Kawasaki 67 z7 wheel loader service repair manual (65j5 8001 and up)

service repair manual

©2016 KCM Corporation. All rights reserved. Printed in Japan (K)
( アメリカ・オセアニア用 )
93207-01041
January 2016
SHOP MANUAL
WHEEL LOADER
67Z7
Disassembly & Reassembly
Powered by ISUZU 4HK1 Engine
Serial No. 65J5-5001 and up
65J5-8001 and up
67Z7
SHOP
MANUAL
Disassembly
&
Reassembly
93207-01041
93207-01041
January 2016
67Z7 D&R
WORK SHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling.......................................................W1-1
Group 2 Tightening..................................................................................................................W1-2
Group 3 Painting .....................................................................................................................W1-3
Group 4 Bleeding Air...............................................................................................................W1-4
Group 5 Releasing Pressure...................................................................................................W1-5
Group 6 Preparation................................................................................................................W1-6
SECTION 2 MAINTENANCE STANDARD
Group 1 Body ..........................................................................................................................W2-1
Group 2 Travel System ...........................................................................................................W2-2
Group 3 Front Attachment.......................................................................................................W2-3
SECTION 3 BODY
Group 1 Cab............................................................................................................................W3-1
Group 2 Counterweight...........................................................................................................W3-2
Group 3 Center Hinge.............................................................................................................W3-3
Group 4 Engine .......................................................................................................................W3-4
Group 5 Radiator Assembly ....................................................................................................W3-5
Group 6 Hydraulic Oil Tank .....................................................................................................W3-6
Group 7 Fuel Tank...................................................................................................................W3-7
Group 8 Pump Device.............................................................................................................W3-8
Group 9 Control Valve.............................................................................................................W3-9
Group 10 Pilot Valve................................................................................................................W3-10
Group 11 Brake Charge Valve ................................................................................................W3-11
Group 12 Manifold Valve.........................................................................................................W3-12
Group 13 Solenoid Valve ........................................................................................................W3-13
Group 14 Priority Valve ...........................................................................................................W3-14
Group 15 Cooling Fan System................................................................................................W3-15
Group 16 Ride Control Device................................................................................................W3-16
Group 17 Exhaust Filter ..........................................................................................................W3-17
67Z7 D&R
SECTION 4 TRAVEL SYSTEM
Group 1 Tire ............................................................................................................................W4-1
Group 2 HST Motor.................................................................................................................W4-2
Group 3 Transmission.............................................................................................................W4-3
Group 4 Axle ...........................................................................................................................W4-4
Group 5 Propeller Shaft ..........................................................................................................W4-5
Group 6 Brake Valve ...............................................................................................................W4-6
Group 7 Steering Device.........................................................................................................W4-7
Group 8 Secondary Steering Device ......................................................................................W4-8
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment.......................................................................................................W5-1
Group 2 Cylinder .....................................................................................................................W5-2
All information, illustrations and specifications in this manual are based on the latest product information available at the
time of publication. The right is reserved to make changes at any time without notice.
INTRODUCTION
IN-01
To The Reader
Additional References
Manual Composition
Page Number
This manual is written for an experienced technician to
provide technical information needed to maintain and
repair this machine.
 Be sure to thoroughly read this manual for correct
product information and service procedures.
Please refer to the other materials (operation and
maintenance manual, parts catalog, engine technical
material, Kawasaki shop materials, etc.) in addition to this
manual.
Our shop manuals consist of the Technical Manual, the
Workshop Manual and the Engine Manual.
 Information included in the Technical Manual:
Technical information needed for machine pre-delivery
and delivery, operation and activation of all devices
and systems, operational performance tests, and
troubleshooting procedures.
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
 Technical Manual: T 1-3-5
T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
 Information included in the Workshop Manual:
Technical information needed for maintenance and
repair of the machine, tools and devices needed for
maintenance and repair, maintenance standards, and
removal / installation and assembly / disassembly
procedures.
 Information included in the Engine Manual:
Technical information needed for machine pre-delivery
and delivery and maintenance and repair of the machine,
operation and activation of all devices and systems,
troubleshooting and assembly / disassembly procedures.
 Workshop Manual: W 1-3-2-5
W Workshop Manual (Disassembly & Reassembly)
1 Section Number
3 Group Number
2 Sub Group Number
5 Consecutive Page Number for Each Group
INTRODUCTION
IN-02
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential
for personal injury of machine damage.
dThis is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
lifting techniques and equipment when lifting heavy
parts.
dCAUTION:
Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
fNOTE:
Indicates supplementary technical information.
Units Used
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3
yd3
1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
fNOTE: The numerical value in this manual might be
different from the above-mentioned table.
SI Units (International System of Units) are used in this
manual. MKSA (Meter, Kilogram, Second, Ampere) system
units and English units are also indicated in parentheses
just behind SI units.
Example: 24.5 MPa (250 kgf/cm2
, 3560 psi)
A table for conversion from SI units to other system units
is shown below for reference purposes.
67Z7 D&R
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling..............................................................W1-1-1-1
Precautions for Using Floating Seal...................W1-1-1-2
Precautions for Using Nylon Sling......................W1-1-1-3
Group 2 Tightening
Tightening Bolts and Nuts..........................................W1-2-1-1
Specified Tightening Torque Chart....................W1-2-1-1
Precautions for Split Flange..................................W1-2-1-3
Nut and Bolt Locking ..............................................W1-2-1-3
Piping Joint ......................................................................W1-2-1-4
Union Joint .................................................................W1-2-1-5
Pipe Joint.....................................................................W1-2-1-6
O-ring Seal Joint .......................................................W1-2-1-6
Quick Coupling..........................................................W1-2-1-7
Screw-In Connection...............................................W1-2-1-8
Seal Tape Application..............................................W1-2-1-8
Low-Pressure-Hose Clamp Tightening.............W1-2-1-8
Connecting Hose......................................................W1-2-1-9
Group 3 Painting
Painting .............................................................................W1-3-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank......................W1-4-1-1
Bleeding Air from Hydraulic System.......................W1-4-1-2
Bleeding Air from Fuel System..................................W1-4-1-4
Bleeding Air from Radiator.........................................W1-4-1-6
Bleeding Air from Brake (Axle)..................................W1-4-1-7
Group 5 Releasing Pressure
Front Attachment Hydraulic Circuit Pressure
Release Procedure....................................................W1-5-1-1
Ride Control Accumulator Pressure
Release Procedure....................................................W1-5-1-2
Group 6 Preparation
Preparation before Inspection and
Maintenance...........................................................W1-6-1-1
Lock of Frame.............................................................W1-6-1-2
Machine Position for Inspection and
Maintenance (lift arm raise)...............................W1-6-1-3
CONTENTS
SECTION 1
GENERAL
Group 1 Precautions for Disassembling and Assembling
SECTION 1 GENERAL
W1-1-1-1
Precautions for Disassembling and
Assembling
Precautions for Disassembling
 Clean the Machine
Thoroughly wash the machine before bringing it
into the shop. Bringing a dirty machine into the shop
may cause machine components to be contaminated
during disassembling / assembling, resulting in
damage to machine components, as well as decreased
efficiency in service work.
 Inspect the Machine
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
incorrect disassembling of components as well as
personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
 The machine model, machine serial number, and
hour meter reading.
 Reason for disassembly (symptoms, failed parts, and
causes).
 Clogging of filters and oil, water or air leaks, if any.
Capacities and condition of lubricants.
 Loose or damaged parts.
 Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the area for
disassembling work.
Precautions for Disassembling and Assembling
 Precautions for Disassembling
 Cap the open ends in case the hoses and pipes
have been disconnected. In addition, attach an
identification tag onto the connectors, hoses, and
pipes for assembling.
 Before disassembling, clean the exterior of the
components and place on a workbench.
 Drain hydraulic oil and gear oil from the hydraulic
components and reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling if
necessary.
 Be sure to use the specified special tools when
instructed.
 If a part or component cannot be removed after
removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), then take the
appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and tag
them if necessary.
 Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
 Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking, or
other damage.
 Measure and record the degree of wear and
clearances.
 Precautions for Assembling
 Be sure to clean all parts and inspect them for any
damage. If any damage is found, repair or replace
part.
 Dirt or debris on the contact or sliding surfaces may
shorten the service life of the machine. Take care not
to contaminate any contact or sliding surfaces.
 Apply appropriate lubricant oil onto parts in order to
prevent them from seizing.
 Be sure to replace O-rings, backup rings, oil seals, and
floating seals with new ones once they have been
disassembled. Apply grease before installing
 Be sure that liquid-gasket-applied surfaces are clean
and dry.
 If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to remove
the agent.
 Fit the matching marks made when disassembling
and assemble them.
 Be sure to use the designated tools to assemble
bearings, bushings, and oil seals.
 Keep a record of the number of tools used for
disassembly / assembly. After assembling is
completed, count the number of tools so as to make
sure that no forgotten tools remain in the assembled
machine.
Group 1 Precautions for Disassembling and Assembling
SECTION 1 GENERAL
W1-1-1-2
Precautions for Using Floating Seal
1. In general, replace the floating seal with a new one
after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding
surface (e) of seal ring (1).
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) for tears, breaks, deformation, or
hardening.
2. If incorrectly assembled, oil leakage or damage
will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air.
 Clean seal ring (1) and O-ring (2) mounting bores.
Check the bore surface for scuffing or scoring by
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
is not twisted, and that it is installed correctly on seal
ring (1).
 After installing the floating seal, check that O-ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f) by measuring the distances
(e) and (f) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating.
1
2
a
b
c
d
a - Correct
b - Incorrect
c - Twist of O-Ring
d - Bend of O-Ring
a - Correct
b - Incorrect
e - Sliding Surface
f - Seal Mating Surface
f
e
2
a A A
B B
b
A=B A≠B
W178-02-11-001
W178-02-11-002
W178-02-11-003
Group 1 Precautions for Disassembling and Assembling
SECTION 1 GENERAL
W1-1-1-3
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings
safely.
 Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
 Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load with
a temperature of 100 °C (212 °F) or more, reduce the
load weight.
 Do not lift acid or alkali chemicals.
 Take care not to allow the sling to become wet. The
load may slip.
 When required to use more than one sling, use slings
with the same width and length to keep the lifted
load balanced.
 When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
 Avoid using twisted, bound, connected, or hitched
slings.
 Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
 When removing the slings from under the load, take
care not to damage the nylon slings. Avoid contact
with protrusions.
 Avoid dragging slings on the ground, throwing
slings, or pushing slings with a metal object.
 When using with other types of slings (wire rope) or
accessories (shackle), protect the joint so that the
nylon sling is not damaged.
 Store the nylon slings indoors so that they won’t
deteriorate with heat, sun light, or chemicals.
a
b
c
a - Correct Eyehole Lifting
Method
b - Incorrect Eyehole Lifting
Method
c - Bent of Sling
W102-04-02-016
W105-04-01-008
W162-01-01-009
Group 1 Precautions for Disassembling and Assembling
SECTION 1 GENERAL
W1-1-1-4
dCAUTION: If a load is lifted with a damaged
nylon sling, serious personal injury may result.
Be sure to visually check the nylon sling for any
damage before using.
2. Before using a nylon sling, visually check the nylon
sling for any damage corresponding to examples
shown to the right. If any damage is found, cut and
discard the sling.
Even if no damage is found, do not use slings older
than 7 years.
Damaged Appearance a
a
a
e
f
b
b
c
c
g
d
a - Broken Sewing Thread a - Broken Sewing Thread e - Separation of Belt
b - Scuffing f - Scoring
b - Scuffing
c - Fuzz d - Broken Sewing Thread
c - Fuzz g - Broken Warp
a - Broken Sewing Thread
W162-01-01-002
W162-01-01-003
W162-01-01-004
W162-01-01-005
W162-01-01-006
W162-01-01-007
W162-01-01-008
Group 1 Precautions for Disassembling and Assembling
SECTION 1 GENERAL
W1-1-1-5
Maintenance Standard Terminology
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable errors will be
indicated if necessary.
“Allowable Limit”
1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this
limit.
3. Repair or adjustment is impossible after exceeding
this limit.
Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the“Allowable
Limit”.
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-1
Tightening Bolts and Nuts
dCAUTION: Use tools appropriate for the work
to be done. Makeshift tools and procedures
can create safety hazards. For loosening and
tightening nuts and bolts, use correct size tools.
Otherwise, tightening tools may slip, potentially
causing personal injure.
IMPORTANT:

Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it)

Clean the bolt and nut threads and remove dirt
or corrosion before installing.
Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used,
use and tighten the correct bolts correctly when
assembling the machine or components.
Specified Tightening Torque Chart
Bolt Dia.
mm (in)
Tightening torque
N·m (kgf·m) (lbf-ft)
Wrench size
mm (in)
Hexagon
Bolt
(8~11T)
Flanged
Bolt
(8T)
Socket Bolt
(11T) (8T) (4T)
6 (0.24) 3~4 (0.3~0.4) (2.2~3) 10 (0.39) 10 (0.39) 5 (0.20)
8 (0.31) 30 (3) (22) 20 (2) (14.8) 10 (1) (7.4) 13 (0.51) 12 (0.47) 6 (0.24)
10 (0.39) 65 (6.5) (48) 50 (5) (36.9) 20 (2) (14.8) 17 (0.67) 14 (0.55) 8 (0.31)
12 (0.47) 110 (11) (81) 90 (9) (66.4) 35 (3.5) (25.8) 19 (0.75) 17 (0.67) 10 (0.39)
14 (0.55) 180 (18) (133) 140 (14) (104) 55 (5.5) (40.6) 22 (0.87) 12 (0.47)
16 (0.63) 270 (27) (199) 210 (21) (155) 80 (8) (59) 24 (0.94) 22 (0.87) 14 (0.55)
18 (0.71) 400 (40) (295) 300 (30) (221) 120 (12) (88.5) 27 (1.06) 14 (0.55)
20 (0.79) 550 (55) (406) 400 (40) (295) 170 (17) (125) 30 (1.18) 27 (1.06) 17 (0.67)
22 (0.87) 750 (75) (553) 550 (55) (406) 220 (22) (162) 32 (1.26)
24 (0.94) 950 (95) (700) 700 (70) (516) 280 (28) (207) 36 (1.42) 32 (1.26) 19 (0.75)
27 (1.06) 1400 (140) (1033) 1050 (105) (774) 400 (40) (295) 41 (1.61)
30 (1.18) 1950 (195) (1438) 1450 (145) (1069) 550 (55) (406) 46 (1.81)
33 (1.30) 2600 (260) (1918) 1950 (195) (1438) 750 (75) (553) 50 (1.97)
36 (1.42) 3200 (320) (2360) 2450 (245) (1807) 950 (95) (700) 55 (2.17)
WDAA-01-02-001
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-2
IMPORTANT: The following items are applied to both
fine and coarse pitch threads.

Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it)

Torque tolerance is ±10 %.

Use the bolts of correct length. The bolts that
are too long cannot be tightened as the bolt tip
comes into contact with the bottom of bolt hole.
Also the bolts that are too short cannot develop
sufficient tightening force.

The torque given in the chart on the previous
page are for general use only, however,
a different torque is given for a specific
application. Use the specified torque.

Clean the nut and bolt threads and remove dirt
or corrosion before installing.
Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.
a
1.4
1 12
13
9
8
4
5
1
2
6
3
7
10
14
11
3
5
2
4
6
2.3
b c
a - Equally tighten upper and
lower alternately
b - Tighten diagonally c - Tighten from center
diagonally
W105-01-01-003
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-3
Precautions for Split Flange
IMPORTANT:

Clean the sealing surfaces. Check if there are
any scratches and roughness on the surface of
the seal that cause oil leaks and damage to the
O-ring.

Use only specified O-rings. Inspect O-rings for
any damage. Do not file the O-ring surfaces.
When installing O-ring into a groove, use grease
in order to hold O-ring in place.

While tightening the bolt by hand, check that
flange is installed to the port correctly. Do not
pinch the O-ring.

Tighten the bolts up and down, left and right
alternately, in order to ensure even tightening
to the specified torque.

Do not use air wrenches. Using an impact
wrench often causes tightening of one bolt fully
before tighten the others, resulting in damage
to O-rings or uneven tightening of bolts.
Nut and Bolt Locking
 Lock Plate
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice.
 Split Pin
IMPORTANT: Do not turn in the loosening direction
in order to align the grooves and holes on the nut.
Always turn in the tightening direction. Do not
reuse the split pins.
 Wire
IMPORTANT: Attach wire to bolts in the bolt-
tightening direction. Do not reuse the wire.
Incorrect
Correct
Correct
Correct
Correct
Correct
Correct
a
a
b
d
c
Incorrect
Incorrect
Incorrect
Incorrect
a- Bend along edge sharply b- Do not bend it round
c- Tighten d- Loosen
WDAA-01-02-005
WDAA-01-02-006
W105-01-01-008
WDAA-01-02-007
WDAA-01-02-008
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-4
Piping Joint
IMPORTANT:
 The torque given in table below are for general
use only, however, a different torque is given for
a specific application. Use the specified torque.

Apply lubricant, such as the Grease Spray to
the bolts and nuts in order to reduce friction
coefficient of them.

Torque tolerance is ±10 %.

Slightly apply lubricant onto the threads first by
using the Grease Spray.
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-5
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT:

Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces (4)
and (5), possibly cracking the adapter. Tighten
union nut (3) to the specifications.

Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint. Take
care not to damage them when connecting /
disconnecting.
2013/09
Description Wrench Size mm Tightening Torque
Union Nut N·m (lbf·ft)
30 ° male 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
55 380 (280)
60 380 (280)
37 ° female 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
fNOTE: Tightening torque of 37 ° male coupling without
union is similar to tightening torque of 37° female.
a - Joint Body
b - Male Union Joint c - Female Union Joint
1
30 °
37 °
b c
4 3 2
a
5
WDAA-01-02-009
WDAA-01-02-010
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-6
Pipe Joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17, 19, 22, 27)
Metal (3) of adapter (1) and pipe (2) seals pressure oil.
 Precautions for use
Do not damage sealing surfaces (4) and (5) when
disassembling and assembling.
Tightening Torque
Use the specified tightening torque in the table below.
2013/09
Wrench Size (mm) 17 19 22 27
Tightening
Torque
N·m 25 30 40 80
(lbf·ft) (18.5) (22) (29.5) (59)
O-ring Seal Joint
O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.
IMPORTANT:

Replace O-ring (6) with a new one when
reinstalling.

Before tightening union nut (9), confirm that
O-ring (6) is seated correctly in O-ring groove
(8). Tightening union nut (9) with O-ring (6)
displaced will damage O-ring (6), resulting in oil
leakage.

Do not damage O-ring groove (8) of adapter (7)
or sealing surface (10) on the hose side. Damage
to O-ring (6) may cause oil leakage.

If union nut (9) is found to be loose, causing
oil leakage, do not tighten it to stop the leak.
Instead, replace O-ring (6) with a new one, then
tighten union nut (9) after confirming that
O-ring (6) is securely seated in O-ring groove (8).
1 4 5 3 2
7 6 9
8 10 a
a - Joint Body
2013/09
Wrench Size mm Tightening Torque
Union Nut N·m (lbf·ft)
19 30 (22)
22 70 (52)
27 95 (70)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
M1M7-07-005
WDAA-01-02-011
Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-7
Quick Coupling
1. Coupling procedure
 Push socket ring (1) into plug (3) by rotating it fully
counterclockwise and then pulling it toward you.
 Release socket ring (1). Check that socket ring (1)
is returned by the spring force and the coupling is
locked completely by ball (2). At this time, check if
socket ring (1) is returned to the original position (to
the rightmost direction).
2. Separating procedure
 Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
check function is attached inside, be careful that oil
flows out.
 Cap the removed hoses using special plug.
dCAUTION:
 When disconnecting, do not damage joint
surface.
 When disconnecting, clean the joint part and
thoroughly wipe off the cleaning solution to
prevent any foreign material from entering.
 Complete the joint disconnecting / connecting
procedure. Check enough if oil leaks especially
after installation.
 After installation, check if socket ring (1)
is returned to the original position (to the
rightmost direction).
1
3
2
M1M7-07-006
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-8
Screw-In Connection
Depending on types of screw and sealing, different
types of screw-in connection are used.
IMPORTANT: Check that the thread pitch and thread
type (tapered or straight) are the correct type
before using any screw-in connection. (In general,
the screw-in connection of male tapered thread (a)
is used except for measurement purpose.)
Seal Tape Application
Seal tape is used in order to seal clearances between
male (d) and female (c) threads so that any leaks
between threads may be prevented. Therefore, apply
just enough seal tape to fill up thread clearances (e). Do
not overwrap.
 Application Procedure
Check that the thread surface is clean and, free of dirt
or damage. Apply the seal tape around threads in order
to leave one to two pitch threads uncovered. Wrap the
seal tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
T-Bolt Type Band Clamp (g):
4.5 N·m (3.3 lbf·ft)
Worm Gear Type Band Clamp (h):
6 to 7 N·m (4.4 to 5.2 lbf·ft)
R
a
c
f
d
b
G
30 °
a - Male Tapered Thread b - Male Straight Thread
c - Internal Thread
d - External Thread
e - Clearance
f - Leave one to two pitch
threads uncovered
2013/09
Wrench Size mm Tightening Torque
Joint Body Cast iron Structural rolled
steel
19 15 (11) 35 (26)
22 30 (22) 50 (37)
27 50 (37) 95 (70)
36 70 (52) 160 (118)
41 110 (81) 200 (148)
50 160 (118) 330 (245)
60 200 (148)
fNOTE: Unit: N·m (lbf·ft)
e
g - T-Bolt Type Band Clamp h - Worm Gear Type Band Clamp
g h
W105-01-01-018
W105-01-01-019
M114-07-041
M114-07-043
WDAA-01-02-012
Group 2 Tightening
SECTION 1 GENERAL
W1-2-1-9
Connecting Hose
dCAUTION: When replacing the hoses, use only
genuine KCM service parts. Using hoses other
than genuine KCM hoses may cause oil leaks, hose
rupture or separation of fitting, possibly resulting
in a fire on the machine. Do not install hoses
kinked. Application of high oil pressure, vibration,
or an impact to a kinked hose may result in oil
leaks, hose rupture or separation of fitting.
Utilize the print marks on hoses when installing
in order to prevent hose from being kinked. Take
necessary measures to protect hoses from rubbing
against each other. If the hoses rub against each
other, wear to the hoses may result and lead to
hose rupture. Take care so that the hoses do not
come into contact with the moving parts or sharp
objects.
a
a - Rubbing Against Each Other
a - Rubbing Against Each Other b - Clamp
a - Rubbing Against Each Other b - Clamp
b b
a
a
b
Incorrect
Incorrect
Incorrect
Incorrect
Correct
Correct
Correct
Correct
W105-01-01-011
W105-01-01-012
W105-01-01-013
W105-01-01-014

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Kawasaki 67 z7 wheel loader service repair manual (65j5 8001 and up)

  • 1. ©2016 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ・オセアニア用 ) 93207-01041 January 2016 SHOP MANUAL WHEEL LOADER 67Z7 Disassembly & Reassembly Powered by ISUZU 4HK1 Engine Serial No. 65J5-5001 and up 65J5-8001 and up 67Z7 SHOP MANUAL Disassembly & Reassembly 93207-01041
  • 2. 93207-01041 January 2016 67Z7 D&R WORK SHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling.......................................................W1-1 Group 2 Tightening..................................................................................................................W1-2 Group 3 Painting .....................................................................................................................W1-3 Group 4 Bleeding Air...............................................................................................................W1-4 Group 5 Releasing Pressure...................................................................................................W1-5 Group 6 Preparation................................................................................................................W1-6 SECTION 2 MAINTENANCE STANDARD Group 1 Body ..........................................................................................................................W2-1 Group 2 Travel System ...........................................................................................................W2-2 Group 3 Front Attachment.......................................................................................................W2-3 SECTION 3 BODY Group 1 Cab............................................................................................................................W3-1 Group 2 Counterweight...........................................................................................................W3-2 Group 3 Center Hinge.............................................................................................................W3-3 Group 4 Engine .......................................................................................................................W3-4 Group 5 Radiator Assembly ....................................................................................................W3-5 Group 6 Hydraulic Oil Tank .....................................................................................................W3-6 Group 7 Fuel Tank...................................................................................................................W3-7 Group 8 Pump Device.............................................................................................................W3-8 Group 9 Control Valve.............................................................................................................W3-9 Group 10 Pilot Valve................................................................................................................W3-10 Group 11 Brake Charge Valve ................................................................................................W3-11 Group 12 Manifold Valve.........................................................................................................W3-12 Group 13 Solenoid Valve ........................................................................................................W3-13 Group 14 Priority Valve ...........................................................................................................W3-14 Group 15 Cooling Fan System................................................................................................W3-15 Group 16 Ride Control Device................................................................................................W3-16 Group 17 Exhaust Filter ..........................................................................................................W3-17
  • 3. 67Z7 D&R SECTION 4 TRAVEL SYSTEM Group 1 Tire ............................................................................................................................W4-1 Group 2 HST Motor.................................................................................................................W4-2 Group 3 Transmission.............................................................................................................W4-3 Group 4 Axle ...........................................................................................................................W4-4 Group 5 Propeller Shaft ..........................................................................................................W4-5 Group 6 Brake Valve ...............................................................................................................W4-6 Group 7 Steering Device.........................................................................................................W4-7 Group 8 Secondary Steering Device ......................................................................................W4-8 SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment.......................................................................................................W5-1 Group 2 Cylinder .....................................................................................................................W5-2 All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.
  • 4. INTRODUCTION IN-01 To The Reader Additional References Manual Composition Page Number This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.  Be sure to thoroughly read this manual for correct product information and service procedures. Please refer to the other materials (operation and maintenance manual, parts catalog, engine technical material, Kawasaki shop materials, etc.) in addition to this manual. Our shop manuals consist of the Technical Manual, the Workshop Manual and the Engine Manual.  Information included in the Technical Manual: Technical information needed for machine pre-delivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures. Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T Technical Manual 1 Section Number 3 Group Number 5 Consecutive Page Number for Each Group  Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assembly / disassembly procedures.  Information included in the Engine Manual: Technical information needed for machine pre-delivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assembly / disassembly procedures.  Workshop Manual: W 1-3-2-5 W Workshop Manual (Disassembly & Reassembly) 1 Section Number 3 Group Number 2 Sub Group Number 5 Consecutive Page Number for Each Group
  • 5. INTRODUCTION IN-02 Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. dThis is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts. dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death. IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. fNOTE: Indicates supplementary technical information. Units Used Quantity To Convert From Into Multiply By Length mm in 0.03937 mm ft 0.003281 Volume L US gal 0.2642 L US qt 1.057 m3 yd3 1.308 Weight kg lb 2.205 Force N kgf 0.10197 N lbf 0.2248 Torque N·m kgf·m 0.10197 Pressure MPa kgf/cm2 10.197 MPa psi 145.0 Power kW PS 1.360 kW HP 1.341 Temperature °C °F °C×1.8+32 Velocity km/h mph 0.6214 min-1 rpm 1.0 Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0 fNOTE: The numerical value in this manual might be different from the above-mentioned table. SI Units (International System of Units) are used in this manual. MKSA (Meter, Kilogram, Second, Ampere) system units and English units are also indicated in parentheses just behind SI units. Example: 24.5 MPa (250 kgf/cm2 , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes.
  • 6. 67Z7 D&R Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling..............................................................W1-1-1-1 Precautions for Using Floating Seal...................W1-1-1-2 Precautions for Using Nylon Sling......................W1-1-1-3 Group 2 Tightening Tightening Bolts and Nuts..........................................W1-2-1-1 Specified Tightening Torque Chart....................W1-2-1-1 Precautions for Split Flange..................................W1-2-1-3 Nut and Bolt Locking ..............................................W1-2-1-3 Piping Joint ......................................................................W1-2-1-4 Union Joint .................................................................W1-2-1-5 Pipe Joint.....................................................................W1-2-1-6 O-ring Seal Joint .......................................................W1-2-1-6 Quick Coupling..........................................................W1-2-1-7 Screw-In Connection...............................................W1-2-1-8 Seal Tape Application..............................................W1-2-1-8 Low-Pressure-Hose Clamp Tightening.............W1-2-1-8 Connecting Hose......................................................W1-2-1-9 Group 3 Painting Painting .............................................................................W1-3-1-1 Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank......................W1-4-1-1 Bleeding Air from Hydraulic System.......................W1-4-1-2 Bleeding Air from Fuel System..................................W1-4-1-4 Bleeding Air from Radiator.........................................W1-4-1-6 Bleeding Air from Brake (Axle)..................................W1-4-1-7 Group 5 Releasing Pressure Front Attachment Hydraulic Circuit Pressure Release Procedure....................................................W1-5-1-1 Ride Control Accumulator Pressure Release Procedure....................................................W1-5-1-2 Group 6 Preparation Preparation before Inspection and Maintenance...........................................................W1-6-1-1 Lock of Frame.............................................................W1-6-1-2 Machine Position for Inspection and Maintenance (lift arm raise)...............................W1-6-1-3 CONTENTS SECTION 1 GENERAL
  • 7. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-1 Precautions for Disassembling and Assembling Precautions for Disassembling  Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling / assembling, resulting in damage to machine components, as well as decreased efficiency in service work.  Inspect the Machine Be sure to thoroughly understand all disassembling / assembling procedures beforehand to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future.  The machine model, machine serial number, and hour meter reading.  Reason for disassembly (symptoms, failed parts, and causes).  Clogging of filters and oil, water or air leaks, if any. Capacities and condition of lubricants.  Loose or damaged parts.  Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. Precautions for Disassembling and Assembling  Precautions for Disassembling  Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling.  Before disassembling, clean the exterior of the components and place on a workbench.  Drain hydraulic oil and gear oil from the hydraulic components and reduction gear.  Be sure to provide appropriate containers for draining fluids.  Use matching marks for easier reassembling if necessary.  Be sure to use the specified special tools when instructed.  If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause (s), then take the appropriate measures to remove it.  Orderly arrange disassembled parts. Mark and tag them if necessary.  Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.  Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage.  Measure and record the degree of wear and clearances.  Precautions for Assembling  Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part.  Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces.  Apply appropriate lubricant oil onto parts in order to prevent them from seizing.  Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been disassembled. Apply grease before installing  Be sure that liquid-gasket-applied surfaces are clean and dry.  If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent.  Fit the matching marks made when disassembling and assemble them.  Be sure to use the designated tools to assemble bearings, bushings, and oil seals.  Keep a record of the number of tools used for disassembly / assembly. After assembling is completed, count the number of tools so as to make sure that no forgotten tools remain in the assembled machine.
  • 8. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-2 Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures:  Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of seal ring (1).  Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear. Check the step part of seal ring (1).  Check O-ring (2) for tears, breaks, deformation, or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble.  Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with compressed air.  Clean seal ring (1) and O-ring (2) mounting bores. Check the bore surface for scuffing or scoring by touching the surface with finger.  After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1).  After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating surface (f) by measuring the distances (e) and (f) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating. 1 2 a b c d a - Correct b - Incorrect c - Twist of O-Ring d - Bend of O-Ring a - Correct b - Incorrect e - Sliding Surface f - Seal Mating Surface f e 2 a A A B B b A=B A≠B W178-02-11-001 W178-02-11-002 W178-02-11-003
  • 9. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-3 Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely.  Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping.  Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight.  Do not lift acid or alkali chemicals.  Take care not to allow the sling to become wet. The load may slip.  When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced.  When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force.  Avoid using twisted, bound, connected, or hitched slings.  Do not place any object on twisted or bent slings. (Refer to the right illustration.)  When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions.  Avoid dragging slings on the ground, throwing slings, or pushing slings with a metal object.  When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged.  Store the nylon slings indoors so that they won’t deteriorate with heat, sun light, or chemicals. a b c a - Correct Eyehole Lifting Method b - Incorrect Eyehole Lifting Method c - Bent of Sling W102-04-02-016 W105-04-01-008 W162-01-01-009
  • 10. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-4 dCAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7 years. Damaged Appearance a a a e f b b c c g d a - Broken Sewing Thread a - Broken Sewing Thread e - Separation of Belt b - Scuffing f - Scoring b - Scuffing c - Fuzz d - Broken Sewing Thread c - Fuzz g - Broken Warp a - Broken Sewing Thread W162-01-01-002 W162-01-01-003 W162-01-01-004 W162-01-01-005 W162-01-01-006 W162-01-01-007 W162-01-01-008
  • 11. Group 1 Precautions for Disassembling and Assembling SECTION 1 GENERAL W1-1-1-5 Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary. “Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is difficult after exceeding this limit. 3. Repair or adjustment is impossible after exceeding this limit. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the“Allowable Limit”.
  • 12. Group 2 Tightening SECTION 1 GENERAL W1-2-1-1 Tightening Bolts and Nuts dCAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injure. IMPORTANT:  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Clean the bolt and nut threads and remove dirt or corrosion before installing. Bolt Types Tighten the nuts or bolts correctly to the torque specifications. As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the machine or components. Specified Tightening Torque Chart Bolt Dia. mm (in) Tightening torque N·m (kgf·m) (lbf-ft) Wrench size mm (in) Hexagon Bolt (8~11T) Flanged Bolt (8T) Socket Bolt (11T) (8T) (4T) 6 (0.24) 3~4 (0.3~0.4) (2.2~3) 10 (0.39) 10 (0.39) 5 (0.20) 8 (0.31) 30 (3) (22) 20 (2) (14.8) 10 (1) (7.4) 13 (0.51) 12 (0.47) 6 (0.24) 10 (0.39) 65 (6.5) (48) 50 (5) (36.9) 20 (2) (14.8) 17 (0.67) 14 (0.55) 8 (0.31) 12 (0.47) 110 (11) (81) 90 (9) (66.4) 35 (3.5) (25.8) 19 (0.75) 17 (0.67) 10 (0.39) 14 (0.55) 180 (18) (133) 140 (14) (104) 55 (5.5) (40.6) 22 (0.87) 12 (0.47) 16 (0.63) 270 (27) (199) 210 (21) (155) 80 (8) (59) 24 (0.94) 22 (0.87) 14 (0.55) 18 (0.71) 400 (40) (295) 300 (30) (221) 120 (12) (88.5) 27 (1.06) 14 (0.55) 20 (0.79) 550 (55) (406) 400 (40) (295) 170 (17) (125) 30 (1.18) 27 (1.06) 17 (0.67) 22 (0.87) 750 (75) (553) 550 (55) (406) 220 (22) (162) 32 (1.26) 24 (0.94) 950 (95) (700) 700 (70) (516) 280 (28) (207) 36 (1.42) 32 (1.26) 19 (0.75) 27 (1.06) 1400 (140) (1033) 1050 (105) (774) 400 (40) (295) 41 (1.61) 30 (1.18) 1950 (195) (1438) 1450 (145) (1069) 550 (55) (406) 46 (1.81) 33 (1.30) 2600 (260) (1918) 1950 (195) (1438) 750 (75) (553) 50 (1.97) 36 (1.42) 3200 (320) (2360) 2450 (245) (1807) 950 (95) (700) 55 (2.17) WDAA-01-02-001
  • 13. Group 2 Tightening SECTION 1 GENERAL W1-2-1-2 IMPORTANT: The following items are applied to both fine and coarse pitch threads.  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Torque tolerance is ±10 %.  Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of bolt hole. Also the bolts that are too short cannot develop sufficient tightening force.  The torque given in the chart on the previous page are for general use only, however, a different torque is given for a specific application. Use the specified torque.  Clean the nut and bolt threads and remove dirt or corrosion before installing. Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. a 1.4 1 12 13 9 8 4 5 1 2 6 3 7 10 14 11 3 5 2 4 6 2.3 b c a - Equally tighten upper and lower alternately b - Tighten diagonally c - Tighten from center diagonally W105-01-01-003
  • 14. Group 2 Tightening SECTION 1 GENERAL W1-2-1-3 Precautions for Split Flange IMPORTANT:  Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the O-ring.  Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces. When installing O-ring into a groove, use grease in order to hold O-ring in place.  While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring.  Tighten the bolts up and down, left and right alternately, in order to ensure even tightening to the specified torque.  Do not use air wrenches. Using an impact wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts. Nut and Bolt Locking  Lock Plate IMPORTANT: Do not reuse the lock plates. Do not try to bend the same point twice.  Split Pin IMPORTANT: Do not turn in the loosening direction in order to align the grooves and holes on the nut. Always turn in the tightening direction. Do not reuse the split pins.  Wire IMPORTANT: Attach wire to bolts in the bolt- tightening direction. Do not reuse the wire. Incorrect Correct Correct Correct Correct Correct Correct a a b d c Incorrect Incorrect Incorrect Incorrect a- Bend along edge sharply b- Do not bend it round c- Tighten d- Loosen WDAA-01-02-005 WDAA-01-02-006 W105-01-01-008 WDAA-01-02-007 WDAA-01-02-008
  • 15. Group 2 Tightening SECTION 1 GENERAL W1-2-1-4 Piping Joint IMPORTANT:  The torque given in table below are for general use only, however, a different torque is given for a specific application. Use the specified torque.  Apply lubricant, such as the Grease Spray to the bolts and nuts in order to reduce friction coefficient of them.  Torque tolerance is ±10 %.  Slightly apply lubricant onto the threads first by using the Grease Spray.
  • 16. Group 2 Tightening SECTION 1 GENERAL W1-2-1-5 Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT:  Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking the adapter. Tighten union nut (3) to the specifications.  Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting / disconnecting. 2013/09 Description Wrench Size mm Tightening Torque Union Nut N·m (lbf·ft) 30 ° male 17 25 (18.5) 19 30 (22) 22 40 (29.5) 27 80 (59) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260) 55 380 (280) 60 380 (280) 37 ° female 17 25 (18.5) 19 30 (22) 22 40 (29.5) 27 80 (59) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260) fNOTE: Tightening torque of 37 ° male coupling without union is similar to tightening torque of 37° female. a - Joint Body b - Male Union Joint c - Female Union Joint 1 30 ° 37 ° b c 4 3 2 a 5 WDAA-01-02-009 WDAA-01-02-010
  • 17. Group 2 Tightening SECTION 1 GENERAL W1-2-1-6 Pipe Joint Pipe connection (metal joint) (Union Nut Wrench Size: 17, 19, 22, 27) Metal (3) of adapter (1) and pipe (2) seals pressure oil.  Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling. Tightening Torque Use the specified tightening torque in the table below. 2013/09 Wrench Size (mm) 17 19 22 27 Tightening Torque N·m 25 30 40 80 (lbf·ft) (18.5) (22) (29.5) (59) O-ring Seal Joint O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil. IMPORTANT:  Replace O-ring (6) with a new one when reinstalling.  Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.  Do not damage O-ring groove (8) of adapter (7) or sealing surface (10) on the hose side. Damage to O-ring (6) may cause oil leakage.  If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in O-ring groove (8). 1 4 5 3 2 7 6 9 8 10 a a - Joint Body 2013/09 Wrench Size mm Tightening Torque Union Nut N·m (lbf·ft) 19 30 (22) 22 70 (52) 27 95 (70) 32 140 (103) 36 180 (133) 41 210 (155) 50 350 (260) M1M7-07-005 WDAA-01-02-011
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  • 19. Group 2 Tightening SECTION 1 GENERAL W1-2-1-7 Quick Coupling 1. Coupling procedure  Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you.  Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked completely by ball (2). At this time, check if socket ring (1) is returned to the original position (to the rightmost direction). 2. Separating procedure  Remove the hose by rotating socket ring (1) fully counterclockwise and then pulling it. Because no check function is attached inside, be careful that oil flows out.  Cap the removed hoses using special plug. dCAUTION:  When disconnecting, do not damage joint surface.  When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering.  Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after installation.  After installation, check if socket ring (1) is returned to the original position (to the rightmost direction). 1 3 2 M1M7-07-006
  • 20. Group 2 Tightening SECTION 1 GENERAL W1-2-1-8 Screw-In Connection Depending on types of screw and sealing, different types of screw-in connection are used. IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. (In general, the screw-in connection of male tapered thread (a) is used except for measurement purpose.) Seal Tape Application Seal tape is used in order to seal clearances between male (d) and female (c) threads so that any leaks between threads may be prevented. Therefore, apply just enough seal tape to fill up thread clearances (e). Do not overwrap.  Application Procedure Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave one to two pitch threads uncovered. Wrap the seal tape in the same direction as the threads. Low-Pressure-Hose Clamp Tightening Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp (g): 4.5 N·m (3.3 lbf·ft) Worm Gear Type Band Clamp (h): 6 to 7 N·m (4.4 to 5.2 lbf·ft) R a c f d b G 30 ° a - Male Tapered Thread b - Male Straight Thread c - Internal Thread d - External Thread e - Clearance f - Leave one to two pitch threads uncovered 2013/09 Wrench Size mm Tightening Torque Joint Body Cast iron Structural rolled steel 19 15 (11) 35 (26) 22 30 (22) 50 (37) 27 50 (37) 95 (70) 36 70 (52) 160 (118) 41 110 (81) 200 (148) 50 160 (118) 330 (245) 60 200 (148) fNOTE: Unit: N·m (lbf·ft) e g - T-Bolt Type Band Clamp h - Worm Gear Type Band Clamp g h W105-01-01-018 W105-01-01-019 M114-07-041 M114-07-043 WDAA-01-02-012
  • 21. Group 2 Tightening SECTION 1 GENERAL W1-2-1-9 Connecting Hose dCAUTION: When replacing the hoses, use only genuine KCM service parts. Using hoses other than genuine KCM hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose from being kinked. Take necessary measures to protect hoses from rubbing against each other. If the hoses rub against each other, wear to the hoses may result and lead to hose rupture. Take care so that the hoses do not come into contact with the moving parts or sharp objects. a a - Rubbing Against Each Other a - Rubbing Against Each Other b - Clamp a - Rubbing Against Each Other b - Clamp b b a a b Incorrect Incorrect Incorrect Incorrect Correct Correct Correct Correct W105-01-01-011 W105-01-01-012 W105-01-01-013 W105-01-01-014