (10) for minor scratches or nicks

and blend with crocus cloth.
Replace pistons that are badly nicked or scratched.
18 5 1 11 14 20 19
7 22 9 10. Pins (4) that are deeply grooved should be

6 replaced or rotated so grooved surface is opposite
brake pad assembly (5) ends.
Brake oil
13
8 7
16 Parking brake (for front) assembling
10
12 21
17 15 For assembly, follow the above procedure in reverse
13
order.
Brake disc 95ZV54034
1. Loosen bolts (3) and slide pins (4) back from the
center of the brake head, and then remove brake
pad assemblies (5) from the brake head.
2. Attach the brake head to a hydraulic pressure

source. Restrain piston (10) opposite cap (8) with a
C-clamp and apply hydraulic pressure until the pis-
ton in inlet side is free of piston bore.
Release pressure, disconnect the brake head from
the pressure source and remove C-clamp.
3. Remove nut (13), washer (7) and press piston (10)

from torque plate assembly (1) by pushing guide
(19) towards the center of the brake head.
4. Remove bolts (6), washers (7) and cap (8) with

attached guide (18). Remove packing (9) from cap
(8).
Note
Do not remove guide (18) from cap (8) except when
replacing it due to a damage.
5. Remove packings (9), (20), boots (11) and bleeder

screws (2) from torque plate assembly (1).
54-37
Parking Brake
Parking brake (for front) assembly cautions - Install new brake pad assemblies (5) by placing fric-
tion material next to the disc and rotating into posi-
tion in the brake head.
Brake oil 1 6
2 8
- Lubricate O.D. of pins (4) with a good anti-seize
compound and install in torque plate assembly (1).
Push the pins toward the disc.
7
- Temporarily tighten bolts (3) until they are seated in
3
pin (4) grooves. This can be checked by limited axial
4 movement of the pins as the bolts are being seated
in the grooves.
After bolts (3) are seated in the grooves, tighten
them firmly.
: Bolt (3): 51 N-m (5.2kgf-m) (38 lb-ft)

18 5 1 11 14 20 19
7 22 9 Note
6 Lubricate pins (4) with a corrosion resistant lubricant
prior to installation, for easier pin removal on the next
Brake oil occasion.
13
8 7
16
10
12 21
17 15
13
Brake disc 95ZV54034
- Lubricate packings (9) (12) (20) and O.D. of pistons

(10) with hydraulic fluid specified in applicable brake
head parts catalog sheet, prior to installation.
- Install cap (8) with attached guide (18) and secure in

place with four each bolts (6) and washers (7).
If guide (18) was removed from cap (8), clean the
screw threads. Coat the screw threads with Loctite®
sealant and reinstall in cap, tightening securely.
- Assemble packing (20) over threaded end of guide

(19) and seat against shoulder of guide. Insert guide
(19) through the closed piston bore (opposite side to
the capped piston bore) with threaded end protrud-
ing from back of torque plate assembly (1).
Secure in place with nut (13) and washer (7).
- Pistons (10) must be installed over guides (18)(19)

from the center of brake head using the provided
adjuster parts. Push pistons through previously
installed boots (11) and packings (12) by hand. With
pistons centered over guides, use a C-clamp or
other suitable device to force the pistons over guides
and into piston bores.
54-38
MEMO
55-1
90ZV-2 Service Standard Brake Group

Brake Group
Brake Valve ............................................................. 55-2

Service Brake .......................................................... 55-4
Parking Brake.......................................................... 55-5
55-2
Brake Valve
Brake Valve
8
7
2
3
5
2
3
85V2E55001
55-3
Brake Valve
Unit: mm (in)
Judgment standard
No. Item Tolerance Solution

Standard
dimension Standard Allowable
Shaft Hole
clearance clearance
-0.020 ~ -0.053
Clearance between spool +0.033~0 0.020~0.086
1 ø22.4 (0.8819) (-0.0008~ 0.096 (0.0038) Replacement
input and cover (+0.0013~0) (0.0008~0.0034)
-0.0020)
Clearance between spool 0.005~0.012 Assembly
2 ø18 (0.7086) — — 0.014 (0.0006)
and body 1, 2 (0.0002~0.0005) replacement
-0.005 ~ -0.010
Clearance between plunger 0.008~0 0.005~0.018 Assembly
3 ø12 (0.4724) (-0.0002~ 0.020 (0.0008)
and spool (0.0003~0) (0.0002~0.0007) replacement
-0.0004)
Judgment standard
Standard dimension Tolerance limit
No. Item Solution
Installation
Free length Installation load Free length Installation load
length
mm (in) N (kgf) (lb) mm (in) N (kgf) (lb)
mm (in)
4 Spool return spring 28.3 (1.1142) 17.2 (0.6772) 15 (1.5) (3.4) — 12.8 (1.3) (2.9)
5 Spool return spring 32.7 (1.2874) 17.2 (0.6772) 39.2 (4.0) (8.8) — 33.3 (3.4) (7.5)
6 Control spring 41.9 (1.6496) 35.3 (1.3898) 204 (20.8) (45.9) — 173 (17.6) (38.9) Replacement
7 Control spring 56.4 (2.2205) 48.8 (1.9212) 110 (11.2) (24.7) — 94 (9.6) (21)
8 Return spring 81 (3.1890) 55 (2.1653) 118 (12) (26.5) — 100 (10.2) (22.5)
55-4
Service Brake
Service Brake
Air bleeder nipple

1, 5 3
3 Slide
caliper
1, 5
Backing
6 2, 5 Steel plate plate
2, 5
Friction
plate
95ZV55001
Unit: mm (in)
Judgment standard
No. Item Solution
Standard dimension Tolerance Wear limit
1 Thickness of steel plate 4.9 (0.1929) ±0.1 (±0.0039) 4.4 (0.1732)
2 Thickness of friction plate 7.0 (0.2756) ±0.1 (±0.0039) 5.7 (0.2244) Replacement
Thickness of brake disc when measured by ±0.3 (±0.0118)~
3 28.8 (1.1339) 25.1 (0.9881)
calipers (with brake applied) -0.5 (-0.0196)
(Manufacturing
-0.210 (-0.0082)~
Outer dia. dimension) —
-0.299 (-0.0117)
355 (13.9763)
4 Piston seal contact face —
(Manufacturing
+0 (+0)~
Inner dia. dimension) —
+0.081 (+0.0032)
310 (12.2047)
0.30 (0.0118) 0.30 (0.0118)
5 Distortion of steel and friction plate —
or less and more
Free length Installation length Installation load (kgf) Replacement
6 Return spring
54 (2.1260) 49 (1.9291) 29.3 (64 lbs)
55-5
Parking Brake
Parking Brake
5
1
Clearance
Spring (4) released

4
95ZV55002
Unit: mm (in)
No. Item Judgment standard Solution
Standard dimension Wear limit
1 Wear of lining
6.15 (0.2421) 2.95 (0.1161)
2 Deflection of drum 0.38 (0.0149) or more
Replacement
3 Lining inspection Grease or oil on the lining
4 Expansion of adjuster spring There is clearance between the spring and the coil
5 Expansion of return spring when the spring is released.
55-6
MEMO
74-1
90ZV-2 Disassembly & Reassembly Operator Station Group

Operator Station Group
Air Conditioner ........................................................ 74-2

74-2
Air Conditioner
Air Conditioner
Air conditioner removing and

installing
Air conditioner removing
IMPORTANT
In case that it is necessary to replace the air condi-
tioner parts, be sure to set the air conditioner mode
as below before removing the air conditioner unit
from the machine.
Temperature control: Max cool
Ventilation mode: Foot
Air intake control: Inside air circulation

- Remover the seat in the cab.
- Collect the air conditioner refrigerant using the
proper recovery method.
- Remove the floor mat in the cab.
1 4 2
1
4
2
3
3
View from operator’s seat
95ZVE74001
74-3
Air Conditioner
Cab
7
12
11
6 5
95ZVE74002 95ZVE74005
1. Remove box (1)(2). 6. Remove air conditioner mounting bolts (11). Then
remove air conditioner (12) from the floor board.
2. Remove cover (3) and plate (4).
3. Remove cover (5)(6)(7) from the cab.

Air conditioner installing
4. Remove duct (8).
To reinstall the air conditioner, follow the above removal
Air conditioner unit Reference

After reinstalling the air conditioner, charge the refriger-
ant, confirm the operation, confirm the gas pressure,
9 then check for gas leaks.
95ZVE74003
Air conditioner unit
10
95ZVE74004
5. Disconnect refrigerant piping (9) and heater hose

(10).
74-4
Air Conditioner
Air conditioner disassembling and

assembling
Air conditioner tightening torque
[Cooling unit]
T2
T6
T4 T3
T2 T2
T6
T3
T6
T4
T4
T5
T6
T2 T4
T1
T5
T6
T5
97ZV74002

T1: 5.4 N-m (0.55 kgf-m) (4 lb-ft)
T2: 1.9 N-m (0.19 kgf-m) (1.4 lb-ft)
T3: 1.0 N-m (0.1 kgf-m) (0.7 lb-ft)
T4: 0.8 N-m (0.08 kgf-m) (0.6 lb-ft)
T5: 1.9 N-m (0.19 kgf-m) (1.4 lb-ft)
T6: 2.5 N-m (0.25 kgf-m) (1.8 lb-ft)
74-5
Air Conditioner
[Heater and accessories] [Air distributor (hood & defroster selection box)]
T3
T1
T3
T2
T2
T2
T4
T1
97ZV74003 95V2U74001
: Bolt tightening torque : Bolt tightening torque

T1: 4.0 N-m (0.4 kgf-m) (2.9 lb-ft) T1: 3.7 N-m (0.38 kgf-m) (2.7 lb-ft)
T4: 5.4 N-m (0.55 kgf-m) (4 lb-ft)
74-6
Air Conditioner
[Air compressor (with magnetic clutch)]
T1
T2
T1
97ZV74005

T1: 4.9 N-m (0.5 kgf-m) (3.6 lb-ft)
T2: 18 N-m (1.8 kgf-m) (13 lb-ft)
[Condenser unit]
T1
T1
T1
T2
T1
95V2U74002

T1: 12 N-m (1.2 kgf-m) (8.7 lb-ft)
T2: 5.4 N-m (0.55 kgf-m) (4 lb-ft)
74-7
Air Conditioner
Air conditioner disassembling 5

3
[Blower assy] 4
Air conditioner Blower assy

unit assy
5
95V2U74005
3. Remove motor cooling pipe (3) from motor assy (4)

and the blower case.
95V2U74003
4. Remove bolt (5) (3 pcs), and then remove motor

assy (4) from the blower case.
1
2
5. Remove the packing from motor assy (4). This
packing is reusable.
95V2U74004
1. Remove tapping screw (1) that fixes blower assy

(2) to the air conditioner unit assy.
2. Pull blower assy (2) upward to separate it from the

air conditioner unit assy.
74-8
Air Conditioner
Screw driver
Lever
8
9 6
Long-nose pliers
95V2U74006
6. Remove clamp (6) using a screw driver.
7. Carefully push the link shaft end using long-nose

pliers and remove link shaft (7) from the lever.
Note
Be careful not to break the link shaft claw.
8. Remove tapping screw (8) (3 pcs) and remove

servo motor (9).
11
10
95V2U74007
9. Remove bolt (10) and then remove relay (11).

74-9
Air Conditioner
[Air conditioner unit assy]
6
Air conditioner
unit assy
5
95V2U74010
95V2U74008
4. Remove tapping screw (4) and then remove plate
(5).
3 1
2 5. Remove lever (6) and lever (7) respectively.
9
95V2U74009
1. Remove tapping screw (1) that fixes blower assy

95V2U74011
(2) to the air conditioner unit assy.
2. Pull blower assy (2) upward to separate it from the 6. Remove clamp (8) using a screw driver. Then
air conditioner unit assy. remove link shaft (9).
3. Remove thermistor assy (3) from the case.
10 10
95V2U74012
7. Remove tapping screw (10) (11 pcs) and separate

the cooler case.
74-10
Air Conditioner
Thermistor
16
+10
(9.3 in)
236 – 5
(3.1 in)
0
80 – 15
Packing 143.5 5
95V2U74013 (5.6 in) 95V2U74016
Note 10. Remove clamp (16) (2 pcs) and remove the ther-
When reassembling, make sure that the packing is mistor from the evaporator.
placed in the case groove.
Note
When reassembling, place clamps (16) in the positions
as shown.
13
11
18
17
21
14 12
19
95V2U74014
20
8. Loosen joints (11)(12) and remove evaporator (13).

95V2U74017
: Joint (11): 32 N-m (3.3 kgf-m) (24 lb-ft)

: Joint (12): 13 N-m (1.3 kgf-m) (9.4 lb-ft) 11. Remove tapping screw (17) and remove clamp 1
(18).
12. Remove tapping screw (19) and remove clamp 2

14 15
(20).
13. Pull heater core (21) upward and remove it.
95V2U74015
9. Remove bolt (15) (2 pcs) and then remove expan-

sion valve (14).
74-11
Air Conditioner
27
22
28
27
95V2U74018 95V2U74021
14. Remove the thermo sensor connector from the 18. Remove tapping screw (27) and remove servo
bracket and remove thermo sensor (22). motor (28).
24
29
30
24
24 24
31
25 32
23
95V2U74019 95V2U74022
15. Remove clamp (23) by using a screw driver. 19. Remove tapping screw (29) (2 pcs) and remove IC
assy (30).
16. Remove tapping screw (24) and remove servo
motor (25). 20. Remove pressure switch (31) from tube (32).
Air conditioner assembling
To reassemble the air conditioner, follow the above pro-

cedure in reverse order.
26
95V2U74020
17. Remove plate (26).

74-12
MEMO
75-1
90ZV-2 Service Standard Operator Station Group

Operator Station Group
Air Conditioner ........................................................ 75-2

75-2
90ZV-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
Inspection/
Magnetic clutch should operate. Abnormal sounds
Compressor Operating status adjustment/
should not be detected.
replacement
Abnormal sounds and backlash should not be Inspection/

Belt tension pulley Operating status
detected. replacement
V belt Damage and tension Damages should not be detected. Replacement
Inspection/
Blower motor and fan Operating status Abnormal sounds or vibration should not be detected.
replacement
Each part should operate in accordance with switch Inspection/

Control mechanism Operating status
operations. replacement
Air quantity should not be so small as to hinder air con-

Air filter for inside/outside air Clogging Cleaning/replacement
ditioning.
Each mounting area and pip- Looseness, gas leak and Looseness, gas leak and damages should not be
Tightening/charge
ing damages detected.
Tightening Torque
Tightening torque for hose and pipes Tightening torque for screws and bolts in
special control regions
Tightening
Pipe size torque
Connection Tightening
Connection area or N-m
type torque
bolt size (kgf-m)
Special control area Bolt size N-m
(lb-ft)
(kgf-m)
15 (lb-ft)
Condenser-
ø8 piping (1.50)
expansion valve 18
(11)
Head bolt of magnetic clutch M6 (1.8)
25 (13)
Compressor-
Nut type D1/2 piping (2.50)
condenser Mounting bolt for servo motor for 0.8
(18)
inside/outside air selection (Tap- (0.08)
34 ping screw) (0.6)
Evaporator-
D5/8 piping (3.50)
compressor 5.4
(25) Fixing nut of blower motor and con-
M6 (0.55)
7 denser fan
M6 bolt (4.0)
Receiver (0.70)
in receiver (4T) 4
(5.1) Fixing bolt of blower motor and con-
Block joint M5 (0.4)
Any M6 bolt 12 denser motor
Evaporator- (2.9)
(6T) other than (1.20)
compressor
above (8.7)
INDEX
A Brake Valve ........................................................... 54-17, 55-2
Accumulator ....................................................................54-11 Brake valve assembling ................................................. 54-23
Accumulator assembling .................................................54-14 Brake valve assembly cautions ...................................... 54-23
Accumulator disassembling ............................................54-13 Brake valve cross section and tightening torque
Accumulator disassembling and assembling ..................54-13 (main valve) ................................................................ 54-19
Accumulator installation cautions ...................................54-12 Brake valve disassembling ............................................. 54-20
Accumulator installing .....................................................54-12 Brake valve disassembling and assembling ................... 54-19
Accumulator removing ....................................................54-11 Brake valve installation cautions .................................... 54-18
Accumulator removing and installing ..............................54-11 Brake valve installing ...................................................... 54-18
Air bleeding procedure ....................................................24-25 Brake valve removing ..................................................... 54-17
Air Cleaner ......................................................................24-16 Brake valve removing and installing ............................... 54-17
Air cleaner installation cautions ......................................24-17 Bucket cylinder installation cautions ............................... 44-19
Air cleaner installing ........................................................24-17 Bucket cylinder installing ................................................ 44-18
Air cleaner removing .......................................................24-16 Bucket cylinder removing ............................................... 44-17
Air cleaner removing and installing .................................24-16 Bucket cylinder removing and installing ......................... 44-17
Air Conditioner ........................................................ 74-2, 75-2
Air conditioner assembling ..............................................74-11 C
Air conditioner disassembling ...........................................74-7 Cab ................................................................................. 14-12
Air conditioner disassembling and assembling .................74-4 Cab installing .................................................................. 14-13
Air conditioner installing ....................................................74-3 Cab removing ................................................................. 14-12
Air conditioner removing ...................................................74-2 Cab removing and installing ........................................... 14-12
Air conditioner removing and installing .............................74-2 Cautions Regarding Handling of Bearing ....................... 00-13
Air conditioner tightening torque .......................................74-4 Cautions regarding parts removal .................................... 00-9
Applying and Storing Articulation Stopper ......................00-15 Cautions regarding reassembly ........................................ 00-9
Applying articulation stopper ...........................................00-15 Cautions Regarding Welding Repair Service ................. 00-11
Attachment Leveler ...........................................................15-6 Center Pin ............................................................. 14-20, 15-4
Attachment leveler ............................................................15-7 Center pin installation cautions ...................................... 14-25
Attachment leveler adjustable angle .................................15-7 Center pin installing ........................................................ 14-25
Axle and Differential Service Standard .............................25-3 Center pin removing ....................................................... 14-22
Axle group .........................................................................25-3 Center pin removing and installing ................................. 14-22
Axle nut tightening ..........................................................24-32 Center pin shim adjustment ................................... 14-20, 15-4
Axle nut tightening procedure ............................. 24-21, 24-45 Clutch Oil Pressure .......................................................... 35-8
Axle Support ...................................................................24-49 Clutch oil pressure standard value ................................... 35-8
Axle support assembling .................................................24-50 Clutch plate ...................................................................... 35-7
Axle support assembly cautions .....................................24-51 Clutch Plate Thickness/Piston Stroke .............................. 35-6
Axle support disassembling ............................................24-50 Control Valve .................................................................... 35-3
Axle support disassembling and assembling ..................24-50 Control valve assembling ............................................... 34-45
Axle support tightening torque ........................................24-49 Control Valve Assembly ................................................. 34-41
Control valve assembly cautions .................................... 34-45
B Control valve disassembling ........................................... 34-44
Bearing cover installing .....................................................15-4 Control valve disassembling and assembling ................ 34-44
Bearing installation cautions ...........................................00-13 Control valve installation cautions .................................. 34-43
Bearing operation test after installation ..........................00-14 Control valve removing ................................................... 34-42
Bearing removal cautions ...............................................00-14 Control valve removing and installing ............................. 34-42
Bolt Tightening Torque .....................................................00-4 Control valve tightening torque ....................................... 34-41
Boom ..............................................................................14-17
Boom cylinder installation cautions .................................44-16 D
Boom cylinder installing ..................................................44-16 Deck ................................................................................. 14-2
Boom cylinder removing .................................................44-15 Deck installing .................................................................. 14-3
Boom cylinder removing and installing ...........................44-15 Deck removing ................................................................. 14-2
Boom installation cautions ..............................................14-19 Deck removing and installing ........................................... 14-2
Boom installing ...............................................................14-19 Differential ............................................................. 24-61, 25-4
Boom removing ...............................................................14-17 Differential Assembly ...................................................... 24-52
Boom removing and installing .........................................14-17 Differential assembly assembling ................................... 24-61
Brake adjustment ............................................................24-33 Differential assembly disassembling .............................. 24-57
Brake pad assemblies replacement procedure ..............54-34
Differential assembly G
disassembling and assembling ................................... 24-55 Gear Pump .......................................................................35-5
Differential assembly installation cautions ..................... 24-54 Gear pump specifications .................................................35-5
Differential assembly installing ....................................... 24-54
Differential assembly removing ...................................... 24-52
Differential removing and installing ................................ 24-52 H
Hose Band Tightening Torque ..........................................00-8
How to wind a seal tape .................................................00-10
E Hydraulic Cylinder .................................................44-15, 45-2
Engine ............................................................................ 24-11 Hydraulic cylinder assembling ........................................44-26
Engine installation cautions ............................................ 24-13 Hydraulic cylinder assembly cautions .............................44-27
Engine installing ............................................................. 24-13 Hydraulic cylinder
Engine removing ............................................................ 24-11 cross section and tightening torque ............................44-22
Engine removing and installing ...................................... 24-11 Hydraulic cylinder disassembling ...................................44-24
Engine Room ................................................................... 14-8 Hydraulic cylinder disassembling and assembling ......... 44-22
Engine room installation cautions .................................. 14-11 Hydraulic parts assembly cautions ...................................44-3
Engine room installing .................................................... 14-10 Hydraulic Parts Disassembly and Assembly Cautions ..... 44-3
Engine room removing ..................................................... 14-8 Hydraulic parts disassembly cautions ..............................44-3
Engine room removing and installing ............................... 14-8 Hydraulic Parts Removal and Installation Warning ..........44-2
Hydraulic pump assembling ...........................................44-12
F Hydraulic Pump Assembly ................................................44-4
Fan ................................................................................... 24-9 Hydraulic pump assembly cautions ................................44-12
Fan installation cautions ................................................. 24-10 Hydraulic pump assembly
Fan installing .................................................................. 24-10 cross section and tightening torque ..............................44-6
Fan Motor ....................................................................... 44-76 Hydraulic pump assembly
Fan motor installation cautions ...................................... 44-78 disassembling and assembling .....................................44-6
Fan motor installing ........................................................ 44-78 Hydraulic pump assembly installing ................................. 44-4
Fan motor removing ....................................................... 44-76 Hydraulic pump assembly removing ................................. 44-4
Fan motor removing and installing ................................. 44-76 Hydraulic pump assembly removing and installing ........... 44-4
Fan removing ................................................................... 24-9 Hydraulic pump disassembling .........................................44-8
Fan removing and installing ............................................. 24-9 Hydraulic pump installation cautions ................................44-4
Floating seal installing .............................. 24-21, 24-30, 24-45 Hydraulic Tank ..................................................................14-5
Floor Board .................................................................... 14-14 Hydraulic tank installation cautions ..................................14-7
Floor board installation cautions .................................... 14-16 Hydraulic tank installing ....................................................14-7
Floor board installing ...................................................... 14-16 Hydraulic tank removing ...................................................14-5
Floor board removing ..................................................... 14-14 Hydraulic tank removing and installing .............................14-5
Floor board removing and installing ............................... 14-14
Forward/reverse clutch pack assembling ....................... 34-33 I
Forward/reverse clutch pack assembly cautions ........... 34-33 Interference fits for a bearing .......................................... 00-13
Forward/reverse clutch pack disassembling .................. 34-31 Internal Gear Hub ........................................................... 24-35
Forward/reverse clutch pack Internal gear hub assembling .........................................24-36
disassembling and assembling ................................... 34-31 Internal gear hub assembly cautions ..............................24-37
Front axle assembling .................................................... 24-29 Internal gear hub disassembling ..................................... 24-35
Front Axle Assembly ...................................................... 24-20 Internal gear hub disassembling and assembling ..........24-35
Front axle assembly cautions ......................................... 24-30 Internal gear hub installing .............................................24-32
Front axle assembly installation cautions ....................... 24-24
Front axle assembly installing ........................................ 24-23
Front axle assembly removing ....................................... 24-22 L
Front axle assembly removing and installing ................. 24-22 Liner clearance adjustment ..............................................15-3
Front axle assembly tightening torque ........................... 24-20 Linkage .............................................................................15-2
Front axle disassembling ............................................... 24-26 Linkage Pin Standard Clearance Values ..........................15-3
Front axle disassembling and assembling ..................... 24-26 Liquid Gasket and Screw Lock Agent ...............................00-9
Front differential tightening torque ................................. 24-55 Lower center pin .............................................................14-21
Fuel Tank ......................................................................... 14-4 Lower center pin bearing outer ring installing ...................15-5
Fuel tank installation cautions .......................................... 14-4
Fuel tank installing ........................................................... 14-4
Fuel tank removing ........................................................... 14-4
Fuel tank removing and installing ..................................... 14-4
M Parking brake actuator installing .................................... 54-25
Manifold Valve Assembly ..................................................54-8 Parking brake actuator removing ................................... 54-25
Muffler .............................................................................24-18 Parking brake actuator removing and installing ............. 54-25
Muffler installation cautions ............................................24-19 Parking brake installation cautions ................................. 54-33
Muffler installing ..............................................................24-19 Parking brake installing and assembling ........................ 54-31
Muffler removing .............................................................24-18 Parking brake removing and disassembling ................... 54-30
Muffler removing and installing .......................................24-18 Parking brake removing and installing /
Multiple Control Valve .....................................................44-51 disassembling and assembling ................................... 54-30
Multiple control valve assembling ...................................44-56 Partition Plate ................................................................. 14-26
Multiple control valve assembly cautions ........................44-56 Partition plate installing .................................................. 14-26
Multiple control valve Partition plate removing .................................................. 14-26
cross section and tightening torque .............................44-53 Partition plate removing and installing ............................ 14-26
Multiple control valve disassembling ..............................44-54 Periodical Inspection/Servicing ........................................ 75-2
Multiple control valve Pilot Valve ........................................................................ 45-4
disassembling and assembling ...................................44-53 Pilot Valve (S/N 9001~9352) .......................................... 44-28
Multiple control valve installation cautions ......................44-52 Pilot Valve (S/N 9353~) .................................................. 44-41
Multiple control valve installing .......................................44-52 Pilot valve assembling ......................................... 44-40, 44-50
Multiple control valve removing ......................................44-51 Pilot valve assembly cautions ............................. 44-40, 44-50
Multiple control valve removing and installing ................44-51 Pilot valve cross section and tightening torque .............. 44-30
Pilot valve disassembling (S/N 9001~9352) ................... 44-32
Pilot valve disassembling (S/N 9353~) ........................... 44-44
N Pilot valve disassembling and assembling ..................... 44-30
Nitrogen gas charging .....................................................54-15 Pilot valve installation cautions ............................ 44-29, 44-42
Nitrogen gas charging procedure ...................................54-15 Pilot valve installing ............................................. 44-29, 44-42
Pilot valve removing ............................................ 44-28, 44-41
O Pilot valve removing and installing ...................... 44-28, 44-41
Oil seal replacement procedure ........................................44-7 Piston stroke ..................................................................... 35-7
Orbitrol® ..........................................................................44-57 Power Line ....................................................................... 24-2
Orbitrol® assembling .......................................................44-63 Power line tightening torque ............................................. 24-2
Orbitrol® cross section and tightening torque .................44-59 Propeller Shaft ................................................................ 24-14
Orbitrol® disassembling ..................................................44-60 Propeller shaft installation cautions ................................ 24-15
Orbitrol® disassembling and assembling ........................44-59 Propeller shaft installing ................................................. 24-15
Orbitrol® installation cautions ..........................................44-58 Propeller shaft removing and installing .......................... 24-14
Orbitrol® installing ...........................................................44-58 Propeller Shaft Service Standard ..................................... 25-2
Orbitrol® removing ..........................................................44-57
Orbitrol® removing and installing ....................................44-57 R
Radiator ............................................................................ 24-3
P Radiator installation cautions ........................................... 24-8
Parking Brake ....................................................... 54-30, 55-5 Radiator installing ............................................................. 24-8
Parking brake (for front) assembling ...............................54-36 Radiator removing ............................................................ 24-5
Parking brake (for front) assembly cautions ...................54-37 Radiator removing and installing ...................................... 24-5
Parking brake (for front) Radiator tightening torque ................................................ 24-3
cross section and tightening torque .............................54-35 Rear Axle Assembly ....................................................... 24-44
Parking brake (for front) disassembling ..........................54-36 Rear axle assembly installing ......................................... 24-48
Parking brake (for front) Rear axle assembly removing ........................................ 24-46
disassembling and assembling ...................................54-35 Rear axle assembly removing and installing .................. 24-46
Parking brake (for front) installing ...................................54-33 Rear axle assembly tightening torque ............................ 24-44
Parking brake (for front) removing ..................................54-32 Rear axle disassembling and assembling ...................... 24-48
Parking brake (for front) removing and installing ............54-32 Rear differential tightening torque .................................. 24-56
Parking Brake Actuator ...................................................54-25
Parking brake actuator adjusting ....................................54-26 S
Parking brake actuator adjustment procedure ................54-26 Screw lock agent application procedure ......................... 00-10
Parking brake actuator assembling ................................54-29 Second propeller shaft removing .................................... 24-14
Parking brake actuator assembly cautions .....................54-29 Service Brake ........................................................ 54-24, 55-4
Parking brake actuator Service brake disassembling and assembling ............... 54-24
cross section and tightening torque .............................54-27 Service brake installation cautions ................................. 54-24
Parking brake actuator disassembling ............................54-28 Special Tool .................................................................... 24-40
Parking brake actuator Special tool for axle ........................................................ 24-40
disassembling and assembling ...................................54-27 Spider Assembly ............................................................ 24-38
Spider assembly assembling ......................................... 24-38 Transmission 2nd speed clutch pack
Spider assembly disassembling ..................................... 24-38 assembly cautions .......................................................34-37
Spider assembly disassembling and assembling ........... 24-38 Transmission 2nd speed clutch pack
Spider assy assembly cautions ...................................... 24-39 disassembling .............................................................34-36
Steering cylinder installation cautions ............................ 44-21 Transmission 2nd speed clutch pack
Steering cylinder installing ............................................. 44-21 disassembling and assembling ...................................34-36
Steering cylinder removing ............................................. 44-20 Transmission 4th Speed Clutch Pack .............................34-38
Steering cylinder removing and installing ....................... 44-20 Transmission 4th speed clutch pack assembling ...........34-39
Steering Valve ....................................................... 44-67, 45-6 Transmission 4th speed clutch pack
Steering valve assembling ............................................. 44-71 assembly cautions .......................................................34-39
Steering valve cross section and tightening torque ........ 44-69 Transmission 4th speed clutch pack
Steering valve disassembling ......................................... 44-70 disassembling .............................................................34-38
Steering valve disassembling and assembling .............. 44-69 Transmission 4th speed clutch pack
Steering valve installation cautions ................................ 44-68 disassembling and assembling ...................................34-38
Steering valve installing ................................................. 44-68 Transmission Assembly .........................................34-19, 35-2
Steering valve removing ................................................. 44-67 Transmission assembly assembling ............................... 34-24
Steering valve removing and installing ........................... 44-67 Transmission assembly bolt tightening torque ...............34-19
Stop Valve ...................................................................... 44-72 Transmission assembly disassembling .......................... 34-20
Stop valve assembling ................................................... 44-75 Transmission assembly
Stop valve cross section and tightening torque .............. 44-74 disassembling and assembling ...................................34-20
Stop valve disassembling ............................................... 44-75 Transmission assembly installation cautions ....................34-9
Stop valve disassembling and assembling .................... 44-74 Transmission Forward/Reverse Clutch Pack .................34-31
Stop valve installation cautions ...................................... 44-73
Stop valve installing ....................................................... 44-72
U
Stop valve removing ....................................................... 44-72
Unloader Valve .................................................................54-2
Stop valve removing and installing ................................. 44-72
Unloader valve assembling ..............................................54-7
Storing articulation stopper ............................................ 00-16
Unloader valve cross section and tightening torque .........54-4
Symbols ........................................................................... 00-2
Unloader valve disassembling ..........................................54-7
Unloader valve disassembling and assembling ................ 54-4
T Unloader valve installation cautions ................................. 54-3
Third propeller shaft removing ....................................... 24-15 Unloader valve installing ...................................................54-3
Tightening torque for hose and pipes ............................... 75-2 Unloader valve removing .................................................. 54-2
Tightening torque for screws and bolts Unloader valve removing and installing ............................ 54-2
in special control regions .............................................. 75-2 Upper center pin .............................................................14-20
Torque Converter and Transmission Assembly ............... 34-2
Torque converter and transmission assembly
V
installing ........................................................................ 34-8
Valve assembly cross section and tightening torque ......54-10
Valve assembly disassembling and assembling ..............54-9
removing ....................................................................... 34-3
Valve assembly installing .................................................54-9
Valve assembly removing .................................................54-8
removing and installing ................................................. 34-3
Valve assembly removing and installing ...........................54-8
tightening torque ........................................................... 34-2
Torque Converter Assembly .......................................... 34-11 W
Torque converter assembly assembling ........................ 34-14 Weight of Main Components ............................................ 00-3
Torque converter assembly bolt tightening torque ......... 34-11
Torque converter assembly disassembling .................... 34-12
Torque converter assembly
disassembling and assembling ................................... 34-12
assembling .................................................................. 34-35
assembly cautions ...................................................... 34-35
disassembling ............................................................. 34-34
disassembling and assembling ................................... 34-34
Transmission 2nd Speed Clutch Pack ........................... 34-36
Transmission 2nd speed clutch pack assembling .......... 34-37
MEMO
Maintenance Log
Date Machine hours Service performed

Notes

90ZV-2 (EU-D&R) CD 9001up CLINT

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93213-00471

Disassembly & Reassembly

- Be sure to release the internal pressure before you

- Be sure to apply the articulation stopper before start-

- While supporting the bottom of the chassis using a

- When the boom or bucket is raised or when a unit is

- Do not start to work in an enclosed area if adequate

Orbitrol® .......................................................................................................................................................... 44-57

Orbitrol® removing and installing ............................................................................................................... 44-57

90ZV-2 General Information

Symbols .................................................................. 00-2

Symbol Item Description

Shows the condition or procedure that will be useful

Shows the weight of a part or unit. The weight

Tightening Shows the tightening torque of a section that should

Shows the type of coating or adhesive and the coat-

Shows the oil or water drain port and the drain

Weight of Main Components

Item Approx. Approx.

Bolt Tightening Torque

Flanged hexagon bolt

1. Bolt type: Metric thread

2. Bolt strength: 8.8 (8T)

3. Thread pitch: Coarse pitch thread (C)

Hose Band Tightening Torque

Low pressure hose

Low pressure hose Tightening torque Tightening torque Tightening torque

Fix the band 2~3 mm (1/8 in)

Liquid Gasket and Screw Lock Agent

Remove the hardened lock agent using a wire brush or

If there is a seal near the screw or shaft to be removed,

If heat has been used to remove the bolt a new bolt

Screw lock agent application pro- How to wind a seal tape

Apply screw lock agent one or two lines on the male

Screw lock agent Leave 1~2 screw

As the screw is tightened by turning clockwise, seal

To avoid a piece of seal tape left in the circuit, leave 1 or

Slightly stretch the tape when cutting it out, and press to

Cautions Regarding Welding Repair Service

5. To ground the welder, check that the electric cur-

(a) Turn the starter switch to "ON".

Do not ground this section.

Do not ground this section.

7. The weld spattered on the hydraulic cylinders and

Plated section (Mask this section.)

Plated section (Mask this section.)

(a) Plated section

Cover the plated sections with heat-resistant cloth,

Scrap material, etc.

(b) Cover the hydraulic units, electrical units, har-

Cautions Regarding Handling of Bearing

Bearing installation cautions Force

If the interference is rather small, put an appropriate tool

Interference fits for a bearing Heating to remove the interference

There are two basic methods for assembly, sometimes

Bearing operation test after installation Bearing removal cautions

Bearing removal tool

When removing bearing unit, use an appropriate tools

Make sure to apply load only to the bearing ring to pull

Applying and Storing Articulation Stopper

Applying articulation stopper

1. Park the machine so that the frame is straight

Storing articulation stopper