70ziv 2 (Exp D&R) (93208 00661)

93208-00661
70ZIV-2
April 2019
SHOP MANUAL
SHOP MANUAL
WHEEL LOADER
Service Standard
Disassembly & Reassembly
70ZIV-2
General Information
93208-00661 Service Standard
Powered by ISUZU A-6BG1T Engine
Serial No. 70J1-1001 and up

©2019 Hitachi Construction Machinery Co., Ltd. All rights reserved. Printed in Japan (k) 70J1-7101 and up
( 輸出一般用 )
93208-00661
April 2019
Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.

Service Standard
Note:
For Troubleshooting and Measurement for Performance Check, refer to the 70ZIV-2 Shop Manual (93208-
00053).
For General Information and Function & Structure, refer to the 70ZIV-2 Shop Manual (93208-00651).
For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
The purpose of this manual is to provide information on the product and the correct maintenance and repair 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 OPERATE!"
tag to the steering wheel.
- Be sure to release the internal pressure before you

remove a pipe, such as the hydraulic oil, air, or
engine coolant pipe.
- Be sure to apply the articulation stopper before 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.
CONTENTS
70ZIV-2 General Information ................................................................................................................................. 00-1
Symbols ............................................................................................................................................................ 00-2
Weight of Main Components ............................................................................................................................. 00-3
Bolt Tightening Torque ...................................................................................................................................... 00-4
Hose Band Tightening Torque ........................................................................................................................... 00-8
Liquid Gasket and Screw Lock Agent ............................................................................................................... 00-9
Cautions regarding parts removal ............................................................................................................... 00-9
Cautions regarding reassembly .................................................................................................................. 00-9
Screw lock agent application procedure ................................................................................................... 00-10
How to wind a seal tape ............................................................................................................................ 00-10
Cautions Regarding Welding Repair Service ...................................................................................................00-11
Applying and Storing Articulation Stopper ....................................................................................................... 00-13
Applying articulation stopper ..................................................................................................................... 00-13
Storing articulation stopper ....................................................................................................................... 00-13
70ZIV-2 Disassembly & Reassembly Chassis Group ........................................................................................... 14-1

Deck .................................................................................................................................................................. 14-2
Deck removing and installing ...................................................................................................................... 14-2
Fuel Tank .......................................................................................................................................................... 14-3
Fuel tank removing and installing ............................................................................................................... 14-3
Hydraulic Tank .................................................................................................................................................. 14-4
Hydraulic tank removing and installing ....................................................................................................... 14-4
Hydraulic tank return filter removing and installing ..................................................................................... 14-6
Hydraulic tank breather valve disassembling and assembling ................................................................... 14-7
Engine Room .................................................................................................................................................... 14-9
Engine room removing and installing .......................................................................................................... 14-9
Cab ................................................................................................................................................................. 14-12
Cab removing and installing ...................................................................................................................... 14-12
Floor Board ..................................................................................................................................................... 14-14
Floor board removing and installing .......................................................................................................... 14-14
Boom ............................................................................................................................................................... 14-16
Boom removing and installing ................................................................................................................... 14-16
Dust Seal ........................................................................................................................................................ 14-19
Dust seal removing and installing ............................................................................................................. 14-19
Bushing ........................................................................................................................................................... 14-20
Bushing removing and installing ............................................................................................................... 14-20
Center Pin ....................................................................................................................................................... 14-21
Upper center pin ........................................................................................................................................ 14-21
Lower center pin ........................................................................................................................................ 14-22
Center pin removing and installing ............................................................................................................ 14-23
70ZIV-2 Service Standard Chassis Group ............................................................................................................ 15-1

Linkage .............................................................................................................................................................. 15-2
Linkage Pin Standard Clearance Values ........................................................................................................... 15-3
Liner clearance adjustment ......................................................................................................................... 15-4
Center Pin ......................................................................................................................................................... 15-5
Center pin shim adjustment ........................................................................................................................ 15-5
Grease nipple installing ............................................................................................................................... 15-5
Lower center pin bearing outer ring installing ............................................................................................. 15-6
Bucket ............................................................................................................................................................... 15-7
Bucket Positioner and Boom Kick-Out (Option) ................................................................................................ 15-8
Bucket positioner ......................................................................................................................................... 15-9
Boom kick-out (option) .............................................................................................................................. 15-10
70ZIV-2 Disassembly & Reassembly Power Group .............................................................................................. 24-1

Power Line ........................................................................................................................................................ 24-2
Power line tightening torque ........................................................................................................................ 24-2
Radiator ............................................................................................................................................................. 24-3
Radiator tightening torque ........................................................................................................................... 24-3
Radiator removing and installing ................................................................................................................. 24-4
Engine ............................................................................................................................................................... 24-7
Engine removing and installing ................................................................................................................... 24-7
Propeller Shaft .................................................................................................................................................. 24-9
Propeller shaft removing and installing ....................................................................................................... 24-9
Air Cleaner ...................................................................................................................................................... 24-11
Air cleaner removing and installing ........................................................................................................... 24-11
Muffler ............................................................................................................................................................. 24-13
Muffler removing and installing ................................................................................................................. 24-13
Front Axle Assembly ....................................................................................................................................... 24-14
Front axle assembly tightening torque ...................................................................................................... 24-14
Front axle assembly removing and installing ............................................................................................ 24-16
Planetary assy disassembling and assembling ........................................................................................ 24-19
Floating Seal (S/N 1201~, 7201~) .................................................................................................................. 24-25
Floating seal installation ............................................................................................................................ 24-25
Floating seal assembling .......................................................................................................................... 24-26
Internal Gear Hub ........................................................................................................................................... 24-27
Internal gear hub disassembling and assembling ..................................................................................... 24-27
Spider Assembly ............................................................................................................................................. 24-29
Spider assy disassembling and assembling ............................................................................................. 24-29
Special Tool ..................................................................................................................................................... 24-31
Special tool for axle ................................................................................................................................... 24-31
Rear Axle Assembly ........................................................................................................................................ 24-36
Rear axle assembly tightening torque ....................................................................................................... 24-36
Rear axle assembly removing and installing ............................................................................................. 24-38
Axle Support ................................................................................................................................................... 24-41
Axle support tightening torque .................................................................................................................. 24-41
Axle support disassembling and assembling ............................................................................................ 24-43
Differential Assembly ...................................................................................................................................... 24-47
Differential assembly removing and installing ........................................................................................... 24-47
Differential assembly disassembling and assembling ............................................................................... 24-49
Front Differential ............................................................................................................................................. 24-62
Front differential removing and installing .................................................................................................. 24-62
70ZIV-2 Service Standard Power Group ............................................................................................................... 25-1

Propeller Shaft Service Standard ...................................................................................................................... 25-2
Axle and Differential Service Standard .............................................................................................................. 25-3
Axle group ................................................................................................................................................... 25-3
Differential ................................................................................................................................................... 25-4
70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group .............................................. 34-1
Torque Converter and Transmission Assembly ................................................................................................. 34-2
Torque converter and transmission assembly tightening torque ................................................................. 34-2
Torque converter and transmission assembly removing and installing ....................................................... 34-3
Transmission assembly bolt tightening torque ............................................................................................ 34-8
Transmission Assembly .................................................................................................................................. 34-10
Transmission assembly disassembling and assembling ........................................................................... 34-10
Torque Converter ............................................................................................................................................ 34-16
Torque converter assembly disassembling and assembling ..................................................................... 34-16
Transmission Clutch Pack ............................................................................................................................... 34-18
Forward/reverse clutch pack disassembling and assembling ................................................................... 34-18
Control Valve Assembly .................................................................................................................................. 34-23
Control valve removing and installing ....................................................................................................... 34-23
Control valve disassembling and assembling ........................................................................................... 34-26
70ZIV-2 Service Standard Torque Converter and Transmission Group ............................................................... 35-1
Torque Converter and Transmission Assembly ................................................................................................. 35-2
70ZIV-2 Disassembly & Reassembly Hydraulic Group ......................................................................................... 44-1

Hydraulic Parts Removal and Installation Warning ........................................................................................... 44-2
Hydraulic Parts Disassembly and Assembly Cautions ...................................................................................... 44-3
Hydraulic parts disassembly cautions ......................................................................................................... 44-3
Hydraulic parts assembly cautions .............................................................................................................. 44-3
Gear Pump ........................................................................................................................................................ 44-4
Gear pump tightening torque ...................................................................................................................... 44-5
Gear pump assembly removing and installing ............................................................................................ 44-6
Gear pump assembly disassembling and assembling ................................................................................ 44-8
Steering Valve (S/N ~2200, ~8250) ................................................................................................................. 44-12
Steering valve removing and installing ...................................................................................................... 44-13
Steering valve disassembling and assembling ......................................................................................... 44-15
Multiple Control Valve ...................................................................................................................................... 44-18
Multiple control valve removing and installing ........................................................................................... 44-18
Multiple control valve disassembling and assembling (S/N ~1481) .......................................................... 44-20
Multiple control valve disassembling and assembling (S/N 1482~) .......................................................... 44-29
Hydraulic Cylinder ........................................................................................................................................... 44-33
Boom cylinder removing and installing ..................................................................................................... 44-33
Bucket cylinder removing and installing .................................................................................................... 44-35
Steering cylinder removing and installing .................................................................................................. 44-37
Hydraulic cylinder disassembling and assembling .................................................................................... 44-39
Pilot Valve ....................................................................................................................................................... 44-51
Pilot valve removing and installing ............................................................................................................ 44-53
Pilot valve disassembling and assembling ................................................................................................ 44-55
Orbitrol® (S/N 2201~, 8251~) .......................................................................................................................... 44-60
Orbitrol® removing and installing ............................................................................................................... 44-60
Orbitrol® disassembling and assembling .................................................................................................. 44-62

Priority Valve (S/N 2201~, 8251~) ................................................................................................................... 44-72
Priority valve removing and installing ........................................................................................................ 44-72
Priority valve disassembling and assembling ........................................................................................... 44-73
Accumulator (S/N 2201~, 8251~) ................................................................................................................... 44-74
Accumulator removing and installing ........................................................................................................ 44-74
70ZIV-2 Service Standard Hydraulic Group .......................................................................................................... 45-1

Steering Linkage (S/N ~2200, ~8250) ............................................................................................................... 45-2
Steering linkage tightening torque .............................................................................................................. 45-3
Gear Pump ........................................................................................................................................................ 45-4
Hydraulic Cylinder ............................................................................................................................................. 45-5
Pilot Valve ......................................................................................................................................................... 45-6
70ZIV-2 Disassembly & Reassembly Brake Group .............................................................................................. 54-1

Brake Valve Assembly ...................................................................................................................................... 54-2
Brake valve removing and installing ........................................................................................................... 54-2
Brake valve disassembling and assembling ............................................................................................... 54-3
Air Master Assembly ......................................................................................................................................... 54-6
Air master removing and installing .............................................................................................................. 54-6
Air master disassembling and assembling .................................................................................................. 54-7
Service Brake ...................................................................................................................................................54-11
Service brake disassembling and assembling ...........................................................................................54-11
Air Cylinder for Parking Brake ......................................................................................................................... 54-12
Parking brake air cylinder removing and installing .................................................................................... 54-12
Parking brake air cylinder disassembling and assembling ........................................................................ 54-14
Parking Brake .................................................................................................................................................. 54-17
Parking brake removing and installing ...................................................................................................... 54-17
Air Tank ........................................................................................................................................................... 54-19
Air tank removing and installing ................................................................................................................ 54-19
70ZIV-2 Service Standard Brake Group ................................................................................................................ 55-1

Brake Valve ....................................................................................................................................................... 55-2
Air Master .......................................................................................................................................................... 55-4
Service Brake .................................................................................................................................................... 55-5
Parking Brake .................................................................................................................................................... 55-6
70ZIV-2 Disassembly & Reassembly Electrical Group ......................................................................................... 64-1

Wiper Motor ....................................................................................................................................................... 64-2
Front wiper motor removing and installing .................................................................................................. 64-2
Rear wiper motor removing and installing ................................................................................................... 64-4
Controller ........................................................................................................................................................... 64-5
Controller removing and installing ............................................................................................................... 64-5
Fuse Box ........................................................................................................................................................... 64-6
Fuse box removing and installing ................................................................................................................ 64-6
70ZIV-2 Disassembly & Reassembly Operator Station Group .............................................................................. 74-1

Air Conditioner .................................................................................................................................................. 74-2
Air conditioner removing and installing ....................................................................................................... 74-3
A/C condenser removing and installing ....................................................................................................... 74-5
A/C compressor removing and installing ..................................................................................................... 74-6
70ZIV-2 Service Standard Operator Station Group ............................................................................................... 75-1

Air Conditioner .................................................................................................................................................. 75-2
Periodical inspection/servicing .................................................................................................................... 75-2
Tightening torque ........................................................................................................................................ 75-2
Compressor adjustment standard ............................................................................................................... 75-3
00-1
70ZIV-2 General Information
Symbols .................................................................. 00-2

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

weight weight Remarks
Unit name Part name (kg) (lb)
Bucket 1,065 2,340 GSN bucket
Boom 810 1,780
"Z" -Lever 255/pc 565/pc
Link (Bucket to Lever) 45/pc 95/pc
Engine room assembly 260 570
Hydraulic tank 145 320 Excluding oil
Chassis Fuel tank 155 340 Excluding fuel
Floor board 150 330
Cab (ROPS) 560 1,230
Deck 45 100 With handrail
Front chassis 1,130 2,490
Rear chassis 1,010 2,220
Counter weight 670 1,480
Engine 515 1,130 Excluding oil
(S/N ~2550) 130 290
Radiator assembly Excluding water and oil
(S/N 2551~) 90 200
Transmission 515 1,130 Excluding oil
Cooling unit (S/N 2551~) 7.5 16.5 Torque converter oil cooler
Second propeller shaft 50 110
Power line
Third propeller shaft 7 15
Air cleaner 7 15
Muffler 7 15
Front axle assembly 840 1,850 Excluding tires and oil
Rear axle assembly 940 2,070 Excluding tires and oil (Including axle support)
Differential 130 290
Multiple control valve 55 120
Steering valve 35 80
®
Orbitrol (S/N 2201~, 8251~) 7 15
(S/N ~1200, ~7200) 45 100
Hydraulic system Gear pump
(S/N 1201~, 7201~) 30 66
Boom cylinder 145/pc 320/pc Excluding oil
Bucket cylinder 140/pc 310/pc Excluding oil
Steering cylinder 25/pc 55/pc Excluding oil
Tire 275/pc 610/pc With rim (20.5-25-16PR)
Other Battery 35/pc 80/pc
Air conditioner unit 40 88 In CAB
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 dia.
M8 8 (C) 1.25 26 38
(C) 1.5 53 76
M10 10
(F) 1.25 55 80
(C) 1.75 90 132
M12 12
(F) 1.25 96 142
(C) 2.0 142 206
M14 14
(F) 1.5 152 221
(C) 2.0 216 314
M16 16
(F) 1.5 226 330
(C) 2.5 299 436
M18 18
(F) 1.5 324 476
Metric thread (C) 2.5 417 608
M20 20
(F) 1.5 451 662
(C) 2.5 559 814
M22 22
(F) 1.5 598 878
(C) 3.0 721 1,030
M24 24
(F) 2.0 770 1,128
(C) 3.0 1,030 1,520
M27 27
(F) 2.0 1,128 1,618
(C) 3.5 1,422 2,109
M30 30
(F) 2.0 1,569 2,256
(C) 3.5 1,912 2,844
M33 33
(F) 2.0 2,059 3,040
5/16 05 18 UNC 25 35
3/8 06 16 UNC 44 65
7/16 07 14 UNC 71 103
1/2 08 13 UNC 103 147
Unified thread 9/16 09 12 UNC 147 216
5/8 10 11 UNC 201 294
3/4 12 10 UNC 358 525
7/8 14 9 UNC 554 809
1 16 8 UNC 868 1,275
Note: Tighten the bolts according to the above list, unless otherwise specified.
00-5
(kgf-m)
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
M8 8 (C) 1.25 2.7 3.9
(C) 1.5 5.4 7.8
M10 10
(F) 1.25 5.6 8.2
(C) 1.75 9.2 13.5
M12 12
(F) 1.25 9.8 14.5
(C) 2.0 14.5 21.0
M14 14
(F) 1.5 15.5 22.5
(C) 2.0 22.0 32.0
M16 16
(F) 1.5 23.0 33.7
(C) 2.5 30.5 44.5
M18 18
(F) 1.5 33.0 48.5
Metric thread (C) 2.5 42.5 62.0
M20 20
(F) 1.5 46.0 67.5
(C) 2.5 57.0 83.0
M22 22
(F) 1.5 61.0 89.5
(C) 3.0 73.5 105.0
M24 24
(F) 2.0 78.5 115.0
(C) 3.0 105.0 155.0
M27 27
(F) 2.0 115.0 165.0
(C) 3.5 145.0 215.0
M30 30
(F) 2.0 160.0 230.0
(C) 3.5 195.0 290.0
M33 33
(F) 2.0 210.0 310.0
5/16 05 18 UNC 2.5 3.6
3/8 06 16 UNC 4.5 6.6
7/16 07 14 UNC 7.2 10.5
1/2 08 13 UNC 10.5 15.0
Unified thread 9/16 09 12 UNC 15.0 22.0
5/8 10 11 UNC 20.5 30.0
3/4 12 10 UNC 36.5 53.5
7/8 14 9 UNC 56.5 82.5
1 16 8 UNC 88.5 130.0
00-6
(lb-ft)
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
M8 8 (C) 1.25 19.5 28
(C) 1.5 39 56
M10 10
(F) 1.25 40 59
(C) 1.75 66 97
M12 12
(F) 1.25 70 105
(C) 2.0 105 150
M14 14
(F) 1.5 110 160
(C) 2.0 160 230
M16 16
(F) 1.5 165 245
(C) 2.5 220 320
M18 18
(F) 1.5 235 350
Metric thread (C) 2.5 305 450
M20 20
(F) 1.5 330 490
(C) 2.5 410 600
M22 22
(F) 1.5 440 650
(C) 3.0 530 760
M24 24
(F) 2.0 565 830
(C) 3.0 760 1,120
M27 27
(F) 2.0 830 1,190
(C) 3.5 1,050 1,550
M30 30
(F) 2.0 1,160 1,660
(C) 3.5 1,410 2,100
M33 33
(F) 2.0 1,520 2,240
5/16 05 18 UNC 18.0 26
3/8 06 16 UNC 32 47
7/16 07 14 UNC 52 76
1/2 08 13 UNC 76 105
Unified thread 9/16 09 12 UNC 110 160
5/8 10 11 UNC 150 215
3/4 12 10 UNC 265 385
7/8 14 9 UNC 410 595
1 16 8 UNC 640 940
00-7
Flanged hexagon bolt
1. Bolt type: Metric thread
2. Bolt strength: 8.8 (8T)
3. Thread pitch: Coarse pitch thread (C)
(N-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 7
M6 1 12
M8 1.25 28
M10 1.5 53
Metric thread
M12 1.75 94
M16 2 231
M20 2.5 441
M24 3 765
(kgf-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 0.7
M6 1 1.2
M8 1.25 2.9
M10 1.5 5.4
Metric thread
M12 1.75 9.6
M16 2 23.5
M20 2.5 45.0
M24 3 78.0
(lb-ft)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 5.0
M6 1 8.6
M8 1.25 20.9
M10 1.5 38.9
Metric thread
M12 1.75 69.1
M16 2 169.2
M20 2.5 324.0
M24 3 561.6
00-8
Hose Band Tightening Torque
Hose Band Tightening Torque
Low pressure hose

(heat resisting hose) Tightening torque Tightening torque Tightening torque
Hose band
(N-m) (kgf-cm) (lb-ft)
Inner dia. (mm) Outer dia. (mm)
6.3 16.5
7.9 18.5 69002-02200 1.6 16 1.2
9.5 20.5
12.7 24.5 69002-02700
15.9 29.9
69002-03100
19.0 30.0
25.4 38.0 69002-04400
31.8 45.8 69002-05200 4 40 2.9
38.1 52.1 69002-05700
50.8 67.8 69002-07100
60.5 76.0 69002-08200
75.5 93.0 69002-09500
Low pressure hose Tightening torque Tightening torque Tightening torque

Hose band
Inner dia. (mm) Outer dia. (mm) (N-m) (kgf-cm) (lb-ft)
6 16.5
8 18.5 69002-02200 1.6 16 1.2
9 20.5
9 22.0 69002-02300
12 24.5
69002-02700
12 26.0
15 29.0
69002-03100
15 30.5
19 32.0
69002-03800
19 34.0
4 40 2.9
25 39.5
69002-04400
25 41.5
32 46.0
69002-05200
32 48.0
38 54.0 69002-05700
50 70.5
69002-07600
50 73.0
To connect the hose to the pipe, tighten the hose band Hose
at the following position: Pipe
Hose band
Center of pipe
protrusion
10~20 mm 70ZV00003
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.
00-10
Screw lock agent application pro- How to wind a seal tape

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

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

tape must be wound up clockwise direction as shown
65ZV00002 above. If not, the tape will be loosened or removed
while tightening the screw, resulting in oil leakage.
To avoid a piece of seal tape left in the circuit, leave 1 or

2 screws from the end of the thread and start threading
it clockwise.
Slightly stretch the tape when cutting it out, and press to

fit the tape onto the screw thread.
00-11
Cautions Regarding Welding Repair Service

If welding is needed to repair the chassis, observe the
following precautions to protect the hydraulic cylinders,
hydraulic units, gear sets, and electrical units from pos-
sible damage.
Cautions
1. Turn the starter switch OFF. 4. To ground the welder, check that the electric cur-
rent will not flow through the cylinders.
2. Remove the battery terminals both positive and Cylinder head covers for some models have a low
negative sides from the battery. conductive metal that will cause spark if the welding
current flows. The spark may damage the cylinder
3. Ground the welder near the section to be welded. 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
5. 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-
nesses, hydraulic hoses, and nylon tubes.
Be sure to mask these units and parts before weld-
ing.
00-12
Hydraulic cylinder
Heat-resistant
cloth
Section to
Plated section (Mask this section.) Hydraulic hose be welded
Nylon tube Remove
Harness and if
necessary
wrap
Pin section with pin Chassis
temporarily inserted
Pin 35A00005
(c) Hydraulic hoses, nylon tubes, or harnesses are

Plated section (Mask this section.) easily damaged by the heat during welding. To pro-
35C00003 tect them from the heat, remove them from the sec-
(a) Plated section tion to be welded to make enough clearance.
Cover the plated sections with heat-resistant cloth,

such as glass wool or canvas.
Note
The weld spattered on the plated sections causes corro-
sion.
Scrap material, etc.

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

nesses, hydraulic hoses, nylon tubes, etc. with
heat-resistant cloth (glass wool or canvas) or scrap
material to protect them from spatter.
00-13
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.

00-14
MEMO
14-1
70ZIV-2 Disassembly & Reassembly Chassis Group
70ZIV-2 Disassembly & Reassembly

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

Fuel Tank................................................................. 14-3
Hydraulic Tank......................................................... 14-4
Engine Room .......................................................... 14-9
Cab.......................................................................... 14-12
Floor Board ............................................................. 14-14
Boom ....................................................................... 14-16
Dust Seal................................................................. 14-19
Bushing ................................................................... 14-20
Center Pin ............................................................... 14-21
14-2
Deck
Deck
Deck removing and installing Deck installing
Deck removing For reinstallation, follow the above procedure in reverse

order.
WARNING
Unexpected movement of the machine could cause
an accident resulting in injury or death. Be sure to
observe the following items before starting deck
removal:
- Position the machine on level ground, and apply
the parking brake.
- Lower the attachment onto the ground, and block
the tires with chocks, etc. to prevent them from
moving.
- Remove the engine key, and hang a "DO NOT
START ENGINE!" tag on the steering wheel.
1. Apply a sling to handrail (1) and remove bolts

(2)(3)(4).
2. Remove deck (5) with the handrail considering the

balance.
: Deck (5) including handrail: 50 kg

14-3
Fuel Tank
Fuel Tank
Fuel tank removing and installing

Fuel tank removing
WARNING
observe the following items before starting fuel tank
removal:
the parking brake.
moving. 2. Disconnect level sensor electrical line coupler (3).
- Remove the engine key, and hang a "DO NOT Put matchmarks on fuel hoses (4) and disconnect
START ENGINE!" tag on the steering wheel. them.
Note
Before starting work: Cover the disconnected hoses with vinyl to protect them
- Drain fuel from the fuel tank. from dust and dirt.
(Fuel tank capacity: 220 L)
- Remove the engine room. 3. Fix eye bolt (5) (M16) to the fuel tank and attach
- Remove the radiator. (Refer to Section 22) sling fuel tank. Then remove bolt (6) and slowly
lower the fuel tank.
: Bolt (6): 417 N-m (42.5 kgf-m)

: Fuel tank: 145 kg (when empty)
Fuel tank installing
For reinstallation, follow the above procedure in reverse

order.
Fuel tank installation cautions

1. Disconnect engine oil drain hose clamp (1) and
radiator drain hose (2). After reinstallation, be sure to completely bleed air in the
fuel line.
Note
Cover the disconnected hoses with vinyl to protect them
from dust and dirt.
14-4
Hydraulic Tank
Hydraulic Tank
Hydraulic tank removing and Hydraulic tank

installing
Hydraulic tank removing
WARNING
observe the following items before starting hydraulic
tank removal:
the parking brake.
2. Remove hose (2) from the hydraulic tank.
moving.
Note
from dust and dirt.
Before starting work:

- Drain hydraulic oil from the hydraulic tank.
(Hydraulic tank capacity: 130 L)
- Remove the deck.
- Clean the area around the tank.
From hydraulic tank
3. Disconnect hoses (3)(4) from the hydraulic tank.
Note
from dust and dirt.
1. Disconnect vinyl tube (1) for the optional window

washer liquid tank, when installed.
14-5
Hydraulic Tank
Hydraulic tank installing
Accumulator assy For reinstallation, follow the above procedure in reverse

6
order.
5 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.
K70ZIV1407
Run the engine idle for five minutes to allow the pumps
to become fully lubricated.
4. Temporarily attach sling to hydraulic tank (5) and

remove bolts (6).
Carefully remove the tank.
: Hydraulic tank: 145 kg (when empty)

: Bolt (6): 216 N-m (22.0 kgf-m)
Note
The accumulators are mounted on the hydraulic tank as
shown on machines S/N 2201/8251 and thereafter.
14-6
Hydraulic Tank
Hydraulic tank return filter remov- 1

2
ing and installing 3
4
Hydraulic tank return filter removing
5
WARNING
6
an accident resulting in injury or death. Therefore, to
provide repair service with the engine running, be (S/N 1214~1269)
sure to observe the following items: (S/N 7208~7236)
- Position the machine on level ground, and apply 65K44005a
the parking brake.
- Lower the attachment onto the ground, and block 1. Remove bolt (1) of cover (2).
the tires with chocks, etc. to prevent them from Using these bolts as remover, remove cover (2).
moving.
- Let the hydraulic oil become cool. 2. Remove O-ring (3), spring (4), relief valve (5) and
- Release the internal pressure from the piping and return filter (6).
the hydraulic tank.
Note
Remove the hose and packing on machines S/Ns
Releasing the residual pressure from piping 1214~1269, 7208~7236.
(a) Keep the bottom surface of the bucket horizontal,

and stop the engine when the bucket is approxi-
mately 30 cm above the ground. Hydraulic tank return filter installing
(b) Tilt down the bucket until it comes in contact with
the ground, and then lower the boom.
(c) Move the bucket and boom levers back and forth For reinstallation, follow the above procedure in reverse
fully to relive the pressure. order.
(d) Press the tank cap to release the residual pressure
from the tank.
Before starting work: Hydraulic tank return filter installation cau-

- Drain the hydraulic oil from the tank. tions
Be sure to replace the O-ring with new one.

14-7
Hydraulic Tank
Hydraulic tank breather valve dis-

2
assembling and assembling 3
Hydraulic tank breather valve disassem- 4

bling
5
(S/N ~2550) (S/N 2551~)
Breather valve 6
Breather valve
65K44007
2. Remove bolts (2) and then remove body (3) and

packing (4).
3. Remove filter (6) by removing stop ring (5).
K70ZIV1401 Note
- After removing the parts, cover the tank port with
Note vinyl to protect it from dust and dirt.
The breather valve is changed as shown on machines - Stop ring (5) is attached on machines S/N
S/N 2551 and thereafter. 1001~1495, 7101~7316 only.
1
10
Starter keyhole 8
7
65K44008
K70ZIV1401
4. Remove stop ring (7), then remove valve assembly

Before starting work: (8).
- Insert the starter key and turn the key 180º counter- 5. Remove filter element (10) and spring (9) from
clockwise to unlock the cap key. (S/N 1001~1600, cover (1).
7101~7350 only)
Note
Do not disassemble valve assembly (8) further since the
1. Remove cap (1) by turning it counterclockwise valve is being setting 1 kPa (0.01 kgf/cm2) for the inlet
while pressing. pressure and 78 kPa (0.8 kgf/cm2) for the exhaust pres-
sure.
14-8
Hydraulic Tank
Hydraulic tank breather valve assembling

Nut
To reassemble the breather valve, follow the above pro-
cedure in reverse order.
Filter element
K70ZIV1408
Note
The breather valve on machines S/N 2551 and thereaf-
ter is configured as shown.
: Nut: 7.06 N-m (0.72 kgf-m)

: With lubricating oil (engine oil or gear oil)
14-9
Engine Room
Engine Room
Engine room removing and install-

ing
Engine room removing
WARNING
observe the following items before starting engine
room removal:
the parking brake.
2. Remove exhaust pipe (3).
moving.
4
- Recover/recycle refrigerant on machine with optional
air conditioner, if required.
(When the optional quick coupler is attached, no
recovery/recycling will be needed.)
- Remove the deck with the handrail both the right and
left side.
65K14007
3. Disconnect sub tank hose (4) for the radiator.
Note
from dust and dirt.
1. Remove screen board covers (1) on both right and

left sides.
14-10
Engine Room
4. Disconnect hose (5) between the air cleaner and 6. Disconnect electrical line coupler (8) for the con-
engine at the engine side. denser and the brake oil tank level sensor.
Remove the clamp for rear axle breather tube (9).
Note
Cover the disconnected hose and port of the turbo-
11
charger to protect the turbocharger from dust and dirt.
10
65K14010
7. Disconnect hose (11) from the optional air condi-

tioner condenser, if equipped.
5. Remove band (7) of brake oil tank (6). Note

Temporarily clamp the brake oil tank to the line fil- - Before hose disconnection, be sure to recover/recy-
ter. cle the refrigerant.
- When the optional quick coupler is attached, no
Note recovery/recycling will be needed.
You don’t have to drain the brake oil tank. - Cover the disconnected hoses with vinyl to protect
them from dust and dirt.
14-11
Engine Room
10. Slowly lift the engine room together with the air
cleaner while checking that there are no obstacles.
: Engine room: 260 kg

(Including air cleaner and condenser)
Engine room installing

order.
8. Open the radiator grill.

Disconnect electrical line coupler (12). Engine room installation cautions
Remove bolts (13).
After reinstallation, be sure to check the air conditioner
: Bolt (M12): 98 N-m (10.0 kgf-m) for refrigerant leakage.
: Bolt (M16): 216 N-m (22.0 kgf-m) Also check that the air cleaner rubber hose connection
band is properly positioned and tightened with proper
torque.
M16
(S/N 1244~)
M12
(S/N 1244~)
(S/N 1244~)
M16 70K14007a
9. Remove hose band (14).

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

: Bolt (M16)(10 each): 216 N-m (22.0 kgf-m)
14-12
Cab
Cab
Cab removing and installing

Cab removing
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 65ZV14014J
the parking brake.
START ENGINE!" tag on the steering wheel. Note
When installing the filter into the cab, be sure to align
the air flow arrow on the filter to point toward the cab.
- Remove the deck both right and left side.
2. Remove cover (3).
1. Cover (1) for the outer filter is located at the right

rear side of the cab.
Turn the rings counterclockwise and then remove
cover (1).
Remove outer filter (2) from the cab.
3. Disconnect vinyl tube (4) for the window washer liq-

uid.
14-13
Cab
Cab
Floor board 13
65V14002
4. Disconnect electrical line coupler (5) and ground 7. Remove bolt (13).
cable (6).
: Bolt (13): 721 N-m (73.5 kgf-m)
14
15
65V14003
5. Remove nut (7) and lever (8).

Then remove cover (9). 8. Remove bolt (14) and seal washer (15).
Install the eye bolt (M16 x 2.0) on cab.
: Nut (7): 34 N-m (3.5 kgf-m) Attach sling and remove the cab.
: Cab: 560 kg
12
10
Cab installing
11 For reinstallation, follow the above procedure in reverse

order.
Cab installation cautions

65K14014
- Check the movement of the wiper and adjust the

6. Remove pin (11) for arm (10). moving angle, if necessary.
Move steering shaft (12) backward. - Tune the clock and the radio.
14-14
Floor Board
Floor Board
Floor board removing and install-

ing
Floor board removing
WARNING
moving.
- Lower the attachment onto the ground, and
release the residual pressure from the hydraulic
1. Disconnect rod (1) from drop arm (2).
tank and lines.
- Disconnect the (-) side of the battery.
- Disconnect the (+) side of the battery.

- Remove the decks on both right and left sides of the
machine.
- Remove the cab.
- Disconnect the hoses and the electrical couplers
between the floor board and the chassis.
- Disconnect the pipes from the optional air condi-
tioner at the self seal couplings, when equipped.
- Collect the air conditioner refrigerant (option) using
the proper recovery method.
Note
2. Put matchmarks on hoses (3)(4) and disconnect
- Before disconnecting the electrical couplers, hoses
them.
and pipes between the floor board and the chassis,
put match marks on them to help during reassembly.
: Hydraulic oil: Approx. 0.5 L
- Prepare a drain pan for the oil.
- Cover the disconnected hoses with vinyl to protect
Note
them from dust and dirt.
from dust and dirt.
14-15
Floor Board
65K14021
5. Remove floor board retaining nut (9).

WARNING Install the eye bolt (M16 × 2.0) to floor board (8) at
Spray from hot coolant could cause burns. Prevent 4 places.
injury by relieving pressure in the radiator. Work on Attach sling then gradually lift floor board (8) while
the system only when cool. checking that there are no obstacles and that all the
pipes, cables, pins, etc. are disconnected.
3. Remove clamp (5) and then disconnect heater
hoses (option) (6) at the intermediate joints. : Floor board: 340 kg
Plug the hose ends to prevent the coolant from run- (including ope. board, air conditioner, seat, etc.)
ning out. : Nut (9): 417 N-m (42.5 kgf-m)
Floor board installing

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

refrigerant, and oil lines for leakage. Also check opera-
tion of the electrical equipment.
4. Disconnect accelerator control cable (7) from the
engine.
14-16
Boom
Boom
Boom removing and installing 1
Boom removing
3
WARNING
an accident resulting in injury or death. 2
moving.
- Lower the attachment onto the ground, and 65ZV14020J
release the residual pressure from the hydraulic
tank and lines.
- Apply the parking brake and remove the starter 1. Remove pins (2)(3) to remove bucket (1).
key.
: Bucket: 1,065 kg
WARNING Note
There are shims in the pin sections. Carefully store the
Hitting the parts quenched such as bearing, shaft, pin
removed shims, and correctly reinsert the shims when
and tooth by a steel-hammer could cause a breakage
reinstalling the bucket.
resulting in injury or death.
- Keep persons away from working area.
- Use a support plate in case a steel hammer is
used.
5
- Use a copper-hammer or a plastic hammer.
- Always wear protection goggles.
6
4
70V2E14026
2. Remove connection pin (6) from rod (4) and lever

(5).
: Link: 42 kg
14-17
Boom
8
5
5
9
7
70ZV14003J 65ZV14024J
3. Attach sling to bucket cylinder (7), and then remove 5. Attach sling to lever (5), and then remove lever pin
connection pin (8) from lever (5) and bucket cylin- (9).
der (7).
: Lever: 225 kg
: Bucket cylinder: 140 kg
10
CAUTION
12
Before removing the connecting pin, hold the lever
with a rope not to tilt the end of the lever.
11
65ZV14025J
6. Start the engine. Lift boom (10) until it is horizontal,

and then place stand (A) to support the bottom of
7 the boom.
Temporarily sling boom cylinders (11), and then
70ZV14004J remove pins (12) from the cylinder rods on both the
right and left sides of the boom.
4. Lift bucket cylinder (7) on the rod side. Apply a
cable from the cab hoisting point to the bucket cyl- CAUTION
inder, and then temporarily turn up the cylinder.
Stop the engine when the boom is approximately 30
cm above the stand (A). Set the boom lever to the
CAUTION boom down position to lower the boom onto the stand
- To temporarily turn up the bucket cylinder, check (A).
that the cylinder angle is 90º or less. Further tilting Open the hydraulic oil tank to release the internal
may cause the cylinder to overturn onto the cab. pressure.
- You have to work on the machine to turn up the
bucket cylinder. Carefully check your step on the
machine.
14-18
Boom
Boom installing

10 order.
Boom installation cautions
13 - Be sure to adjust the clearance of the retainer pin

sections using the liners.
70ZV14005J
- After reinstallation, grease the boom, and then oper-
ate it. During operation, check the boom for abnor-
7. Attach sling to torque tube of boom (10), and then mal noise.
remove pins (13) from the boom on both the right
and left side of the boom.
Note
The pin sections are adjusted (to 1.2 mm or less clear-
ance) using liners. Do not lose the liners during the ser-
vice work.
8. Slowly lift boom (10) to remove it from the machine.
: Boom: 810 kg
WARNING
Losing control of the boom structure during removal
or installation could result in injury or death.
When you sling the boom, be sure to check that the
boom is horizontal. If the boom is inclined, it may
unexpectedly tilt the end of the boom resulting in loss
of control. Stay clear of the boom.
14-19
Dust Seal
Dust Seal
Dust seal removing and installing Dust seal installing
Dust seal removing
K70ZIV1403.tif
Use tool and install the seal.
CAUTION
K70ZIV1402.tif Make sure that the direction of the seal lip is as
shown.
Remove the seal using a screw driver as illustrated.
14-20
Bushing
Bushing
Bushing removing and installing Bushing installing
Bushing removing
New bushing
Pulling direction
K70ZIV1406.tif
K70ZIV1404.tif Put clean grease on the bushings then use a hydraulic

jack (A) and adapter (1). Install them from each side.
Use a hydraulic jack (A), adapter (1) and (2). Remove Make sure to prepare the space for dust seal.
two bushings at once.
CAUTION
Adapter (1) Adapter (2) If there is a grease hole or groove on the bushing,
make sure to align the hole or groove before installing
the bushing.
Inspection hole
K70ZIV1405.tif
Adapter specifications
Adapter (1) Adapter (2)

Material SS41 SS41
Dimension (A) Bushing outer diameter
Bushing outer diameter - 2
(mm) + 20
Dimension (B) Bushing inner diameter
Bushing inner diameter - 1
(mm) +5
Dimension (C)
Jack rod diameter +2 —
(mm)
Length (L)
— Bushing length x 2
(mm)
14-21
Center Pin
Center Pin
Upper center pin
1
8 4
10
3
5
11
6
T1
Front chassis
2
12 Rear chassis
9 Upper
70ZA1208
Split
shim
T2 L1
70ZIV1401
:
T1: Bolt (10): 216 N-m (22.0 kgf-m)
T2: Bolt (9): 422 N-m (43.0 kgf-m)
L1: Bolt (9): With lubrication oil

(Engine oil or gear oil)
Center pin shim adjustment
Adjust the clearance to 0.1±0.05 mm using the shim.

After that, tighten bolt (T1).
14-22
Center Pin
Lower center pin

(S/N ~1204)
5
2
7
6
4
Front chassis
Rear chassis
1
Lower
70ZA1209
70ZIV1402
[Lower]
3
Front Rear
Split of outer bearing
20
Grease nipple
installation direction 70ZV15004
14-23
Center Pin
Center pin removing and installing 2 4
Center pin removing
WARNING
observe the following items before starting center pin
removal:
- Place the machine on level and paved ground.
- Lower the attachment onto the ground, and block 3 70ZV14008J
the front tires with chocks, etc. to prevent them
from moving.
- Apply the stopper to the rear wheel oscillation sec- 2. Disconnect brake hose (2) and high pressure
tion to prevent the machine from oscillation. hoses (3), and disconnect electrical line (4) from
- Release the residual pressure from the hydraulic the coupler.
line, and also release the internal pressure from
the hydraulic tank. : Brake oil: Approx. 3 L
- Cover the steering cylinder rod to prevent it from : Hydraulic oil: Approx. 5 L
being scratched.
Note
Plug or cover the disconnected hoses to protect them
from dust and dirt.
6
1
70ZV14007J
70ZV14009J
1. Remove bolts (1) and disconnect the second pro-

peller shaft. 3. Remove right and left steering cylinder retainer pins
(5) and shims (6).
: Bolt (1): 142 N-m (14.5 kgf-m)
: Screw lock agent (Three Bond 1327) Note
Wrap the steering cylinder rods to prevent accidental
Note damage to the chrome rods.
- 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.
14-24
Center Pin
14
10
8
12
Jack screw
70K14017a
Remover bolt: M12 (Pitch 1.75), totally threaded
Steering valve M12 x 1.75
11
70
70K14015
65ZV14011
4. The upper center pin will come in contact with the

steering rod (7) as the upper center pin is removed.
6. Screw the M12 (Pitch 1.75) bolt of approximately
To smoothly remove the upper center pin, remove
70 mm length into the center of bushing (14) to
steering rod (7), arm (8), steering rod (9) and
push out the bushing. This bolt is used as a jack
bracket (10).
screw.
: Castle nut (11): 191 N-m (19.5 kgf-m)
: Bolt (12): 216 N-m (22.0 kgf-m)
: With lubrication oil (Engine oil or gear oil)
15
Jack
13
70K14018
7. Before disconnecting front chassis (15) from the

70ZV14011J rear chassis, be sure to support front chassis (15)
using the jack and blocks so that the front chassis
will not fall backward.
5. Remove upper center pin retainer bolt (13).
: Bolt (13): 422 N-m (43.0 kgf-m)

14-25
Center Pin
16
18
70K14019 70K14021
8. Before disconnecting the front chassis from the 10. Support the bottom of hydraulic tank (18) using a
rear chassis, be sure to sling the rear chassis using rolling floor jack.
a crane (apply sling to pin (16)) so that the rear
chassis will not fall backward.
WARNING
When using a crane, insufficient signal and sling
could cause an accident resulting in injury or death. 19
To prevent such an accident, observe the following
items:
- Check the sling before using it and do not use
improper sling.
- Use the signals as agreed upon before starting
work.
- Stay out of the working area while using a crane. 70K14022
11. Remove the lock bolt from the lower center pin.
Push out lower center pin (19) using another jack to
remove the pin.
WARNING
17 Chassis separation is dangerous work. To ensure
your safety, be careful in doing this work.
Jack
70K14020
9. Push out upper center pin (17) using a jack.

14-26
Center Pin
24
23
Bar
70ZV14018 70K14024
12. Slowly turn the rear tires both the right and the left 14. Remove shim (23).
sides using a bar to separate the rear chassis.
Note
Note If taper roller bearing (24) is replaced, be sure to adjust
While turning the rear tires, check that the rolling floor the clearance using shims.
jack under the hydraulic tank is rolling backward Thickness of shim: 0.1, 0.2, 0.3, 0.5, and 1.0 mm
together with the rear chassis.
In addition, adjust the height using the rear crane when-
ever height adjustment is necessary.
24
20
70K14025
22
21
15. Replace dust seals (24) in the upper center pin and
70K14023
the lower center pin with new ones.
13. Remove ring (20) and remove bolts (22) from plate
(21).
: Bolt (22): 216 N-m (22.0 kgf-m)

14-27
Center Pin
Center pin installing

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

ate them. During operation, check the pins for abnor-
70ZV14024
mal noise and looseness.
- Check each section for oil leakage.
- No oil leakage should be found in any part.
Note - Be sure to completely bleed the brake of air.
Take care of the correct direction of dust seals as For air bleeding procedure, refer to the "Service
shown above. brake air bleeding procedure" page 24-18.
WARNING
Insufficient air bleeding in brake oil line could cause
an accident resulting in injury or death be sure to
completely bleed the brake of air.
25
70K14026
16. Check and replace dust seal (25) of the lower cen-
ter pin in the same way as step 15.
14-28
MEMO
15-1
70ZIV-2 Service Standard Chassis Group
70ZIV-2 Service Standard

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

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

Steering cylinder Rear chassis
8 4
7
9
2
5 11
10
1 70V2E12001
15-3
Linkage Pin Standard Clearance Values
Unit: mm (in)
Judgment standard
No. Item Solution

Pin standard
Standard clearance Tolerance
dimension
ø70 0.100~0.250 1.0

* 1 Joint section between attachment and boom
(ø2.7559) (0.0039~0.0098) (0.0393)
Replacement
ø110 0.120~0.295 1.0

2 Joint section between boom and lever Replacement
(ø4.3307) (0.0047~0.0116) (0.0393)
ø80 0.120~0.295 1.0

3 Joint section between boom and boom cylinder Replacement
(ø3.1496) (0.0047~0.0116) (0.0393)
ø90 0.120~0.295 1.0

4 Joint section between front chassis and boom Replacement
(ø3.5433) (0.0047~0.0116) (0.0393)
ø80 0.120~0.295 1.0

* 5 Joint section between attachment and link
(ø3.1496) (0.0047~0.0116) (0.0393)
Replacement
ø80 0.120~0.295 1.0

* 6 Joint section between lever and link
(ø3.1496) (0.0047~0.0116) (0.0393)
Replacement
ø90 0.120~0.295 1.0

7 Joint section between lever and bucket cylinder Replacement
(ø3.5433) (0.0047~0.0116) (0.0393)
ø90 0.120~0.295 1.0

8 Joint section between bucket cylinder and front chassis Replacement
(ø3.5433) (0.0047~0.0116) (0.0393)
ø80 0.120~0.295 1.0

9 Joint section between boom cylinder and front chassis Replacement
(ø3.1496) (0.0047~0.0116) (0.0393)
ø45 0.080~0.205 1.0

* 10 Joint section between front chassis and steering cylinder
(ø1.7716) (0.0031~0.0080) (0.0393)
Replacement
ø45 0.080~0.205 1.0

* 11 Joint section between steering cylinder and rear chassis
(ø1.7716) (0.0031~0.0080) (0.0393)
Replacement
15-4
Liner clearance adjustment
70ZV15001
Adjustment procedure (for adjustment of liner clear-

ance 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.
15-5
Center Pin
Center Pin
Center pin shim adjustment Grease nipple installing
1 [Upper]
8 4
10
3 Front
5
11
Front chassis
6 22.5
Grease nipple
Front chassis
2 Install bearing cover (3) so that the grease nipple
12 Rear chassis
9 Upper mounting hole is positioned at the specified angle as
70ZA1208 shown in the figure above.
The clearance between the front chassis and bearing

cover (3) is 0.75±0.5 mm (0.0295±0.0197 in) before
shim adjustment.
Add shims so that the clearance is 0.1±0.05 mm
(0.0039±0.0020 in).
:
Bolt (10): 216 N-m (22.0 kgf-m) (159 lb-ft)
Bolt (9): 422 N-m (43.0 kgf-m) (311 lb-ft)
(with lubrication oil (engine oil or gear oil))
15-6
Center Pin
Lower center pin bearing outer

ring installing
[Lower]
5 3
2
7
6
4 Front Rear
Split of outer bearing
3
20
Front chassis
Grease nipple
Rear chassis
Install bearing outer ring (3) so that the split is perpen-
1 dicular to the front-rear line of the machine.
Lower
70ZA1209
15-7
Bucket
Bucket
(Tooth mounting section)
Tooth
:
Tooth mounting bolt (5): 834N-m (85.0 kgf-m)
(Wear edge mounting section) (Wear plate mounting section)
Edge
Center 28
Side 32
Wear edge Wear plate (option)
: :
Wear edge mounting bolt (6): 834N-m (85.0 kgf-m) Wear plate mounting bolt (7): 834N-m (85.0 kgf-m)
15-8
Bucket Positioner and Boom Kick-Out (Option)

Kick-out adjusting plate
Bucket positioner
15-9
Bucket positioner
3
Adjusting plate
Indicator lamp
5
Proximity switch
3
2.5
5 2
1 K70ZIV1501
Bucket positioner adjustable angle
-7º 0 +15º
Adjusting distance (5): 6 mm 46 mm 134 mm
K90ZV15001
No. Item Judgment standard Solution
1 Clearance of bucket positioner switch 5±2 mm Adjustment
3 Adjusting plate mounting bolt tightening torque 94 N-m (9.6 kgf-m) Tightening
4 Switch mounting nut tightening torque 20 N-m (2.0 kgf-m) Tightening
5 Bucket positioner adjustable angle (distance (5)) -7º ~ +15º (6 ~ 134 mm) Adjustment
15-10
Boom kick-out (option)

Boom highest position
Adjusting plate
Connector
Proximity
switch Direction of
indicator lamp
Boom kick-out hoist angle
6
15-11
2 Clearance of boom kick-out switch 5 ± 1 mm Adjustment
3 Adjusting plate mounting bolt tightening torque 53 N-m (5.4 kgf-m) Tightening
4 Switch mounting nut tightening torque 20 N-m (2.0 kgf-m) Tightening
6 Boom kick-out adjustable angle 8 ~ 43º Adjustment

15-12
MEMO
24-1
70ZIV-2 Disassembly & Reassembly Power Group

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

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

Radiator assy
T2 L3
Engine
T3 L1
T2 L3
T2 L3
T4 L1 T1 L3
Oil pump
T3 L1
Rear differential
Transmission
3rd propeller shaft (S/N 1973~, 7772~)
(S/N ~1023, ~7107) T4 L2
(S/N 1024~, 7108~) T7 L2
3rd propeller shaft
T6 L2 (S/N 1001~1972, 7101~7771)
(S/N 1001~1023,
7101~7107)
T5 L2 T2 L3
T5 L2
(S/N 1001~1023,
7101~7107) T6 L2
T4 L1
2nd propeller shaft
Front differential
70K24001
:
T1: 53 N-m (5.4 kgf-m) L1: Screw lock agent (Loctite® 262)
T2: 417 N-m (42.5 kgf-m) L2: Screw lock agent (Three Bond 1327)
T3: 55 N-m (5.6 kgf-m) L3: With lubrication oil (Engine oil or gear oil)
T4: 230 N-m (23.5 kgf-m)
T5: 142 N-m (14.5 kgf-m) Note
T6: 80 N-m (8.2 kgf-m) Always replace drive shaft bolts with new ones - never
T7: 441 N-m (45 kgf-m) reuse them.
24-3
Radiator
Radiator
Radiator tightening torque
(S/N 1001~1600)
(S/N 7101~7350) Radiator assy
T1 L2
Fan guard T1 L2
T2 L1
Engine
70N24004
:
T1: 94 N-m (9.5 kgf-m)
T2: 90 N-m (9.2 kgf-m)
L1: Screw lock agent (Loctite® 262)

L2: With lubrication oil (Engine oil or gear oil)
24-4
Radiator
Radiator removing and installing

Radiator removing
WARNING
an accident resulting in injury or death. To prevent
such an accident, observe the following items:
- Park the machine on level ground.
- Apply the articulation stopper.
- Block the front wheels with chocks or the like to
prevent the wheels from moving.
- Before starting work, be sure to remove the engine
key, and hang a "DO NOT START!" tag on the 2. Disconnect coolant hose (2) from the radiator.
steering wheel, or disconnect the negative side of
the battery. Note
Cover the disconnected hoses with vinyl to protect the
hoses from dust and dirt.
- Remove the engine room (Refer to Section 14).
3. Remove plate (3) for both right and left sides.
: Retainer bolt (a): 94 N-m (9.6 kgf-m)

1. Remove drain plug (1) to drain the coolant.
: Retainer bolt (b): 90 N-m (9.2 kgf-m)
: Coolant in system: 35 L : Screw lock agent (Loctite® 262)
24-5
Radiator
4. Disconnect coolant hose (4) and remove fan guard

(5).
Note
Cover the disconnected hoses with caps to protect them
from dust and dirt.
6. Disconnect hoses (8)(9) from the hydraulic oil

cooler.
: Hydraulic oil: 2 L
Note
Cover the disconnected hoses with plastic caps to pro-
5. Remove covers (6)(7). tect them from dust and dirt.
24-6
Radiator
7. Temporarily sling radiator (10). 9. Disconnect transmission cooler hose (13) and radi-
Remove the right and left retainer bolts (11). ator drain hose (14).
: Bolt (11): 94 N-m (9.6 kgf-m) Note

: With lubrication oil (Engine oil or gear oil) Cover the disconnected hoses with plastic caps to pro-
tect them from dust and dirt.
10. Lift the radiator to remove it from the rear chassis.
: Radiator: 135 kg
Radiator installing

order.
8. Lift the radiator about 10 cm and disconnect trans- Radiator installation cautions
mission cooler hose (12).
Reinstall the radiator while checking that the right and
Note left clearances between the fan and the radiator guard
Cover the disconnected hoses with plastic caps to pro- are equal at both sides.
tect them from dust and dirt.
24-7
Engine
Engine
Engine removing and installing 3. Disconnect the fuel hose, and then remove the
heater hose and cooler hose. Disconnect the pipe
from the air compressor, and then remove the drain
Engine removing
hose.
WARNING Note
Cover the disconnected hoses with caps to protect them
Unexpected movement of the machine could cause from dust and dirt.
such an accident, observe the following items: 4. Disconnect the accelerator control cable.
2 Engine
key, and hang a "DO NOT START!" tag on the
steering wheel.
2
- Select correct tooling to remove the engine and the
transmission.

- Remove the fan and radiator, if necessary.
Note 70K24004
After removing the cooling fan, the engine maybe

removed without removing the radiator. 5. Temporarily sling the engine and the transmission,
- Collect the air conditioner refrigerant (option) using and then remove engine assembly mounting bolts
the proper recovery method. (2).
: Bolt (2): 417 N-m (42.5 kgf-m)

: With lubricating oil (Engine oil or gear oil)
Negative side
: Engine assy: Approx. 600 kg (excluding oil)
1. Disconnect the negative side of the battery cable.

Then remove the positive cable.
2. Remove the wiring from the alternator, each sen-

sor, preheat, air conditioner and engine stop motor.
24-8
Engine
Engine installing
O-ring
3
order.
Engine installation cautions
- Refill the engine with the proper quantity and type of

the engine oil.
70K24005
Refill the radiator with the properly premixed coolant.
- After reinstalling the engine, completely bleed the

6. Slowly lift the engine while checking that there are fuel line of air.
no obstacles and that all the pipes, cables, pins,
etc. are disconnected, and then remove bolt (3). - Set the starter key to ON, and then check the moni-
tor lamps of electrical equipment.
: Bolt (3): 53 N-m (5.3 kgf-m)
: With lubricating oil (Engine oil or gear oil) - Operate the engine at the idling speed for 5 minutes.
After that, check the amount of the coolant.
Note
- Place a support, like a wooden block, under the - While gradually increasing the engine speed, check
transmission case. operation of the electrical equipment, and check for
- There is an O-ring in the housing between the leakage.
engine and torque converter. Be sure to replace the
O-ring with a new one. When the ring gear interlock-
ing is hard, open the flywheel cover and slowly rotate
the transmission ring gear.
7. Separate the engine and the transmission from

each other, and then lift the engine.
Note
Lift the engine approximately 100 mm.
Insert wooden piece of approximately 200 mm thick-
ness into the clearance between the flywheel bottom
and the rear axle to separate the engine and the trans-
mission. Repeat this two to three times to completely
separate the engine and the transmission from each
other.
Carefully lift the engine while checking that there are no
obstacles around it.
24-9
Propeller Shaft
Propeller Shaft
Propeller shaft removing and

installing 5
4
Second propeller shaft removing
6
2
WARNING
Unexpected movement of the machine could cause 1
an accident resulting in injury or death. To prevent 2nd propeller shaft
- Park the machine on level ground. Front differential
- Apply the articulation stopper. 70V24011
1. Remove bolt (2) from the transmission side of sec-
ond propeller shaft (1).
: Bolt (2): 142 N-m (14.5 kgf-m)
the battery.
: Screw lock agent (Three Bond 1327)
2. Disconnect the grease pipe, and remove bolt (5)

from pillow unit bearing (4).
: Bolt (5) with washer (S/N ~1023):

230 N-m (23.5 kgf-m)
: Bolt (5) (S/N 1024~): 441 N-m (45.0 kgf-m)
3. Remove bolt (6) to disconnect the propeller shaft

from the front differential.
Support the shaft by cable or garage jack. Take out
the second propeller shaft to the front.
: Bolt (6): 142 N-m (14.5 kgf-m)

: Second propeller shaft: 50 kg
Note
agent, heat the bolt head to about 235ºC using slow
flame of a gas burner.
- Do not reuse the bolts, always replace with new
ones.
24-10
Propeller Shaft
Third propeller shaft removing Propeller shaft installing

(S/N ~1972, ~7771)
order.
Propeller shaft installation cautions
- During reinstallation, align the direction of the flange

yokes on the second and third propeller shaft sides
of the transmission. (Refer to Section 22.)
Rear differential
[Difference in the yoke phase (direction) will cause
the propeller shaft damage and "knocking" during a
7 70V24012
turn.]
- Adjust the shafts so that the grease nipples on them

(S/N 1973~, 7772~) come to the same direction.
Rear differential
7 70V24012a
1. Remove bolt (7).
: Bolt (7): 80 N-m (8.2 kgf-m)

2. Remove the third propeller shaft.
: Third propeller shaft: 7.6 kg

24-11
Air Cleaner
Air Cleaner
Air cleaner removing and install-

ing 5
1
6
Air cleaner removing
3
WARNING 4
Unexpected movement of the machine could cause 2

- Apply the articulation stopper. 70K24007
1. Release cap nut (1), and then remove cover (2).
2. Release wing nut (3), and then remove outer ele-
ment (4).
the battery.
3. Release wing nut (5), and then remove inner ele-
ment (6).
Note
Removing inside elements reduces the weight and
makes air cleaner case removal work easier.
4. Remove the rubber valve on the bottom of the air

cleaner case, and inspect it for any damage.
Replace it if necessary.
5. Disconnect air duct (7).

Disconnect indicator wire coupler (8).
Inspect duct (7) for damage or wear. Replace if
there is any damage or wear.
24-12
Air Cleaner
Air cleaner installing

order.
Air cleaner installation cautions
If the bands of the air duct are not properly positioned or

tightened, the duct will draw in dust that will cause an
engine problem. Carefully reinstall the air duct.
6. Remove cover (10) from the top of engine room (9).
7. While supporting air cleaner case (11) with your

hand, remove band retainer nuts (12).
Lower the air cleaner case.
8. Take out air cleaner case (13) from the opening.

24-13
Muffler
Muffler
Muffler removing and installing 4

(S/N ~1204,
~7200)
Muffler removing (S/N ~1600,
6 ~7350)
CAUTION
You may get burned if you remove the muffler before
7
the engine is cold enough. To prevent such an inci-
5
dent, be sure to stop the engine, and open the
access panels.
Start the muffler removal work when the engine is
8
cold enough.
Engine 70K24014a
2. Disconnect drain pipe (3), remove band (4) and nut

(5).
: Nut (5): 55 N-m (5.6 kgf-m)
3. Remove nuts (7)(8), and then remove muffler (6).
: Nut (7): 53 N-m (5.4 kgf-m)

: Nut (8): 10 N-m (1.0 kgf-m)
: Muffler: 7 kg
1. Remove clamp (1), and then remove exhaust pipe
(2). Note
After disconnection, cover the pipe and the turbo-
charger side with vinyl, plugs or the like to protect the
turbocharger from dust and dirt.
Muffler installing

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

and vibration.
24-14
Front Axle Assembly
Front Axle Assembly
Front axle assembly tightening torque
T1 L3 T2 L1
(S/N ~1200, ~7200)
Front differential
B
T7 L1
(S/N 1601~1919)
T7 L2 (S/N 7351~7615)
(S/N 1201~, 7201~)

T6 L1
T4 L1
T5
T3
T4 L1
(S/N ~1009)
70V24014a
:
T1: 687 N-m (70.0 kgf-m) (S/N ~1684, ~7417) L1: Screw lock agent (Three Bond 1327)
T1: 721 N-m (73.5 kgf-m) (S/N 1685~, 7418~) L2: Liquid gasket (Three Bond 1215)
T3: 892 N-m (91.0 kgf-m)
T4: 90 N-m (9.2 kgf-m)
T5: 86 N-m (8.8 kgf-m)
T6: 53 N-m (5.4 kgf-m)
T7: 10 N-m (1.0 kgf-m)
24-15
Front Axle Assembly
Axle nut tightening procedure
1. Tighten axle nut (A) with 1,177 N-m (120 kgf-m)

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

torque as above 1.
4. Turn the wheel hub 2~3 turns back and forth, and
measure the preload applied to the bolt screw hole
in housing (B).
Preload at housing (B): 206~245 N (21~25 kgf)
Note
This is "breakaway" force, which is required to start the
wheel turning.
24-16
Front Axle Assembly
Front axle assembly removing and

installing
1
Front axle assembly removing
WARNING
- Apply the parking brake and the articulation stop- 70ZV24018J
per.
- The stands must be able to support the gross
3. Disconnect air bleeder tube (1) from the upper part
weight of the front chassis, boom and the attach-
of the axle housing. Install plastic caps on hose and
ment.
fitting.
Note
Clean the nylon breather tube before reinstalling.
Stand
Stand
70ZV24017
70ZV24019J
1. Lift the front wheel using the attachment, and then
place a stand under the front chassis to support the
chassis. 4. Remove second propeller shaft retainer bolt (2).
Lift the boom until it is horizontal, and place a stand
under the boom to support it or install a boom cylin- : Bolt (2): 142 N-m (14.5 kgf-m)
der lock collar. : Screw lock agent (Three Bond 1327)
2. Press the hydraulic tank oil filler cap to release the

trapped tank pressure.
Release the accumulator pressure, by slowly and
fully depressing and releasing the brake pedal
many times until it feels light.
24-17
Front Axle Assembly
6
90ZV24033 90ZV24035
5. Remove right and left wheel and tire assemblies 7. Temporarily sling axle assembly (5), and then
(3). remove retainer bolts (6).
: Retainer bolt: 892 N-m (91.0 kgf-m) : Bolt (6):

: 1 tire: 275 kg 687 N-m (70.0 kgf-m) (S/N ~1684, ~7417)
721 N-m (73.5 kgf-m) (S/N 1685~, 7418~)
: Axle assembly: 840 kg
Note
During reassembly be sure both mating surfaces are
clean and free of paint.
8. Place axle assembly (5) on a carrier or garage jack

with special adapter to smoothly pull out the
assembly.
70ZV24021J Front axle assembly installing
6. Disconnect brake pipes (4). For reinstallation, follow the above procedure in reverse
order.
: Brake oil: 3 L
Note
Install plastic caps to avoid the dirt from entering the fit-
tings or pipes.
24-18
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.
4. Slightly loosen the air bleeder nipple, and then

press the brake pedal several times. When the oil
flows from the air bleeder nipple, close the nipple.
After that, each time you press the pedal, open the
air bleeder nipple to slightly discharge oil, and then
immediately close the nipple.
Repeat this for all wheels until there is no air in the
oil.
: Air bleeder nipple: 10 N-m (0.9 kgf-m)

24-19
Front Axle Assembly
Planetary assy disassembling and

assembling 1
Planetary assy 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 the wheel and tire assembly (1) from the
- Block the rear wheels with chocks or the like to
side to be disassembled (example: left side).
: Retainer bolt: 892 N-m (91.0 kgf-m)
weight of the front chassis, boom, and the attach-
ment.
: Tire: 275 kg / each
Differential section
Stand
Stand 2
70ZV24025J
70ZV24017
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. 30 L
to support it. Check that the tires are off the ground.
2. Lift the boom until it is horizontal. Place a stand

under the boom to support it.
24-20
Front Axle Assembly
4
90ZV24054
5. Turn drain plug (4) to the bottom of wheel hub (3) to 6. Temporarily sling the spider using hoisting tool (A).
drain oil. and (E).
Remove four spider retainer bolts (6) to remove spi-
: Gear oil: Approx. 32 L der assembly (7).
Note : Bolt (6): 86 N-m (8.8 kgf-m)

To replace the oil, refer to the oil amount described : Spider assembly: 60 kg
below.
Wheel hub section:

10 L for left side, 10 L for right side
Differential section (front): 30 L

Total oil amount for front axle: 50 L
Reference
Differential section (rear): 34 L
Total oil amount for rear axle: 52 L
TOP
7. Remove snap ring (8), and then remove sun gear
(9).
8. Remove friction plate (10).
90ZV24055
Remove cover (5).
: Retainer bolt: 90 N-m (9.2 kgf-m)

24-21
Front Axle Assembly
Turnbuckle
E
90ZV24060
9. Remove steel plate (11) and disc gear (12). 11. Turn wheel hub (3) until the drain plug is positioned
on the top.
Note Connect the turnbuckle to eye bolt (E) to lock the
Clean the brake plates, and then check the plates for wheel hub, and then place a wooden block under
distortion, discoloration and wear. the wheel hub to support it.
Refer to Section 52 and for additional information.
Note
Be sure to lock the wheel hub, or the hub will drop when
the axle nut is removed and the internal gear hub is
removed.
10. Remove axle shaft (13) and wear ring (14).

Remove retainer bolts (15), and then remove lock
plate (16).
: Bolt (15): 53 N-m (5.4 kgf-m) 12. Remove axle nut (17).
: Nut (17): 1,177 N-m (120 kgf-m)
Note Axle nut width across flat: 120 mm
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).
24-22
Front Axle Assembly
Extension D
E
3
Jig (B)
18 19
Wooden block
80ZV24027 Wooden block 80ZV24029
13. Pull out internal gear hub (18) to the extension end 15. 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).
14. Sling internal gear hub (18) using internal gear hub
hoisting tool (C), and remove hub (18). 16. Remove taper roller bearing (19).
Also remove the sleeve from the axle on machines
S/N 1001~1200, 7101~7200.
Note
For easy removal, heat the inner race using a gas
burner with slow flame.
24-23
Front Axle Assembly
Planetary assy assembling Internal gear hub installation
To reassemble the front axle, follow the above proce- Internal gear
dure in reverse order. Brake oil
holes
Brake oil holes at

2 locations
Planetary assy assembly cautions
IMPORTANT
- Replace all the O-rings and seals with new ones.
- Clean and check all the parts. If a part is damaged, Axle housing
replace it. extension
Before reinstalling the internal gear hub assembly, align

Oil seal installation (S/N ~1200, ~7200) the brake oil holes of the axle housing extension with
that of the internal gear hub assembly.
Oil seal
Grease Axle nut tightening
Sleeve
Use wheel hub oil seal press-in jig (F) to insert the oil
seal into the wheel hub.
17
80V2E24024
Fill the clearance between the oil seal and sleeve with
grease. 1. Tighten axle nut (17) with 1,177 N-m (120 kgf-m)
tightening torque to install the taper roller bearing,
and then loosen axle nut (17).
2. Again tighten axle nut (17) so that the preload of

the tire mounting hole section becomes 206~245 N
(21~25 kgf).
Note
This is the force to start the wheel hub moving or
"breakaway" force. Before measuring the preload, turn
the wheel hub 2~3 turns back and forth.
24-24
Front Axle Assembly
Brake adjustment
Wheel hub
Spider "TOP" mark Brake oil line

(at top)
Drain plug
(at bottom)
90ZV24077
Brake oil
inlet port
90ZV24074
3. Check that the wheel hub drain plug is at the bot-
tom when the spider "TOP" mark is at top.
4. After reinstalling the tires, be sure to completely

bleed the brake of air.
Shut off valve Note

After reinstalling tires, check that manual rotation of the
tires is possible. Also check the wheels for oil leakage.
Air supply
PT 1/4
Air pressure gauge
Jig (G)
90ZV24071
1. Disconnect the brake pipe and the elbow from the

brake oil inlet port on the axle housing, and attach
jig (G) to the port.
2. Apply 588 kPa (6 kgf/cm2) air pressure for approxi-

mately 1 minute. Shut off the valve. Check that the
pressure does not fall.
Note
If the pressure falls, air is leaking from the brake piston
O-rings or the internal gear hub O-rings. Disassemble
the internal gear hub again to repair the leakage.
24-25
Floating Seal (S/N 1201~, 7201~)
Floating seal installation

Ring
1. Checking before floating seal installation.
Bearing
O-ring
Wheel hub
O-ring
Axle Remove oil

housing
Put thin gear oil

(Do not use grease)
Seal ring
Ring 90ZV24065
(a) Checking seal Do not touch

- Check the seal ring for distortion and scratches. (It may cause rusting)
90ZV24066
- Check the O-ring for scratches.
(b) Check the wheel hub and the ring for burr. If any (c) Clean the O-ring installation part on the wheel hub
remove it by sand paper etc. and the seal ring, and remove oil on them.
Note
The rotating ring and the fixing ring are exactly the
same. They can be used on either side.
24-26
Floating seal assembling

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

- Put thin gear oil on the O-ring.
- Insert the O-ring and seal ring into the ring and the
wheel hub pushing the O-ring by fingers. (Make 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.
Before installation
95ZVE24011
2. In case jig is used
1 2
3
Guide jig Installation jig
70ZV24095J
1. Wheel hub After installation

2. Guide jig
95ZVE24010
3. Installation jig
4. Floating seal
- Install the guide jig to the wheel hub and / or the ring. 3. Caution before operation
- Put thin gear oil on the O-ring.
- Insert the floating seal into the guide jig. - After assembling, turn the wheel hub 2~3 turns by
- Fix the installation jig to the floating seal, and push it hands.
until it reaches to the guide jig. (Make sub assembly) - Check if it turns lightly by hands. If it is tight to turn
- Remove the guide jig and the installation jig from the the wheel hub, the O-ring may be twisted. In this
floating seal. case it is necessary to disassemble 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.
24-27
Internal Gear Hub
Internal Gear Hub
Internal gear hub disassembling

and assembling 1
Internal gear hub disassembling
3
70ZV24038J
2. Temporarily sling internal gear (1) to remove gear

(3).
2
A
: Internal gear: 25 kg
70ZV24020
4
Screwdriver
Bend slightly
70ZV24039J
70ZV24019
3. Remove O-rings (4).

1. Put the internal gear hub assembly on a platform or
a level place.
There is snap ring (A) that connects internal gear
(1) to internal gear hub (2).
Shift the snap ring to the inside using a screwdriver
or the like.
24-28
Internal Gear Hub
Internal gear hub assembly cautions
IMPORTANT
- Replace all the O-rings with new ones.
- Clean and check all the parts. If a part is damaged,
replace it with a new one.
- Check that the snap ring is properly inserted into the

groove of internal gear.
5
70ZV24040J
4. Remove taper roller bearing (5).
Note
For easy removal, heat the inner race using a gas
burner with slow flame.
5. Remove the brake piston from the internal gear

hub.
5
70ZV24041J
Internal gear hub assembling

- Before reinstallation of taper roller bearing (5), be
sure to heat the bearing to 120~150ºC in oil.
To reassemble the internal gear hub, follow the proce-
dure described in reverse order. - Apply grease to the O-rings.
- For disassembling and reassembling the brake pis-

ton, refer to Section 54.
24-29
Spider Assembly
Spider Assembly
Spider assy disassembling and

assembling 5
6
Spider assy disassembling
7
70ZV24044J
2
3. Remove thrust washers (7) and bearing (5)(6) from
1 planetary gear (4).
90ZV24136
Note
- Install the bearings so that bearing (5) comes out-
1. Remove lock bolts (1), and then remove plate (2). side (cover side) and bearing (6) inside (brake
retainer side).
: Lock bolt (1): 90 N-m (9.2 kgf-m)
: Screw lock agent (Three Bond 1327) Bearing (5) width: 20 mm
Bearing (6) width: 25 mm
: Spider assy: 95 kg
1
3
4
8
80V2E24019
90ZV24137
4. Turn spider (8) upside down. Using a plastic ham-

2. Insert lock bolt (1) into planetary pin (3), and mer, tap brake retainer (9) off the spider.
remove the pin. Remove planetary gear (4) with
thrust washers and bearings as a unit.
24-30
Spider Assembly
Spider assy assembling Spider assy assembly cautions
To reassemble the spider assembly, follow the above - To reinstall the brake retainer, check that there is no
procedure in reverse order. clearance between the spider and the brake retainer.
Before starting work: - The brake retainer may only be installed as it was
- Clean all the parts. removed. It may not be flipped over due to the roll
- Check the brake retainer, pins, bearings, planetary pin hole design.
gears, wear ring, for distortion and wear.
- Replace the O-ring and defective parts with new
ones.
- Inspect the internal bores of the spider for wear. 1
3
90ZV24137
- To insert planetary pin (3), align the core holes of the

planetary gear with that of the wear ring.
- The lock bolt (1) hole of planetary pin (3) is shifted

from the center. Check that the bolt hole is shifted to
the inside.
- Manually turn planetary gear (4) to check that the

gear smoothly rotates.
24-31
Special Tool
Special Tool
Special tool for axle

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

mm (in) (Material: SS41)
t12(0.5)
25(1)
M12x1.75 4x 12(0.5)
25(1)
156(6.1) 80(3.1)
160(6.3)
312(12.3)
345(13.6)
70ZV24021
24-32
Special Tool
(C) Internal gear hub hoisting tool

75(3.0)
75 (3.0) t12(0.5)
ø13 mm (0.5 in) drilled
35(1.4)
20
R .8)
t12 (0.5)
0 (
35(1.4)
20
R .8)
15
6 ) 0
0. 35 (
R
235(9.3) (
345(14) (1.4)
15
)
.6
R
235 (9.3)
107(4.2)
(0 35
345 (14) (1.4)
107 (4.2)
25 155(6.1)
(1.0)
R1 .6) (0
25 155 (6.1)
(0.5)
(0
5 R .6)
13
(1.0)
(1.4)
(1.4) (0.5)
15
35
R2 .8) (0
13
(0
0 R .8)
35
434(17)
20
R2 .8) (0
(0
0 R .8)
452 (17.8)
20
270(10.6)
215(8.5)
292(11.5)
288 (11.3)
215 (8.5)
310 (12.2)
35
(1.4)
t9(0.4)
R6
35
0(2 R
t9 56(2.2)
(0.6)10 (0.4)
(0.3)
10
7
(1.4)
.4) 60
(0.4) t9(0.4)
t9 56 (2.2)
(0.4)
(0.1) (0.6) (0.3)
(2
25 (1.0)
(0.6)
7
25
.4)
(0.4)
15
15
R1 .4) (0
A
(1.0)
(0
(0.1)
0 R .4)
27.5 35(1.4) 27.5

(0.6)
3
15
R1 .6) (0
15
(1.1) (1.1)
(0
(0.6)
5 R .6)
90(3.5)
15
A
10
27.5 35 (1.4) 27.5

3
A (1.1) (1.1)
15
A 90
- A(3.5)
(0.6)
15
A A-A 90ZV24087
70ZV24036
24-33
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).

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

R
(0.4)
55(2.2)
45(1.8)
d
*
ille
25(1.0)
dr
t6(0.2)
.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

mm (in)
M24x2
30(1.2) Cut the threaded area off the M10 eye bolt before use.
90ZV24089
24-34
Special Tool
(F) Wheel hub oil seal press-in tool

30
C2
5 Welded
30
C1
R
13
20
7
R
4 230
238
70ZIV2404
(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 +0 (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
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
24-35
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
24-36
Rear Axle Assembly
Rear Axle Assembly
Rear axle assembly tightening torque
T4 L1
(S/N ~1200, ~7200)
B
T5
T4 L1
T6 L1
(S/N ~1009)
T1
(S/N ~1919, ~7615)
C
T7 L1
(S/N 1601~1919)
T7 L2 (S/N 7351~7615)
(S/N 1201~, 7201~)
C Rear differential
T2 L1
70N24002a
:
T3: 892 N-m (91.0 kgf-m) L2: Liquid gasket (Three Bond 1215)
T4: 90 N-m (9.2 kgf-m)
T5: 86 N-m (8.8 kgf-m)
T6: 53 N-m (5.4 kgf-m)
T7: 10 N-m (1.0 kgf-m)
24-37
Rear Axle Assembly
Axle nut tightening procedure
1. Tighten axle nut (A) with 1,177 N-m (120 kgf-m)

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

torque as 1 above.
4. Turn the wheel hub 2~3 turns back and forth, and
measure the preload applied to the bolt screw hole
in housing (B).
Preload at housing (B): 206~245 N (21~25 kgf)
Note
This is "breakaway" force, which is required to start the
wheel turning.
24-38
Rear Axle Assembly
Rear axle assembly removing and

installing
Rear axle assembly removing
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death. To prevent such
an accident, observe the following items: B
- Apply the articulation stopper. 70ZV24054J
2. Lift the boom, and then roll the attachment back to
level. Check that the rear wheels are off the
ground. Place stand (B) under the counter weight to
support it.
Wooden blocks
Block
70ZV24024
3. Insert wooden blocks into the swing stopper section

to prevent the axle from swinging. Block both sides.
WARNING
The axle will not be balanced when a tire is removed.
If wooden blocks are not inserted, your fingers or
A
body may be caught in the machine.
70ZV24053J
1. Lower the attachment onto the ground. Lift the front

attachment. Place stand (A) under the rear chassis
(behind the center pin) to support the chassis.
24-39
Rear Axle Assembly
70ZV24056J
4. Remove right and left wheel and tire assemblies 6. Disconnect air bleeder hose (3).
(1).
Note
: Tire of 1 wheel: 275 kg - Before disconnecting the hose, press the oil filler cap
: Retainer bolt: 892 N-m (91.0 kgf-m) of the hydraulic tank to release the tank pressure.
- Release the accumulator pressure by slowly and
fully depressing and releasing the brake pedal many
times until it feels light.
- Remove and clean hose (3) before reinstalling.
- Install plastic cap on the breather fitting.
5. Remove retainer bolts to remove third propeller

shaft (2).
: Bolt (2): 80 N-m (8.2 kgf-m)

: Screw lock agent (Loctite® 262)
: Third propeller shaft: 10 kg (25 lbs) 7. Disconnect front and rear grease pipes (4) and
brake hose (5).
Note
Replace propeller shaft retainer bolts (2) with new ones. : Brake oil: Approx. 3 L
Do not reuse them when reassembling.
Clean all threads with a thread lock primer to assure a Note
fast strong bond. Cover and plug the hose and fittings to prevent dirt
entry.
24-40
Rear Axle Assembly
CAUTION
Wooden block 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
24-18 for air bleeding in the service brake.
Rear axle disassembling and assembling
For disassembling and reassembling the rear axle

assembly, refer to the front axle disassembling and
reassembling procedures.
8. Temporarily sling rear axle (6), and remove right

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

then pull out the rear axle.
Note
- The rear support is locked by not only the bolts but
also dowel pins. Carefully remove or reinstall the
support while checking the dowel pins.
- Be careful not to bend or damage the oil pipes.
- Do not reuse the retainer bolts. Replace them with
new ones.
24-41
Axle Support
Axle Support
Axle support tightening torque

(S/N 1001~1919, 7101~7615)
(S/N ~1841, ~7582)
Rear axle assembly
(S/N 1842~, 7583~)
T3 L1
T1 L2
FRONT
T2 L1
Front axle support
T1 L2
Rear axle support
70N24003a
:
T1: 687 N-m (70.0 kgf-m) (S/N ~1684, ~7417) L1: Screw lock agent (Three Bond 1327)
T1: 721 N-m (73.5 kgf-m) (S/N 1685~, 7418~) L2: With lubricating oil (Engine oil or gear oil)
T2: 231 N-m (23.5 kgf-m) (S/N ~1919, ~7615)
T2: 314 N-m (32.0 kgf-m) (S/N 1920~, 7616~)
T3: 53 N-m (5.4 kgf-m) (39 lb-ft)
24-42
Axle Support
(S/N 1920~, 7616~)
Rear axle assembly

(S/N ~1935)
(S/N ~7881)
T1 L2
(S/N ~1935)
(S/N ~7881)
Front axle support
T3 L1
T2 L1
T1 L2
FRONT
T2 L1
Rear axle support
K70ZIV2401
:
T2: 314 N-m (32.0 kgf-m) L2: With lubricating oil (Engine oil or gear oil)
T3: 53 N-m (5.4 kgf-m)
24-43
Axle Support
Axle support disassembling and 4. Remove bushing (7), O-ring (8) and packing (9).
Remove ring (10) (S/N 1842~, 7583~ only).
assembling
Breather (A)
Axle support disassembling
(S/N 1001~1919, 7101~7615)
16
19
Before starting work 12
11
- Remove the rear axle assembly from the rear chas-
sis. 13
17 15
18 14
(S/N 1001~1841)
(S/N 7101~7582)
1
21
20 70K24033
6 5. Temporarily sling rear axle support (11) and

5 Rear axle assy
Snap ring
9 remove bolt (12).
8
: Bolt (12): 231 N-m (23.5 kgf-m)
7
FRONT 70V24017
6. Remove plate (13), packing (14), wear ring (15),
and O-ring (16) from rear axle support (11).
(S/N 1842~1919)
(S/N 7583~7615) 6 7. Remove and clean breather fitting (A).
5
4 Note
3
When the fitting is reinstalled, apply Liquid gasket AA03
(Three Bond 1215) on the threads.
7 Lubricate after reassembly to be sure grease comes out
of the breather.
FRONT
8. Remove rear axle support (11) from the rear axle

Rear axle
2 1
10 assy assembly.
9
8
70V24017a : Axle support (rear) (11): 51 kg
9. Remove packing (17) and wear ring (18).

1. Temporarily sling front axle support (1) and remove
by sliding it off the rear axle assembly. 10. Remove bushing (19), ring (20), and O-ring (21)
from the rear axle support.
: Axle support (front) (1): 50 kg
2. (S/N 1001~1841, 7101~7582)

Remove snap ring (9).
(S/N 1842~1919, 7583~7615)

Remove bolt (2), plate (3) and ring (4).
: Bolt (2): 53 N-m (5.4 kgf-m) (40 lb-ft)
3. Remove packing (5) and O-ring (6).

24-44
Axle Support
Axle support disassembling

(S/N 1920~, 7616~) 8
Rear support
10
Before starting work
- Remove the rear axle assembly from the rear chas- 12
6
sis.
7
Rear axle
9
11
Front support
13
70V2E24039
3
2 5. Temporarily sling the rear axle rear support.
1 Remove bolt (6).
5 Remove plate (7) and wear ring (8). Remove bolt
(9), plate (10) and wear ring (11).
4
70ZIV2406 : Bolt (6)(9): 314 N-m (32.0 kgf-m)
1. Remove bolt (1) and attach sling to the rear axle
: Axle support (rear): 60 kg
front support.
6. Remove the rear axle rear support from the rear
: Bolt (1): 53 N-m (5.4 kgf-m)
axle.
7. Remove bushing (12) and packing (13) from the
: Axle support (front): 55 kg
rear support.
2. Remove ring (2). Remove the rear axle front sup-
port from the rear axle.
3. Remove packing (3) from ring (2). Axle support assembling
4. Remove bushing (4) and packing (5) from the front To reassemble the axle support, follow the above pro-
support. cedure in reverse order.
Axle support assembly cautions
IMPORTANT
replace it.
24-45
Axle Support
Bushing installation
Front support (S/N ~1919, ~7615) Front support (S/N 1920~, 7616~)
Axle support
Axle support
5
2
Bushing 1
3
Swing shaft
Front
Swing shaft
4 70ZV24029
1. Before installing, put the bushing into hot water to 1. Before installing, put bushing (2) into dry ice.
heat it to 80ºC.
2. Install lip seal packing (1) on the axle support.
2. Install packing (1) and O-ring (2) on the swing
shaft. 3. Install cooled bushing (2) to the front axle support
as shown in the illustration.
3. Install the heated bushing onto the swing shaft as After installing, be sure to press bushing (2) until
shown in the illustration. stopped by the stopper of the axle support.
4. Carefully install the axle support onto the swing

shaft.
IMPORTANT
When installing the bushing onto the differential
swing shaft, make sure no oil is left on the outer sur-
CAUTION face of the bushing or the swing shaft surface.
When installing the bushing onto the differential If oil is left on them, the bushing may turn alone caus-
swing shaft, make sure no oil is left on the inner sur- ing the bushing wear.
face of the bushing or the swing shaft surface. If oil is
left on them, the bushing may turn alone causing the
4. Carefully install the axle support onto the swing
bushing wear.
shaft.
Avoid damage to lip seal packings (1)(8).
Avoid damage to lip seal packings (1)(4).
5. After installing the axle support, install O-ring (7), 5. Install ring (3) and lip seal packing (4).
packing (8) and snap ring (9).
6. Tighten bolts (5).
: Bolt: 53 N-m (5.4 kgf-m)

24-46
Axle Support
Rear support (S/N ~1919, ~7615) Rear support (S/N 1920~, 7616~)
Axle support [Rear support] Rear

Axle support
Bushing
6
7
8
Swing
shaft 13 12 10 11
70ZV24030
1. Before installing, put the bushing into hot water to 1. Before installing, put bushing (10) into dry ice.
heat it to 80ºC.
2. Install cooled bushing (10) to the rear axle support
2. Install packing (3), wear ring (4), ring (5), O-ring (6) as shown in the illustration.
on the swing shaft. After installing, be sure to press bushing (10) until
stopped by the stopper of the axle support.
3. Install the heated bushing onto the swing shaft as
shown in the illustration. Note
The side with a groove on bushing (10) should come to
4. Carefully install the axle support onto the swing the rear side.
shaft.
3. Install lip seal packing (11) onto the axle support
and install snap ring (12).
CAUTION
When installing the bushing onto the differential 4. Carefully install the axle support onto the swing
swing shaft, make sure no oil is left on the inner sur- shaft. Avoid damage to packing (11).
face of the bushing or the swing shaft surface. If oil is
left on them, the bushing may turn alone causing the
bushing wear.
CAUTION
Avoid damage to lip seal packings (3)(13). When installing the bushing onto the differential
swing shaft, make sure no oil is left on the outer sur-
5. After installing the axle support, install O-ring (10), face of the bushing or the swing shaft surface.
wear ring (11), and then install packing (13) to plate If oil is left on them, the bushing may turn alone caus-
(12). 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 (shaded area).
Note
- When installing the axle support, fill enough grease
between the packing and the axle support as shown
in the illustration.
- The side with a groove on bushing (13) should come
to the rear side.
24-47
Differential Assembly
Differential assembly removing

A
and installing Spider assembly
2
Differential assembly removing
TOP
1
Cover bolt
90ZV24079
1. Temporarily sling the spider using hoisting tool (A).

Remove the cover bolts and cover (1).
Remove retainer bolts (2) to remove the spider
assembly.
70ZV24067J
: Bolt (2): 86 N-m (8.8 kgf-m)

Before starting work: : Spider assembly: 60 kg (132 lbs)
- Drain oil from the axle assembly.

3
- Remove the axle from the machine.
Note
Refer to "Front Differential" page 24-62 when removing
the front differential without removing the front axle from
the machine.
- For the rear axle, remove the axle supports.

Refer to "Rear axle assembly removing and install-
ing" page 24-38.
70ZV24069J
- Place the axle assembly on work benches.

: Axle assembly (Front): 840 kg
2. Pull out right and left axle shafts (3) by approxi-
: Axle assembly (Rear): 940 kg
mately 30 cm.
24-48
90ZV24081 90ZV24084
3. Remove bolts (5) from differential (4). 5. Lift the differential using the sling, and then remove
O-ring (7).
: Front differential retainer bolts:
132 N-m (13.5 kgf-m)
Rear differential retainer bolts:
314 N-m (32.0 kgf-m) Differential assembly installing
order.
Differential assembly installation cautions
- After reinstallation, refill with the specified oil until the

4 oil level reaches the level check plug.
- Refill the oil in each planetary assy.
- Manually turn the flange yoke of the differential to
6 check that the right and left wheel hubs turn
90ZV24083
smoothly.
- Check the differential for oil leakage.
4. Temporarily sling differential (4), and insert bolts

into remover tap (Jack Screw) holes (6) to slightly
lift the differential.
: Differential: 130 kg
Note
Carefully sling the differential so that it is balanced and
is lifted straight up.
24-49
Differential assembly disassembling and assembling

Front differential tightening torque
T2 L1
T5 L1
T3 L1
T7 L1
E Shim
(T=0.07~
0.50)
D
B (T=16.70~16.98)
F A
T6 L1
T1 L1
T4 L1
L2
70V24033
: Note
T1: 883 N-m (90.0 kgf-m) - To tighten nut (T1), measure the preload at the bolt
T2: 515 N-m (52.5 kgf-m) screw hole in flange (A).
T3: 231 N-m (23.5 kgf-m)
T4: 314 N-m (32.0 kgf-m) Preload at flange (A): 57~66 N (5.8~6.7 kgf)
T5: 132 N-m (13.5 kgf-m)
T6: 330 N-m (33.7 kgf-m) Use spacer (B) to adjust the preload.
T7: 55 N-m (5.6 kgf-m)
- Use shim (E) to adjust the tooth contact of spiral
bevel gears (C) and (D).
L1: Screw lock agent (Three Bond 1327) Adjust the backlash by nut (F).
L2: Liquid gasket (Three Bond 1215, or a locally
procured RTV that does not contain acetic acid.)
24-50
Rear differential tightening torque (S/N 1001~1919, 7101~7615)
T6 L1
D T3 L1
T2 L1
T7 L1
A T5 L1
Shim
E
(T=0.07~0.50)
B T4 L1
T1 L1 (T=16.70~16.98)
L2
70V24021
: Note
T3: 230 N-m (23.5 kgf-m)
T5: 132 N-m (13.5 kgf-m)
T7: 55 N-m (5.6 kgf-m)
24-51
Rear differential tightening torque (S/N 1920~, 7616~)
T6 L1
T3 L1
D
F T2 L1
T7 L1
A
(T=0.07~0.50)
E Shim T5 L1
B
(T=16.70~
16.98) F
L2
T4 L1
T1 L1
70V24021a
: Note
T3: 230 N-m (23.5 kgf-m)
T5: 132 N-m (13.5 kgf-m)
T7: 55 N-m (5.6 kgf-m)
24-52
Differential assembly disassembling 3
Adjust nut Shim 3

Nut
Bevel gear 4
Pinion 2 90V2E24038
Adjust nut
70ZV24031 2. Remove bolts (3), bearing cap (4), and adjustment
nut (2).
- Fix the differential assembly onto the disassembly : Bolt (3, L.H with bushing):
workbench. 230 N-m (23.5 kgf-m)
- Insert a straight-end screwdriver or the like into the : Bolt (3, R.H without bushing):
clearance between the pinion and the bevel gear to 515 N-m (52.5 kgf-m)
prevent the gear from rotating. : Screw lock agent (Three Bond 1327)
Loosen the pinion nut.
5
: Pinion nut: 883 N-m (90 kgf-m)
: Nut width across flat: 57.1 mm
6
90ZV24150
3. Remove bearing outer race (5). Lift differential cage

1
2
assembly (6) to remove it.
90V2E24037
1. Remove right and left lock plates (1) from adjust-

ment nut (2).
24-53
12
7
8
Matchmark 11
90ZV24107 13 90ZV24109
4. Put a matchmark on the alignment point of differen- 6. Remove spider (11) with pinion gears (12) and
tial cage (7). Remove bolts (8), and then separate thrust washers (13) as a unit.
the differential cage.
: Bolt (8): 132 N-m (13.5 kgf-m)

14
90ZV24110
10
9
7. Remove side gear (14).
90ZV24108
5. Remove thrust washer (9) and side gear (10). 15
90ZV24111
8. Remove thrust washer (15).

24-54
20
17
21
16
90ZV24112 90ZV24114
9. Turn the differential upside down. 11. Remove nut (20) and O-ring (21).
Remove bolts (17) from bevel gear (16) to separate
the gear. : Nut (20): 883 N-m (90.0 kgf-m)
: Nut width across flat: 57.1 mm
: Bolt (17): 330 N-m (33.7 kgf-m) : Screw lock agent (Three Bond 1327)
Trunnion
22
19
18 90ZV24115
90ZV24113
12. Remove flange yoke (22).

10. Remove bolts (18) to remove pinion (19).
At the same time, remove the shim.
23
: Bolt (18): 314 N-m (32.0 kgf-m)
Note
The rear differential assembly (S/N 1920~, 7616~) has
the trunnion installed with bolts (18) as shown.
24
90ZV24116
13. Remove pinion (23) from cage (24).

24-55
25
90ZV24117
14. Remove taper roller bearing (25).
26
90ZV24118
15. Remove spacer (26).

24-56
Differential assy 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 (20): 883 N-m (90.0 kgf-m)
- 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 : Standard preload∗: 57~66 N (5.8~6.7 kgf)

27
23 28 A
22
90ZV24120
∗Preload here is the force required to start the cage
moving-breakaway force (not a rolling force).
(a) Install new roller bearing (27) on pinion (23) if (f) If the preload is out of the above range, replace
replacement is needed. spacer ring (26) to adjust the preload to the speci-
fied range.
Note
Pinion There are 15 types of spacers (16.70~16.98 mm) in
Bearing
increments of 0.02 mm. Thicker spacers reduce pre-
load; thinner spacers increase preload.
Pinion
(g) Remove nut (20) and flange yoke (22).
Stake
at 3 points
90ZV24121
Note
After attachment, stake the bearing at three points as
shown in the right figure.
(b) Install new taper roller bearing (28) and spacer (26)
on pinion (23) if replacement is needed.
(c) Install cage (24) and taper roller bearing (25).

24-57
Front Rear
Shim Shim
18 18
Check direction
of the lips
29
Apply liquid gasket

(AA03) to these 30 30
surfaces
24
90ZV24122
31 31 70V2E24043
2. Install oil seal (29) to cage (24). 4. Install O-ring (30) and the shims (those removed
during disassembly) to the cage.
Note Insert the cage into differential case (31), and
Before installing oil seal (29), be sure to apply grease to tighten retainer bolt (18).
the lip, and also apply liquid gasket to the outside of the
seal. Note
Install the trunnion to the rear differential assembly.
: Bolt (18): 314 N-m (32.0 kgf-m)

22
20
21
90ZV24123
3. Install flange yoke (22), and O-ring (21).

Apply liquid gasket to nut (20), and then tighten the
nut.
: Nut (20): 883 N-m (90.0 kgf-m) 5. Install thrust washer and side gear (14) to differen-
: Nut width across flat: 57.1 mm tial cage (32).
: Liquid gasket (Three Bond 1215)
24-58
11 16
12
13 17
90ZV24145 90ZV24148
6. Attach spider (11) with side gears (12) and thrust 9. Tighten bolts (17) in bevel gear (16).
washers (13) as a unit.
: Bolt (17): 330 N-m (33.7 kgf-m)
90ZV24149
7. Install side gear (10) and thrust washer (9).
10. Install differential cage assembly (6) in the carrier

8
assembly.
7
3
Matchmark
4
90ZV24147
Adjust nut
8. Align differential cage (7) with the matchmark, and

90ZV24131
then tighten bolts (8).
: Retainer bolt (8): 132 N-m (13.5 kgf-m) 11. Reinstall bearing cap (4), and then temporarily
: Screw lock agent (Three Bond 1327) tighten bolts (3). Reinstall the adjustment nut.
(For both the right and left sides)
24-59
1
34
3
2
4
Dial gauge (A)
16
33
70ZV24032 90ZV24133
12. Adjust the backlash as follows: 13. Tighten bolts (3) of bearing cap (4).
(a) Tighten adjustment nut (33) on the bevel gear side : Bolt (3, Bevel gear side):
until the backlash is "0". Then back off the adjust- 231 N-m (23.5 kgf-m)
ment nut 2 to 3 notches. : Bolt (3, Opposite side (without bushing)):
515 N-m (52.5 kgf-m)
(b) Tighten opposite side adjustment nut (1). After you : Screw lock agent (Three Bond 1327)
feel that the nut is tight, turn it one more notch.
14. Mount lock plate (2), and then tighten bolts (34) to
(c) Attach the dial gauge stand to the carrier. Attach fix the lock plate.
dial gauge (A) to a tooth of bevel gear (16).
Read the backlash value indicated on the dial : Bolt (34): 53 N-m (5.35 kgf-m)
gauge. : Screw lock agent (Three Bond 1327)
(d) Adjust the backlash.
Standard backlash: 0.25~0.33 mm
- Tighten adjustment nut (33) on the bevel gear side

or loosen adjustment nut (1) on the opposite side to
reduce the backlash.
- Loosen adjustment nut (33) on the bevel gear side or

tighten adjustment nut (1) on the opposite side to
increase the backlash.
24-60
Adjusting tooth contact
Tooth contact Possible cause Adjusting method
A Correct
Loosen the bearing adjuster on the rear

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

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

2
D, and makes drive pinion approach the
Drive pinion is too far from the
E ring gear.
ring gear.
Check again the backlash and tooth
contact.
1
After adjusting the backlash to the standard value,

check that manual rotation of the gear is possible. After
that, paint blue or red on the tooth surface of ring gear,
and check the tooth contact. To adjust the tooth contact,
adjust the thickness of the shim between the pinion and
cage, and turn the adjustment nut.
24-61
Three types of tooth contact shown below are accept-

able as the 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.
24-62
Front Differential
Front Differential
Front differential removing and

installing
(Without removing the front axle assembly)
WARNING Differential section

Unexpected movement of the machine or compo-
nents could cause an accident resulting in injury or
lowing items:
- Park the machine on level ground, and then apply 2
the parking brake. 70ZV24025J

- Block the rear wheels with chocks or the like to 3. Remove drain plug (2) from the differential section
prevent the wheels from moving. to drain oil.
weight of the front chassis, boom, and the attach- : Gear oil: Approx. 30 L
ment.
Stand
Stand
70ZV24017
4. Remove grease pipe (3) and bolts (4).
1. Lower the attachment onto the ground. Lift the front

attachment. Place a stand under the front chassis
to support it. Check that the tires are off the ground.
2. Lift the boom until it is horizontal. Place a stand

under the boom to support it.
24-63
Front Differential
70K24058
5. Disconnect brake pipe (5) and remove bolts (7). 7. Holding sun gear (A), pull out left axle shaft (9)
Then disconnect 2nd propeller shaft (6) from the about 300 mm.
differential.
Note
: Bolt (7): 132 N-m (13.5 kgf-m) If shaft (9) is pulled out with sun gear (A), the plate and
: Screw lock agent (Three Bond 1327) the disc also come out.
To prevent it, holding the sun gear.
8. Pull out the right axle shaft about 300 mm.
70K24059 11

70K24061
9. Remove all the bolts from the differential except

bolt (11) to prevent the differential falls down.
24-64
Front Differential
Front differential removing and installing tool
Thickness: t15 mm
Material: SS41
Jack
10. Attach a special jig (12) installed on a jack to the

differential by using bolts (13).
11. Remove bolt (11).
12. Remove the differential assy (1) from the axle

housing.
25-1
70ZIV-2 Service Standard Power Group

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

Axle and Differential Service Standard.................... 25-3
25-2
Propeller Shaft Service Standard
Propeller Shaft Service Standard
1
Bearing play
Third propeller shaft
2: Circumferential play 6
3: Transverse play Second propeller shaft

70ZV25001
Unit: mm (in)
No. Item Tolerance Solution
Second, third
1 Spider bearing play 0.25 Replacement
propeller shaft
Second propeller
2 Spline circumferential play 0.8 Replacement
shaft
Second propeller
3 Spline transverse play 1.0 Replacement
shaft
4 Bolt tightening torque 69 N-m (7.0 kgf-m) Tightening
5 Bolt tightening torque 155 N-m (15.8 kgf-m) Tightening
6 Clearance 7.34 ± 3 —
25-3
Axle and Differential Service Standard
Axle group
2,3 4
1,3
70ZV25002J
Unit: mm
Judgment standard
No. Item Solution
Standard dimension Tolerance
1 Backlash between sun gear and planetary gear 0.196~0.564 0.196~0.564 Replacement
2 Backlash between planetary gear and internal gear 0.216~0.604 0.216~0.604 Replacement
3 Tooth contact of gear No abnormality Replacement
4 Bushing and wear ring wear Oil groove 1.0 No oil groove Replacement
25-4
Differential
5, 6
5, 6
K70V2E25003
Unit: mm
Judgment standard
No. Item Solution
Standard valve Tolerance
1 Backlash between ring gear and drive pinion 0.25~0.33 0.25~0.33 Adjustment
2 Backlash between side gear and pinion gear 0.23~0.45 0.23~0.45 Adjustment
3 Clearance between pinion gear and spider 0.102~0.153 0.102~0.153 Replacement
Adjustment or
4 Runout of ring gear rear surface (when assembled) 0.076 0.076
replacement
5 Tooth surface wear (each gear) Abnormal wear or missing Replacement
6 Tooth contact No abnormality Replacement

34-1
70ZIV-2 Disassembly & Reassembly Torque Converter and Transmission Group

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

Transmission Assembly .......................................... 34-10
Torque Converter .................................................... 34-16
Transmission Clutch Pack ....................................... 34-18
Control Valve Assembly .......................................... 34-23
34-2
Torque Converter and Transmission Assembly
Torque converter and transmission assembly tightening torque

Radiator assy
T2 L3
Engine
T3 L1
T2 L3
T2 L3
T4 L1 T1 L3
Oil pump
T3 L1
Rear differential
Transmission
3rd propeller shaft (S/N 1973~, 7772~)
(S/N ~1023, ~7107) T4 L2
(S/N 1024~, 7108~) T7 L2
3rd propeller shaft
T6 L2 (S/N 1001~1972, 7101~7771)
(S/N 1001~1023,
7101~7107)
T5 L2 T2 L3
T5 L2
(S/N 1001~1023,
7101~7107) T6 L2
T4 L1
2nd propeller shaft
Front differential
70K24001
:
T1: 53 N-m (5.4 kgf-m) L1: Screw lock agent (Loctite® 262)
T4: 230 N-m (23.5 kgf-m)
T5: 142 N-m (14.5 kgf-m) Note
T6: 80 N-m (8.2 kgf-m) Always replace drive shaft bolts with new ones - never
T7: 441 N-m (45 kgf-m) reuse them.
34-3
Torque converter and transmission assembly removing and installing

Torque converter and transmission assem-
bly removing
WARNING
Unexpected movement of machine could cause an
an accident, observe the following items:
- Lower the attachment onto the ground, and then
block the tires with chocks to prevent the wheels
from moving.
- Disconnect the ground cable from the negative
side of the battery.
1. Remove drain plug (1) to drain the transmission oil.
: Transmission oil: 22 L
- Stop the engine. Depress the brake pedal many
times until there is no brake pressure.
2. Disconnect hose (2) for the transmission oil level
- Press the hydraulic tank cap, and relieve the internal
gauge.
pressure from the hydraulic tank.
- Remove the cab and the floor board (Refer to Sec-
Note
tion 14).
Cover the disconnected hose with vinyl to protect the
hose from dust and dirt.
- Remove the steering valve (Refer to Section 44).
- Remove the air cylinder and bracket for the parking
brake (Refer to Section 54).
3. Remove multiple control valve return pipe (3).
Note
Cover the disconnected pipe with vinyl to protect the
pipe from dust and dirt.
34-4
Hydraulic pump
4. Remove pipe (4) and hoses (5) (at the hidden end 6. Disconnect hoses (9)(10) between the torque con-
in the above illustration). verter and the oil cooler.
Note Note
After removing the pipes and hose, plug or cover the Cover the disconnected hose with vinyl to protect the
disconnected parts with clean vinyl to protect from dust hose from dust and dirt.
and dirt.
Remove bolts (6) and remove the hydraulic pump

assembly.
: Bolt (6): 142 N-m (14.5 kgf-m)

: Pump: 45 kg
Note
Be sure to replace the gasket of the hydraulic pump
flange with a new one.
7. Disconnect speed meter sensor coupler (11), the

electric wire coupler for speed sensor (auto shift)
(13) and clutch pressure measuring hose (12).
Note
- Cover the disconnected hose with vinyl to protect the
- Speed meter sensor coupler (11) is for the machine
S/Ns 1001~1600, 7101~7350.
5. Disconnect hose (7) between the torque converter

pump and the line filter.
Disconnect hose (8) between the line filter and the
control valve.
Note
Cover the disconnected hose with vinyl to protect the
34-5
8. Disconnect electric wire coupler (14) for the sole- 10. Disconnect bolts (15) from the third propeller shaft
noid valve on the control valve. on the transmission side.
: Bolt: 80 N-m (8.2 kgf-m)

Note
agent, heat the bolt head using slow flame of a gas
burner.
- Do not reuse the bolt once heated.
9. Remove bolts (14) from the second propeller shaft

on the transmission side only.
: Bolt: 142 N-m (14.5 kgf-m)

11. Temporarily sling the transmission assembly and

then remove bolts (16).
: Bolt (16): 417 N-m (42.5 kgf-m)

: Transmission assembly: 515 kg
34-6
Torque converter and transmission assem-

bly installing
To reinstall the torque converter and transmission

assembly, follow the above removal procedure in
reverse order.
Transmission assembly installation cau-

tions
Rotate the engine flywheel to align the ring gear.

12. Insert wooden pieces (17) into the clearance
Transmission assembly operation check
between the bottom of the engine flywheel housing
and the rear axle housing.
After reinstallation, check operation of the transmission
assembly by the following procedure.
WARNING
To prevent such an accident, be sure to stop the
engine, and block to the tires with chocks before you
start service work. During the service work clearly
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.
13. Remove 12 bolts (18) connecting the transmission
housing and the engine flywheel.
2. Check each section for oil leakage.
: Bolt (18): 53 N-m (5.4 kgf-m)
3. Adjust the transmission oil level to the specified
point with the level gauge.
14. Pull the transmission assembly straight out approx-
4. Perform the start-up tests as shown on the
imately 30 mm to the front then slowly lift it.
attached sheet.
CAUTION
Slowly lift the transmission assembly while checking
that there are no obstacles.
34-7
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
Copy as required. Make attachments if needed.

34-8
Transmission assembly bolt tightening torque
9 T8
11
10
2 3 1
T1
7 12 14 15
6
13
52T
52T
T5 53T
R F
Hydraulic pump installation
T6 T1
24
23
28T
17 21 29T
4 28T
19
37T
5
57T
1ST
20
2ND
43T
22 Idler shaft
T3
8
20T
31
16 32T
51T
48T 43T
T1
18
37T
32
23T
30
34 35
33T
4TH 3RD
36T
26
25
T4
29
33
27
28
37
T2
T4
T1
T1 36
T7
70ZA3206a
34-9
1. Pump impeller 21. Counter gear B

2. Turbine impeller 22. Counter shaft A
3. Stator 23. Idle shaft
4. Turbine shaft 24. Idle gear
5. Stator shaft (Fixed) 25. 4th speed clutch
6. Ring gear 26. 4th speed clutch gear
7. Drive cover 27. 3rd speed clutch
8. P.T.O. drive gear 28. 3rd speed clutch gear
9. T/C pump drive gear 29. Counter gear C
10. Hydraulic pump drive gear 30. Counter shaft B
11. T/C pump 31. Counter gear D
12. Reverse clutch 32. Counter gear E
13. Reverse clutch gear 33. Output shaft
14. Forward clutch 34. Output shaft gear
15. Forward clutch gear 35. Parking brake
16. Counter gear A 36. Speed sensor drive (S/N 1001~1600, 7101~7350)
17. 2nd speed clutch 37. Suction strainer
18. 2nd speed clutch gear
19. 1st speed clutch
20. 1st speed clutch gear
Transmission type:
CT160A01 (S/N ~70J1-1972, ~70J1-7771)
CT160A02 (S/N 70J1-1973~, 70J1-7772~)
:
T1: 68.6 N-m (7.0 kgf-m)
T2: 108 N-m (11.0 kgf-m)
T3: 26.0 N-m (2.65 kgf-m)
T4: 255 N-m (26.0 kgf-m)
T5: 53 N-m (5.4 kgf-m)
T6: 66 N-m (6.7 kgf-m)
T7: 28 N-m (2.85 kgf-m)
T8: 46 N-m (4.7 kgf-m)
Control valve assy: 34.3 N-m (3.5 kgf-m)

Solenoid body (F, R, 1st, 2nd):
32.3 N-m (3.3 kgf-m)
Solenoid body (3rd, 4th): 33 N-m (3.4 kgf-m)
34-10
Transmission Assembly
Transmission assembly disassembling and assembling

Transmission assembly disassembling

- Clean the transmission assembly.
- Remove the torque converter assembly.
Suction pipe
3. Remove pump retainer bolt (3), and remove the

pump.
: Bolt (3): 46 N-m (4.7 kgf-m)
4. Remove the retainer bolt and remove the suction

pipe.
: Bolt: 38 N-m (3.9 kgf-m)
1. Remove the bolt and disconnect pipe (1).

Remove the strainer inside.
: Bolt: 68.6 N-m (7.0 kgf-m)
2. Remove suction hose (2). 5. Remove retainer bolt (4) for the transmission hous-
ing.
: Hose band: 43 N-m (4.4 kgf-m)
: Bolt (4): 68.6 N-m (7.0 kgf-m)
Note
Cover the disconnected pipe and hose with vinyl to pro- Use a jacking bolt (M10x1.5) to separate the torque
tect the hose from dust and dirt. converter housing and the transmission housing.
34-11
T/M oil
PTO gear pump pump
6. Remove snap ring (5) for hydraulic pump drive gear 8. Remove snap ring (10) from the torque converter
(6). charge pump side, then remove adapter (11).
9. Remove bolt (13) then remove gear (12), shaft (14),

bearing (15) and snap ring (16) as an assembly.
: Bolt (13): 73.6 N-m (7.5 kgf-m)

7. Remove snap ring (7) from the hydraulic pump

side.
Remove shaft (8) with bearings (9) as an assembly.
Note
When removing shaft (8), support pump drive gear (6)
by hand. 10. Remove plug (17) for the clutch oil regulator valve,
then remove springs (19)(20) and piston (21).
Also remove plug (18) for the torque converter inlet
pressure regulator valve, then remove spring (22)
and piston (23).
: Plug (17)(18): 73 N-m (7.4 kgf-m)

34-12
11. Remove plug (24) for the torque converter outlet 13. Remove bolt (29) and plate (30) from the torque
pressure regulator valve, then remove spring (25) converter housing.
and piston (26).
: Bolt (29): 25.5 N-m (2.6 kgf-m)
: Plug (24): 73 N-m (7.4 kgf-m)
31
Stopper
Stopper
65K34038
14. Remove forward/reverse clutch pack (31) using a

12. Remove cover (27) for the 1st speed pressure 16mm eye bolt.
detection valve and cover (28) for the 2nd speed
pressure detection valve.
: Bolt for covers: 15.7 N-m (1.6 kgf-m) Special tool
32
33
CAUTION
The spring and stopper for the 1st speed pressure
detection valve and the 2nd speed pressure detec-
tion valve are not the same.
Carefully install them when assembling.
65K34039
15. Remove 1st/2nd speed clutch pack (32) and 3rd/

4th speed clutch pack (33) at the same time using a
special tool.
34-13
Special tool for removing speed range clutch

(Tool No. KL03-200-1 for North American dealer)
7
3
5 2
4 1
6
1. Plate
15 250
20 7 7
R 13 R 28
50
24 25 24
65 180
35.4 35.4
150
280
135
95
6 9
2. Lock
10
7 7 10
R 13
39 R 31
250
135
95
6 13
70ZV34004
1. Plate
2. Lock
3. Eye bolt
4. Nut (M12)
5. Bolt (M6)
6. Nut (M6)
7. Split pin
34-14
3rd propeller shaft
37
41
34
65K34017
38
36
18. Remove speedometer drive gear (41).
35
2nd propeller shaft 65K34015
16. Remove bolt (34), then remove drum (35) and

flange (36).
Remove bolt (37) and brake assy (38).
: Bolt (34)(37): 255 N-m (26 kgf-m)

42 Bolt
40
65K34018
Socket bolt
19. Remove shroud (42) in the housing.
: Bolt for shroud: 25 N-m (2.5 kgf-m)

39 65K34016a
17. Remove bolt (39).

Using a jack bolt (M10x1.5), remove meter drive 43
case (40).
: Bolt (39): 68.6 N-m (7.0 kgf-m)

: Socket bolt: 15.7 N-m (1.6 kgf-m)
65K34040
20. Remove output shaft (43) using a 16mm eye bolt.

34-15
Transmission assy assembly cautions
(a) When installing oil seal apply grease to inner lip

and liquid gasket (AA03) to outside seal.
44
(b) When installing O-ring, apply lithium grease to O-
ring.
45
Bolt
Abutment joint
Overlap
65V34004
Remove snap ring (44) and the bolt for idle gear shaft
(45).
Remove idle gear shaft (45) from the housing.
Seal ring When installed
: Bolt: 68.6 N-m (7.0 kgf-m)
Note
When removing the shaft, support the gear by hand.
Tightening torque for assembly (c) When installing seal ring to the shaft, install it as
shown in the figure.
Do not open the abutment joint wider before install-
ing.
Transmission assembly assembling Apply grease to the shaft before installing seal ring.
To reassemble the transmission assembly, follow the

above procedure in reverse order.
IMPORTANT
Make sure to rotate the shaft by hand during assem-
- Clean and check all the parts. If a part is damaged, bly and after assembly.
replace it with a new one. Refer to Section 35 for If it is hard to rotate the shaft by hand, disassemble
wear limits. and check the cause.
- When assembling, apply transmission oil to the
parts.
- Replace all the seals and packings with new ones.
34-16
Torque Converter
Torque Converter
Torque converter assembly disassembling and assembling

Torque converter assembly disassembling

- Clean the transmission assembly.
Stator shaft
- Prepare a can for oil.
3. Remove snap ring (3) and lock nut (4) and then
remove stator (5).
: Lock nut (7): 66 N-m (6.7 kgf-m)
IMPORTANT
1. Remove 2 each of plug (1) from drive cover and
drain oil from the transmission and the torque con- If stator (5) is installed upside down, the stator will not
verter. properly function.
Correctly install stator (5) as shown in the figure.
: Plug (1): 10 N-m (1.0 kgf-m)
: Transmission oil: 0.5 L
2. Remove bolt (2).

Using a jacking bolt (M10x1.5), remove the drive
cover. Stator shaft
: Bolt (2): 31 N-m (3.1 kgf-m)
4. Remove pump impeller assy (6) from the stator

shaft. Then remove gear (7) and bearings (8) from
the pump impeller assy.
34-17
Torque Converter
Torque converter assembly assembling

Stator shaft
To reassemble the torque converter assembly, follow
the procedure in the reversed direction.

- Clean and check all the parts. If a part is worn or
damaged, replace it with a new one.
- Before reassembly, apply transmission oil to the
parts.
- Be sure to replace O-rings and seals with new ones.
- Install new bearing if replacement is needed.
After reassembling, make sure to rotate the drive cover

5. Remove stator shaft retainer bolt (9), then remove by hand.
the stator shaft retainer shaft.
: Bolt (9): 53 N-m (5.4 kgf-m)

34-18
Transmission Clutch Pack

The disassembling procedure for the forward/reverse
clutch pack is described below.
For the other clutch pack, refer to the following proce-
dure.
Forward/reverse clutch pack disassembling and assembling

Forward/reverse clutch pack disassem-
bling
5
6
7
8
T/C side 8
9
10 65K34021
2. Remove snap ring (5), then remove plate (6), back

1
plate (7), friction disc (clutch plate) (8), separation
2 disc (steel plate) (9), and plate (10).
3
4
65K34020
1. Remove seal ring (1) from the turbine shaft. 12

Remove bearing (2), washer (3) and gear (4) with 11
bearings. 13
11
65K34022
3. Pressing washer (11) using a special tool, then

remove snap ring (12).
Remove washer (11) and spring (13).
34-19
Special tool to remove snap ring
For forward/reverse clutch pack For other speed clutch pack
100 (mm)
80 0.5
85
72 0.5
360
370
60
65
5
60
40
65
79 0.5
5
40
92 0.5
65ZV34031J
4. Feed air and remove clutch piston (14).

14
IMPORTANT
Do not remove the clutch drum from the shaft.
65V34005
34-20
Air inlet port
WARNING Forward/reverse clutch pack assembling

If the air pressure is applied suddenly, the piston may
jump out from the clutch. Feed air slowly. For reassembling, follow the above procedure in
reverse order.
15
65K34030
5. Remove seal rings (15) from the shaft and the pis-
ton.
6. Follow the same steps for the forward clutch

assembling.
34-21
Clutch pack assembly cautions
Thrust washer press-fit for 1st speed clutch

Clutch pack assembling direction
1st speed clutch
Be careful of the direction when assembling the indi-
Thrust washer press-fit cated parts in each clutch pack.
Transmission output gear
Output gear
1st speed clutch cross section
Boss side
This thrust washer is press-fitted to the shaft. Carefully
remove it when disassembling.
Forward/Reverse clutch pack
Back plate (convex part faces to outside)

Washer
Washer
Grooved side
Grooved side
34-22
1st/2nd speed clutch pack
Back plate
Thrust washer
(inner diameter Ø52)
Washer
Chamfered side
Grooved side
Thrust washer
(inner diameter Ø50)
3rd/4th speed clutch pack
Back plate
Washer
Washer
Chamfered side
Grooved side Grooved side

34-23
Control Valve Assembly
Control valve removing and

installing
Control valve removing
WARNING
Unexpected movement of machine could cause an
an accident, observe the following items:
- Park the machine on level ground, and then lower
the attachment onto the ground.
- Apply the parking brake, and block the tires with
chocks to prevent the wheels from moving.
2. Put match mark on each coupler and remove elec-
- Remove the starter key, and hang a "DO NOT
tric wiring coupler (1) for each solenoid valve.
START!" tag on the steering wheel.
Control valve
mount
Bolt
Cover
K70ZIV3401
3. Remove main clutch pressure measuring hose (2).
1. Remove the cover for the control valve. Note

Cover the disconnected hoses with vinyl to protect the
: Bolt: 37 N-m (3.8 kgf-m) hoses from dust and dirt.
Note
The cover is fixed with the valve block using this bolt.
34-24
Control valve
for 3rd & 4th
Control valve
for F, R, 1st & 2nd
4. Remove bolts (5)(6) and the control valve. 5. If necessary, remove sub plate (7) and plate (8).
: Bolt (5)(6): 34.3 N-m (3.5 kgf-m) : Bolt (9): 25.5 N-m (2.6 kgf-m)
: Bolt (10): 29 N-m (2.85 kgf-m)
: Control valve (F, R, 1st, 2nd): 15 kg
: Control valve (3rd, 4th): 5 kg
IMPORTANT
After removing or while reinstalling the control valve,
take care not to allow any foreign material into the
main body or the control valve. Carefully remove or
reinstall the control valve and the gasket.
34-25
Control valve installation Control valve installation cautions
For reinstallation, follow the removing procedure in - Be sure to replace all the O-rings and gaskets with
reverse order. new ones.
- Sequentially tighten the bolts in the order from the

center to the outside. Apply equal (specified) torque
to all the bolts.
- Align the matchmarks of the electric wire couplers,

and then connect the couplers while checking that
the electric wires are not tangled with each other.
- Install the cover while checking that the emergency

operation bolts are positioned over the center of the
solenoid valves.
- During installation, be careful not to damage the gas-

ket.
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.
- At the completion of installation, start the engine,

and check that the shift lever properly functions at all
the positions.
- Check oil leakage.
- Adjust the transmission oil level to the specified point

with the dipstick.
34-26
Control valve disassembling and

assembling
Control valve disassembling
Note
Clean the control valve.
[ Tool A ]
Heat treated (HB 212~253)

and press fit.
65K34027
1. Remove nut (1).
(Tool number for North America: KL03-102-2)

: Nut: 9.8 N-m (1.0 kgf-m)
2. Remove solenoid valve (2) using tool (A).
: Solenoid valve: 29.4 N-m (3.0 kgf-m)

Valve width across flat: 30 mm
34-27
Control valve assembling
To reassemble the control valve, follow the disassem-

bling procedure in reverse order.
Control valve assembly cautions
- Before you insert the regulator valve, apply transmis-

sion oil to the valve. After insertion, check that the
valve operates smoothly.
- Check the operation of the solenoid valves.

(Also check movement by pressing the manual
plunger. The plunger should move freely and
smoothly in both directions (spring return).)
- Replace all seals, O-rings and gaskets.
3. Remove covers (3)(4) by removing bolts (a).

Remove the spools and springs.
: Bolt for covers (a): 9.8 N-m (1.0 kgf-m)
CAUTION
When removing the cover, the spring may jump out.
Slowly loosen the bolt for the cover.
IMPORTANT
Do not loosen set screw and nut (5) when disassem-
bling the control valve unless necessary.
If fail to do, screw adjustment is necessary. Mis-
adjustment may cause shift shock or clutch plate slip-
ping. Refer to the procedure described in the follow-
ing “Control valve assembly cautions”.
4. Follow the same steps for the 3rd/4th speed control

valve.
34-28
Screw adjustment procedure
If the adjusting screw is loosen, follow the procedure

below to re-adjust it.
See the enlarged

figure below. 65V34006
A 1
2 65V34007
(a) Loosen nut (1).

: Nut (1): 10.8 N-m (1.1 kgf-m)
(b) Loosen set screw (2) until it comes out 20 mm (A).
(c) Screw in set screw (2) until the tip of the screw con-
tacts to spring retainer (3).
(d) From this position, turn the screw clockwise 5 turns.
(e) Tighten nut (1) to lock set screw (2).
(f) After the adjustment, confirm that "A" is 12 mm.

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

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

35-2

Piston or spool-housing clearance
Standard value (A - B) Allowable limit

Item
(mm) (mm)
Clearance between clutch oil regulator piston and housing 0.015~0.049 0.070
Clearance between torque converter oil inlet regulator piston and

0.020~0.071 0.090
housing
Clearance between torque converter oil outlet regulator piston
0.020~0.061 0.080
and housing
Clearance between accumulator (1st,2nd) piston and housing 0.020~0.062 0.080
Clearance between pressure detection valve (1st,2nd) spool and

0.020~0.059 0.080
housing
Clearance between control valve detection valve spool and body 0.020~0.058 0.080
Clearance between control valve 1st,2nd speed shift spool and

0.020~0.062 0.080
body
A: Housing inner diameter
B: Piston outer diameter Clearance between control valve accumulator piston and body 0.020~0.075 0.095
(spool)
Clearance between control valve 3rd, 4th speed shift spool and
0.020~0.061 0.080
body
Spring free length and installed load
Item Standard value Allowable limit

C mm 107.96 106.5
Clutch oil regulator spring (S) D mm 94.0
E N (kgf) 314 (32) 282 (28.8)
C mm 98.58 95.9
Clutch oil regulator spring (L) D mm 72.0
E N (kgf) 294 (30) 265 (27.0)
C mm 99.75 97.5
Torque converter oil inlet regulator spring D mm 75.0
E N (kgf) 287 (29.26) 258 (26.3)
C mm 91.2 89.1
Torque converter oil outlet regulator spring D mm 71.0
E N (kgf) 49 (5) 45 (4.5)
C mm 111 105.3
Accumulator (1st) spring D mm 52.8
E N (kgf) 201 (20.5) 181 (18.5)
C: Free length (reference) C mm 50.5 49.7
D: Installed length
E: Installed load Pressure detection valve (1st) spring D D mm 42.9
E N (kgf) 104 (10.6) 93 (9.5)
C mm 134.8 127.9
Pressure detection valve (2nd) spring (S) D mm 77.8
E N (kgf) 191 (19.5) 173 (17.6)
(Continued)
35-3

C mm 111 105.3
Pressure detection valve (2nd) spring (L) D mm 52.8
E N (kgf) 201 (20.5) 181 (18.5)
C mm 50.5 49.7
Pressure detection valve (2nd) spool spring D mm 42.9
E N (kgf) 104 (10.6) 93 (9.5)
C mm 72.5 62.4
F/R clutch return spring D mm 32
E N (kgf) 1765 (180) 1324 (135)
C mm 60.32 59.5
1,2,3,4 speed clutch return spring D mm 30.5
E N (kgf) 1451 (148.0) 1306 (133.2)
C mm 127.57 125.84
Control valve accumulator spring (S) D mm 99.0
E N (kgf) 588 (60.0) 530 (54.0)
C mm 132.44 130.65
Control valve accumulator spring (M) D mm 99.0
E N (kgf) 881 (89.8) 793 (80.82)
C mm 100.31 98.95
C: Free length (reference)
D: Installed length Control valve accumulator spring (L) D mm 64.0
E: Installed load E N (kgf) 245 (25.0) 221 (22.5)
C mm 43.19 42.6
Control valve pressure detection valve spool spring (L) D mm 30.2
E N (kgf) 134 (13.7) 121 (12.33)
C mm 44.56 43.96
Control valve pressure detection valve spool spring (S) D mm 30.2
E N (kgf) 62 (6.3) 56 (5.67)
C mm 43.13 42.6
Control valve D mm 38.0
E N (kgf) 62 (6.3) 56 (5.67)
C mm 40.47 40.0
3/4 speed control valve detent spring D mm 22.0
E N (kgf) 29 (3.0) 26 (2.7)
Oil seal lip and shaft diameter
F Ø mm — 129
Torque converter impeller hub seal
G Ø mm 129.9~130.00 129.22
F Ø mm — 80
Output flange seal
G Ø mm 79.92~80.00 79.80
F Ø mm — 9.7
F: Inner diameter Speedometer driven gear seal
G: Outer diameter G Ø mm 9.96 ~10.00 9.91
35-4
Seal ring (Piston ring)

I mm 2.30~2.35 2.10
J mm 3.1~3.3 2.9
Stator shaft ring
K Ø mm 76.00~76.03 76.20
J
L mm 2.44~2.49 2.65
I mm 2.36~2.41 2.16
I F/R Clutch J mm 3.25~3.55 3.05
Piston ring (L) K Ø mm 92.00~92.03 92.15
70ZA3507
L mm 2.51~2.58 2.70
I: Width I mm 2.87~2.92 2.67

J: Thickness F/R Clutch J mm 3.0~3.2 2.8
Piston ring (S) K Ø mm 80.00~80.04 80.15
L mm 3.10~3.15 3.30
I mm 2.35~2.40 2.15
F/R Clutch J mm 2.0~2.2 1.8
Shaft seal ring K Ø mm 55.20~55.25 55.45
L mm 2.50~2.51 2.65
I mm 2.82~2.92 2.62
K: Seal contact face diameter 1,2,3,4 speed clutch J mm 3.85~4.15 3.65
L: Groove width Piston ring (L) K Ø mm 155.08~155.13 155.33
L mm 3.025~3.125 3.175
I mm 2.28~2.33 2.08
1,2,3,4 speed clutch J mm 3.4~3.6 3.2
Piston ring (S) K Ø mm 70.00~70.05 70.15
L mm 2.49~2.50 2.65
I mm 2.93~2.98 2.73
1,2,3,4 speed clutch J mm 1.6~1.8 1.4
Shaft seal ring K Ø mm 40.20~40.25 40.35
L mm 3.07~3.15 3.30
Clutch thrust washer
M
1st clutch (a) M mm 3.92~4.00 3.57
1st clutch (b) M mm 3.92~4.00 3.57

M: Thickness
70ZA3509 1st clutch (c) M mm 1.92~2.00 1.75

35-5
Clutch plate, Steel plate, Clutch clearance

F/R clutch
N mm 2.9~3.1 2.5
Clutch plate
F/R clutch
O mm 1.92~2.08 1.80
Steel plate
F/R clutch
P mm 2.8~3.2 4.0
Clutch clearance
1,2,3,4 speed clutch
N mm 2.6~2.8 2.3
Clutch plate
O mm 1.92~2.08 1.80
Steel plate
1,2 speed clutch
P mm 2.2~2.6 4.5
Clutch clearance
3 speed clutch
N: Clutch plate thickness P mm 2.3~2.5 4.5
Clutch clearance
O: Steel plate thickness
P: Clutch clearance 4 speed clutch
P mm 1.7~1.9 4.5
Clutch clearance
Clutch conical plate

F/R clutch
Q mm 3.35~3.65 3.15
Conical drive plate
F/R clutch
Q mm 6.10~6.30 5.75
Conical plate
Q mm 4.15~4.45 3.85
Q: Free height Conical plate
35-6
MEMO
44-1
70ZIV-2 Disassembly & Reassembly Hydraulic Group

Hydraulic Group
Hydraulic Parts Removal and Installation Warning ........44-2

Hydraulic Parts Disassembly and Assembly Cautions...44-3
Gear Pump .....................................................................44-4
Steering Valve (S/N ~2200, ~8250)................................44-12
Multiple Control Valve.....................................................44-18
Hydraulic Cylinder ..........................................................44-33
Pilot Valve.......................................................................44-51
Orbitrol® (S/N 2201~, 8251~) .........................................44-60
Priority Valve (S/N 2201~, 8251~)..................................44-72
Accumulator (S/N 2201~, 8251~)...................................44-74
44-2
Hydraulic Parts Removal and Installation Warning
Hydraulic Parts Removal and Installation Warning

Disassembly and reassembly work of hydraulic parts
greatly depends on the working area and working 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.
44-3
Hydraulic Parts Disassembly and Assembly Cautions

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.
44-4
Gear Pump
Gear Pump
Triple pump
Center (for loading) Rear (for loading)

Front (for steering)
1. Oil seals : Gear pump: 44 kg

2. Driven gear
3. Drive gear
4. Pressure plates
5. Plate seal
6. Coupling
7. Coupling
44-5
Gear Pump
Gear pump tightening torque
:
T1: 34 N-m (3.5 kgf-m)
T2: 69 N-m (7.0 kgf-m)
T3: 118 N-m (12.0 kgf-m)
44-6
Gear Pump
Gear pump assembly removing

and installing
Gear pump assembly removing
WARNING
- Park the machine on level ground, and apply the
parking brake. In addition, block tires with chocks
to prevent wheels from moving.
- Disconnect the negative side of the battery cable.
3. Disconnect gear pump (1) from the torque con-
- Relieve the internal pressure from the loading line,
verter using a bar, and then remove gear pump (1).
and also relieve the internal pressure from the
hydraulic tank to prevent the oil from spouting out.
: Gear pump: 44 kg

- Remove the deck by referring to Section 14.
- Clean the area around the hydraulic pump. Gear pump assembly installing
To reinstall the gear pump assembly, follow the above

removal procedure in reverse order.
Replace all gaskets and O-rings during reinstallation.
1. Disconnect outlet hoses (2) and suction hoses (3)

from gear pump (1).
Note
Cover the disconnected hoses with plastic, plugs or
caps to protect from dust and dirt.
2. Remove gear pump retainer bolts (4).
: Bolt: 245 N-m (25.0 kgf-m)

44-7
Gear Pump
Gear pump installation cautions

IMPORTANT
When replacing gear pump or when draining hydraulic - Fill the inlet port of the hydraulic pump with clean
oil for extended periods, it is important to prime the hydraulic oil and rotate the pump shaft by hand
hydraulic system properly. Air will be in the lines that go prior to installing the pump. It should rotate
to and come from the pump. After a pump has been smoothly.
installed, or when the hydraulic oil has been drained for Prior to installing pump and plumbing to pump,
extended time periods, air will not purge easily from the remove all caps, plugs, and covers from pump and
lines, and this could lead to pump damage. piping.
- While reinstalling the gear pump, take care not to
allow dust, dirt, or foreign material into the case.
WARNING - Check the oil level of the hydraulic tank.
Oil injection hazard! - Close the cap of the hydraulic tank, and remove
Hydraulic oil can penetrate skin. When performing the plugs of the pump suction pipe. Pour hydraulic
this procedure: oil into the plug port until the oil overflows from the
- Release all trapped circuit pressure prior to start- port (approx. 4 L).
ing any procedure involving hydraulic oil. - Run the engine at low-idling speed for 5 minutes or
- Wear protective gloves. more. Do not operate any hydraulic functions dur-
- Wear eye and face protection. ing this period.
- Stay clear of areas where air may be purged. Note
- Route oil into a receiving canister [such as a 5 gal- If the engine speed is set to high-idling just after
lon bucket] by use of an additional hose. starting, the pump may be seized.
- Rotate pump at a low RPM. - 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.
Oil filling port

44-8
Gear Pump
Gear pump assembly disassem-

bling 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.
44-9
Gear Pump
Gear pump disassembling
Matchmark
1. Clean the pump and put match marks on the con-

necting sections of the pump.
2. Remove bolts (1)(2) to separate the pump sections.

- Front pump (3)
- Center pump (4)
- Rear pump (5)
: Bolt (1)(2): 34 N-m (3.5 kgf-m)

44-10
Gear Pump
1. Disassembling front pump
Front cover
Rear cover
4. Remove dust seal (14) from the mounting flange

using screw driver or the like and remove snap ring
1. Remove coupling (6), and then remove retainer (15) and oil seal (16).
bolts (7).
Note
: Bolt (7): 118 N-m (12.0 kgf-m) Do not remove the oil seal unless absolutely necessary
(unless it was damaged).
2. Remove the rear cover.
2. Disassembling center pump
3. Put matchmarks and remove bearing box (8), wear

plate (9), drive shaft (10), driven shaft (11), wear
plate (12) and bearing box (13) in order. 1. Remove bolt (17) and front cover (18).
Remove bolt (19) and rear cover (20).
Note
- Before removing the gears, put matchmarks on both : Bolt (17)(19): 69 N-m (7.0 kgf-m)
sides ends of the gears using oil stone or the like.
When reassembling the gears, align the matchmarks 2. Put matchmarks and remove bearing box (21),
so that the gears will be smoothly engaged. wear plate (22), drive shaft (23), driven shaft (24),
- Correctly insert the wear plate so that the inlet and wear plate (25) and bearing box (26) in order.
outlet sides of the plate are properly positioned when
assembling. Note
Before removing the gears, put matchmarks on both
sides ends of the gears using oil stone or the like. When
reassembling the gears, align the matchmarks so that
the gears will be smoothly engaged.
44-11
Gear Pump
3. Disassembling rear pump Gear pump assembling
To reassemble the gear pump assembly, follow the

Gear pump assembly cautions
- Replace the O-ring with new one.
1. Remove coupling (27), bolts (28) and front cover

(29).
Remove bolt (30) and rear cover (31).
: Bolt (28)(30): 69 N-m (7.0 kgf-m)
2. Put matchmarks and remove bearing box (32),

wear plate (33), drive shaft (34), driven shaft (35),
wear plate (36) and bering box (37) in order.
- Assemble the center pump and the rear pump to the
Note
front pump so that the matchmarks (1)(2) are
Before removing gears, put match marks on both sides
aligned.
ends of the gears using oil stone or the like. When reas-
sembling the gears, align the match marks so that the
- Pour hydraulic oil into the oil port until the oil over-
gears will be smoothly engaged.
flows from the port and turn the drive shaft by hand.
44-12
Steering Valve (S/N ~2200, ~8250)
1. Steering plunger :
2. Flow control plunger T1: 59 N-m (6.0 kgf-m)
3. Main relief valve T2: 25 N-m (2.5 kgf-m)
4. Overload relief valve T3: 63 N-m (6.4 kgf-m)
5. Check valve T4: 98 N-m (10.0 kgf-m)
6. Cover
7. Cap : 35kg
8. Spring guide
9. Spring
10. Retainer
11. Wiper
12. Oil seal
13. O-ring
14. Valve body
44-13
Steering valve removing and

installing
Steering valve removing
WARNING
Unexpected movement of the machine, attachment,
or boom during service work could cause serious
injury or death. To prevent such an accident, observe
the following items:
- Apply the parking brake. In addition, block the tires
with chocks to prevent the wheels from moving.
1. Remove pipe (3) from the steering valve.
: Hydraulic oil: 1 L
- Spilled oil on the parking brake shoe section may
Note
cause malfunction. To prevent such a problem,
Cover the disconnected pipe with vinyl, plugs or caps to
cover the shoe section with vinyl before removing
protect them from dust and dirt.
the valve.

- Remove the seat and seat bracket in the cab.
1. Remove hoses (4)(5).
Note
Cover the disconnected hoses with vinyl, plugs or caps
to protect them from dust and dirt.
1. Disconnect hoses (2) from steering valve (1).
Note
44-14
Steering valve installing
To reinstall the steering valve, follow the above proce-

dure in reversed order.
Steering valve installation cautions
WARNING
Entering the articulation area while engine is running
could cause serious injury or death.
When entering the area, stop the engine and place
1. Remove split pin (6), castle nut (7) and pin (8). "DO NOT START" or "DO NOT OPERATE" tag on
steering wheel.
: Castle nut (7): 255 N-m (26.0 kgf-m)
2. Remove steering valve retainer bolt (9), and then At the completion of reinstallation, check operation of
remove the valve. the steering valve by following the procedure below:
: Bolt (9): 88 N-m (9.0 kgf-m) Drop arm

: Steering valve: 35 kg
Drop arm stopper bolt
(a) Start the engine and confirm that the drop arm
comes in contact with the stoppers by turning the
steering wheel clockwise and counterclockwise.
(b) Check around the valve for oil leakage.
(c) Measure various values for performance check.
Measure the time required for full steering.
Measure the relief valve setting pressure.
(Refer to the Section 03 Measurement for Perfor-
mance Check).
44-15
Steering valve disassembling and

assembling
IMPORTANT
Before disassembly or reassembly, read and under- 6 5 4
Steering valve disassembling 70ZIV44022

- Clean the valve body.
1
23
23
1
3. Remove bolts (4) and cover (5).

70ZIV44020
: Bolt (4): 25 N-m (2.5 kgf-m)

1. Remove plugs (1) and overload relief valves (23).
4. Remove plunger assembly (6).
: Plug (1): 63 N-m (6.4 kgf-m)
7
8
8
7
3
Plunger
Plunger assembly
2 70ZIV44023
70ZIV44021
5. Remove front and rear wipers (7) and seals (8).

2. Remove bolts (2) and plate (3).
: Bolt (2): 25 N-m (2.5 kgf-m)

44-16
Shim 12
9
10 20
14 13
11 22
10 21
15 13 14
16
Plunger
Spring
Sleeve
17 Plunger assembly 19
70ZIV44024 70ZIV44025
6. Gently clamp the two flats of the plunger assembly 7. Remove cap (19) and the spring.
using wooden blocks in a vice, and then loosen
screws (9) and (17). : Cap (19): 98 N-m (10.0 kgf-m)
Remove spring seat (10), spring (11), plate (12),
spring (13), poppet (14), O-ring (15) and back-up 8. Remove cap (20) and flow control plunger (21).
ring (16) from plunger (18).
: Cap (20): 98 N-m (10.0 kgf-m)
: Screw (9)(17): 59 N-m (6.0 kgf-m)
: Screw lock agent (Loctite® 262) 9. Remove main relief valve (22).
Note : Valve (22): 63 N-m (6.4 kgf-m)

- Cover the spool to protect it from being scratched.
- A thread adhesive is applied to the threaded section
of the spool end. To disassemble the spool, heat the
adhesive of the threaded section using an industrial Steering valve assembling
drier (heat gun) or the equivalent. Do not heat the
threaded section to 200ºC or more. If overheated, To reassemble the steering valve, follow the above dis-
replace the spring with a new one. assembly procedure in reverse order.
- All seals should be replaced with new ones because
they were heated. Before starting work:
- Clean and check all the parts. Replace all O-rings
and seals.
- Before reassembly, apply a coating of hydraulic oil to
all the parts.
- Be sure to apply the specified torque to tighten each
part.
44-17
Steering valve assembly cautions Main Relief and Overload Inspection
[Example of defective valve]
Foreign matters
Valve body
Plate
Adjusting screw
Clogged orifice
Broken spring
Adjusting screw
Worn-out poppet
Seal Wiper
Adjusting screw
Attach the seal and wiper to the valve body as shown

above.
During disassembly and inspection of the main relief
Note valve and overload relief valves be sure to check the
Carefully insert the plunger so that the seals are not pilot valve, valve seat, and orifices as shown above.
scratched or cut.
Ball joint
Rod Steering valve
To insert the ball joint, adjust the distance as shown

above.
44-18
Multiple Control Valve
Multiple control valve removing

and installing
Multiple control valve removing
WARNING
- Apply the parking brake. In addition, block the tires
with chocks to prevent the wheels from moving.
1. Put match marks on hoses (1) of the pilot line, and
- Remove the engine key, and hang a "DO
then disconnect them.
operator's seat.
Note
Cover the disconnected hose with plastic, cap or plug to
Before starting work: protect them from dust, water and dirt.
- If possible carefully clean the area around the multi-
ple control valve, dirt or water entering the hydraulic
system can cause many future problems.
Releasing residual pressure from pipe
Keep the bottom surface of the bucket horizontal, and

stop the engine when the bucket is approximately 30 cm
above the ground.
Tilt down the bucket until it comes in contact with the
ground, and then lower the boom.
Press the hydraulic tank breather valve cap or open the
tank cap. 2. Put match marks on hoses (2)(3) then disconnect
them.
: Hydraulic oil: Approx. 5 L
Note
Cover the disconnected hoses with plastic, cap or plug
to protect them from dust, water and dirt.
44-19
Multiple control valve installation cautions
WARNING
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.
3. Remove return pipe (4). - Wash the multiple control valve mounting area.
- Attach the pressure gauge, and then start the

engine. Measure the pressure, and adjust it to the
specified value. For a detailed description of pres-
sure adjustment, refer to the 70ZIV-2 Shop Manual
Function & Structure, Section 03.
- Operate the bucket and the boom, and check that

they operate correctly.
- Check each section for oil leakage.
- Add hydraulic oil to the tank until the oil level rises to
the specified point.
4. Use a hoist and strap to support control valve (6)

and remove control valve (6) by removing bolts (5).
: Bolt: 90 N-m (9.2 kgf-m)

: Multiple control valve: 55 kg
Multiple control valve installing
To reinstall the multiple control valve, follow the above

44-20
Multiple control valve disassembling and assembling (S/N ~1481)

Multiple control valve cross section and tightening torque
1. Valve housing 11. Cap 21. O-ring

2. Spool (Bucket) 12. O-ring 22. Plug assembly
3. Spool (Boom) 13. Socket head bolt 23. Plug
4. Spring seat 14. O-ring 24. Plug
5. Spring (Bucket) 15. Cover 25. Main relief valve
6. Spring (Boom) 16. O-ring 26. Overload relief valve
7. Spool end (Bucket) 17. Socket head bolt (with make-up function)
8. Spool end (Boom) 18. Plug 27. Make-up valve
9. Cap (Bucket) 19. Spring 28. Cap
10. Cap (Boom) 20. Poppet
:
T1: 98 N-m (10.0 kgf-m)
T2: 42 N-m (4.3 kgf-m)
IMPORTANT
T3: 132 N-m (13.5 kgf-m) Before disassembly or reassembly, read and under-
T4: 157 N-m (16.0 kgf-m) stand the aforementioned "Hydraulic Parts Disas-
T5: 83 N-m (8.5 kgf-m) sembly and Assembly Cautions" page 44-3.
T6: 103 N-m (10.5 kgf-m)
T7: 12 N-m (1.2 kgf-m)
: 55 kg
44-21
Multiple control valve disassembling (S/N ~1481)
3. Remove make-up valve (3).

1. Remove main relief valve (1).
: Valve (3): 83 N-m (8.5 kgf-m)
: Valve (1): 103 N-m (10.5 kgf-m) Hexagon width across flat: 32 mm
Hexagon width across flat: 38 mm
4. Remove socket head bolt (4) from the bucket side

2. Remove right and left overload relief valve (2). of the cap.
: Valve (2): 83 N-m (8.5 kgf-m) : Bolt (4): 42 N-m (4.3 kgf-m)
Hexagon width across flat: 32 mm Hexagon width across flat: 8 mm
44-22
5. Remove cap (5) with the O-ring of the flange as a

unit.
8. Slowly pull out spool (8) from the bucket side, and
spool (9) from the boom side as an assembly.
6. Remove socket head bolt (6) from the boom side of Note
the cap. Carefully pull out the spool so that it is not forced out or
distorted. Handle the spool with extreme care. Even a
: Bolt (6): 42 N-m (4.3 kgf-m) small nick, dent, or scratch could ruin the spool, result-
Hexagon width across flat: 8 mm ing in replacement of the entire valve.
7. Remove cap (7) with the O-ring of the flange as a

unit.
44-23
9. Remove socket head bolt (10) to remove cap (11). 11. Remove plugs (15), and remove spring (16) and
Also remove the O-ring of the flange from the cap. poppet (17) inside.
Also remove the O-ring from the plug.
: Bolt (10): 42 N-m (4.3 kgf-m)
Hexagon width across flat: 8 mm : Plug (15): 132 N-m (13.5 kgf-m)
10. Remove socket head bolt (12) to remove cover

(13). Also remove O-ring (14) of the flange from 12. Remove the hexagon bolts and remove cap kit
the cap. (18).
: Bolt (12): 157 N-m (16.0 kgf-m) : Bolt: 42 N-m (4.3 kgf-m)
44-24
20 21
22
21
Adhesive
Heat Spool
K70ZIV4417
13. Remove plug assembly (19) and remove the O- 14. Gently clamp the spool assembly using wooden
ring. blocks in a vice.
After that loosen spool end (20) to remove it.
: Plug (19): 98 N-m (10.0 kgf-m)
Hexagon width across flat: 17 mm : Spool end (20): 12 N-m (1.2 kgf-m)
15. Remove spring seat (21) and spring (22) from each
spool (there are two spools).
Note
- Cover the spool to protect it from being scratched.
- A thread adhesive is applied to the threaded section
of the spool end.
To disassemble the spool, heat the adhesive of the
threaded section using an industrial drier (heat gun)
or the equivalent.
Do not heat the threaded section to 200ºC or more.
If it is overheated, replace the spring with a new one.
44-25
Multiple control valve assembling (S/N

~1481)
Spool
3. Reinstall cap kit (5).
: Bolt: 42 N-m (4.3 kgf-m)

1. Attach spring seats (1) and spring (2) to the spool,
and then tighten bolt head at spool end (3).
Note
Carefully tighten the bolts so that the O-ring of the
: Spool end (3): 12 N-m (1.2 kgf-m)
flange is not caught and damaged.
Thread lock agent (Loctite® 262)
Note
Carefully clean all threads of any oil film using a non-oil
based solvent or locquic primer.
4. Sequentially insert poppet (6) and then spring (7)

into the housing seat section. After that, attach a
new O-ring (8) to plug (9), and then reinstall the
plug.
: Plug (9): 132 N-m (13.5 kgf-m)

2. Reinsert plug assembly (4).
: Plug (4): 98 N-m (10.0 kgf-m)
Note
Excessive torque on these plugs can cause the body to
crack or the poppets to stick.
44-26
Spool
5. Attach a new O-ring to the groove of the cover (10), 7. Slowly and carefully insert the spool assembly of
and then reinstall the cover on the valve housing. the bucket side into the valve housing.
Tighten socket head bolts (11). Apply hydraulic oil to the spool.
: Bolt (11): 157 N-m (16.0 kgf-m)

Note
Before reinstalling the cover, be sure to check the mat-
ing faces of the valve housing and the cover for foreign Spool
material or sharp pointed material.
8. Slowly and carefully insert the spool assembly of

the boom side into the valve housing in the same
way.
Apply hydraulic oil to the spool.
6. Insert the O-rings to caps (12), and then reinstall

the caps on the valve housing.
Tighten socket head bolts (13).
: Bolt (13): 42 N-m (4.3 kgf-m)

44-27
9. Insert a new O-ring to cap (14), and then reinstall 12. Tighten socket head bolts (17).
the cap on the spool of the bucket side.
Do not confuse the spools or caps since they are : Bolt (17): 42 N-m (4.3 kgf-m)
similar but different. Hexagon width across flat: 8 mm
10. Tighten socket head bolts (15). 13. Reinstall make-up valve (18).
: Bolt (15): 42 N-m (4.3 kgf-m) : Valve (18): 83 N-m (8.5 kgf-m)
11. Attach a new O-ring to cap (16), and then install the
cap on the spool of the boom side.
44-28
Multiple control valve assembly cautions
- Clean and check all the parts. If a part is defective,

replace or repair it.
- Apply a thin coat of hydraulic oil or grease to each
part before reassembly.
- Apply the specified torque to tighten each main part.
14. Reinstall the right and left overload relief valves

(19).
: Valve (19): 83 N-m (8.5 kgf-m)

Note
If the overload relief valves or main relief valve have
been disassembled back the adjusting screws out and
readjust after start up.
15. Reinstall the main relief valve (20).
: Valve (20): 103 N-m (10.5 kgf-m)

44-29
Multiple control valve disassembling and assembling (S/N 1482~)
Overload relief valve

with make-up function T7
Lock
T9 nut
T3 T8
Lock nut
T9 Main relief
T3 valve
T2
T6
T1
T3
Bucket spool
Lock nut
T9
T3
Make-up valve Lock
T9 nut
T6
Overload relief valve
with make-up function
T2
T4 L1
T4
Boom spool L1
T5
70ZV44001a
:
T1: 180 N-m (18.4 kgf-m) L1: Screw lock agent (Loctite® 262) application
T2: 39 N-m (4.0 kgf-m)
T3: 78 N-m (8.0 kgf-m) : 55 kg
T4: 18 N-m (1.8 kgf-m)
T5: 34 N-m (3.5 kgf-m)
T6: 410 N-m (41.8 kgf-m)
IMPORTANT
T7: 260 N-m (26.5 kgf-m) Before disassembly or reassembly, read and under-
T8: 65 N-m (6.6 kgf-m) stand the aforementioned "Hydraulic Parts Disas-
T9: 31 N-m (3.2 kgf-m) (Lock nut) sembly and Assembly Cautions" page 44-3.
44-30
Multiple control valve disassembling (S/N

1482~)
IMPORTANT
stand the aforementioned "Hydraulic Parts Disas- 3
70ZV44011J
1 3. Loosen the lock nut and remove make-up valve (3).
: Lock nut: 31 N-m (3.2 kgf-m)

: Valve: 78 N-m (8.0 kgf-m)
70ZV44009J
1. Loosen the lock nut and remove main relief valve 4

(1).
5 6
7 70ZV44012J
4. Remove socket head bolt (4)(5) from the bucket

and boom side of the cap. Then remove cap (6)(7).
2 : Bolt (4)(5): 34 N-m (3.5 kgf-m)

70ZV44010J
2. Loosen the lock nut and remove right and left over-
load relief valves (2).

44-31
15
8 O-ring
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)
distorted. Hexagon width across flat: 12 mm
16
11
19
13 17
18
12
10
70ZV44014J 70ZV44016J
6. Remove socket head bolt (10)(11) to remove caps 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)
Hexagon width across flat: 6 mm : Plug (16)(19): 260 N-m (26.5 kgf-m)
44-32
22 23
20
24
25
23
Spool
70ZV44017J 85ZV44024
9. Remove the hexagon bolts and remove cap (20). 11. Set the spool assembly in a rise, and then loosen
bolt (22) to remove.
: Bolt (20): 65 N-m (6.6 kgf-m)
Hexagon width across flat: 8 mm : Bolt (22): 18 N-m (1.8 kgf-m)
: Screw lock agent (Loctite® 262) application
12. Remove spring seat (23), spring (24), stopper (25)

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

70ZV44018J
To reassemble the multiple control valve, follow the
10. Remove plug assembly (21) and remove the O-
ring.
: Plug (21): 410 N-m (41.8 kgf-m) Multiple control valve assembly cautions
replace or repair it.
44-33
Hydraulic Cylinder
Hydraulic Cylinder
Boom cylinder removing and

installing
Boom cylinder removing
(The illustration shows the left side of the machine.)
WARNING
1. Attach sling to boom cylinder (1).
- Raise the boom until it is horizontal, and then place
: Boom cylinder: 145 kg
stand (A) under the boom to support it.
2. Disconnect hoses (2) (3).
: Oil: Approx. 10 L
- Use a stepladder or work platform, and do not
stand on the machine.
Note
Cover the disconnected hoses and pipes with plastic,
Before starting work: plugs, or caps to protect them from dust, water and dirt.
- Clean the area around the cylinder and piping.
Stand
85ZV44003
3. Remove lock bolt (4) and pin (5).

Relieving residual pressure from pipe
(a) Raise the boom. When the boom is approximately 4. Remove lock bolt (6) on the bottom side and
30 cm above the stand, stop the engine. remove retainer pin (7)
(b) Tilt the bucket all the way down, and then lower the
boom onto the stand. Move the bucket and boom 5. Sling boom cylinder (1) and lower it onto the
levers back and forth to fully relieve the pressure. ground.
(c) First press down on the hydraulic tank cap to vent
residual pressure, then open the cap of the hydrau- For the detailed description of cylinder disassembly and
lic tank. Leave hydraulic tank cap loosely on top of reassembly, refer to "Hydraulic cylinder disassembling
tank opening. and assembling" page 44-39.
44-34
Hydraulic Cylinder
Boom cylinder installing
To reinstall the boom cylinder, follow the above removal

procedure in reverse order.
Boom cylinder installation cautions
Be sure the pins accept grease after installation.
Cylinder air bleeding procedure
IMPORTANT
After repairing or replacing a cylinder, be sure to
bleed the cylinder of air, or the piston seal or back-up
ring may be seized.
(a) While operating the engine at low-idling speed,

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

ends 4 to 5 times.
(c) Add hydraulic oil to the tank, and check the cylinder
and its piping for oil leakage.
44-35
Hydraulic Cylinder
Bucket cylinder removing and

installing
Bucket cylinder removing
WARNING
Unexpected movement of machine, bucket, or boom
during service work could cause serious injury or
lowing items:
2. Disconnect hoses (4)(5).
- Place the boom and the bucket onto the ground.
Note
Cover the disconnected hose and the cylinder with plas-
tic, caps or plugs to protect them from dust, water and
- Use a step, and do not stand on the machine.
dirt.

- Clean the area around the cylinder and piping.
Relieving residual pressure from pipe
(a) Lower the boom and the bucket onto the ground.
(b) Stop the engine and move the bucket and boom
levers back and forth.
(c) Open the cap of the hydraulic tank to relieve the
residual pressure.
3. Attach sling to bucket cylinder (6).

After that, remove lock bolt (7) and pin (8).
1. Remove the coupler of bucket positioner switch (1),

and then remove bracket (2).
Remove rod (3) for the bucket positioner.
44-36
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.
4. Disconnect grease pipe (9). Refer to "Bucket positioner" page 15-9.
IMPORTANT
bleed the cylinder of air, or the piston seal or back-up
ring may be seized.

Note
5. Remove lock bolt (10) and pin (11). Stop the piston about 100 mm before stroking fully.
6. Slowly lift up bucket cylinder (6) and remove the (b) After that, stroke the cylinder piston fully to both
shim. ends 4 to 5 times.
Lower the bucket cylinder onto the ground.
For the detailed description of cylinder disassembly and its piping for oil leakage.
and reassembly, refer to "Hydraulic cylinder disas-
sembling and assembling" page 44-39.
Bucket cylinder installing
To reinstall the bucket cylinder, follow the above

44-37
Hydraulic Cylinder
Steering cylinder removing and

installing
Steering cylinder removing
WARNING
Unexpected movement of machine could cause seri-
ous injury or death. To prevent such an accident,
parking brake. In addition, block the tires with
chocks to prevent the wheels from moving.
- Place the boom and the attachment onto the
2. There is a pin (5) between front chassis (3) and
ground.
steering cylinder (4).
- Stop the engine, and turn the steering wheel clock-
Remove pin (5), and then push rod (6) into the cyl-
wise and counterclockwise to relieve the pressure
inder to shorten the length of the cylinder.
from the line.
- Press cap downward to vent, then open the cap of
: Approx. 2 L
the hydraulic tank to relieve the internal pressure
Oil will be drained from the oil port of the cylinder.
from the tank.
Place a container at the oil port to catch the drained
- Place a "DO NOT START!" tag on the steering
oil.
wheel or the operator's seat.

- Clean the area around the cylinder to be removed.
3. Disconnect grease pipe (6).
1. Disconnect hoses (1)(2).
Note
Cover the disconnected hoses with plastic, caps, or
plugs to protect them from dust, water, and dirt.
44-38
Hydraulic Cylinder
Steering cylinder installation cautions
Pin installation
Be sure the pins accept grease after installation.
IMPORTANT
Insert shims so that the clearance between the chas-
sis and the cylinder is 1.2 mm or less.
Place approximately the same number of shims
under the cylinder as on top of the cylinder. Refer to
"Linkage Pin Standard Clearance Values" page 15-3.
4. Remove bolt (7) and pin (8).
WARNING
5. Remove steering cylinder assembly (4).
Note that two persons are needed to remove and Articulation area is a crush zone. Moving the machine
lift the assembly. with a person in this area can cause injury or death.
When turning the steering wheel while engine is run-
: Steering cylinder: 26 kg ning, do not enter the articulation area of the
machine.
Note If a person is in the articulation area, do not start the
For detailed description of cylinder disassembly and engine.
reassembly, refer to "Hydraulic cylinder disassembling
and assembling" page 44-39.
Steering cylinder installing IMPORTANT

To reinstall the steering cylinder, follow the above bleed the cylinder of air, or the piston seal or back-up
removal procedure in reverse order. ring may be seized.

Note
Stop the piston about 100 mm before stroking fully.
(b) After that, stroke the cylinder piston fully to both

ends 4 to 5 times.
and its piping for oil leakage.
44-39
Hydraulic Cylinder
Hydraulic cylinder disassembling and assembling
IMPORTANT
Hydraulic cylinder cross section and tightening torque
Boom cylinder
T1 T2
70N44005
(S/N 1001~1056, 7101~7128) : Boom cylinder: 145 kg

T1: 2,648 N-m (270 kgf-m)
T2: 588 N-m (60 kgf-m)
(S/N 1057~1200, 7129~7200)

T1: 2,648 N-m (270 kgf-m)
T2: 471 N-m (48 kgf-m)
(S/N 1201~, 7201~)

T1: 3,040 N-m (310 kgf-m)
T2: 471 N-m (48 kgf-m)
T1: Piston nut width across flats: 80 mm

44-40
Hydraulic Cylinder
22
6
(S/N ~1200, ~7200)
8
7
6
22
1
7 12
13
15
14 11
20
18 3
19
16
17
4
5
23
(S/N 1227~, 21
7224~) 25
2
(S/N ~1056,
~7128)
9
10
9
70N44003a
1. Cylinder tube 16. O-ring

2. Rod 17. Back-up ring
3. Piston 18. U-packing
4. Rod cover 19. Back-up ring
5. Bushing 20. Buffer ring
6. Bushing 21. Scraper ring
7. Piston nut 22. Dust seal
8. Stop ring 23. Stop ring
9. Bolt 24. —
10. Spring washer 25. Stop ring
11. Wear ring
12. Square ring
13. Slipper ring
14. O-ring
15. Wear ring
44-41
Hydraulic Cylinder
Bucket cylinder (S/N ~1964, ~7775)
T1 T2
70N44006

T1: 4,217 N-m (430 kgf-m)
T2: 880 N-m (90 kgf-m) : Bucket cylinder: 141 kg
(S/N ~1226, ~7223)

22
6
1 22
12
25
13
24
8 14
7 (S/N 1048~,
11
7126~) 15
16
17
18
19
20
4
5
23
2
21
10 22
9 6
26 22
(S/N 1048~, 7126~) 70K44027a
1. Cylinder tube 10. Spring washer 19. U-packing

2. Rod 11. Wear ring 20. Back-up ring
3. Piston 12. Square ring 21. Scraper ring
4. Rod cover 13. Slipper ring 22. Dust seal
5. Bushing 14. Wear ring 23. Stop ring
6. Bushing 15. O-ring 24. Plug
7. Piston nut 16. O-ring 25. O-ring
8. Stop ring 17. Back-up ring 26. Plug
9. Bolt 18. Buffer ring
44-42
Hydraulic Cylinder
Bucket cylinder (S/N 1965~, 7776~)
T1 T2
70N44006a
(S/N 1965~2550, 7776~) (S/N 2551~)

T1: 5,900±300 N-m (602±31 kgf-m) T1: 5,900±300 N-m (602±31 kgf-m)
T2: 880±90 N-m (90±9 kgf-m) T2: 500±65 N-m (56±6.6 kgf-m) (S/N 2551~)
880±90 N-m 500±65 N-m

(90±9 kgf-m) (56±6.6 kgf-m)
Cylinder bolt (20) tightening torque

K70V2J42023
Note
Number of cylinder fixing bolt (T2) has increased on S/N
70J1-2551 and thereafter.
44-43
Hydraulic Cylinder
22
1 6
22 11
3
24 25 8
25
24 14
15
7
17
23
5
18
19
20
4
22 2
21 6
22
9
K70ZIV4403
1. Cylinder tube 10. — 19. U-packing

2. Rod 11. Wear ring 20. Back-up ring
3. Piston 12. — 21. Scraper ring
4. Rod cover 13. — 22. Dust seal
5. Bushing 14. Wear ring 23. Stop ring
6. Bushing 15. O-ring 24. Plug
7. Piston nut 16. — 25. O-ring
8. — 17. Back-up ring
9. Bolt 18. Buffer ring
44-44
Hydraulic Cylinder
Steering cylinder (S/N 1001~1972, 7101~7771)
T1
T2
70N44007

T1: 1,471 N-m (150 kgf-m)
T2: 1,569 N-m (160 kgf-m) : Steering cylinder: 26 kg
(S/N ~1226, ~7223)

11
1 6
11
1
3
13
14
16 15
8 17 12
(S/N 1227~, 7224~) 18
20
10
(S/N ~1226,
~7223)
22 21 (S/N 1048~, 7126~)
19 (S/N ~1047, ~7125) 2

9
7
5 11
6
11
70N44004a
1. Cylinder tube 10. O-ring 19. Back-up ring

2. Rod 11. Dust seal 20. Back-up ring
3. Piston 12. Wear ring 21. Buffer ring
4. Rod cover 13. Square ring 22. Screw
5. Bushing 14. Slipper ring
6. Bushing 15. O-ring
7. Scraper ring 16. O-ring
8. Piston nut 17. Back-up ring
9. Stop ring 18. U-packing
44-45
Hydraulic Cylinder
Steering cylinder (S/N 1973~, 7772~)
T1 T2
70N44007
T1: 930±50 N-m (95±5 kgf-m)

T2: 300±30 N-m (31±3 kgf-m)
(S/N 1973~1982, 7772~7852)
11
6
11
1
3
12 12
8
9
5
16
17
18
4
13 2
14
15
11
6 11
K70ZIV4404
1. Cylinder tube 9. Clip 17. Back-up ring

2. Rod 10. — 18. O-ring
3. Piston 11. Dust seal 19. Buffer ring
4. Rod cover (case) 12. Wear ring
5. Bushing 13. Packing
6. Bushing 14. Back-up ring
7. Packing 15. Dust seal
8. Piston nut 16. O-ring
44-46
Hydraulic Cylinder
(S/N 1983~, 7853~)
11
6
11
3
1
7
12
12
8 9
16
17
13
18 14
4
2
5
9
15
11
6
11
K70ZIV4405
1. Cylinder tube
2. Rod : Steering cylinder: 24 kg
3. Piston
4. Rod cover (case)
5. Bushing
6. Bushing
7. Packing
8. Piston nut
9. Clip
10. —
11. Dust seal
12. Wear ring
13. Packing
14. Back-up ring
15. Dust seal
16. O-ring
17. Back-up ring
18. O-ring
19. Buffer ring
44-47
Hydraulic Cylinder
Hydraulic cylinder disassembling
Note
The boom 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)
(Bucket cylinder) (S/N ~2550)
880 N-m (90 kgf-m)
(Bucket cylinder) (S/N 2551~)
500 N-m (56 kgf-m)
: Rod cover (1):

(Steering cylinder) (S/N ~1972, ~7771)
1,569 N-m (160 kgf-m)
(Steering cylinder) (S/N 1973~, 7772~)
300 N-m (31kgf-m)
44-48
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.
8. Remove wear ring (8), square ring (9), slipper ring
(10), O-ring (11), wear ring (12) and piston packing
6 (19).
(There is no square ring (9), slipper ring (10) and O-
C ring (11) for the bucket cylinder and the steering
cylinder.)
Note
Hydraulic jack Refer to "Boom cylinder" page 44-39 through "Steering
cylinder (S/N 1973~, 7772~)" page 44-45 for each parts.
Hydraulic cylinder
95ZV44009
1
6. Use a hydraulic jack or hydraulic cylinder to loosen

piston nut (6).
Piston nut width

Tightening torque
across flats
(S/N ~1200, ~7200) 4
2,648 N-m (270 kgf-m)
Boom cylinder 80 mm
(S/N 1201~, 7201~)
3,040 N-m (310) kgf-m)
95ZV44013
(S/N ~1964, ~7775)
4,217 N-m (430 kgf-m)
Bucket cylinder 90 mm
(S/N 1965~, 7776~)
5,900 N-m (602 kgf-m)
9. Remove rod cover (1) from piston rod (4).
(S/N ~1972, ~7771)
1,471 N-m (150 kgf-m) 10. Remove scraper ring (13), back-up ring (14), U-
Steering cylinder 50 mm
(S/N 1973~, 7772~) packing (15), buffer ring (18), back-up ring (16), O-
930 N-m (95 kgf-m) ring (17), stop ring (20) and dust seal (21) from rod
cover (1).
Note
Refer to "Boom cylinder" page 44-39 through "Steering
cylinder (S/N 1973~, 7772~)" page 44-45 for each parts.
44-49
Hydraulic Cylinder
Hydraulic cylinder assembling Hydraulic cylinder assembly cautions
To reassembling the hydraulic cylinders, follow the Before starting work:

above removal procedure in reverse order. - Be sure to replace all the seals and packings.
replace it.
- Before reassembling the parts, apply a coat of
hydraulic oil to the parts.
CAUTION
Hot oil can cause injury or burns.
Avoid contact with hot oil.
Slipper ring installation
Slipper ring
Piston nut
Example of boom cylinder K70ZIV4406
Put the slipper ring into hot oil to heat the ring to
120~150ºC.
Note
- This is because the inner diameter of the slipper ring
is smaller than the outer diameter of the piston.
Therefore, heat the slipper ring to expand its inner
diameter for easy attachment.
- Attach the slipper ring while taking care not to dam-
age the ring by over expansion.
- After attaching the slipper ring, cool the slipper ring
so that it is contracted to the original size.
44-50
Hydraulic Cylinder
Back-up ring installation Rod cover installation
95ZV44017 K65V2E44013
Before installing back-up ring (2) and O-ring (3), heat When installing the rod cover of the steering cylinder,
the back-up ring. screw the 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 :
easily attach the back-up ring to the rod cover, heat the 1,569 N-m (160 kgf-m) (S/N ~1972, ~7771)
ring to soften it. The soft ring can be easily expanded. 300 N-m (31 kgf-m) (S/N 1973~, 7772~)
Be careful not to over expand the back-up ring. After

installation, wait until the back-up ring is cooled, and
then insert the rod cover into the cylinder tube.
Caulking
Caulking
Caulk rod cover (1) at four points to prevent scraper ring

(13) from coming out.
44-51
Pilot Valve
Pilot Valve
For bucket control
Neutral For bucket For boom

1 control control
Roll back Dump
(Detent)
8
2
3
To tank port
4
5 P
6
From pump port
7
Bucket Boom
spool in spool in
To / from MCV oil packs MCV MCV
View from the rear side
80ZV42017
1. Lever
2. Disc
3. Push rod
4. Spring seat
5. Spring for secondary pressure
6. Return spring
7. Spool
8. Detent magnet solenoid
44-52
Pilot Valve
For boom control
Raise Neutral Down Float

(Detent) (Detent)
To tank port
95ZV42012
44-53
Pilot Valve
Pilot valve removing and installing PUS switch

Pilot valve
Pilot valve removing

6
WARNING
observe the following items: 7
- Park the machine on level ground, and then block
tires with chocks to prevent wheels from moving.
- Apply the parking brake. 70N44008
- Lower the attachment onto the ground, and then
relieve the internal pressure from the line.
- Relieve the internal pressure from the hydraulic 3. Separate the PUS switch.
tank. Disconnect electrical line (6) of the PUS switch.
4. Disconnect electrical line (7) from the pilot valve.
Note
Cover mount Before disconnecting the electrical couplers, be sure to
put matchmarks on them.
Pilot valve
Control box
1. Open the cab door (the right hand side).

Remove cover (1) from the control box.
Pilot valve
5. Disconnect hoses (8)(9)(10) from the pilot valve.
: Drain oil: Approx. 1 L
Note
Before disconnecting the hoses, be sure to put
matchmarks on them.
Cover the disconnected hoses with plastic, caps, or
plugs to protect them from dust and dirt.
2. Remove the knobs, boot (2), and covers (3)(4)(5).

44-54
Pilot Valve
Pilot valve installing
To reinstall the pilot valve, follow the removal procedure

in reverse order.
Pilot valve
Pilot valve installation cautions
After reinstallation, check operation of the pilot valve. In

addition, check the pilot valve for oil leakage.
If the oil level is too low, add hydraulic oil to the tank.
6. Loosen nut (11) and disconnect the rod from the

pilot valve.
Remove bolt (12) (4 pcs) and pull up the pilot valve
to remove it.
: Bolt (12): 28 N-m (2.9 kgf-m)

: Pilot valve: 9.5 kg
44-55
Pilot Valve
Pilot valve disassembling and assembling
IMPORTANT
Pilot valve tightening torque
For boom
FRONT
Bucket side Boom side
For bucket
T1 T1
T3 L1 T3 L1
T3
T5 T5
T4 T4
T3
T4
T1 T1 T4
T1 T1
:
T1: 29 N-m (3.0 kgf-m)
T2
T2: 36 N-m (3.7 kgf-m)
T3: 17 N-m (1.7 kgf-m)
T4: 42 N-m (4.3 kgf-m)
T5: 12 N-m (1.2 kgf-m) T1 T1 95ZV44021
: L1: Screw lock agent (Three Bond 1327) : Pilot valve: 9.5 kg
44-56
Pilot Valve
Pilot valve disassembling 3. Loosen the lock nut for solenoid (3), and then
remove solenoid from cover (2).
IMPORTANT : Solenoid: 42 N-m (4.3 kgf-m)

- Place the removed parts, in order, on a clean
paper or cloth. 4. Be sure to carefully store ball (4).
- Carefully disassemble the pilot valve so that the
parts are not scratched.
5
(Illustrated on the boom side. Disassemble the bucket 6
side in the same manner.)
7
1. Plug all ports of the pilot valve and rinse it with illu-
minating kerosene.
1
97ZV44024
3
4
5. Loosen socket bolt (5).
Put a matchmark on lever (6) and disc (7) and
remove lever (6) from disc (7).
2
: Bolt (5): 29 N-m (3.0 kgf-m)
8
97ZV44023
2. Clamp the pilot valve in a vise.

Pull up boot (1) to remove it from cover (2).
Lock nut
9
97ZV44025
6. Loosen socket bolt (8).

Remove cam shaft (9).
: Bolt (8): 17 N-m (1.7 kgf-m)

95ZV44076
Note
Note In case the cam shaft cannot be pulled out, use the
Before removing solenoid (3), measure the distance (A) hexagon wrench to push it out.
between solenoid (3) and cover (2).
44-57
Pilot Valve
11
12
7 10
13
14
97ZV44026 97ZV44028
7. Temporarily tighten socket bolt (5). 10. Put matchmark on plug (11), push rod (12) and
Put matchmark on disc (7) and cover (2). case assembly (14).
Pull up socket bolt (5) with disc (7) to remove it. Remove plug (11) together with push rod (12).
8. Loosen socket bolt (10). Note

- Carefully store the spring and spring seat in the push
: Bolt (10): 12 N-m (1.2 kgf-m) rod.
- Carefully remove plug (11) as it may spring out by
Note the spring force. Be careful so that the parts are not
In case the spring force for the return spring is strong, damaged.
alternately loosen the socket bolts so that cover (2) can - In case plug (11) does not come out, use a screw-
be level. driver to remove it.
11. Put matchmark on reducing valve assembly and

A case assembly. Remove reducing valve assembly
2
(13) from case assembly (14).
A
11
12
97ZV44027
19
20
9. Put matchmark on cover (2) and the case assem-
bly.
97ZV44032
Remove cover (2) from the case assembly.
12. Disassemble plug (11).

- Remove spring (19) and spring seat (20) from
push rod (12), when mounted.
- Remove push rod (12) from plug (11).
Note
Keep the disassembled parts per each port.
44-58
Pilot Valve
24
23
25 Carefully install the

spool into the case.
26
22
97ZV44033 95ZV44022
13. Disassemble reducing valve (13). Note

- Push down spring seat (23). When installing, carefully install the spool assembly so
- Remove plain washer (24). that the end of the spool does not hit the hole corner in
- Remove spring (25) and shim (26), if any, the case assembly.
from spool (22).
Note 17
- Carefully remove plain washer so that the spool is 18
not damaged.
- Do not push down spring seat (23) 4 mm or more.
- Shim is for the secondary pressure adjustment.
16
14
97ZV44031
14
15 15. Clamp case assembly (14) in a vise up side down.

Put matchmark on plate (18) and case assembly
(14).
Loosen socket bolt (17) and remove plate (18) from
the case assembly.
97ZV44029
: Bolt (17): 29 N-m (3.0 kgf-m)

14. Put matchmark on return springs (15)(16) and case
assembly (14).
Remove return springs (15)(16) from case assem-
bly (14).
44-59
Pilot Valve
Pilot valve assembling Pilot valve assembly cautions
To reassemble the pilot valve, follow the above disas- - Clean and check all the parts. If any part is defective,
sembly procedure in reverse order. replace or repair it.

- Measure the resistance of each coil magnet assem-

bly. The resistance should be 138 Ω at normal room
temperature (20ºC). If measured in extremely low
temperatures the resistance will be less, and at oper-
ating temperature the resistance will be higher.
24
Sharp edge
side
22
95ZV44023
- Install plain washer (24) so that the plain washer

sharp edge side comes to the top.
- Do not push spring seat (23) 4 mm or more.

44-60
Orbitrol® (S/N 2201~, 8251~)
Orbitrol® (S/N 2201~, 8251~)
Orbitrol® removing and installing

Orbitrol® removing
WARNING
- Park the machine on level ground, and lower the 2
attachment onto the ground.
- Block tires with chocks to prevent wheels from K70IV2EX44001
moving.
- Before starting work, be sure to remove the engine 1. Remove cover (1).
steering wheel or the operator's seat. 2. Remove floor mat (2).
- Relieve the internal pressure from the steering
hydraulic line by turning the steering wheel left and
right.
tank.
3
Note
This work should be done by two persons. One person
should support the Orbitrol® under the machine. The
person in the cab should remove the retainer bolt. Orbitrol®
K70IV2EX44002
3. Put matchmarks on hoses (3), and then disconnect

them from Orbitrol® (4).
44-61
Orbitrol® (S/N 2201~, 8251~)
Orbitrol® installation cautions
At the completion of reinstallation, check operation of

the Orbitrol® by following the procedure below:
WARNING
5 Entering the articulation area while engine is running
4
may cause serious injury or death.
So, when entering the area, stop the engine and
place "DO NOT START" or "DO NOT OPERATE" tag
Orbitrol®
on steering wheel or the operator's seat.
K70IV2EX44003
Start the engine and check around the Orbitrol® for oil
4. Remove bolts (4) (5), and then remove the leakage.
Orbitrol®.
: Bolt (4)(5): 53 N-m (5.4 kgf-m)

: Orbitrol®: 7.3 kg
Orbitrol® installing
To reinstall the Orbitrol®, follow the above removal pro-

44-62
Orbitrol® (S/N 2201~, 8251~)
Orbitrol® disassembling and

assembling
IMPORTANT
Orbitrol® cross section and tightening torque
Centering springs
Push spool O-ring

Plate
Check value
Sleeve O-ring
Make-up valve T1
Needle bearing Ball

Housing
O-ring
Seal unit
Spacer End cap

Overload relief
valve
Rotor assembly
Drive shaft
Retainer
70V2E44014
: : 7.3 kg
T1: 28 N-m (2.9 kgf-m)
44-63
Orbitrol® (S/N 2201~, 8251~)
Orbitrol® disassembling
[ Disassembling rotor ]
1
Make matchmarks
before disassembling
unit. 25 A
(1 m m
in)
Housing
70V2E44015
Copper plate
1
60ZV44123
5
®
1. Set the Orbitrol in a vise so that the rotor side
1
comes to the top position.
Use a copper plates on a vise and do not tighten
the vise too strong.
3
70V2E44016
2. Remove seven bolts (1), end cap (3), O-ring (4)

and spacer (5).
Note
The make-up valve installed in the housing is tightened
with bolts (A).
When removing the bolts, take care not to drop the
make-up valve.
44-64
Orbitrol® (S/N 2201~, 8251~)
7
13
14
12
16
8 6 15
60ZV44081 70V2E44017
3. Remove rotor assembly (6) and O-ring (7). 5. Remove the housing from the vise.
Remove adapter screw (12), Spring pin (14) and
Note ball (13) of the emergency check valve by a screw
Keep star (8) in rotor assembly (6). driver.
Also remove pin (15) and ball (16) of the make-up
valve.
10
9
11
60ZV44082
4. Remove drive shaft (9), spacer plate (10) and O-

ring (11).
44-65
Orbitrol® (S/N 2201~, 8251~)
[ Disassembling valve ]
18 19
20
60ZV44086
17
60ZV44084
8. Remove Y-packing seal (19) and dust seal (20)
from seal retainer (18).
6. Remove retainer ring (17) with a screw driver.
Note
Note Take care not to damage seal retainer (18).
Carefully remove the retainer ring so that it does not
spring out.
23
21
18
22
60ZV44087
60ZV44085
9. Remove races (21), needle bearing (22), and O-
ring (23).
7. Place the housing horizontally on clean cloth.
Rotate the spool and sleeve so that the pin can be
in a horizontal position. Remove seal retainer (18)
by pressing the spool and sleeve from behind with
your fingers.
44-66
Orbitrol® (S/N 2201~, 8251~)
27
Housing
26
25
Spool / sleeve
assembly
60ZV44088 60ZV44090
10. Pull the spool and sleeve assembly out slowly, turn- 12. Push spool (25) slightly out of sleeve (26), and
ing it clockwise and counterclockwise from the remove centering springs (27).
housing.
Note
Take care so that the spool and sleeve assembly do not
damage the housing.
26
Spool / sleeve 26
assembly 25
25
60ZV44091
24
13. Pull spool (25) from sleeve (26) while slowly turning
the spool clockwise and counterclockwise.
Matchmark
60ZV44089
11. Pull out pin (24) from the spool and sleeve assem-
bly.
Note
Before pulling out pin (24), put matchmarks on spool 31
30
(25) and sleeve (26) for reassembly. 29
28
27
Overload relief valve units

70V2E44018
14. Remove plug (27) to remove O-ring (28) from the

plug using a hexagon (allen) wrench (width across
flat: 5 mm).
Take out spring (29), poppet (30) and seat (31) (2
places).
44-67
Orbitrol® (S/N 2201~, 8251~)
Orbitrol® assembling
32 [ Reassembling valve ]
Spring groove
26
Spring groove
60ZV44093
25
Note
Inlet check valve (32) built in port P is connected with Matchmark
the housing and cannot be removed. 60ZV44094
1. Assemble spool (25) and sleeve (26) so that the

spring grooves in them are lined up. Use light oil for
assembly of parts
Note
- Confirm that the spool can be turned easily in the
sleeve.
- Align the matchmarks on the spool and sleeve.
25
27
26
60ZV44095
2. Install centering springs (27) through the spring

grooves in spool (25) and sleeve (26) using a
spring insertion jig.
Note
Assemble two sets of 2 springs each, back to back, with
the flat plate in between the sets, and install with the
notches at the ends facing downward.
44-68
Orbitrol® (S/N 2201~, 8251~)
26
22 21
23
25
24
Matchmark
60ZV44096 60ZV44098
3. Insert pin (24) in the holes in spool (25) and sleeve 5. Install O-ring (23), races (21), and needle bearing
(26) until the end of the pin is flush with the surface (22).
of the sleeve.
18 19
Housing 20
Spool / sleeve
assembly
60ZV44086
60ZV44097
6. Insert dust seal (20) and Y-packing seal (19) in seal

4. Insert the spool and sleeve assembly squarely retainer (18).
inward from the back of housing.
Note
- Take care not to tilt the assembly and cause damage 17
during insertion.
- Insert the assembly until the back end of the assem-
bly is flush with the back end of the housing. 18
- Confirm that the assembly can be turned easily in
the housing. 25
60ZV44099
7. Insert seal retainer (18) onto spool (25), and then

tap it gently into position with a plastic-faced ham-
mer. Then install retainer ring (17).
44-69
Orbitrol® (S/N 2201~, 8251~)
[ Reassembling rotor ]
Screw driver
Dust seal
Retainer ring
Seal retainer 25
(1 m m
in)
Y-packing seal
O-ring
Housing
Plate
80V2E44019
60ZV44102
Note
Be sure that the position and direction of the seals are
placed correctly. 9. Set the Orbitrol® in a vise so that the rotor side
comes to the top position.
Use a copper plates on a vise and do not tighten
27 the vise too strong.
28
Overload relief 29
valve units 30
31 10
Housing
11 12
15
14
16 13
70V2E44019
8. Insert O-ring (28) in plug (27). Apply grease to ball

70V2E44020
holder (30) and install ball (31).
Insert ball holder (30) and spring (29) into the hous-
ing, and then insert plug (27) using the hexagon 10. Insert ball (16) and pin (15) of the make-up valve to
wrench (width across flat: 5 mm). the housing.
Insert ball (13) and spring pin (14) of the emer-
gency check valve and tighten adapter screw (12)
by a screw driver.
Then install O-ring (11) to the housing and put on
spacer plate (10).
Align the bolt holes in the plate with those in the
housing.
44-70
Orbitrol® (S/N 2201~, 8251~)
Grooves in rotor bore A

Port face
B
9
Drive shaft
C
Parallelize with
port face D
Pin
Port face
24 95ZV44029
11. Insert drive shaft (9) to mate its yoke with pin (24). 13. Holding the rotor assembly with the O-ring side fac-
Rotate the spool and sleeve so that the pin (24) can ing the spacer plate, install the assembly so that
be parallel with the port face. the grooves in the star-shaped bore mesh with the
drive shaft.
Note
Put a matchmark on the end face of the drive shaft par- Note
allel with the pin. - Align the bolt holes in the rotor assembly with those
in the housing without disengaging the drive shaft
from the rotor assembly's star-shaped bore.
- Confirm that lines A, B, C and D are all parallel.
6
1
7 1
2
60ZV44105
3
12. Put O-ring (7) in rotor assembly (6).

K70V2J44022
14. Install spacer (4), O-ring (3) and end cap (2).
Provisionally tighten bolt (1).
: Provisional tightening torque:

15 N-m (1.5 kgf-m)
Tightening torque: 28 N-m (2.9 kgf-m)
44-71
Orbitrol® (S/N 2201~, 8251~)
6 4
1 2
3 7
5
60ZV44112
15. Evenly tighten the seven bolts in the order shown

above.
44-72
Priority Valve (S/N 2201~, 8251~)
Priority valve removing and

installing 8
5
Priority valve removing
6
WARNING
1
- Park the machine on level ground, and lower the
attachment onto the ground. K70IV2EX44005
- Block tires with chocks to prevent wheels from
moving.
2. Disconnect hoses (5)(6) to the Orbitrol® and drain
hose (7).
Note
steering wheel or the operator's seat.
- Approximately 1 L of hydraulic oil will be drained
- Relieve the internal pressure from the steering
from the disconnected hoses. Place a container to
hydraulic line by turning the steering wheel left and
receive the drained oil.
right.
- Cover the disconnected hoses with vinyl, plugs or
caps to protect them from dust and dirt.
tank.
3. Loosen bolt (8) to remove priority valve (1).
- Release residual pressure in the loading and steer- : Priority valve: Approx. 6 kg
ing lines.
Priority valve installing

2
To reinstall the priority valve, follow the above removal

K70IV2EX44004
1. Disconnect hoses (2)(3) from the pump, hose (4) to

the multiple control valve.
Note
44-73
Priority valve disassembling and assembling
IMPORTANT
Priority valve cross section and tightening torque
T2 T2
2
T1
70V2E44023
:(S/N ~2429) Priority valve disassembly cautions

T1: 25 N-m (2.5 kgf-m)
T2: 54 N-m (5.5 kgf-m) Carefully remove plug (1) or (2). It may spring out by the
spring force. Alternately loosen plug (1)(2) to reduce the
:(S/N 2430~) spring force and remove them.
T1: 21 N-m (2.1 kgf-m)
T2: 44 N-m (4.5 kgf-m)
44-74
Accumulator (S/N 2201~, 8251~)
Accumulator (S/N 2201~, 8251~)
Accumulator removing and install-

ing
Accumulator removing
2
WARNING
- Park the machine on level ground, and lower the
attachment onto the ground.
- Block tires with chocks to prevent wheels from
moving.
steering wheel or the operator's seat, or discon-
nect the negative side of the battery. 1
Accumulator
- Press the hydraulic oil tank cap, and relieve the 4
3
internal pressure from the hydraulic tank.
K70IV2EX44006
1. Remove cover (1) from the hydraulic oil tank.
2. Remove hose (2).
3. Remove nut (3) and then remove band (4).
4. Remove accumulator.
: Accumulator: 2.7 kg/pc
Accumulator installing
To reinstall the accumulator, follow the above removal

Accumulator installation cautions
- Replace all O-rings and seals during reinstallation.

- After reinstallation, completely bleed the brake line
of air, and check performance of the accumulator.
45-1
70ZIV-2 Service Standard Hydraulic Group

Hydraulic Group
Steering Linkage (S/N ~2200, ~8250) ..................... 45-2

Gear Pump .............................................................. 45-4
Hydraulic Cylinder ................................................... 45-5
Pilot Valve................................................................ 45-6
45-2
Steering Linkage (S/N ~2200, ~8250)
Center of
center pin
Drop arm
Left-turn position
45-3
Steering linkage tightening torque
No. Item Standard value Solution
1 Steering valve retainer bolt tightening torque 52.5 N-m (5.35 kgf-m)
2 Link bracket retainer bolt tightening torque 216 N-m (22.0 kgf-m)
3 Ball joint retainer nut tightening torque 191 N-m (19.5 kgf-m)
4 Ball joint lock nut tightening torque 113 N-m (11.5 kgf-m) Tightening
5 Steering valve bracket retainer bolt tightening torque 216 N-m (22.0 kgf-m)
6 Overload relief valve tightening torque 83 N-m (8.5 kgf-m)
7 Main relief valve tightening torque 103 N-m (10.5 kgf-m)

45-4
Gear Pump
Gear Pump
Front (for steering) Center (for loading) Rear (for loading)
1 Deviation of the gear width 0.01 mm or less Replacement of pump assy
2 Deviation of the drive and the driven shaft outer diameter 0.01 mm or less Replacement of pump assy
3 Deviation of the inner diameter of the bushing 0.02 mm or less Replacement of pump assy
4 Roughness of the pressure plate surface 0.02 mm or less Replacement of pump assy
5 Pump connection bolt tightening torque 34 N-m (3.5 kgf-m) Tightening
6 Pump connection bolt tightening torque 34 N-m (3.5 kgf-m) Tightening

45-5
Hydraulic Cylinder
Hydraulic Cylinder
Boom cylinder
Steering cylinder
Unit: mm
Judgment standard
No. Item Standard rod Standard value Standard Limit Solution
diameter Rod Bushing clearance Bushing Clearance
Boom cylinder ø75 -0.030~-0.076 +0.195~+0.060 0.090~0.271 +0.295 0.371 Replacement
1 Bucket cylinder ø80 -0.030~-0.076 +0.190~+0.060 0.090~0.266 +0.290 0.366 Replacement
Steering cylinder ø45 -0.025~-0.064 +0.105~0 0.025~0.169 +0.205 0.269 Replacement
No. Item Boom cylinder Bucket cylinder Steering cylinder

(S/N ~1200, ~7200) (S/N ~1964, ~7775) (S/N ~1972, ~7771)
2,648 N-m (270 kgf-m) 4,217 N-m (430 kgf-m) 1,471 N-m (150 kgf-m)
Piston nut tightening torque
(S/N 1201~, 7201~) (S/N 1965~, 7776~) (S/N 1973~, 7772~)
2 3,040 N-m (310 kgf-m) 5,900 N-m (602 kgf-m) 930 N-m (95 kgf-m)
Piston nut size (mm) M52 x 2 M62 x 2 M33 x 3
Piston nut width across flat (mm) 80 90 50
(S/N 1001~2550, 7101~) (S/N ~1972, ~7771)
880 N-m (90 kgf-m) 1,569 N-m (160 kgf-m)
Rod cover bolt tightening torque 471 N-m (48 kgf-m)
3 (S/N 2551~) (S/N 1973~, 7772~)
500 N-m (56 kgf-m) 300 N-m (31 kgf-m)
Bolt size (mm) M20 M24 (Rod cover)
4 Piston stroke (mm) 754 502 380
45-6
Pilot Valve
Pilot Valve
97ZV45002a
Judgment standard
No. Item Solution
Standard valve Allowable limit
Wear
1 mm
2 Push rod 36 mm 35 mm Replacement
85V2E45003 Ø 7 mm
54-1
70ZIV-2 Disassembly & Reassembly Brake Group

Brake Group
Brake Valve Assembly............................................. 54-2

Air Master Assembly ............................................... 54-6
Service Brake .......................................................... 54-11
Air Cylinder for Parking Brake ................................. 54-12
Parking Brake.......................................................... 54-17
Air Tank ................................................................... 54-19
54-2
Brake Valve Assembly
Brake valve removing and install-

ing
Brake valve removing
WARNING
- Block the front wheels with chocks to prevent the
wheels from moving.
- Relieve the air pressure from the air tank.
3. The person in the cab should remove three connec-
tion bolts (5) from brake pedal (4), and the person
Before starting work: under the machine should remove the brake valve.
- Stop the engine. Depress the brake pedal many Remove pedal assembly (4) from the top side.
times until there is no brake pressure.
- Clean the area around the brake valve.
Brake valve installing
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.
To check or adjust the brake valve, refer to the 70ZIV-2
Shop Manual, Function & Structure, Section 53.
1. Disconnect air pipes (1), tee (2), and then discon-

nect air hose (3).
Note
Cover the disconnected hoses and pipes with plastic,
plugs or caps to protect them from dust and dirt.
2. One person should support the brake valve under

the machine, and another person should enter the
cab.
54-3
Brake valve disassembling and assembling

Brake valve cross section and tightening torque (main valve)
:
T1: 12 N-m (1.2 kgf-m)
T2: 6 N-m (0.6 kgf-m)
T3: 34 N-m (3.5 kgf-m)
:
L1: Liquid gasket
(Loctite® gasket 568)
L2: Anti-seize compound
1. Diaphragm
2. Cover
3. Inlet / exhaust valve
assembly
4. Body
5. Piston
6. Relay piston assembly
7. Valve assembly
8. Body
9. Upper piston assembly
10. Spring seat
11. Boot
12. Plunger
13. Roller
14. .Spring
15. Pin
16. Pedal
54-4
Brake valve disassembling

- Clean the outer surface of the valve.
4. Remove retainer ring (4), spring seat (5), O-rings

(6)(7), retainer (8), valve spring (9), and inlet
exhaust valve (10).
Also remove body retainer bolt (11).
1. Remove diaphragm (1) and cover (2).
5. Separate the body into two sections (12)(13).
2. Remove inlet exhaust valve assembly (3).
6. Loosen and remove nut (14), and then remove

spring set (15), piston assemblies (16)(17), rubber
3. Disassemble inlet exhaust valve assembly (3). spring (18), and piston return springs (19)(20).
54-5
Brake valve assembling
To reassemble the brake valve, follow the above disas-

sembly procedure in reverse order.
Brake valve assembly cautions

replace or repair the part.
- Apply lithium-based grease to all the sliding surfaces

of the body, O-rings, and O-ring grooves.
Note
Certain cleaners and solvents can damage rubber
parts, use only approved cleaners and solvents.
- Apply the specified torque to tighten each main

parts.
- After reassembly, reinstall the brake valve on the

machine, and check that no air is leaking.
Also check operation of the brake valve referring to
"Checking Brake Valve" in Section 53.
54-6
Air Master Assembly
Air Master Assembly
Air master removing and installing

Air master removing
WARNING
wheels from moving.

- Remove the left side deck (refer to Section 14).
2. Disconnect stroke indicator connectors (4), and
remove brake pipe (3).
1. Disconnect air hoses (1) and brake hose (2).

3. Remove bolts (5) and then remove air master (6).
Note
- Cover the disconnected hoses and pipes with plas-
tic, plugs or caps to protect them from dust and dirt.
- The brake oil will be drained. Place a container to Air master installing
catch the drained oil.
To reinstall the air master, follow the above removal
: Brake oil: 1.5 L procedure in reverse order.
Replace all O-rings and seals during reinstallation.
Note
- After reinstallation, completely bleed the brake line
of air, and check performance of the air master.
- To bleed the brake line of air, refer to the 70ZIV-2
Shop Manual, Function and Structure, Section 53.
54-7
Air Master Assembly
Air master disassembling and assembling

Air master tightening torque
1. Pressure plate 21. Gasket

2. Non-pressure plate 22. Piston stopper plate
3. Diaphragm 23. C-ring
4. Return spring 24. Spring guide
5. Push rod assembly 25. Gasket
6. Clamp ring 26. Stroke indicator
7. Bolt 27. Bolt
8. Nut 28. Ball
9. Push nut 29. Bleeder screw
10. Nut 30. Cap
11. Spring nut
12. Nut
13. Cylinder :
14. Return spring T1: 20 N-m (2.0 kgf-m)
15. O-ring T2: 64 N-m (6.5 kgf-m)
16. ST seal T3: 88 N-m (9.0 kgf-m)
17. SKY seal T4: 10 N-m (1.0 kgf-m)
18. O-ring T5: 29 N-m (3.0 kgf-m)
19. Piston
20. Valve assembly
L1: Screw lock agent (Three Bond 1327) application
54-8
Air Master Assembly
Air master disassembling
IMPORTANT
- Clean the outer surface of the air master.
- Put match marks on the parts before disassembly.
- Sequentially place the removed parts in the disas-
sembly order.
- Carefully remove each part so that it is not
scratched or dented.
3. Remove bleeder screw (8) and then remove the

ball.
: Bleeder screw (8): 10 N-m (1.0 kgf-m)
Press machine
1. Put match marks on the air master body to show

Snap ring
the direction of the fittings (1)(2)(3) for reassem-
bling.
4. Disassemble the cylinder.

Press the spring as shown, and remove the snap
ring.
WARNING
The inner spring may spring out causing injury.
To prevent this, be sure to press the spring using a
press until the spring loses the spring force, and then
remove the snap ring.
When reducing the pressure of the press, be sure to
reduce it slowly.
2. Remove stroke indicator (4) and nut (5), and then
separate chamber (6) and cylinder (7).
CAUTION
: Nut (5): 88 N-m (9.0 kgf-m)
: Stroke indicator (4): 29 N-m (3.0 kgf-m) When compressing the spring with the press, press
: Screw lock agent (Three Bond 1327) the center of the cylinder with the press to prevent the
cylinder from being inclined.
54-9
Air Master Assembly
Press machine
Match mark
5. Remove snap ring (9) and piston (10). 8. Press the spring as shown, and disassemble the
chamber.
Put match marks on the section and remove bolts
(14), and then remove clamp (15).
: Bolt (14): 20 N-m (2.0 kgf-m)
WARNING
remove the bolts.
reduce it slowly.
6. Remove piston stopper plate (11) and return spring

(12).
9. Slowly reduce the pressure of the press and then

remove the inner parts.
7. Do not disassemble valve assembly (13) in piston

(10).
54-10
Air Master Assembly
Air master assembly cautions
- Clean the metal parts using approved brake cleaning

solvent, and then blow the compressed air to dry
them.
- After cleaning, check the parts for damage and wear.

If a part is defective, replace it with a new one.
- Use brake oil (engine oil SAE 5W or equivalent).
- Use lithium grease.

10. Remove pressure plate (16), diaphragm (17), push
rod (18) and return spring (19).
Air master assembling
To reassemble the air master, follow the above disas-

54-11
Service Brake
Service Brake
Service brake disassembling and assembling

Refer to "Planetary assy disassembling and assem-
bling" page 24-19 for the procedures.
Service brake installation cautions

Air bleeding procedure
- After reinstalling tires, check that manual rotation of
the tires is possible. (a) Connect a vinyl tube to the air bleeder nipple, and
- Check the wheels for oil leakage. place an oil can to receive the oil.
(b) Fill the brake oil tank.
(c) Slightly loosen the air bleeder nipple, and then
press the brake pedal several times. When the oil
flows from the air bleeder nipple, close the nipple.
(d) After that, each time you press the pedal, open the
air bleeder nipple to slightly discharge oil, and then
immediately close the nipple.
(e) Repeat this until there is no air in the oil.
(f) Completely bleed each wheel of air.
Note
When the oil level in the reservoir is low, add oil to the
Socket bolt tank.
Spider 95ZV54024
WARNING Brake disc installation cautions

Before air bleeding in the brake oil line, be sure that
the wheel and tire assemblies are installed on the CAUTION
wheel hub. If fail to do, the bolts (4 pcs) temporarily
tighten the spider and the wheel hub may be broken When only the friction plates or the steel plates are to
by the brake piston. Finally the spider and the cover be replaced, if the brake piston and brake stroke
may fall off and it could cause serious injury or death. adjusting mechanism are installed as they are, the
brake may drag and the brake discs may seize.
After reinstalling tires, check that manual rotation of
the tires is possible.
54-12
Air Cylinder for Parking Brake
Parking brake air cylinder remov- From brake line

ing and installing
Parking brake air cylinder removing
WARNING
Unexpected movement of the machine could cause Air cylinder
- When removing the parking brake air cylinder, the
machine may move. To prevent the machine from
moving, park the machine on level ground, and
lower the attachment onto the ground.
Brake assy
- Block the tires with chocks to prevent the wheels
from moving.
1. If there is an oil source, release the parking brake,

and then remove split pin (1) and pin (2).
Note
If there is no oil source, apply a cable to the link, and
pull it down using a bar to overcome the spring force,
and then remove the pin.
2. Release the residual air pressure. Disconnect the

air hose.
Note
Cover the disconnected hoses with plastic, plugs or
caps to protect them from dust and dirt.
3. Loosen lock nut (3) to remove joint (4).

Remove retainer bolts (5) to remove parking brake
air cylinder (6).
: Bolt (5): 59 N-m (6.0 kgf-m)

: Parking brake air cylinder: 8 kg
54-13
Parking brake air cylinder installing Parking brake air cylinder installation cau-
tions
To reinstall the parking brake air cylinder, follow the
above removal procedure in reverse order. To insert the connection pin to connect the parking
brake air cylinder to the parking brake, observe the fol-
lowing items:
- Start the engine to build oil pressure in the accumu-

lator.
- Release the parking brake.
- Slightly raise the parking brake lever by hand, and

adjust the position of the joint hole between the park-
ing brake air cylinder and the parking brake. After
that, insert the connection pin into the joint hole.
To check performance of the parking brake, refer to
the 70ZIV-2 Shop Manual, Function & Structure,
Section 53.
54-14
Parking brake air cylinder disassembling and assembling
IMPORTANT
1. Cylinder tube : Air cylinder: 8.0 kg

2. Piston rod
3. Rod cover
4. Rod cap
5. Piston
6. U-nut
7. Spring
8. Bushing
9. U-packing
10. Dust seal
11. O-ring
12. O-ring
13. Filter
14. Set screw
15. Retainer bolt
54-15
Parking brake air cylinder disassembling
WARNING
remove the rod cap.
reduce it slowly.
3. Press down the rod cover with a pipe (outer diame-

ter: 50 mm or less, inner diameter: 30 mm or more,
length: 80 mm).
Loosen the rod cap with hand and remove the rod
cap.
: Piston nut: 245 N-m (25.0 kgf-m)
1. Put a matchmark on the rod cap and cylinder tube.

Cut off the punched area of the set screw with a
drill of 15~20 mm diameter, and remove the rod
cap.
Note
- Set screw is locked by punching.
- Be sure to install the set screw at the same position
during reassembly.
4. Disassemble the cylinder.
< Component parts >

1. Cylinder tube
2. Rod Cap
3. Spring
4. Piston
5. Piston rod
6. Rod cover
7. Piston nut
2. Using the threaded hole of the rod cap, slightly

loosen the rod cap about 1/8 turn.
54-16
Parking brake air cylinder assembling Air cylinder linkage adjustment
To reassemble the air cylinder, follow the above disas-

Parking brake air cylinder assembly cau-

tions
- Tighten the rod cap to the position until the

matchmarks are aligned, tighten the screw, and
punch it for locking.
CAUTION
When compressing the spring with the press, press
the center of the cylinder with the press to prevent the
cylinder from being inclined.
1. Air cylinder
2. Lock nut
95ZV54027
3. Link
4. Bracket
5. Pin
6. Split pin
7. Washer
1. Release parking brake (OFF).
2. Measure dimension "A".
3. If the dimension “A” is not 97 mm, remove pin (5),

split pin (6), and washer (7) and loosen lock nut (2).
And adjust the linkage length by turning link (3) so
that dimension "A" becomes 97 mm.
4. Tighten lock nut (2) and reinstall pin (5), split pin (6)
and washer (7).
5. Confirm the parking brake performance referring to

Section 53.
54-17
Parking Brake
Parking Brake
Parking brake removing and installing

Parking brake removing and disassem-
bling
IMPORTANT
When removing the parking brake, the machine may
move and it could cause serious injury or death. To
prevent such an accident, observe the following item:
- Lower the attachment onto the ground.
- Block the tires with chocks to prevent the wheels
from moving.
3. Release the parking brake, and then remove con-

nection pin (2) from the air cylinder.
1. Drain the transmission oil.
: Transmission oil: 20 L
4. Remove retainer bolt (3) and remove lock plate (4)

and the O-ring.
Remove flange yoke (5).
2. Disconnect second propeller shaft (1) at the trans-
mission end.
: Bolt (3): 29 N-m (3.0 kgf-m)
: Bolt: 137 N-m (14.0 kgf-m)
54-18
Parking Brake
12
11
65V54002
5. Remove brake drum (6). 9. Remove shoe hold pins (11) by turning 90 degree.
Remove brake shoes (12).
13
14
65V54003
6. Remove retainer bolt (7) and remove brake assem-

bly (8). 10. Remove spring (13), and then remove adjusting
screw (14).
: Bolt (7): 157 N-m (16.0 kgf-m)
: Screw lock agent (Three Bond 1327) Note
Measure the wear of the brake shoes. If the shoes are
extremely worn, replace them.
10
Refer to Section 53 or Section 55 inspection standards.
9 9
Parking brake installing and assembling
To reinstall and reassemble the parking brake, follow

the above removal and disassembly procedure in
reverse order.
Note
65V54001
To adjust and check performance of the parking brake,
refer to the 70ZIV-2 Shop Manual, Function & Structure,
7. Remove spring (9) using pliers. Section 53.
8. Remove plate (10).

54-19
Air Tank
Air Tank
Air tank removing and installing

Air tank removing
WARNING
wheels from moving.
3. Temporarily sling cover (3), and remove retainer

Before starting work: bolts (4) and then remove cover (3).
- Remove the left side deck (refer to Section 14).
4. Disconnect wire (5) for the wet air tank and piping
(6).
5. Remove retainer bolts (7) and then remove wet air
tank (8).
2. Disconnect wire (2) for drain.

54-20
Air Tank
6. Disconnect pipes (9) from dry air tank (10).
7. Remove the retainer bolts, and then remove dry air

tank (10).
Air tank installing
To reinstall the air tank, follow the above removal proce-

dure in reverse order.
55-1
70ZIV-2 Service Standard Brake Group

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

Air Master ................................................................ 55-4
Service Brake .......................................................... 55-5
Parking Brake.......................................................... 55-6
55-2
Brake Valve
Brake Valve
1 Mounting plate retainer bolt tightening torque 12 N-m (1.2 kgf-m)
2 Rubber spring setting nut tightening torque 6 N-m (0.6 kgf-m)

Tightening
3 Lower body retainer bolt tightening torque 6 N-m (0.6 kgf-m)
4 Plug tightening torque 34 N-m (3.5 kgf-m)

55-3
Brake Valve
Unit: mm
No. Item Nominal Service standard Wear limit Note
5 Pedal pin hole diameter 10 10.25
Outer diameter of pin (pins for both roller and mounting

6 10 9.85
plate)
Inner diameter 10 10.1

7 Roller
Outer diameter 23.2 23
Inner diameter or pin bushing 10 10.25

8 Mounting plate
Inner diameter or plunger bushing 26.5 26.65
9 Outer diameter or plunger 26.5 26.16
10 Free height of rubber spring 14 12
Free length 71.4

Spring
11
(Piston return) When spring is
Load 113 N (11.5 kgf)
14.6 mm long
Free length 41.3

Spring
12
(Upper valve) When spring is
Load 44 N (4.5 kgf)
14.3 mm long
Free length 35.6

Spring
13
(Inner valve) When spring is
Load 28 N (2.8 kgf)
16.0 mm long
Free length 41.0

Spring
14
(Outer stem) When spring is
Load 39 N (4.0 kgf)
16.0 mm long
Free length 39.5

Spring
15
(Relay piston) When spring is
Load 46 N (4.7 kgf)
12.1 mm long
Free length 16.5

Spring
16
(Lower valve) When spring is
Load 29 N (3.0 kgf)
16.0 mm long
Free angle 131º

Spring
17
(Pedal return) When the pedal
Load 115º
is returned
55-4
Air Master
Air Master
1 Clearance between push nut and piston 1.0 mm Replacement
2 Stroke of air chamber push rod 45 ± 1.5 mm —
3 Stroke to overstroke switch 40 mm —
4 Hydraulic cylinder retainer nut tightening torque 88 N-m (9.0 kgf-m) —
5 Clamp ring retainer nut tightening torque 20 N-m (2.0 kgf-m) Tightening
6 Locknut tightening torque 64 N-m (6.5 kgf-m) Tightening
7 Overstroke switch tightening torque 29 N-m (3.0 kgf-m) Tightening
8 Air bleeder nipple tightening torque 10 N-m (1.0 kgf-m) Tightening

55-5
Service Brake
Service Brake
Unit: mm
Judgment standard
No. Item Solution
Standard dimension Tolerance Wear limit
+0
Thickness 5.0 4.4
- 0.2
1 Steel plate
Distortion 0.3 or less 0.3 —
Replacement
2 Thickness of friction plate 7.4 ± 0.1 5.9
Thickness of brake disc when measured

3 17.4 ± 0.2 15.1
by calipers (with brake applied)
Outer diameter 355 - 0.22 ~ - 0.29 —

4 Piston —
Inner diameter 285 0.05 ~ 0.15 —
55-6
Parking Brake
Parking Brake
5
1
Clearance
Spring (4) released

4
95ZV55002
Standard dimension Wear limit

1 Wear of lining (mm)
5.45 4.0
2 Deflection of drum (mm) 0.38 or more

Replacement
3 Lining inspection Grease or oil on the lining
4 Expansion of adjuster spring There is clearance between the coils when the spring
is released.
5 Expansion of return spring
64-1
70ZIV-2 Disassembly & Reassembly Electrical Group

Electrical Group
Wiper Motor............................................................. 64-2

Controller................................................................. 64-5
Fuse Box ................................................................. 64-6
64-2
Wiper Motor
Wiper Motor
Front wiper motor removing and

installing
Front wiper motor removing
3. Remove nut (4) and bolt (5).

After that, remove wiper arm (3).
4. Remove cover (6) and cover (7).
2. Remove nut (2) and then remove wiper arm (3).
5. Remove defroster hose (8).

Disconnect electrical line coupler (9) from the wiper
motor.
64-3
Wiper Motor
Front wiper motor installing
To reinstall the front wiper motor, follow the above

Note
When reinstalling the wiper arm, adjust the operation
angle by nut (2).
6. Remove motor retainer bolt (10), and remove

ground cable (11).
7. Disconnect coupler (12) for the relay.
8. Remove wiper motor (13).

64-4
Wiper Motor
Rear wiper motor removing and

installing
Rear wiper motor removing
5. Disconnect coupler (6) for wiper motor (8).
6. Remove motor retainer bolts (7).
7. Remove wiper motor (8).
2. Remove nut (2), and then remove wiper arm (3).
Rear wiper motor installing
To reinstall the rear wiper motor, follow the above

Note
When reinstalling the wiper arm, adjust the operation
angle by nut (2).
3. Remove nut (4) and then remove wiper arm (3).

64-5
Controller
Controller
Controller removing and installing

Controller removing
WARNING
Before removing the controller, be sure to stop the
engine, remove the engine key, and hang a "DO NOT
START!" tag on the steering wheel.
3. Remove bolt (4) (4 pcs), and then remove controller

(5).
Controller installing
To reinstall the controller, follow the above removal pro-

1. Remove catch (1), and then remove cover (2).

Controller installation cautions
- After reinstallation, set the starter key to the ON

position, and check the function of the LED indicator.
- Run the machine, and check operation of the

machine.
- The following items may have caused the controller

to fail. Test and correct any problems before install-
ing a new controller.
1. Shortcircuit in the output circuit

2. Defective diode allowing voltage surges.
Identify and test each diode by referring to the pro-
2. Disconnect electrical coupler (3). cedures written in the 70ZIV-2 Shop Manual Func-
tion & Structure, Section 63,
64-6
Fuse Box
Fuse Box
Fuse box removing and installing Fuse No.

Fuse
capacity Protective circuit
(A)
Fuse box removing (inside control box) Lighting
1 20A
Head light
2 10A Rear working light Spare
WARNING Boom kickout
3 10A 20A
Before removing a fuse box, be sure to turn off the Bucket leveler
starter key or disconnect the negative side of the bat- Back lamp
4 15A Spare
Stop lamp
tery.
Parking brake
5 10A 15A
Controller
Buzzer
6 5A Spare
Monitor
7 15A Spare
10A
8 15A Spare
9 15A Spare Spare
Turn signal
10 15A 5A
Horn
11 15A Preheat
12 5A Spare
13 5A Engine stop motor
14 5A Neutral relay
15 5A Battery relay
Fuse
Fuse No. capacity Protective circuit
1. Remove catch (1), and then open cover (2). (A)
2 persons cab front wiper (LH)
16 5A
(option)
2 persons cab front wiper (RH)
17 5A Spare
(option)
18 5A Rear wiper
20A
19 10A Front wiper
20 10A Cigar lighter Spare
21 10A Front working light
15A
22 3A Radio
23 10A Spare Spare
24 10A Spare
10A
25 5A Spare
26 5A Spare Spare
27 5A Air conditioner (option)
5A
2. Remove covers (3)(4), and remove the fuse boxes
(5)(6).
30 20A Spare
Fuse box installing (inside control box)
To reinstall the fuse box, follow the above removal pro-

74-1
70ZIV-2 Disassembly & Reassembly Operator Station Group

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

74-2
Air Conditioner
Air Conditioner
Cover unit
Air damper unit

Air conditioner unit
Floor board
74-3
Air Conditioner
Air conditioner removing and

installing
Air conditioner removing
WARNING
- Lower the attachment onto the ground and block
the front wheels with chocks to prevent the wheels
from moving.
1. Remove covers (1) ~ (5).
operator's seat.

- Remove the floor mat in the cab.
- Remover the seat and the seat stand in the cab.
- Collect the air conditioner refrigerant using the
proper recovery method.
- Disconnect the air conditioner pipes at the self-seal-
ing coupling.
2. Disconnect wiring (7) of air conditioner (6) and wir-

ing (9) of air damper (8) at each coupler.
Air conditioner
3. Disconnect refrigerant piping (10) and heater hose

(11).
74-4
Air Conditioner
Air conditioner installing
To reinstall the air conditioner, follow the above removal

Reference
After reinstalling the air conditioner, charge the refriger-
ant, confirm the operation, confirm the gas pressure,
then check for gas leaks.
4. Remove air conditioner mounting bolts (12) and air

damper mounting bolts (13).
Remove air conditioner (6) and air damper (8).
74-5
Air Conditioner
A/C condenser removing and

installing
A/C condenser removing
WARNING
- Park the machine on level ground. Condenser
the front wheels with chocks to prevent the wheels
from moving.
1. Disconnect condenser hose (1).
Receiver dryer
operator's seat.
Condenser
- Remove the air cleaner, etc. for easier removal.
2. Disconnect the condenser wiring at coupler (2).

Remove condenser mounting nut (3), and remove
the condensers.
A/C condenser installing
To reinstall the condenser, follow the above removal

Reference
After reinstalling the condenser, charge the refrigerant,
confirm the operation, confirm the gas pressure, then
check for gas leaks.
74-6
Air Conditioner
A/C compressor removing and installing
Engine
1. Compressor A/C compressor removing

2. Bracket
3. Idler pulley shaft
4. Tension pulley WARNING
5. V belt Unexpected movement of the machine could cause
6. Compressor mounting bolt an accident resulting in injury or death. To prevent
7. Compressor mounting nut such an accident, observe the following items:
8. Adjustment bolt - Park the machine on level ground.
: the front wheels with chocks to prevent the wheels
T1: 31 N-m (3.2 kgf-m) from moving.
T2: 29 N-m (3.0 kgf-m) - Be sure to remove the engine key, and hang a "DO
operator's seat.

74-7
Air Conditioner
A/C condenser installing
To reinstall the compressor, follow the above removal

A/C condenser installation cautions
- After installing the compressor, adjust the tension of

Engine the V-belt. Refer to the 70ZIV-2 Shop Manual, Func-
tion and Structure, Section 72 for the adjustment
procedure.
1. Loosen tension pulley (1) lock nut and lock bolt (2).
: Pulley (1) lock nut: 31 N-m (3.2 kgf-m)
2. Turn adjustment bolt (3) to make V-belt (4) slack,

then remove the V-belt from the compressor.
3. Disconnect the compressor wiring and the cooler

piping (5).
4. Remove compressor mounting nut (6), and remove

compressor (7). Belt tension at A: 637 ± 98 N (65 ± 10 kgf)
: Nut (6): 28 N-m (2.9 kgf-m) - Charge the refrigerant, confirm the operation, con-
firm the gas pressure, then check for gas leak.
- The quantity of the compressor lubricating oil (ND-

O1L2) is 180 cm3. Never use or mix any other oil.
74-8
MEMO
75-1
70ZIV-2 Service Standard Operator Station Group

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

75-2
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
Connection torque
Connection area or Tightening
type N-m
bolt size torque
(kgf-m) Special control area Bolt size
N-m
Condenser- 15 (kgf-m)
ø8 piping
expansion valve (1.50)
13
Head bolt of magnetic clutch M6
(1.35)
Compressor- 25
Nut type D1/2 piping
condenser (2.50)
Mounting bolt for servo motor for 0.5
M5
inside/outside air selection (0.05)
Evaporator- 34
D5/8 piping
compressor (3.50)
Fixing nut of blower motor and con- 5
M6
denser fan (0.55)
M6 bolt 7
Receiver
in receiver (4T) (0.70)
Fixing bolt of blower motor and con- 3
Block joint M5
Any M6 bolt denser motor (0.30)
Evaporator- 12
(6T) other than
compressor (1.20)
above
75-3
Air Conditioner
Compressor adjustment standard
Fan pulley
Crank pulley
1 V-Belt tension 637±98 N (65±10 kgf) Adjustment
2 Tension pulley mounting nut tightening torque 31 N-m (3.2 kgf-m) Tightening
3 Compressor mounting bolt tightening torque 29 N-m (3.0 kgf-m) Tightening
4 Compressor lubricating oil amount 180 cm3 Adjustment
Note
- Use a tension gauge to measure the belt tension.
- Refer to Section 72 in the 70ZIV-2 Shop Manual,
Function and Structure for the adjustment.
- Use ND-OIL8 or equivalent to lubricate the compres-
sor. Never mix any other oil.
75-4
MEMO
INDEX
A Boom cylinder removing and installing ........................... 44-33
A/C compressor removing ................................................74-6 Boom installation cautions .............................................. 14-18
A/C compressor removing and installing ..........................74-6 Boom installing ............................................................... 14-18
A/C condenser installation cautions ..................................74-7 Boom kick-out (option) ................................................... 15-10
A/C condenser installing ......................................... 74-5, 74-7 Boom kick-out hoist angle .............................................. 15-10
A/C condenser removing ..................................................74-5 Boom removing .............................................................. 14-16
A/C condensor removing and installing ............................74-5 Boom removing and installing ........................................ 14-16
Accumulator (S/N 2201~, 8251~) ...................................44-74 Brake disc installation cautions ...................................... 54-11
Accumulator installation cautions ...................................44-74 Brake Valve ...................................................................... 55-2
Accumulator installing .....................................................44-74 Brake valve assembling ................................................... 54-5
Accumulator removing ....................................................44-74 Brake Valve Assembly ..................................................... 54-2
Accumulator removing and installing ..............................44-74 Brake valve assembly cautions ........................................ 54-5
Air Cleaner ......................................................................24-11 Brake valve cross section and tightening torque
Air cleaner installation cautions ......................................24-12 (main valve) .................................................................. 54-3
Air cleaner installing ........................................................24-12 Brake valve disassembling ............................................... 54-4
Air cleaner removing .......................................................24-11 Brake valve disassembling and assembling ..................... 54-3
Air cleaner removing and installing .................................24-11 Brake valve installation cautions ...................................... 54-2
Air Conditioner ........................................................ 74-2, 75-2 Brake valve installing ........................................................ 54-2
Air conditioner installing ....................................................74-4 Brake valve removing ....................................................... 54-2
Air conditioner removing ...................................................74-3 Brake valve removing and installing ................................. 54-2
Air conditioner removing and installing .............................74-3 Bucket .............................................................................. 15-7
Air Cylinder for Parking Brake ........................................54-12 Bucket cylinder installation cautions ............................... 44-36
Air Master .........................................................................55-4 Bucket cylinder installing ................................................ 44-36
Air master assembling ....................................................54-10 Bucket cylinder removing ............................................... 44-35
Air Master Assembly .........................................................54-6 Bucket cylinder removing and installing ......................... 44-35
Air master assembly cautions .........................................54-10 Bucket positioner .............................................................. 15-9
Air master disassembling ..................................................54-8 Bucket positioner adjustable angle ................................... 15-9
Air master disassembling and assembling .......................54-7 Bucket Positioner and Boom Kick-Out (Option) ............... 15-8
Air master installing ..........................................................54-6 Bushing .......................................................................... 14-20
Air master removing ..........................................................54-6 Bushing installing ........................................................... 14-20
Air master removing and installing ....................................54-6 Bushing removing ........................................................... 14-20
Air master tightening torque ..............................................54-7 Bushing removing and installing ..................................... 14-20
Air Tank ..........................................................................54-19
Air tank installing .............................................................54-20 C
Air tank removing ............................................................54-19 Cab ................................................................................. 14-12
Air tank removing and installing ......................................54-19 Cab installation cautions ................................................ 14-13
Applying and Storing Articulation Stopper ......................00-13 Cab installing .................................................................. 14-13
Applying articulation stopper ...........................................00-13 Cab removing ................................................................. 14-12
Axle and Differential Service Standard .............................25-3 Cab removing and installing ........................................... 14-12
Axle group .........................................................................25-3 Cautions regarding parts removal .................................... 00-9
Axle nut tightening procedure ............................. 24-15, 24-37 Cautions regarding reassembly ........................................ 00-9
Axle Support ...................................................................24-41 Cautions Regarding Welding Repair Service ................. 00-11
Axle support assembling .................................................24-44 Center Pin ............................................................. 14-21, 15-5
Axle support assembly cautions .....................................24-44 Center pin installation cautions ...................................... 14-27
Axle support disassembling Center pin installing ........................................................ 14-27
(S/N 1001~1919, 7101~7615) .....................................24-43 Center pin removing ....................................................... 14-23
Axle support disassembling (S/N 1920~, 7616~) ...........24-44 Center pin removing and installing ................................. 14-23
Axle support disassembling and assembling ..................24-43 Center pin shim adjustment ................................... 14-21, 15-5
Axle support tightening torque ........................................24-41 Clutch pack assembly cautions ...................................... 34-21
Compressor adjustment standard .................................... 75-3
B Control valve assembling ............................................... 34-27
Bolt Tightening Torque .....................................................00-4 Control Valve Assembly ................................................. 34-23
Boom ..............................................................................14-16 Control valve assembly cautions .................................... 34-27
Boom cylinder installation cautions .................................44-34 Control valve disassembling ........................................... 34-26
Boom cylinder installing ..................................................44-34 Control valve disassembling and assembling ................ 34-26
Boom cylinder removing .................................................44-33 Control valve installation ................................................ 34-25
Control valve installation cautions .................................. 34-25 Front Differential .............................................................24-62
Control valve removing .................................................. 34-23 Front differential removing and installing ........................24-62
Control valve removing and installing ............................ 34-23 Front differential tightening torque ..................................24-49
Controller installation cautions ......................................... 64-5 Front wiper motor installing ..............................................64-3
Controller installing ........................................................... 64-5 Front wiper motor removing ..............................................64-2
Controller removing .......................................................... 64-5 Front wiper motor removing and installing ........................64-2
Controller removing and installing .................................... 64-5 Fuel Tank ..........................................................................14-3
Fuel tank installation cautions ..........................................14-3
Fuel tank installing ............................................................14-3
D
Fuel tank removing ...........................................................14-3
Deck ................................................................................. 14-2
Fuel tank removing and installing .....................................14-3
Deck installing .................................................................. 14-2
Fuse Box ..........................................................................64-6
Deck removing ................................................................. 14-2
Fuse box installing (inside control box) ............................ 64-6
Deck removing and installing ........................................... 14-2
Fuse box removing (inside control box) ............................ 64-6
Differential ........................................................................ 25-4
Fuse box removing and installing .....................................64-6
Differential Assembly ..................................................... 24-47
Differential assembly disassembling .............................. 24-52
Differential assembly disassembling and assembling G
.................................................................................... 24-49 Gear Pump .......................................................................44-4
Differential assembly installation cautions ..................... 24-48 Gear pump assembling ..................................................44-11
Differential assembly installing ....................................... 24-48 Gear pump assembly cautions .......................................44-11
Differential assembly removing ...................................... 24-47 Gear pump assembly disassembling and assembling
Differential assembly removing and installing ................ 24-47 ......................................................................................44-8
Differential assy assembling .......................................... 24-56 Gear pump assembly installing ........................................44-6
Dust Seal ........................................................................ 14-19 Gear pump assembly removing ........................................44-6
Dust seal installing ......................................................... 14-19 Gear pump assembly removing and installing ..................44-6
Dust seal removing ........................................................ 14-19 Gear pump disassembling ................................................44-9
Dust seal removing and installing .................................. 14-19 Gear pump installation cautions ....................................... 44-7
Gear pump tightening torque ............................................ 44-5
Grease nipple installing ....................................................15-5
E
Engine .............................................................................. 24-7
Engine installation cautions .............................................. 24-8 H
Engine installing ............................................................... 24-8 Hose Band Tightening Torque ..........................................00-8
Engine removing .............................................................. 24-7 How to wind a seal tape .................................................00-10
Engine removing and installing ........................................ 24-7 Hydraulic Cylinder .................................................44-33, 45-5
Engine Room ................................................................... 14-9 Hydraulic cylinder assembling ........................................44-49
Engine room installation cautions .................................. 14-11 Hydraulic cylinder assembly cautions .............................44-49
Engine room installing .................................................... 14-11 Hydraulic cylinder cross section and tightening torque
Engine room removing ..................................................... 14-9 ....................................................................................44-39
Engine room removing and installing ............................... 14-9 Hydraulic cylinder disassembling ...................................44-47
Hydraulic cylinder disassembling and assembling ......... 44-39
Hydraulic parts assembly cautions ...................................44-3
F
Floating Seal (S/N 1201~, 7201~) .................................. 24-25
......................................................................................44-3
Floating seal assembling ................................................ 24-26
Hydraulic parts disassembly cautions ..............................44-3
Floating seal installation ................................................. 24-25
Hydraulic Parts Removal and Installation Warning ..........44-2
Floor Board .................................................................... 14-14
Hydraulic Tank ..................................................................14-4
Floor board installation cautions .................................... 14-15
Hydraulic tank breather valve assembling ........................14-8
Floor board installing ...................................................... 14-15
Hydraulic tank breather valve disassembling ...................14-7
Floor board removing ..................................................... 14-14
Hydraulic tank breather valve
Floor board removing and installing ............................... 14-14
disassembling and assembling .....................................14-7
Forward/reverse clutch pack assembling ....................... 34-20
Hydraulic tank installation cautions ..................................14-5
Forward/reverse clutch pack disassembling .................. 34-18
Hydraulic tank installing ....................................................14-5
Forward/reverse clutch pack
Hydraulic tank removing ...................................................14-4
disassembling and assembling ................................... 34-18
Hydraulic tank removing and installing .............................14-4
Front Axle Assembly ...................................................... 24-14
Hydraulic tank return filter installation cautions ................ 14-6
Front axle assembly installation cautions ....................... 24-18
Hydraulic tank return filter installing ..................................14-6
Front axle assembly installing ........................................ 24-17
Hydraulic tank return filter removing ................................. 14-6
Front axle assembly removing ....................................... 24-16
Hydraulic tank return filter removing and installing ........... 14-6
Front axle assembly removing and installing ................. 24-16
Front axle assembly tightening torque ........................... 24-14
I Parking brake air cylinder removing ............................... 54-12
Internal Gear Hub ...........................................................24-27 Parking brake air cylinder removing and installing ......... 54-12
Internal gear hub assembling .........................................24-28 Parking brake installing and assembling ........................ 54-18
Internal gear hub assembly cautions ..............................24-28 Parking brake removing and disassembling ................... 54-17
Internal gear hub disassembling .....................................24-27 Parking brake removing and installing ........................... 54-17
Internal gear hub disassembling and assembling ...........24-27 Periodical Inspection/Servicing ........................................ 75-2
Pilot Valve ............................................................. 44-51, 45-6
Pilot valve assembling .................................................... 44-59
L Pilot valve assembly cautions ........................................ 44-59
Liner clearance adjustment ...............................................15-4 Pilot valve cross section and tightening torque .............. 44-55
Linkage .............................................................................15-2 Pilot valve disassembling ............................................... 44-56
Linkage Pin Standard Clearance Values ..........................15-3 Pilot valve disassembling and assembling ..................... 44-55
Liquid Gasket and Screw Lock Agent ...............................00-9 Pilot valve installation cautions ....................................... 44-54
Lower center pin .............................................................14-22 Pilot valve installing ........................................................ 44-54
Lower center pin bearing outer ring installing ...................15-6 Pilot valve removing ....................................................... 44-53
Pilot valve removing and installing ................................. 44-53
M Planetary assy assembling ............................................. 24-23
Muffler .............................................................................24-13 Planetary assy assembly cautions ................................. 24-23
Muffler installation cautions ............................................24-13 Planetary assy disassembling ........................................ 24-19
Muffler installing ..............................................................24-13 Planetary assy disassembling and assembling .............. 24-19
Muffler removing .............................................................24-13 Power Line ....................................................................... 24-2
Muffler removing and installing .......................................24-13 Power line tightening torque ............................................. 24-2
Multiple Control Valve .....................................................44-18 Priority Valve (S/N 2201~, 8251~) .................................. 44-72
Multiple control valve assembling ...................................44-32 Priority valve cross section and tightening torque .......... 44-73
Multiple control valve assembling (S/N ~1481) ...............44-25 Priority valve disassembling and assembling ................. 44-73
Multiple control valve assembly cautions ............ 44-28, 44-32 Priority valve disassembly cautions ................................ 44-73
Multiple control valve Priority valve installing .................................................... 44-72
cross section and tightening torque .............................44-20 Priority valve removing ................................................... 44-72
Multiple control valve disassembling (S/N ~1481) ..........44-21 Priority valve removing and installing ............................. 44-72
Multiple control valve disassembling (S/N 1482~) ..........44-30 Propeller Shaft .................................................................. 24-9
Multiple control valve Propeller shaft installation cautions ................................ 24-10
disassembling and assembling (S/N ~1481) ...............44-20 Propeller shaft installing ................................................. 24-10
Multiple control valve Propeller shaft removing and installing ............................ 24-9
disassembling and assembling (S/N 1482~) ...............44-29 Propeller Shaft Service Standard ..................................... 25-2
Multiple control valve installation cautions ......................44-19
Multiple control valve installing .......................................44-19 R
Multiple control valve removing ......................................44-18 Radiator ............................................................................ 24-3
Multiple control valve removing and installing ................44-18 Radiator installation cautions ........................................... 24-6
Radiator installing ............................................................. 24-6
O Radiator removing ............................................................ 24-4
Orbitrol® (S/N 2201~, 8251~) ...................................................44-60 Radiator removing and installing ...................................... 24-4
Orbitrol® assembling .......................................................44-67 Radiator tightening torque ................................................ 24-3
Orbitrol® cross section and tightening torque .................44-62 Rear Axle Assembly ....................................................... 24-36
Orbitrol® disassembling ..................................................44-63 Rear axle assembly installing ......................................... 24-40
Orbitrol® disassembling and assembling ........................44-62 Rear axle assembly removing ........................................ 24-38
Orbitrol® installation cautions ..........................................44-61 Rear axle assembly removing and installing .................. 24-38
Orbitrol® installing ...........................................................44-61 Rear axle assembly tightening torque ............................ 24-36
Orbitrol® removing ..........................................................44-60 Rear axle disassembling and assembling ...................... 24-40
Orbitrol® removing and installing ....................................44-60 Rear differential tightening torque
(S/N 1001~1919, 7101~7615) .................................... 24-50
Rear differential tightening torque (S/N 1920~, 7616~)
P .................................................................................... 24-51
Parking Brake ....................................................... 54-17, 55-6 Rear wiper motor installing ............................................... 64-4
Parking brake air cylinder assembling ............................54-16 Rear wiper motor removing .............................................. 64-4
Parking brake air cylinder assembly cautions .................54-16 Rear wiper motor removing and installing ........................ 64-4
Parking brake air cylinder disassembling .......................54-15
Parking brake air cylinder
disassembling and assembling ...................................54-14
Parking brake air cylinder installation cautions ...............54-13
Parking brake air cylinder installing ................................54-13
S U
Screw lock agent application procedure ........................ 00-10 Upper center pin .............................................................14-21
Second propeller shaft removing ..................................... 24-9
Service Brake ........................................................ 54-11, 55-5
W
Service brake air bleeding procedure ............................ 24-18
Weight of Main Components ............................................ 00-3
Service brake disassembling and assembling ............... 54-11
Wiper Motor ......................................................................64-2
Service brake installation cautions ................................. 54-11
Special Tool ................................................................... 24-31
Special tool for axle ........................................................ 24-31
Spider Assembly ............................................................ 24-29
Spider assy assembling ................................................. 24-30
Spider assy assembly cautions ...................................... 24-30
Spider assy disassembling ............................................. 24-29
Spider assy disassembling and assembling .................. 24-29
Steering cylinder installation cautions ............................ 44-38
Steering cylinder installing ............................................. 44-38
Steering cylinder removing ............................................. 44-37
Steering cylinder removing and installing ....................... 44-37
Steering Linkage (S/N ~2200, ~8250) .............................. 45-2
Steering Valve (S/N ~2200, ~8250) ............................... 44-12
Steering valve assembling ............................................. 44-16
Steering valve assembly cautions .................................. 44-17
Steering valve disassembling ......................................... 44-15
Steering valve disassembling and assembling .............. 44-15
Steering valve installation cautions ................................ 44-14
Steering valve installing ................................................. 44-14
Steering valve removing ................................................. 44-13
Steering valve removing and installing ........................... 44-13
Storing articulation stopper ............................................ 00-13
Symbols ........................................................................... 00-2
T
Third propeller shaft removing ....................................... 24-10
Tightening torque for hose and pipes ............................... 75-2
Tightening torque for screws and bolts
in special control regions .............................................. 75-2
Torque Converter ........................................................... 34-16
Torque Converter and Transmission Assembly ...... 34-2, 35-2
Torque converter and transmission assembly
installing ........................................................................ 34-6
removing ....................................................................... 34-3
removing and installing ................................................. 34-3
tightening torque ........................................................... 34-2
Torque converter assembly assembling ........................ 34-17
Torque converter assembly disassembling .................... 34-16
Torque converter assembly
Transmission Assembly ................................................. 34-10
Transmission assembly assembling .............................. 34-15
Transmission assembly bolt tightening torque ................. 34-8
Transmission assembly disassembling .......................... 34-10
Transmission assembly
Transmission assembly installation cautions ................... 34-6
Transmission assy assembling ...................................... 34-15
MEMO
Maintenance Log
Date Machine hours Service performed

Notes

70ziv 2 (Exp D&R) (93208 00661)

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70ziv 2 (Exp D&R) (93208 00661)

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Serial No. 70J1-1001 and up

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-

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

70ZIV-2 Service Standard Chassis Group ............................................................................................................ 15-1

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

70ZIV-2 Service Standard Power Group ............................................................................................................... 25-1

70ZIV-2 Disassembly & Reassembly Hydraulic Group ......................................................................................... 44-1

Orbitrol® (S/N 2201~, 8251~) .......................................................................................................................... 44-60

Orbitrol® removing and installing ............................................................................................................... 44-60

Orbitrol® disassembling and assembling .................................................................................................. 44-62

70ZIV-2 Service Standard Hydraulic Group .......................................................................................................... 45-1

70ZIV-2 Disassembly & Reassembly Brake Group .............................................................................................. 54-1

70ZIV-2 Service Standard Brake Group ................................................................................................................ 55-1

70ZIV-2 Disassembly & Reassembly Electrical Group ......................................................................................... 64-1

70ZIV-2 Disassembly & Reassembly Operator Station Group .............................................................................. 74-1

70ZIV-2 Service Standard Operator Station Group ............................................................................................... 75-1

70ZIV-2 General Information

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

Symbol Item Description

Shows the condition or procedure that will be useful

Shows the weight of a part or unit. The weight

Tightening Shows the tightening torque of a section that should

Shows the type of coating or adhesive and the coat-

Shows the oil or water drain port and the drain

Weight of Main Components

Item Approx. Approx.

Bolt Tightening Torque

Flanged hexagon bolt

1. Bolt type: Metric thread

2. Bolt strength: 8.8 (8T)

3. Thread pitch: Coarse pitch thread (C)

Hose Band Tightening Torque

Low pressure hose

Low pressure hose Tightening torque Tightening torque Tightening torque

Liquid Gasket and Screw Lock Agent

Remove the hardened lock agent using a wire brush or

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

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

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

Apply screw lock agent one or two lines on the male

Screw lock agent Leave 1~2 screw

As the screw is tightened by turning clockwise, seal

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

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

Cautions Regarding Welding Repair Service

Do not ground this section.

Do not ground this section.

5. The weld spattered on the hydraulic cylinders and

(c) Hydraulic hoses, nylon tubes, or harnesses are

Cover the plated sections with heat-resistant cloth,

Scrap material, etc.

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