This document provides instructions for disassembling and reassembling the key components of a Komatsu 135ZV-2 wheel loader. It begins with general safety information and cautions regarding proper maintenance procedures. The document is organized by component groups, with sections devoted to the chassis group including instructions for removing and installing the deck, fuel tank, hydraulic tank, engine room, ROPS, cab, and floor board. Detailed procedures and torque specifications are provided to guide technicians in properly servicing the vehicle.
Komatsu 6D125 Diesel Engine Service Repair Manualuejjdksemme
This is the Highly Detailed factory service repair manual for theKOMATSU 6D125 DIESEL ENGINE, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.KOMATSU 6D125 DIESEL ENGINE Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General
Structure and Function
Testing and Adjusting
Disassembly and Assembly
Maintenance Standard
Repair and Replacement of Parts
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
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Komatsu 6D125 Diesel Engine Service Repair Manualuejjdksemme
This is the Highly Detailed factory service repair manual for theKOMATSU 6D125 DIESEL ENGINE, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.KOMATSU 6D125 DIESEL ENGINE Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
General
Structure and Function
Testing and Adjusting
Disassembly and Assembly
Maintenance Standard
Repair and Replacement of Parts
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveKOMATSU 6D125 DIESEL ENGINE Service Repair Workshop Manual.
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MITSUBISHI FGE15N FORKLIFT TRUCKS Service Repair Manual SN:F25C-50001-UPkjsekmd fhsemmd
This is the Highly Detailed factory service repair manual for theMITSUBISHI FGE15N FORKLIFT TRUCKS, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.MITSUBISHI FGE15N FORKLIFT TRUCKS Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Chassis and Mast: Foreword
Chassis and Mast: General Information
Chassis and Mast: Cooling System
Chassis and Mast: Electrical System
Chassis and Mast: Electrical Schematics
Chassis and Mast: Controllers
Chassis and Mast: Power Train
Chassis and Mast: Clutches
Chassis and Mast: Manual Transmission
Chassis and Mast: Power shift Transmission
Chassis and Mast: Front Axle and Reduction Differential
Chassis and Mast: Rear Axle
Chassis and Mast: Brake System
Chassis and Mast: Steering System
Chassis and Mast: Hydraulic System
Chassis and Mast: Mast and Forks
Chassis and Mast: Service Data
Engine: K15, K21, K25 Gasoline: Foreword
Engine: K15, K21, K25 Gasoline: General Information
Engine: K15, K21, K25 Gasoline: Maintenance
Engine: K15, K21, K25 Gasoline: Tune up
Engine: K15, K21, K25 Gasoline: Mechanical
Engine: K15, K21, K25 Gasoline: Control
Engine: K15, K21, K25 Gasoline: Lubrication and Cooling
Engine: K15, K21, K25 Gasoline: Fuel
Engine: K15, K21, K25 Gasoline: Electrical
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
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MITSUBISHI FGE15N FORKLIFT TRUCKS Service Repair Manual SN:F25C-50001-UPkjsekmd fhsemmd
This is the Highly Detailed factory service repair manual for theMITSUBISHI FGE15N FORKLIFT TRUCKS, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.MITSUBISHI FGE15N FORKLIFT TRUCKS Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Chassis and Mast: Foreword
Chassis and Mast: General Information
Chassis and Mast: Cooling System
Chassis and Mast: Electrical System
Chassis and Mast: Electrical Schematics
Chassis and Mast: Controllers
Chassis and Mast: Power Train
Chassis and Mast: Clutches
Chassis and Mast: Manual Transmission
Chassis and Mast: Power shift Transmission
Chassis and Mast: Front Axle and Reduction Differential
Chassis and Mast: Rear Axle
Chassis and Mast: Brake System
Chassis and Mast: Steering System
Chassis and Mast: Hydraulic System
Chassis and Mast: Mast and Forks
Chassis and Mast: Service Data
Engine: K15, K21, K25 Gasoline: Foreword
Engine: K15, K21, K25 Gasoline: General Information
Engine: K15, K21, K25 Gasoline: Maintenance
Engine: K15, K21, K25 Gasoline: Tune up
Engine: K15, K21, K25 Gasoline: Mechanical
Engine: K15, K21, K25 Gasoline: Control
Engine: K15, K21, K25 Gasoline: Lubrication and Cooling
Engine: K15, K21, K25 Gasoline: Fuel
Engine: K15, K21, K25 Gasoline: Electrical
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveMITSUBISHI FGE15N FORKLIFT TRUCKS Service Repair Workshop Manual.
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Thanks for visiting!
What Does the Active Steering Malfunction Warning Mean for Your BMWTanner Motors
Discover the reasons why your BMW’s Active Steering malfunction warning might come on. From electrical glitches to mechanical failures and software anomalies, addressing these promptly with professional inspection and maintenance ensures continued safety and performance on the road, maintaining the integrity of your driving experience.
Symptoms like intermittent starting and key recognition errors signal potential problems with your Mercedes’ EIS. Use diagnostic steps like error code checks and spare key tests. Professional diagnosis and solutions like EIS replacement ensure safe driving. Consult a qualified technician for accurate diagnosis and repair.
"Trans Failsafe Prog" on your BMW X5 indicates potential transmission issues requiring immediate action. This safety feature activates in response to abnormalities like low fluid levels, leaks, faulty sensors, electrical or mechanical failures, and overheating.
Core technology of Hyundai Motor Group's EV platform 'E-GMP'Hyundai Motor Group
What’s the force behind Hyundai Motor Group's EV performance and quality?
Maximized driving performance and quick charging time through high-density battery pack and fast charging technology and applicable to various vehicle types!
Discover more about Hyundai Motor Group’s EV platform ‘E-GMP’!
5 Warning Signs Your BMW's Intelligent Battery Sensor Needs AttentionBertini's German Motors
IBS monitors and manages your BMW’s battery performance. If it malfunctions, you will have to deal with an array of electrical issues in your vehicle. Recognize warning signs like dimming headlights, frequent battery replacements, and electrical malfunctions to address potential IBS issues promptly.
Why Is Your BMW X3 Hood Not Responding To Release CommandsDart Auto
Experiencing difficulty opening your BMW X3's hood? This guide explores potential issues like mechanical obstruction, hood release mechanism failure, electrical problems, and emergency release malfunctions. Troubleshooting tips include basic checks, clearing obstructions, applying pressure, and using the emergency release.
Things to remember while upgrading the brakes of your carjennifermiller8137
Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
What Exactly Is The Common Rail Direct Injection System & How Does It WorkMotor Cars International
Learn about Common Rail Direct Injection (CRDi) - the revolutionary technology that has made diesel engines more efficient. Explore its workings, advantages like enhanced fuel efficiency and increased power output, along with drawbacks such as complexity and higher initial cost. Compare CRDi with traditional diesel engines and discover why it's the preferred choice for modern engines.
𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
Over the 10 years, we have gained a strong foothold in the market due to our range's high quality, competitive prices, and time-lined delivery schedules.
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
In this presentation, we have discussed a very important feature of BMW X5 cars… the Comfort Access. Things that can significantly limit its functionality. And things that you can try to restore the functionality of such a convenient feature of your vehicle.
2. 93217-00210
March 2012
Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.
Disassembly & Reassembly
Service Standard
For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
The purpose of this manual is to provide information on the product and the correct maintenance and repair meth-
ods. Please read this manual to ensure correct troubleshooting and good repair service.
This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or
requests, please inform us.
3. Safety precautions
The most important point in providing repair service is
safety. To ensure safety, observe the general cautions
described below.
- This manual is intended for properly trained and
equipped service technicians.
- Any work on the machine must be performed by the
trained personnel only.
- Carefully read this manual to thoroughly understand
the operation method before you operate or repair
the machine.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles.
- Place the machine on level and solid ground, and
place chocks against the wheels to prevent move-
ment.
- Remove the cable from the battery before starting
the service work, and attach a "DO NOT OPERATE!"
tag to the operation board.
- 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.
- Always store the tools in good condition, and use
them properly.
- Keep the work area clean. Clean up spills immedi-
ately.
- Avoid the use of flammable solvents and cleaners.
- When working outdoors keep work areas, ladders,
steps, decks and work platforms clear of snow, ice,
and mud.
- Use safe work platforms to reach higher areas of the
machine.
- Any technician that operates a refrigerant recovery
and recycling machine must first be certified through
an EPA approved testing program.
IMPORTANT
If a battery terminal is removed from a machine in
less than 30 seconds after the key is put into the
“OFF” position, it can corrupt the ECM program,
which can disable the engine. Always wait 1 full
minute to be sure to be past this “write to memory
function” prior to removing battery terminals.
4. 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.
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.
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.
6. CONTENTS
135ZV-2 General Information ................................................................................................................................ 00-1
Symbols ............................................................................................................................................................ 00-2
Weight of Main Components ............................................................................................................................. 00-3
Bolt Tightening Torque ...................................................................................................................................... 00-4
Hose Band Tightening Torque ........................................................................................................................... 00-8
Liquid Gasket and Screw Lock Agent ............................................................................................................... 00-9
Cautions regarding parts removal ............................................................................................................... 00-9
Cautions regarding reassembly .................................................................................................................. 00-9
Screw lock agent application procedure ................................................................................................... 00-10
How to wind a seal tape ............................................................................................................................ 00-10
Cautions Regarding Welding Repair Service ...................................................................................................00-11
Cautions Regarding Handling of Bearing ........................................................................................................ 00-13
Bearing installation cautions ..................................................................................................................... 00-13
Interference fits for a bearing .................................................................................................................... 00-13
Bearing removal cautions ......................................................................................................................... 00-14
Applying and Storing Articulation Stopper ....................................................................................................... 00-15
Applying articulation stopper ..................................................................................................................... 00-15
Storing articulation stopper ....................................................................................................................... 00-15
135ZV-2 Disassembly & Reassembly Chassis Group .......................................................................................... 14-1
Deck .................................................................................................................................................................. 14-2
Deck removing and installing ...................................................................................................................... 14-2
Fuel Tank .......................................................................................................................................................... 14-4
Fuel tank removing and installing ............................................................................................................... 14-4
Hydraulic Tank .................................................................................................................................................. 14-6
Hydraulic tank removing and installing ....................................................................................................... 14-6
Engine Room .................................................................................................................................................... 14-8
Engine room removing and installing .......................................................................................................... 14-8
ROPS .............................................................................................................................................................. 14-12
ROPS removing and installing .................................................................................................................. 14-12
Cab ................................................................................................................................................................. 14-13
Cab removing and installing ...................................................................................................................... 14-13
Floor Board ..................................................................................................................................................... 14-15
Floor board removing and installing .......................................................................................................... 14-15
Boom ............................................................................................................................................................... 14-19
Boom removing and installing ................................................................................................................... 14-19
7. Center Pin ....................................................................................................................................................... 14-22
Upper center pin ....................................................................................................................................... 14-22
Lower center pin ....................................................................................................................................... 14-23
Center pin removing and installing ............................................................................................................ 14-24
135ZV-2 Service Standard Chassis Group ........................................................................................................... 15-1
Linkage ............................................................................................................................................................. 15-2
Linkage Pin Standard Clearance Values ........................................................................................................... 15-3
Liner clearance adjustment ......................................................................................................................... 15-3
Shim adjustment ......................................................................................................................................... 15-4
Center Pin ......................................................................................................................................................... 15-6
Center pin shim adjustment ........................................................................................................................ 15-6
Bearing cover installing ............................................................................................................................... 15-6
Lower center pin bearing outer ring installing ............................................................................................. 15-7
Attachment Leveler ........................................................................................................................................... 15-8
Attachment leveler ...................................................................................................................................... 15-9
Attachment leveler adjustable angle ........................................................................................................... 15-9
135ZV-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
Torque Converter Oil Cooler ............................................................................................................................. 24-7
Torque converter oil cooler removing and installing .................................................................................... 24-7
Fan .................................................................................................................................................................... 24-9
Fan removing and installing ........................................................................................................................ 24-9
Engine ..............................................................................................................................................................24-11
Engine removing and installing ..................................................................................................................24-11
Propeller Shaft ................................................................................................................................................ 24-14
Propeller shaft removing and installing ..................................................................................................... 24-14
Air Cleaner ...................................................................................................................................................... 24-17
Air cleaner removing and installing ........................................................................................................... 24-17
Muffler ............................................................................................................................................................. 24-19
Muffler removing and installing ................................................................................................................. 24-19
8. Front Axle Assembly ....................................................................................................................................... 24-20
Front axle assembly tightening torque ...................................................................................................... 24-20
Front axle assembly removing and installing ............................................................................................ 24-22
Front axle disassembling and assembling ................................................................................................ 24-25
Front axle assembly cautions ................................................................................................................... 24-29
Spider Assembly ............................................................................................................................................. 24-33
Spider assembly disassembling and assembling ...................................................................................... 24-33
Special Tool ..................................................................................................................................................... 24-34
Special tool for axle ................................................................................................................................... 24-34
Rear Axle Assembly ........................................................................................................................................ 24-38
Rear axle assembly tightening torque ....................................................................................................... 24-38
Rear axle assembly removing and installing ............................................................................................. 24-40
Rear axle disassembling and assembling ................................................................................................. 24-43
Axle Support ................................................................................................................................................... 24-44
Axle support tightening torque .................................................................................................................. 24-44
Axle support disassembling and assembling ............................................................................................ 24-45
Axle support assembly cautions ............................................................................................................... 24-46
Differential Assembly ...................................................................................................................................... 24-47
Differential assembly removing and installing ........................................................................................... 24-47
Differential assembly disassembling and assembling ............................................................................... 24-50
135ZV-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
135ZV-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 Assembly .............................................................................................................................. 34-3
Torque converter removing and installing ................................................................................................... 34-3
Torque converter assembly bolt tightening torque ...................................................................................... 34-6
Torque converter assembly disassembling and assembling ....................................................................... 34-7
9. Transmission Assembly .................................................................................................................................. 34-13
Transmission removing and installing ....................................................................................................... 34-13
Transmission assembly bolt tightening torque .......................................................................................... 34-18
Transmission assembly disassembling and assembling ........................................................................... 34-19
Clutch Assembly ............................................................................................................................................. 34-28
Clutch assembly disassembling and assembling ...................................................................................... 34-28
Clutch Spider Assembly .................................................................................................................................. 34-42
Forward and 3rd clutch spiders disassembling and assembling ............................................................... 34-42
2nd Clutch Spider ............................................................................................................................................ 34-44
2nd clutch spider disassembling and assembling ..................................................................................... 34-44
Reverse Clutch Spider .................................................................................................................................... 34-46
Reverse clutch spider disassembling and assembling ............................................................................. 34-46
1st Clutch Assembly ........................................................................................................................................ 34-48
1st clutch assembly disassembling and assembling ................................................................................. 34-48
Input Gear Box Assembly ............................................................................................................................... 34-51
Input gear box disassembling and assembling ......................................................................................... 34-51
Control Valve Assembly .................................................................................................................................. 34-53
Control valve removing and installing ....................................................................................................... 34-53
Control valve disassembling and assembling ........................................................................................... 34-56
Special Tool ..................................................................................................................................................... 34-58
135ZV-2 Service Standard Torque Converter and Transmission Group .............................................................. 35-1
Transmission Assembly .................................................................................................................................... 35-2
Transmission ............................................................................................................................................... 35-2
Torque converter ......................................................................................................................................... 35-3
Torque Converter Gear Pump ........................................................................................................................... 35-6
Gear pump specifications ........................................................................................................................... 35-7
Clutch Train and Number of Teeth .................................................................................................................... 35-8
Clutch specifications ................................................................................................................................... 35-9
Clutch Oil Pressure ......................................................................................................................................... 35-10
135ZV-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
10. Hydraulic Pump ................................................................................................................................................. 44-4
Hydraulic pump removing and installing ..................................................................................................... 44-4
Hydraulic pump assembly disassembling and assembling ....................................................................... 44-10
Regulator disassembling and assembling ................................................................................................ 44-16
Hydraulic pilot (triple) pump disassembling and assembling .................................................................... 44-23
Pilot Valve (for Loading) .................................................................................................................................. 44-24
Pilot valve (for loading) removing and installing ........................................................................................ 44-24
Pilot valve (for loading) disassembling and assembling ........................................................................... 44-26
Pilot Valve (for Steering) ................................................................................................................................. 44-33
Pilot valve (for steering) removing and installing ...................................................................................... 44-33
Pilot valve (for steering) disassembling and assembling .......................................................................... 44-35
Steering Valve ................................................................................................................................................. 44-39
Steering valve removing and installing ...................................................................................................... 44-39
Steering valve disassembling and assembling ......................................................................................... 44-42
Multiple Control Valve ..................................................................................................................................... 44-46
Multiple control valve removing and installing ........................................................................................... 44-46
Multiple control valve disassembling and assembling .............................................................................. 44-49
Stop Valve ....................................................................................................................................................... 44-54
Stop valve removing and installing ............................................................................................................ 44-54
Stop valve disassembling and assembling ............................................................................................... 44-56
Hydraulic Cylinder ........................................................................................................................................... 44-58
Hydraulic cylinder removing and installing ................................................................................................ 44-58
Boom cylinder removing and installing ..................................................................................................... 44-58
Bucket cylinder removing and installing .................................................................................................... 44-61
Steering cylinder removing and installing .................................................................................................. 44-63
Hydraulic cylinder disassembling and assembling .................................................................................... 44-66
Special tool for hydraulic cylinder disassembling ...................................................................................... 44-73
135ZV-2 Service Standard Hydraulic Group ......................................................................................................... 45-1
Hydraulic Cylinder ............................................................................................................................................. 45-2
135ZV-2 Disassembly & Reassembly Brake Group ............................................................................................. 54-1
Brake Valve ....................................................................................................................................................... 54-2
Brake valve removing and installing ........................................................................................................... 54-2
Brake valve disassembling and assembling ............................................................................................... 54-4
11. Unloader Valve ................................................................................................................................................ 54-10
Unloader valve removing and installing .................................................................................................... 54-10
Unloader valve disassembling and assembling ........................................................................................ 54-12
Manifold Valve Assembly ................................................................................................................................ 54-14
Valve assembly removing and installing ................................................................................................... 54-14
Valve assembly disassembling and assembling ....................................................................................... 54-16
Accumulator .................................................................................................................................................... 54-17
Accumulator removing and installing ........................................................................................................ 54-17
Accumulator disassembling and assembling ............................................................................................ 54-19
Nitrogen gas charging ............................................................................................................................... 54-25
Service Brake .................................................................................................................................................. 54-27
Service brake disassembling and assembling .......................................................................................... 54-27
Parking Brake .................................................................................................................................................. 54-31
Parking brake removing and installing ...................................................................................................... 54-31
Parking brake disassembling and assembling .......................................................................................... 54-32
135ZV-2 Service Standard Brake Group .............................................................................................................. 55-1
Brake Valve ....................................................................................................................................................... 55-2
Service Brake .................................................................................................................................................... 55-4
Parking Brake .................................................................................................................................................... 55-5
135ZV-2 Disassembly & Reassembly Operator Station Group ............................................................................ 74-1
Air Conditioner .................................................................................................................................................. 74-2
Air conditioner removing and installing ....................................................................................................... 74-2
Air conditioner disassembling and assembling ........................................................................................... 74-4
135ZV-2 Service Standard Operator Station Group ............................................................................................. 75-1
Air Conditioner .................................................................................................................................................. 75-2
Periodical Inspection/Servicing ................................................................................................................... 75-2
Tightening Torque ....................................................................................................................................... 75-2
12. 00-1
135ZV-2 General Information
135ZV-2 General Information
Symbols .................................................................. 00-2
Weight of Main Components ................................... 00-3
Bolt Tightening Torque ............................................ 00-4
Hose Band Tightening Torque................................. 00-8
Liquid Gasket and Screw Lock Agent ..................... 00-9
Cautions Regarding Welding Repair Service .......... 00-11
Cautions Regarding Handling of Bearing................ 00-13
Applying and Storing Articulation Stopper ............... 00-15
13. 00-2
135ZV-2 General Information
Symbols
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Abbreviation
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the follow-
ing abbreviation list.
Symbol Item Description
Reference
Shows the condition or procedure that will be useful
or efficient in doing service work.
Weight
Shows the weight of a part or unit. The weight
should be considered in selecting wire rope or cable
for slinging work or determining the working pos-
ture.
Tightening
torque
Shows the tightening torque of a section that should
be carefully tightened during assembly work.
Coating
Shows the type of coating or adhesive and the coat-
ing section.
Oil or
water
supply
Shows the oil or water supply port and the refill
amount.
Drainage
Shows the oil or water drain port and the drain
amount.
IMPORTANT
If the specified conditions are not satisfied or the specified procedure is not
observed, there is a strong possibility that the product will be damaged or the per-
formance of the product will be reduced.
The message shows the preventive measures.
E/G ........... Engine
T/C ........... Torque converter
T/M ........... Transmission
SOL ........... Solenoid valve
SW ........... Switch
F ........... Front or Forward
A/M ........... Auto/Manual
B ........... Battery
R ........... Rear or Reverse
RH ........... Right hand side
LH ........... Left hand side
H ........... High
L ........... Low
GND........... Ground
OPT ........... Option
Assy ........... Assembly
1st ........... 1st speed
2nd ........... 2nd speed
3rd ............3rd speed
4th ............4th speed
M/C ............Machine
min-1
............RPM
ELS ............Efficient loading system
MODM ........Machine operation
diagnostic module
MCU............Machine control unit
14. 00-3
135ZV-2 General Information
Weight of Main Components
Weight of Main Components
Item Approx.
weight
(kg)
Approx.
weight
(lb)
Remarks
Unit name Part name
Chassis
Bucket 7,100 15,655 RTV bucket
Boom 5,900 13,010
"Z" -Lever 800/pc 1,765/pc
Link (Bucket to Lever) 165/pc 360/pc
Engine room assembly 590 1,300
Hydraulic tank
Main tank 530 1,170 Excluding oil
Sub tank 115 250 Excluding oil
Fuel tank 610 1,345 Excluding fuel
Floor board 165 365
Cab 335 740
ROPS 1,190 2,625
Deck
Left 150 325 With handrail
Center 75 165
Right 140 310 With handrail
Front chassis 6,690 14,750
Rear chassis 6,300 13,890
Counter weight 1,125 2,480
Power line
Engine 3,200 7,055 Excluding water and oil
Radiator assembly 970 2,140 Excluding water and oil
Torque converter 540 1,190 Excluding oil
Transmission 3,850 8,480 Excluding oil
First propeller shaft 40 90
Second propeller shaft 210 465
Third propeller shaft 45 100
Front axle assembly 6,430 14,180 Excluding tires and oil
Rear axle assembly 7,375 16,260 Excluding tires and oil (Including axle support)
Differential
Front 1,180 2,600
Rear 1,270 2,800
Hydraulic system
Multiple control valve 100 220
Pilot valve 6 13 Single lever
Steering valve 82 180
Hydraulic
pump
Switch 85 185
Main 125 275
Triple 50 105
Boom cylinder 810/pc 1,790/pc Excluding oil
Bucket cylinder 385/pc 850/pc Excluding oil
Steering cylinder 130/pc 290/pc Excluding oil
Other
Tire 2,900/pc 6,395/pc With rim (45/65-R39); No Hydro Inflation
Battery 60/pc 130/pc
19. 00-8
135ZV-2 General Information
Hose Band Tightening Torque
Hose Band Tightening Torque
To connect the hose to the pipe, tighten the hose band
at the following position:
Low pressure hose
(heat resisting hose) Hose band
Tightening torque
(N-m)
Tightening torque
(kgf-cm)
Tightening torque
(lb-ft)
Inner dia. (mm) Outer dia. (mm)
6.3 16.5
69002-02200 1.6 16 1.2
7.9 18.5
9.5 20.5
12.7 24.5 69002-02700
4 40 2.9
15.9 29.9
69002-03100
19.0 30.0
25.4 38.0 69002-04400
31.8 45.8 69002-05200
38.1 52.1 69002-05700
50.8 67.8 69002-07100
60.5 76.0 69002-08200
75.5 93.0 69002-09500
Low pressure hose
Hose band
Tightening torque
(N-m)
Tightening torque
(kgf-cm)
Tightening torque
(lb-ft)
Inner dia. (mm) Outer dia. (mm)
6 16.5
69002-02200 1.6 16 1.2
8 18.5
9 20.5
9 22.0 69002-02300
4 40 2.9
12 24.5
69002-02700
12 26.0
15 29.0
69002-03100
15 30.5
19 32.0
69002-03800
19 34.0
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
K50V200002
Hose
Pipe
Fix the band
avoiding the beading.
Hose band
2~3 mm (1/8 in)
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21. 00-9
135ZV-2 General Information
Liquid Gasket and Screw Lock Agent
Liquid Gasket and Screw Lock Agent
To reassemble the disassembled parts, be sure to use
the specified liquid gasket or screw lock agent or the
equivalent according to the following lists:
Cautions regarding parts removal
If a screw or shaft to be removed has been locked by
one of the above agents, remove the screw or shaft
using a general tool, such as a wrench or puller.
If it is difficult to remove the screw or shaft, heat the bolt
to soften the agent (200~250°C) using a soldering iron
or gas torch.
Caution
If there is a seal near the screw or shaft to be removed,
carefully use the heating method for removal, to avoid
damage to the seal.
If heat has been used to remove the bolt a new bolt
should be used during reassembly.
Cautions regarding reassembly
To reassemble a screw
Completely remove the hardened lock agent from the
screw and the threaded hole before reassembling the
screw.
Note
A piece of hardened lock agent may be peeled off and
remain in the component. The remaining piece may
cause malfunction during fastener installation.
To bond a plane or to fit a shaft
Remove the hardened lock agent using a wire brush or
the like, and polish the surface using sand paper. Use of
a Loctite®
primer like Locquic ® Primer T prepares
metal surface of the threads and speeds curing time.
Antiseize Agent
Code Manufacturer Product name
Liquid Gas-
ket
AA01
AA02
AA03
Loctite®
Loctite®
Three Bond
Plastic Gasket 568
Hydraulic sealant
Three Bond 1215
Screw Lock
Agent
AB01
AB02
AB03
Loctite®
Three Bond
Three Bond
Loctite®
262
Three Bond 1327
Three Bond 1374
Code Manufacturer Product name
AC01 Loctite®
Loctite®
767
(Paste or spray)
22. 00-10
135ZV-2 General Information
Liquid Gasket and Screw Lock Agent
Screw lock agent application pro-
cedure
Through-hole
Apply screw lock agent one or two lines on the male
threads.
How to wind a seal tape
As the screw is tightened by turning clockwise, seal
tape must be wound up clockwise direction as shown
above. If not, the tape will be loosened or removed
while tightening the screw, resulting in oil leakage.
To avoid a piece of seal tape left in the circuit, leave 1 or
2 screws from the end of the thread and start threading
it clockwise.
Slightly stretch the tape when cutting it out, and press to
fit the tape onto the screw thread.
65ZV00002
Screw lock agent
65ZV00004a
Seal tape
Leave 1~2 screw
23. 00-11
135ZV-2 General Information
Cautions Regarding Welding Repair Service
Cautions Regarding Welding Repair Service
If welding is needed to repair the chassis, observe the
following precautions to protect the hydraulic cylinders,
hydraulic units, gear sets, and electrical units from pos-
sible damage.
Cautions
1. Turn the starter switch OFF.
2. Remove the battery terminals both positive and
negative sides from the battery.
3. Disconnect the connector for MCU (machine con-
troller), ECM (engine controller) and air conditioner.
4. Ground the welder near the section to be welded.
5. To ground the welder, check that the electric current
will not flow through the cylinders.
Cylinder head covers for some models have a low
conductive metal that will cause spark if the welding
current flows. The spark may damage the cylinder
rod.
6. Calibrate throttle pedal to ECM.
(a) Turn the starter switch to "ON".
(b) Fully depress and release the throttle pedal
three times.
(c) Turn the starter switch to "OFF".
IMPORTANT
If a battery terminal is removed from a machine in
less than 30 seconds after the key is put into the
“OFF” position, it can corrupt the ECM program,
which can disable the engine. Always wait 1 full
minute to be sure to be past this “write to memory
function” prior to removing battery terminals.
35C00002
Section to be welded
Ground this section.
(correct grounding)
Example 1
Electric current may flow
through the cylinders.
Do not ground this section.
35C00006
Section to be welded Ground this section.
(correct grounding)
Electric current may flow
through the cylinders.
Example 2
Do not ground this section.