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70Z7B

93208-00870

SHOP MANUAL Disassembly & Reassembly Vol.1

Printed in Japan (K) （アメリカ用）

93208-00870

May 2017

Volume 1

SHOP MANUAL WHEEL LOADER

70Z7B Disassembly & Reassembly

93208-00870 Volume 1

SECTION AND GROUP SECTION 1 GENERAL Group 1 Precautions for Disassembling and CONTENTS Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Preparation WORKSHOP MANUAL

SECTION 2 MAINTENANCE STANDARD Group 1 Body Group 2 Front Attachment

SECTION 3 BODY

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.

Group 1 Cab Group 2 Counterweight Group 3 Center Hinge Group 4 Engine Group 5 Radiator Assembly Group 6 Hydraulic Oil Tank Group 7 Fuel Tank Group 8 Pump Device Group 9 Control Valve Group 10 Pilot Valve Group 11 Brake Charge Valve Group 12 Manifold Valve Group 13 Solenoid Valve Group 14 Flow Regulator Valve Group 15 Cooling Fan System Group 16 Ride Control Device Group 17 Battery Disconnect Switch Group 18 Aftertreatment Device Group 19 DEF Tank Group 20 Coolant Control Valve Group 21 DEF Supply Module Group 22 Exterior Components

(Blank)

SECTION 1

GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling .................................................................W1-1-1-1

Group 2 Tightening Tightening Bolts and Nuts ..........................................W1-2-1-1 Piping Joint ......................................................................W1-2-1-4

Group 3 Painting Group 4 Bleeding Air Bleed Air from the Hydraulic System. .....................W1-4-1-1 Bleed Air from the Fuel System .................................W1-4-1-2 Bleeding Air from Brake (Axle) ..................................W1-4-1-3

Group 5 Preparation Preparations for Inspection and Maintenance ....W1-5-1-1 Releasing Pressure from Hydraulic Circuit ............W1-5-1-6 Releasing Pressure from Ride Control Accumulator ...............................................................W1-5-1-7 Releasing Pressure from Parking Brake Accumulator ...............................................................W1-5-1-8 Releasing Pressure from Hydraulic Oil Tank .........W1-5-1-9 Releasing Pressure from Expansion Tank ........... W1-5-1-10

70Z7B D&R

(Blank)

70Z7B D&R

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling 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 identification tags 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), and 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 to 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.

W1-1-1-1

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling 1

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 to 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.

W178-02-11-001

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 between (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct O-ring (2) seating.

c b d W178-02-11-002 ab-

Correct Incorrect

cd-

Twist of O-Ring Bend of O-Ring

f a

A=B

A≠B W178-02-11-003

ab-

W1-1-1-2

Correct Incorrect

ef-

Sliding Surface Seal Mating Surface

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Nylon Sling a

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 the temperature of the lifted load is over 100 °C (212 °F), do not lift the load.  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.

W102-04-02-016 a-

Correct Eyehole Lifting Method b

W105-04-01-008 b-

Incorrect Eyehole Lifting Method

c c-

W1-1-1-3

Bent of Sling

W162-01-01-009

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling If a load is lifted with a damaged dCAUTION: 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 following examples. 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

W162-01-01-002 a-

Broken Sewing Thread

Separation of Belt

W162-01-01-003 b-

W162-01-01-006

Scuffing

b b-

Scuffing

W162-01-01-007

Scoring

c c

W162-01-01-004 W162-01-01-008 c-

Fuzz

Broken Sewing Thread ca

W162-01-01-005 a-

Broken Sewing Thread

W1-1-1-4

Fuzz

Broken Warp

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling 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”.

W1-1-1-5

SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling (Blank)

W1-1-1-6

SECTION 1 GENERAL Group 2 Tightening Tightening Bolts and Nuts Use tools appropriate for the work dCAUTION: 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. 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.

WDAA-01-02-001

Specified Tightening Torque Chart 2013/09 Bolt Dia. mm

Hexagon Head Bolt Wrench Size mm WDAA-01-02-002

N·m 6 8 10 12 14 16 18 20 22 24 27 30 33 36

30 65 110 180 270 400 550 750 950 1400 1950 2600 3200

(lbf·ft) (22) (48) (81) (133) (200) (300) (410) (550) (700) (1030) (1440) (1920) (2360)

WDAA-01-02-003

N·m 20 50 90 140 210 300 400 550 700 1050 1450 1950 2450

(lbf·ft) (15) (37) (66) (103) (155) (220) (300) (410) (520) (770) (1070) (1440) (1810)

Socket Bolt Socket Bolt

Wrench Size mm

WDAA-01-02-004

N·m 3 to 4 10 20 35 55 80 120 170 220 280 400 550 750 950

(lbf·ft) (2.2 to 3) (7.4) (15) (26) (41) (59) (89) (125) (162) (205) (300) (410) (550) (700)

W1-2-1-1

10 13 17 19 22 24 27 30 32 36 41 46 50 55

N·m

(lbf·ft)

20 50 90 140 210 300 400

(15) (37) (66) (103) (155) (220) (300)

5 6 8 10 12 14 14 17

SECTION 1 GENERAL Group 2 Tightening 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.

1 1, 4

4 2 2, 3

W105-01-01-003 a-

Equally tighten upper and lower alternately

Tighten diagonally

W1-2-1-2

Tighten from center diagonally

SECTION 1 GENERAL Group 2 Tightening Precautions for Spilt 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, right and left alternately, in order to ensure even tightening to the specified torque.  Do not use an impact wrench. It is difficult to evenly tighten the bolts by using an impact wrench. Using an impact wrench often causes uneven tightening of bolts or damage to O-rings.

WDAA-01-02-005

Incorrect

WDAA-01-02-006

Nut and Bolt Locking W105-01-01-008

 Lock Plate IMPORTANT: Do not reuse the lock plates. Do not try to bend the same point twice.

Incorrect

Correct

 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.

b Incorrect

Correct

 Wire IMPORTANT: Attach wires to bolts in the bolttightening direction. Do not reuse the wires. a WDAA-01-02-007 a-

Bend along edge sharply

Correct

Do not bend it round

Correct

Incorrect

WDAA-01-02-008 c-

W1-2-1-3

Tighten

Loosen

SECTION 1 GENERAL Group 2 Tightening 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.

W1-2-1-4

SECTION 1 GENERAL Group 2 Tightening 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)

Joint Body

WDAA-01-02-009

37 ° 30 °

b b-

fNOTE: Tightening torque of 37 ° male coupling without union is similar to tightening torque of 37° female.

W1-2-1-5

Male Union Joint

c c-

Female Union Joint WDAA-01-02-010

SECTION 1 GENERAL Group 2 Tightening 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 N·m 25 30 40 80 Torque (lbf·ft) (18.5) (22) (29.5) (59)

M1M7-07-005

O-Ring Face Seal Joint O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil. IMPORTANT:  Replace O-ring (6) with the 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 the new one, and then tighten union nut (9) after confirming that O-ring (6) is securely seated in O-ring groove (8).

8 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)

W1-2-1-6

WDAA-01-02-011

SECTION 1 GENERAL Group 2 Tightening Quick Coupling 3

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. CAUTION:

 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).

W1-2-1-7

M1M7-07-006

SECTION 1 GENERAL Group 2 Tightening R

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.

a a-

Male Tapered Thread

Male Straight Thread W105-01-01-018

2013/09 Wrench Size mm Joint Body 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.

19 22 27 36 41 50 60

Tightening Torque Cast iron Structural rolled steel 15 (11) 35 (26) 30 (22) 50 (37) 50 (37) 95 (70) 70 (52) 160 (118) 110 (81) 200 (148) 160 (118) 330 (245) 200 (148)

fNOTE: Unit: N·m (lbf·ft) c

Low-Pressure-Hose Clamp Tightening

cd-

Internal Thread External Thread

Low-pressure-hose clamp tightening torque differs depending on the type of clamp. Tighten them according to each step.

W105-01-01-019

Clearance

 T-Bolt Type Band Clamp (g)  Worm Gear Type Band Clamp (h)

Leave one to two pitch threads uncovered g

M114-07-041 h

M114-07-043

WDAA-01-02-012 g-

W1-2-1-8

T-Bolt Type Band Clamp

Worm Gear Type Band Clamp

SECTION 1 GENERAL Group 2 Tightening Connecting Hose When replacing the hoses, use only dCAUTION: genuine KCM/Hitachi service parts. Using hoses

Correct

Incorrect

other than genuine KCM/Hitachi hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install kinked hoses. 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.

W105-01-01-011

Incorrect

Correct

W105-01-01-012 a-

Rubbing Against Each Other

Incorrect

Correct

W105-01-01-013 a-

Rubbing Against Each Other

Clamp

Correct

Incorrect

a b W105-01-01-014 a-

W1-2-1-9

Rubbing Against Each Other

Clamp

SECTION 1 GENERAL Group 2 Tightening (Blank)

W1-2-1-10

SECTION 1 GENERAL Group 3 Painting

6 10 5 11 4 12

3 2

1 14 15 16 17

18 19 WNEK50-01-03-001

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Surfaces to Be Painted Lift Arm Bell Crank Pipe Bracket (Control Valve) Bracket (Bucket Auto-Leveler) Bucket Cylinder Lift Arm Auto Leveler Bracket (Pipe) Pipe Pin (Lift Arm) Pipe (Lift Arm Cylinder) Pin (Lift Arm Cylinder) Lift Arm Cylinder Pin (Bucket Cylinder) Pin (Bell Crank) Pin (Bucket Link) Bucket Link Bucket Teeth

Painting Colour YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] YR1-02 [TAXI Yellow] YR1-03 [TAXI Yellow] YR1-04 [TAXI Yellow] YR1-05 [TAXI Yellow] YR1-06 [TAXI Yellow] YR1-07 [TAXI Yellow] YR1-08 [TAXI Yellow] YR1-09 [TAXI Yellow]

W1-3-1-1

SECTION 1 GENERAL Group 3 Painting

8 2

3 7 4

1 2 3 4 5 6 7 8

Surfaces to Be Painted Cab (Outside) Plate Rear Console (Inner) Seat Bracket Cab Under Cover Cockpit Side Console (Inner) Cab (Inside)

Painting Colour P1-01 [High Grade Black] Y1-03 [Shining Silver] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black]

W1-3-1-2

WNEK50-01-03-002

SECTION 1 GENERAL Group 3 Painting

12 10

23 22 21 20

19 18

WNEK50-01-03-004

15 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Surfaces to Be Painted Horn Bracket Light Bracket Articulation Lock Bar Hydraulic Oil Tank Cap Filter Cover Engine cover Cover Pipe (Rain Cap) Cover Rear Cover Cover Rear Grill Bracket (Combination Light) Side Cover (Rear) Plate Handle Side Cover (Front) Lower Cover Pipe Pipe Guard Steering Cylinder Pin (Steering Cylinder)

Painting Colour YR1-01 [TAXI Yellow] P1-01 [High Grade Black] TCM Red P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] Refer to W1-3-1-4. P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow]

W1-3-1-3

SECTION 1 GENERAL Group 3 Painting

2 WNDB-01-03-108

1 2

Surfaces to Be Painted Side Cover (Front) (Top) Side Cover (Front) (Bottom)

Painting Colour YR1-01 [TAXI Yellow] P1-01 [High Grade Black]

W1-3-1-4

SECTION 1 GENERAL Group 3 Painting

14 4

2 1

9 11 13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

WNEK50-01-03-005

Surfaces to Be Painted Step Battery Box Rear Fender (Front) Tool Box Handrail Rear Fender (Front) (Cover) DEF Tank Box Step (Rear) Deck Step (Front) Front Fender (Cover) Front Fender Front Cover Rear Fender (Rear) Bracket (Rear Fender (Rear)) Bracket (Mud Guard)

Painting Colour P1-01 [High Grade Black] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] P1-01 [High Grade Black] Do not paint it. YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] Do not paint it. YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Do not paint it. P1-01 [High Grade Black] P1-01 [High Grade Black]

W1-3-1-5

SECTION 1 GENERAL Group 3 Painting

2 5

1 6

12 7 8 9

WNEK50-01-03-006

1 2 3 4 5 6 7 8 9 10 11 12

Surfaces to Be Painted Front Frame Plate Support (Real Axle) Pin Counterweight Fuel Tank Rear Axle Inspection Cover Rear Frame Front Axle Guard Under Guard

Painting Colour YR1-01 [TAXI Yellow] P1-01 [High Grade Black] P1-01 [High Grade Black] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Refer to W1-3-1-8. YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] Refer to W1-3-1-9. P1-01 [High Grade Black] YR1-01 [TAXI Yellow]

W1-3-1-6

SECTION 1 GENERAL Group 3 Painting

WNEK50-01-03-003

Surfaces to Be Painted Rim

Painting Colour YR1-01 [TAXI Yellow]

W1-3-1-7

SECTION 1 GENERAL Group 3 Painting

View A

View C

WNEC-01-03-008 View B

WNEC-01-03-010 WNEC-01-03-009

1 2 3 4 5 6 7 8

Surfaces to Be Painted Rear Axle Rim (Wheel) Mounting Part (Shaded Area) Axle End and Rim (Wheel) Boss Part (Shaded Area) Boss Part (Shaded Area) Flange Part (Shaded Area) Name Plate End of Boss Part (Shaded Area)

Painting Colour P1-01 [High Grade Black] Do not paint it. YR1-01 [TAXI Yellow] Do not paint it. Do not paint it. Do not paint it. Do not paint it. Do not paint it.

W1-3-1-8

WNEC-01-03-007

SECTION 1 GENERAL Group 3 Painting

View A

WNEC-01-03-012

1 2 3 4 5 6 7 8

Surfaces to Be Painted Rim (Wheel) Mounting Part (Shaded Area) Axle End and Rim (Wheel) Front Axle Axle Mounting Part (Shaded Area) Flange Part (Shaded Area) Name Plate Nut Surface (Shaded Area) Connector

Painting Colour Do not paint it. YR1-01 [TAXI Yellow] P1-01 [High Grade Black] Do not paint it. Do not paint it. Do not paint it. Do not paint it. Do not paint it.

W1-3-1-9

WNEC-01-03-011

SECTION 1 GENERAL Group 3 Painting (Blank)

W1-3-1-10

SECTION 1 GENERAL Group 4 Bleeding Air Bleed Air from the Hydraulic System Bleed air from the hydraulic system as follows when hydraulic oil has been drawn, the suction filter and suction pipe have been replaced, or the pump device and cylinders have been removed/installed. IMPORTANT: If air is accumulated inside of the pump and if the engine starts in lacking of hydraulic oil, the pump may be damaged.  Bleeding Air from Pump 1. Remove reducer (1) with the bleeder valve on top of the pump. Add hydraulic oil to the pump. j : 41 mm 2. After filling hydraulic oil in the pump, install reducer (1) with the bleeder valve. j : 41 mm m : 80 N·m (59 lbf·ft)

IMPORTANT: If air is accumulated inside of the cylinder and if the cylinder is operated suddenly in lacking of hydraulic oil, the seal may be damaged or the cylinder may seize.  Bleeding Air from Hydraulic Circuit 1. After refilling hydraulic oil, start the engine. Operate each cylinder several times evenly. Slowly start each operation. At this time, never fully stroke the cylinders during initial operation stage. 2. As the pilot circuit has an air bleed device, air in the pilot circuit will be bled while performing the above operation. 3. Reset the front attachment in position for checking hydraulic oil level. 4. Stop the engine. Check hydraulic oil level. Add hydraulic oil if necessary.

WNEK50-03-08-014

W1-4-1-1

SECTION 1 GENERAL Group 4 Bleeding Air Bleed Air from the Fuel System IMPORTANT: Air in the fuel system may make the engine hard to start or make it run irregularly. After running the fuel tank dry, draining water from fuel filter or fuel pre-filter (a) or replacing the fuel filter, be sure to bleed the air from the fuel system. 1. Loosen air bleed plug (1), operate feed pump (2) until no air bubble is observed in the fuel from the air bleed plug. 2. After no air bubble is spouted from air bleed plug (1), tighten air bleed plug (1) and operate the feed pump (2) until it becomes difficult to move. 3. Once the feed pump (2) becomes difficult to move, push the disk part of feed pump (2) back to the original position.

a a-

Pre-Filter

4. Start the engine. Check the fuel system for fuel leaks.

MNEK-07-006

b b-

Main Filter

MNEK-07-007 a-

W1-4-1-2

Pre-Filter

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Brake (Axle) If air is mixed in the service brake dCAUTION: circuit, the brake function is reduced and serious hazard may occur. Bleed air from the service brake system after removing and installing the pipe lines and changing hydraulic oil.

1, 2 1, 2

fNOTE: Perform this work on all wheels (4 places) by two or more persons. Air bleeder (1) is located around the center on the front and rear axles.

T4GB-05-04-004

1. Set the parking brake switch of front console to the ON position, start the engine, and increases service brake oil pressure. 2. Remove cap (2) of air bleeder (1). Insert one side of clear vinyl tube (3) into air bleeder (1) and insert the other side into container (4) to prevent hydraulic oil from scattering.

3 1

3. Depress brake pedal (5) several times. Loosen air bleeder (1) for 1/2 to 1 turn to drain hydraulic oil oil while depressing brake pedal (4).

j : 10 mm 4. After draining hydraulic oil, tighten air bleeder (1), and then return brake pedal (5).

T4GB-05-04-005

5. Repeat steps 3 to 4 until flesh hydraulic oil without no air bobbles flows out in vinyl tube (3). 6. When no air bobbles are observed in vinyl tube (3), tighten air bleeder (1) while depressing brake pedal (5). j : 10 mm m : 10 N·m (0.7 lbf·ft) 7. Bleed air at other 2 places in the same way as step 3 to step 6. After completing above air bleeding dCAUTION: procedures at 4 places, repeat the same procedure at 4 places again to ensure that air is completely bled.

W1-4-1-3

T4GB-05-04-006

SECTION 1 GENERAL Group 4 Bleeding Air (Blank)

W1-4-1-4

SECTION 1 GENERAL Group 5 Preparation Preparations for Inspection and Maintenance Components, hydraulic oil, lubricant, dCAUTION: and coolant just after operation are too hot. Allow

them to cool before starting any work. If ride control switch (2) is in the AUTO dCAUTION: position, the lift arm may unexpectedly rise. Set ride control switch (2) to the OFF position. If the vehicle is unexpectedly moved, dCAUTION: a serious accident may result. Be sure to apply the parking brake when parking the vehicle. Securing work place and work staffs Before starting the work, park the vehicle in a firm and large space, keep bystanders clear of the vehicle. Slowly move the front attachment. Secure work staffs for the work. When using a signal person, coordinate hand signals before starting.

MNEC-07-001

Inspection and Maintenance Position Unless otherwise specified, set the vehicle for inspection and maintenance position as described below before starting work.

1. Park the vehicle on a level and solid surface. 2. Lower the working device such as bucket to the ground. 3. Run the engine at slow idle speed without load for five minutes. 4. Set the control lever lock switch (1) to the lock position.

MNEC-01-036

5. Turn OFF ride control switch (2). 6. Set forward/reverse lever (3) to the neutral N position. Set neutral lever lock (5) to the LOCK position. 7. Apply the parking brake. (Turn ON parking brake (4).) 8. Turn OFF the key switch. Stop the engine. Remove the key. 9. Secure the tires.

W1-5-1-1

MNEC-01-058

SECTION 1 GENERAL Group 5 Preparation 10. Before performing any work on the vehicle, attach tag (Inspection and Maintenance) on the door or front attachment control lever.

MNEC-01-036

W1-5-1-2

SECTION 1 GENERAL Group 5 Preparation Lock Frames Before beginning to work near the dCAUTION: frame center hinge (2), install articulation lock bar (3) to securely lock and prohibit movement between the front and rear frames. 5

1. Align the front and rear frame centers with each other.

2. Remove β-form pin (4) and remove set pin (5) from the rear frame hole. 3. Rotate articulation lock bar (3) and align it with the front frame hole (1).

WNEK50-01-05-001

4. Install set pin (5) to front frame hole (1) and the articulation lock bar (3) tip end hole. Install β-form pin (4). Secure articulation lock bar (3) in the specified position.

5 WNEK50-01-05-002

W1-5-1-3

SECTION 1 GENERAL Group 5 Preparation Never attempt to maintain the vehicle dCAUTION: when the engine is running in order to prevent the accident. If maintenance work while engine running is unavoidable, strictly comply with the following items.  One person should take the operator's seat to be ready to stop the engine any time while communicating with other workers.  When working around moving parts is unavoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled.

SA-2294

 If parts or tools are dropped or inserted into the fan or the belt, they may fly off or be cut off. Do not drop or insert parts and tools into the moving parts.  Set the pilot control shut-off lever (1) to the LOCK position so that the front attachment will not move.  Never touch the control levers and pedals. If operating the control levers or pedals is unavoidable, signal co-workers to evacuate to safer place.

SA-026

MNEC-07-001

W1-5-1-4

SECTION 1 GENERAL Group 5 Preparation Inspection and Maintenance Position (Lift Arm Raise) Support the lift arm by using a solid dCAUTION: support for inspection and maintenance with the

lift arm raised. Set the vehicle position for inspection and maintenance in the same way as the previous procedures other than following procedures. (Refer to W1-5-1-1.)

1. Raise lift arm (3) and dump bucket (2). 2. Support lift arms (3) (both sides) certainly by using solid support (1). 3. Set the control lever lock switch (4) to the lock position.

WNEC-01-06-001

4. Turn OFF the key switch. Stop the engine. Remove the key.

MNEC-07-001

W1-5-1-5

SECTION 1 GENERAL Group 5 Preparation Releasing Pressure from Hydraulic Circuit Release any remaining pressure by following the procedures below when removing and installing the front attachment.

1. Run the engine at slow idle speed without load for five minutes. 2. Set the key switch to the ON position. Set the control lever lock switch (1) to the UNLOCK (b) position. 3. With the key switch set in the ON position, operate the control lever 4 to 5 times in order to release any pressure from the hydraulic circuit. 4. Return the control lever lock switch (1) to the LOCK (a) position. 5. Turn OFF the key switch.

MNEC-07-001

MNEC-01-015 a-

W1-5-1-6

LOCK Position

UNLOCK Position

SECTION 1 GENERAL Group 5 Preparation Releasing Pressure from Ride Control Accumulator

1 2

Release any remaining pressure as follows before removing and installing the ride control accumulator. 1. Set the vehicle position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1-5.) 2. Release any pressure from the hydraulic circuit. (Refer to W1-5-1-1.) 3. Bleed air from the hydraulic oil tank. (Refer to W1-41.) 4. Remove bolts, washers (2) (4 used). Remove cover (1).

WNEC-04-08-003

j : 17 mm IMPORTANT: Loosen nut (5) while securing drain plug (4) by using a hexagonal wrench in order not to turn them. 5. Loosen nut (5) of ride control valve (3). j : 13 mm l : 4 mm IMPORTANT: Do not loosen drain plug (4) over 2 turns. It may come out due to remaining pressure. 6. Loosen drain plug (4) by one turn and release any remaining pressure. Tighten drain plug (4).

l : 4 mm m : 7 to 9 N·m (5.2 to 6.6 lbf·ft) IMPORTANT: Tighten nut (5) while securing drain plug (4) by using a hexagonal wrench in order not to turn them. 7. Install nut (5). j : 13 mm

TNED-03-02-003

Detail A

m : 10 to 12 N·m (7.4 to 8.9 lbf·ft) l : 4 mm 4

WNDB-01-05-001

W1-5-1-7

SECTION 1 GENERAL Group 5 Preparation Releasing Pressure from Parking Brake Accumulator Release any remaining pressure as follows before removing and installing the parking brake accumulator.

1. Park the vehicle on a level and solid surface. 2. Lower the working device such as bucket to the ground. 3. Run the engine at slow idle speed without load for five minutes. 4. Set key switch (2) to the OFF position. Stop the engine. 5. Depress brake pedal (3) at least 50 times and release pressure from the service brake circuit.

MNEC-01-036

6. Set key switch (2) to the ON position again. Turn ON and OFF parking brake switch (1) at least 50 times and release pressure from the parking brake circuit.

7. Set parking brake switch (1) to ON position (b). Turn OFF the key switch.

fNOTE: The service brake primary pressure and parking brake pressure can be monitored by using the service menu of monitor (4). (Refer to T5-2 in the separated volume, Technical Manual.)

W1-5-1-8

OFF Position

ON Position

MNEC-01-058

SECTION 1 GENERAL Group 5 Preparation Releasing Pressure from Hydraulic Oil Tank Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious injury. Release pressure before disconnecting the hydraulic piping or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns. Allow oil to cool before starting any work. Preparation 1. Park the vehicle on a solid and level surface. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1-1.) 1

2. Stop the engine. Push air bleed button (1) of hydraulic oil tank (3) and bleed air from hydraulic oil tank (3).

fNOTE: When installing and operating vacuum pump

W1R7-01-04-001

(a) to the position where cap (2) has been removed, hydraulic oil tank (3) becomes negative. This prevents hydraulic oil from flowing out when disconnecting hoses. Operate vacuum pump (a) continuously while working.

b c

W1R7-01-04-002 abc-

W1-5-1-9

Vacuum Pump Hose Adapter

SECTION 1 GENERAL Group 5 Preparation Releasing Pressure from Expansion Tank Do not loosen the radiator cap until dCAUTION: the system has cooled. Hot steam may spout out and cause severe burns. Allow coolant to cool before loosening the cap slowly. Release all pressure and remove the cap. Preparation

1. Park the vehicle on a solid and level surface. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1-1.) 2. Remove cap (1). 3. Stop the engine. Remove cap (2) from expansion tank (3).

WNEK50-03-22-008

WNEK50-01-05-003

W1-5-1-10

SECTION 2

MAINTENANCE STANDARD CONTENTS Group 1 Body Center Hinge....................................................................W2-1-1-1

Group 2 Front Attachment Pin and Bushing..............................................................W2-2-1-1 Standard Dimensions for Lift Arm and Bucket ....W2-2-2-1 Bucket Stopper Clearance ..........................................W2-2-2-2 Cylinder .............................................................................W2-2-3-1

70Z7B D&R

(Blank)

70Z7B D&R

SECTION 2 MAINTENANCE STANDARD Group 1 Body Center Hinge  Lower Hinge Part (A) 4

6 a

WNEC-02-01-002

Part Name Pin (4) Bushings (5), (6)

Standard (a) 75 (2.95) 75 (2.95)

W2-1-1-1

Allowable Limit (a) 74 (2.91) 76.5 (3.01)

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 1 Body (Blank)

W2-1-1-2

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment Pin and Bushing 1 E

F a

C G H

WNEC-02-03-001

2 A

W4GB-04-01-008

A B C D E F G H I

Part Name Pin Bushing (Lift Arm) Pin Bushing (Bucket Link) Pin Bushing (Bell Crank) Pin Bushing (Bucket Cylinder) Pin Bushing (Bucket Cylinder) Pin Bushing (Lift Arm) Pin Bushing (Lift Arm Cylinder) Pin Bushing (Lift Arm Cylinder) Pin Bushing (Bucket Link)

Standard (a) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 115 (4.53) 115 (4.53) 85 (3.35) 85 (3.35) 85 (3.35) 85 (3.35) 100 (3.94) 100 (3.94) 85 (3.35) 85 (3.35) 85 (3.35) 85 (3.35) 75 (2.95) 75 (2.95)

W2-2-1-1

Bushing

Allowable Limit (a) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 114.0 (4.49) 116.5 (4.59) 84.0 (3.31) 86.5 (3.41) 84.0 (3.31) 86.5 (3.41) 99.0 (3.90) 101.5 (4.00) 84.0 (3.31) 86.5 (3.41) 84.0 (3.31) 86.5 (3.41) 74.0 (2.91) 76.5 (3.01)

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment (Blank)

W2-2-1-2

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment Standard Dimensions for Lift Arm and Bucket 1

d b

a e f

c WNEC-02-03-003

a b c d e f g h i

Bucket

Lift Arm

Unit: mm (in) Dimensions 75 (2.95) 75 (2.95) 887 (34.9) 109 (4.29) 113 (4.45) 113 (4.45) 250 (9.84) 382 (15.0) 20 (0.79)

W2-2-2-1

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment Bucket Stopper Clearance a b

2 c

1 T4GB-04-04-010

T4GB-04-04-008 a-

Bucket Dump Stopper

Cross Pipe Dump Stopper (Lever Stopper)

Bucket Roll Back Stopper

Bucket Link

Bell Crank

Bucket Dump Stopper

Bucket Roll Back Stopper

 Cylinder Strokes (A and B) Bucket Cylinder (A) Lift Arm Cylinder (B) mm (in) mm (in) 285±1.5 (11.2±0.60) 990±2 (39±0.08)

 Cylinder Strokes (D and E) Bucket Cylinder (D) Lift Arm Cylinder (E) mm (in) mm (in) 610 (24.0) 326 (12.8)

 Bucket Dump Angle (C) C (deg.) 50±2

 Bucket Roll Back (Tilt) Angle (F) F (deg.) 50±2

 Clearance between Lever Stopper and Cross Tube (b) Clearance between Stopper and Tube mm (in) Standard 3 (0.12) or less Limit -

 Height from Ground to Bucket Lowest Point (G) G (mm) (in) 395 (15.6)

 Clearance between Bucket Dump Stopper and Lift Arm (a) Clearance at Longitudinal and Unsymmetrical Lateral Clearance of Contact Each Stopper mm (in) mm (in) Standard 0 0 Limit 2.0 (0.08) 5 (0.20)

 Clearance between Bucket Rollback Stopper and Lift Arm (c) Clearance at Longitudinal and Unsymmetrical Lateral Clearance of Contact Each Stopper mm (in) mm (in) Standard 0 0 Limit

3.0 (0.12)

4.0 (0.16)

fNOTE: Refer to Troubleshooting S/M, p.T4-4-8 for details.

W2-2-2-2

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment Cylinder Rod

Rod Bend and Run Out b a A

W166-04-02-022 c W105-04-02-094

Cylinder Name Lift Arm Bucket Steering

Unit: mm (in) Recommended Size After Remanufacturing (A) 75-0.01-0.023 (2.95-0.0004-0.0009) 85-0.012-0.027 (3.35-0.0005-0.0010) 45-0.009-0.020 (1.78-0.0004-0.0008)

ab-

Cylinder Rod Dial Gauge

Bend 1.0 mm/1 m (0.039 in/39.4 in)

d cd-

V Block 1 m (39.4 in)

Run Out 2.0 mm/1 m (0.079 in/39.4 in)

Remedy Replace

IMPORTANT: When measuring the items, bend and run out of the cylinder rod, the distance (d) may not be able to keep 1 m (39.4 in). In this case, the distance (d) of measurement is the full length of the rod.

W2-2-3-1

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment (Blank)

W2-2-3-2

SECTION 3

BODY CONTENTS Group 1 Cab Removal and Installation of Cab ..............................W3-1-1-1

Group 2 Counterweight Removal and Installation of Counterweight ........W3-2-1-1

Group 3 Center Hinge Removal and Installation of Center Hinge ............W3-3-1-1

Group 4 Engine Removal and Installation of Engine ........................W3-4-1-1

Group 5 Radiator Assembly Removal and Installation of Radiator Assembly .....................................................................W3-5-1-1

Group 6 Hydraulic Oil Tank Removal and Installation of Hydraulic Oil Tank ...............................................................................W3-6-1-1

Group 7 Fuel Tank Removal and Installation of Fuel Tank ....................W3-7-1-1

Group 8 Pump Device Removal and Installation of Pump Device ............W3-8-1-1 Disassembly of Pump Device ....................................W3-8-2-1 Assembly of Pump Device ..........................................W3-8-2-3 Disassembly of Main Pump ........................................W3-8-3-1 Assembly of Main Pump..............................................W3-8-3-5 Disassembly of Regulator ...........................................W3-8-4-1 Assembly of Regulator .................................................W3-8-4-3 Structure of Priority Valve ...........................................W3-8-5-1 Structure of Pilot Pump ...............................................W3-8-6-1 Removal and Installation of Priority Valve ............W3-8-7-1

Group 9 Control Valve Removal and Installation of Control Valve ............W3-9-1-1 Disassembly of Control Valve ....................................W3-9-2-1 Assembly of Control Valve ..........................................W3-9-2-5

Group 10 Pilot Valve Removal and Installation of Pilot Valve (Single-Lever Type)........................................................................... W3-10-1-1 Removal and Installation of Pilot Valve (Two Lever Type) .................................................... W3-10-2-1 Disassembly of Pilot Valve (Single-Lever Type) .......................................................................... W3-10-3-1 Assembly of Pilot Valve (Single-Lever Type) ...... W3-10-3-4

Disassembly of Pilot Valve (Two Lever Type)..... W3-10-4-1 Assembly of Pilot Valve (Two Lever Type) .......... W3-10-4-7

Group 11 Brake Charge Valve Removal and Installation of Brake Charge Valve ........................................................................... W3-11-1-1 Structure of Brake Charge Valve ............................ W3-11-2-1 Removal and Installation of Brake Accumulator ............................................................ W3-11-3-1

Group 12 Manifold Valve Removal and Installation of Manifold Valve ...... W3-12-1-1 Disassembly of Manifold Valve .............................. W3-12-2-1 Assembly of Manifold Valve .................................... W3-12-2-4

Group 13 Solenoid Valve Removal and Installation of Parking Brake Solenoid Valve Unit............................................... W3-13-3-1 Structure of Parking Brake Solenoid Valve Unit ............................................................................. W3-13-4-1 Structure of Parking Brake Solenoid Valve ........ W3-13-5-1

Group 14 Flow Regulator Valve Removal and Installation of Flow Regulator Valve ........................................................................... W3-14-1-1 Structure of Flow Regulator Valve ........................ W3-14-2-1

Group 15 Cooling Fan System Removal and Installation of Fan Valve................. W3-15-1-1 Structure of Fan Valve................................................ W3-15-2-1 Removal and Installation of Fan Motor ............... W3-15-3-1 Structure of Fan Motor .............................................. W3-15-4-1 Removal and Installation of Fan Pump ............... W3-15-5-1 Disassembly of Fan Pump ........................................ W3-15-6-1 Assembly of Fan Pump ............................................. W3-15-6-3

Group 16 Ride Control Device Removal and Installation of Ride Control Valve ........................................................................... W3-16-1-1 Disassembly of Ride Control Valve ....................... W3-16-2-1 Assembly of Ride Control Valve ............................. W3-16-2-4 Removal and Installation of Ride Control Accumulator ............................................................ W3-16-3-1

Group 17 Battery Disconnect Switch Removal and Installation of Battery Disconnect Switch ........................................................................ W3-17-1-1

70Z7B D&R

Group 18 Aftertreatment Device Removal and Installation of Aftertreatment Device ........................................................................ W3-18-1-1

Group 19 DEF Tank Removal and Installation of DEF Tank ................. W3-19-1-1

Group 20 Coolant Control Valve Removal and Installation of Coolant Control Valve ........................................................................... W3-20-1-1

Group 21 DEF Supply Module Removal and Installation of DEF Supply Module ...................................................................... W3-21-1-1

Group 22 Exterior Components Removal and Installation of Exterior Components ........................................................... W3-22-1-1

70Z7B D&R

SECTION 3 BODY Group 1 Cab Removal and Installation of Cab

2, 3

1 WNEK50-03-06-001

Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious

Operate the steering wheel in right dCAUTION: and left several times, and release any pressure in

injury. Release the pressure before disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns. Allow oil to cool before starting any work. IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

the circuit. Operate the brake pedal more than 50 dCAUTION: times and release any pressure in the circuit. Release any pressure from hydraulic dCAUTION: oil tank (1). (Refer to W1-5-1.) 2. Remove bolts, washers (4) (6 used). Remove the cover (2) assembly and O-ring (3). j : 17 mm 3. Place a container. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.)

W3-1-1-1

(37 US gal)

SECTION 3 BODY Group 1 Cab

2 Detail A

3 5, 6

Battery Box

WNEK50-03-01-001

 Without battery disconnect switch 4. Open covers (2, 3). 5. Remove bolt, washer (1). Remove rubber plate (4). j : 17 mm 6. Remove bolt, washer (5) and clip (6). j : 17 mm IMPORTANT: Turn the key switch to the OFF position, wait 5 minutes or longer, and then disconnect ground (7). 7. Loosen bolt (8). Disconnect ground (7). j : 17 mm

W3-1-1-2

WNEK50-03-01-002

SECTION 3 BODY Group 1 Cab

Detail A

1 A

Battery Box

WNEK50-03-17-001

b c bc-

 With battery disconnect switch 8. Open cover (1). IMPORTANT: Turn the key switch to the OFF position, wait 5 minutes or longer, and then turn battery disconnect switch (2) to the OFF position. 9. Set battery disconnect switch (2) to OFF position (b).

W3-1-1-3

OFF Position ON Position

WNEK50-03-22-043

SECTION 3 BODY Group 1 Cab

3 1

WNEK50-03-19-003

10. Release any pressure in the the expansion tank. (Refer to W1-5-1.) 11. Open left and right side covers (front) (1). 12. Place a container under hose (2). Loosen cock (3). Drain off coolant. Close cock (3).

fNOTE: Amount of coolant: 33 L (8.7 US gal) 13. Release refrigerant of the air conditioner. (Refer to T5-7 in the separated volume, Technical Manual.)

W3-1-1-4

WNEK50-03-19-010

SECTION 3 BODY Group 1 Cab

8, 9

14. Remove following exterior components from left and right side. (Refer to W3-22-1.)

WPD850-03-01-003

WNEK50-03-22-003

15. Remove the following parts. (Refer to W3-22-1.)  Cab Under Cover (1)

 Step (3)

 Deck (2)

 Rear Fender (Front) (5)

 Inspection Cover (4, 7, 9)

 Lower Cover (6)

 Battery Box (8)

W3-1-1-5

SECTION 3 BODY Group 1 Cab

WPD850-03-01-001

16. Remove bolts, washers (3) (4 used). Remove rubber plate (4). j : 17 mm 17. Remove bolts, washers (1) (1 used). Remove bracket (2). j : 17 mm

W3-1-1-6

SECTION 3 BODY Group 1 Cab

Detail A 1

WNEK50-03-01-004

a a-

18. Disconnect hoses (1) (4 used). j : 19 mm 19. Disconnect hose (2). j : 22 mm

W3-1-1-7

Flow Regulator Valve

WNEK50-03-01-005

SECTION 3 BODY Group 1 Cab Detail A

b WNEK50-03-01-007

WNEK50-03-01-006 A ab-

20. Disconnect hose (1). j : 27 mm

W3-1-1-8

Suction Pipe Flow Regulator Valve

SECTION 3 BODY Group 1 Cab b

Detail A

4, 5

A WNEK50-03-01-009

Detail B 6, 7

C a-

Vehicle Front Side

1 b-

8, 9

Cab

WNEK50-03-01-008

21. Remove bolt, washer (4) and clip (5). j : 17 mm

Flow Regulator Valve

22. Disconnect connectors (1, 2) and connectors (3) (3 used). 23. Disconnect connector (8) (only the machine with the ride control device). Remove connector (8) from bracket (9). 24. Remove bolt, washer (6). Remove bracket (7).

WNEK50-03-01-010

Detail C 10

j : 17 mm 25. Disconnect connectors (10) (2 used). Remove connectors (10) (2 used) from brackets (11, 12).

W3-1-1-9

WNDB-03-01-105

SECTION 3 BODY Group 1 Cab

C B

Detail A

1, 2, 3

4 a-

WNEK50-03-01-012

Washer Tank

WNEK50-03-01-011

View B

5, 6, 7

27. Remove bolt, washer (1) and clips (2, 3). j : 17 mm 28. Disconnect hoses (4) (2 used). 29. Remove bolt, washer (5), nut (6), and clip (7). j : 17 mm 30. Remove hoses (4) (9 used) from clips (8, 2) (2 used for each). 31. Disconnect hose (10). Remove O-ring (11) from hose (10).

WNEK50-03-01-013

j : 27 mm 32. Disconnect hose (12). Remove O-ring (13) from hose (12).

Detail C

j : 19 mm 10, 11

12, 13 b

W3-1-1-10

Hydraulic Oil Tank

WNEK50-03-01-014

SECTION 3 BODY Group 1 Cab C

Detail C

B WPD850-03-01-002 WNEK50-03-01-011

33. Disconnect hose (7).

Detail B

j : 27 mm 34. Disconnect hoses (8) (2 used). j : 27 mm 35. Disconnect hose (9). j : 19 mm

WPD850-04-06-007

W3-1-1-11

SECTION 3 BODY Group 1 Cab

Detail A

WNEK50-03-01-017

WNEK50-03-01-016

View B

36. Disconnect hose (1). j : 22 mm 3

37. Remove bolt, washer (4), nut (5), and clip (6). j : 17 mm 38. Loosen clamps (2) (2 used). Disconnect hoses (3) (2 used).

4, 5 6

j : 7 mm WNEK50-03-01-018

W3-1-1-12

SECTION 3 BODY Group 1 Cab

Detail A

1 B A

2, 3

WNEK50-03-01-016

WNEK50-03-01-021

View B

39. Remove bolt, washer (2), nut (3), and clips (1) (2 used). j : 17 mm 40. Disconnect hoses (4) (2 used). j : 22 mm 4

WNEK50-03-01-022

W3-1-1-13

SECTION 3 BODY Group 1 Cab

Detail A

2, 3

WNEK50-03-01-023

WPD850-03-01-005

41. Remove bolt, washer (2) and clip (3).

View B

j : 17 mm 42. Disconnect connector (1). 43. Disconnect hoses (6) (2 used). j : 19 mm

WPD850-03-01-004

W3-1-1-14

SECTION 3 BODY Group 1 Cab

1 2 3 4

Eyebolt Mounting Hole WNEK50-03-01-028

44. Remove bolts (1) (4 used), washers (2) (4 used), plates (3) (4 used), and seal (4) (4 used). j : 24 mm

The cab (5) assembly weight: 1150 kg dCAUTION: (2540 lb) 45. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a) (4 places) of the cab (5) assembly. Attach nylon slings onto the eyebolts (4 used). Hoist and hold the cab (5) assembly.

W3-1-1-15

SECTION 3 BODY Group 1 Cab

Detail A

Detail B 9

1 a a

2 3 4 5

7 13

8 2

WNEK50-03-01-030 a-

10 11

14 15

WNEK50-03-01-029 a-

Rubber Cushion

Vehicle Front Side WNEK50-03-01-031 a-

Rubber Cushion

46. Remove bolts (8) (2 used), plates (7) (2 used), and spacers (6) (2 used). j : 30 mm 47. Remove bolts (9) (2 used), nuts (12) (2 used), plates (11) (2 used), and spacers (10) (2 used). j : 46 mm

fNOTE: LOCTITE #263 or equivalent has been applied to the thread part of bolt (9). 48. Remove nuts (5, 15) (2 used for each) and washers (4, 14) (2 used for each).

IMPORTANT: Do not allow the cab (1) assembly to come in contact with the front frame and hydraulic oil tank when removing/installing the cab (1) assembly. 49. Remove the cab (1) assembly and washers (3, 13) (2 used for each) from rear frame (2). Place the cab (1) assembly on wooden blocks.

j : 24 mm

fNOTE: LOCTITE #263 or equivalent has been applied to the thread part of rubber cushion (a).

W3-1-1-16

SECTION 3 BODY Group 1 Cab

Eyebolt Mounting Hole WNEK50-03-01-028

Installation The cab (1) assembly weight: 1150 kg dCAUTION: (2540 lb) 1. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a) (4 places) of the cab (1) assembly. Attach nylon slings onto the eyebolts (4 used). Hoist the cab (1) assembly.

W3-1-1-17

SECTION 3 BODY Group 1 Cab

Detail A

Detail B 9

1 a a

2 3 4 5

7 13

8 2

WNEK50-03-01-030 a-

Rubber Cushion

14 15

WNEK50-03-01-029 a-

Vehicle Front Side WNEK50-03-01-031 a-

Rubber Cushion

IMPORTANT: Do not allow the cab (1) assembly to come in contact with the front frame and hydraulic oil tank when removing/installing the cab (1) assembly. 2. Install washers (3, 13) (2 used for each) and the cab (1) assembly to rear frame (2). 3. Apply LOCTITE #263 or equivalent to the thread part of rubber cushions (a) (4 used). Install washers (4, 14) (2 used for each) and nuts (5, 15) (2 used for each).

5. Install spacers (6) (2 used), plates (7) (2 used), and bolts (8) (2 used).

j : 24 mm

j : 30 mm m : 100 N·m (74 lbf·ft)

m : 205 N·m (151 lbf·ft) 4. Apply LOCTITE #263 or equivalent onto the thread part of bolts (9) (2 used). Install bolts (9) (2 used), spacers (10) (2 used), plates (11) (2 used), and nuts (12) (2 used). j : 46 mm m : 216 N·m (159 lbf·ft)

W3-1-1-18

SECTION 3 BODY Group 1 Cab

1 2 3 4

WNEK50-03-01-028

6. Install seals (4) (4 used), plates (3) (4 used), washers (2) (4 used), and bolts (1) (4 used). j : 24 mm m : 80 N·m (133 lbf·ft)

W3-1-1-19

SECTION 3 BODY Group 1 Cab

Detail A

2, 3

WNEK50-03-01-023

WPD850-03-01-005

View B

7. Connect hoses (6) (2 used). j : 19 mm m : 30 N·m (22 lbf·ft) 8. Connect connector (1). 9. Secure harness (7) with clip (3) and bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft)

WPD850-03-01-004

W3-1-1-20

SECTION 3 BODY Group 1 Cab

Detail A

1 B A

2, 3

WNEK50-03-01-016

WNEK50-03-01-021

View B

10. Connect hoses (4) (2 used). j : 22 mm m : 40 N·m (29.5 lbf·ft) 11. Secure hoses (4) (2 used) with clips (1) (2 used), nut (3), and bolt, washer (2). 4

j : 17 mm m : 50 N·m (37 lbf·ft)

WNEK50-03-01-022

W3-1-1-21

SECTION 3 BODY Group 1 Cab

Detail A

WNEK50-03-01-017

WNEK50-03-01-016

View B

12. Connect hoses (3) (2 used) with clamps (2) (2 used). j : 7 mm 3

m : 4.5 N·m (3.3 lbf·ft) 13. Secure hoses (3) (2 used) with clip (6), nut (5) and bolt, washer (4). j : 17 mm

4, 5 6

m : 50 N·m (37 lbf·ft) WNEK50-03-01-018

14. Connect hose (1). j : 22 mm m : 40 N·m (30 lbf·ft)

W3-1-1-22

SECTION 3 BODY Group 1 Cab

Detail B

WPD850-04-06-007

WNEK50-03-01-011

15. Connect hoses (8) (2 used).

Detail C

j : 27 mm m : 95 N·m (70 lbf·ft) 16. Connect hose (9). j : 19 mm

m : 30 N·m (22 lbf·ft) 17. Connect hose (7). j : 27 mm m : 80 N·m (59 lbf·ft)

WPD850-03-01-002

W3-1-1-23

SECTION 3 BODY Group 1 Cab

Detail A

1, 2

3, 4

a a-

WNEK50-03-01-014

Hydraulic Oil Tank

WNEK50-03-01-011

18. Apply ND-OIL8 to O-ring (4). Install O-ring (4) to hose (3). Connect hose (3).

19. Apply ND-OIL8 to O-ring (2). Install O-ring (2) to hose (1). Connect hose (1).

j : 19 mm

j : 27 mm

m : 11.8 to 14.7 N·m (8.7 to 11 lbf·ft)

m : 29.4 to 34.3 N·m (21.5 to 25.5 lbf·ft) 20. Add compressor oil. (Refer to T5-7 in the separated volume, Technical Manual.)

W3-1-1-24

SECTION 3 BODY Group 1 Cab

C B

Detail A

1, 2, 3

Washer Tank

WNEK50-03-01-012

WNEK50-03-01-011

5, 6, 7

View B

21. Connect hoses (4) (2 used). 22. Secure hoses (4) (2 used) and harness (14) with clips (2, 3) and bolt, washer (1). j : 17 mm m : 50 N·m (37 lbf·ft) 23. Secure hoses (4) (2 used) with clip (7), nut (6) and bolt, washer (5). j : 17 mm

WNEK50-03-01-013

m : 50 N·m (37 lbf·ft) 24. Secure hoses (4) (2 used) with clips (8, 9) (2 used for each).

Detail C

W3-1-1-25

Hydraulic Oil Tank

WNEK50-03-01-014

SECTION 3 BODY Group 1 Cab b

Detail A

4, 5

WNEK50-03-01-009

Detail B 6, 7

8, 9

WNEK50-03-01-008 C a-

Vehicle Front Side

1 b-

Cab

25. Install connectors (10) (2 used) to brackets (11, 12). Connect connectors (10) (2 used). 26. Secure wire harness (14) with bracket (7) and bolt, washer (6).

14 c-

WNEK50-03-01-010

Flow Regulator Valve

j : 17 mm Detail C 10

m : 50 N·m (37 lbf·ft)

27. Install connector (8) to bracket (9) (only for the machine with the ride control device). Connect connector (8). 28. Connect connectors (1, 2) and connectors (3) (3 used). 29. Secure harness (13) with clip (5) and bolt, washer (4). j : 17 mm m : 50 N·m (37 lbf·ft) 12

W3-1-1-26

WNDB-03-01-105

SECTION 3 BODY Group 1 Cab Detail A

WNEK50-03-01-006

WNEK50-03-01-007

A a-

30. Connect hose (1). j : 27 mm m : 80 N·m (59 lbf·ft)

W3-1-1-27

Suction Pipe

Flow Regulator Valve

SECTION 3 BODY Group 1 Cab

Detail A 1

WNEK50-03-01-004

a a-

31. Connect hose (2). j : 22 mm m : 40 N·m (29.5 lbf·ft) 32. Connect hoses (1) (4 used). j : 19 mm m : 30 N·m (22 lbf·ft)

W3-1-1-28

Flow Regulator Valve

WNEK50-03-01-005

SECTION 3 BODY Group 1 Cab

2, 3

1 WNEK50-03-06-001

33. Add coolant to the radiator.

fNOTE: Amount of coolant: 33 L (8.7 US gal) 34. Fill hydraulic oil tank (1) with hydraulic oil.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 35. Install O-ring (3).

36. Install the cover (2) assembly with bolts, washers (4) (6 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-1-1-29

SECTION 3 BODY Group 1 Cab

WNEK50-03-22-003

8, 9

37. Install the following parts. (Refer to W3-22-1.)  Inspection Cover (9)  Battery Box (8)

W3-1-1-30

SECTION 3 BODY Group 1 Cab

2 Detail A

3 5, 6

Battery Box

WNEK50-03-01-001

 Without battery disconnect switch 38. Connect ground (7). Tighten bolt (8). j : 17 mm m : 50 N·m (37 lbf·ft) 39. Secure ground (7) with clip (6) and bolt, washer (5). j : 17 mm m : 50 N·m (37 lbf·ft) 40. Install rubber plate (4) with bolt, washer (1). j : 17 mm m : 50 N·m (37 lbf·ft) 41. Close covers (2, 3).

W3-1-1-31

WNEK50-03-01-002

SECTION 3 BODY Group 1 Cab

Detail A

1 A

Battery Box

WNEK50-03-17-001

b c bc-

 With battery disconnect switch 42. Set battery disconnect switch (2) to ON position (c). 43. Close cover (1).

W3-1-1-32

OFF Position ON Position

WNEK50-03-22-043

SECTION 3 BODY Group 1 Cab

WPD850-03-01-001

44. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil or water leaks. 45. Operate the steering wheel to the stroke end several times and bleed air from the circuit.

48. Install bracket (2) with bolts, washers (1) (1 used). j : 17 mm m : 50 N·m (37 lbf·ft) 49. Install rubber plate (3) with bolts, washers (4) (4 used). j : 17 mm

46. Bleed air from the brake (axle). (Refer to W1-4-1.) 47. Fill refrigerant in the air conditioner. (Refer to T5-7 in the separated volume, Technical Manual.)

W3-1-1-33

m : 50 N·m (37 lbf·ft)

SECTION 3 BODY Group 1 Cab

WPD850-03-01-003

50. Install the following parts. (Refer to W3-22-1.)  Cab Under Cover (1)

WNEK50-03-22-003

51. Install following exterior components to left and right side. (Refer to W3-22-1.)  Lower Cover (6)

 Deck (2)

 Rear Fender (Front) (5)

 Inspection Cover (4, 7)

 Step (3) 52. Close left and right side covers (8).

W3-1-1-34

SECTION 3 BODY Group 2 Counterweight Removal and Installation of Counterweight

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) IMPORTANT: If rear grill (1) is kept closed and counterweight (2) is removed, rear grill (1) may be damaged. 2. Open rear grill (1).

W3-2-1-1

WNEK50-03-22-008

SECTION 3 BODY Group 2 Counterweight

2 5

Hoisting Position

WNEK50-03-02-001

Counterweight (4) weight: 1460 kg dCAUTION: (3220 lb) 3. Attach the nylon slings onto hoisting positions (a) (2 places) of counterweight (4). Hoist and hold counterweight (4). 4. Remove bolts (5) (4 used), nuts (1) (2 used), and washers (2) (6 used). Remove counterweight (4) from rear frame (3). j : 46 mm

W3-2-1-2

SECTION 3 BODY Group 2 Counterweight

2 5

Hoisting Position

WNEK50-03-02-001

View A

Installation IMPORTANT: Keep the rear grill open when installing.

Counterweight (4) weight: 1460 kg dCAUTION: (3220 lb) 1. Attach nylon slings onto hoisting positions (a) (2 places) of counterweight (4). Hoist and fit counterweight (4) to the mounting holes on rear frame (3). IMPORTANT: When installing counterweight (4), install counterweight (4) while positions (b) (2 places) of counterweight (4) with rear frame (3). 2. Install counterweight (4) to rear frame (3) with bolts (5) (4 used), washers (2) (6 used), and nuts (1) (2 used). j : 46 mm m : 1510 N·m (1110 lbf·ft)

W3-2-1-3

WPD850-03-02-001

SECTION 3 BODY Group 2 Counterweight

WNEK50-03-22-008

3. Close rear grill (1).

W3-2-1-4

SECTION 3 BODY Group 3 Center Hinge Removal and Installation of Center Hinge

Stand a

WNEK50-03-03-021

WNDF-03-03-006

Removal IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.)

Base Machine Weight: 14980 kg dCAUTION: (33100 lb) 4. Support front frame (1) and rear frame (2) by using stable stands (a).

2. Remove the following parts.  Front Attachment (Refer to W5-1-1.)  Cab Assembly (Refer to W3-1-1.)  Propeller Shaft (Refer to W4-4-1.)  Steering Cylinder (Refer to W4-6-7.) 3. Remove front cover (3). (Refer to W3-22-1.)

W3-3-1-1

SECTION 3 BODY Group 3 Center Hinge A

Detail A

WNEK50-04-06-005 a-

Control Valve

WPD850-03-09-004

5. Remove bolt, washer (5) and clip (4). j : 17 mm

View B

6. Disconnect hoses (3) (3 used). j : 19 mm

7. Disconnect hoses (2) (2 used). j : 41 mm

WNEK50-03-03-001

W3-3-1-2

SECTION 3 BODY Group 3 Center Hinge View A

1 WPD850-03-03-015 a-

Control Valve

WPD850-03-03-016 b-

9. Disconnect hoses (1) (3 used). j : 19 mm 10. Disconnect hoses (2) (2 used). j : 17 mm

W3-3-1-3

Ride Control Valve

SECTION 3 BODY Group 3 Center Hinge Detail A

4, 5 WPD850-03-03-002

WPD850-03-03-001

11. Remove bolts, washers (4) (2 used) and clips (5) (2 used).

View B

j : 17 mm 12. Remove bolts, washers (7) (2 used) and clips (8) (2 used). j : 17 mm

7, 8 WPD850-03-03-003

W3-3-1-4

SECTION 3 BODY Group 3 Center Hinge A

Detail A

b a ab-

8, 9

WNEK50-03-03-022

Front Axle Vehicle Front Side

13. Remove bolts, washers (8) (2 used) and clips (9) (2 used). j : 17 mm 14. Disconnect hose (10). j : 27 mm

W3-3-1-5

Front Axle

WNDB-03-03-002

SECTION 3 BODY Group 3 Center Hinge Detail A

WPD850-03-03-017

9, 10

Detail B

6 5 4

Front Frame

WPD850-03-03-004

7 8

WNEK50-03-03-011

18. Bind and place the disconnected hoses and wire harnesses outside of the work area.

15. Remove bolt, washer (9) and clip (10). j : 17 mm 16. Disconnect connectors (11) (2 used). 17. Put matching marks on clamp (6), each hose and harnesses in order to be clear about the position for securing the hoses when installing. Remove bolts, washers (4) (2 used), washers (7) (2 used), and nuts (8) (2 used). Remove plate (5) and clamp (6). j : 19 mm

W3-3-1-6

SECTION 3 BODY Group 3 Center Hinge Detail A

1, 2

3 WPD850-03-03-005 A

19. Remove bolts, washers (1) (4 used), nuts (2) (4 used), and clamps (3) (2 used). j : 19 mm

W3-3-1-7

WPD850-03-03-006

SECTION 3 BODY Group 3 Center Hinge Section of Lower Hinge (a) 2

3 4

1 a-

Lower Hinge

WNEK50-03-03-014

 Lower Hinge (a) Side Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury. 20. Remove bolt (2) and washers (3, 4). Remove pin (1) from lower hinge (a) by using a round bar and a hammer. j : 24 mm

W3-3-1-8

WPD850-03-03-018

SECTION 3 BODY Group 3 Center Hinge Section of Upper Hinge (b) 9

7 6

10 b-

Upper Hinge

WNEK50-03-03-014

 Upper Hinge (b) Side 21. Remove bolts (7) (4 used), bolts (8) (3 used), and washers (6) (7 used). Remove flange (9) and shims (5) (2 used).

WPD850-03-03-019

Remove pin (10) while holding it. Do dCAUTION: not drop pin (10). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury.

j : 24 mm

fNOTE: LOCTITE #263 or equivalent has been applied to the bolts (7, 8).

22. Remove pin (10) from upper hinge (b) by using a round bar and a hammer.

W3-3-1-9

SECTION 3 BODY Group 3 Center Hinge Section of Upper Hinge (b) 11 13 b

13 b-

Upper Hinge

WNEK50-03-03-014

IMPORTANT: When bushing (11) has been removed, replace it with the new one. 23. Weld handles in diagonal position on the upper side of bushing (11). Attach a pry bar onto the handles. Raise and remove bushing (11) from rear frame (13).

W3-3-1-10

WPD850-03-03-020

SECTION 3 BODY Group 3 Center Hinge Section of Upper Hinge (b)

13 14 12

15 b-

Upper Hinge

WNEK50-03-03-014

The front frame (12) assembly weight: dCAUTION: 2730 kg (6020 lb) Support front frame (12) by using dCAUTION: stable stands. IMPORTANT: Do not allow cap (14) and bushing (15) to come in contact with rear frame (13). 24. Attach nylon slings onto the front frame (12) assembly. Hoist and hold the front frame (12) assembly. Move the front frame (12) assembly forward and remove it. Support the front frame (12) assembly by using a stand.

W3-3-1-11

13 WPD850-03-03-021

SECTION 3 BODY Group 3 Center Hinge

17 15

WPD850-03-03-022

Upper Hinge

 Upper Hinge (b) Side

26. Remove bolts (18) (6 used). Remove caps (14, 17) and shim (16) from front frame (12).

IMPORTANT: When bushing (15) has been removed, replace it with the new one. 25. Remove bushing (15) from cap (17) by using a pry bar.

j : 19 mm

fNOTE: LOCTITE #263 or equivalent has been applied to

W3-3-1-12

bolt (18).

SECTION 3 BODY Group 3 Center Hinge

19 14

20 21

19 17 WPD850-03-03-023

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

28. Remove grease fitting (20) from front frame (12).

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: When dust seal (19) has been removed, replace it with the new one. 27. Remove dust seals (19) (2 used) from caps (14, 17) by using a screwdriver and a hammer. Smooth the punch marks (2 places for each) of caps (14, 17).

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

j : 10 mm

such as goggles, hard hat, etc. in order to prevent personal injury. 29. Remove bearing (21) from front frame (12) by using a round bar and a hammer.

fNOTE: LOCTITE #263 or equivalent has been applied to the outer circumference of dust seal (19).

fNOTE: Caps (14, 17) have been crimped by using a

punch (2 places for each) in order to secure dust seals (19) (2 used).

W3-3-1-13

SECTION 3 BODY Group 3 Center Hinge 12

23 24

Lower Hinge

 Lower Hinge (a) Side 30. Remove bolts (22) (6 used). Remove caps (23, 25) and shim (24) from front frame (12). j : 19 mm

fNOTE: LOCTITE #263 or equivalent has been applied to bolt (22).

W3-3-1-14

WNEK50-03-03-016

SECTION 3 BODY Group 3 Center Hinge

23 26

27 28

25 26

WPD850-03-03-024

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: When dust seal (26) has been removed, replace it with the new one. 31. Remove dust seals (26) (2 used) from caps (23, 25) by using a screwdriver and a hammer. Smooth the punch marks (2 places for each) of caps (23, 25).

such as goggles, hard hat, etc. in order to prevent personal injury. 33. Remove bearing (28) from front frame (12) by using a round bar and a hammer.

fNOTE: LOCTITE #263 or equivalent has been applied to the outer circumference of dust seal (26).

fNOTE: Caps (23, 25) have been crimped by using a

punch (2 places for each) in order to secure dust seals (26) (2 used). 32. Remove grease fitting (27) from front frame (12). j : 10 mm

W3-3-1-15

SECTION 3 BODY Group 3 Center Hinge 13

Lower Hinge

WNEK50-03-03-017

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: When bushing (29) has been removed, replace it with the new one. 34. Remove bushings (29) (2 used) from rear frame (13) by using a round bar and a hammer if necessary.

W3-3-1-16

SECTION 3 BODY Group 3 Center Hinge Section of Lower Hinge 26

22 23

13 c

24 12

28 25

5 mm (0.02 in)

WPD850-03-03-024

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installing the center hinge. Replace them if any defect is observed. (Refer to W2-1-1.) IMPORTANT: The seals and bushings which have been removed cannot be reused. IMPORTANT: Apply grease onto the inner circumference of bushings and dust seals when installing the pin.  Lower Hinge Side

IMPORTANT: Check the direction to install dust seal (26). 3. Apply LOCTITE #263 or equivalent to the outer circumference of dust seals (26) (2 used). Install dust seals (26) (2 used) to caps (23, 25) by using a plastic hammer. Crimp and secure caps (23, 25) (2 places for each) by using a punch and secure dust seals (19) (2 used). 4. Apply LOCTITE #263 or equivalent to bolts (22) (6 used). Install shim (26) to front frame (12) so that top surface height difference between front frame (12) and bearing (28) are 5 mm (0.02 in). Install caps (23, 25) with bolts (22) (6 used).

fNOTE: Shim (24) thickness: 0.4 mm (0.016 in)

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury. 1. Install bushings (29) (2 used) to rear frame (13) by using special tool (ST 7881) and a hammer. IMPORTANT: Check the position to install bearing (28). 2. Install bearing (28) to front frame (12) by using a copper hammer.

W3-3-1-17

j : 19 mm m : 88 N·m (65 lbf·ft)

SECTION 3 BODY Group 3 Center Hinge Section of Upper Hinge 18

18 14 16

12 17

15 WPD850-03-03-026

19 d-

8 mm (0.32 in)

 Upper Hinge Side Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury. 5. Install bearing (21) to front frame (12) by using a copper hammer. 6. Apply LOCTITE #263 or equivalent to the outer circumference of dust seals (19) (2 used). Install dust seals (19) (2 used) to caps (14, 17) by using a plastic hammer. Crimp and secure caps (14, 17) (2 places for each) by using a punch and secure dust seals (19) (2 used).

7. Apply LOCTITE #263 or equivalent to bolts (18) (6 used). Install shim (16) to front frame (12) so that top surface height difference between front frame (12) and bearing (21) are 8 mm (0.32 in). Install caps (14, 17) with bolts (18) (6 used).

fNOTE: Shim (16) thickness: 0.4 mm (0.016 in) j : 19 mm m : 88 N·m (65 lbf·ft) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: Check the position to install bearing (5). 8. Insert bushing (15) to cap (17) by using a copper hammer until bushing (15) comes in contact with bearing (21).

W3-3-1-18

SECTION 3 BODY Group 3 Center Hinge Section of Upper Hinge (b)

13 14

15 a

WPD850-03-03-020 WNEK50-03-03-014

Lower Hinge

Upper Hinge

The front frame (12) assembly weight: dCAUTION: 2730 kg (6020 lb) Support front frame (12) by using dCAUTION: stable stands. IMPORTANT: Do not allow cap (14) and bushing (15) to come in contact with rear frame (13). 9. Attach nylon slings onto the front frame (12) assembly. Hoist the front frame (12) assembly. Fit the mounting holes of upper hinge (b) and lower hinge (a) of the front frame (12) assembly and the rear frame (13) assembly. Support the front frame (12) assembly by using a stand.

W3-3-1-19

SECTION 3 BODY Group 3 Center Hinge Section of Upper Hinge 8

6 11

12 20

 Upper Hinge Side Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury. 10. Insert bushing (11) to upper hinge (b) by using a copper hammer until bushing (11) comes in contact with bearing (21).

dCAUTION: Do not drop pin (10).

11. Install and hold pin (10) to upper hinge (b) by using a jack.

WPD850-03-03-027

12. Apply LOCTITE #263 or equivalent to bolts (8) (3 used) and bolts (7) (4 used). Install shim (5) and flange (9) to rear frame (13) with washers (6) (7 used), bolts (8) (3 used) and bolts (7) (4 used). Remove the jack. j : 24 mm m : 205 N·m (151 lbf·ft) IMPORTANT: Face the end of grease fitting (20) to the left side of the machine. 13. Install grease fitting (20) to front frame (12). Apply grease. j : 10 mm m : 4 N·m (3 lbf·ft)

W3-3-1-20

SECTION 3 BODY Group 3 Center Hinge Section of Lower Hinge 1

2 3

13 12

WPD850-03-03-028

Boss

 Lower Hinge Side

IMPORTANT: Face the end of grease fitting (27) to the left side of the machine. 15. Install grease fitting (27) to front frame (12). Apply grease.

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury.

j : 10 mm m : 4 N·m (3 lbf·ft)

14. Fit pin (1) to the boss (e) hole of rear frame (13). Install pin (1) to lower hinge (a) by using a hammer. Install washers (3, 4) and bolt (2). j : 24 mm m : 210 N·m (155 lbf·ft)

W3-3-1-21

SECTION 3 BODY Group 3 Center Hinge Detail A

9, 10

11 WPD850-03-03-005 A

16. Secure hoses (12) (9 used) with brackets (11) (2 used), bolts, washers (9) (4 used) and nuts (10) (4 used). j : 19 mm m : 90 N·m (66 lbf·ft)

W3-3-1-22

WPD850-03-03-006

SECTION 3 BODY Group 3 Center Hinge Detail A

WPD850-03-03-017

9, 10

18. Secure hoses (13) (4 used) and harness (14) with clamp (6), plate (5), bolts, washers (4) (2 used), washers (7) (2 used) and nuts (8) (2 used) by fitting the matching marks.

WPD850-03-03-004

Detail B

17. Connect connectors (11) (2 used).

6 5 4

7 8

j : 19 mm m : 90 N·m (66 lbf·ft) 19. Secure harness (14) with clip (10) and bolt, washer (9).

j : 17 mm m : 50 N·m (37 lbf·ft)

W3-3-1-23

Front Frame

WNEK50-03-03-011

SECTION 3 BODY Group 3 Center Hinge Detail A

4, 5

WPD850-03-03-002

WPD850-03-03-001

20. Secure hoses (22) (9 used) with clips (4) (2 used) and bolts, washers (5) (2 used). j : 17 mm

7, 8

m : 50 N·m (37 lbf·ft) 21. Secure hoses (18) (2 used) with clips (8) (2 used) and bolts, washers (7) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-3-1-24

WPD850-03-03-003

SECTION 3 BODY Group 3 Center Hinge A

b a ab-

8, 9

Detail A

WNEK50-03-03-022

Front Axle Vehicle Front Side

22. Connect hose (10). j : 27 mm m : 80 N·m (59 lbf·ft) 23. Secure hose (10) with clips (9) (2 used) and bolts, washers (8) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-3-1-25

WNDB-03-03-002

SECTION 3 BODY Group 3 Center Hinge View A

b 1 WPD850-03-03-015

Control Valve

24. Connect hoses (1) (3 used).

WPD850-03-03-016 b-

Ride Control Valve

View A

j : 19 mm

m : 30 N·m (22 lbf·ft) B

25. Connect hoses (2) (2 used). j : 17 mm m : 15 N·m (11 lbf·ft) IMPORTANT: Check the angle to install clip (8). 26. Secure hoses (2) (2 used) with clip (8) and bolt, washer (7).

7, 8

WPD850-03-03-003

j : 17 mm m : 50 N·m (37 lbf·ft)

Detail B

W3-3-1-26

30 °

WPD850-03-03-012

SECTION 3 BODY Group 3 Center Hinge A

View A

2 b

WPD850-03-03-013

3 WPD850-03-09-004

45°

Detail B

Control Valve

IMPORTANT: Check the angle to install hose (2). 27. Connect hoses (2) (2 used). j : 41 mm m : 210 N·m (155 lbf·ft)

IMPORTANT: Check the angle to install hose (3). 28. Connect hoses (3) (3 used). j : 19 mm m : 30 N·m (22 lbf·ft)

W3-3-1-27

10°

WPD850-03-03-014

SECTION 3 BODY Group 3 Center Hinge A

Detail A

3 3 a-

WNEK50-03-03-001

Control Valve

WNEK50-04-06-005

29. Secure hoses (3) (3 used) with clip (4) and bolt, washer (5). j : 17 mm m : 50 N·m (37 lbf·ft) 30. Install front cover (1). (Refer to W3-22-1.)

WNEK50-03-03-021

W3-3-1-28

SECTION 3 BODY Group 3 Center Hinge

Stand

Tire

WNDF-03-03-006

Base Machine Weight: 14980 kg dCAUTION: (33100 lb) 31. Remove stands (a) from front frame (1) and rear frame (2). Secure tires (b) (4 used) by using wheel stoppers. 32. Install the following parts.  Front Attachment (Refer to W5-1-1.)  Cab Assembly (Refer to W3-1-1.)  Propeller Shaft (Refer to W4-4-1.)  Steering Cylinder (Refer to W4-6-7.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-3-1-29

SECTION 3 BODY Group 3 Center Hinge (Blank)

W3-3-1-30

SECTION 3 BODY Group 4 Engine Removal and Installation of Engine

2, 3

1 WNEK50-03-06-001

Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious

Operate the steering wheel in right dCAUTION: and left several times, and release any pressure in

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) IMPORTANT: After stopping the engine, the DEF pump continues to be operated for a specified time in order to return DEF from the hose to the DEF tank. When 5 minutes pass after the engine has been stopped, start the work.

W3-4-1-1

(37 US gal)

SECTION 3 BODY Group 4 Engine

2 Detail A

3 5, 6

ab-

Vehicle Front Side Battery Box

WNEK50-03-01-001

 Without battery disconnect switch (Step 4 to step 7) 4. Open covers (2, 3). 5. Remove bolt, washer (1). Remove rubber plate (4). j : 17 mm 6. Remove bolt, washer (5) and clip (6). j : 17 mm 7. Loosen bolt (8). Disconnect ground (7). j : 17 mm

W3-4-1-2

WNEK50-03-01-002

SECTION 3 BODY Group 4 Engine

Detail A

1 A

ab-

Vehicle Front Side Battery Box

WNEK50-03-17-001

c d cd-

 With battery disconnect switch (Step 8 to step 9) 8. Open cover (1). 9. Set battery disconnect switch (2) to OFF position (c).

W3-4-1-3

OFF Position ON Position

WNEK50-03-22-043

SECTION 3 BODY Group 4 Engine 1

10, 11

10. Remove following exterior components from left and right side. (Refer to W3-22-1.)

WPD850-03-01-003

WNEK50-03-22-003

11. Remove the following parts. (Refer to W3-22-1.)  Cab Under Cover (7)

 Step (5)

 Deck (6)

 Rear Fender (Front) (3)

 Inspection Cover (4, 9, 11)

 Lower Cover (2)

 Engine Cover (1)  Under Guard Rear (8) (Only for the machine with under guard)  Battery Box (10)

W3-4-1-4

SECTION 3 BODY Group 4 Engine

WNEK50-03-19-010

Vehicle Front Side

12. Release any pressure in the the expansion tank. (Refer to W1-5-1.) 13. Place a container under hose (1). Loosen cock (2). Drain off coolant. Close cock (2).

fNOTE: Amount of coolant: 33 L (8.7 US gal)

W3-4-1-5

SECTION 3 BODY Group 4 Engine

9 4 8

3 6

7 WNEK50-03-04-001

Vehicle Front Side

Fuel Tank

a WNEK50-03-04-002

14. Place a container under drain plug (3). Loosen drain plug (3). Drain off engine oil. Tighten drain plug (3).

Vehicle Front Side

17. Loosen clamps (6) (2 used). Disconnect the both ends of hose (7).

j : 24 mm

j : 7 mm 18. Remove propeller shafts (5, 9) from drive unit (8). (Refer to W4-4-1.)

m : 93 N∙m (69 lbf·ft)

fNOTE: Amount of engine oil: 25 L

19. Release refrigerant of the air conditioner. (Refer to T5-7 in the separated volume, Technical Manual.)

15. Loosen clamp (1). Disconnect hose (2). IMPORTANT: Do not apply liquid packing onto drain plug (4). 16. Place a container under drain plug (4). Remove drain plug (4). Drain off transmission oil. Install drain plug (4).

20. Remove the cab assembly. (Refer to W3-1-1.)

j : 22 mm m : 80 N·m (59 lbf·ft)

fNOTE: Amount of transmission oil: 30 L (7.9 US gal)

W3-4-1-6

SECTION 3 BODY Group 4 Engine 1

Vehicle Front Side

21. Disconnect hoses (1, 2, 3). j : 17 mm 22. Disconnect hoses (4) (2 used). j : 19 mm

W3-4-1-7

WPD850-03-04-013

SECTION 3 BODY Group 4 Engine

Vehicle Front Side

23. Disconnect hose (1). j : 36 mm 24. Disconnect hose (2). j : 41 mm 25. Disconnect hose (3). j : 27 mm

W3-4-1-8

WPD850-03-04-014

SECTION 3 BODY Group 4 Engine 9

1, 4, 10

3 7 5

6, 8

Vehicle Front Side

WPD850-03-04-015

26. Remove bolts, washers (1) (2 used) and clips (4, 10) (2 used for each). j : 17 mm

28. Place a container under the disconnecting part of suction pipe (7). Loosen clamps (3) (4 used). Disconnect the both ends of the suction pipe (9) assembly.

fNOTE: Clip (10) is used for the machine equipped with the secondary steering device. 27. Disconnect hose (5).

j : 11 mm 29. Remove socket bolts (6) (4 used). Disconnect suction pipe (7). Remove O-ring (8).

j : 36 mm

l : 10 mm 30. Remove hydraulic oil tank (12). (Refer to W3-6-1.)

W3-4-1-9

SECTION 3 BODY Group 4 Engine 1, 2

5, 6, 7 View A 10 3, 4

A WPD850-03-04-016 WPD850-03-04-005

31. Disconnect hose (10).

34. Loosen clamp (1). Disconnect hose (2). j : 7 mm

j : 19 mm 32. Remove bolt, washer (7), clip (5), and collar (6).

35. Disconnect hoses (9) (2 used). j : 41 mm

j : 17 mm 33. Remove bolt, washer (3) and clip (4). j : 19 mm

W3-4-1-10

SECTION 3 BODY Group 4 Engine

2, 3

1 2, 4

WNEK50-03-04-055

WNEK50-03-04-056

36. Remove the aftertreatment device (1) assembly. (Refer to W3-18-1.) 37. Remove bolts, washers (2) (4 used) and clips (3, 4) (2 used for each). j : 17 mm 38. Remove bolt, washer (5), clips (6, 7), and collar (8).

2, 3

j : 17 mm 39. Disconnect connectors (12) (2 used).

2, 4

40. Remove bolt, washer (9), brackets (10) (2 used), and collar (11).

12 5, 6, 7, 8

j : 17 mm 9, 10, 11

W3-4-1-11

WNEK50-03-04-057

SECTION 3 BODY Group 4 Engine

View A

WNEK50-03-04-082

Detail B WNEK50-03-04-058

5, 6

41. Loosen clamps (2) (2 used). Disconnect hoses (1, 3). j : 7 mm 7

42. Remove bolt, washer (5) and clip (6).

WNEK50-03-04-060

j : 17 mm Detail C

43. Loosen clamp (7). Disconnect hose (4). j : 7 mm 44. Loosen clamp (9). Disconnect hose (8). j : 7 mm

8 WNEK50-03-04-061

W3-4-1-12

SECTION 3 BODY Group 4 Engine Detail A 4

6, 7 8 9

10 WNEK50-03-04-063

1, 2, 3

WNEK50-03-04-062

Detail B

45. Loosen clamps (10) (2 used). Disconnect the both ends of hose (11).

j : 11 mm 46. Remove bolts, washers (8) (4 used). Remove plate (6) and rubber plate (7).

j : 17 mm 47. Loosen clamps (4, 9). Disconnect the both ends of hose (5). 16

j : 11 mm 48. Remove bolts, washers (1) (2 used), clips (2) (2 used), and collars (3) (2 used). j : 17 mm

49. Remove bolts, washers (15) (2 used) and clips (16) (2 used). j : 17 mm 50. Loosen clamps (12) (2 used). Disconnect hoses (13, 14). j : 7 mm

W3-4-1-13

13 WNEK50-03-04-064

SECTION 3 BODY Group 4 Engine

Detail A

5 3, 4

WNEK50-03-04-066

WNEK50-03-04-065

Detail B

51. Remove bolt, washer (3) and clip (4).

j : 17 mm 52. Disconnect connector (5). 53. Loosen clamp (1). Disconnect hose (2).

13,14

54. Disconnect connectors (6) (2 used). 55. Remove bolt, washer (13) and the bracket (14) assembly. j : 17 mm 56. Remove bolt, washer (11) and the bracket (12) assembly.

7 11,12

j : 17 mm 9

57. Disconnect hoses (7, 8). 58. Lower lock (9). Disconnect connector (10).

WNEK50-03-04-067

W3-4-1-14

SECTION 3 BODY Group 4 Engine A

7 8

2 18 10

17 4

WNEK50-03-04-069

13, 14, 15, 16

59. Remove bolts, washers (3) (4 used) and plate (4).

Detail A

WNEK50-03-04-070

Detail B

j : 17 mm 60. Remove bolts, washers (1) (2 used). Remove the rubber plate (2) assembly. j : 17 mm 1

61. Remove bolt, washer (13), nut (14), clip (15) and rubber bushing (16). j : 17 mm

WNEK50-03-04-083

WNEK50-03-04-084

62. Loosen clamps (8) (2 used) and clamp (17). Disconnect the both ends of hose (18). 64. Loosen clamp (9). Disconnect hose (10).

j : 11 mm

fNOTE: THREEBOND #1207B has been applied on the

connecting surface of hose (18). 63. Loosen clamps (5, 7). Disconnect the both ends of hose (6).

j : 7 mm 65. Loosen clamp (11). Disconnect hose (12).

j : 11 mm

W3-4-1-15

SECTION 3 BODY Group 4 Engine 1, 2 5, 6, 7

8, 9, 10

3, 4

17, 18

12, 13, 14

15 aa-

Vehicle Front Side

WNEK50-03-04-071

66. Remove clip band (1). Disconnect connectors (2) (2 used). 67. Remove clip band (3). Disconnect connector (4). 68. Remove bolt, washer (8), nut (9), and clip (10). j : 17 mm 69. Remove bolt, washer (5), clip (6), and washer (7). j : 17 mm 70. Remove bolt, washer (12), clip (13), and collar (14). j : 17 mm 71. Disconnect connector (16). Remove connector (17) from bracket (18). 72. Disconnect hose (15). Remove hose (15) from plate (11).

W3-4-1-16

Vehicle Front Side

WNEK50-03-04-072

SECTION 3 BODY Group 4 Engine 1, 2

73. Remove bolt, washer (1) and clip (2). j : 17 mm 74. Remove bolts, washers (3) (4 used). Remove pipe (4). j : 17 mm

W3-4-1-17

WNEK50-03-04-073

SECTION 3 BODY Group 4 Engine a a

4 4

Vehicle Front Side

WNEK50-03-04-074 a-

75. Remove bolts, washers (4) (4 used). Remove the air cleaner (3) assembly. j : 17 mm 76. Remove bolt, washer (1) and the bracket (2) assembly. j : 17 mm 77. Remove bolts, washers (5) (5 used). Remove plates (6, 8) and rubber plate (7). j : 17 mm

W3-4-1-18

Vehicle Front Side

6 WNEK50-03-04-075

SECTION 3 BODY Group 4 Engine 1

2 4

WNEK50-03-04-076

78. Remove bolts, washers (2) (4 used). Remove the plate (1) assembly. j : 17 mm The plate (3) assembly weight: 26 kg dCAUTION: (58 lb) 79. Attach nylon slings onto the plate (3) assembly. Hoist and hold the plate (3) assembly. 80. Remove bolts, washers (4) (5 used). Remove the plate (3) assembly. j : 17 mm

W3-4-1-19

WNEK50-03-04-077

SECTION 3 BODY Group 4 Engine

1, 2

Detail A

11, 12

4, 5

13 WNEK50-03-04-079

9, 10

6, 7 WNEK50-03-04-078

The support (3) assembly weight: 22 dCAUTION: kg (49 lb) 81. Attach the nylon slings onto support (3). Hoist and hold the support (3) assembly. 82. Remove bolts (1, 4) (2 used for each) and washers (2, 5) (2 used for each). Remove the support (3) assembly. j : 24 mm 83. Remove socket bolts (11) (2 used) and washers (12) (2 used). Place fuel pre-filter (13) outside the work area. l : 8 mm

dCAUTION: Support (8) weight: 20 kg (45 lb)

84. Attach the nylon slings onto support (8). Hoist and hold the support. 85. Remove bolts (6, 9) (2 used for each) and washers (7, 10) (2 used for each). Remove support (8). j : 24 mm

W3-4-1-20

SECTION 3 BODY Group 4 Engine

a a

6 a-

Vehicle Front Side

WNEK50-03-04-023

Vehicle Front Side

7 WNEK50-03-04-024

89. Remove bolt, washer (10) and clip (9).

86. Loosen clamp (1). Disconnect hose (2).

j : 17 mm

j : 11 mm

fNOTE: THREEBOND #1207B has been applied on the

90. Loosen clamp (7). Disconnect hose (8).

connecting surface of hose (2). 87. Remove bolt, washer (5) and the bracket (6) assembly.

j : 7 mm

j : 17 mm 88. Loosen clamp (3). Disconnect hose (4). j : 7 mm

W3-4-1-21

SECTION 3 BODY Group 4 Engine Detail A

1, 2, 3

B a-

Vehicle Front Side

8, 9, 10, 11

4, 5, 6, 7

WNEK50-03-04-026

Alternator

Detail B

WNEK50-03-04-025

91. Remove bolt (1) and washer (2). Disconnect ground (3). j : 13 mm

92. Remove covers (4) (2 used), nuts (5) (2 used), and washers (6) (2 used). Disconnect terminals (7) (2 used). j : 8 mm WNEK50-03-04-027

93. Remove cover (8), nut (9), and washer (10). Disconnect terminal (11). j : 13 mm 94. Remove bolts, washers (12) (2 used) and bracket (13) assembly. j : 19 mm

W3-4-1-22

SECTION 3 BODY Group 4 Engine A

View A

1, 2 3

WNEK50-03-04-029 b-

Starter

Detail B a-

B Vehicle Front Side

WNEK50-03-04-028

8, 9

95. Remove clip bands (3) (2 used).

96. Disconnect connector (11). Remove connector (1) from bracket (2). 97. Remove cover (4), nut (5), and washer (6). Disconnect terminal (7). j : 19 mm 98. Remove nut (8) and washer (9). Disconnect ground (10).

4, 5, 6, 7 b-

j : 19 mm

W3-4-1-23

Starter

WNEK50-03-04-030

SECTION 3 BODY Group 4 Engine

2 6

Vehicle Front Side

WNEK50-03-04-031

99. Remove bolts, washers (3) (2 used). Remove cover (4).

101. Loosen adjusting bolt (2) and loosen belt (1). Remove belt (1). j : 14 mm

j : 13 mm 100. Loosen nut (6) of tension pulley (5). j : 14 mm

W3-4-1-24

SECTION 3 BODY Group 4 Engine Detail A

18 2, 3 17 a

15, 16 13

WNEK50-03-04-032

Vehicle Front Side

4, 5, 6

10 9

102. Remove bolt, washer (4), nut (5), and clip (6). j : 17 mm 103. Remove bolt, washer (9), clips (10, 12), and collar (11).

WNEK50-03-04-033

106. Remove bolts (2, 15) (2 used for each) and washers (3, 16) (2 used for each). Remove brackets (7, 17), compressor (8) assembly and collars (1) (4 used). Place the compressor (8) assembly outside of the work area. l : 6 mm

j : 17 mm 104. Remove bolt, washer (13) and the bracket (14) assembly. j : 17 mm 105. Disconnect connector (18).

W3-4-1-25

SECTION 3 BODY Group 4 Engine B

Detail A

11 9

1 6

WNEK50-03-04-035

Detail B

4, 5

3 a-

Vehicle Front Side

2 WNEK50-03-04-034

14 12, 13

107. Loosen clamps (1) (2 used). Disconnect the both ends of hose (2).

WNEK50-03-04-036

j : 11 mm 108. Remove bolt, washer (4). Disconnect ground (5). j : 17 mm 109. Remove bolt, washer (3) and bolts, washers (7) (3 used). Remove the bracket (6) assembly. j : 17 mm 110. Remove clip bands (11) (5 used).

111. Remove socket bolts (10) (2 used) and clip (9). l : 4 mm 112. Disconnect connectors (8, 15). 113. Remove nut (12) and washer (13). Disconnect ground (14). j : 10 mm

W3-4-1-26

SECTION 3 BODY Group 4 Engine Detail A

5 a-

Vehicle Front Side

2 b-

Fan Pump WPD850-03-15-012

114. Disconnect hose (5). j : 27 mm 115. Disconnect hose (2). j : 27 mm 116. Disconnect hose (1). j : 41 mm 117. Loosen clamps (3) (2 used). Disconnect hoses (4) (2 used). j : 7 mm

W3-4-1-27

Fan Pump

WNEK50-03-04-038

SECTION 3 BODY Group 4 Engine 1

Detail A

Detail B

7 9 A

9 6

6 10 B

10 WNEK50-03-04-040

WNEK50-03-04-039 ab-

Lifting Bracket (Engine) Lifting Bracket (Drive Unit)

Mount Bracket of Rear Frame (2)

118. Remove clip bands (1) (2 used). The engine (3) assembly weight: 1260 dCAUTION: kg (2778 lb) 119. Install shackles (4 used) to lifting brackets (a, b) (2 places for each) of engine (3) and drive unit (4). Attach nylon slings onto the shackles (4 used). Hoist and hold the engine (3) assembly. 120. Remove nuts (10) (4 used), washers (6) (4 used), plates (9) (4 used), and rubbers (7, 8) (2 used for each) at the plate (9) side.

121. Remove the engine (3) assembly from rear frame (2). Remove bolts (5) (4 used) and washers (6) (4 used) from the engine (3) assembly. 122. Remove rubbers (7, 8) (2 used for each) from mount brackets (c) (4 places) of rear frame (2).

fNOTE: Rubber (8) is marked with the yellow identification color.

fNOTE: Rubber (7) is marked with the white identification color.

j : 27 mm

fNOTE: Rubber (8) is marked with the yellow identification color.

fNOTE: Rubber (7) is marked with the white identification color.

W3-4-1-28

SECTION 3 BODY Group 4 Engine 3

2 4 1

d c

a ac-

Stand 435 mm

bd-

Stand 575 mm

Place the engine (3) assembly onto dCAUTION: stable stands (a, b) in order not to fall down.

fNOTE: Secure the engine (3) side on stand (b) by using engine mount brackets (rear side) (4) (2 used). 123. Remove pump device (1) from drive unit (2). (Refer to W3-8-1.)

124. Remove drive unit (2) from engine (3). (Refer to W42-1.) 125. Remove the adapters from engine (3) if necessary.

W3-4-1-29

WNEK50-04-02-001

SECTION 3 BODY Group 4 Engine 3

d c

a ac-

Stand 435 mm

bd-

Stand 575 mm

Installation 1. Install all removed adapters to engine (3). 2. Install drive unit (2) to engine (3). (Refer to W4-2-1.) 3. Install pump device (1) to drive unit (2). (Refer to W3-8-1.)

W3-4-1-30

WNEK50-04-02-001

SECTION 3 BODY Group 4 Engine 1

Detail A

Detail B

7 9 A

9 6

6 10 B

10 WNEK50-03-04-040

WNEK50-03-04-039 ab-

Lifting Bracket (Engine) Lifting Bracket (Drive Unit)

Mount Bracket of Rear Frame (2)

The engine (3) assembly weight: 1260 dCAUTION: kg (2778 lb) 4. Install shackles (4 used) to lifting brackets (a, b) (2 places for each) of engine (3) and drive unit (4). Attach nylon slings onto the shackles (4 used). Hoist the engine (3) assembly. 5. Install rubbers (7, 8) (2 used for each) to mount brackets (c) (4 places) of rear frame (2).

fNOTE: Rubber (8) is marked with the yellow identification color.

NOTE: Rubber (7) is marked with the white identification color.

6. Install the engine (3) assembly to mount brackets (c) (4 places) of rear frame (2) with nuts (10) (4 used), plates (9) (4 used), rubbers (7, 8) (2 used for each), washers (6) (8 used) and bolts (5) (4 used). j : 27 mm m : 315 N·m

fNOTE: Rubber (8) is marked with the yellow identification color.

fNOTE: Rubber (7) is marked with the white identification color. 7. Install clip bands (1) (2 used).

W3-4-1-31

SECTION 3 BODY Group 4 Engine Detail A

4 D

4 5

B a-

Vehicle Front Side

Fan Pump

WNEK50-03-04-038

View B

WPD850-03-15-012

View D c

b bd-

25°

8. Connect hoses (4) (2 used) with clamps (3) (2 used). j : 7 mm

30˚

WPD850-03-15-014

IMPORTANT: Check the angle to install hose (2). 10. Connect hose (2). j : 27 mm

m : 4.1 N·m (3 lbf·ft) IMPORTANT: Check the angle to install hose (1). 9. Connect hose (1). j : 41 mm

Fan Pump

WPD850-03-15-015

m : 95 N·m (70 lbf·ft) IMPORTANT: Check the angle to install hose (5). 11. Connect hose (5). j : 27 mm

m : 210 N·m (155 lbf·ft)

m : 95 N·m (70 lbf·ft)

W3-4-1-32

SECTION 3 BODY Group 4 Engine B

Detail A

11 9

10 15 16

1 6

WNEK50-03-04-035

Detail B

4, 5

3 a-

Vehicle Front Side

2 WNEK50-03-04-034

12, 13

12. Connect ground (14) with washer (13) and nut (12). WNEK50-03-04-036

j : 10 mm m : 3 to 4 N·m (2.2 to 3 lbf·ft) 17. Connect ground (5) with bolt, washer (4).

13. Connect connectors (8, 16).

j : 17 mm

14. Secure harness (15) with clip (9) and socket bolts (10) (2 used).

m : 50 N·m (37 lbf·ft)

j : 4 mm

18. Connect the both ends of hose (2) with clamps (1) (2 used).

m : 9 N·m (6.6 lbf·ft) 15. Install clip bands (11) (5 used).

j : 11 mm

16. Install the bracket (6) assembly with bolt, washer (3) and bolts, washers (7) (3 used).

m : 12 N·m (8.9 lbf·ft)

j : 17 mm m : 50 N·m (37 lbf·ft)

W3-4-1-33

SECTION 3 BODY Group 4 Engine Detail A

18 2, 3 17 a

19 15, 16 13, 14

WNEK50-03-04-032

Vehicle Front Side

4, 5, 6

10 21

19. Install collars (1) (4 used), compressor (8) assembly and brackets (7, 17) with washers (3, 16) (2 used for each) and socket bolts (2, 15) (2 used for each).

20 14 8

WNEK50-03-04-033

22. Secure harness (20) and hose (21) with collar (11), clips (10, 12), and bolt, washer (9). j : 17 mm

l : 6 mm

m : 50 N·m (37 lbf·ft)

m : 24.5 to 29.4 N·m (18 to 22 lbf·ft)

23. Secure hose (19) with clip (6), nut (5) and bolt, washer (4).

20. Connect connector (18). 21. Secure harness (20) with the bracket (14) assembly and bolt, washer (13).

j : 17 mm m : 50 N·m (37 lbf·ft)

W3-4-1-34

SECTION 3 BODY Group 4 Engine

1 b

a c

WNEK50-03-04-042

6 mm (0.2 in), 98 N (72 lbf )

cd-

Compressor Pulley Fan Pulley

5 a-

WNEK50-03-04-031

Vehicle Front Side

24. Install belt (1). Adjust the belt (1) tension correctly by moving tension pulley (5) by using adjusting bolt (2).

26. Install cover (4) with bolts, washers (3) (2 used). j : 13 mm m : 10 N·m (7.4 lbf·ft)

j : 14 mm 25. Tighten nut (6) of tension pulley (5). j : 14 mm m : 32 to 46 N·m (23.5 to 34 lbf·ft) IMPORTANT: The belt does not fit when replacing with a new one. Therefore, adjust the belt tension again after running the engine at slow idle for 3 to 5 minutes.

W3-4-1-35

SECTION 3 BODY Group 4 Engine A

View A

11 1, 2

WNEK50-03-04-029 b-

Starter

Detail B a-

B Vehicle Front Side

WNEK50-03-04-028

8, 9

27. Connect ground (10) with washer (9) and nut (8). j : 19 mm m : 35 N·m (26 lbf·ft) 28. Connect terminal (7) with washer (6) and nut (5). Install cover (4).

4, 5, 6, 7 b-

Starter

j : 19 mm m : 35 N·m (26 lbf·ft) 29. Install connector (1) to bracket (2). Connect connector (11).

30. Install clip bands (3) (2 used).

W3-4-1-36

WNEK50-03-04-030

SECTION 3 BODY Group 4 Engine Detail A

1, 2, 3

B a-

Vehicle Front Side

8, 9, 10, 11

4, 5, 6, 7

WNEK50-03-04-026

Alternator

Detail B

WNEK50-03-04-025

31. Install the bracket (13) assembly with bolts, washers (12) (2 used). j : 19 mm

m : 90 N·m (66 lbf·ft) 32. Connect terminal (11) with washer (10) and nut (9). Install cover (8). j : 13 mm

WNEK50-03-04-027

m : 10 N·m (7.4 lbf·ft) 33. Connect terminals (7) (2 used) with washers (6) (2 used) and nuts (5) (2 used). Install covers (4) (2 used).

34. Connect ground (3) with washer (2) and bolt (1).

j : 8 mm

j : 13 mm

m : 2.5 N·m (1.8 lbf·ft)

m : 10 N·m (7.4 lbf·ft)

W3-4-1-37

SECTION 3 BODY Group 4 Engine

a a

6 a-

Vehicle Front Side

WNEK50-03-04-023

Vehicle Front Side

7 WNEK50-03-04-024

38. Secure hose (4) and harness (11) with the bracket (6) assembly and bolt, washer (5).

35. Connect hose (8) with clamp (7). j : 7 mm

j : 17 mm

m : 5.4 N·m (4 lbf·ft) 36. Secure hose (8) with clip (9) and bolt, washer (10). j : 17 mm m : 50 N·m (37 lbf·ft) 37. Connect hose (4) with clamp (3). j : 7 mm m : 5.4 N·m (4 lbf·ft)

W3-4-1-38

m : 50 N·m (37 lbf·ft)

SECTION 3 BODY Group 4 Engine b

Detail A

1 a

2 WNEJ-03-04-006 c-

A WNEK50-03-04-023 a-

Vehicle Front Side

Engine

IMPORTANT: Do not apply THREEBOND #1207B onto the parts except hose (2) connecting part (c) of engine (b). 39. Apply THREEBOND #1207B onto hose (2) connecting part (c) of engine (b). Connect hose (2) with clamp (1).

W3-4-1-39

Hose (2) Connecting Part of Engine (b)

SECTION 3 BODY Group 4 Engine

1, 2

Detail A

11, 12

4, 5

13 WNEK50-03-04-079

9, 10

6, 7 WNEK50-03-04-078

dCAUTION: Support (8) weight: 20 kg (45 lb)

The support (3) assembly weight: 22 dCAUTION: kg (49 lb)

40. Attach the nylon slings onto support (8). Hoist support (8). 41. Install support (8) with washers (7, 10) (2 used for each) and bolts (6, 9) (2 used for each). j : 24 mm

43. Attach nylon slings onto the support (3) assembly. Hoist the support (3) assembly. 44. Install the support (3) assembly with washers (2, 5) (2 used for each) and bolts (1, 4) (2 used for each). j : 24 mm

m : 210 N·m (155 lbf·ft) 42. Install fuel pre-filter (13) with washers (12) (2 used) and socket bolts (11) (2 used). l : 8 mm m : 50 N·m (37 lbf·ft)

W3-4-1-40

m : 210 N·m (155 lbf·ft)

SECTION 3 BODY Group 4 Engine 3

2 4

WNEK50-03-04-077

The plate (3) assembly weight: 26 kg dCAUTION: (58 lb) 45. Attach nylon slings onto the plate (3) assembly. Hoist the plate (3) assembly. 46. Install the plate (3) assembly with bolts, washers (4) (5 used). j : 17 mm m : 50 N·m (37 lbf·ft) 47. Install the plate (1) assembly with bolts, washers (2) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-4-1-41

WNEK50-03-04-076

SECTION 3 BODY Group 4 Engine a a

4 4

Vehicle Front Side

WNEK50-03-04-074 a-

48. Install rubber plate (7) and plates (6, 8) with bolts, washers (5) (5 used). j : 17 mm m : 50 N·m (37 lbf·ft) 49. Install the bracket (2) assembly with bolt, washer (1). j : 17 mm m : 50 N·m (37 lbf·ft) 50. Install the air cleaner (3) assembly with bolts, washers (4) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-4-1-42

Vehicle Front Side

6 WNEK50-03-04-075

SECTION 3 BODY Group 4 Engine 1, 2

51. Install pipe (4) with bolts, washers (3) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft) 52. Install clip (2) with bolt, washer (1). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-4-1-43

WNEK50-03-04-073

SECTION 3 BODY Group 4 Engine 1, 2

Detail A a

5, 6, 7

8, 9, 10

17, 18 3, 4 12, 13, 14 16 15 aWNEK50-03-04-071

53. Pass hose (15) to plate (11). Connect hose (15). 54. Install connector (17) to bracket (18). Connect connector (16). 55. Install collar (14) and clip (13) with bolt, washer (12). j : 17 mm m : 50 N·m (37 lbf·ft) 56. Install washer (7) and clip (6) with bolt, washer (5). j : 17 mm m : 50 N·m (37 lbf·ft) 57. Install clip (10) with nut (9) and bolt, washer (8). j : 17 mm m : 50 N·m (37 lbf·ft) 58. Connect connector (4). Install clip band (3). 59. Connect connectors (2) (2 used). Install clip band (1).

W3-4-1-44

Vehicle Front Side

WNEK50-03-04-072

SECTION 3 BODY Group 4 Engine a

Detail A c

A f

WNEK50-03-04-080 c-

Pipe

60 mm (2.4 in.)

Detail B e

WNEK50-03-04-070 ab-

Marking (Circle) Marking (Line)

cf-

Pipe Intercooler WNEK50-03-04-081 e-

IMPORTANT: Check the direction to connect and installation overlap width of hose (2). 60. Connect both ends of hose (2) with clamps (1, 3). j : 11 mm m : 12 N·m (8.9 lbf·ft)

W3-4-1-45

65 mm (2.6 in.) (Reference)

Intercooler

SECTION 3 BODY Group 4 Engine Detail A c

7 1

8 7 A b

WNEK50-03-05-026 c-

Hose (7) Connection Part of Radiator (a)

6 Detail B WNEK50-03-04-070

2, 3, 4, 5 a-

Radiator

Engine

IMPORTANT: Do not apply THREEBOND #1207B onto the parts except hose (7) connecting part (c) of radiator (a) and hose (7) connecting part (d) of engine (b). IMPORTANT: Install hose (7) until it contacts with radiator (a). 61. Apply THREEBOND #1207B onto hose (7) connecting part (c) of radiator (a) and hose (7) connecting part (d) of engine (b). Pass hose (7) to support (8). Temporary install the both ends of hose (7) with clamps (1) (2 used) and clamp (6). 62. Secure hose (7) with rubber bushing (5), clip (4), nut (3) and bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft) 63. Tighten clamps (1) (2 used) and clamp (6). j : 7 mm m : 7.1 N·m (5 lbf·ft)

W3-4-1-46

d b

WNEK50-03-04-054 d-

Hose (7) Connecting Part of Engine (b)

SECTION 3 BODY Group 4 Engine

64. Connect hose (2) with clamp (1). j : 7 mm m : 3.4±0.3 N·m (2.5±0.2 lbf·ft) 65. Connect hose (4) with clamp (3).

W3-4-1-47

WNEK50-03-04-070

SECTION 3 BODY Group 4 Engine

Detail A

5 3, 4

WNEK50-03-04-066

WNEK50-03-04-065

66. Connect connector (10). Raise lock (9) to lock. Detail B

67. Connect hoses (7, 8).

68. Install the bracket (12) assembly with bolt, washer (11). 13,14

j : 17 mm m : 50 N·m (37 lbf·ft) 69. Install the bracket (14) assembly with bolt, washer (13). j : 17 mm

7 11,12

m : 50 N·m (37 lbf·ft) 70. Connect connectors (6) (2 used).

71. Connect hose (2) with clamp (1).

72. Connect connector (5).

WNEK50-03-04-068

73. Install clip (4) with bolt, washer (3). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-4-1-48

SECTION 3 BODY Group 4 Engine Detail A 4

6, 7 8 9

a B

10 WNEK50-03-04-063

1, 2, 3

WNEK50-03-04-062

Marking

74. Connect hoses (13, 14) with clamps (12) (2 used). Detail B

j : 7 mm 16

m : 4.5 N·m (3.3 lbf·ft) 75. Install clips (16) (2 used) with bolts, washers (15) (2 used). j : 17 mm

m : 50 N·m (37 lbf·ft) 76. Install collars (3) (2 used) and clips (2) (2 used) with bolts, washers (1) (2 used). 16

77. Connect hose (5) with clamps (4, 9). j : 11 mm m : 12 N·m (8.9 lbf·ft) 78. Install rubber plate (7) and plate (6) with bolts, washers (8) (4 used).

13 WNEK50-03-04-064

j : 17 mm m : 50 N·m (37 lbf·ft) IMPORTANT: Check the direction to install hose (11). 79. Connect the both ends of hose (11) with clamps (10) (2 used). j : 11 mm m : 12 N·m (8.9 lbf·ft)

W3-4-1-49

SECTION 3 BODY Group 4 Engine

Detail A

WNEK50-03-04-082

Detail B WNEK50-03-04-058

5, 6

80. Connect hose (8) with clamp (9). j : 7 mm m : 4.1 N·m (3 lbf·ft) 81. Connect hose (4) with clamp (7). j : 7 mm

m : 4.1 N·m (3 lbf·ft)

WNEK50-03-04-060

82. Install clip (6) with bolt, washer (5).

Detail C

j : 17 mm m : 50 N·m (37 lbf·ft) 83. Connect hoses (1, 3) with clamps (2) (2 used). j : 7 mm m : 4.1 N·m (3 lbf·ft) 9

8 WNEK50-03-04-061

W3-4-1-50

SECTION 3 BODY Group 4 Engine

2, 3

2, 4 12 5, 6, 7, 8

9, 10, 11

2, 4

WNEK50-03-04-057

WNEK50-03-04-056

84. Install collar (11) and bracket (10) with bolt, washer (9). j : 17 mm m : 50 N·m (37 lbf·ft) 85. Connect connectors (12) (2 used). 86. Install collar (8) and clips (6, 7) with bolt, washer (5). j : 17 mm m : 50 N·m (37 lbf·ft) 87. Install the clips (3, 4) (2 used for each) with the bolts, washers (2) (4 used).

j : 17 mm m : 50 N·m (37 lbf·ft) 88. Install the aftertreatment device (1) assembly. (Refer to W3-18-1.)

W3-4-1-51

WNEK50-03-04-055

SECTION 3 BODY Group 4 Engine 1, 2

5, 6, 7

View A 10 3, 4

A WPD850-03-04-016

IMPORTANT: Check the angle to install hoses (9) (2 used). 89. Connect hoses (9) (2 used).

WPD850-03-04-005

View B

j : 41 mm

m : 110 N·m (81 lbf·ft) 90. Connect hose (2) with clamp (1). j : 7 mm

10˚

WNEK50-03-04-043

m : 4.1 N·m (3 lbf·ft) 91. Secure hose (2) with collar (6), clip (5), and bolt, washer (7).

View C

j : 17 mm m : 46 N·m (34 lbf·ft) 92. Secure hose (2) with clip (4) and bolt, washer (3). j : 19 mm m : 35 N·m (26 lbf·ft) b

93. Connect hose (10). j : 19 mm m : 30 N·m (22 lbf·ft) b-

30˚ WPD850-03-04-009

W3-4-1-52

SECTION 3 BODY Group 4 Engine 9

1, 4, 10

View A

3 7 5

40˚

WPD850-03-04-010

6, 8

a a-

WPD850-03-04-015

Vehicle Front Side

94. Install hydraulic oil tank (12). (Refer to W3-6-1.) 95. Install O-ring (8). Install suction pipe (7) with socket bolts (6) (4 used).

IMPORTANT: Check the angle to install hose (5). 97. Connect hose (5). j : 36 mm

j : 10 mm m : 90 N·m (66 lbf·ft) 96. Connect the both ends of the suction pipe (9) assembly with clamps (3) (4 used).

m : 180 N·m (133 lbf·ft) 98. Secure hoses (2, 5) with bolts, washers (1) (2 used) and clips (4, 10) (2 used for each). j : 17 mm

j : 11 mm m : 10 N·m (7.4 lbf·ft)

m : 50 N·m (37 lbf·ft)

fNOTE: Hose (2) and clips (10) are used for the machine with secondary steering device.

W3-4-1-53

SECTION 3 BODY Group 4 Engine

View A

1 b-

20°

a A

3 a-

WPD850-03-04-014

Vehicle Front Side

IMPORTANT: Check the angle to install hose (1). 99. Connect hose (1).

101. Connect hose (2). j : 41 mm

j : 36 mm

m : 210 N·m (155 lbf·ft)

m : 93 N·m (69 lbf·ft) 100. Connect hose (3). j : 27 mm m : 95 N·m (70 lbf·ft)

W3-4-1-54

WNEK50-03-08-006

SECTION 3 BODY Group 4 Engine 1

View A

B c

2 b-

30°

25°

WPD850-03-04-011

View B 3

Vehicle Front Side

WPD850-03-04-013

102. Connect hoses (4) (2 used). j : 19 mm m : 30 N·m (22 lbf·ft) IMPORTANT: Check the angle to install hoses (1, 2, 3). 103. Connect hoses (1, 2, 3). j : 17 mm m : 25 N·m (18.5 lbf·ft)

W3-4-1-55

50°

WPD850-03-04-012

SECTION 3 BODY Group 4 Engine

5 b

1 WNEK50-03-04-001

WNEK50-03-04-002 a-

Vehicle Front Side

Fuel Tank

104. Install the cab assembly. (Refer to W3-1-1.) 105. Install propeller shafts (5, 9) to drive unit (8). (Refer to W4-4-1.) 106. Connect the both ends of hose (7) with clamps (6) (2 used). j : 7 mm m : 5.4 N·m (4 lbf·ft) 107. Connect hose (2) with clamp (1). m : 3 N·m (2.2 lbf·ft) 108. Add engine oil to the engine.

fNOTE: Amount of engine oil: 25 L (6.6 US gal)

11 WNEK50-03-11-012

109. Add coolant to the radiator.

fNOTE: Amount of coolant: 33 L (8.7 US gal) 110. Open cap (11). Add transmission oil to drive unit (8).

fNOTE: Amount of transmission oil: 30 L (7.9 US gal)

W3-4-1-56

SECTION 3 BODY Group 4 Engine

3, 4

2 WNEK50-03-22-009

111. Install engine cover (1). (Refer to W3-22-1.) 112. Fill hydraulic oil tank (2) with hydraulic oil.

fNOTE: Total oil amount of hydraulic oil tank (2): 140 L (37 US gal) 113. Install O-ring (4).

114. Install the cover (3) assembly with bolts, washers (5) (6 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-4-1-57

WNEK50-03-06-001

SECTION 3 BODY Group 4 Engine

2 Detail A

3 5, 6

Battery Box

WNEK50-03-01-001

 Without battery disconnect switch (Step 115 to step 118) 115. Connect ground (7). Tighten bolt (8). j : 17 mm m : 50 N·m (37 lbf·ft) 116. Secure ground (7) with clip (6) and bolt, washer (5). j : 17 mm m : 50 N·m (37 lbf·ft) 117. Install rubber plate (4) with bolt, washer (1). j : 17 mm m : 50 N·m (37 lbf·ft) 118. Close covers (2, 3).

W3-4-1-58

WNEK50-03-01-002

SECTION 3 BODY Group 4 Engine

Detail A

1 A

Battery Box

WNEK50-03-17-001

b c bc-

 With battery disconnect switch (Step 119 to step 120) 119. Set battery disconnect switch (2) to ON position (c). 120. Close cover (1).

W3-4-1-59

OFF Position ON Position

WNEK50-03-22-043

SECTION 3 BODY Group 4 Engine A

2 Detail A

Detail B

WNEK50-03-04-083

WNEK50-03-04-084

WNEK50-03-04-085

121. Fill refrigerant in the air conditioner. (Refer to T5-7 in the separated volume, Technical Manual.)

124. Operate the steering wheel to the stroke end several times and bleed air from the circuit.

122. Bleed air from the fuel system. (Refer to W1-4-1.)

125. Bleed air from the brake (axle). (Refer to W1-4-1.)

123. Bleed air from the hydraulic system. (Refer to W1-41.)

126. Install the rubber plate (2) assembly with bolts, washers (3) (2 used).

IMPORTANT: Check the hydraulic oil level, transmission oil level, coolant level, and engine oil level. Start the engine and check for any oil or water leaks. IMPORTANT: Warm up the engine. Warm up the engine and increase the SCR exhaust temperature over 190 °C (374 °F). Check the DEF hose for DEF leaks.

j : 17 mm m : 50 N·m (37 lbf·ft) 127. Install plate (4) with bolts, washers (1) (4 used).

W3-4-1-60

j : 17 mm m : 50 N·m (37 lbf·ft)

SECTION 3 BODY Group 4 Engine 10

11 12

2 WPD850-03-01-003

128. Install the following parts. (Refer to W3-22-1.)  Under Guard Rear (8) (Only for the machine with under guard)

WNEK50-03-22-003

129. Install following exterior components to left and right side. (Refer to W3-22-1.)  Lower Cover (2)

 Inspection Cover (4, 9)

 Rear Fender (Front) (3)

 Deck (6)

 Step (5)

 Cab Under Cover (7)

 Rear Fender (rear) (10) (only for the machine with rear fender)

 Rear Cover (12)  Rear Grill (13)

W3-4-1-61

SECTION 3 BODY Group 4 Engine (Blank)

W3-4-1-62

SECTION 3 BODY Group 5 Radiator Assembly Removal and Installation of Radiator Assembly

2, 3

1 WNEK50-03-06-001

Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious

Release any pressure from hydraulic dCAUTION: oil tank (1). (Refer to W1-5-1.)

injury. Release the pressure before disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns. Allow oil to cool before starting any work. IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

2. Remove bolts, washers (4) (6 used). Remove the cover (2) assembly and O-ring (3). j : 17 mm 3. Place a container. Remove hydraulic oil using an oil supply pump.

fNOTE: Total amount of hydraulic oil tank (1): 171 L

fNOTE: When disassembling or assembling the radiator assembly, disassemble or assemble the radiator, intercooler, and torque converter oil cooler respectively.

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.)

W3-5-1-1

(45.2 US gal)

SECTION 3 BODY Group 5 Radiator Assembly

3 5

WNEK50-03-19-003

4. Release any pressure in the the expansion tank. (Refer to W1-5-1.) 5. Open left and right side cover (3). 6. Place a container under hose (5). Loosen cock (4). Drain off coolant. Close cock (4).

fNOTE: Amount of coolant: 33 L (8.7 US gal) 7. Remove cover (1) and left and right covers (2). (Refer to W3-22-1.)

W3-5-1-2

WNEK50-03-19-010

SECTION 3 BODY Group 5 Radiator Assembly

Detail A

7 4

5 9 6

WNEK50-03-05-002

WNEK50-03-05-001

11. Remove bolt, washer (9) and clips (7, 8).

8. Remove bolts, washers (1) (4 used) and plate (2).

j : 17 mm

j : 17 mm 9. Remove bolts, washers (4) (2 used). Remove the rubber plate (3) assembly. j : 17 mm 10. Remove bolts, washers (5) (2 used). Remove bracket (6). j : 17 mm

W3-5-1-3

SECTION 3 BODY Group 5 Radiator Assembly View A A

2, 3

9, 10

7, 8

WNEK50-03-05-003

4, 5, 6

WNEK50-03-05-004

View B 1

12. Loosen clamp (7). Disconnect hose (8). j : 7 mm 13. Loosen clamp (2). Disconnect hose (3). 14. Loosen clamp (9). Disconnect hose (10).

j : 7 mm 15. Remove bolt, washer (6), clip (5), and washer (4).

j : 17 mm

14, 15

WNEK50-03-05-005

16. Remove bolt, washer (14) and clip (15). j : 17 mm

17. Disconnect connector (11). 18. Loosen clamp (12). Disconnect hose (13). 19. Remove bolts, washers (16) (4 used). Remove the expansion tank (1) assembly. j : 17 mm

W3-5-1-4

SECTION 3 BODY Group 5 Radiator Assembly 1

20. Loosen clamps (4, 6). Disconnect the both ends of hose (5). j : 11 mm 21. Disconnect hose (3). j : 36 mm 22. Loosen clamps (1) (2 used). Disconnect hose (2). j : 7 mm

fNOTE: THREEBOND #1207B has been applied to the outer surface of hose (2) connection part.

W3-5-1-5

WNEK50-03-05-006

SECTION 3 BODY Group 5 Radiator Assembly

View A

4 6

2 WNEK50-03-05-031

WNEK50-03-05-007

23. Disconnect connectors (1) (2 used). 24. Disconnect connector (5). 25. Loosen clamp (7). Disconnect hose (6). j : 11 mm 26. Loosen clamp (3). j : 7 mm 27. Remove bolts, washers (2) (4 used). Remove air cleaner (4) assembly. j : 19mm

W3-5-1-6

SECTION 3 BODY Group 5 Radiator Assembly View A

7 4

2 4 2

WNEK50-03-05-008

28. Remove bolts, washers (2) (4 used). Remove bracket (7).

WNEK50-03-05-009

31. Remove the adapters from torque converter cooler (1) if necessary.

j : 17 mm 29. Disconnect hoses (3, 6). j : 41 mm 30. Remove bolts, washers (4) (4 used). Remove torque converter cooler (1) from frame (5). j : 17 mm

W3-5-1-7

SECTION 3 BODY Group 5 Radiator Assembly A

View A

5 5

2 4

WNEK50-03-05-010

32. Remove bolts, washers (4) (2 used). Remove bracket (1).

WNEK50-03-05-011

Detail B 6

7, 8

j : 17 mm 33. Remove bolt, washer (7) and clip (8). j : 17 mm 34. Disconnect connector (6). IMPORTANT: When disassembling or assembling the condenser (2) assembly, be sure not to damage the core and hoses. 35. Remove bolts, washers (3) (4 used). Remove the condenser (2) assembly from frame (5) and place it outside of the working area. j : 17 mm

W3-5-1-8

WNEK50-03-05-012

SECTION 3 BODY Group 5 Radiator Assembly

3, 4

36. Loosen clamp (1). Disconnect hose (2). 37. Loosen clamp (3). Disconnect hose (4). 38. Loosen clamps (6) (2 used). Disconnect hose (5). j : 7 mm

fNOTE: THREEBOND #1207B has been applied to the outer surface of radiator (7) connection part.

W3-5-1-9

1, 2

WNEK50-03-05-013

SECTION 3 BODY Group 5 Radiator Assembly Detail A

4 WNEK50-03-05-015

Vehicle Front Side

4 2 A a-

Intercooler

3 b-

WNEK50-03-05-014

Engine

43. Disconnect hose (1).

39. Disconnect connector (6). 40. Remove bolts, washers (5) (2 used).

j : 36 mm

j : 17 mm 41. Loosen clamp (2). Disconnect the engine (b) side of the pipe (3) assembly. j : 11 mm 42. Loosen clamp (4). Disconnect the intercooler (a) side of the pipe (3) assembly. j : 11 mm

W3-5-1-10

SECTION 3 BODY Group 5 Radiator Assembly Installation of radiator (1)

3 4

5 WNEK50-03-05-016

44. Remove bolts (2) (2 used) and washers (3) (2 used). Remove radiator (1) and collars (6) (2 used) from frame (7). 7

j : 12 mm 45. Remove rubber plates (8) (2 used) from radiator (1).

fNOTE: Rubber plates (8) may be remaining in the frame (7) side. 46. Remove rubber plates (4) (2 used) and tubes (5) (2 used) from frame (7).

1 8

W3-5-1-11

WNEK50-03-05-017

SECTION 3 BODY Group 5 Radiator Assembly Installation of oil cooler (1)

5 WNEK50-03-05-018

47. Remove bolts, washers (2) (2 used). Remove oil cooler (1) from frame (3). j : 17 mm 48. Remove rubber seals (4) (4 used) and rubber seals (5) (2 used) from oil cooler (1). 49. Remove the adapters from oil cooler (1) if necessary.

4 1 WNEK50-03-05-019

W3-5-1-12

SECTION 3 BODY Group 5 Radiator Assembly Installation of intercooler (1)

6 5 1

WNEK50-03-05-020

7 WNEK50-03-05-021

50. Remove bolt (2) and washer (3). Remove intercooler (1) from frame (6).

52. Remove rubber plate (4) and tube (5) from frame (6).

j : 12 mm 51. Remove rubber plate (7) from intercooler.

fNOTE: Rubber plate (7) may be remaining in the frame (6) side.

W3-5-1-13

SECTION 3 BODY Group 5 Radiator Assembly Installation of intercooler (1)

6 5 1

WNEK50-03-05-020

Installation 1. Install rubber plate (4) and tube (5) to frame (6). 2. Install rubber plate (7) to intercooler (1). 3. Install intercooler (1) to frame (6) with washer (3) and bolt (2). j : 12 mm

7 WNEK50-03-05-021

m : 17.6 N·m (13 lbf·ft)

W3-5-1-14

SECTION 3 BODY Group 5 Radiator Assembly Installation of oil cooler (1)

5 WNEK50-03-05-018

4. Install all removed adapters to oil cooler (1). IMPORTANT: Check the direction to install rubber seals (4) (4 used) and rubber seals (5) (2 used). 5. Install rubber seals (4) (4 used) and rubber seals (5) (2 used) to oil cooler (1).

6. Install oil cooler (1) to frame (3) with bolts, washers (2) (2 used).

WNEK50-03-05-019

j : 17 mm m : 36.2 N·m (26.5 lbf·ft)

View A

1 5

W3-5-1-15

39 mm (1.5 in)

WNEK50-03-05-022

Align the ends

SECTION 3 BODY Group 5 Radiator Assembly Installation of radiator (1)

3 4

5 WNEK50-03-05-016

IMPORTANT: Check the direction to install tubes (5) (2 used). 7. Install rubber plates (4) (2 used) and tubes (5) (2 used) to frame (7).

8. Install rubber plates (8) (2 used) to radiator (1). IMPORTANT: Check the direction to install collars (6) (2 used). 9. Install radiator (1) and collars (6) (2 used) to frame (7) with washers (3) (2 used) and bolts (2) (2 used). 1

j : 12 mm

WNEK50-03-05-017

m : 17.6 N·m (13 lbf·ft)

View A

W3-5-1-16

WNEK50-03-05-023

SECTION 3 BODY Group 5 Radiator Assembly View A

1 a

1 a-

WNEK50-03-05-014

IMPORTANT: Check the connection angle of hose (1). 10. Connect hose (1). j : 36 mm m : 180 N·m (133 lbf·ft)

W3-5-1-17

30°

WNEK50-03-05-024

SECTION 3 BODY Group 5 Radiator Assembly Detail A

WNEK50-03-05-015 c-

Vehicle Front Side

4 2 A a-

Intercooler

3 b-

Detail B WNEK50-03-05-014

Engine

IMPORTANT: Check the installation overlap width of the pipe (3) assembly. 11. Temporally secure the pipe (3) assembly and clamps (2, 4) with bolts, washers (5) (2 used). 12. Tighten clamps (2, 4).

d a-

j : 11 mm m : 12 N·m (8.9 lbf·ft) 13. Tighten bolts, washers (5) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 14. Connect the connector (6).

W3-5-1-18

Intercooler

WNEK50-03-05-025

65 mm (2.6 in)

SECTION 3 BODY Group 5 Radiator Assembly Detail A

5 b

6 a b-

A a-

3, 4

Radiator

Hose (5) Connection Part of Radiator (a)

1, 2 WNEK50-03-05-013

IMPORTANT: Install hose (5) until it contacts with radiator (a). IMPORTANT: Be sure to apply THREEBOND #1207B only on the hose (5) connection part (b) of radiator (a). 15. Apply THREEBOND #1207B on the hose (5) connection part (b) of radiator (a). Connect hose (5) with clamps (6) (2 used).

16. Connect hose (4) with clamp (3). 17. Connect hose (2) with clamp (1).

j : 7 mm m : 7.1±0.7 N·m (5.2±0.5 lbf·ft)

W3-5-1-19

WNEK50-03-05-026

SECTION 3 BODY Group 5 Radiator Assembly A

View A

5 5

2 4

WNEK50-03-05-010

WNEK50-03-05-011

Detail B 6

IMPORTANT: When disassembling or assembling the condenser (2) assembly, be sure not to damage the core and hoses. 18. Install the condenser (2) assembly to frame (5) with bolts, washers (3) (4 used).

7, 8

j : 17 mm m : 50 N·m (37 lbf·ft) 19. Connect the connector (6). 9

20. Secure harness (9) with bolt, washer (7) and clip (8).

WNEK50-03-05-012

j : 17 mm m : 50 N·m (37 lbf·ft) 21. Install bracket (1) with bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-5-1-20

SECTION 3 BODY Group 5 Radiator Assembly View A

7 4

2 4 2

WNEK50-03-05-008

WNEK50-03-05-009

25. Install bracket (7) with bolts, washers (2) (4 used).

22. Install all removed adapters to torque converter cooler (1). 23. Install torque converter cooler (1) to frame (5) with bolts, washers (4) (4 used). j : 17 mm m : 36.2 N·m (26.5 lbf·ft) 24. Connect hoses (3, 6). j : 41 mm m : 110 N·m (81 lbf·ft)

W3-5-1-21

j : 17 mm m : 50 N·m (37 lbf·ft)

SECTION 3 BODY Group 5 Radiator Assembly

View A

4 6

2 WNEK50-03-05-031

WNEK50-03-05-007

26. Install the air cleaner (4) assembly with bolts, washers (2) (4 used).

29. Connect the connector (5). 30. Connect connectors (1) (2 used).

j : 19 mm m : 90 N·m (66 lbf·ft) 27. Tighten clamp (3). j : 7 mm m : 4 N·m (3 lbf·ft) 28. Connect hose (6) with clamp (7). j : 11 mm m : 12 N·m (8.9 lbf·ft)

W3-5-1-22

SECTION 3 BODY Group 5 Radiator Assembly 1

Detail A B

b a

2 b-

Hose (2) Connection Part of Radiator (a)

WNEK50-03-05-027

View B

Radiator

WNEK50-03-05-006

IMPORTANT: Install hose (2) until it contacts with radiator (a). IMPORTANT: Be sure to apply THREEBOND #1207B only on the hose (2) connection part (b) of radiator (a). 31. Apply THREEBOND #1207B on the hose (2) connection part (b) of radiator (a). Connect hose (2) with clamps (1) (2 used).

40°

WNEK50-03-05-028

IMPORTANT: Check the connection angle of hose (3). 32. Connect hose (3).

j : 7 mm

j : 36 mm m : 180 N·m (133 lbf·ft)

m : 7.1±0.7 N·m (5.2±0.5 lbf·ft)

W3-5-1-23

SECTION 3 BODY Group 5 Radiator Assembly a

Detail A e

WNEK50-03-05-029

60 mm

Detail B c

WNEK50-03-05-006

B ab-

Marking (Circle) Pipe

cd-

Intercooler Marking (Line)

IMPORTANT: Check the direction to connect and installation overlap width of hose (5). 33. Connect both ends of hose (5) with clamps (4, 6). j : 11 mm m : 12 N·m (8.9 lbf·ft)

W3-5-1-24

65 mm (2.6 in) (just for reference)

WNEK50-03-05-030

SECTION 3 BODY Group 5 Radiator Assembly View A A

2, 3

9, 10

18 7, 8

WNEK50-03-05-003

4, 5, 6

WNEK50-03-05-004

View B 1

34. Install the expansion tank (1) assembly with bolts, washers (16) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

35. Connect hose (13) with clamp (12). 36. Connect connector (11). 13

37. Secure harness (17) with bolt, washer (14) and clip (15).

14, 15

j : 17 mm 39. Connect hose (10) with clamp (9).

m : 50 N·m (37 lbf·ft) 38. Secure hose (18) with bolt, washer (6), clip (5) and washer (4).

j : 7 mm m : 3.4±0.3 N·m (2.5±0.2 lbf·ft)

j : 17 mm m : 50 N·m (37 lbf·ft)

40. Connect hose (3) with clamp (2). 41. Connect hose (8) with clamp (7). j : 7 mm m : 3.4±0.3 N·m (2.5±0.2 lbf·ft)

W3-5-1-25

WNEK50-03-05-005

SECTION 3 BODY Group 5 Radiator Assembly 10

Detail A

WNEK50-03-05-001

IMPORTANT: Check the angle to install clip (7). 42. Secure hoses (10, 11) with bolts, washers (9) and clips (7, 8). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-5-1-26

30°

WNEK50-03-05-002

SECTION 3 BODY Group 5 Radiator Assembly

2, 3

1 WNEK50-03-06-001

43. Add coolant to the radiator.

fNOTE: Amount of coolant: 33 L (8.7 US gal)

47. Install the cover (2) assembly with bolts, washers (4) (6 used).

44. Refill transmission oil in the transmission.

j : 17 mm

fNOTE: Transmission oil amount: 40 L (10.6 US gal)

m : 50 N·m (37 lbf·ft)

45. Fill hydraulic oil tank (1) with hydraulic oil.

fNOTE: Total amount of hydraulic oil tank (1): 171 L (45.2 US gal) 46. Install O-ring (3).

48. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level, transmission oil level and coolant level. Start the engine and check for any oil or water leaks.

W3-5-1-27

SECTION 3 BODY Group 5 Radiator Assembly

3 7

6 9

WNEK50-03-19-003

WNEK50-03-05-001

49. Install bracket (6) with bolts, washers (5) (2 used). j : 17 mm

52. Install left and right cover (8) and cover (7). (Refer to W3-22-1.) 53. Close left and right side covers (9).

m : 50 N·m (37 lbf·ft) 50. Install the rubber plate (3) assembly with bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 51. Install plate (2) with bolts, washers (1) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-5-1-28

SECTION 3 BODY Group 6 Hydraulic Oil Tank Removal and Installation of Hydraulic Oil Tank

2, 3

1 WNEK50-03-06-001

Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious

Release any pressure from hydraulic dCAUTION: oil tank (1). (Refer to W1-5-1.)

2. Remove bolts, washers (4) (6 used). Remove the cover (2) assembly and O-ring (3). j : 17 mm 3. Place a container. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.)

W3-6-1-1

(37 US gal)

SECTION 3 BODY Group 6 Hydraulic Oil Tank 1

4. Remove engine cover (1). (Refer to W3-22-1.) 5. Remove following exterior components from left and right side. (Refer to W3-22-1.)  Rear Fender (Front) (3)  Lower Cover (2)

W3-6-1-2

WPD850-03-01-003

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

1, 2

WPD850-03-06-008

3, 4 View B 5, 6 WPD850-03-06-007 A

6. Remove bolt, washer (5) and clip (6). j : 17 mm 7. Remove bolt, washer (8). Remove the air breather (7) assembly and place it outside of the working area.

View C

WPD850-03-06-001

1, 2

j : 17 mm 8. Remove bolts, washers (3) (2 used) and clips (4) (2 used). j : 17 mm 9. Remove bolts, washers (1) (4 used) and clips (2) (4 used). j : 17 mm

WNEK50-03-06-005

W3-6-1-3

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

1 8

2 4

WNEK50-03-06-008

3 View B 2

WNEK50-03-06-006

10. Remove bolts, washers (4) (4 used). Remove bracket (2).

j : 19 mm 11. Remove bolts, washers (5, 6) (2 used for each). Remove bracket (3).

j : 19 mm 12. Remove bolts, washers (7, 8) (2 used for each). Remove bracket (1). j : 19 mm

W3-6-1-4

WNEK50-03-06-007

SECTION 3 BODY Group 6 Hydraulic Oil Tank 6

WPD850-03-06-002

13. Remove bolts, washers (1) (3 used). Remove cover (2).

15. Remove bolts, washers (3) (1 used). Remove bracket (4). j : 17 mm

j : 17 mm 14. Remove bolts, washers (5) (4 used). Remove rubber plate (6). j : 17 mm

W3-6-1-5

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

7 6 11

5 5

3, 4

9, 10

12 1, 2

8 WPD850-03-06-003

16. Remove bolt, washer (9) and clip (10).

WPD850-03-06-004

21. Remove bolt, washer (3) and clip (4).

j : 17 mm

17. Disconnect hose (11).

22. Disconnect hose (5).

j : 17 mm

j : 36 mm

18. Disconnect hose (6).

23. Remove bolt, washer (1) and clip (2). j : 17 mm

j : 17 mm 19. Disconnect hoses (7) (2 used). j : 19 mm

24. Remove the secondary steering pump (8) assembly. (Refer to W4-7-1) (Only for the machine with secondary steering)

20. Disconnect hose (12). j : 27 mm

W3-6-1-6

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

2, 3

WNEK50-03-06-012

WPD850-03-06-005

25. Disconnect hose (5). (Only for the machine with secondary steering) j : 27 mm 26. Remove bolts, washers (2) (2 used) and clips (3) (2 used). j : 17 mm 27. Disconnect connectors (1, 4). 28. Disconnect hose (6). j : 27 mm

WNEK50-03-01-011

Detail C

WPD850-03-01-002

W3-6-1-7

SECTION 3 BODY Group 6 Hydraulic Oil Tank Detail A 1

12 a

3, 4, 5 11

WNEK50-03-06-012

WNEK50-03-06-015 a-

Vehicle Front Side

Washer Tank

32. Disconnect hose (11).

29. Remove bolt, washer (3), nut (4), and clip (5).

j : 41 mm

j : 17 mm 30. Remove hoses (6) (2 used) from clips (1, 2) (2 used for each). 31. Loosen clamps (8, 9) (2 used for each). Disconnect the both ends of hoses (7, 10).

33. Place a container under disconnected part of hose (12). Loosen clamps (13) (2 used). Disconnect the both ends of hose (12).

j : 9.5 mm

W3-6-1-8

j : 11 mm

SECTION 3 BODY Group 6 Hydraulic Oil Tank

WNEK50-03-06-016

Hydraulic oil tank (1) weight: 155 kg dCAUTION: (345 lb) 34. Attach nylon slings onto hydraulic oil tank (1). Hoist and hold hydraulic oil tank (1). IMPORTANT: When removing/installing hydraulic oil tank (1) from/to the machine body, be careful not to contact hydraulic oil tank (1) with the cab rear glass or rear work lights. 35. Remove bolts (2) (6 used) and washers (3) (6 used). Remove hydraulic oil tank (1) from rear frame (4). j : 24 mm 36. Remove the adapters from hydraulic oil tank (1) if necessary.

W3-6-1-9

SECTION 3 BODY Group 6 Hydraulic Oil Tank

WNEK50-03-06-016

Installation 1. Install all removed adapters to hydraulic oil tank (1). Hydraulic oil tank (1) weight: 155 kg dCAUTION: (345 lb) 2. Attach nylon slings onto hydraulic oil tank (1). Hoist hydraulic oil tank (1). IMPORTANT: When removing/installing hydraulic oil tank (1) from/to the machine body, be careful not to contact hydraulic oil tank (1) with the cab rear glass or rear work lights. 3. Install hydraulic oil tank (1) to rear frame (4) with washers (3) (6 used) and bolts (2) (6 used). j : 24 mm m : 270 N·m (200 lbf·ft)

W3-6-1-10

SECTION 3 BODY Group 6 Hydraulic Oil Tank Detail A 1

12 a

3, 4, 5 11

WNEK50-03-06-012

WNEK50-03-06-015 a-

4. Connect the both ends of hose (12) with clamps (13) (2 used).

Vehicle Front Side

Washer Tank

7. Secure hoses (6) (2 used) with clips (1, 2) (2 used for each). 8. Secure hoses (6) (2 used) with bolt, washer (3), nut (4) and clip (5).

j : 11 mm m : 10 N·m (7.4 lbf·ft)

j : 17 mm

5. Connect hose (11).

m : 50 N·m (37 lbf·ft)

j : 41 mm m : 210 N·m (155 lbf·ft) 6. Connect both ends of hoses (7, 10) with clamps (8, 9) (2 used for each). j : 9.5 mm m : 7.5 N·m (5.5 lbf·ft)

W3-6-1-11

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

1 2, 3

WNEK50-03-06-012

WPD850-03-06-005

9. Connect connectors (1, 4). 10. Secure harness (7) with bolts, washers (2) (2 used) and clips (3) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 11. Connect hose (5). (Only for the machine with secondary steering) j : 27 mm m : 80 N·m (59 lbf·ft) 12. Connect hose (6). j : 27 mm m : 80 N·m (59 lbf·ft)

WNEK50-03-01-011

Detail C

WPD850-03-01-002

W3-6-1-12

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

5 B

3, 4

1, 2

8 WPD850-03-06-003

13. Install the secondary steering pump (8) assembly. (Refer to W4-7-1) (Only for the machine with secondary steering)

WPD850-03-06-004

Detail B b

IMPORTANT: Check the angle to install clip (2). 14. Secure hose (13) with bolt, washer (1) and clip (2). j : 17 mm m : 50 N·m (37 lbf·ft) 15. Connect hose (5). j : 36 mm a

m : 180 N·m (133 lbf·ft) IMPORTANT: Check the angle to install clip (4). 16. Secure hose (5) with bolt, washer (3) and clip (4).

j : 17 mm m : 50 N·m (37 lbf·ft)

W3-6-1-13

35°

15°

WPD850-03-06-006

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

6 11

9, 10

WPD850-03-06-004

WPD850-03-06-003

17. Connect hose (12).

20. Connect hose (11).

j : 27 mm

j : 17 mm

m : 80 N·m (59 lbf·ft)

m : 25 N·m (18.5 lbf·ft)

18. Connect hose (6). j : 17 mm

21. Secure hoses (6) (3 used), hose (7), hose (11) and hoses (12) (2 used) with bolts, washers (9) and clip (10).

m : 25 N·m (18.5 lbf·ft)

j : 17 mm

19. Connect hoses (7) (2 used).

m : 50 N·m (37 lbf·ft)

j : 19 mm m : 30 N·m (22 lbf·ft)

W3-6-1-14

SECTION 3 BODY Group 6 Hydraulic Oil Tank

3 1 2

5 WPD850-03-06-002

22. Install bracket (4) with bolts, washers (3) (1 used).

24. Install cover (2) with bolts, washers (1) (3 used).

j : 17 mm

m : 50 N·m (37 lbf·ft)

23. Install rubber plate (5) with bolts, washers (6) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-6-1-15

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

1 8

2 3

WNEK50-03-06-008

View B 2 2

WNEK50-03-06-006

25. Temporary secure brackets (1, 2, 3) with bolts, washers (4) (4 used), and bolts, washers (5, 6, 7, 8) (2 used for each).

26. Tighten bolts, washers (7, 8) (2 used for each). j : 19 mm m : 90 N·m (66 lbf·ft)

27. Tighten bolts, washers (5, 6) (2 used for each). j : 19 mm m : 90 N·m (66 lbf·ft) 28. Tighten bolts, washers (4) (4 used). j : 19 mm m : 90 N·m (66 lbf·ft)

W3-6-1-16

WNEK50-03-06-007

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

1, 2

WPD850-03-06-008

3, 4 View B 5, 6 9

WPD850-03-06-007

29. Secure harness (9) with bolts, washers (1) (4 used) and clips (2) (4 used). 8

j : 17 mm m : 50 N·m (37 lbf·ft)

View C

1, 2

WPD850-03-06-001

30. Secure hose (10) with bolts, washers (3) (2 used) and clips (4) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 31. Install the air breather (7) assembly with bolt, washer (8). j : 17 mm m : 50 N·m (37 lbf·ft) 32. Secure hose (11) with bolt, washer (5) and clip (6). WNEK50-03-06-005

j : 17 mm m : 50 N·m (37 lbf·ft)

W3-6-1-17

SECTION 3 BODY Group 6 Hydraulic Oil Tank

2, 3

1 WNEK50-03-06-001

33. Fill hydraulic oil tank (1) with hydraulic oil.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 34. Install O-ring (3).

35. Install the cover (2) assembly with bolts, washers (4) (6 used). j : 17 mm m : 50 N·m (37 lbf·ft) 36. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-6-1-18

SECTION 3 BODY Group 6 Hydraulic Oil Tank 1

37. Install following exterior components to left and right side. (Refer to W3-22-1.)  Lower Cover (2)  Rear Fender (Front) (3) 38. Install engine cover (1). (Refer to W3-22-1.)

W3-6-1-19

WPD850-03-01-003

SECTION 3 BODY Group 6 Hydraulic Oil Tank (Blank)

W3-6-1-20

SECTION 3 BODY Group 7 Fuel Tank Removal and Installation of Fuel Tank 1

WNEK50-03-07-010

Fuel is highly flammable. Never bring dCAUTION: a fire close to fuel. IMPORTANT: The hose and pipe contain fuel. When removing the hose and pipe, receive oil with a container in order to avoid spilling fuel. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) 2. Open side covers (1) at the right and left sides and rear grill (2). 3. Open the hydraulic drive fan (3) assembly.

W3-7-1-1

SECTION 3 BODY Group 7 Fuel Tank

Detail A

8 B

7 6 WNEK50-03-07-011 View B

10 WNEK50-03-07-018

WNEK50-03-07-012

9. Remove bolts, washers (12) (2 used).

4. Remove cap (6). 5. Place a container. Drain off fuel by using an oil feed pump.

NOTE: Total fuel amount of fuel tank (3): 260 L (69 US gal) 6. Remove bolt, washer (8), clip (7), and collar (9).

j : 17 mm 10. Loosen clamp (11). Disconnect the fuel filler port (10) assembly.

j : 17 mm 7. Loosen clamp (2). Disconnect hose (1). j : 7 mm 8. Loosen clamp (5). Disconnect hose (4). j : 7 mm

W3-7-1-2

j : 7 mm

SECTION 3 BODY Group 7 Fuel Tank

Detail A

WNEK50-03-07-008 Detail B a-

Vehicle Front Side

WNEK50-03-19-010

11. Remove bolt, washer (2) and clip (1). j : 17 mm 12. Loosen clamp (4). Disconnect hose (3).

W3-7-1-3

WNEK50-03-07-009

SECTION 3 BODY Group 7 Fuel Tank

Detail A

WNEK50-03-07-005

13. Remove bolt, washer (2) and bracket (1). j : 17 mm

W3-7-1-4

WNEK50-03-07-006

SECTION 3 BODY Group 7 Fuel Tank

Detail A A

2, 3

WPD850-03-07-001

WNEK50-03-07-002

14. Remove connector (2) from bracket (3). Disconnect connector (2).

15. Remove bolts, washers (4) (2 used). Remove cover (1). j : 17 mm

W3-7-1-5

SECTION 3 BODY Group 7 Fuel Tank

Detail A

3 2

5 B

WNEK50-03-07-002

WNEK50-03-07-004

6 Detail B

WNEK50-03-07-014

19. Place a container. Remove plug (7). Open valve (6). Drain off fuel completely.

16. Disconnect connector (3). 17. Remove bolts, washers (5) (2 used). Remove the drain hose (4) assembly.

j : 17 mm

j : 17 mm 18. Loosen clamps (1) (4 used). Disconnect hoses (2) (4 used).

20. Close valve (6). Install a seal tape onto the thread part of plug (7). Install plug (7).

j : 7 mm

j : 17 mm m : 15 N·m

W3-7-1-6

SECTION 3 BODY Group 7 Fuel Tank a

2 1 2 1

3 4 11

10 6 a

8 7

WPD850-03-07-003

Guide

5 WPD850-03-07-002

The fuel tank (5) assembly weight: 215 dCAUTION: kg (475 lb) 21. Attach nylon slings onto left and right side steps (rear) (6). Hoist and hold the fuel tank (5) assembly. Hold the bottom side of fuel tank (5) assembly by using a jack and the wooden blocks. 22. Remove bolts (3) (2 used) and washers (4) (2 used).

24. Remove bolts, washers (10) (2 used). Remove the bracket (11) assembly from fuel tank (5). j : 17 mm 25. Disconnect hoses (8) from guides (a) (4 places) of fuel tank (5). 26. Remove left and right side steps (rear) (6) from fuel tank (5). (Refer to W3-22-1.)

j : 36 mm 23. Remove bolts (2) (2 used) and washers (1) (2 used). Remove the fuel tank (5) assembly from rear frame (7). j : 30 mm

W3-7-1-7

SECTION 3 BODY Group 7 Fuel Tank a

2 1 2 1

3 4

10 6 a

8 a-

WPD850-03-07-003

Guide

5 WPD850-03-07-002

Installation 1. Install left and right side steps (rear) (6) to fuel tank (5). (Refer to W3-22-1.) 2. Install the bracket (11) assembly to fuel tank (5) with bolts, washers (10) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 3. Pass hoses (8) through guides (a) (4 places) of fuel tank (5).

The fuel tank (5) assembly weight: 215 dCAUTION: kg (475 lb) 4. Attach nylon slings onto left and right side steps (rear) (6). Hoist and hold the fuel tank (5) assembly. Raise the bottom side of fuel tank (5) assembly by using a jack and the wooden blocks. 5. Temporarily install the fuel tank (5) assembly to rear frame (7) with washers (1) (2 used) and bolts (2) (2 used). 6. Temporarily tighten washers (4) (2 used) and bolts (3) (2 used). 7. Tighten bolts (2) (2 used). j : 30 mm m : 450 N·m (330 lbf·ft) 8. Tighten bolts (3) (2 used). j : 36 mm m : 780 N·m (580 lbf·ft)

W3-7-1-8

SECTION 3 BODY Group 7 Fuel Tank

Detail A

3 2

WNEK50-03-07-002

9. Connect hoses (2) (4 used) with clamps (1) (4 used). j : 7 mm m : 4.1 N·m (3 lbf·ft) 10. Install the drain hose (4) assembly with bolts, washers (5) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 11. Connect connector (3).

W3-7-1-9

WNEK50-03-07-004

SECTION 3 BODY Group 7 Fuel Tank

Detail A A

2, 3

WNEK50-03-07-002

12. Install connector (2) to bracket (3). Connect connector (2).

W3-7-1-10

WPD850-03-07-001

SECTION 3 BODY Group 7 Fuel Tank

Detail A

WNEK50-03-07-005

13. Secure hoses (3) (2 used) with bracket (1) and bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-7-1-11

WNEK50-03-07-006

SECTION 3 BODY Group 7 Fuel Tank

Detail A

WNEK50-03-07-008 Detail B a-

Vehicle Front Side

WNEK50-03-19-010

14. Connect hose (3) with clamp (4). 15. Secure wire harness (5) with clip (1) and bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft) 3

W3-7-1-12

WNEK50-03-07-009

SECTION 3 BODY Group 7 Fuel Tank

Detail A

8 B

7 6

WNEK50-03-07-011

C View B

10 WNEK50-03-07-018

16. Temporally install the fuel filler port (10) assembly with clamp (11). 17. Temporarily install the fuel filler port (10) assembly with bolts, washers (12) (2 used). 12

18. Tighten clamp (11).

j : 7 mm WNEK50-03-07-012

m : 6.8 N·m (5 lbf·ft) 19. Tighten bolts, washers (12) (2 used). View C

j : 17 mm

m : 50 N·m (37 lbf·ft) 20. Connect hose (4) with clamp (5). j : 7 mm a

m : 3.4 N·m (2.5 lbf·ft) 21. Connect hose (1) with clamp (2). j : 7 mm m : 3.4 N·m (2.5 lbf·ft) IMPORTANT: Check the angle to install clip (7). 22. Secure hose (1) with collar (9), clip (7), and bolt, washer (8). j : 17 mm m : 50 N·m (37 lbf·ft)

7 WNEK50-03-07-017 a-

45°

23. Fill fuel tank (3) with fuel.

fNOTE: Total fuel amount of fuel tank (3): 260 L (69 US gal) 24. Install cap (6).

W3-7-1-13

SECTION 3 BODY Group 7 Fuel Tank

WNEK50-03-07-010

WNEK50-03-07-002

Detail A

25. Close the hydraulic drive fan (3) assembly. 26. Bleed air from the fuel system. (Refer to W1-4-1.) IMPORTANT: Start the engine and check for any oil leaks. 27. Close rear grill (2) and side covers (1) at the right and left sides.

28. Install cover (5) with bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) WNEK50-03-07-003

W3-7-1-14

SECTION 3 BODY Group 8 Pump Device Removal and Installation of Pump Device

2, 3

1 WNEK50-03-06-001

Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious

Release any pressure from hydraulic dCAUTION: oil tank (1). (Refer to W1-5-1.)

2. Remove bolts, washers (4) (6 used). Remove the cover (2) assembly and O-ring (3). j : 17 mm 3. Place a container. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 4. Remove the cab (5) assembly. (Refer to W3-1-1.)

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.)

W3-8-1-1

SECTION 3 BODY Group 8 Pump Device 1

Vehicle Front Side

5. Disconnect connector (6). 6. Disconnect hoses (1, 2, 4). j : 17 mm 7. Disconnect hose (5). j : 36 mm 8. Disconnect hoses (7) (2 used). j : 19 mm

W3-8-1-2

WPD850-03-04-013

SECTION 3 BODY Group 8 Pump Device

Vehicle Front Side

9. Disconnect hose (1). j : 36 mm 10. Disconnect hose (2). j : 41 mm 11. Disconnect hose (3). j : 27 mm

W3-8-1-3

WPD850-03-08-004

SECTION 3 BODY Group 8 Pump Device 8

1, 4, 10

3 5

6, 7

Vehicle Front Side

WPD850-03-08-005

12. Remove bolts, washers (1) (2 used) and clips (4, 10) (2 used for each). j : 17 mm

fNOTE: Hose (2) and clip (10) are equipped for the

14. Place a container under the disconnecting part of the suction pipe (8) assembly. Loosen clamp (3). Remove socket bolts (6) (4 used). Disconnect the both ends of the suction pipe (8) assembly. Remove O-ring (7).

machine with secondary steering device. 13. Disconnect hose (5).

j : 11 mm l : 10 mm

j : 36 mm

W3-8-1-4

SECTION 3 BODY Group 8 Pump Device

2 3, 4 ST 0251

6 11 a

WNEK50-03-08-004

Vehicle Front Side

7 WNEK50-03-08-005

Eyebolt

19. Remove socket bolts (9) (4 used). Remove spacer (10) from drive unit (5).

15. Remove nuts (3) (2 used) and the bracket (4) assemblies (2 used).

l : 10 mm

j : 19 mm

dCAUTION: Pump device (1) weight: 94 kg (210 lb) 16. Remove reducer (2) with the bleeder valve. Install special tool (ST 0251) and eyebolt (b) (M12, Pitch 1.75 mm) to the mounting hole of reducer (2) with the bleeder valve. Attach nylon slings onto eyebolt (b). Hoist and hold pump device (1).

20. Remove O-ring (11) from spacer (10). 21. Remove the adapters from pump device (1) if necessary.

j : 41 mm 17. Remove socket bolts (6, 7) (2 used for each). Remove pump device (1) from spacer (10) and place it onto wooden blocks. l : 10 mm 18. Remove O-ring (8) from pump device (1).

W3-8-1-5

SECTION 3 BODY Group 8 Pump Device

2 3, 4 ST 0251

6 11 a

7 9

WNEK50-03-08-005

Eyebolt

Installation 1. Install all removed adapters to pump device (1). 2. Install O-ring (11) to spacer (10). 3. Install spacer (10) to drive unit (5) with socket bolts (9) (4 used).

WNEK50-03-08-004

Vehicle Front Side

IMPORTANT: If air is accumulated inside of the pump and if the engine starts in lacking of hydraulic oil, the pump may be damaged. 7. Remove eyebolt (b) (M12, Pitch 1.75 mm) and special tool (ST 0251) (a). Add hydraulic oil to the pump. After filling hydraulic oil in the pump, install reducer (2) with the bleeder valve.

l : 10 mm

j : 41 mm

m : 90 N·m (66 lbf·ft)

m : 80 N·m (59 lbf·ft)

4. Install O-ring (8) to pump device (1).

CAUTION: Pump device (1) weight: 94 kg (210 lb) 5. Install eyebolt (b) (M12, Pitch 1.75 mm) and the special tool (ST 0251) to the mounting hole of reducer (2) with the bleeder valve. Attach nylon slings onto eyebolt (b). Hoist pump device (1).

IMPORTANT: Install nut (3) while securing socket bolt (9) by using a hexagonal wrench in order not to turn them. 8. Secure harness (12) to socket bolts (9) (2 used) with nuts (3) (2 used) and the bracket (4) assembly (2 used).

6. Install pump device (1) to spacer (10) with socket bolts (6, 7) (2 used for each).

j : 19 mm m : 90 N·m (66 lbf·ft)

l : 10 mm m : 90 N·m (66 lbf·ft)

W3-8-1-6

SECTION 3 BODY Group 8 Pump Device 8

1, 4, 10

2 View A 5

3 b

5 A

6, 7

a a-

40˚

WPD850-03-04-010

WPD850-03-08-005

Vehicle Front Side

9. Install O-ring (7). Connect the both ends of the suction pipe (8) assembly with clamp (3) and socket bolts (6) (4 used).

IMPORTANT: Check the angle to install hose (5). 10. Connect hose (5). j : 36 mm

j : 11 mm m : 10 N·m (7.4 lbf·ft) l : 10 mm

m : 180 N·m (133 lbf·ft) 11. Secure hoses (2, 5) with bolts, washers (1) (2 used) and clips (4, 10) (2 used for each). j : 17 mm

m : 90 N·m (66 lbf·ft)

m : 50 N·m (37 lbf·ft)

fNOTE: Hose (2) and clip (10) are equipped for the machine with secondary steering device.

W3-8-1-7

SECTION 3 BODY Group 8 Pump Device

View A

1 b-

3 a-

Vehicle Front Side

WPD850-03-08-004

IMPORTANT: Check the angle to install hose (1). 12. Connect hose (1). j : 36 mm m : 93 N·m (69 lbf·ft) 13. Connect hose (3). j : 27 mm m : 95 N·m (70 lbf·ft) 14. Connect hose (2). j : 41 mm m : 210 N·m (155 lbf·ft)

W3-8-1-8

20°

WNEK50-03-08-006

SECTION 3 BODY Group 8 Pump Device

View B 5

a a-

Vehicle Front Side

WPD850-03-04-013

15. Connect hoses (7) (2 used). j : 19 mm m : 30 N·m (22 lbf·ft) IMPORTANT: Check the angle to install hose (5). 16. Connect hose (5). j : 36 mm m : 180 N·m (133 lbf·ft)

W3-8-1-9

ac-

Vehicle Front Side 15°

WNDB-03-08-021

SECTION 3 BODY Group 8 Pump Device 1

2 1

2 abc-

Vehicle Front Side 30° 25°

WPD850-03-04-011

View B a-

Vehicle Front Side

WPD850-03-04-013 d

IMPORTANT: Check the angle to install hoses (1, 2, 4). 17. Connect hoses (1, 2, 4). j : 17 mm m : 25 N·m (18.5 lbf·ft) 18. Connect connector (6).

W3-8-1-10

ad-

Vehicle Front Side 50°

WPD850-03-04-012

SECTION 3 BODY Group 8 Pump Device

2, 3

1 WNEK50-03-06-001

19. Install the cab (5) assembly. (Refer to W3-1-1.) 20. Fill hydraulic oil tank (1) with hydraulic oil.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 21. Install O-ring (3).

22. Install the cover (2) assembly with bolts, washers (4) (6 used). j : 17 mm m : 50 N·m (37 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-8-1-11

SECTION 3 BODY Group 8 Pump Device (Blank)

W3-8-1-12

SECTION 3 BODY Group 8 Pump Device Disassembly of Pump Device

WNDB-03-08-001

00- Main Pump 01A- Regulator 01B- Socket Bolt (4 Used)

02- Pilot Pump 03- O-Ring 04- Socket Bolt (2 Used)

05- Spring Washer (2 Used) 06- Washer (2 Used) 07- Reducer

W3-8-2-1

SECTION 3 BODY Group 8 Pump Device Disassembly of Pump Device

dCAUTION: Pump Device: 94 kg (210 lb)

3. Remove socket bolts (01B) (4 used) from regulator (01A).

1. Remove reducer (07) with the bleeder valve attached of regulator (01A). Install the special tool (ST 0251) and eyebolts (a) (M12, Pitch 1.75 mm) to the mounting reducer (07) holes. Attach the nylon slings onto eyebolts (a). Hoist the pump device. Place the pump device onto wooden blocks (b) of approx. 100 mm square (3.9 in square) with regulator (01A) up.

l : 8 mm IMPORTANT: Do not drop O-ring between regulator (01A) and main pump (00). (Refer to W3-8-3-1.) 4. Remove regulator (01A) from main pump (00).

fNOTE: Pull regulator (01A) obliquely upward as illustrated when it floats up.

j : 41 mm a

01A

ST 0251

01A 00

WNDB-03-08-003 b WNDB-03-08-002 ab-

Eyebolt Wooden Block

2. Remove socket bolts (04) (2 used), spring washers (05) (2 used), and washers (06) (2 used) from pilot pump (02). Remove pilot pump (02) and O-ring (03) from main pump (00). l : 8 mm

W3-8-2-2

SECTION 3 BODY Group 8 Pump Device Assembly of Pump Device 01A

01B

06 03 WNDB-03-08-004

00- Main Pump 01A- Regulator 01B- Socket Bolt (4 Used)

02- Pilot Pump 03- O-Ring 04- Socket Bolt (2 Used)

05- Spring Washer (2 Used) 06- Washer (2 Used) 07- Reducer

W3-8-2-3

SECTION 3 BODY Group 8 Pump Device Assembly of Pump Device IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: Check that O-rings (d) (5 used) have been installed in the regulator (01A) mounting surface. (Refer to W3-8-3-1.) 1. Adjust sleeves (2 used) in regulator (01A) so that the grooves of sleeves can be in line.

5. Install O-ring (03) to pilot pump (02). 6. Install pilot pump (02) to main pump (00) with socket bolts (04) (2 used), spring washers (05) (2 used), and washers (06) (2 used).

2. Place regulator (01A) on main pump (00). Insert pin (b) of feedback link (a) into the grooves of sleeves (2 used). 3. Move regulator (01A) so that knock pins (c) (2 used) can enter regulator (01A). 4. Install regulator (01A) to main pump (00) with socket bolts (01B) (4 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

01A

01B a

WNDB-03-08-005 ab-

Feedback Link Pin

cd-

Knock Pin O-Ring

W3-8-2-4

l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

SECTION 3 BODY Group 8 Pump Device Disassembly of Main Pump

WNDB-03-08-006

0001020304050607080911131415-

Front Casing Drive Shaft Inner Race Retaining Ring Roller Bearing Retaining Ring (2 Used) Knock Pin Cradle Plate Socket Bolt (4 Used) Swash Plate Knock Pin Spring (7 Used) Bushing Retainer

1718192022232425262728293031-

O-Ring Pump Casing Needle Bearing Knock Pin Servo Piston (3 Used) Knock Pin Restrictor Pin Backup Ring (2 Used) O-Ring (2 Used) Pin Feedback Link Link Pin Pin Spring Pin

32- Spring Pin 33- Socket Bolt (8 Used) 35A- Plug (2 Used) 35B- O-Ring (2 Used) 36A- Plug 36B- O-Ring 37A- Plug 37B- O-Ring 38- Plug (4 Used) 40- Spring Pin (2 Used) 41- O-Ring 42- O-Ring (5 Used) 43- O-Ring 44- Oil Seal

W3-8-3-1

45- Retaining Ring 46- Piston (7 Used) 48A- Pressure Sensor 48B- O-Ring 49- Cam Plate 50A- Valve Plate 50B- Rotor 63A- Plug (2 Used) 63B- O-Ring (2 Used) 64A- Plug 64B- O-Ring 66A- Plug 66B- O-Ring

SECTION 3 BODY Group 8 Pump Device Disassembly of Main Pump

d CAUTION: Pump device weight: 83 kg

fNOTE: When removing the front casing (00) assembly,

raise the pump casing (18) assembly side a little in order to prevent the rotor (50B) assembly from falling off.

1. Secure the main pump assembly on a workbench with the regulator side up.

fNOTE: The restrictor pin (24) assembly of front casing

CAUTION: Front casing (00) weight: 36 kg (79.5 dlb) 2. Remove socket bolts (33) (8 used) from front casing (00). l : 12 mm IMPORTANT: Inner race (02) of the drive shaft (01) assembly cannot be replaced. Do not damage it. IMPORTANT: Do not remove retaining ring (03) of the drive shaft (01) assembly. IMPORTANT: Do not remove the restrictor pin (24) assembly and knock pin (23) of front casing (00) unless necessary. 3. Hoist front casing (00) by using the special tool (ST 0250). Remove the front casing (00) assembly and O-ring (17) from the pump casing (18) assembly.

(00) may stay in the pump casing (18) assembly. 4. Place the front casing (00) assembly onto wooden pieces (120 mm square or more) with the rotor (50B) side up.

IMPORTANT: The valve plate (50A) side of rotor (50B) is a sliding surface. Do not damage it. IMPORTANT: Do not remove knock pin (20) of valve plate (50A) unless necessary. 5. Remove the rotor (50B) assembly from drive shaft (01). Place the rotor (50B) assembly with the valve plate (50A) side down. 6. Remove retainer (15) and pistons (46) (7 used) from rotor (50B). 7. Remove bushing (14) and springs (13) (7 used) from the rotor (50B) assembly.

ST 0250

WNEC-03-08-010

W3-8-3-2

SECTION 3 BODY Group 8 Pump Device IMPORTANT: Do not remove knock pin (11) of cam plate (49) unless necessary.

13. Remove retaining ring (45) and oil seal (44) from front casing (00).

8. Remove cam plate (49) from swash plate (09).

fNOTE: When tapping the yoke part with cam plate (49)

IMPORTANT: Do not remove plugs (38) (2 used) of pump casing (18). 14. Remove servo pistons (22) (3 used), O-ring (41), O-rings (42) (5 used), and spring pins (40) (2 used) from pump casing (18).

IMPORTANT: Do not remove plugs (38) (3 used) of cradle plate (07). IMPORTANT: Do not remove knock pin (06) of the front casing (00) assembly unless necessary. 9. Remove socket bolts (08) (4 used) from cradle plate (07). Remove cradle plate (07) and O-ring (43) from the front casing (00) assembly.

IMPORTANT: Do not disassemble the feedback link (28) assembly unless necessary. 15. Remove the feedback link (28) assembly from pump casing (18).

up, cam plate (49) is raised.

16. Remove pressure sensor (48) from pump casing (18).

l : 6 mm

j : 27 mm

10. Remove the drive shaft (01) assembly from front casing (00). IMPORTANT: When removing retaining ring (05), do not damage the seal lip contacting surface of drive shaft (01). 11. Remove retaining rings (05) (2 used) from drive shaft (01).

17. Remove plug (35A) and O-ring (35B) from pump casing (18). l : 5 mm 18. Remove plug (36A) and O-ring (36B) from pump casing (18). l : 6 mm

12. Remove the roller and outer ring of roller bearing (04).

W3-8-3-3

SECTION 3 BODY Group 8 Pump Device 19. Remove plug (37A) and O-ring (37B) from pump casing (18). l : 8 mm 20. Remove plugs (63A) (2 used) from pump casing (18). Remove O-rings (63B) (2 used) from plugs (63A) (2 used). j : 41 mm 21. Remove plug (64A) from pump casing (18). Remove O-ring (64B) from plug (64A). j : 50 mm 22. Remove plug (66A) from pump casing (18). Remove O-ring (66B) from plug (66A). j : 36 mm 23. Remove needle bearing (19) from pump casing (18).

W3-8-3-4

SECTION 3 BODY Group 8 Pump Device Assembly of Main Pump

18 50A

50B

Section BB

65A

27 31 28

32 30 29

65B

03 01

35A B B

35B

02 20 View C

13 14

15 49 11 38 40

Section DD 63A 63B

05 37A 37B 04 06 44 Detail A

66A

24 38

36A

66B 36B

48A, 48B 64A

64B WPD850-03-08-001

0001020304050607080911131415-

Front Casing Drive Shaft Inner Race Retaining Ring Roller Bearing Retaining Ring (2 Used) Knock Pin Cradle Plate Socket Bolt (4 Used) Swash Plate Knock Pin Spring (7 Used) Bushing Retainer

1718192022232425262728293031-

O-Ring Pump Casing Needle Bearing Knock Pin Servo Piston (3 Used) Knock Pin Restrictor Pin Backup Ring (2 Used) O-Ring (2 Used) Pin Feedback Link Link Pin Pin Spring Pin

W3-8-3-5

45- Retaining Ring 46- Piston (7 Used) 48A- Pressure Sensor 48B- O-Ring 49- Cam Plate 50A- Valve Plate 50B- Rotor 63A- Plug (2 Used) 63B- O-Ring (2 Used) 64A- Plug 64B- O-Ring 66A- Plug 66B- O-Ring

SECTION 3 BODY Group 8 Pump Device Assembly of Main Pump IMPORTANT: Before assembling, apply hydraulic oil to parts in order to prevent them from seizing. 1. Install needle bearing (19) to pump casing (18) by using the special tool and a hammer. 2. Place pump casing (18) with the regulator mounting side up. IMPORTANT: Valve plate (50A) and rotor (50B) should be replaced as an assembly. IMPORTANT: Install valve plate (50A) of the rotor (50B) assembly with the slotted hole (opposite side of regulator mounting side) down. 3. Apply grease to the flat surface of valve plate (50A). Fit valve plate (50A) to knock pin (20). Install valve plate (50A) to pump casing (18). 4. Install servo pistons (22) (3 used) to pump casing (18).

IMPORTANT: Check the direction to install feedback link (28). 5. Fit the groove for pin (27). Install the feedback link (28) assembly to pump casing (18).

fNOTE: Face link pin (29) to the front casing (00) side. fNOTE: Both surfaces of pin (27) are parallel to each

other. Fit parallel surface (a) to the groove and install pin (27). 27

a a-

W176-02-04-016

Parallel Surface

 Assembly of the rotor (50B) assembly 6. Place rotor (50B) with the center projection part up. 7. Install springs (13) (7 used) to rotor (50B). 8. Install bushing (14) to rotor (50B).

fNOTE: Fit the spline of bushing (14) to the spline of

rotor (50B) when installing bushing (14). This makes it easy to install the shaft. 9. Install the flat surface of pistons (46) (7 used) to retainer (15). Install the piston (46) assembly to rotor (50B).

W3-8-3-6

SECTION 3 BODY Group 8 Pump Device IMPORTANT: Do not damage the sliding surface for oil seal (44) of drive shaft (01). 10. Install retaining ring (05) to the groove closer to the end surface of drive shaft (01). IMPORTANT: Check the direction to install the inner ring roller bearing (04). 11. Install the inner ring of roller bearing (04) to drive shaft (01) by using the special tool (ST 7861) and a plastic hammer. 04 a

01 b

Inner Ring Rotor Side

14. Install retaining ring (05) to drive shaft (01).  Assembly of the front casing (00) assembly 15. Place front casing (00) with the pump casing (18) side down. 16. Apply grease to the inner surface of oil seal (44). 17. Install oil seal (44) to front casing (00) by using the special tool (ST 7860) and a plastic hammer. 18. Install retaining ring (45) to front casing (00).

19. Turn over front casing (00). Place it on wooden pieces (120 mm square or more).

W4GB-02-04-004 ab-

13. Install the inner ring plate of roller bearing (04) to drive shaft (01) with stamped mark (d) facing to rotor side (b).

20. Install O-ring (43) to front casing (00). 21. Install the drive shaft (01) assembly to front casing (00).

Input Side

12. Install the roller and outer ring of roller bearing (04) to drive shaft (01) with stamped mark (d) facing to input side (c).

fNOTE: Roller bearing (04) can be installed by tapping

WNEC-03-08-009 d-

Stamped Mark

W3-8-3-7

the drive shaft (01) assembly by using a plastic hammer.

SECTION 3 BODY Group 8 Pump Device 25. Apply grease to the knock pin (11) hole side of cam plate (49). Fit the knock pin (11) position. Install cam plate (49) to swash plate (09).

22. Fit the knock pin (06) position. Install cradle plate (07) to front casing (00) with socket bolts (08) (4 used). l : 6 mm m : 30 N·m (22 lbf·ft) 23. Install O-ring (17) to front casing (00). IMPORTANT: Check the direction to install the restrictor pin (24) assembly. 24. When restrictor pin (24) has been removed, install backup rings (25) (2 used) and O-rings (26) (2 used) to restrictor pin (24). Install the restrictor pin (24) assembly to front casing (00).

IMPORTANT: Install swash plate (09) with the mounting part of link pin (29) in swash plate (09) up (facing to the regulator mounting side). 26. Apply grease to the cylindrical surface of swash plate (09). Fit the cylindrical surface of cradle plate (07) to that of swash plate (09). Install swash plate (09) to the front casing (00) assembly. d

25 W176-02-04-018

26 ab-

Cradle Plate (07) Side Front Casing (00) Side

W4GB-02-04-005

Mounting Part of Link Pin

IMPORTANT: Take care not to drop plunger (46) from the rotor (50B) assembly. 27. Install the rotor (50B) assembly to the front casing (00) assembly.

Orifice

W3-8-3-8

SECTION 3 BODY Group 8 Pump Device The front casing (00) assembly weight: dCAUTION: 36 kg (79.5 lb) 28. Raise the front casing (00) assembly to the vertical position and hold it.

fNOTE: Do not raise the front casing (00) assembly excessively as swash plate (09) may come off.

IMPORTANT: Install the front casing (00) assembly so that link pin (29) can be inserted to the mouting concave part with the feedback link (28) assembly in swash plate (09). 30. Install the front casing (00) assembly to pump casing (18) while fitting knock pin (23) and link pin (29). 31. Install front casing (00) to pump casing (18) with socket bolts (33) (8 used).

The front casing (00) assembly weight: dCAUTION: 36 kg (79.5 lb)

l : 12 mm m : 180 N·m (133 lbf·ft)

IMPORTANT: Do not tilt the front casing (00) assembly as center of gravity is at the rotor (50B) side. Rotor (50B) may come off. 29. Hoist the front casing assembly (00) by using the special tool (ST 0250).

32. Install O-ring (41), O-rings (42) (5 used), and spring pins (40) (2 used) to pump casing (18). 41

ST 0250 W176-02-04-014

33. Install pressure sensor (48) to pump casing (18). j : 27 mm m : 100 N·m (74 lbf·ft) 00

WNEC-03-08-010

W3-8-3-9

SECTION 3 BODY Group 8 Pump Device 34. Install O-ring (35B) to plug (35A). Install plug (35A) to the pump casing (18) assembly. l : 5 mm m : 15 N·m (11 lbf·ft) 35. Install O-ring (36B) to plug (36A). Install plug (36A) to the pump casing (18) assembly. l : 6 mm m : 35 N·m (26 lbf·ft) 36. Install O-ring (37B) to plug (37A). Install plug (37A) to the pump casing (18) assembly. l : 8 mm m : 50 N·m (37 lbf·ft) 37. Install O-ring (66B) to plug (66A). Install plug (66A) to pump casing (18). j : 36 mm m : 240 N·m (177 lbf·ft) 38. Install O-ring (64B) to plug (64A). Install plug (64A) to pump casing (18). j : 50 mm m : 550 N·m (406 lbf·ft) 39. Install O-rings (63B) (2 used) to plugs (63A) (2 used). Install plugs (63A) (2 used) to pump casing (18). j : 41 mm m : 450 N·m (332 lbf·ft)

W3-8-3-10

SECTION 3 BODY Group 8 Pump Device Disassembly of Regulator

WNDB-03-08-012

00- Casing 02- Sleeve 03- Spool 05- Cylinder 06- Piston 07- O-Ring 08- Backup Ring 09- O-Ring 11- Stopper

12- Stopper 13- O-Ring (3 Used) 14- O-Ring 15- Lock Nut 16- Lock Nut 18A- Spool 18B- Sleeve 20- Cylinder 21- Piston (2 Used)

23- Cylinder 24- Stopper 25- O-Ring 26- Lock Nut 27- Nut 29- Spring 30- Spring 31- Spring 33- Set Screw

W3-8-4-1

34- Lock Nut 35- Cover 37- Cover 39- Socket Bolt (8 Used) 131- Reducer 132- Bleeder Valve 137- O-Ring

SECTION 3 BODY Group 8 Pump Device Disassembly of Regulator IMPORTANT: As the setting changes, do not disassemble adjusting screws (11, 12, 15, 16, 23, 24, 26, 27, 33, and 34) of the regulator. If it is disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 1. Remove socket bolts (39) (4 used) from cover (35). Remove the cover (35) assembly from casing (00). l : 6 mm

fNOTE: The set screw (33) assembly and the stopper (11) assembly are removed together with cover (35). 2. Remove O-ring (13) from stopper (12).

IMPORTANT: Do not rotate lock nut (26) and nut (27). If rotating, the setting changes. 3. Remove socket bolts (39) (4 used) from cover (37). Remove the cover (37) assembly from casing (00).

5. Remove springs (29, 30) from casing (00). 6. Insert a round bar into the hole on casing (00). Push the end surface of spool (03). Remove the cylinder (05) assembly, sleeve (02), and spool (03) from casing (00). 7. Remove piston (06), O-ring (07), backup ring (08), and O-ring (09) from cylinder (05). 8. Insert a round bar into the hole on casing (00). Push the end surface of spool (18A). Remove the cylinder (20) assembly, spring (31), sleeve (18B), and spool (18A) from casing (00). 9. Remove piston (21) and O-ring (13) from cylinder (20).

l : 6 mm

fNOTE: The stopper (24) assembly is removed together with cover (37). 4. Remove piston (42) and O-ring (13) from the stopper (24) assembly.

W3-8-4-2

SECTION 3 BODY Group 8 Pump Device Assembly of Regulator 27

23 26

24 25 13

18B 18A

07 06

03 02

00 31

14 12 15

137

WNDB-03-08-013

08 39

29 131 132

WNDB-03-08-014

00- Casing 02- Sleeve 03- Spool 05- Cylinder 06- Piston 07- O-Ring 08- Backup Ring 09- O-Ring 11- Stopper

12- Stopper 13- O-Ring (3 Used) 14- O-Ring 15- Lock Nut 16- Lock Nut 18A- Spool 18B- Sleeve 20- Cylinder 21- Piston (2 Used)

23- Cylinder 24- Stopper 25- O-Ring 26- Lock Nut 27- Nut 29- Spring 30- Spring 31- Spring 33- Set Screw

W3-8-4-3

34- Lock Nut 35- Cover 37- Cover 39- Socket Bolt (8 Used) 131- Reducer 132- Bleeder Valve 137- O-Ring

SECTION 3 BODY Group 8 Pump Device Assembly of Regulator IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The sleeve holes (2 places) of casing (00) are the same bores. The shapes of various parts are very similar. Assemble it while checking the illustration in order not to confuse. IMPORTANT: Check the direction to install sleeve (18B) and spool (18A). 1. Install spool (18A) to sleeve (18B). Install the sleeve (18B) assembly to casing (00) by using a round bar. 2. Install O-ring (13) and spring (31) to cylinder (20).

7. Install O-ring (13) and piston (42) to the stopper (24) assembly which has installed to the cover (37) assembly. Install the cover (37) assembly to casing (00) with socket bolts (39) (4 used). l : 6 mm m : 19.6 N·m (14.5 lbf·ft) 8. Install O-ring (13) and springs (29, 30) to the stopper (11) assembly which has installed to the cover (35) assembly. Install the cover (35) assembly to casing (00) with socket bolts (39) (4 used).

3. Install piston (21) to the cylinder (20) assembly. Install the cylinder (20) assembly to casing (00).

l : 6 mm

IMPORTANT: Check the direction to install sleeve (02) and spool (03). 4. Install spool (03) to sleeve (02). Install the sleeve (02) assembly to casing (00) by using a round bar. 5. Install O-rings (07, 09) and backup ring (08) to cylinder (05). 6. Install piston (06) to the cylinder (05) assembly. Install the cylinder (05) assembly to casing (00).

W3-8-4-4

m : 19.6 N·m (14.5 lbf·ft)

SECTION 3 BODY Group 8 Pump Device Structure of Priority Valve 16

9 1

No. Part Name

Q’ty

1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Housing Spool Spring O-Ring Washer Retaining Ring O-Ring Spring Poppet Orifice Seat Pilot Seat Cartridge Washer Orifice Orifice Plug O-Ring Case O-Ring

Wrench Size

Tightening Torque N·m lbf·ft

5 13 12

WNDB-03-14-004

Remark

Diameter of Orifice: φ0.7

j : 24

32.5 Diameter of Orifice: φ1.2 Diameter of Orifice: φ0.65

l : 14

170

125

j : 38

221

163

fNOTE: Replace the parts except for O-rings (8, 19, 21) as the priority valve assembly. W3-8-5-1

SECTION 3 BODY Group 8 Pump Device (Blank)

W3-8-5-2

SECTION 3 BODY Group 8 Pump Device Structure of Pilot Pump

WNEC-03-08-005

W3-8-6-1

SECTION 3 BODY Group 8 Pump Device IMPORTANT: The housing is made of aluminum. Do not damage the housing. Take extreme care in order to control the tightening torque.

No.

Part Name

Q’ty

Wrench Size (mm)

Tightening Torque N·m lbf·ft

Remark

Flange

Oil Seal

Apply grease to the lip part when assembling. Identification color: Yellow

5 6 7

Retaining Ring Seal Cover

1 2 1

Identification color: White

Backup Ring

Apply grease to the lip part when assembling.

Key

O-Ring

Gear

Washer

Bushing

28 29 41

Knock Pin Bolt Housing

2 4 1

Apply grease to the lip part when assembling. Torque while turning right: 0.4 to 2 N·m (0.3 to 1.5 lbf·ft) Apply hydraulic oil when assembling. Apply hydraulic oil when assembling. j : 17

35 to 40

W3-8-6-2

26 to 30

SECTION 3 BODY Group 8 Pump Device Removal and Installation of Priority Valve

WNDB-03-14-001

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils. IMPORTANT: 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. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from hydraulic dCAUTION: oil tank. (Refer to W1-5-1.) 2. Remove cover (1). (Refer to W3-22-1.)

W3-8-7-1

SECTION 3 BODY Group 8 Pump Device

Detail A

8 2 5, 6, 7

3 WNDB-03-14-002

3. Disconnect hoses (1) (2 used). j : 41 mm

WNDB-03-14-003

7. Remove bolts (5) (2 used) and washers (6) (2 used). Remove priority valve (4). j : 19 mm

4. Disconnect hose (2). j : 19 mm

8 Remove the adapters with priority valve (4) attached if necessary.

5. Disconnect hose (3). j : 17 mm 6. Disconnect hose (8). j : 27 mm

W3-8-7-2

SECTION 3 BODY Group 8 Pump Device

Detail A

8 2 5, 6, 7

3 WNDB-03-14-002

Installation 1. Install all removed adapters to priority valve (4).

5. Connect hose (2).

2. Install priority valve (4) with bolts (5) (2 used) and washers (6) (2 used).

j : 19 mm m : 30 N·m (22 lbf·ft)

j : 19 mm m : 90 N·m (66 lbf·ft)

6. Connect hoses (1) (2 used). j : 41 mm

3. Connect hose (8).

m : 210 N·m (155 lbf·ft)

j : 27 mm m : 95 N·m (70 lbf·ft) 4. Connect hose (3). j : 17 mm m : 25 N·m (18.5 lbf·ft)

W3-8-7-3

WNDB-03-14-003

SECTION 3 BODY Group 8 Pump Device

WNDB-03-14-001

7. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Install cover (1). (Refer to W3-22-1.)

W3-8-7-4

SECTION 3 BODY Group 9 Control Valve Removal and Installation of Control Valve 2, 3

2, 3

WNEK50-03-13-001

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. Removal

WNEK50-03-09-001

4. Remove bolts, washers (3) (2 used) and clips (2) (2 used).

1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Remove cover (1). (Refer to W3-22-1.) Release any pressure in the front dCAUTION: attachment hydraulic circuit and the ride control accumulator (only for the machine with ride control device). (Refer to W1-5-1.) 3. Disconnect hoses (4) (2 used). j : 36 mm

W3-9-1-1

j : 19 mm

SECTION 3 BODY Group 9 Control Valve

WPD850-03-09-004

5. Disconnect hoses (3) (3 used). j : 19 mm 6. Disconnect hose (1). j : 41 mm 7. Disconnect hoses (4) (2 used). j : 41 mm 8. Disconnect pipe (2). j : 36 mm

W3-9-1-2

SECTION 3 BODY Group 9 Control Valve

WNDB-03-09-002

Disconnect hose (1). j : 27 mm

10. Disconnect pipe (3). j : 36 mm 11. Disconnect hose (2). j : 41 mm

W3-9-1-3

SECTION 3 BODY Group 9 Control Valve

WPD850-03-09-001

12. Disconnect hoses (1) (3 used). j : 19 mm

W3-9-1-4

SECTION 3 BODY Group 9 Control Valve View A 1

2 3

2 4 WNDB-03-09-004

WNDB-03-09-005 a-

dCAUTION: Control valve (3) weight: 41 kg (89 lb)

Eyebolt Mounting

Hole

15. Remove the adapters from control valve (3) if necessary.

13. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to eyebolt mounting holes (a) (2 places) of control valve (3). Attach nylon slings onto the eyebolts (2 used). Hoist and hold control valve (3).

14. Remove socket bolts (1) (3 used), washers (2) (6 used), and nuts (4) (3 used). Remove control valve (3) from bracket (5). l : 10 mm

W3-9-1-5

SECTION 3 BODY Group 9 Control Valve View A 1

2 3

2 4 WNDB-03-09-004

WNDB-03-09-005 a-

Eyebolt Mounting

Hole

3. Install control valve (3) to bracket (5) with nuts (4) (3 used), washers (2) (6 used), and socket bolts (1) (3 used).

Installation 1. Install all removed adapters to control valve (3).

dCAUTION: Control valve (3) weight: 41 kg (89 lb) 2. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to eyebolt mounting holes (a) (2 places) of control valve (3). Attach nylon slings onto the eyebolts (2 used). Hoist control valve (3).

l : 10 mm m : 133 N·m (98 lbf·ft)

W3-9-1-6

SECTION 3 BODY Group 9 Control Valve View A A

a b c

WPD850-03-09-002 ab-

WPD850-03-09-001

IMPORTANT: Check the angle to install hose (1). 4. Connect hoses (1) (3 used). j : 19 mm m : 30 N·m (22 lbf·ft)

W3-9-1-7

40 ° 30 °

15 °

SECTION 3 BODY Group 9 Control Valve A

4, 5

WNDB-05-02-001

WNDB-03-09-002

View A 2

IMPORTANT: Check the angle to install hose (2). 5. Connect hose (2).

j : 41 mm m : 210 N·m (155 lbf·ft) 6. Connect hose (1). j : 27 mm m : 180 N·m (133 lbf·ft) 7. Temporarily install pipe (3), clamp (5), and bolt, washer (4). 8. Tighten pipe (3).

j : 36 mm m : 180 N·m (133 lbf·ft) 9. Tighten bolt, washer (4). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-9-1-8

75 °

WNDB-03-09-006

SECTION 3 BODY Group 9 Control Valve 5, 6

WPD850-03-09-004

WNDB-05-02-001

View A

IMPORTANT: Check the angle to install hose (1). 10. Connect hose (1).

1 a

j : 41 mm m : 210 N·m (155 lbf·ft) 11. Connect hose (4). j : 41 mm m : 210 N·m (155 lbf·ft) 12. Temporarily install pipe (2), clamp (6), and bolt, washer (5). 13. Tighten pipe (2).

85 °

j : 36 mm m : 180 N·m (133 lbf·ft) 14. Tighten bolt, washer (5). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-9-1-9

WNDB-03-09-006

SECTION 3 BODY Group 9 Control Valve

View A

4 a A

15 ° WPD850-03-09-003

3 WPD850-03-09-004

IMPORTANT: Check the angle to install hose (4). 15. Connect hose (4).

View B

j : 41 mm m : 210 N·m (155 lbf·ft) IMPORTANT: Check the angle to install hose (2). 16. Connect hose (2).

j : 19 mm m : 30 N·m (22 lbf·ft) 17. Connect hoses (3) (2 used).

j : 19 mm

10 ° WPD850-03-03-014

m : 30 N·m (22 lbf·ft)

W3-9-1-10

SECTION 3 BODY Group 9 Control Valve 4

WNEK50-03-09-001

18. Connect hoses (4) (2 used). j : 36 mm m : 180 N·m (133 lbf·ft) 19. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-5-1.) 20. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 21. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.) 22. Install cover (1). (Refer to W3-22-1.)

W3-9-1-11

WNEK50-03-13-001

SECTION 3 BODY Group 9 Control Valve (Blank)

W3-9-1-12

SECTION 3 BODY Group 9 Control Valve Disassembly of Control Valve

f g h

j b

WNDB-03-09-007 12345678910111213-

Main Relief Valve Poppet Spring (2 Used) O-Ring (3 Used) Plug Plug Plug Poppet Poppet Plug Socket Bolt (9 Used) O-Ring (5 Used) Plug

14151617181920212223242526-

Spring Poppet Poppet Spring O-Ring Backup Ring Spring Seat (4 Used) Spring Bolt Socket Bolt (2 Used) Pilot Housing Pilot Housing Bolt

27282930313233343536373839-

Spring Pilot Housing Relief Valve Plug (2 Used) Housing O-Ring (2 Used) Spool Relief Valve Relief Valve Spool Plug Pilot Housing (2 Used) O-Ring

4041424344454647484950-

O-Ring End Plate Socket Bolt (4 Used) Poppet Spring Plug *O-Ring (3 Used) *O-Ring *O-Ring *O-Ring (3 Used) *O-Ring

ghi-

Lift Arm Spool Bucket Spool Overload Relief Valve (Lift Arm: Bottom Side)

Overload Relief Valve (Bucket: Bottom Side) Pump Control Valve Overload Relief Valve (Bucket: Rod Side)

fNOTE: As for the item with mark*, refer to W3-9-2-5 to W3-9-2-7.

abc-

Main Relief Valve Make-Up Valve (Lift Arm: Rod Side) Load Check Valve (Lift Arm Circuit)

def-

Load Check Valve (Bucket Circuit) Bucket Flow Rate Control Valve Low-Pressure Relief Valve

W3-9-2-1

kl-

SECTION 3 BODY Group 9 Control Valve Disassembly of Control Valve 1. Remove plug (10) from housing (31). Remove O-ring (48) from plug (10).

6. Remove socket bolts (23) (2 used) from pilot housing (24). Remove pilot housing (24) from pilot housing (28). l : 8 mm

l : 17 mm  Disassembly of Low-Pressure Relief Valve (f ) 2. Remove plug (13) from housing (31). Remove spring (14) and poppet (15) from housing (31). Remove O-ring (4) from plug (13). j : 36 mm  Disassembly of Overload Relief Valve (Bucket: Rod Side) (l) IMPORTANT: Do not disassemble the overload relief valve. If it has been disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) IMPORTANT: Attach a spanner onto the hexagonal part of the relief valve case. 3. Remove relief valve (29) from housing (31). Remove O-ring (50) from relief valve (29).

7. Remove O-ring (12) from pilot housing (24). 8. Put the matching marks on the spools (33, 36) assemblies and housing (31). Remove the spools (33, 36) assemblies from housing (31).  Disassembly of Bucket Spool (h) 9. Secure the spool (36) assembly in a vise by using wooden pieces as illustrated. Remove bolt (26), spring seats (20) (2 used), and spring (27) from spool (36). j : 19 mm

j : 32 mm 4. Remove socket bolts (11) (6 used) from pilot housings (38) (2 used) and pilot housing (25). Remove pilot housings (38) (2 used) and pilot housing (25) from housing (31). l : 8 mm W4GB-02-05-002

5. Remove O-rings (12) (3 used) from pilot housings (38) (2 used) and pilot housing (25).

W3-9-2-2

SECTION 3 BODY Group 9 Control Valve  Disassembly of Lift Arm Spool (g) 10. Secure the spool (33) assembly in a vise by using wooden pieces as illustrated. Remove bolt (22), O-ring (32), spring seats (20) (2 used), and spring (21) from spool (33).

 Disassembly of Pump Control Valve (k) 15. Remove plug (45), spring (44), and poppet (43) from end plate (41). Remove O-ring (49) from plug (45). l : 12 mm  Disassembly of Overload Relief Valves (Lift Arm: Bottom Side) (i) and Overload Relief Valves (Bucket: Bottom Side) (j) IMPORTANT: Do not disassemble the overload relief valve. 16. Remove relief valves (34, 35) from housing (31). Remove O-rings (49) (2 used) from relief valves (34, 35).

j : 19 mm

j : 27 mm

W4GB-02-05-002

11. Remove plug (37) from spool (33). Remove O-ring (32) from plug (37). j : 8 mm  Disassembly of Make-Up Valves (Lift Arm: Rod Side) (b) 12. Remove socket bolts (11) (3 used) from pilot housing (28). Remove pilot housing (28) from housing (31).

 Disassembly of Main Relief Valve (a) IMPORTANT: Do not disassemble the main relief valve. If it has been disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) IMPORTANT: Attach a spanner onto the hexagonal part of the relief valve case. 17. Remove main relief valve (1) from housing (31). Remove O-ring (47) from main relief valve (1).

l : 8 mm 13. Remove backup ring (19) and O-rings (12, 18) from pilot housing (28). 14. Remove spring (17) and poppet (16) from housing (31).

W3-9-2-3

j : 27 mm

SECTION 3 BODY Group 9 Control Valve  Disassembly of Load Check Valve (Bucket Circuit) (d) and Bucket Flow Rate Control Valve (e) 18. Remove plug (7) from housing (31). Remove spring (3) and poppets (8, 9) from housing (31) by using a magnet. Remove O-ring (4) from plug (7). j : 36 mm  Disassembly of Load Check Valve (Lift Arm Circuit) (c) 19. Remove plug (5) from housing (31). Remove spring (3) and poppet (2) from housing (31) by using a magnet. Remove O-ring (4) from plug (5). j : 36 mm 20. Remove socket bolts (42) (4 used) from end plate (41). Remove end plate (41) from housing (31). Remove O-rings (39, 40) from end plate (41). l : 10 mm 21. Remove plugs (30) (2 used) and plug (6) from housing (31). Remove O-rings (46) (3 used) from plugs (30) (2 used) and plug (6). l : 10 mm

W3-9-2-4

SECTION 3 BODY Group 9 Control Valve Assembly of Control Valve 11

6, 46

W3-9-2-5

WNDB-03-09-008

SECTION 3 BODY Group 9 Control Valve

WNDB-03-09-009

Section A-A

19 16

5 2

WNDB-03-09-010

Section B-B c

3 4

b g

37 24

28 20 32

W3-9-2-6

49 34 32

WNDB-03-09-011

SECTION 3 BODY Group 9 Control Valve

Section C-C 8

50 e

h j

20 36

Section D-D

WNDB-03-09-012

Section E-E 40

WNDB-03-09-013

41 WNDB-03-09-014

12345678910111213-

Main Relief Valve Poppet Spring (2 Used) O-Ring (3 Used) Plug Plug Plug Poppet Poppet Plug Socket Bolt (9 Used) O-Ring (5 Used) Plug

14151617181920212223242526-

Spring Poppet Poppet Spring O-Ring Backup Ring Spring Seat (4 Used) Spring Bolt Socket Bolt (2 Used) Pilot Housing Pilot Housing Bolt

27282930313233343536373839-

Spring Pilot Housing Relief Valve Plug (2 Used) Housing O-Ring (2 Used) Spool Relief Valve Relief Valve Spool Plug Pilot Housing (2 Used) O-Ring

4041424344454647484950-

O-Ring End Plate Socket Bolt (4 Used) Poppet Spring Plug O-Ring (3 Used) O-Ring O-Ring O-Ring (3 Used) O-Ring

ab-

Main Relief Valve Make-Up Valve (Lift Arm: Rod Side) Load Check Valve (Lift Arm Circuit)

Load Check Valve (Bucket Circuit) Bucket Flow Rate Control Valve Low-Pressure Relief Valve

ghi-

Lift Arm Spool Bucket Spool Overload Relief Valve (Lift Arm: Bottom Side)

Overload Relief Valve (Bucket: Bottom Side) Pump Control Valve Overload Relief Valve (Bucket: Rod Side)

ef-

W3-9-2-7

kl-

SECTION 3 BODY Group 9 Control Valve Assembly of Control Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-rings (46) (3 used) to plugs (30) (2 used) and plug (6). Install plugs (30) (2 used) and plug (6) to housing (31). l : 10 mm m : 120 to 140 N·m (89 to 103 lbf·ft) 2. Install O-rings (39, 40) to end plate (41). Install end plate (41) to housing (31) with socket bolts (42) (4 used). l : 10 mm m : 90 to 95 N·m (66 to 70 lbf·ft)  Assembly of Load Check Valve (Lift Arm Circuit) (c) 3. Install poppet (2) and spring (3) to housing (31). Install O-ring (4) to plug (5). Install plug (5) to housing (31).

 Assembly of Main Relief Valve (a) IMPORTANT: If the main relief valve has been disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) IMPORTANT: Attach a spanner onto the hexagonal part of the relief valve case. 5. Install O-ring (47) to main relief valve (1). Install main relief valve (1) to housing (31). j : 27 mm m : 180 to 210 N·m (133 to 155 lbf·ft)  Assembly of Pump Control Valve (k) 6. Install poppet (43) and spring (44) to end plate (41). Install O-ring (49) to plug (45). Install plug (45) to end plate (41). l : 12 mm m : 180 to 210 N·m (133 to 155 lbf·ft)  Assembly of Make-Up Valve (Lift Arm: Rod Side) (b) 7. Install poppet (16) and spring (17) to housing (31).

j : 36 mm m : 280 to 310 N·m (205 to 230 lbf·ft)  Assembly of Load Check Valve (Bucket Circuit) (d) and Bucket Flow Rate Control Valve (e) 4. Install poppets (9, 8) and spring (3) to housing (31). Install O-ring (4) to plug (7). Install plug (7) to housing (31).

8. Install O-rings (18, 12) and backup ring (19) to pilot housing (28). Install pilot housing (28) to housing (31) with socket bolts (11) (3 used).

j : 36 mm m : 280 to 310 N·m (205 to 230 lbf·ft)

W3-9-2-8

l : 8 mm m : 50 to 55 N·m (37 to 41 lbf·ft)

SECTION 3 BODY Group 9 Control Valve  Assembly of Bucket Spool (h) 9. Secure spool (36) in a vise by using wooden pieces as illustrated. Install spring seats (20) (2 used) and spring (27) to spool (36) with bolt (26). j : 19 mm

12. Fit the matching marks made when disassembling and install the spools (33, 36) assemblies to housing (31). 13. Install O-ring (12) to pilot housing (24). Install pilot housing (24) to pilot housing (28) with socket bolts (23) (2 used).

m : 25 to 30 N·m (18.5 to 22 lbf·ft)

l : 8 mm m : 50 to 55 N·m (37 to 41 lbf·ft) 14. Install O-ring (12) to pilot housing (25). Install pilot housing (25) to housing (31) with socket bolts (11) (2 used). l : 8 mm m : 50 to 55 N·m (37 to 41 lbf·ft) W4GB-02-05-002

 Assembly of Lift Arm Spool (g) 10. Secure spool (33) in a vise by using wooden pieces as illustrated. Install spring seats (20) (2 used), spring (21), and O-ring (32) to spool (33) with bolt (22). j : 19 mm m : 25 to 30 N·m (18.5 to 22 lbf·ft)

15. Install O-rings (12) (2 used) to pilot housings (38) (2 used). Install pilot housings (38) (2 used) to housing (31) with socket bolts (11) (4 used). l : 8 mm m : 50 to 55 N·m (37 to 41 lbf·ft)  Assembly of Overload Relief Valve (Lift Arm: Bottom Side) (i) and Overload Relief Valve (Bucket: Bottom Side) (j) 16. Install O-rings (49) (2 used) to relief valves (34, 35). Install relief valves (34, 35) to housing (31). j : 27 mm m : 240 to 270 N·m (175 to 200 lbf·ft)

W4GB-02-05-002

11. Install O-ring (32) to plug (37). Install plug (37) to spool (33). j : 8 mm m : 25 to 30 N·m (18.5 to 22 lbf·ft)

W3-9-2-9

SECTION 3 BODY Group 9 Control Valve  Assembly of Overload Relief Valve (Bucket: Rod Side) (l) IMPORTANT: If the overload relief valve has been disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) IMPORTANT: Attach a spanner onto the hexagonal part of the relief valve case. 17. Install O-ring (50) to relief valve (29). Install relief valve (29) to housing (31). j : 32 mm m : 85 to 90 N·m (63 to 66 lbf·ft)  Assembly of Low-Pressure Relief Valve (f ) 18. Install poppet (15) and spring (14) to housing (31). Install O-ring (4) to plug (13). Install plug (13) to housing (31). j : 36 mm m : 180 to 210 N·m (133 to 155 lbf·ft) 19. Install O-ring (48) to plug (10). Install plug (10) to housing (31). l : 17 mm m : 180 to 210 N·m (133 to 155 lbf·ft)

W3-9-2-10

SECTION 3 BODY Group 10 Pilot Valve Removal and Installation of Pilot Valve (Single-Lever Type)

3 1

2 4

WNEK50-03-10-001

WNEK50-03-10-002

3. Remove screws (3) (5 used). Remove cover (4).

1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Remove screws (2) (2 used). Remove cover (1).

W3-10-1-1

SECTION 3 BODY Group 10 Pilot Valve

View A

WNEK50-03-10-003

4. Remove screws (1) (3 used). Remove cover (2).

WNEK50-03-10-004

View B

5. Remove screws (3) (3 used). Remove cover (4). 6. Remove screws (5) (4 used). Remove cover (6). 3 6

3 WNEK50-03-10-005

W3-10-1-2

SECTION 3 BODY Group 10 Pilot Valve

Detail A

1 1

WNEK50-03-10-010

View B

WNEK50-03-10-006

7. Disconnect hoses (1) (6 used). j : 19 mm

8. Remove clip (3). 9. Disconnect connectors (2) (2 used).

W3-10-1-3

WNEK50-03-10-007

SECTION 3 BODY Group 10 Pilot Valve

1 4

2 3

WNEK50-03-10-008

10. Raise boot (1) and remove bolts, washers (4) (4 used). j : 10 mm 11. Remove pilot valve (2) from bracket (3). 12. Remove the adapters from pilot valve (2) if necessary.

W3-10-1-4

WNEK50-03-10-009

SECTION 3 BODY Group 10 Pilot Valve

1 4

2 3

WNEK50-03-10-008

Installation 1. Install all removed adapters to pilot valve (2). 2. Raise boot (1). Install pilot valve (2) to bracket (3) with bolts, washers (4) (4 used). Lower boot (1). j : 10 mm m : 5 N·m (3.7 lbf·ft)

W3-10-1-5

WNEK50-03-10-009

SECTION 3 BODY Group 10 Pilot Valve

Detail A

1 1

WNEK50-03-10-010

View B

WNEK50-03-10-006

3. Connect connectors (2) (2 used). 4. Secure harness (4) (2 used) with clip (3). 2

5. Connect hoses (1) (6 used). j : 19 mm m : 30 N·m (22 lbf·ft) 6. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-10-1-6

WNEK50-03-10-007

SECTION 3 BODY Group 10 Pilot Valve

View A

WNEK50-03-10-003

7. Install cover (6) with screws (5) (4 used).

WNEK50-03-10-004

View B

8. Install cover (4) with screws (3) (3 used). 9. Install cover (2) with screws (1) (3 used). 3 6

3 WNEK50-03-10-005

W3-10-1-7

SECTION 3 BODY Group 10 Pilot Valve

3 1

2 4

WNEK50-03-10-002

10. Install cover (4) with screws (3) (5 used). 11. Install cover (1) with screws (2) (2 used).

W3-10-1-8

WNEK50-03-10-001

SECTION 3 BODY Group 10 Pilot Valve Removal and Installation of Pilot Valve (Two Lever Type)

WNEK50-03-10-020

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Fully move the right console (2) assembly to the front by operating slide lever (1). 3. Open door (3).

W3-10-2-1

SECTION 3 BODY Group 10 Pilot Valve 1 1

WNEK50-03-10-021

3 View A

WNEK50-03-10-022

4. Remove screws (2) (3 used). Raise cover (1). 5. Disconnect connector (3). Remove connector (3) from cover (4). 6. Disconnect connector (5). 7. Remove cover (1).

W3-10-2-2

WNEK50-03-10-023

SECTION 3 BODY Group 10 Pilot Valve 1

View A

WNEK50-03-10-025

5 View A 1

WNEK50-03-10-024

8. Remove screws (1) (5 used). Remove cover (2). 9. Remove rubber seal (3). 10. Remove screws (5) (3 used). Remove cover (4). 11. Remove screws (7) (4 used). Remove cover (6). 12. Remove screws (8) (3 used). Remove cover (9). 13. Remove screws (10) (4 used). Remove cover (11).

WNEK50-03-10-026

View B

10 8 WNEK50-03-10-027

W3-10-2-3

SECTION 3 BODY Group 10 Pilot Valve View A

2 6 1

3 WNEK50-03-10-030

4 2

WNEK50-03-10-029

14. Remove clips (2) (4 used). 15. Disconnect connectors (4) (3 used) and connectors (5) (8 used). Place harness (1) outside the work area. 16. Remove connectors (4) (3 used) from bracket (3). 17. Remove rubber seal (6).

W3-10-2-4

SECTION 3 BODY Group 10 Pilot Valve A

Detail A

1 2 3

WNEK50-03-10-031

WNEK50-03-10-032

Detail A

18. Lower cover (5). Pull out grip (1) harness (4) from cover (5). 19. Loosen nut (2). Turn grip (1) counterclockwise. Remove grip (1) from lever (3). 3

j : 17 mm 20. Remove nut (2) from lever (3).

j : 17 mm 21. Remove cover (5) from lever (3). 22. Loosen nut (6). j : 19 mm 23. Remove lever (3) from pilot valve (7). Remove nut (6) from lever (3). j : 19 mm 24. Remove other lever (3) in the same way as step 18 to step 23.

W3-10-2-5

WNEK50-03-10-033

SECTION 3 BODY Group 10 Pilot Valve View A

2 4

WNEK50-03-10-035

WNEK50-03-10-034 B

View B

25. Disconnect hoses (4) (4 used). j : 19 mm

26. Disconnect hoses (5) (2 used). j : 19 mm 27. Remove socket bolts (3) (4 used). l : 8 mm 28. Remove pilot valve (2) from frame (1). 29. Remove the adapters from pilot valve (2) if necessary.

WNEK50-03-10-036

W3-10-2-6

SECTION 3 BODY Group 10 Pilot Valve View A

2 4

WNEK50-03-10-035

WNEK50-03-10-034

View B

Installation 1. Install all removed adapters to pilot valve (2).

2. Install pilot valve (2) to frame (1) with socket bolts (3) (4 used). l : 8 mm m : 50 N·m (37 lbf·ft) 3. Connect hoses (5) (2 used). j : 19 mm m : 30 N·m (22 lbf·ft)

WNEK50-03-10-036

4. Connect hoses (4) (4 used). j : 19 mm m : 30 N·m (22 lbf·ft)

W3-10-2-7

SECTION 3 BODY Group 10 Pilot Valve A

Detail A

3 6

WNEK50-03-10-031

WNEK50-03-10-033

Detail A

5. Temporarily install nut (6) to lever (3). 6. Install lever (3) to pilot valve (7). Tighten nut (6).

j : 19 mm 2 3

m : 40 N·m (29.5 lbf·ft) 7. Install cover (5) to lever (3). 8. Temporarily install nut (2) to lever (3).

IMPORTANT: Check the position to install grip (1). 9. Turn grip (1) clockwise. Install grip (1) to lever (3). Tighten nut (2).

j : 17 mm m : 20 N·m (15 lbf·ft) WNEK50-03-10-032

10. Pass grip (1) harness (4) into cover (5). Raise cover (5). Install cover (5) to grip (1).

11. Install another grip (1) in the same way as step 5 to step 10.

ab-

W3-10-2-8

146 mm (5.7 in.) 223 mm (8.8 in.)

cd-

WNEC-03-10-020 8 ° (Reference) Vehicle Front Side

SECTION 3 BODY Group 10 Pilot Valve 7

View A

2 6 1 8

2 9 3 WNEK50-03-10-030

4 2

WNEK50-03-10-029

12. Install rubber seal (6). 13. Install harness (1) in between grips (7) (2 used). 14. Install connectors (4) (3 used) to bracket (3). 15. Connect connectors (5) (8 used) and connectors (4) (3 used). 16. Secure harness (1), harnesses (8) (2 used) and harnesses (9) (3 used) with clips (2) (4 used).

W3-10-2-9

SECTION 3 BODY Group 10 Pilot Valve 1

View A

WNEK50-03-10-025

5 6

View A 1

WNEK50-03-10-024

17. Install cover (11) with screws (10) (4 used). 18. Install cover (9) with screws (8) (3 used). 19. Install cover (6) with screws (7) (4 used). 20. Install cover (4) with screws (5) (3 used). 21. Install rubber seal (3). 22. Install cover (2) with screws (1) (5 used).

WNEK50-03-10-026

View B

10 8 WNEK50-03-10-027

W3-10-2-10

SECTION 3 BODY Group 10 Pilot Valve 6

View A

WNEK50-03-10-023

1 3

WNEK50-03-10-022

23. Install cover (1) through grips (6). 24. Connect connector (5). 25. Install connector (3) to cover (4). Connect connector (3). 2

26. Install cover (1) with screws (2) (3 used). 27. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-10-2-11

WNEK50-03-10-021

SECTION 3 BODY Group 10 Pilot Valve

WNEK50-03-10-020

28. Operate slide lever (1) and moves the right console (2) assembly to the original position. 29. Close door (3).

W3-10-2-12

SECTION 3 BODY Group 10 Pilot Valve Disassembly of Pilot Valve (Single-Lever Type)

WNEC-03-10-001 1- Handle 11A- Lever 11B- Screw 11C- Nut 13- Boot 35A- Nut 35B- Washer 35C- Cam

35D- Shim (Several) 35E- Shim (Several) 35F- Shim (Several) 35G- Shim (Several) 35H- Shim (Several) 35I- Universal Joint 50A- Retaining Ring (3 Used) 50B- Armature (3 Used)

51- Plate 53B- Pusher (3 Used) 53C- Solenoid (3 Used) 53D- O-Ring (3 Used) 60A- Guide 60B- Pusher 60C- Plate 60D- Retaining Ring

W3-10-3-1

60E- O-Ring 62- Spool 63- Spool (3 Used) 65- Spring (4 Used) 66A- Socket (3 Used) 66B- Spring (3 Used) 80- Casing

SECTION 3 BODY Group 10 Pilot Valve Disassembly of Pilot Valve IMPORTANT: Keep the disassembled parts together by each port in order not to confuse. IMPORTANT: Casing (80) is made of aluminium. Strong force deforms it. Handle it with care. 1. Remove boot (13) from plate (51). Raise boot (13). 2. Remove the harness of handle (1) from plate (51). 3. Remove boot (13) from handle (1). Lower boot (13). 4. Remove screw (11B) from handle (1) by using a star screwdriver. 5. Remove handle (1) from lever (11A). 6. Loosen nut (11C) from lever (11A).

8. Remove boot (13) and nut (11C) from the lever (11A) assembly. 9. Remove retaining ring (50A) and armature (50B) from pusher (53B). 10. Remove other retaining rings (50A) (2 used) and armatures (50B) (2 used) in the same way as step 9. IMPORTANT: The quantity and kind of shims (35D, 35E, 35F, 35G, and 35H) have been determined for each pilot valve. Do not lose shims (35D, 35E, 35F, 35G, and 35H). 11. Remove nut (35A), washer (35B), cam (35C), and shims (35D, 35E, 35F, 35G, and 35H) from universal joint (35I).

j : 19 mm j : 27 mm

7. Remove the lever (11A) assembly from universal joint (35I).

fNOTE: LOCTITE #263 or equivalent has been applied to

fNOTE: LOCTITE #263 or equivalent has been applied to lever (11A).

W3-10-3-2

nut (35A).

SECTION 3 BODY Group 10 Pilot Valve 18. Remove spool (62) and spring (65) from hole (a) on port 2 of casing (80) by using a pair of pliers.

12. Remove universal joint (35I) from casing (80) by using a wrench. l : 8 mm

fNOTE: LOCTITE #263 or equivalent has been applied to

universal joint (35I).

fNOTE: Hold plate (51) against spring (65) when

removing universal joint (35I). 13. Remove plate (51) from casing (80).

b d

14. Remove plate (60C) and the guide (60A) assembly from casing (80) by using a screwdriver. 15. Remove the solenoid (53C) assemblies (3 used) from casing (80) by using a screwdriver. 16. Remove pusher (60B), retaining ring (60D), and O-ring (60E) from guide (60A).

WNEC-03-10-003

17. Remove pushers (53B) (3 used) and O-rings (53D) (3 used) from solenoids (53C) (3 used).

ab-

Hole on Port 2 Hole on Port 1

cd-

Hole on Port 3 Hole on Port 4

IMPORTANT: Keep the disassembled parts together by each port in order not to confuse. 19. Remove spools (63) (3 used), springs (65) (3 used), sockets (66A) (3 used), and springs (66B) (3 used) from hole (b) on port 1, hole (c) on port 3, and hole (d) on port 4 of casing (80) by using a pair of pliers.

W3-10-3-3

SECTION 3 BODY Group 10 Pilot Valve Assembly of Pilot Valve (Single-Lever Type)

Section A

11B

11A 11C 13

35D, 35E, 35F, 35G, 35H

35A

35I

35B

60B 60C

35C 50A

50B 53B 53C

60A 60E

53D

60D

66A

66B 62 63

65 80 WNEC-03-10-002 a

1- Handle 11A- Lever 11B- Screw 11C- Nut 13- Boot 35A- Nut 35B- Washer 35C- Cam

35D- Shim (Several) 35E- Shim (Several) 35F- Shim (Several) 35G- Shim (Several) 35H- Shim (Several) 35I- Universal Joint 50A- Retaining Ring (3 Used) 50B- Armature (3 Used)

Section of Port 2

51- Plate 53B- Pusher (3 Used) 53C- Solenoid (3 Used) 53D- O-Ring (3 Used) 60A- Guide 60B- Pusher 60C- Plate 60D- Retaining Ring

Sections of Port 1, 3, and 4

W3-10-3-4

60E- O-Ring 62- Spool 63- Spool (3 Used) 65- Spring (4 Used) 66A- Socket (3 Used) 66B- Spring (3 Used) 80- Casing

SECTION 3 BODY Group 10 Pilot Valve 3. Install pushers (53B) (3 used) and O-rings (53D) (3 used) to solenoids (53C) (3 used).

Assembly of Pilot Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling. IMPORTANT: Casing (80) is made of aluminium. Strong force deforms it. Handle it with care. 1. Check the port hole number and install the same parts before disassembling. Install springs (66B) (3 used), sockets (66A) (3 used), springs (65) (3 used), and spools (63) (3 used) to hole (b) on port 1, hole (c) on port 3, and hole (d) on port 4 of casing (80).

4. Install the solenoid (53C) assemblies (3 used) to hole (b) on port 1, hole (c) on port 3, and hole (d) on port 4 of casing (80). 5. Install pusher (60B), retaining ring (60D), and O-ring (60E) to guide (60A). 6. Install the guide (60A) assembly and plate (60C) to hole (a) on port 2 of casing (80). 7. Fit projection (f ) on the lower surface of plate (51) to groove (e) on the side of solenoids (53C) (3 used). Place plate (51) onto casing (80).

a c

b d

WNEC-03-10-003 ab-

Hole on Port 2 Hole on Port 1

cd-

Hole on Port 3 Hole on Port 4

Groove on Side of Solenoid (53C)

f, g fg-

2. Install spring (65) and spool (62) to hole (a) on port 2 of casing (80).

W3-10-3-5

WNEC-03-10-004 Projection on Lower Surface of Plate (51) Groove on Side of Plate (60C)

SECTION 3 BODY Group 10 Pilot Valve 8. Apply LOCTITE #263 or equivalent to the thread part of casing (80). Install plate (51) to casing (80) with universal joint (35I). l : 8 mm m : 50±5 N·m (37±4 lbf·ft)

IMPORTANT: Replace retaining ring (50A) with the new one. 12. Install retaining ring (50A) to pusher (53B). 13. Install other armatures (50B) (2 used) and retaining rings (50A) (2 used) in the same way as step 11 to step 12.

fNOTE: Hold plate (51) against spring (65) by hand. 9. Install shims (35D, 35E, 35F, 35G, and 35H), cam (35C), and washer (35B) to universal joint (35I).

fNOTE: Insert a screwdriver into the hole on the side of

cam (35C) and tighten it to the specified torque when installing nut (35A). 10. Apply LOCTITE #263 or equivalent to the thread part of universal joint (35I). Install nut (35A) to universal joint (35I). j : 27 mm

11. Install armature (50B) between the end of cam (35C) and pusher (53B).

14. Temporarily tighten nut (11C) to the lever (11A) assembly. j : 19 mm IMPORTANT: Check the direction to install the lever (11A) assembly. 15. Apply LOCTITE #263 or equivalent to the thread part of universal joint (35I). Install the lever (11A) assembly to universal joint (35I).

m : 30±3 N·m (22±2 lbf·ft)

W3-10-3-6

SECTION 3 BODY Group 10 Pilot Valve IMPORTANT: Install the harness of handle (1) by winding around lever (11A). At this time, adjust the harness in order not to rub. 21. Install bracket (b) of the harness of handle (1) to groove (a) on plate (51). Secure the harness.

16. Tighten nut (11C) to the specified torque. j : 19 mm m : 40±4 N·m (30±3 lbf·ft) 17. Install boot (13) to the lever (11A) assembly. IMPORTANT: Check the direction to install handle (1). 18. Install handle (1) to lever (11A). IMPORTANT: The thread part of handle (1) is made of resin. Take care not to tighten screw (11B) excessively. 19. Install screw (11B) to handle (1) by using a star screwdriver.

20. Install boot (13) to handle (1).

WNEC-03-10-005 a-

Groove

Bracket

22. Lower and install boot (13) to handle (51).

W3-10-3-7

SECTION 3 BODY Group 10 Pilot Valve (Blank)

W3-10-3-8

SECTION 3 BODY Group 10 Pilot Valve Disassembly of Pilot Valve (Two Lever Type) 5 6 2 3

5 6

2 3 4

7 8

10 11 12

2 3

9 7

7 8

9 7 10 11 12 51 13 14 15 16 17

51 13 14 15 16 17

14 15 17

13 14 15 16 17

10 11 12

2 3 4

42 43 20

22 21 22

21 22 23

24 25 26 27 28

24 25 26 27

25 29

26 30

27 31

28 29 30 31

32 a c

28 46 30 31

31 32

52 53 d

WNEC-03-10-006

W3-10-4-1

SECTION 3 BODY Group 10 Pilot Valve

1 - Socket Bolt (8 Used) 2 - Lock Nut (4 Used) 3 - Screw (4 Used) 4 - Lever (2 Used) 5 - Boot (2 Used) 6 - Lock Plug (2 Used) 7 - Bushing (4 Used) 8 - Cam Shaft (2 Used) 9 - Cover (2 Used) 10 - Detent Ring (3 Used) 11 - Spring (3 Used)

12 - Push Rod (3 Used) 13 - O-Ring (4 Used) 14 - Bushing (4 Used) 15 - Detent Bushing (4 Used) 16 - Steel Ball (12 Used) 17 - Scraper (4 Used) 18 - Push Rod 19 - Solenoid 20 - Detent Casing 21 - Spring Guide (4 Used) 22 - Spring (4 Used)

23 - Plate (2 Used) 24 - Seal (4 Used) 25 - Plug (4 Used) 26 - O-Ring (4 Used) 27 - Push Rod (4 Used) 28 - Spring Seat (4 Used) 29 - Spring (2 Used) 30 - Spring (4 Used) 31 - Washer (4 Used) 32 - Spool (4 Used) 42 - Solenoid

43 - Solenoid 44 - Detent Casing 45 - Spring 46 - Spring 50 - Casing 51 - Shim (3 Used) 52 - Socket Bolt 53 - Band

Hole on Port 1

Hole on Port 2

Hole on Port 3

W3-10-4-2

Hole on Port 4

SECTION 3 BODY Group 10 Pilot Valve 6. Remove the spring seat (28) assemblies (2 used) and springs (30) (2 used) from the holes on port 3 and port 4 of casing (50).

Disassembly of Pilot Valve (Two Lever Type) 1. Remove socket bolt (52) and band (53) from casing (50).  Disassembly of Pilot Valve Assemblies at Port 3 Section and Port 4 Section IMPORTANT: Casing (50) is made of aluminium. Strong force deforms it. Handle it with care. 2. Secure casing (50) in a vise by using wooden pieces. Remove boot (5) from cover (9). IMPORTANT: Put the matching marks on casing (50), detent casing (20), and cover (9) before disassembling. 3. Remove socket bolts (1) (2 used) from the deeper mounting part of cover (9).

IMPORTANT: Do not damage the surface of spool (32). IMPORTANT: Take care that spring seat (28) is not lowered 6 mm or more. 7. Lower spring seat (28) of the spring seat (28) assembly in the hole of port 3. Move spring seat (28) sideways while compressing spring (45). Remove the spool (32) assembly from larger hole (a) of spring seat (28). a

l : 5 mm 4. Remove the cover (9) assembly from casing (50). IMPORTANT: Keep the disassembled parts together by each port in order not to confuse. IMPORTANT: Take care that the plug (25) assembly does not fly out due to spring (30) when removing. 5. Remove the plug (25) assemblies (2 used) from casing (50) by using a screwdriver.

Hole

WNEC-03-10-008

8. Remove spring (45) and washer (31) from spool (32).

W3-10-4-3

SECTION 3 BODY Group 10 Pilot Valve 9. Remove spring seat (28), spring (46), washer (31), and spool (32) from the spring seat (28) assembly in the hole of port 4 in the same way as step 7 and step 8. 10. Remove push rods (27) (2 used) and O-rings (26) (2 used) from the plug (25) assemblies (2 used). IMPORTANT: Do not damage the inner surface of plug (25). 11. Remove seals (24) (2 used) from plugs (25) (2 used). IMPORTANT: As the spring force is applied to the cover (9) assembly, remove socket bolts (1) alternately. 12. Secure plate (23) of the cover (9) assembly in a vise. Remove socket bolts (1) (2 used) from the shallower mounting part of cover (9).

14. Remove springs (22) (2 used), spring guides (21) (2 used), and shims (51) (2 used) from plate (23). 15. Remove the detent casing (20) assembly from the cover (9) assembly. IMPORTANT: Do not pull the lead wire when removing solenoids (42, 43). 16. Remove solenoids (42, 43) from detent casing (20). 17. Remove lock plug (6) from lever (4) of the cover (9) assembly. l : 3 mm 18. Remove cam shaft (8) from cover (9). 19. Remove lever (4) from cover (9). 20. Remove nuts (2) (2 used) and screws (3) (2 used) from lever (4).

l : 5 mm IMPORTANT: Spring guides (21) (2 used) may be stuck to detent case (20) by grease. Do not drop them. 13. Remove the cover (9) assembly from plate (23).

W3-10-4-4

j : 13 mm

SECTION 3 BODY Group 10 Pilot Valve 21. Remove the detent bushing (15) assemblies (2 used) from the mounting side by using the special tools as illustrated. a

f b c

24. Remove push rods (12) (2 used) from detent bushings (15) (2 used). 25. Remove detent rings (10) (2 used) and springs (11) (2 used) from detent bushings (15) (2 used). IMPORTANT: Do not damage the inner surface of detent bushing (15) when removing scraper (17). 26. Remove scrapers (17) (2 used) from detent bushings (15) (2 used).

W4GB-02-06-012 abc-

Dia. 10-0.3-0.4 mm (Dia. 0.39-0.012-0.016 in) 30 mm (1.18 in) 40 mm (1.58 in)

def-

2 mm (0.079 in) Dia. 8-0.2-0.3 mm (Dia. 0.32-0.008-0.012 in) 30°

22. Remove O-rings (13) (2 used) from cover (9). IMPORTANT: Keep the disassembled parts together by each port in order not to confuse. IMPORTANT: Do not drop steel ball (16). 23. Compress springs (11) (2 used) while holding detent rings (10) (2 used). Remove steel balls (16) (8 used) from detent bushings (15) (2 used).

W3-10-4-5

SECTION 3 BODY Group 10 Pilot Valve  Disassembly of Pilot Valve Assemblies at Port 1 Section and Port 2 Section 27. Disassemble the pilot valve assemblies at port 1 section and port 2 section in the same way of step 2 to step 26.

fNOTE: Springs (45, 46), detent casing (20), solenoids

(42, 43), and push rod (12) are not equipped for the pilot valve assembly at port 1 side. Spring (29), detent casing (44), solenoid (19), and push rod (18) are quipped for it.

fNOTE: Detent ring (10), spring (11), shim (51), and steel balls (16) (4 used) are not equipped for the pilot valve assembly at port 1 side.

fNOTE: Springs (45, 46) and detent casing (20) are

not quipped for the pilot valve assembly at port 2 side. Spring (29) and detent casing (44) are equipped for it.

fNOTE: Solenoids (42, 43) are not equipped for the pilot valve assembly at port 2 side.

W3-10-4-6

SECTION 3 BODY Group 10 Pilot Valve Assembly of Pilot Valve (Two Lever Type)

4 5 3 2

14 16 12 16 10 11 17 15

6 10 11 17 15

1 13 9

42 12 19 44 51

20 21 51

53 52

24 25 26 50

28 45

46 30

29 29

32 31

Section A-A

Section B-B

d WNEC-03-10-007

W3-10-4-7

SECTION 3 BODY Group 10 Pilot Valve

43 - Solenoid 44 - Detent Casing 45 - Spring 46 - Spring 50 - Casing 51 - Shim (3 Used) 52 - Socket Bolt 53 - Band

Port 1

Port 2

Port 3

W3-10-4-8

Port 4

SECTION 3 BODY Group 10 Pilot Valve Assembly of Pilot Valve (Two Lever Type) IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.  Assembly of Pilot Valve Assemblies at Port 3 Section and Port 4 Section IMPORTANT: Check the direction to install scraper (17). 1. Apply grease onto scrapers (17) (2 used). Install scrapers (17) (2 used) to detent bushings (15) (2 used).

Take care that detent rings (10) (2 dCAUTION: used) do not fly out due to springs (11) (2 used). IMPORTANT: Adjust push rods (12) (2 used) so that steel balls (16) (8 used) fit on the constricted parts of push rods (12) (2 used). 4. Compress springs (11) (2 used) while holding detent rings (10) (2 used). Apply grease onto steel balls (16) (8 used). Install steel balls (16) (8 used) to the detent bushing (15) assemblies (2 used). 5. Install O-rings (13) (2 used) to cover (9). 6. Check the position before disassembling and install the detent bushing (15) assemblies (2 used) to cover (9).

15 17

7. Temporarily tighten screws (3) (2 used) and nuts (2) (2 used) to lever (4).

W4GB-02-06-014

2. Apply grease onto the sliding surface of detent bushings (15) (2 used) and detent rings (10) (2 used). Install detent rings (10) (2 used) and springs (11) (2 used) to detent bushings (15) (2 used). IMPORTANT: Check the direction to install push rods (12) (2 used). 3. Install push rods (12) (2 used) to the detent bushing (15) assemblies (2 used).

W3-10-4-9

SECTION 3 BODY Group 10 Pilot Valve 8. Apply grease onto top and bottom of push rods (12) (2 used), the sliding surface of lever (4) side surface, and the sliding surface of cam shaft (8). Secure cover (9) in a vise. Install lever (4) and cam shaft (8) to cover (9). 9. Apply LOCTITE #241 onto lock plug (6). Install lock plug (6) to lever (4). l : 3 mm m : 7 N·m (5.2 lbf·ft) IMPORTANT: Engage the rubber bushing of the lead wire passage position into the detent casing (20) groove. 10. Check the position before disassembling and install solenoids (42, 43) to detent casing (20).

12. Apply grease onto the mounting surface of spring of spring guides (21) (2 used). Check the position before disassembling and install spring (22) (2 used) and spring guides (21) (2 used) to plate (23). Take care that spring (22) (2 used) do dCAUTION: not fly out when installing the cover (9) assembly. 13. Install the cover (9) assembly and detent casing (20) to plate (23). Temporarily tighten socket bolts (1) (2 used) to the the shallower mounting part of cover (9). l : 5 mm 14. Secure plate (23) in a vise. Tighten socket bolts (1) (2 used) to cover (9) to the specified torque. Spray antirust oil to the spring chamber of detent casing (20).

IMPORTANT: Check the direction to install detent casing (20). 11. Install shims (51) (2 used) and detent casing (20) to push rods (12) (2 used) of the cover (9) assembly.

W3-10-4-10

l : 5 mm m : 9 N·m (6.6 lbf·ft)

SECTION 3 BODY Group 10 Pilot Valve IMPORTANT: Check the direction to install seal (24). 15. Install O-rings (26) (2 used), seals (24) (2 used), and push rods (27) (2 used) to plugs (25) (2 used).

IMPORTANT: Take care that spring seats (28) (2 used) are not lowered 6 mm or more. 17. Install the spool (32) assembly to larger hole (a) of spring seats (28) (2 used). Lower spring seats (28) (2 used). Move spring seats (28) (2 used) sideways while compressing springs (45, 46).

28 27

W4GB-02-06-015

16. Install springs (45, 46) and washers (31) (2 used) to spools (32) (2 used).

Hole

W3-10-4-11

WNEC-03-10-008

SECTION 3 BODY Group 10 Pilot Valve IMPORTANT: Do not fit bottom of spools (32) (2 used) to casing (50) too strongly. 18. Install springs (30) (2 used), the spool (32) assemblies (2 used), and the plug (25) assemblies (2 used) to the holes on port 3 and port 4 of casing (50). 19. Apply grease onto top of push rods (27) (2 used). 20. Secure casing (50) in a vise by using wooden pieces. Install the cover (9) assembly to casing (50). Install socket bolts (1) (2 used) to the deeper mounting part of cover (9). l : 5 mm

IMPORTANT: The clearance between screws (3) (2 used) and push rod (12) produces a small amount of play when starting the lever (4) operation. After tightening nut (2), recheck that no play is present. IMPORTANT: When pushing push rods (12) (2 used) with screws (3) (2 used) too strongly, the front attachment may be operated unexpectedly when starting the engine. 21. Adjust the height of screws (3) (4 used) so that levers (4) (2 used) are perpendicular to top of covers (9) (2 used). Turn the lever from side to side. Check that no play is present with the lever in neutral. Tighten it with nuts (2) (4 used). l : 13 mm

m : 9 N·m (6.6 lbf·ft)

m : 17 N·m (13 lbf·ft) IMPORTANT: When boot (5) is not installed correctly, waterproof is reduced. 22. Spray anti-rust oil to the parts inside boots (5) (2 used). Install top of boots (5) (2 used) to the grooves of levers (4) (2 used). Install bottom of boots (5) (2 used) to the grooves of covers (9) (2 used).

W3-10-4-12

SECTION 3 BODY Group 10 Pilot Valve  Assembly of Pilot Valve Assemblies at Port 1 Side and Port 2 Side 23. Assemble the pilot valve assemblies at port 1 side and port 2 side in the same way of step 1 to step 22.

24. Install socket bolt (52) and band (53) to casing (50).

fNOTE: Springs (45, 46), detent casing (20), solenoids

(42, 43), and push rod (12) are not quipped for the pilot valve assembly at port 1 side. Spring (29), detent casing (44), solenoid (19), and push rod (18) are equipped for it.

fNOTE: Detent ring (10), spring (11), shim (51), and steel balls (16) (4 used) are not equipped for the pilot valve assembly at port 1 side.

fNOTE: Springs (45, 46) and detent casing (20) are

not quipped for the pilot valve assembly at port 2 side. Spring (29) and detent casing (44) are equipped for it.

fNOTE: Solenoids (42, 43) are not equipped for the pilot valve assembly at port 2 side.

W3-10-4-13

SECTION 3 BODY Group 10 Pilot Valve (Blank)

W3-10-4-14

SECTION 3 BODY Group 11 Brake Charge Valve Removal and Installation of Brake Charge Valve

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. Removal 1. Operate the steering wheel in right to the steering end. 2. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Operate the brake pedal more than 50 dCAUTION: times and release any pressure in the circuit. Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 3. Remove inspection cover (1). (Refer to W3-22-1.)

W3-11-1-1

WPD850-03-01-003

SECTION 3 BODY Group 11 Brake Charge Valve View A 3

a A

Vehicle Front Side

WNEK50-03-11-001

4. Remove clip band (4). Disconnect connector (2). 5. Disconnect hose (1). j : 27 mm 6. Disconnect hose (3). j : 27 mm

W3-11-1-2

WPD850-03-11-001

SECTION 3 BODY Group 11 Brake Charge Valve View A

10 3 9 4 8 7 5

WNEK50-03-11-001

7. Disconnect hoses (1, 10). j : 27 mm 8. Disconnect hoses (7, 8, 9).

WPD850-03-11-002

10. Remove bolts, washers (2, 6) (2 used for each), washers (3) (2 used) and cushions (11) (2 used). Remove the bracket (5) assembly from rear frame (4). j : 17 mm

j : 19 mm 9. Disconnect hoses (12, 13). j : 22 mm

W3-11-1-3

SECTION 3 BODY Group 11 Brake Charge Valve 1

5 2

WNEK50-03-11-004

11. Remove bolt, washer (5), bolts, washers (2) (2 used) and nut (1). Remove brake charge valve (4) from the bracket (3) assembly. j : 17 mm 12. Remove the adapters from brake charge valve (4) if necessary.

W3-11-1-4

SECTION 3 BODY Group 11 Brake Charge Valve 1

5 2

WNEK50-03-11-004

Installation 1. Install all removed adapters to brake charge valve (4). 2. Install brake charge valve (4) to the bracket (3) assembly with nut (1), bolts, washers (2) (2 used) and bolt, washer (5). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-11-1-5

SECTION 3 BODY Group 11 Brake Charge Valve View A

3 4 8 7 5

Vehicle Front Side

WNEK50-03-11-001

3. Install the bracket (5) assembly to rear frame (4) with cushions (11) (2 used), washers (3) (2 used) and bolts, washers (2, 6) (2 used for each).

WPD850-03-11-002

View B

j : 17 mm Bolt, Washer (2) m : 20 N·m (15 lbf·ft) Bolt, Washer (6)

a b

m : 50 N·m (37 lbf·ft) 4. Connect hoses (12, 13). j : 22 mm

m : 40 N·m (29.5 lbf·ft)

IMPORTANT: Check the angle to install hoses (7, 8). 5. Connect hoses (7, 8, 9). j : 19 mm m : 30 N·m (22 lbf·ft) 6. Connect hoses (1, 10). j : 27 mm Hose (10) m : 80 N·m (59 lbf·ft) Hose (1) m : 95 N·m (70 lbf·ft)

W3-11-1-6

15˚

7 b-

30˚

WNEK50-03-11-005

SECTION 3 BODY Group 11 Brake Charge Valve View A 3

WPD850-03-11-001

WNEK50-03-11-001

7. Connect hose (3).

View B a

j : 27 mm m : 80 N·m (59 lbf·ft) 1

IMPORTANT: Check the angle to install hoses (1). 8. Connect hose (1). j : 27 mm m : 80 N·m (59 lbf·ft) 9. Connect connector (2). Install clip band (4).

W3-11-1-7

45˚

WPD850-03-11-003

SECTION 3 BODY Group 11 Brake Charge Valve

10. Bleed air from the hydraulic system and brake (axle). (Refer to W1-4-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 11. Install inspection cover (1). (Refer to W3-22-1.)

W3-11-1-8

WPD850-03-01-003

SECTION 3 BODY Group 11 Brake Charge Valve Structure of Brake Charge Valve 24

Section A-A

20 22 23 19 18 17

21 1 10 7

6 B

26 5

Section B-B C

Section C-C

TNED-03-07-017

30 29 12345678-

Body Valve Seat Check Valve Spring Plug O-Ring Filter Spring

910111213141516-

Priority Valve Plug Orifice Plug O-Ring Plug O-Ring Pilot Piston

1718192021222324-

Spring Seat Spring Spring Plug O-Ring Seat O-Ring Screw

W3-11-2-1

28 31 25262728293031-

Lock Nut Piston Spring Spool Washer Spring Orifice

SECTION 3 BODY Group 11 Brake Charge Valve Structure of Brake Charge Valve No.

Part Name

Q’ty

1 2

Body Valve Seat

1 1

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Check Valve Spring Plug O-Ring Filter Spring Priority Valve Plug Orifice Plug O-Ring Plug O-Ring Pilot Piston Spring Seat Spring Spring Plug O-Ring Seat O-Ring Screw

1 1 1 5 1 1 1 4 1 1 1 2 2 1 1 1 1 1 1 1 1 1

Lock Nut

26 27 28 29 30 31

Piston Spring Spool Washer Spring Orifice

1 1 1 2 2 2

Wrench Size mm

Tightening Torque N·m (lbf·ft)

Remark

Do not disassemble. j : 27

50 to 85

(37 to 63)

10 to 15

(7.4 to 11)

l : 10 l:5 l:6

50 to 85 10 to 15 30 to 40

(37 to 63) (7.4 to 11) (22 to 30)

l:5

17 to 23

(12 to 17)

j : 41

120 to 140

(89 to 103)

Do not disassemble. Do not disassemble.

l:5

IMPORTANT: Do not disassemble valve seat (2). IMPORTANT: If lock nut (25) and screw (24) are loosened, the accumulated brake pressure value changes. Loose lock nut (25) and screw (24) and release the spring (19) force when removing plug (20).

W3-11-2-2

10 to 15

(7.4 to 11)

SECTION 3 BODY Group 11 Brake Charge Valve Removal and Installation of Brake Accumulator

dCAUTION:  Use only the qualified parts for the accumulator.  Allow only qualified personnel to handle the accumulator.  Never hit or bring a fire close to the accumulator.  Do not process the accumulator directly. Do not weld the accumulator housing.  Be sure to release pressure before starting to work on the piping lines. IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

WPD850-03-01-003

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Operate the brake pedal more than 50 dCAUTION: times and release any pressure in the circuit. Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Remove the following parts. (Refer to W3-22-1.)  Under Guard (Rear) (1) (only for the machine with under guard)  Rear Fender (Front) (2)  Inspection Cover (3)

W3-11-3-1

SECTION 3 BODY Group 11 Brake Charge Valve

1 b

WNEK50-03-04-002 a-

Vehicle Front Side

Drive Unit

IMPORTANT: Do not apply liquid packing onto drain plug (1). 3. Place a container under drain plug (1). Remove drain plug (1). Drain off transmission oil. Install drain plug (1). j : 22 mm m : 80 N·m (59 lbf·ft)

fNOTE: Amount of transmission oil: 30 L (7.9 US gal) 4. Loosen clamps (2) (2 used). Disconnect the both ends of hose (3). j : 7 mm

W3-11-3-2

SECTION 3 BODY Group 11 Brake Charge Valve A

WPD850-03-11-005

5 WPD850-03-11-004 Detail A

5. Disconnect hoses (5) (2 used). j : 19 mm Remove the bracket (2) assembly dCAUTION: while holding it. Do not drop the bracket (2) assembly. IMPORTANT: When removing the bracket (2) assembly, be sure not to contact the bracket (2) assembly with pipe (4). 6. Remove bolts, washers (1) (4 used). Remove the bracket (2) assembly from rear frame (3).

WPD850-03-11-006

j : 17 mm

W3-11-3-3

SECTION 3 BODY Group 11 Brake Charge Valve 2 1

3 3

WNDB-03-11-005

7. Remove nuts (3) (16 used) and U-bolts (4) (4 used). Remove brake accumulators (1) (2 used) from bracket (2). j : 17 mm 8. Remove the adapters from brake accumulators (1) (2 used) if necessary.

W3-11-3-4

SECTION 3 BODY Group 11 Brake Charge Valve

View A

4 3 a-

WNEK50-03-11-008

No clearance

4 View B

A b

WNDB-03-11-005 B

Installation 1. Install all removed adapters to brake accumulators (1) (2 used). IMPORTANT: Check the position to install brake accumulators (1) (2 used). 2. Install brake accumulators (1) (2 used) to bracket (2) with nuts (3) (16 used) and U-bolts (4) (4 used).

2 WNDB-03-11-006 b-

j : 17 mm m : 20 N·m (15 lbf·ft)

W3-11-3-5

25˚

SECTION 3 BODY Group 11 Brake Charge Valve A

WPD850-03-11-005

5 WPD850-03-11-004 Detail A

IMPORTANT: When installing the bracket (2) assembly, be sure not to contact the bracket (2) assembly with pipe (4). 3. Install the bracket (2) assembly to rear frame (3) with bolts, washers (1) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft) 4. Connect hoses (5) (2 used). WPD850-03-11-006

j : 19 mm m : 30 N·m (22 lbf·ft)

W3-11-3-6

SECTION 3 BODY Group 11 Brake Charge Valve

2 11

2 WNEK50-03-04-002

5. Connect the both ends of hose (3) with clamps (2) (2 used). j : 7 mm m : 5.4 N·m (4 lbf·ft) 6. Open cap (11). Add transmission oil to drive unit (10).

fNOTE: Amount of transmission oil: 30 L (7.9 US gal)

W3-11-3-7

WNEK50-03-11-012

SECTION 3 BODY Group 11 Brake Charge Valve

IMPORTANT: Check the hydraulic oil level and transmission oil level. Start the engine and check for any oil leaks. 7. Bleed air from the hydraulic system and brake (axle). (Refer to W1-4-1.) 8. Install the following parts. (Refer to W3-22-1.)  Inspection Cover (3)  Rear Fender (Front) (2)  Under Guard (Rear) (1) (only for the machine with under guard)

W3-11-3-8

WPD850-03-01-003

SECTION 3 BODY Group 12 Manifold Valve Removal and Installation of Manifold Valve

WPD850-03-01-003

Removal

1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) Operate the steering wheel to the dCAUTION: right and left several times, and release any pressure in the circuit. Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.)

 Be sure to release pressure before starting to work on the piping lines.

2. Remove the following parts. (Refer to W3-22-1.) IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

W3-12-1-1

 Step (Front) (2)  Deck (3)  Rear Fender (Front) (4)  Cab Under Cover (1)

SECTION 3 BODY Group 12 Manifold Valve View A B A

WNEK50-03-12-001

3. Disconnect connectors (4) (3 used).

WNDB-03-12-002

View B

4. Disconnect hoses (3) (2 used). j : 19 mm 5. Disconnect hose (2). j : 17 mm 6. Disconnect hose (1). j : 27 mm

WNDB-03-12-003

W3-12-1-2

SECTION 3 BODY Group 12 Manifold Valve

WNDB-03-12-004

7. Disconnect hoses (1) (2 used). j : 17 mm 8. Disconnect hose (2). j : 27 mm 9. Disconnect hose (3). j : 19 mm

W3-12-1-3

SECTION 3 BODY Group 12 Manifold Valve A

Detail A 3 1

5 4 WNEK50-03-12-006 WNEC-03-12-012

10. Remove bolts, washers (3) (3 used), washers (4) (6 used), and rubber cushions (5) (3 used). Remove the bracket (2) assembly from rear frame (1). j : 19 mm

W3-12-1-4

SECTION 3 BODY Group 12 Manifold Valve

1 2

3 6 5

WPD850-03-12-001

15. Remove the adapters from manifold valve (1) if necessary.

11. Remove connectors (6) (7 used). j : 19 mm 12. Remove bolts, washers (4) (3 used). Remove manifold valve (1) from bracket (5). j : 17 mm 13. Remove accumulator (2) from manifold valve (1). j : 36 mm 14. Remove pressure sensor (3) from manifold valve (1). j : 24 mm

W3-12-1-5

SECTION 3 BODY Group 12 Manifold Valve

1 2

3 6 5

Installation 1. Install all removed adapters to manifold valve (1).

WPD850-03-12-001

4. Install manifold valve (1) to bracket (5) with bolts, washers (4) (3 used). j : 17 mm

2. Install pressure sensor (3) to manifold valve (1).

m : 50 N·m (37 lbf·ft)

j : 24 mm m : 16 N·m (12 lbf·ft)

5. Install connectors (6) (2 used).

3. Install accumulator (2) to manifold valve (1). j : 36 mm m : 98 N·m (72 lbf·ft)

W3-12-1-6

SECTION 3 BODY Group 12 Manifold Valve A

Detail A 3 1

5 4 WNEK50-03-12-006 WNEC-03-12-012

6. Install the bracket (2) assembly to rear frame (1) with rubber cushions (5) (3 used), washers (4) (6 used) and bolts, washers (3) (3 used). j : 19 mm m : 40 N·m (29.5 lbf·ft)

W3-12-1-7

SECTION 3 BODY Group 12 Manifold Valve View A 3

WNEK50-03-12-001

7. Connect hose (3). j : 19 mm m : 30 N·m (22 lbf·ft) 8. Connect hoses (1) (2 used). j : 17 mm m : 25 N·m (18.5 lbf·ft) 9. Connect hose (2). j : 22 mm m : 40 N·m (29.5 lbf·ft)

W3-12-1-8

WNDB-03-12-004

SECTION 3 BODY Group 12 Manifold Valve View A a a

WNDB-03-12-006

10. Connect hoses (3) (2 used). j : 19 mm m : 30 N·m (22 lbf·ft) IMPORTANT: Check the angle to install hose (2). 11. Connect hose (2). j : 17 mm m : 25 N·m (18.5 lbf·ft) IMPORTANT: Check the angle to install hose (1). 12. Connect hose (1). j : 27 mm m : 80 N·m (59 lbf·ft)

W3-12-1-9

75°

WPD850-03-12-002

SECTION 3 BODY Group 12 Manifold Valve

Detail A A

1 WNEK50-03-12-002

WNEK50-03-12-001

13. Connect connectors (1) (3 used). 14. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine. Operate the steering wheel to the steering end several times and check for any oil leaks.

W3-12-1-10

SECTION 3 BODY Group 12 Manifold Valve

18. Install the following parts. (Refer to W3-22-1.)  Cab Under Cover (1)  Rear Fender (Front) (4)  Deck (3)  Step (Front) (2)

W3-12-1-11

WPD850-03-01-003

SECTION 3 BODY Group 12 Manifold Valve (Blank)

W3-12-1-12

SECTION 3 BODY Group 12 Manifold Valve Disassembly of Manifold Valve

WNEC-03-12-001

01020304050607080910-

Plug Shim (Several) Poppet Spring Shim (Several) Plunger Spring Spring Plug Sleeve

12131415161720212224-

Filter Screw Spool Stopper Filter Solenoid Spring Solenoid Body Plug (7 Used)

25262728293032333435-

Plug Plug (2 Used) Plug Socket Bolt (4 Used) Washer Nut O-Ring O-Ring (7 Used) O-Ring (2 Used) O-Ring

W3-12-2-1

36- O-Ring (2 Used) 37- O-Ring (2 Used) 38- O-Ring 39- O-Ring 40- O-Ring 41- O-Ring 43A- Sleeve 43B- Spool

SECTION 3 BODY Group 12 Manifold Valve Disassembly of Manifold Valve IMPORTANT: Keep the disassembled parts together by each port in order not to confuse. IMPORTANT: The quantity and kind of shims (02, 05) have been determined for each manifold valve. Do not lose shims (02, 05). 1. Remove plug (01), O-ring (37), spring (04), shims (05, 02), and poppet (03) from body (22).

5. Measure and record mounting dimension (a) before removing screw (13). 22 13

j : 36 mm 2. Remove plug (09), O-ring (34), spring (07), and plunger (06) from body (22).

l : 6 mm 3. Remove socket bolts (28) (2 used) from solenoid (17). Remove solenoid (17), O-ring (41), sleeve (43A), O-rings (40, 39, 38), spool (43B), and spring (20) from body (22).

WNEC-03-12-005 a-

Mounting Dimension

6. Remove O-ring (34) and screw (13) from body (22).

l : 4 mm 4. Remove nut (30) from body (22). j : 17 mm

l : 6 mm 7. Remove socket bolts (28) (2 used) from solenoid (21). Remove solenoid (21), O-ring (32), and the sleeve (10) assembly from body (22). l : 4 mm

W3-12-2-2

SECTION 3 BODY Group 12 Manifold Valve 8. Remove spool (14) from sleeve (10).

fNOTE: Spring (08) and washer (29) cannot be

disassembled as stopper (15) has been press fitted to sleeve (10).

9. Remove plugs (24) (7 used) and O-rings (33) (7 used) from body (22). l : 5 mm 10. Remove plug (25) and O-ring (35) from body (22). l : 6 mm 11. Remove plug (27) and O-ring (37) from body (22). l : 12 mm 12. Remove plugs (26) (2 used) and O-rings (36) (2 used) from body (22). l : 8 mm

fNOTE: Filters (12, 16) cannot be disassembled as they have been press fitted to body (22).

W3-12-2-3

SECTION 3 BODY Group 12 Manifold Valve Assembly of Manifold Valve

24, 33

W V

28 17

21 22

24, 33 WNEC-03-12-002

Section V

Section W

35 12

43A 43B 20 30 13

41 32 10

39 38

14 29 08 15 WNEC-03-12-003

W3-12-2-4

TNED-03-07-012

SECTION 3 BODY Group 12 Manifold Valve Section X-X

Section Y-Y

09 34 16 06 33 24 26 36 33 24 TNED-03-07-011

TNED-03-07-010

Section Z-Z

27 02, 05 37 33 24 03

33 24 36 26

WNEC-03-12-004

01020304050607080910-

Plug Shim (Several) Poppet Spring Shim (Several) Plunger Spring Spring Plug Sleeve

12131415161720212224-

Filter Screw Spool Stopper Filter Solenoid Spring Solenoid Body Plug (7 Used)

25262728293032333435-

Plug Plug (2 Used) Plug Socket Bolt (4 Used) Washer Nut O-Ring O-Ring (7 Used) O-Ring (2 Used) O-Ring

W3-12-2-5

36- O-Ring (2 Used) 37- O-Ring (2 Used) 38- O-Ring 39- O-Ring 40- O-Ring 41- O-Ring 43A- Sleeve 43B- Spool

SECTION 3 BODY Group 12 Manifold Valve 5. Install spool (14) to sleeve (10). Install the sleeve (10) assembly to body (22). Install O-ring (32) to solenoid (21). Install solenoid (21) to body (22) with socket bolts (28) (2 used).

Assembly of Manifold Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-rings (36) (2 used) to plugs (26) (2 used). Install plug (26) to body (22).

l : 4 mm m : 3.92±0.4 N·m (2.9±0.3 lbf·ft)

l : 8 mm m : 48.5±4.9 N·m (36±3.6 lbf·ft)

6. Install O-ring (34) to screw (13). Install screw (13) to body (22) so that a clearance can be equal to mounting dimension (a) before disassembling.

2. Install O-ring (37) to plug (27). Install plug (27) to body (22).

l : 6 mm

l : 12 mm m : 98±9.8 N·m (72±7.2 lbf·ft)

3. Install O-ring (35) to plug (25). Install plug (25) to body (22).

l : 6 mm m : 26.5±2.9 N·m (20±2.1 lbf·ft) a

4. Install O-rings (33) (7 used) to plugs (24) (7 used). Install plugs (24) (7 used) to body (22). l : 5 mm m : 9.8±1 N·m (7.2±0.7 lbf·ft)

WNEC-03-12-005 a-

Mounting Dimension

7. Install nut (13) to screw (30). j : 17 mm m : 19.6±2 N·m (14±1.5 lbf·ft)

W3-12-2-6

SECTION 3 BODY Group 12 Manifold Valve 8. Install O-rings (40, 39, and 38) to sleeve (43A). Install spool (43B) to sleeve (43A). 9. Install spring (20) and the sleeve (43A) assembly to body (22). 10. Install O-ring (41) to solenoid (17). Install solenoid (17) to body (22) with socket bolts (28) (2 used). l : 4 mm m : 3.92±0.4 N·m (2.9±0.3 lbf·ft) 11. Install O-ring (34) to plug (09). Install plunger (06), spring (07), and plug (09) to body (22). l : 6 mm m : 12.0±1.2 N·m (8.9±0.9 lbf·ft) 12. Install O-ring (37) to plug (01). Install poppet (03), spring (04), shims (02, 05), and plug (01) to body (22). j : 36 mm m : 98±9.8 N·m (72±7.2 lbf·ft)

W3-12-2-7

SECTION 3 BODY Group 12 Manifold Valve (Blank)

W3-12-2-8

SECTION 3 BODY Group 13 Solenoid Valve Removal and Installation of Parking Brake Solenoid Valve Unit

CAUTION:

 Use only the qualified parts for the accumulator.  Allow only qualified personnel to handle the accumulator.

WPD850-03-01-003

 Never hit or bring a fire close to the accumulator.  Do not process the accumulator directly. Do not weld the accumulator housing.  Be sure to release pressure before starting to work on the piping lines. IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) Release any pressure from the parking dCAUTION: brake circuit. (Refer to W1-5-1.) 2. Remove inspection cover (1) and step (2). (Refer to W3-22-1.)

W3-13-3-1

SECTION 3 BODY Group 13 Solenoid Valve View A A

9 a

5 1 WPD850-03-04-005 a-

Vehicle Front Side

6 WPD850-03-13-001

3. Disconnect connectors (4, 7). 4. Disconnect hoses (1) (3 used) and hose (2). j : 19 mm, 22 mm 5. Remove bolts, washers (5) (2 used) and bracket (6). Remove parking brake solenoid valve unit (8) from rear frame (9). j : 19 mm

W3-13-3-2

SECTION 3 BODY Group 13 Solenoid Valve

WNEK50-03-13-005

6. Remove accumulator (1) from the parking brake solenoid valve unit (3) assembly. j : 36 mm 7. Remove pressure switch (2) from parking brake solenoid valve unit (3). j : 27 mm 8. Remove the adapters from parking brake solenoid valve unit (3) if necessary.

W3-13-3-3

SECTION 3 BODY Group 13 Solenoid Valve

WNEK50-03-13-005

Installation 1. Install all removed adapters to parking brake solenoid valve unit (3). 2. Install pressure switch (2) to parking brake solenoid valve unit (3). j : 27 mm m : 98 N·m (72 lbf·ft) 3. Install accumulator (1) to parking brake solenoid valve unit (3). j : 36 mm m : 98 N·m (72 lbf·ft)

W3-13-3-4

SECTION 3 BODY Group 13 Solenoid Valve View A A

1 B

9 a

5 1 WPD850-03-04-005 a-

Vehicle Front Side

6 WPD850-03-13-001

View B

4. Install parking brake solenoid valve unit (8) and bracket (6) to rear frame (9) with bolts, washers (5) (2 used). j : 19 mm m : 90 N·m (66 lbf·ft) IMPORTANT: Check the angle to install hose (2). 5. Connect hoses (1) (3 used) and hose (2).

j : 19 mm

2 WNEC-03-13-006

m : 30 N·m (22 lbf·ft) b-

j : 22 mm m : 40 N·m (29.5 lbf·ft) 6. Connect connectors (4, 7).

W3-13-3-5

50°

SECTION 3 BODY Group 13 Solenoid Valve

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 7. Bleed air from the hydraulic system. (Refer to W1-41.) 8. Install inspection cover (1) and step (2). (Refer to W3-22-1.)

W3-13-3-6

WPD850-03-01-003

SECTION 3 BODY Group 13 Solenoid Valve Structure of Parking Brake Solenoid Valve Unit 1

3 3 3 3

5 6

WNEJ-03-13-001

No.

Part Name

Q’ty

Wrench Size (mm) l: 4

1 2 3 4 5

Socket Bolt Solenoid Valve O-Ring Block O-Ring

4 1 4 1 2

6 7

O-Ring Filter

2 2

Tightening Torque N·m lbf·ft 5+1 3.7+0.7

Remark

Apply grease onto the outer surface when assembling. l: 6

25+5

W3-13-4-1

18.5+3.7

SECTION 3 BODY Group 13 Solenoid Valve (Blank)

W3-13-4-2

SECTION 3 BODY Group 13 Solenoid Valve Structure of Parking Brake Solenoid Valve

W4GB-03-10-003

No.

Part Name

Q’ty

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Housing Spool Spring Seat Spring O-Ring Rod Stopper Plunger Spring Rod Inner Housing Coil Spacer Screw

1 1 2 2 4 1 1 1 1 1 1 1 1 1

15 16 17 18 19 20 21 24

O-Ring Spring O-Ring Washer Retaining Ring Plug Pipe Socket Bolt

2 1 1 1 1 1 1 4

Wrench Size (mm)

N·m

Tightening Torque (lbf·ft)

j : 32

30 to 40

(22 to 30)

l : 14

30 to 40

(22 to 30)

l : 2.5

5 to 6

(3.7 to 4.4)

W3-13-5-1

Remark

Apply LOCTITE #243 or equivalent.

SECTION 3 BODY Group 13 Solenoid Valve (Blank)

W3-13-5-2

SECTION 3 BODY Group 14 Flow Regulator Valve Removal and Installation of Flow Regulator Valve

WNEK50-03-22-003

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Remove the following parts. (Refer to W3-22-1.)  

W3-14-1-1

Rear Fender (Front) (2) Cab Under Cover (1)

SECTION 3 BODY Group 14 Flow Regulator Valve Detail A

2 B

WNEK50-03-14-001

WPD850-03-14-001

View B

3. Remove clip band (9). Disconnect connector (6).

4. Disconnect hoses (1) (4 used). j : 19 mm 5. Disconnect hoses (8) (4 used). j : 19 mm 6. Remove bolts, washers (10) (2 used). Remove flow regulator valve (5) assembly. j : 17 mm 7. Remove bolts, washers (2) (2 used). Remove flow regulator valve (5) from bracket (4). 8

j : 17 mm 8. Remove sensors (7) (1 used). (only the machine with the ride control device) j : 24 mm 9. Remove the adapters from flow regulator valve (5) if necessary.

W3-14-1-2

WPD850-03-14-002

SECTION 3 BODY Group 14 Flow Regulator Valve Detail A

2 B

WNEK50-03-14-001

WPD850-03-14-001

View B

Installation

1. Install all removed adapters to flow regulator valve (5). 2. Install sensor (7). (only the machine with the ride control device) j : 24 mm m : 16 N·m (12 lbf·ft) 3. Install flow regulator valve (5) to bracket (4) with bolts, washers (2) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft)

4. Install flow regulator valve (5) assembly with bolts, washers (10) (2 used).

6. Connect hoses (1) (4 used).

j : 17 mm

j : 19 mm

m : 50 N·m (37 lbf·ft)

m : 30 N·m (22 lbf·ft)

5. Connect hoses (8) (4 used).

WPD850-03-14-002

7. Connect connector (6). Install clip band (9).

j : 19 mm m : 30 N·m (22 lbf·ft)

W3-14-1-3

SECTION 3 BODY Group 14 Flow Regulator Valve

1 WNEK50-03-22-003

8. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

9. Install the following parts. (Refer to W3-22-1.)  

W3-14-1-4

Cab Under Cover (1) Rear Fender (Front) (2)

SECTION 3 BODY Group 14 Flow Regulator Valve Structure of Flow Regulator Valve

12 10 13 4

2 3 14, 1 4 13 5 Section W-W

Section X-X

10 13 8

4 7 2 3 14, 1 4 13

5 WNEC-03-14-001

Section Y-Y

Section Z-Z

W3-14-2-1

SECTION 3 BODY Group 14 Flow Regulator Valve No.

Part Name

Q’ty

1 2

Spool Ring

2 2

Orifice

4 5 6 7 8

Spring Plug Spool Body Plug

4 2 1 1 2

9 10 11 12 13 14

Plug Plug Snap Ring O-Ring O-Ring Spool

1 2 1 1 4 2

Wrench Size (mm)

Tightening Torque N·m (lbf·ft)

Remark

Do not disassemble. Do not disassemble. l:8

(37) Do not disassemble.

l:6 l:8

W3-14-2-2

25 50

(18) (37)

SECTION 3 BODY Group 15 Cooling Fan System Removal and Installation of Fan Valve 1

A WNEK50-03-15-001

WNEK50-03-15-002

Detail A

1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Open side cover (front) (1). 3. Disconnect connectors (2) (3 used). 2

W3-15-1-1

WNEK50-03-15-003

SECTION 3 BODY Group 15 Cooling Fan System 1, 2

WNEK50-03-15-004

4. Disconnect hose (3).

8. Disconnect hose (9).

j : 36 mm

j : 19 mm

5. Disconnect hose (4). j : 36 mm

9. Remove socket bolts (1) (3 used) and washers (2) (3 used). Remove fan valve (6) from bracket (5). l : 8 mm

6. Disconnect hoses (7) (3 used). j : 27 mm

10. Remove the adapters from fan valve (6) if necessary.

7. Disconnect hose (8). j : 17 mm

W3-15-1-2

SECTION 3 BODY Group 15 Cooling Fan System Detail A

1, 2

A WNEK50-03-15-002 B

WNEK50-03-15-004

Installation 1. Install all removed adapters to fan valve (6).

View B

2. Install fan valve (6) to bracket (5) with washers (2) (3 used) and socket bolts (1) (3 used). l : 8 mm

m : 50 N·m (37 lbf·ft) 3. Connect hose (9).

j : 19 mm m : 30 N·m (22 lbf·ft) 4. Connect hose (8).

25°

WNEK50-03-15-005

j : 17 mm m : 25 N·m (16.5 lbf·ft) 5. Connect hoses (7) (3 used).

IMPORTANT: Check the angle to install hose (4). 6. Connect hose (4).

j : 27 mm

j : 36 mm

m : 95 N·m (70 lbf·ft)

m : 180 N·m (133 lbf·ft) 7. Connect hose (3). j : 36 mm m : 180 N·m (133 lbf·ft)

W3-15-1-3

SECTION 3 BODY Group 15 Cooling Fan System

WNEK50-03-15-003

8. Connect connectors (2) (3 used). 9. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 10. Close side cover (front) (1).

W3-15-1-4

WNEK50-03-15-001

SECTION 3 BODY Group 15 Cooling Fan System Structure of Fan Valve

4 3 2

2 1

B A C

Section A

WNEC-03-15-001

Section C 8

9 10 11 12 7 6 5

WJBA-03-16-005

WNEC-03-15-002

Section B

Section D 20

19 18

WJBA-03-16-004

W3-15-2-1

WJBA-03-16-006

SECTION 3 BODY Group 15 Cooling Fan System No.

Part Name

Q’ty

Wrench Size (mm)

Tightening Torque N·m

(lbf·ft)

l :4

4.9~6.9

3.6~5.1

l :8

70~84

52~62

l : 10

120~144

89~106

Solenoid Valve

Socket Bolt

Solenoid Valve

Plug

Relief Valve

Plug

O-Ring

Spring

Check Valve

O-Ring

Spring

Plug

j : 30

177~206

131~152

Plug

l :6

35~42

26~31

Orifice

Plug

l :5

15~18

11~13.5

Plug

l :8

35~40

26~29.5

O-Ring

W3-15-2-2

Remark

SECTION 3 BODY Group 15 Cooling Fan System Removal and Installation of Fan Motor Detail A

3 WNEK50-03-15-020

WNEK50-03-22-033

3. Disconnect hoses (2) (2 used). j : 27 mm 4. Disconnect hose (3).

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Open rear grill (1).

W3-15-3-1

j : 17 mm

SECTION 3 BODY Group 15 Cooling Fan System

3, 4, 5

WNEK50-03-15-022

WNEK50-03-15-021

Detail A

5. Open the hydraulic drive fan (9) assembly.

6. Remove bolts, washers (2) (8 used). Remove guard (1). j : 17 mm IMPORTANT: When removing fan (6) assembly, do not lose key (7). 7. Remove bolt (3), spring washer (4), and washer (5). Remove fan (6) assembly from fan motor (8). j : 17 mm

fNOTE: LOCTITE #263 or equivalent has been applied on bolt (3). 8. Remove key (7) from fan motor (8).

WNEK50-03-15-024

W3-15-3-2

SECTION 3 BODY Group 15 Cooling Fan System

WNEK50-03-15-025

9. Remove bolts, washers (1) (2 used). Remove fan motor (2) from bracket (3). j : 19 mm 10. Remove the adapters from fan motor (2) if necessary.

W3-15-3-3

SECTION 3 BODY Group 15 Cooling Fan System

WNEK50-03-15-025

Installation 1. Install all removed adapters to fan motor (2). 2. Install fan motor (2) to bracket (3) with bolts, washers (1) (2 used). j : 19 mm m : 90 N·m (66 lbf·ft)

W3-15-3-4

SECTION 3 BODY Group 15 Cooling Fan System

A Detail A

3, 4, 5 6 WNEK50-03-15-024 WNEK50-03-15-022

3. Install key (7) to fan motor (8). IMPORTANT: When installing fan (6) assembly, do not drop and lose key (7). 4. Install fan (6) assembly with key (7) to fan motor (8). 5. Apply LOCTITE #263 or equivalent to bolt (3). Secure fan (6) assembly to fan motor (8) with washer (5), spring washer (4) and bolt (3). j : 17 mm m : 50 N·m (37 lbf·ft)

6. Install guard (1) with bolts, washers (2) (8 used). j : 17 mm m : 50 N·m (37 lbf·ft) 7. Close the hydraulic drive fan (9) assembly.

WNEK50-03-15-021

W3-15-3-5

SECTION 3 BODY Group 15 Cooling Fan System

Detail A

5, 6 1

WNEK50-03-22-033

8. Connect hose (3). j : 17 mm

l : 6 mm m : 23 N·m (17 lbf·ft)

9. Connect hoses (4) (2 used).

m : 95 N·m (70 lbf·ft)

WNEK50-03-15-020

10. Remove plug (5). Fill hydraulic oil from port (6). Install plug (5).

m : 25 N·m (18.5 lbf·ft)

j : 27 mm

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 11. Close rear grill (1).

W3-15-3-6

SECTION 3 BODY Group 15 Cooling Fan System Structure of Fan Motor 1

22 21

20 19 18

17 16

12 11

10 WJBA-03-17-001

W3-15-4-1

SECTION 3 BODY Group 15 Cooling Fan System

No.

Part Name

Q’ty

Roller Bearing

O-Ring

Plunger

Swash Plate

Roller Bearing

Key

Shaft

Retaining Ring

Oil Seal

Housing

Holder

Retainer

Spring seat

Rotor

Spring

Washer

Retaining Ring

Valve Plate

Socket Bolt

Rear Cover

Wrench Size (mm)

l : 10

W3-15-4-2

Tightening Torque N·m

(lbf·ft)

(66)

Remark

SECTION 3 BODY Group 15 Cooling Fan System Removal and Installation of Fan Pump

2 WNEK50-03-22-003

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Open side cover (front) (1).

3. Remove lower cover (2). (Refer to W3-22-1.)

Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.)

W3-15-5-1

SECTION 3 BODY Group 15 Cooling Fan System

3, 4, 5

WNEK50-03-15-010

4. Remove bolt, washer (3). Remove clips (4, 5). j : 17 mm 5. Remove bolts, washers (2) (2 used). Place the washer fluid tank (1) assembly outside of the work area. j : 17 mm

W3-15-5-2

WNEK50-03-15-011

SECTION 3 BODY Group 15 Cooling Fan System

3 7

5 WPD850-03-15-012

6. Disconnect hose (2). j : 27 mm 7. Disconnect hose (7). j : 27 mm 8. Disconnect hose (1). j : 41 mm IMPORTANT: Gasket (3) cannot be reused. 9. Remove bolts, washers (5) (2 used). Remove fan pump (4) and gasket (3) from engine (6). j : 17 mm 10. Remove the adapters with fan pump (4) attached if necessary.

W3-15-5-3

4 WNEE-03-15-040

SECTION 3 BODY Group 15 Cooling Fan System

Detail A

3 5 WNEK50-03-15-013

Installation 1. Install all removed adapters to fan pump (4). IMPORTANT: Replace gasket (3) with the new one. 2. Install gasket (3) and fan pump (4) to engine (6) with bolts, washers (5) (2 used). j : 17 mm m : 50 N∙m (37 lbf·ft)

W3-15-5-4

4 WNEE-03-15-040

SECTION 3 BODY Group 15 Cooling Fan System

1 View A

1 WPD850-03-15-012

30°

WPD850-03-15-014

IMPORTANT: Check the angle to install hose (1). 3. Connect hose (1). j : 41 mm m : 210 N∙m (155 lbf·ft) 4. Connect hose (2). j : 27 mm

m : 95 N∙m (70 lbf·ft) 5. Connect hose (7). j : 27 mm m : 95 N∙m (70 lbf·ft)

W3-15-5-5

25°

WPD850-03-15-015

SECTION 3 BODY Group 15 Cooling Fan System

3, 4, 5

WNEK50-03-15-011

6. Install the washer fluid tank (1) assembly with bolts, washers (2) (2 used). j : 17 mm m : 50 N∙m (37 lbf·ft) 7. Install clips (4, 5) with bolt, washer (3). j : 17 mm m : 50 N∙m (37 lbf·ft)

W3-15-5-6

SECTION 3 BODY Group 15 Cooling Fan System

2 WNEK50-03-22-003

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Install lower cover (2). (Refer to W3-22-1.) 9. Close side cover (front) (1).

W3-15-5-7

SECTION 3 BODY Group 15 Cooling Fan System (Blank)

W3-15-5-8

SECTION 3 BODY Group 15 Cooling Fan System Disassembly of Fan Pump 8 7 6 5 4 3 2 1

6 14 13

10 12 4 5 6 7 11 WNEC-03-15-010

1234-

Retaining Ring Oil Seal Front Cover Gasket (2 Used)

5678-

Gasket (2 Used) Bushing (4 Used) Side Plate (2 Used) Body

10111213-

Drive Gear Driven Gear Rear Cover Washer (4 Used)

W3-15-6-1

14- Bolt (4 Used)

SECTION 3 BODY Group 15 Cooling Fan System 5. Remove drive gear (10) from body (8).

Disassembly of Fan Pump IMPORTANT: Put the matching marks on front cover (3), body (8), and rear cover (12) before disassembling. 1. Secure the front cover (3) mounting part in a vise with the rear cover (12) side up. 2. Remove bolts (14) (4 used) and washers (13) (4 used) from rear cover (12). Remove rear cover (12) from body (8). l : 10 mm IMPORTANT: Check the position and direction of side plate (7) and gaskets (4, 5) for assembling. 3. Remove gaskets (4, 5) from rear cover (12). Remove side plate (7) from the body (8) assembly.

6. Remove body (8) from front cover (3). IMPORTANT: Check the position and direction of side plate (7) and gaskets (4, 5) for assembling. 7. Remove gaskets (4, 5) and side plate (7) from front cover (3). 8. Remove retaining ring (1) from front cover (3). IMPORTANT: Do not damage the oil seal hole of front cover (3). 9. Remove oil seal (2) from front cover (3) by using a screwdriver. 2

IMPORTANT: The front and rear shapes of driven gear (11) are symmetrical. Put the matching marks for assembling. 4. Remove driven gear (11) from body (8).

W4GB-02-08-012

W3-15-6-2

SECTION 3 BODY Group 15 Cooling Fan System Assembly of Fan Pump

WNEC-03-15-011

1234-

Retaining Ring Oil Seal Front Cover Gasket (2 Used)

5678-

Gasket (2 Used) Bushing (4 Used) Side Plate (2 Used) Body

10111213-

Drive Gear Driven Gear Rear Cover Washer (4 Used)

W3-15-6-3

14- Bolt (4 Used)

SECTION 3 BODY Group 15 Cooling Fan System 4. Fit the matching marks and install body (8) to front cover (3).

Assembly of Fan Pump IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Secure front cover (3) in a vise with the body (8) mounting surface up. IMPORTANT: Check the direction to install gaskets (4, 5). 2. Apply grease onto oil gaskets (4, 5). Install gaskets (4, 5) to front cover (3). 3

IMPORTANT: Check the direction to install driven gear (11). IMPORTANT: Drive gear (10) and driven gear (11) have asymmetrical tooth shape. Mesh the gears with the small notch and install them. 5. Install drive gear (10) and driven gear (11) to the body (8) assembly.

l j

W4GB-02-08-014

3. Install side plate (7) to front cover (3) so that the yellow surface faces the gear side and long hole (a) faces the suction side. 7

hij-

Delivery Side Suction Side Large Notch (Non-Mesh Side)

e W4GB-02-08-015

Delivery Side Suction Side

de-

Small Notch (Non-Mesh Side) Rotation Direction of Drive Gear (10)

6. Install side plate (7) to drive gear (10) and driven gear (11) so that the yellow surface faces the gear side and long hole (a) faces the suction side.

Short Hole Long Hole

3 f g

fg-

kl-

bc-

WNEC-03-15-012

WNEC-03-15-005

Delivery Side Suction Side

W3-15-6-4

SECTION 3 BODY Group 15 Cooling Fan System IMPORTANT: Check the direction to install gaskets (4, 5). 7. Apply grease onto oil gaskets (4, 5). Install gaskets (4, 5) to rear cover (12). 12

11. Install oil seal (2) to front cover (3) with oil seal guide (e).

5 e

3 W4GB-02-08-014

8. Fit the matching marks and install rear cover (12) to the body (8) assembly with washers (13) (4 used) and bolts (14) (4 used).

W4GB-02-08-018 e-

l : 10 mm

Oil Seal Guide

m : 90 to 95 N·m (66 to 70 lbf·ft) 9. Turn over the body (8) assembly. Secure front cover (3) in a vise.

12. Install retaining ring (1) to front cover (3).

10. Apply grease between main lip (b) and dust lip (c) of oil seal (2).

d b W4GB-02-08-017 bc-

Main Lip Dust Lip

Apply grease.

W4GB-02-08-019

W3-15-6-5

SECTION 3 BODY Group 15 Cooling Fan System (Blank)

W3-15-6-6

SECTION 3 BODY Group 16 Ride Control Device Removal and Installation of Ride Control Valve 1 2

2 8

3, 4, 5

2 WNEC-04-08-003

WNDB-03-16-005

3. Disconnect hose (8). j : 27 mm 4. Disconnect hose (7). j : 36 mm 5. Remove socket bolts (3) (4 used) and flanges (4) (2 used). Disconnect hose (6). Remove O-ring (5). l : 8 mm

Removal 1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.) Release any pressure from the dCAUTION: hydraulic oil tank. (Refer to W1-5-1.) 2. Remove cover (1). (Refer to W3-22-1.) Release pressure from the hydraulic dCAUTION: circuit and the ride control accumulator. (Refer to W1-5-1.)

W3-16-1-1

SECTION 3 BODY Group 16 Ride Control Device

1, 2, 3

4 7

9 10

5 8

WNDB-03-16-007

WNDB-03-16-006

6. Remove socket bolts (1) (4 used) and flanges (2) (2 used). Disconnect hose (4). Remove O-ring (3).

10. Remove bolts, washers (10) (3 used). Remove ride control valve (7) from bracket (9). j : 19 mm

l : 8 mm

11. Remove adapters from ride control valve (7) if necessary.

7. Disconnect hoses (6) (2 used). j : 17 mm 8. Disconnect connector (5). 9. Remove bolts, washers (8) (4 used). Remove the ride control valve (7) assembly. j : 19 mm

W3-16-1-2

SECTION 3 BODY Group 16 Ride Control Device

1, 2, 3 7

9 10

5 8

WNDB-03-16-007

WNDB-03-16-006

View A

Installation 1. Install all removed adapters to ride control valve (7). 2. Install ride control valve (7) to bracket (9) with bolts, washers (10) (3 used).

j : 19 mm m : 90 N·m (66 lbf·ft) 3. Install the ride control valve (7) assembly with bolts, washers (8) (4 used). j : 19 mm

4 a-

10 °

WNDB-03-16-008

m : 90 N·m (66 lbf·ft) 4. Connect connector (5). 5. Connect hoses (6) (2 used).

IMPORTANT: Check the angle to install hose (4). 6. Install O-ring (3). Install hose (4) with flanges (2) (2 used) and socket bolts (1) (4 used).

j : 17 mm

l : 8 mm

m : 25 N·m (18.5 lbf·ft)

m : 50 N·m (37 lbf·ft)

W3-16-1-3

SECTION 3 BODY Group 16 Ride Control Device 7 8

1, 2, 3 A

8 WNEC-04-08-003

WNDB-03-16-005 View A

IMPORTANT: Check the angle to install hose (4). 7. Install O-ring (3). Install hose (4) with flanges (2) (2 used) and socket bolts (1) (4 used). l : 8 mm

j : 50 N·m (37 lbf·ft) 8. Connect hose (5). 4

j : 36 mm

30 °

WNDB-03-16-008

m : 180 N·m (133 lbf·ft) 9. Connect hose (6). 13. Install cover (7) with bolts, washers (8) (4 used).

j : 27 mm

j : 17 mm

m : 80 N·m (59 lbf·ft)

m : 50 N·m (37 lbf·ft)

10. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-5-1.) 11. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 12. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.)

W3-16-1-4

SECTION 3 BODY Group 16 Ride Control Device Disassembly of Ride Control Valve

WNDB-03-16-001

02- Spring 03- Plug 04- O-Ring (2 Used) 05- Plug 05A- O-Ring 07- Plug 08- Solenoid Valve 08A- Sleeve 08B- Spool 08C- Solenoid 08D- Spring 08E- Plate

08F- Washer 08G- Socket Bolt (2 Used) 08H- O-Ring 08I- O-Ring 08J- O-Ring 08K- O-Ring 10- Plug 13- Spring 16- O-Ring 17- Backup Ring 18- Check Valve 19- Spring

20- Plug 21- O-Ring 22- Drain Plug 23- O-Ring 24- Nut 25- Plug 25A- O-Ring 26- Plug 26A- O-Ring 27- Plug 27A- O-Ring 28- Plug

W3-16-2-1

28A- O-Ring 32A- Housing 32B- Spool 32C- Spool 34- Relief Valve 34A- O-Ring 34B- Backup Ring 34C- O-Ring 36- Orifice

SECTION 3 BODY Group 16 Ride Control Device 8. Remove plug (03) from housing (32A). Remove O-ring (04) from plug (03).

Disassembly of Ride Control Valve 1. Loosen nut (24).

j : 41 mm

j : 13 mm 2. Remove the drain plug (22) assembly from housing (32A). Remove O-ring (23) from drain plug (22). l : 4 mm IMPORTANT: Do not replace solenoid (08C) and spring (08D) as a single unit. Replace them as an assembly of the ride control valve. IMPORTANT: Spring (08D) may fly out when removing solenoid (08C) from housing (32A). IMPORTANT: Do not disassemble solenoid (08C). 3. Remove socket bolts (08G) (2 used). Remove solenoid (08C) and O-ring (08H) from housing (32A). Remove spring (08D) from solenoid (08C). l : 4 mm IMPORTANT: Do not replace sleeve (08A), spool (08B), and plate (E) as a single unit. Replace them as an assembly of the ride control valve. 4. Remove the sleeve (08A) assembly from housing (32A). Remove spool (08B) and O-rings (08I, 08J, 08K) from sleeve (08A). 5. Remove plate (08E) and washer (08F) from housing (32A). 6. Remove plug (07) from housing (32A). l : 6 mm

IMPORTANT: Remove spool (32B) by rotating. When it cannot be removed smoothly, return it to the original position and remove it again. IMPORTANT: Do not replace spool (32B) as a single unit. Replace it as an assembly of the ride control valve. 9. Remove spring (02) and spool (32B) from housing (32A). 10. Remove plug (10) from housing (32A). Remove O-ring (04) from plug (10). j : 41 mm IMPORTANT: Remove the spool (32C) assembly by rotating the spool (32C) assembly. When it cannot be removed smoothly, return it to the original position and remove it again. 11. Remove spring (13) and the spool (32C) assembly from housing (32A). Remove backup ring (17) and O-ring (16) from spool (32C). IMPORTANT: Do not replace spool (32C) as a single unit. Replace it as an assembly of the ride control valve. 12. Secure the spool (32C) assembly in a vise by using wooden pieces as illustrated. Remove plug (20), spring (19), and check valve (18) from spool (32C). Remove O-ring (21) from plug (20).

IMPORTANT: Do not disassemble relief valve (34). If it has been disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 7. Remove relief valve (34) from housing (32A). Remove O-rings (34A, 34C) and backup ring (34B) from relief valve (34).

j : 10 mm

j : 27 mm W4GB-02-05-002

W3-16-2-2

SECTION 3 BODY Group 16 Ride Control Device 13. Remove plug (25) from housing (32A). Remove O-ring (25A) from plug (25). l : 6 mm 14. Remove plug (26) from housing (32A). Remove O-ring (26A) from plug (26). l : 5 mm 15. Remove plug (27) from housing (32A). Remove O-ring (27A) from plug (27). l : 8 mm 16. Remove plug (28) from housing (32A). Remove O-ring (28A) from plug (28). l : 12 mm 17. Remove plug (05) from housing (32A). Remove O-ring (05A) from plug (05). l : 17 mm 18. Remove orifice (36) from housing (32A). l : 5 mm

fNOTE: THREEBOND #1324 has been applied on orifice (36).

W3-16-2-3

SECTION 3 BODY Group 16 Ride Control Device Assembly of Ride Control Valve

A B

26, 26A A

27, 27A

TNDB-03-12-001

Section A-A a

Section B-B

32A

28A

23 24 22

02 05A 05 32B

03 04 34C

25A

WNDB-03-16-002

W3-16-2-4

34A

34B

T4GD-03-08-001

SECTION 3 BODY Group 16 Ride Control Device Detail a (Solenoid Valve (08) Assembly)

08H

Detail b

08K

32C

08J 08I 08E 08F

08C

10 08G

08A

08B

WNDB-03-16-003

02- Spring 03- Plug 04- O-Ring (2 Used) 05- Plug 05A- O-Ring 07- Plug 08- Solenoid Valve 08A- Sleeve 08B- Spool 08C- Solenoid 08D*- Spring 08E- Plate

08F- Washer 08G- Socket Bolt (2 Used) 08H- O-Ring 08I- O-Ring 08J- O-Ring 08K- O-Ring 10- Plug 13- Spring 16- O-Ring 17- Backup Ring 18- Check Valve 19- Spring

WNDB-03-16-004

20- Plug 21- O-Ring 22- Drain Plug 23- O-Ring 24- Nut 25- Plug 25A- O-Ring 26- Plug 26A- O-Ring 27- Plug 27A- O-Ring 28- Plug

fNOTE: As for the item with mark *, refer to W3-16-2-1.

W3-16-2-5

28A- O-Ring 32A- Housing 32B- Spool 32C- Spool 34- Relief Valve 34A- O-Ring 34B- Backup Ring 34C- O-Ring 36- Orifice

SECTION 3 BODY Group 16 Ride Control Device Assembly of Ride Control Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: After installing orifice (36), wait for 60 minutes or more in order to let it dry. 1. Apply THREEBOND #1324 onto the thread part of orifice (36). Install orifice (36) to housing (32A). l : 5 mm m : 10 to 13 N·m (7.4 to 9.6 lbf·ft) 2. Install O-ring (21) to plug (20). Secure spool (32C) in a vise by using wooden pieces as illustrated. Install check valve (18) and spring (19) to spool (32C) with plug (20).

5. Install O-ring (04) to plug (10). Install plug (10) to housing (32A). j : 41 mm m : 177 to 206 N·m (131 to 152 lbf·ft) IMPORTANT: Install spool (32B) by rotating. When it cannot be installed smoothly, return it to the original position and install it again. 6. Install spool (32B) and spring (02) to housing (32A). 7. Install O-ring (04) to plug (03). Install plug (03) to housing (32A). j : 41 mm m : 177 to 206 N·m (131 to 152 lbf·ft) 8. Install O-ring (05A) to plug (05). Install plug (05) to housing (32A).

j : 10 mm m : 8 to 12 N·m (5.9 to 8.9 lbf·ft)

j : 17 mm m : 177 to 206 N·m (131 to 152 lbf·ft) 9. Install O-ring (25A) to plug (25). Install plug (25) to housing (32A). l : 6 mm m : 34 to 39 N·m (25 to 29 lbf·ft) W4GB-02-05-002

3. Install O-ring (16) and backup ring (17) to spool (32C). IMPORTANT: Install the spool (32C) assembly by rotating. When it cannot be installed smoothly, return it to the original position and install it again. 4. Apply grease onto the sliding surfaces of O-ring (16). Install the spool (32C) assembly and spring (13) to housing (32A).

W3-16-2-6

SECTION 3 BODY Group 16 Ride Control Device 10. Install O-ring (26A) to plug (26). Install plug (26) to housing (32A). l : 5 mm m : 15 to 18 N·m (11 to 13.5 lbf·ft)

IMPORTANT: When installing solenoid (08C), do not drop spring (08D) and O-ring (08H). 17. Install O-rings (08H) to housing (32A). Install spring (08D) to solenoid (08C). Install solenoid (08C) to housing (32A) with socket bolts (08G) (2 used).

11. Install O-ring (27A) to plug (27). Install plug (27) to housing (32A). l : 8 mm

l : 4 mm m : 5 to 7 N·m (3.7 to 5.2 lbf·ft) 18. Install O-ring (23) to drain plug (22). Install drain plug (22) to housing (32A).

m : 69 to 74 N·m (51 to 55 lbf·ft) 12. Install O-ring (28A) to plug (28). Install plug (28) to housing (32A). l : 12 mm m : 235 to 264 N·m (175 to 195 lbf·ft) 13. Install O-rings (34A, 34C) and backup ring (34B) to relief valve (34). Install relief valve (34) to housing (32A).

l : 4 mm m : 7 to 9 N·m (5.2 to 6.6 lbf·ft) IMPORTANT: Install nut (24) while securing drain plug (22) by using a hexagonal wrench in order not to turn them. l : 4 mm 19. Install nut (24) to drain plug (22).

j : 27 mm

j : 13 mm

m : 177 to 206 N·m (131 to 152 lbf·ft)

m : 10 to 12 N·m (7.4 to 8.9 lbf·ft)

14. Install plug (07) to housing (32A). l : 6 mm m : 10 to 13 N·m (7.4 to 9.6 lbf·ft) 15. Install washer (08F) and plate (08E) to housing (32A). 16. Install O-rings (08I, 08J, 08K) and spool (08B) to sleeve (08A). Install the sleeve (08A) assembly to housing (32A).

W3-16-2-7

SECTION 3 BODY Group 16 Ride Control Device (Blank)

W3-16-2-8

SECTION 3 BODY Group 16 Ride Control Device Removal and Installation of Ride Control Accumulator 1

WNEK50-03-13-001

WNEK50-03-16-001

 Use only the qualified parts for the accumulator.

dCAUTION:  High-pressure nitrogen gas is enclosed in the accumulator. Pay attention to prevent fire.  Never hit or bring a fire close to the accumulator.  Do not process the accumulator directly. Do not weld the accumulator housing.  Be sure to release pressure before starting to work on the piping lines. IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

Removal 1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.)

dCAUTION: Release any pressure from the hydraulic oil tank. (Refer to W1-5-1.) 2. Remove cover (1). (Refer to W3-22-1.)

dCAUTION: Release any pressure from the front

attachment hydraulic circuit and the ride control accumulator. (Refer to W1-5-1.) 3. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-5-1.) 4. Remove propeller shaft (2). (Refer to W4-4-1.)

W3-16-3-1

SECTION 3 BODY Group 16 Ride Control Device

Detail A

2, 3

WPD850-03-16-001

WNEK50-03-16-002 a-

Vehicle Front Side

7. Remove elbow (6) from ride control accumulator (5) if necessary.

5. Disconnect hose (7). j : 36 mm

dCAUTION: Remove ride control accumulator

(5) while holding it. Do not drop ride control accumulator (5). 6. Remove bolts, washers (1) (4 used), clip (4), clamps (2) (2 used), and rubber stoppers (3) (2 used). Remove ride control accumulator (5) from front frame (8). j : 19 mm

W3-16-3-2

SECTION 3 BODY Group 16 Ride Control Device

Detail A

2, 3

WPD850-03-16-001

WNEK50-03-16-002 a-

Vehicle Front Side

View B b

Installation 1. Install elbow (6) to ride control accumulator (5). IMPORTANT: Check the angle to install elbow (6). 2. Install ride control accumulator (5) and wire harness (9) to front frame (8) with rubber stoppers (3) (2 used), clamps (2) (2 used), clip (4), and bolts, washers (1) (4 used). j : 19 mm

90°

3. Connect hose (7).

m : 90 N·m (66 lbf·ft)

j : 36 mm m : 180 N·m (133 lbf·ft)

W3-16-3-3

WNDB-03-16-012

SECTION 3 BODY Group 16 Ride Control Device

WNEK50-03-16-001

4. Install propeller shaft (2). (Refer to W4-4-1.) 5. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 6. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.) 7. Install cover (1). (Refer to W3-22-1.) j : 17 mm m : 50 N·m (37 lbf·ft)

W3-16-3-4

WNEK50-03-13-001

SECTION 3 BODY Group 17 Battery Disconnect Switch Removal and Installation of Battery Disconnect Switch 5 Detail A

4 5 a

WNEK50-03-22-042 a-

bc-

Battery Box

IMPORTANT: When disconnecting connectors or terminals, attach an identification tag onto the connectors or terminals for assembling. If the clips which secure the wire harnesses have been removed, install the clips after connecting the connectors or terminals. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.) 2. Open cover (1, 6). IMPORTANT: Set the key switch to the OFF position. Wait 5 minutes or longer, and then set battery disconnect switch (2) to the OFF position. 3. Set battery disconnect switch (2) to the OFF position (b). Remove lever (3). 4. Remove bolts, washers (4) (2 used). Remove rubber plates (5) (2 used). j : 17 mm

W3-17-1-1

OFF Position ON Position

WNEK50-03-22-043

SECTION 3 BODY Group 17 Battery Disconnect Switch

1, 2

3, 4

5, 6

7, 8

ab-

Battery Battery Disconnect Switch

5. Loosen nut (7). Disconnect terminal (8). j : 10 mm 6. Loosen nut (1). Disconnect terminal (2). j : 10 mm 7. Loosen nuts (5, 3). Disconnect terminals (6, 4). j : 10 mm

W3-17-1-2

WNEK50-03-22-044

SECTION 3 BODY Group 17 Battery Disconnect Switch

Detail A

10 9 8 7 6 a

3 4 5

Battery Box

WNEK50-03-22-042

8. Remove nut (4). Disconnect terminal (5). j : 17 mm 9. Remove nut (2). Disconnect terminal (1). j : 17 mm 10. Remove bolts, washers (6) (2 used). Remove the bracket (8) assembly from bracket (3). j : 17 mm 11. Remove nuts (7) (2 used) and bolts, washers (10) (2 used). Remove battery disconnect switch (9) from bracket (8). j : 10 mm

W3-17-1-3

WNEK50-03-17-003

SECTION 3 BODY Group 17 Battery Disconnect Switch

Detail A

10 9 8 7

6 a

Battery Box

WNEK50-03-22-042

WNEK50-03-17-003

4. Connect terminal (5) with nut (4).

Installation 1. Install battery disconnect switch (9) to bracket (8) with nuts (7) (2 used) and bolts, washers (10) (2 used). j : 10 mm m : 3 to 4 N·m (2.2 to 3.0 lbf·ft) 2. Install the bracket (8) assembly to bracket (3) with bolts, washers (6) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 3. Connect terminal (1) with nut (2). j : 17 mm m : 22±1.1 N·m (16.2 lbf·ft)

W3-17-1-4

j : 17 mm m : 22±1.1 N·m (16.2 lbf·ft)

SECTION 3 BODY Group 17 Battery Disconnect Switch

1, 2

3, 4

5, 6

7, 8

ab-

Battery Battery Disconnect Switch

5. Connect terminals (6, 4). Tighten nuts (5, 3).

WNEK50-03-22-044

7. Connect terminal (8). Tighten nut (7).

j : 10 mm

m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)

6. Connect terminal (2). Tighten nut (1). j : 10 mm m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)

W3-17-1-5

SECTION 3 BODY Group 17 Battery Disconnect Switch

Detail A

4 5 3

b c

5 a-

Battery Box

WNEK50-03-22-042

bc-

8. Install lever (3). Set battery disconnect switch (2) to the ON position (c). 9. Install rubber plate (5) (2 used) with bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 10. Close cover (1, 6).

W3-17-1-6

OFF Position ON Position

WNEK50-03-22-043

SECTION 3 BODY Group 18 Aftertreatment Device Removal and Installation of Aftertreatment Device 1

WNEK50-03-19-010

WNEK50-03-19-003

3. Remove engine cover (1). (Refer to W3-22-1.) 4. Place a container under hose (2). Loosen cock (3). Drain off coolant. Close cock (3).

fNOTE: Amount of coolant: 33 L (8.7 US gal)

W3-18-1-1

SECTION 3 BODY Group 18 Aftertreatment Device 1

Detail A

5, 6

WNEK50-03-18-002 Detail B

10, 11, 12

3 13 a-

Vehicle Front Side

WNEK50-03-18-001

5. Disconnect connectors (1) (2 used). 6. Remove bolt, washer (10), clip (11), and collar (12). j : 17 mm 7. Remove bolts, washers (7) (2 used). j : 17 mm 8. Remove bolt, washer (13). j : 17 mm 9. Loosen clamps (9) (2 used) and clamp (8). Disconnect the both ends of the pipe (2) assembly. j : 7 mm 10. Loosen clamps (3, 5). Disconnect the both ends of exhaust pipe (4). Remove gasket (6). j : 11 mm

W3-18-1-2

WNEK50-03-18-003

SECTION 3 BODY Group 18 Aftertreatment Device 1

View A

4, 5, 6

9, 10

7, 8 3

View B

a a-

WNEK50-03-18-005

WNEK50-03-18-004

Vehicle Front Side

11. Remove bolt, washer (4) and clips (5, 6).

WNEK50-03-18-006

fNOTE: Disconnect hose (12) by pushing lock button (green) of hose (12).

j : 17 mm 12. Remove bolt, washer (7) and clip (8). j : 17 mm 13. Remove bolt, washer (9) and clip (10). j : 17 mm 14. Remove bolts, washers (2) (4 used). Remove the bracket (3) assembly. j : 17 mm 15. Disconnect connector (11). 16. Disconnect hoses (12, 13, 14). Place the water tank (1) assembly outside of the work area.

W3-18-1-3

SECTION 3 BODY Group 18 Aftertreatment Device 10

9 View A

7, 8 1 5

6 5 15

12, 13, 14 WNEK50-03-18-008

A a-

Vehicle Front Side

2, 3 WNEK50-03-18-007

17. Remove bolt, washer (2) and bracket (3).

22. Remove bolt, washer (12) and clips (13, 14).

j : 17 mm

18. Disconnect connectors (1) (2 used).

23. Remove bolts, washers (11) (2 used). Remove and place the washer fluid tank (15) assembly outside of the work area.

19. Loosen clamps (5) (2 used). Disconnect the both ends of hose (6).

j : 17 mm

j : 7 mm 20. Remove nuts (7) (4 used), U-bolt (8), and clamp (9). Disconnect exhaust pipe (10). j : 17 mm 21. Remove cover (4). (Refer to W3-22-1.)

W3-18-1-4

SECTION 3 BODY Group 18 Aftertreatment Device

Detail of Installation of Pipe (1) Assembly

1 a

7 2, 3

Vehicle Front Side

WNEK50-03-18-009

24. Remove bolts, washers (2) (3 used) and clips (3) (3 used).

4, 5, 6

j : 17 mm 25. Remove bolt, washer (4), nut (5), and clip (6). j : 17 mm 26. Remove bolts, washers (7) (2 used). Disconnect the pipe (1) assembly. j : 17 mm

W3-18-1-5

WNEK50-03-18-010

SECTION 3 BODY Group 18 Aftertreatment Device 2

Lifting Bracket

27. Remove bolts, washers (5, 6). Remove cover (4).

WNEK50-03-18-011

29. Remove bolts, washers (2) (9 used). Remove the aftertreatment device (1) assembly from bracket (3).

j : 17 mm

j : 19 mm

The aftertreatment device (1) dCAUTION: assembly weight: 120 kg (265 lb) 28. Attach nylon slings onto lifting brackets (a) (4 places). Hoist and hold the aftertreatment device (1) assembly.

W3-18-1-6

SECTION 3 BODY Group 18 Aftertreatment Device

2 Detail A

8 3, 4 7

12 6

3, 4, 5 A WNEK50-03-18-013

WNEK50-03-18-012

30. Remove sensor (1).

33. Remove bolt, washer (8), bolts (9) (2 used), and washers (10) (2 used). Remove clip (11), sensor unit (7), and covers (12, 13).

j : 22 mm 31. Remove bolts (3) (2 used) and washers (4) (2 used). Remove clip (5) and sensor unit (6). j : 10 mm 32. Remove sensors (2) (2 used). j : 14 mm

W3-18-1-7

j : 10 mm

SECTION 3 BODY Group 18 Aftertreatment Device

3, 4

10, 11, 12 5

6, 7, 8

WNEK50-03-18-014

38. Remove bolts (3) (2 used) and washers (4) (2 used). Remove sensor unit (2).

34. Remove bolt (10), washer (11), and clip (12). j : 10 mm

j : 10 mm

35. Remove sensor (9). j : 22 mm 36. Remove bolts (6) (2 used) and washers (7) (2 used). Remove clips (8) (2 used) and sensor unit (1). j : 10 mm 37. Remove sensors (5) (2 used). j : 14 mm

W3-18-1-8

SECTION 3 BODY Group 18 Aftertreatment Device

Detail A

WNEK50-03-18-015

39. Remove socket bolts (9) (2 used) and guard (8). l : 5 mm 40. Remove connectors (5) (2 used) and cover (7). Remove O-rings (6) (2 used) from connectors (5) (2 used). j : 15 mm 41. Remove bolts (1) (3 used) and collars (2) (3 used). Remove dosing valve (3) and gasket (4). j : 10 mm

W3-18-1-9

5, 6

WNEK50-03-18-016

SECTION 3 BODY Group 18 Aftertreatment Device 1 2 3

5 13

6 12

11 8 9

WNEK50-03-18-017

42. Put the matching marks on DOC (10), clamp (8), and elbow (7). Loosen clamp (8). Remove elbow (7) from DOC (10). Remove gasket (9). j : 11 mm

fNOTE: DOC (Diesel Oxidation Catalyst) 43. Put the matching marks on SCR (11), clamp (12), and elbow (1). Loosen clamp (12). Remove elbow (1) from SCR (11). Remove gasket (13).

fNOTE: SCR (Selective Catalytic Reduction) 44. Put the matching marks on dosing module (4), clamp (2), and elbow (1). Put the matching marks on dosing module (4), clamp (6), and elbow (7). Loosen clamps (2, 6). Disconnect the both ends of dosing module (4) from elbows (1, 7). Remove gaskets (3, 5).

j : 11 mm

W3-18-1-10

j : 11 mm

SECTION 3 BODY Group 18 Aftertreatment Device a

10 17

16 15 14 14

Lifting Bracket

WNEK50-03-18-018

dCAUTION: DOC (10) weight: 26 kg (58 lb)

45. Attach nylon slings onto lifting brackets (a) (2 places). Hoist and hold DOC (10). 46. Remove nuts (14) (8 used), washers (15) (4 used), and U-bolts (17) (2 used). Remove DOC (10) from brackets (16) (2 used). j : 17 mm

W3-18-1-11

SECTION 3 BODY Group 18 Aftertreatment Device

18 19 20 20 21

Lifting Bracket

WNEK50-03-18-019

dCAUTION: SCR (11) weight: 44 kg (98 lb)

47. Attach nylon slings onto lifting brackets (b) (2 places). Hoist and hold SCR (11). 48. Remove nuts (20) (8 used), washers (19) (4 used), and U-bolts (18) (2 used). Remove SCR (11) from brackets (21) (2 used). j : 17 mm

W3-18-1-12

SECTION 3 BODY Group 18 Aftertreatment Device

A View A

11 c

18 19 20 20 21

Lifting Bracket

WNEK50-03-18-019

Installation

dCAUTION: SCR (11) weight: 44 kg (98 lb)

1. Attach nylon slings onto lifting brackets (b) (2 places). Hoist SCR (11).

IMPORTANT: Check the position to install SCR (11). 2. Temporary install SCR (11) to brackets (21) (2 used) with U-bolts (18) (2 used), washers (19) (4 used), and nuts (20) (8 used).

W3-18-1-13

WNEK50-03-18-020 c-

136 mm (5.4 in)

96 mm (3.8 in)

SECTION 3 BODY Group 18 Aftertreatment Device A a

View A

10 10

16 15

WNEK50-03-18-021

14 e-

Lifting Bracket

WNEK50-03-18-018

dCAUTION: DOC (10) weight: 26 kg (58 lb)

3. Attach nylon slings onto lifting brackets (a) (2 places). Hoist DOC (10).

IMPORTANT: Check the position to install DOC (10). 4. Temporary install DOC (10) to brackets (16) (2 used) with U-bolts (17) (2 used), washers (15) (4 used), and nuts (14) (8 used).

W3-18-1-14

55 mm (2.2 in)

100 mm (3.9 in)

SECTION 3 BODY Group 18 Aftertreatment Device 1 2 3

5 13

6 12

11 8 9

WNEK50-03-18-017

IMPORTANT: Replace gaskets (3, 5) with the new ones. 5. Fit the matching marks made when removing. Temporary install clamps (2, 6), gaskets (3, 5), and the both ends of dosing module (4) to elbows (1, 7).

IMPORTANT: Replace gasket (9) with the new one. 7. Fit the matching marks made when removing. Temporary install gasket (9), clamp (8), and elbow (7) to DOC (10).

IMPORTANT: Replace gasket (13) with the new one. 6. Fit the matching marks made when removing. Temporary install clamp (12), gasket (13), and elbow (1) to SCR (11).

W3-18-1-15

SECTION 3 BODY Group 18 Aftertreatment Device 2 6 12

20 14

8. Tighten clmaps (2, 6, 8, 12). j : 11 mm m : 13.5±0.5 N·m (10±0.4 lbf·ft) 9. Tighten nuts (14, 20) (8 used for each). j : 17 mm m : 20 N·m (15 lbf·ft)

W3-18-1-16

WNEK50-03-18-022

SECTION 3 BODY Group 18 Aftertreatment Device 1

Detail A

WNEK50-03-18-015

IMPORTANT: Replace gasket (4) with the new one. 10. Temporary install gasket (4) and dosing valve (3) with collars (2) (3 used) and bolts (1) (3 used). Temporary install bolts (1) (3 used) in the order as illustrated.

5, 6

WNEK50-03-18-016

12. Apply lubricant (Lubriplate #105 or equivalent: CUMMINS part No. #3163086) to O-rings (6) (2 used). Install O-rings (6) (2 used) to connectors (5) (2 used). Install cover (7) and connectors (5) (2 used). j : 15 mm

m : 6 N·m (4.4 lbf·ft) 13. Install guard (8) with socket bolts (9) (2 used). l : 5 mm m : 9 N·m (6.6 lbf·ft)

WNEK50-03-18-023

11. Tighten bolts (1) (3 used) in the order as illustrated. j : 10 mm m : 9 N·m (6.6 lbf·ft) 1

3 WNEK50-03-18-023

W3-18-1-17

SECTION 3 BODY Group 18 Aftertreatment Device

3, 4

10, 11, 12 5

6, 7, 8

14. Apply anti-seize (LOCTITE Silver Grade Anti-Seize, Anti-Seize C5-A or equivalent) to the thread part of sensors (5) (2 used). Install sensors (5) (2 used).

WNEK50-03-18-014

17. Install sensor unit (1) and clips (8) (2 used) with washers (7) (2 used) and bolts (6) (2 used). j : 10 mm

j : 14 mm

m : 14 N·m (10.5 lbf·ft)

m : 30 N·m (22 lbf·ft)

18. Install clip (12) with washer (11) and bolt (10).

15. Install sensor unit (2) with washers (4) (2 used) and bolts (3) (2 used).

j : 10 mm m : 14 N·m (10.5 lbf·ft)

j : 10 mm m : 14 N·m (10.5 lbf·ft) 16. Apply anti-seize (LOCTITE Silver Grade Anti-Seize or equivalent) to the thread part of sensor (9). Install sensor (9). j : 22 mm m : 50 N·m (37 lbf·ft)

W3-18-1-18

SECTION 3 BODY Group 18 Aftertreatment Device

2 Detail A

8 3, 4 7

12 6

3, 4, 5 A WNEK50-03-18-013

WNEK50-03-18-012

19. Apply anti-seize (LOCTITE Silver Grade Anti-Seize, Anti-Seize C5-A or equivalent) to the thread part of sensors (2) (2 used). Install sensors (2) (2 used).

21. Apply anti-seize (LOCTITE Silver Grade Anti-Seize or equivalent) to the thread part of sensor (1). Install sensor (1).

j : 14 mm

j : 22 mm

m : 30 N·m (22 lbf·ft)

m : 50 N·m (37 lbf·ft)

20. Install covers (12, 13), sensor unit (7), and clip (11) with washers (10) (2 used), bolts (9) (2 used), and bolt, washer (8).

22. Install sensor unit (6) and clip (5) with washers (4) (2 used) and bolts (3) (2 used).

j : 10 mm

j : 10 mm m : 14 N·m (10.5 lbf·ft)

Bolt, Washer (8) m : 3 to 4 N·m (2.2 to 3.0 lbf·ft) Bolt (9) m : 14 N·m (10.5 lbf·ft)

W3-18-1-19

SECTION 3 BODY Group 18 Aftertreatment Device 2

Lifting Bracket

The aftertreatment device (1) dCAUTION: assembly weight: 120 kg (265 lb)

WNEK50-03-18-011

25. Install cover (4) with bolts, washers (5, 6). j : 17 mm

23. Attach nylon slings onto lifting brackets (a) (4 places). Hoist the aftertreatment device (1) assembly.

m : 50 N·m (37 lbf·ft)

24. Install the aftertreatment device (1) assembly to bracket (3) with bolts, washers (2) (9 used). j : 19 mm m : 90 N·m (66 lbf·ft)

W3-18-1-20

SECTION 3 BODY Group 18 Aftertreatment Device

Detail of Installation of Pipe (1) Assembly

1 a

7 2, 3

Vehicle Front Side

WNEK50-03-18-009

26. Temporarily install the pipe (1) assembly with bolts, washers (2) (3 used), bolt, washer (4), bolts, washers (7) (2 used), clips (3) (3 used), clip (6), and nut (5).

4, 5, 6

27. Tighten bolts, washers (7) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft)

WNEK50-03-18-010

28. Tighten bolts, washers (2) (3 used) and nut (5). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-18-1-21

SECTION 3 BODY Group 18 Aftertreatment Device

View A

11 a

12, 13, 14 WNEK50-03-18-008

Vehicle Front Side

WNEK50-03-18-007

29. Install the washer fluid tank (15) assembly with the bolts, washers (11) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 30. Secure wire harness (16) and hoses (17) (2 used) with clips (13, 14) and bolt, washer (12). j : 17 mm m : 50 N·m (37 lbf·ft) 31. Install cover (4). (Refer to W3-22-1.)

W3-18-1-22

SECTION 3 BODY Group 18 Aftertreatment Device 10

1 View B

9 10 7, 8 1 5

a c

6 9

B b-

8 mm (0.32 in)

WNEK50-03-18-024 c-

45 mm (1.8 in)

5 View C

10 18 2, 3 a-

Vehicle Front Side

WNEK50-03-18-007

IMPORTANT: Check the position to install clamp (9) and exhaust pipe (10). IMPORTANT: Check the angle to install exhaust pipe (10). 32. Install exhaust pipe (10) with clamp (9), U-bolt (8), and nuts (7) (4 used). j : 17 mm

WNEK50-03-18-025 d-

45°

34. Connect connectors (1) (2 used). 35. Secure wire harness (18) with bracket (3) and bolt, washer (2). j : 17 mm

m : 20 N·m (15 lbf·ft) 33. Connect the both ends of hose (6) with clamps (5) (2 used). j : 7 mm m : 4 N·m (3.0 lbf·ft)

W3-18-1-23

m : 50 N·m (37 lbf·ft)

SECTION 3 BODY Group 18 Aftertreatment Device View A

4, 5, 6

16 12

9, 10

7, 8 3

WNEK50-03-18-005

WNEK50-03-18-006

View B

WNEK50-03-18-004

Vehicle Front Side

36. Connect hoses (12, 13, 14).

fNOTE: Connect hose (12) by pushing lock button

(green) of hose (12). 37. Connect connector (11).

38. Install the bracket (3) assembly with bolts, washers (2) (4 used).

41. Secure hose (15) and wire harness (16) with clips (5, 6) and bolt, washer (4).

j : 17 mm

m : 50 N·m (37 lbf·ft) 39. Secure hose (14) with clip (10) and bolt, washer (9). j : 17 mm m : 50 N·m (37 lbf·ft) 40. Secure hose (12) with clip (8) and bolt, washer (7). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-18-1-24

m : 50 N·m (37 lbf·ft)

SECTION 3 BODY Group 18 Aftertreatment Device 1 Detail A

5, 6

7 4 WNEK50-03-18-002 Detail B

10, 11, 12 3 a-

13 Vehicle Front Side

WNEK50-03-18-001

IMPORTANT: Replace gasket (6) with the new one. 42. Install gasket (6). Connect the both ends of exhaust pipe (4) with clamps (3, 5).

WNEK50-03-18-003

44. Tighten bolts, washers (7) (2 used), bolt, washer (10), and bolt, washer (13).

j : 11 mm Clamp (3)

j : 17 mm

m : 8.5±0.5 N·m (6.3±0.4 lbf·ft)

m : 50 N·m (37 lbf·ft)

Clamp (5)

45. Tighten clamps (9) (2 used) and clamp (8).

m : 13.5±1.5 N·m (10±1.1 lbf·ft)

j : 7 mm

43. Temporarily install the both ends of the pipe (2) assembly with clamps (9) (2 used), clamp (8), bolts, washers (7) (2 used), bolt, washer (10), bolt, washer (13), collar (12), and clip (11).

Clamp (8) m : 3.4±0.3 N·m (2.5±0.2 lbf·ft) Clamp (9) m : 4.1±0.4 N·m (3.0±0.3 lbf·ft) 46. Connect connectors (1) (2 used).

W3-18-1-25

SECTION 3 BODY Group 18 Aftertreatment Device

WNEK50-03-19-003

47. Add coolant to the radiator.

fNOTE: Amount of coolant: 33 L (8.7 US gal) IMPORTANT: Check the coolant level. Start the engine and check for any water leaks. IMPORTANT: Warm up the engine. Warm up the engine and increase the SCR exhaust temperature over 190 °C (374 °F). Check the DEF hose for DEF leaks. 48. Install engine cover (1). (Refer to W3-22-1.)

W3-18-1-26

SECTION 3 BODY Group 19 DEF Tank Removal and Installation of DEF Tank

View A

3 2

A WNEK50-03-19-001

WNEK50-03-19-002

2. Remove bolts, washers (2) (2 used). Remove cover (1). j : 17 mm 3. Place a container under drain plug (3). Slowly loosen drain plug (3). Drain off DEF completely. Tighten drain plug (3).

Removal

l : 6 mm

1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.)

m : 4.5 to 6.9 N·m (3.3 to 5.1 lbf·ft)

IMPORTANT: After stopping the engine, the DEF pump continues to be operated for a specified time in order to return DEF from the hose to the DEF tank. When 5 minutes pass after the engine has been stopped, start the work.

fNOTE: Total amount of DEF tank: 38 L (10 US gal)

W3-19-1-1

SECTION 3 BODY Group 19 DEF Tank

WNEK50-03-19-010

WNEK50-03-19-003

4. Release any pressure in the the expansion tank. (Refer to W1-5-1.) 5. Open side cover (1). 6. Place a container under hose (2). Loosen cock (3). Drain off coolant. Close cock (3). 4

fNOTE: Amount of coolant: 28 L (7.4 US gal) 7. Open cover (4). 8. Remove bolts, washers (5) (3 used). Remove bracket (6) and rubber plate (7).

j : 13 mm

WNEK50-03-19-004

W3-19-1-2

SECTION 3 BODY Group 19 DEF Tank

Vehicle Front Side

DEF Tank Box

WNEK50-03-19-005

dCAUTION: Cover (2) weight: 21 kg (47 lb)

9. Remove bolts, washers (1) (8 used). Remove cover (2). j : 17 mm

W3-19-1-3

SECTION 3 BODY Group 19 DEF Tank

Detail A

8, 9

13 1 12

WNEK50-03-19-006

WNEK50-03-19-007

10. Disconnect connector (13). Remove connector (13) from bracket (12).

13. Remove clamps (8) (2 used). Disconnect hoses (9) (2 used).

11. Remove bolt, washer (11). Remove clips (6, 7) and collar (5).

14. Remove bolts, washers (2) (4 used) and brackets (1) (2 used). Remove DEF tank (3) from DEF tank box (4).

j : 17 mm

12. Disconnect hoses (10) (2 used).

W3-19-1-4

SECTION 3 BODY Group 19 DEF Tank

Detail A

8, 9

13 1 12 B

WNEK50-03-19-006

WNEK50-03-19-007

Installation

View B

1. Install DEF tank (3) to DEF tank box (4) with brackets (1) (2 used) and bolts, washers (2) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

6, 7

IMPORTANT: Check that the hose (9) connecting surface is dry before connecting hose (9). 2. Connect hoses (9) (2 used) with clamps (8) (2 used). a-

3. Connect hoses (10) (2 used). IMPORTANT: Check the angle to install clips (6, 7). 4. Secure hoses (9, 10) (2 used for each) with collar (5), clips (6, 7), and bolt, washer (11).

30 °

WNEK50-03-19-008

5. Install connector (13) to bracket (12). Connect connector (13).

j : 17 mm m : 50 N·m (37 lbf·ft)

W3-19-1-5

SECTION 3 BODY Group 19 DEF Tank

View A

A WNEK50-03-19-006

6. Add coolant to the radiator.

fNOTE: Amount of coolant: 28 L (7.4 US gal) 7. Check that drain plug (2) is tightened. 8. Fill DEF tank (1) with DEF.

fNOTE: Total amount of DEF tank (1): 38 L (10 US gal) IMPORTANT: Check the DEF level and coolant level. Start the engine and check for any water leaks.

W3-19-1-6

WNEK50-03-19-002

SECTION 3 BODY Group 19 DEF Tank

Vehicle Front Side

DEF Tank Box

WNEK50-03-19-005

dCAUTION: Cover (2) weight: 21 kg (47 lb)

9. Install cover (2) with bolts, washers (1) (8 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-19-1-7

SECTION 3 BODY Group 19 DEF Tank

WNEK50-03-19-004

WNEK50-03-19-001

10. Open cover (3). 11. Install rubber plate (6) and bracket (5) with bolts, washers (4) (3 used).

j : 13 mm m : 10 N·m (7.4 lbf·ft) 12. Install cover (1) with bolts, washers (2) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 13. Close cover (3). 14. Close side cover (7).

WNEK50-03-19-003

W3-19-1-8

SECTION 3 BODY Group 20 Coolant Control Valve Removal and Installation of Coolant Control Valve

3 1

WNEK50-03-19-003

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) 2. Release any pressure in the the expansion tank. (Refer to W1-5-1.) 3. Open side cover (1). 4. Place a container under hose (2). Loosen cock (3). Drain off coolant. Close cock (3).

fNOTE: Amount of coolant: 28 L (7.4 US gal)

W3-20-1-1

WNEK50-03-19-010

SECTION 3 BODY Group 20 Coolant Control Valve Detail A

WNEK50-03-20-001

2 a-

Coolant Control Valve WNEK50-03-20-002

View B

5. Disconnect connector (4).

6. Remove bolt, washer (2), clip (3), and bracket (1). 5, 6

j : 17 mm

5, 6

7. Remove bolt, washer (9) and clip (10). j : 17 mm 10

8. Remove bolt, washer (7) and clip (8).

9. Loosen clamps (5) (2 used). Disconnect hoses (6) (2 used). j : 7 mm

9 a-

W3-20-1-2

Coolant Control Valve

8 WNEK50-03-20-008

SECTION 3 BODY Group 20 Coolant Control Valve

3 a-

Vehicle Rear Side

WNEK50-03-20-004

10. Remove bolts, washers (2) (2 used). Remove the bracket (4) assembly from rear frame (5). j : 17 mm 11. Remove screws (3) (2 used). Remove coolant control valve (1) from bracket (4).

W3-20-1-3

SECTION 3 BODY Group 20 Coolant Control Valve Detail A A

4 B

WNEK50-03-20-001

3 a a-

WNEK50-03-20-004

Vehicle Rear Side

Installation IMPORTANT: Install coolant control valve (1) with triangular mark (b) facing to the rear side of the vehicle. 1. Install coolant control valve (1) to bracket (4) with screws (3) (2 used).

View B

2. Install the bracket (4) assembly to rear frame (5) with bolts, washers (2) (2 used).

j : 17 mm

m : 50 N·m (37 lbf·ft) 4 a-

Vehicle Rear Side

Triangular Mark WNEK50-03-20-005

W3-20-1-4

SECTION 3 BODY Group 20 Coolant Control Valve View A

A a

4 5, 6 5, 6 a b

12 ab-

Coolant Control Valve Vehicle Rear Side

11 14

WNEK50-03-20-008 a-

WNEK50-03-20-002

Coolant Control Valve

View B

3. Connect hoses (6) (2 used) with clamps (5) (2 used). j : 7 mm m : 4.5 N·m (3.3 lbf·ft) IMPORTANT: Check the angle to install clip (8). 4. Secure hoses (11) (2 used) with clip (8) and bolt, washer (7). j : 17 mm m : 50 N·m (37 lbf·ft)

5. Secure hose (12) with clip (10) and bolt, washer (9).

8 c-

45°

WNEK50-03-20-006

j : 17 mm m : 50 N·m (37 lbf·ft)

6. Secure wire harness (13) and hose (14) with bracket (1), clip (3), and bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft) 7. Connect connector (4).

W3-20-1-5

SECTION 3 BODY Group 20 Coolant Control Valve

WNEK50-03-19-003

8. Add coolant to the radiator.

fNOTE: Amount of coolant: 28 L (7.4 US gal) IMPORTANT: Check the coolant level. Start the engine and check for any water leaks. 9. Close side cover (1).

W3-20-1-6

SECTION 3 BODY Group 21 DEF Supply Module Removal and Installation of DEF Supply Module

WNEK50-03-19-003

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. Removal 1. Set the vehicle position for inspection and maintenance. (Refer to W1-5-1.) IMPORTANT: After stopping the engine, the DEF pump continues to be operated for a specified time in order to return DEF from the hose to the DEF tank. When 5 minutes pass after the engine has been stopped, start the work. 2. Open side cover (1).

W3-21-1-1

SECTION 3 BODY Group 21 DEF Supply Module Detail A A

5 1

WNEK50-03-20-001

2 B

WNEK50-03-21-001

3. Lower lock (6) Disconnect connector (3). 4. Disconnect hoses (1) (3 used). 5. Remove socket bolts (2) (3 used). Remove DEF supply module (4) from support (5). Detail B

l : 6 mm

TDC1-05-01-005

W3-21-1-2

SECTION 3 BODY Group 21 DEF Supply Module Detail A A

5 1

WNEK50-03-20-001

2 WNEK50-03-21-001

Installation 1. Install DEF supply module (4) to support (5) with socket bolts (2) (3 used). l : 6 mm

Detail B

m : 20 N·m (15 lbf·ft) 2. Connect hoses (1) (3 used). 3. Connect connector (3). Raise and lock lock (6).

WDC150-03-17-003

W3-21-1-3

SECTION 3 BODY Group 21 DEF Supply Module

WNEK50-03-19-003

IMPORTANT: Warm up the engine. Warm up the engine over 15 minutes. Check that the SCR exhaust temperature is over 190°C (374°F) by using the monitor. Check the DEF hose for DEF leaks. 4. Close side cover (1).

W3-21-1-4

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Exterior Components

101

102

103

104

105

106

107

108 WNEK50-03-22-001

117

116 115

109

110

111

110

111

112

113

114 WPD850-03-01-003

118

119 120 121

122 WNEK50-03-22-003

W3-22-1-1

SECTION 3 BODY Group 22 Exterior Components No.

Parts

Page

101 102 103 104 105 106 107

Front Cover Front Fender Deck Step (Front) Rear Fender (Front) Rear Fender (Rear) Engine Cover

W3-22-1-3 W3-22-1-4 W3-22-1-5 W3-22-1-5 W3-22-1-5 W3-22-1-7 W3-22-1-9

108

Rear Cover

109 110 111 112 113 114 115

Cab Under Cover Mud Guard Inspection Cover Lower Cover Step (Rear) DEF Tank Box Side Cover (Front)

Related Parts 1

Rear Fender (Rear) (106) W3-22-1-21 Rear Grill (116)

116 117 118 119 120 121

Rear Grill Left Side Cover (Rear) Right Side Cover (Rear) Tool Box Under Guard (Rear) Battery Box

W3-22-1-25 W3-22-1-26 W3-22-1-28 W3-22-1-31 W3-22-1-28 W3-22-1-28 W3-22-1-32 (without Rear Fender (Rear)) W3-22-1-38 (with Rear Fender (Rear)) W3-22-1-44 W3-22-1-51 W3-22-1-55 W3-22-1-28 W3-22-1-59 W3-22-1-60

122

Under Guard (Front)

W3-22-1-70

Side Cover (Front) (115)

Rear Grill (116)

Rear Cover (108)

Battery Box (121)

DEF Tank

Rear Fender (Rear) (106)

Rear Fender (Front) (105)

W3-22-1-2

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Front Cover (101)

02 01

WNEK50-03-22-004

No.

Part Name

Q'ty

Wrench Size Tightening Torque mm N·m (lbf·ft)

01 02

Bolt, Washer Cover

4 1

j : 17

Weight kg (lb)

(37)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.)

W3-22-1-3

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Front Fender (102)

WPD850-03-22-001

No.

Part Name

Q'ty

01 02 03 04 05 11 12 13 14

Fender Fender Washer Washer Nut Cover Cover Screw Plug

1 1 8 8 8 1 1 10 8

Wrench Size Tightening Torque mm N·m (lbf·ft)

j : 19

Weight kg (lb)

(2.6)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.)

W3-22-1-4

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Deck (103), Step (Front) (104) and Rear Fender (Front) (105)

104

103 105

105

104

WPD850-03-22-002

W3-22-1-5

SECTION 3 BODY Group 22 Exterior Components No.

Part Name

 Deck (103) 01 Deck 02 Bolt, Washer  Fender (Front) (105) 05 Fender 06 Fender 07 Bolt, Washer 08 Bolt, Washer 09 Bolt, Washer 12 Cover 13 Cover 14 Screw  Step (Front) (104) 19 Handrail 20 Bolt, Washer 21 Washer 22 Nut 24 Handrail 25 Bolt, Washer 26 Washer 27 Nut 30 Step 31 Bolt, Washer 32 Step 33 Bolt, Washer 34 Nut 37 Step 38 Bolt, Washer

Q'ty

1 4 1 1 3 3 8 1 1 8 1 2 2 2 1 2 2 2 1 4 1 4 4 1 4

Wrench Size Tightening Torque mm N·m (lbf·ft)

j : 19

(66)

j : 19 j : 19 j : 19

90 90 90

(66) (66) (66)

j : 19

(66)

j : 19

(66)

j : 19

(66)

j : 19

(66)

j : 19

(66)

j : 17 j : 17

50 50

(37) (37)

j : 17

(37)

Weight kg (lb)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.)

W3-22-1-6

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Rear Fender (Rear) (106) 24 25

03 03

01 23 14 16 15 16 15

06 17

07 19

17 19

13 16

20 10

07 06 10 08 20

22 21

WPD850-03-22-003

W3-22-1-7

SECTION 3 BODY Group 22 Exterior Components No.

Part Name

Q'ty

01 02 03 06 07 08 09 10 13*1 14*1 15 16 17 19 20 21 22 23 24 25

Fender Fender Bolt, Washer Bracket Bolt, Washer Bracket Bracket Bolt, Washer Cover Cover Bolt Washer Bracket Bolt, Washer Nut Bracket Bolt, Washer Bracket Bracket Bolt, Washer

1 1 8 2 4 1 1 6 1 1 8 8 2 4 4 2 4 2 2 6

Wrench Size Tightening Torque mm N·m (lbf·ft)

j : 17

(37)

j : 19

(66)

j : 19

(66)

j : 17

(37)

j : 17 j : 17

20 50

(15) (37)

j : 17

(37)

j : 17

(37)

Weight kg (lb)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.) *1: Install covers (13, 14) with the glossy surface facing to the front side of the machine.

W3-22-1-8

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Engine Cover (107)

115

106

4 2 108

3 116

WNEK50-03-22-008

Removal

WNEK50-03-22-009

4. Remove bolts, washers (3) (4 used). Remove tail pipe (2).

1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.)

j : 17 mm

2. Remove the following exterior components. (Refer to W3-22-1-1.)  Left and Right Rear Fender (Rear) (106)  Left and Right Side Cover (Front) (115)  Rear Grill (116)  Rear Cover (108) 3. Remove bolts, washers (1) (5 used). Remove cover (4). j : 17 mm

W3-22-1-9

SECTION 3 BODY Group 22 Exterior Components

Detail A A

3 2

WNEK50-03-22-010

5. Remove bolts, washers (2, 3) (2 used for each). Remove and place the water tank (1) assembly outside the work area. j : 17 mm

W3-22-1-10

WNEK50-03-22-011

SECTION 3 BODY Group 22 Exterior Components

Detail A

4 WNEK50-03-22-013

3 a-

1, 2

Machine Front Side

WNEK50-03-22-012

6. Remove bolt, washer (1) and clip (2). j : 17 mm 7. Remove wire harnesses (3) from clip (4) and clips (5) (2 used).

W3-22-1-11

SECTION 3 BODY Group 22 Exterior Components

3 a-

WNEK50-03-22-014

Machine Front Side

8. Remove seal trim (5). 9. Remove bolts, washers (3, 4) (2 used for each). Remove bracket (1) and the bracket (2) assembly. j : 19 mm

W3-22-1-12

SECTION 3 BODY Group 22 Exterior Components

Detail A

WNEK50-03-22-016

6 a-

2, 3

WNEK50-03-22-015

Machine Front Side

10. Remove bolt, washer (2) and clip (3). j : 17 mm 11. Remove wire harness (1) from clips (7, 8). 12. Remove seal trim (6), bracket (4) assembly and bracket (5) in the same way as step 8 to step 9.

W3-22-1-13

SECTION 3 BODY Group 22 Exterior Components

2 1

4 13 3

5 6 7

10 a

WNEK50-03-22-017

Machine Front Side

13. Remove caps (1) (4 used).

dCAUTION: Engine cover (2) weight: 52 kg (115 lb) 14. Install eyebolts (M16, Pitch 2 mm) (4 used) to the cap (1) mounting holes (4 places). Attach nylon slings onto the eyebolts (4 used). Hoist and hold engine cover (2).

15. Remove bolts, washers (3) (4 used). Remove bracket (4). j : 19 mm 16. Remove bolts (8, 10) (4 used for each), washers (7, 11) (4 used for each), collars (6) (4 used) and washers (5, 12) (4 used for each). Remove engine cover (2) from hydraulic oil tank (9) and support (13). j : 24 mm

W3-22-1-14

SECTION 3 BODY Group 22 Exterior Components

2 1

4 13 3

5 6 7

10 a

WNEK50-03-22-017

Machine Front Side

4. Tighten bolts (8, 10) (4 used for each).

Installation

dCAUTION: Engine cover (2) weight: 52 kg (115 lb)

1. Install eyebolts (M16, Pitch 2 mm) (4 used) to the cap (1) mounting holes (4 places). Attach nylon slings onto the eyebolts (4 used). Hoist engine cover (2). 2. Temporally install engine cover (2) to hydraulic oil tank (9) and support (13) with washers (5, 12) (4 used for each), collars (6) (4 used), washers (7, 11) (4 used for each) and bolts (8, 10) (4 used for each).

j : 24 mm m : 210 N·m (155 lbf·ft) 5. Tighten bolts, washers (3) (4 used). j : 19 mm m : 90 N·m (66 lbf·ft) 6. Install caps (1) (4 used).

3. Temporarily install bracket (4) with bolts, washers (3) (4 used).

W3-22-1-15

SECTION 3 BODY Group 22 Exterior Components a b

4 3 B

Machine Front Side

WNEK50-03-22-014

Engine Cover

View A

View B b

5 d

WNEK50-03-22-018 c-

End faces of engine cover (b) and seal trim (5) must be in a same line.

7. Install bracket (1) and bracket (2) assembly with bolts, washers (3, 4) (2 used for each). j : 19 mm

WNEK50-03-22-019

5 d-

10 mm (0.4 in)

IMPORTANT: Check the position to install seal trim (5). 8. Install seal trim (5).

m : 90 N·m (66 lbf·ft)

W3-22-1-16

SECTION 3 BODY Group 22 Exterior Components

Detail A

A a

4 WNEK50-03-22-013

3 a-

1, 2

Machine Front Side

WNEK50-03-22-012

IMPORTANT: When securing harness (3) with clip (4), fit the tape mark of wire harness (3) with clip (4). 9. Secure harness (3) with clip (4) and clips (5) (2 used). 10. Secure harness (3) with clip (2) and bolt, washer (1). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-22-1-17

SECTION 3 BODY Group 22 Exterior Components

Detail A

WNEK50-03-22-016

6 a-

2, 3

WNEK50-03-22-015

Machine Front Side

11. Install the bracket (4) assembly, bracket (5) and seal trim (6) in the same way as step 7 to step 8. IMPORTANT: When securing wire harness (1) with clip (7), fit the tape mark of wire harness (1) with clip (7). 12. Secure harness (1) with clips (7, 8). 13. Secure harness (1) with clip (3) and bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-22-1-18

SECTION 3 BODY Group 22 Exterior Components

Detail A A

3 2

WNEK50-03-22-010

14. Install the water tank (1) assembly with bolts, washers (2, 3) (2 used for each). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-22-1-19

WNEK50-03-22-011

SECTION 3 BODY Group 22 Exterior Components

115

106

4 2 108

3 116

WNEK50-03-22-008

WNEK50-03-22-009

15. Install tail pipe (2) with bolts, washers (3) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

 Rear Cover (108)  Rear Grill (116)  Left and Right Side Cover (Front) (115)  Left and Right Rear Fender (Rear) (106)

16. Install cover (4) with bolts, washers (1) (5 used). j : 17 mm m : 50 N·m (37 lbf·ft) 17. Install the following exterior components. (Refer to W3-22-1-1.)

W3-22-1-20

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Rear Cover (108)

2, 3

View A

116

B WNEK50-03-22-020

WNEK50-03-22-049

View B

Removal

1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.)

2. Open left and right side covers (front) (1). 3. Remove the following exterior components. (Refer to W3-22-1-1.) 6

 Rear Grill (116) 4. Remove bolt, washer (2) and clip (3). j : 17 mm

5. Loosen clamp (7). j : 7 mm 6. Remove bolts, washers (4) (4 used). Remove air pipe (5) from air hose (6). j : 17 mm

W3-22-1-21

WNEK50-03-22-021

SECTION 3 BODY Group 22 Exterior Components 1 9 2

3 8 7

6 5

7. Remove bolts, washers (1) (3 used). j : 17 mm The rear cover (2) assembly weight: 25 dCAUTION: kg (55 lb) 8. Remove bolts, washers (9) (2 used), nuts (5) (2 used), and washers (6) (2 used). Remove the rear cover (2) assembly and washers (8) (2 used) from engine cover (3) and frame (4). j : 19 mm 9. Remove rubbers (7) (2 used) from frame (4).

W3-22-1-22

WNEK50-03-22-023

SECTION 3 BODY Group 22 Exterior Components 1 9 2

3 8 7

6 5

Installation 1. Install rubbers (7) (2 used) to frame (4).

4. Tighten bolts, washers (1) (3 used).

The rear cover (2) assembly weight: 25 dCAUTION: kg (55 lb) 2. Temporally install the rear cover (2) assembly and washers (8) (2 used) to engine cover (3) and frame (4) with bolts, washers (9) (2 used), washers (6) (2 used), nuts (5) (2 used) and bolts, washers (1) (3 used). 3. Tighten bolts, washers (9) (2 used) and nuts (5) (2 used). j : 19 mm m : 90 N·m (66 lbf·ft)

W3-22-1-23

j : 17 mm m : 50 N·m (37 lbf·ft)

WNEK50-03-22-023

SECTION 3 BODY Group 22 Exterior Components

2, 3

View A

116

B WNEK50-03-22-020

WNEK50-03-22-049

View B

5. Temporarily install air pipe (5) to air hose (6) with clamp (7) and bolts, washers (4) (4 used).

6. Tighten bolts, washers (4) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft) 6

7. Tighten clamp (7). j : 7 mm

m : 6.7±0.7 N·m (4.9±0.52 lbf·ft) 8. Secure hose (8) with clip (3) and bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft)

WNEK50-03-22-021

9. Install the following exterior components. (Refer to W3-22-1-1.)  Rear Grill (116)

10. Close left and right side covers (front) (1).

W3-22-1-24

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Cab Under Cover (109)

02 01 03 03 03 04

03 05

WNEK50-03-22-024

No.

Part Name

Q'ty

01 02 03 04 05 06

Cover Cover Bolt, Washer Cover Cover Cover

1 1 14 1 1 1

Wrench Size Tightening Torque mm N·m (lbf·ft)

j : 17

Weight kg (lb)

(37)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.)

W3-22-1-25

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Mud Cover (110)

WPD850-03-22-004

W3-22-1-26

SECTION 3 BODY Group 22 Exterior Components No.

Part Name

Q'ty

01*1 02*1 03 04 05 06 07 08 09

Cover Cover Bracket Bracket Bracket Bolt, Washer Washer Bolt Washer

1 1 1 1 2 12 6 4 4

14*2 15*2 16 17 18 19 20 21 22 23 24 25

Cover Cover Bracket Bracket Bolt, Washer Washer Nut Bolt, Washer Bolt Washer Bolt, Washer Bolt, Washer

1 1 1 1 3 3 4 1 6 6 2 1

Wrench Size Tightening Torque mm N·m (lbf·ft)

j : 17

(37)

j : 17

(37)

j : 17

(37)

j : 17 j : 17 j : 17

50 50 50

(37) (37) (37)

j : 17 j : 17

50 50

(37) (37)

Weight kg (lb)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.) *1: Install covers (01, 02) with the pearskin surface facing to the rear side of the machine. *2: Install covers (14, 15) with the glossy surface facing to the front side of the machine.

W3-22-1-27

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Inspection Cover (111), Step (Rear) (113), DEF Tank Box (114) and Tool Box (119)

119

111

113

114

111- Inspection Cover 113- Step (Rear)

113

WPD850-03-22-005

114- DEF Tank Box 119- Tool Box

W3-22-1-28

SECTION 3 BODY Group 22 Exterior Components No.

Part Name

 Inspection Cover (111) 01 Plate 02 Rubber Seal 03 Cover 04 Rubber Seal 05 Bolt, Washer 06*1 Cover 07 Rubber Bushing  DEF Tank Box (114), Tool Box (119) 10*2 Box 11 Cover

Q'ty

1 1 2 2 16 1 1

Wrench Size Tightening Torque mm N·m (lbf·ft)

j : 17

(37)

1 1

11A

Hinge

11B

Clip

11C

Screw

Bolt, Washer

14 14A 14A1 14B 14B1 14C 14D 14E 15 16 17 18 20 21 24

Tool Box Cover Hinge Box Hinge Collar Clip Screw Washer Washer Nut Washer Cover Bolt, Washer Rubber Plate

1 1 2 1 2 2 1 2 8 8 8 8 1 2 1

Weight kg (lb)

22 (49) 21 (47)

j : 17

(37) 27 (60)

j : 19

(26)

j : 17

(37)

W3-22-1-29

SECTION 3 BODY Group 22 Exterior Components No.

Part Name

Q'ty

25 26 27 28 30 31 32 33 35

Bracket Bolt, Washer Rubber Plate Rubber Seal Seal Trim Rubber Seal Trim Handle Rubber Stopper

1 3 1 1 1 1 1 2 2

Washer

Nut

Rubber Cushion

Screw

42 Bracket 43 Bolt, Washer 44 Trim  Step (Rear) (113) 51 Step 52 Step 53 Bolt, Washer 56 Step 57 Washer 58 Washer 59 Nut

1 2 1 1 1 4 1 2 2 2

Wrench Size Tightening Torque mm N·m (lbf·ft) j : 13

j:8

2.5

j : 17

(37)

j : 19

(66)

j : 19

(26)

Weight kg (lb)

(7.4)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.) *1: Remove battery box (121) before removing cover (06). (Refer to W3-22-1-1.) *2: Remove the DEF tank before removing box (10). (Refer to W3-19-1.)

W3-22-1-30

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Lower Cover (112)

WPD850-03-22-006

No.

Part Name

Q'ty

Wrench Size Tightening Torque mm N·m (lbf·ft)

01 02 03 04 05

Bolt, Washer Cover Rubber Seal Cover Rubber Seal

10 1 1 1 1

j : 17

Weight kg (lb)

(37)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.)

W3-22-1-31

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Side Cover (Front) (115) (without Rear Fender (Rear))

WNEK50-03-22-050

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.) 2. Open side cover (front) (1).

W3-22-1-32

SECTION 3 BODY Group 22 Exterior Components

Detail A

2 3

6 A

WNEK50-03-22-051

2 7

WNEK50-03-22-052

Side cover (front) (1) weight: 28 kg (62 dCAUTION: lb) IMPORTANT: Attach nylon slings onto the frame side of side cover (front) (1). 3. Attach nylon slings onto side cover (front) (1). Hoist and hold side cover (front) (1).

5. Remove nut (8). Remove the damper (2) assembly from bracket (7). j : 13 mm

fNOTE: When loosening nut (8), secure bolt (6) with a wrench to fix it.

4. Remove nut (5). Disconnect the damper (2) assembly from bracket (4). j : 13 mm

fNOTE: When loosening nut (5), secure bolt (3) with a wrench to fix it.

j : 12 mm

W3-22-1-33

j : 12 mm

SECTION 3 BODY Group 22 Exterior Components

WNEK50-03-22-031

6. Remove bolts, washers (3) (4 used). Remove side cover (front) (1) from engine cover (2). j : 19 mm 7. Remove other side cover (front) (1) in the same way as step 2 to step 6.

W3-22-1-34

SECTION 3 BODY Group 22 Exterior Components

WNEK50-03-22-031

Installation Side cover (front) (1) weight: 28 kg (62 dCAUTION: lb) IMPORTANT: Attach nylon slings onto the frame side of side cover (front) (1). 1. Attach nylon slings onto side cover (front) (1). Hoist side cover (front) (1). 2. Install side cover (front) (1) to engine cover (2) with bolts, washers (3) (4 used). j : 19 mm m : 90 N·m (66 lbf·ft)

W3-22-1-35

SECTION 3 BODY Group 22 Exterior Components

Detail A

2 3

WNEK50-03-22-051

2 7

WNEK50-03-22-052

IMPORTANT: Set the direction of part (b) of the dumper (2) assembly as illustrated. 3. Install the damper (2) assembly to bracket (7) with nut (8).

IMPORTANT: Set the direction of part (a) of the dumper (2) assembly as illustrated. 4. Install the damper (2) assembly to bracket (4) with nut (5).

j : 13 mm

m : 10 N·m (7.4 lbf·ft)

fNOTE: When tightening nut (8), secure bolt (6) with a wrench to fix it.

fNOTE: When tightening nut (5), secure bolt (3) with a wrench to fix it.

j : 12 mm

W3-22-1-36

SECTION 3 BODY Group 22 Exterior Components

WNEK50-03-22-050

5. Close side cover (front) (1). 6. Install other side cover (front) (1) in the same way as step 1 to step 5.

W3-22-1-37

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Side Cover (Front) (115) (with Rear Fender (Rear))

106

WNEK50-03-22-008

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.) 2. Remove the following exterior components. (Refer to W3-22-1-1.)  Rear Fender (Rear) (106) 3. Open side cover (front) (1).

W3-22-1-38

SECTION 3 BODY Group 22 Exterior Components

Detail A

WNEK50-03-22-029

WNEK50-03-22-028

Detail B

Side cover (front) (1) weight: 28 kg (62 dCAUTION: lb)

IMPORTANT: Attach nylon slings onto the frame side of side cover (front) (1). 4. Attach nylon slings onto side cover (front) (1). Hoist and hold side cover (front) (1).

9 10

5. Remove lock pin (6), washer (5), and pin (3). Disconnect dampers (2) (2 used) from bracket (4). 6. Remove lock pin (9), washer (10), and pin (7). Remove dampers (2) (2 used) from bracket (8).

WNEK50-03-22-030

W3-22-1-39

SECTION 3 BODY Group 22 Exterior Components

WNEK50-03-22-031

7. Remove bolts, washers (3) (4 used). Remove side cover (front) (1) from engine cover (2). j : 19 mm 8. Remove other side cover (front) (1) in the same way as step 2 to step 7.

W3-22-1-40

SECTION 3 BODY Group 22 Exterior Components

WNEK50-03-22-031

W3-22-1-41

SECTION 3 BODY Group 22 Exterior Components

Detail A

a WNEK50-03-22-029

WNEK50-03-22-028

Detail B

IMPORTANT: Set the direction of part (b) of dumpers (2) (2 used) as illustrated. 3. Install dampers (2) (2 used) to bracket (8) with pin (7), washer (10), and lock pin (9).

IMPORTANT: Set the direction of part (a) of dumpers (2) (2 used) as illustrated. 4. Install dampers (2) (2 used) to bracket (4) with pin (3), washer (5), and lock pin (6).

2 b

WNEK50-03-22-030

W3-22-1-42

SECTION 3 BODY Group 22 Exterior Components

106

WNEK50-03-22-008

5. Close side cover (front) (1). 6. Install the following exterior components. (Refer to W3-22-1-1.)  Rear Fender (Rear) (106) 7. Install other side cover (front) (1) in the same way as step 1 to step 6.

W3-22-1-43

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Rear Grill (116)

View A

B WNEK50-03-22-057 WNEK50-03-22-056

Removal

Detail B 5, 6

1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.)

2. Open rear grill (1).

7, 8

3. Remove bolts, washers (2) (2 used) and cover (3). j : 17 mm 4. Remove bolts, washers (5) (2 used), bolt, washer (7), bolt washer (9), clips (6) (2 used), clip (8), and clip (10). j : 17 mm 5. Disconnect the connectors (4) (2 used). 6. Loosen clip (11). Disconnect connector (12). j : 17 mm

W3-22-1-44

11, 12

9, 10 WNEK50-03-22-058

SECTION 3 BODY Group 22 Exterior Components

Detail A

WNEK50-03-22-034

WNEK50-03-22-033

Detail B

The rear grill (1) assembly weight: 35 dCAUTION: kg (78 lb) 7. Attach nylon slings onto the rear grill (1) assembly. Hoist and hold the rear grill (1) assembly.

9 10

8. Put a mark on bracket (4) to indicate the position of pin (3) installation hole. Remove lock pin (6), washer (5), and pin (3). Disconnect damper (2) from bracket (4).

fNOTE: Position of pin (3) installation hole varies

depending on the machine model. 9. Put a mark on bracket (8) to indicate the position of pin (7) installation hole. Remove lock pin (10), washer (9), and pin (7). Remove damper (2) from bracket (8).

fNOTE: Position of pin (7) installation hole varies

depending on the machine model. 10. Remove other damper (2) from brackets (4, 8) in the same way as step 8 to step 9.

W3-22-1-45

WNEK50-03-22-035

SECTION 3 BODY Group 22 Exterior Components

2 3

WNEK50-03-22-055

11. Remove bolts, washers (2) (4 used). Remove the rear grill (1) assembly from rear cover (3). j : 17 mm

W3-22-1-46

SECTION 3 BODY Group 22 Exterior Components

View A

2 1

Lip Part

WNEK50-03-22-055

Installation The rear grill (1) assembly weight: 35 dCAUTION: kg (78 lb) 1. Attach nylon slings onto the rear grill (1) assembly. Hoist the rear grill (1) assembly. IMPORTANT: When installing the rear grill (1) assembly, put rip (a) of trim seal (4) on rear cover (3). 2. Install the rear grill (1) assembly to rear cover (3) with bolts, washers (2) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-22-1-47

WNEK50-03-22-037

SECTION 3 BODY Group 22 Exterior Components

Detail A

B a

WNEK50-03-22-034

WNEK50-03-22-033

Detail B

IMPORTANT: Set the direction of part (b) of dumper (2) as illustrated. 3. Install pin (7), washer (9) and lock pin (10) to the marked position when removing damper (2) on bracket (8).

fNOTE: Position of pin (7) installation hole varies

depending on the machine model. IMPORTANT: Set the direction of part (a) of dumper (2) as illustrated. 4. Install pin (3), washer (5) and lock pin (6) to the marked position when removing damper (2) on bracket (4).

NOTE: Position of pin (3) installation hole varies depending on the machine model. 5. Install other damper (2) to bracket (4, 8) in the same way as step 3 to step 4.

W3-22-1-48

2 WNEK50-03-22-035 b

SECTION 3 BODY Group 22 Exterior Components

View A

B WNEK50-03-22-057 WNEK50-03-22-056

6. Connect connector (12). Tighten clip (11).

Detail B 5, 6

j : 17 mm

m : 50 N·m (37 lbf·ft) 7, 8

7. Connect the connectors (4) (2 used). IMPORTANT: Fit clip (8) to the tape marking of harness (13) when installing clip (8). 8. Secure harness (13) with clips (6) (2 used), clip (8), clip (10), bolts, washers (5) (2 used), bolt, washer (7), and bolt, washer (9). j : 17 mm m : 50 N·m (37 lbf·ft) 9. Install cover (3) with bolts, washers (2) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 10. Close rear grill (1).

W3-22-1-49

13 11, 12

9, 10 WNEK50-03-22-058

SECTION 3 BODY Group 22 Exterior Components

View A

3 1 4 1

Clearance

WNEK50-03-22-020

11. Ensure that clearance (a) of rear grill (3) and left and right side covers (rear) (2, 4) is 10±5 mm (0.4±0.19 in). If the clearance (a) is not 10±5 mm (0.4±0.19 in), adjust the clearance (a) by loosening bolts, washers (1) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-22-1-50

WNEK50-03-22-038

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Left Side Cover (Rear) (117)

WNEK50-03-22-008

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.) 2. Open left side cover (front) (2). 3. Open rear grill (1). 4. Disconnect connector (3).

W3-22-1-51

WNEK50-03-22-022

SECTION 3 BODY Group 22 Exterior Components

3 4

WNEK50-03-22-039

5. Remove bolts, washers (6) (2 used). j : 19 mm Left side cover (rear) (1) assembly dCAUTION: weight: 26 kg (58 lb) 6. Remove bolts, washers (3, 7) (2 used) and bracket (2). Remove the left side cover (rear) (1) assembly from frames (4, 5). j : 17 mm

W3-22-1-52

SECTION 3 BODY Group 22 Exterior Components

3 4

WNEK50-03-22-039

3. Tighten bolts, washers (6) (2 used).

Installation Left side cover (rear) (1) assembly dCAUTION: weight: 26 kg (58 lb)

j : 19 mm

1. Temporally install the side cover (rear) (1) assembly to frames (4, 5) with bracket (2) and bolts, washers (3, 6, 7) (2 used for each). 2. Tighten bolts, washers (3, 7) (2 used for each). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-22-1-53

m : 90 N·m (66 lbf·ft)

SECTION 3 BODY Group 22 Exterior Components

WNEK50-03-22-022

4. Connect connector (3). 5. Close rear grill (1). 6. Close left side cover (front) (2).

W3-22-1-54

WNEK50-03-22-008

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Right Side Cover (Rear) (118)

3 4

WNEK50-03-22-020

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.) 2. Open right side cover (front) (1). 3. Open rear grill (2). 4. Remove wire harness (5) from clip (4). 5. Disconnect connector (3).

W3-22-1-55

WNEK50-03-22-040

SECTION 3 BODY Group 22 Exterior Components

1 7

WNEK50-03-22-041

6. Remove bolts, washers (5) (2 used). j : 19 mm Right side cover (rear) (3) assembly dCAUTION: weight: 26 kg (57 lb) 7. Remove bolts, washers (1, 4) (2 used) and bracket (2). Remove the right side cover (rear) (3) assembly from frames (6, 7). j : 17 mm

W3-22-1-56

SECTION 3 BODY Group 22 Exterior Components

1 7

WNEK50-03-22-041

Installation

3. Tighten bolts, washers (5) (2 used).

Right side cover (rear) (3) assembly dCAUTION: weight: 26 kg (57 lb) 1. Temporally install the right side cover (rear) (3) assembly to frames (6, 7) with bracket (2) and bolts, washers (1, 4, 5) (2 used for each). 2. Tighten bolts, washers (1, 4) (2 used for each). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-22-1-57

j : 19 mm m : 90 N·m (66 lbf·ft)

SECTION 3 BODY Group 22 Exterior Components

3 4

WNEK50-03-22-040

4. Connect connector (3). 5. Secure wire harness (5) with clip (4). 6. Close rear grill (2). 7. Close right side cover (front) (1).

W3-22-1-58

WNEK50-03-22-020

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Under Guard (Rear) (120)

WPD850-03-22-007

No.

Part Name

Q'ty

01 02 03 04 05 06

Guard Plate Bolt Washer Washer Bolt, Washer

1 1 4 4 4 7

Wrench Size Tightening Torque mm N·m (lbf·ft)

Weight kg (lb) 80 (176)

j : 24

210

(155)

j : 17

(37)

Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.) CAUTION: While removing or installing guard (01), place a stand and jack under guard (01) to hold guard (01). Do not drop guard (01).

W3-22-1-59

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Battery Box (121)

Detail A

105 A

3 1 a

WNEK50-03-22-043

b WNEK50-03-22-042

Removal IMPORTANT: When disconnecting connectors or terminals, attach an identification tag onto the connectors and terminals for assembling. If the clips which secure the wire harnesses is removed, install the clips after connecting the connectors or terminals. 1. Set the machine position for inspection and maintenance. (Refer to W1-5-1.)

ab-

OFF Position ON Position

IMPORTANT: Set the key switch to the OFF position. Wait 5 minutes or longer, and then set battery disconnect switch (5) to the OFF position. 4. Set battery disconnect switch (5) to OFF position (a). 5. Remove bolts, washers (4) (2 used). Remove rubber plates (1) (2 used).

2. Remove the following exterior components. (Refer to W3-22-1-1.)  Right Rear Fender (Front) (105) 3. Open covers (2, 3).

W3-22-1-60

j : 17 mm

SECTION 3 BODY Group 22 Exterior Components

13, 14

2 3, 4

11, 12 5

10 3, 4 8, 9

6, 7

5 1

9. Remove nuts (3) (4 used), washers (4) (4 used), brackets (2) (2 used), and rod (5) (4 used). Remove batteries (1) (2 used).

6. Loosen nut (13). Disconnect terminal (14). j : 10 mm 7. Loosen nuts (8, 11). Disconnect terminals (9, 12). j : 10 mm 8. Loosen nut (6). Disconnect terminal (7).

WNEK50-03-22-044

j : 17 mm 10. Remove battery disconnect switch (10). (Refer to W3-17-1.)

j : 10 mm

dCAUTION: Battery (1) weight: 40 kg (88 lb)

W3-22-1-61

SECTION 3 BODY Group 22 Exterior Components

1, 2

17 16

15 9 10 11 14

11. Remove bolts, washers (1) (2 used) and clips (2, 12). j : 17 mm

1, 12

WNEK50-03-22-045

16. Remove screws (11) (2 used). Remove starter relay (10). 17. Remove screws (13) (2 used). Remove intake air heater relay (14).

12. Remove bolt, washer (16), nut (15), and clip (17). j : 17 mm 13. Remove bolt, washer (3). Disconnect ground (4). j : 17 mm 14. Remove fusible link (5) from bracket (6). 15. Remove fusible link (8) and fusible links (9) (2 used) from bracket (7).

W3-22-1-62

SECTION 3 BODY Group 22 Exterior Components

Detail A 1

5 6

7 4 12 11

WNEK50-03-22-046

10 9 a-

Battery Relay

18. Remove screws (1) (2 used). Disconnect terminals (2, 3). 19. Remove bolts, washers (4) (2 used). Disconnect terminals (5, 6, 7, 8, 9, 10, 11, 12). j : 13 mm

W3-22-1-63

8 WNEK50-03-22-047

SECTION 3 BODY Group 22 Exterior Components

3 WNEK50-03-22-048 a-

Hole

The battery box (5) assembly weight: dCAUTION: 110 kg (243 lb) 20. Attach nylon slings onto the battery box (5) assembly. Hoist and hold the battery box (5) assembly. Hold the lower part of the battery box (5) assembly by using a jack and wooden blocks. Remove bolts (3) (4 used) and washers (4) (4 used). Remove the battery box (5) assembly from rear frame (1) while pulling the wire harness (2) assembly from hole (a) on battery box (5). j : 24 mm

W3-22-1-64

SECTION 3 BODY Group 22 Exterior Components

3 WNEK50-03-22-048 a-

Hole

Installation The battery box (5) assembly weight: dCAUTION: 110 kg (243 lb) 1. Attach nylon slings onto the battery box (5) assembly. Hoist and hold the battery box (5) assembly. Raise the lower part of the battery box (5) assembly by using a jack and wooden blocks. Pass through the wire harness (2) assembly to battery box (5) via hole (a). Install the battery box (5) assembly to rear frame (1) with washers (4) (4 used) and bolts (3) (4 used). j : 24 mm m : 210 N·m (55 lbf·ft)

W3-22-1-65

SECTION 3 BODY Group 22 Exterior Components

Detail A 1

5 6

7 4 12 11

WNEK50-03-22-046

10 9 a-

Battery Relay

2. Connect terminals (5, 6, 7, 8, 9, 10, 11, 12) with bolts, washers (4) (2 used). j : 13 mm m : 5 N·m (3.7 lbf·ft) 3. Connect terminals (2, 3) with screws (1) (2 used).

W3-22-1-66

8 WNEK50-03-22-047

SECTION 3 BODY Group 22 Exterior Components

1, 2

19 7

17 16

15 9 10 11 18

4. Install intake air heater relay (14) with screws (13) (2 used).

1, 12

WNEK50-03-22-045

10. Secure harnesses (18, 19) with clips (2, 12) and bolts, washers (1) (2 used).

5. Install starter relay (10) with screws (11) (2 used).

j : 17 mm

6. Install fusible links (9) (2 used) and fusible link (8) to bracket (7).

m : 50 N·m (37 lbf·ft)

7. Install fusible link (5) to bracket (6). 8. Connect ground (4) with bolt, washer (3). j : 17 mm m : 50 N·m (37 lbf·ft) 9. Secure wire harness (18) with clip (17), nut (15), and bolt, washer (16). j : 17 mm m : 50 N·m (37 lbf·ft)

W3-22-1-67

SECTION 3 BODY Group 22 Exterior Components

13, 14

2 3, 4

11, 12 5

10 3, 4 8, 9

6, 7

5 1

dCAUTION: Battery (1) weight: 40 kg (88 lb)

WNEK50-03-22-044

13. Connect terminals (9, 12). Tighten nuts (8, 11). j : 10 mm

11. Install batteries (1) (2 used) with rods (5) (4 used), brackets (2) (2 used), washers (4) (4 used) and nuts (3) (4 used).

m : 3 to 4 N·m (2.2 to 3.0 lbf·ft) 14. Connect terminal (14). Tighten nut (13).

j : 17 mm j : 10 mm

m : 10 N·m (7.4 lbf·ft)

m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)

12. Connect terminal (7). Tighten nut (6). j : 10 mm

15. Install battery disconnect switch (10). (Refer to W317-1.)

m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)

W3-22-1-68

SECTION 3 BODY Group 22 Exterior Components

Detail A

105 A

3 1 a b WNEK50-03-22-042

ab-

OFF Position ON Position

16. Install rubber plates (1) (2 used) with bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 17. Set battery disconnect switch (5) to ON position (b). 18. Close covers (2, 3). 19. Install the following exterior components. (Refer to W3-22-1-1.)  Right Rear Fender (Front) (105)

W3-22-1-69

WNEK50-03-22-043

SECTION 3 BODY Group 22 Exterior Components Removal and Installation of Under Guard (Front) (122)

WPD850-03-22-008

No.

Part Name

Q'ty

01 02 03 04 05 06

Guard Cover Bolt Washer Washer Bolt, Washer

1 1 6 6 6 4

Wrench Size Tightening Torque mm N·m (lbf·ft)

Weight kg (lb) 74 (165)

j : 24

210

(155)

j : 17

(37)

W3-22-1-70