80Z5 (Ex D&R) 00563

93209-00563
80Z5
April 2019
SHOP MANUAL
SHOP MANUAL
WHEEL LOADER
Service Standard
Disassembly & Reassembly
80Z5
General Information
93209-00563 Service Standard
Powered by HINO J08C-TI ENGINE

©2019 Hitachi Construction Machinery Co., Ltd. All rights reserved. Printed in Japan (K)
（輸出一般用） Serial No. 80H1-0501~
93209-00563
April 2019
Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.

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
- Always store the tools in good condition, and use
The most important point in providing repair service is them properly.
safety. To ensure safety, observe the general cautions
described below. - Keep the work area clean. Clean up spills immedi-
ately.
- This manual is intended for properly trained and
equipped service technicians. - Avoid the use of flammable solvents and cleaners.
- Any work on the machine must be performed by the - When working outdoors keep work areas, ladders,
trained personnel only. steps, decks and work platforms clear of snow, ice,
and mud.
- Carefully read this manual to thoroughly understand
the operation method before you operate or repair - Use safe work platforms to reach higher areas of the
the machine. machine.
- Be sure to wear appropriate clothes and protectors, - Any technician that operates a refrigerant recovery
such as safety boots, hard hat and goggles. and recycling machine must first be certified through
an EPA approved testing program.
- Place the machine on level and solid ground, and
place chocks against the wheels to prevent move-
ment.
- Remove the cable from the battery before starting

the service work, and attach a "DO NOT OPER-
ATE!" tag to the steering wheel.
- Be sure to release the internal pressure before you

remove a pipe, such as the hydraulic oil, air, or
engine coolant pipe.
- Be sure to apply the articulation stopper before 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.
- To remove a heavy unit (20 kg (40 lbs) or more), be

sure to use a crane or other lifting device.
- Just after stopping operation, be careful not to

directly touch a hot component. You may get burned.
- Contact tire manufacturer's local dealer for tire ser-

vicing and changing.
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
00 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 ....................................................................................................................... 00-15
14 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 .................................................................................................................................................... 14-7
Engine room removing and installing .......................................................................................................... 14-7
Cab ................................................................................................................................................................. 14-10
Cab removing and installing ...................................................................................................................... 14-10
Floor Board ..................................................................................................................................................... 14-12
Floor board removing and installing .......................................................................................................... 14-12
Boom ............................................................................................................................................................... 14-15
Boom removing and installing ................................................................................................................... 14-15
Center Pin ....................................................................................................................................................... 14-18
Upper center pin ........................................................................................................................................ 14-18
Lower center pin ........................................................................................................................................ 14-19
Center pin removing and installing ............................................................................................................ 14-20
15 Service Standard Chassis Group ..................................................................................................................... 15-1
Linkage .............................................................................................................................................................. 15-2
Linkage Pin Standard Clearance Values ........................................................................................................... 15-3
Liner clearance adjustment ......................................................................................................................... 15-4
Center Pin ......................................................................................................................................................... 15-5
Center pin shim adjustment ........................................................................................................................ 15-5
Bearing cover installing ............................................................................................................................... 15-5
Lower center pin bearing outer ring installing ............................................................................................. 15-6
Attachment Leveler ........................................................................................................................................... 15-7
Attachment leveler ...................................................................................................................................... 15-8
Attachment leveler adjustable angle ........................................................................................................... 15-8
24 Disassembly & Reassembly Power Group ....................................................................................................... 24-1
Power Line ........................................................................................................................................................ 24-2
Power line tightening torque ........................................................................................................................ 24-2
Radiator ............................................................................................................................................................. 24-3
Radiator tightening torque ........................................................................................................................... 24-3
Radiator removing and installing ................................................................................................................. 24-4
Fan .................................................................................................................................................................... 24-7
Fan removing and installing ........................................................................................................................ 24-7
Engine ............................................................................................................................................................... 24-9
Engine removing and installing ................................................................................................................... 24-9
Propeller Shaft ................................................................................................................................................ 24-12
Propeller shaft removing and installing ..................................................................................................... 24-12
Air Cleaner ...................................................................................................................................................... 24-14
Air cleaner removing and installing ........................................................................................................... 24-14
Muffler ............................................................................................................................................................. 24-16
Muffler removing and installing ................................................................................................................. 24-16
Front Axle Assembly ....................................................................................................................................... 24-17
Front axle assembly tightening torque ...................................................................................................... 24-17
Front axle assembly removing and installing ............................................................................................ 24-19
Front axle disassembling and assembling ................................................................................................ 24-22
Front axle assembly cautions ................................................................................................................... 24-26
Internal Gear Hub ........................................................................................................................................... 24-31
Internal gear hub disassembling and assembling ..................................................................................... 24-31
Spider Assembly ............................................................................................................................................. 24-34
Spider assembly disassembling and assembling ...................................................................................... 24-34
Special Tool ..................................................................................................................................................... 24-36
Special tool for axle ................................................................................................................................... 24-36
Rear Axle Assembly ........................................................................................................................................ 24-41
Rear axle assembly tightening torque ....................................................................................................... 24-41
Rear axle assembly removing and installing ............................................................................................. 24-43
Rear axle disassembling and assembling ................................................................................................. 24-45
Axle Support ................................................................................................................................................... 24-46
Axle support tightening torque .................................................................................................................. 24-46
Axle support disassembling and assembling ............................................................................................ 24-47
Differential Assembly ...................................................................................................................................... 24-49
Differential assembly removing and installing ........................................................................................... 24-49
Differential assembly disassembling and assembling ............................................................................... 24-51
25 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
34 Disassembly & Reassembly Torque Converter and Transmission Group ....................................................... 34-1
Torque Converter and Transmission Assembly ................................................................................................ 34-2
Torque converter and transmission assembly tightening torque ................................................................. 34-2
Torque converter and transmission assembly removing and installing ....................................................... 34-3
Transmission assembly installation cautions .............................................................................................. 34-9
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 ........................................................................... 34-21
Transmission Forward/Reverse Clutch Pack .................................................................................................. 34-32
Forward/reverse clutch pack disassembling and assembling ................................................................... 34-32
Transmission 1st/3rd Speed Clutch Pack ........................................................................................................ 34-35
Transmission 1st/3rd speed clutch pack disassembling and assembling ................................................. 34-35
Transmission 2nd Speed Clutch Pack ............................................................................................................. 34-37
Transmission 2nd speed clutch pack disassembling and assembling ...................................................... 34-37
Transmission 4th Speed Clutch Pack .............................................................................................................. 34-39
Transmission 4th speed clutch pack disassembling and assembling ....................................................... 34-39
Control Valve Assembly .................................................................................................................................. 34-42
Control valve tightening torque ................................................................................................................. 34-42
Control valve removing and installing ....................................................................................................... 34-43
Control valve disassembling and assembling ........................................................................................... 34-45
35 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
44 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 pump assembly disassembling and assembling ......................................................................... 44-6
Hydraulic Cylinder ............................................................................................................................................. 44-8
Boom cylinder removing and installing ....................................................................................................... 44-8
Bucket cylinder removing and installing .................................................................................................... 44-10
Steering cylinder removing and installing .................................................................................................. 44-13
Hydraulic cylinder disassembling and assembling .................................................................................... 44-15
Pilot Valve ....................................................................................................................................................... 44-21
Pilot valve removing and installing ............................................................................................................ 44-21
Pilot valve disassembling and assembling ................................................................................................ 44-23
Multiple Control Valve ..................................................................................................................................... 44-33
Multiple control valve removing and installing ........................................................................................... 44-33
Multiple control valve disassembling and assembling .............................................................................. 44-35
Orbitrol® .......................................................................................................................................................... 44-39
Orbitrol® removing and installing ............................................................................................................... 44-39
Orbitrol® disassembling and assembling .................................................................................................. 44-41

Steering Valve ................................................................................................................................................. 44-49
Steering valve removing and installing ...................................................................................................... 44-49
Steering valve disassembling and assembling ......................................................................................... 44-51
Stop Valve ....................................................................................................................................................... 44-54
Stop valve removing and installing ............................................................................................................ 44-54
Stop valve disassembling and assembling ............................................................................................... 44-56
Fan Motor ........................................................................................................................................................ 44-58
Fan motor removing and installing ............................................................................................................ 44-58
45 Service Standard Hydraulic Group ................................................................................................................... 45-1
Hydraulic Cylinder ............................................................................................................................................. 45-2
Pilot Valve ......................................................................................................................................................... 45-4
Steering Valve ................................................................................................................................................... 45-6
54 Disassembly & Reassembly Brake Group ....................................................................................................... 54-1
Unloader Valve .................................................................................................................................................. 54-2
Unloader valve removing and installing ...................................................................................................... 54-2
Unloader valve disassembling and assembling .......................................................................................... 54-4
Manifold Valve Assembly .................................................................................................................................. 54-6
Valve assembly removing and installing ..................................................................................................... 54-6
Valve assembly disassembling and assembling ......................................................................................... 54-7
Accumulator ...................................................................................................................................................... 54-9
Accumulator removing and installing .......................................................................................................... 54-9
Accumulator disassembling and assembling ............................................................................................ 54-10
Nitrogen gas charging ............................................................................................................................... 54-12
Brake Valve ..................................................................................................................................................... 54-14
Brake valve removing and installing .......................................................................................................... 54-14
Brake valve disassembling and assembling ............................................................................................. 54-16
Service Brake .................................................................................................................................................. 54-22
Service brake disassembling and assembling .......................................................................................... 54-22
Parking Brake Actuator ................................................................................................................................... 54-23
Parking brake actuator removing and installing ........................................................................................ 54-23
Parking brake actuator disassembling and assembling ............................................................................ 54-25
Parking Brake .................................................................................................................................................. 54-28
Parking brake removing and installing / disassembling and assembling .................................................. 54-28
55 Service Standard Brake Group ........................................................................................................................ 55-1
Brake Valve ....................................................................................................................................................... 55-2
Service Brake .................................................................................................................................................... 55-4
Parking Brake .................................................................................................................................................... 55-5
74 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
75 Service Standard Operator Station Group ....................................................................................................... 75-1
Air Conditioner .................................................................................................................................................. 75-2
Periodical Inspection/Servicing ................................................................................................................... 75-2
Tightening Torque ....................................................................................................................................... 75-2
80Z5 EX DR 00-1
00 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
80Z5 EX DR 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
F ........... Front or Forward OPT ........... Option
A/M ........... Auto/Manual Assy ........... Assembly
B ........... Battery 1st ........... 1st speed
R ........... Rear or Reverse 2nd ........... 2nd speed
80Z5 EX DR 00-3
Weight of Main Components
Weight of Main Components
Item Approx. Approx.

weight weight Remarks
Unit name Part name (kg) (lb)
Bucket 1,430 3,150 GSC bucket
Boom 1,130 2,490
"Z" -Lever 310/pc 685/pc
Link (Bucket to Lever) 65/pc 145/pc
Engine room assembly 280 620
Hydraulic tank 125 275 Excluding oil
Fuel tank 150 330 Excluding fuel
Chassis
Floor board 230 507
Cab (ROPS) 500 1,100
Left side 65 145 With handrail
Deck
Right side 65 145 With handrail
Front chassis 1,445 3,180
Rear chassis 1,355 2,980
Counter weight 2,000 4,409
Engine 580 1,280 Excluding oil
Radiator assembly 380 840 Excluding water and oil
Transmission 600 1,320 Excluding oil
Second propeller shaft 50 110
Power line
Third propeller shaft 15 35
Front axle assembly 960 2,110 Excluding tires and oil
Rear axle assembly 1,120 2,460 Excluding tires and oil (Including axle support)
Differential 170 375
Multiple control valve 55 120
Pilot valve 10 25
Steering valve 25 55
Orbitrol® 6 15
Hydraulic system Gear pump 35 80 Triple pump
Fan motor 17 37
Boom cylinder 140/pc 310/pc Excluding oil
Bucket cylinder 200/pc 440/pc Excluding oil
Steering cylinder 25/pc 55/pc Excluding oil
Tire 520/pc 1,150/pc With rim (23.5R25 )
Other
Battery 30/pc 65/pc
80Z5 EX DR 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.
80Z5 EX DR 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
80Z5 EX DR 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
80Z5 EX DR 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
80Z5 EX DR 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
To connect the hose to the pipe, tighten the hose band 2~3 mm
Avoid the beading
at the following position:
Pipe
Hose
Hose band
K50V200002
80Z5 EX DR 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
AC01 Loctite®
to soften the agent (200~250°C) using a soldering iron (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.
80Z5 EX DR 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
65ZV00004
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
65ZV00002 it clockwise.
80Z5 EX DR 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.
2. Remove the battery terminals both positive and 5. To ground the welder, check that the electric current
negative sides from the battery. will not flow through the cylinders.
Cylinder head covers for some models have a low
3. Disconnect the connector for transmission control- conductive metal that will cause spark if the welding
ler and air conditioner. current flows. The spark may damage the cylinder
rod.
Example 1
Section to be welded
Do not ground this section.

Electric current may flow
through the cylinders.
Ground this section.
(correct grounding)
35C00002
Example 2
Do not ground this section.

Electric current may flow Section to be welded Ground this section.
through the cylinders. (correct grounding)
35C00006
80Z5 EX DR 00-12
6. 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.
80Z5 EX DR 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.
80Z5 EX DR 00-14
Bearing operation test after installation Bearing removal cautions

Manually turn the shaft or housing after installing a bear-
ing. 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.
80Z5 EX DR 00-15
Applying and Storing Articulation Stopper
Applying and Storing Articulation Stopper
Applying articulation stopper

2
Locked position
IL12-2(70ZV-D&R)
IL14-1(90ZV-D&R)
2. Turn rod (2) (articulation stopper) until it comes in
contact with pin (3). Insert the pin (3) into the rod to
lock the front chassis to the rear chassis.
WARNING
Unexpected movement of machine could cause 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
Storing articulation stopper
IL12-1(70ZV-D&R)
2
1. Park the machine so that the frame is straight

ahead. Using a 17 mm wrench remove bolt (1) from
the articulation stopper on the front chassis.
Stored position
IL12-3(70ZV-D&R)
Store rod (2) and pin (3) as shown.

80Z5 EX DR 00-16
MEMO
80Z5 EX DR 14-1
14 Disassembly & Reassembly Chassis Group
14 Disassembly & Reassembly

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

Fuel Tank................................................................. 14-4
Hydraulic Tank......................................................... 14-5
Engine Room .......................................................... 14-7
Cab.......................................................................... 14-10
Floor Board ............................................................. 14-12
Boom ....................................................................... 14-15
Center Pin ............................................................... 14-18
80Z5 EX DR 14-2
Deck
Deck
Deck removing and installing

Deck removing Window washer
liquid tank
WARNING
6
Unexpected movement of the machine could cause
an accident resulting in injury or death. Be sure to
observe the following items before starting deck
removal:
- Position the machine on level ground, and apply 5
the parking brake. 85V2E14002
- 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 1
3 6 Screen board
1
Hydraulic tank
4
9
K80Z514001
Fuel tank
2
K85V2J14001 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 : Bolt (8)(9): 90 N-m (9.2 kgf-m)
remove bolts (2)(3). : Deck (6) (with handrails): 70 kg (155 lbs)
: Bolt (2)(3): 90 N-m (9.2 kgf-m) 4. While considering the balance, remove decks (4)(6)
: Deck (4) (with handrails): 80 kg (175 lbs) together with the handrails.
80Z5 EX DR 14-3
Deck
Fuel tank
10
11
K80Z514002
5. Remove bolt (10) to remove ladder (11).
: Ladder: 9 kg (20 lbs)
Deck installing
For reinstallation, follow the above procedures in

reverse order.
80Z5 EX DR 14-4
Fuel Tank
Fuel Tank
Fuel tank removing and installing

Fuel tank removing
4
WARNING
observe the following items before starting fuel tank
removal: Fuel tank
- Position the machine on level ground, and apply
the parking brake. K80Z514004
moving. 5. 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:
- Drain fuel from the fuel tank.
(Fuel tank capacity: 300 L (80 gal))
- Remove the deck and the ladder.
Fuel tank installing

reverse order.
3
3
1
Fuel tank installation cautions
Cover
Fuel After reinstallation, be sure to completely bleed air in the

tank fuel line.
K80Z514003
1. Remove bolt (1) and then remove the cover.
2. Disconnect level sensor electrical line coupler (2).
3. Temporarily sling the fuel tank.
: Fuel tank: 150 kg (330 lbs) (when empty)
4. Remove retainer bolts (3).
: Bolt (3): 441 N-m (45.0 kgf-m) (326 lb-ft)

80Z5 EX DR 14-5
Hydraulic Tank
Hydraulic Tank
Hydraulic tank removing and (S/N ~0510)

Breather valve
(S/N 0511~)
Breather valve
installing
Hydraulic tank removing
WARNING
observe the following items before starting hydraulic
tank removal:
- Position the machine on level ground, and apply K80Z514015
the parking brake.
moving.
1
- Remove the engine key, and hang a "DO NOT

- Drain hydraulic oil from the hydraulic tank.
(Hydraulic tank capacity: 140 L (37 gal)) Hydraulic tank
- Remove the deck.
- Clean the area around the tank.
K80Z514005
1. Disconnect hose (1).
Note
Cover or plug the disconnected hoses to protect them
from dust, water and dirt.
80Z5 EX DR 14-6
Hydraulic Tank
5
6
2 9
K80Z514006 K80Z514008
2. Disconnect hoses (2)~(6). 4. Disconnect hose (9) to the oil pump.
Note Note
Cover or plug the disconnected hoses to protect them Cover or plug the disconnected hoses to protect them
from dust, water and dirt. from dust, water and dirt.
Rear chassis
10
K80Z514007 K80Z514009
3. Disconnect hose (7), and pipe (8). 5. Temporarily sling the hydraulic tank, and remove
bolts (10).
Note
Cover or plug the disconnected hoses to protect them : Hydraulic tank:
from dust, water and dirt. 130 kg (330 lbs) (when empty)
: Bolt (10): 230 N-m (23.5 kgf-m) (170 lb-ft)
Hydraulic tank installing

reverse 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.
80Z5 EX DR 14-7
Engine Room
Engine Room
Engine room removing and install-

ing
3
Engine room removing
2
WARNING
observe the following items before starting engine
room removal:
- Position the machine on level ground, and apply K85Z514008
the parking brake.
2. Remove bolt (2) and exhaust pipe (3).
moving.
: Bolt (2): 53 N-m (5.4 kgf-m) (39 lb-ft)

- Remove the decks. 4
- Recover/recycle refrigerant on machine with optional
5
air conditioner, if required.
Note
4
If the quick coupler is attached, no recovery/recycling
will be needed.
6 K85Z514009
1 3. Disconnect sub tank hoses (4) for the radiator.

Remove nut (5) and remove tank (6).
Engine
7 access
85ZV14010J panel
1. Remove covers (1) at both right and left sides.
K80Z514010
4. Remove wires (7) for the engine access panel.

80Z5 EX DR 14-8
Engine Room
13 12
9
Engine
12
Screen board Radiator guard

8
85ZV14034J K85Z514010
5. Remove hose (8) between the air cleaner and tur- 7. Remove nut (12) for engine roof (13) and lift the
bocharger at the turbocharger side. roof.
Disconnect indicator wire coupler (9).
: Nut (12): 53 N-m (5.4 kgf-m) (39 lb-ft)
Note : Engine roof: 35 kg (77 lbs)
Cover the hose and port of the turbocharger to protect
the turbocharger from dust and dirt.
14 16
14
10 Condenser
11
Receiver
tank
15
15
K85V2E14002
Screen board
K85V2J14015
8. Remove round bar (14) of engine access panel
(15). Sling engine access panel (15), and remove
6. Disconnect hoses (10)(11) from the condenser and bolt (16) to remove the panel.
the receiver tank.
: Engine access panel: 25 kg (55 lbs)
Note
Before disconnecting the hoses, be sure to recover/
recycle the refrigerant.
(If the quick coupler is attached, no recovery/recycling
will be needed.)
80Z5 EX DR 14-9
Engine Room
17
Screen board
17
Rear chassis
K80Z514011
9. Remove screen board retainer bolt (17) and lift the

screen board.
Note
Slowly lift the screen board while checking that there
are no obstacles.
: Bolt (17): 230 N-m (23.5 kgf-m) (169 lb-ft)

: Screen board
(with condenser and air cleaner)
130 kg (287 lbs)
Engine room installing

reverse order.
Engine room installation cautions
After reinstallation, be sure to check the air conditioner

for refrigerant leakage. Also check that the air cleaner
rubber hose connection band is properly positioned and
tightened with proper torque.
80Z5 EX DR 14-10
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).
- Remove the deck both right and left side.
- Disconnect the electrical line couplers.
Filter
65ZV14014J
1 3. Remove the filter from the cab.

95V2E14013
Note
When installing the filter into the cab, be sure to align
1. Remove covers (1) and (2). the air flow arrow on the filter to point toward the cab.
80Z5 EX DR 14-11
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

reverse order.
80Z5 EX DR 14-12
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
tank and lines.
- Disconnect the (-) side of the battery. 85V2E14024
- Disconnect the (+) side of the battery.
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 and pipes with vinyl to
- Collect the air conditioner refrigerant (option) using protect them 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.
Operation stand
Orbitrol®
95V2E14016
2. Put matchmarks and disconnect pilot hydraulic line

hose (2) from the Orbitrol®.
Note
Cover the disconnected hoses and pipes with vinyl to
protect them from dust and dirt.
80Z5 EX DR 14-13
Floor Board
Brake valve
3 8
Combination
valve
9
4
K80Z514012
10
3. Disconnect brake line hoses (3)(4) from the brake

valve.
Note
protect them from dust and dirt. Rear chassis
Air conditioner
Hydraulic
tank
7
K80Z514013
6
5. Disconnect pilot hydraulic line hose (8) from the
5 pilot valve at the port located on the hydraulic tank.
Disconnect hose (9) to the combination valve.
Disconnect pilot hydraulic line hose (10) from the
pilot valve at the chassis side.
Floor board Note

K80V2J14014
4. Disconnect hoses (5)~(7) from the air conditioner
unit.
Note
80Z5 EX DR 14-14
Floor Board
Floor board installing
Floor board
11
reverse order.
12
Floor board installation cautions
After reinstallation, start the engine, and then check the

refrigerant, and oil lines for leakage.
Also check operation of the electrical equipment.
Rubber
cushion
K80Z514014
6. Remove elastic plug (11) and floor board retaining

nut (12).
Temporarily sling then gradually lift the floor board
while checking that there are no obstacles and that
all pipes, cables, pins, etc. are disconnected.
: Nut (12): 441 N-m (45.0 kgf-m) (324 lb-ft)

: Floor board assy including ope. stand,
control box, etc.: 230 kg (507 lbs)
Reference
: Bolt for the rubber cushion:
90 N-m (9.2 kgf-m) (67 lb-ft)
80Z5 EX DR 14-15
Boom
Boom
Boom removing and installing

2
Boom removing
4
WARNING
3
an accident resulting in injury or death. 1
moving. 5
- Lower the attachment onto the ground, and 85ZV14015
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): 65 kg (143 lbs)

80Z5 EX DR 14-16
Boom
CAUTION
You have to work at a high position to remove the
grease pipe.
Always use a stepladder for the following work. 7
11
85ZV14019
8
6. Temporarily sling lever (7), and then remove lever

9 pin (11).
7. Remove lever (7).

7
: Lever: 310 kg (683 lbs)
85ZV14017
4. Temporarily sling bucket cylinder (8), and then

remove connection pin (9) from lever (7) and
bucket cylinder (8).
12
: Bucket cylinder: 200 kg (440 lbs) 13
10
K85ZV14001
8. Temporarily sling boom cylinder (12), and then

remove pins (13) from the cylinder rod, on both the
right and left sides of the boom.
85ZV14018
5. Start the engine and shorten bucket cylinder rod

(10). Stop the engine.
Lower bucket cylinder rod (10) on the machine.
80Z5 EX DR 14-17
Boom
Boom installing

reverse order.
14
Boom installation cautions

Boom cylinder
After reinstallation, grease the boom, and then operate
it. During operation, check the boom for abnormal
85ZV14021
noise.
9. Start the engine and shorten boom cylinder rod

(14). Stop the engine.
Lower boom cylinder rod (14) on the machine.
15
85ZV14022
10. Temporarily sling the cross pipe of boom (4), and

then remove pins (15) from the boom on both the
right and left side of the boom.
11. Slowly lift boom (4) to remove it from the machine.
: Boom: 1,135 kg (2,500 lbs)
CAUTION
Loss of control of the boom structure during removal
or installation could result in injury or machine dam-
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.
80Z5 EX DR 14-18
Center Pin
Center Pin
Upper center pin :

T1: 216 N-m (22 kgf-m) (159 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
Shim adjustment Center pin shim adjustment
Adjust the clearance to 0.1±0.05 mm (0.0039±0.0020

in) using the shim. After that, tighten bolt (T1).
Front chassis
T2 L1 Rear chassis
80V2E14022
T1
Shim
T2 L1
80V2E14023
80Z5 EX DR 14-19
Center Pin
Lower center pin
Front chassis
Bearing outer ring
Rear chassis80V2E14024
80V2E14025
80Z5 EX DR 14-20
Center Pin
Center pin removing and installing

Center pin removing 3
WARNING 4

observe the following items before starting center pin
removal:
- Place the machine on level and paved ground. Front chassis Steering cylinder
- Lower the attachment onto the ground, and block 80ZV14020
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 hoses. Disconnect the electrical
line from the couplers.
Note
Transmission Cover the disconnected hoses with vinyl to protect the
hoses from dust and dirt.
2
5
80ZV14019
1. Remove bolt (1) and disconnect second propeller

shaft (2).
80ZV14021
: Bolt (1): 142 N-m (14.5 kgf-m) (105 lb-ft)

: Screw lock agent application 4. Remove upper center pin retainer bolt (5).
(Three Bond 1327)
: Bolt (5): 422 N-m (43.0 kgf-m) (311 lb-ft)
Note
If the retainer bolt is too tight due to the screw lock
agent, heat the bolt head to about 235ºC (450ºF) using
slow flame of a gas burner.
Keep the flame away from the seals of the coupling.
Do not reuse the bolts, always replace with new ones.
80Z5 EX DR 14-21
Center Pin
Jack
screw
80ZV14022 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.
Jack
By Jack
80ZV14023
90ZV14030
8. Push out upper center pin (9) using a jack.

6. Before disconnecting front chassis (7) from the rear
chassis, be sure to support front chassis (7) using
the jack and blocks so that the front chassis will not
fall backward.
80Z5 EX DR 14-22
Center Pin
10
By Jack 12
80ZV14024
9. While supporting the bottom of the fuel tank using a 11

garage jack, remove the lock bolt from lower center
pin (10), and then push out lower center pin (10)
using another jack to remove the pin. 13
14
80ZV14025
11. Remove ring (11).
Bar 12. Remove bolts (12) from bearing cover (13).
90W14014 : Bolt (12): 216 N-m (22.0 kgf-m) (159 lb-ft)
10. Slowly turn the rear tires both the right and the left
sides using a bar to separate the rear chassis.
Note Grease nipple

installation direction
While turning the rear tires, check that the garage jack B
under the fuel tank shifts backward together with the Front
30
rear chassis. In addition, adjust the height using the rear

crane whenever the height adjustment is necessary. 22.5
WARNING B
B B
Grease nipple
When the chassis is separated, unless the support installation
direction 80V2E14026
for the chassis is sufficient, it could cause an accident
resulting in injury or death.
To prevent such an accident, make sure the blocks, Note
support and jack are placed in the right position to When reinstalling bearing cover (13), be careful with the
properly support the chassis. installation direction.
80Z5 EX DR 14-23
Center Pin
13. Remove shim (14). Center pin installing

Note For reinstallation, follow the above procedure in reverse
If the taper roller bearing is replaced, be sure to adjust order.
the clearance using shims.
Thickness of shim: 0.1, 0.2, 0.3, 0.5, and 1.0 mm
(0.004, 0.008, 0.012, 0.020 and 0.040 in)
Center pin installation cautions
14. Replace the dust seals in the upper center pin and
the lower center pin with new ones.
- After reinstallation, grease the center pins, and oper-
ate them. During operation, check the pins for abnor-
mal noise and looseness.
- Check each section for oil leakage.
- No oil leakage should be found in any part.
(Top) (Bottom) - Be sure to completely bleed the brake of air.
For air bleeding procedure, refer to the "Service
brake air bleeding procedure" page 24-21.
WARNING
Insufficient air bleeding in brake oil line could cause
an accident resulting in injury or death be sure to
90ZV14036
completely bleed the brake of air.
Note
Take care of the correct direction of dust seals as shown
above.
Bearing outer ring
Front
Split of outer bearing

Grease nipple
installation
direction
40
80ZV14026
15. When the spherical bearing for the lower center pin
is replaced, install the bearing outer ring so that the
split is perpendicular to the front - rear line of the
machine.
80Z5 EX DR 14-24
MEMO
80Z5 EX DR 15-1
15 Service Standard Chassis Group
15 Service Standard
Chassis Group
Linkage.................................................................... 15-2
Linkage Pin Standard Clearance Values ................. 15-3
Center Pin ............................................................... 15-5
Attachment Leveler ................................................. 15-7
80Z5 EX DR 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
9
2
5
11
10
1 80ZV12002
80Z5 EX DR 15-3
Linkage Pin Standard Clearance Values
Unit: mm (in)
Judgment standard
No. Item Solution

Pin standard
Standard clearance Tolerance
dimension
ø70 0.104~0.213 1.0

* 1 Joint section between attachment and boom
(ø2.7559) (0.0041~0.0083) (0.0393)
Replacement
ø120 0.127~0.256 1.0

* 2 Joint section between boom and lever
(ø4.7244) (0.0050~0.0100) (0.0393)
Replacement
ø80 0.101~0.217 1.0

3 Joint section between boom and boom cylinder Replacement
(ø3.1496) (0.0039~0.0085) (0.0393)
ø90 0.117~0.242 1.0

** 4 Joint section between front chassis and boom
(ø3.5433) (0.0046~0.0095) (0.0393)
Replacement
ø80 0.101~0.217 1.0

* 5 Joint section between attachment and link
(ø3.1496) (0.0039~0.0085) (0.0393)
Replacement
ø80 0.101~0.217 1.0

* 6 Joint section between lever and link
(ø3.1496) (0.0039~0.0085) (0.0393)
Replacement
ø100 0.117~0.242 1.0

* 7 Joint section between lever and bucket cylinder
(ø3.9370) (0.0046~0.0095) (0.0393)
Replacement
ø100 0.117~0.242 1.0

* 8 Joint section between bucket cylinder and front chassis
(ø3.9370) (0.0046~0.0095) (0.0393)
Replacement
ø80 0.101~0.217 1.0

9 Joint section between boom cylinder and front chassis Replacement
(ø3.1496) (0.0039~0.0085) (0.0393)
ø45 0.078~0.1778 1.0

* 10 Joint section between front chassis and steering cylinder
(ø1.7716) (0.0030~0.0069) (0.0393)
Replacement
ø45 0.078~0.1778 1.0

* 11 Joint section between steering cylinder and rear chassis
(ø1.7716) (0.0030~0.0069) (0.0393)
Replacement
80Z5 EX DR 15-4
Liner clearance adjustment
80ZV15009
Adjustment procedure
(for adjustment of liner clearance marked with
asterisk):
Adjust the liner clearance (marked with "*") between the

bosses to 1.2 mm (0.0472 in) or less using liner of 1 mm
(0.0393 in) thickness.
For the steering cylinder, adjust the liner clearance on

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

chassis. Excessive vertical free play in the steering cyl-
inders can result in loud knocking noises when the
steering wheel is turned.
At pin No. 4 (marked with "**"), only in case where the

clearance at the machine center side is more than 4.5
mm (0.1772 in), adjust using liner of 4.5 mm (0.1772 in)
thickness.
80Z5 EX DR 15-5
Center Pin
Center Pin
Center pin shim adjustment Bearing cover installing
T1
Grease nipple
Bearing cover installation direction
B
Front
30
Shim adjustment
22.5
B B
Front chassis Grease nipple B
Rear chassis installation
T2 L1 80V2E14022 direction 80V2E14026
The clearance between the front chassis and bearing Install the bearing cover so that the grease nipple
cover is 0.75±0.5 mm (0.0295±0.0197 in) before shim mounting hole is positioned at the specified angle as
adjustment. shown in the right figure.
Add shims so that the clearance is 0.1±0.05 mm
(0.0039±0.0020 in).
:
T1: 216 N-m (22.0 kgf-m) (159 lb-ft)
T2: 422 N-m (43.0 kgf-m) (311 lb-ft)

80Z5 EX DR 15-6
Center Pin
Lower center pin bearing outer

ring installing
Front chassis
Bearing outer ring
Rear chassis 80V2E14024
Bearing outer ring
Front
Split of outer bearing

Grease nipple
installation
direction
40
80ZV14026
Install the bearing outer ring so that the split is perpen-

dicular to the front-rear line of the machine.
80Z5 EX DR 15-7
Attachment Leveler
Attachment Leveler
Attachment leveler
80V2E15002
80Z5 EX DR 15-8
Attachment Leveler
Attachment leveler
Adjusting plate 5
4 Direction of indicator lamp
Indicator lamp
2 Proximity switch
2.5
5 2
3
1
85V2E15003
Attachment leveler adjustable angle
-7º 0 +12º
Adjusting distance * (4): 6 mm (0.236 in) 51 mm (2.008 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 Attachment leveler adjustable angle (distance * (4)) -7º ~ +12º (6 mm ~ 134 mm) Adjustment
80Z5 EX DR 24-1
24 Disassembly & Reassembly Power Group

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

Radiator................................................................... 24-3
Fan .......................................................................... 24-7
Engine ..................................................................... 24-9
Propeller Shaft......................................................... 24-12
Air Cleaner .............................................................. 24-14
Muffler ..................................................................... 24-16
Front Axle Assembly ............................................... 24-17
Internal Gear Hub.................................................... 24-31
Spider Assembly ..................................................... 24-34
Special Tool ............................................................. 24-36
Rear Axle Assembly ................................................ 24-41
Axle Support............................................................ 24-46
Differential Assembly............................................... 24-49
80Z5 EX DR 24-2
Power Line
Power Line
Power line tightening torque
Engine
T1 L1
Rear
T3 L3 chassis
T2 L1 T4 L1
T5 L2
T3 L3
T1 L1 Rear differential
3rd propeller shaft
T5 L2
2nd propeller
T6 L1 shaft
Transmission
T5 L2
T5 L2
Front differential
K80Z524001
:
T1: 417 N-m (42.5 kgf-m) (307 lb-ft) L1: Screw lock agent (Loctite® 262)
T2: 230 N-m (23.5 kgf-m) (170 lb-ft) L2: Screw lock agent (Three Bond 1327)
T3: 53 N-m (5.4 kgf-m) (39 lb-ft) L3: With lubrication oil (Engine oil or gear oil)
T4: 94 N-m (9.6 kgf-m) (69 lb-ft)
T5: 142 N-m (14.5 kgf-m) (105 lb-ft)
T6: 441 N-m (45.0 kgf-m) (325 lb-ft) Always replace drive shaft bolts with new ones - never
reuse them.
80Z5 EX DR 24-3
Radiator
Radiator
Radiator tightening torque

T5 L2
T4 L1
Fan guard
Radiator
T2 L2
Fan
Fan motor
T3 L2
T1 L2
T2 L2
T2 L2
Rear chassis
K80Z524002
:
T1: 355 N-m (36.0 kgf-m) (262 lb-ft)
T2: 94 N-m (9.6 kgf-m) (69 lb-ft)
T3: 53 N-m (5.4 kgf-m) (39 lb-ft)
T4: 230 N-m (23.5 kgf-m) (170 lb-ft)
T5: 49 N-m (5.0 kgf-m) (36 lb-ft)
L1: Screw lock agent (Loctite® 262)

80Z5 EX DR 24-4
Radiator
Radiator removing and installing

Radiator
5
Radiator removing 3
WARNING
an accident resulting in injury or death. To prevent Engine
such an accident, observe the following items: 4
- Park the machine on level ground.
- Apply the articulation stopper.
- Block the front wheels with chocks or the like to Drain line 6 K85Z524003
prevent the wheels from moving.
- Before starting work, be sure to remove the engine
key, and hang a "DO NOT START!" tag on the 3. Disconnect coolant hoses (3)~(6) from the radiator.
steering wheel, or disconnect the negative side of
the battery. Note
Cover the disconnected hoses with vinyl to protect the
- Remove the engine roof (Refer to Section 14).
- Remove the fan guard (Refer to "Fan" pages within
this section). For easier work, release or remove the
Air cooler
duct and the fan.
7
1. Drain the coolant from the engine and the radiator.
: Coolant: 33 L (8.7 gal)

Engine
8
85ZV24071J
2
4. Disconnect air cooler hoses (7)(8) from the air
cooler.
1
: Hose band: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft)
Rear chassis
Note
- Cover the disconnected hoses and air cooler open-
K80Z524003 ings with caps, plugs, or vinyl to protect them from
dust and dirt.
- During reassembly, carefully inspect and clean the
2. Remove bolt (1). hoses and air cooler of any contamination as it will
Sling radiator guard (2), and then remove it. go directly into the engine causing extensive engine
damage.
: Bolt (1): 230 N-m (23.5 kgf-m) (170 lb-ft)
: Radiator guard: 90 kg (200 lbs)
80Z5 EX DR 24-5
Radiator
14
Oil cooler
10
13 15
K80Z524004
5. Remove hoses (9)(10) from the hydraulic oil cooler.
: Hydraulic oil: 4.2 L (1.0 gal)
Note
Radiator
11
Rear chassis
K80Z524006
7. Temporarily sling radiator (13).

Remove the right and left retainer bolts (14)(15),
and then lift the radiator.
: Radiator: 380 kg (840 lbs)

Transmission
12 : Bolt (14): 49 N-m (5.0 kgf-m) (36 lb-ft)
T/C oil cooler
K80Z524005 : With lubricating oil (Engine oil or gear oil)
: Bolt (15): 230 N-m (23.5 kgf-m) (170 lb-ft)
: Screw lock agent (Loctite® 262) application
6. Disconnect hoses (11)(12) from the torque con-
verter oil cooler.
: Torque converter oil: 9 L (2.4 gal)
Note
80Z5 EX DR 24-6
Radiator
Radiator installing

reverse order.
Radiator installation cautions
Clearance
K85Z524006
Reinstall the radiator while checking that the right and

left clearances between the fan and the radiator guard
are equal at both sides.
80Z5 EX DR 24-7
Fan
Fan
Fan removing and installing

Fan removing
10 Radiator
WARNING See the details below.
If a person starts the engine without informing the

service man who is repairing the machine, an acci- 8
dent resulting in injury or death could occur. To pre- 7
vent such an accident: Base bracket
key, and hang a "DO NOT START!" tag on the K85Z524008
the battery.
3. Temporarily sling the fan (10).
Before starting work: 4. Remove bolts (7) and release fan motor bracket (8)
- Remove the engine roof (Refer to Section 14). from the base bracket. Slide it to the engine side to
make clearance between the fan.
5
: Bolt (7): 94 N-m (9.6 kgf-m) (69 lb-ft)
: With lubrication oil (Engine oil or gear oil)
4
6
1
Fan motor
3
2 9
6
K85Z524007
10
1. Remove bolts (1)(2) and remove fan guards (3).
Take the fan guards out of the machine. K85Z524009
Note 5. Remove retainer bolts (9) for fan (10).

Removing the radiator grill may help the following work.
: Bolt (9): 94 N-m (9.6 kgf-m) (69 lb-ft)
2. Disconnect the coolant hose (4), T/C oil cooler : With lubrication oil (Engine oil or gear oil)
hose (5), air cooler hose (6).
6. Sling fan (10) and take it out from the top opening.
: Air cooler hose band:
: 5.7 N-m (0.58 kgf-m) (4.2 lb-ft) : 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.
80Z5 EX DR 24-8
Fan
Fan installing

reverse order.
Fan installation cautions
Clearance
K85Z524006
Reinstall the fan while checking that the right and left
clearances between the fan and the radiator shroud are
equal at both sides.
Refer to "Fan Motor" page 44-58 to remove and/or dis-
assemble the fan motor.
80Z5 EX DR 24-9
Engine
Engine
Engine removing and installing

Engine removing
WARNING
an accident resulting in injury or death. To prevent
such an accident, observe the following items:
- Apply the articulation stopper. Battery
- Block the front wheels with chocks or the like to 85ZV24013J
key, and hang a "DO NOT START!" tag on the 1. Disconnect the negative side of battery cable.
steering wheel. Then remove the positive cable.
2. Remove the wires from the alternator, starter motor

Before starting work: and the oil pressure switch.
- Remove the engine room (Refer to Section 14). Remove the connector for the engine pressure
- Remove the floor board with the cab (Refer to Sec- switch, tachometer and the coolant temperature
tion 14). gauge.
- Remove the muffler (Refer to “Muffler“ pages in this Disconnect the heater hose and the fuel control
section). cable and the fuel hose also disconnect the air con-
- Remove the fan guard and the fan (Refer to "Fan" ditioner lines from the compressor.
pages in this section).
- Collect the air conditioner refrigerant (option) using 3. Remove the engine oil drain hose.
the proper recovery method.
- Drain engine oil
: Engine oil: Approx. 23 L (6.1 gal)
Air cooler
Engine
85ZV24011J
4. Remove the air cooler hoses (1).

80Z5 EX DR 24-10
Engine
4
1mm 1mm Bracket
Lock nut Rear

Bracket 3 chassis
80ZV24011
7. Remove bolts (3)(4) (both sides).
80ZV24009J : Bolt (4): 417 N-m (42.5 kgf-m) (307 lb-ft)

5. Temporarily sling the engine and the transmission
assembly. Note
When installing bolt (3) to the rear chassis, adjust it with
: Engine and transmission assembly: the lock nut so that the clearance between bolt (3) and
1,200 kg (2,646 lbs) the bracket becomes 1 mm (0.4 in) as shown above.
8. Disconnect the 2nd propeller shaft and the 3rd pro-

peller shaft from the transmission assembly.
2
2
9. Carefully lift the engine and the transmission
assembly while checking that there are no obsta-
Engine
cles around them.
: Engine and transmission assembly:

1,200 kg (2,646 lbs)
10. Remove the engine and the transmission assembly

from the rear chassis.
85ZV24014J Place them on the stand.
6. Remove engine assembly mounting bolts (2).
: Bolt (2): 417 N-m (42.5 kgf-m) (308 lb-ft)

80Z5 EX DR 24-11
Engine
Engine installation cautions

5
6
80ZV24011J
11. Sling the engine assembly and remove bolts (5) 80ZV24012J
from the housing between the engine flywheel and
the transmission. - There is an O-ring (6) in the housing between the
engine and the torque converter.
: Bolt (4): 53 N-m (5.4 kgf-m) (39 lb-ft) Be sure to replace the O-ring with a new one.
: With lubrication oil (Engine oil or gear oil) : With lubrication oil (Engine oil or gear oil)
: Engine assembly: 580 kg (1,279 lbs)
- Refill the engine with the proper quantity and type
12. Move the engine assembly back side to disengage engine oil.
the flywheel ring gear.
- After reinstalling the engine, completely bleed the
13. After confirming that the ring gear is disengaged, fuel line of air.
remove the engine assembly by lifting it slowly.
- Set the starter key to ON, and then check the moni-
tor lamps of electrical equipment.
Engine installing - Operate the engine at the idling speed for 5 minutes.
After that, check the amount of the coolant.
reverse order. - While gradually increasing the engine speed, check
operation of the electrical equipment.
80Z5 EX DR 24-12
Propeller Shaft
Propeller Shaft
Propeller shaft removing and

installing
Second propeller shaft removing 3
5 4
WARNING
an accident resulting in injury or death. To prevent 2
1
- Apply the articulation stopper. 80V2E24011
- 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.
: Screw lock agent (Three Bond 1327)
application
2. Disconnect the grease pipe, and remove bolt (3)

from pillow unit (4).
: Bolt (3): 441 N-m (45.0 kgf-m) (325 lb-ft)

3. Remove bolt (5) 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 (5): 142 N-m (14.5 kgf-m) (105 lb-ft)

application
: Second propeller shaft: 50 kg (110 lbs)
Note
If the retainer bolt is too tight due to the screw lock
agent, heat the bolt head to about 235ºC (450ºF) using
slow flame of a gas burner.
Keep the flame away from the seals of the coupling.
Do not reuse the bolts, always replace with new ones.
80Z5 EX DR 24-13
Propeller Shaft
Third propeller shaft removing Propeller shaft installing
For reinstallation, follow the above procedure in reverse

order.
Transmission
Rear
differential Propeller shaft installation cautions
Engine
Transmission
6
3rd propeller shaft
K80ZV24015E
1. Remove bolt (6).
: Bolt (6): 142 N-m (14.5 kgf-m) (105 lb-ft)

application 2nd propeller shaft 3rd propeller shaft
80V2E24012
2. Remove the third propeller shaft.

During reinstallation, align the direction of the flange
: Third propeller shaft: 12 kg (26.5 lbs) yokes on the second and third propeller shaft sides of
the transmission. (Refer to 80ZV-2 Shop Manual, Func-
tion and Structure, Section 22.)
[Difference in the yoke phase (direction) will cause the
propeller shaft damage and "knocking" during a turn.]
80Z5 EX DR 24-14
Air Cleaner
Air Cleaner
Air cleaner removing and installing

8
Engine
Air cleaner removing
WARNING
- Block the front wheels with chocks or the like to 7
85ZV24019J
key, and hang a "DO NOT START!" tag on the 5. Disconnect air duct (7).
steering wheel, or disconnect the negative side of Disconnect indicator wire coupler (8).
the battery. Inspect duct (7) and replace it if there is any dam-
age or wear.
10
5
1
6
9
3
K85Z524010
90ZV24022
6. Remove cover (10) from the top of screen board

1. Release wing nut (1), and then remove cover (2). (9).
2. Release wing nut (3), and then remove outer ele-
ment (4).
3. Release wing nut (5), and then remove inner ele-

ment (6).
4. Remove the rubber valve on the bottom of the air

cleaner case, and inspect it for any damage.
Replace it if necessary.
Note
Removing inside elements reduces the weight and
makes air cleaner case removal work easier.
80Z5 EX DR 24-15
Air Cleaner
Air cleaner installing

12
reverse order.
Screen board
11 Air cleaner installation cautions
Air duct insertion amount and hose band position

K85Z524011
Hose band (Worm gear for hose band should
be placed a half turns away from each other.)
2~3 mm
7. While supporting air cleaner case (11) with your (0.08-0.12 in)
Fix hose band on convex
hand, remove band retainer nuts (12), and then part of air duct.
lower the air cleaner case. Air duct
Engine side
27 mm (1.1 in)
or more
Hose
Air cleaner side
32 mm (1.3 in)
or more 60ZV24012J
13
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.
90ZV24026
8. Take out air cleaner case (13) from the opening.

80Z5 EX DR 24-16
Muffler
Muffler
Muffler removing and installing 7

6 6
Muffler removing
CAUTION 5
You may get burned if you remove the muffler before 3 4

the engine is cold enough. To prevent such an inci-
dent, be sure to stop the engine, and open the
access panels.
Start the muffler removal work when the engine is
cold enough. Engine K85Z514013
3. Disconnect drain pipe (3).

Remove U-clamp (4) and remove exhaust pipe (5).
2 4. Remove retainer bolt (6) for muffler (7), and lift it for
1 removing.
: Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft)

Engine roof
: Muffler: 23 kg (50 lbs)
Muffler
K85Z514012
Muffler installing

1. Remove bolt (1) and then remove exhaust pipe (2). reverse order.
: Bolt (1): 53 N-m (5.4 kgf-m) (39 lb-ft)
2. Remove the engine roof by referring to "Engine Muffler installation cautions

Room" page 14-7.
: Engine roof: 35 kg (77 lbs) After reinstallation, check all the joints for gas leakage
and vibration.
80Z5 EX DR 24-17
Front Axle Assembly
Front Axle Assembly
Front axle assembly tightening torque
T2 L2 T4 L1
Front differential
T7 T7
A T8 L1
B
T3 L1
T6
T7
T1
T5 L1
80V2E24017
:
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)
80Z5 EX DR 24-18
Front Axle Assembly
Axle nut tightening procedure
1. Tighten axle nut (A) with 1,177 N-m (120 kgf-m)

(868 lb-ft) tightening torque to install the taper roller
bearing.
2. Loosen axle nut (A).
3. Tighten axle nut (A) again with the same tightening

torque as above 1.
4. Turn the wheel hub 2~3 turns back and forth, and
measure the preload applied to the bolt screw hole
in housing (B).
Preload at housing (B):

206~245 N (21~25 kgf) (46~55 lbf)
Note
This is "breakaway" force, which is required to start the
wheel turning.
Floating seal installation
Use jig to install the floating seal to the axle assembly.
Refer to Front axle assembly, "Front axle assembly cau-

tions" page 24-26 for details.
80Z5 EX DR 24-19
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).
: Retainer bolt:
892 N-m (91.0 kgf-m) (658 lb-ft)
: 1 tire: 520 kg (1,150 lbs)
Stand
1
Stand
85ZV24018
1. Lower the attachment onto the ground. Lift the front

wheels while supporting the machine with the Front axle
attachment. Place a stand under the front chassis
80V2E24018
to support it. Check that the tires are off the ground.
Lift the boom until it is horizontal. Place a stand
under the boom to support it or install a boom cylin- 4. Disconnect air breather tube (1) from the upper part
der lock collar. of the axle housing.
2. Press the hydraulic tank oil filler cap to release the Note
trapped tank pressure. When assembling, clean the nylon breather tube before
Release the accumulator pressure, by slowly and installing it.
fully depressing and releasing the brake pedal at
least 40 times.
80Z5 EX DR 24-20
Front Axle Assembly
6
80ZV24022 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 (Three Bond 1327) : Bolt (6): 721 N-m (73.5 kgf-m) (532 lb-ft)
application : Axle assembly: 960 kg (2,110 lbs)
Note
4 During reassembly be sure both mating surfaces are
clean and free of paint.
8. Place axle assembly (5) on a carrier or garage jack

with special carrier to smoothly pull out the assem-
4 bly.
Front axle
Front axle assembly installing
K80Z524007
order.
6. Disconnect brake pipes (4).
Note
Cover the disconnected pipes with plastic caps or vinyl
to avoid the dirt from entering the pipes or fittings.
80Z5 EX DR 24-21
Front Axle Assembly
Front axle assembly installation cautions Service brake air bleeding procedure
After reinstallation, completely bleed air in the service

and parking brake lines.
IMPORTANT
Before bleeding the service brakes, it is important to
remove all air from the brake valve manifold block,
and all related valves.
These include the reducing valve and park brake
valve. Failure to do this correctly will result in unsatis-
factory brake modulation.
Spider Air bleeder nipple

Socket bolt
90ZV24036
CAUTION
Before air bleeding in the brake oil line, be sure that Vinyl tube
the wheel and tire assemblies are installed on the
wheel hub. If fail to do, the bolts (4 pcs) temporarily 70ZV52019
tighten the spider and the wheel hub may be broken

by the brake piston.
1. Start and run the engine to build brake accumulator
Finally the spider and the cover may fall off.
pressure. Shut "off" the engine. Rebuild brake
accumulator pressure as often as needed.
2. Turn the parking brake solenoid valve release knob

counterclockwise, then back to neutral five times at
5-second interval between each turn. Position this
back to the normal position when finished.
3. Connect a clean vinyl tube to the air bleeder nipple,

and place an oil can to receive the oil, or route to
hydraulic tank.
4. Slightly loosen the air bleeder nipple, and then

press the brake pedal several times. When the oil
flows from the air bleeder nipple, close the nipple.
After that, each time you press the pedal, open the
air bleeder nipple to slightly discharge oil, and then
immediately close the nipple.
Repeat this until there is no air in the oil. Com-
pletely bleed each wheel of air.
: Air bleeder nipple:

: 9 N-m (0.9 kgf-m) (6.5 lb-ft)
80Z5 EX DR 24-22
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).
- The stands must be able to support the gross
: Retainer bolt:
weight of the front chassis, boom, and the attach-
892 N-m (91.0 kgf-m) (658 lb-ft)
ment.
: Tire of 1 wheel: 520 kg (1,150 lbs)
Stand
2 Differential section
Stand
90ZV24053
85ZV24018
4. Remove drain plug (2) from the differential section

1. Lower the attachment onto the ground. Lift the front to drain oil.
wheels while supporting the machine with the
attachment. Place a stand under the front chassis : Gear oil: Approx. 32 L (8.5 gal)
to support it. Check that the tires are off the ground.
Lift the boom until it is horizontal. Place a stand
under the boom to support it or install a boom cylin-
der lock collar.
2. Press the hydraulic tank oil filler cap to release the

trapped tank pressure.
Release the accumulator pressure, by slowly and
fully depressing and releasing the brake pedal at
least 40 times.
80Z5 EX DR 24-23
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. 22 L (5.8 gal)
: Bolt (6): 86 N-m (8.8 kgf-m) (64 lb-ft)
Note : Spider assembly: 75 kg (165 lbs)
To replace the oil, refer to the oil amount described
below.
: Wheel hub section:

11 L (2.9 gal) for left side,
11 L (2.9 gal) for right side 9
Differential section (front): 32 L (8.4 gal) 8

Total oil amount for front axle: 54 L (14.3.5 gal)
Reference
Differential section (rear): 37 L (9.8 gal)
Total oil amount for rear axle: 59 L (15.6 gal)
10 80V2E24020
8. Remove snap ring (8), and then remove sun gear

TOP (9).
9. Remove friction plate (10).
90ZV24055
6. Remove cover (5).
: Retainer bolt: 90 N-m (9.2 kgf-m) (67 lb-ft)

application
80Z5 EX DR 24-24
Front Axle Assembly
Turnbuckle
E
11
12
80V2E24021 90ZV24060
10. Remove steel plate (separation disc) (11) and disc 12. Turn wheel hub (3) until the drain plug is positioned
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 80ZV-2 Shop Manual, Function and Struc- Be sure to lock the wheel hub, or the hub will drop when
ture, Section 52 and "Service Brake" page 55-4 for addi- the axle nut is removed and the internal gear hub is
tional information. removed.
13 16
15
17
14 80V2E24022 80V2E24023
11. Remove axle shaft (13) and wear ring (14). 13. Remove axle nut (17).
Remove retainer bolts (15) and then remove lock Refer to "Axle nut tightening procedure" page 24-
plate (16). 18.
: Bolt (15): 53 N-m (5.4 kgf-m) (39 lb-ft) : Nut (17):

: Screw lock agent (Three Bond 1327) 1,177 N-m (120 kgf-m) (868 lb-ft)
application
Note
Note Axle nut width across flat: 120 mm (4.72 in)
When reassembling axle shaft (13) into the axle hous-
ing, applying the principle of leverage, insert axle shaft
(13) making sure the toothing between the side gear of
the differential and shaft (13).
80Z5 EX DR 24-25
Front Axle Assembly
Extension D
E
3
Jig (B)
18 19
Wooden block
80ZV24027 Wooden block 80ZV24029
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-
80ZV24028
dure in reverse order.
15. Sling internal gear hub (18) using internal gear hub
hoisting tool (C), and remove hub (18).
80Z5 EX DR 24-26
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
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.
80Z5 EX DR 24-27
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.
80Z5 EX DR 24-28
Front Axle Assembly
Internal gear hub installation Axle nut tightening
Spring pin
18
17
80ZV24032 80V2E24024
1. Tighten axle nut (17) with 1,177 N-m (120 kgf-m)

Internal gear hub assembly (868 lb-ft) tightening torque to install the taper roller
Brake oil bearing and, after that, once loosen axle nut (17).
Brake oil holes
holes at 2 2. Again tighten axle nut (17) so that the preload of
locations the tire mounting hole section becomes 206~245 N
(21~25 kgf) (46~55 lbf).
Note
This is the force to start the wheel hub moving or
"breakaway" force. Measure the minimum pulling force
Axle housing to rotate the wheel hub using a spring scale.
80ZV24033 Example LF extension
Refer to "Axle nut tightening procedure" page 24-18.
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.
80Z5 EX DR 24-29
Front Axle Assembly
Brake adjustment
Jig (F)
80ZV24036
Brake oil
inlet port
90ZV24074 2. Use jig (F) 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.
Note
Shut off valve If the pressure falls, air is leaking from the brake piston
O-rings or the internal gear hub O-rings. Disassemble
the internal gear hub again to repair the leakage.
Air supply
PT 1/4 A
Air pressure gauge
Brake piston
Jig (H)
90ZV24071
1. Attach jig (H) to the brake oil inlet port on the axle
Wheel hub
housing.
80V2E24025
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......100.25~101.40 mm (3.95~3.99 in)
Note
Dimension A should be equal at the top and bottom
sides.
80Z5 EX DR 24-30
Front Axle Assembly
Wheel hub
Spider "TOP" mark Brake oil line

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

tom when the spider "TOP" mark is at top.
5. 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.
80Z5 EX DR 24-31
Internal Gear Hub
Internal Gear Hub
Internal gear hub disassembling 4

and assembling F
Internal gear hub disassembling
1
80V2E24029
2 3. Place the jig B at the end face of the internal gear

hub. Install the jig F to the remover bolt hole for
brake piston (4).
Remove brake piston (4) by tightening the center
80ZV24037
remover bolt.
1. Turn up internal gear hub (1), and then remove two

O-rings (2).
3 6
80ZV24040
4. Remove brake piston O-rings (5)(6).

80ZV24038
2. Remove taper roller bearing (3).
Note
For easy removal, heat the inner race using a gas
burner with slow flame.
80Z5 EX DR 24-32
Internal Gear Hub
Internal gear hub assembling

8
To reassemble the internal gear hub, follow the proce-
dure described in reverse order.
80ZV24078
5. There is snap ring (7) that connects internal gear

(8) to internal gear hub (1). Shift snap ring (7) to
inside using a round bar or the like.
1
80ZV24042
6. Sling internal gear (8) to remove it.
: Internal gear: 27 kg (60 lbs)

80Z5 EX DR 24-33
Internal Gear Hub
Internal gear hub assembly cautions
IMPORTANT
- Replace all the O-rings with new ones.
replace it with a new one. 3
9 Be certain these
plugs are tight.
80ZV24038
Oil holes
- Before reinstallation of taper roller bearing (3), be
sure to heat the bearing to 90~120ºC (194~248ºF) in
oil.
8 - Apply grease to the O-rings.

1
Example LF
80ZV24080
F
- When reassembling internal gear (8) to internal gear
hub (1), align the oil holes of internal gear hub (1)
with that of spring pin (9).
Note Bolt
To reinstall the internal gear hub (1) on the axle, the
brake oil path should be aligned to these oil grooves. In
addition, the oil grooves are used for alignment of spring
pin (9).
Moreover, spring pin (9) is used for the target to mea- 80ZV24046
sure the brake disc wear.
- Check that the snap ring is properly inserted into the - When reassembling the piston, temporarily install
groove of internal gear (8). the piston and then tighten the bolt evenly using jig
(F).
Confirm that the piston is fully retracted.
Refer to "Service Brake" page 54-22.
80Z5 EX DR 24-34
Spider Assembly
Spider Assembly
Spider assembly disassembling 5

and assembling 6
Spider assembly disassembling
7
70ZV24044J
2 3. Remove wear rings (7) and bearing (5)(6) from

planetary gear (4).
1
Note
90ZV24136
- Install the bearings so that bearing (5) locates out-
side (cover side) and bearing (6) inside (brake back-
1. Remove lock bolts (1) and then plate (2). ing plate side).
Bearing (5) width: 20 mm (0.787 in)
: Lock bolt (1): Bearing (6) width: 25 mm (0.984 in)
216 N-m (22.0 kgf-m) (159 lb-ft)
application 9
1
3
8
4
80V2E24019
4. Turn spider (8) upside down. Using a plastic ham-

90ZV24137
mer, tap brake backing plate (9) off the spider.
2. Insert lock bolt (1) into planetary pin (3), and

remove the pin. Remove planetary gear (4) with the
wear rings and the bearings (5)(6) as a unit.
80Z5 EX DR 24-35
Spider Assembly
Spider assembly assembling Spider assembly assembly cautions
To reassemble the spider assembly, follow the above - To reinstall the brake backing plate, check that there
procedure in reverse order. is no clearance between the spider and the brake
backing plate.
- Clean all the parts. - The brake backing plate may only be installed as it
- Check the brake backing plate, pins, bearings, plan- was removed. It may not be flipped over due to the
etary gears, wear ring, for distortion and wear. roll pin hole design.
- Replace the O-ring and defective parts with new
ones.
- Inspect the internal bores of the spider for wear.
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.
80Z5 EX DR 24-36
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.
30
46(1.8)
4(0.2) 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) 30 (1.2)
2 x 12 (0.5)
80 (3.1)
160 (6.3)
230 (9.1)
80ZV24047
80Z5 EX DR 24-37
Special Tool
(C) Internal gear hub hoisting tool

mm (in)
(Material: SS41)
75 (3.0)
ø13 mm (0.5 in) drilled
t12 (0.5)
35(1.4)
20
R .8)
(0
15
)
235 (9.3) .6
R
(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
423 (16.7)
R2 .8)
(0
0
259 (10.2)
215 (8.5)
281 (11)
35
(1.4)
t9(0.4)
R6
t9 38.7 (1.52)
0(2
(0.4)
(0.3)
10
7
(0.4)
.4)
(1.0)
(0.1) (0.6)
25
(0.6)
15
15
R1 .4)
A
(0
27.5 35 (1.4) 27.5

0
3
R1 .6)
(1.1) (1.1)
(0
90 (3.5)
(0.6)
5
15
A A-A
80ZV24048
80Z5 EX DR 24-38
Special Tool
(D) Wheel hub hoisting tool

Cut the threaded area off the M10 eye bolt before use.
10(0.4)
4(0.2)
C 2(0.08)
The inside of this area

should not be welded
(0 20
)
R
.8
(for both sides).

4(0.2) 3(0.1)
2)
3 t6 t6 3
0.
5(
20(0.8) 10 (0.1) (0.2) (0.2) (0.1)

R
(0.4)
45(1.8)
55(2.2)
*
d
ille
25(1.0)
t6(0.2)
dr
.0 m
(1 5-m
4(0.2)
20(0.8)
)
2
(0.1)
3
C2 C2
(0.08) C2
(0.08)
(0.08)
60(2.4)
90ZV24088
(E) Eye bolt
M24x2
30(1.2) Cut the threaded area off the M10 eye bolt before use.
90ZV24089
80Z5 EX DR 24-39
Special Tool
(F) Brake piston puller

t12 (0.5)
30 (1.2) 30 (1.2)
M16x2 4x 12 (0.5)
156 (6.1) 80 (3.1)
160 (6.3)
312 (12.3)
355 (14)
80ZV24049
(G) Floating seal jig
1. For wheel hub

[ P/N for tool set: 99202-01790 ]
mm (in)
1. 2. ( )
15(0.6) 20(0.8)
3(0.1) 8–0.2
(0.31–0.008) 3(0.1)
+0.05 (8.4 +0.002 )
+0.004
209.4–0.1(8.2–0.004)
+0.3 (8.8 +0.012 )
+0.010
235(9.3)
240(9.5)
224.8(8.9)
209.6 (8.2–0.004)
201.1–0.1(7.9–0.004)
214.6 +00.1 (8.4 0.004)
214 +0.1
190(7.5)
230(9.1)
+0
223 +0.25
+0.1
+0
10–0.3
5(0.2) (0.4–0.01)
10–0.3
(0.4–0.01)
C
R0.3
(0.01)
R0.2~R0.5
(0.008~0.02)
80V2E24040
80Z5 EX DR 24-40
Special Tool
2. For ring
[ P/N for tool set: 99202-01760 ]
mm (in)
1. 2. ( )
13(0.5) 20(0.8)
11–0.2
3(0.1) (0.43–0.008)
3C
3(0.1)
3(0.1)
209.4–0.1(8.2–0.004)
0.05 (8.9 0.014 )

0.35 (8.9 0.014 )
0.012
0.012
270(10.6)
224.8(8.9)
209.6 +0 (8.2–0.004)
201.1–0.1(7.9–0.004)
214.6 +00.1 (8.4 0.004)
226 0.30
214.8 0.1
190(7.5)
230(9.1)
+0
10–0.3
+0.1
(0.4–0.01)
10.4–0.3
(0.41–0.01)
C
R0.3
(0.01)
R0.2~R0.5
(0.008~0.02)
80V2E24041
80Z5 EX DR 24-41
Rear Axle Assembly
Rear Axle Assembly
Rear axle assembly tightening torque
T6
T6
T6
T2 L1
T7 L1
A
B
T3 L1
T6 T5 T1
T4 L1
80V2E24026
: Bolt tightening torque

T1: 892 N-m (91.0 kgf-m) (658 lb-ft) L1: Screw lock agent (Three Bond 1327) application
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)
80Z5 EX DR 24-42
Rear Axle Assembly
Axle nut tightening procedure
1. Tighten axle nut (A) with 1,177 N-m (120 kgf-m)

(868 lb-ft) tightening torque to install the taper roller
bearing.
2. Loosen axle nut (A).
3. Tighten axle nut (A) again with the same tightening

torque as 1 above.
4. Turn the wheel hub 2~3 turns back and forth, and
measure the preload applied to the bolt screw hole
in housing (B).
Preload at housing (B):

206~245 N (21~25 kgf) (46~55 lbf)
Note
This is "breakaway" force, which is required to start the
wheel turning.
Use jig to install the floating seal to the axle assembly.
Refer to "Front axle assembly cautions" page 24-26 for

details.
80Z5 EX DR 24-43
Rear Axle Assembly
Rear axle assembly removing and

installing
Rear axle assembly removing 1
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death. To prevent such
an accident, observe the following items:
- Apply the articulation stopper. K80Z524008
- Block the front wheels with chocks or the like to
3. Remove lower cover (1).
: Lower cover: 23 kg (50 lbs)
Wooden blocks
90ZV24039
90ZV24041
1. Lower the attachment onto the ground. Lift the front

wheels while supporting the machine with the 4. Insert wooden blocks into the swing stopper section
attachment. Place stand (A) under the rear chassis to prevent the axle from swinging. Block both sides.
(behind the center pin) to support the chassis.
WARNING
The axle will not be balanced when a tire is removed.
If wooden blocks are not inserted, your fingers or
body may be caught in the machine.
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.
80Z5 EX DR 24-44
Rear Axle Assembly
4
Breather nipple
7
Rear axle
90V2E24023 80V2E24031
5. Remove right and left wheel and tire assemblies 7. Disconnect air breather tube (7).
(4).
Note
: Tire of 1 wheel: - Before disconnecting the tube, press the oil filler cap
520 kg (1,150 lbs) (without hydro-inflation) of the hydraulic tank to release the tank pressure.
: Retainer bolt: - Release the accumulator pressure by slowly and
892 N-m (91.0 kgf-m) (658 lb-ft) fully depressing and releasing the brake pedal at
least 40 times.
- Remove and clean tube (7) before reinstalling.
Transmission
Rear
differential
Rear axle
5 6
80V2E24030
5
80V2E24032
6. Remove retainer bolts (6) to remove third propeller
shaft (5).
8. Disconnect the front and rear grease pipes.
: Bolt (6): 142 N-m (14.5 kgf-m) (105 lb-ft)
: Screw lock agent (Three Bond 1327) 9. Disconnect hose (8) from the brake oil inlet side.
application
: Third propeller shaft: 15 kg (35 lbs) Note
Cover and plug the hose and fittings to prevent dirt
Note entry.
- Replace propeller shaft retainer bolts (6) with new
ones. Do not reuse them when reassembling.
- Clean all threads with a thread lock primer to assure
a fast strong bond.
80Z5 EX DR 24-45
Rear Axle Assembly
10
Rear axle disassembling and
assembling
For disassembling and reassembling the rear axle
assembly, refer to "Front axle disassembling and
assembling" page 24-22.
9
90V2E24027
10. 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):
1,110 kg (2,447 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.
11. Lower rear axle assembly (9) evenly on the carrier,

and then, pull out the rear axle.
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 assembly installing

order.
Refer to "Service brake air bleeding procedure" page
24-21 for air bleeding in the service brake.
80Z5 EX DR 24-46
Axle Support
Axle Support
Axle support tightening torque
T1 L2
T3 L1
T2 L1
T1 L2
FRONT
T2 L1
80V2E24033

T1: 721 N-m (73.5 kgf-m) (532 lb-ft)
T2: 314 N-m (32.0 kgf-m) (232 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)
80Z5 EX DR 24-47
Axle Support
Axle support disassembling and

Rear support 8
assembling 10
11
Axle support disassembling 13
6
7
Before starting work 12
- Remove the rear axle assembly from the rear chas- 9
sis.
Rear axle
Front support
4 80V2E24035
4. Remove bolt (6).
3 : Bolt (6): 314 N-m (32.0 kgf-m) (232 lb-ft)

2
Rear axle
1 application
5. Remove plate (7) and wear ring (8).

5
80V2E24034
6. Remove bolt (9). Remove plate (10) and wear ring
(11).
1. Remove bolt (1).
: Bolt (9): 314 N-m (32.0 kgf-m) (232 lb-ft)
: Bolt (1): 53 N-m (5.4 kgf-m) (40 lb-ft) : Screw lock agent (Three Bond 1327)
application
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): 66 kg (145 lbs)
: Axle support (rear): 81 kg (179 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-

80Z5 EX DR 24-48
Axle Support
Axle support assembly cautions Bushing installation
IMPORTANT [Front support]

replace it.
Front
Grease
Swing shaft
80ZV24067
[Rear support]
13
Rear
Grease
Swing shaft 80ZV24068
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.
80Z5 EX DR 24-49
Differential Assembly
Differential assembly removing and installing

Differential assembly removing
[ Front axle assembly ]
30 cm (1 ft)
85ZV24057J
80V2E24036 2. Pull out right and left axle shafts (3) 30 cm (1 foot).

- Drain oil from the axle assembly. 4
- Remove the axle from the machine.
- Place the axle assembly on work benches.
: Axle assembly (Front): 960 kg (2,110 lbs)
: Axle assembly (Rear): 1,120 kg (2,460 lbs)
- For the rear axle, remove the axle supports.
Refer to "Rear axle assembly removing and install-
ing" page 24-43.
90ZV24081
A
Spider assembly
2 3. Remove bolts (5) from differential (4).
: Bolt (5)
(Front): 132 N-m (13.5 kgf-m) (98 lb-ft)
TOP
(Rear): 314 N-m (32.0 kgf-m) (232 lb-ft)

application
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.
: Cover bolt: 90 N-m (9.2 kgf-m) (67 lb-ft)

: Bolt (2): 86 N-m (8.8 kgf-m) (64 lb-ft)
: Spider assembly: 75 kg (165 lbs)
80Z5 EX DR 24-50
mark sections:
Spacers are installed.
80ZV24070 90ZV24084
Note 5. Lift the differential using the sling, and then remove
Spacers are inserted in six "" mark sections of the front O-ring (7).
differential.
Differential assembly installing

order.
6
Differential assembly installation cautions
90ZV24083
- After reinstallation, refill with the specified oil until the
oil level reaches the level check plug.
4. Temporarily sling differential (4), and insert bolts - Refill the oil in each planetary assy.
into remover tap (Jack Screw) holes (6) to slightly - Manually turn the flange yoke of the differential to
lift the differential. check that the right and left wheel hubs turn
smoothly.
: Differential: 165 kg (365 lbs) - Check the differential for oil leakage.
Note
Carefully sling the differential so that it is balanced and
is lifted straight up.
80Z5 EX DR 24-51
Differential assembly disassembling and assembling

Front differential tightening torque
T4 L1
Torque proportional
differential
Limited slip T5 L1
differential
T2 L1 (option) F
T7 L1
C
Shim E
T6 L1
(T=0.07) A
~
(T=0.50)
F
T3 L1 B (T=16.70) T1 L2
~
(T=16.98)
T4 L1
K80V2U24003
: Bolt tightening torque 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) 57~66 N (5.8~6.7 kgf) (13~15 lbf)
T: 132 N-m (13.5 kgf-m) (98 lb-ft)
T7: 53 N-m (5.35 kgf-m) (39 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).
80Z5 EX DR 24-52
Rear differential tightening torque
T2 L1
T6 L1
F T3 L1
Limited slip
differential (opt)
D
T4 L1
C
T5 L1
F
T4 L1
Torque proportional
differential
E Shim
(T=0.07)
~
(T=0.50)
A
T1 L2 (T=16.70) B
~
(T=16.98)
T4 L1
K80V2U24004
: Bolt tightening torque 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) 57~66 N (5.8~6.7 kgf) (13~15 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 or a locally pro- bevel gears (C) and (D).
cured Room Temperature Vulcanizer (RTV) that Use nut (F) to adjust the backlash.
does not contain acetic acid.)
80Z5 EX DR 24-53
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 (Three Bond 1327)
- Insert a straight-end screwdriver or the like into the application
clearance between the pinion and the bevel gear to
prevent the gear from rotating. 5
Loosen pinion nut (A).
: Nut (A): 883 N-m (90 kgf-m) (651 lb-ft) 6

: 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.
1
2
: Differential: 100 kg (220 lbs)
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)

application
80Z5 EX DR 24-54
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 optional limited slip differential, remove the
the differential cage. clutch assy, which is assembled instead of thrust
washer (9).
: Retainer bolt (8, Torque proportional diff.):
235 N-m (24.0 kgf-m) (174 lb-ft)
: Retainer bolt (8, Limited slip diff.): 12
314 N-m (32.0 kgf-m) (232 lb-ft)
application
11
13 90ZV24109
10 6. Remove spider (11) with pinion gears (12) and

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

80Z5 EX DR 24-55
17
15
16
90ZV24111 90ZV24112
8. Remove thrust washer (15). 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)

application
Trunnion
Clutch assy
90V2E24039
19
Note
For the optional limited slip differential, remove the
18
clutch assy, which is assembled instead of thrust
90ZV24113
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)

application
Note
The rear differential assembly has the trunnion installed
with bolts (18) as shown.
80Z5 EX DR 24-56
20
21
25
90ZV24114 90ZV24117
11. Remove nut (20) and O-ring (21). 14. Remove taper roller bearing (25).
: Nut: 883 N-m (90.0 kgf-m) (651 lb-ft)

application
26
Note
Nut width across flat: 57.1 mm (2.25 in)
22
90ZV24118
15. Remove spacer (26).
90ZV24115
12. Remove flange yoke (22).
23
24
90ZV24116
13. Remove pinion (23) from cage (24).

80Z5 EX DR 24-57
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 57~66 N (5.8~6.7 kgf) (13~15 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 (16.70~16.98 mm)
(0.66~0.67 in) in increments of 0.02 mm (0.0008 in).
Pinion
Thicker spacers reduce preload; thinner spacers
Stake increase preload.
at 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).

80Z5 EX DR 24-58
Front Rear
Shim Shim
18 18
Check direction
of the lips
29
31 31
Apply liquid gasket
(AA03) to these
surfaces Trunnion
24 30 30
90ZV24122 80V2E24039
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
Before installing oil seal, be sure to apply grease to tighten 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 (Three Bond 1327)
application
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.
80Z5 EX DR 24-59
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 application
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)

application
80Z5 EX DR 24-60
6
A
16
90ZV24149 33 80ZV24077
10. Install differential cage assembly (6) in the carrier 12. Adjust the backlash as follows:
assembly.
(a) Tighten adjustment nut (33) on the bevel gear side
until the backlash is "0". Then back off the adjust-
3 ment nut 2 to 3 notches.
(b) Tighten opposite side adjustment nut (1). After you
feel that the nut is tight, turn it one more notch.
4 (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.

Adjust nut
Standard backlash:
90ZV24131 0.26~0.38 mm (0.0102~0.0149 in)
- Tighten adjustment nut (33) on the bevel gear side or

11. Reinstall bearing cap (4), and then temporarily
loosen adjustment nut (1) on the opposite side to
tighten bolts (3). Reinstall the adjustment nut.
reduce the backlash.
(For both the right and left sides)
- Loosen adjustment nut (33) on the bevel gear side or
tighten adjustment nut (1) on the opposite side to
increase the backlash.
80Z5 EX DR 24-61
34
3
2
90ZV24133
13. Tighten bolts (3) of bearing cap (4).
: Bolt (3): 515 N-m (52.5 kgf-m) (380 lb-ft)

application
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)

application
80Z5 EX DR 24-62
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.
80Z5 EX DR 24-63
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.
80Z5 EX DR 24-64
MEMO
80Z5 EX DR 25-1
25 Service Standard Power Group
25 Service Standard
Power Group
Propeller Shaft Service Standard ............................ 25-2

Axle and Differential Service Standard.................... 25-3
80Z5 EX DR 25-2
Propeller Shaft Service Standard
Propeller Shaft Service Standard
1. Bearing play
Third propeller shaft
1
c a 2 Measurement of circumferential play
b
4 3 Measurement of transverse play
Second propeller shaft K80V2E25001
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 7.34 ± 3 (0.29 ± 0.12) —
Note
Bolt tightening torque
a: 69 N-m (7.0 kgf-m) (51 lb-ft)
b: 155 N-m (15.8 kgf-m) (114 lb-ft)
c: 17.2 N-m (1.75 kgf-m) (12.7 lb-ft)
80Z5 EX DR 25-3
Axle and Differential Service Standard
Axle group
6
5
4
2, 3
1, 3
5
7
80V2E25002
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 291 +0.081

0 (11.4567 +0.0032
0 ) Dia.: 1.0 (0.0393)/
4 Axle support wear Radius: 0.5 (0.0196) Replacement
Rear ø 176 +0.063 (6.9291 +0.0025 ) (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 280 -0.081 (11.0236 -0.0032 ) Radius: 0.5 (0.0196) Replacement
(stepped)
Dia.: 1.0 (0.0393)/
0 0
7 Sleeve wear ø 165 -0.100 (6.4961 -0.0039 ) Radius: 0.5 (0.0196) Replacement
(stepped)
80Z5 EX DR 25-4
Differential
5, 6
5, 6
K80V2E25002
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)
Adjustment or
4 Runout of ring gear rear surface (when assembled) 0.076 (0.0029) 
replacement
5 Tooth surface wear (each gear) Abnormal wear or missing Replacement
6 Tooth contact No abnormality Replacement

80Z5 EX DR 34-1
34 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 .......... 34-32
Transmission 1st/3rd Speed Clutch Pack................ 34-35
Transmission 2nd Speed Clutch Pack..................... 34-37
Transmission 4th Speed Clutch Pack...................... 34-39
Control Valve Assembly .......................................... 34-42
80Z5 EX DR 34-2
Torque Converter and Transmission Assembly
Torque converter and transmission assembly tightening torque
Engine
T1 L1
Rear
T3 L3 chassis
T2 L1 T4 L1
T5 L2
T3 L3
T1 L1 Rear differential
3rd propeller shaft
T5 L2
2nd propeller
T6 L1 shaft
Transmission
T5 L2
T5 L2
Front differential
K80Z524001
:
T1: 417 N-m (42.5 kgf-m) (307 lb-ft) L1: Screw lock agent (Loctite® 262)
T2: 230 N-m (23.5 kgf-m) (170 lb-ft) L2: Screw lock agent (Three Bond 1327)
T4: 94 N-m (9.6 kgf-m) (69 lb-ft)
T5: 142 N-m (14.5 kgf-m) (105 lb-ft) Note
T6: 441 N-m (45.0 kgf-m) (325 lb-ft) Always replace drive shaft bolts with new ones - never
reuse them.
80Z5 EX DR 34-3
Torque converter and transmission assembly removing and installing

Torque converter and transmission assem- 3
bly removing
2
WARNING
Unexpected movement of machine could cause an
5
- Lower the attachment onto the ground, and then, 4
block the tires with chocks to prevent the wheels
from moving.
R80V2E34002
- Disconnect the ground cable from the negative
side of the battery.
2. Disconnect bolts (3) from third propeller shaft (2) on
the transmission side.
Remove bolt (5) from second propeller shaft (4) on
- Stop the engine. Depress the brake pedal many
the transmission side only.
times until there is no brake pressure.
- Press the hydraulic tank cap, and relieve the internal
: Bolt (3)(5): 142 N-m (14.5 kgf-m) (105 lb-ft)
pressure from the hydraulic tank.
- Remove the cab and the floor board (Refer to Sec-
application
tion 14).
- Remove the engine room (Refer to Section 14).
Note
- Consider the type of failure and if the T/C oil cooler
- If the retainer bolts are too tight due to the screw lock
must also be removed for cleaning or replacement.
agent, heat the bolt head using slow flame of a gas
- If a small amount of contamination is found in the
burner.
transmission strainer and filter the cooler does not
- Keep the flame away from the seals of the coupling.
need removal.
- Do not reuse the bolts, always replace with new
- If a large amount of contamination is found, the
ones.
cooler must be removed and thoroughly cleaned or
replaced.
- Lines to cooler must be also replaced.
6
K80Z534001
3. Disconnect electric wire (6) from the speed sensor

80ZV34002 and T/C oil temperature switch.
1. Remove drain plug (1) to drain the transmission oil.
: Transmission oil: 35 L (9.2 gal)

80Z5 EX DR 34-4
Valve assembly
13
Actuator
K80Z534002 80ZV34006
4. Release the parking brake and disconnect the link 7. Disconnect hose (13) from the transmission level
of the actuator. If the machine has low accumulator gauge.
oil pressure, feed oil into hose (7) from an external
source. Note
Cover or plug the disconnected hose and fitting to pro-
Note tect them from dust and dirt.
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. Stop valve
12
10 Bracket Steering valve

11
Rear
9 chassis
8
80V2E34003
8. Disconnect all the hoses and the pipes from the

90ZV34005
steering valve and the stop valves. Remove the
bracket with the valves.
5. Remove split pin (8), and then remove pin (9).
: Bracket (with valves): 40 kg (88 lbs)
6. Remove bolts (11) from actuator mounting bracket
(10). Disconnect the oil source, and then remove Note
actuator (12). Cover or plug the disconnected hose and fitting to pro-
tect them from dust and dirt.
: Actuator (with bracket): 10 kg (22 lbs)
80Z5 EX DR 34-5
Oil pump
Transmission
21 20
14
16
15
K80Z534003 K80Z534005
9. Disconnect hoses and pipes (14)(15)(16) from the 11. Disconnect the electrical wire for torque converter
oil pump. temperature switch sensor (20).
Disconnect main clutch pressure outlet hose (21).
Note
Cover the disconnected hoses and the pump ports with Note
caps to protect them from dust and dirt. Cover or plug the disconnected hose and fitting to pro-
22
17
18
19 Multiple control valve

K80Z534004
K80Z534006
10. Remove suction pipes (17)(18), and then remove

pump assembly (19). 12. Put matchmarks on hoses (22) in the pilot line, and
then, disconnect them.
: Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft)
: Gear pump: 31 kg (68 lbs) Note
Cover or plug the disconnected hoses and fittings to
Note protect them from dust and dirt.
Cover the disconnected hoses and the pump ports with
caps to protect them from dust and dirt.
Refer to "Hydraulic pump assembly installing" page 44-
4 for the reinstallation.
80Z5 EX DR 34-6
24
26
27
23
Multiple control valve

K80Z534007 80V2E34008
13. Disconnect hoses (23)(24). 15. Temporarily sling the multiple control valve, and
remove bracket (27) from the rear chassis.
Note
Cover or plug the disconnected hoses and fittings to : Bolt (26): 94 N-m (9.6 kgf-m) (69 lb-ft)
protect them from dust and dirt. : Bracket (with multiple control valve):
72 kg (159 lbs)
28 29
Multiple control valve 25
K80Z534008
K80Z534009
14. Remove return pipe (25).

16. Disconnect the two hoses (28) between the torque
Note converter and the cooler.
Cover or plug the disconnected pipe and port to protect Disconnect the two hoses (29) between the line fil-
them from dust and dirt. ter and the transmission.
Note
Cover or plug the disconnected hoses and fittings to
80Z5 EX DR 34-7
30
34
1mm 1mm Bracket
31
35
Lock nut Rear

Bracket 35 chassis
80ZV34016 80ZV34086
17. Remove all electric wire couplers (31) from control 19. Remove bolts (34)(35) (both sides).
valve (30).
: Bolt (34): 417 N-m (42.5 kgf-m) (307 lb-ft)
Note : Screw lock agent (Loctite® 262) application
Before disconnecting the couplers, be sure to put
matchmarks on the couplers. Note
For reassembly, refer to the connection illustration on When installing bolt (35) to the rear chassis, adjust it
"Control valve installation cautions" page 34-44. with the lock nut so that the clearance between bolt (35)
and the bracket becomes 1 mm (0 04 in).
33 Engine flywheel housing
32 Flywheel
Pilot boss
Pull to separate
transmission
Transmission Ring gear
K80Z534010
Engine-transmission joint section K80Z534011
18. Temporarily attach a sling to transmission assembly

(32), and then, remove 12 each of bolts (33) from Note
the engine flywheel housing. The joint section between the engine and the transmis-
sion consists of the pilot boss and the gear coupling as
: Bolt (33): 53 N-m (5.4 kgf-m) (39 lb-ft) shown in the figure. The pilot boss is inserted for center-
: With lubrication oil (Engine oil or gear oil) ing, and the gear coupling is used for power transmis-
: Transmission assembly: 600 kg (1,320 lbs) sion.
To separate the transmission from the engine, remove
the bolts from the engine flywheel housing, and then,
pull the transmission straight out to the front.
80Z5 EX DR 34-8
36
Wooden piece
80V2E34009 80V2E34024
21. Slowly lift transmission assembly (36) while avoid-

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

bly installing
To reinstall the torque converter and transmission

Wooden piece assembly, follow the above removal procedure in
reverse order.
R80V2E34018
20. 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 this procedure 2 to 3 times while pulling the
transmission away from the engine to separate them.
80Z5 EX DR 34-9
Transmission assembly installa- Transmission assembly operation check

tion cautions
After reinstallation, check operation of the transmission
assembly by the following procedure.
Joint between the torque converter and the
engine
WARNING
1
To prevent such an accident, be sure to stop the
engine, and block to the tires with chocks before you
start service work. During the service work clearly
communicate with the person in the operator seat
using signals as agreed upon before hand.
1. At the completion of reinstallation, start the engine,

and check that the shift lever properly functions at
all the positions.
80ZV34023
2. Check each section for oil leakage.
- Be sure to replace O-ring (1) with new one. 3. Adjust the transmission oil level to the specified
point with the level gauge.
4. Perform the start-up tests as shown on the

Transmission side Engine side
attached sheet.
Flywheel
O-ring (1)
Ring gear
K80Z534012
- Be sure pilot boss bushing (ring) is installed.
- Rotate the engine flywheel to align the ring gear.

80Z5 EX DR 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.
80Z5 EX DR 34-11
Torque Converter Assembly
Torque converter assembly bolt tightening torque
T2 L 3
T2 L 3 T1 L 3
K80Z534013

T1: 29 N-m (3 kgf-m) (22 lb-ft)
T2: 59 N-m (6 kgf-m) (43 lb-ft)

80Z5 EX DR 34-12
Torque converter assembly disas-

sembling and assembling
Torque converter assembly disassembling 7

8
- Clean the torque converter assembly.
- Drain oil from the transmission and the torque con-
verter. Shim
4
80ZV34028
1 2
3 4. Remove front cover (7).
After removing the front cover, remove ball bearing
(8).
Note
If a shim is attached, remove the shim from the bearing
and store it for reassembly.
5
K80Z534014
1. Remove control valve (2) from transmission hous-

ing (1).
Note
For disassembling control valve, refer to page 34-45. 9
2. Remove hose (3), and then, remove bolts (4) and

cover (5).
Note R80V2E34008
Cover or plug the disconnected hose and fitting to pro-

5. Remove turbine impeller assembly (9).
6
10
11
12
80ZV34027
R80V2E34009
3. To remove the front cover from the pump impeller,

6. Remove thrust bearing (10), thrust washer (11),
remove bolts (6). (Number of bolts: 18)
and sleeve (12).
80Z5 EX DR 34-13
25
13
14
26
27
R80V2E34010 R80V2E34013
7. Remove snap ring (13) and stator (14). 10. Remove seal ring (25), bolts (26), and then stator
shaft (27).
: Remover bolt installation position

15
Torque converter housing
16
Transmission housing
R80V2E34011
R80V2E34029
8. Remove bolt (15) and plate (16).

11. Attach sling to the torque converter housing.
Separate the torque converter housing from the
transmission housing.
23
18
19
20
21
22
24 17
R80V2E34012
9. Remove pump impeller assembly (17), thrust

washer (18), thrust bearing (19), spacer (20), snap
ring (21), needle bearing (22), gear (23), and snap
ring (24) in order.
80Z5 EX DR 34-14
30 29 28
Torque converter
housing
31
80ZV34035
12. Remove seal ring (28).
13. Turn over the torque converter housing.
14. Remove snap ring (29) and turbine shaft bearing

(30).
15. Remove turbine shaft (31).
Torque converter
housing
36 32
35
34
33
80V2E34025
16. Remove nut (32) from bolt (33).
17. Remove bolt (33) from the torque converter hous-

ing.
18. Remove spring (34) and washers (35)(36) from bolt

(33).
80Z5 EX DR 34-15
Torque converter assembly assembling

25
IMPORTANT
- Clean and check all the parts. If a part is damaged, 26
replace it with a new one. 27
28
- Before reassembly, apply transmission oil to the 29
30
parts.
1. Turn over the torque converter housing.

31
R80V2E34017
Torque converter
housing 5. Install turbine shaft bearing (30).
36 32 6. Install turbine shaft (31) and snap ring (29).
7. Connect the torque converter housing to the trans-

mission housing.
35
34 8. Attach seal ring (28).
33
80V2E34025
: Apply grease to seal ring (28), and then
insert it into the groove.
9. Tighten bolts (26) to fix stator shaft (27), and then

install seal ring (25).

: Bolt: 59 N-m (6 kgf-m) (43 lb-ft)
15

18
19
20 16

21
22
24
17
2. Install spring (34) and washer (35) to bolt (33). 23
3. Install bolt (33) to the housing.
R80V2E34019
IMPORTANT
Adjust the clearance between the torque converter 10. Install needle bearing (22) and snap rings (21)(24)
housing and bolt (33) to 38.3 mm. into gear (23).
Install plate (16) to pump impeller (17), and then,
4. Install washer (36) and nut (32) onto bolt (33). attach spacer (20), thrust bearing (19), and thrust
washer (18) in order.
: nut (32): Screw lock agent
(Three Bond 1327) application : Bolt: 59 N-m (6 kgf-m) (43 lb-ft)
80Z5 EX DR 34-16
13
14
R80V2E34010 R80V2E34008
11. Install stator (14), and attach snap ring (13). 13. Install turbine impeller assembly (9).
IMPORTANT
If stator (14) is installed upside down, the stator will
IMPORTANT
not function properly. Carefully install stator (14) in Adjust the thrust clearance here as follows.
correction direction.
17 8
10
11
12
80ZV34039
R80V2E34009
(a) Measure the distance from ball bearing (8) to the

12. Attach sleeve (12), thrust washer (11), and thrust mounting face of pump impeller assembly (17).
bearing (10). Regard the obtained distance as dimension A.
80Z5 EX DR 34-17
(d) After shim adjustment, remove the ball bearing,

and then sequentially attach the shim and then the
ball bearing to the front cover.
6
7
80ZV34040
(b) Measure the distance from the mounting face of

front cover (7) to the end face of the bearing
receiver.
80ZV34027
Regard the obtained distance as dimension B.
B – A = 0.2~0.4 mm A
14. Install the front cover, and then tighten bolts (6) to
(0.008~0.016 in) Front cover connect the front cover to the pump impeller
assembly.
Number of bolts (6): 18

B
: Bolt (6): 29 N-m (3 kgf-m) (22 lb-ft)

Ball
bearing
5
4
K80Z534015
Front cover
Wooden block
K80Z534016
Ball bearing
15. Install cover (5), and then tighten bolts (4).
Adjusting shim
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)
90ZV34032 : With lubrication oil (Engine oil or gear oil)
Note
(c) Adjust the difference between distance B and dis-
At the completion of reassembly, manually turn the front
tance A (thrust clearance) to 0.2~0.4 mm
cover to check that it rotates smoothly.
(0.008~0.016 in) using a shim as shown in the fig-
ure above.
80Z5 EX DR 34-18
Transmission housing
80ZV34044
16. Install the torque converter housing on to the trans-

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

1 2
3
K80Z534017
17. Install control valve (2).

Connect hose (3) between the torque converter
housing and transmission housing (1).
80Z5 EX DR 34-19
Transmission Assembly
Transmission assembly bolt tightening torque
T2 L 3
T7 L 3
T6 L 3
T7 L 3
T1 L 3
T5 L 1
T2 L 3
T3
T4 L 2
T6 L 3
T6 L 3
K80Z534018
80Z5 EX DR 34-20
:
T1: 29 N-m (3 kgf-m) (22 lb-ft)
T2: 59 N-m (6 kgf-m) (43 lb-ft)
T3: 216 N-m (22 kgf-m) (159 lb-ft)
T4: 392 N-m (40 kgf-m) (289 lb-ft)
T5: 94 N-m (9.6 kgf-m) (69 lb-ft)
T6: 53 N-m (5.4 kgf-m) (39 lb-ft)
T7: 50 N-m (5.1 kgf-m) (37 lb-ft)
L1: Screw lock agent (Loctite® 262) application

L2: Molybdenum disulfide grease /
MOS2 application
80Z5 EX DR 34-21
Transmission assembly disassem-

bling and assembling 4
Transmission assembly disassembling

- Clean the transmission assembly.
- Remove the coupling yoke, the oil seal and the snap
ring of the ball bearing for the third propeller shaft.
Unless removed, they will fall off.
- Place the transmission assembly so that the parking
brake side is up. 3 90ZV34039
- For disassembling and reassembling for the parking

brake, refer to "Parking Brake" page 54-28.
3. Remove bolt (3), and remove brake drum (4).
Coupling yoke
Snap ring Oil seal
90ZV34040
R80V2E34020
4. Remove nut (5), then remove flange yoke (6).
Strainer
R80V2E34021
7
90ZV34041
1. Disconnect hose (1) and the strainer.

5. Remove bolt (7), and then remove brake assembly
2. Remove control valve (2).
(8).
: Control valve assembly: 20 kg (44 lb)
Note
Refer to "Control valve removing and installing" page
34-43 to remove control valve assy (2).
80Z5 EX DR 34-22
14
Gasket
10
9
90ZV34042 80V2E34013
6. Remove bolt (9) and then remove drive cover 9. Remove gear (14).
assembly (10).
11
Ball bearing
75 mm (3 in)
Torque converter 15
80V2E34027
80V2E34011
10. Remove bolt (15).

7. Hit in output shaft (11) (approx. 75 mm (3 in)), after
that, remove output shaft (11) with the ball bearing. 16 17
13
12 12
80V2E34014
80V2E34012
11. Remove bearing (16), and then, remove 4th speed
clutch pack assembly (17).
8. Remove bolts (12), and then, remove cover (13).
80Z5 EX DR 34-23
18
21
Ball bearing
80V2E34015 80ZV34052
12. Remove 1st speed clutch pack assembly (18). 15. Remove 3rd and forward speed clutch pack assem-
bly (21).
Note
Pull out the 1st speed clutch pack assembly. It is tight
22
due to the ball bearing between the housing and the
shaft.
19
80ZV34053
16. Remove 2nd and reverse speed clutch pack

assembly (22).
90ZV34119
Note
13. Remove bolt (19). Pull out the 2nd and the reverse speed clutch pack
assembly. It is tight due to the ball bearing between the
housing and the shaft.
20
90ZV34120
14. Lift transmission housing (20) slowly.

80Z5 EX DR 34-24
31
23
24
25
27
26
30
90ZV34125
19. Remove bolt (30), and then, remove charge pump

assembly (31).
80V2E34016
17. Remove bolt (23), plate (24), gear (25), snap ring
(26) and bearing (27).
28
29
80ZV34055
18. Remove bolt (28) and then remove shaft (29).

80Z5 EX DR 34-25
Transmission assembly assembling
Note
- For clutch pack disassembly and reassembly, refer 28
to the "disassembling and assembling" section of
each clutch pack.
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.
80ZV34055
31 32 2. Install shaft (29) with bolt (28).
: Bolt: 59 N-m (6 kgf-m) (43 lb-ft)
23
24
25
30
90ZV34126 27
26
1. Install torque converter gear pump (31) with bolt
(30).
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)
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 80V2E34016
soft hammer to check the thrust clearance, if necessary.
3. Install gear (25), bearing (27) and snap ring (26)
onto shaft (29).
Install plate (24) and tighten bolt (23).
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)

80Z5 EX DR 34-26
19
22
90ZV34127 90ZV34119
4. Install 2nd and reverse speed clutch pack assembly 7. Tighten bolt (19).
(22).
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)
21
17
18
80ZV34052
90ZV34132
5. Install 3rd and forward speed clutch assembly (21).

8. Install 1st speed clutch pack assembly (18) and 4th
speed clutch pack assembly (17).
20
18 16 17
Gasket
85V2E34033
80V2E34017
6. Install transmission housing (20) onto the T/C hous-
ing.
9. Install bearing (16) onto 1st speed clutch pack
assembly (18).
80Z5 EX DR 34-27
11 34 Snap ring
15
R80V2E34022 85ZV34015
10. Install small end bearing (34) on output shaft (11) 13. Tighten bolt (15).
and install the snap ring.
: Bolt: 53 N-m (5.4 kgf-m) (39 lb-ft)
11
20
14
Snap ring
R80V2J34022
11 90ZV34137
11. Install output shaft (11) into housing (20).

14. Install gear (14) onto output shaft (11).
Note
Support output shaft (11) from the bottom side to pre-
vent it from falling down.
12. Install the snap ring.

80Z5 EX DR 34-28
17
18
18
90ZV34138 90ZV34140
15. Measure and record the clearance between 1st 17. Measure the distance from the bearing of 1st speed
speed clutch pack gear (18) and 4th speed clutch clutch pack (18) to the mounting face (including the
pack gear (17). gasket) of the housing.
Regard the obtained distance as dimension A'.
Note
The clearance between them should be 0.5~1.0 mm
(0.02~0.04 in).
13
17
R80V2J34027
18. Measure the distance from the mounting face of

90ZV34139
cover (13) to the end face of the bearing receiver
for the 4th speed clutch pack.
16. Measure the distance from the bearing of 4th speed Regard the obtained distance as dimension B.
clutch pack (17) to the mounting face (including the
gasket) of the housing.
Regard the obtained distance as dimension A.
80Z5 EX DR 34-29
36
13
R80V2J34028 R80V2J34030
19. Measure the distance from the mounting face of

cover (13) to the end face of the bearing receiver
for the 1st speed clutch pack.
Regard the obtained distance as dimension B'. 36 35
35
Clutch shaft cover
R80V2J34033
21. Adjust the difference between the distance B' and

the distance A' (thrust clearance) to 0.5~1.0 mm
using shim (36).
R80V2J34029
B' – A' = 0.5~1.0 mm (0.02~0.04 in)
Remove clutch shaft covers.
20. Adjust the difference between the distance B and
the distance A (thrust clearance) to 0.5~1.0 mm
using shim (35). C C
B – A = 0.5~1.0 mm (0.02~0.04 in)
R80V2E34024
Note
Insert the shim into the section C so that the difference
between the distance A (A') and the distance B (B') is
adjusted to a clearance of 0.5~1.0 mm (0.02~0.04 in).
80Z5 EX DR 34-30
Clutch shaft cover 10
O-ring
Gasket
13
R80V2J34032 90ZV34143
22. Install cover (13) onto the transmission housing. 24. Install drive cover assembly (10) and tighten bolt
(9).
: Bolt (9): 53 N-m (5.4 kgf-m) (39 lb-ft)

37 38
12
80V2E34019
90ZV34144
37 25. Tighten bolts (12). Install brake assembly (8) and

38
tighten bolt (7).
: Bolt (12): 53 N-m (5.4 kgf-m) (39 lb-ft)

: Bolt (7): 216 N-m (22 kgf-m) (159 lb-ft)
90ZV34057
23. Install ball bearing (37) and gear (38) onto the out-
put shaft.
80Z5 EX DR 34-31
85W34038
26. Install brake drum (4) and tighten bolt (3).
: Bolt (3): 94 N-m (9.6 kgf-m) (69 lb-ft)

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

: Molybdenum disulfide grease /
MOS2 application
K80Z534019
27. Install control valve assembly (2) and hose (1).
Note
Refer to "Control valve removing and installing" page
34-43 to reinstall control valve assy (2).
80Z5 EX DR 34-32
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
that of the reverse clutch pack. Therefore, to disassem-
ble or reassemble the forward clutch pack, follow the 90ZV34059
reverse clutch pack procedure.
3
80ZV34060
&8 -!"
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 bearing. Remove thrust washer (4).
Note
To disassemble the forward clutch pack, remove the
roller bearing inner race.
For inspection and wear standard refer to "Service stan-
dard".
80Z5 EX DR 34-33
11
12
13
5
6
7
8
80ZV34061 80ZV34063
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 ring (12) and plate (13).
plate (8).
Note
When reassembling, install thrust washers (4)(6) so that
the notch faces to gear (2).
16
14
15
17
18
19
9
R80V2E34025
6. Remove 20 springs (14), and then, turn over the

clutch and tap the shaft on a wooden block to
10 remove piston (15).
80ZV34062
Note
4. Alternately remove friction plates (9) and steel When reassembling, install piston (15) into place using
plates (10). a plastic hammer or a driver.
Note 7. Remove U-ring (17) from piston (15).

- Number of friction plates: 8
Number of steel plates: 7 8. Remove piston ring (18)(19) from shaft assy (16).
- After reinstalling piston (15), be sure to insert friction
plate (9) first.
80Z5 EX DR 34-34
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 3.8 ± 0.3 mm (0.15 ± 0.01 in)
Reverse 4.3 ± 0.3 mm (0.17 ± 0.01 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.
80Z5 EX DR 34-35
Transmission 1st/3rd Speed Clutch Pack
Transmission 1st/3rd speed clutch

2
pack disassembling and assem-
bling
Transmission 1st/3rd speed clutch pack
disassembling 3 4
Note
This disassembling and reassembling procedures for
the 1st and 3rd clutch packs are basically the same. The
different points are described for each procedure. 5
80ZV34065
2. Remove thrust washer (2), and then, remove rear

gear (3).
Using an internal or blind hole puller, remove nee-
dle bearings (4) and thrust washer (5).
Spacer Note
the notch faces to gear (3).
85K34099
1. Remove ball bearing (1) using a puller.

12
Note
11 Shaft assembly
Use a spacer over the shaft to protect the shaft and
inner bearing from damage.
90ZV34072
3. Remove snap ring (6) and backing plate (7).

80Z5 EX DR 34-36
9
Transmission 1st/3rd speed clutch pack
assembling

reverse order.
8
Note
Shaft assembly
12 - To assemble the 1st/3rd speed clutch pack, be sure
11 to apply transmission oil.
10 80V2E34022
- Be sure the residual pressure prevention orifices are
not plugged. Pass a small wire through the orifices.
4. Alternately remove friction plates (8) and steel plate
(9).
Note Transmission 1st/3rd speed clutch pack

After reinstalling piston (13), be sure to insert friction assembly cautions
plate (8) first.
Number of friction plate

Number of steel plate (9)
(8)
1st speed 10 9
3rd speed 5 4
5. Remove snap ring (10) and rings (11)(12).
16
15
14 85K34107
13 After assembling clutch pack.

- Using a straight edge and depth micrometer apply
Shaft assembly clutch oil port at the end of the shaft, and then mea-
80V2E34023
Piston stroke
1st speed 3.8 +0.5 +0.02
-1.0 mm (0.15 -0.04 in)
6. Remove 16 springs (13), and then, turn over the
clutch and tap the shaft on a wooden block to 3rd speed 3.0 ± 1.0 mm (0.12 ± 0.04 in)
remove piston (14).
Note
Note If the piston stroke value is beyond the above range,
When reassembling, install piston (14) into place using replace the parts, or check that the parts are not warped
a plastic hammer or a driver. and are correctly reassembled.
7. Remove U-ring (15) from piston (14).
8. Remove piston ring (16) from the shaft assembly.

80Z5 EX DR 34-37
Transmission 2nd Speed Clutch Pack
Transmission 2nd speed clutch

pack disassembling and assem-
bling
Transmission 2nd speed clutch pack disas-
sembling
7
3
2 8
6 80ZV34071
1
3. Remove thrust washer (6), thrust bearing (7) and
thrust washer (8). Store the thrust washers for pos-
sible reuse.
80ZV34069
1. Remove gear (1). After that, remove snap ring (2)

and backing plate (3).
11
10
9
4
80ZV34072
5 4. Depress plate (10) and remove snap ring (9), and

plate (10).
5. Remove 16 springs (11).
80ZV34070
2. Remove friction plates (4) and steel plates (5).
Note
Number of steel plates: 4
plate (4) first.
80Z5 EX DR 34-38
Transmission 2nd speed clutch pack

assembly cautions
14
13
12
Shaft assembly
80ZV34073
6. Turn over the clutch and tap the shaft on a wooden

block to remove piston (13). 85K34107

After assembling clutch pack
8. Remove piston ring (15) from the shaft assembly.
- Using a straight edge and depth micrometer, apply
Transmission 2nd speed clutch pack
assembling Piston stroke
2nd speed 3.0 ± 1.0 mm (0.12 ± 0.04 in)
reverse order. Note
If the piston stroke value is beyond the above range,
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.
80Z5 EX DR 34-39
Transmission 4th Speed Clutch Pack
Transmission 4th speed clutch

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

sembling
80ZV34076
3. Remove snap ring (6) and backing plate (7).

1
80ZV34074
1. Using a puller, remove ball bearing (1).

9
5
80ZV34077
4
2 4. Remove friction plates (8) and steel plates (9).

3
Note
Number of steel plate: 4
80ZV34075 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
notch faces to gear (3).
80Z5 EX DR 34-40
Transmission 4th speed clutch pack

assembling

reverse order.
Note
12
11 - Clean and check all the parts. If a part is damaged,
10 replace it with a new one. Be sure to use new piston
- To reassemble the 4th speed clutch pack, be sure to
apply transmission oil.
80ZV34078
5. Depress ring (11) and remove snap ring (10), ring

(11) and plate (12).
16 17
15
14
13
Shaft assembly
80ZV34079
6. Remove 16 springs (13), and then turn over the

clutch and tap the shaft on a wooden block to
remove piston (14).
Note
When reassembling, install piston (14) into place using
a plastic hammer or a driver.
8. Remove piston ring (16)(17) from the shaft assem-

bly.
80Z5 EX DR 34-41
Transmission 4th speed clutch pack

assembly cautions Depth micrometer
Straight edge
Air line
Shaft
Backing plate
Gear
85W34041
Clutch drum 2. After assembling clutch pack.

90ZV34114
- Using a straight edge and depth micrometer, apply
1. When installing the gear to the shaft, follow the pro-
cedure below.
- Assemble the gear onto the clutch drum with the
Piston stroke
bolts.
- Heat them up to 190ºC (374ºF). 4th speed 2.95 ± 1.0 mm (0.12 ± 0.04 in)
- Insert the shaft into the clutch drum and gear.
Note
: Bolt: 86 N-m (8.8 kgf-m) (64 lb-ft) If the piston stroke value is beyond the above range,
: With lubrication oil (Engine oil or gear oil) replace the parts, or check that the parts are not warped
and are correctly reassembled.
80Z5 EX DR 34-42
Control Valve Assembly
Control valve tightening torque
T1
T4
T1
T2
T3
K80Z534020
:
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)
80Z5 EX DR 34-43
Control valve removing and

5
installing
4
Control valve removing
WARNING 3 6
Unexpected movement of machine could cause an 5

- Park the machine on level ground, and then lower
the attachment onto the ground. R80V2E34016
- Apply the parking brake, and block the tires with
chocks to prevent the 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)(5).
START!" tag on the steering wheel.
: Bolt (4): 39 N-m (4.0 kgf-m) (29 lb-ft)
: Bolt (5): 20 N-m (2.0 kgf-m) (14 lb-ft)
Note
Do not remove two trimmer bolts (6).
1
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 any foreign material into the
R80V2E34015 main body or the control valve. Carefully remove or
reinstall the control valve and the gasket.
1. Disconnect all electric wire couplers (1) and hose
(2) for checking the clutch pressure. : Control valve: 20 kg (44 lbs)
Note
Put matchmarks on the electric wire couplers.
80Z5 EX DR 34-44
Control valve installation cautions

WARNING
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,

LW and check that the shift lever properly functions at
all the positions.
LR 4
F (g) Check oil leakage.
LY 1
(h) Adjust the transmission oil level to the specified
LG R point with the dipstick.
3 2
LBr
LO
80ZV34087
(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.
80Z5 EX DR 34-45
Control valve disassembling and

assembling
Control valve disassembling
Note
Clean the control valve.
R80V2E34028
3. Remove valve (4) using a 17 mm wrench.
: Valve: 34 N-m (3.5 kgf-m) (24 lb-ft)

1
R80V2E34026
5
1. Remove nut (1). 7
: Nut: 10 N-m (1.0 kgf-m) (7 lb-ft) 6
Note
Nut width across flat: 30 mm
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 R80V2E34027
2. Remove O-ring (2), and then, remove coil (3).
Note
For other solenoid valves, follow the same procedure.
80Z5 EX DR 34-46
Control valve assembly cautions
- Before you insert the regulator valve, apply transmis-

12
8
sion oil to the valve. After insertion, check that the
11 valve operates smoothly.
10
- Placing shims under the springs to increase pres-
9
sure or change modulation is not recommended.
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).)
90ZV34110
- Replace all seals, O-rings and gaskets.
- Check coil resistance.
5. Remove regulator valve (8), trimmer plug (9), Resistance: Approx. 27 
springs (10), spring retainer (11), and plug (12).
Control valve assembling
To reassemble the control valve, follow the disassem-

bling procedure in reverse order.
80Z5 EX DR 35-1
35 Service Standard Torque Converter and Transmission Group
35 Service Standard
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
80Z5 EX DR 35-2
13
12
4
5 16
18
14
17 17
14
18
15
16
10 11
Note
Numbers correspond to the REF. number on page 35-4. K80Z535001
80Z5 EX DR 35-3
Control Valve
Control Valve
3 7 6 2
90ZV35002
Note
Numbers correspond to the REF. number on page 35-4.
80Z5 EX DR 35-4
Control Valve
mm (in), kg (lbs)
Judgement criteria
REF. ITEM Solution
Standard clearance Allowable limit
Control valve regulator valve ~ 0.030~0.061 0.09
1 Replacement
valve body (0.0011~0.0024) (0.0035)
Control valve regulator valve ~ 0.016~0.045 0.07
2 Clearance Replacement
seal retainer (0.0006~0.0017) (0.0027)
Control valve trimmer plug ~ 0.025~0.066 0.09
3 Replacement
valve 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 diameter Replacement
(1.6507~1.6535) (1.6456)
Replace oil
74.92~75.0 74.8 seal when
9 Rear yoke shaft diameter Replacement
(2.9496~2.9528) (2.9449) disassem-
Oil seal
79.92~80.0 79.8 bling and
10 Front yoke shaft diameter reassem- Replacement
(3.1464~3.1496) (3.1417)
bling
Speedometer driven gear shaft 11.95~12.0 11.8
11 Replacement
diameter (0.4704~0.4724) (0.4645)
0 0 2.5
W 2.8 -0.1 (0.1102 -0.0039 )
(0.0984)
12 Torque converter inlet Replacement
2.5±0.05 2.3
H
(0.0984±0.0019) (0.0905)
2.8±0.1 2.5
W
(0.1102±0.0039) (0.0984)
13 Seal ring Torque converter outlet Replacement
2.2±0.05 2.0
H
(0.0866±0.0019) (0.0787)
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)
4.3±0.1 4.1
15 Piston outer dia. (F, R) H Replacement
(0.1693±0.0039) (0.1614)
4.3±0.1 4.1
16 Piston outer dia. (1~4 speed) H Replacement
(0.1693±0.0039) (0.1614)
4.05
17 Piston inner diameter H 4.25+0.015
0 (0.1673+0.0006
0 ) Replacement
(0.1595)
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)
80Z5 EX DR 35-5
Gear Pump
Gear Pump
Gear pump specifications
Theoretical 64.5 cm3/rev (3.9 in3/rev)
Maximum
2 MPa (20 kgf/cm2) (284 psi)
1 operation pressure
Maximum
4 2,400 min-1 (rpm)
operation 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.
80Z5 EX DR 35-6
Clutch Plate Thickness/Piston Stroke
T2 L 3
T7 L 3
T2 L 3
T7 L 3
T1 L 3
T2 L 3
T5 L 1
T3 L 1
T4 L 2
T6 L 3
T6 L 3
K80Z535002

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: 50 N-m (5.1 kgf-m) (37 lb-ft)
80Z5 EX DR 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 8 7 20
Reverse clutch 8 7 20
1st speed clutch 10 9 16
2nd speed clutch 5 4 16
3rd speed clutch 5 4 16
4th speed clutch 5 4 16
Outer dia. ø167 (6.57 in) ø182 (7.17 in) —

Dimension
(mm) (in)
Inner dia. ø104.8 (4.13 in) ø116 (4.57 in) —
When new 2.0±0.1 (0.08±0.004 in) 1.8±0.1 (0.07±0.004 in) —

Thick-
ness
Wear limit 1.8 (0.07 in) 1.6 (0.06 in) —
Piston stroke
mm (in)
Clutch Standard value
Forward clutch 3.8±0.3 (0.15±0.01)
Reverse clutch 4.3±0.3 (0.17±0.01)
1st speed clutch 3.8 +0.5

-1.0 (0.15 +0.02
-0.04 )
2nd speed clutch 3.0±1.0 (0.12±0.04)
3rd speed clutch 3.0±1.0 (0.12±0.04)
4th speed clutch 2.95±1.0 (0.12±0.04)

80Z5 EX DR 35-8
Clutch Oil Pressure
Clutch Oil Pressure
8
2
4
9 6
3 5
7
4
5
6
K80Z535003
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 PT1/4 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 PT1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) Reverse
5 1st speed clutch oil pressure PT1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) 1st speed
6 2nd speed clutch oil pressure PT1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) 2nd speed
7 3rd speed clutch oil pressure PT1/4 1.3±0.2 (13±2) (185±28) 1.5±0.2 (15±2) (213±28) 3rd speed
8 4th speed clutch oil pressure PT1/4 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
80Z5 EX DR 44-1
44 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 ................................................... 44-8
Pilot Valve................................................................ 44-21
Multiple Control Valve.............................................. 44-33
Orbitrol® ................................................................... 44-39
Steering Valve ......................................................... 44-49
Stop Valve ............................................................... 44-54
Fan Motor ................................................................ 44-58
80Z5 EX DR 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
serious injury or death. To prevent such an accident,
observe the following items:
- Park the machine on level and solid ground.
- Apply the parking brake and block tires with
chocks to prevent wheels from moving.
- Be sure to remove the engine key, and hang a "DO
NOT START!" tag on the steering wheel or the
operator's seat.
- Relieve the internal pressure from the hydraulic
line and hydraulic tank.
- Use signals as agreed upon before starting work.
- Do not enter the hazardous area.
- When removing a heavy load over 20 kg (44 lbs),
use a crane or a lift device.
- Stay out of the working area while using a crane.
- While working with the boom raised, put safety
blocks or supports to prevent it from dropping 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.
80Z5 EX DR 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 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.
80Z5 EX DR 44-4
Hydraulic Pump Assembly
Hydraulic pump assembly remov-

Transmission
ing and installing
Hydraulic pump assembly removing
DANGER 3
Entering the articulation area while engine is running
may cause serious injury or death. 1
So, when entering the area, stop the engine and
place "DO NOT START" or "DO NOT OPERATE" tag
on steering wheel. 2 K80Z544001
CAUTION 1. Disconnect outlet hose (2) and suction hose (3)

from hydraulic pump (1).
Removing hoses and plugs without bleeding residual
pressure could cause injuries or burns from hot oil Note
under pressure. Cover the disconnected hoses with plastic, plugs or
Before removing hoses and plugs, relieve residual caps to protect from dust and dirt.
pressure. Relieve internal pressure from hydraulic
tank to prevent oil from spraying. 2. Remove the hydraulic pump retainer bolts.
Before starting work: : Bolt: 142 N-m (14.5 kgf-m) (105 lb-ft)
- Remove the cab and the floor board by referring to
Section 14. 3. Remove hydraulic pump (1).
- Clean the area around the hydraulic pump.
: Hydraulic pump: 31 kg (68 lbs)
Hydraulic pump assembly installing
To reinstall the hydraulic pump assembly, follow the

above removal procedure in reverse order.
Replace all gaskets and O-rings during reinstallation.
80Z5 EX DR 44-5
Hydraulic pump installation cautions

IMPORTANT
When replacing hydraulic pumps or when draining
hydraulic oil for extended periods, it is important to - Fill the inlet port of the hydraulic pump with clean
prime the hydraulic system properly. Air will be in the hydraulic oil and rotate the pump shaft by hand
lines that go to and come from the pump. After a pump prior to installing the pump. It should rotate
has been installed, or when the hydraulic oil has been smoothly.
drained for extended time periods, air will not purge Prior to installing pump and plumbing to pump,
easily from the lines, and this could lead to pump dam- remove all caps, plugs, and covers from pump and
age. piping.
- While reinstalling the hydraulic pump, take care
not to allow dust, dirt, or foreign material into the
WARNING case.
Oil injection hazard! - Check the oil level of the hydraulic tank.
Hydraulic oil can penetrate skin. When performing - Close the cap of the hydraulic tank, and remove
this procedure: the plugs of the pump suction pipe. Pour hydraulic
- Release all trapped circuit pressure prior to start- oil into the plug port until the oil overflows from the
ing any procedure involving hydraulic oil. port (approx. 4 L).
- Wear protective gloves. - Run the engine at low-idling speed for 5 minutes or
- Wear eye and face protection. more. Do not operate any hydraulic functions dur-
- Stay clear of areas where air may be purged. ing this period.
- Route oil into a receiving canister [such as a 5 gal- Note
lon bucket] by use of an additional hose. If the engine speed is set to high-idling just after
- Rotate pump at a low RPM. 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.
80Z5 EX DR 44-6
Hydraulic pump assembly disassembling and assembling
IMPORTANT
Before disassembly or reassembly, read and under-
stand the aforementioned "Hydraulic Parts Disas-
sembly and Assembly Cautions" page 44-3.
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.
If a pump must be repaired, be sure no pieces of dam-

aged pump material has scatted through hydraulic sys-
tem. New parts must be "broken in" and performance
must be checked.
Do not disassemble the pump except when necessary
to replace oil seals and O-rings between the double and
triple pumps which are able to be separated.
Hydraulic pump assembly cross section and tightening torque
T2 T1
80V2E44002

T1: 177 N-m (18 kgf-m) (130 lb-ft)
T2: 275 N-m (28 kgf-m) (203 lb-ft)
80Z5 EX DR 44-7
Oil seal replacement procedure There are two kinds of the pump drive gear shaft unit.
One has one oil seal only, and the other has an addi-
[Example 1] tional dust seal or oil seal outside.
Oil seal Snap ring In case of example 2
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

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

Drive gear shaft to protect the splines.
4. Apply a thin coat of grease to the oil seal and the lip
unit.
5. Install the seal straight.
Front cover
90ZV44048
[Example 2]
Front cover
Drive gear shaft
Oil seal
Oil seal Snap ring
90ZV44049
80Z5 EX DR 44-8
Hydraulic Cylinder
Hydraulic Cylinder
Boom cylinder removing and

installing
Boom cylinder removing
(The illustration shows the left side of the machine.)
WARNING
Unexpected movement of machine, bucket, or boom
1
during service work could cause serious injury or
lowing items: K80ZV44001
- Park the machine on level ground, and apply the
parking brake. In addition, block tires with chocks
1. Attach sling to boom cylinder (1).
to prevent wheels from moving.
- Raise the boom until it is horizontal, and then place
: Boom cylinder: 140 kg (310 lbs)
stand (A) under the boom to support it.
- Relieve the internal pressure from the loading line,
and also relieve the internal pressure from the
hydraulic tank to prevent the oil from spouting out.
- Use a stepladder or work platform, and do not
stand on the machine.
Before starting work: 3

- Clean the area around the cylinder and piping.
80V2E44003
2. Disconnect hoses (2)(3).
Note
Cover the disconnected hoses with plastic, plugs, or
Stand (A) caps to protect them from dust, water and dirt.
85ZV44003
Relieving residual pressure from pipe

(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.
80Z5 EX DR 44-9
Hydraulic Cylinder
5 4
9
K80ZV44002 80ZV44024J
3. Remove lock bolt (4) and pin (5). 6. Sling boom cylinder (1), and lower it onto the
ground.
: Bolt (4): 265 N-m (27.0 kgf-m) (195 lb-ft) After that, remove pipe (9) from the cylinder.
Note
Cover the disconnected hoses with plastic, plugs, or
caps to protect them from dust, water and dirt.
For the detailed description of cylinder disassembly and
reassembly, refer to "Hydraulic cylinder disassembling
and assembling" page 44-15.
6 Boom cylinder installing
To reinstall the boom cylinder, follow the above removal

85ZV44014
procedure in reverse order.
4. Place a container to receive the oil from the oil port

on the cylinder bottom side. Then, push in rod (6).
8
7
80ZV44005
5. Remove lock bolts (7), and then, remove pin (8).
: Lock bolt: 265 N-m (27.0 kgf-m) (195 lb-ft)

80Z5 EX DR 44-10
Hydraulic Cylinder
Boom cylinder installation cautions Bucket cylinder removing and

Be sure the pins accept grease after installation.
installing
Bucket cylinder removing
Cylinder air bleeding procedure
WARNING
IMPORTANT
After repairing or replacing a cylinder, be sure to during service work could cause serious injury or
bleed the cylinder of air, or the piston seal or back-up death. To prevent such an accident, observe the fol-
ring may be seized. lowing items:
(a) While operating the engine at low-idling speed, parking brake. In addition, block tires with chocks
operate the cylinder piston for 4 to 5 strokes. to prevent wheels from moving.
- Place the boom and the bucket onto the ground.
Note - Relieve the internal pressure from the loading line,
Stop the piston about 100 mm (4.0 in) before stroking and also relieve the internal pressure from the
fully. hydraulic tank to prevent the oil from spouting out.
- Use a step, and do not stand on the machine.
(b) After that, stroke the cylinder piston fully to both
ends 4 to 5 times. Before starting work:
- Clean the area around the cylinder and piping.
(c) Add hydraulic oil to the tank, and check the cylinder
and its piping for oil leakage.
Relieving residual pressure from pipe
(a) Lower the boom and the bucket onto the ground.
(b) Stop the engine and move the bucket and boom
levers back and forth.
(c) Open the cap of the hydraulic tank to relieve the
residual pressure.
Bucket cylinder
3 80ZV44007
1. Remove the coupler of bucket leveler switch (1),

and then, remove bracket (2).
2. Remove rod (3).

80Z5 EX DR 44-11
Hydraulic Cylinder
9 Grease pipe
5
4
Bucket cylinder 8
Bucket cylinder
80ZV44025J 80ZV44010
3. Attach sling to the bucket cylinder. 5. Disconnect the grease pipe and then remove lock
After that, remove lock bolt (4) and pin (5). bolt (8) and pin (9).
: Lock bolt: 265 N-m (27.0 kgf-m) (195 lb-ft) : Lock bolt: 265 N-m (27.0 kgf-m) (195 lb-ft)
: Bucket cylinder: 200 kg (440 lbs)
6. Slowly lift up the bucket cylinder. Lower the bucket
cylinder onto the ground.
7 For the detailed description of cylinder disassembly

Bucket cylinder and reassembly, refer to "Hydraulic cylinder disas-
sembling and assembling" page 44-15.
Bucket cylinder installing
6 To reinstall the bucket cylinder, follow the above

Cylinder rod removal procedure in reverse order.
80ZV44009
4. Start the engine and shorten the cylinder rod.

Stop the engine and disconnect hoses (6)(7).
Note
Cover the disconnected hose and the cylinder with plas-
tic, caps or plugs to protect them from dust, water and
dirt.
80Z5 EX DR 44-12
Hydraulic Cylinder
Bucket cylinder installation cautions
WARNING
During service work, do not stand on the machine.
Standing on tire, boom or linkage may cause acci-
dents and serious injury or death. Use a stepladder,
ladder, or work platform, and do not stand on the
machine.
- Be sure the pins accept grease after installation.
- 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 15-7.
Cylinder air bleeding procedure
IMPORTANT
After repairing or replacing a cylinder, be sure to
bleed the cylinder of air, or the piston seal or back-up
ring may be seized.
(a) While operating the engine at low-idling speed,

operate the cylinder piston for 4 to 5 strokes.
Note
Stop the piston about 100 mm (4.0 in) before stroking
fully.
(b) After that, stroke the cylinder piston fully to both

ends 4 to 5 times.
80Z5 EX DR 44-13
Hydraulic Cylinder
Steering cylinder removing and 5

3
installing
6
Steering cylinder removing
WARNING
Unexpected movement of machine could cause seri-
ous injury or death. To prevent such an accident,
4
parking brake. In addition, block the tires with 80ZV44012
- Place the boom and the attachment onto the
2. There is pin (6) at the link between front chassis (3)
ground.
and steering cylinder (4).
- Stop the engine, and turn the steering wheel clock-
Remove lock bolt (5) and pin (6), and then push the
wise and counterclockwise to relieve the pressure
rod into the cylinder to shorten the length of the cyl-
from the line.
inder.
- Press cap downward to vent, then open the cap of
the hydraulic tank to relieve the internal pressure
: Oil will be drained from the oil port of the
from the tank.
cylinder. Place a container at the oil port
- Place a "DO NOT START!" tag on the steering
to catch the drained oil.
wheel or the operator's seat.
7 8
- Clean the area around the cylinder to be removed. 9
4
80ZV44013
2
3. Disconnect grease pipe (7).
Steering cylinder
4. Remove pin lock bolts (8).
80ZV44011
5. Tap pin (9) from the bottom side to remove it from

1. Disconnect hoses (1)(2). the top side.
Note
Cover the disconnected hoses with plastic, caps, or
plugs to protect them from dust, water, and dirt.
80Z5 EX DR 44-14
Hydraulic Cylinder
6. Remove steering cylinder assembly (4). Cylinder air bleeding procedure

Note that two persons are needed to remove and
lift the assembly.
IMPORTANT
: Steering cylinder: 25 kg (55 lbs) After repairing or replacing a cylinder, be sure to
bleed the cylinder of air, or the piston seal or back-up
Note ring may be seized.
For detailed description of cylinder disassembly and
reassembly, refer to "Hydraulic cylinder disassembling
(a) While operating the engine at low-idling speed,
and assembling" page 44-15.
operate the cylinder piston for 4 to 5 strokes.
Note
Stop the piston about 100 mm (4.0 in) before stroking
Steering cylinder installing fully.
To reinstall the steering cylinder, follow the above (b) After that, stroke the cylinder piston fully to both
removal procedure in reverse order. ends 4 to 5 times.
Steering cylinder installation cautions
Pin installation
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.
80Z5 EX DR 44-15
Hydraulic Cylinder
Hydraulic cylinder disassembling and assembling
IMPORTANT
Hydraulic cylinder cross section and tight-

ening torque
Boom cylinder
T1 T2
80ZV44001J
: Piston nut width across flats: 90 mm (3.54 in)

T1: 3,923 N-m (400 kgf-m) (2,894 lb-ft) Thread size: M58 x 2
T2: 471 N-m (48 kgf-m) (347 lb-ft)
Bucket cylinder
T3 T4
80ZV44002J
: Piston nut width across flats: 100 mm (3.94 in)

T3: 4,903 N-m (500 kgf-m) (3,618 lb-ft) Thread size: M68 x 2
T4: 686 N-m (70 kgf-m) (506 lb-ft)
80Z5 EX DR 44-16
Hydraulic Cylinder
Steering cylinder
T5 T6
80V2E44004
:
T5: 930 N-m (94.8 kgf-m) (686 lb-ft)
T6: 300 N-m (30.6 kgf-m) (221 lb-ft)
Piston nut width across flats: 46 mm (1.81 in)

Thread size: M30 x 2
80Z5 EX DR 44-17
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):
(Boom cylinder)
471 N-m (48.0 kgf-m) (347 lb-ft)
(Bucket cylinder)
686 N-m (70.0 kgf-m) (506 lb-ft)
Rod cover (1):

(Steering cylinder)
300 N-m (30.6kgf-m) (221 lb-ft)
80Z5 EX DR 44-18
Hydraulic Cylinder
5 Matchmark
4
6 7 4
95ZV44008 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.
6 21 10 21 12 8 22 8
8 9
Hydraulic jack
11
(Bucket cylinder) (Steering cylinder)
Hydraulic cylinder 80V2E44005
95ZV44009
6. Use a hydraulic jack or hydraulic cylinder to loosen

piston nut (6). 8 9 10 12
Piston nut width

Tightening torque
across flats
N-m (kgf-m) (lb-ft)
mm (in)
Boom cylinder 90 (3.54) 3,923 (40) (2,894)
Bucket cylinder 110 (4.33) 4,903 (500) (3,618)
Steering cylinder 46 (1.81) 930 (94.8) (686) 11
(Boom cylinder)
85ZV44029
8. Remove wear ring (8), back-up ring (21), square

ring (9), slipper ring (10), O-ring (11), wear ring (12)
and piston packing (22).
(There is no wear ring (12) for steering cylinder.)
80Z5 EX DR 44-19
Hydraulic Cylinder
Hydraulic cylinder assembling
To reassembling the hydraulic cylinders, follow the

1
Hydraulic cylinder assembly cautions
4 Before starting work:

- Be sure to replace all the seals and packings.
95ZV44013
replace it.
- Before reassembling the parts, apply a coat of
9. Remove rod cover (1) from piston rod (4). hydraulic oil to the parts.
1 1 CAUTION
19 19
20 20 Hot oil can cause injury or burns.
16 16 Avoid contact with hot oil.
17 17
15
18 13 18 14
Slipper ring installation
(Bucket cylinder) (Boom cylinder) 10

K80V2E44001
18 20 19 17 16 21 13
95ZV44016
Put slipper ring (10) into hot oil to heat the ring to
(Steering cylinder) 120~150ºC (250~300ºF).
80V2E44006
Note
- This is because the inner diameter of the slipper ring
is smaller than the outer diameter of the piston.
10. Remove dust seal (13), stop ring (14), scraper ring Therefore, heat the slipper ring to expand its inner
(15), back-up ring (16), U-packing (17), buffer ring diameter for easy attachment.
(18), back-up ring (19) O-rings (20)(21) from rod - Attach the slipper ring while taking care not to dam-
cover (1). age the ring by over expansion.
- After attaching the slipper ring, cool the slipper ring
so that it is contracted to the original size.
80Z5 EX DR 44-20
Hydraulic Cylinder
Back-up ring installation Rod cover installation
95ZV44017 K65V2E44013
Before installing back-up ring (2) and O-ring (3), heat Install the rod cover of the steering cylinder, screw the
the back-up ring. rod cover using a spanner wrench.
Screw in and tighten the set screw.
Note Stake the set screw.
This is because the inner diameter of the back-up ring is
smaller than the outer diameter of the rod cover. To eas- : 1,569 N-m (160 kgf-m) (1,158 lb-ft)
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.
80Z5 EX DR 44-21
Pilot Valve
Pilot Valve
Pilot valve removing and installing Downshift

button Pilot valve
Pilot valve removing
2
WARNING
- Park the machine on level ground, and then block 3
tires with chocks to prevent wheels from moving. In
addition, apply the parking brake. 95ZVE44039
- Lower the attachment onto the ground, and then
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).
80Z5 EX DR 44-22
Pilot Valve
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 reverse order.
: Drain oil: Approx. 1 L (0.3 gal)
Note Pilot valve installation cautions

Before disconnecting the hoses, be sure to put match-
marks 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.
80Z5 EX DR 44-23
Pilot Valve
Pilot valve disassembling and

assembling
IMPORTANT
80Z5 EX DR 44-24
Pilot Valve
Pilot valve cross section and tightening torque
T1 L1
A B
T4 T4
T2 L1 T2 L1
T3
T3
T6
T5
P T
2 4
A B
Port 1, 2 Port 3, 4
Port 1 Port 2 Port 3 Port 4
Cross section A-A Cross section B-B

K85Z544001
80Z5 EX DR 44-25
Pilot Valve
:
T1: 1.6 N-m (0.16 kgf-m) (1.2 lb-ft)
T2: 7.9 N-m (0.8 kgf-m) (5.8 lb-ft)
T3: 9.8 N-m (1.0 kgf-m) (7.2 lb-ft)
T4: 17.7 N-m (1.8 kgf-m) (13 lb-ft)
T5: 53.9 N-m (5.5 kgf-m) (40 lb-ft)
T6: 31.4 N-m (3.2 kgf-m) (23 lb-ft)
Port 1~4 (adapter:

31.4 N-m (3.2 kgf-m) (23 lb-ft)
: Pilot valve: 6.5 kg (14.5 lbs)

80Z5 EX DR 44-26
Pilot Valve
Pilot valve disassembling

2
(Illustrated on the boom side. Disassemble the bucket
side in the same manner.)
1
3 4
1
K90Z544010
4. Put matchmarks 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.
80Z5 EX DR 44-27
Pilot Valve
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 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).
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 44-24 for the port location.
80Z5 EX DR 44-28
Pilot Valve
26
26
2
27
25
7 15 6 95ZVE44013 95ZVE44016
10. Remove push rod (7) from plug (6). Remove O-ring 12. Clamp center plate (25) in a vise. Remove socket
(15) from plug (6). bolts (26) in the shallow pits with a hexagon (Allen)
wrench.
: Socket bolt (3):

16
8.8 N-m (0.90 kgf-m) (6.5 lb-ft)
27
28
25
95ZVE44014
11. Remove seal (16) from plug (6) using a small

screwdriver.
95ZVE44023
Note
Take care not to damage the internal surface of plug (6). 13. Remove cover (2) and detent casing (27) from cen-
ter plate (25).
Note Be advised that fixing discs (29) on outer springs
Item numbers (17) through (24) are intentionally omitted (28) may be stuck to detent casing (27) with
in the following steps. grease, and could be dropped.
80Z5 EX DR 44-29
Pilot Valve
29
27
28 25
30
95ZVE44022 95ZVE44020
14. Remove outer springs (28) and fixing discs (29) on 16. Remove solenoid coil (30) from detent casing (27).
center plate (25).
Note
While removing solenoid coil (30), do not pull the electri-
2 cal harness.
32
31
27
95ZVE44021
15. Remove detent casing (27) from cover (2).

95ZVE44028
Note
The push rod may be fall off the detent bush without the 17. Remove lever (31) by loosening socket bolt (32)
steel ball. with a hexagon (Allen) wrench.
: 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.
80Z5 EX DR 44-30
Pilot Valve
35 (with pre-detent)
31
37
35 (without pre-detent)
33
2
2 95ZVE44027 F95ZVE44025
18. Remove cam shaft (33).
19. Take out lever (31) from cover (2).
31
2 Tool
95ZVE44024
34
21. Remove assembled detent bush (35), push rod
(37), etc. from cover (2) using the tool.
95ZVE44026
Tool
20. Clamp lever (31) in a vise, and remove nuts (34). (Material: SS400)
: Nut (34): 16.7 N-m (1.70 kgf-m) (12.3 lb-ft)

Center hole (ø2 or less)
30
35 2
45
115V2E44021
80Z5 EX DR 44-31
Pilot Valve
2 37 40 38
39
36
95ZVE44032 95ZVE44030
22. Remove O-rings (36) from cover (2). 24. [For the port with pre-detent]
Hold detent ring (38) and press to compress spring
Note (39), and then take out balls (40).
Take care not to damage O-rings (36).
Note
Be sure to keep balls (40) (4 pcs.).
25. Pull out push rod (37).

35
39
35
37
95ZVE44031
38
23. [For the port without pre-detent]

Remove push rod (37) from detent bush (35). Put a
95ZVE44029
match-mark on them beforehand.
26. Remove detent ring (38) and spring (39) from

detent bush (35).
80Z5 EX DR 44-32
Pilot Valve
41
Push rod (37)

Detent
bush (35)
Scraper (41)
A Scraper (41)
35
Detail of A
95ZVE44033 95ZVE44035
27. Remove scraper (41) from detent bush (35). - Insert scraper (41) in correct direction.
Note - Do not push push rod (37) too much with the set
Be sure not to damage scraper (41) or the internal sur- screw while adjusting the position of the lever (31). It
face of detent bush (35). may cause bumping at Neutral position, resulting in
unexpected movement at starting the engine.
Pilot valve assembling
To reassemble the pilot valve, follow the above disas-

Push rod (7)
sembly procedures 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  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.
80Z5 EX DR 44-33
Multiple Control Valve
Multiple control valve removing 3

24
and installing
Multiple control valve removing
WARNING
Unexpected movement of machine, bucket, or boom 23
2
during service work could cause serious injury or

lowing items: (FM)
- Park the machine on level ground. K80Z534007
- Lower the attachment onto the ground.
- Apply the parking brake. In addition, block the tires
2. Put matchmarks on hoses (2)(3) and disconnect
with chocks to prevent the wheels from moving.
them.
- Relieve the internal pressure from the loading line,
and also relieve the internal pressure from the
Note
hydraulic tank to prevent the oil from spouting out.
Cover the disconnected hoses with plastic, caps or
- Be sure to remove the engine key, and place a
plugs to protect them from dust, water and dirt.
"DO NOT START!" tag on the steering wheel or the
operator's seat.
1
22
Multiple control valve 25
4
(FM)
K80Z534008
(FM) 3. Remove return hose (4) from the multiple control

K80Z534006
valve.
1. Put matchmarks on hoses (1) of the pilot line, and Note

then, disconnect them. Cover the disconnected hose with plastic, cap or plug to
protect it from dust, water and dirt.
Note
Cover the disconnected hoses with plastic, caps or
plugs to protect them from dust, water and dirt.
80Z5 EX DR 44-34
Multiple control valve installation cautions
WARNING
5 Unexpected movement of the machine may cause
serious injury or death.
engine before you start working. In addition, block
tires with chocks to prevent wheels from moving.
While working, carefully keep contact with the person
in the cab by giving signals to each other.
80V2E44010
4. Sling the multiple control valve, and remove - Wash the multiple control valve mounting area.
bracket (5) from the rear chassis.
- Attach the pressure gauge, and then start the
: Bolt: 94 N-m (9.6 kgf-m) (69 lb-ft) engine. Measure the pressure, and adjust it to the
: Multiple control valve: 72 kg (159 lbs) specified value. For a detailed description of pres-
(with bracket) sure adjustment, refer to the Section 03.
- Operate the bucket and the boom, and check that

they operate correctly.
Multiple control valve installing
- Check each section for oil leakage.
To reinstall the multiple control valve, follow the above
removal procedure in reverse order. - Add hydraulic oil to the tank until the oil level rises to
the specified point.
80Z5 EX DR 44-35
Multiple control valve disassembling and assembling
IMPORTANT
Multiple control valve cross section and tightening torque

T7
T8
T3
T3
Main relief
valve T2
T6
T1
T3
Bucket spool
T3
Make-up valve
T6
Overload relief valve
with make-up function
T2
T4 L1
Boom spool
T4
L1
T1: 180 N-m (18.4 kgf-m) (133 lb-ft) T5
T2: 39 N-m (4.0 kgf-m) (29 lb-ft)
85ZV44022
T3: 78 N-m (8.0 kgf-m) (58 lb-ft)
T4: 18 N-m (1.8 kgf-m) (13 lb-ft)
T5: 34 N-m (3.5 kgf-m) (25 lb-ft)
T6: 410 N-m (41.8 kgf-m) (302 lb-ft) L1: Screw lock agent (Loctite® 262) application
T7: 260 N-m (26.5 kgf-m) (192 lb-ft)
T8: 65 N-m (6.6 kgf-m) (48 lb-ft) : 55 kg (121 lbs)
80Z5 EX DR 44-36
Multiple control valve disassembling
3
1
70ZV44011J
70ZV44009J 3. Remove make-up valve (3).
1. Remove main relief valve (1). : Valve (3): 78 N-m (8.0 kgf-m) (58 lb-ft)
: Hexagon width across flat: 32 mm (1.26 in)
: Valve (1): 78 N-m (8.0 kgf-m) (58 lb-ft)
5 6
7 70ZV44012J
70ZV44010J 4. Remove socket head bolt (4)(5) from the bucket

and boom side of the cap. Then remove cap (6)(7).
2. Remove right and left overload relief valve (2).
: Bolt (4)(5): 34 N-m (3.5 kgf-m) (25 lb-ft)
: Valve (2): 78 N-m (8.0 kgf-m) (58 lb-ft) : Hexagon width across flat: 6 mm (0.24 in)
80Z5 EX DR 44-37
15
14
9
70ZV44013J 85ZV44023
5. Slowly pull out spool (8) from the bucket side, and 7. Remove four socket head bolts (14), and remove
spool (9) from the boom side as an assembly. cover (15). Also remove the O-ring from the mating
face.
Note
Carefully pull out the spool so that it is not forced out or : Bolt (14): 180 N-m (18.4 kgf-m) (133 lb-ft)
distorted. : Hexagon width across flat: 12 mm (0.47 in)
16
11
19
13 17
18
12
10
70ZV44014J 70ZV44016J
6. Remove socket head bolt (10)(11) to remove cap 8. Remove plug (16) from the bucket side to remove
(12)(13). Also remove the O-ring of the flange from spring (17) and poppet (18). Also remove plug (19)
the cap. from the boom side.
Remove the O-ring from the plug.
: Bolt (10)(11): 34 N-m (3.5 kgf-m) (25 lb-ft)
: Hexagon width across flat: 6 mm (0.24 in) : Plug (16)(19):
260 N-m (26.5 kgf-m) (192 lb-ft)
80Z5 EX DR 44-38
22 23
20
24
25
23
Spool
70ZV44017J 85ZV44024
9. Remove the hexagon bolts and remove cap kit 11. Set the spool assembly in a rise and then loosen
(20). bolt (22) to remove.
: Bolt: 65 N-m (6.6 kgf-m) (48 lb-ft) : Bolt (22): 18 N-m (1.8 kgf-m) (13 lb-ft)
: Hexagon width across flat: 8 mm (0.31 in) : Screw lock agent (Loctite® 262) application
12. Remove spring seat (23), spring (24), stopper (25)

from each spool (there are two spools).
21
Note
Cover the spool to protect it from being scratched.
Multiple control valve assembling
To reassemble the multiple control valve, follow the

70ZV44018J
10. Remove plug assembly (21) and remove the O-

ring.
Multiple control valve assembly cautions
: Plug (21): 410 N-m (41.8 kgf-m) (302 lb-ft)
: Hexagon width across flat: 17 mm (0.67 in) - Clean and check all the parts. If a part is defective,
replace or repair it.
- Apply the specified torque to tighten each main part.
80Z5 EX DR 44-39
Orbitrol®
Orbitrol®
Orbitrol® removing and installing

Orbitrol® removing
WARNING
1
- Park the machine on level ground, and lower the
attachment onto the ground.
- Block 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.
Note
This work should be done by two persons. One person
should support the Orbitrol® under the machine. The 2
person in the cab should remove the retainer bolt. 85V2E44009
2. Remove floor mat (2).
85V2E44010
3. Put matchmarks on hoses (3), and then disconnect

them from Orbitrol® (4).
80Z5 EX DR 44-40
Orbitrol®
Orbitrol® installation cautions
At the completion of reinstallation, check operation of

the Orbitrol® by following the procedure below:
WARNING
5 may cause serious injury or death.
on steering wheel or the operator's seat.
85V2E44011
1. Start the engine and confirm that the stop valve

4. Remove bolt (5), and then remove the Orbitrol®. comes in contact with the stoppers by turning the
steering wheel clockwise and counterclockwise.
: Bolt: 29 N-m (3.0 kgf-m) (22 lb-ft)
: Orbitrol®: 7 kg (15 lbs) 2. Check around the Orbitrol® for oil leakage.
Orbitrol® installing
To reinstall the Orbitrol®, follow the above removal pro-

cedure in reverse order.
80Z5 EX DR 44-41
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)
80Z5 EX DR 44-42
Orbitrol®
Orbitrol® disassembling
4
(Disassembling rotor)
Copper plate
97ZV44048
3. Remove rotor assembly (4), spacer (5) and O-ring

(6).
95ZV44025
Note
®
1. Set the Orbitrol in a vise so that the rotor side Keep rotor (7) in rotor assembly (4).
comes to the top position.
Use a copper plates on a vise and do not tighten
the vise too strong.
1 8
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).

80Z5 EX DR 44-43
Orbitrol®
(Disassembling valve)
13 14
15
11 97ZV44052
97ZV44050
7. Remove Y-packing seal (14) and dust seal (15)
from seal retainer (13).
5. 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
6. Rotate the spool and sleeve so that the pin can be 8. 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.
80Z5 EX DR 44-44
Orbitrol®
24
22
22
19 23
20 23
97ZV44054 97ZV44056
9. Pull out spool and sleeve assembly (19) slowly 11. Push spool (23) slightly out of sleeve (22), and
from housing (20) while turning the assembly clock- remove centering springs (24). Pull the spool from
wise and counterclockwise. 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
12. Remove O-ring (25) from the housing.

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

10. Pull out pin (21) from the spool and sleeve assem-
bly (19). Note
Do not disassemble, unless absolutely necessary.
80Z5 EX DR 44-45
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.
80Z5 EX DR 44-46
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
80V2E44019
Note
Be sure the position and direction of the seals.
80Z5 EX DR 44-47
Orbitrol®
Grooves in rotor bore A

9
B
Drive shaft
C
10 D
Pin
97ZV44066
Port face 95ZV44029
9. Put O-ring (10), then align the bolt holes in plate (9) 12. Holding the rotor assembly with the O-ring side fac-
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
95ZV44028
10. Insert drive shaft (8) to fit its yoke with pin (21).
97ZV44068
11. Put O-ring (6) in rotor assembly (4).

80Z5 EX DR 44-48
Orbitrol®
1
2
97ZV44070
13. Install spacer (5), O-ring (3) and end cap (2).
: Temporary tightening torque:

15 N-m (1.5 kgf-m) (11 lb-ft)
Fully tightening torque:
23 N-m (2.3 kgf-m) (17 lb-ft)
Tightening order
95ZV44030
Note
Temporarily tighten bolt (1), then tighten them fully and
securely in the order shown above.
80Z5 EX DR 44-49
Steering Valve
Steering Valve
Steering valve removing and 9

7 6 8
installing 10
Steering valve removing
WARNING
serious injury or death. To prevent such an accident,
- Park the machine on level ground, and lower the 5
Steering valve
attachment onto the ground. 80V2E44012
- Block the tires with chocks to prevent the wheels
from moving.
2. Remove hoses (5)~(9) and block (10).
tank.
Note
- Oil spilled on the parking brake shoe section may
Cover the disconnected hoses with plastic, plugs or
cause malfunction. To prevent such a problem,
cover the shoe section with plastic before valve
removal.
Steering valve

- Remove the seat and seat bracket in the cab. 11
Steering valve
3
4
2
80ZV44020
1
3. Remove bolt (11), and then, remove the steering
valve.
: Bolt (11): 49 N-m (5.0 kgf-m) (36 lb-ft)

80V2E44011
: Steering valve: 25 kg (55 lbs)
1. Disconnect hoses (1)~(4) from the steering valve. Note

Cover the disconnected hoses and the valve with plas-
Note tic, plugs or caps to protect them from dust and dirt.
80Z5 EX DR 44-50
Steering Valve
Steering valve installing Steering valve installation cautions
To reinstall the steering valve, follow the above removal At the completion of reinstallation, check operation of
procedure in reverse order. the steering valve by following the procedure below:
WARNING
may cause serious injury or death.
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).
80Z5 EX DR 44-51
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
: 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)
T2: 79 N-m (8.0 kgf-m) (58 lb-ft) T6: 130 N-m (13.3 kgf-m) (96 lb-ft)
T3: 62 N-m (6.3 kgf-m) (46 lb-ft) T7: 108 N-m (11 kgf-m) (80 lb-ft)
80Z5 EX DR 44-52
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
Width across flat: 32 mm (1.26 in) Carefully pull out the steering spool so that it is not dam-
aged. Put matchmark to make sure the direction of the
: 79 N-m (8.0 kgf-m) (59 lb-ft) steering spool.
90ZV44010J
90ZV44008J
2. Remove bolt (2). Remove end cover (3). 4. Slightly loosen plug (7).
Hexagon hole width across flat: 8 mm (0.315 in)
Width across flat: 14 mm (0.551 in)
: 62 N-m (6.3 kgf-m) (46 lb-ft)
: 353 N-m (36 kgf-m) (260 lb-ft)
Note
Carefully loosen plug (7). It may spring out by the spring
force.
80Z5 EX DR 44-53
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 at step 4.

80Z5 EX DR 44-54
Stop Valve
Stop Valve
Stop valve removing and installing 6

1 3
Stop valve removing
WARNING
Unexpected movement of the machine, attachment,
or boom during service work could cause serious 7 4
injury or death. To prevent such an accident, observe
the following items:
- Park the machine on level ground, and apply the 2
parking brake. In addition, block the tires with
tank to prevent the oil from spouting out. 5
80ZV44021
(The illustration shows the machine right hand side.)
1. Remove hoses (1)~(5) from the stop valve.
Note
2. Remove bolt (6) and then remove stop valve (7).
Stop valve installing

order.
80Z5 EX DR 44-55
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
Stopper (bolt) (rear chassis)
: 90 N-m (9.2 kgf-m) (67 lb-ft)
(LH, RH)
Front chassis
Reference dimension
33.8~38.7 mm
(1.33~1.52 in)
Stopper (bolt) length

90ZVE43005
Front chassis
8º 3
36º~
Rear chassis
Reference dimension
13.7~27.5 mm (0.54~1.08 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 "13.7~27.5 mm
(0.54~1.08 in)" shown in the table below.
Reference dimension
Articulation angle (º) 38 37 36

Clearance between machine 13.7 20.6 27.5
body and stopper (mm) (in) (0.54) (0.81) (1.08)
33.8 36.2 38.7
Stopper (bolt) length (mm) (in)
(1.33) (1.42) (1.52)
The target value should be the articulation angle "37º".

80Z5 EX DR 44-56
Stop Valve
Stop valve disassembling and

assembling
IMPORTANT
Stop valve cross section and tightening

torque
T1
T2
T3
85V2E44015
:
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)
80Z5 EX DR 44-57
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)

80Z5 EX DR 44-58
Fan Motor
Fan Motor
Fan motor removing and installing 4
Fan motor removing

3
5
WARNING
during service work could cause serious injury or 2
lowing items:
parking brake. In addition, block tires with chocks 5
K85Z544014
to prevent wheels from moving.
tank to prevent the oil from spouting out. 2. Remove fan guard (2) from the radiator assembly.
START ENGINE!" tag on the steering wheel. 3. Remove coolant hose (3), T/C oil cooler hose (4),
air cooler hoses (5).
: Air cooler hose band:

1 : 5.7 N-m (0.58 kgf-m) (4.2 lb-ft)
Note
7 6
K85Z544013
7
1. Remove roof (1) from the engine room.
8 K85Z544015
4. Remove hoses (6)~(8) from the fan motor. Use a

drain pan to catch all escaping oil.
Note
80Z5 EX DR 44-59
Fan Motor
12
13
K85Z544016 K85Z544018
5. Remove bolts (9) and release the fan motor bracket 8. Attach sling to the fan motor.
from the base bracket. Slide it to the engine side to Remove nut (12) and bolts (13), and then remove
make clearance between the fan. the fan motor.
: Bolt (9): 94 N-m (9.6 kgf-m) (69 lb-ft) : Nut (12): 355 N-m (36 kgf-m) (262 lb-ft)
: With lubrication oil (engine oil or gear oil) : Screw lock agent (Loctite® 262) application
: Bolt (13): 53 N-m (5.4 kgf-m) (39 lb-ft)

: With lubrication oil (engine oil or gear oil)
: Fan motor: 15 kg (33 lbs)

Fan motor
10
11
K85Z544017
6. Remove retainer bolts (10) for fan (11).
: Bolt (10): 94 N-m (9.6 kgf-m) (69 lb-ft)

: With lubrication oil (engine oil or gear oil)
7. Sling fan (11) 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.
80Z5 EX DR 44-60
Fan Motor
Fan motor installing Fan motor installation cautions
For reinstallation, follow the above procedures in - Do not reuse the flange, and always replace with a
reverse order. new one when the fan motor is replaced.
Flange installation procedure
Clearance
Flange
Nut
K85Z524006
Shaft
K85Z544019
- Be sure that the right and left clearance between the
fan and the radiator guard must be equal.
1. Verify that position of the motor is correct, with the
relief valve positioned to the down.
2. Thoroughly clean and remove all oil from tapered

shaft of motor.
3. Thoroughly clean and remove all oil from tapered

bore of flange.
4. Install flange and tighten the nut with the specified

torque.
: Bolt: 355 N-m (36 kgf-m) (262 lb-ft)

80Z5 EX DR 45-1
45 Service Standard Hydraulic Group
45 Service Standard
Hydraulic Group
Hydraulic Cylinder ................................................... 45-2

Pilot Valve................................................................ 45-4
Steering Valve ......................................................... 45-6
80Z5 EX DR 45-2
Hydraulic Cylinder
Hydraulic Cylinder
Boom cylinder
3
2 1
80ZV45002
Steering cylinder
2 1 3
80V2E45001
Unit: mm (in)
Judgment standard
No. Item Standard Standard value Limit Solution
Standard
dimension of
Rod Bushing clearance Bushing Clearance
rod dia.
-0.030 +0.190 0.090
(-0.0011) (+0.0075) (0.0035)
ø75 +0.290 0.366
Boom cylinder ~ ~ ~ Replacement
(ø2.9527) (+0.0114) (0.0144)
-0.076 +0.060 0.266
(-0.0030) (+0.0023) (0.0104)
-0.036 +0.195 0.090
(-0.0014) (+0.0076) (0.0035)
ø90 +0.295 0.385
1 Bucket cylinder ~ ~ ~ Replacement
(ø3.5433) (+0.0116) (0.0151)
-0.090 +0.060 0.285
(-0.0035) (+0.0023) (0.0112)
-0.025 +0.105 0.030
(-0.0010) (+0.0041) (0.0012)
ø45 +0.205 0.251
Steering cylinder ~ ~ ~ Replacement
(ø1.7716) (+0.0080) (0.0099)
-0.046 0 0.151
(-0.0018) (0) (0.0059)
80Z5 EX DR 45-3
Hydraulic Cylinder
No. Item Boom cylinder Bucket cylinder Steering cylinder

M58 x 2 M68 x 2 M30 x 2
Piston nut tightening torque N-m (kgf-m) (lb-ft)
2 3,923 (400) (2,894) 4,903 (500) (3,618) 930 (94.8) (686)
Piston nut width across flat mm (in) 90 (3.54) 100 (3.94) 46 (1.81)
M22 M22 (Rod cover)
3 Rod cover bolt tightening torque N-m (kgf-m) (lb-ft)
471 (48) (347) 686 (70) (506) 300 (30.6) (221)
80Z5 EX DR 45-4
Pilot Valve
Pilot Valve
K80Z545001
80Z5 EX DR 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
ø8 mm ø7.5 mm
3 Bush with detent
(0.315 in) (0.295 in)
solenoid sub
85V2E45002
80Z5 EX DR 45-6
Steering Valve
Steering Valve
80ZV45001
Tightening torque
Unit: N-m (kgf-m) (lb-ft)
No. Item Standard value Solution
1 Steering valve retainer bolt 49 (5) (36)
Tightening
2 Steering valve bracket retainer bolt 230 (23.5) (170)
80Z5 EX DR 54-1
54 Disassembly & Reassembly Brake Group

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

Manifold Valve Assembly ........................................ 54-6
Accumulator ............................................................ 54-9
Brake Valve ............................................................. 54-14
Service Brake .......................................................... 54-22
Parking Brake Actuator ........................................... 54-23
Parking Brake.......................................................... 54-28
80Z5 EX DR 54-2
Unloader Valve
Unloader Valve
Unloader valve removing and installing

Unloader valve removing
Unloader valve
WARNING
Unexpected movement of the machine could cause 4
5
- Block the front wheels with chocks to prevent the
wheels from moving.
K80Z554002
steering wheel or the operator's seat, or discon-
nect the negative side of the battery.
2. Remove hoses (4)(5) from the unloader valve.
- Stop the engine. Depress the brake pedal many Note
times until there is no brake pressure. Cover the disconnected hoses with plastic, plugs or
- Press the hydraulic tank cap, and relieve the internal caps to protect them from dust and dirt.
- Prepare a container to catch drained oil.
Unloader valve
Unloader valve Brackets

1
Rear chassis
2 K80Z554003
3. Remove bolts (6) and then remove the unloader

K80Z554001 valve.
1. Remove hoses (1)(2)(3) from the unloader valve. : Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft)
: Unloader valve: 4 kg (8.8 lbs)
Note
80Z5 EX DR 54-3
Unloader Valve
Unloader valve installing
To reinstall the unloader valve, follow the above removal

Unloader valve installation cautions
- Replace all O-rings and seals during reinstallation.
- After reinstallation, completely bleed the brake line of

air, and check performance of the unloader valve.
- To bleed the brake line of air, refer to "Service brake

air bleeding procedure" page 24-21.
- To check performance of the unloader valve, refer to

80ZV-2 Shop Manual, Function and Structure, Sec-
tion 53.
80Z5 EX DR 54-4
Unloader Valve
Unloader valve disassembling and

assembling
IMPORTANT
Unloader valve cross section and tighten-

ing torque
T5 T3
T2 L1
T1
T4
T3
T6
T7
K85Z554004
:
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)
T6: 137 N-m (14 kgf-m) (101 lb-ft) Width across flats 41 mm (1.614 in)

80Z5 EX DR 54-5
Unloader Valve
Unloader valve disassembling
Pressure governor assembly
92V2U54005
Remove plug (1), then pull out spool (2) and spring (3).
Note
Carefully remove plug (1). It may spring out by the
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.
Unloader valve assembling
To reassemble the unloader valve, follow the above dis-

assembly procedures in reverse order.
80Z5 EX DR 54-6
Manifold Valve Assembly
Valve assembly removing and

installing
6
Valve assembly removing
7
WARNING
such an accident, observe the following items: Valve assembly
- Block the front wheels with chocks to prevent the K80Z554005
wheels from moving.
3. Remove hoses (6)(7) from the valve assembly.
Note
times until there is no brake pressure. Valve assembly
8 Bracket
1. Repeatedly depress the brake pedal till you feel the

pedal becomes light. That will release oil pressure
in brake line.
Rear chassis
1 K80Z554006
3
Valve
2 assembly
4. Remove bolt (8) and then remove the valve assem-
bly.
4
: Bolt (8): 53 N-m (5.4 kgf-m) (39 lb-ft)

: Valve assembly: 10 kg (22 lbs)
Unloader valve 5
K80Z554004
Valve assembly installing
2. Remove hoses (1)~(5) from the valve assembly. To reinstall the valve assembly, follow the above
removal procedure in reverse order.
Note
80Z5 EX DR 54-7
Valve assembly installation cautions Valve assembly disassembling

and assembling
- Replace all O-rings and seals during reinstallation.
- After reinstallation, completely bleed the brake line of IMPORTANT

air, and check performance of the valve assembly.
To bleed the brake line from air, refer to "Service Before disassembly or reassembly, read and under-
brake air bleeding procedure" page 24-21. stand the aforementioned "Hydraulic Parts Disas-
- To check performance of the valve assembly, refer to
80ZV-2 Shop Manual, Function & Structure, Section
53.
80Z5 EX DR 54-8
Valve assembly cross section and tightening torque
T1 T1 T5
T1
(T)
T4
(P)
(TA)
(PI) (Parking)
ACF
(ACCR) (ACCF)
(PA)
(Z1)
(Z2)
(Z) (PPI)
T3
High pressure
test ports
T2
K80Z554007
:
T1: 50 N-m (5.1 kgf-m) (37 lb-ft)
CAUTION
T2: 23.5 N-m (2.4 kgf-m) (17 lb-ft) High pressure test ports contain accumulator pres-
T3: 38 N-m (3.9 kgf-m) (28 lb-ft) sure [11.8 MPa (1,706 psi)] that can escape from
T4: 11 N-m (1.1 kgf-m) (8 lb-ft) these 2 plugs.
T5: 8 N-m (0.8 kgf-m) (5.8 lb-ft) Completely depress brake pedal 80~100 times to
relieve all pressure before removing plugs.
80Z5 EX DR 54-9
Accumulator
Accumulator
Accumulator removing and install-

ing
Accumulator removing
WARNING 6 Bracket

- Block the front wheels with chocks to prevent the
wheels from moving.
key, and hang a "DO NOT START!" tag on the 5
steering wheel or the operator's seat, or discon- Rear chassis
Accumulator
K80Z554009
1. Repeatedly depress the brake pedal till you feel the 3. Remove bolts (5), nut (6) and then remove the
pedal becomes light. That will release oil pressure accumulator.
in brake line.
: Bolt (5): 53 N-m (5.4 kgf-m) (39 lb-ft)
: Accumulator: 13.5 kg (30 lbs)/pc
2
Accumulator
3
K80Z554008
2. Remove hoses (1)~(4) from the accumulator.
Note
80Z5 EX DR 54-10
Accumulator
Accumulator installing Accumulator disassembling and

assembling
To reinstall the accumulator, follow the above removal
Replace all O-rings and seals during reinstallation. IMPORTANT
Accumulator installation cautions sembly and Assembly Cautions" page 44-3.
- After reinstallation, completely bleed the brake line of

air, and check performance of the accumulator. To Accumulator disassembling
bleed the brake line of air, refer to "Service brake air
bleeding procedure" page 24-21.
WARNING
- To check performance of the accumulator, refer to Disassembly without breathing the inner gas could
80ZV-2 Shop Manual, Function and Structure, Sec- cause serious injury or death by explosion. To pre-
tion 53. vent such an accident, observe the following item:
- Carefully handle the accumulator that has the high
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.
IMPORTANT
- Take care not to scratch the cylinder to prevent gas
leak.
- Carefully remove each part so that it is not
scratched or dented.
80Z5 EX DR 54-11
Accumulator
7 7
2 4 1 3 2 4 1 3
13 13
10 10
12 12
11 11
5,6 8,9 5,6 8,9

97ZV54007 97ZV54007
Hydraulic cap (2)

Gas cap (3)
95ZV54002 95ZV54003
1. Loosen bolt (13) to remove gas valve guard (12). 4. Insert three bolts into hydraulic cap (2) and remove
it by using a long bar.
2. Remove the cap of gas valve (10) and install the
charging valve to gas valve (10), then bleed the gas Screw size: 1/2-20UNF-2B
completely from the accumulator.
5. Push out piston (4) toward the hydraulic end by
3. Insert three pins into gas cap (3). Remove the gas using a bar.
cap by using a long bar.
Pin hole: ø11.4 (0.4 in)

Accumulator assembling
To reassemble the accumulator, follow the above disas-

sembly procedure in reverse order.
After reassembly, carry out the gas charging.
80Z5 EX DR 54-12
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.
80Z5 EX DR 54-13
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.
80Z5 EX DR 54-14
Brake Valve
Brake Valve
Brake valve removing and install-

ing
Brake valve removing
WARNING Brake valve

- Block the front wheels with chocks to prevent the K80Z554010
wheels from moving.
1. Remove all hoses and pipes shown on the above
illustration.
Note
Cover the disconnected hoses and pipes with plastic,
Before starting work: plugs or caps to protect them from dust and dirt.
- Press the hydraulic tank cap, and relieve the internal Brake valve
Cover
K80Z554011
Cover 2. Remove all adapters and fittings and electrical cou-

plers shown on the above illustration.
K90V2E54001
- Remove the cover.

80Z5 EX DR 54-15
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.
80V2E54011
To check or adjust the brake valve, refer to 80ZV-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)

80Z5 EX DR 54-16
Brake Valve
Brake valve disassembling and assembling
IMPORTANT
Brake valve cross section and tightening

torque (main valve)
T1
T2
T4
T3
T2

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)
80V2E54012
80Z5 EX DR 54-17
Brake Valve
Brake valve disassembling

12 13 15 16 15 14 11
Pedal cover 9
10 8 7
85V2E54017
85V2E54015 3. Remove nut (7), washer (8) and bolt (9) to remove
plate (10).
1. Remove the pedal covers.
: Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)
3 6 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.
2 1
19 18 17
20
Shaft assembly
Shaft assembly 5 4
85V2E54016
2. Pull out pin (1). Remove washer (2), right pedal (3),
21
mounting plate (4), pedal collar (5) and spring (6)
from the shaft assembly. 85V2E54018
5. Remove nut (17), washer (18) and bolt (19).
: Bolt: 34.3 N-m (3.5 kgf-m) (25.3 lb-ft)
6. Pull out the shaft assembly and remove left pedal

(20) and pedal collar (21).
80Z5 EX DR 54-18
Brake Valve
38
23 24 26 27 26 25 22
37
34 36
35
85V2E54019 80V2E54013
7. Pull out pin (22), pedal pin (23), L-shape pin (24) 10. Loosen bolt (34) and remove spring washer (35)
and washer (25), and then, remove collar (26) and and mounting plate (36).
roller (27).
: Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)
11. Remove dust cover (37) and seat (38).

32 31 29 28 33
30 Joint
85V2E54020
8. Remove ring (28) and pull out boot (29).
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).
80Z5 EX DR 54-19
Brake Valve
45
44
50
46
49 48
47
Cover
Body 1 Body 2
70V2E54011
41
13. Place the Body 1 and Body 2 on a workbench
upside down. Remove C-ring (44), and then,
42
remove plug (45) and spring (46).
40 14. Slowly pull out spool (47) from the Body 1 and
remove plunger (49). Also pull out spool (48) from
the Body 2 and remove plunger (50).
Body 2 Cover
43
51
Body 1
80V2E54015
39
15. Place the cover on a workbench upside down.

80V2E54014 Slowly pull out spool input (51) together with the
spring and the spring case.
12. Loosen bolt (39), and separate the brake valve into
the Body 1, Body 2 and the Cover. Remove springs
(40)(41)(43) and spring seat (42).
: Bolt: 25.5 N-m (2.6 kgf-m) (18.8 lb-ft)

80Z5 EX DR 54-20
Brake Valve
Brake valve assembling

52 To reassemble the brake valve, follow the above disas-
54 53 sembly procedure in reverse order.
51
80V2E54016
16. Loosen bolt (52) mounted in spool input (51), and

remove retainer (53) and spring seat (54).
: Bolt: 8.83 N-m (0.9 kgf-m) (6.5 lb-ft)
Note
When fixing spool input (51) in a vise to loosen bolt (52),
make sure to protect the spool input with a cloth, etc. to
avoid the damage on the surface of the spool.
56 55
Installation tool
57 40 mm
(1.57 in)
New seal
22 mm
(0.87 in)
Cover Reassembly process
80V2E54017
17. Place the cover on a workbench. Remove C-ring

(55), plate (56) and oil seal (57).
Note
Do not reuse the oil seal; replace it with a new one
when reassembling.
80Z5 EX DR 54-21
Brake Valve
Brake valve assembly cautions Brake pedal adjustment
- Clean and check all the parts. If a part is defective,

replace or repair the part.
0.5 mm (0.02 in)

27
- Apply the specified torque to tighten each main
or less
parts. Adjusting screw

38 Nut
Left pedal
(0.118~0.138 in)
3.0~3.5 mm
Adjusting screw 16
58
Nut
Right pedal
80V2E54018
- Adjust the left pedal using the adjusting screws on

the right and left pedals so that the opening between
seat (38) and roller (27) for the left pedal becomes
0.5 mm (0.02 in) or less when the pedal is not
depressed. Tighten the nut when adjusted.
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 (58) and roller (16) for the right
pedal becomes 3.0~3.5 mm (0.118~0.138 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)

80Z5 EX DR 54-22
Service Brake
Service Brake
Service brake disassembling and 1. Loosen the axle housing air bleeder nipple.
assembling
WARNING
Refer to "Front axle disassembling and assembling" When replacing only the brake discs without remov-
page 24-22 for the procedures. ing the brake piston, loosen the air bleeder nipple
first. Push back the brake piston, and then, install the
brake discs.
If the brake piston is not pushed back, the brake may
drag and the brake discs may seize.
Service brake installation cautions After installing the tires, check that manual rotation of
the tires is possible.
Wheel hub
Socket bolt Brake piston

Spider 85V2E54029
80ZVE53004
WARNING 2. After pushing back the piston, confirm dimension A

Before air bleeding in the brake oil line, be sure that from the piston end face to the wheel hub end face.
the wheel and tire assemblies are installed on the
wheel hub. If fail to do, the bolts (4 pcs) temporarily A: 100.25~101.40 mm (3.95~3.99 in)
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. IMPORTANT
The wheel bearings must be adjusted correctly to get
an accurate measurement for dimension A.
The dimensions should be equal at top and bottom.
Reference
Piston stroke B: 1.55~3.40 mm (0.061~0.134 in)
3. After finishing the installation work, bleed air com-

pletely from the brake line.
80Z5 EX DR 54-23
Parking Brake Actuator
Parking brake actuator removing 1. If there is an oil source, release the parking brake,
and then, remove split pin (1) and pin (2).
and installing
Note
Parking brake actuator removing If there is no oil source, apply a cable to the link, and
then pull it down using a bar to overcome the spring
force, and then remove the pin.
WARNING
Unexpected movement of the machine could cause 2. Release the residual air pressure in hydraulic tank.
serious injury or death. To prevent such an accident, Disconnect oil hose (3).
- When removing the parking brake actuator, the Note
machine may move. To prevent the machine from Cover the disconnected hoses with plastic, plugs or
moving, park the machine on level ground, and caps to protect them from dust and dirt.
lower the attachment onto the ground.
- In addition, block the tires with chocks to prevent 3. Loosen locknut (4) to remove joint (5).
the wheels from moving. Remove retainer bolts (6) to remove parking brake
actuator (7).
: Bolt (6): 53 N-m (5.4 kgf-m) (39 lb-ft)

: Parking brake actuator: 8 kg (18 lbs)
3
Parking brake actuator installing
To reinstall the parking brake actuator, follow the above

removal procedure in reverse order.
7
Note
To insert the connection pin to connect the parking
brake actuator to the parking brake, observe the follow-
6
ing items:
- Start the engine to build oil pressure in the accumu-
lator.
Brake assembly 4 Transmission
- Release the parking brake.
5 - Slightly raise the parking brake lever by hand, and
1 adjust the position of the joint hole between the park-
ing brake actuator and the parking brake. After that,
insert the connection pin into the joint hole.
2 To check performance of the parking brake, refer to
80ZV-2 Shop Manual, Function and Structure, Sec-
tion 53.
80V2E54019
80Z5 EX DR 54-24
Parking brake actuator adjusting Parking brake actuator adjustment procedure
1. Release parking brake (OFF).

WARNING
When remove the parking brake, the machine may 2. Measure dimension "A" if it is 87 mm (3.43 in).
move and it could cause serious injury or death. To
prevent such an accident, observe the following item: 3. If not, remove pin (5), split pin (6), and washer (7)
- Park the machine on level ground. and loosen lock nut (2).
- Lower the attachment onto the ground. And adjust the linkage length by turning link (3) so
- Apply the articulation stopper. that dimension "A" is 87 mm (3.43 in).
4. Tighten lock nut (2) and reinstall pin (5), split pin (6)
and washer (7).
4
5. Confirm the parking brake performance.
1
(Refer to 80ZV-2 Shop Manual, Function & Struc-
ture, Section 53.)
A
2
4
2
3
5,6,7
Parking brake "OFF" position

80ZV54013
1. Parking brake actuator

2. Lock nut
3. Link
4. Bracket
5. Pin
6. Split pin
7. Washer
80Z5 EX DR 54-25
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.
80Z5 EX DR 54-26
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.
80Z5 EX DR 54-27
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. CAUTION
- During reassembling, align the matchmarks and When compressing the spring with the press, press
install the set screw at the same position. the center of the cylinder with the press to prevent the
cylinder from being inclined.
8 Tighten the rod cap to the position where the match-

mark was marked before disassembly, screw in the
4
screw, and punch it for locking.
9
10 6
7
1
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).
80Z5 EX DR 54-28
Parking Brake
Parking Brake
Parking brake removing and installing /

disassembling and assembling
Parking brake removing and disassem-
bling
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:
- Lower the attachment onto the ground. 5
4
80ZV54014
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 application
7
3
90ZV54012J
8
9
2. Release the parking brake, and then remove pin (3)
to disconnect link (1) and lever (2).
6 80V2E54020
4. Remove bolt (6) of the 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)
: Bolt (6): Screw lock agent (Loctite® 262)
: Nut (8): Molybdenum disulfide grease/
MOS2 application
80Z5 EX DR 54-29
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 Service Standard
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 80Z5 Shop Manual, Function and Structure,
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)

80Z5 EX DR 54-30
MEMO
80Z5 EX DR 55-1
55 Service Standard Brake Group
55 Service Standard
Brake Group
Brake Valve ............................................................. 55-2

Service Brake .......................................................... 55-4
Parking Brake.......................................................... 55-5
80Z5 EX DR 55-2
Brake Valve
Brake Valve
7
6
2
5 3
2
3
80V2E55001
80Z5 EX DR 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)
Replacement
6 Control spring 56.4 (2.2205) 48.8 (1.9212) 110 (11.2) (24.7) — 94 (9.6) (21)
7 Return spring 81 (3.1890) 55 (2.1653) 118 (12) (26.5) — 100 (10.2) (22.5)
80Z5 EX DR 55-4
Service Brake
Service Brake
1 3
Slide caliper
Backing
plate
1
(Steel plate)
2
(Friction plate)
80ZV55001
Unit: mm (in)
Judgment standard
No. Item Solution
Standard dimension Tolerance Wear limit
Thickness 4.9 (0.1929) ±0.1 (±0.0039) 4.4 (0.1732)
1 Steel plate 0.30 (0.0118) 0.30 (0.0118)
Distortion —
or less and more
Replacement
2 Thickness of friction plate 7.2 (0.2682) ±0.15 (±0.0059) 5.9 (0.2322)
Thickness of brake disc when mea-
3 17.2 (0.6772) ±0.2 (±0.0078) 15.1 (0.5944)
sured by calipers (with brake applied)
(Manufacturing dimension) -0.220 (-0.0086)~
Outer dia. —
355 (13.9763) -0.290 (-0.0114)
4 Piston seal contact face —
(Manufacturing dimension) +0.05 (+0.0019)~
Inner dia. —
285 (11.2205) +0.15 (+0.0059)
80Z5 EX DR 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.
80Z5 EX DR 55-6
MEMO
80Z5 EX DR 74-1
74 Disassembly & Reassembly Operator Station Group

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

80Z5 EX DR 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
80Z5 EX DR 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).
80Z5 EX DR 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)
80Z5 EX DR 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)
80Z5 EX DR 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)
80Z5 EX DR 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.
80Z5 EX DR 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).

80Z5 EX DR 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.
80Z5 EX DR 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. Incorrect positioning of the thermistor may
13 cause frost or temperature control malfunction.
11
18
17
14 21
12
95V2U74014
19
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).
14 15
12. Remove tapping screw (19) and remove clamp 2
(20).
13. Pull heater core (21) upward and remove it.
95V2U74015
9. Remove bolt (15) (2 pcs) and then remove expan-

sion valve (14).
80Z5 EX DR 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).

80Z5 EX DR 74-12
MEMO
80Z5 EX DR 75-1
75 Service Standard Operator Station Group
75 Service Standard
Operator Station Group
Air Conditioner ........................................................ 75-2

80Z5 EX DR 75-2
75 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 assembly cautions ...................................... 54-21
Accumulator ......................................................................54-9 Brake valve cross section and tightening torque
Accumulator assembling .................................................54-11 (main valve) ............................................................... 54-16
Accumulator disassembling ............................................54-10 Brake valve disassembling ............................................. 54-17
Accumulator disassembling and assembling ..................54-10 Brake valve disassembling and assembling ................... 54-16
Accumulator installation cautions ...................................54-10 Brake valve installation cautions .................................... 54-15
Accumulator installing .....................................................54-10 Brake valve installing ...................................................... 54-15
Accumulator removing ......................................................54-9 Brake valve removing ..................................................... 54-14
Accumulator removing and installing ................................54-9 Brake valve removing and installing ............................... 54-14
Air Cleaner ......................................................................24-14 Bucket cylinder installation cautions ............................... 44-12
Air cleaner installation cautions ......................................24-15 Bucket cylinder installing ................................................ 44-11
Air cleaner installing ........................................................24-15 Bucket cylinder removing ............................................... 44-10
Air cleaner removing .......................................................24-14 Bucket cylinder removing and installing ......................... 44-10
Air cleaner removing and installing .................................24-14
Air Conditioner ........................................................ 74-2, 75-2 C
Air conditioner assembling ..............................................74-11 Cab ................................................................................. 14-10
Air conditioner disassembling ...........................................74-7 Cab installing .................................................................. 14-11
Air conditioner disassembling and assembling .................74-4 Cab removing ................................................................. 14-10
Air conditioner installing ....................................................74-3 Cab removing and installing ........................................... 14-10
Air conditioner removing ...................................................74-2 Cautions Regarding Handling of Bearing ....................... 00-13
Air conditioner removing and installing .............................74-2 Cautions regarding parts removal .................................... 00-9
Air conditioner tightening torque .......................................74-4 Cautions regarding reassembly ........................................ 00-9
Applying and Storing Articulation Stopper ......................00-15 Cautions Regarding Welding Repair Service ................. 00-11
Applying articulation stopper ...........................................00-15 Center Pin ............................................................. 14-18, 15-5
Attachment Leveler ...........................................................15-7 Center pin installation cautions ...................................... 14-23
Attachment leveler ............................................................15-8 Center pin installing ........................................................ 14-23
Attachment leveler adjustable angle .................................15-8 Center pin removing ....................................................... 14-20
Axle and Differential Service Standard .............................25-3 Center pin removing and installing ................................. 14-20
Axle group .........................................................................25-3 Center pin shim adjustment ................................... 14-18, 15-5
Axle nut tightening ..........................................................24-28 Clutch Oil Pressure .......................................................... 35-8
Axle nut tightening procedure ............................. 24-18, 24-42 Clutch oil pressure standard value ................................... 35-8
Axle Support ...................................................................24-46 Clutch plate ...................................................................... 35-7
Axle support assembling .................................................24-47 Clutch Plate Thickness/Piston Stroke .............................. 35-6
Axle support assembly cautions .....................................24-48 Control Valve .................................................................... 35-3
Axle support disassembling ............................................24-47 Control valve assembling ............................................... 34-46
Axle support disassembling and assembling ..................24-47 Control Valve Assembly ................................................. 34-42
Axle support tightening torque ........................................24-46 Control valve assembly cautions .................................... 34-46
Control valve disassembling ........................................... 34-45
B Control valve disassembling and assembling ................ 34-45
Bearing cover installing .....................................................15-5 Control valve installation cautions .................................. 34-44
Bearing installation cautions ...........................................00-13 Control valve removing ................................................... 34-43
Bearing operation test after installation ..........................00-14 Control valve removing and installing ............................. 34-43
Bearing removal cautions ...............................................00-14 Control valve tightening torque ....................................... 34-42
Bolt Tightening Torque .....................................................00-4
Boom ..............................................................................14-15 D
Boom cylinder installation cautions .................................44-10 Deck ................................................................................. 14-2
Boom cylinder installing ....................................................44-9 Deck installing .................................................................. 14-3
Boom cylinder removing ...................................................44-8 Deck removing ................................................................. 14-2
Boom cylinder removing and installing .............................44-8 Deck removing and installing ........................................... 14-2
Boom installation cautions ..............................................14-17 Differential ........................................................................ 25-4
Boom installing ...............................................................14-17 Differential Assembly ...................................................... 24-49
Boom removing ...............................................................14-15 Differential assembly assembling ................................... 24-57
Boom removing and installing .........................................14-15 Differential assembly disassembling .............................. 24-53
Brake adjustment ............................................................24-29 Differential assembly disassembling and assembling
Brake Valve .......................................................... 54-14, 55-2 .................................................................................... 24-51
Brake valve assembling ..................................................54-20 Differential assembly installation cautions ...................... 24-50
Differential assembly installing ....................................... 24-50 H
Differential assembly removing ...................................... 24-49 Hose Band Tightening Torque .......................................... 00-8
Differential assembly removing and installing ................ 24-49 How to wind a seal tape ................................................. 00-10
Hydraulic Cylinder ...................................................44-8, 45-2
E Hydraulic cylinder assembling ........................................ 44-19
Engine .............................................................................. 24-9 Hydraulic cylinder assembly cautions ............................. 44-19
Engine installation cautions ............................................ 24-11 Hydraulic cylinder cross section and tightening torque
Engine installing ............................................................. 24-11 ....................................................................................44-15
Engine removing .............................................................. 24-9 Hydraulic cylinder disassembling ................................... 44-17
Engine removing and installing ........................................ 24-9 Hydraulic cylinder disassembling and assembling ......... 44-15
Engine Room ................................................................... 14-7 Hydraulic parts assembly cautions ................................... 44-3
Engine room installation cautions .................................... 14-9 Hydraulic Parts Disassembly and Assembly Cautions
Engine room installing ...................................................... 14-9 ......................................................................................44-3
Engine room removing ..................................................... 14-7 Hydraulic parts disassembly cautions ..............................44-3
Engine room removing and installing ............................... 14-7 Hydraulic Parts Removal and Installation Warning ..........44-2
Hydraulic Pump Assembly ................................................ 44-4
Hydraulic pump assembly cross section and
F tightening torque ..........................................................44-6
Fan ................................................................................... 24-7 Hydraulic pump assembly disassembling and
Fan installation cautions ................................................... 24-8 assembling ...................................................................44-6
Fan installing .................................................................... 24-8 Hydraulic pump assembly installing .................................44-4
Fan Motor ....................................................................... 44-58 Hydraulic pump assembly removing .................................44-4
Fan motor installation cautions ...................................... 44-60 Hydraulic pump assembly removing and installing ........... 44-4
Fan motor installing ........................................................ 44-60 Hydraulic pump installation cautions ................................ 44-5
Fan motor removing ....................................................... 44-58 Hydraulic Tank ..................................................................14-5
Fan motor removing and installing ................................. 44-58 Hydraulic tank installation cautions .................................. 14-6
Fan removing ................................................................... 24-7 Hydraulic tank installing ....................................................14-6
Fan removing and installing ............................................. 24-7 Hydraulic tank removing ................................................... 14-5
Floating seal installation ........................... 24-18, 24-26, 24-42 Hydraulic tank removing and installing ............................. 14-5
Floor Board .................................................................... 14-12
Floor board installation cautions .................................... 14-14
Floor board installing ...................................................... 14-14 I
Floor board removing ..................................................... 14-12 Interference fits for a bearing ..........................................00-13
Floor board removing and installing ............................... 14-12 Internal Gear Hub ...........................................................24-31
Forward/reverse clutch pack assembling ....................... 34-34 Internal gear hub assembling ......................................... 24-32
Forward/reverse clutch pack assembly cautions ........... 34-34 Internal gear hub assembly cautions .............................. 24-33
Forward/reverse clutch pack disassembling .................. 34-32 Internal gear hub disassembling .....................................24-31
Forward/reverse clutch pack disassembling and Internal gear hub disassembling and assembling .......... 24-31
assembling ................................................................. 34-32 Internal gear hub installation ..........................................24-28
Front axle assembling .................................................... 24-25
Front Axle Assembly ...................................................... 24-17 J
Front axle assembly cautions ......................................... 24-26 Joint between the torque converter and the engine ......... 34-9
Front axle assembly installation cautions ....................... 24-21
Front axle assembly installing ........................................ 24-20
Front axle assembly removing ....................................... 24-19 L
Front axle assembly removing and installing ................. 24-19 Liner clearance adjustment .............................................. 15-4
Front axle assembly tightening torque ........................... 24-17 Linkage ............................................................................. 15-2
Front axle disassembling ............................................... 24-22 Linkage Pin Standard Clearance Values .......................... 15-3
Front axle disassembling and assembling ..................... 24-22 Liquid Gasket and Screw Lock Agent ............................... 00-9
Front differential tightening torque ................................. 24-51 Lower center pin ............................................................. 14-19
Fuel Tank ......................................................................... 14-4 Lower center pin bearing outer ring installing ...................15-6
Fuel tank installation cautions .......................................... 14-4
Fuel tank installing ........................................................... 14-4 M
Fuel tank removing ........................................................... 14-4 Manifold Valve Assembly ................................................. 54-6
Fuel tank removing and installing ..................................... 14-4 Muffler ............................................................................. 24-16
Muffler installation cautions ............................................ 24-16
G Muffler installing ..............................................................24-16
Gear Pump ....................................................................... 35-5 Muffler removing ............................................................. 24-16
Gear pump specifications ................................................. 35-5 Muffler removing and installing .......................................24-16
Multiple Control Valve .....................................................44-33
Multiple control valve assembling ...................................44-38 Propeller Shaft ................................................................ 24-12
Multiple control valve assembly cautions ........................44-38 Propeller shaft installation cautions ................................ 24-13
Multiple control valve cross section and Propeller shaft installing ................................................. 24-13
tightening torque .........................................................44-35 Propeller shaft removing and installing .......................... 24-12
Multiple control valve disassembling ..............................44-36 Propeller Shaft Service Standard ..................................... 25-2
Multiple control valve disassembling and
assembling .................................................................44-35
R
Multiple control valve installation cautions ......................44-34
Radiator ............................................................................ 24-3
Multiple control valve installing .......................................44-34
Radiator installation cautions ........................................... 24-6
Multiple control valve removing ......................................44-33
Radiator installing ............................................................. 24-6
Multiple control valve removing and installing ................44-33
Radiator removing ............................................................ 24-4
Radiator removing and installing ...................................... 24-4
N Radiator tightening torque ................................................ 24-3
Nitrogen gas charging .....................................................54-12 Rear Axle Assembly ....................................................... 24-41
Nitrogen gas charging procedure ...................................54-12 Rear axle assembly installing ......................................... 24-45
Rear axle assembly removing ........................................ 24-43
Rear axle assembly removing and installing .................. 24-43
O
Rear axle assembly tightening torque ............................ 24-41
Oil seal replacement procedure ........................................44-7
Rear axle disassembling and assembling ...................... 24-45
Orbitrol® ..........................................................................44-39
Rear differential tightening torque .................................. 24-52
Orbitrol® assembling .......................................................44-45
Orbitrol® cross section and tightening torque .................44-41
Orbitrol® disassembling ..................................................44-42 S
Orbitrol® disassembling and assembling ........................44-41 Screw lock agent application procedure ......................... 00-10
Orbitrol® installation cautions ..........................................44-40 Second propeller shaft removing .................................... 24-12
Orbitrol® installing ...........................................................44-40 Service Brake ........................................................ 54-22, 55-4
Orbitrol® removing ..........................................................44-39 Service brake air bleeding procedure ............................. 24-21
Orbitrol® removing and installing ....................................44-39 Service brake disassembling and assembling ............... 54-22
Service brake installation cautions ................................. 54-22
Special Tool .................................................................... 24-36
P
Special tool for axle ........................................................ 24-36
Parking Brake ....................................................... 54-28, 55-5
Spider Assembly ............................................................ 24-34
Parking Brake Actuator ...................................................54-23
Spider assembly assembling .......................................... 24-35
Parking brake actuator adjusting ....................................54-24
Spider assembly assembly cautions .............................. 24-35
Parking brake actuator assembling ................................54-27
Spider assembly disassembling ..................................... 24-34
Parking brake actuator cross section and
Spider assembly disassembling and assembling ........... 24-34
tightening torque .........................................................54-25
Steering cylinder installation cautions ............................ 44-14
Parking brake actuator disassembling ............................54-26
Steering cylinder installing .............................................. 44-14
Parking brake actuator disassembling and
Steering cylinder removing ............................................. 44-13
assembling .................................................................54-25
Steering cylinder removing and installing ....................... 44-13
Parking brake actuator installing .....................................54-23
Steering Valve ....................................................... 44-49, 45-6
Parking brake actuator removing ....................................54-23
Steering valve assembling ............................................. 44-53
Parking brake actuator removing and installing ..............54-23
Steering valve cross section and tightening torque ........ 44-51
Parking brake installing and assembling ........................54-29
Steering valve disassembling ......................................... 44-52
Parking brake removing and disassembling ...................54-28
Steering valve disassembling and assembling ............... 44-51
Parking brake removing and installing / disassembling and
Steering valve installing .................................................. 44-50
assembling .................................................................54-28
Steering valve removing ................................................. 44-49
Periodical Inspection/Servicing .........................................75-2
Steering valve removing and installing ........................... 44-49
Pilot Valve ............................................................. 44-21, 45-4
Stop Valve ...................................................................... 44-54
Pilot valve assembling ....................................................44-32
Stop valve assembling ................................................... 44-57
Pilot valve assembly cautions .........................................44-32
Stop valve cross section and tightening torque .............. 44-56
Pilot valve cross section and tightening torque ...............44-24
Stop valve disassembling ............................................... 44-57
Pilot valve disassembling ................................................44-26
Stop valve disassembling and assembling ..................... 44-56
Pilot valve disassembling and assembling .....................44-23
Stop valve installation cautions ...................................... 44-55
Pilot valve installation cautions .......................................44-22
Stop valve installing ........................................................ 44-54
Pilot valve installing ........................................................44-22
Stop valve removing ....................................................... 44-54
Pilot valve removing ........................................................44-21
Stop valve removing and installing ................................. 44-54
Pilot valve removing and installing ..................................44-21
Storing articulation stopper ............................................. 00-15
Piston stroke .....................................................................35-7
Symbols ............................................................................ 00-2
Power Line ........................................................................24-2
Power line tightening torque .............................................24-2
T Unloader valve disassembling and assembling ................54-4
Third propeller shaft removing ....................................... 24-13 Unloader valve installation cautions .................................54-3
Tightening torque for hose and pipes ............................... 75-2 Unloader valve installing ................................................... 54-3
Tightening torque for screws and bolts in special Unloader valve removing ..................................................54-2
control regions ............................................................. 75-2 Unloader valve removing and installing ............................ 54-2
Torque Converter and Transmission Assembly ............... 34-2 Upper center pin ............................................................. 14-18
Torque converter and transmission assembly installing
...................................................................................... 34-8 V
Torque converter and transmission assembly removing Valve assembly cross section and tightening torque ........54-8
...................................................................................... 34-3 Valve assembly disassembling and assembling .............. 54-7
Torque converter and transmission assembly removing and Valve assembly installation cautions ................................ 54-7
installing ....................................................................... 34-3 Valve assembly installing ................................................. 54-6
Torque converter and transmission assembly Valve assembly removing ................................................. 54-6
tightening torque .......................................................... 34-2 Valve assembly removing and installing ...........................54-6
Torque Converter Assembly .......................................... 34-11
Torque converter assembly assembling ........................ 34-15
Torque converter assembly bolt tightening torque ......... 34-11 W
Torque converter assembly disassembling .................... 34-12 Weight of Main Components ............................................00-3
Torque converter assembly disassembling and
assembling ................................................................. 34-12
Transmission 1st/3rd speed clutch pack assembling
.................................................................................... 34-36
Transmission 1st/3rd speed clutch pack assembly
cautions ..................................................................... 34-36
Transmission 1st/3rd speed clutch pack disassembling
.................................................................................... 34-35
Transmission 1st/3rd speed clutch pack disassembling and
assembling ................................................................. 34-35
Transmission 2nd Speed Clutch Pack ........................... 34-37
Transmission 2nd speed clutch pack assembling .......... 34-38
Transmission 2nd speed clutch pack assembly cautions
.................................................................................... 34-38
Transmission 2nd speed clutch pack disassembling
.................................................................................... 34-37
Transmission 2nd speed clutch pack disassembling and
assembling ................................................................. 34-37
Transmission 4th Speed Clutch Pack ............................ 34-39
Transmission 4th speed clutch pack assembling ........... 34-40
Transmission 4th speed clutch pack assembly cautions
.................................................................................... 34-41
Transmission 4th speed clutch pack disassembling
.................................................................................... 34-39
Transmission 4th speed clutch pack disassembling and
assembling ................................................................. 34-39
Transmission Assembly ........................................ 34-19, 35-2
Transmission assembly assembling .............................. 34-25
Transmission assembly bolt tightening torque ............... 34-19
Transmission assembly disassembling .......................... 34-21
Transmission assembly disassembling and assembling
.................................................................................... 34-21
Transmission assembly installation cautions ................... 34-9
Transmission assembly operation check ......................... 34-9
Transmission Forward/Reverse Clutch Pack ................. 34-32
U
Unloader Valve ................................................................. 54-2
Unloader valve assembling .............................................. 54-5
Unloader valve cross section and tightening torque ........ 54-4
Unloader valve disassembling ......................................... 54-5
MEMO
Maintenance Log
Date Machine hours Service performed

Notes

80Z5 (Ex D&R) 00563

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80Z5 (Ex D&R) 00563

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93209-00563

Powered by HINO J08C-TI ENGINE

Disassembly & Reassembly

- Remove the cable from the battery before starting

- 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

- To remove a heavy unit (20 kg (40 lbs) or more), be

- Just after stopping operation, be careful not to

- Contact tire manufacturer's local dealer for tire ser-

Orbitrol® .......................................................................................................................................................... 44-39

Orbitrol® removing and installing ............................................................................................................... 44-39

Orbitrol® disassembling and assembling .................................................................................................. 44-41

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

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

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

Cautions Regarding Welding Repair Service

Do not ground this section.

Do not ground this section.

6. 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

Storing articulation stopper

1. Park the machine so that the frame is straight