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62Z7

93207-01070

SHOP MANUAL Disassembly & Reassembly

Printed in Japan (K) ( アメリカ用 )

93207-01070

April 2015

SHOP MANUAL WHEEL LOADER

62Z7 Disassembly & Reassembly

93207-01070 April 2015

WORK SHOP MANUAL SECTION 1

GENERAL INFORMATION

Group 1

Precautions for Disassembling and Assembling....................................................... W1-1

Group 2

Tightening.................................................................................................................. W1-2

Group 3

Painting ..................................................................................................................... W1-3

Group 4

Bleeding Air ............................................................................................................... W1-4

Group 5

Releasing Pressure ................................................................................................... W1-5

Group 6

Preparation ................................................................................................................ W1-6

SECTION 2

MAINTENANCE STANDARD

Group 1

Body .......................................................................................................................... W2-1

Group 2

Travel System ........................................................................................................... W2-2

Group 3

Front Attachment ....................................................................................................... W2-3

SECTION 3

BODY

Group 1

Cab ............................................................................................................................ W3-1

Group 2

Counterweight ........................................................................................................... W3-2

Group 3

Center Hinge ............................................................................................................. W3-3

Group 4

Engine ....................................................................................................................... W3-4

Group 5

Radiator Assembly .................................................................................................... W3-5

Group 6

Hydraulic Oil Tank ..................................................................................................... W3-6

Group 7

Fuel Tank ................................................................................................................... W3-7

Group 8

Pump Device ............................................................................................................. W3-8

Group 9

Control Valve ............................................................................................................. W3-9

Group 10 Pilot Valve................................................................................................................ W3-10 Group 11 Brake Charge Valve ................................................................................................ W3-11 Group 12 Manifold Valve ......................................................................................................... W3-12 Group 13 Solenoid Valve ........................................................................................................ W3-13 Group 14 Priority Valve ........................................................................................................... W3-14 Group 15 Cooling Fan System ................................................................................................ W3-15 Group 16 Ride Control Device ................................................................................................ W3-16 Group 17 Exhaust Filter .......................................................................................................... W3-17

62Z7 D&R

SECTION 4

TRAVEL SYSTEM

Group 1

Tire ............................................................................................................................ W4-1

Group 2

HST Motor ................................................................................................................. W4-2

Group 3

Transmission ............................................................................................................. W4-3

Group 4

Axle ........................................................................................................................... W4-4

Group 5

Propeller Shaft .......................................................................................................... W4-5

Group 6

Brake Valve ............................................................................................................... W4-6

Group 7

Steering Device ......................................................................................................... W4-7

Group 8

Secondary Steering Device ...................................................................................... W4-8

SECTION 5

FRONT ATTACHMENT

Group 1

Front Attachment ....................................................................................................... W5-1

Group 2

Cylinder ..................................................................................................................... W5-2

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

62Z7 D&R

INTRODUCTION To The Reader This manual is written for trained and skilled technicians to provide technical information needed to maintain and repair this machine. y Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (Operation and Maintenance Manual, parts catalog, engine technical material and Kawasaki Shop Manual, etc.) in addition to this manual.

Manual Composition y Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assembly / disassembly procedures.

This manual consists the Technical Manual, the Workshop Manual and the Engine Manual. y Information included in the Technical Manual: Technical information needed for machine pre-delivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

y Information included in the Engine Manual: Technical information needed for machine pre-delivery and delivery and maintenance and repair of the engine, operation and activation of all devices and systems, troubleshooting and assembly / disassembly procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example: y Shop Manual: T 1-3-5 T 1 3 5

y Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

IN-01

Workshop Manual (disassembly and reassembly) Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or machine damage.

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

This is the safety alert symbol. When you see this

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

NOTE: Indicates supplementary technical information.

Units Used Example: 24.5 MPa (250 kgf/cm2, 3560 psi)

SI Units (International System of Units) are used in this manual. MKSA (Meter, Kilogram, Second, Ampere) system units and English units are also indicated in parentheses just behind SI units.

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

0.03937

0.003281

Volume

US gal

0.2642

US qt

1.057

L 3

1.308

Weight

2.205

Force

kgf

0.10197

lbf

0.2248

N·m

kgf·m

Torque Pressure

0.10197 2

MPa

kgf/cm

10.197

MPa

psi

145.0

1.360

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

-1

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Power

Flow rate

NOTE: The numerical value in this manual might be different from the above-mentioned table.

IN-02

SECTION 1

GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ..............................................................W1-1-1-1 Precautions for Using Floating Seal ...................W1-1-1-2 Precautions for Using Nylon Sling ......................W1-1-1-3

Group 2 Tightening Tightening Bolts and Nuts ..........................................W1-2-1-1 Specified Tightening Torque Chart ....................W1-2-1-1 Precautions for Split Flange ..................................W1-2-1-3 Nut and Bolt Locking ..............................................W1-2-1-3 Piping Joint ......................................................................W1-2-1-4 Union Joint .................................................................W1-2-1-5 Pipe Joint .....................................................................W1-2-1-6 O-ring Seal Joint .......................................................W1-2-1-6 Quick Coupling..........................................................W1-2-1-7 Screw-In Connection...............................................W1-2-1-8 Seal Tape Application..............................................W1-2-1-8 Low-Pressure-Hose Clamp Tightening .............W1-2-1-8 Connecting Hose ......................................................W1-2-1-9

Group 5 Releasing Pressure Front Attachment Hydraulic Circuit Pressure Release Procedure ....................................................W1-5-1-1 Ride Control Accumulator Pressure Release Procedure (Option) ..................................W1-5-1-2

Group 6 Preparation Preparation before Inspection and Maintenance ...........................................................W1-6-1-1 Lock of Frame.............................................................W1-6-1-2 Machine Position for Inspection and Maintenance (lift arm raise) ...............................W1-6-1-3

Group 3 Painting Painting .............................................................................W1-3-1-1

Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank ......................W1-4-1-1 Bleeding Air from Hydraulic System .......................W1-4-1-2 Bleeding Air from Fuel System ..................................W1-4-1-4 Bleeding Air from Radiator .........................................W1-4-1-6 Bleeding Air from Brake (Axle) ..................................W1-4-1-7

62Z7(US)D&R

(Blank)

62Z7(US)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 an identification tag onto the connectors, hoses, and pipes for assembling.  Before disassembling, clean the exterior of the components and place on a workbench.  Drain hydraulic oil and gear oil from the hydraulic components and reduction gear.  Be sure to provide appropriate containers for draining fluids.  Use matching marks for easier reassembling if necessary.  Be sure to use the specified special tools when instructed.

 If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause (s), then take the appropriate measures to remove it.  Orderly arrange disassembled parts. Mark and tag them if necessary.  Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.  Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage.  Measure and record the degree of wear and clearances.  Precautions for Assembling  Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part.  Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces.  Apply appropriate lubricant oil onto parts in order to prevent them from seizing.  Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been disassembled. Apply grease before installing  Be sure that liquid-gasket-applied surfaces are clean and dry.  If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent.  Fit the matching marks made when disassembling and assemble them.  Be sure to use the designated tools to assemble bearings, bushings, and oil seals.  Keep a record of the number of tools used for disassembly / assembly. After assembling is completed, count the number of tools so as to make sure that no forgotten tools remain in the assembled machine.

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 onto sliding surface (e) of seal ring (1).  Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear. Check the step part of seal ring (1).  Check O-ring (2) for tears, breaks, deformation, or hardening.

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 (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 unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight.  Do not lift acid or alkali chemicals.  Take care not to allow the sling to become wet. The load may slip.  When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced.  When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force.  Avoid using twisted, bound, connected, or hitched slings.  Do not place any object on twisted or bent slings. (Refer to the right illustration.)  When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions.  Avoid dragging slings on the ground, throwing slings, or pushing slings with a metal object.  When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged.  Store the nylon slings indoors so that they won’t deteriorate with heat, sun light, or chemicals.

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 examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7 years.

Damaged Appearance

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 CAUTION: to be done. Makeshift tools and procedures

can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injure. IMPORTANT: y 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) y Clean the bolt and nut threads and remove dirt or corrosion before installing.

WDAA-01-02-001

Bolt Types Tighten the nuts or bolts correctly to the torque specifications. As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the machine or components. Specified Tightening Torque Chart Tightening torque N·m (kgf·m) (lbf-ft)

Wrench size mm (in)

Bolt Dia. mm (in) (11T) 6 (0.24) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 18 (0.71) 20 (0.79) 22 (0.87) 24 (0.94) 27 (1.06) 30 (1.18) 33 (1.30) 36 (1.42)

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

(3) (6.5) (11) (18) (27) (40) (55) (75) (95) (140) (195) (260) (320)

(8T) (22) (48) (81) (133) (199) (295) (406) (553) (700) (1033) (1438) (1918) (2360)

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

(2) (14.8) (5) (36.9) (9) (66.4) (14) (104) (21) (155) (30) (221) (40) (295) (55) (406) (70) (516) (105) (774) (145) (1069) (195) (1438) (245) (1807)

3~4 10 20 35 55 80 120 170 220 280 400 550 750 950

W1-2-1-1

(4T) (0.3~0.4) (2.2~3) (1) (7.4) (2) (14.8) (3.5) (25.8) (5.5) (40.6) (8) (59) (12) (88.5) (17) (125) (22) (162) (28) (207) (40) (295) (55) (406) (75) (553) (95) (700)

Hexagon Bolt (8~11T)

Flanged Bolt Socket Bolt (8T)

10 (0.39) 13 (0.51) 17 (0.67) 19 (0.75) 22 (0.87) 24 (0.94) 27 (1.06) 30 (1.18) 32 (1.26) 36 (1.42) 41 (1.61) 46 (1.81) 50 (1.97) 55 (2.17)

10 (0.39) 12 (0.47) 14 (0.55) 17 (0.67)

27 (1.06)

5 (0.20) 6 (0.24) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 14 (0.55) 17 (0.67)

32 (1.26)

19 (0.75)

22 (0.87)

SECTION 1 GENERAL Group 2 Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. y 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) y Torque tolerance is ±10 %. y 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. y 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. y 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 Split Flange IMPORTANT: y 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. y 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. y While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring. y Tighten the bolts up and down, left and right alternately, in order to ensure even tightening to the specified torque. y Do not use air wrenches. Using an impact wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.

WDAA-01-02-005

Incorrect

WDAA-01-02-006

Nut and Bolt Locking x Lock Plate IMPORTANT: Do not reuse the lock plates. Do not try to bend the same point twice.

W105-01-01-008

Incorrect

Correct

x 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.

Correct

Incorrect

x Wire IMPORTANT: Attach wire to bolts in the bolttightening direction. Do not reuse the wire. a a-

WDAA-01-02-007

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: y 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. y Apply lubricant, such as the Grease Spray to the bolts and nuts in order to reduce friction coefficient of them. y Torque tolerance is ±10 %. y 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: y 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. y 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-

NOTE: 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. y 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 Seal Joint O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil. IMPORTANT: y Replace O-ring (6) with a new one when reinstalling. y 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. y 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. y If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in O-ring groove (8).

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

1. Coupling procedure x Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you. x 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 x 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. x Cap the removed hoses using special plug. CAUTION:

y When disconnecting, do not damage joint surface. y When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering. y Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after installation. y 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 Screw-In Connection

G 30 °

Depending on types of screw and sealing, different types of screw-in connection are used. IMPORTANT: Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. (In general, the screw-in connection of male tapered thread (a) is used except for measurement purpose.)

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. x 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)

NOTE: Unit: N·m (lbf·ft) c

d cd-

Internal Thread External Thread

Low-Pressure-Hose Clamp Tightening

W105-01-01-019

Clearance

Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp (g): 4.5 N·m (3.3 lbf·ft) Worm Gear Type Band Clamp (h): 6 to 7 N·m (4.4 to 5.2 lbf·ft) f-

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 CAUTION: genuine KCM service parts. Using hoses other

Correct

Incorrect

than genuine KCM hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose from being kinked. Take necessary measures to protect hoses from rubbing against each other. If the hoses rub against each other, wear to the hoses may result and lead to hose rupture. Take care so that the hoses do not come into contact with the moving parts or sharp objects.

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 Painting 5

2 13 7

8 12

WNEC-01-03-002

WNDB-01-03-001

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

Surfaces to Be Painted Pipe Pipe (Lift Arm Cylinder) Pipe Bracket (Control Valve) Cab (Outside) Plate Handrail Rear Console (Inner) Seat Bracket Cockpit Skirt Cockpit Side Console (Inner) Cab (Inside)

Painting Color High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black Shining Silver High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black

Paint the painted surface except the above list in YR-01(TAXI Yellow).

W1-3-1-1

SECTION 1 GENERAL Group 3 Painting

4 2

10 9

7 8 WMDF-01-03-101

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

Surfaces to Be Painted Light Bracket Support Hood Articulation Lock Bar Air Duct Grill Engine Cover Plate Handrail Side Cover (Lower) Lower Cover Pipe Filter Bracket

Painting Color High Grade Black High Grade Black Red High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black

Paint the painted surface except the above list in YR-01(TAXI Yellow).

W1-3-1-2

SECTION 1 GENERAL Group 3 Painting

5 WMDF-01-03-102

1 2 3 4 5

Surfaces to Be Painted Rear Fender Bracket (Full Fender) Bracket (Mud Guard) Deck Plate Step

Painting Color High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black

Paint the painted surface except the above list in YR-01(TAXI Yellow).

W1-3-1-3

SECTION 1 GENERAL Group 3 Painting

2 1

WMDF-01-03-103

1 2 3 4

Surfaces to Be Painted Plate Support (Real Axle) Rear Axle Front Axle

Painting Color High Grade Black High Grade Black Refer to W1-3-1-6. Refer to W1-3-1-7.

Paint the painted surface except the above list in YR-01(TAXI Yellow).

W1-3-1-4

SECTION 1 GENERAL Group 3 Painting

WMDF-01-03-104

1 2

Surfaces to Be Painted Rim (17.5) Rim (20.5) Bracket (Under Mirror )

Painting Color YR-01 [TAXI Yellow] YR-01 [TAXI Yellow] High Grade Black

W1-3-1-5

SECTION 1 GENERAL Group 3 Painting B

3 4

2 2

WMDF-01-03-105

6 View A

View B

WMDF-01-03-106

1 2 3 4 5 6 7 8

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

Painting Color High Grade Black Do not paint it. YR-01 [TAXI Yellow] Do not paint it. Do not paint it. Do not paint it. Do not paint it. Do not paint it.

W1-3-1-6

WMDF-01-03-107

SECTION 1 GENERAL Group 3 Painting 1

6 7

WMDF-01-03-108 A

View A

WNEC-01-03-012

1 2 3 4 5 6 7

Surfaces to Be Painted Rim (Wheel) Mounting Part End of Axle Front Axle Axle Mounting Part Flange Part Name Plate Nut Surface

Painting Color Do not paint it. YR-01 [TAXI Yellow] High Grade Black Do not paint it. Do not paint it. Do not paint it. Do not paint it.

W1-3-1-7

SECTION 1 GENERAL Group 3 Painting (Blank)

W1-3-1-8

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank 1

Preparation 1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level.

W4FC-01-04-001

2. Stop the engine. Push air bleed button (1) of hydraulic oil tank (2) and bleed air from hydraulic oil tank (2). 3, 4, 5

3. Remove bolts, washers (3) (4 used). Remove cover (4) and O-ring (5) of hydraulic oil tank (2). j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

4. Install vacuum pump (a) to the position where cover (4) has been removed. Operate vacuum pump (a) and maintain negative pressure in hydraulic oil tank (2).

MNDF-07-010

fNOTE: Operate vacuum pump (a) continuously while working.

b c

W1R7-01-04-002 abc-

W1-4-1-1

Vacuum Pump Hose Adapter

SECTION 1 GENERAL Group 4 Bleeding Air IMPORTANT: If air is accumulated inside of the hydraulic pipings in the transmission charge pump and if the engine starts in lacking of transmission oil , the transmission charge pump and HST motor may be damaged and the travel operation may become impossible.  Bleeding Air from Transmission Charge Pump

Bleeding Air from 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 HST pump, transmission charge pump, and cylinders have been removed/installed.

IMPORTANT: If air is accumulated inside of the HST pump and if the engine starts in lacking of hydraulic oil, the HST pump may be damaged.  Bleeding Air from HST Pump 1. Remove air bleed plug (1) on top of the HST pump. Add hydraulic oil to the HST pump.

l : 6 mm

WMDF-01-04-003

fNOTE: Amount of oil: 2.5 L (2.6 US gt)

4-Gear Pump Unit

Transmission Charge Pump

1. Open cover (4) of the step (2) part at the left side. Place a container under transmission oil filter (3). Check that the engine has not started. Remove case (5) of transmission oil filter (3). j : 27 mm

4 WMDF-01-04-001

2. After the HST pump is filled with hydraulic oil, temporarily tighten air bleed plug (1). Then, start the engine and run it at slow idle speed.

3. Slightly loosen air bleed plug (1) and bleed air from the HST pump until hydraulic oil comes out from the gap.

MNDF-07-007

4. After air bleeding work is completed, tighten air bleed plug (1). l : 6 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

5 M4GB-07-050

W1-4-1-2

SECTION 1 GENERAL Group 4 Bleeding Air 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. While operating each cylinder several times evenly. Slowly start the operation. At this time, never fully stroke the cylinders during initial operation stage.

2. Start the engine. Stop the engine as soon as transmission oil vigorously comes out of the transmission oil filter.

fNOTE: Reference of engine operating time: 5 to 7 seconds

3. Install case (5) of the transmission oil filter. j : 27 mm

2. As the pilot circuit has an air bleed device, air in the pilot circuit will be bled while performing the above operation.

m : 78.6±4 N·m (7.9±0.4 kgf·m, 58±3 lbf·ft)

3. Reset the front attachment in position for checking hydraulic oil level. 4. Stop the engine. Check hydraulic oil level. Replenish hydraulic oil if necessary.

5 M4GB-07-050

4. After completing the work, check transmission oil level. Replenish transmission oil if necessary.

W1-4-1-3

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Fuel System Air in the fuel system can prevent the engine from starting or cause rough idle. After each fuel filter change, draining water and sediment from the fuel filter, or when the engine has run out of fuel, be sure to bleed air from fuel system. Air Bleeding Procedures This machine is equipped with a fuel solenoid pump. CAUTION: Fuel leaks may lead to fires. 1. Set the key switch to the ON position and hold it in that position for approx. three minutes. The electrical fuel pump operates and starts to bleed air.

2. While holding the key switch in the ON position, reciprocate fuel main filter priming pump (1). After air is bled from the main filter, return priming pump (1) to the original position. 3. After the main filter is filled with fuel, hold the key switch in the ON position for 30 seconds. 4. Start the engine. Check the fuel system for fuel leaks. IMPORTANT: Even if air is not thoroughly bled, do not hold the key switch in the ON position for more than five minutes. In case air is not thoroughly bled, first return the key switch to the OFF position. Then, after waiting for more than 30 seconds, set the key switch to the ON position again. Failure to do so may cause damage to the fuel solenoid pump and/or discharging the batteries.

W1-4-1-4

M81U-07-030

SECTION 1 GENERAL Group 4 Bleeding Air Air Bleeding by Priming Pump In case air is not bled due to malfunction of the fuel solenoid pump, operating the priming pump only can bleed air. 1. Loosen air bleed plug (2) on the fuel main filter. j : 10 mm 2

2. Supply fuel by reciprocating priming pump (3). After no air bubbles are spouted through air bleed plug (2), tighten air bleed plug (2). j : 10 mm

3. After tightening air bleed plug (2), reciprocate priming pump (3) approx. 150 strokes.

WMDF-01-04-002

4. Wipe off any spilled fuel. 5. Start the engine. Check that no fuel leaks are present. If the engine does not start, repeat the above procedures from step 1.

After Changing the Common Rail Bleed air from the fuel system after changing the common rail. 1. Bleed air enough up to the engine supply pump port according to the above-mentioned procedures. 2. Operate the starter motor for long cranking within 20 seconds. If the engine fails to start, return the key switch to the OFF position. Wait more than about 60 seconds, then try again.

M81U-07-030

W1-4-1-5

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Radiator Do not loosen the radiator cap until dCAUTION: the system has cooled. Hot steam may spout out and cause severe burns. Wait until coolant cools and loosen the radiator cap slowly. Release all pressure and remove the radiator cap. Preparation 1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level. 2. Stop the engine. Remove the radiator cap. 1

3. Loosen air bleed plug (1) of EGR cooler (a). Add coolant to the radiator until no air bubble is observed from air bleed plug (1).

j : 14 mm 4. After no air bubble is spouted, tighten air bleed plug (1). j : 14 mm m : 22±3 N·m (2.2±0.3 kgf·m, 16±2.2 lbf·ft) 5. Start the engine. Check the coolant system for any leaks. 6. After a warm up operation of the engine, stop the engine. Wait until coolant cools and check the coolant level of the coolant reservoir. When the coolant level is low, add coolant.

W1-4-1-6

EGR Cooler

MNDF-07-058

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Brake (Axle) If air is mixed in the brake system, dCAUTION: the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil. In addition, bleed air from the brake system until hydraulic oil (about 0.5 liters (0.53 US gt)) is drawn from each wheel (4 places) after bubbles stops.

1 1

T4GB-05-04-004

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

1. Set the parking brake switch of front console to the ON position, start the engine, and increases service brake oil pressure.

2 1

2. Attach clear vinyl tube (2) onto one end of air bleed plug (1). Insert other of clear vinyl tube (2) into clear container (3) filled with hydraulic oil. 3

3. Depress brake pedal (4) several times. Then, depress and hold brake pedal (4) to the stroke end. 4. Loosen air bleed plug (1) under condition in step 3 and drain hydraulic oil and air for several seconds.

T4GB-05-04-005

5. Tighten air bleed plug (1). 6. Drain hydraulic oil after bubbles stops in steps 3 to 5 repeatedly.

fNOTE: When bubbles does not stop after hydraulic oil

(about 0.5 liters (0.53 US gt)) is drawn, repeat step 3 to step 5. 7. Bleed air at other 3 places in the same way as step 3 to step 5.

IMPORTANT: After air bleeding work is completed at 4 places, bleed air at 4 places again. Bleed air in the same way as step 3 to step 5 twice and check that no air is remained inside.

W1-4-1-7

T4GB-05-04-006

SECTION 1 GENERAL Group 4 Bleeding Air (Blank)

W1-4-1-8

SECTION 1 GENERAL Group 5 Releasing Pressure Front Attachment Hydraulic Circuit Pressure Release Procedure 1

Release any remaining pressure as follows before removing/installing the front attachment. 1. Run the engine at slow idle speed without load for five minutes. 2. Set the key switch to the OFF position. Stop the engine. 3. Set the key switch to the ON position again. Set front control lever lock switch (1) to the UNLOCK (b) position. 4. With the key switch set in the ON position, operate the control lever in order to release any pressure in the hydraulic circuit 4 to 5 times.

MNDF-01-006

5. Return front control lever lock switch (1) to the LOCK (a) position. 6. Turn the key switch OFF.

MNEC-01-015 a-

W1-5-1-1

LOCK

UNLOCK

SECTION 1 GENERAL Group 5 Releasing Pressure Ride Control Accumulator Pressure Release Procedure (Option)

Release any remaining pressure as follows before removing and installing the ride control valve or the ride control accumulator. 1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) 2. Release any pressure in the front attachment hydraulic circuit. (Refer to W1-5-1-1.)

3. Bleed air from the hydraulic oil tank. (Refer to W1-41.) 4. Remove bolts, washers (1) (4 used). Remove cover (2). : 19 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).

WMDF-03-09-005

: 13 mm : 4 mm IMPORTANT: Do not loosen drain plug (4) more than two turns. It may come off due to the remaining pressure. 6. Loosen drain plug (4) by one turn and release any remaining pressure. Tighten drain plug (4). A

: 4 mm : 7 to 9 N·m (0.7 to 0.9 kgf·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. Tighten nut (5).

WMDF-03-16-001

Detail A

: 13 mm : 10 to 12 N·m (1 to 1.2 kgf·m, 7.4 to 8.9 lbf·ft) : 4 mm

WNDB-01-05-001

W1-5-1-2

SECTION 1 GENERAL Group 6 Preparation Preparation before Inspection and Maintenance 1

Components, hydraulic oil, lubricant, dCAUTION: and coolant just after operation are too hot. Wait until they cool. Then, start the work. The lift arm may raise with ride dCAUTION: control switch (2) set in the AUTO position. Set ride control switch (2) to the OFF position. Caution that an unexpected accident may occur due to the lift arm movement. CAUTION: If the machine is unexpectedly dmoved, a serious accident may result in. Apply the parking brake when parking the machine. MNDB-01-055

Before performing the maintenance procedures given in the following chapters, park the machine as described below, unless otherwise specified.

1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Set front control lever lock switch (1) to the LOCK position. 4. Turn ride control switch (2) OFF. 5. Set forward/reverse lever (3) to the neutral (N) position. Set neutral lever lock (5) to the LOCK position. MNDB-01-001

6. Apply the parking brake. (Parking brake switch (4): ON position) 7. Choke the tires. 8. Run the engine at slow idle speed without load for five minutes.

9. Set key switch (6) to the OFF position. Stop the engine. Remove the key from key switch (6). Use two people whenever the engine must be running for service work. 10. Before performing any work on the machine, attach tag (2) on the door or front attachment control lever.

W1-6-1-1

MNEC-01-058

SECTION 1 GENERAL Group 6 Preparation Lock of Frame Before beginning to work near dWARNING: frame axle (4), install articulation lock bar (2) and securely lock the front and rear frames. Avoid accidents due to unexpected movement of the machine.

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

2. Remove β-form pin (5). Remove set pin (1) from the hole.

2 MNEC-01-060

3. Rotate articulation lock bar (2) and fit it to hole (3) of the front frame. 4. Install set pin (1) to hole (3) of the front frame and the tip hole of articulation lock bar (2). Install β-form pin (5). Secure articulation lock bar (2) in the position.

MNEC-01-061

W1-6-1-2

SECTION 1 GENERAL Group 6 Preparation Machine Position for Inspection and Maintenance (lift arm raise) Support the lift arm by using a solid dCAUTION: support for inspection and maintenance with the

lift arm raised. Take care that due to lowering the lift arm may result in the accidents. 1

Set the machine position for inspection and maintenance in the same way as the previous procedures followings. 1. Raise lift arm (3) and dump bucket (2).

WNEC-01-06-001

2. Support lift arms (3) (both sides) by using a solid support (1). 4

3. Set front control lever lock switch (4) to the LOCK position. 4. Stop the engine.

MNDB-01-055

W1-6-1-3

SECTION 1 GENERAL Group 6 Preparation (Blank)

W1-6-1-4

SECTION 2

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

Group 2 Travel System Axle .....................................................................................W2-2-1-1

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

62Z7(US)D&R

(Blank)

62Z7(US)D&R

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

 Lower Hinge Part (B)

2 4 6

WMDF-02-01-002

WMDF-02-01-001

A B

Part Name Pin (1) Bushings (2), (3) Pin (4) Bushings (5), (6)

Standard (a) 75 (2.95) 75 (2.95) 70 (2.76) 70 (2.76)

W2-1-1-1

Allowable Limit (a) 74.0 (2.91) 76.5 (3.01) 69.0 (2.72) 71.5 (2.82)

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 1 Body (Blank)

W2-1-1-2

SECTION 2 MAINTENANCE STANDARD Group 2 Travel System Axle 1

WMDF-04-04-040

 Axle Equipped with TPD

 Axle Equipped with LSD 3 7

8 6

4 4

WMDF-04-04-041 123-

Friction Disc (2 Used) Separation Disc (2 Used) Wear Ring (4 Used)

456-

Spider Gear (2 Used) Wear Ring (2 Used)

WMDF-04-04-043 789-

Gear (4 Used) Friction Disc (2 Used) Friction Disc (2 Used)

fNOTE: The quantity of parts is the quantity per one axle. W2-2-1-1

10- Separation Disc (2 Used)

SECTION 2 MAINTENANCE STANDARD Group 2 Travel System 1. Inner diameter (a) of gear (7) Standard 23.94 (0.943)

Unit: mm (in) Allowable Limit -

WNDB-02-02-001

2. Pin diameter (b) of spider (4) Standard 23.81 (0.937)

Unit: mm (in) Allowable Limit -

3. Clearance (c) between gear (7) and spider (4) Standard -

Unit: mm (in) Allowable Limit 0.15 (0.006)

c=a−b

W2-2-1-2

WNDB-02-02-002

SECTION 2 MAINTENANCE STANDARD Group 2 Travel System 4. Thickness (d) of friction disc (1) Standard 9.2 (0.362)

Unit: mm (in) Allowable Limit 7.9 (0.311)

5. Thickness (e) of separation disc (2) Standard 7.9 (0.311)

Unit: mm (in) Allowable Limit 7.7 (0.303)

WMDF-02-02-001

6. Thickness (f ) of wear ring (3) in gear (7)  Axle Equipped with TPD Standard 0.76 (0.030)

Unit: mm (in) Allowable Limit 0.66 (0.026)

WNCC-02-02-006 f

7. Thickness (g) of wear ring (6) in gear (5)  Axle Equipped with TPD Standard 2.6 (0.102)

Unit: mm (in) Allowable Limit 1.7 (0.067)

6 g

WNDB-02-02-006

W2-2-1-3

SECTION 2 MAINTENANCE STANDARD Group 2 Travel System 8. Thickness total (h) of friction disc (8), friction disc (9), and separation disc (10)  Axle Equipped with LSD Standard 8.8 (0.346)

Unit: mm (in) Allowable Limit 8.5 (0.335)

WMDF-02-02-002

W2-2-1-4

SECTION 2 MAINTENANCE STANDARD Group 3 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) 100 (3.94) 100 (3.94) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 85 (3.35) 85 (3.35) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95)

W2-3-1-1

Bushing

Allowable Limit (a) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 99.0 (3.40) 101.5 (4.00) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 84.0 (3.31) 86.5 (3.41) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01)

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Blank)

W2-3-1-2

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Standard Dimensions for Lift Arm and Bucket 1

e f

c WMDF-02-03-001

a b c d e f g h i

Bucket

Lift Arm

Unit: mm (in) Dimensions 75 (2.95) 75 (2.95) 844 (9.23) 94 (3.70) 96 (3.78) 96 (3.78) 230 (9.06) 356 (2.02) 55 (2.17)

W2-3-2-1

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Blank)

W2-3-2-2

SECTION 2 MAINTENANCE STANDARD Group 3 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) 65-0.010-0.023 (2.56-0.0004-0.0009) 85-0.012-0.027 (3.35-0.00050-0.0011) 40-0.009-0.020 (1.58-0.0004-0.0008)

ab-

Cylinder Rod Dial Gauge

Bend 0.5 (0.020) 1.0 (0.039)

W2-3-3-1

d cd-

Run Out 1.0 (0.039) 2.0 (0.079)

V Block 1 m (39.4 in)

Unit: mm (in) Remedy Repair Replace

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Blank)

W2-3-3-2

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 Removal and Installation of Battery Box (Without Battery Disconnect Switch)................W3-2-2-1 Removal of Battery Box (Right)............................W3-2-2-1 Removal of Battery Box (Left)...............................W3-2-2-2 Removal and Installation of Battery Box (Attached Battery Disconnect Switch) ..............W3-2-3-1 Removal of Battery Box (Right)............................W3-2-3-1 Removal and Installation of Battery Disconnect Switch ...........................................................................W3-2-4-1

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 Removal and Installation of Exterior Parts ...........W3-4-2-1 Removal and Installation of Engine Cover and Rear Cover ................................................................W3-4-2-2 Removal and Installation of Support and Cover (Lower) ..........................................................W3-4-2-4 Removal and Installation of Side Cover............W3-4-2-5 Removal and Installation of Rear Fender (Rear) ..........................................................................W3-4-2-7 Removal and Installation of Front Fender .......W3-4-2-9 Removal and Installation of Rear Fender (Front), Deck, and Step (Front)....................... W3-4-2-10 Removal and Installation of Rear Grill ............ W3-4-2-13 Removal and Installation of Inspection Cover and Step (Rear) .................................................... W3-4-2-14 Removal and Installation of Air Cleaner ................W3-4-3-1

Group 5 Radiator Assembly Replacement of Radiator, Oil Cooler, and Intercooler ..................................................................W3-5-1-1

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

Group 8 Pump Device Removal and Installation of Pump Device ............W3-8-1-1 Disassembly of HST Pump ..........................................W3-8-2-1 Assembly of HST Pump ................................................W3-8-2-5 Disassembly of 4-Gear Pump Unit ...........................W3-8-3-1 Disassembly of Transmission Charge Pump ...W3-8-3-3 Disassembly of Pilot Pump ...................................W3-8-3-5 Disassembly of Main Pump ..................................W3-8-3-6 Disassembly of Steering Pump............................W3-8-3-7 Assembly of 4-Gear Pump Unit.................................W3-8-3-8

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 ..........................................W3-9-2-6

Group 10 Pilot Valve Removal and Installation of Pilot Valve .............. W3-10-1-1 Removal and Installation of Pilot Valve (Two Lever Type ) ................................................. W3-10-2-1 Disassembly of Pilot Valve ....................................... W3-10-3-1 Assembly of Pilot Valve ............................................. 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 .................................... W3-12-2-3

Group 13 Solenoid Valve Removal and Installation of Exhaust Filter Regeneration Control Solenoid Valve ............ W3-13-1-1 Structure of Exhaust Filter Regeneration Control Solenoid Valve ........................................ W3-13-2-1

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

62Z7(US)D&R

Group 14 Priority Valve Removal and Installation of Priority Valve (without Secondary Steering) ........................... W3-14-1-1 Removal and Installation of Priority Valve (with Secondary Steering).................................. W3-14-2-1 Structure of Priority Valve ........................................ W3-14-3-1

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

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

Group 17 Exhaust Filter Removal and Installation of Exhaust Filter ........ W3-17-1-1 Disassembly of Exhaust Filter ................................. W3-17-2-1 Assembly of Exhaust Filter ....................................... W3-17-2-3

62Z7(US)D&R

SECTION 3 BODY Group 1 Cab Removal and Installation of Cab 1, 2

WMDF-03-02-007

WMDF-03-02-012

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

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

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. Wait for oil in order to cool before starting any work. 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

pressure in the circuit. Operate the brake pedal more than dCAUTION: fifty times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open the cover of battery box (3). 3. Loosen nut (1). Disconnect ground (2). j : 10 mm 4. Open side covers (4) at left and right sides.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

W3-1-1-1

SECTION 3 BODY Group 1 Cab 1

WMDF-03-01-001

5. Remove rubber cap (1). 6. Bleed air from the radiator. (Refer to W1-4-1.) 7. Place a container under hose (2). Loosen cock (3). Drain off coolant. Close cock (3).

fNOTE: Amount of coolant: 24 L (6.3 US gal) 8. Release refrigerant of the air conditioner. (Refer to T5-8 in the separated volume, Technical Manual.) 9. Remove following parts at the right and left sides. (Refer to W3-4-2.)  Step (Front) (5)  Deck (4)  Rear Fender (Front) (7)  Covers (6, 8)

W3-1-1-2

WMDF-04-08-002

SECTION 3 BODY Group 1 Cab

2 1

6 2

15 8

13 12

WMDF-03-06-006

10. Remove bolts, washers (2) (4 used). Remove cover (1).

14. Remove bolts, washers (4) (2 used). Remove cover (3). j : 17 mm

j : 17 mm 11. Remove bolts, washers (14) (2 used). Remove cover (15).

15. Remove bolts, washers (6) (3 used). Remove covers (5, 7). j : 17 mm

j : 17 mm 12. Remove bolts, washers (13) (2 used). Remove cover (12).

16. Remove bolts, washers (8) (2 used). Remove cover (9).

j : 17 mm

13. Remove bolts, washers (11) (2 used). Remove cover (10). j : 17 mm

W3-1-1-3

SECTION 3 BODY Group 1 Cab

WMDF-03-06-002

17. Disconnect connectors (1) (2 used). 18. Disconnect hoses (4) (2 used). 19. Remove bolts, washers (3) (2 used). Remove the washer fluid tank (2) assembly. j : 17 mm

W3-1-1-4

SECTION 3 BODY Group 1 Cab

Detail A

1, 2

6 5

WMDF-03-01-002

20. Remove bolt, washer (1) and clip (2). j : 17 mm 21. Disconnect connectors (5) (3 used). 22. Disconnect connectors (4) (2 used). 23. Disconnect connectors (3) (2 used) only with the emergency steering attached. 24. Disconnect hoses (6) (7 used). j : 19 mm

W3-1-1-5

WMDF-03-01-003

SECTION 3 BODY Group 1 Cab a

WMDF-03-01-004

Suction Pipe

Brake Valve

25. Disconnect hose (2). j : 27 mm 26. Disconnect hose (1). j : 17 mm

W3-1-1-6

SECTION 3 BODY Group 1 Cab 1

WMDF-03-01-006

WMDF-03-01-005

27. Disconnect hose (4).

30. Remove cover (5). (Refer to W3-4-2.)

j : 27 mm

31. Disconnect hose (8).

28. Disconnect hose (3).

j : 17 mm

j : 19 mm

32. Remove clamp (6). Disconnect hose (7). j : 7 mm

29. Remove clamp (1). Disconnect hose (2). j : 7 mm

W3-1-1-7

SECTION 3 BODY Group 1 Cab

2 9 3, 4

WMDF-03-01-007 a-

Manifold Valve

Brake Valve

j : 17 mm

WMDF-03-01-008

Steering Valve

View A

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

34. Disconnect connectors (1, 2). 35. Remove bolt, washer (8), tube (6), and brackets (5, 7). j : 17 mm 36. Disconnect hoses (9) (2 used). j : 22 mm

W3-1-1-8

WMDF-03-01-013

SECTION 3 BODY Group 1 Cab

8 7

4 WMDF-03-01-009

WMDF-03-01-014

37. Disconnect hose (2).

Eyebolt Mounting Hole

j : 19 mm 38. Disconnect hoses (1, 3). j : 27 mm 39. Disconnect the adapter (5) side of hose (4). j : 27 mm 40. Disconnect the pipe (6) side of hose (7). j : 27 mm

The cab (9) assembly weight: 1150 kg dCAUTION: (2540 lb) 42. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a) (4 places) of the cab (9) assembly. Attach nylon slings onto the eyebolts (4 used). Hoist and hold the cab (9) assembly.

41. Remove caps (8) (4 used).

W3-1-1-9

SECTION 3 BODY Group 1 Cab

Detail A

Detail B

A a

1 B

2 b

7 WMDF-03-01-010 WMDF-03-01-015 ab-

43. Remove bolt (7), plate (6), and spacer (5).

Rubber Cushion Frame

j : 30 mm

9 10

44. Remove bolt (8), nut (11), plate (10), and spacer (9).

j : 46 mm

WNEC-03-01-012

NOTE: LOCTITE #262 has been applied on the thread part of bolt (8). 45. Remove the mounting bolts and nuts for the other side of cab (1) assembly in the same way as step 43 to step 44. 46. Remove nuts (4, 14) (2 used for each) and washers (3, 13) (2 used for each). j : 24 mm

ab-

Rubber Cushion Frame

IMPORTANT: Do not allow the cab (1) assembly to come in contact with the front frame or support when removing/installing the cab (1) assembly. 47. Remove the cab (1) assembly and washers (2, 12) (2 used for each). Place the cab (1) assembly on wooden blocks.

fNOTE: LOCTITE #262 has been applied on the thread part of rubber cushion (a).

W3-1-1-10

SECTION 3 BODY Group 1 Cab

WMDF-03-01-014 a-

Eyebolt Mounting Hole

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.

W3-1-1-11

SECTION 3 BODY Group 1 Cab

Detail A

Detail B

A a

1 B

2 b

7 WMDF-03-01-010 WMDF-03-01-015 ab-

Rubber Cushion Frame

IMPORTANT: Do not allow the cab (1) assembly to come in contact with the front frame or support when removing/installing the cab (1) assembly. 2. Install the cab (1) assembly and washers (2, 12) (2 used for each) to frame (b).

14 WNEC-03-01-012

ab-

Rubber Cushion Frame

5. Install spacer (5), plate (6), and bolt (7). j : 30 mm

4. Apply LOCTITE #262 onto the thread part of bolt (8). Install bolt (8), spacer (9), plate (10), and nut (11).

m : 215.6 N·m (21.6 kgf·m, 159 lbf·ft)

m : 205 N·m (20.5 kgf·m, 151 lbf·ft)

j : 46 mm

9 10

3. Apply LOCTITE #262 onto the thread part of rubber cushion (a). Install washers (3, 13) (2 used for each) and nuts (4, 14) (2 used for each). j : 24 mm

m : 215.6 N·m (21.6 kgf·m, 159 lbf·ft) 6. Install the mounting bolts and nuts for the other side of cab (1) assembly in the same way as step 4 to step 5.

W3-1-1-12

SECTION 3 BODY Group 1 Cab

8 a

4 WMDF-03-01-009

WMDF-03-01-014 a-

View A

Eyebolt Mounting Hole b

7. Remove the eyebolts (4 used). Install caps (8) (4 used) to eyebolt mounting holes (a) (4 places).

8. Connect the pipe (6) side of hose (7). b-

j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

WMDF-03-01-012

60°

View B

IMPORTANT: Check the angle to install hose (4). 9. Connect the adapter (5) side of hose (4). j : 27 mm

d c

m : 80 N·m (8 kgf·m, 59 lbf·ft) IMPORTANT: Check the angle to install hose (1). IMPORTANT: Check the angle to install hose (3) as for the machine without the emergency steering. 10. Connect hoses (1, 3). j : 27 mm

3 c-

1 30°

15°

11. Connect hose (2).

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-1-1-13

WMDF-03-01-011

SECTION 3 BODY Group 1 Cab

2 9 3, 4

B a

b b-

Brake Valve

WMDF-03-01-007

WMDF-03-01-008 a-

Steering Valve

Manifold Valve

View A

12. Connect hoses (9) (2 used).

View B 2

j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

13. Install brackets (5, 7) and tube (6) with bolt, washer (8).

WMDF-03-01-013

4 WMDF-03-01-016

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) 14. Connect connectors (1, 2). IMPORTANT: Check the angle to install clip (4). 15. Install clip (4) with bolt, washer (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-14

45°

SECTION 3 BODY Group 1 Cab 1

WMDF-03-01-006

WMDF-03-01-005

16. Connect hose (7) with clamp (6). j : 7 mm

j : 19 mm m : 11.8 to 14.7 N·m (1.2 to 1.5 kgf·m, 8.7 to 11 lbf·ft)

17. Connect hose (8).

21. Apply ND-OIL8 onto the O-ring of hose (4) connecting part. Connect hose (4).

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

j : 27 mm

18. Install cover (5). (Refer to W3-4-2.)

m : 29.4 to 34.3 N·m (2.9 to 3.4 kgf·m, 21.5 to 25.5 lbf·ft)

19. Connect hose (2) with clamp (1). j : 7 mm

20. Apply ND-OIL8 onto the O-ring of hose (3) connecting part. Connect hose (3).

m : 3.5 to 5 N·m (0.4 to 0.5 kgf·m, 2.6 to 3.7 lbf·ft)

j : 17 mm

22. Add compressor oil. (Refer to T5-8 in the separated volume, Technical Manual.)

m : 3.5 to 5 N·m (0.4 to 0.5 kgf·m, 2.6 to 3.7 lbf·ft)

W3-1-1-15

SECTION 3 BODY Group 1 Cab a

WMDF-03-01-004

Suction Pipe

Brake Valve

23. Connect hose (1). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 24. Connect hose (2). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-1-1-16

SECTION 3 BODY Group 1 Cab

Detail A

1, 2

6 5

WMDF-03-01-002

25. Connect hoses (6) (7 used). j : 19 mm

28. Connect connectors (5) (3 used). 29. Install clip (2) with bolt, washer (1). j : 17 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

26. Connect connectors (3) (2 used) only with the emergency steering attached. 27. Connect connectors (4) (2 used).

W3-1-1-17

WMDF-03-01-003

SECTION 3 BODY Group 1 Cab 1, 2

WMDF-03-01-001

WMDF-03-02-012

30. Add coolant to the radiator.

35. Operate the steering cylinder to the stroke end several times and bleed air from the circuit.

fNOTE: Amount of coolant: 24 L (6.3 US gal)

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

31. Bleed air from the radiator. (Refer to W1-4-1.)

37. Fill refrigerant in the air conditioner. (Refer to T5-8 in the separated volume, Technical Manual.)

32. Connect ground (2). Tighten nut (1). j : 10 mm

38. Install rubber cap (4).

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 33. Close the cover of battery box (3). 34. 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 and coolant leaks.

W3-1-1-18

SECTION 3 BODY Group 1 Cab

WMDF-03-06-002

39. Install the washer fluid tank (2) assembly with bolts, washers (3) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 40. Connect hoses (4) (2 used). 41. Connect connectors (1) (2 used).

W3-1-1-19

SECTION 3 BODY Group 1 Cab

2 1

6 2

15 8

13 12

WMDF-03-06-006

46. Install cover (12) with bolts, washers (13) (2 used).

42. Install cover (9) with bolts, washers (8) (2 used). j : 17 mm

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

43. Install covers (5, 7) with bolts, washers (6) (3 used).

47. Install cover (15) with bolts, washers (14) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

44. Install cover (3) with bolts, washers (4) (2 used).

48. Install cover (1) with bolts, washers (2) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

45. Install cover (10) with bolts, washers (11) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-20

SECTION 3 BODY Group 1 Cab

49. Install following parts at the right and left sides. (Refer to W3-4-2.)  Covers (3, 5)  Rear Fender (Front) (4)  Deck (1)  Step (2)

W3-1-1-21

WMDF-04-08-002

SECTION 3 BODY Group 1 Cab (Blank)

W3-1-1-22

SECTION 3 BODY Group 2 Counterweight Removal and Installation of Counterweight 1

4 2

WMDF-03-02-007

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 machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Open side covers (1) at left and right sides. 3. Disconnect connectors (3) (2 used). 4. Remove rear grill (4). (Refer to W3-4-2.) 5. Open the covers of battery boxes (2) at left and right sides.

W3-2-1-1

WMDF-03-02-011

SECTION 3 BODY Group 2 Counterweight

2, 3

5, 6

WMDF-03-02-002

6. Disconnect connector (1). 7. Remove bolt, washer (2) and bracket (3). j : 17 mm 8. Disconnect connector (4). 9. Remove bolt, washer (5) and bracket (6). j : 17 mm

W3-2-1-2

WMDF-03-02-004

SECTION 3 BODY Group 2 Counterweight

1 a

2 a

6 4

5 WMDF-03-02-009

Hoisting Position

10. Remove bolts (3) (4 used). Remove rear combination light (6). l : 5 mm 11. Remove bolts (3) (4 used). Remove rear combination light (2). l : 5 mm

Counterweight (1) weight: 480 kg dCAUTION: (1060 lb) 12. Attach the nylon slings onto hoisting positions (a) (2 places) of counterweight (1). Hoist and hold counterweight (1). 13. Remove bolts (5) (4 used) and washers (4) (4 used). Remove counterweight (1). j : 46 mm

W3-2-1-3

SECTION 3 BODY Group 2 Counterweight

1 9 a

7 2 a

8 4

6 4

5 WMDF-03-02-009

Hoisting Position

3. Pass connector (7) through the battery box (right). Install rear combination light (2) with bolts (3) (4 used).

Installation Counterweight (1) weight: 480 kg dCAUTION: (1060 lb) 1. Attach the nylon slings onto hoisting positions (a) (2 places) of counterweight (1). Hoist and fit counterweight (1) to the bolt (5) holes (4 places) on rear frame (9). 2. Install counterweight (1) with washers (4) (4 used) and bolts (5) (4 used).

l : 5 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 4. Pass connector (8) through the battery box (left). Install rear combination light (6) with bolts (3) (4 used). l : 5 mm

j : 46 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

m : 1510 N·m (151 kgf·m, 1110 lbf·ft)

W3-2-1-4

SECTION 3 BODY Group 2 Counterweight

2, 3

5, 6

WMDF-03-02-004

5. Connect connector (4). 6. Install bracket (6) with bolt, washer (5). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 7. Connect connector (1). 8. Install bracket (3) with bolt, washer (2). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-2-1-5

WMDF-03-02-002

SECTION 3 BODY Group 2 Counterweight

4 WMDF-03-02-011

9. Close the covers of battery boxes (2) at left and right sides. 10. Install rear grill (4). (Refer to W3-4-2.) 11. Connect connectors (3) (2 used). 12. Close side covers (1) at left and right sides.

W3-2-1-6

WMDF-03-02-007

SECTION 3 BODY Group 2 Counterweight Removal and Installation of Battery Box (Without Battery Disconnect Switch) 1, 2

17, 18

11, 12 3, 4 8, 9

5 6

13, 14, 15

WMDF-03-02-012

WMDF-03-02-002

7. Remove bolt, washer (17) and bracket (18).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

j : 17 mm 8. Disconnect connector (16). Remove the harnesses from all clips of battery box (5).

Removal of Battery Box (Right)

dCAUTION: Battery box (5) weight: 25 kg (56 lb)

2. Open the cover of battery box (5).

9. Remove nuts (13) (4 used) and washers (14, 15) (4 used for each). Remove battery box (5) while pulling connector (16) and terminal (4) out of it.

3. Loosen nut (1). Disconnect ground (2). j : 10 mm

j : 19 mm

4. Loosen nut (3). Disconnect terminal (4). j : 10 mm

dCAUTION: Battery (6) weight: 20 kg (45 lb)

5. Remove nuts (8) (2 used) and washers (9) (2 used). Remove rods (7) (2 used) and bracket (10). Remove battery (6). j : 17 mm 6. Remove bolt, washer (11). Disconnect ground (12). j : 17 mm

W3-2-2-1

SECTION 3 BODY Group 2 Counterweight

1 11

9, 10

2, 3

7, 8

12, 13

14, 15, 16

WMDF-03-02-013

WMDF-03-02-004

15. Disconnect connector (11). Remove the harnesses from all clips of battery box (6).

Removal of Battery Box (Left) 10. Open the cover of battery box (6).

dCAUTION: Battery box (6) weight: 24 kg (53 lb)

11. Loosen nut (7). Disconnect terminal (8).

16. Remove nuts (14) (4 used) and washers (15, 16) (4 used for each). Remove battery box (6) while pulling connector (11) and terminals (8, 10) out of it.

j : 10 mm 12. Loosen nut (9). Disconnect terminal (10).

j : 19 mm

j : 10 mm

dCAUTION: Battery (5) weight: 20 kg (45 lb)

13. Remove nuts (2) (2 used) and washers (3) (2 used). Remove rods (4) (2 used) and bracket (1). Remove battery (5). j : 17 mm

14. Remove bolt, washer (12) and bracket (13). j : 17 mm

W3-2-2-2

SECTION 3 BODY Group 2 Counterweight

1 11

9, 10

2, 3

7, 8 12, 13

14, 15, 16

WMDF-03-02-004

Installation

WMDF-03-02-013

dCAUTION: Battery (5) weight: 20 kg (45 lb)

Installation of Battery Box (Left)

4. Place battery (5) on battery box (5).

CAUTION: Battery box (6) weight: 24 kg (53 lb) 1. Pass connector (11) and terminals (8, 10) through battery box (6). Install battery box (6) with washers (15, 16) (4 used for each) and nuts (14) (4 used).

5. Install bracket (1) and rods (4) (2 used) with washers (3) (2 used) and nuts (2) (2 used). j : 17 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)

j : 19 mm

6. Connect terminal (10). Tighten nut (9).

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

j : 10 mm

2. Connect connector (11). Install the harnesses to all clips of battery box (6). 3. Install bracket (13) with bolt, washer (12).

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 7. Connect terminal (8). Tighten nut (7).

j : 17 mm

j : 10 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 8. Close the cover of battery box (6).

W3-2-2-3

SECTION 3 BODY Group 2 Counterweight

1, 2

17, 18 10

11, 12 3, 4 8, 9

5 13, 14, 15

WMDF-03-02-002

Installation of Battery Box (Right)

CAUTION: Battery box (5) weight: 25 kg (56 lb) 9. Pass connector (16) and terminal (4) through battery box (5). Install battery box (5) with washers (14, 15) (4 used for each) and nuts (13) (4 used).

13. Place battery (6) on battery box (5).

14. Install bracket (10) and rods (7) (2 used) with washers (9) (2 used) and nuts (8) (2 used). j : 17 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)

m : 35 N·m (3.5 kgf·m, 26 lbf·ft) 10. Connect connector (16). Install the harnesses to all clips of battery box (5).

15. Connect terminal (4). Tighten nut (3). j : 10 mm

11. Install bracket (18) with bolt, washer (17).

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 16. Connect ground (2). Tighten nut (1).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 10 mm

12. Connect ground (12) with bolt, washer (11). j : 17 mm

WMDF-03-02-012

dCAUTION: Battery (6) weight: 20 kg (45 lb)

j : 19 mm

j : 17 mm

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 17. Close the cover of battery box (5).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-2-2-4

SECTION 3 BODY Group 2 Counterweight Removal and Installation of Battery Box (Attached Battery Disconnect Switch) 21, 22 12

10, 11 13, 14 1 20

2, 3

7, 8

5, 6

WMDF-03-02-014

17, 18, 19

WMDF-03-02-006

8. Remove bolt, washer (13). Disconnect ground (14).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

j : 17 mm 9. Remove bolt, washer (21) and bracket (22). j : 17 mm

Removal of Battery Box (Right)

10. Disconnect connector (20). Remove the harnesses from all clips of battery box (4).

2. Open the cover of battery box (4). 3. Loosen nut (2). Disconnect ground (3).

dCAUTION: Battery box (4) weight: 25 kg (56 lb)

j : 10 mm

11. Remove nuts (17) (4 used) and washers (18, 19) (4 used for each). Remove battery box (4) while pulling connector (20) and terminal (6) out of it.

4. Loosen nut (5). Disconnect terminal (6). j : 10 mm

j : 19 mm

5. Remove nut (7). Disconnect ground (8).

12. Remove the battery box (left). (Refer to W3-2-2.)

j : 17 mm 6. Remove bolts, washers (16) (3 used). Remove the battery disconnect switch (15) assembly. j : 17 mm

dCAUTION: Battery (1) weight: 20 kg (45 lb)

7. Remove nuts (10) (2 used) and washers (11) (2 used). Remove rods (9) (2 used) and bracket (12). Remove battery (1). j : 17 mm

W3-2-3-1

SECTION 3 BODY Group 2 Counterweight

21, 22 12

10, 11 13, 14 1 20

17, 18, 19

2, 3

7, 8

WMDF-03-02-006

Installation of Battery Box (Right)

WMDF-03-02-014

j : 17 mm

dCAUTION: Battery box (4) weight: 25 kg (56 lb)

2. Pass connector (20) and terminal (6) through battery box (4). Install battery box (4) with washers (18, 19) (4 used for each) and nuts (17) (4 used).

m : 20 N·m (2 kgf·m, 15 lbf·ft) 8. Install the battery disconnect switch (15) assembly with bolts, washers (16) (3 used).

j : 19 mm

j : 17 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect connector (20). Install the harnesses to all clips of battery box (4).

9. Connect ground (8) with nut (7). j : 17 mm

4. Install bracket (22) with bolt, washer (21).

m : 21 to 23 N·m (2.1 to 2.3 kgf·m, 15.5 to 17 lbf·ft)

j : 17 mm

10. Connect terminal (6). Tighten nut (5).

5. Connect ground (14) with bolt, washer (13).

j : 10 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

7. Install bracket (12) and rods (9) (2 used) with washers (11) (2 used) and nuts (10) (2 used).

1. Install the battery box (left). (Refer to W3-2-2.)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

5, 6

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 11. Connect ground (3). Tighten nut (2).

dCAUTION: Battery (1) weight: 20 kg (45 lb)

j : 10 mm

6. Place battery (1) on battery box (4).

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 12. Close the cover of battery box (4).

W3-2-3-2

SECTION 3 BODY Group 2 Counterweight Removal and Installation of Battery Disconnect Switch

WMDF-03-02-007 View A

WMDF-03-02-014

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

2. Open cover (1) of the battery box (right). 3. Set lever (2) to the OFF position.

b a-

W3-2-4-1

OFF

WNEE-03-18-002 b-

SECTION 3 BODY Group 2 Counterweight

1, 2

3, 4

6, 7 5 WMDF-03-02-014

4. Remove nut (1). Disconnect terminal (2). j : 17 mm 5. Remove nut (3). Disconnect ground (4). j : 17 mm 6. Remove nuts (6) (2 used) and bolts, washers (7) (2 used). Remove battery disconnect switch (5). j : 10 mm

W3-2-4-2

SECTION 3 BODY Group 2 Counterweight

1, 2

3, 4

6, 7 5 WMDF-03-02-014

Installation 1. Install battery disconnect switch (5) with nuts (6) (2 used) and bolts, washers (7) (2 used). j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 2. Connect ground (4) with nut (3). j : 17 mm m : 21 to 23 N·m (2.1 to 2.3 kgf·m, 15.5 to 17 lbf·ft) 3. Connect terminal (2) with nut (1). j : 17 mm m : 21 to 23 N·m (2.1 to 2.3 kgf·m, 15.5 to 17 lbf·ft)

W3-2-4-3

SECTION 3 BODY Group 2 Counterweight

View A

b a-

OFF

WNEE-03-18-002 b-

WMDF-03-02-014

4. Set lever (2) of the battery disconnect switch to the ON position. 5. Close cover (1) of the battery box (right).

W3-2-4-4

WMDF-03-02-007

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

3, 4

5, 6, 7 1

a a-

WNEC-03-03-019

Stand

WMDF-03-03-001 b-

Removal 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. 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Control Valve

Front Axle

dCAUTION: Machine weight: 7400 kg (16400 lb)

3. Support front frame (1) and rear frame (2) by using stable stands (a). 4. Remove bolts, washers (3) (2 used) and clips (4) (2 used). j : 17 mm 5. Remove bolt, washer (5), nut (6), and clip (7). j : 17 mm 6. Disconnect hose (8).

2. Remove the following parts.  Front Attachment (Refer to W5-1-1.)  The Cab Assembly (Refer to W3-1-1.)  Propeller Shaft (Refer to W4-5-1.)  Steering Cylinder (Refer to W4-7-3.)

j : 17 mm 7. Disconnect hoses (9) (3 used). j : 19 mm

W3-3-1-1

SECTION 3 BODY Group 3 Center Hinge a

2, 3

5, 6, 7

b a-

Muffler Filter Regeneration Control Solenoid Valve

Front Axle

8. Remove bolt, washer (2) and clip (3). j : 17 mm 9. Disconnect hoses (1) (2 used). j : 17 mm 10. Remove bolts, washers (5) (3 used) and clips (6, 7) (3 used for each). j : 17 mm 11. Disconnect hose (4). j : 17 mm

W3-3-1-2

WMDF-03-03-002

SECTION 3 BODY Group 3 Center Hinge

2, 3

6 14 b

12, 13 7

11 10 a-

Front Frame

8, 9

Control Valve

12. Remove bolts, washers (14) (2 used) and clamp (1).

16. Disconnect connectors (7) (2 used). 17. Disconnect hoses (10) (2 used).

j : 19 mm 13. Remove bolts, washers (4) (2 used), clamp (2), and rubber plate (3).

j : 19 mm 18. Disconnect hose (5).

j : 17 mm

j : 41 mm

14. Remove bolts, washers (11) (4 used), clamps (12) (2 used), and rubber plates (13) (2 used).

19. Disconnect hose (6). j : 50 mm

j : 17 mm 15. Remove bolt, washer (8) and clip (9). j : 17 mm

W3-3-1-3

WMDF-03-03-003

SECTION 3 BODY Group 3 Center Hinge

1 2

4 3 WMDF-03-03-004

Upper Hinge

 Upper Hinge (a) Side 20. Remove bolts (1) (3 used) and cap (2). j : 24 mm

Remove pin (5) while holding it. Do dCAUTION: not drop pin (5). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

fNOTE: LOCTITE #262 has been applied on bolts (1) (3

such as goggles, hard hat, etc. in order to prevent personal injury.

used). 21. Remove bolt (3) and washer (4).

22. Remove pin (5) by using a round bar and a hammer. j : 24 mm

W3-3-1-4

SECTION 3 BODY Group 3 Center Hinge

WMDF-03-03-004 a-

Upper Hinge

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: If bushing (1) has been removed, replace it with a new one. 23. Weld and install the handrails in diagonal position on the upper side of bushing (1). Attach pry bars onto the handrails. Move bushing (1) until it can be removed from front frame (2). Tap the bottom of bushing (1) by using a round bar and a hammer. Remove bushing (1).

W3-3-1-5

SECTION 3 BODY Group 3 Center Hinge

1 2 3

WMDF-03-03-005

Lower Hinge

 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. 24. Remove bolt (1) and washer (2). Remove pin (3) by using a round bar and a hammer. j : 24 mm

W3-3-1-6

SECTION 3 BODY Group 3 Center Hinge 2

WMDF-03-03-004

Upper Hinge

Upper Hinge (a) Part (Section)

d Support front frame (1) by using dCAUTION: stable stands.

CAUTION: The front frame (1) assembly weight: 2240 kg (4940 lb)

IMPORTANT: Take care that cap (2) and bushing (3) do not come in contact with rear frame (4). 25. Attach nylon slings onto the front axle (1) assembly. Hoist and hold the front frame (1) assembly. Move the front frame (1) assembly forward. Remove the front frame (1) assembly from rear frame (4). Support it by using stands.

4 3 WMDF-03-03-006

W3-3-1-7

SECTION 3 BODY Group 3 Center Hinge 1

WMDF-03-03-004

Upper Hinge

 Upper Hinge (a) Side

27. Remove bolts (4) (6 used). Remove caps (1, 3) and shims (2) (2 used).

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

j : 19 mm

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: If bushing (5) has been removed, replace it with a new one. 26. Remove busing (5) by using pry bars.

fNOTE: LOCTITE #262 has been applied on bolts (4) (6

W3-3-1-8

used).

SECTION 3 BODY Group 3 Center Hinge 1

WMDF-03-03-004

Upper Hinge

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

29. Remove grease fitting (4).

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: If dust seal (1) has been removed, replace it with a new one. 28. Remove dust seals (1) (2 used) from caps (2, 5) by using a screwdriver and a hammer.

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. 30. Remove bearing (3) by using a round bar and a hammer.

fNOTE: LOCTITE #262 has been applied on the outer surface of dust seals (1) (2 used).

W3-3-1-9

SECTION 3 BODY Group 3 Center Hinge

WMDF-03-03-005

Lower Hinge

 Lower Hinge (a) Side 31. Remove bolts (1) (4 used). Remove caps (2, 4) and shims (3) (2 used). j : 19 mm

fNOTE: LOCTITE #262 has been applied on bolts (1) (4 used).

W3-3-1-10

SECTION 3 BODY Group 3 Center Hinge

6 4

WMDF-03-03-005

Lower Hinge

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: If dust seal (1) has been removed, replace it with a new one. 32. Remove dust seals (1) (2 used) from caps (2, 6) by using a screwdriver and a hammer.

such as goggles, hard hat, etc. in order to prevent personal injury. 34. Remove bearing (3) by using a round bar and a hammer.

fNOTE: LOCTITE #262 has been applied on the outer surface of dust seals (1) (2 used). 33. Remove grease fitting (5). j : 10 mm

W3-3-1-11

SECTION 3 BODY Group 3 Center Hinge

1 4 2

9 8 7

WMDF-03-03-008

5 2 4

1 WMDF-03-03-007

3 mm (0.12 in)

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installation. Replace them if there are some detects. (Refer to W2-1-1.) IMPORTANT: The seals and bushings which have been removed cannot be reused. IMPORTANT: Apply grease onto the inner surface of bushings and dust seals when installing the pin.  Lower 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. 1. Install bushings (4) (2 used) to rear frame (2) by using the special tool (ST 7883) and a hammer.

IMPORTANT: Face the end of grease fitting (10) to the left side of body. 3. Install grease fitting (10) to front frame (6). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft) IMPORTANT: Check the direction to install dust seals (1) (2 used). 4. Apply LOCTITE #262 onto the outer surface of dust seals (1) (2 used). Install dust seals (1) (2 used) to caps (5, 8) by using a plastic hammer. Crimp the cap (5, 8) side by using a punch (2 places). 5. Apply LOCTITE #262 onto bolts (9) (4 used). Install caps (5, 8) and shims (7) (2 used) to front frame (6) with bolts (9) (4 used).

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

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: Check the position to install bearing (3). 2. Install bearing (3) to front frame (6) by using a copper hammer.

W3-3-1-12

SECTION 3 BODY Group 3 Center Hinge

8 a

9 1

WMDF-03-03-010

2 3 WMDF-03-03-009 a-

9 mm (3.54 in)

 Upper Hinge Side

9. Apply LOCTITE #262 onto bolts (4) (6 used). Install caps (5, 8) and shims (7) (2 used) to front frame (6) with bolts (4) (6 used).

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 (1). 6. Install bearing (1) to front frame (6) by using a copper hammer. IMPORTANT: Face the end of grease fitting (9) to the left side of body. 7. Install grease fitting (9) to front frame (6). Apply grease.

j : 19 mm m : 90 N·m (9 kgf·m, 66 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. 10. Install busing (2) to the position where it comes in contact with bearing (1) by using a copper hammer.

j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft) IMPORTANT: Check the direction to install dust seals (3) (2 used). 8. Apply LOCTITE #262 onto the outer surface of dust seals (3) (2 used). Install dust seals (3) (2 used) to caps (5, 8) by using a plastic hammer. Crimp the cap (5, 8) side by using a punch (2 places).

W3-3-1-13

SECTION 3 BODY Group 3 Center Hinge 2

WMDF-03-03-004

Upper Hinge

Lower Hinge

Upper Hinge (a) Part (Section)

d Support front frame (1) by using dCAUTION: stable stands.

CAUTION: The front frame (1) assembly weight: 2240 kg (4940 lb)

IMPORTANT: Take care that cap (2) and bushing (3) do not come in contact with rear frame (4). 11. Attach nylon slings onto the front frame (1) assembly. Hoist the front frame (1) assembly. Fit the mounting holes of upper hinge (a) and lower hinge (b) of the front frame (1) assembly and the rear frame (4) assembly. Support them by using stands.

4 3 WMDF-03-03-006

W3-3-1-14

SECTION 3 BODY Group 3 Center Hinge

WMDF-03-03-007

Boss

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

12. Fit pin (1) to the boss (a) hole. Install pin (1) to the lower hinge by using a hammer. Install bolt (2) and washer (3). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-3-1-15

SECTION 3 BODY Group 3 Center Hinge

2 3

5 7

6 WMDF-03-03-009

Boss

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

15. Apply LOCTITE #262 onto bolts (1) (3 used). Install cap (2) with bolts (1) (3 used). Remove the jack.

13. Install busing (3) to the position where it comes in contact with bearing (4) by using a copper hammer.

dCAUTION: Do not drop pin (7).

14. Fit pin (7) to the boss (a) hole. Install and hold pin (7) to the upper hinge by using a jack. Install bolt (6) and washer (5). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-3-1-16

j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

SECTION 3 BODY Group 3 Center Hinge A

5 a a-

WNEC-03-03-019

Stand

WMDF-03-03-003

6 b-

Front Frame

Control Valve

View A

CAUTION: Machine weight: 7400 kg (16400 lb) 16. Remove stands (a) from front frame (1) and rear frame (2). Secure tires (4 used) by using wheel stoppers.

IMPORTANT: Check the angle to install hose (4). 17. Connect hose (4). j : 50 mm m : 350 N·m (35 kgf·m, 260 lbf·ft) IMPORTANT: Check the angle to install hose (3). 18. Connect hose (3). j : 41 mm

3 e

m : 210 N·m (21 kgf·m, 155 lbf·ft) 19. Connect hoses (6) (2 used).

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 20. Connect connectors (5) (2 used).

W3-3-1-17

40°

10°

WMDF-03-09-008

SECTION 3 BODY Group 3 Center Hinge 1

2, 3

7 8, 9

5, 6 a-

Front Frame

WMDF-03-03-003

Control Valve

23. Install rubber plate (3) and clamp (2) with bolts, washers (4) (2 used).

21. Install clip (6) with bolt, washer (5). j : 17 mm

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) 22. Install rubber plates (9) (2 used) and clamps (8) (2 used) with bolts, washers (7) (4 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 24. Install clamp (1) with bolts, washers (10) (2 used).

j : 17 mm

j : 19 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-3-1-18

SECTION 3 BODY Group 3 Center Hinge a

2, 3

5, 6, 7

b a-

Muffler Filter Regeneration Control Solenoid Valve

WMDF-03-03-002

Front Axle

25. Connect hose (4).

27. Connect hoses (1) (2 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

26. Install clips (6, 7) (3 used for each) with bolts, washers (5) (3 used).

28. Install clip (3) with bolt, washer (2). j : 17 mm

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-3-1-19

SECTION 3 BODY Group 3 Center Hinge

1, 2

3, 4, 5 7

b WMDF-03-03-001

Control Valve

Front Axle

29. Connect hose (6). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 30. Connect hoses (7) (3 used). j : 19 mm

33. Install the following parts.  Steering Cylinder (Refer to W4-7-3.)  Propeller Shaft (Refer to W4-5-1.)  The Cab Assembly (Refer to W3-1-1.)  Front Attachment (Refer to W5-1-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

m : 30 N·m (3 kgf·m, 22 lbf·ft) 31. Install clip (5) with bolt, washer (3) and nut (4). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 32. Install clips (2) (2 used) with bolts, washers (1) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-3-1-20

SECTION 3 BODY Group 4 Engine Removal and Installation of Engine 1, 2

WMDF-03-02-007

WMDF-03-02-012

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

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

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 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

pressure in the circuit. Depress the brake pedal more than 50 dCAUTION: times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open the cover of battery box (3). 3. Loosen nut (1). Disconnect ground (2). j : 10 mm 4. Remove side covers (4) at right and left sides. (Refer to W3-4-2.)

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

W3-4-1-1

SECTION 3 BODY Group 4 Engine 1

2 3

WMDF-03-04-015

WMDF-03-06-012

5. Place a container under hydraulic oil tank (4). Remove drain plug (5). Remove bolts, washers (2) (4 used). Remove cover (3) and O-ring (1). Drain off hydraulic oil. Install drain plug (5).

6. Place a container under plug (6). Loosen plug (6). Drain off engine oil. Tighten plug (6). j : 24 mm

Bolt, Washer (2):

m : 93 N·m (9.3 kgf·m, 69 lbf·ft)

j : 10 mm

fNOTE: Amount of engine oil: 18 L (4.8 US gal)

Drain Plug (5):

7. Remove clamp (8). Disconnect hose (7). j : 7 mm

j : 36 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)

fNOTE: Total oil amount of hydraulic oil tank (4): 115 L (30.4 US gal)

W3-4-1-2

SECTION 3 BODY Group 4 Engine 1

WMDF-03-01-001

8. Remove rubber cap (1). 9. Bleed air from the radiator. (Refer to W1-4-1.) 10. Place a container under hose (2). Open cock (3). Drain off coolant. Close cock (3).

fNOTE: Amount of coolant: 24 L (6.4 US gal) 11. Release refrigerant of the air conditioner. (Refer to T5-8 in the separated volume, Technical Manual.) 12. Remove cab (4). (Refer to W3-1-1.)

W3-4-1-3

WMDF-04-08-002

SECTION 3 BODY Group 4 Engine 5

6, 7

2 1

WMDF-03-08-001

13. Remove the muffler filter (4) assembly. (Refer to W317-1.) 14. Remove the air cleaner (3) assembly. (Refer to W3-43.) 15. Remove brackets (8) at right and left sides. (Refer to W3-4-2.)

WMDF-03-08-002

17. Remove covers (1, 2). (Refer to W3-4-2.) 18. Remove the wire harnesses from all clips of cover (5). The cover (5) assembly weight: 53 kg dCAUTION: (120 lb) 19. Remove the cover (5) assembly. (Refer to W3-4-2.)

16. Remove bolts, washers (6) (3 used) and clips (7) (3 used). j : 17 mm

W3-4-1-4

SECTION 3 BODY Group 4 Engine

3 4

2 5, 6, 7

8, 9

WMDF-03-08-003

20. Remove bolts, washers (1) (4 used). Remove cover (2). j : 13 mm 21. Disconnect connectors (4) (6 used). 22. Remove bolt, washer (5), nut (6), and clip (7).

WMDF-03-08-004

24. Remove the wire harnesses from all clips of support (3). The support (3) assembly weight: 62 dCAUTION: kg (140 lb) 25. Remove the support (3) assembly. (Refer to W3-4-2.)

j : 17 mm 23. Remove bolts, washers (8) (2 used) and clips (9) (2 used). j : 17 mm

W3-4-1-5

SECTION 3 BODY Group 4 Engine

5 2

4 6, 7

26. Place a container under pump device (5). 27. Disconnect hoses (8, 9).

WMDF-03-08-016

30. Remove socket bolts (6) (4 used). Disconnect and place the suction pipe (2) assembly outside the work area. Remove O-ring (7).

j : 36 mm

l : 10 mm

28. Remove clamps (3) (2 used). Disconnect the both ends of hose (4). j : 9.5 mm 29. Remove clamp (1). j : 11 mm

W3-4-1-6

SECTION 3 BODY Group 4 Engine

1 6 18 2

3, 4, 5

15, 16, 17

WMDF-03-08-006

10, 11, 12 WMDF-03-08-007

31. Disconnect connector (1). 32. Remove socket bolts (3) (16 used) and flanges (4) (8 used). Disconnect hoses (6) (4 used). Remove O-rings (5) (4 used).

35. Disconnect hose (9). j : 27 mm 36. Disconnect hose (18). j : 27 mm

l : 10 mm 33. Disconnect hoses (2) (2 used). j : 27 mm

37. Remove bolts (10, 15) (4 used for each) and flanges (11, 16) (2 used for each). Disconnect hoses (13, 14). Remove O-rings (12, 17).

34. Remove clamp (8). Disconnect hose (7).

j : 14 mm

j : 9.5 mm

W3-4-1-7

SECTION 3 BODY Group 4 Engine

4 2 WMDF-03-08-008

38. Disconnect hose (1). j : 41 mm 39. Disconnect hose (4). j : 36 mm 40. Remove clamps (2) (2 used). Disconnect the both ends of hose (3). j : 11 mm

W3-4-1-8

SECTION 3 BODY Group 4 Engine Detail A 1

8, 9, 10

16, 17, 18

2, 3 a

12, 13

14, 15 a-

Alternator

WMDF-03-04-016

WMDF-03-04-017

45. Remove bolt, washer (16), nut (17), and clip (18).

41. Remove nuts (2) (8 used) and U-bolts (3) (2 used).

j : 17 mm

j : 19 mm 42. Remove clamps (1, 4). Disconnect the both ends of the pipe (5) assembly. j : 11 mm

46. Disconnect connector (11). 47. Remove nut (8) and washer (9). Disconnect terminal (10). j : 10 mm

43. Remove clamp (6). Disconnect hose (7). j : 11 mm

48. Remove screw (12). Disconnect terminal (13).

fNOTE: THREEBOND #1207B has been applied on mounting surface of hose (7). 44. Remove bolt, washer (14) and clip (15). j : 17 mm

W3-4-1-9

SECTION 3 BODY Group 4 Engine B

View A

18, 19, 20

14 15

13 22, 23

1, 2, 3 View B

WMDF-03-04-019

4, 5

9, 10, 11, 12

6, 7, 8 WMDF-03-04-018

27, 28

WMDF-03-04-020

54. Remove bolts, washers (18) (2 used), nuts (19) (2 used), and clips (20) (2 used).

49. Remove bolt, washer (1), nut (2), and clip (3). j : 17 mm

j : 17 mm

50. Remove bolt, washer (4) and clip (5).

55. Remove bolts, washers (22) (3 used) and clips (23) (3 used).

j : 17 mm 51. Remove bolt, washer (6) and clips (7, 8).

j : 17 mm

j : 17 mm 52. Remove bolt, washer (9), nut (10), and clips (11, 12).

56. Remove clamps (15) (4 used). Disconnect the both ends of hose (16) and hoses (17, 21). j : 7 mm

j : 17 mm 53. Remove clamp (14). Disconnect hose (13).

57. Remove bolt, washer (27) and clip (28). j : 17 mm

j : 7 mm

58. Disconnect connectors (26) (2 used). 59. Remove bolts, washers (25) (4 used). Remove the fuel filter (24) assembly. j : 17 mm

W3-4-1-10

SECTION 3 BODY Group 4 Engine Detail A

12 26, 27 25 13 14

23, 24

15, 16

22 10

5, 6, 7

20, 21

1, 2, 3, 4 a-

Compressor

WMDF-03-04-021

WMDF-03-04-022

66. Remove bolts, washers (25) (2 used). Disconnect hoses (23, 26). Remove O-rings (24, 27).

60. Remove bolts, washers (10) (2 used). j : 17 mm 61. Remove clamps (8, 11). Disconnect the both ends of the pipe (9) assembly.

j : 10 mm 67. Remove bolt, washer (17) and clip (18).

j : 11 mm

j : 17 mm

62. Remove bolt, washer (1), nut (2), collar (3), and clips (4) (2 used).

68. Disconnect connector (22). 69. Remove bolt, washer (20). Disconnect ground (21).

j : 17 mm 63. Remove bolt, washer (5), nut (6), and clips (7) (2 used).

j : 17 mm 70. Remove clamp (13). Disconnect hose (19). j : 11 mm

j : 17 mm 64. Remove bolt, washer (15) and clips (16) (2 used).

17, 18

fNOTE: THREEBOND #1207B has been applied on mounting surface of hose (19).

j : 17 mm 65. Remove clamp (12). Disconnect hose (14). j : 7 mm

W3-4-1-11

SECTION 3 BODY Group 4 Engine Detail A 1

2, 3

1 WMDF-03-04-024

WMDF-03-04-023

71. Remove bolts, washers (2) (2 used) and clips (3) (2 used). j : 17 mm 72. Disconnect connectors (1) (5 used).

W3-4-1-12

SECTION 3 BODY Group 4 Engine Detail of Starter (a) Wire Harness a

5, 6, 7

8, 9

b a-

1, 2, 3

Starter

4 b-

11 a-

Fuel Tank

Starter

10 b-

WMDF-03-04-025

Fuel Tank WMDF-03-04-026

77. Disconnect connector (11).

73. Remove bolt, washer (1), clip (2), and bracket (3).

78. Remove connector (11) from bracket (10).

j : 17 mm 74. Disconnect hoses (4) (2 used). j : 36 mm 75. Remove nut (5) and washer (6). Disconnect terminal (7). j : 14 mm 76. Remove bolt, washer (8). Disconnect ground (9). j : 17 mm

W3-4-1-13

SECTION 3 BODY Group 4 Engine Detail A a

Detail B

5 6

10 b

B a-

4-Gear Pump Unit Mounting Flange

Rear Frame

Lifting Bracket WMDF-03-04-028 cWMDF-03-04-027

Rear Frame WMDF-03-04-029

The engine (2) assembly weight: 700 dCAUTION: kg (1550 lb) 79. Install shackles (2 used) to lifting brackets (b) (2 places) of engine (2). Attach nylon slings onto shackles (2 used) and the 4-gear pump unit mounting flange (a) part of pump device (1). Hoist and hold the engine (2) assembly. 80. Remove bolts (3, 8) (2 used for each), washers (4, 9) (4 used for each), plates (5, 11) (2 used for each), rubbers (6, 10) (4 used for each), and nuts (7, 12) (2 used for each).

IMPORTANT: Do not allow the engine (2) assembly to come in contact with the radiator coolant reservoir when removing / installing the engine (2) assembly. 81. Remove the engine (2) assembly. Secure it onto a stable stand. 82. Remove pump device (1) from engine (2). (Refer to W3-8-1.) 83. Remove the adapter with engine (2) attached if necessary.

j : 24 mm

W3-4-1-14

SECTION 3 BODY Group 4 Engine Detail A a

Detail B

5 6

10 b

B a-

4-Gear Pump Unit Mounting Flange

Rear Frame

Lifting Bracket WMDF-03-04-028 c-

Rear Frame

WMDF-03-04-027 WMDF-03-04-029

Installation 1. Install all removed adapters to engine (2). 2. Install pump device (1) to engine (2). (Refer to W3-81.) The engine (2) assembly weight: 700 dCAUTION: kg (1550 lb) 3. Install shackles (2 used) to lifting brackets (b) (2 places) of engine (2). Attach nylon slings onto shackles (2 used) and the 4-gear pump unit mounting flange (a) part of pump device (1). Hoist the engine (2) assembly.

IMPORTANT: Do not allow the engine (2) assembly to come in contact with the radiator coolant reservoir when removing / installing the engine (2) assembly. 4. Install the engine (2) assembly with bolts (3, 8) (2 used for each), washers (4, 9) (4 used for each), plates (5, 11) (2 used for each), rubbers (6, 10) (4 used for each), and nuts (7, 12) (2 used for each).

W3-4-1-15

j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf∙ft)

SECTION 3 BODY Group 4 Engine Detail of Starter (a) Wire Harness a

5, 6, 7

8, 9

b a-

1, 2, 3

Starter

Fuel Tank

Starter

10 b-

Fuel Tank WMDF-03-04-026

WMDF-03-04-025

5. Install connector (11) to bracket (10).

9. Connect hoses (4) (2 used).

6. Connect connector (11).

j : 36 mm

7. Connect ground (9) with bolt, washer (8).

m : 180 N·m (18 kgf·m, 133 lbf∙ft)

j : 17 mm

10. Install clip (2) and bracket (3) with bolt, washer (1).

m : 50 N·m (5 kgf·m, 37 lbf∙ft)

j : 17 mm

8. Install terminal (7) with washer (6) and nut (5).

m : 50 N·m (5 kgf·m, 37 lbf∙ft)

j : 14 mm m : 15.7 to 19.6 N·m (1.6 to 2 kgf·m, 11.5 to 14.5 lbf∙ft)

W3-4-1-16

SECTION 3 BODY Group 4 Engine Detail A 1

2, 3

1 WMDF-03-04-024

WMDF-03-04-023

11. Connect connectors (1) (5 used). 12. Install clips (3) (2 used) with bolts, washers (2) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf∙ft)

W3-4-1-17

SECTION 3 BODY Group 4 Engine Detail A

1 15, 16 14 2 3

12, 13

4, 5

11 9, 10 a-

Compressor

WMDF-03-04-021

IMPORTANT: Do not apply THREEBOND #1207B onto the inner surface of the hose (8) mounting part of the engine and inner surface of hose (8). 13. Apply THREEBOND #1207B onto the outer surface of the hose (8) mounting part of the engine. Connect hose (8) with clamp (2).

WMDF-03-04-022

17. Add compressor oil. (Refer to T5-8 in the separated volume, Technical Manual.) 18. Apply ND-OIL8 onto O-rings (13, 16). Install O-rings (13, 16). Connect hoses (12, 15) with bolts, washers (14) (2 used). j : 10 mm

j : 11 mm m : 12 N·m (1.2 kgf·m, 8.9 lbf∙ft)

6, 7

m : 4 to 6.8 N·m (0.4 to 0.7 kgf·m, 3 to 5 lbf∙ft) 19. Connect hose (3) with clamp (1).

14. Connect ground (10) with bolt, washer (9). j : 7 mm

j : 17 mm

m : 3.5 to 5 N·m (0.4 to 0.5 kgf·m, 2.6 to 3.7 lbf∙ft)

m : 50 N·m (5 kgf·m, 37 lbf∙ft) 15. Connect connector (11).

20. Install clips (5) (2 used) with bolt, washer (4).

16. Install clip (7) with bolt, washer (6).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf∙ft)

W3-4-1-18

SECTION 3 BODY Group 4 Engine

5, 6, 7

1, 2, 3, 4 WMDF-03-04-021

21. Install clips (7) (2 used) with bolt, washer (5) and nut (6).

24. Tighten clamps (8, 11). j : 11 mm

j : 17 mm

m : 12 N·m (1.2 kgf·m, 8.9 lbf∙ft)

m : 50 N·m (5 kgf·m, 37 lbf∙ft)

25. Tighten bolts, washers (10) (2 used).

22. Install clips (4) (2 used) and collar (3) with bolt, washer (1) and nut (2).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf∙ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf∙ft) 23. Temporarily install the both ends of the pipe (9) assembly with clamps (8, 11) and bolts, washers (10) (2 used).

W3-4-1-19

SECTION 3 BODY Group 4 Engine B

View A

4, 5, 6

8, 9 View B

WMDF-03-04-019

A WMDF-03-04-018

13, 14

WMDF-03-04-020

30. Install clips (9) (3 used) with bolts, washers (8) (3 used).

26. Install the fuel filter (10) assembly with bolts, washers (11) (4 used). j : 17 mm

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf∙ft)

27. Connect connectors (12) (2 used).

31. Install clips (6) (2 used) with bolts, washers (4) (2 used) and nuts (5) (2 used).

28. Install clip (14) with bolt, washer (13).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf∙ft)

m : 50 N·m (5 kgf·m, 37 lbf∙ft) 29. Connect the both ends of hose (2) and hoses (3, 7) with clamps (1) (4 used). j : 7 mm m : 4 N·m (0.4 kgf·m, 3 lbf∙ft)

W3-4-1-20

SECTION 3 BODY Group 4 Engine

1, 2, 3

4, 5

9, 10, 11, 12

6, 7, 8 WMDF-03-04-018

32. Connect hose (13) with clamp (14).

35. Install clip (5) with bolt, washer (4).

j : 7 mm

j : 17 mm

m : 3.5 to 5 N·m (0.4 to 0.5 kgf·m, 2.6 to 3.7 lbf∙ft)

m : 50 N·m (5 kgf·m, 37 lbf∙ft) 36. Install clip (3) with bolt, washer (1) and nut (2).

33. Install clips (11, 12) with bolt, washer (9) and nut (10).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf∙ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf∙ft) 34. Install clips (7, 8) with bolt, washer (6). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf∙ft)

W3-4-1-21

SECTION 3 BODY Group 4 Engine Detail A 1

8, 9, 10

16, 17, 18

2, 3 a

12, 13

14, 15 a-

Alternator

WMDF-03-04-016

37. Connect terminal (13) with screw (12). 38. Connect terminal (10) with nut (8) and washer (9).

WMDF-03-04-017

42. Apply THREEBOND #1207B onto the outer surface of the hose (7) mounting part of the engine. Connect hose (7) with clamp (6).

j : 10 mm

j : 11 mm

m : 4.9 to 6.9 N·m (0.5 to 0.7 kgf·m, 3.6 to 5.1 lbf∙ft)

m : 12 N·m (1.2 kgf·m, 8.9 lbf∙ft)

39. Connect connector (11). 40. Install clip (18) with bolt, washer (16) and nut (17).

43. Temporarily install the pipe (5) assembly with clamps (1, 4), U-bolts (3) (2 used), and nuts (2) (8 used). 44. Tighten clamps (1, 4).

j : 17 mm

j : 11 mm

m : 50 N·m (5 kgf·m, 37 lbf∙ft) 41. Install clip (15) with bolt, washer (14).

m : 12 N·m (1.2 kgf·m, 8.9 lbf∙ft) 45. Tighten nuts (2) (8 used).

j : 17 mm

j : 19 mm

m : 50 N·m (5 kgf·m, 37 lbf∙ft) IMPORTANT: Do not apply THREEBOND #1207B onto the inner surface of the hose (7) mounting part of the engine and inner surface of hose (7).

W3-4-1-22

m : 35 N·m (3.5 kgf·m, 26 lbf∙ft)

SECTION 3 BODY Group 4 Engine A

1 View A

b b-

4 2 3 a-

WMDF-03-08-008

Pump Device

46. Connect the both ends of hose (3) with clamps (2) (2 used). j : 11 mm m : 9.8 N·m (1 kgf·m, 7.2 lbf∙ft) 47. Connect hose (4). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf∙ft) IMPORTANT: Check the angle to install hose (1). 48. Connect hose (1). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf∙ft)

W3-4-1-23

30°

WMDF-03-08-012

SECTION 3 BODY Group 4 Engine

1 6 18 2

15, 16, 17

10, 11, 12

3, 4, 5

WMDF-03-08-007

WMDF-03-08-006

View A

IMPORTANT: Check the angle to install hoses (13, 14). 49. Install O-rings (12, 17). Connect hoses (13, 14) with flanges (11, 16) (2 used for each) and bolts (10, 15) (4 used for each).

13 b a

j : 14 mm m : 43 N·m (4.3 kgf·m, 31.5 lbf∙ft) 50. Connect hose (18).

WMDF-03-08-013

14 a-

20°

35°

j : 27 mm 53. Connect hoses (2) (2 used). m : 80 N·m (8 kgf·m, 59 lbf∙ft) j : 27 mm

51. Connect hose (9).

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 52. Connect hose (7) with clamp (8).

54. Install O-rings (5) (4 used). Connect hoses (6) (4 used) with flanges (4) (8 used) and socket bolts (3) (16 used).

j : 9.5 mm

j : 10 mm

m : 4.5 N·m (0.5 kgf·m, 3.3 lbf∙ft)

m : 90 N·m (9 kgf·m, 66 lbf∙ft) 55. Connect connector (1).

W3-4-1-24

SECTION 3 BODY Group 4 Engine

Detail A

5, 6 1 a-

Mark

4-Gear Pump Unit

WMDF-03-08-014

View B

c B

56. Temporarily install the suction pipe (2) assembly and O-ring (6) with socket bolts (5) (4 used) and clamp (1). 57. Tighten socket bolts (5) (4 used).

7 c-

45°

WMDF-03-08-016

WMDF-03-08-015

IMPORTANT: Connect hose (4) with mark (a) facing to the left side of body. 59. Connect the both ends of hose (4) with clamps (3) (2 used).

l : 10 mm

j : 9.5 mm

m : 105 N·m (10.5 kgf·m, 77 lbf∙ft)

m : 7.2 N·m (0.7 kgf·m, 5.3 lbf∙ft)

58. Tighten clamp (1). j : 11 mm

IMPORTANT: Check the angle to install hose (7). 60. Connect hoses (7, 8). j : 36 mm

m : 9.8 N·m (1 kgf·m, 7.2 lbf∙ft)

m : 180 N·m (18 kgf·m, 133 lbf∙ft)

W3-4-1-25

SECTION 3 BODY Group 4 Engine

3 4

2 5, 6, 7

8, 9

WMDF-03-08-004

The support (3) assembly weight: 62 dCAUTION: kg (140 lb)

WMDF-03-08-003

65. Install clip (7) with bolt, washer (5) and nut (6). j : 17 mm

61. Install the support (3) assembly. (Refer to W3-4-2.) 62. Install the wire harnesses to all clips of support (3).

m : 50 N·m (5 kgf·m, 37 lbf∙ft) 66. Install cover (2) with bolts, washers (1) (4 used).

63. Connect connectors (4) (6 used).

j : 13 mm

64. Install clips (9) (2 used) with bolts, washers (8) (2 used).

m : 10 N·m (1 kgf·m, 23 lbf∙ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf∙ft)

W3-4-1-26

SECTION 3 BODY Group 4 Engine 5

6, 7

2 1

WMDF-03-08-002

The cover (5) assembly weight: 53 kg dCAUTION: (120 lb)

WMDF-03-08-001

71. Install the muffler filter (4) assembly. (Refer to W317-1.) 72. Install the air cleaner (3) assembly. (Refer to W3-4-3.)

67. Install the cover (5) assembly. (Refer to W3-4-2.)

73. Install covers (1, 2). (Refer to W3-4-2.)

68. Install the wire harnesses to all clips of cover (5). 69. Install brackets (8) at right and left sides. (Refer to W3-4-2.) 70. Install clips (7) (3 used) with bolts, washers (6) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf∙ft)

W3-4-1-27

SECTION 3 BODY Group 4 Engine 3

4 5

WMDF-03-04-015

WMDF-03-06-012

77. Install O-ring (3) and cover (5) with bolts, washers (4) (4 used).

74. Connect hose (1) with clip (2). j : 7 mm

j : 10 mm

m : 3.25 to 5 N·m (0.3 to 0.5 kgf·m, 2.4 to 3.7 lbf∙ft)

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf∙ft) 78. Bleed air from the HST pump. (Refer to W1-4-1.)

75. Add engine oil to the engine.

fNOTE: Amount of engine oil: 18 L (4.8 US gal) 76. Add hydraulic oil to hydraulic oil tank (6) through the cover (5) mounting part.

fNOTE: Total oil amount of hydraulic oil tank (6): 115 L (30.4 US gal)

W3-4-1-28

SECTION 3 BODY Group 4 Engine 1

2, 3

WMDF-04-08-002

79. Install cab (1). (Refer to W3-1-1.)

WMDF-03-02-012

86. Bleed air from the transmission charge pump. (Refer to W1-4-1.)

80. Add coolant to the radiator.

87. Operate the steering cylinder to the stroke end several times and bleed air from the circuit.

fNOTE: Amount of coolant: 24 L (6.4 US gal) 81. Bleed air from the radiator. (Refer to W1-4-1.)

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

82. Connect ground (3). Tighten nut (2).

89. Fill refrigerant in the air conditioner. (Refer to T5-8 in the separated volume, Technical Manual.)

j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf∙ft) 83. Close the cover of battery box (4). 84. Bleed air from the fuel system. (Refer to W1-4-1.) 85. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level, coolant level, transmission oil level, and engine oil level. Start the engine and check for any oil and coolant leaks.

W3-4-1-29

SECTION 3 BODY Group 4 Engine

WMDF-03-02-007

90. Install side covers (2) at right and left sides. (Refer to W3-4-2.) 91. Install rubber cap (1).

W3-4-1-30

SECTION 3 BODY Group 4 Engine Removal and Installation of Exterior Parts 3

5 1

13 WMDF-03-04-001

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove the following parts. x Engine Cover (1) x Rear Cover (2) x Support (3) and Cover (Lower) (4) x Side Cover (5) x Rear Fender (Rear) (6) x Front Fender (7) x Rear Fender (Front) (8) x Deck (9) and Step (Front) (10) x Rear Grill (11) x Inspection Cover (12) x Step (Rear) (13)

W3-4-2-1

SECTION 3 BODY Group 4 Engine Removal and Installation of Engine Cover and Rear Cover

WMDF-03-04-002

W3-4-2-2

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

01 02 03 04 09 13 17 18 19

Engine Cover Bolt Washer Washer Cover Rear Cover Bolt, Washer Bolt, Washer Cover

1 5 5 5 1 1 12 4 1

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 24

210

155

j : 17 j : 17

50 50

5 5

37 37

When removing and installing the dCAUTION: following parts, hoist and hold them by using nylon slings.  Engine cover (01) weight: 33 kg (73 lb)

W3-4-2-3

Weight kg lb 33 73

SECTION 3 BODY Group 4 Engine Removal and Installation of Support and Cover (Lower)

WMDF-03-04-003

No.

Part Name

Q’ty

01 02 03 07 08 17 18 19 23 24

Support Washer Bolt Cover Bolt, Washer Cover (Lower) (Left) Cover (Lower) (Right) Bolt, Washer Bracket Bolt

1 10 6 1 3 1 1 10 2 4

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 24

210

155

j : 17

j : 24

210

155

When removing and installing the dCAUTION: following parts, hoist and hold them by using nylon slings.  Support (01) weight: 52 kg (115 lb) IMPORTANT: Install the slotted hole side of bracket (23) to support (01).

W3-4-2-4

Weight kg lb 52 115

SECTION 3 BODY Group 4 Engine Removal and Installation of Side Cover

WMDF-03-04-004

W3-4-2-5

SECTION 3 BODY Group 4 Engine Detail A

Detail B

WMDF-03-04-005

No.

Part Name

Q’ty

01 02 03 04 16 30 31 32 33 34 35 36 37 38 39 40

Rod Washer Lock Pin Holder Bolt, Washer Side Cover (Left) Side Cover (Right) Bracket Bracket Bracket Bolt, Washer Damper Pin Washer Lock Pin Damper (Only with Rear Fender (Rear) Attached)

2 2 2 2 8 1 1 2 1 1 14 2 4 4 4 2

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 19

Weight kg lb

66 33 33

j : 17

Side covers (30, 31) weight: 33 kg (73 dCAUTION: lb)

73 73

fNOTE: Remove the rear fender (rear) before removing

IMPORTANT: When removing and installing side covers (30, 31), hoist and hold them by using nylon slings.

W3-4-2-6

side covers (30, 31).

SECTION 3 BODY Group 4 Engine Removal and Installation of Rear Fender (Rear)

WMDF-03-04-006

W3-4-2-7

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

01 02 06 07 08 12 13 17 21 22 23 27 28 29

Bracket Bolt, Washer Bracket (Left) Bracket (Right) Bolt, Washer Bracket Bolt, Washer Bracket Mud Guard (Left) Mud Guard (Right) Bolt, Washer Rear Fender (Rear) (Left) Rear Fender (Rear) (Right) Bolt, Washer

2 6 1 1 6 2 4 2 1 1 8 1 1 12

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 17

j : 19

j : 17

Weight kg lb

4 4 j : 17

Remove the rear fender (rear) (27, 28) dCAUTION: assemblies while holding them. Do not drop the rear fender (rear) (27, 28) assemblies. IMPORTANT: Before installing bolt, washer (23), apply LOCTITE #262 onto it.

W3-4-2-8

9 9

SECTION 3 BODY Group 4 Engine Removal and Installation of Front Fender

05 04 03 01, 02

03 08, 09

03 05

12 06, 07

WMDF-03-04-008

WMDF-03-04-007 a-

Front Frame

No.

Part Name

Q’ty

01 02 03 04 05 06 07 08 09 10 11 12 13

Front Fender (Left) Front Fender (Right) Washer Washer Nut Mud Guard (Left) Mud Guard (Right) Plate (Left) Plate (Right) Bolt, Washer Bolt, Washer Washer Nut

1 1 8 8 8 1 1 1 1 6 4 4 4

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 19

3.5

j : 17 j : 17

50 50

5 5

37 37

j : 17

IMPORTANT: Before installing bolt, washer (11), apply LOCTITE #262 onto it.

W3-4-2-9

Weight kg lb 16 36 16 36

SECTION 3 BODY Group 4 Engine Removal and Installation of Rear Fender (Front), Deck, and Step (Front)

WMDF-03-04-009

W3-4-2-10

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

01 02 03 04 14 15 16 17 21 22 23 24 25 29 30 31 32 33

Step Bolt, Washer Step Bolt, Washer Rear Fender (Front) (Left) Rear Fender (Front) (Right) Bolt, Washer Bolt, Washer Step Bolt, Washer Step Bolt, Washer Nut Step Collar Bolt, Washer Collar Bolt, Washer

1 3 1 4 1 1 6 5 1 4 1 4 4 1 2 2 2 2

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 17

Weight kg lb

14 16 j : 19 j : 19

90 90

9 9

66 66

j : 17

When removing and installing the dCAUTION: following parts as an assembly, hoist and hold them by using nylon slings.  The rear fender (front) (left) (14) assembly weight: 42 kg (93 lb)  The rear fender (front) (right) (15) assembly weight: 31 kg (69 lb)

W3-4-2-11

31 36

SECTION 3 BODY Group 4 Engine

WMDF-03-04-010

Rear Fender (Front) (Left)

No.

Part Name

Q’ty

12 13 14 15 16 17 18 19 20 21

Mud Guard (Left) Mud Guard (Right) Plate (Left) Plate (Right) Bolt, Washer Washer Nut Bolt, Washer Washer Nut

1 1 1 1 6 6 6 8 8 8

Rear Fender (Front) (Right)

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 17

IMPORTANT: Before installing bolt, washer (19), apply LOCTITE #262 onto it.

W3-4-2-12

Weight kg lb

SECTION 3 BODY Group 4 Engine Removal and Installation of Rear Grill

WMDF-03-04-011

No.

Part Name

Q’ty

01 02

Rear Grill Bolt, Washer

1 4

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 17

IMPORTANT: When removing and installing the rear grill, disconnect the connector of the work light.

W3-4-2-13

Weight kg lb

SECTION 3 BODY Group 4 Engine Removal and Installation of Inspection Cover and Step (Rear)

WMDF-03-04-012

No.

Part Name

Q’ty

01 02 06 07 08 12 13 14 15 41 42 43 44

Cover Bolt, Washer Step Step Bolt, Washer Step Washer Washer Nut Cover Washer Washer Nut

2 8 1 1 4 1 2 2 2 1 6 6 6

Wrench Size (mm)

Tightening Torque N·m kgf·m lbf·ft

j : 17

j : 19

Weight kg lb

23 j : 19

When removing and installing the dCAUTION: following parts, hoist and hold them by using nylon slings.  Cover (41) weight: 23 kg (51 lb)

W3-4-2-14

3.5

SECTION 3 BODY Group 4 Engine Removal and Installation of Air Cleaner

1 6

4 WMDF-03-02-007

WMDF-03-04-014

3. Remove clamps (5) (2 used). Disconnect hose (4). j : 7 mm 4. Remove bolts, washers (6) (4 used). Remove air duct (2) and rubber plate (3). j : 17 mm

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Open side covers (1) at the right and left sides.

W3-4-3-1

SECTION 3 BODY Group 4 Engine 1

5. Disconnect connectors (4) (2 used).

WMDF-03-04-013

Remove and install the air cleaner dCAUTION: (5) assembly while holding it. Do not drop the air

6. Disconnect connector (2).

cleaner (5) assembly. 10. Remove bolts, washers (3) (4 used). Remove the air cleaner (5) assembly.

7. Remove bolts, washers (1) (2 used). j : 17 mm 8. Remove clamp (6).

j : 17 mm

j : 7 mm 9. Remove clamp (7). Disconnect the both ends of the hose (8) assembly. j : 11 mm

W3-4-3-2

SECTION 3 BODY Group 4 Engine 1

WMDF-03-04-013

Installation Remove and install the air cleaner dCAUTION: (5) assembly while holding it. Do not drop the air cleaner (5) assembly. 1. Install the air cleaner (5) assembly with bolts, washers (3) (4 used).

4. Tighten clamp (6). j : 7 mm m : 8 N·m (0.8 kgf·m, 5.9 lbf·ft) 5. Tighten bolts, washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

2. Temporarily install the both ends of the hose (8) assembly with clamps (6, 7) and bolts, washers (1) (2 used).

6. Connect connector (2). 7. Connect connectors (4) (2 used).

3. Tighten clamp (7). j : 11 mm m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)

W3-4-3-3

SECTION 3 BODY Group 4 Engine

3 1

4 WMDF-03-04-014

8. Temporarily install hose (4), rubber plate (3), and air duct (2) with clamps (5) (2 used) and bolts, washers (6) (4 used). 9. Tighten clamps (5) (2 used). j : 7 mm m : 7 N·m (0.7 kgf·m, 5.2 lbf·ft) 10. Close side covers (1) at the right and left sides. 11. Tighten bolts, washers (6) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-3-4

WMDF-03-02-007

SECTION 3 BODY Group 5 Radiator Assembly Replacement of Radiator, Oil Cooler, and Intercooler 1

WMDF-03-06-012

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

Bleed air from hydraulic oil tank (4). dCAUTION: (Refer to W1-4-1.)

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 staring any work. 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

2. Place a container under hydraulic oil tank (4). Remove drain plug (5). Remove bolts, washers (2) (4 used). Remove cover (3) and O-ring (1). Drain off hydraulic oil. Install drain plug (5). Bolt, Washer (2): j : 10 mm Drain Plug (5): j : 36 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)

fNOTE: Total oil amount of hydraulic oil tank (4): 115 L

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

W3-5-1-1

(30.4 US gal)

SECTION 3 BODY Group 5 Radiator Assembly

2 1 4

5 WMDF-03-02-007

3. Remove covers (1, 2). (Refer to W3-4-2.) 4. Open side covers (3) at left and right sides. 5. Disconnect connectors (4) (2 used). 6. Remove rear grill (5). (Refer to W3-4-2.)

W3-5-1-2

WMDF-03-02-011

SECTION 3 BODY Group 5 Radiator Assembly 1

2 13

3 4

WMDF-03-05-001

9, 10, 11

WMDF-03-05-002

12. Remove clamps (8, 13). Disconnect the both ends of hose (12).

7. Bleed air from the radiator. (Refer to W1-4-1.) 8. Place a container under hose (4). Open cock (3). Drain off coolant. Close cock (3).

j : 11 mm

fNOTE: Amount of coolant: 24 L (6.3 US gal)

13. Remove clamps (6) (2 used). Disconnect hose (7).

9. Disconnect hose (5).

j : 7 mm

j : 41 mm

fNOTE: THREEBOND #1207B has been applied on

10. Remove clamp (1). Disconnect hose (2).

mounting surface of hose (7).

j : 7 mm 11. Remove bolts, washers (9) (4 used) and plates (10) (2 used). Remove rubber plate (11). j : 17 mm

W3-5-1-3

SECTION 3 BODY Group 5 Radiator Assembly 1

7 10

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

WMDF-03-15-003

17. Remove bolts, washers (9) (4 used). Remove cover (10).

j : 17 mm

15. Remove bolts, washers (4) (2 used). Remove cover (3). j : 17 mm 16. Remove bolts, washers (5) (4 used). Remove cover (6).

IMPORTANT: Do not allow cover (8) to come in contact with the radiator, oil cooler, and intercooler when removing / installing cover (8). 18. Remove bolts, washers (7) (5 used). Remove cover (8).

j : 17 mm

W3-5-1-4

j : 17 mm

SECTION 3 BODY Group 5 Radiator Assembly

7 6 15

4 9 3

WMDF-03-07-002

19. Remove bolts, washers (6) (3 used). Remove rubber plate (5). j : 17 mm 20. Remove bolts, washers (8) (4 used). Remove rubber plate (7). j : 17 mm

WMDF-03-05-003

23. Remove bolts, washers (14) (2 used). j : 17 mm 24. Remove clamps (12, 13). Disconnect the both ends of hose (15). j : 11 mm 25. Remove clamps (10) (2 used). Disconnect hose (11).

21. Remove bolts, washers (4) (4 used). Remove cover (3).

j : 7 mm

fNOTE: THREEBOND #1207B has been applied on

j : 17 mm 22. Remove bolts, washers (2) (4 used). Remove cover (1).

mounting surface of hose (11). 26. Disconnect hose (9). j : 41 mm

j : 17 mm

W3-5-1-5

SECTION 3 BODY Group 5 Radiator Assembly

27. Remove bolts, washers (4) (2 used). Remove oil cooler (1). j : 17 mm 28. Remove rubber seals (2) (3 used) and rubber seals (3) (2 used) from oil cooler (1). 29. Remove the adapters with oil cooler (1) attached if necessary.

W3-5-1-6

WMDF-03-05-005

SECTION 3 BODY Group 5 Radiator Assembly 1

30. Remove bolts, washers (5) (2 used), washers (4) (2 used), rubbers (3) (2 used), and tubes (2) (2 used). Remove radiator (1). j : 13 mm

W3-5-1-7

WMDF-03-05-005

SECTION 3 BODY Group 5 Radiator Assembly

31. Remove bolt, washer (5), washer (6), rubber (7), and tube (4). Remove intercooler (3). j : 13 mm 32. Remove rubber seals (1) (2 used) and rubber seal (2) from intercooler (3).

W3-5-1-8

WMDF-03-05-005

SECTION 3 BODY Group 5 Radiator Assembly

Installation 1. Install rubber seal (2) and rubber seals (1) (2 used) to intercooler (3). 2. Install intercooler (3) with tube (4), rubber (7), washer (6), and bolt, washer (5). j : 13 mm m : 17.6 N·m (1.8 kgf·m, 13 lbf·ft)

W3-5-1-9

WMDF-03-05-005

SECTION 3 BODY Group 5 Radiator Assembly 1

3. Install radiator (1) with tubes (2) (2 used), rubbers (3) (2 used), washers (4) (2 used), and bolts, washers (5) (2 used). j : 13 mm m : 17.6 N·m (1.8 kgf·m, 13 lbf·ft)

W3-5-1-10

WMDF-03-05-005

SECTION 3 BODY Group 5 Radiator Assembly

4. Install all removed adapters to oil cooler (1). 5. Install rubber seals (3) (2 used) and rubber seals (2) (3 used) to oil cooler (1). 6. Install oil cooler (1) with bolts, washers (4) (2 used). j : 17 mm m : 36.2 N·m (3.6 kgf·m, 26.5 lbf·ft)

W3-5-1-11

WMDF-03-05-005

SECTION 3 BODY Group 5 Radiator Assembly

Detail A

A b

1 3

WMDF-03-05-003

a a-

7. Connect hose (1). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) IMPORTANT: Do not apply THREEBOND #1207B onto the inner surface of the hose (3) mounting part of radiator (a) and inner surface of hose (3). IMPORTANT: Insert hose (3) 45 mm (1.8 in) with mark (b) up. 8. Apply THREEBOND #1207B onto the outer surface of the hose (3) mounting part of radiator (a). Connect hose (3) with clamps (2) (2 used). j : 7 mm m : 5.4 to 6.6 N·m (0.5 to 0.7 kgf·m, 4 to 4.9 lbf·ft)

W3-5-1-12

Radiator

2 b-

Mark

WMDF-03-05-004

SECTION 3 BODY Group 5 Radiator Assembly

Detail A

WMDF-03-05-003

B WMDF-03-05-006

IMPORTANT: Insert hose (2) 50 mm (2 in) with mark (a) up. IMPORTANT: Check the angle to install clamps (1, 3). 9. Connect the both ends of hose (2) with clamps (1, 3).

Mark

View B

Intercooler

Section C c d

3 1

j : 11 mm m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) WMDF-03-05-007

10. Install bolts, washers (4) (2 used). c-

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-13

30°

WMDF-03-05-008 d-

60°

SECTION 3 BODY Group 5 Radiator Assembly 1

7 10

IMPORTANT: Do not allow cover (8) to come in contact with the radiator, oil cooler, and intercooler when removing / installing cover (8). 11. Install cover (8) with bolts, washers (7) (5 used). j : 17 mm

WMDF-03-15-003

13. Install cover (6) with bolts, washers (5) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 14. Install cover (3) with bolts, washers (4) (2 used). j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) 12. Install cover (10) with bolts, washers (9) (4 used). j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) 15. Install cover (2) with bolts, washers (1) (3 used). j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-14

SECTION 3 BODY Group 5 Radiator Assembly A

a Detail A

WMDF-03-05-002 WMDF-03-05-004 a-

IMPORTANT: Do not apply THREEBOND #1207B onto the inner surface of the hose (2) mounting part of radiator (a) and inner surface of hose (2). IMPORTANT: Insert hose (2) 45 mm (1.8 in) with mark (b) up. 16. Apply THREEBOND #1207B onto the outer surface of the hose (2) mounting part of radiator (a). Connect hose (2) with clamps (1) (2 used). j : 7 mm m : 5.4 to 6.6 N·m (0.5 to 0.7 kgf·m, 4 to 4.9 lbf·ft)

W3-5-1-15

Radiator

Mark

SECTION 3 BODY Group 5 Radiator Assembly A B

Detail A

2, 3, 4

WMDF-03-05-002 b WMDF-03-05-006 a-

IMPORTANT: Insert hose (5) 50 mm (2 in) with mark (a) up. IMPORTANT: Check the angle to install clamps (1, 6). 17. Connect the both ends of hose (5) with clamps (1, 6).

Mark

Intercooler

View C

View B

j : 11 mm m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) 18. Install rubber plate (4) with plates (3) (2 used) and bolts, washers (2) (4 used).

c WMDF-03-05-009

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

WMDF-03-05-010

W3-5-1-16

60°

90°

SECTION 3 BODY Group 5 Radiator Assembly 1

3 8

WMDF-03-05-001

WMDF-03-06-012

23. Add coolant to radiator (1).

19. Connect hose (3) with clamp (2).

fNOTE: Amount of coolant: 24 L (6.3 US gal)

j : 7 mm

24. Bleed air from radiator (1). (Refer to W1-4-1.)

m : 5.4 to 6.6 N·m (0.5 to 0.7 kgf·m, 4 to 4.9 lbf·ft)

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

20. Connect hose (4).

IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil and coolant leaks.

j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 21. Add hydraulic oil to hydraulic oil tank (8) from the cover (7) mounting part.

fNOTE: Total oil amount of hydraulic oil tank (8): 115 L (30.4 US gal) 22. Install O-ring (5) and cover (7) with bolts, washers (6) (4 used). j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

W3-5-1-17

SECTION 3 BODY Group 5 Radiator Assembly

7 6 5

WMDF-03-07-002

26. Install cover (1) with bolts, washers (2) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 27. Install cover (3) with bolts, washers (4) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 28. Install rubber plate (7) with bolts, washers (8) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 29. Install rubber plate (5) with bolts, washers (6) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-18

SECTION 3 BODY Group 5 Radiator Assembly

2 1 4

5 WMDF-03-02-011

30. Install rear grill (5). (Refer to W3-4-2.) 31. Connect connectors (4) (2 used). 32. Close side covers (3) at left and right sides. 33. Install covers (1, 2). (Refer to W3-4-2.)

W3-5-1-19

WMDF-03-02-007

SECTION 3 BODY Group 5 Radiator Assembly (Blank)

W3-5-1-20

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

WMDF-03-06-001

Removal

Escaping fluid under pressure may dCAUTION: penetrate the skin and eyes, and cause serious 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. Wait for oil in order to cool before starting any work. 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.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from hydraulic oil tank (2). dCAUTION: (Refer to W1-4-1.) 2. Remove the following parts. (Refer to W3-4-2.)  Rear Fender (Front) (4)  Step (Front) (3)  Deck (1)

W3-6-1-1

SECTION 3 BODY Group 6 Hydraulic Oil Tank

6 7

WMDF-03-06-006

3. Remove bolts, washers (2) (4 used). Remove cover (1). j : 17 mm 4. Remove bolts, washers (4) (2 used). Remove cover (3). j : 17 mm 5. Remove bolts, washers (6) (3 used). Remove covers (5, 7). j : 17 mm

W3-6-1-2

SECTION 3 BODY Group 6 Hydraulic Oil Tank 1

WMDF-03-06-002

WMDF-03-06-012

6. Place a container under hydraulic oil tank (4). Remove drain plug (5). Remove bolts, washers (2) (4 used). Remove cover (3) and O-ring (1). Drain off hydraulic oil. Install drain plug (5). Bolt, Washer (2):

7. Disconnect connectors (6) (2 used). 8. Disconnect hoses (9) (2 used). 9. Remove bolts, washers (8) (2 used). Remove the washer fluid tank (7) assembly. j : 17 mm

j : 10 mm Drain Plug (5): j : 36 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)

fNOTE: Total oil amount of hydraulic oil tank (4): 115 L (30.4 US gal)

W3-6-1-3

SECTION 3 BODY Group 6 Hydraulic Oil Tank

4, 5 3

2 6 11 7

WMDF-03-06-003

10. Disconnect hoses (1) (2 used).

13. Disconnect hose (10) (only with the emergency steering attached).

j : 17 mm 17. Disconnect hoses (11) (2 used). j : 19 mm

j : 11 mm 12. Disconnect connectors (7) (2 used).

16. Disconnect hoses (4) (2 used).

j : 17 mm 11. Remove clamps (2) (2 used). Disconnect hose (3).

18. Remove elbow (5). j : 22 mm 19. Remove elbow (9).

j : 36 mm

j : 41 mm

14. Disconnect hose (8). j : 41 mm 15. Disconnect hose (6) (only with the emergency steering attached). j : 17 mm

W3-6-1-4

WMDF-03-06-004

SECTION 3 BODY Group 6 Hydraulic Oil Tank

2 b

10 8 4 11 6, 7 12

WMDF-03-06-005 a-

Lifting Hole

Lifting Hole WMDF-03-06-008

20. Remove bolts, washers (4) (2 used).

25. Remove bolts (10) (3 used), washers (11) (6 used), and nuts (12) (3 used). Remove hydraulic oil tank (9).

j : 17 mm

j : 30 mm

21. Remove clamp (3). Disconnect the hose (5) assembly.

26. Remove the adapters with hydraulic oil tank (9) attached if necessary.

j : 11 mm 22. Remove bolt, washer (6), nut (7), and clamp (8). j : 19 mm 23. Remove clamp (2). Disconnect the hose (1) assembly. j : 11 mm Hydraulic oil tank (9) weight: 120 kg dCAUTION: (265 lb) 24. Install an eyebolt (M10, Pitch 1.5 mm) to lifting hole (a) and an eyebolt and nut to lifting hole (b) of hydraulic oil tank (9). Attach the nylon slings onto the eyebolts (2 used). Hoist and hydraulic oil tank (9).

W3-6-1-5

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

1 3 4

Lifting Hole

cd-

Lifting Hole WMDF-03-06-008

Installation 1. Install the removed adapters which have been removed in step 26 of removal to hydraulic oil tank (1). Hydraulic oil tank (1) weight: 120 kg dCAUTION: (265 lb) 2. Install an eyebolt (M10, Pitch 1.5 mm) to lifting hole (a) and an eyebolt and nut to lifting hole (b) of hydraulic oil tank (1). Attach the nylon slings onto the eyebolts (2 used). Hoist hydraulic oil tank (1). IMPORTANT: Place hydraulic oil tank (1) onto stopper plate (d) of rear frame (c). 3. Install hydraulic oil tank (1) with nuts (4) (3 used), washers (3) (6 used), and bolts (2) (3 used). j : 30 mm m : 550 N·m (55 kgf·m, 410 lbf·ft)

W3-6-1-6

Rear Frame Stopper Plate

c WMDF-03-06-009

SECTION 3 BODY Group 6 Hydraulic Oil Tank 1 2

3 9

8 4 6, 7

WMDF-03-06-005

WMDF-03-06-004

A View A

4. Connect the hose (1) assembly with clamp (2). j : 11 mm m : 9.8 N·m (1 kgf·m, 7.2 lbf·ft) 5. Install clamp (8) with nut (7) and bolt, washer (6). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

6. Connect the hose (5) assembly with clamp (3).

WMDF-03-06-011

30˚

j : 11 mm m : 9.8 N·m (1 kgf·m, 7.2 lbf·ft) 7. Install bolts, washers (4) (2 used).

IMPORTANT: Check the angle to install elbow (10). 9. Install elbow (10).

j : 17 mm

j : 41 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 210 N·m (21 kgf·m, 155 lbf·ft)

8. Install elbow (9). j : 22 mm m : 70 N·m (7 kgf·m, 52 lbf·ft)

W3-6-1-7

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

1 6

10˚

WMDF-03-06-010

6 3

WMDF-03-06-004

10. Connect hoses (6) (2 used).

13. Connect hose (4).

j : 19 mm

j : 41 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

m : 210 N·m (21 kgf·m, 155 lbf·ft)

11. Connect hoses (1) (2 used).

IMPORTANT: Check the angle to install hose (5). 14. Connect hose (5) (only with the emergency steering attached).

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

j : 36 mm

12. Connect hose (2) (only with the emergency steering attached). j : 17 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft) 15. Connect connectors (3) (2 used).

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-6-1-8

SECTION 3 BODY Group 6 Hydraulic Oil Tank 5

4 2

WMDF-03-06-003

WMDF-03-06-012

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

16. Connect hose (4) with clamps (3) (2 used). j : 11 mm

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

m : 9.8 N·m (1 kgf·m, 7.2 lbf·ft) 17. Connect hoses (1) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 18. Add hydraulic oil to hydraulic oil tank (2) through the cover (7) mounting part.

fNOTE: Total oil amount of hydraulic oil tank (2): 115 L (30.4 US gal) 19. Install O-ring (5) and cover (7) with bolts, washers (6) (4 used). j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

W3-6-1-9

SECTION 3 BODY Group 6 Hydraulic Oil Tank

WMDF-03-06-002

21. Install the washer fluid tank (2) assembly with bolts, washers (3) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 22. Connect hoses (4) (2 used). 23. Connect connectors (1) (2 used).

W3-6-1-10

SECTION 3 BODY Group 6 Hydraulic Oil Tank

6 7

WMDF-03-06-006

24. Install covers (5, 7) with bolts, washers (6) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 25. Install cover (3) with bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 26. Install cover (1) with bolts, washers (2) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-6-1-11

SECTION 3 BODY Group 6 Hydraulic Oil Tank

27. Install following parts. (Refer to W3-4-2.)  Deck (1)  Step (Front) (2)  Rear Fender (Front) (3)

W3-6-1-12

WMDF-03-06-001

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

3 WMDF-03-02-007

Fuel is highly flammable. Never bring dCAUTION: a fire close to fuel. 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 machine position for inspection and maintenance. (Refer to W1- 6-1.) 2. Open side covers (1) at left and right sides. 3. Disconnect connectors (2) (2 used). 4. Remove rear grill (3). (Refer to W3-4-2.)

W3-7-1-1

WMDF-03-02-011

SECTION 3 BODY Group 7 Fuel Tank

6 14

13 12 11

10 4 9

WMDF-03-07-001

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

fNOTE: Total oil amount of fuel tank: 205 L (54.2 US gal) 7. Remove clip (2). Disconnect hose (1).

WMDF-03-07-002

10. Remove bolts, washers (12) (3 used). Remove rubber plate (11). j : 17 mm 11. Remove bolts, washers (14) (4 used). Remove rubber plate (13). j : 17 mm

j : 7 mm

12. Remove bolts, washers (10) (4 used). Remove cover (9).

8. Remove bolts, washers (6) (2 used). j : 13 mm 9. Remove clamp (3). Disconnect the oil filler port (4) assembly.

j : 17 mm 13. Remove bolts, washers (8) (4 used). Remove cover (7).

j : 7 mm

j : 17 mm

W3-7-1-2

SECTION 3 BODY Group 7 Fuel Tank

3, 4, 5, 6

7, 8, 9 27 26 31

30 25 10 31

22, 23, 24

30 11, 12, 13, 14 20, 21

15, 16 WMDF-03-07-004

WMDF-03-07-003

21. Remove bolts, washers (7) (2 used), clips (8) (2 used), and collars (9) (2 used).

14. Remove clips (2, 26). Disconnect hoses (1, 25). j : 7 mm

j : 17 mm

15. Remove bolt, washer (22), clip (23), and bracket (24).

22. Place a container. Remove plug (20). Open valve (21). Drain off fuel completely.

j : 17 mm 16. Remove bolts, washers (18) (2 used). Remove block (17).

j : 17 mm 23. Install a seal tape onto the thread part of plug (20). Close valve (21). Install plug (20).

j : 17 mm 17. Disconnect connectors (10, 19).

j : 17 mm

18. Remove bolt, washer (15) and clip (16).

m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

j : 17 mm 19. Remove bolt, washer (11), clips (12, 13), and collar (14). j : 17 mm 20. Remove bolt, washer (3), clip (4), bracket (5), and collar (6).

dCAUTION: Fuel tank (29) weight: 140 kg (310 lb) 24. Hold the bottom side of fuel tank (29) by using a hydraulic jack and the wooden blocks. 25. Remove bolts (30) (2 used), bolt (28), washers (31) (2 used), and washer (27). Remove fuel tank (29).

j : 17 mm

j : 36 mm

W3-7-1-3

SECTION 3 BODY Group 7 Fuel Tank 1

3, 4, 5, 6

7, 8, 9 25 30 24 29

28 23 10 29 28 20, 21, 22 11, 12, 13, 14

27 19

15, 16

WMDF-03-07-004

Installation

dCAUTION: Fuel tank (27) weight: 140 kg (310 lb)

WMDF-03-07-003

7. Install collar (14) and clips (12, 13) with bolt, washer (11). j : 17 mm

1. Install fuel tank (27) to rear frame (30) by using a hydraulic jack and the wooden blocks.

m : 50 N·m (5 kgf·m, 37 lbf·ft)

2. Install washers (29) (2 used), washer (25), bolts (28) (2 used), and bolt (26).

8. Install block (17) with bolts, washers (18) (2 used). j : 17 mm

j : 36 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 950 N·m (95 kgf·m, 700 lbf·ft) 3. Install collars (9) (2 used) and clips (8) (2 used) with bolts, washers (7) (2 used).

9. Install bracket (22) and clip (21) with bolt, washer (20). j : 17 mm

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft) 4. Connect connectors (10, 19).

10. Connect hoses (1, 23) with clips (2, 24). j : 7 mm

5. Install clip (15) with bolt, washer (16).

m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 6. Install collar (6), bracket (5), and clip (4) with bolt, washer (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-7-1-4

SECTION 3 BODY Group 7 Fuel Tank

6 14

13 12 11

10 4 9

WMDF-03-07-001

WMDF-03-07-002

18. Install cover (7) with bolts, washers (8) (4 used).

11. Temporarily install the oil filler port (4) assembly with clamp (3) and bolts, washers (6) (2 used).

j : 17 mm

12. Tighten clamp (3).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 7 mm

19. Install cover (9) with bolts, washers (10) (4 used).

m : 6.7 N·m (0.67 kgf·m, 4.9 lbf·ft)

j : 17 mm

13. Tighten bolts, washers (6) (2 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 13 mm

20. Install rubber plate (13) with bolts, washers (14) (4 used).

m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 14. Connect hose (1) with clip (2).

j : 17 mm

j : 7 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

21. Install rubber plate (11) with bolts, washers (12) (3 used).

15. Fill the fuel tank with fuel.

fNOTE: Total oil amount of fuel tank: 205 L (54.2 US gal)

j : 17 mm

16. Install cap (5).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

17. Bleed air from the fuel system. (Refer to W1-4-1.) IMPORTANT: Start the engine and check for any oil leaks.

W3-7-1-5

SECTION 3 BODY Group 7 Fuel Tank

3 WMDF-03-02-011

22. Install rear grill (3). (Refer to W3-4-2.) 23. Connect connectors (2) (2 used). 24. Close side covers (1) at left and right sides.

W3-7-1-6

WMDF-03-02-007

SECTION 3 BODY Group 8 Pump Device Removal and Installation of Pump Device 1

WMDF-03-06-012

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

Bleed air from hydraulic oil tank (4). dCAUTION: (Refer to W1-4-1.)

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 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

fNOTE: Total oil amount of hydraulic oil tank (4): 115 L

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

W3-8-1-1

(30.4 US gal)

SECTION 3 BODY Group 8 Pump Device

1 2

WMDF-03-02-007

3. Remove side covers (1) at right and left sides. (Refer to W3-4-2.) 4. Remove cab (2). (Refer to W3-1-1.)

W3-8-1-2

SECTION 3 BODY Group 8 Pump Device 5

6, 7

2 1

WMDF-03-08-001

5. Remove the muffler filter (4) assembly. (Refer to W317-1.) 6. Remove the air cleaner (3) assembly. (Refer to W3-43.) 7. Remove brackets (8) at right and left sides. (Refer to W3-4-2.)

WMDF-03-08-002

9. Remove covers (1, 2). (Refer to W3-4-2.) 10. Remove the harnesses from all clips of cover (5). The cover (5) assembly weight: 53 kg dCAUTION: (120 lb) 11. Remove the cover (5) assembly. (Refer to W3-4-2.)

8. Remove bolts, washers (6) (3 used) and clips (7) (3 used). j : 17 mm

W3-8-1-3

SECTION 3 BODY Group 8 Pump Device

3 4

2 5, 6, 7

8, 9

WMDF-03-08-003

12. Remove bolts, washers (1) (4 used). Remove cover (2). j : 13 mm

WMDF-03-08-004

16. Remove the harnesses from all clips of support (3). The support (3) assembly weight: 62 dCAUTION: kg (140 lb) 17. Remove the support (3) assembly. (Refer to W3-4-2.)

13. Disconnect connectors (4) (6 used). 14. Remove bolts, washers (5) (2 used), nuts (6) (2 used), and clips (7) (2 used). j : 17 mm 15. Remove bolts, washers (8) (2 used) and clips (9) (2 used). j : 17 mm

W3-8-1-4

SECTION 3 BODY Group 8 Pump Device

5 2

4 6, 7

18. Place a container under pump device (5). 19. Disconnect hoses (8, 9).

WMDF-03-08-016

22. Remove socket bolt (6)(4 used). Disconnect and place the suction pipe (2) assembly outside the work area. Remove O-ring (7).

j : 36 mm

l : 10 mm

20. Remove clamps (3) (2 used). Disconnect the both ends of hose (4). j : 9.5 mm 21. Remove clamp (1). j : 11 mm

W3-8-1-5

SECTION 3 BODY Group 8 Pump Device

1 6 18 2

3, 4, 5

15, 16, 17

WMDF-03-08-006

10, 11, 12 WMDF-03-08-007

23. Disconnect connector (1). 24. Remove socket bolts (3) (16 used) and flanges (4) (8 used). Disconnect hoses (6) (4 used). Remove O-rings (5) (4 used).

27. Disconnect hose (9). j : 27 mm 28. Disconnect hose (18). j : 27 mm

l : 10 mm 25. Disconnect hoses (2) (2 used). j : 27 mm

29. Remove bolts (10, 15) (4 used for each) and flanges (11, 16) (2 used for each). Disconnect hoses (13, 14). Remove O-rings (12, 17).

26. Remove clamp (8). Disconnect hose (7).

j : 14 mm

j : 9.5 mm

W3-8-1-6

SECTION 3 BODY Group 8 Pump Device

2 6

5 3 WMDF-03-08-008

34. Remove bolts (6) (12 used) and bracket (7). Remove and place pump device (2) on wooden blocks.

30. Disconnect hose (1). j : 41 mm

j : 17 mm

31. Disconnect hose (5).

35. Remove the adapters with pump device (2) attached if necessary.

j : 36 mm 32. Remove clamps (3) (2 used). Disconnect the both ends of hose (4). j : 11 mm Pump device (2) weight: 170 kg (375 dCAUTION: lb) 33. Attach nylon slings onto pump device (2). Hoist and hold pump device (2).

W3-8-1-7

SECTION 3 BODY Group 8 Pump Device

2 3 4 5

12 11

WMDF-03-08-009

7, 8

39. Remove O-ring (5) from HST pump (4).

36. Remove socket bolts (2) (8 used). Remove rubber coupling (1) from engine (13).

40. Remove socket bolt (11). Remove gear coupling (12) from HST pump (4).

l : 8 mm 4-gear pump unit (6) weight: 43 kg (95 dCAUTION: lb) 37. Attach nylon slings onto 4-gear pump unit (6). Hoist and hold 4-gear pump unit (6).

l : 10 mm 41. Remove bolts (9) (6 used) and washers (10) (6 used). Remove pump cover (3) from HST pump (4).

38. Remove bolts (7) (4 used) and washers (8) (4 used). Remove 4-gear pump unit (6) from HST pump (4). j : 19 mm

W3-8-1-8

j : 24 mm

SECTION 3 BODY Group 8 Pump Device

1 2 3

10 9 a-

M16 Tap WMDF-03-08-009

5, 6

Installation IMPORTANT: Install pump cover (1) with M16 tap (a) up. 1. Install pump cover (1) to HST pump (2) with washers (8) (6 used) and bolts (7) (6 used). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

WMDF-03-08-010

IMPORTANT: Check the position to install gear coupling (10). 2. Install gear coupling (10) to HST pump (2) with socket bolt (9).

0±0.5 mm (0±0.02 in)

5. Install 4-gear pump unit (4) with washers (6) (4 used) and bolts (5) (4 used).

l : 10 mm m : 86 N·m (8.6 kgf·m, 63 lbf·ft)

j : 19 mm

3. Install O-ring (3) to HST pump (2). m : 90 N·m (9 kgf·m, 66 lbf·ft)

CAUTION: 4-gear pump unit (4) weight: 43 kg (95 lb) 4. Attach nylon slings onto 4-gear pump unit (4). Hoist 4-gear pump unit (4).

W3-8-1-9

SECTION 3 BODY Group 8 Pump Device

WMDF-03-08-009

IMPORTANT: Check the direction to install rubber coupling (1). 6. Install rubber coupling (1) to engine (3) with socket bolts (2) (8 used).

l : 8 mm m : 49 N·m (4.9 kgf·m, 36 lbf·ft)

W3-8-1-10

HST Pump

WMDF-03-08-011

SECTION 3 BODY Group 8 Pump Device A

View A

2 6 a a-

30°

WMDF-03-08-012

5 3 4

WMDF-03-08-008

7. Install all removed adapters to pump device (2).

11. Connect hose (5).

Pump device (2) weight: 170 kg (375 dCAUTION: lb)

j : 36 mm

8. Attach nylon slings onto pump device (2). Hoist pump device (2). 9. Install pump device (2) and bracket (7) with bolts (6) (12 used).

m : 180 N·m (18 kgf·m, 133 lbf·ft) IMPORTANT: Check the angle to install hose (1). 12. Connect hose (1).

j : 17 mm

j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft) 10. Connect the both ends of hose (4) with clamps (3) (2 used). j : 11 mm m : 9.8 N·m (1 kgf·m, 7.2 lbf·ft)

W3-8-1-11

SECTION 3 BODY Group 8 Pump Device

1 6 18 2

15, 16, 17

10, 11, 12

3, 4, 5

WMDF-03-08-007

WMDF-03-08-006

View A

IMPORTANT: Check the angle to install hoses (13, 14). 13. Install O-rings (12, 17). Connect hoses (13, 14) with flanges (11, 16) (2 used for each), and bolts (10, 15) (4 used for each).

13 b a

j : 14 mm m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft) 14. Connect hose (18).

WMDF-03-08-013

14 a-

20°

35°

j : 27 mm 17. Connect hoses (2) (2 used). m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 27 mm

15. Connect hose (9).

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 16. Connect hose (7) with clamp (8).

18. Install O-rings (5) (4 used). Connect hoses (6) (4 used) with flanges (4) (8 used) and socket bolts (3) (16 used).

j : 9.5 mm

j : 10 mm

m : 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft) 19. Connect connector (1).

W3-8-1-12

SECTION 3 BODY Group 8 Pump Device

Detail A

5, 6 1 a-

Mark

4-Gear Pump Unit

WMDF-03-08-014

View B

c B

20. Temporarily install the suction pipe (2) assembly and O-ring (6) with socket bolts (5) (4 used) and clamp (1). 21. Tighten socket bolts (5) (4 used).

7 c-

45°

WMDF-03-08-016

WMDF-03-08-015

IMPORTANT: Connect hose (4) with mark (a) facing to the left side of body. 23. Connect the both ends of hose (4) with clamps (3) (2 used).

l : 10 mm

j : 9.5 mm

m : 105 N·m (10.5 kgf·m, 77 lbf·ft)

m : 7.2 N·m (0.7 kgf·m, 5.3 lbf·ft)

22. Tighten clamp (1). j : 11 mm

IMPORTANT: Check the angle to install hose (7). 24. Connect hoses (7, 8). j : 36 mm

m : 9.8 N·m (1 kgf·m, 7.2 lbf·ft)

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W3-8-1-13

SECTION 3 BODY Group 8 Pump Device

3 4

2 5, 6, 7

8, 9

WMDF-03-08-004

The support (3) assembly weight: 62 dCAUTION: kg (140 lb)

WMDF-03-08-003

29. Install clips (7) (2 used) with bolts, washers (5) (2 used) and nuts (6) (2 used).

25. Install the support (3) assembly. (Refer to W3-4-2.)

j : 17 mm

26. Install the harnesses to all clips of support (3).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

27. Connect connectors (4) (6 used).

30. Install cover (2) with bolts, washers (1) (4 used).

28. Install clips (9) (2 used) with bolts, washers (8) (2 used).

j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-8-1-14

SECTION 3 BODY Group 8 Pump Device 5

6, 7

2 1

WMDF-03-08-002

The cover (5) assembly weight: 53 kg dCAUTION: (120 lb)

WMDF-03-08-001

35. Install the muffler filter (4) assembly. (Refer to W317-1.) 36. Install the air cleaner (3) assembly. (Refer to W3-4-3.)

31. Install the cover (5) assembly. (Refer to W3-4-2.)

37. Install covers (1, 2). (Refer to W3-4-2.)

32. Install the harnesses to all clips of cover (5). 33. Install brackets (8) at right and left sides. (Refer to W3-4-2.) 34. Install clips (7) (3 used) with bolts, washers (6) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-8-1-15

SECTION 3 BODY Group 8 Pump Device 1

5 6 4

WMDF-03-02-007

WMDF-03-06-012

38. Add hydraulic oil to hydraulic oil tank (4) through the cover (3) mounting part.

fNOTE: Total oil amount of hydraulic oil tank (4): 115 L 39. Install O-ring (1) and cover (3) with bolts, washers (2) (4 used). j : 10 mm

41. Install cab (6). (Refer to W3-1-1.) 42. Bleed air from the transmission charge pump. (Refer to W1-4-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 43. Install side covers (5) at right and left sides. (Refer to W3-4-2.)

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 40. Bleed air from the HST pump. (Refer to W1-4-1.)

W3-8-1-16

SECTION 3 BODY Group 8 Pump Device Disassembly of HST Pump C A

WMDF-03-08-032 D

Section A-A

11 2

10 4

6 WMDF-03-08-033

W3-8-2-1

SECTION 3 BODY Group 8 Pump Device Section B-B

16 17

WMDF-03-08-034

View C

WMDF-03-08-035

W3-8-2-2

SECTION 3 BODY Group 8 Pump Device Section D

20 21

22 23 24

25 b

c 24 28

23 22 27

Section E

WMDF-03-08-036

Detail of Shuttle Valve (b)

33 WMDF-03-08-038

WMDF-03-08-037

123456789-

Gasket Gear Pump Flange Drive Shaft O-Ring O-Ring Plate Kant Seal O-Ring

101112131415-

Retaining Ring Shaft Seal Flange Pump Case Gasket Forward / Reverse Control Solenoid Valve 16- Socket Bolt (4 Used) 17- Socket Bolt (8 Used)

18- Pump Displacement Angle Control Solenoid Valve 19- Socket Bolt (6 Used) 20- Screw (2 Used) 21- O-Ring (2 Used) 22- O-Ring (2 Used) 23- Spring (2 Used) 24- Valve (2 Used) 25- Bolt

2627282930313233-

Valve O-Ring Spring O-Ring Screw O-Ring Piston Sleeve

High-Pressure Relief Valve (2 Used)

Cutoff Valve

Shuttle Valve

Low-Pressure Relief Valve

W3-8-2-3

SECTION 3 BODY Group 8 Pump Device Disassembly of HST Pump

dCAUTION: HST pump weight: 94 kg (210 lb)

IMPORTANT: Do not disassemble the parts other than instructed ones. If the setting changes, the machine troubles may occur. 1. Remove socket bolts (19) (6 used). Remove pump displacement angle control solenoid valve (18) and gasket (1) from pump case (13).

IMPORTANT: If valve (26) has been replaced with the new one, the setting changes and the machine troubles occur. 11. Remove valve (26) and spring (28) from pump case (13). Remove O-ring (27) from valve (26). j : 27 mm 12. Remove bolt (25) from pump case (13). j : 19 mm

l : 5 mm 2. Remove socket bolts (16) (4 used). Remove forward / reverse control solenoid valve (15) and gasket (14) from pump case (13).

13. Remove screw (30), piston (32), and sleeve (33) from pump case (13). l : 8 mm 14. Remove O-rings (29, 31) from screw (30).

l : 5 mm 3. Remove socket bolts (17) (8 used). Remove flange (3) and plate (7) from pump case (13). l : 8 mm 4. Remove O-ring (5) from flange (3). 5. Remove O-ring (6) from plate (7). 6. Remove kant seal (8) and O-ring (9) from pump case (13). 7. Remove gear pump (2) from drive shaft (4). 8. Remove retaining ring (10) from flange (12). 9. Remove shaft seal (11) from flange (12) by using the special tool (Rexroth tool No.: R902733342). IMPORTANT: If valves (24) (2 used) have been replaced with the new ones, the setting changes and the machine troubles occur. 10. Remove screws (20) (2 used), springs (23) (2 used), and valves (24) (2 used) from pump case (13). Remove O-rings (21, 22) (2 used for each) from screws (20) (2 used). j : 24 mm

W3-8-2-4

SECTION 3 BODY Group 8 Pump Device Assembly of HST Pump C A

WMDF-03-08-032 D

Section A-A

11 2

10 4

6 WMDF-03-08-033

W3-8-2-5

SECTION 3 BODY Group 8 Pump Device Section B-B

16 17

WMDF-03-08-034

View C

WMDF-03-08-035

W3-8-2-6

SECTION 3 BODY Group 8 Pump Device Section D

20 21

22 23 24

25 b

c 24 28

23 22 27

Section E

WMDF-03-08-036

Detail of Shuttle Valve (b)

33 WMDF-03-08-038

WMDF-03-08-037

123456789-

Gasket Gear Pump Flange Drive Shaft O-Ring O-Ring Plate Kant Seal O-Ring

101112131415-

Retaining Ring Shaft Seal Flange Pump Case Gasket Forward / Reverse Control Solenoid Valve 16- Socket Bolt (4 Used) 17- Socket Bolt (8 Used)

18- Pump Displacement Angle Control Solenoid Valve 19- Socket Bolt (6 Used) 20- Screw (2 Used) 21- O-Ring (2 Used) 22- O-Ring (2 Used) 23- Spring (2 Used) 24- Valve (2 Used) 25- Bolt

2627282930313233-

Valve O-Ring Spring O-Ring Screw O-Ring Piston Sleeve

High-Pressure Relief Valve (2 Used)

Cutoff Valve

Shuttle Valve

Low-Pressure Relief Valve

W3-8-2-7

SECTION 3 BODY Group 8 Pump Device Assembly of HST Pump IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-rings (29, 31), piston (32), and sleeve (33) to screw (30). 2. Install the screw (30) assembly to pump case (13). l : 8 mm m : 50 N·m(5 kgf·m, 37 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: Do not damage shaft seal (11) with the spline part of drive shaft (4). 6. Apply grease onto shaft seal (11). Install shaft seal (11) to flange (12) by using the special tool (Rexroth tool No.: R902730499). 7. Install retaining ring (10) to flange (12).

3. Install bolt (25) to pump case (13).

8. Install gear pump (2) to drive shaft (4).

j : 19 mm

9. Install kant seal (8) and O-ring (9) to pump case (13). m : 5.5 N·m(0.6 kgf·m, 4.1 lbf·ft)

10. Install O-ring (6) to plate (7).

IMPORTANT: If valve (26) has been replaced with the new one, the setting changes and the machine troubles occur. 4. Install O-ring (27) and spring (28) to valve (26). Install the valve (26) assembly to pump case (13).

11. Install O-ring (5) to flange (3). 12. Install flange (3) and plate (7) to pump case (13) with socket bolts (17) (8 used). l : 8 mm

j : 27 mm

m : 54 N·m(5.4 kgf·m, 40 lbf·ft)

m : 90 N·m(9 kgf·m, 66 lbf·ft) IMPORTANT: If valves (24) (2 used) have been replaced with the new ones, the setting changes and the machine troubles occur. 5. Install O-rings (21, 22) (2 used for each), valves (24) (2 used), and springs (23) (2 used) to screws (20) (2 used). Install the screw (20) assemblies (2 used) to pump case (13). j : 24 mm

13. Install gasket (14) and forward / reverse control solenoid valve (15) to pump case (13) with socket bolts (16) (4 used). l : 5 mm m : 11.3 N·m(1.1 kgf·m, 8.3 lbf·ft) 14. Install gasket (1) and pump displacement angle control solenoid valve (18) to pump case (13) with socket bolts (19) (6 used). l : 5 mm

m : 250 N·m(25 kgf·m, 185 lbf·ft)

m : 16.5 N·m(1.7 kgf·m, 12 lbf·ft)

W3-8-2-8

SECTION 3 BODY Group 8 Pump Device Disassembly of 4-Gear Pump Unit

Section A-A D

WMDF-03-08-017

W3-8-3-1

SECTION 3 BODY Group 8 Pump Device View B

Section C-C

WMDF-03-08-019

WMDF-03-08-018

Detail E

Detail D

WMDF-03-08-020

WMDF-03-08-021 0102030405060708091011121314-

Flange Cover Body Body Cover Body Gear Gear Gear Gear Gear Gear Spacer Spacer

1516171819202122232425262728-

Washer (4 Used) Stud Bolt (4 Used) Nut (4 Used) Washer (4 Used) Bolt (4 Used) Socket Bolt (2 Used) Seal Retaining Ring Plate (2 Used) Seal (2 Used) Seal (2 Used) Plate (2 Used) Seal (2 Used) Seal (2 Used)

2930323334353637383940414243-

Seal Knock Pin (2 Used) Body Plug O-Ring (5 Used) Seal Shaft Shaft Shaft Dowel Pin (8 Used) Dowel Pin (3 Used) Washer (4 Used) Bolt (4 Used) Bushing (4 Used)

44454647484950515253545556-

Seal (4 Used) Seal (4 Used) Seal (4 Used) Bushing (4 Used) Bushing (4 Used) Housing Housing Gear Gear Seal (2 Used) Retaining Ring O-Ring Seal

Steering Pump

Main Pump

Pilot Pump

Transmission Charge Pump

W3-8-3-2

SECTION 3 BODY Group 8 Pump Device Disassembly of 4-Gear Pump Unit 4-gear pump unit weight: 43 kg (95 dCAUTION: lb) IMPORTANT: When securing the 4-gear pump unit, do not fasten port part (a). 1. Attach nylon slings onto the 4-gear pump unit. Hoist the 4-gear pump unit. Secure the 4-gear pump unit in vise (b) by using wooden pieces (c) with flange (01) down.

 Disassembly of Transmission Charge Pump (d) IMPORTANT: Cover (02), body (32), housings (50, 49), body (06), and spacer (14) are secured to spacer (13) by bolts (42) (4 used). Prevent the parts from carelessly disassembling. IMPORTANT: Do not damage the mating surfaces of cover (02) and body (32) when removing cover (02). 3. Remove bolts (42) (4 used) and washers (41) (4 used). Remove cover (02) from body (32). j : 17 mm 4. Remove seal (46) from body (32). IMPORTANT: Do not damage the mating surfaces of body (32) and housing (50) when removing body (32). IMPORTANT: Do not remove dowel pins (39) (2 used). 5. Remove body (32) from housing (50). 6. Remove seal (46) from body (32).

IMPORTANT: If bushings (43) (2 used) are not installed to the original position, the pump may be damaged. 7. Put the matching marks on bushings (43) (2 used). Remove bushings (43) at the cover (02) side from gears (51, 52).

45 e

32 c

WMDF-03-08-022 a-

Port Part

Vise

Wooden Pieces

2. Put the matching marks on cover (02), body (32), housings (50, 49), body (06), spacers (14, 13), cover (05), bodies (04, 03), and flange (01).

44 45

52 f e-

W3-8-3-3

WMDF-03-08-023 Cover (02) Side

Housing (50) Side

SECTION 3 BODY Group 8 Pump Device 8. Remove seals (44, 45) from bushing (43). IMPORTANT: If the meshed position of gears (51, 52) changes, volumetric efficiency of the pump may be decreased. IMPORTANT: Do not remove gears (51, 52) by hitting them. 9. Put the matching marks on gears (51, 52). Remove gears (51, 52) from bushing (43) at the housing (50) side. 10. Remove bushing (43) from housing (50). 11. Remove seals (44, 45) from bushing (43). IMPORTANT: Do not damage the mating surfaces of housings (50, 49) when removing housing (50). 12. Remove housing (50) and shaft (38) from housing (49). 13. Remove O-ring (55) from housing (50). IMPORTANT: Do not damage the mounting surfaces of seals (53) (2 used) when removing seals (53) (2 used). 14. Remove seals (53) (2 used) and retaining ring (54) from housing (50).

W3-8-3-4

SECTION 3 BODY Group 8 Pump Device  Disassembly of Pilot Pump (c) IMPORTANT: Do not damage the mating surfaces of housings (49) and body (06) when removing housing (49). IMPORTANT: Do not remove dowel pins (39) (2 used). 15. Remove housing (49) from body (06). 16. Remove seal (46) from body (06). IMPORTANT: Do not damage the mating surfaces of body (06) and spacer (14) when removing body (06). IMPORTANT: Do not remove dowel pins (39, 40). 17. Remove body (06) from spacer (14). 18. Remove seal (46) from body (06). IMPORTANT: If bushings (43) (2 used) are not installed to the original position, the pump may be damaged. 19. Put the matching marks on bushings (43) (2 used). Remove bushings (43) at the housing (49) side from gears (11, 12).

IMPORTANT: If the meshed position of gears (11, 12) changes, volumetric efficiency of the pump may be decreased. IMPORTANT: Do not remove gears (11, 12) by hitting them. 21. Put the matching marks on gears (11, 12). Remove gears (11, 12) from bushing (43) at the spacer (14) side. 22. Remove bushing (43) from spacer (14). 23. Remove seals (44, 45) from bushing (43). IMPORTANT: Do not damage the mating surfaces of spacers (14, 13) when removing spacer (14). IMPORTANT: Do not remove dowel pins (39) (3 used). 24. Remove spacer (14) and shaft (37) from spacer (13). 25. Remove O-ring (34) from spacer (13). IMPORTANT: Do not damage the mating surfaces of spacer (13) and cover (05) when removing spacer (13). IMPORTANT: Do not remove dowel pins (40) (2 used). 26. Remove socket bolts (20) (2 used). Remove spacer (13) from cover (05).

l : 8 mm a

27. Remove O-ring (34) from cover (05).

11 43 44 45

12 b

WMDF-03-08-023

Housing (49) Side

Spacer (14) Side

20. Remove seals (44, 45) from bushing (43).

W3-8-3-5

SECTION 3 BODY Group 8 Pump Device  Disassembly of Main Pump (b) IMPORTANT: Cover (05) and body (04) are secured to body (03) by bolts (19) (4 used). Prevent the parts from carelessly disassembling. IMPORTANT: Do not damage the mating surfaces of cover (05) and body (04) when removing cover (05). 28. Remove bolts (19) (4 used) and washers (18) (4 used). Remove cover (05) from body (04). j : 19 mm surfaces of body (04) and cover (05). 29. Remove seal (35) from body (04).

IMPORTANT: Do not damage the mating surfaces of body (04, 03) when removing body (04). IMPORTANT: Do not remove knock pins (30) (2 used) and bushings (48) (4 used). 35. Remove body (04) and shaft (36) from body (03).

IMPORTANT: If plates (23) (2 used) are not installed to the original position, the pump may be damaged. 30. Put the matching marks on plate (23) at the cover (05) side. Remove plates (23) at the cover (05) side from gears (09, 10).

33. Put the matching marks on plate (23) at the body (03) side. Remove plate (23) at the body (03) side from body (04). 34. Remove seals (24, 25) from plate (23).

fNOTE: LOCTITE #518 has been applied on the mating

IMPORTANT: If the meshed position of gears (09, 10) changes, volumetric efficiency of the pump may be decreased. IMPORTANT: Do not remove gears (09, 10) by hitting them. 32. Put the matching marks on gears (09, 10). Remove gears (09, 10) from plate (23) at the body (03) side.

36. Remove O-rings (34) (3 used) from body (04).

25 a

09 23 24 25 04

WMDF-03-08-024

Cover (05) Side

Body (03) Side

31. Remove seals (24, 25) from plate (23).

W3-8-3-6

SECTION 3 BODY Group 8 Pump Device  Disassembly of Steering Pump (a) IMPORTANT: When securing steering pump (a), do not fasten the port part. 37. Turn over steering pump (a). Secure steering pump (a) in a vise by using wooden pieces with flange (01) up. IMPORTANT: Do not damage the mating surfaces of flange (01) and body (03) when removing flange (01). IMPORTANT: Do not remove stud bolts (16) (4 used) and plug (33). 38. Remove nuts (17) (4 used) and washers (15) (4 used). Remove flange (01) from body (03). j : 22 mm

41. Remove seals (27, 28) from plate (26). IMPORTANT: If the meshed position of gears (07, 08) changes, volumetric efficiency of the pump may be decreased. IMPORTANT: Do not remove gears (07, 08) by hitting them. 42. Put the matching marks on gears (07, 08). Remove gears (07, 08) from plate (26) at the body (04) side. 43. Put the matching marks on plate (26) at the body (04) side. Remove plate (26) at the body (04) side from body (03). IMPORTANT: Do not remove bushings (47) (4 used). 44. Remove seals (27, 28) from plate (26). IMPORTANT: Do not damage the mounting surfaces of seals (21, 56) when removing seals (21, 56). 45. Remove seals (21, 56) and retaining ring (22) from flange (01).

fNOTE: LOCTITE #518 has been applied on the mating surfaces of body (03) and flange (01). 39. Remove seal (29) from flange (01).

IMPORTANT: If plates (26) (2 used) are not installed to the original position, the pump may be damaged. 40. Put the matching marks on plate (26) at the flange (01) side. Remove plates (26) at the flange (01) side from gears (07, 08).

03 b

07 26 27 28

08 c b-

WMDF-03-08-025 Body (04) Side

Flange (01) Side

W3-8-3-7

SECTION 3 BODY Group 8 Pump Device Assembly of 4-Gear Pump Unit

Section A-A D

WMDF-03-08-017

W3-8-3-8

SECTION 3 BODY Group 8 Pump Device View B

Section C-C

WMDF-03-08-019

WMDF-03-08-018

Detail E

Detail D

WMDF-03-08-020

WMDF-03-08-021 0102030405060708091011121314-

Flange Cover Body Body Cover Body Gear Gear Gear Gear Gear Gear Spacer Spacer

1516171819202122232425262728-

2930323334353637383940414243-

Seal Knock Pin (2 Used) Body Plug O-Ring (5 Used) Seal Shaft Shaft Shaft Dowel Pin (8 Used) Dowel Pin (3 Used) Washer (4 Used) Bolt (4 Used) Bushing (4 Used)

44454647484950515253545556-

Seal (4 Used) Seal (4 Used) Seal (4 Used) Bushing (4 Used) Bushing (4 Used) Housing Housing Gear Gear Seal (2 Used) Retaining Ring O-Ring Seal

Steering Pump

Main Pump

Pilot Pump

Transmission Charge Pump

W3-8-3-9

SECTION 3 BODY Group 8 Pump Device Assembly of 4-Gear Pump Unit IMPORTANT: Fit the matching marks made when disassembling and correctly assemble cover (02), body (32), housings (50, 49), body (06), spacers (14, 13), cover (05), bodies (04, 03), and flange (01).  Assembly of Steering Pump (a) IMPORTANT: Before assembling, apply hydraulic oil to parts in order to prevent them from seizing. IMPORTANT: Check the direction to install seal (21). 1. Apply grease to the lip part of seal (21). Install seal (21) to flange (01) by using the special tool (ST 7028) and a press. Install retaining ring (22) to flange (01).

IMPORTANT: When securing body (03), do not fasten port part (c). 3. Secure body (03) in vise (d) by using wooden pieces (e) with flange (01) up. c

03 56

WMDF-03-08-027

01 c-

WMDF-03-08-026 b-

Body (03) Side

IMPORTANT: Check the direction to install seal (56). 2. Apply grease to the lip part of seal (56). Install seal (56) to flange (01) by using the special tool (ST 7028) and a press.

W3-8-3-10

Port Part

Vise

Wooden Pieces

SECTION 3 BODY Group 8 Pump Device IMPORTANT: Check the positions to install plates (26) (2 used) and seals (27, 28). 4. Apply grease to seals (27, 28). Install seal (27) to plate (26) which was installed at the body (04) side. Install seal (28) to seal (27). 03 a

IMPORTANT: If the meshed position of gears (07, 08) changes, volumetric efficiency of the pump may be decreased. IMPORTANT: Do not damage seals (21, 56) with the spline part of gear (07). 6. Install the special tool (ST 7014) to the spline part of gear (07). Install gears (07, 08) to plate (26). At this time, fit the meshed position of gears (07, 08) to the matching marks made when disassembling. 7. Install seals (27, 28) to plate (26) which was installed at the flange (01) side in the same way as step 4.

8. Fit the matching marks made when disassembling and install plate (26) to gears (07, 08).

9. Apply grease to seal (29). Install seal (29) to flange (01).

27 28

08 b a-

WMDF-03-08-025 Body (04) Side

Flange (01) Side

IMPORTANT: Do not drop seal (29) from flange (01). 10. Apply LOCTITE #518 to the circumference on the flange (01) mating surface of body (03). Install flange (01) to body (03) with nuts (17) (4 used) and washers (15) (4 used). Remove the special tool (ST 7014) from gear (07). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)

View A 26

28 01 29 c

WMDF-03-08-028

WMDF-03-08-029

IMPORTANT: Do not drop seals (27, 28) from plate (26). 5. Fit the matching marks made when disassembling and install plate (26) to body (03).

W3-8-3-11

Mating Surface

SECTION 3 BODY Group 8 Pump Device  Assembly of Main Pump (b) IMPORTANT: Before assembling, apply hydraulic oil to parts in order to prevent them from seizing. IMPORTANT: When securing steering pump (a), do not fasten the port part. 11. Turn over steering pump (a). Secure steering pump (a) in a vise by using wooden pieces with flange (01) down.

View A 23

12. Install shaft (36) to gear (07).

13. Apply grease to O-rings (34) (3 used). Install O-rings (34) (3 used) to body (04).

WMDF-03-08-028

IMPORTANT: Do not drop seals (24, 25) from plate (23). 16. Fit the matching marks made when disassembling and install plate (23) to body (04).

IMPORTANT: Do not drop O-rings (34) (3 used) from body (04). 14. Install body (04) to body (03).

IMPORTANT: If the meshed position of gears (09, 10) changes, volumetric efficiency of the pump may be decreased. 17. Install gears (09, 10) to plate (23). At this time, fit the meshed position of gears (09, 10) to the matching marks made when disassembling.

IMPORTANT: Check the positions to install plates (23) (2 used) and seals (24, 25). 15. Apply grease to seals (24, 25). Install seal (24) to plate (23) which was installed at the body (03) side. Install seal (25) to seal (24).

18. Install seals (24, 25) to plate (23) which was installed at the cover (05) side in the same way as step 15.

19. Fit the matching marks made when disassembling and install plates (23) to gears (09, 10).

25 a

09 23 24 25 04

WMDF-03-08-024 a-

Cover (05) Side

Body (03) Side

W3-8-3-12

SECTION 3 BODY Group 8 Pump Device 20. Apply grease to seal (35). Install seal (35) to cover (05). IMPORTANT: Do not drop seal (35) from cover (05). 21. Apply LOCTITE #518 to the circumference on the cover (05) mating surface of body (04). Install cover (05) to body (04). 05

35 a

04 WMDF-03-08-030 a-

Mating Surface

22. Secure cover (05) and body (04) with bolts (19) (4 used) and washers (18) (4 used). j : 19 mm m : 48±4 N·m (4.8±0.4 kgf·m, 35±3 lbf·ft) 23. Install O-ring (34) to cover (05). 24. Install spacer (13) to cover (05) with socket bolts (20) (2 used). l : 8 mm m : 40±4 N·m (4±0.4 kgf·m, 29.5±3 lbf·ft) 25. Install shaft (37) to gear (09). 26. Install O-ring (34) to spacer (13). 27. Install spacer (14) to spacer (13).

W3-8-3-13

SECTION 3 BODY Group 8 Pump Device  Assembly of Pilot Pump (c) IMPORTANT: Before assembling, apply hydraulic oil to parts in order to prevent them from seizing. IMPORTANT: Check the positions to install bushings (43) (2 used) and seals (44, 45). 28. Apply grease to seals (44, 45). Install seal (44) to bushing (43) which was installed at the spacer (14) side. Install seal (45) to seal (44).

31. Apply grease to seal (46). Install seal (46) to body (06). IMPORTANT: Do not drop seal (46) from body (06). 32. Install body (06) to spacer (14).

45 a

IMPORTANT: If the meshed position of gears (11, 12) changes, volumetric efficiency of the pump may be decreased. 30. Install gears (11, 12) to bushing (43). At this time, fit the meshed position of gears (11, 12) to the matching marks made when disassembling.

33. Install seals (44, 45) to bushing (43) which was installed at the housing (49) side in the same way as step 28. 34. Fit the matching marks made when disassembling and install bushings (43) to gears (11, 12).

35. Install seal (46) to body (06).

44 45

36. Install housing (49) to body (06). 37. Install shaft (38) to gear (11). 12

b WMDF-03-08-023 a-

Housing (49) Side

Spacer (14) Side

View A 43

WMDF-03-08-028

IMPORTANT: Do not drop seals (44, 45) from bushing (43). 29. Fit the matching marks made when disassembling and place bushing (43) onto spacer (14).

W3-8-3-14

SECTION 3 BODY Group 8 Pump Device  Assembly of Transmission Charge Pump (d) IMPORTANT: Before assembling, apply transmission oil to parts in order to prevent them from seizing. IMPORTANT: Check the direction to install seal (53). 38. Apply grease to the lip part of seal (53). Install seal (53) at the body (32) side to housing (50) by using the special tool (ST 7029) and a press. Install retaining ring (54) to housing (50).

IMPORTANT: Check the positions to install bushings (43) (2 used) and seals (44, 45). 40. Apply grease to seals (44, 45). Install seal (44) to bushing (43) which was installed at the housing (50) side. Install seal (45) to seal (44).

45 c

32 53

50 51 43

44 45

WMDF-03-08-031 a-

Body (32) Side

Housing (49) Side

WMDF-03-08-023 c-

Cover (02) Side

IMPORTANT: Check the direction to install seal (53). 39. Apply grease to the lip part of seal (53). Install seal (53) at the housing (49) side to housing (50) by using the special tool (ST 7029) and a press.

Housing (50) Side

View A 43

W3-8-3-15

WMDF-03-08-028

SECTION 3 BODY Group 8 Pump Device IMPORTANT: Do not drop seals (44, 45) from bushing (43). 41. Fit the matching marks made when disassembling and place bushing (43) onto housing (50). IMPORTANT: If the meshed position of gears (51, 52) changes, volumetric efficiency of the pump may be decreased. 42. Install gears (51, 52) to bushing (43). At this time, fit the meshed position of gears (51, 52) to the matching marks made when disassembling. 43. Apply grease to seal (46). Install seal (46) to the housing (50) side of body (32). IMPORTANT: Do not drop seal (46) from body (32). 44. Install body (32) to housing (50). 45. Install seals (44, 45) to bushing (43) which was installed at the cover (02) side in the same way as step 40. 46. Fit the matching marks made when disassembling and install bushings (43) to gears (51, 52). 47. Install seal (46) to body (32). 48. Install cover (02) to body (32). 49. Secure cover (02), body (32), housings (50, 49), body (06), and spacer (14) with bolts (42) (4 used) and washers (41) (4 used). j : 17 mm m : 49 N·m (4.9 kgf·m, 36 lbf·ft)

W3-8-3-16

SECTION 3 BODY Group 9 Control Valve Removal and Installation of Control Valve 1

3 6

2 4

WMDF-03-09-005

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

WMDF-03-09-001

4. Disconnect the both ends of hoses (4, 5). j : 41 mm 5. Disconnect hose (3) (only the machine with the ride control device).

1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.) 2. Remove bolts, washers (1) (4 used). Remove cover (2). j : 19 mm 3. Disconnect hose (6) (only the machine with the ride control device). j : 41 mm

W3-9-1-1

j : 41 mm

SECTION 3 BODY Group 9 Control Valve

WMDF-03-09-002

6. Disconnect connector (2). 7. Disconnect hoses (1) (4 used). j : 19 mm 8. Disconnect hoses (5) (2 used). j : 36 mm 9. Disconnect hose (4). j : 41 mm 10. Disconnect hose (3). j : 50 mm

W3-9-1-2

WMDF-03-09-003

SECTION 3 BODY Group 9 Control Valve View A A

5, 6

WMDF-03-09-006 a-

Eyebolt Mounting Hole

WMDF-03-09-004

15. Remove socket bolts (5) (3 used) and washers (6) (3 used). Remove control valve (4).

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

l : 10 mm

12. Disconnect hoses (2) (2 used).

16. Remove the adapters with control valve (4) attached if necessary.

j : 19 mm 13. Disconnect hose (3). j : 17 mm

dCAUTION: Control valve (4) weight: 73 kg (165 lb) 14. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to eyebolt mounting holes (a) (2 places) of control valve (4). Attach the nylon slings onto the eyebolts (2 used). Hoist and hold control valve (4).

W3-9-1-3

SECTION 3 BODY Group 9 Control Valve View A

B A

5, 6

WMDF-03-09-006 a-

Eyebolt Mounting Hole

WMDF-03-09-004

View B

Installation

1. Install all removed adapters to control valve (4).

dCAUTION: Control valve (4) weight: 73 kg (165 lb) 2. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to eyebolt mounting holes (a) (2 places) of control valve (4). Attach the nylon slings onto the eyebolts (2 used). Hoist control valve (4).

3. Install control valve (4) with washers (6) (3 used) and socket bolts (5) (3 used). 1

l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

60°

WMDF-03-09-007

4. Connect hose (3). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

IMPORTANT: Check the angle to install hose (1). 6. Connect hose (1).

5. Connect hoses (2) (2 used). j : 27 mm

j : 19 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-9-1-4

SECTION 3 BODY Group 9 Control Valve A

3 2

WMDF-03-09-003

WMDF-03-09-002

1 View A

IMPORTANT: Check the angle to install hose (3). 7. Connect hose (3).

j : 50 mm m : 350 N·m (35 kgf·m, 260 lbf·ft) IMPORTANT: Check the angle to install hose (4). 8. Connect hose (4). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 9. Connect hoses (5) (2 used). j : 36 mm

WMDF-03-09-008

b a-

m : 180 N·m (18 kgf·m, 133 lbf·ft) 10. Connect hoses (1) (4 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 11. Connect connector (2).

W3-9-1-5

40°

10°

SECTION 3 BODY Group 9 Control Valve B

View A

1 4

2 c

ab-

Control Valve 15°

View B

WMDF-03-09-009

b c-

10°

3 WMDF-03-09-001

12. Connect hose (1) (only the machine with the ride control device). j : 41 mm d-

m : 210 N·m (21 kgf·m, 155 lbf·ft)

5°

WMDF-03-09-010

IMPORTANT: Check the angle to install hoses (2, 3). 13. Connect the both ends of hoses (2, 3). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 14. Connect hose (4) (only the machine with the ride control device). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 15. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

16. 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. 17. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.)

W3-9-1-6

SECTION 3 BODY Group 9 Control Valve

1 a

155 mm (6.1 in)

210 mm (8.3 in)

WMDF-03-09-005

IMPORTANT: Check the direction to install cover (2). 18. Install cover (2) with bolts, washers (1) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

fNOTE: Turn cover (2) by 180 degrees and install it in case of the machine with the quick coupler.

W3-9-1-7

SECTION 3 BODY Group 9 Control Valve (Blank)

W3-9-1-8

SECTION 3 BODY Group 9 Control Valve Disassembly of Control Valve

e f g

j b

m l

WMDF-03-09-011

W3-9-2-1

SECTION 3 BODY Group 9 Control Valve 0104050607080910111214151617192122-

Housing Spool Spool Bolt (2 Used) Spring Collar (6 Used) Spring (2 Used) O-Ring (7 Used) Pilot Housing (2 Used) Bolt Spring Pilot Housing Socket Bolt (13 Used) Socket Bolt (2 Used) Pilot Housing (3 Used) Pilot Housing Poppet (2 Used) Poppet (2 Used)

23- Spring (3 Used) 24- Plug (2 Used) 25- O-Ring (4 Used) 27- Plug 28- O-Ring (2 Used) 29A- Plug 29B- O-Ring 29C- Backup Ring 29D- O-Ring 30- Relief Valve 30A- O-Ring 31- Poppet 32- Spring 33- O-Ring 34- Backup Ring 36- Relief Valve 36A- O-Ring

38- Relief Valve 38A- O-Ring 39- Relief Valve 39A- O-Ring 45- Poppet 46- Spring 47- Plug 50- Relief Valve 50A- O-Ring 50B- Backup Ring 50C- O-Ring 53- Plug (2 Used) 53A- O-Ring (2 Used) 56- Housing 57- Spool 58- End Plate 61- Plug

61A- O-Ring 65- O-Ring (2 Used) 66- O-Ring (2 Used) 68- Socket Bolt (4 Used) 74- Plug (2 Used) 74A- O-Ring (2 Used) 75- Plug (2 Used) 75A- O-Ring (2 Used) 76- Plug 76A- O-Ring 77- Plug 77A- O-Ring 79- Plug 79A- O-Ring 90- Plug 91- Poppet

ab-

Main Relief Valve Make-Up Valve (Lift Arm: Rod Side) Load Check Valve (Lift Arm Circuit) Load Check Valve (Bucket Circuit)

cd-

fghi-

Check Valve (Bucket Flow Rate Control Valve) Low-Pressure Relief Valve Lift Arm Spool Bucket Spool Overload Relief Valve (Lift Arm: Bottom Side)

Overload Relief Valve (Bucket: Bottom Side) k- Overload Relief Valve (Bucket: Rod Side) lMuffler Filter Regeneration/ Quick Coupler Spool m- Neutral Circuit

W3-9-2-2

op-

Load Check Valve (Muffler Filter Regeneration/Quick Coupler) Overload Relief Valve (Quick Coupler Circuit) Orifice (Muffler Filter Regeneration)

SECTION 3 BODY Group 9 Control Valve Disassembly of Control Valve 1. Remove plug (77) from housing (01). Remove O-ring (77A) from plug (77).

6. Remove socket bolts (15) (10 used) from pilot housings (17) (3 used) and pilot housings (10) (2 used). Remove pilot housings (17) (3 used) and pilot housings (10) (2 used) from housing (01).

l : 17 mm

l : 8 mm

 Disassembly of Low-Pressure Relief Valve (f ) 2. Remove plug (47) from housing (01). Remove spring (46) and poppet (45) from housing (01). Remove O-ring (25) from plug (47). j : 36 mm  Disassembly of Overload Relief Valve (Bucket: Rod Side) (k) 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 (30) from housing (01). Remove O-ring (30A) from relief valve (30). j : 32 mm  Disassembly of Overload Relief Valve (Quick Coupler Circuit) (o) 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. 4. Remove relief valve (36) from housing (56). Remove O-ring (36A) from relief valve (36).

7. Remove O-rings (09) (5 used) from pilot housings (17) (3 used) and pilot housings (10) (2 used). 8. Remove socket bolts (16) (2 used) from pilot housing (14). Remove pilot housing (14) from pilot housing (19). l : 8 mm 9. Remove O-ring (09) from pilot housing (14). 10. Put the matching marks on the spools (04, 05) assemblies and housing (01). Remove the spools (04, 05) assemblies from housing (01). 11. Put the matching marks on the spool (57) assembly and housing (56). Remove the spool (57) assembly from housing (56).  Disassembly of Bucket Spool (h) 12. Secure the spool (04) assembly in a vise by using wooden pieces as illustrated. Remove bolt (06), spring seats (07) (2 used), and spring (08) from spool (04). j : 19 mm

j : 32 mm  Disassembly of Orifice (Muffler Filter Regeneration) (p) 5. Remove plug (29A) from housing (56). Remove O-rings (29B, 29D) and backup ring (29C) from plug (29A). j : 24 mm

W3-9-2-3

W4GB-02-05-002

SECTION 3 BODY Group 9 Control Valve  Disassembly of Lift Arm Spool (g) 13. Secure the spool (05) assembly in a vise by using wooden pieces as illustrated. Remove bolt (11), O-ring (28), spring seats (07) (2 used), and spring (12) from spool (05).

 Disassembly of Make-Up Valve (Lift Arm: Rod Side) (b) 16. Remove socket bolts (15) (3 used) from pilot housing (19). Remove pilot housing (19) from housing (01).

j : 19 mm

l : 8 mm 17. Remove backup ring (34) and O-rings (09, 33) from pilot housing (19). 18. Remove spring (32) and poppet (31) from housing (01).

W4GB-02-05-002

14. Remove plug (27) from spool (05). Remove O-ring (28) from plug (27). j : 8 mm  Disassembly of Muffler Filter Regeneration/Quick Coupler Spool (l) 15. Secure the spool (57) assembly in a vise by using wooden pieces as illustrated. Remove bolt (06), spring seats (07) (2 used), and spring (08) from spool (57). j : 19 mm

 Disassembly of Overload Relief Valve (Lift Arm: Bottom Side) (i) and Overload Relief Valve (Bucket: Bottom Side) (j) IMPORTANT: Do not disassemble the overload relief valve. 19. Remove relief valves (38, 39) from housing (01). Remove O-rings (38A, 39A) from relief valves (38, 39). j : 27 mm  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. 20. Remove main relief valve (50) from housing (01). Remove O-rings (50A, 50C) and backup ring (50B) from main relief valve (50). j : 27 mm

W4GB-02-05-002

W3-9-2-4

SECTION 3 BODY Group 9 Control Valve  Disassembly of Load Check Valve (Bucket Circuit) (d) and Check Valve (Bucket Flow Rate Control Valve) (e) 21. Remove plug (24) from housing (01). Remove spring (23) and poppets (21, 22) from housing (01) by using a magnet. Remove O-ring (25) from plug (24). j : 36 mm  Disassembly of Load Check Valve (Lift Arm Circuit) (c) 22. Remove plug (90) from housing (01). Remove spring (23) and poppet (91) from housing (01) by using a magnet. Remove O-ring (25) from plug (90).

27. Remove plug (76) from housing (56). Remove O-ring (76A) from plug (76). l : 12 mm 28. Remove plug (61) from end plate (58). Remove O-ring (61A) from plug (61). l : 12 mm 29. Remove plugs (74) (2 used) from end plate (58). Remove O-rings (74A) (2 used) from plugs (74) (2 used).

j : 36 mm

l : 8 mm

 Disassembly of Load Check Valves (Muffler Filter Regeneration/ Quick Coupler) (n) and (Neutral Circuit) (m) 23. Remove plug (24) from housing (56). Remove spring (23) and poppets (21, 22) from housing (56) by using a magnet. Remove O-ring (25) from plug (24). j : 36 mm 24. Remove socket bolts (68) (4 used) from end plate (58). Remove housing (56) and end plate (58) from housing (01). Remove O-rings (65, 66) (2 used for each) from housing (56) and end plate (58). l : 10 mm 25. Remove plugs (53, 75) (2 used for each) from housing (01). Remove O-rings (53A, 75A) (2 used for each) from plugs (53, 75) (2 used for each). l : 10 mm 26. Remove plug (79) from housing (56). Remove plug (79). Remove O-ring (79A) from plug (79). j : 36 mm

W3-9-2-5

SECTION 3 BODY Group 9 Control Valve Assembly of Control Valve 75, 75A

16 75, 75A A

15 D E D

WMDF-03-09-012

W3-9-2-6

SECTION 3 BODY Group 9 Control Valve

50A, 50B

Section A

77A

50C

34 31

90 91

WNDB-03-09-010

Section B 32

23 25

b g

27 14

19 07 28

53 53A

39A 39 28

WNDB-03-09-011

Section C 22 24

09 30A

h j

07 04

53A

W3-9-2-7

38A

WNDB-03-09-012

SECTION 3 BODY Group 9 Control Valve

66 Section D

WMDF-03-09-013

Section E

79A

22 24

21 n

76A

36A

29C, 29D m

29B

29A 09

10 07

08 06

WMDF-03-09-014

09 l

Section F 74

74A

61 61A

74A

WMDF-03-09-015

W3-9-2-8

SECTION 3 BODY Group 9 Control Valve 0104050607080910111214151617192122-

ab-

Main Relief Valve Make-Up Valve (Lift Arm: Rod Side) Load Check Valve (Lift Arm Circuit) Load Check Valve (Bucket Circuit)

cd-

fghi-

Check Valve (Bucket Flow Rate Control Valve) Low-Pressure Relief Valve Lift Arm Spool Bucket Spool Overload Relief Valve (Lift Arm: Bottom Side)

Overload Relief Valve (Bucket: Bottom Side) k- Overload Relief Valve (Bucket: Rod Side) lMuffler Filter Regeneration/ Quick Coupler Spool m- Neutral Circuit

W3-9-2-9

op-

Load Check Valve (Muffler Filter Regeneration/Quick Coupler) Overload Relief Valve (Quick Coupler Circuit) Orifice (Muffler Filter Regeneration)

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 (74A) (2 used) to plugs (74) (2 used). Install plugs (74) (2 used) to end plate (58).

 Assembly of Load Check Valves (Muffler Filter Regeneration/Quick Coupler) (n) and (Neutral Circuit) (m) 7. Install poppets (21, 22) and spring (23) to housing (56). Install O-ring (25) to plug (24). Install plug (24) to housing (56).

l : 8 mm

j : 36 mm

m : 69 to 74 N·m (6.9 to 7.4 kgf·m, 51 to 55 lbf·ft)

m : 275 to 304 N·m (27.5 to 30.4 kgf·m, 205 to 225 lbf·ft)

2. Install O-ring (61A) to plug (61). Install plug (61) to end plate (58). l : 12 mm

 Assembly of Load Check Valve (Lift Arm Circuit) (c) 8. Install poppet (91) and spring (23) to housing (01). Install O-ring (25) to plug (90). Install plug (90) to housing (01).

m : 177 to 206 N·m (17.7 to 20.6 kgf·m, 131 to 152 lbf·ft)

j : 36 mm m : 275 to 304 N·m (27.5 to 30.4 kgf·m, 205 to 225 lbf·ft)

3. Install O-ring (76A) to plug (76). Install plug (76) to housing (56). l : 12 mm m : 235 to 264 N·m (23.5 to 26.4 kgf·m, 175 to 195 lbf·ft) 4. Install O-ring (79A) to plug (79). Install plug (79) to housing (56).

 Assembly of Load Check Valve (Bucket Circuit) (d) and Check Valve (Bucket Flow Rate Control Valve) (e) 9. Install poppets (21, 22) and spring (23) to housing (01). Install O-ring (25) to plug (24). Install plug (24) to housing (01).

j : 36 mm

j : 36 mm m : 275 to 304 N·m (27.5 to 30.4 kgf·m, 205 to 225 lbf·ft)

m : 240 to 269 N·m (24 to 26.9 kgf·m, 175 to 200 lbf·ft) 5. Install O-rings (53A, 75A) (2 used for each) to plugs (53, 75) (2 used for each). Install plugs (53, 75) (2 used for each) to housing (01). l : 10 mm m : 118 to 138 N·m (11.8 to 13.8 kgf·m, 87 to 102 lbf·ft) 6. Install O-rings (65, 66) (2 used for each) to housing (56) and end plate (58). Install housing (56) and end plate (58) to housing (01) with socket bolts (68) (4 used). l : 10 mm m : 88 to 93 N·m (8.8 to 9.3 kgf·m, 65 to 69 lbf·ft)

W3-9-2-10

SECTION 3 BODY Group 9 Control Valve  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. 10. Install O-rings (50A, 50C) and backup ring (50B) to main relief valve (50). Install main relief valve (50) to housing (01).

 Assembly of Bucket Spool (h) 14. Secure spool (04) in a vise by using wooden pieces as illustrated. Install spring seats (07) (2 used) and spring (08) to spool (04) with bolt (06). j : 19 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

j : 27 mm m : 177 to 206 N·m (17.7 to 20.6 kgf·m, 131 to 152 lbf·ft)  Assembly of Make-Up Valve (Lift Arm: Rod Side) (b) 11. Install poppet (31) and spring (32) to housing (01). 12. Install O-rings (09, 33) and backup ring (34) to pilot housing (19). Install pilot housing (19) to housing (01) with socket bolts (15) (3 used).

W4GB-02-05-002

l : 8 mm m : 49 to 54 N·m (4.9 to 5.4 kgf·m, 36 to 40 lbf·ft)  Assembly of Muffler Filter Regeneration/Quick Coupler Spool (l) 13. Secure spool (57) in a vise by using wooden pieces as illustrated. Install spring seats (07) (2 used) and spring (08) to spool (57) with bolt (06).

 Assembly of Lift Arm Spool (g) 15. Secure spool (05) in a vise by using wooden pieces as illustrated. Install spring seats (07) (2 used), spring (12), and O-ring (28) to spool (05) with bolt (11). j : 19 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

j : 19 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

W4GB-02-05-002

16. Install O-ring (28) to plug (27). Install plug (27) to spool (05). j : 8 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

W3-9-2-11

SECTION 3 BODY Group 9 Control Valve 17. Fit the matching marks made when disassembling and install the spools (04, 05) assemblies to housing (01). 18. Fit the matching marks made when disassembling and install the spool (57) assembly to housing (56). 19. Install O-ring (09) to pilot housing (14). Install pilot housing (14) to pilot housing (19) with socket bolts (16) (2 used).

 Assembly of Overload Relief Valve (Bucket: Rod Side) (k) 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. 24. Install O-ring (30A) to relief valve (30). Install relief valve (30) to housing (01).

l : 8 mm

j : 32 mm

m : 49 to 54 N·m (4.9 to 5.4 kgf·m, 36 to 40 lbf·ft)

m : 83 to 88 N·m (8.3 to 8.8 kgf·m, 61 to 65 lbf·ft)

20. Install O-rings (09) (2 used) to pilot housings (10) (2 used). Install pilot housings (10) (2 used) to housings (01, 56) with socket bolts (15) (4 used).

 Assembly of Overload Relief Valve (Quick Coupler Circuit) (o) 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. 25. Install O-ring (36A) to relief valve (36). Install relief valve (36) to housing (56).

l : 8 mm m : 49 to 54 N·m (4.9 to 5.4 kgf·m, 36 to 40 lbf·ft) 21. Install O-rings (09) (3 used) to pilot housings (17) (3 used). Install pilot housings (17) (3 used) to housings (01, 56) with socket bolts (15) (6 used). l : 8 mm

j : 32 mm

m : 49 to 54 N·m (4.9 to 5.4 kgf·m, 36 to 40 lbf·ft)

m : 83 to 88 N·m (8.3 to 8.8 kgf·m, 61 to 65 lbf·ft)

 Assembly of Overload Relief Valve (Lift Arm: Bottom Side) (i) and Overload Relief Valve (Bucket: Bottom Side) (j) 22. Install O-rings (38A, 39A) to relief valves (38, 39). Install relief valves (38, 39) to housing (01).

 Assembly of Low-Pressure Relief Valve (f ) 26. Install poppet (45) and spring (46) to housing (01). Install O-ring (25) to plug (47). Install plug (47) to housing (01). j : 36 mm

j : 27 mm m : 235 to 264 N·m (23.5 to 26.4 kgf·m, 175 to 195 lbf·ft)  Assembly of Orifice (Muffler Filter Regeneration) (p) 23. Install O-rings (29B, 29D) and backup ring (29C) to plug (29A). Install plug (29A) to housing (56).

m : 177 to 206 N·m (17.7 to 20.6 kgf·m, 131 to 152 lbf·ft) 27. Install O-ring (77A) to plug (77). Install plug (77) to housing (01). l : 17 mm m : 177 to 206 N·m (17.7 to 20.6 kgf·m, 131 to 152 lbf·ft)

j : 24 mm m : 83 to 88 N·m (8.3 to 8.8 kgf·m, 61 to 65 lbf·ft)

W3-9-2-12

SECTION 3 BODY Group 10 Pilot Valve Removal and Installation of Pilot Valve 1

7 8 9 7

10 9

WNEC-03-10-010

5. Remove cover (10) and screws (9) (3 used). 6. Remove cover (8) and screws (7) (4 used).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) CAUTION: Bleeding air from the hydraulic oil dtank. (Refer to W1-4-1.) 2. Remove cover (2) and screws (1) (2 used). 3. Remove cover (4) and screws (3) (5 used). 4. Remove cover (6) and screws (5) (3 used).

W3-10-1-1

SECTION 3 BODY Group 10 Pilot Valve

9 8 7

9 1

5 4

WNEC-03-10-018 WNEC-03-10-011

7. Disconnect hoses (1, 2, 3, 4, 5, and 6). j : 19 mm 8. Remove clip (9). 9. Disconnect connectors (7, 8).

W3-10-1-2

SECTION 3 BODY Group 10 Pilot Valve

3 2

WNEC-03-10-021

10. Remove bolts, washers (3) (4 used) from bracket (2). j : 10 mm 11. Remove pilot valve (1) from bracket (2). 12. Remove the adapters with pilot valve (1) attached if necessary.

W3-10-1-3

SECTION 3 BODY Group 10 Pilot Valve

3 2

WNEC-03-10-021

Installation 1. Install all removed adapters to pilot valve (1). 2. Install pilot valve (1) to bracket (5) with bolts, washers (3) (4 used). j : 10 mm m : 5 N·m (0.5 kgf·m, 3.7 lbf·ft)

W3-10-1-4

SECTION 3 BODY Group 10 Pilot Valve

9 8 7

9 1

5 4

WNEC-03-10-018 WNEC-03-10-011

3. Connect hoses (1, 2, 3, 4, 5, and 6). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Connect connectors (7, 8). 5. Connect clip (9). 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.

W3-10-1-5

SECTION 3 BODY Group 10 Pilot Valve

7 8 9 7

10 9

WNEC-03-10-010

7. Install cover (8) with screws (7) (4 used). 8. Install cover (10) with screws (9) (3 used). 9. Install cover (6) with screws (5) (3 used). 10. Install cover (4) with screws (3) (5 used). 11. Install cover (2) with screws (1) (2 used).

W3-10-1-6

SECTION 3 BODY Group 10 Pilot Valve Removal and Installation of Pilot Valve (Two Lever Type ) 2

8 2 9

11 8

5 12

WNEC-03-10-013

WNEC-03-10-019

5. Remove cover (7) and screws (6) (3 used). 6. Remove cover (11) and screws (10) (3 used). 7. Remove cover (9) and screws (8) (4 used).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) CAUTION: Bleed air from the hydraulic oil tank. d(Refer to W1-4-1.) 2. Remove cover (2) and screws (1) (3 used). 3. Disconnect connectors (3, 12). 4. Remove cover (5) and screws (4) (5 used).

W3-10-2-1

SECTION 3 BODY Group 10 Pilot Valve

1 1

2 2

3 4 5 5

6 7

6 4

7 9

9 WNEC-03-10-015

8. Remove clips (3, 8). 9. Disconnect connectors (4) (8 used) and connectors (9) (3 used).

WNEC-03-10-017

14. Remove levers (6) (2 used). Remove nuts (7) (2 used) from levers (6) (2 used).

10. Loosen nuts (2) (2 used). Pull out harnesses of grips (1) (2 used) from covers (5) (2 used). Remove grips (1) (2 used). j : 17 mm 11. Remove nuts (2) (2 used). j : 17 mm 12. Remove covers (5) (2 used). 13. Loosen nuts (7) (2 used). j : 19 mm

W3-10-2-2

j : 17 mm

SECTION 3 BODY Group 10 Pilot Valve

8 1 8 9 1

2 3 4 7

5 WNEC-03-10-014

15. Disconnect hoses (2, 3, 4, 5, 6, and 7). j : 19 mm 16. Remove socket bolts (8) (4 used). l : 8 mm 17. Remove pilot valve (1) from frame (9). 18. Remove the adapters with pilot valve (1) attached if necessary.

W3-10-2-3

WNEC-03-10-016

SECTION 3 BODY Group 10 Pilot Valve

2 1 2 3 1

4 5 6 9

8 WNEC-03-10-016

Installation 1. Install all removed adapters to pilot valve (1). 2. Install pilot valve (1) to frame (3) with socket bolts (2) (4 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect hoses (4, 5, 6, 7, 8, and 9). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-10-2-4

7 WNEC-03-10-014

SECTION 3 BODY Group 10 Pilot Valve

1 1

2 2

3 4 5 5

6 7

6 4

7 10

10 WNEC-03-10-015

WNEC-03-10-017

4. Temporarily tighten nuts (7) (2 used) to levers (6) (2 used).

1 d

j : 19 mm 5. Install levers (6) (2 used) to pilot valve (8). Tighten nuts (7) (2 used) to the specified torque.

j : 19 mm m : 40 N·m (4 kgf·m, 30 lbf·ft) 6. Install covers (5) (2 used). Temporarily tighten nuts (2) (2 used).

WNEC-03-10-020

j : 17 mm IMPORTANT: Check the mounting dimension to install grip (1). 7. Install harnesses of grips (1) (2 used) through covers (5) (2 used). Install grips (1) (2 used). Tighten nuts (2) (2 used) to the specified torque.

ab-

146 mm (5.7 in) 223 mm (8.8 in)

cd-

(8˚) Machine Front

8. Connect connectors (4) (8 used) and connectors (10) (3 used).

j : 17 mm

9. Install clips (3, 9).

m : 20 N·m (2 kgf·m, 15 lbf·ft)

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

fNOTE: Install grip (1) while turning cover (5).

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-10-2-5

SECTION 3 BODY Group 10 Pilot Valve

8 2 9

11 8

5 12

WNEC-03-10-013

11. Install cover (9) with screws (8) (4 used). 12. Install cover (11) with screws (10) (3 used). 13. Install cover (7) with screws (6) (3 used). 14. Install cover (5) with screws (4) (5 used). 15. Connect connectors (3, 12). 16. Install cover (2) with screws (1) (3 used).

W3-10-2-6

WNEC-03-10-019

SECTION 3 BODY Group 10 Pilot Valve Disassembly of Pilot Valve

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 #262 has been applied on nut (35A).

fNOTE: LOCTITE #262 has been applied on lever (11A).

W3-10-3-2

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 #262 has been applied on 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

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 Assembly of Pilot Valve

3. Install pushers (53B) (3 used) and O-rings (53D) (3 used) to solenoids (53C) (3 used).

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 #262 onto the thread part of casing (80). Install plate (51) to casing (80) with universal joint (35I). l : 8 mm m : 50±5 N·m (5±0.5 kgf·m, 37±4 lbf·ft)

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

j : 27 mm

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.

cam (35C) and tighten it to the specified torque when installing nut (35A). 10. Apply LOCTITE #262 onto the thread part of universal joint (35I). Install nut (35A) to universal joint (35I).

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 #262 onto the thread part of universal joint (35I). Install the lever (11A) assembly to universal joint (35I).

m : 30±3 N·m (3±0.3 kgf·m, 22±2 lbf·ft)

W3-10-3-6

SECTION 3 BODY Group 10 Pilot Valve 16. Tighten nut (11C) to the specified torque.

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.

j : 19 mm m : 40±4 N·m (4±0.4 kgf·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 (0.7 kgf·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 (0.9 kgf·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 (0.9 kgf·m, 6.6 lbf·ft)

m : 17 N·m (1.7 kgf·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

WMDF-03-04-001

2. Remove the following parts. (Refer to W3-4-2.)  Step (Front) (2)  Rear Fender (Front) (4) Deck (1)  Cover (3)

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Operate the brake pedal more than dCAUTION: fifty times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.)

W3-11-1-1

SECTION 3 BODY Group 11 Brake Charge Valve

2 1

4 6

WMDF-03-06-006

3. Remove bolts, washers (2) (4 used). Remove cover (1). j : 17 mm 4. Remove bolts, washers (4) (2 used). Remove cover (3). j : 17 mm 5. Remove bolts, washers (6) (2 used). Remove cover (5). j : 17 mm

W3-11-1-2

SECTION 3 BODY Group 11 Brake Charge Valve

1, 2

4, 5

6, 7, 8

6. Disconnect connectors (3) (5 used). 7. Remove bolts, washers (1, 4) and brackets (2, 5). j : 17 mm 8. Remove bolt, washer (6), clip (7), and collar (8). j : 17 mm

W3-11-1-3

WMDF-03-12-001

SECTION 3 BODY Group 11 Brake Charge Valve

13 b

12 4 12 5

11 8, 9, 10

6, 7 WMDF-03-12-002

Manifold Valve

WMDF-03-12-016

Brake Charge Valve

14. Disconnect hoses (5) (2 used).

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

j : 22 mm

10. Disconnect the brake charge valve (b) side of hose (2). j : 19 mm

15. Disconnect hose (13). j : 27 mm 16. Remove bolt (8), nut (9), and clamp (10).

11. Disconnect the brake charge valve (b) side of hose (3). j : 22 mm

j : 19 mm 17. Disconnect pipe (12). j : 24 mm

12. Disconnect hoses (4, 11). j : 19 mm 13. Remove bolt, washer (6) and clip (7). j : 17 mm

W3-11-1-4

SECTION 3 BODY Group 11 Brake Charge Valve

4, 5, 6

18. Remove bolt, washer (4) and clips (5, 6). j : 17 mm 19. Disconnect hose (2). j : 19 mm 20. Disconnect hoses (1) (2 used). j : 19 mm 21. Disconnect hose (3). j : 17 mm 22. Disconnect hose (7). j : 19 mm

W3-11-1-5

WMDF-03-12-003

SECTION 3 BODY Group 11 Brake Charge Valve

Detail A 6 1 2

5 7 4

WNEC-03-12-012 WMDF-03-12-004

The brake charge valve (4) assembly dCAUTION: weight: 30 kg (67 lb) 23. Attach nylon slings onto the brake charge valve (4) assembly. Hoist and hold the brake charge valve (4) assembly. Remove bolts, washers (6) (4 used), washers (7) (8 used), and rubber cushions (8) (4 used). Remove the brake charge valve (4) assembly. j : 19 mm 24. Remove bolts, washers (2) (2 used), nut (1), and bolt, washer (5). Remove brake charge valve (4) from bracket (3). j : 17 mm 25. Remove the adapters with brake charge valve (4) attached if necessary.

W3-11-1-6

SECTION 3 BODY Group 11 Brake Charge Valve

Detail A 6 1 2

5 7 4

WNEC-03-12-012 WMDF-03-12-004

Installation 1. Install all removed adapters to brake charge valve (4). 2. Install bracket (3) to brake charge valve (4) with bolt, washer (5), nut (1), and bolts, washers (2) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) The brake charge valve (4) assembly dCAUTION: weight: 30 kg (67 lb) 3. Attach nylon slings onto the brake charge valve (4) assembly. Hoist the brake charge valve (4) assembly. Install the brake charge valve (4) assembly with rubber cushions (8) (4 used), washers (7) (8 used), and bolts, washers (6) (4 used). j : 19 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

W3-11-1-7

SECTION 3 BODY Group 11 Brake Charge Valve

View A 7

WMDF-03-12-011

A a-

75°

View B 4, 5, 6

WMDF-03-12-003

IMPORTANT: Check the angle to install hose (7). 4. Connect hose (7). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

5. Connect hose (3).

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

WMDF-03-12-012 b-

5°

6. Connect hoses (1) (2 used). j : 19 mm

View C c

m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install hose (2). 7. Connect hose (2).

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install clips (5, 6). 8. Install clips (5, 6) with bolt, washer (4). c

j : 17mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-11-1-8

45°

5 WMDF-03-12-005

SECTION 3 BODY Group 11 Brake Charge Valve

8 b

7 1

4, 5, 6

2, 3 WMDF-03-12-002

Manifold Valve

WMDF-03-12-016

Brake Charge Valve

9. Connect pipe (7).

12. Connect hoses (1) (2 used).

j : 24 mm

j : 22 mm

m : 93 N·m (9.3 kgf·m, 69 lbf·ft)

m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

10. Install clamp (6) with bolt (4) and nut (5).

13. Install clip (3) with bolt, washer (2).

j : 19 mm

j : 17 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

11. Connect hose (8). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

W3-11-1-9

SECTION 3 BODY Group 11 Brake Charge Valve B

View A a

WMDF-03-12-013

c c-

5 WMDF-03-12-002 a-

Manifold Valve

15°

View B d

Brake Charge Valve

IMPORTANT: Check the angle to install hoses (4, 5). 14. Connect hoses (4, 5). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install hose (3). 15. Connect the brake charge valve (b) side of hose (3). j : 19 mm d-

35°

m : 30 N·m (3 kgf·m, 22 lbf·ft) 16. Connect the brake charge valve (b) side of hose (2). j : 19 mm

17. Connect hose (1). j : 27 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

W3-11-1-10

WMDF-03-11-001

SECTION 3 BODY Group 11 Brake Charge Valve

1, 2

4, 5

View A

2 3

60°

6, 7, 8 WMDF-03-12-001

18. Connect connectors (3) (5 used). 19. Install collar (8) and clip (7) with bolt, washer (6). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) IMPORTANT: Check the angle to install bracket (2). 20. Install brackets (2, 5) with bolts, washers (1, 4). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-11-1-11

WMDF-03-12-015

SECTION 3 BODY Group 11 Brake Charge Valve

2 1

4 6

WMDF-03-06-006

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 21. Bleed air from the hydraulic system and brake (axle). (Refer to W1-4-1.)

23. Install cover (3) with bolts, washers (4) (2 used).

22. Install cover (5) with bolts, washers (6) (2 used).

24. Install cover (1) with bolts, washers (2) (4 used).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-11-1-12

SECTION 3 BODY Group 11 Brake Charge Valve

25. Install the following parts. (Refer to W3-4-2.)  Cover (3) Deck (1)  Step (Front) (2)  Rear Fender (Front) (4)

W3-11-1-13

WMDF-03-04-001

SECTION 3 BODY Group 11 Brake Charge Valve (Blank)

W3-11-1-14

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 (kgf·m)

Remark (lbf·ft) Do not disassemble.

j : 27

50 to 85

(5 to 8.5)

(37 to 63)

10 to 15

(1 to 1.5)

(7.4 to 11)

l : 10 l:5 l:6

50 to 85 10 to 15 30 to 40

(5 to 8.5) (1 to 1.5) (3 to 4)

(37 to 63) (7.4 to 11) (22 to 30)

l:5

17 to 23

(1.7 to 2.3)

(12 to 17)

j : 41

120 to 140

(12 to 14)

(89 to 103)

Do not disassemble. Do not disassemble.

l:5

10 to 15

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

(1 to 1.5)

(7.4 to 11)

SECTION 3 BODY Group 11 Brake Accumulator Removal and Installation of Brake Accumulator

WMDF-03-04-001

Removal

dCAUTION:

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

 Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. Caution is required to prevent fires from occurring.  Never strike the accumulator. Keep the accumulator away from sparks and/or flames.

Operate the brake pedal more than dCAUTION: fifty times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove the following parts. (Refer to W3-4-2.)  Step (Front) (2)  Rear Fender (Front) (4)  Deck (1)  Cover (3)

 Do not directly heat the accumulator. Do not weld the accumulator housing.  Be sure to release pressure before starting to work on the piping lines. 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.

W3-11-3-1

SECTION 3 BODY Group 11 Brake Accumulator

4 4 3

6 2

WMDF-03-11-002

3. Disconnect hoses (1) (2 used). j : 19 mm IMPORTANT: Remove brake accumulator (2) while holding the assembly. Do not drop the assembly. 4. Remove bolts, washers (3) (2 used). Remove the brake accumulator (2) assembly. j : 17 mm 5. Remove nuts (4) (16 used) and U-bolts (6) (4 used). Remove brake accumulators (2) (2 used) from bracket (5). j : 17 mm 6. Remove the adapters with brake accumulators (2) (2 used) attached if necessary.

W3-11-3-2

WMDF-03-11-003

SECTION 3 BODY Group 11 Brake Accumulator

4 A

5 2

WMDF-03-11-002

1 B

WMDF-03-11-003

View A

Installation

View B

5 a

1. Install all removed adapters to brake accumulators (2) (2 used).

1 2

IMPORTANT: Check the position to install brake accumulators (2) (2 used). 2. Install brake accumulators (2) (2 used) to bracket (5) with nuts (4) (16 used) and U-bolts (6) (4 used).

j : 17 mm

WMDF-03-11-005 d-

m : 20 N·m (2 kgf·m, 15 lbf·ft) IMPORTANT: Check the position to install the brake accumulator (2) assembly. 3. Install the brake accumulator (2) assembly with bolts, washers (3) (2 used).

c ab-

0 mm (0 in) 0 mm (0 in)

15°

WMDF-03-11-004 c-

Bracket

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) IMPORTANT: Check the angle to install hoses (1) (2 used). 4. Connect hoses (1) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-11-3-3

SECTION 3 BODY Group 11 Brake Accumulator

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 5. Bleed air from the hydraulic system and brake (axle). (Refer to W1-4-1.) 6. Install following parts. (Refer to W3-4-2.)  Cover (3)  Deck (1)  Step (Front) (2)  Rear Fender (Front) (4)

W3-11-3-4

WMDF-03-04-001

SECTION 3 BODY Group 12 Manifold Valve Removal and Installation of Manifold Valve

WMDF-03-04-001

Removal

CAUTION:

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Operate the brake pedal more than dCAUTION: fifty times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.) 2. Remove the following parts. (Refer to W3-4-2.)

 Be sure to release pressure before starting to work on the piping lines. 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.

 Step (Front) (2)  Rear Fender (Front) (4) Deck (1)  Cover (3)

W3-12-1-1

SECTION 3 BODY Group 12 Manifold Valve

2 1

4 6

WMDF-03-06-006

W3-12-1-2

SECTION 3 BODY Group 12 Manifold Valve

1, 2

4, 5

6, 7, 8

6. Disconnect connectors (3) (5 used). 7. Remove bolts, washers (1, 4) and brackets (2, 5). j : 17 mm 8. Remove bolt, washer (6), clip (7), and collar (8). j : 17 mm

W3-12-1-3

WMDF-03-12-001

SECTION 3 BODY Group 12 Manifold Valve

b c

4 c

8 6, 7

WMDF-03-12-002 ab-

Manifold Valve Brake Charge Valve

Pipe

WMDF-03-12-016 c-

Pipe

13. Remove bolt, washer (6) and clip (7).

9. Disconnect hose (1).

j : 17 mm

j : 27 mm 10. Disconnect the manifold valve (a) side of hose (2).

14. Disconnect hoses (5) (2 used). j : 22 mm

j : 19 mm 11. Disconnect the manifold valve (a) side of hose (3).

15. Disconnect hose (9). j : 27 mm

j : 22 mm 12. Disconnect hoses (4, 8). j : 19 mm

W3-12-1-4

SECTION 3 BODY Group 12 Manifold Valve

4, 5, 6

16. Remove bolt, washer (4) and clips (5, 6). j : 17 mm 17. Disconnect hose (2). j : 19 mm 18. Disconnect hoses (1) (2 used). j : 19 mm 19. Disconnect hose (3). j : 17 mm 20. Disconnect hose (7). j : 19 mm

W3-12-1-5

WMDF-03-12-003

SECTION 3 BODY Group 12 Manifold Valve

2 1

Detail A 6 3

7 A

4 4

8 7

WNEC-03-12-012 WMDF-03-12-004

24. Remove the adapters with manifold valve (2) attached if necessary.

The manifold valve (2) assembly dCAUTION: weight: 30 kg (67 lb) 21. Attach nylon slings onto the manifold valve (2) assembly. Hoist and hold the manifold valve (2) assembly. Remove bolts, washers (6) (4 used), washers (7) (8 used), and rubber cushions (8) (4 used). Remove the manifold valve (2) assembly. j : 19 mm 22. Remove bolts, washers (5) (3 used). Remove manifold valve (2) from bracket (4). j : 17 mm 23. Remove accumulators (1, 3) from manifold valve (2). j : 36 mm

W3-12-1-6

SECTION 3 BODY Group 12 Manifold Valve

2 1

Detail A 6 3

7 A

4 4

8 7

WNEC-03-12-012 WMDF-03-12-004

Installation 1. Install all removed adapters to manifold valve (2). IMPORTANT: The accumulated pressure in accumulators (1, 3) are different. Check the direction to install accumulator (1) (stamped mark: 5.94M) and accumulator (3) (stamped mark: 1.57M). 2. Install accumulators (1, 3) to manifold valve (2).

The manifold valve (2) assembly dCAUTION: weight: 30 kg (67 lb) 4. Attach nylon slings onto the manifold valve (2) assembly. Hoist the manifold valve (2) assembly. Install the manifold valve (2) assembly with rubber cushions (8) (4 used), washers (7) (8 used), and bolts, washers (6) (4 used).

j : 36 mm

j : 19 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

m : 98 N·m (9.8 kgf·m, 72 lbf·ft) 3. Install bracket (4) to manifold valve (2) with bolts, washers (5) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-12-1-7

SECTION 3 BODY Group 12 Manifold Valve

View A 7

WMDF-03-12-011

A a-

75°

View B 4, 5, 6

WMDF-03-12-003

IMPORTANT: Check the angle to install hose (7). 5. Connect hose (7). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

6. Connect hose (3).

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

WMDF-03-12-012 b-

5°

7. Connect hoses (1) (2 used). j : 19 mm

View C c

m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install hose (2). 8. Connect hose (2).

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install clips (5, 6). 9. Install clips (5, 6) with bolt, washer (4). c

j : 17mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-12-1-8

45°

5 WMDF-03-12-005

SECTION 3 BODY Group 12 Manifold Valve

b c

2, 3 WMDF-03-12-002 ab-

Manifold Valve Brake Charge Valve

Pipe

WMDF-03-12-016 c-

10. Connect hose (4). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 11. Connect hoses (1) (2 used). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 12. Install clip (3) with bolt, washer (2). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-12-1-9

Pipe

SECTION 3 BODY Group 12 Manifold Valve B

View A a

WMDF-03-12-013

c c-

15°

WMDF-03-12-002 a-

Manifold Valve

View B

Brake Charge Valve

IMPORTANT: Check the angle to install hoses (4, 5). 13. Connect hoses (4, 5). d

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

3 d-

45°

IMPORTANT: Check the angle to install hose (3). 14. Connect the manifold valve (a) side of hose (3). j : 19 mm

16. Connect hose (1). j : 27 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) 15. Connect the manifold valve (a) side of hose (2).

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-12-1-10

WMDF-03-12-014

SECTION 3 BODY Group 12 Manifold Valve

1, 2

4, 5

View A

2 3

60°

6, 7, 8 WMDF-03-12-001

17. Connect connectors (3) (5 used). 18. Install collar (8) and clip (7) with bolt, washer (6). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) IMPORTANT: Check the angle to install bracket (2). 19. Install brackets (2, 5) with bolts, washers (1, 4). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-12-1-11

WMDF-03-12-015

SECTION 3 BODY Group 12 Manifold Valve

2 1

4 6

WMDF-03-06-006

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 20. Bleed air from the hydraulic system and brake (axle). (Refer to W1-4-1.)

22. Install cover (3) with bolts, washers (4) (2 used).

21. Install cover (5) with bolts, washers (6) (2 used).

23. Install cover (1) with bolts, washers (2) (4 used).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-12-1-12

SECTION 3 BODY Group 12 Manifold Valve

24. Install the following parts. (Refer to W3-4-2.)  Cover (3) Deck (1)  Step (Front) (2)  Rear Fender (Front) (4)

W3-12-1-13

WMDF-03-04-001

SECTION 3 BODY Group 12 Manifold Valve (Blank)

W3-12-1-14

SECTION 3 BODY Group 12 Manifold Valve Disassembly of Manifold Valve

WMDF-03-12-006

01020304050608-

Plunger Spring Spring (2 Used) Plug Sleeve (2 Used) Spool Spool (2 Used)

09101112131415-

Stopper (2 Used) Plug Plug Filter Solenoid (2 Used) Body Spring

17181920212223-

Plug (8 Used) Plug Plug (2 Used) Socket Bolt (4 Used) Screw Washer (2 Used) Nut

W3-12-2-1

252627282930-

O-Ring (2 Used) O-Ring (8 Used) O-Ring O-Ring (2 Used) O-Ring (2 Used) O-Ring

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: Do not disassemble screw (21) and nut (23) unless necessary. If they have been disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 1. Measure and record mounting dimension (a) before loosening nut (23).

6. Remove plug (04) from body (14). Remove O-ring (27) from plug (04). l : 6 mm 7. Remove spring (02) and plunger (01) from body (14). 8. Remove socket bolts (20) (2 used) from solenoid (13). Remove solenoid (13) from body (14). Remove O-ring (25) from solenoid (13). l : 4 mm IMPORTANT: Replace the sleeve (05) assembly as the manifold valve assembly. 9. Remove the sleeve (05) assembly from body (14).

10. Remove spool (08) from sleeve (05).

fNOTE: Spring (03) and washer (22) cannot be

disassembled as stopper (09) has been press fitted to sleeve (05). 11. Remove another solenoid (13) assembly in the same way as step 8 to step 10.

12. Remove plugs (19) (2 used) from body (14). Remove O-rings (29) (2 used) from plugs (19) (2 used). l : 8 mm

WMDF-03-12-010 a-

Mounting Dimension

fNOTE: Filter (12) cannot be disassembled as it has been press fitted to body (14). 13. Remove plugs (17) (8 used) from body (14). Remove O-rings (26) (8 used) from plugs (17) (8 used).

2. Loosen nut (23). j : 17 mm 3. Remove screw (21) and nut (23) from plug (10).

l : 5 mm

14. Remove plug (18) from body (14). Remove O-ring (28) from plug (18).

The spring force is applied to plug dCAUTION: (10). Slowly loosen plug (10).

l : 6 mm

4. Remove plug (10) from body (14). Remove O-ring (30) from plug (10). j : 27 mm IMPORTANT: Replace the spool (06) assembly as the manifold valve assembly. 5. Remove plug (11), spring (15), and spool (06) from body (14). Remove O-ring (28) from plug (11).

W3-12-2-2

SECTION 3 BODY Group 12 Manifold Valve 17, 26

Assembly of Manifold Valve

14 17, 26

17, 26

TNDF-03-09-002

Section B-B

Section A-A

21 23

25 05

15 09 06

TNDF-03-09-006

29 18

WMDF-03-12-007

W3-12-2-3

SECTION 3 BODY Group 12 Manifold Valve Section C-C

Section D-D

01 25

29 WMDF-03-12-008

TNDF-03-09-007

252627282930-

O-Ring (2 Used) O-Ring (8 Used) O-Ring O-Ring (2 Used) O-Ring (2 Used) O-Ring

Section E-E

WMDF-03-12-009

01020304050608-

Plunger Spring Spring (2 Used) Plug Sleeve (2 Used) Spool Spool (2 Used)

09101112131415-

Stopper (2 Used) Plug Plug Filter Solenoid (2 Used) Body Spring

17181920212223-

Plug (8 Used) Plug Plug (2 Used) Socket Bolt (4 Used) Screw Washer (2 Used) Nut

W3-12-2-4

SECTION 3 BODY Group 12 Manifold Valve Assembly of Manifold Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-rings (29) (2 used) to plugs (19) (2 used). Install plugs (19) (2 used) to body (14). j : 8 mm

IMPORTANT: Replace the spool (06) assembly as the manifold valve assembly. 10. Install spool (06), spring (15), and plug (11) to body (14). 11. Install O-ring (30) to plug (10). Install plug (10) to body (14). j : 27 mm

m : 48.5±4.9 N·m (4.9±0.5 kgf·m, 36±3.6 lbf·ft)

m : 49.1±5 N·m (5±0.5 kgf·m, 36±3.7 lbf·ft)

2. Install O-ring (28) to plug (18). Install plug (18) to body (14).

12. Install screw (21) to plug (10) so that a clearance can be equal to mounting dimension (a) before disassembling.

l : 6 mm m : 26.5±2.7 N·m (2.7±0.3 kgf·m, 19.5±2 lbf·ft)

l : 5 mm

3. Install O-rings (26) (8 used) to plugs (17) (8 used). Install plugs (17) (8 used) to body (14).

l : 5 mm 10

m : 9.8±1 N·m (1 kgf·m, 7.2±0.7 lbf·ft) IMPORTANT: Replace the sleeve (05) assembly as the manifold valve assembly. 4. Install spool (08) to sleeve (05). Install the sleeve (05) assembly to body (14). 5. Install O-ring (25) to solenoid (13). Install solenoid (13) to body (14) with socket bolts (20) (2 used). l : 4 mm

WMDF-03-12-010 a-

Mounting Dimension

m : 3.92±0.4 N·m (0.4 kgf·m, 2.9±0.3 lbf·ft) 6. Install another solenoid (13) assembly in the same way as step 4 to step 5. 7. Install plunger (01) and spring (02) to body (14). 8. Install O-ring (27) to plug (04). Install plug (04) to body (14).

IMPORTANT: Install nut (23) while securing screw (21) by using a hexagonal wrench in order not to turn them. 13. Install nut (23) to screw (21). j : 17 mm

l : 6 mm

m : 15.7±1.6 N·m (1.6±0.2 kgf·m, 11.5±1.2 lbf·ft)

m : 12.0±1.2 N·m (1.2±0.1 kgf·m, 8.9±0.9 lbf·ft)

l : 5 mm

9. Apply grease onto O-ring (28). Install O-ring (28) to plug (11).

W3-12-2-5

SECTION 3 BODY Group 12 Manifold Valve (Blank)

W3-12-2-6

SECTION 3 BODY Group 13 Solenoid Valve Removal and Installation of Exhaust Filter Regeneration Control Solenoid Valve

2 4 5 6

WMDF-03-09-005

WMDF-03-13-003

5. Disconnect hoses (4) (3 used). : 17 mm 6. Disconnect hoses (5) (2 used) (only the machine with the ride control device). : 17 mm 7. Remove socket bolts (6) (2 used). Remove exhaust filter regeneration control solenoid valve (8). : 6 mm 8. Remove the adapters with exhaust filter regeneration control solenoid valve (8) attached if necessary.

2. Remove bolts, washers (1) (4 used). Remove cover (2). : 19 mm 3. Disconnect connector (7). 4. Disconnect hose (3). : 19 mm

W3-13-1-1

SECTION 3 BODY Group 13 Solenoid Valve View A

1 A

15°

WMDF-03-13-002

3 4

WMDF-03-13-003

IMPORTANT: Check the angle to install hose (1). 5. Connect hose (1).

Installation 1. Install all removed adapters to exhaust filter regeneration control solenoid valve (6).

: 19 mm

2. Install exhaust filter regeneration control solenoid valve (6) with socket bolts (4) (2 used).

6. Connect connector (5).

: 6 mm

7. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

: 20 N·m (2 kgf·m, 15 lbf·ft) 3. Connect hoses (3) (2 used) (only the machine with the ride control device). : 17 mm

: 30 N·m (3 kgf·m, 22 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.)

: 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 4. Connect hoses (2) (3 used). : 17 mm : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-13-1-2

SECTION 3 BODY Group 13 Solenoid Valve

1 a

155 mm (6.1 in)

210 mm (8.3 in)

WMDF-03-09-005

IMPORTANT: Check the direction to install cover (2). 9. Install cover (2) with bolts, washers (1) (4 used). : 19 mm : 90 N·m (9 kgf·m, 66 lbf·ft)

NOTE: Turn cover (2) by 180 degrees and install it in case of the machine with the quick coupler.

W3-13-1-3

SECTION 3 BODY Group 13 Solenoid Valve (Blank)

W3-13-1-4

SECTION 3 BODY Group 13 Solenoid Valve Structure of Exhaust Filter Regeneration Control Solenoid Valve

WMDF-03-13-001

W3-13-2-1

SECTION 3 BODY Group 13 Solenoid Valve No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Part Name Solenoid Socket Bolt O-Ring Spool Sleeve O-Ring O-Ring O-Ring Plate Washer Plug Housing Solenoid Valve Assembly

Q’ty 1 2 1 1 1 1 1 1 1 1 2 1

Wrench Size

Tightening Torque N·m kgf·m

lbf·ft

5 to 5.2

0.5 to 0.52

3.7 to 3.8

10 to 13

1 to 1.3

7.4 to 9.6

NOTE: x Replace solenoid (1), spool (4), sleeve (5), and plate (9) as solenoid valve assembly (13). x Replace housing (12) as the exhaust filter regeneration control solenoid valve assembly.

W3-13-2-2

Remark

SECTION 3 BODY Group 14 Priority Valve Removal and Installation of Priority Valve (without Secondary Steering)

WMDF-03-04-001

2. Remove the following parts. (Refer to W3-4-2.)

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Operate the brake pedal more than CAUTION: fifty times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. CAUTION: (Refer to W1-4-1.) Release any pressure in the front CAUTION: attachment hydraulic circuit. (Refer to W1-5-1.)

W3-14-1-1

x Step (Front) (2) x Rear Fender (Front) (4) x Deck (1) x Cover (3)

SECTION 3 BODY Group 14 Priority Valve

2 1

4 6

WMDF-03-06-006

W3-14-1-2

SECTION 3 BODY Group 14 Priority Valve

5 10

7, 8, 9

WMDF-03-12-001

6. Remove the manifold valve (1) assembly. (Refer to W3-12-1.) 7. Disconnect hose (10). j : 27 mm

9. Disconnect hose (2).

WMDF-03-14-002

11. Disconnect hose (4). j : 17 mm 12. Remove bolts (7) (2 used), washers (8) (2 used), and nuts (9) (2 used). Remove priority valve (6).

8. Disconnect hoses (5, 11). j : 41 mm

j : 13 mm 13. Remove the adapters with priority valve (6) attached if necessary.

j : 36 mm 10. Disconnect hose (3). j : 19 mm

W3-14-1-3

SECTION 3 BODY Group 14 Priority Valve A

4 C

5 10

7, 8, 9

WMDF-03-14-002

Installation

WMDF-03-12-001

View B

View A

1. Install all removed adapters to priority valve (6). 2. Install priority valve (6) with nuts (9) (2 used), washers (8) (2 used), and bolts (7) (2 used).

j : 13 mm m : 20 N·m (2 kgf·m, 15 lbf·ft) 3. Connect hose (4).

2 a-

WMDF-03-14-004

35˚

WMDF-03-14-005 b-

View C

15˚

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 4. Connect hose (3). j : 19 mm WMDF-03-14-006

m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install hose (2). 5. Connect hose (2). j : 36 mm

60˚

IMPORTANT: Check the angle to install hose (10). 7. Connect hose (10).

m : 180 N·m (18 kgf·m, 133 lbf·ft) IMPORTANT: Check the angle to install hose (5). 6. Connect hoses (5, 11). j : 41 mm

j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 8. Install the manifold valve (1) assembly. (Refer to W312-1.)

m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-14-1-4

SECTION 3 BODY Group 14 Priority Valve

2 1

4 6

WMDF-03-06-006

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 9. Bleed air from the hydraulic system and brake (axle). (Refer to W1-4-1.)

11. Install cover (3) with bolts, washers (4) (2 used).

10. Install cover (5) with bolts, washers (6) (2 used).

12. Install cover (1) with bolts, washers (2) (4 used).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-14-1-5

SECTION 3 BODY Group 14 Priority Valve

13. Install the following parts. (Refer to W3-4-2.)  Cover (3) Deck (1)  Step (Front) (2)  Rear Fender (Front) (4)

W3-14-1-6

WMDF-03-04-001

SECTION 3 BODY Group 14 Priority Valve Removal and Installation of Priority Valve (with Secondary Steering)

WMDF-03-04-001

2. Remove the following parts. (Refer to W3-4-2.)

W3-14-2-1

x Step (Front) (2) x Rear Fender (Front) (4) x Deck (1) x Cover (3)

SECTION 3 BODY Group 14 Priority Valve

2 1

4 6

WMDF-03-06-006

3. Remove bolts, washers (2) (4 used). Remove cover (1). : 17 mm 4. Remove bolts, washers (4) (2 used). Remove cover (3). : 17 mm 5. Remove bolts, washers (6) (2 used). Remove cover (5). : 17 mm

W3-14-2-2

SECTION 3 BODY Group 14 Priority Valve 1

2 12

6 11

8, 9, 10

WMDF-03-14-001

6. Remove the manifold valve (2) assembly. (Refer to W3-12-1.) 7. Remove secondary steering pump (1). (Refer to W48-1.)

9. Disconnect hoses (6, 12). : 41 mm 10. Disconnect hose (3).

WMDF-03-14-003

11. Disconnect hose (4). : 19 mm 12. Disconnect hose (5). : 17 mm

8. Disconnect hose (11). : 27 mm

13. Remove bolts (8) (2 used), washers (9) (2 used), and nuts (10) (2 used). Remove priority valve (7). : 13 mm 14. Remove the adapters with priority valve (7) attached if necessary.

: 36 mm

W3-14-2-3

SECTION 3 BODY Group 14 Priority Valve A

2 12

6 11 B

8, 9, 10

WMDF-03-14-003

WMDF-03-14-001

View B

View A

Installation

1. Install all removed adapters to priority valve (7). 2. Install priority valve (7) with nuts (10) (2 used), washers (9) (2 used), and bolts (8) (2 used).

3 a-

WMDF-03-14-004

35˚

WMDF-03-14-005 b-

15˚

: 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft) 3. Connect hose (5).

IMPORTANT: Check the angle to install hose (6). 6. Connect hoses (6, 12). : 41 mm

: 17 mm

: 210 N·m (21 kgf·m, 155 lbf·ft)

: 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 4. Connect hose (4).

7. Connect hose (11). : 27 mm

: 19 mm

: 95 N·m (9.5 kgf·m, 70 lbf·ft)

: 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install hose (3). 5. Connect hose (3). : 36 mm

8. Install secondary steering pump (1). (Refer to W4-81.) 9. Install the manifold valve (2) assembly. (Refer to W312-1.)

: 180 N·m (18 kgf·m, 133 lbf·ft)

W3-14-2-4

SECTION 3 BODY Group 14 Priority Valve

2 1

4 6

WMDF-03-06-006

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 10. Bleed air from the hydraulic system and brake (axle). (Refer to W1-4-1.)

12. Install cover (3) with bolts, washers (4) (2 used).

11. Install cover (5) with bolts, washers (6) (2 used).

13. Install cover (1) with bolts, washers (2) (4 used).

: 17 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

: 17 mm

: 50 N·m (5 kgf·m, 37 lbf·ft)

W3-14-2-5

SECTION 3 BODY Group 14 Priority Valve

14. Install the following parts. (Refer to W3-4-2.) x Cover (3) x Deck (1) x Step (Front) (2) x Rear Fender (Front) (4)

W3-14-2-6

WMDF-03-04-001

SECTION 3 BODY Group 14 Priority Valve Structure of Priority Valve

10 11 12

W4FC-03-11-003

No.

Part Name

Q’ty

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

Relief Valve Adjusting Screw O-Ring Spring Guide Spring Poppet Valve Seat Ring Screen Housing O-Ring Plug Orifice Spool Orifice Spring Plug

1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1

Wrench Size (mm) j : 24

Tightening Torque N·m kgf·m lbf·ft 21 2.1 15.5

j : 26

4.5

Remark

32.5 Diameter of Orifice: φ0.8 Diameter of Orifice: φ0.65

j : 26

4.5

32.5

Diameter of Orifice: φ1.5

fNOTE: Replace the parts except for O-rings (3, 11), plugs (12, 17), spring (16), and relief valve (1) as the priority valve assembly.

W3-14-3-1

SECTION 3 BODY Group 14 Priority Valve (Blank)

W3-14-3-2

SECTION 3 BODY Group 15 Cooling Fan System Removal and Installation of Fan Valve 2

1 9

8 7 6

WMDF-03-02-007

WMDF-03-07-002

3. Remove bolts, washers (7) (3 used). Remove rubber plate (6). j : 17 mm 4. Remove bolts, washers (9) (4 used). Remove rubber plate (8). j : 17 mm 5. Remove bolts, washers (5) (4 used). Remove cover (4).

Removal

j : 17 mm

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

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

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open side covers (1) at the right and left sides.

W3-15-1-1

j : 17 mm

SECTION 3 BODY Group 15 Cooling Fan System

7. Disconnect connectors (3) (2 used).

11. Disconnect hoses (2) (2 used).

8. Disconnect hose (6). j : 36 mm 9. Disconnect hose (1).

j : 17 mm 12. Remove bolts, washers (5) (3 used). Remove fan valve (4). j : 17 mm

j : 27 mm 10. Disconnect hoses (7) (2 used).

WMDF-03-15-001

13. Remove the adapters with fan valve (4) attached if necessary.

j : 27 mm

W3-15-1-2

SECTION 3 BODY Group 15 Cooling Fan System

Installation

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

1. Install all removed adapters to fan valve (4).

j : 27 mm

2. Install fan valve (4) with bolts, washers (5) (3 used). j : 17 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 5. Connect hose (1).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 27 mm

3. Connect hoses (2) (2 used). j : 17 mm

WMDF-03-15-001

m : 80 N·m (8 kgf·m, 59 lbf·ft) 6. Connect hose (6).

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 7. Connect connectors (3) (2 used).

W3-15-1-3

SECTION 3 BODY Group 15 Cooling Fan System

3 1

8 7 6

WMDF-03-02-007

WMDF-03-07-002

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Install cover (2) with bolts, washers (3) (4 used).

10. Install rubber plate (8) with bolts, washers (9) (4 used). j : 17 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 9. Install cover (4) with bolts, washers (5) (4 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 11. Install rubber plate (6) with bolts, washers (7) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft) 12. Close side covers (1) at right and left sides.

W3-15-1-4

SECTION 3 BODY Group 15 Cooling Fan System Structure of Fan Valve

WMDF-03-15-004

No.

Part Name

Q’ty

1 2 3 4 5 6 7 8 9 10 11

Relief Valve O-Ring O-Ring Backup Ring Backup Ring O-Ring Plug O-Ring Spring Valve Housing

1 1 1 1 1 1 1 1 1 1 1

Wrench Size (mm) j : 32

Tightening Torque N·m kgf·m 18+30 180+300

lbf·ft 133+220

l:8

70+150

52+110

7+1.50

Remark

fNOTE: Replace the parts except for O-rings (2, 3, 6, 8), backup rings (4, 5), and plug (7) as the fan valve assembly.

W3-15-2-1

SECTION 3 BODY Group 15 Cooling Fan System (Blank)

W3-15-2-2

SECTION 3 BODY Group 15 Cooling Fan System Removal and Installation of Fan Motor 1

3 WMDF-03-15-006

WMDF-03-02-007

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.

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open side covers (1) at the left and right sides. 3. Remove bolts, washers (2) (8 used). Remove cover (3).

4. Disconnect hose (6). j : 17 mm 5. Disconnect hoses (4, 5).

j : 17 mm

j : 27 mm

W3-15-3-1

WMDF-03-15-002

SECTION 3 BODY Group 15 Cooling Fan System 1

WMDF-03-15-003

6. Remove bolts, washers (7) (4 used). Remove cover (6). j : 17 mm

8. Remove key (8) from fan motor (1). 9. Remove bolts, washers (9) (2 used). Remove fan motor (1).

fNOTE: Even if cover (6) at either right or left side is

j : 19 mm

removed, the fan (5) assembly can be accessed. IMPORTANT: Do not contact the radiator, oil cooler, and intercooler when removing and installing the fan (5) assembly. 7. Remove bolt (4), spring washer (3), and washer (2). Remove the fan (5) assembly.

10. Remove the adapters with fan motor (1) attached if necessary.

j : 17 mm

fNOTE: LOCTITE #262 has been applied on bolt (4).

W3-15-3-2

SECTION 3 BODY Group 15 Cooling Fan System 1

WMDF-03-15-003

5. Apply LOCTITE #262 onto bolt (4). Install washer (2), spring washer (3), and bolt (4).

Installation 1. Install all removed adapters to fan motor (1).

j : 17 mm

2. Install fan motor (1) with bolts, washers (9) (2 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 19 mm

6. Install cover (6) with bolts, washers (7) (4 used).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 17 mm

3. Install key (8) to fan motor (1). IMPORTANT: Do not contact the radiator, oil cooler, and intercooler when removing and installing the fan (5) assembly. IMPORTANT: Do not tap the fan (5) assembly when installing it. 4. Fit the fan (5) assembly to key (8). Install it.

W3-15-3-3

m : 50 N·m (5 kgf·m, 37 lbf·ft)

SECTION 3 BODY Group 15 Cooling Fan System

3 5

6 WMDF-03-15-006

WMDF-03-15-002

7. Add hydraulic oil through elbow (4).

fNOTE: Amount of oil: 0.15 to 0.23 L (0.16 to 0.24 US qt) 8. Connect hose (1). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 9. Connect hose (2). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 10. Connect hose (3). j : 17 mm

WMDF-03-02-007

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 11. Install cover (6) with bolts, washers (5) (8 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 12. Close side covers (7) at the left and right sides.

W3-15-3-4

SECTION 3 BODY Group 15 Cooling Fan System Structure of Fan Motor

23 21

14 WMDF-03-15-005

W3-15-4-1

SECTION 3 BODY Group 15 Cooling Fan System No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Part Name Ball Bearing Pin O-Ring Pin Pin Plunger Swash Plate Ball Bearing Key Shaft Retaining Ring Oil Seal Pin Housing Holder Retainer Spring Seat Rotor Spring Washer Retaining Ring Valve Plate Socket Bolt Rear Cover Plug O-Ring

Q’ty 1 1 1 2 3 9 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 2 2

Wrench Size (mm)

Tightening Torque N·m kgf·m

lbf·ft

Remark

l :8

61.3±2.45

6.1±0.2

45±1.8

l :8

29.4±2

2.9±0.2

21.5±1.5

fNOTE: Replace pin (5), plunger (6), housing (14), holder (15), retainer (16), spring seat (17), rotor (18), spring (19), washer (20), retaining ring (21), and rear cover (24) as the fan motor assembly.

W3-15-4-2

SECTION 3 BODY Group 16 Ride Control Device Removal and Installation of Ride Control Valve (Option)

4, 5, 6

2 7

WMDF-03-09-005

WMDF-03-16-001

3. Remove bolts (4) (4 used) and flanges (5) (2 used). Disconnect hose (7). Remove O-ring (6). : 17 mm 4. Disconnect hose (8). : 36 mm 5. Disconnect hose (3).

Removal 1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. CAUTION: (Refer to W1-4-1.) Release any pressure in the hydraulic CAUTION: circuit and the ride control accumulator. (Refer to W1-5-1.) 2. Remove bolts, washers (1) (4 used). Remove cover (2). : 19 mm

W3-16-1-1

: 27 mm

SECTION 3 BODY Group 16 Ride Control Device

2, 3, 4

10 11

WNDB-03-16-007

WMDF-03-16-002

6. Remove bolts (2) (4 used) and flanges (3) (2 used). Disconnect hose (1). Remove O-ring (4).

10. Remove bolts, washers (11) (3 used). Remove ride control valve (8) from bracket (10). j : 19 mm

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

11. Remove the adapters with ride control valve (8) attached if necessary.

8. Disconnect connector (6). 9. Remove bolts, washers (9) (4 used) and clip (5). Remove the ride control valve (8) assembly. j : 19 mm

W3-16-1-2

SECTION 3 BODY Group 16 Ride Control Device

2, 3, 4

1 8

10 11

WNDB-03-16-007 WMDF-03-16-002

View A

Installation 1. Install all removed adapters to ride control valve (8). a

2. Install ride control valve (8) to bracket (10) with bolts, washers (11) (3 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 3. Install the ride control valve (8) assembly and clip (5) with bolts, washers (9) (4 used).

65°

WMDF-03-16-006

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 4. Connect connector (6). 5. Connect hoses (7) (2 used).

IMPORTANT: Check the angle to install hose (1). 6. Install O-ring (4). Install hose (1) with flanges (3) (2 used) and bolts (2) (4 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-16-1-3

SECTION 3 BODY Group 16 Ride Control Device View A

2, 3, 4

20°

WMDF-03-16-006

WMDF-03-16-001

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

7. Connect hose (1). j : 27 mm

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 W1-6-1.)

m : 80 N·m (8 kgf·m, 59 lbf·ft) 8. Connect hose (6). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) IMPORTANT: Check the angle to install hose (5). 9. Install O-ring (4). Install hose (5) with flanges (3) (2 used) and bolts (2) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 10. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

W3-16-1-4

SECTION 3 BODY Group 16 Ride Control Device

1 a

155 mm (6.1 in)

210 mm (8.3 in)

WMDF-03-09-005

IMPORTANT: Check the direction to install cover (2). 13. Install cover (2) with bolts, washers (1) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

fNOTE: Turn cover (2) by 180 degrees and install it in case of the machine with the quick coupler.

W3-16-1-5

SECTION 3 BODY Group 16 Ride Control Device (Blank)

W3-16-1-6

SECTION 3 BODY Group 16 Ride Control Device Disassembly of Ride Control Valve (Option)

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. Remove nut (24) from drain plug (22).

j : 41 mm

j : 13 mm 2. Remove drain plug (22) from housing (32A). Remove O-ring (23) from drain plug (22). l : 4 mm IMPORTANT: Replace solenoid (08C) and spring (08D) as the ride control valve assembly. 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: Replace sleeve (08A) and spool (08B) as the ride control valve assembly. 4. Remove the sleeve (08A) assembly from housing (32A). Remove spool (08B) and O-rings (08I, 08J, 08K) from sleeve (08A). IMPORTANT: Replace plate (08E) as the ride control valve assembly. 5. Remove plate (08E) and washer (08F) from housing (32A).

IMPORTANT: Remove spool (32B) by rotating. When it cannot be removed smoothly, return it to the original position and remove it again. IMPORTANT: Replace spool (32B) as the ride control valve assembly. 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 spool (32C) 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: Replace spool (32C) as the ride control valve assembly. 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).

6. Remove plug (07) from housing (32A). j : 10 mm l : 6 mm IMPORTANT: Do not disassemble relief valve (34). 7. Remove relief valve (34) from housing (32A). Remove O-rings (34A, 34C) and backup ring (34B) from relief valve (34). 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 (Option)

A B

26, 26A

27, 27A

A 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 (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft) IMPORTANT: Replace spool (32C) as the ride control valve assembly. 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 (18 to 21 kgf·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. IMPORTANT: Replace spool (32B) as the ride control valve assembly. 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 (18 to 21 kgf·m, 131 to 152 lbf·ft)

j : 10 mm m : 8 to 12 N·m (0.8 to 1.2 kgf·m, 5.9 to 8.9 lbf·ft)

8. Install O-ring (05A) to plug (05). Install plug (05) to housing (32A). l : 17 mm m : 177 to 206 N·m (18 to 21 kgf·m, 131 to 152 lbf·ft) 9. Install O-ring (25A) to plug (25). Install plug (25) to housing (32A). l : 6 mm

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

m : 34 to 39 N·m (3.5 to 4 kgf·m, 25 to 29 lbf·ft)

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 (1.5 to 1.8 kgf·m, 11 to 13.5 lbf·ft) 11. Install O-ring (27A) to plug (27). Install plug (27) to housing (32A).

IMPORTANT: When installing solenoid (08C), do not drop spring (08D) and O-ring (08H). IMPORTANT: Replace solenoid (08C) and spring (08D) as the ride control valve assembly. 17. Install O-ring (08H) to housing (32A). Install spring (08D) to solenoid (08C). Install solenoid (08C) to housing (32A) with socket bolts (08G) (2 used). l : 4 mm

l : 8 mm

m : 5 to 7 N·m (0.5 to 0.7 kgf·m, 3.7 to 5.2 lbf·ft)

m : 69 to 74 N·m (7 to 7.6 kgf·m, 51 to 55 lbf·ft) 12. Install O-ring (28A) to plug (28). Install plug (28) to housing (32A).

18. Install O-ring (23) to drain plug (22). Install drain plug (22) to housing (32A). l : 4 mm

l : 12 mm

m : 7 to 9 N·m (0.7 to 0.9 kgf·m, 5.2 to 6.6 lbf·ft)

m : 235 to 264 N·m (24 to 27 kgf·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).

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 (18 to 21 kgf·m, 131 to 152 lbf·ft) 14. Install plug (07) to housing (32A). l : 6 mm m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft) IMPORTANT: Replace plate (08E) as the ride control valve assembly. 15. Install washer (08F) and plate (08E) to housing (32A). IMPORTANT: Replace sleeve (08A) and spool (08B) as the ride control valve assembly. 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

m : 10 to 12 N·m (1 to 1.2 kgf·m, 7.4 to 8.9 lbf·ft)

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 (Option) 1

WMDF-03-09-005

WMDF-03-16-003

Removal

CAUTION:

1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.)

y Allow only qualified personnel to handle the accumulator. y High-pressure nitrogen gas is enclosed in the accumulator. Caution is required to prevent fires from occurring. y Never strike the accumulator. Keep the accumulator away from sparks and/or flames. y Do not directly heat the accumulator. Do not weld the accumulator housing.

Bleed air from the hydraulic oil tank. CAUTION: (Refer to W1-4-1.) Release any pressure in the hydraulic CAUTION: circuit and the ride control accumulator. (Refer to W1-5-1.) 2. Remove bolts, washers (1) (4 used). Remove cover (2). : 19 mm

y Be sure to release pressure before starting to work on the piping lines.

3. Disconnect hose (3).

W3-16-3-1

: 36 mm

SECTION 3 BODY Group 16 Ride Control Device

WMDF-03-16-004

4. Remove bolts, washers (3) (4 used) and clamps (2) (2 used). Remove ride control accumulator (1). j : 19 mm 5. Remove the elbows with ride control accumulator (1) attached if necessary.

W3-16-3-2

SECTION 3 BODY Group 16 Ride Control Device

View A

3 a A

WMDF-03-16-004

View B

Installation

1. Install all removed elbows to ride control accumulator (1). IMPORTANT: Check the position to install ride control accumulator (1). 2. Install ride control accumulator (1) with clamps (2) (2 used) and bolts, washers (3) (4 used). j : 19 mm

WMDF-03-16-007

0 mm (0 in)

WMDF-03-16-005 b-

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-3-3

90 °

SECTION 3 BODY Group 16 Ride Control Device

1 a

WMDF-03-16-003

155 mm (6.1 in)

210 mm (8.3 in) WMDF-03-09-005

IMPORTANT: Check the direction to install cover (2). 7. Install cover (2) with bolts, washers (1) (4 used).

3. Connect hose (3). j : 36 mm

j : 19 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft)

4. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 5. Bleed air from the hydraulic system. (Refer to W1-41.)

fNOTE: Turn cover (2) by 180 degrees and install it in

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 W1-6-1.)

W3-16-3-4

case of the machine with the quick coupler.

SECTION 3 BODY Group 17 Exhaust Filter Removal and Installation of Exhaust Filter

2 3 4

5, 6, 7

8, 9 10

WMDF-03-02-007

WMDF-03-17-001

5. Disconnect connector (4) and connectors (10) (2 used). 6. Remove connectors (10) (2 used) from bracket (3). 7. Open side cover (1).

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove cover (2). (Refer to W3-4-2.) 3. Remove bolt, washer (5), nut (6), and clip (7). : 17 mm 4. Remove bolt, washer (8) and clip (9). : 13 mm

W3-17-1-1

SECTION 3 BODY Group 17 Exhaust Filter 1, 2, 3

9, 10 5 8

WMDF-03-17-002

6, 7

WMDF-03-17-003

Lifting Bracket

8. Remove bolts (9) (2 used) and washers (10) (2 used). : 10 mm IMPORTANT: Nuts (6) (3 used) cannot be reused. 9. Remove nuts (6) (3 used) and washers (7) (3 used). Remove cover (8). : 13 mm IMPORTANT: Bolts (1) (3 used), nuts (3) (3 used), and gaskets (4) (2 used) cannot be reused. 10. Remove bolts (1) (3 used), washers (2) (6 used), and nuts (3) (3 used). Disconnect exhaust pipe (5). Remove gaskets (4) (2 used).

b b-

WNEC-03-16-005

Pipe

: 13 mm Exhaust filter (11) assembly weight: CAUTION: 46 kg (105 lb) 11. Attach the nylon slings onto lifting brackets (a) (2 places) of exhaust filter (11). Hoist and hold the exhaust filter (11) assembly.

12. Remove bolts, washers (12) (4 used). : 19 mm IMPORTANT: Take care not to break pipe (b). 13. Remove the exhaust filter (11) assembly.

W3-17-1-2

SECTION 3 BODY Group 17 Exhaust Filter View A

5 16 9

12 13

14, 15

WMDF-03-17-004

14. Remove clamp (6). Remove exhaust pipe (5). : 7 mm IMPORTANT: Do not loosen screws (2) (4 used). If screw (2) has been loosened, differential pressure sensor (3) should be replaced. IMPORTANT: When disconnecting hoses (8, 9), differential pressure sensor (3) may be damaged by the force except for the force applied to the disconnecting direction. 15. Remove clips (7) (4 used). Disconnect hoses (8, 9).

WMDF-03-17-005

IMPORTANT: Do not remove bolt (10) unless necessary. 19. Remove bolts (1) (4 used). Remove bracket (4).

16. Remove harnesses (12, 16) from clips (15) (3 used). 17. Remove bolts (14) (3 used) and clips (15) (3 used). : 12 mm 18. Remove sensors (11, 13). : 14 mm

W3-17-1-3

: 13 mm

SECTION 3 BODY Group 17 Exhaust Filter View A A

1 3 8

4 5

6, 7

WMDF-03-17-004

WMDF-03-17-005

Installation

1. Install bracket (2) with bolts (1) (4 used). : 13 mm : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 2. Apply anti-seize onto the thread part of sensors (3, 5). Install sensors (3, 5). : 14 mm

: 30 N·m (3 kgf·m, 22 lbf·ft)

NOTE: Anti-seize has been applied on new sensors (3, 5). IMPORTANT: Check the angle to install clips (7) (3 used). 3. Install clips (7) (3 used) with bolts (6) (2 used).

WMDF-03-17-006 b

: 12 mm : 10 N·m (1 kgf·m, 7.4 lbf·ft) IMPORTANT: Bind clips (7) (3 used) onto harnesses (4, 8) by 1.5 turns or more in order to prevent them from coming off. 4. Install harnesses (4, 8) to clips (7) (3 used).

W3-17-1-4

60°

90°

SECTION 3 BODY Group 17 Exhaust Filter

1 2 8

IMPORTANT: The specified length of hoses (6, 8) are 210 mm (8.3 in). Cut YA00009338 (Length: 3000 mm (118 in)) for hoses (6, 8). IMPORTANT: Replace clips (4) (4 used) and hoses (6, 8) with the new ones. IMPORTANT: Insert the differential pressure sensor (1) sides of hoses (6, 8) until they comes in contact with differential pressure sensor (1). Insert the pipe (5, 7) sides of hoses (6, 8) 28 mm (1.1 in). After inserting, reduce slack of hoses (6, 8). 5. Connect hoses (6, 8) with clips (4) (4 used). 6. Install exhaust pipe (2) with clamp (3). : 7 mm : 13 N·m (1.3 kgf·m, 9.6 lbf·ft)

W3-17-1-5

WMDF-03-17-004

SECTION 3 BODY Group 17 Exhaust Filter a

b b-

2 a-

WNEC-03-16-005

Pipe

WMDF-03-17-003

Lifting Bracket

Exhaust filter (1) assembly weight: CAUTION: 46 kg (105 lb) 7. Attach the nylon sling onto lifting brackets (a) (2 places) of exhaust filter (1). Hoist the exhaust filter (1) assembly. IMPORTANT: Take care not to break pipe (b). IMPORTANT: Check the direction to install exhaust filter (1). 8. Fit pipe (b) of exhaust filter (1) to pipe hole (c). Install the exhaust filter (1) assembly with bolts, washers (2) (4 used).

c c-

: 19 mm : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-17-1-6

Pipe Hole

WMDF-03-17-007

SECTION 3 BODY Group 17 Exhaust Filter 1, 2, 3

9, 10

13, 14, 15 5

8 16, 17 18

WMDF-03-17-002

6, 7 a-

Exhaust Filter

WMDF-03-17-001

6, 7 b-

Turbocharger

IMPORTANT: Replace nuts (6) (3 used) and gasket (4) with the new ones. 9. Connect exhaust pipe (5), gasket (4), and cover (8) to turbocharger (b). Temporarily install washers (7) (3 used), nuts (6) (3 used), washers (10) (2 used), and bolts (9) (2 used).

13. Tighten bolts (9) (2 used).

IMPORTANT: Replace bolts (1) (3 used), nuts (3) (3 used), and gasket (4) with the new ones. 10. Connect exhaust pipe (5) and gasket (4) to exhaust filter (a). Temporarily install nuts (3) (3 used), washers (2) (6 used), and bolts (1) (3 used).

15. Connect connectors (18) (2 used) and connector (12).

: 10 mm : 5 N·m (0.5 kgf·m, 3.7 lbf·ft) 14. Install connectors (18) (2 used) to bracket (11).

16. Install clip (17) with bolt, washer (16). : 13 mm : 10 N·m (1 kgf·m, 7.4 lbf·ft)

11. Tighten nuts (3) (3 used) and bolts (1) (3 used). : 13 mm

17. Install clip (15) with nut (14) and bolt, washer (13). : 17 mm

: 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

: 50 N·m (5 kgf·m, 37 lbf·ft)

12. Tighten nuts (6) (3 used). : 13 mm : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-17-1-7

SECTION 3 BODY Group 17 Exhaust Filter

WMDF-03-02-007

18. Close side cover (1). 19. Install cover (2). (Refer to W3-4-2.) IMPORTANT: When the differential pressure sensor has been replaced, perform the Zero-point calibration with MPDr. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.)

W3-17-1-8

SECTION 3 BODY Group 17 Muffler Filter Disassembly of Exhaust Filter

WMDF-03-17-008

03050709-

Diesel Oxidation Catalyst Filter Muffler Bracket

11131517-

Bracket (2 Used) Bracket (2 Used) Gasket (2 Used) Pipe

18242526-

Pipe Clip (2 Used) Clip (2 Used) Bolt (2 Used)

W3-17-2-1

29303132-

Bolt (12 Used) Bolt (8 Used) Nut (20 Used) Washer (20 Used)

SECTION 3 BODY Group 17 Muffler Filter Disassembly of Exhaust Filter 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. IMPORTANT: The gasket, bolt, and nut cannot be reused. 1. Loosen pipes (17, 18).

7. Remove bolts (30) (2 used), nuts (31) (2 used), and washers (32) (2 used). Remove bracket (11) from the filter (05) assembly. : 12 mm 8. Remove bolts (30) (2 used), nuts (31) (2 used), and washers (32) (2 used). : 12 mm 9. Remove bolts (29) (6 used), nuts (31) (6 used), and washers (32) (6 used). Remove bracket (13) from the muffler (07) assembly.

: 14 mm

: 12 mm

2. Remove bolts (26) (2 used) and clips (24, 25) (2 used for each) from brackets (11) (2 used).

10. Remove the filter (05) assembly and gasket (15) from the muffler (07) assembly.

: 10 mm 3. Disconnect pipes (17, 18) from the diesel oxidation catalyst (03) assembly and the muffler (07) assembly. : 14 mm 4. Remove bolts (30) (4 used), nuts (31) (4 used), and washers (32) (4 used). Remove brackets (09, 11) from the diesel oxidation catalyst (03) assembly. : 12 mm 5. Remove bolts (29) (6 used), nuts (31) (6 used), and washers (32) (6 used). Remove bracket (13) from the diesel oxidation catalyst (03) assembly. : 12 mm 6. Remove the diesel oxidation catalyst (03) assembly and gasket (15) from the filter (05) assembly.

W3-17-2-2

SECTION 3 BODY Group 17 Muffler Filter Assembly of Exhaust Filter

WMDF-03-17-008

03050709-

Diesel Oxidation Catalyst Filter Muffler Bracket

11131517-

Bracket (2 Used) Bracket (2 Used) Gasket (2 Used) Pipe

18242526-

Pipe Clip (2 Used) Clip (2 Used) Bolt (2 Used)

W3-17-2-3

29303132-

Bolt (12 Used) Bolt (8 Used) Nut (20 Used) Washer (20 Used)

SECTION 3 BODY Group 17 Muffler Filter Assembly of Exhaust Filter

8. Tighten nuts (31) (8 used) and bolts (30) (8 used).

IMPORTANT: The gasket, bolt, and nut cannot be reused. Replace them with the new ones. 1. Temporarily install gasket (15), the filter (05) assembly, and bracket (13) to the muffler (07) assembly with washers (32) (6 used), nuts (31) (6 used), and bolts (29) (6 used).

: 12 mm : 29 N·m (2.9 kgf·m, 21.5 lbf·ft) 9. Clean the thread surfaces of pipes (18, 17). Apply anti-seize onto the thread surfaces of pipes (18, 17). 10. Temporarily install clips (24, 25) (2 used for each) to brackets (11) (2 used) with bolts (26) (2 used).

: 12 mm 2. Temporarily install gasket (15), the diesel oxidation catalyst (03) assembly, and bracket (13) to the filter (05) assembly with washers (32) (6 used), nuts (31) (6 used), and bolts (29) (6 used).

: 10 mm 11. Temporarily install pipes (18, 17) to the muffler (07) assembly and the diesel oxidation catalyst (03) assembly.

: 12 mm

: 14 mm

3. Temporarily install bracket (11) to the filter (05) assembly with washers (32) (2 used), nut (31) (2 used), and bolts (30) (2 used).

12. Tighten pipes (18, 17). : 14 mm

: 12 mm

: 35 N·m (3.5 kgf·m, 26 lbf·ft)

4. Temporarily install washers (32) (2 used), nut (31) (2 used), and bolts (30) (2 used) to the filter (05) assembly.

13. Tighten bolts (26) (2 used). : 10 mm

: 12 mm

: 10 N·m (1 kgf·m, 7.4 lbf·ft)

5. Temporarily install brackets (11, 09) to the diesel oxidation catalyst (03) assembly with washers (32) (4 used), nut (31) (4 used), and bolts (30) (4 used). : 12 mm 6. Place the filter (05) assembly on the flat and level surface to keep the mounting surfaces of brackets (13) (2 used) horizontally. 7. Tighten nuts (31) (12 used) and bolts (29) (12 used). : 12 mm : 29 N·m (2.9 kgf·m, 21.5 lbf·ft)

W3-17-2-4

SECTION 4

TRAVEL SYSTEM CONTENTS Group 1 Tire Removal and Installation of Front Tire ...................W4-1-1-1 Applicable Tire Size ..................................................W4-1-1-3 Removal and Installation of Rear Tire .....................W4-1-2-1 Applicable Tire Size ..................................................W4-1-2-5

Group 2 HST Motor Removal and Installation of HST Motor .................W4-2-1-1 Disassembly of HST Motors 1, 2................................W4-2-2-1 Assembly of HST Motors 1, 2 .....................................W4-2-2-3

Group 3 Transmission Removal and Installation of Transmission ............W4-3-1-1 Disassembly of Transmission .....................................W4-3-2-1 Assembly of Transmission........................................ W4-3-2-10 Disassembly of Clutch Assembly..............................W4-3-3-1 Assembly of Clutch Assembly ...................................W4-3-3-3 Disassembly of Clutch Pressure Control Solenoid Valve ...........................................................W4-3-4-1 Assembly of Clutch Pressure Control Solenoid Valve ...........................................................W4-3-4-3

Group 6 Brake Valve Removal and Installation of Brake Valve................W4-6-1-1 Disassembly of Brake Valve ........................................W4-6-2-1 Assembly of Brake Valve ..............................................W4-6-2-3

Group 7 Steering Device Removal and Installation of Steering Valve ..........W4-7-1-1 Disassembly of Steering Valve ..................................W4-7-2-1 Assembly of Steering Valve ........................................W4-7-2-4 Removal and Installation of Steering Cylinder ....W4-7-3-1 Disassembly of Steering Cylinder ............................W4-7-4-1 Assembly of Steering Cylinder ..................................W4-7-4-5 Removal and Installation of Steering Accumulator ...............................................................W4-7-5-1

Group 8 Secondary Steering Device Removal and Installation of Secondary Steering Pump (Option) ...........................................................W4-8-1-1

Group 4 Axle Removal and Installation of Front Axle ..................W4-4-1-1 Removal and Installation of Rear Axle....................W4-4-2-1 Disassembly of Axle ......................................................W4-4-3-1 Axle Equipped with TPD ........................................W4-4-3-1 Axle Equipped with LSD ........................................W4-4-3-3 Disassembly of Spider ......................................... W4-4-3-10 Removal of Differential Housing ...................... W4-4-3-11 Removal of Housing ............................................. W4-4-3-13 Disassembly of Differential Housing (Axle Equipped with TPD)................................ W4-4-3-15 Disassembly of Differential Housing (Axle Equipped with LSD)................................ W4-4-3-16 Assembly of Axle ......................................................... W4-4-3-17 Rotation Resistance Adjustment of Pinion... W4-4-3-26 Airtight Test of Piston ........................................... W4-4-3-30 Backlash Adjustment and Teeth Engagement Adjustment of Ring Gear and Pinion........... W4-4-3-31 Preload Adjustment of Axle Shaft Bearing (Shim Adjustment) ............................................. W4-4-3-38

Group 5 Propeller Shaft Removal and Installation of Propeller Shaft .........W4-5-1-1

62Z7(USA)D&R

(Blank)

62Z7(USA)D&R

SECTION 4 TRAVEL SYSTEM Group 1 Tire Removal and Installation of Front Tire 1

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove front fender (1). (Refer to W3-4-2.) 3. Loosen wheel bolts (3) (13 used) one turn. j : 36 mm 3, 4

dCAUTION: Machine weight: 11160 kg (24700 lb) 4. Raise the machine until tire (2) slightly gets away from the ground. Securely support the machine by using stand (a). Lower the bucket onto the ground.

b W4GB-03-03-101

Stand

Wheel Stopper

dCAUTION: Tire (2) weight: 360 kg (795 lb)

5. Attach lifting tools onto tire (2). Hoist and hold tire (2). 6. Remove wheel bolts (3) (13 used) and washers (4) (13 used). Remove tire (2).

j : 36 mm 2

W4GB-03-01-003 c-

W4-1-1-1

Lifting Tool

SECTION 4 TRAVEL SYSTEM Group 1 Tire Installation

dCAUTION: Tire (2) weight: 360 kg (795 lb)

1. Hoist and install tire (2) to the front axle.

2. Temporarily tighten tire (2) with washers (4) (13 used) and wheel bolts (3) (13 used). j : 36 mm

dCAUTION: Machine weight: 11160 kg (24700 lb) 3. Remove stand (a) from the machine. Lower the machine and place tire (2) onto the ground.

3, 4

b W4GB-03-03-101

4. Tighten wheel bolts (3) (13 used) according to the order as illustrated.

Stand

Wheel Stopper

j : 36 mm

m : 890 N·m (91 kgf·m, 660 lbf·ft) 5. Install front fender (1). (Refer to W3-4-2.)

fNOTE: Air Pressure of Tires: 20.5R25

IMPORTANT: Check air pressure of the tires. Check for abnormal wear and damage of the tires.

Standard Tire Size

Standard Air Pressure 400 kPa (4.00 kgf/cm2, 58 PSI)

9 4

11 2

13 MNDF-07-031

W4-1-1-2

SECTION 4 TRAVEL SYSTEM Group 1 Tire Applicable Tire Size

fNOTE: The machine may vibrate while driving

depending on the tread pattern of tires. This is a sympathetic vibration due to tread pattern, not a malfunction.

Applicable Tire Size

Standard Size Standard Air Pressure Standard Tire Optional

Radial Tires Manufacturer Michelin Michelin Bridgestone

20.5 R 25 400 kPa (4.00 kgf/cm2, 58 PSI) L3 20.5 R 25 (XHA2) L5 (XLDD2) L5 (XMINE D2) L3 (VJTZ)

fNOTE: Adjust air pressure according to the size and

type of tires provided in the table above regardless of the tread pattern. Adjust tire pressure in conformity with the work mode the machine is engaged in.  Driving on Public Roads: ... Standard pressure  Loading/excavation on normal ... Standard or slightly higher than standard pressure  Heavy-duty excavation: ... Higher pressure in the standard pressure range  Operation on soft terrain or ... Radial Tires: sandy territory: Standard pressure

Air pressure adjustment range Radial Tires: 400 to 450 kPa (4.00 to 4.50 kgf/cm2, 58 to 65 PSI)

W4-1-1-3

SECTION 4 TRAVEL SYSTEM Group 1 Tire (Blank)

W4-1-1-4

SECTION 4 TRAVEL SYSTEM Group 1 Tire Removal and Installation of Rear Tire

1 WMDF-03-04-001

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove the following parts. (Refer to W3-4-2.)  Rear fender (front) (2)  Rear fender (rear) (1)

W4-1-2-1

SECTION 4 TRAVEL SYSTEM Group 1 Tire 3. Insert wooden blocks (b) between rear frame (4) and rear axle (5) on both right and left sides in order to prevent rear axle (5) from moving.

4. Loosen wheel bolts (1) (13 used) one turn. j : 36 mm

dCAUTION: Machine weight: 11160 kg (24700 lb) 5. Raise the machine until tire (3) slightly gets away from the ground. Securely support the machine by using stand (a).

CAUTION: Tire (3) weight: 360 kg (795 lb) 6. Attach lifting tools onto tire (3). Hoist and hold tire (3).

1, 2 WMDF-04-01-001

Stand

Wheel Stopper

7. Remove wheel bolts (1) (13 used) and washers (2) (13 used). Remove tire (3). j : 36 mm

Detail B b

5 W4FC-03-01-005 b-

Wooden Block

W4GB-03-01-003 c-

W4-1-2-2

Lifting Tool

SECTION 4 TRAVEL SYSTEM Group 1 Tire Installation

dCAUTION: Tire (3) weight: 360 kg (795 lb)

1. Hoist and install tire (3) to rear axle (5).

2. Temporarily tighten tire (3) with washers (2) (13 used) and wheel bolts (1) (13 used). j : 36 mm a

CAUTION: Machine weight: 11160 kg (24700 lb) 3. Remove wooden block (b) and stand (a) from the machine. Lower the machine and place tire (3) onto the ground. 4. Tighten wheel bolts (1) (13 used) according to the order as illustrated.

1, 2 WMDF-04-01-001

Stand

Wheel Stopper

j : 36 mm Detail B

m : 890 N·m (91 kgf·m, 660 lbf·ft)

IMPORTANT: Check air pressure of the tires. Check for abnormal wear and damage of the tires.

fNOTE: Air Pressure of Tires (3): Standard Tire Size 20.5R25

Standard Air Pressure 400 kPa (4.00 kgf/cm2, 58 PSI)

5 W4FC-03-01-005 b-

Wooden Block

3 12

9 4

11 2

13 MNDF-07-031

W4-1-2-3

SECTION 4 TRAVEL SYSTEM Group 1 Tire

1 WMDF-03-04-001

5. Install the following parts. (Refer to W3-4-2.)  Rear fender (rear) (1)  Rear fender (front) (2)

W4-1-2-4

SECTION 4 TRAVEL SYSTEM Group 1 Tire Applicable Tire Size

fNOTE: The machine may vibrate while driving

depending on the tread pattern of tires. This is a sympathetic vibration due to tread pattern, not a malfunction.

Applicable Tire Size

Standard Size Standard Air Pressure Standard Tire Optional

Radial Tires Manufacturer Michelin Michelin Bridgestone

20.5 R 25 400 kPa (4.00 kgf/cm2, 58 PSI) L3 20.5 R 25 (XHA2) L5 (XLDD2) L5 (XMINE D2) L3 (VJTZ)

fNOTE: Adjust air pressure according to the size and

Air pressure adjustment range Radial Tires: 400 to 450 kPa (4.00 to 4.50 kgf/cm2, 58 to 65 PSI)

W4-1-2-5

SECTION 4 TRAVEL SYSTEM Group 1 Tire (Blank)

W4-1-2-6

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor Removal and Installation of HST Motor 1 2

WMDF-03-02-007

CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious 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 staring any work.

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove side covers (1) at right and left sides. (Refer to W3-4-2.) 3. Remove cab (2). (Refer to W3-1-1.)

W4-2-1-1

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor 4

WMDF-03-08-001

4. Remove the muffler filter (3) assembly. (Refer to W317-1.) 5. Remove the air cleaner (2) assembly. (Refer to W3-43.) 6. Remove support (1) and pump device (4). (Refer to W3-8-1.)

W4-2-1-2

WMDF-03-08-006

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor

6, 7

WMDF-04-02-002

2, 3, 4

WMDF-04-03-018

8, 9, 10

7. Remove bolts (2) (16 used) and flanges (3) (8 used). Disconnect hoses (1) (4 used). Remove O-rings (4) (4 used). j : 19 mm 8. Disconnect connectors (5) (2 used).

9. Remove bolts, washers (6) (2 used) and brackets (7) (2 used). j : 17 mm 10. Remove bolt, washer (8), nut (9), and clips (10) (2 used). j : 17 mm 12

11. Disconnect hose (13). j : 27 mm

12. Disconnect hoses (11, 12). WMDF-04-03-019

j : 36 mm

W4-2-1-3

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor

7 11

2 1

WMDF-04-02-001

WMDF-04-03-020

13. Disconnect hoses (1, 2).

HST motor 2 (11) weight: 50 kg (115 dCAUTION: lb)

j : 36 mm

dCAUTION: HST motor 1 (3) weight: 50 kg (115 lb) 14. Attach nylon slings onto HST motor 1 (3). Hoist and hold HST motor 1 (3). 15. Remove bolts (4) (4 used) and washers (5) (4 used). Remove HST motor 1 (3) from transmission (7). Remove O-ring (6) from HST motor 1 (3). j : 24 mm 16. Remove the adapter with HST motor 1 (3) attached if necessary.

17. Attach nylon slings onto HST motor 2 (11). Hoist and hold HST motor 2 (11). 18. Remove bolts (10) (4 used) and washers (9) (4 used). Remove HST motor 2 (11) from transmission (7). Remove O-ring (8) from HST motor 2 (11). j : 24 mm 19. Remove the adapter with HST motor 2 (11) attached if necessary.

W4-2-1-4

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor

8 7 a-

Flushing Valve

WMDF-04-02-001

IMPORTANT: Check the positions to install HST motor 1 (1) and HST motor 2 (9). HST motor 2 (9) is equipped with flushing valve (a). Installation 1. Install all removed adapters to HST motor 2 (9).

CAUTION: HST motor 2 (9) weight: 50 kg (115 lb) 2. Install O-ring (6) to HST motor 2 (9). Attach nylon slings onto HST motor 2 (9). Hoist HST motor 2 (9).

4. Install all removed adapters to HST motor 1 (1).

dCAUTION: HST motor 1 (1) weight: 50 kg (115 lb) 5. Install O-ring (4) to HST motor 1 (1). Attach nylon slings onto HST motor 1 (1). Hoist HST motor 1 (1).

6. Install HST motor 1 (1) to transmission (5) with bolts (2) (4 used) and washers (3) (4 used).

3. Install HST motor 2 (9) to transmission (5) with bolts (8) (4 used) and washers (7) (4 used). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W4-2-1-5

j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor

View A

View B 2 1

1 A WMDF-04-03-020

IMPORTANT: Check the angle to install hoses (1, 2). 7. Connect hoses (1, 2). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

W4-2-1-6

5°

WMDF-04-03-025 b-

60°

WMDF-04-03-026

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor

1, 2, 3 7

8, 9 5 6

WMDF-04-02-002 WMDF-04-03-019

8. Connect hoses (4, 5).

11. Install brackets (9) (2 used) with bolts, washers (8) (2 used).

j : 36 mm

j : 17 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

9. Connect hose (6).

12. Connect connectors (7) (2 used).

j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 10. Install clips (3) (2 used) with bolt, washer (1) and nut (2). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-2-1-7

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor

View A

View B 1

1 1

2, 3, 4

WMDF-04-03-018

IMPORTANT: Check the angle to install hoses (1) (4 used). 13. Install O-rings (4) (4 used). Install hoses (1) (4 used) with flanges (3) (8 used) and bolts (2) (16 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W4-2-1-8

15°

WMDF-04-03-027

bc-

35° 70°

WMDF-04-03-028

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor

WMDF-03-08-006

WMDF-03-08-001

14. Install pump device (1) and support (2). (Refer to W3-8-1.)

15. Install the air cleaner (3) assembly. (Refer to W3-4-3.)

16. Install the muffler filter (4) assembly. (Refer to W317-1.) 17. Install cab (6). (Refer to W3-1-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 18. Install side covers (5) at right and left sides. (Refer to W3-4-2.)

WMDF-03-02-007

W4-2-1-9

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor (Blank)

W4-2-1-10

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor Disassembly of HST Motors 1, 2

6 5

11 12

3 2 1

A: B:

HST Motor 1 HST Motor 2 WMDF-04-02-003

123456-

Retaining Ring Plate Shaft Seal Ring Housing Valve Block O-Ring (3 Used) (HST Motor 2: 6 Used)

789101112-

Socket Bolt (4 Used) Cover Block Socket Bolt (4 Used) Cover Block Valve Seat (2 Used) Check Valve (2 Used)

13- Motor Displacement Angle Control Solenoid Valve 14- Socket Bolt (4 Used) 15- O-Ring 16- *Spring 17- *Collar 18- *Collar

fNOTE: As for the item with mark*, refer to 4-2-2-3. W4-2-2-1

192021222324-

*Bushing *Nut *Screw *Pin *Spring *Spring

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor Disassembly of HST Motors 1, 2

dCAUTION: HST motors 1, 2 weight: 50 kg (115 lb)

IMPORTANT: Do not disassemble the parts other than instructed ones. If the setting changes, the machine troubles may occur.

fNOTE: The difference between HST motors 1 and 2 is

4. Measure and record mounting dimension (b) before removing motor displacement angle control solenoid valve (13). Loosen nut (20). Remove screw (21) from motor displacement angle control solenoid valve (13). Screw (21)

only cover blocks (8, 10). 1. Remove retaining ring (1) and plate (2) from housing (4).

l : 3 mm Nut (20)

2. Install tapping screws (a) (M4, Length approx 20 mm(0.79 in)) (2 used) to the shaft seal ring (3) holes (2 places). Remove shaft seal ring (3) from housing (4) by holding tapping screws (a) (2 used) by using a pair of pliers.

j : 10 mm 20

a b-

Tapping Screw

Mounting Dimension

W4FC-03-03-003

3. HST Motor 1 Put the matching marks on valve block (5) and cover block (8). Remove socket bolts (7) (4 used). Remove cover block (8) and O-rings (6) (3 used) from valve block (5). l : 8 mm

WMDF-04-02-007

IMPORTANT: Slowly remove socket bolts (14) (4 used) alternately as the spring force is applied to motor displacement angle control solenoid valve (13). 5. Remove socket bolts (14) (4 used). Remove motor displacement angle control solenoid valve (13), pin (22), collars (17, 18), bushing (19), and springs (16, 23, 24) from valve block (5). Remove O-ring (15) from motor displacement angle control solenoid valve (13). l : 5 mm 6. Remove check valves (12) (2 used) and valve seats (11) (2 used) from valve block (5).

HST Motor 2 Put the matching marks on valve block (5) and cover block (10). Remove socket bolts (9) (4 used). Remove cover block (10) and O-rings (6) (6 used) from valve block (5). l : 8 mm

W4-2-2-2

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor Assembly of HST Motors 1, 2 4

7, 9

8, 10

1 2

16 14

24 17 23

11 19 12

22 21 20

WMDF-04-02-004

123456-

Retaining Ring Plate Shaft Seal Ring Housing Valve Block O-Ring (3 Used) (HST Motor 2: 6 Used)

789101112-

Socket Bolt (4 Used) Cover Block Socket Bolt (4 Used) Cover Block Valve Seat (2 Used) Check Valve (2 Used)

13- Motor Displacement Angle Control Solenoid Valve 14- Socket Bolt (4 Used) 15- O-Ring 16- Spring 17- Collar 18- Collar

W4-2-2-3

192021222324-

Bushing Nut Screw Pin Spring Spring

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor Assembly of HST Motors 1, 2 IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

4. HST Motor 1

fNOTE: The difference between HST motors 1 and 2 is

only cover blocks (8, 10). 1. Install valve seats (11) (2 used) and check valves (12) (2 used) to valve block (5). 2. Install O-ring (15), springs (16, 23, 24), collars (17, 18), and bushing (19) to motor displacement angle control solenoid valve (13). Install the motor displacement angle control solenoid valve (13) assembly to valve block (5) with socket bolts (14) (4 used).

l : 8 mm m : 75 N·m (7.5 kgf·m, 55 lbf·ft) HST Motor 2

l : 5 mm

Install O-rings (6) (6 used) to valve block (5). Fit the matching marks made when disassembling and install cover block (10) to valve block (5) with socket bolts (9) (4 used).

m : 15.5 N·m (1.6 kgf·m, 11.5 lbf·ft)

l : 8 mm

IMPORTANT: Secure screw (21) with nut (20) lock screw (21) by using a hexagonal wrench in order not to turn them. 3. Install pin (22) and screw (21) to motor displacement angle control solenoid valve (13) so that a clearance can be equal to mounting dimension (a) before disassembling. Secure screw (21) with nut (20). Screw (21) l : 3 mm Nut (20) j : 10 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

22 a-

Install O-rings (6) (3 used) to valve block (5). Fit the matching marks made when disassembling and install cover block (8) to valve block (5) with socket bolts (7) (4 used).

Mounting Dimension

a WMDF-04-02-007

W4-2-2-4

m : 75 N·m (7.5 kgf·m, 55 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor IMPORTANT: Do not damage shaft seal ring (3) with the spline part of shaft (c). 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. Apply grease onto the lip part of shaft seal ring (3). Install special tool (a) (Rexroth tool No.: R909877394) to special tool (b) (Rexroth tool No.: R909877385) as illustrated. Install shaft seal ring (3) to housing (4) by using special tools (a, b). After installing shaft seal ring (3), check that groove (d) on special tool (b) is fit to the housing (4) end. a b c

4 d

3 a-

Special Tool b-

Special Tool c-

Shaft

Groove

WMDF-04-02-008

6. Install plate (2) and retaining ring (1) to housing (4).

W4-2-2-5

SECTION 4 TRAVEL SYSTEM Group 2 HST Motor (Blank)

W4-2-2-6

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Removal and Installation of Transmission 5

WMDF-03-02-007

WMDF-04-03-017

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

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

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 staring any work. 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

IMPORTANT: Do not apply liquid packing onto drain plug (2). 2. Place a container under drain plug (2). Remove drain plug (2). Drain off transmission oil. Install drain plug (2). l : 12 mm m : 70 N·m (7 kgf·m, 5.2 lbf·ft)

fNOTE: Amount of transmission oil: 10 L (2.6 US gal) 3. Remove propeller shafts (1, 4) from transmission (3). (Refer to W4-5-1.) 4. Remove side covers (5) at right and left sides. (Refer to W3-4-2.) 5. Remove cab (6). (Refer to W3-1-1.)

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

W4-3-1-1

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

WMDF-03-08-001

6. Remove the muffler filter (3) assembly. (Refer to W317-1.) 7. Remove the air cleaner (2) assembly. (Refer to W3-43.) 8. Remove support (1) and pump device (4). (Refer to W3-8-1.)

W4-3-1-2

WMDF-03-08-006

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

7, 8, 9

11 12 2, 3, 4

WMDF-04-03-018

9. Remove bolts (2) (16 used) and flanges (3) (8 used). Disconnect hoses (1) (4 used). Remove O-rings (4) (4 used). j : 19 mm

WMDF-04-03-019

11. Remove bolt, washer (7), nut (8), and clips (9) (2 used). j : 17 mm 12. Disconnect hose (12).

10. Remove clamp (5). Disconnect hose (6). j : 7 mm

j : 27 mm 13. Disconnect hoses (10, 11). j : 36 mm

W4-3-1-3

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 9 2

1 3

9 6

15 4 14 5 WMDF-04-03-020

14. Remove clamp (1). Disconnect hose (2). j : 9.5 mm 15. Remove clamp (5). Disconnect hose (4). j : 7 mm 16. Disconnect hoses (3, 6). WMDF-04-03-022

j : 36 mm 17. Disconnect connectors (9) (6 used). 18. Remove bolt, washer (8), clip (7), and nut (13).

20. Remove bolts, washers (12, 14). Remove the bracket (15) assembly. Bolt, Washer (12)

j : 17 mm

j : 19 mm

19. Remove bolt, washer (10) and bracket (11).

Bolt, Washer (14)

j : 17 mm

W4-3-1-4

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

3 1

6 3

Lifting Hole

WMDF-04-03-021

4 5 3 2

The transmission (1) assembly weight: dCAUTION: 330 kg (730 lb) 21. Install the special tools (ST 0073) (3 used) to lifting holes (a) (3 places) of the transmission (1) assembly. Attach nylon slings onto the special tools (ST 0073) (3 used). Hoist and hold the transmission (1) assembly.

WMDF-04-03-023

23. Remove the adapters with the transmission (1) assembly attached if necessary.

22. Remove bolts (6) (4 used), washers (3) (8 used), plates (5) (4 used), rubbers (4) (8 used), and nuts (2) (4 used). Remove the transmission (1) assembly. Place it onto a stable stand. j : 27 mm

W4-3-1-5

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 2

7 3

4 1 5

6 WMDF-04-03-024

5 WMDF-04-03-021

24. Remove HST motor 1 (2) and HST motor 2 (1) from transmission (3). (Refer to W4-2-1.) 25. Remove bolts (6) (4 used) and washers (5) (4 used). Remove bracket (4) from transmission (3). j : 24 mm

fNOTE: LOCTITE #262 has been applied on bolts (6) (4

used). 26. Remove another bracket (7) in the same way as step 25.

W4-3-1-6

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 2

WMDF-04-03-024

WMDF-04-03-021

Installation 1. Apply LOCTITE #262 onto bolts (6) (4 used). Install bracket (4) to transmission (3) with bolts (6) (4 used) and washers (5) (4 used). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 2. Install another bracket (7) in the same way as step 1. 3. Install HST motor 1 (2) and HST motor 2 (1) to transmission (3). (Refer to W4-2-1.)

W4-3-1-7

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

6 3

Lifting Hole

WMDF-04-03-021

4. Install all removed adapters to the transmission (1) assembly. The transmission (1) assembly weight: dCAUTION: 330 kg (730 lb) 5. Install the special tools (ST 0073) (3 used) to lifting holes (a) (3 places) of the transmission (1) assembly. Attach nylon slings onto the special tools (ST 0073) (3 used). Hoist the transmission (1) assembly. 6. Install the transmission (1) assembly with bolts (6) (4 used), washers (3) (8 used), plates (5) (4 used), rubbers (4) (8 used), and nuts (2) (4 used). j : 27 mm m : 315 N·m (31.5 kgf·m, 230 lbf·ft)

W4-3-1-8

4 5 3 2 WMDF-04-03-023

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 9 7

1 3 B

14 5

WMDF-04-03-020

View A

View B 6 3

d c-

5°

WMDF-04-03-025 d-

WMDF-04-03-022

7. Install the bracket (15) assembly with bolts, washers (12, 14).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) IMPORTANT: Check the angle to install hoses (3, 6). 11. Connect hoses (3, 6).

Bolt, Washer (14)

j : 36 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 180 N·m (18 kgf·m, 133 lbf·ft) 12. Connect hose (4) with clamp (5).

8. Install bracket (11) with bolt, washer (10).

j : 7 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

WMDF-04-03-026

10. Install clip (7) with bolt, washer (8) and nut (13).

Bolt, Washer (12) j : 19 mm

60°

m : 4 N·m (0.4 kgf·m, 3 lbf·ft) 13. Connect hose (2) with clamp (1).

9. Connect connectors (9) (6 used).

j : 9.5 mm m : 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)

W4-3-1-9

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

7, 8, 9

11 12 WMDF-04-03-019

WMDF-04-03-018

2, 3, 4

View A

View B 1

14. Connect hoses (10, 11).

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

15. Connect hose (12). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 16. Install clips (9) (2 used) with bolt, washer (7) and nut (8).

15°

WMDF-04-03-027

bc-

35° 70°

WMDF-04-03-028

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 17. Connect hose (6) with clamp (5). j : 7 mm

IMPORTANT: Check the angle to install hoses (1) (4 used). 18. Install O-rings (4) (4 used). Install hoses (1) (4 used) with flanges (3) (8 used) and bolts (2) (16 used). j : 19 mm

m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W4-3-1-10

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

6 4

5 1 M4FC-07-019

WMDF-04-03-017

19. Install propeller shafts (1, 3) to transmission (2). (Refer to W4-5-1.) 20. Open cover (6). Remove oil gauge (4). Add transmission oil through oil filler (5).

fNOTE: Amount of transmission oil: 10 L (2.6 US gal) 21. Install oil gauge (4). Close cover (6).

W4-3-1-11

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

WMDF-03-08-006

WMDF-03-08-001

22. Install pump device (1) and support (2). (Refer to W3-8-1.)

23. Install the air cleaner (3) assembly. (Refer to W3-4-3.)

24. Install the muffler filter (4) assembly. (Refer to W317-1.) 25. Install cab (6). (Refer to W3-1-1.) IMPORTANT: Check the hydraulic oil level and transmission oil level. Start the engine and check for any oil leaks. 26. Install side covers (5) at right and left sides. (Refer to W3-4-2.)

WMDF-03-02-007

W4-3-1-12

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Disassembly of Transmission 123 11

4 5 6

10 7

85 86

83 82 81

80 15

122

92a 21 19

21 23

95a 20 18 17

38 37 36 35 77 76

34, 121

32 40

41 42

43 44

49 49

45 49

55 73

56 57

58 59 70

52 73 72

56 57

69 68 67

61 66

64 63 62 WMDF-04-03-003

W4-3-2-1

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

91 92 93 94 95

97 98 99 100

101

102 103 104 105

106

107

108 109 110 111 98

114

97 115 116 117 118 119

120 W4FC-03-04-002

W4-3-2-2

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 12345678910111213141517181920212223252627282931-

Bolt (3 Used) Retainer Plate Shim O-Ring Flange Bearing Cap Rotation Sensor Socket Bolt (2 Used) Sensor Transmission Case Socket Bolt (2 Used) Clutch Pressure Control Solenoid Valve Gasket Pin (2 Used) Bolt (27 Used) Plug O-Ring Bearing Cap Bolt (4 Used) Elbow (3 Used) Adapter Pipe Pipe Adapter Tee Orifice Pipe Pipe

3233343536373839404142434445464749525354555657585960616263-

Adapter Orifice Plug Orifice Bolt (4 Used) Plug Distributor Cap Gasket (2 Used) Washer (5 Used) Bolt (5 Used) Flange Plug Retaining Ring Bearing Cap O-Ring (2 Used) Brake Housing Plate (7 Used) D-Ring D-Ring Pin (2 Used) Spring (24 Used) Washer (4 Used) Socket Bolt (4 Used) O-Ring Plug Washer Orifice Bolt (2 Used) Washer (2 Used)

64- Bolt 65- Nut 66- Washer 67- Washer 68- Brake Cap 69- O-Ring 70- Piston 71- Piston Housing 72- End Plate 73- Disc (6 Used) 74- Pin (2 Used) 75- Socket Bolt (2 Used) 76- Plug 77- O-Ring 78- Plug 79- Adapter 80- Transmission Cover 81- Strainer 82- O-Ring 83- Gasket 84- Bolt (4 Used) 85- Suction Tube 86- Bolt (5 Used) 89- Retaining Ring 90- Bearing 91- Input Gear 1 92- Bearing 92a- Retaining Ring 93- Spacer

W4-3-2-3

94- Retaining Ring 95- Clutch Assembly 95a- Retaining Ring 96- Spacer 97- O-Ring (2 Used) 98- Oil Seal (2 Used) 99- Spacer 100- Bearing 101- Spacer 102- Output Gear 103- Oil Baffle 104- Washer (2 Used) 105- Washer (2 Used) 106- Bolt (2 Used) 107- Output Shaft 108- Bearing 109- Spacer 110- Retaining Ring 111- Spacer 114- Retaining Ring 115- Bearing 116- Input Gear 2 117- Bearing 118- Retaining Ring 119- Disc Hub 120- Retaining Ring 121- O-Ring 122- Bracket 123- Socket Bolt (6 Used)

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 6. Remove bolts (84) (4 used). Remove suction tube (85), gasket (83), O-ring (82), and strainer (81) from transmission case (10).

Disassembly of Transmission The transmission assembly weight: dCAUTION: 210 kg (465 lb)

j : 17 mm 1. Disconnect the both ends of pipes (23, 25, 29, 31) from the transmission assembly.

7. Install the special tools (ST 0073) (3 used) to lifting holes (b) (3 places) of the transmission assembly. Attach the nylon slings onto the special tools (ST 0073) (3 used). Hoist the transmission assembly. Place the transmission assembly with transmission cover (80) up.

j : 22 mm 2. Loosen lock nut (a) of rotation sensor (7). j : 27 mm a

10 b b-

W4FC-03-04-020 a-

WMDF-04-03-004

Lifting Hole

8. Remove socket bolts (57) (4 used), washers (56) (4 used), and washer (60). Remove the brake cap (68) assembly from brake housing (47). l : 8 mm

Lock Nut

3. Remove rotation sensor (7) from transmission case (10).

56, 57

j : 24 mm 4. Remove socket bolts (8) (2 used). Remove sensor (9) from transmission case (10).

56, 57, 60

l : 5 mm 5. Remove socket bolts (11) (2 used) and socket bolts (123) (6 used). Remove clutch pressure control solenoid valve (12) and gasket (13) from transmission case (10) .

l : 6 mm

W4-3-2-4

WMDF-04-03-005

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 18. Remove retaining ring (95a) from clutch assembly (95).

Spring (55) may fly out if loosening dCAUTION: bolts (62) (2 used) quickly. Loosen bolts (62) (2 used) alternately.

9. Remove bolts (62) (2 used) and washers (63) (2 used). Remove brake cap (68) and O-ring (69) from piston housing (71). j : 17 mm 10. Remove springs (55) (24 used) from piston (70). 11. Remove piston (70) from piston housing (71). Remove D-rings (52, 53) from piston (70).

95a

12. Remove O-ring (46) and end plate (72) from the piston housing (71) side of brake housing (47). W4FC-03-04-004

13. Remove socket bolts (75) (2 used). Remove brake housing (47) from transmission cover (80).

19. Remove bolts (20) (4 used). Remove bearing cap (19) and gasket (39) from transmission cover (80).

l : 8 mm 14. Remove O-ring (46) from the transmission cover (80) side of brake housing (47). 15. Remove plates (49) (7 used) and discs (73) (6 used) from disc hub (119).

j : 17 mm 20. Remove flange (42) from the output shaft (107) assembly. Remove retaining ring (44) and plug (43) from flange (42).

16. Remove retaining ring (120) and disc hub (119) from the input gear 2 (116) assembly. 17. Remove bolts (36) (4 used). Remove distributor cap (38) and gasket (39) from transmission cover (80). l : 17 mm

W4-3-2-5

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 21. Remove bolts (41) (5 used) and washers (40) (5 used). Install bolts (41) (2 used) which have been removed to thread parts (a) (2 places) of bearing cap (45). Tighten them evenly. Remove bearing cap (45) and spacer (111) from transmission cover (80). Remove bolts (41) (2 used). j : 19 mm

Transmission cover (80) weight: 42 kg dCAUTION: (93 lb) 25. Install the special tools (ST 0072, ST 0073) to transmission cover (80). Attach the nylon slings onto the special tools (ST 0072, ST 0073). Hoist and hold transmission cover (80). 26. Remove bolts (15) (27 used) and bracket (122). Remove transmission cover (80) from transmission case (10).

j : 19 mm 45

fNOTE: LOCTITE #5127 has been applied on the mating surfaces of transmission case (10) and transmission cover (80).

fNOTE: Remove the input gear 1 (91) assembly together a

with transmission cover (80). Clutch assembly (95), the output shaft (107) assembly, and the input gear 2 (116) assembly should be left in transmission case (10).

W4FC-03-04-005 a-

116

Thread Part

ST 0073

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

107 ST 0072

such as goggles, helmets, etc in order to prevent personal injury. 22. Remove oil seal (98) from bearing cap (45) by using a screwdriver and a hammer.

fNOTE: LOCTITE #262 has been applied on the outer surface of oil seal (98).

23. Remove O-ring (97) from bearing cap (45). 24. Remove retaining ring (110) and spacer (109) from the output shaft (107) assembly.

W4-3-2-6

W4FC-03-04-007

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 27. Remove retaining ring (92a) from bearing (92). Remove the input gear 1 (91) assembly from transmission cover (80).

Clutch assembly (95) weight: 29 kg (64 dCAUTION: lb) 33. Install the special tool (ST 0071) to lifting hole (b) of clutch assembly (95). Attach the nylon slings onto the special tool (ST 0071). Hoist and remove clutch assembly (95) from transmission case (10).

95 92a W4FC-03-04-008

28. Remove retaining ring (94) and spacer (93) from input gear 1 (91). Remove bearing (92) from input gear 1 (91) by using a puller. 29. Remove retaining ring (89) from input gear 1 (91). Remove bearing (90) from input gear 1 (91) by using a puller. 30. Remove retaining ring (118) from transmission cover (80).

b WMDF-04-03-006

ab-

Drilled Hole Lifting Hole

Plug

34. Remove the input gear 2 (116) assembly from transmission case (10).

31. Remove bearing (117) from input gear 2 (116) by using a puller. 32. Remove bearing (108) from transmission cover (80) by using a puller.

35. Remove retaining ring (114) from input gear 2 (116). Remove bearing (115) from input gear 2 (116) by using a separator and a puller.

115

116

W4FC-03-04-027

W4-3-2-7

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Transmission case (10) weight: 66 kg dCAUTION: (150 lb) 36. Install the special tools (ST 0073) (3 used) to lifting holes (a) (3 places) of transmission case (10). Attach the nylon slings onto the special tools (ST 0073) (3 used). Hoist transmission case (10). Place transmission case (10) vertically. Remove bolts (1) (3 used). Remove retainer plate (2), shim (3), O-ring (4), and flange (5) from output shaft (107).

37. Remove bolts (86) (5 used). Install bolts (86) (2 used) which have been removed to thread parts (b) (2 places) of bearing cap (6). Tighten them evenly. Remove bearing cap (6) from transmission case (10). Remove bolts (86) (2 used). j : 17 mm

j : 19 mm

fNOTE: LOCTITE #262 has been applied on the thread part of bolts (1) (3 used).

86 6 W4FC-03-04-010 b-

Thread Part

38. Remove O-ring (97) from bearing cap (6). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury.

Lifting Hole

WMDF-04-03-007

39. Remove oil seal (98) from bearing cap (6) by using a screwdriver and a hammer.

fNOTE: LOCTITE #262 has been applied on the outer surface of oil seal (98).

W4-3-2-8

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 40. Remove spacer (99) from the output shaft (107) assembly. 41. Hoist transmission case (10). Place transmission case (10) with the transmission cover (80) mounting surface up. 42. Remove bolts (106) (2 used), washers (105) (2 used), and washers (104) (2 used). Remove the output shaft (107) assembly and oil baffle (103) from transmission case (10). j : 19 mm 43. Remove bearing (100), spacer (101), output gear (102), and spacer (96) from output shaft (107) by using a puller.

W4-3-2-9

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Assembly of Transmission

65 66

WMDF-04-03-008 D View B

21, 23, 27

21, 31, 32 D

21, 22, 29 36

17, 18

122

13 62, 63 20 57, 56 25, 26 E

57, 56, 60

76, 77 15

W4-3-2-10

40, 41

WMDF-04-03-009

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

View A

123

11 8 9

123

WMDF-04-03-010

View C

6 85 86 84

G WMDF-04-03-011

W4-3-2-11

SECTION 4 TRAVEL SYSTEM Group 3 Transmission

Section D-D

39 19 92a 92 90

94 28

39 95a 108 38 109 95 110

33 35

102

34, 121 37

101

107 44

100

43 111 98 97

1 2

5 3 46 73 49

99 53 52 61 70, 54 68 55 58, 59

114 115 116

117 118 119 120 47, 74, 75

69 WMDF-04-03-012

W4-3-2-12

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Section F-F

Section E-E

103, 104, 105, 106

WMDF-04-03-014

WMDF-04-03-013

Section G-G

83 WMDF-04-03-015

12345678910111213141517181920212223252627282931-

3233343536373839404142434445464749525354555657585960616263-

W4-3-2-13

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Assembly of Transmission IMPORTANT: Before assembling, apply transmission oil onto parts in order to prevent them from seizing. 1. Install spacers (96, 101) and output gear (102) to output shaft (107).

j : 19 mm

2. Install bearing (100) to output shaft (107) by using a press and the special tool (ST 7567).

CAUTION: (135 lb)

4. Install oil baffle (103) to the output shaft (107) assembly. Install the output shaft (107) assembly to transmission case (10). Secure oil baffle (103) which has been installed to transmission case (10) with washers (104, 105) (2 used for each) and bolts (106) (2 used).

Transmission case (10) weight: 61 kg

m : 34 N·m (3.5 kgf·m, 25 lbf·ft) 5. Install bearing (115) to input gear 2 (116) by using a press and the special tool (ST 7567). 6. Install retaining ring (114) to input gear 2 (116).

3. Install the special tools (ST 0073) (3 used) to lifting holes (a) (3 places) of transmission case (10). Attach the nylon slings onto the special tools (ST 0073) (3 used). Hoist transmission case (10). Place transmission case (10) with the transmission cover (80) mounting surface up.

7. Install the input gear 2 (116) assembly to transmission case (10). 8. Install bearing (90) to input gear 1 (91) by using a press and the special tool (ST 7567). 9. Install retaining ring (89) to input gear 1 (91). 10. Install bearing (92) to input gear 1 (91) by using a press and the special tool (ST 7650).

11. Install spacer (93) and retaining ring (94) to input gear 1 (91).

WMDF-04-03-007 a-

Lifting Hole

W4-3-2-14

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Transmission cover (80) weight: 35 kg dCAUTION: (78 lb)

Clutch assembly (95) weight: 29 kg (64 dCAUTION: lb)

12. Install the special tools (ST 0072, ST 0073) to transmission cover (80). Attach the nylon slings onto the special tools (ST 0072, ST 0073).

15. Install the special tool (ST 0071) to lifting hole (b) of clutch assembly (95). Attach the nylon slings onto the special tool (ST 0071). Hoist clutch assembly (95). Place clutch assembly (95) with the retaining ring (95a) mounting side up.

ST 0073

c ST 0072 W4FC-03-04-015

b WMDF-04-03-006

13. Hoist transmission cover (80) with the transmission case (10) mounting surface down. 14. Install transmission cover (80) to the input gear 1 (91) assembly. Install retaining ring (92a) to the input gear 1 (91) assembly.

ab-

Drilled Hole Lifting Hole

16. Install transmission cover (80) to clutch assembly (95). Install retaining ring (95a) to clutch assembly (95).

80 92

Plug

92a W4FC-03-04-008 W4FC-03-04-015

W4-3-2-15

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 17. Apply LOCTITE #5127 onto the mating surfaces of transmission case (10) and the transmission cover (80) assembly. Fit transmission cover (80) assembly to pins (14) (2 used) of transmission case (10). Install the transmission cover (80) assembly and bracket (122) to transmission case (10) with bolts (15) (27 used).

IMPORTANT: Install brake housing (47) as illustrated below. 23. Install O-ring (46) to the transmission cover (80) side of brake housing (47). Install brake housing (47) to transmission cover (80) with socket bolts (75) (2 used).

j : 19 mm

l : 8 mm

m : 34 N·m (3.5 kgf·m, 25 lbf·ft)

m : 52 N·m (5.3 kgf·m, 38 lbf·ft)

18. Install gasket (39) and bearing cap (19) to transmission cover (80) with bolts (20) (4 used). a

j : 17 mm m : 19.5 N·m (2.0 kgf·m, 14.5 lbf·ft)

19. Install gasket (39) and distributor cap (38) to transmission cover (80) with bolts (36) (4 used). j : 17 mm m : 19.5 N·m (2.0 kgf·m, 14.5 lbf·ft) 75

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

W4FC-03-04-017

such as goggles, helmets, etc in order to prevent personal injury.

20. Install bearing (117) to transmission cover (80) by using a hammer and the special tool (ST 7651).

24. Install plates (49) (7 used) and discs (73) (6 used) to disc hub (119) alternately.

21. Install retaining ring (118) to transmission cover (80).

25. Install O-ring (46) and end plate (72) to the piston housing (71) side of brake housing (47).

22. Install disc hub (119) and retaining ring (120) to input gear 2 (116).

26. Install D-rings (52, 53) to piston (70).

W4-3-2-16

SECTION 4 TRAVEL SYSTEM Group 3 Transmission IMPORTANT: Install piston housing (71) and piston (70) as illustrated below. a

30. Install the brake cap (68) assembly to brake housing (47) with washer (60), washers (56) (4 used), and socket bolts (57) (4 used).

IMPORTANT: Install the brake cap (68) assembly as illustrated below.

l : 8 mm m : 52 N·m (5.3 kgf·m, 38 lbf·ft)

W4FC-03-04-018 a-

56, 57

27. Install piston (70) and O-ring (69) to piston housing (71).

56, 57, 60 WMDF-04-03-016

28. Install springs (55) (24 used) to piston (70).

56, 57

IMPORTANT: Fit springs (55) (24 used) to the hole (24 places) of brake cap (68). Tighten bolts (62) (2 used) alternately. 29. Install brake cap (68) to piston housing (71) with washers (63) (2 used) and bolts (62) (2 used).

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

j : 17 mm m : 52 N·m (5.3 kgf·m, 38 lbf·ft)

31. Install bearing (108) to transmission cover (80) by using a hammer and the special tool (ST 7567). 32. Install spacer (111) to transmission cover (80).

W4-3-2-17

SECTION 4 TRAVEL SYSTEM Group 3 Transmission 33. Install spacer (109) and retaining ring (110) to the output shaft (107) assembly.

39. Install spacer (99) to the output shaft (107) assembly.

34. Apply LOCTITE #262 onto the outer surface of oil seal (98). Apply grease onto the inner surface of it. Install oil seal (98) to bearing cap (45) by using a plastic hammer.

40. Apply LOCTITE #262 onto the outer surface of oil seal (98). Apply grease onto the inner surface of it. Install oil seal (98) to bearing cap (6) by using a plastic hammer.

35. Install O-ring (97) to bearing cap (45).

41. Install O-ring (97) to bearing cap (6).

36. Install bearing cap (45) to transmission cover (80) with washers (40) (5 used) and bolts (41) (5 used).

42. Install bearing cap (6) to transmission case (10) with bolts (86) (5 used).

j : 19 mm

j : 17 mm

m : 91 N·m (9.3 kgf·m, 67 lbf·ft)

m : 19.5 N·m (2.0 kgf·m, 14.5 lbf·ft)

37. Install plug (43) and retaining ring (44) to flange (42). Apply grease onto the chamfered part and sliding part of flange (42). Install flange (42) to the output shaft (107) assembly.

CAUTION: The transmission assembly weight: 190 kg (420 lb) 38. Install the special tools (ST 0073) (3 used) to lifting holes (a) (3 places) of the transmission assembly. Attach the nylon slings onto the special tools (ST 0073) (3 used). Hoist the transmission assembly. Place the transmission assembly vertically.

43. Apply grease onto the chamfered part and sliding part of flange (5). Install flange (5) and retainer plate (2) to output shaft (107) with bolts (1) (3 used).

fNOTE: Step 43 is the temporary assembly in order to select shim (3).

j : 19 mm m : 135 N·m (14.0 kgf·m, 100 lbf·ft) 44. Remove bolts (1) (3 used) and retainer plate (2). Measure the end of output shaft (107) and step (X) of flange (5). Select shim (3) so that step (X) should be within 0 to 0.09 mm (0 to 0.004 in).

80 107

10 a a-

WMDF-04-03-004

Lifting Hole

W4FC-03-04-019

W4-3-2-18

SECTION 4 TRAVEL SYSTEM Group 3 Transmission IMPORTANT: As for shim (3), use the number which has been selected in step 44. 45. Apply LOCTITE #262 onto the thread part of bolts (1) (3 used). Install O-ring (4), shims (3), and retainer plate (2) to output shaft (107) with bolts (1) (3 used).

IMPORTANT: Contact rotation sensor (7) to output gear (102). Turn rotation sensor (7) by two turns counterclockwise. 49. Install rotation sensor (7) to transmission case (10). j : 24 mm

j : 19 mm m : 135 N·m (14.0 kgf·m, 100 lbf·ft)

46. Install strainer (81), O-ring (82), gasket (83), and suction tube (85) to transmission case (10) with bolts (84) (4 used).

102

j : 17 mm m : 19.5 N·m (2.0 kgf·m, 14.5 lbf·ft) 47. Install gasket (13) and clutch pressure control solenoid valve (12) to transmission case (10) with socket bolts (11) (2 used) and socket bolts (123) (6 used). l : 6 mm W4FC-03-04-020

m : 26 N·m (2.7 kgf·m, 19 lbf·ft) 48. Install sensor (9) to transmission case (10) with socket bolts (8) (2 used).

Lock Nut

l : 5 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

IMPORTANT: Tighten lock nut (a) while securing rotation sensor (7) by using a spanner in order not to turn them. 50. Secure rotation sensor (7) with lock nut (a). j : 27 mm m : 49 N·m (5.0 kgf·m, 36 lbf·ft) 51. Connect the both ends of pipes (23, 25, 29, and 31) to the transmission assembly. j : 22 mm m : 49 N·m (5.0 kgf·m, 36 lbf·ft)

W4-3-2-19

SECTION 4 TRAVEL SYSTEM Group 3 Transmission (Blank)

W4-3-2-20

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Disassembly of Clutch Assembly 1

4 5 6 25

23 22

7 8

18 17

9 10

12 13 14

W4FC-03-04-021

1234567-

Retaining Ring Spacer Bearing Needle Bearing (2 Used) Thrust Washer (2 Used) Hub Gear Plate (7 Used)

891011121314-

Disc (6 Used) Plug Seal Ring (2 Used) Bearing Spacer Retaining Ring Shaft Drum

15161718192021-

Orifice Seal Ring Seal Ring Piston Return Spring (6 Used) End Plate Retaining Ring

W4-3-3-1

22232425-

Thrust Bearing Thrust Washer Thrust Bearing Spacer

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Disassembly of Clutch Assembly The clutch assembly weight: 29 kg (64 dCAUTION: lb)

6. Push end plate (20) by using a press and the special tool (ST 7877). Remove retaining ring (21). Remove end plate (20) from shaft drum (14) by releasing a press gradually. 7. Remove plates (7) (7 used), discs (8) (6 used), and return springs (19) (6 used) from shaft drum (14).

1. Remove seal rings (10) (2 used) from shaft drum (14).

8. Add the compressed air through port (a) of shaft drum (14). Float and remove piston (18) from shaft drum (14).

2. Remove retaining ring (13) and spacer (12) from shaft drum (14). Remove bearing (11) from shaft drum (14) by using a puller.

3. Remove retaining ring (1) and spacer (2) from shaft drum (14). Remove bearing (3) from shaft drum (14) by using a puller. 4. Remove spacer (25), thrust bearing (24), thrust washer (23), and hub gear (6) from shaft drum (14).

5. Remove needle bearings (4) (2 used), thrust washers (5) (2 used), and thrust bearing (22) from shaft drum (14). IMPORTANT: As the force of return springs (19) (6 used) is applied to end plate (20), push end plate (20) down by using a press and the special tool (ST 7877).

W4FC-03-04-023 ST 7877

9. Remove seal ring (17) from piston (18).

10. Remove seal ring (16) from shaft drum (14).

W4FC-03-04-022

W4-3-3-2

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Assembly of Clutch Assembly 1

13 W4FC-03-04-024

1234567-

Retaining Ring Spacer Bearing Needle Bearing (2 Used) Thrust Washer (2 Used) Hub Gear Plate (7 Used)

891011121314-

Disc (6 Used) Plug Seal Ring (2 Used) Bearing Spacer Retaining Ring Shaft Drum

15161718192021-

Orifice Seal Ring Seal Ring Piston Return Spring (6 Used) End Plate Retaining Ring

W4-3-3-3

22232425-

Thrust Bearing Thrust Washer Thrust Bearing Spacer

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Assembly of Clutch Assembly

7. Apply grease onto needle bearings (4) (2 used). Install thrust washers (5) (2 used), thrust bearing (22), and needle bearings (4) (2 used) to shaft drum (14).

IMPORTANT: Before assembling, apply transmission oil onto parts in order to prevent them from seizing. 1. Place shaft drum (14) with orifice (15) up.

8. Apply grease onto thrust bearing (24). Install hub gear (6), thrust washer (23), thrust bearing (24), and spacer (25) to shaft drum (14).

2. Apply grease onto the outer surface of seal ring (16). Install seal ring (16) to shaft drum (14).

9. Install bearing (3) to shaft drum (14) by using a press and the special tool (ST 7568).

3. Apply grease onto the outer surface of seal ring (17). Install seal ring (17) to piston (18).

10. Install spacer (2) to shaft drum (14) with retaining ring (1).

4. Apply grease onto the inside of shaft drum (14) and the inside of piston (18). Install piston (18) to shaft drum (14).

The shaft drum (14) assembly weight: dCAUTION: 29 kg (64 lb) 11. Install the special tool (ST 0071) to lifting hole (b) of shaft drum (14). Attach nylon slings onto the special tool (ST 0071). Hoist and turn over the shaft drum (14) assembly.

IMPORTANT: Install return spring (19) so that the slits of return spring (19) are not in the same position in a row. 5. Install plates (7) (7 used), discs (8) (6 used), and return springs (19) (6 used) to shaft drum (14) alternately.

6. Install end plate (20) to shaft drum (14). Push end plate (20) down by using a press and the special tool (ST 7877) until the retaining ring (21) groove can be seen. Install retaining ring (21) to shaft drum (14). c a ST 7877

b WMDF-04-03-006

ab-

Drilled Hole Lifting Hole

Plug

12. Install bearing (11) to shaft drum (14) by using a press and the special tool (ST 7650). 13. Install spacer (12) to shaft drum (14) with retaining ring (13). W4FC-03-04-022

14. Install seal rings (10) (2 used) to shaft drum (14).

W4-3-3-4

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Disassembly of Clutch Pressure Control Solenoid Valve

5 4 3 17

2 16

1 15 14 13

27 28 29 26

WMDF-04-03-001

123456789-

Plug O-Ring Spring Spring Valve Piston Valve Body Plug Gasket Plug

101112131415161718-

Gasket Spring Spool Filter O-Ring Solenoid Valve Body Washer (4 Used) Bolt (4 Used) Washer

192021222324252627-

Plate O-Ring O-Ring O-Ring O-Ring Solenoid Valve Assembly Socket Bolt (2 Used) Plug Orifice

W4-3-4-1

28293031-

Piston Spring Socket Bolt (6 Used) Valve Body

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Disassembly of Clutch Pressure Control Solenoid Valve 1. Remove socket bolts (25) (2 used). Remove solenoid valve assembly (24), O-ring (23), plate (19), and washer (18) from solenoid valve body (15).

8. Remove spool (12), springs (11, 29), and piston (28) from valve body (31).

l : 4 mm 2. Remove O-rings (20, 21, 22) from solenoid valve assembly (24). 3. Remove socket bolts (30) (6 used). Remove the valve body (31) assembly and gasket (8) from valve body (6). l : 6 mm The spring force is applied to plug (1). dCAUTION: Slowly loosen plug (7). 4. Remove plug (1), springs (3, 4), and valve piston (5) from valve body (6). l : 12 mm 5. Remove O-ring (2) from plug (1). 6. Remove bolts (17) (4 used) and washers (16) (4 used). Remove solenoid valve body (15) and gasket (10) from the valve body (31) assembly. j : 13 mm IMPORTANT: Do not disassemble orifice (27). 7. Remove filter (13) and O-ring (14) from solenoid valve body (15).

W4-3-4-2

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Assembly of Clutch Pressure Control Solenoid Valve

25 16, 17

26 8 A

7 B

Section A-A

Section B-B

21 20

2 WMDF-04-03-002

123456789-

Plug O-Ring Spring Spring Valve Piston Valve Body Plug Gasket Plug

101112131415161718-

Gasket Spring Spool Filter O-Ring Solenoid Valve Body Washer (4 Used) Bolt (4 Used) Washer

192021222324252627-

Plate O-Ring O-Ring O-Ring O-Ring Solenoid Valve Assembly Socket Bolt (2 Used) Plug Orifice

W4-3-4-3

28293031-

Piston Spring Socket Bolt (6 Used) Valve Body

SECTION 4 TRAVEL SYSTEM Group 3 Transmission Assembly of Clutch Pressure Control Solenoid Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install springs (11, 29), spool (12), and piston (28) to valve body (31). 2. Install O-ring (14) and filter (13) to solenoid valve body (15).

7. Install O-rings (20, 21, 22) to solenoid valve assembly (24). 8. Apply grease onto O-ring (23). Install washer (18), plate (19), O-ring (23), and solenoid valve assembly (24) to solenoid valve body (15) with socket bolts (25) (2 used). l : 4 mm

3. Install gasket (10) and solenoid valve body (15) to the valve body (31) assembly with washers (16) (4 used) and bolts (17) (4 used).

m : 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)

j : 13 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft) 4. Install O-ring (2) to plug (1). 5. Install valve piston (5), springs (3, 4), and plug (1) to valve body (6). l : 12 mm m : 50 N·m (5.0 kgf·m, 37 lbf·ft) 6. Install gasket (8) and the valve body (31) assembly to valve body (6) with socket bolts (30) (6 used). l : 6 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

W4-3-4-4

SECTION 4 TRAVEL SYSTEM Group 4 Axle Removal and Installation of Front Axle

WMDF-04-04-004

2. Remove the front tires from front axle (3). (Refer to W4-1-1.) 3. Remove propeller shaft (2). (Refer to W4-5-1.) 4. Disconnect hoses (1) (2 used). j : 17 mm 5. Disconnect the both ends of pipes (4) (2 used).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Operate the brake pedal more than dCAUTION: fifty times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

W4-4-1-1

j : 17 mm

SECTION 4 TRAVEL SYSTEM Group 4 Axle

1 5

W4GB-03-03-106 a-

Stand

WMDF-04-04-006

CAUTION: Front axle (3) weight: 530 kg (1170 lb) 6. Attach nylon slings onto front axle (3). Hoist and hold front axle (3).

9. Remove the adapters with front axle (3) attached if necessary.

7. Place stand (a) under front axle (3). In case front axle (3) has been dCAUTION: removed for a long time, set a stand under the axle fixed part of front frame (5) in order to keep the machine stable. 8. Remove bolts (1) (8 used), washers (2) (16 used), and nuts (4) (8 used). Remove front axle (3). Place it onto stand (a). j : 36 mm

W4-4-1-2

SECTION 4 TRAVEL SYSTEM Group 4 Axle

1 5

W4GB-03-03-106 a-

WMDF-04-04-006

Installation 1. Install all removed adapters to front axle (3). 2. Place front axle (3) onto stand (a). Set it under the mounting position of front frame (5).

dCAUTION: Front axle (3) weight: 530 kg (1170 lb) 3. Attach nylon slings onto front axle (3). Hoist front axle (3).

4. Install front axle (3) with bolts (1) (8 used), washers (2) (16 used), and nuts (4) (8 used). j : 36 mm m : 785 N·m (78.5 kgf·m, 580 lbf·ft)

W4-4-1-3

Stand

SECTION 4 TRAVEL SYSTEM Group 4 Axle

5. Connect the both ends of pipes (4) (2 used). j : 17 mm m : 15.7 to 23.5 N·m (1.6 to 2.4 kgf·m, 11.5 to 17.5 lbf·ft) 6. Connect hoses (1) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lb·ft) 7. Install propeller shaft (2). (Refer to W4-5-1.) 8. Install the front tires to front axle (3). (Refer to W4-11.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 9. Bleed air from the brake (axle). (Refer to W1-4-1.)

W4-4-1-4

WMDF-04-04-004

SECTION 4 TRAVEL SYSTEM Group 4 Axle Removal and Installation of Rear Axle 4

2, 3

1 1

6 WMDF-04-04-005

4. Disconnect hoses (4) (2 used). j : 17 mm 5. Remove bolt, washer (2) and clip (3). j : 17 mm 6. Disconnect the both ends of pipes (1) (2 used). j : 17 mm 7. Disconnect the both ends of pipes (6) (2 used).

Removal j : 17 mm

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Operate the brake pedal more than dCAUTION: fifty times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove the rear tires from rear axle (7). (Refer to W4-1-2.) 3. Remove propeller shaft (5). (Refer to W4-5-1.)

W4-4-2-1

SECTION 4 TRAVEL SYSTEM Group 4 Axle

1 2 4 5 7

2 9

3 5

W4GB-03-03-113 a-

Stand

WMDF-04-04-007

The rear axle (8) assembly weight: 640 dCAUTION: kg (1420 lb) 8. Secure support (9) to rear axle (8) by using wires. Attach nylon slings onto the rear axle (8) assembly. Hoist and hold the rear axle (8) assembly. 9. Place stand (a) under rear axle (8).

11. Remove bolts (4) (4 used), washers (5) (8 used), and nuts (6) (4 used). Remove the rear axle (8) assembly. Place it onto stand (a). j : 36 mm 12. Remove the adapters with the rear axle (8) assembly attached if necessary.

In case rear axle (8) has been removed dCAUTION: for a long time, set a stand under the axle fixed part of rear frame (7) in order to keep the machine stable. 10. Remove bolts (1) (4 used), washers (2) (8 used), and nuts (3) (4 used). j : 30 mm

W4-4-2-2

SECTION 4 TRAVEL SYSTEM Group 4 Axle

12 13

9 10

WMDF-04-04-008

18. Remove thrust washer (10).

dCAUTION: Support (2) weight: 43 kg (95 lb)

13. Attach nylon slings onto support (2). Hoist and hold support (2). Remove the wires for fasting support (2) that have been installed in step 8. 14. Remove support (2) from rear axle (5).

19. Remove bolts (9) (8 used). Remove thrust plate (8) and thrust washer (7). j : 19 mm

fNOTE: LOCTITE #262 has been applied on the thread part of bolts (9) (8 used). 20. Remove support (6) from rear axle (5).

15. Remove dust seals (1, 4) and bushing (3) from support (2).

dCAUTION: Support (6) weight: 55 kg (125 lb)

16. Attach nylon slings onto support (6). Hoist and hold support (6).

21. Remove dust seal (1) and bushing (3) from support (6).

17. Remove bolts (13) (9 used) and washers (12) (9 used). Remove cap (11). j : 19 mm

fNOTE: LOCTITE #262 has been applied on the thread part of bolts (13) (9 used).

W4-4-2-3

SECTION 4 TRAVEL SYSTEM Group 4 Axle

1 b

a a

10 11 1

ab-

Direction to Install Groove

3 c-

WMDF-04-04-008

Installation IMPORTANT: Check the direction to install dust seal (2) and bushing (3). IMPORTANT: Install bushing (3) with grease groove (c) up. 1. Install bushing (3) and dust seal (2) to support (4).

Grease Groove

WMDF-04-04-009

IMPORTANT: Check the direction to install thrust washers (5, 8). 3. Apply LOCTITE #262 onto bolts (7) (8 used). Install thrust washer (5). Install thrust plate (6) with bolts (7) (8 used). Apply grease onto thrust washer (8). Install thrust washer (8). j : 19 mm

dCAUTION: Support (4) weight: 55 kg (125 lb)

2. Apply grease onto the inner surface of bushing (3). Attach nylon slings onto support (4). Hoist support (4). Install support (4) to rear axle (1).

m : 110 N·m (11 kgf·m, 81 lbf·ft) 4. Apply LOCTITE #262 onto bolts (11) (9 used). Install cap (9) with washers (10) (9 used) and bolts (11) (9 used). j : 19 mm m : 110 N·m (11 kgf·m, 81 lbf·ft)

W4-4-2-4

SECTION 4 TRAVEL SYSTEM Group 4 Axle

1 WMDF-04-04-008

ab-

Direction to Install Groove

4 c-

Grease Groove WMDF-04-04-010

IMPORTANT: Check the direction to install dust seals (1, 4) and bushing (3). IMPORTANT: Install bushing (3) with grease groove (c) up. 5. Install bushing (3) and dust seals (1, 4) to support (2).

dCAUTION: Support (2) weight: 43 kg (95 lb)

6. Apply grease onto the inner surface of bushing (3). Attach nylon slings onto support (2). Hoist support (2). Install support (2) to rear axle (5). 7. Secure rear axle (5) and support (2) by using the wires.

W4-4-2-5

SECTION 4 TRAVEL SYSTEM Group 4 Axle

1 2 4 5 7

2 9

3 5

W4GB-03-03-113 a-

Stand

WMDF-04-04-007

8. Install all removed adapters to the rear axle (8) assembly. 9. Place the rear axle (8) assembly onto stand (a). Set it under the mounting position of rear frame (7).

11. Install the rear axle (8) assembly with bolts (1, 4) (4 used for each), washers (2, 5) (8 used for each), and nuts (3, 6) (4 used for each). Remove the wires for fasting support (9) that have been installed in step 7.

The rear axle (8) assembly weight: 640 dCAUTION: kg (1420 lb) 10. Attach nylon slings onto the rear axle (8) assembly. Hoist the rear axle (8) assembly.

Bolt (1): j : 30 mm m : 550 N·m (55 kgf·m, 410 lbf·ft) Bolt (4): j : 36 mm m : 950 N·m (95 kgf·m, 700 lbf·ft)

W4-4-2-6

SECTION 4 TRAVEL SYSTEM Group 4 Axle

2, 3

1 1

6 WMDF-04-04-005

12. Connect the both ends of pipes (6) (2 used).

16. Install propeller shaft (5). (Refer to W4-5-1.)

j : 17 mm

17. Install the rear tires to rear axle (7). (Refer to W4-1-2.)

m : 15.7 to 23.5 N·m (1.6 to 2.4 kgf·m, 11.5 to 17.5 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 18. Bleed air from the brake (axle). (Refer to W1-4-1.)

13. Connect the both ends of pipes (1) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 14. Install clip (3) with bolt, washer (2). Apply grease. j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 15. Connect hoses (4) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W4-4-2-7

SECTION 4 TRAVEL SYSTEM Group 4 Axle (Blank)

W4-4-2-8

SECTION 4 TRAVEL SYSTEM Group 4 Axle Disassembly of Axle  Axle Equipped with TPD

WMDF-04-04-011

W4-4-3-1

SECTION 4 TRAVEL SYSTEM Group 4 Axle

WMDF-04-04-012

W4-4-3-2

SECTION 4 TRAVEL SYSTEM Group 4 Axle  Axle Equipped with LSD

WMDF-04-04-011

W4-4-3-3

SECTION 4 TRAVEL SYSTEM Group 4 Axle

WMDF-04-04-077

W4-4-3-4

SECTION 4 TRAVEL SYSTEM Group 4 Axle 010203040506070809101112131415161718192021-

Differential Housing Housing Internal Gear (2 Used) Spider (2 Used) Shaft (2 Used) Piston (2 Used) Sun Gear (2 Used) Planetary Gear (6 Used) Separation Disc (2 Used) Pin (6 Used) Friction Disc (2 Used) Bearing (2 Used) Bearing (2 Used) Pin (8 Used) Spring Pin (6 Used) Washer (2 Used) Shim O-Ring (2 Used) O-Ring (2 Used) Retainer

222324252627282932333435363738394041424344-

Wear Ring (12 Used) Needle Cage (12 Used) Seal (2 Used) Plug (2 Used) Seal (2 Used) Bolt (32 Used) Washer (32 Used) Bolt (2 Used) Nut O-Ring Yoke Sleeve Gear (2 Used) Housing Shim Housing Bearing (2 Used) Bearing Pinion Wear Ring (4 Used) Wear Ring (2 Used)

454647484950515253545556575859606162-

Spider Flange (2 Used) Nut (2 Used) Bearing (2 Used) Air Bleed Plug (2 Used) O-Ring (2 Used) O-Ring Plate Gasket Seal Magnet Plug (3 Used) Seal (3 Used) Ring Plate (2 Used) Gear (4 Used) Housing A Retaining Ring Bolt (12 Used) (Front Axle: 6 Used) 63- Bolt (18 Used) 64- Bolt (4 Used)

fNOTE: The quantity of parts is the quantity per one axle.

W4-4-3-5

65666768697071727374757677787980-

Bolt (8 Used) Bolt (4 Used) Bolt (8 Used) Bolt (14 Used) Nut (18 Used) Washer (12 Used) (Front Axle: 6 Used) Ring Gear Housing B Housing B Friction Disc (2 Used) Separation Disc (2 Used) Friction Disc (2 Used) Gear (2 Used) Pin (4 Used) Housing A Socket Bolt (8 Used)

SECTION 4 TRAVEL SYSTEM Group 4 Axle Disassembly of Axle The axle assembly weight: 550 kg dCAUTION: (1220 lb)

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

Removal of Housing (02, 03) Assemblies 1. Attach nylon slings onto the axle assembly. Hoist the axle assembly. Place the axle assembly on a workbench. Secure the axle assembly with supports (a, b).

such as goggles, hard hat, etc. in order to prevent personal injury. 4. Tap the jointed parts of differential (01) and housing (02) by using a hammer. Remove the housing (02) assembly from differential (01).

fNOTE: THREEBOND #1215 has been applied on the

mating surfaces of differential (01) and housing (02). 01

b WMDF-04-04-014

Support

Support WMDF-04-04-015

2. Place a container under housing (39). Remove magnet plug (55) from housing (39). Drain gear oil from the axle assembly. Install magnet plug (55).

5. Remove friction disc (12) from sun gear (08).

12.7 mm square m : 20 N·m (2 kgf·m, 15 lbf·ft)

NOTE: Amount of gear oil: 25 L (6.6 US gal)

The housing (02) assembly weight: dCAUTION: 190 kg (420 lb) 3. Attach nylon slings onto the housing (02) assembly. Hoist and hold the housing (02) assembly. Remove bolts (27) (16 used) and washers (28) (16 used) from housing (02).

WMDF-04-04-016

j : 24 mm

fNOTE: THREEBOND #1327 has been applied on the thread part of bolts (27) (16 used).

6. Axle equipped with TPD Remove sun gear (08) from gear (36) of differential (01). Axle equipped with LSD Remove sun gear (08) from gear (77) of differential (01).

W4-4-3-6

SECTION 4 TRAVEL SYSTEM Group 4 Axle 7. Remove separation disc (10) from differential (01). 01

WMDF-04-04-017

8. Remove the housing (03) assembly at the opposite side in the same way as step 3 to step 7.

W4-4-3-7

SECTION 4 TRAVEL SYSTEM Group 4 Axle 11. Remove bolt (29) from spider (05).

Disassembly of Housing (02, 03) Assemblies The housing (02) assembly weight: dCAUTION: 190 kg (420 lb)

j : 24 mm

9. Attach nylon slings onto the housing (02) assembly. Hoist the housing (02) assembly. Secure the housing (02) assembly with the differential (01) mounting surface up by using the special tool (ST 5132).

fNOTE: THREEBOND #1327 has been applied on the thread part of bolt (29).

ST 5132

WMDF-04-04-019 WMDF-04-04-018

10. Remove retainer (21) from internal gear (04).

The spider (05) assembly weight: 28 dCAUTION: kg (62 lb) 12. Install the special tools (ST 0274) (3 used) to the spider (05) assembly. Attach nylon slings onto the special tools (ST 0274) (3 used). Remove the spider (05) assembly and shim (18) from shaft (06).

ST 0274 ST 0274

WMDF-04-04-020

ST 0274

WMDF-04-04-078

W4-4-3-8

SECTION 4 TRAVEL SYSTEM Group 4 Axle IMPORTANT: Do not lose pins (15) (4 used) when removing internal gear (04). 13. Install bolt (29) which has been removed in step 11 to shaft (06) in order to protect the thread part of shaft (06). Remove internal gear (04) and pins (15) (4 used) from housing (02) by using a gear puller. Remove bolt (29).

15. Remove the inner race of bearing (13) from housing (02). 16. Remove the special tool (ST 5132) from shaft (06). 17. Remove the inner race of bearing (14) from shaft (06) by using a pry bar. Remove seal (24) from shaft (06).

fNOTE: Hold the gear puller shaft with bolt (29).

04 24 02

WMDF-04-04-021

WMDF-04-04-022

dCAUTION: Housing (02) weight: 160 kg (355 lb) 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. 14. Attach nylon slings onto housing (02). Hoist housing (02) by 50 mm (1.97 in). Attach a plate onto the flange part of shaft (06). Tap it by using a hammer. Remove housing (02) from shaft (06).

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. 18. Remove the outer race of bearings (13, 14) at the differential (01) side and wheel side from housing (02) by using a bar and a hammer. Remove the outer race of bearings (13, 14) by tapping the outer surface evenly. 19. Disassemble the housing (03) assembly at the opposite side in the same way as step 9 to step 18.

ST 5132

06 WMDF-04-04-018

W4-4-3-9

SECTION 4 TRAVEL SYSTEM Group 4 Axle Disassembly of Spider (05) Assembly 20. Place the spider (05) assembly with the housing (02) side up onto wooden blocks (a) (2 used).

23. Remove the planetary gear (09) assembly and wear rings (22) (2 used) from spider (05). 05

05 22

09 a

WMDF-04-04-025 WMDF-04-04-023 a-

Wooden Block

24. Remove needle cages (23) (2 used) from planetary gear (09).

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. 21. Install spring pin (16) to pin (11) by using the special tool (ST 1801) and a hammer. Remove pin (11) from planetary gear (09) toward the differential (01) side by using bar (b).

b WMDF-04-04-026

25. Remove other planetary gear (09) assemblies (2 used) in the same way as step 21 to step 24.

26. Remove washer (17) from spider (05).

11 b-

WMDF-04-04-024

Bar

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. 22. Remove spring pin (16) from pin (11) by using the special tool (ST 1801) and a hammer.

WMDF-04-04-027

27. Disassemble the spider (05) assembly at the opposite side in the same way as step 20 to step 26.

W4-4-3-10

SECTION 4 TRAVEL SYSTEM Group 4 Axle Removal of Differential Housing 28. Remove bolts (68) (14 used). Remove plate (52) and gasket (53) from housing (39). j ：19 mm 68

30. Connect the air hose to pipe connecting port (c) of differential (01). Slowly add the compressed air 98 to 196 kPa (1 to 2 kgf/cm2, 14.2 to 28.4 PSI) to the air hose. Remove piston (07) from differential (01). Remove bolts (a) (M16, Pitch 2 mm) (4 used) and the special tool (ST 4188). a ST 4188

52, 53

01 39 WMDF-04-04-028

c WMDF-04-04-054

29. Install the special tool (ST 4188) with protruded part (b) (3 places) outside to the bolt (27) mounting holes (4 places) of differential (01) with bolts (a) (M16, Pitch 2 mm) (4 used). ST 4188

Bolt

Pipe Connecting Port

31. Remove O-ring (20) from piston (07). 32. Remove piston (07) at the opposite side in the same way as step 29 to step 31. The differential housing weight: 73 kg dCAUTION: (165 lb)

33. Install the special tool (ST 0275) to ring gear (71). Attach nylon slings onto the special tool (ST 0275). Hoist and hold the differential housing.

01 b a-

Bolt

WMDF-04-04-076 Protruded Part

ST 0275

WMDF-04-04-030

W4-4-3-11

SECTION 4 TRAVEL SYSTEM Group 4 Axle 34. Remove bolts (66) (2 used). Remove plate (58) from flange (46).

The differential housing weight: 73 kg dCAUTION: (165 lb)

j : 13 mm IMPORTANT: When removing and installing the differential housing, do not allow the inner races (2 used) of bearings (48) (2 used) to come in contact with housing (39). 39. Remove the differential housing from housing (39).

fNOTE: THREEBOND #1327 has been applied on the thread part of bolts (66) (2 used).

46 39

ST0275

58 WMDF-04-04-029

35. Remove bolts (67) (4 used). Remove the flange (46) assembly and O-ring (50) from housing (39). j : 24 mm WMDF-04-04-031

fNOTE: THREEBOND #1327 has been applied on the thread part of bolts (67) (4 used). 36. Remove nut (47) from flange (46) by using the special tool (ST 3425).

37. Remove O-ring (19) and the outer race of bearing (48) from flange (46). 38. Remove flange (46) at the opposite side in the same way as step 34 to step 37.

W4-4-3-12

SECTION 4 TRAVEL SYSTEM Group 4 Axle Removal of Housing (37) Assembly 40. Front Axle Remove bolts (62) (6 used) and washers (70) (6 used) from housing (37). j : 19 mm

fNOTE: THREEBOND #1327 has been applied on the thread part of bolts (62) (6 used). Rear Axle

Remove bolts (62) (12 used) and washers (70) (12 used) from housing (37). j : 19 mm

fNOTE: THREEBOND #1327 has been applied on the

thread part of bolts (62) (12 used). 41. Install bolts (62) (2 used) which have been removed in step 40 to pulling-out bolt holes (a) (2 places) of housing (37). Tighten bolts (62) (2 used) evenly. Remove the housing (37) assembly and shims (38) from housing (39). Remove bolts (62) (2 used). Record the thickness and quantity of shims (38) which have been removed. Keep them. j : 19 mm a

37, 38

62, 70 a-

Pulling-Out Bolt Hole

a WMDF-04-04-032

W4-4-3-13

SECTION 4 TRAVEL SYSTEM Group 4 Axle 48. Tap the spline side end of pinion (42) by using a plastic hammer. Remove the pinion (42) assembly from housing (37).

Disassembly of Housing (37) Assembly 42. Remove O-ring (51) from housing (37). 43. Install the special tool (ST 5133) to yoke (34) with bolts (a) (M10, Pitch 1.25 mm) (4 used). Secure the housing (37) assembly in vise (b) by using the special tool (ST 5133). 37

34 ST 5133

WMDF-04-04-033 a

49. Remove ring (57) from pinion (42). Remove the inner race of bearing (40) from pinion (42) by using a separator. 40

b ab-

Bolt Vise

WMDF-04-04-036

44. Remove nut (32) and O-ring (33) from yoke (34). j : 38.1 mm

WMDF-04-04-034

fNOTE: THREEBOND #1215 has been applied on the

thread part of nut (32). 45. Remove the housing (37) assembly from yoke (34).

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

50. Remove retaining ring (61) from pinion (42). Remove bearing (41) from pinion (42) by using a separator. 61

such as goggles, hard hat, etc. in order to prevent personal injury. 46. Remove seal (54) from housing (37) by using a screwdriver and a hammer.

41 42

fNOTE: THREEBOND #1215 has been applied on the mounting surface of seal (54). 47. Remove sleeve (35) from pinion (42).

WMDF-04-04-035

51. Remove the inner race of bearing (40) from housing (37). 52. Remove the outer races of bearings (40) (2 used) from housing (37).

W4-4-3-14

SECTION 4 TRAVEL SYSTEM Group 4 Axle Disassembly of Differential Housing (Axle Equipped with TPD) The differential housing weight: 73 kg dCAUTION: (165 lb) 53. Place the differential housing vertically with housing A (60) up.

56. Tap the center of spider (45) by using a plastic hammer. Remove housing A (60) from housing B (72). 57. Remove gears (36) (2 used), spider (45), gears (59) (4 used), wear rings (44) (2 used), and wear rings (43) (4 used) from housing B (72) and housing A (60).

54. Remove bolts (63) (18 used) and nuts (69) (18 used). Remove ring gear (71) from housing B (72).

j : 19 mm

fNOTE: THREEBOND #1327 has been applied on the thread part of bolts (63) (18 used).

44 72

44 WMDF-04-04-039

58. Remove the inner races (2 used) of bearings (48) (2 used) from housing B (72) and housing A (60) by using a bearing puller.

63, 69 WMDF-04-04-037

55. Put matching marks (a) at the jointed part between housing B (72) and housing A (60). Remove bolts (64) (4 used) and bolts (65) (8 used).

48 60

j : 19 mm

fNOTE: THREEBOND #1327 has been applied on the

thread part of bolts (64) (4 used) and bolts (65) (8 used). 64

65 60

WMDF-04-04-038 a-

Matching Mark

W4-4-3-15

W4GB-03-03-027

SECTION 4 TRAVEL SYSTEM Group 4 Axle Disassembly of Differential Housing (Axle Equipped with LSD) The differential housing weight: 73 kg dCAUTION: (165 lb) 59. Place the differential housing vertically with housing A (79) up. 60. Remove bolts (63) (18 used) and nuts (69) (18 used). Remove ring gear (71) from housing B (73). j : 19 mm

fNOTE: THREEBOND #1327 has been applied on the

62. Tap the center of spider (45) by using a plastic hammer. Remove housing A (79) from housing B (73). IMPORTANT: Replace friction disc (74), separation disc (75), and friction disc (76) as an assembly. 63. Remove pins (78) (4 used), friction discs (74) (2 used), separation discs (75) (2 used), friction discs (76) (2 used), gears (77) (2 used), spider (45), gears (59) (4 used), and wear rings (43) (4 used) from housing B (73) and housing A (79). 78 79

thread part of bolts (63) (18 used).

43 59 45

73 71

75 76 77 76 75

63, 69 WMDF-04-04-070

61. Put matching marks (a) at the jointed part between housing B (73) and housing A (79). Remove socket bolts (80) (8 used). l : 10 mm

74 WMDF-04-04-072

64. Remove the inner races (2 used) of bearings (48) (2 used) from housing B (73) and housing A (79) by using a bearing puller.

fNOTE: THREEBOND #1327 has been applied on the thread part of socket bolts (80) (8 used).

79 48

80 a

73 WMDF-04-04-073 WMDF-04-04-071 a-

Matching Mark

W4-4-3-16

SECTION 4 TRAVEL SYSTEM Group 4 Axle Assembly of Axle  Axle Equipped with TPD 10 17 08 05 15 21 12

01 02

18 25, 26

24 14

16 27, 28 22 09 23 04 19 20 WMDF-04-04-040

43 60

68 44

64, 65

66 58

47 48

55, 56 67

63, 69

55, 56

62, 70

35 37 54 33 42

34 WMDF-04-04-041

W4-4-3-17

WMDF-04-04-042

SECTION 4 TRAVEL SYSTEM Group 4 Axle  Axle Equipped with LSD

10 17 08 05 15 21 12

01 02

18 25, 26

24 14

16 27, 28 22 09 23 04 19 20 WMDF-04-04-040

43 79 76

74 66

58 77 78

47 48

55, 56

67 50

63, 69

55, 56

41 51

57 40 35 37 54

62, 70

33 42

34 WMDF-04-04-043

W4-4-3-18

WMDF-04-04-042

SECTION 4 TRAVEL SYSTEM Group 4 Axle 010203040506070809101112131415161718192021-

222324252627282932333435363738394041424344-

454647484950515253545556575859606162-

fNOTE: The quantity of parts is the quantity per one axle.

W4-4-3-19

65666768697071727374757677787980-

SECTION 4 TRAVEL SYSTEM Group 4 Axle Assembly of Axle IMPORTANT: Before assembling, apply gear oil onto parts in order to prevent them from seizing.

4. Engage the spider (45) assembly with gear (36) and install it to housing B (72).

Assembly of Differential Housing (Axle Equipped with TPD) The inner races (2 used) of bearings dCAUTION: (48) (2 used) are too hot. Be careful of burns. Heat gear oil by using an electric dCAUTION: heater. Heating by using fire may cause a fire. 1. Heat the inner races (2 used) of bearings (48) (2 used) to 90 to 120 °C (194 to 248 °F) in gear oil which is heated. Install the inner races (2 used) of bearings (48) (2 used) to housing A (60) and housing B (72). 2. Place housing B (72) with the housing A (60) mounting surface up. Install wear ring (44) and gear (36) to housing B (72). 60

72 WMDF-04-04-074

5. Engage gear (36) with gear (59) (4 used) of housing B (72) and install it. 6. Place housing A (60) with the housing B (72) mounting surface up. 7. Apply grease onto wear ring (44) in order to prevent it from coming off. Install wear ring (44) to housing A (60).

44 WMDF-04-04-039

3. Install gear (59) (4 used) and wear rings (43) (4 used) to spider (45).

W4-4-3-20

SECTION 4 TRAVEL SYSTEM Group 4 Axle 8. Turn over housing A (60). Fit matching marks (a) made when disassembling and install housing A (60) to housing B (72). Tap housing A (60) and housing B (72) by using a plastic hammer so that each housing surfaces contact each other. 64

11. Apply THREEBOND #1327 onto the thread part of bolts (63) (18 used). Install bolts (63) (18 used) and nuts (69) (18 used).

fNOTE: Refer to the illustration for the order to tighten bolts (63) (18 used). j : 19 mm

m : 132 N·m (13.5 kgf·m, 97 lbf·ft) 60 a

72 7

14 WMDF-04-04-038 a-

Matching Mark

9. Apply THREEBOND #1327 onto the thread part of bolts (64) (4 used) and bolts (65) (8 used). Install bolts (64) (4 used) and bolts (65) (8 used) in diagonal order.

13 15

j : 19 mm

m : 132 N·m (13.5 kgf·m, 97 lbf·ft)

17 WMDF-04-04-068

10. Fit the bolt (63) holes (18 places for each) of ring gear (71) and housing B (72). Install ring gear (71) to housing B (72). Contact ring gear (71) to the flange surface of housing B (72) by using a plastic hammer.

72 71

63, 69 WMDF-04-04-037

W4-4-3-21

SECTION 4 TRAVEL SYSTEM Group 4 Axle Assembly of Differential Housing (Axle Equipped with LSD)

15. Engage gear (77) with separation disc (75) and install it to housing B (73).

The inner races (2 used) of bearings dCAUTION: (48) (2 used) are too hot. Be careful of burns. Heat gear oil by using an electric dCAUTION: heater. Heating by using fire may cause a fire.

16. Install gears (59) (4 used) and wear rings (43) (4 used) to spider (45). 17. Engage the spider (45) assembly with gear (77) and install it to housing B (73).

12. Heat the inner races (2 used) of bearings (48) (2 used) to 90 to 120 °C (194 to 248 °F) in gear oil which is heated. Install the inner races (2 used) of bearings (48) (2 used) to housing A (79) and housing B (73).

IMPORTANT: Face the larger-chamfered side to the hosing A (79). Install pins (78) (4 used). 13. Place housing B (73) with the housing A (79) mounting surface up. Install pins (78) (4 used) to housing B (73).

WMDF-04-04-075

79 43 59 45

18. Engage gear (77) with gears (59) (4 used) of housing B (73) and install it. IMPORTANT: Replace friction disc (74), separation disc (75), and friction disc (76) as an assembly. 19. Match the pin holes of friction disc (76) with pins (78) (4 used). Install friction disc (76) to housing B (73).

75 76

20. Engage separation disc (75) with gear (77) and install it to housing B (73).

77 76 75

74 WMDF-04-04-072

IMPORTANT: When installing friction disc (74), face the lining surface to separation disc (75). IMPORTANT: Replace friction disc (74), separation disc (75), and friction disc (76) as an assembly. 14. Match the pin holes of friction disc (74) and friction disc (76) with pins (78) (4 used). Install friction disc (74), separation disc (75), and friction disc (76) in sequence to housing B (73).

IMPORTANT: When installing friction disc (74), face the lining surface to separation disc (75). 21. Match the pin holes of friction disc (74) with pins (78) (4 used). Install friction disc (74) to housing B (73).

W4-4-3-22

SECTION 4 TRAVEL SYSTEM Group 4 Axle 22. Fit matching marks (a) made when disassembling and install housing A (79) to housing B (73). Tap housing A (79) and housing B (73) by using a plastic hammer so that each housing surfaces contact each other.

25. Apply THREEBOND #1327 onto the thread part of bolts (63) (18 used). Install bolts (63) (18 used) and nuts (69) (18 used).

fNOTE: Refer to the illustration for the order to tighten bolts (63) (18 used).

j : 19 mm

m : 132 N·m (13.5 kgf·m, 97 lbf·ft)

73 14

WMDF-04-04-071 a-

Matching Mark

23. Apply THREEBOND #1327 onto the thread part of socket bolts (80) (8 used). Install socket bolts (80) (8 used) in diagonal order.

l : 10 mm

13 6

m : 127 N·m (13 kgf·m, 94 lbf·ft) 24. Fit the bolt (63) holes (18 places for each) of ring gear (71) and housing B (73). Install ring gear (71) to housing B (73). Contact ring gear (71) to the flange surface of housing B (73) by using a plastic hammer.

73 71

63, 69 WMDF-04-04-070

W4-4-3-23

15 4

17 WMDF-04-04-068

SECTION 4 TRAVEL SYSTEM Group 4 Axle Assembly of Housing (37) Assembly Bearing (41) is too hot. Be careful of dCAUTION: burns. Heat gear oil by using an electric dCAUTION: heater. Heating by using fire may cause a fire. IMPORTANT: Install bearing (41) with its stamped mark side facing to the gear side of pinion (42). 26. Heat bearing (41) to 90 to 120 °C (194 to 248 °F) in gear oil which is heated. Install bearing (41) to pinion (42). Install retaining ring (61) to pinion (42) after cooling bearing (41). 61

28. Install the outer races (2 used) of bearings (40) (2 used) to housing (37). 29. Install the pinion (42) assembly to housing (37). The inner race of bearing (40) is too dCAUTION: hot. Be careful of burns. Heat gear oil by using an electric dCAUTION: heater. Heating by using fire may cause a fire. 30. Heat the inner race of bearing (40) to 90 to 120 °C (194 to 248 °F) in gear oil which is heated. Install the inner race of bearing (40) to housing (37). Apply grease onto sleeve (35) in order to prevent it from coming off. Install sleeve (35) to housing (37) after cooling the inner race of bearing (40).

41 37 42 35

WMDF-04-04-035 WMDF-04-04-044

d Heat gear oil by using an electric dCAUTION: heater. Heating by using fire may cause a fire.

CAUTION: The inner race of bearing (40) is too hot. Be careful of burns.

27. Heat the inner race of bearing (40) to 90 to 120 °C (194 to 248 °F) in gear oil which is heated. Install the inner race of bearing (40) to pinion (42). Install ring (57) to pinion (42) after cooling the inner race of bearing (40). 40

WMDF-04-04-034

W4-4-3-24

SECTION 4 TRAVEL SYSTEM Group 4 Axle 31. Install the special tool (ST 5133) to yoke (34) with the bolts (M10, Pitch 1.25 mm) (4 used). Secure yoke (34) in vise (a) by using the special tool (ST 5133).

33. Install O-ring (33) and nut (32) to pinion (42). Remove the housing (37) assembly from vise (a). Remove the special tool (ST 5133) and the bolts (M10, Pitch 1.25 mm) (4 used) from yoke (34). j : 38.1 mm m : 363 N·m (37 kgf·m, 270 lbf·ft)

ST 5133

37 33

ST 5133

34 a-

Vise

WMDF-04-04-045

a a-

32. Install the housing (37) assembly to yoke (34).

fNOTE: When adjusting the rotation resistance of pinion (42), removal and installation of pinion (42) are required. Therefore, seal (54) should be installed after adjusting the rotation resistance of pinion (42). 42

WMDF-04-04-047

W4-4-3-25

Vise

WMDF-04-04-048

SECTION 4 TRAVEL SYSTEM Group 4 Axle Rotation Resistance Adjustment of Pinion (42) 34. Secure the housing (37) assembly in vise (a). Install bolt (b) (M10, Pitch 1.25 mm) to yoke (34). Attach a spring balance onto bolt (b). Measure the rotation resistance.

38. Install housing (37) to yoke (34) in the same way as step 29 to step 31. At this time, apply THREEBOND #1215 onto nut (32). 39. Install O-ring (51) to housing (37).

fNOTE: Rotation resistance standard value: 40 to 79 N(4.1 to 8.1 kgf, 9 to 15.8 ldf)

a a-

Vise

Bolt

WMDF-04-04-049

35. When the rotation resistance is not within the standard value, replace ring (57) for the adjustment. When the rotation resistance is lower than the standard value, decrease the ring (57) thickness. When the rotation resistance is higher than the standard value, increase the ring (57) thickness.

fNOTE: Thickness of ring (57): 14.68 to 15.08 mm (0.58 to 0.59 in) 36. Remove nut (32) and O-ring (33) from yoke (34) after adjusting the rotation resistance. Remove yoke (34) from pinion (42). j : 38.1 mm 37. Apply grease onto part (c) of seal (54). Apply THREEBOND #1215 onto part (d) of seal (54). Install seal (54) to housing (37). 34 c

54 d

37 WMDF-04-04-050

W4-4-3-26

SECTION 4 TRAVEL SYSTEM Group 4 Axle Installation of Housing (37) Assembly 40. Front Axle Apply THREEBOND #1327 onto the thread part of bolts (62) (6 used). Check the shim (38) condition recorded before disassembling. Install shims (38) and the housing (37) assembly to housing (39) with bolts (62) (6 used) and washers (70) (6 used). j : 19 mm m : 132 N·m (13.5 kgf·m, 97 lbf·ft) Rear Axle Apply THREEBOND #1327 onto the thread part of bolts (62) (12 used). Check the shim (38) condition recorded before disassembling. Install shims (38) and the housing (37) assembly to housing (39) with bolts (62) (12 used) and washers (70) (12 used). j : 19 mm m : 132 N·m (13.5 kgf·m, 97 lbf·ft)

37, 38

62, 70

WMDF-04-04-032

W4-4-3-27

SECTION 4 TRAVEL SYSTEM Group 4 Axle Installation of Differential Housing 41. Apply hydraulic oil onto O-rings (50) (2 used). Install O-rings (50) (2 used) to housing (39).

The differential housing weight: 73 kg dCAUTION: (165 lb) IMPORTANT: When removing and installing the differential housing, do not allow the inner races (2 used) of bearings (48) (2 used) to come in contact with housing (39). 45. Install the special tool (ST 0275) to ring gear (71). Attach nylon slings onto the special tool (ST 0275). Hoist the differential housing. Hold the differential housing inside housing (39).

39 WMDF-04-04-067

ST 0275

42. Apply hydraulic oil onto O-ring (19). Install the outer race of bearing (48) and O-ring (19) to flange (46). 43. Turn and install nut (47) to flange (46) until it touches the outer race of bearing (48).

WMDF-04-04-031 W4GB-03-03-047

44. Assemble flange (46) at the opposite side in the same way as step 42 to step 43.

W4-4-3-28

SECTION 4 TRAVEL SYSTEM Group 4 Axle 46. Apply THREEBOND #1327 onto the thread part of bolts (67) (4 used). Fit the inner race of bearing (48) of the differential housing to the outer race of bearing (48) of flange (46). Install the flange (46) assembly to housing (39) with bolts (67) (4 used). j : 24 mm

50. Install the special tool (ST 4188) with the protruded part (3 places) inside to the bolt (27) mounting holes (4 places) of differential (01) with bolts (a) (M16, Pitch 2 mm) (4 used). Tighten bolts (a) (4 used) evenly. Push piston (07) in differential (01).

m : 206 N·m (21 kgf·m, 152 lbf·ft)

ST 4188

46 a

39 67

01 WMDF-04-04-053 a-

WMDF-04-04-029

47. Install the flange (46) assembly at the opposite side in the same way as step 46. 48. Apply hydraulic oil onto O-ring (20). Install O-ring (20) to piston (07). IMPORTANT: Do not damage O-rings (19, 20) when installing piston (07) to differential (01). 49. Apply hydraulic oil onto the piston (07) mounting surface of differential (01). Temporarily install piston (07) to differential (01).

01 WMDF-04-04-052

W4-4-3-29

Bolt

SECTION 4 TRAVEL SYSTEM Group 4 Axle Airtight Test of Piston (07) 51. Connect the air hose to pipe connecting port (a) of differential (01). Add the compressed air 588 kPa (6 kgf/cm2, 85.3 PSI) to the brake. 01

b ST 4188

a WMDF-04-04-054 a-

Pipe Connecting Port

Bolt

52. Put soapy water on piston (07) and air bleed plug (49). Check for any air leaks. 53. When air leaks are not found, stop adding the compressed air. Loosen air bleed plug (49) and release the compressed air from the brake. Remove the air hose. Tighten air bleed plug (49). Remove bolts (b) (M16, Pitch 2 mm) (4 used) and the special tool (ST 4188). Check that piston (07) is set inside differential (01). j : 11 mm m : 25 N·m (2.61 kgf·m, 18.5 lbf·ft) 54. When air leaks are found, remove piston (07) and flange (46) and replace O-rings (19, 20, 50). After replacing O-rings (19, 20, 50), perform the airtight test of piston (07) again. 55. Install piston (07) at the opposite side in the same way as step 48 to step 54.

W4-4-3-30

SECTION 4 TRAVEL SYSTEM Group 4 Axle Backlash Adjustment and Teeth Engagement Adjustment of Ring Gear (71) and Pinion (42)  The adjustment methods for the axles equipped with TPD and LSD are common. The adjustment method for the axle equipped with TPD is explained here. 56. Secure pinion (42). Turn ring gear (71) forward and backward. Tighten nut (47) at the housing B (72) side by using the special tool (ST 3425) until backlash becomes 0 mm (0 in). Loosen nut (47) by 2 to 3 notches after backlash reaches zero. 60

60. If backlash is bigger than the standard value, loosen nut (47) at the housing A (60) side, tighten nut (47) at the housing B (72) side, and move ring gear (71) close to pinion (42). If backlash is small, adjust it in the contrary way.

fNOTE: Ring gear (71) backlash: 0.20 to 0.28 mm (0.008

to 0.011 in) 61. Apply a film of red lead primer onto 3 to 4 teeth of ring gear (71). Turn ring gear (71) forward and backward by hand and check engagement of teeth.

WMDF-04-04-055

57. Tighten nut (47) at the housing A (60) side. After a reaction is felt, further tighten nut (47) by one notch.

W4GB-03-03-054

62. For adjustment of engagement of teeth, refer to (A) to (E) in the following. After adjusting engagement of teeth, check backlash again.

58. Install a dial gauge to the tooth outer end of ring gear (71). 59. Secure pinion (42), turn ring gear (71) forward and backward, and measure backlash.

a d

b c

W4GB-03-03-055 ab-

W4GB-03-03-053

W4-4-3-31

Tow Part (Small End) Face

cd-

Flank Heel Part (Big End)

SECTION 4 TRAVEL SYSTEM Group 4 Axle A. Normal Engagement

B. Contact of Tow Part

Normal engagement of the tooth surface is 40 % or more around the center of the tooth. The adjustments of (B) to (E) are the checking method for the convexity of the teeth. Be careful as the engagement is reverse for the concave side.

For the adjustment, loosen nut (47) at the housing B (72) side, tighten nut (47) at the housing A (60) side, and move ring gear (71) away from pinion (42). Next, decrease the shim (38) thickness of housing (37) and move pinion (42) close to ring gear (71). NOTE: Thickness of shim (38): 0.075 mm (0.003 in), 0.1 mm (0.004 in), 0.25 mm (0.010 in), 0.5 mm (0.020 in), 0.8 mm (0.031 in)

71 42

W4GB-03-03-056

fNOTE: The followings are normal teeth engagements. They are all accepted.

W4GB-03-03-057

a b

C. Contact of Heel Part

WMDF-04-04-056

Pattern 1 Pattern 2 Pattern 3

Position and Length (Ratio) of Teeth Engagement a b c d e 10 1 5 4 4 to 5 10 2 4 4 4 to 5 10 3 4 3 4 to 5

For the adjustment, loosen nut (47) at the housing A (60) side, tighten nut (47) at the housing B (72) side, and move ring gear (71) close to pinion (42). Next, increase the shim (38) thickness of housing (37) and move pinion (42) away from ring gear (71). NOTE: Thickness of shim (38): 0.075 mm (0.003 in), 0.1 mm (0.004 in), 0.25 mm (0.010 in), 0.5 mm (0.020 in), 0.8 mm (0.031 in)

f 10 10 10 42

W4GB-03-03-058

W4-4-3-32

SECTION 4 TRAVEL SYSTEM Group 4 Axle D. Contact of Face Part For the adjustment, decrease the shim (38) thickness of housing (37) and move pinion (42) close to ring gear (71). Next, loosen nut (47) at the housing B (72) side, tighten nut (47) at the housing A (60) side, and move ring gear (71) away from pinion (42). NOTE: Thickness of shim (38): 0.075 mm (0.003 in), 0.1 mm (0.004 in), 0.25 mm (0.010 in), 0.5 mm (0.020 in), 0.8 mm (0.031 in)

W4GB-03-03-059

E. Contact of Flank Part For the adjustment, increase the shim (38) thickness of housing (37) and move pinion (42) away from ring gear (71). Next, loosen nut (47) at the housing A (60) side, tighten nut (47) at the housing B (72) side, and move ring gear (71) close to pinion (42). NOTE: Thickness of shim (38): 0.075 mm (0.003 in), 0.1 mm (0.004 in), 0.25 mm (0.010 in), 0.5 mm (0.020 in), 0.8 mm (0.031 in)

W4GB-03-03-060

W4-4-3-33

SECTION 4 TRAVEL SYSTEM Group 4 Axle 63. After backlash adjustment and teeth engagement adjustment of ring gear (71) and pinion (42), apply THREEBOND #1327 onto the thread part of bolts (66) (2 used). Secure nut (47) with plate (58) and bolts (66) (2 used). Secure nut (47) at the opposite side in the same way. j : 13 mm m : 26 N·m (2.7 kgf·m, 19 lbf·ft) 66 58

47 WMDF-04-04-052

64. Install gasket (53) and plate (52) to housing (39) with bolts (68) (14 used). j : 19 mm m : 19.6 N·m (2 kgf·m, 14.5 lbf·ft) 68

52, 53

39 WMDF-04-04-028

W4-4-3-34

SECTION 4 TRAVEL SYSTEM Group 4 Axle Assembly of Spider (05) Assembly

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

65. Install washer (17) to spider (05).

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: Do not stick out spring pin (16) from spider (05) when installing. 68. Fit pin hole (a) of pin (11) to pin hole (b) of spider (05). Install pin (11) to spider (05). Install spring pin (16) to pin holes (a, b) by using the special tool (ST 1801) and a hammer.

05 WMDF-04-04-066 b

66. Install needle cages (23) (2 used) to planetary gear (09). 23

09 WMDF-04-04-058 a-

Pin Hole

69. Install other planetary gear (09) assemblies (2 used) in the same way as step 66 to step 68. WMDF-04-04-026

70. Assemble the spider (05) assembly at the opposite side in the same way as step 65 to step 69.

67. Install wear rings (22) (2 used) to the both sides of planetary gear (09). Install the planetary gear (09) assembly to spider (05). 05 22

WMDF-04-04-057

W4-4-3-35

SECTION 4 TRAVEL SYSTEM Group 4 Axle Assembly of Housing (02, 03) Assemblies 71. Temporarily install the outer race of bearing (14) to housing (02) by using a plastic hammer. Install the special tools (ST 8078, ST 8079, ST 8080) to housing (02) with nuts (a) (M16, Pitch 2 mm) (2 used) and nut (b) (M16, Pitch 2 mm) as illustrated. Tighten nut (b) by tightening torque 220 N·m (22 kgf·m, 162 lbf·ft) and push the outer race of bearing (14) in housing (02). Remove the special tools (ST 8078, ST 8079, ST 8080), nuts (a) (2 used), and nut (b). ST 8080

ST 8078

73. Install shaft (06) to the special tool (ST 5132). Apply gear oil onto outer ring (f ) of seal (24). Install outer ring (f ) of seal (24) to shaft (06) so that outer ring (f ) is located under the inner race mounting surface of bearing (14).

ST 5132

ST 8079

b 14

a WMDF-04-04-059

Nut

Nut WMDF-04-04-079 Detail of Seal (24)

72. Temporarily install the outer race of bearing (13) to housing (02) by using a plastic hammer. Install the special tools (ST 8078, ST 8079, ST 8080) to housing (02) with nut (c) (M16, Pitch 2 mm) and nuts (d) (M16, Pitch 2 mm) (2 used) as illustrated. Tighten nut (c) by tightening torque 220 N·m (22 kgf·m, 162 lbf·ft) and push the outer race of bearing (13) in housing (02). Remove the special tools (ST 8078, ST 8079, ST 8080), nuts (d) (2 used), and nut (c).

e g

f g

ST 8080

ST 8078

g WMDF-04-04-060

ST 8079 ef-

Inner Ring Outer Ring

gh-

Lip Part Inner Race Mounting Surface of Bearing (14)

74. Apply grease to lip part (g) (4 places) on outer ring (f ) of seal (24). Fit inner ring (e) of seal (24) to outer ring (f ) of seal (24). d c-

Nut

fNOTE: Clearance between inner ring (e) and outer ring

13 c d-

(f) of seal (24): 0 mm (0 in)

Nut WMDF-04-04-080

W4-4-3-36

SECTION 4 TRAVEL SYSTEM Group 4 Axle The inner race of bearing (14) is too dCAUTION: hot. Be careful of burns. Heat gear oil by using an electric dCAUTION: heater. Heating by using fire may cause a fire.

The inner race of bearing (13) is too dCAUTION: hot. Be careful of burns. Heat gear oil by using an electric dCAUTION: heater. Heating by using fire may cause a fire.

75. Heat the inner race of bearing (14) to 90 to 120 °C (194 to 248 °F) in gear oil which is heated. Install the inner race of bearing (14) to shaft (06).

78. Heat the inner race of bearing (13) to 90 to 120 °C (194 to 248 °F) in gear oil which is heated. Install the inner race of bearing (13) to housing (02).

dCAUTION: Housing (02) weight: 82 kg (185 lb)

76. Attach nylon slings onto housing (02). Hoist housing (02) with the differential (01) mounting surface up. Install housing (02) to shaft (06).

02 14 06

WMDF-04-04-061

77. Push the inner ring of seal (24) in housing (02) by using a hammer.

24 WMDF-04-04-062

W4-4-3-37

SECTION 4 TRAVEL SYSTEM Group 4 Axle Preload Adjustment of Axle Shaft Bearing (Shim Adjustment)

81. Remove bolt (29). Remove the spider (05) assembly and shim (18) from housing (02). Keep selected shims (18).

79. Install shims (18) and the spider (05) assembly to shaft (06) with bolt (29).

j : 24 mm

j : 24 mm m : 460 N·m (47 kgf·m, 340 lbf·ft) 05

29 a

18 06

WMDF-04-04-063 a-

Level Difference

80. Measure the rotation resistance of the axle shaft bearing by pulling the top of mounting pitch circle of housing (02) by using a spring balance. If the measured values are out of 61 to 85 N (6.2 to 8.7 kg·f, 13.7 to 19.1 lbf ), adjust the shim again. If the value is small, decrease the shim (18) thickness. If the value is big, increase the shim (18) thickness.

fNOTE: Thickness of shim (18): 0.1 mm (0.004 in), 0.2

mm (0.008 in), 0.3 mm (0.012 in), 0.35 mm (0.014 in), 0.5 mm (0.020 in), 1 mm (0.039 in)

fNOTE: Install a spring balance by using the bolt (27) mounting holes of housing (02).

fNOTE: Turn housing (02) before measuring the rotation resistance.

WMDF-04-04-064

W4-4-3-38

SECTION 4 TRAVEL SYSTEM Group 4 Axle 82. Install one of pins (15) (4 used) to housing (02). Install internal gear (04) to housing (02) by using a press. Install other pins (15) (3 used) to housing (02) by using a plastic hammer.

84. Install retainer (21) to housing (02).

04 WMDF-04-04-020

15 WMDF-04-04-065

85. Assemble the housing (03) assembly at the opposite side in the same way as step 71 to step 84.

IMPORTANT: Use shims (18) which have been selected at the preload adjustment of the axle shaft bearing. 83. Apply THREEBOND #1327 onto the thread part of bolt (29). Install shims (18) and the spider (05) assembly to shaft (06) with bolt (29). j : 24 mm m : 460 N·m (47 kgf·m, 340 lbf·ft)

06 WMDF-04-04-063

W4-4-3-39

SECTION 4 TRAVEL SYSTEM Group 4 Axle Installation of Housing (02, 03) Assemblies

The housing (02) assembly weight: dCAUTION: 190 kg (420 lb)

86. Install separation disc (10) to differential (01). 01

90. Apply THREEBOND #1327 onto the thread part of bolts (27) (16 used). Attach nylon slings onto the housing (02) assembly. Hoist the housing (02) assembly. Install the housing (02) assembly to differential (01) with washers (28) (16 used) and bolts (27) (16 used).

j : 24 mm m : 314 N·m (32 kgf·m, 230 lbf·ft) WMDF-04-04-017

87. Axle equipped with TPD Install sun gear (08) to gear (36) of differential (01). Axle equipped with LSD Install sun gear (08) to gear (75) of differential (01). 01

WMDF-04-04-015

91. Install the housing (03) assembly at the opposite side in the same way as step 86 to step 90.

WMDF-04-04-016

88. Install friction disc (12) to sun gear (08). 89. Apply THREEBOND #1215 onto the housing (02) mounting surface of differential (01).

W4-4-3-40

SECTION 4 TRAVEL SYSTEM Group 4 Axle 92. Install plugs (25) (2 used) to housings (02, 03). Add gear oil from the plug (25) hole at the housing (03) side until gear oil comes out of the plug (25) hole at the housing (02) side. Install plugs (25) (2 used). 12.7 m square m : 20 N·m (2 kgf·m, 15 lbf·ft)

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

W4-4-3-41

SECTION 4 TRAVEL SYSTEM Group 4 Axle (Blank)

W4-4-3-42

SECTION 4 TRAVEL SYSTEM Group 5 Propeller Shaft Removal and Installation of Propeller Shaft 1

WMDF-04-04-001

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 machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove bolt, washer (1) and clips (2) (2 used). j : 17 mm 3. Disconnect the both ends of pipe (3). j : 14 mm

W4-5-1-1

SECTION 4 TRAVEL SYSTEM Group 5 Propeller Shaft

3 2 1

WMDF-04-04-002

4. Remove grease fitting (5).

Detail A

j : 10 mm

fNOTE: Remove grease fitting (5) in order to drain grease.

Remove propeller shaft (2) while dCAUTION: holding it. Do not drop propeller shaft (2). The propeller shaft (2) assembly dCAUTION: weight: 22 kg (49 lb) IMPORTANT: If removing propeller shaft (2) individually, the spline seal is damaged. Propeller shaft (2) should be removed as an assembly. 5. Set a stand and a jack under propeller shaft (2). Hold propeller shaft (2). 6. Put the matching marks at the mating part between propeller shaft (2) and propeller shaft (4). 7. Remove bolts (1) (4 used). j : 17 mm

WMDF-04-04-003

8. Remove bolts (3) (4 used). Remove propeller shaft (2). j : 17 mm

fNOTE: LOCTITE #262 has been applied on bolt (3).

fNOTE: LOCTITE #262 has been applied on bolt (1).

W4-5-1-2

SECTION 4 TRAVEL SYSTEM Group 5 Propeller Shaft

1 2 3

6 5

WMDF-04-04-002

Remove propeller shaft (1) while dCAUTION: holding it. Do not drop propeller shaft (1). 9. Set a stand and a jack under propeller shaft (1). Hold propeller shaft (1). 10. Remove bolts (6) (4 used). j : 17 mm

fNOTE: LOCTITE #262 has been applied on bolt (6). 11. Remove bolts (2) (2 used), nuts (4) (2 used), and washers (3) (4 used) from support bearing (5). Remove propeller shaft (1). j : 24 mm

W4-5-1-3

SECTION 4 TRAVEL SYSTEM Group 5 Propeller Shaft

1 2

WMDF-04-04-002

Remove propeller shaft (3) while dCAUTION: holding it. Do not drop propeller shaft (3). 12. Remove bolts (2) (4 used). j : 17 mm

fNOTE: LOCTITE #262 has been applied on bolt (2). 13. Remove bolts (1) (4 used). Remove propeller shaft (3). j : 17 mm

fNOTE: LOCTITE #262 has been applied on bolt (1).

W4-5-1-4

SECTION 4 TRAVEL SYSTEM Group 5 Propeller Shaft

7 1 2

WMDF-04-04-002

Installation IMPORTANT: Fit the flanges of propeller shafts (6, 7, and 4). Install the grease fittings of propeller shafts (6, 7, and 4) with them set on the same side. At this time, raise the machine off the ground in order to rotate tires. 1. Apply LOCTITE #262 onto bolts (1) (4 used). Install the transmission (5) side of propeller shaft (4) with bolts (1) (4 used). j : 17 mm m : 74±3.4 N·m (7.4±0.34 kgf·m, 55±2.5 lbf·ft) 2. Apply LOCTITE #262 onto bolts (2) (4 used). Install the rear axle (3) side of propeller shaft (4) with bolts (2) (4 used). j : 17 mm m : 74±3.4 N·m (7.4±0.34 kgf·m, 55±2.5 lbf·ft)

W4-5-1-5

SECTION 4 TRAVEL SYSTEM Group 5 Propeller Shaft 1 2

3 4

5 9 8 4 7 6

WMDF-04-04-002

IMPORTANT: Fit the flanges of propeller shafts (2, 5, and 6). Install the grease fittings of propeller shafts (2, 5, and 6) with them set on the same side. At this time, raise the machine off the ground in order to rotate tires. 3. Set a stand and a jack under propeller shaft (2). Hold propeller shaft (2).

5. Apply LOCTITE #262 onto bolts (9) (4 used). Install the front axle (1) side of propeller shaft (2) with bolts (9) (4 used).

4. Install support bearing (8) with washers (4) (4 used), nuts (7) (2 used), and bolts (3) (2 used). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W4-5-1-6

j : 17 mm m : 74±3.4 N·m (7.4±0.34 kgf·m, 55±2.5 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 5 Propeller Shaft 1

7 6 5 4

3 2

WMDF-04-04-002 Detail A

The propeller shaft (5) assembly dCAUTION: weight: 22 kg (49 lb) IMPORTANT: Fit the flanges of propeller shafts (5, 7, and 2). Install the grease fittings of propeller shafts (5, 7, and 2) with them set on the same side. At this time, raise the machine off the ground in order to rotate tires. 6. Set a stand and a jack under propeller shaft (5). Hold propeller shaft (5). WMDF-04-04-003

7. Apply LOCTITE #262 onto bolts (6) (4 used). Fit the matching marks made when removing and install propeller shaft (5) to propeller shaft (7) with bolts (6) (4 used). j : 17 mm

8. Apply LOCTITE #262 onto bolt (4). Install the transmission (3) side of propeller shaft (5) with bolts (4) (4 used).

m : 74±3.4 N·m (7.4±0.34 kgf·m, 55±2.5 lbf·ft)

j : 17 mm m : 74±3.4 N·m (7.4±0.34 kgf·m, 55±2.5 lbf·ft) 9. Install grease fitting (8). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W4-5-1-7

SECTION 4 TRAVEL SYSTEM Group 5 Propeller Shaft

WMDF-04-04-001

10. Connect the both ends of pipe (3). j : 14 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 11. Install clips (2) (2 used) with bolt, washer (1). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 12. Apply grease.

W4-5-1-8

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve Removal and Installation of Brake Valve

WMDF-03-04-001

2. Remove rear fender (front) (1). (Refer to W3-4-2.)

W4-6-1-1

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve

2 1

6 2

13 12

WMDF-03-06-006

3. Remove bolts, washers (2) (4 used). Remove cover (1).

6. Remove bolts, washers (11) (2 used). Remove cover (10). j : 17 mm

j : 17 mm 4. Remove bolts, washers (14) (2 used). Remove cover (15).

7. Remove bolts, washers (4) (2 used). Remove cover (3). j : 17 mm

j : 17 mm 5. Remove bolts, washers (13) (2 used). Remove cover (12).

8. Remove bolts, washers (6) (3 used). Remove covers (5, 7). j : 17 mm

j : 17 mm

W4-6-1-2

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve

3, 4 1

a a-

Brake Valve WMDF-04-06-100

a a-

Brake Valve

WMDF-03-01-008

9. Disconnect hoses (1) (2 used). j : 22 mm 10. Remove bolt, washer (3) and clip (4). j : 17 mm 11. Disconnect hose (2). j : 17 mm

W4-6-1-3

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve a

3, 4

WMDF-03-01-004

Suction Pipe

Brake Valve

12. Remove bolt, washer (3) and clips (4) (2 used). j : 17 mm 13. Disconnect hose (2). j : 27 mm 14. Disconnect hose (1). j : 17 mm

W4-6-1-4

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve

10 4

8 5

1 12

WMDF-04-06-105

WMDF-04-06-101

15. Secure the hexagonal part of ball joint (8) by using a wrench. Remove nut (6) and washer (5) from ball joint (8).

19. Remove brake valve (1) from bracket (2). 20. Disconnect hose (10) from brake valve (1). j : 27 mm

j : 14 mm, 17 mm

21. Disconnect hoses (11, 12) from brake valve (1).

16. Remove ball joint (8) from bell crank (7).

j : 17 mm

17. Remove ball joint (8) and nut (9) from brake valve (1).

22. Remove the adapters with brake valve (1) attached if necessary.

j : 17 mm 18. Remove bolts, washers (4) (4 used) from brake valve (1). j : 17 mm

W4-6-1-5

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve 10

12 WMDF-04-06-105

8 5 6

1 4 7

9 1

WMDF-04-06-101

Installation 1. Install all removed adapters to brake valve (1). 2. Connect hoses (11, 12) to brake valve (1).

133 mm (5.24 in)

IMPORTANT: Check dimension (a) to install ball joint (8) and nut (9). 5. Install nut (9) and ball joint (8) to brake valve (1).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect hose (10) to brake valve (1). j : 27 mm

WNEC-04-05-011

6. Secure the hexagonal part of ball joint (8) by using a wrench. Install ball joint (8) to bell crank (7) with washer (5) and nut (6).

m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 14 mm, 17 mm

4. Install brake valve (1) to bracket (2) with bolts, washers (4) (4 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-6-1-6

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve a

3, 4

WMDF-03-01-004

Suction Pipe

Brake Valve

7. Connect hose (1). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 8. Connect hose (2). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 9. Install clips (4) (2 used) with bolt, washer (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-6-1-7

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve

3, 4 1

a a-

Brake Valve WMDF-04-06-100 a a-

10. Connect hose (2). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 11. Install clip (4) with bolt, washer (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 12. Connect hoses (1) (2 used). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 13. Bleed air from the brake (axle). (Refer to W1-4-1.)

W4-6-1-8

Brake Valve

WMDF-03-01-008

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve

2 1

6 2

13 12

WMDF-03-06-006

14. Install covers (5, 7) with bolts, washers (6) (3 used).

17. Install cover (12) with bolts, washers (13) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

15. Install cover (3) with bolts, washers (4) (2 used).

18. Install cover (15) with bolts, washers (14) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

16. Install cover (10) with bolts, washers (11) (2 used).

19. Install cover (1) with bolts, washers (2) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-6-1-9

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve

20. Install rear fender (front) (1). (Refer to W3-4-2.)

W4-6-1-10

WMDF-03-04-001

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve Disassembly of Brake Valve

WMDF-04-06-102

010203040506070809-

Body Spool (2 Used) Spring Seat (2 Used) Retaining Ring (2 Used) Plunger (2 Used) Spring (2 Used) Plug O-Ring Retaining Ring

101112131415161718-

Orifice (2 Used) O-Ring (2 Used) Body Cover Oil Seal End Plate Retaining Ring Piston Spring

192021222324252627-

Guide Spring Seat Retaining Ring End Plate Socket Bolt Spring Spring Spring Seat Socket Bolt (4 Used)

W4-6-2-1

282930313233-

Boot Push Rod Washer Retaining Ring Plug (2 Used) O-Ring (2 Used)

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve 8. Remove orifices (10) (2 used) from bodies (01, 12).

Disassembly of Brake Valve IMPORTANT: Put the matching marks on cover (13), body (12), and body (01) before disassembling. 1. Remove push rod (29) and boot (28) from cover (13).

l : 5 mm 9. Remove O-rings (11) (2 used) from bodies (01, 12). IMPORTANT: Do not damage piston (17). 10. Remove socket bolt (23) and end plate (22) from piston (17).

2. Remove retaining ring (31) and washer (30) from push rod (29). IMPORTANT: Keep the disassembled parts together by each body in order not to confuse. 3. Remove plugs (32) (2 used) and O-rings (33) (2 used) from bodies (01, 12). l : 6 mm

l : 4 mm 11. Remove guide (19) and spring (18) from cover (13). Remove retaining ring (21) and spring seat (20) from guide (19). 12. Remove piston (17) from cover (13).

4. Remove socket bolts (27) (4 used) from body (01). Remove body (12), cover (13), springs (06, 24, 25), and spring seat (26) from body (01).

IMPORTANT: Strong force deforms cover (13). Handle it with care. 13. Secure cover (13) with the oil seal (14) side up.

l : 6 mm 5. Remove retaining ring (09), plug (07), spring (06), and O-ring (08) from body (01). 6. Remove spools (02) (2 used) from bodies (01, 12). 7. Remove plungers (05) (2 used), retaining rings (04) (2 used), and spring seats (03) (2 used) from spools (02) (2 used).

IMPORTANT: Oil seal (14) cannot be reused. If oil seal (14) has been removed, replace it with the new one when assembling. 14. Remove retaining ring (16), end plate (15), and oil seal (14) from cover (13).

W4-6-2-2

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve Assembly of Brake Valve

11 10

02 05 03

06 06 07

Section A-A

02 a-

WMDF-04-06-103

Lithium Grease Applying Position

08 09

21 20 22

27 01

15 14

13 24

32 33 12

33 WMDF-04-06-104

010203040506070809-

Body Spool (2 Used) Spring Seat (2 Used) Retaining Ring (2 Used) Plunger (2 Used) Spring (2 Used) Plug O-Ring Retaining Ring

101112131415161718-

Orifice (2 Used) O-Ring (2 Used) Body Cover Oil Seal End Plate Retaining Ring Piston Spring

192021222324252627-

Guide Spring Seat Retaining Ring End Plate Socket Bolt Spring Spring Spring Seat Socket Bolt (4 Used)

W4-6-2-3

282930313233-

Boot Push Rod Washer Retaining Ring Plug (2 Used) O-Ring (2 Used)

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve Assembly of Brake Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The brake valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling. IMPORTANT: The seals which have been removed cannot be reused. 1. Install orifices (10) (2 used) to bodies (01, 12).

8. Install socket bolts (27) (4 used) to the body (01) assembly. Place it on a horizontal workbench. 9. Install spring (06) to spool (02) of the body (12) assembly. 10. Fit the matching marks and install the body (12) assembly to the body (01) assembly.

m : 9.81 to 14.7 N·m (1.0 to 1.5 kgf·m, 7.2 to 11.0 lbf·ft)

IMPORTANT: Apply lithium grease onto the outer surface of oil seal (14), lip inner surface, inner surface on oil seal (14) mounting groove of cover (13), and sliding surface of piston (17) before assembling. 11. Install oil seal (14) to cover (13) by using the special tool (ST 7884) and a press.

2. Install spring seats (03) (2 used) and retaining rings (04) (2 used) to spools (02) (2 used).

12. Install end plate (15) and retaining ring (16) to the cover (13) assembly.

l : 5 mm

IMPORTANT: Move plunger (05) by 2 to 3 times in order to check that it can move smoothly. 3. Install plungers (05) (2 used) to the spool (02) assemblies (2 used).

13. Install piston (17) to the cover (13) assembly. 14. Install spring seat (20) and retaining ring (21) to guide (19).

IMPORTANT: Move the spool (02) assembly by 2 to 3 times in order to check that it can move smoothly. 4. Install the spool (02) assemblies (2 used) to bodies (01, 12).

15. Install spring (18), the guide (19) assembly, and end plate (22) to the cover (13) assembly with socket bolt (23).

5. Install O-ring (08) to plug (07). 6. Install spring (06), plug (07), and retaining ring (09) to the body (01) assembly. 7. Install O-rings (11) (2 used) to the body (01, 12) assemblies.

W4-6-2-4

l : 4 mm m : 6.86 to 8.83 N·m (0.7 to 0.9 kgf·m, 5.1 to 6.5 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve IMPORTANT: Check the direction to install spring (25). 16. Install spring (25) to the cover (13) assembly. 25

WMDF-04-06-106

17. Install spring (24) and spring seat (26) to the cover (13) assembly. 18. Fit the matching marks and install the cover (13) assembly to the body (12) assembly with socket bolts (27) (4 used). l : 6 mm m : 19.6 to 25.5 N·m (2.0 to 2.6 kgf·m, 14.5 to 19.0 lbf·ft) 19. Install O-rings (33) (2 used) to plugs (32) (2 used). Install plugs (32) (2 used) to the body (01, 12) assemblies. 20. Install washer (30) and retaining ring (31) to push rod (29). 21. Install push rod (29) to boot (28). 22. Install the push rod (29) assembly to piston (17). 23. Install boot (28) to the cover (13) assembly with the hole of boot (28) down.

a a-

Hole

a WMDF-04-06-106

W4-6-2-5

SECTION 4 TRAVEL SYSTEM Group 6 Brake Valve (Blank)

W4-6-2-6

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Removal and Installation of Steering Valve

2 1

WMDF-03-06-006

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

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Operate the steering wheel to the dCAUTION: right and the left several times, and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove bolts, washers (2) (4 used). Remove cover (1). j : 17 mm

W4-7-1-1

j : 17 mm

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

6 3 7

WMDF-03-01-009

4. Disconnect hose (2). j : 19 mm 5. Disconnect hoses (1, 3). j : 27 mm 6. Remove adapters (5, 6). j : 24 mm 7. Disconnect hose (4). j : 27 mm 8. Disconnect hose (7). j : 27 mm

W4-7-1-2

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

1 2 1

1 WNEC-04-06-002

9. Remove screws (1) (6 used). Remove cover (2). Remove steering valve (4) while dCAUTION: holding it. Do not drop steering valve (4). 10. Remove bolts, washers (3) (4 used). Remove steering valve (4). j : 17 mm 11. Remove other adapters with steering valve (4) attached if necessary.

W4-7-1-3

WNEC-04-06-004

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

3 1

1 2 4

1 WNEC-04-06-004

Installation 1. Install all adapters which have been removed in step 11 for removal to steering valve (4). 2. Install steering valve (4) with bolts, washers (3) (4 used). j : 17 mm m : 39±5 N·m (3.9±0.5 kgf·m, 29±3.7 lbf·ft) 3. Install cover (2) with screws (1) (6 used).

W4-7-1-4

1 WNEC-04-06-002

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

View A

b c

3 7

1 ab-

30° 30°

15°

WMDF-03-01-011

WMDF-03-01-009

4. Connect hose (7). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

IMPORTANT: Check the angle to install hose (1). IMPORTANT: Check the angle to install hose (3) as for the machine without the emergency steering. 7. Connect hoses (1, 3).

IMPORTANT: Check the angle to install hose (4). 5. Connect hose (4). j : 27 mm

j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 8. Connect hose (2).

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

j : 19 mm

6. Install adapters (5, 6) of hoses (1, 3).

m : 30 N·m (3 kgf·m, 22 lbf·ft)

j : 24 mm m : 60±6 N·m (6±0.6 kgf·m, 44±4.4 lbf·ft)

W4-7-1-5

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device 3

2 1

WMDF-03-06-006

IMPORTANT: Check the hydraulic oil level. Start the engine. Operate the steering cylinder to the stroke end several times and check for any oil leaks. 9. Install cover (3) with bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 10. Install cover (1) with bolts, washers (2) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-7-1-6

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Disassembly of Steering Valve

11 31 9

30 8

29 10 7

6 22

6 5 4 3 25

2 24

1 29 20

16 18 19 27 26 17

16 15 WLAA-03-17-001

12345678-

Dust Seal Retaining Ring Bushing O-Ring Seal Bearing Race (2 Used) Thrust Needle Housing

910111314151617-

Sleeve Pin Centering Spring (4 Used) Spool O-Ring Plate O-Ring (2 Used) Drive

1819202122232425-

Gerotor Ring Star Spacer Cap Ball Adapter Screw Spring Pin Screw (7 Used)

W4-7-2-1

262728293031-

Ball (2 Used) Spring Pin (2 Used) Relief Valve Overload Relief Valve (2 Used) Check Valve Centering Spring (2 Used)

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Disassembly of Steering Valve IMPORTANT: As the setting changes, do not disassemble relief valve (28). IMPORTANT: As the setting changes, do not disassemble overload relief valves (29) (2 used). IMPORTANT: Strong force deforms housing (8). Handle it with care. 1. Secure housing (8) in vise (a) with the cap (21) side up. 21 a

As retaining ring (2) may fly out from dCAUTION: housing (8), always wear safety glasses. IMPORTANT: Do not drop or lose ball (22) and balls (26) (2 used). IMPORTANT: Check the position of the holes where balls (22, 26) have been installed. 6. Remove housing (8) from vise (a). Turn over housing (8). Remove ball (22), balls (26) (2 used), spring pin (24), and spring pins (27) (2 used). Place housing (8) on a clean cloth in order not to damage the finished surface. Remove retaining ring (2) from housing (8) by using a screwdriver.

Vise

W202-02-14-002

2 W202-02-14-006

2. Remove check valve (30). 3. Remove screws (25) (7 used) from cap (21). Remove cap (21) from housing (8). Remove O-ring (16) from cap (21). j : 8 mm

7. Turn spool (13) and sleeve (9) and set pin (10) horizontally. Push spool (13) and sleeve (9) from the cap (21) side and remove bushing (3) from housing (8).

IMPORTANT: Do not drop star (19) when removing gerotor ring (18). 4. Remove gerotor ring (18) and star (19) from housing (8). Remove spacer (20) from gerotor ring (18). 5. Remove drive (17), plate (15), and O-rings (16, 14) from housing (8). Remove adapter screw (23) from housing (8) by using a screwdriver.

W4-7-2-2

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device IMPORTANT: When removing seal (5), do not damage bushing (3). 8. Remove seal (5) and dust seal (1) from bushing (3). 9. Remove bearing races (6) (2 used) and thrust needle (7) from spool (13).

As centering springs (11, 31) may fly dCAUTION: out, always wear safety glasses. 12. Push spool (13) in sleeve (9) forward. Remove centering springs (11) (4 used) and centering springs (31) (2 used) from spool (13).

10. Remove the sleeve (9) assembly from housing (8).

fNOTE: Slowly turn and remove the sleeve (9) assembly from housing (8) so that sleeve (9) does not stick to housing (8).

IMPORTANT: Put matching marks (a) on sleeve (9) and spool (13) before disassembling. 11. Remove pin (10) from the sleeve (9) assembly.

11 13

10 13

a a-

W202-02-14-021

W4GB-03-07-002

Matching Mark

13. Remove spool (13) from sleeve (9) by turning. 14. Remove O-ring (4) from housing (8).

W4-7-2-3

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Assembly of Steering Valve

6 5

11 31

17 13

14 15 16 19

T4FC-03-04-003

Section D-D

TCJB-03-10-008

D D T4FC-03-04-010

12345678-

Dust Seal Retaining Ring Bushing O-Ring Seal Bearing Race (2 Used) Thrust Needle Housing

910111314151617-

Sleeve Pin Centering Spring (4 Used) Spool O-Ring Plate O-Ring (2 Used) Drive

1819202122232425-

Gerotor Ring Star Spacer Cap Ball Adapter Screw Spring Pin Screw (7 Used)

fNOTE: As for the item with mark *, refer to W4-7-2-1. W4-7-2-4

262728293031-

Ball (2 Used) Spring Pin (2 Used) *Relief Valve *Overload Relief Valve (2 Used) Check Valve Centering Spring (2 Used)

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Assembly of Steering Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install spool (13) to sleeve (9) by turning. Fit matching marks (a) on spool (13) and sleeve (9).

3. Insert pin (10) into the holes of spool (13) and sleeve (9). Fit the ends of pin (10) and the outer surface of sleeve (9). 9 13 10

13 b

W202-02-14-021

4. Install the sleeve (9) assembly from the cap (21) side of housing (8).

fNOTE: When installing the sleeve (9) assembly, prevent a ab-

W202-02-14-019

Matching Mark Spring Groove

As centering springs (11, 31) may fly dCAUTION: out, always wear safety glasses. 2. Fit the spring groove (b) positions of spool (13) and sleeve (9) and place them on a flat plate. Fit centering springs (11, 13) back to back and install them to the special tool (ST 2497). Install centering springs (11) (4 used) and centering springs (31) (2 used) to spring grooves (b) of spool (13) and sleeve (9) by using the special tool (ST 2497).

13 ST2497

11 31 11 W4GB-03-07-003

W4-7-2-5

sticking. While keeping pin (10) horizontally, turn pin (10) right and left. Insert pin (10) until the ends behind the sleeve (9) assembly and housing (8) come to the same position.

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device 5. Install O-ring (4) to housing (8).

As retaining ring (2) may fly out from dCAUTION: housing (8), always wear safety glasses. 9. Install retaining ring (2) to housing (8).

fNOTE: After installing retaining ring (2), extend the bore of retaining ring (2) by using screwdriver (a) so that it enters the groove on housing (8) correctly.

IMPORTANT: Strong force deforms housing (8). Handle it with care. 10. Secure housing (8) in a vise.

W202-02-14-023

6. Install bearing races (6) (2 used) and thrust needle (7) to spool (13). 7. Install dust seal (1) and seal (5) to bushing (3). IMPORTANT: Check that bushing (3) and bearing race (6) contact each other horizontally. 8. Tap and install bushing (3) to spool (13) by using a plastic hammer.

IMPORTANT: Do not drop or lose ball (22), balls (26) (2 used), spring pin (24), and spring pins (27) (2 used). 11. Install O-ring (14) to housing (8). Install ball (22), balls (26) (2 used), adapter screw (23), spring pin (24), and spring pins (27) (2 used) to housing (8) at the position as illustrated below. Place plate (15) on housing (8).

26 26

23 24 22

8 5 6

4 3 WLAA-03-17-003

W212-02-14-002 a-

Screwdriver

W4-7-2-6

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device 12. Turn the sleeve (9) assembly and set pin (10) and port side (d) of housing (8) in parallel (h). Draw line (a) onto the spline side end so that line (a) is parallel to line (b) on yoke part (c) of drive (17). Install drive (17). Assemble yoke part (c) of drive (17) and pin (10). Set line (a) of the spline side end of drive (17) and port side (d) of housing (8) in parallel.

13. Install O-ring (16) to gerotor ring (18). 14. Face the O-ring (16) side of gerotor ring (18) to the plate (15) side. Install star (19) while aligning the splines of star (19) and drive (17) so that line (j) connecting concave part (i) of star (19) is parallel to line (a) on the spline side end of drive (17). Check that line (j) connecting concave part (i) of star (19), line (a) on the spline side end, line (b) on yoke part (c) of drive (17), and line (g) connecting the centers of port L (e) and port T (f ) are parallel. Fit bolt hole (k) on gerotor ring (18) while mating drive (17) and star (19).

a b

17 18

W487-03-08-006

19 d

b g

15 g

10 c

abcde-

Line at the Spline Side End Line on the York Yoke Part Port Side Port L

b W487-03-08-007

fgh-

Port T Line Connecting the Centers of Port L and Port T Set (b) and (g) in parallel.

d W202-02-14-031

ijk-

W4-7-2-7

Concave Part Line Connecting the Concave Part Bolt Hole

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device 15. Install spacer (20) to gerotor ring (18). Install O-ring (16) to cap (21). Place cap (21) on gerotor ring (18). 16. Install cap (21) to housing (8) with screws (25) (7 used). j : 8 mm m : 28 N·m (2.8 kgf·m, 20.5 lbf·ft) 17. Install check valve (30).

W4-7-2-8

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Removal and Installation of Steering Cylinder 1 3 4 3 4

WMDF-04-07-104

WMDF-03-09-005

3. Disconnect hoses (3, 4) (2 used for each).

Removal 1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) Operate the steering wheel to the dCAUTION: right and the left several times, and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove bolts, washers (1) (4 used). Remove cover (2). j : 19 mm

W4-7-3-1

j : 22 mm

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

8 6

3 4 WMDF-04-07-105

4. Remove bolts, washers (3) (2 used) and clips (4) (2 used). j : 17 mm 5. Disconnect the both ends of pipe (2). j : 17 mm 6. Remove elbow (1). j : 12 mm 7. Remove bolt, washer (7) and clips (8) (2 used). j : 17 mm 8. Disconnect the both ends of pipe (6). j : 17 mm 9. Remove elbow (5). j : 12 mm

W4-7-3-2

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

12 4 11 5

1 7

10 8

WMDF-04-07-106

10. Remove grease fitting (1).

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

j : 10 mm 11. Attach nylon slings onto steering cylinder (9). Hoist and hold steering cylinder (9). 12. Remove bolt, washer (5) and washer (6). j : 19 mm

such as goggles, hard hat, etc. in order to prevent personal injury. 15. Remove pin (11) and shim (10) by using a bar and a hammer. 16. Remove steering cylinder (9).

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

17. Remove the adapters with steering cylinder (9) attached if necessary.

such as goggles, hard hat, etc. in order to prevent personal injury. 13. Remove pin (7) and shim (8) by using a bar and a hammer.

18. Remove another steering cylinder (4) in the same way as step 10 to step 17.

14. Remove bolt, washer (13) and washer (12). j : 19 mm

W4-7-3-3

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

View B

WMDF-04-07-107

3 WMDF-04-07-106

Detail A

Installation

1. Install all removed adapters to steering cylinder (1).

1 a

2. Attach nylon slings onto steering cylinder (1). Hoist steering cylinder (1). 3. Fit the hole at the steering cylinder (1) bottom side to the mounting hole on rear frame (2). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

WNEC-04-08-011

such as goggles, hard hat, etc. in order to prevent personal injury. 4. Fit shim (3) to the mounting hole on rear frame (2) so that clearance (a) is adjusted within 1 mm (0.039 in). Install pin (4) to rear frame (2) by using a hammer.

fNOTE: Shim (3) thickness: 1 mm (0.039 in), 0.5 mm (0.2

Clearance

5. Install bolt, washer (5) and washer (6). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) IMPORTANT: Check the direction to install grease fitting (8). 6. Install grease fitting (8).

in)

j : 10 mm 7. Apply grease.

W4-7-3-4

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

2 5 6

1 WMDF-04-07-106 Detail A

8. Fit the hole at the steering cylinder (1) rod side to the mounting hole on front frame (2).

2 a

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. 9. Fit shim (3) to the mounting hole on front frame (2) so that clearance (a) is adjusted within 1 mm (0.039 in). Install pin (4) to front frame (2) by using a hammer.

WNEC-04-08-010

fNOTE: Shim (3) thickness:

1 mm (0.039 in), 0.5 mm (0.2 in) 10. Install bolt, washer (5) and washer (6). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 11. Install another steering cylinder (8) in the same way as step 1 to step 10.

W4-7-3-5

Clearance

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

View A

2 2

25°

30° WMDF-04-07-108

4 WMDF-04-07-105

IMPORTANT: Check the angle to install elbow (5). 12. Install elbow (5).

IMPORTANT: Check the angle to install elbow (1). 15. Install elbow (1). j : 12 mm

j : 12 mm 13. Connect the both ends of pipe (6).

16. Connect the both ends of pipe (2).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

14. Install clips (8) (2 used) with bolt, washer (7). j : 17 mm

17. Install clips (4) (2 used) with bolts, washers (3) (2 used). j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft) 18. Apply grease.

W4-7-3-6

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device

3 a

1 2

1 2 4

WMDF-04-07-104 a-

155 mm (6.1 in)

210 mm (8.23 in) WMDF-03-09-005

19. Connect hoses (1, 2) (2 used for each). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the engine. Operate the steering cylinder to the stroke end several times and check for any oil leaks. 20. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) IMPORTANT: Check the direction to install cover (4). 21. Install cover (4) with bolts, washers (3) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

fNOTE: Turn cover (4) by 180 degrees and install it in case of the machine with the quick coupler.

W4-7-3-7

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device (Blank)

W4-7-3-8

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Disassembly of Steering Cylinder

5 10 3 4 2

7 9

6 8

16 15 17 13 18

WMDF-04-07-100

1234-

Cylinder Rod Dust Seal U-Ring Backup Ring

5678-

Cylinder Head Washer O-Ring O-Ring

9101315-

Backup Ring Bushing O-Ring Seal Ring

W4-7-4-1

16171820-

Piston Wear Ring Nut Cylinder Tube

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Disassembly of Steering Cylinder

4. Loosen cylinder head (5) by using hook wrench (b).

1. Hoist the cylinder. Secure the cylinder on a workbench horizontally. Drain off hydraulic oil from the cylinder.

Diameter of cylinder head (5): 78 mm

W102-04-02-027

2. Install a protective cover to cylinder rod (1). 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: Do not damage the sliding surface of cylinder rod (1). 3. Extend the stopper (a) part of washer (6) by using a chisel and a hammer. Make it flat.

W506-04-02-004

Hook Wrench

5. Remove the cylinder rod (1) assembly from cylinder tube (20). Secure it on the special tool (ST 5908) for cylinder.

Special Tool for Cylinder: ST 5908 W158-04-02-022

a a-

WNDB-04-06-002

Stopper

W4-7-4-2

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device 6. Remove nut (18) by using the special tool (ST 5908) for cylinder and the special tool for nut.

8. Remove cylinder head (5) from cylinder rod (1) by using a plastic hammer.

fNOTE: LOCTITE #262 has been applied on nut (18).

9. Remove wear ring (17) from piston (16). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

Special Tool for Nut: ST 3450: 50 mm

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: Do not damage the seal groove. 10. Remove backup rings (15a) (2 used) from piston (16). Cut seal ring (15b) and ring (15c) by using a screwdriver and a hammer. Remove seal ring (15b) and ring (15c) from piston (16). Special Tool for Cylinder: ST 5908 a

W158-04-02-022

7. Remove piston (16) by using the special tool (ST 5908) for cylinder and the special tool for piston. Special Tool for Piston: ST 3415: 46 mm

ab-

Special Tool for Cylinder: ST 5908 W158-04-02-022

W4-7-4-3

Backup Ring Seal Ring

Ring

WMDF-04-07-110

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device 11. Remove O-ring (13) from piston (16) by using a spatula.

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

12. Remove backup ring (9) and O-rings (7, 8) from cylinder head (5) by using a spatula.

such as goggles, hard hat, etc. in order to prevent personal injury.

13. Remove U-ring (3), backup ring (4a), and buffer ring (4b) from cylinder head (5) by using an awl.

IMPORTANT: Do not damage cylinder head (5). 14. Secure cylinder head (5) in a vise. Remove dust seal (2) from cylinder head (5) by using a screwdriver and a hammer. IMPORTANT: Bushing (10) cannot be reused. If bushing (10) has been removed, replace it with the new one when assembling. 15. Remove bushing (10).

fNOTE: Bushing (10) cannot be tapped and removed 4

WNDB-04-06-005

Detail A a

WDBE-05-02-008 a-

Backup Ring

Buffer Ring

W4-7-4-4

from cylinder head (5). Cut off bushing (10) by using a lathe. Insert a screwdriver strongly and remove busing (10).

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Assembly of Steering Cylinder

7 10 3, 4

8, 9

15 17 16

WMDF-04-07-101

1234-

Cylinder Rod Dust Seal U-Ring Backup Ring

5678-

Cylinder Head Washer O-Ring O-Ring

9101315-

Backup Ring Bushing O-Ring Seal Ring

W4-7-4-5

16171820-

Piston Wear Ring Nut Cylinder Tube

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Assembly of Steering Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The seals which have been removed cannot be reused. 1. Install bushing (10) to cylinder head (5) by using the special tool for bushing.

IMPORTANT: Check the direction to install backup ring (4a). 3. Install U-ring (3), buffer ring (4b), and backup ring (4a) to cylinder head (5).

Special Tool for Bushing (Rod Outer Diameter):

ST 3416: 40 mm 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. 2. Install dust seal (2) to cylinder head (5) by using the special tool for dust seal and a hammer.

A WMDF-04-07-109

Detail A

Special Tool for Dust Seal (Rod Outer Diameter):

ST 3417: 40 mm

WDBE-05-02-008 a-

Backup Ring

Buffer Ring

4. Install O-rings (7, 8) and backup ring (9) to cylinder head (5).

W4-7-4-6

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Seal ring (15b) is too hot. Be careful of dCAUTION: burns. IMPORTANT: Check the direction to install backup ring (15a). 5. Install ring (15c) to piston (16) by using a screw driver with rounded corners. Dip seal ring (15b) for approximately five minutes in hydraulic oil which is heated at 150 to 180 °C (302 to 356 °F) by using the electric heater in order to make seal ring (15b) soft. Install seal ring (15b) to piston (16) by using the special tool for seal ring. After installing seal ring (15b), adjust it by using the special tool for seal ring. Install backup rings (15a) (2 used) to piston (16). Special Tool for Seal Ring (Tube Inner Diameter):

7. Hoist and secure cylinder rod (1) on the special tool (ST 5908) for cylinder.

Special Tool for Cylinder: ST 5908 W158-04-02-022

8. Install the cylinder head (5) assembly to cylinder rod (1) by using the special tool for cylinder head.

ST 3418: 65 mm

Special Tool for Cylinder Head (Rod Outer Diameter):

Special Tool for Seal Ring (Tube Inner Diameter):

ST 3420: 40 mm 9. Install the piston (16) assembly to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for piston.

ST 3419: 65 mm

Special Tool for Piston:

ST 3415: 46 mm 16

m : 491±49 N·m (50±5 kgf·m, 360±36 lbf·ft)

ab-

Backup Ring Seal Ring

WMDF-04-07-110

Ring

Special Tool for Cylinder: ST 5908 W158-04-02-022

6. Install O-ring (13) to piston (16).

W4-7-4-7

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device 10. Apply LOCTITE #262 onto nut (18). Install nut (18) to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for nut.

IMPORTANT: Align the cylinder rod (1) assembly with the center of cylinder tube (20) and install it straight in order not to damage the rings.

Special Tool for Nut: 12. Secure cylinder tube (20) on a workbench horizontally. Install washer (6) and the cylinder rod (1) assembly to cylinder tube (20). At this time, fit the bent part of washer (6) to notch (a) of cylinder tube (20) and install washer (6).

ST 3450: 50 mm m : 637±63 N·m (65±6.5 kgf·m, 470±46 lbf·ft)

fNOTE: New washer (6) is not bent. The position adjustment of washer (6) is not necessary.

Special Tool for Cylinder: ST 5908

W158-04-02-022

11. Install wear ring (17) to piston (16).

17 a

WNDB-04-06-003 a-

WMDF-04-07-110

W4-7-4-8

Notch

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device IMPORTANT: Do not damage the sliding surface of cylinder rod (1). 13. Tighten cylinder head (5) to cylinder tube (20) by using a hook wrench. Diameter of cylinder head (5): 78 mm m : 736±74 N·m (75±7.5 kgf·m, 540±55 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. 14. Bend washer (6) by using a chisel and a hammer in order not to loosen cylinder head (5). At this time, bend one of the three notches (b) for the hook wrench of cylinder head (5) in order not to loosen. (In case of new washer (6), bend notch (a) of cylinder tube (20) in order not to loosen.)

b a-

Notch

WNDB-04-06-004 b-

Notch

W4-7-4-9

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device (Blank)

W4-7-4-10

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device Removal and Installation of Steering Accumulator 2

7 A WMDF-04-07-102 B

Removal

CAUTION:

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

Operate the steering wheel in right dCAUTION: and left several times, and release any pressure in the circuit. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Disconnect hoses (6, 7).

 Do not heat the accumulator directly. Do not weld the accumulator housing.

j : 19 mm

 Be sure to release pressure before starting to work on the piping lines.

3. Remove bolts, washers (5) (3 used). Remove the steering accumulator (3) assembly.

j : 17 mm 4. Remove nuts (1) (16 used) and U-bolts (2) (4 used). Remove steering accumulators (3) (2 used) from bracket (4). j : 17 mm 5. Remove the adapters with steering accumulators (3) (2 used) attached if necessary.

W4-7-5-1

SECTION 4 TRAVEL SYSTEM Group 7 Steering Device 2

View A

ab-

20° Mark

WMDF-04-07-103 A B

WMDF-04-07-102

Installation

IMPORTANT: Check the angle to install hose (6). 4. Connect hoses (6, 7).

1. Install all removed adapters to steering accumulators (3) (2 used).

j : 19 mm

2. Mark (b) is stamped on steering accumulator (3). Install steering accumulators (3) (2 used) to bracket (4) with U-bolts (2) (4 used) and nuts (1) (16 used) so that mark (b) can be seen. j : 17 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine. Operate the steering cylinder to the stroke end several times and check for any oil leaks.

m : 20 N·m (2 kgf·m, 15 lbf·ft) 3. Install the steering accumulator (3) assembly with bolts, washers (5) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-7-5-2

SECTION 4 TRAVEL SYSTEM Group 8 Secondary Steering Device Removal and Installation of Secondary Steering Pump (Option) 1, 2

WMDF-04-08-002

WMDF-03-02-012

2. Open the cover of battery box (3). 3. Loosen nut (1). Disconnect ground (2). : 10 mm 4. Remove the following parts. (Refer to W3-4-2.) x Step (Front) (5) x Rear Fender (Front) (7) x Deck (4) x Cover (6)

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Operate the brake pedal more than CAUTION: fifty times and release any pressure in the circuit. Bleed air from the hydraulic oil tank. CAUTION: (Refer to W1-4-1.) Release any pressure in the front CAUTION: attachment hydraulic circuit. (Refer to W1-5-1.)

W4-8-1-1

SECTION 4 TRAVEL SYSTEM Group 8 Secondary Steering Device

2 1

4 6

WMDF-03-06-006

5. Remove bolts, washers (2) (4 used). Remove cover (1). : 17 mm 6. Remove bolts, washers (4) (2 used). Remove cover (3). : 17 mm 7. Remove bolts, washers (6) (2 used). Remove cover (5). : 17 mm

W4-8-1-2

SECTION 4 TRAVEL SYSTEM Group 8 Secondary Steering Device 1 12

11 10

3 4, 5 6 8

WMDF-03-12-001

8. Remove the manifold valve (1) assembly. (Refer to W3-12-1.)

10. Remove nut (4). Disconnect terminal (5).

: 17 mm 15. Remove bolts, washers (12) (4 used) and ground (7). Remove secondary steering pump (11) from bracket (10).

: 12 mm 11. Disconnect connector (6). 12. Disconnect hose (3).

WMDF-04-08-001

14. Remove bolts, washers (9) (3 used). Remove the secondary steering pump (11) assembly.

9. Remove bolt, washer (8). Disconnect ground (7). : 17 mm

: 17 mm 16. Remove the adapters with secondary steering pump (11) attached if necessary.

: 36 mm 13. Disconnect hose (2). : 22 mm

W4-8-1-3

SECTION 4 TRAVEL SYSTEM Group 8 Secondary Steering Device

View A

60°

WMDF-04-08-003

3, 4 5 7

WMDF-04-08-001

Installation 1. Install all removed adapters to secondary steering pump (10). 2. Install secondary steering pump (10) and ground (6) to bracket (9) with bolts, washers (11) (4 used). At this time, temporarily tighten bolts, washers (11) which secure ground (6).

IMPORTANT: Check the direction to install hose (2). 5. Connect hose (2). : 36 mm : 180 N·m (18 kgf·m, 133 lbf·ft) 6. Connect connector (5). 7. Connect terminal (4) with nut (3).

: 17 mm

: 12 mm

: 50 N·m (5 kgf·m, 37 lbf·ft)

: 8.2 to 9.8 N·m (0.8 to 1 kgf·m, 6 to 7.2 lbf·ft)

3. Install the secondary steering pump (10) assembly with bolts, washers (8) (3 used).

8. Connect ground (6) with bolt, washer (7).

: 17 mm

: 50 N·m (5 kgf·m, 37 lbf·ft)

4. Connect hose (1).

9. Tighten bolts, washers (11) which have been tighten temporarily in step 2.

: 22 mm

: 17 mm

: 40 N·m (4 kgf·m, 29.5 lbf·ft)

: 50 N·m (5 kgf·m, 37 lbf·ft)

W4-8-1-4

SECTION 4 TRAVEL SYSTEM Group 8 Secondary Steering Device 1

2, 3

4 WMDF-03-12-001

10. Install the manifold valve (1) assembly. (Refer to W312-1.) 11. Connect ground (3). Tighten nut (2). : 10 mm : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 12. Bleed air from the hydraulic system and brake (axle). (Refer to W1-4-1.) 13. Close the cover of battery box (4).

W4-8-1-5

WMDF-03-02-012

SECTION 4 TRAVEL SYSTEM Group 8 Secondary Steering Device

2 1

4 6

WMDF-03-06-006

14. Install cover (5) with bolts, washers (6) (2 used). : 17 mm : 50 N·m (5 kgf·m, 37 lbf·ft) 15. Install cover (3) with bolts, washers (4) (2 used). : 17 mm : 50 N·m (5 kgf·m, 37 lbf·ft) 16. Install cover (1) with bolts, washers (2) (4 used). : 17 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-8-1-6

SECTION 4 TRAVEL SYSTEM Group 8 Secondary Steering Device

WMDF-04-08-002

17. Install following parts. (Refer to W3-4-2.) x Cover (3) x Deck (1) x Step (Front) (2) x Rear Fender (Front) (4)

W4-8-1-7

SECTION 4 TRAVEL SYSTEM Group 8 Secondary Steering Device (Blank)

W4-8-1-8

SECTION 5

FRONT ATTACHMENT CONTENTS Group 1 Front Attachment Removal and Installation of Front Attachment...W5-1-1-1 Position to Install (Lift Arm) ..................................W5-1-1-6 Position to Install (Bucket Cylinder) ...................W5-1-1-7 Removal and Installation of Bell Crank (Lever)....W5-1-2-1 Position to Install (Bell Crank (Lever))................W5-1-2-4 Position of Install (Bucket Link) ...........................W5-1-2-5 Position to Install (Bucket Cylinder) ...................W5-1-2-6 Removal and Installation of Bucket.........................W5-1-3-1 Position to Install (Lift Arm) ..................................W5-1-3-3 Position of Install (Bucket Link) ...........................W5-1-3-4

Group 2 Cylinder Removal and Installation of Lift Arm Cylinder.....W5-2-1-1 Position to Install (Lift Arm Cylinder).................W5-2-1-4 Removal and Installation of Bucket Cylinder .......W5-2-2-1 Position to Install (Bucket Cylinder) ...................W5-2-2-7 Disassembly of Lift Arm Cylinder .............................W5-2-3-1 Assembly of Lift Arm Cylinder ...................................W5-2-3-5 Disassembly of Bucket Cylinder................................W5-2-4-1 Assembly of Bucket Cylinder ....................................W5-2-4-5

62Z7(US)D&R

(Blank)

62Z7(US)D&R

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Front Attachment 8

1 4 3 9

2 14

14 10 11 13

5 6

WMDF-05-01-100

4. Remove bolts (6) (4 used) and washers (7) (4 used). Remove the head light (1) assembly and rubber cushions (5) (4 used). j : 19 mm 5. Remove bolt, washer (13), brackets (14) (2 used) and tube (9). j : 17 mm 6. Disconnect connector (15).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

7. Remove bolts (10) (4 used) and washers (11) (4 used). Remove the head light (8) assembly and rubber cushions (12) (4 used). j : 19 mm

2. Remove bolt, washer (3) and bracket (4). j : 17 mm 3. Disconnect connector (2).

W5-1-1-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

9 11 10 8

3 7

1 4 5

WMDF-05-01-101

8. Remove bolts, washers (7, 8), clips (10, 11) and collar (9). Disconnect connector (3). j : 17 mm 9. Put the matching marks onto bolt, washer (5) and bracket (2). Remove bolts, washers (4, 5) and washer (6). Remove bracket (2) and collars (1) (2 used). j : 17 mm

W5-1-1-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

5 2 3

1 3 WMDF-05-01-102

10. Remove bolt, washer (3). Remove and place horn (2) outside of the work area. j : 13 mm 11. Remove another horn (1) in the same way as step 10. Place it outside of the work area. Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1- 4-1.) Release any pressure in the front dCAUTION: hydraulic circuit. (Refer to W1-5-1.) IMPORTANT: After removing bucket cylinder (5), do not operate the bucket. 12. Remove bucket cylinder (5). (Refer to W5-2-2.)

W5-1-1-3

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

Detail A

8 7

3, 4

WNDB-05-01-008

WMDF-05-02-115

The front attachment assembly dCAUTION: weight: 1890 kg (4170 lb) Take care that lift arm (1) may lower. dCAUTION: Set the front control lever lock switch to the lock

18. Remove spacer (9) and shim (8) from lift arm (1).

position securely before removing the stand. 13. Start the engine. Raise lift arm (1). Set lift arm cylinder (2) in the horizontal position. Hold the end of lift arm (1) by using a stand.

21. Start the engine. Retract the rod side of lift arm cylinder (2).

14. Stop the engine. Place wooden blocks under lift arm cylinder (2).

19. Lower lift arm cylinder (2) onto wooden blocks. 20. Remove another pin (7) in the same way as step 14 to step 19.

22. Stop the engine. In order not to extend the rod, pass the wires through the rod hole of lift arm cylinder (2) and secure the rod to the cylinder tube.

Lift arm cylinder (2) weight: 110 kg dCAUTION: (245 lb) 15. Attach nylon slings onto lift arm cylinder (2). Hoist and hold lift arm cylinder (2). 16. Remove grease fitting (6). j : 10 mm 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. 17. Remove bolt, washer (3) and washer (4). Remove pin (7) from lift arm cylinder (2) by using a round bar and a hammer. j : 19 mm

W5-1-1-4

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

4, 5, 6

7 Detail A

9 WNDB-05-01-008

WMDF-05-01-106

27. Remove another pin (3) in the same way as step 24 to step 26.

The front attachment assembly dCAUTION: weight: 1890 kg (4170 lb)

IMPORTANT: Move the machine back slowly. At this time, do not contact the front attachment assembly with the front frame mounting part. 28. Start the engine. Move the machine back. Remove the front attachment assembly from front frame (2). Stop the engine.

23. Attach nylon slings onto the front attachment assembly. Hoist and hold the front attachment assembly. 24. Remove grease fitting (7). j : 10 mm

29. Place the front attachment assembly on wooden blocks.

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. 25. Remove bolt (4) and washers (5, 6). Remove pin (3) from front frame (2) by using a round bar and a hammer. j : 24 mm 26. Remove spacers (8, 9) from lift arm (1).

W5-1-1-5

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Position to Install (Lift Arm)

b WNEC-05-01-024

12-

Bushing Lift Arm

ab-

5 mm (0.20 in) 7 mm (0.28 in)

Direction to Install (Lift Arm)

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installation. Replace them if there are some defects. (Refer to W2-2-1.) IMPORTANT: Apply grease onto the inner surface of bushings and dust seals when installing the pin. In addition, apply anti-rust oil onto the inner surface of the boss. IMPORTANT: Refer to the illustration when installing the bushing of lift arm. IMPORTANT: For handling of HN bushing for the front attachment, check the followings.

WNEC-05-01-028 c-

Precautions for installing bushing If a hammer is used to install the bushing, the bushing may be damaged. Use a press for installing bushing. After installing bushing, install dust seal. Special tool when installing bushing (bushing inner diameter) (ST 7692, ST 7859): 75 mm (ST 7693): 85 mm (ST 7722): 100 mm Precautions when reinforcing lift arm The heat when welding in order to reinforce the lift arm may cause oil leakage and decrease lubrication performance. When lubrication oil leaks, replace the bushing.

W5-1-1-6

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Position to Install (Bucket Cylinder)

2 a

b WNEC-05-01-029

12-

Bushing Bucket Cylinder

ab-

6.5 mm (0.26 in) 6.5 mm (0.26 in)

IMPORTANT: Refer to the illustration when installing the bushing of bucket cylinder.

Direction to Install (Bucket Cylinder) c

WNEC-05-01-028 c-

W5-1-1-7

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

4, 5, 6

Detail A

9 WMDF-05-01-106

WNDB-05-01-008

fNOTE: Fit at least one spacer (8) or spacer (9) to the

both side of lift arm (1) mounting hole.

fNOTE: Thickness of spacer (8, 9): 1.6 mm (0.063 in), 2.3

1 a

mm (0.091 in) 4. Install washers (5, 6) and bolt (4). j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft) WNEC-05-01-020 a-

5. Install grease fitting (7). Apply grease.

Clearance

j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

The front attachment assembly dCAUTION: weight: 1890 kg (4170 lb)

6. Install another pin (3) in the same way as step 3 to step 5.

1. Attach nylon slings onto the front attachment assembly. Hoist and hold the front attachment assembly. 2. Start the engine. Move the machine forward. Fit the lift arm (1) mounting holes to front frame (2). Stop the engine. 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. 3. Fit spacer (8, 9) to the lift arm (1) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (3) to front frame (2) by using a hammer.

W5-1-1-8

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

Detail A

1 9

8 WMDF-05-02-115

3, 4

WNDB-05-01-008

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. Fit spacer (9) and shim (8) to the lift arm (1) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (7) to lift arm cylinder (2) by using a hammer.

fNOTE: Fit at least one spacer (9) or shim (8) to the both side of lift arm (1) mounting hole.

1 a-

WNEC-05-01-017

Clearance

fNOTE: Thickness of spacer (9): 2.3 mm (0.091 in), thickness of shim (8): 1.6 mm (0.063 in) 11. Install washer (4) and bolt, washer (3). j : 19 mm

7. Remove the wires from the rod holes of lift arm cylinders (2) (2 used).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

CAUTION: Lift arm cylinder (2) weight: 110 kg (245 lb) 8. Attach nylon slings onto lift arm cylinder (2). Hoist lift arm cylinder (2).

9. Start the engine. Extend the rod of lift arm cylinder (2). Fit the rod to the lift arm cylinder (2) mounting holes of lift arm (1). Stop the engine.

12. Install grease fitting (6). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft) 13. Install another pin (7) in the same way as step 8 to step 12.

W5-1-1-9

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

WNDB-05-01-008

14. Start the engine. Raise lift arm (1). Take care that lift arm (1) may lower. dCAUTION: Set the front control lever lock switch to the lock position securely before removing wooden blocks. 15. Stop the engine. Remove wooden blocks under lift arm (1).

W5-1-1-10

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

5 2 3

1 3 WMDF-05-01-102

16. Install bucket cylinder (5). (Refer to W5-2-2.) 17. Install horn (2) with bolt, washer (3). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 18. Install another horn (1) in the same way as step 17.

W5-1-1-11

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

9 11 10 8

3 7

1 4 5

WMDF-05-01-101

19. Fit the matching marks made when removing and install bracket (2) and collars (1) (2 used) with bolts, washers (4, 5) and washer (6). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 20. Connect connector (3). Install bolts, washers (7, 8), clips (10, 11) and collar (9). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W5-1-1-12

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

1 4 3 9

2 14

14 10 11 13

5 6

WMDF-05-01-100

21. Install the head light (8) assembly and rubber cushions (12) (4 used) with washers (11) (4 used) and bolts (10) (4 used).

25. Connect connector (2). 26. Install bracket (4) with bolt, washer (3). j : 17 mm

j : 19 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

27. Bleed air from the hydraulic system. (Refer to W14-1.)

22. Connect connector (15). 23. Install brackets (14) (2 used) and tube (9) with bolt, washer (13).

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 24. Install the head light (1) assembly and rubber cushions (5) (4 used) with washers (7) (4 used) and bolts (6) (4 used). j : 19 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W5-1-1-13

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment (Blank)

W5-1-1-14

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Bell Crank (Lever) 5

Detail A

8 3, 4

9 A

WMDF-05-01-104

WMDF-05-01-107

5. Remove spacer (7) and shim (8) from bucket link (2). 6. Lower and remove the bell crank (5) side of bucket link (2) from bell crank (5). Bleed air from the hydraulic oil tank. CAUTION: (Refer to W1- 4-1.) Release any pressure in the front CAUTION: hydraulic circuit. (Refer to W1-5-1.) IMPORTANT: After removing bucket cylinder (6), do not operate the bucket. 7. Remove bucket cylinder (6). (Refer to W5-2-2.)

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

CAUTION: Bucket link (2) weight: 38 kg (84 lb) 2. Attach nylon slings onto bucket link (2). Hoist and hold bucket link (2). 3. Remove grease fitting (9). : 10 mm Metal fragments may fly off when CAUTION: a hammer is used. Wear necessary protection,

such as goggles, hard hat, etc. in order to prevent personal injury. 4. Remove bolt, washer (3) and washer (4). Remove pin (1) from bell crank (5) by using a round bar and a hammer. : 19 mm

W5-1-2-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

Detail A

1 11 10 8

3, 4, 5

WNEC-05-01-016

WMDF-05-01-103

10. Remove grease fitting (7).

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. 8. Install pin (11) to bell crank (1) by using a hammer. Install washer (10) and bolt, washer (8). j : 19 mm m : 90 N·m (9 kgf·m, 66 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. 11. Remove bolt (3) and washers (4, 5). Remove pin (6) from lift arm (2) by using a round bar and a hammer.

dCAUTION: Bell crank (1) weight: 130 kg (290 lb) 9. Attach nylon slings onto pin (11) which has been installed in step 8. Hoist and hold bell crank (1).

W5-1-2-2

j : 24 mm

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

Detail A

1 8 7 5 A

WNEC-05-01-016

12. Remove spacer (3) and shim (4) from bell crank (1). 13. Hoist and remove bell crank (1) from lift arm (2). 14. Place bell crank (1) on wooden blocks. 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. 15. Remove bolt, washer (5) and washer (7). Remove pin (8) from bell crank (1) by using a round bar and a hammer. j : 19 mm

W5-1-2-3

WMDF-05-01-103

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Position to Install (Bell Crank (Lever))

WNEC-05-01-027

12-

Bell Crank Bushing

7 mm (0.28 in)

Direction to Install (Bell Crank)

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installation. Replace them if there are some troubles. (Refer to W2-2-1.) IMPORTANT: Apply grease onto the inner surface of bushings and dust seals when installing the pin. In addition, apply anti-rust oil onto the inner surface of the boss. IMPORTANT: Refer to the illustration when installing the bushing of bell crank. IMPORTANT: For handling of HN bushing for the front attachment, check the followings. Precautions for installing bushing If a hammer is used to install the bushing, the bushing may be damaged. Use a press for installing bushing. After installing bushing, install dust seal.

WNEC-05-01-028 b-

Special tool when installing bushing (bushing inner diameter) (ST 7692, ST 7859): 75 mm (ST 7693): 85 mm (ST 7722): 100 mm Precautions when reinforcing bucket link and bell crank The heat when welding in order to reinforce the bucket link and bell crank may cause oil leakage and decrease lubrication performance. When lubrication oil leaks, replace the bushing.

W5-1-2-4

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Position of Install (Bucket Link)

a WNEC-05-01-026 12-

Bucket Link Bushing

5 mm (0.20 in)

IMPORTANT: Refer to the illustration when installing the bushing of bucket link.

Direction to Install (Bucket Link) b

WNEC-05-01-028 b-

W5-1-2-5

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Position to Install (Bucket Cylinder)

2 a

b WNEC-05-01-029

12-

Bushing Bucket Cylinder

ab-

6.5 mm (0.26 in) 6.5 mm (0.26 in)

IMPORTANT: Refer to the illustration when installing the bushing of bucket cylinder.

Direction to Install (Bucket Cylinder) c

WNEC-05-01-028 c-

W5-1-2-6

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

Detail A

1 8 7 5 A

WMDF-05-01-103

2 1

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. 3. Fit spacer (3) and shim (4) to bell crank (1) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (9) to lift arm (2) by using a hammer.

WNEC-05-01-021 a-

WNEC-05-01-016

Clearance

fNOTE: Fit at least one spacer (3) or shim (4) to the both side of bell crank (1) mounting hole.

fNOTE: Thickness of spacer (3): 2.3 mm (0.091 in), thickness of shim (4): 1.6 mm (0.063 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 pin (8) to bell crank (1) by using a hammer. Install washer (7) and bolt, washer (5). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) Bell crank (1) weight: 130 kg (290 dCAUTION: lbf·ft) 2. Attach nylon slings onto pin (8) which has been installed in step 2. Hoist and hold bell crank (1). Fit bell crank (1) mounting holes to lift arm (2).

W5-1-2-7

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

Detail A

1 11 10 8

3, 4, 5

WNEC-05-01-016

WMDF-05-01-103

7. Install bucket cylinder (2). (Refer to W5-2-2.)

4. Install washers (4, 5) and bolt (3) to pin (6). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 5. Install grease fitting (7). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 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. 6. Remove bolt, washer (8) and washer (10). Remove pin (11) from bell crank (1) by using a round bar and a hammer. j : 19 mm

W5-1-2-8

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

Detail A

7 WMDF-05-01-107

3, 4

9 A

WMDF-05-01-104

fNOTE: Fit at least one spacer (7) or shim (8) to the both

side of bucket link (2) mounting hole.

fNOTE: Thickness of spacer (7): 2.3 mm (0.091 in), thickness of shim (8): 1.6 mm (0.063 in) 10. Install bolt, washer (3) and washer (4). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 11. Install grease fitting (9). Apply grease.

Clearance

WNEC-05-01-023

j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

dCAUTION: Bucket link (2) weight: 38 kg (84 lb)

8. Attach nylon slings onto bucket link (2). Hoist and hold bucket link (2). Fit bucket link (2) mounting holes to bell crank (6).

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

12. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

such as goggles, hard hat, etc. in order to prevent personal injury. 9. Fit spacer (7) and shim (8) to bucket link (2) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (1) to bell crank (6) by using a hammer.

W5-1-2-9

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment (Blank)

W5-1-2-10

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Bucket Detail A

9 10 7 8 A

WMDF-05-01-105

WMDF-05-01-107

6. Lower and remove the bucket (1) side of bucket link (7) from bucket (1).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Start the engine. Operate lift arm (2). Set bucket (1) horizontally and place it on wooden blocks. Stop the engine.

7. Remove O-rings (10) (2 used), spacer (9) and shim (8) from bucket link (7).

dCAUTION: Bucket link (7) weight: 38 kg (84 lb)

3. Attach nylon slings onto bucket link (7). Hoist and hold bucket link (7).

4. Remove grease fitting (5). j : 10 mm 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. Remove bolt, washer (6) and washer (4). Remove pin (3) from bucket (1) by using a round bar and a hammer. j : 19 mm

W5-1-3-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

Detail A

10 WMDF-05-01-105

WMDF-05-01-108

11. Remove O-rings (10) (2 used), spacer (9) and shim (8) from lift arm (2).

dCAUTION: Bucket (1) weight: 950 kg (2100 lb)

8. Attach nylon slings onto bucket (1). Hoist and hold bucket (1).

9. Remove grease fitting (4).

12. Remove another pin (3) in the same way as step 9 to step 11. 13. Hoist and remove bucket (1) from lift arm (2).

j : 10 mm

14. Place bucket (1) on wooden blocks.

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. Remove bolt, washer (7) and washer (5). Remove pin (3) from bucket (1) by using a round bar and a hammer. j : 19 mm

W5-1-3-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Position to Install (Lift Arm)

a WNEC-05-01-024 12-

Bushing Lift Arm

5 mm (0.20 in)

Installation

Direction to Install (Lift Arm)

IMPORTANT: Check outer diameter, inner diameter, wear, and damege of all pins and bushins before installation. Replace them if there are some troubles. (Refer to W2-2-1.) IMPORTANT: Apply grease onto the inner surface of bushings and dust seals when installing the pin. In addition, apply anti-rust oil onto the inner surface of the boss. IMPORTANT: Refer to the illustration when installing the bushing of lift arm. IMPORTANT: For handling of HN bushing for the front attachment, check the followings.

WNEC-05-01-028

Precautions for installing bushing If a hammer is used to install the bushing, the bushing may be damaged. Use a press for installing bushing. After installing bushing, install dust seal.

Special tool when installing bushing (bushing inner diameter) (ST 7692, ST 7859): 75 mm (ST 7693): 85 mm (ST 7722): 100 mm Precautions when reinforcing lift arm and bucket link The heat when welding in order to reinforce the lift arm and bucket link may cause oil leakage and decrease lubrication performance. When lubrication oil leaks, replace the bushing.

W5-1-3-3

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Position of Install (Bucket Link)

12-

Bushing Bucket Link

WNEC-05-01-026

5 mm (0.20 in)

IMPORTANT: Refer to the illustration when installing the bushing of bucket link.

Direction to Install (Bucket Link) b

WNEC-05-01-028 b-

W5-1-3-4

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

Detail A

1 9

WMDF-05-01-108

WMDF-05-01-105

fNOTE: Fit at least one spacer (9) or shim (8) to the both side of lift arm (2) mounting hole.

1 2

fNOTE: Thickness of spacer (9): 2.3 mm (0.091 in), thickness of shim (8): 1.6 mm (0.063 in) 4. Install washer (5) and bolt, washer (7).

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

WNEC-05-01-022 a-

Clearance

5. Install grease fitting (4). Apply grease.

Boss part

j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

1. Install O-rings (10) (4 used) to the boss part (b) positions (4 places) of bucket (1).

6. Install another pin (3) in opposite side in the same way as step 3 to step 5.

dCAUTION: Bucket (1) weight: 950 kg (2100 lb)

2. Attach nylon slings onto bucket (1). Hoist and hold bucket (1). Fit bucket (1) mounting holes to lift arm (2).

7. Move O-rings (10) (4 used) which have installed to the boss part (b) positions (4 places) of bucket (1) to the connecting part of bucket (1) and lift arm (2).

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. 3. Fit spacer (9) and shim (8) to the lift arm (2) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (3) to bucket (1) by using a hammer.

W5-1-3-5

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

Detail A

1 9 10 7

8 A

WMDF-05-01-107

WMDF-05-01-105

11. Fit spacer (9) and shim (8) to bucket link (7) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (3) to bucket (1) by using a hammer.

fNOTE: Fit at least one spacer (9) or shim (8) to the both

side of bucket link (7) mounting hole.

b b

fNOTE: Thickness of spacer (9): 2.3 mm (0.091 in), thickness of shim (8): 1.6 mm (0.063 in) 12. Install washer (4) and bolt, washer (6).

WNEC-05-01-019 a-

Clearance

j : 19 mm

Boss part

m : 90 N·m (9 kgf·m, 66 lbf·ft) 8. Install O-rings (10) (2 used) to the boss part (b) positions (2 places) of bucket (1).

13. Install grease fitting (5). Apply grease. j : 10 mm

dCAUTION: Bucket link (7) weight: 38 kg (84 lb)

9. Attach nylon slings onto bucket link (7). Hoist and hold bucket link (7).

10. Start the engine. Operate the bucket cylinder. Fit bucket link (7) mounting holes to bucket (1). Stop the engine.

m : 4 N·m (0.4 kgf·m, 3 lbf·ft) 14. Move O-rings (10) (2 used) which have installed to the boss part (b) positions (2 places) of bucket (1) to the connecting part of bucket (1) and bucket link (7).

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.

W5-1-3-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Lift Arm Cylinder Detail A

WMDF-05-02-115

3, 4

WNEC-05-01-004

such as goggles, hard hat, etc. in order to prevent personal injury. 5. Remove bolt, washer (3) and washer (4). Remove pin (7) from lift arm cylinder (2) by using a round bar and a hammer. j : 19 mm 6. Remove spacer (9) and shim (10) from lift arm (1).

Removal

7. Remove another lift arm cylinder (2) from lift arm (1) in the same way as step 3 to step 6.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Start the engine. Raise lift arm (1). Set lift arm cylinder (2) in the horizontal position. Operate the bucket cylinder. Dump and place the bucket on wooden blocks. Stop the engine.

dCAUTION: Lift arm cylinder (2) weight: 110 kg

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

(245 lb) 3. Attach nylon slings onto lift arm cylinder (2). Hoist and hold lift arm cylinder (2).

8. Start the engine. Retract lift arm cylinders (2) in the right and left sides. Remove lift arm cylinders (2) in the right and left sides from lift arm (1). 9. Stop the engine. In order not to extend the rod, pass the wires through the rod hole of lift arm cylinders (2) in the right and left sides and secure the rod to the cylinder tube.

4. Remove grease fitting (6). j : 10 mm

W5-2-1-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

1 WMDF-05-02-100

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.) 10. Disconnect hoses (1) (2 used). j : 36 mm 11. Disconnect another hoses (1) (2 used) in the same way as step 10.

W5-2-1-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

Detail A

1 7 A

2, 3

5 10

6 9

8 WMDF-05-02-105

WNEC-05-01-004

15. Hoist and remove lift arm cylinder (7).

12. Remove grease fitting (5).

16. Remove another lift arm cylinder (7) in the same way as step 12 to step 15.

j : 10 mm 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. 13. Remove bolt, washer (2) and washer (3). Remove pin (6) from front frame (1) by using a round bar and a hammer. j : 19 mm 14. Remove shim (10), spacer (8) and shim (9) from lift arm cylinder (7).

W5-2-1-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Position to Install (Lift Arm Cylinder)

2 a

WNEC-05-01-030 12-

Lift Arm Cylinder Bushing

6.5 mm (0.26 in)

Direction to Install (Lift Arm Cylinder)

WNEC-05-01-028 b-

W5-2-1-4

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder IMPORTANT: For handling of HN bushing for the front attachment, check the followings. Precautions for installing bushing If a hammer is used to install the bushing, the bushing may be damaged. Use a press for installing bushing. Install the dust seal after installing the bushing. Special tool when installing bushing (bushing inner diameter) (ST 7692, ST 7859): 75 mm (ST 7693): 85 mm (ST 7722): 100 mm Precautions when reinforcing lift arm The heat when welding in order to reinforce the lift arm may cause oil leakage and decrease lubrication performance. When lubrication oil leaks, replace the bushing.

W5-2-1-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

Detail A

2,3

5 6

10 9

WMDF-05-02-105

WNEC-05-01-004

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. 3. Fit spacer (8) and shim (9) to another side of lift arm cylinder (7) mounting hole so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (6) to front frame (1) by using a hammer.

fNOTE: Fit spacer (8) and shim (9) to the lift arm cylinder mounting hole.

7 WNDB-05-02-005 a-

Clearance

fNOTE: Thickness of spacer (8): 2.3 mm (0.091 in), thickness of shim (9): 1.6 mm (0.063 in) 4. Install washer (3) and bolt, washer (2). j : 19 mm

CAUTION: Lift arm cylinder (7) weight: 110 kg (245 lb) 1. Attach nylon slings onto lift arm cylinder (7). Hoist and hold lift arm cylinder (7). Fit mounting holes on the bottom side of lift arm cylinder (7) to front frame (1).

2. Fit shim (10) to lift arm cylinder (7) mounting hole.

fNOTE: Thickness of shim (10): 3.2 mm (0.126 in)

m : 90 N·m (9 kgf·m, 66 lbf·ft) 5. Install grease fitting (5). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft) 6. Install another lift arm cylinder (7) in the same way as step 1 to step 5.

W5-2-1-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

1 WMDF-05-02-100

7. Connect hoses (1) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 8. Connect another hoses (1) (2 used) in the same way as step 7.

W5-2-1-7

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

Detail A

1 9

WMDF-05-02-115

3, 4

WNEC-05-01-004

10. Fit spacer (9) and shim (10) to the lift arm (1) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (7) to lift arm cylinder (2) by using a hammer.

fNOTE: Fit at least one spacer (9) or shim (10) to the both side of lift arm cylinder mounting hole.

fNOTE: Thickness of spacer (9): 2.3 mm (0.091 in), thickness of shim (10): 1.6 mm (0.063 in) 11. Install washer (4) and bolt, washer (3). j : 19 mm 1 a-

WNEC-05-01-017

m : 90 N·m (9 kgf·m, 66 lbf·ft)

Clearance

12. Install grease fitting (6). Apply grease. 9. Remove the wires from the rod holes of lift arm cylinders (2) in the right and left sides. Start the engine. Extend lift arm cylinders (2) in the right and left sides. Fit the rod to the lift arm (1) mounting holes. Stop the engine. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft) 13. Install another lift arm cylinder (2) in the same way as step 9 to step 12. 14. Bleed air from the hydraulic system. (Refer to W1-41.)

such as goggles, hard hat, etc. in order to prevent personal injury.

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W5-2-1-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Bucket Cylinder 5

7 WMDF-05-02-108

WMDF-05-02-101

j : 19 mm 3. Remove bolt, washer (6), nut (8), and clip (7). WMDF-05-02-102

j : 17 mm 4. Disconnect connector (4).

W5-2-2-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

5 2 4

9 WMDF-05-02-102

5. Remove bolts, washers (7) (2 used) and nuts (6) (2 used). Remove bracket (5). j : 17 mm 6. Remove bolts, washers (3) (2 used) and washers (2) (2 used). Remove the proximity switch (4) assembly and brackets (1, 9). j : 17 mm

W5-2-2-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

WMDF-05-02-103

7. Remove bolt, washer (4) and clip (3). j : 17 mm 8. Disconnect the both ends of pipe (1). j : 17 mm 9. Remove elbow (2). j : 12 mm

W5-2-2-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5

1, 2

Detail A

WNEC-05-01-016

WMDF-05-02-117

13. Remove spacer (8) and shim (9) from bucket cylinder (4).

Bucket cylinder (4) weight: 130 kg dCAUTION: (290 lb) 10. Attach nylon slings onto bucket cylinder (4). Hoist and hold bucket cylinder (4).

14. Start the engine. Retract bucket cylinder (4). Remove bucket cylinder (4) from bell crank (5). 15. Stop the engine. In order not to extend the rod, pass wires through the rod hole of bucket cylinder (4) and secure the rod to the cylinder tube.

11. Remove grease fitting (7). j : 10 mm 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. 12. Remove bolt, washer (1) and washer (2). Remove pin (6) from bell crank (5) by using a round bar and a hammer. j : 19 mm

W5-2-2-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

WMDF-05-02-104

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.) 16. Disconnect hoses (1) (2 used). j : 36 mm

W5-2-2-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

Detail A

2 7

4, 5

8 WNDB-05-02-004

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. 17. Remove bolt, washer (4) and washer (5). Remove pin (1) from front frame (3) by using a round bar and a hammer. j : 19 mm 18. Remove spacer (7) and shim (8) from bucket cylinder (2). 19. Remove bucket cylinder (2) from front frame (3).

W5-2-2-6

WMDF-05-02-117

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Position to Install (Bucket Cylinder)

2 a

b WNEC-05-01-029

12-

Bushing Bucket Cylinder

ab-

6.5 mm (0.26 in) 6.5 mm (0.26 in)

Direction to Install (Bucket Cylinder)

WNEC-05-01-028 c-

W5-2-2-7

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder IMPORTANT: For handling of HN bushing for the front attachment, check the followings. Precautions for installing bushing If a hammer is used to install the bushing, the bushing may be damaged. Use a press for installing bushing. Install the dust seal after installing the bushing. Special tool when installing bushing (bushing inner diameter) (ST 7692, ST7859): 75 mm (ST 7693): 85 mm (ST 7722): 100 mm Precautions when welding bell crank The heat when welding in order to reinforce the bell crank may cause oil leakage and decrease lubrication performance. When lubrication oil leaks, replace the bushing.

W5-2-2-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

Detail A

2 7

4, 5

8 WMDF-05-02-117

WNDB-05-02-004

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. 2. Fit spacer (7) and shim (8) to bucket cylinder (2) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (1) to front frame (3) by using a hammer.

WNEC-05-02-032 a-

Clearance

fNOTE: Fit at least one spacer (7) or shim (8) to the both side of bucket cylinder (2) mounting hole.

fNOTE: Thickness of spacer (7): 2.3 mm (0.091 in),

dCAUTION: Bucket cylinder (2) weight: 130 kg

thickness of shim (8): 1.6 mm (0.063 in) 3. Install washer (5) and bolt, washer (4).

(290 lb) 1. Attach nylon slings onto bucket cylinder (2). Hoist and hold bucket cylinder (2). Fit bucket cylinder (2) mounting holes to front frame (3).

W5-2-2-9

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

WMDF-05-02-104

4. Connect hoses (1) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

W5-2-2-10

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5

Detail A

1, 2

WMDF-05-02-117

WNEC-05-01-016

6. Fit spacer (8) and shim (9) to bucket cylinder (4) mounting holes so that clearance (a) is adjusted within 1.5 mm (0.059 in). Install pin (6) to bell crank (5) by using a hammer.

fNOTE: Fit at least one spacer (8) or shim (9) to the both side of bucket cylinder (4) mounting hole.

fNOTE: Thickness of spacer (8): 2.3 mm (0.091 in), thickness of shim (9): 1.6 mm (0.063 in) 7. Install washer (2) and bolt, washer (1).

WNEC-05-01-018 a-

j : 19 mm

Clearance

m : 90 N·m (9 kgf·m, 66 lbf·ft) 5. Remove wires from the rod holes of bucket cylinder (4). Start the engine. Extend bucket cylinder (4). Fit the rod to bell crank (5) mounting holes. Stop the engine.

8. Install grease fitting (7). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 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.

W5-2-2-11

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

3 5

WMDF-05-02-101

WMDF-05-02-103

9. Install elbow (5). j : 12 mm

12. Install guard (2) to bucket cylinder (3) with bolts, washers (1) (2 used) and nuts (9) (2 used). j : 19 mm

10. Connect the both ends of pipe (8).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 11. Install clip (7) with bolt, washer (6). Apply grease. j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W5-2-2-12

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

13 6

5 11 12

2 4

WMDF-05-02-102

13. Temporary tighten the proximity switch (4) assembly and brackets (1, 9) with washers (2) (2 used) and bolts, washers (3) (2 used). j : 17 mm 14. Connect connector (10). 15. Install clip (12) with bolt, washer (11) and nut (13). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 16. Install bracket (5) with nuts (6) (2 used) and bolts, washers (7) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W5-2-2-13

WMDF-05-02-108

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

A b b-

73 mm (2.87 in)

WMDF-05-02-109 a

Section A-A 4 4

Bracket

3 a WMDF-05-02-102 c ac-

17. Adjust the mounting position of the proximity switch (4) assembly. Tighten bolts, washers (3) (2 used). (Refer to the operator's manual.)

Bracket 5~10 mm (0.20~0.39 in) WMDF-05-02-110

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 18. 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.

W5-2-2-14

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Lift Arm Cylinder

5 9

10 4 3 2

6 8

16 18 15 14

20 19

WMDF-05-02-106

12345-

Cylinder Rod Dust Seal U-Ring Buffer Ring Cylinder Head

678910-

O-Ring O-Ring Backup Ring Bushing Retaining Ring

1314151617-

Backup Ring (2 Used) O-Ring Dust Seal Seal Ring Piston

W5-2-3-1

18192021-

Wear Ring Nut Set Screw Cylinder Tube

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Lift Arm Cylinder  The procedure starts on the premise that the pipes and the bands securing the pipes have been removed. CAUTION: Lift arm cylinder weight: 110 kg (245 lb) 1. Hoist the cylinder. Secure the cylinder horizontally on a workbench. Drain off hydraulic oil from the cylinder.

The cylinder rod (1) assembly weight: dCAUTION: 47 kg (105 lb) 5. Remove the cylinder rod (1) assembly from cylinder tube (21). Secure it on the special tool (ST 5908) for cylinder.

Special Tool for Cylinder: ST 5908 W158-04-02-022

W102-04-02-027

6. Cut away the crimped parts by using a hand drill. Remove set screw (20). l : 4 mm

2. Install a protective cover to cylinder rod (1).

fNOTE: Set screw (20) has been crimped by using a

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

punch (2 places) after installing.

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: Do not damage the sliding surface of cylinder rod (1). 3. Extend the stopper (a part of cylinder tube (21)) in the groove of cylinder head (5) by using a chisel and a hammer. Make it flat.

fNOTE: LOCTITE #242 has been applied on set screw

4. Loosen cylinder head (5) by using hook wrench (a). Diameter of cylinder head (5): 146 mm

1 a-

W506-04-02-004

Hook Wrench

W5-2-3-2

(20).

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 7. Remove nut (19) by using the special tool (ST 5908) for cylinder and the special tool for nut.

10. Remove wear ring (18) and dust seal (15) from piston (17).

Special Tool for Nut: ST 3410: 79 mm

14 13

Special Tool for Cylinder: ST 5908 WMDF-05-02-113

W158-04-02-022 ab-

8. Remove piston (17) by using the special tool (ST 5908) for cylinder and the special tool for piston.

Backup Ring Seal Ring

Ring

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

Special Tool for Piston: ST 3411: 80 mm

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: Do not damage the seal groove. 11. Remove backup rings (16a) (2 used) from piston (17). Cut seal ring (16b) and ring (16c) by using a screwdriver and a hammer. Remove seal ring (16b) and ring (16c) from piston (17). 12. Remove backup rings (13) (2 used) and O-ring (14) from piston (17) by using a spatula.

Special Tool for Cylinder: ST 5908 W158-04-02-022

9. Remove cylinder head (5) from cylinder rod (1) by using a plastic hammer.

W5-2-3-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 13. Remove backup ring (8) and O-rings (6, 7) from cylinder head (5) by using a spatula.

IMPORTANT: Bushing (9) cannot be reused. If bushing (9) has been removed, replace it with the new one when assembling. 16. Remove retaining ring (10) and bushing (9).

fNOTE: Bushing (9) cannot be removed from cylinder

head (5) by tapping. Cut off bushing (9) by using a lathe. Insert a screwdriver strongly and remove busing (9).

9 WMDF-05-02-111

Detail A a

WDBE-05-02-008 a-

Backup Ring

Buffer Ring

14. Remove U-ring (3), backup ring (4a), and buffer ring (4b) from cylinder head (5) by using an awl. 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: Do not damage cylinder head (5). 15. Secure cylinder head (5) in a vise. Remove dust seal (2) from cylinder head (5) by using a screwdriver and a hammer.

W5-2-3-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Lift Arm Cylinder

3 4 9 7, 8 5

15 16 18 13, 14, 13 19 20

WMDF-05-02-001

12345-

Cylinder Rod Dust Seal U-Ring Buffer Ring Cylinder Head

678910-

O-Ring O-Ring Backup Ring Bushing Retaining Ring

1314151617-

Backup Ring (2 Used) O-Ring Dust Seal Seal Ring Piston

W5-2-3-5

18192021-

Wear Ring Nut Set Screw Cylinder Tube

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Lift Arm Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The seals which have been removed cannot be reused. 1. Install bushing (9) to cylinder head (5) by using the special tool for bushing.

IMPORTANT: Check the direction to install backup ring (4a). 4. Install U-ring (3), buffer ring (4b), and backup ring (4a) to cylinder head (5).

Special Tool for Bushing (Rod Outer Diameter):

ST 3412: 65 mm 2. Install retaining ring (10) to cylinder head (5). 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. 3. Install dust seal (2) to cylinder head (5) by using the special tool for dust seal and a hammer.

9 WMDF-05-02-111

Special Tool for Dust Seal (Rod Outer Diameter):

Detail A

ST 3413: 65 mm a

WDBE-05-02-008 a-

Backup Ring

Buffer Ring

5. Install O-rings (6, 7) and backup ring (8) to cylinder head (5).

W5-2-3-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Seal ring (16b) is too hot. Be careful of dCAUTION: burns.

dCAUTION: Cylinder rod (1) weight: 37 kg (82 lb)

8. Hoist and secure cylinder rod (1) on the special tool (ST 5908) for cylinder.

IMPORTANT: Check the direction to install backup ring (16a). 6. Install ring (16c) to piston (17) by using a screwdriver with rounded corners. Dip seal ring (16b) for approximately five minutes in hydraulic oil which is heated at 150 to 180 °C (302 to 356 °F) by using the electric heater in order to make seal ring (16b) soft. Install seal ring (16b) to piston (17) by using the special tool for seal ring. After installing seal ring (16b), adjust it by using the special tool for seal ring. Install backup rings (16a) (2 used) to piston (17).

Special Tool for Cylinder: ST 5908 W158-04-02-022

9. Install the cylinder head (5) assembly to cylinder rod (1) by using the special tool for cylinder head.

Special Tool for Seal Ring (Tube Inner Diameter): ST 7649: 125 mm

Special Tool for Cylinder Head (Rod Outer Diameter):

Special Tool for Seal Ring (Tube Inner Diameter):

ST 3414: 65 mm

ST 7685: 125 mm a

10. Install the piston (17) assembly to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for piston.

Special Tool for Piston: 17 13

ST 3411: 80 mm

m : 686±68 N·m (70±7 kgf·m, 510±50 lbf·ft)

c WMDF-05-02-113 ab-

Backup Ring Seal Ring

Ring

7. Install O-ring (14) and backup rings (13) (2 used) to piston (17).

W5-2-3-7

Special Tool for Cylinder: ST 5908 W158-04-02-022

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 11. Install nut (19) to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for nut.

Cylinder tube (21) weight: 50 kg (115 dCAUTION: lb) The cylinder rod (1) assembly weight: dCAUTION: 47 kg (105 lb)

Special Tool for Nut: ST 3410: 79 mm m : 981±98 N·m (100±10 kgf·m, 720±72 lbf·ft)

IMPORTANT: Align the cylinder rod (1) assembly with the center of cylinder tube (21) and install it straight in order not to damage the rings. 14. Secure cylinder tube (21) on a workbench horizontally. Install the cylinder rod (1) assembly to cylinder tube (21). IMPORTANT: Do not damage the sliding surface of cylinder rod (1).

Special Tool for Cylinder: ST 5908 W158-04-02-022

15. Tighten cylinder head (5) to cylinder tube (21) by using hook wrench (a). Diameter of cylinder head (5): 146 mm

12. Apply LOCTITE #242 onto set screw (20). Install set screw (20) to nut (19). Crimp set screw (20) by using a punch (2 places). l : 4 mm

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. 16. Bend the stopper (a part of cylinder tube (21)) in the groove of cylinder head (5) by using a chisel and a hammer in order not to loosen cylinder head (5).

m : 15 N·m (1.5 kgf·m, 11.0 lbf·ft) 13. Install wear ring (18) and dust seal (15) to piston (17).

m : 736±74 N·m (75±7.5 kgf·m, 540±55 lbf·ft)

WMDF-05-02-113

W5-2-3-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Bucket Cylinder

12 5

9 10 4 3 17

6 8

18 15 15 14

13 20

WMDF-05-02-107 123456-

Cylinder Rod Dust Seal U-Ring Buffer Ring Cylinder Head O-Ring

789101112-

O-Ring Backup Ring Bushing Retaining Ring Socket Bolt (14 Used) Screw

131415161718-

Backup Ring (2 Used) O-Ring Dust Seal (2 Used) Seal Ring Piston Wear Ring

W5-2-4-1

19- Nut 20- Set Screw 21- Cylinder Tube

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Bucket Cylinder  The procedure starts on the premise that the pipes and the bands securing the pipes have been removed. CAUTION: Bucket cylinder weight: 130 kg (290 lb) 1. Hoist the cylinder. Secure the cylinder horizontally on a workbench. Drain off hydraulic oil from the cylinder.

The cylinder rod (1) assembly weight: dCAUTION: 66 kg (150 lb) 4. Remove the cylinder rod (1) assembly from cylinder tube (21). Secure it on the special tool (ST 5908) for cylinder.

Special Tool for Cylinder: ST 5908 W158-04-02-022

W102-04-02-027

5. Cut away the crimped parts by using a hand drill. Remove set screw (20). l : 4 mm

IMPORTANT: Do not damage the sliding surface of cylinder rod (1). 2. Install a protective cover to cylinder rod (1). Remove socket bolts (11) (14 used) from cylinder head (5).

fNOTE: Set screw (20) has been crimped by using a punch (2 places) after installing.

fNOTE: LOCTITE #242 has been applied on set screw (20).

l : 14 mm 3. Install screw (12) in the flange part of cylinder head (5) in order to obtain the clearance between cylinder head (5) and cylinder tube (21). Expand the clearance by using a screwdriver. Remove cylinder head (5) from cylinder tube (21). Return screw (12) to the original position. l : 8 mm

W5-2-4-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 6. Remove nut (19) by using the special tool (ST 5908) for cylinder and the special tool for nut.

9. Remove wear ring (18) and dust seals (15) (2 used) from piston (17).

Special Tool for Nut: ST 3403: 97 mm

18 15

14 13

Special Tool for Cylinder: ST 5908 WMDF-05-02-114

W158-04-02-022 ab-

7. Remove piston (17) by using the special tool (ST 5908) for cylinder and the special tool for piston.

Backup Ring Seal Ring

Ring

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

ST 3401: 120 mm

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: Do not damage the seal groove. 10. Remove backup rings (16a) (2 used) from piston (17). Cut seal ring (16b) and ring (16c) by using a screwdriver and a hammer. Remove seal ring (16b) and ring (16c) from piston (17).

Special Tool for Cylinder: ST 5908 W158-04-02-022

8. Remove cylinder head (5) from cylinder rod (1) by using a plastic hammer.

11. Remove backup rings (13) (2 used) and O-ring (14) from piston (17) by using a spatula.

W5-2-4-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 12. Remove backup ring (8) and O-rings (6, 7) from cylinder head (5) by using a spatula.

IMPORTANT: Bushing (9) cannot be reused. If bushing (9) has been removed, replace it with the new one when assembling. 15. Remove retaining ring (10) and bushing (9).

fNOTE: Bushing (9) cannot be removed from cylinder

head (5) by tapping. Cut off bushing (9) by using a lathe. Insert a screwdriver strongly and remove busing (9).

5 10

9 WMDF-05-02-112

Detail A a

WDBE-05-02-008 a-

Backup Ring

Buffer Ring

13. Remove U-ring (3), backup ring (4a), and buffer ring (4b) from cylinder head (5) by using an awl. 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: Do not damage cylinder head (5). 14. Secure cylinder head (5) in a vise. Remove dust seal (2) from cylinder head (5) by using a screwdriver and a hammer.

W5-2-4-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Bucket Cylinder

D E C

7, 8

13, 14, 13 9

15 16 18

15 19

12 17

Detail E

Detail D View C

WMDF-05-02-002

123456-

Cylinder Rod Dust Seal U-Ring Buffer Ring Cylinder Head O-Ring

789101112-

O-Ring Backup Ring Bushing Retaining Ring Socket Bolt (14 Used) Screw

131415161718-

Backup Ring (2 Used) O-Ring Dust Seal (2 Used) Seal Ring Piston Wear Ring

W5-2-4-5

19- Nut 20- Set Screw 21- Cylinder Tube

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Bucket Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The seals which have been removed cannot be reused. 1. Install bushing (9) to cylinder head (5) by using the special tool for bushing.

IMPORTANT: Check the direction to install backup ring (4a). 4. Install U-ring (3), buffer ring (4b), and backup ring (4a) to cylinder head (5).

Special Tool for Bushing (Rod Outer Diameter): 5

ST 7639: 85 mm

2. Install retaining ring (10) to cylinder head (5). 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. 3. Install dust seal (2) to cylinder head (5) by using the special tool for dust seal and a hammer.

Special Tool for Dust Seal (Rod Outer Diameter):

Detail A

9 WMDF-05-02-112

ST 7637: 85 mm

WDBE-05-02-008 a-

Backup Ring

Buffer Ring

5. Install O-rings (6, 7) and backup ring (8) to cylinder head (5).

W5-2-4-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Seal ring (16b) is too hot. Be careful of dCAUTION: burns.

dCAUTION: Cylinder rod (1) weight: 45 kg (100 lb) 8. Hoist and secure cylinder rod (1) on the special tool (ST 5908) for cylinder.

Special Tool for Cylinder: ST 5908 W158-04-02-022

9. Install the cylinder head (5) assembly to cylinder rod (1) by using the special tool for cylinder head.

Special Tool for Seal Ring (Tube Inner Diameter): ST 7648: 150 mm

Special Tool for Cylinder Head (Rod Outer Diameter):

Special Tool for Seal Ring (Tube Inner Diameter):

ST 7635: 85 mm

ST 7684: 150 mm

10. Install the piston (17) assembly to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for piston.

Special Tool for Piston: 17

ST 3401: 120 mm

14 13

m : 981±98 N·m (100±10 kgf·m, 720±72 lbf·ft)

c WMDF-05-02-114 ab-

Backup Ring Seal Ring

Ring

Special Tool for Cylinder: ST 5908

7. Install O-ring (14) and backup rings (13) (2 used) to piston (17).

W5-2-4-7

W158-04-02-022

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 11. Install nut (19) to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for nut.

Cylinder tube (21) weight: 55 kg (125 dCAUTION: lb) The cylinder rod (1) assembly weight: dCAUTION: 66 kg (150 lb)

Special Tool for Nut: ST 3403: 97 mm

IMPORTANT: Align the cylinder rod (1) assembly with the center of cylinder tube (21) and install it straight in order not to damage the rings.

m : 1860±186 N·m (190±19 kgf·m, 1370±137 lbf·ft)

14. Secure cylinder tube (21) on a workbench horizontally. Install the cylinder rod (1) assembly to cylinder tube (21).

IMPORTANT: Do not damage the sliding surface of cylinder rod (1).

Special Tool for Cylinder: ST 5908 W158-04-02-022

15. Install cylinder head (5) to cylinder tube (21) with socket bolts (11) (14 used).

12. Apply LOCTITE #242 onto set screw (20). Install set screw (20) to nut (19). Crimp set screw (20) by using a punch (2 places). l : 4 mm m : 15 N·m (1.5 kgf·m, 11.0 lbf·ft) 13. Install wear ring (18) and dust seals (15) (2 used) to piston (17).

18 15

WMDF-05-02-114

W5-2-4-8

l : 14 mm m : 343 to 363 N·m (35 to 37 kgf·m, 255 to 270 lbf·ft)

INDEX 1 4-Gear Pump Unit, Assembly ..........................................W3-8-3-8 4-Gear Pump Unit, Disassembly ....................................W3-8-3-1 A Air Cleaner, Removal and Installation ..........................W3-4-3-1 Airtight Test of Piston ...................................................... W4-4-3-30 Applicable Tire Size ........................................ W4-1-1-3, W4-1-2-5 Assembly of 4-Gear Pump Unit ......................................W3-8-3-8 Assembly of Axle .............................................................. W4-4-3-17 Assembly of Brake Valve ...................................................W4-6-2-3 Assembly of Bucket Cylinder ..........................................W5-2-4-5 Assembly of Clutch Assembly.........................................W4-3-3-3 Assembly of Clutch Pressure Control Solenoid Valve ..............................................................................................W4-3-4-3 Assembly of Control Valve................................................W3-9-2-6 Assembly of Exhaust Filter ............................................ W3-17-2-3 Assembly of Gear Pump Unit ..........................................W3-8-3-8 Assembly of HST Motors 1, 2 ...........................................W4-2-2-3 Assembly of HST Pump .....................................................W3-8-2-5 Assembly of Lift Arm Cylinder ........................................W5-2-3-5 Assembly of Manifold Valve.......................................... W3-12-2-3 Assembly of Multiple Control Valve ..............................W3-9-2-6 Assembly of Pilot Valve................................................... W3-10-3-4 Assembly of Pilot Valve (Two Lever Type) ................ W3-10-4-7 Assembly of Ride Control Valve (Option) ................. W3-16-2-4 Assembly of Steering Cylinder .......................................W4-7-4-5 Assembly of Steering Valve..............................................W4-7-2-4 Assembly of Transmission ............................................. W4-3-2-10 Axle ...........................................................................................W4-4-1-1 Axle, Assembly .................................................................. W4-4-3-17 Axle, Disassembly ................................................................W4-4-3-1 Axle, Standard.......................................................................W2-2-1-1 Axle Equipped with LSD ...................................................W4-4-3-3 Axle Equipped with TPD ...................................................W4-4-3-1 Axle Shaft Bearing, Preload Adjustment .................. W4-4-3-38 B Backlash Adjustment of Ring Gear and Pinion ...... W4-4-3-31 Battery Box (Left), Removal..............................................W3-2-2-2 Battery Box (Right), Removal...................... W3-2-2-1, W3-2-3-1 Battery Box (with Battery Disconnect Switch), Removal and Installation ............................................W3-2-3-1 Battery Box (without Battery Disconnect Switch), Removal and Installation ............................................W3-2-2-1 Battery Disconnect Switch, Removal and Installation ..............................................................................................W3-2-4-1 Bell Crank, Position to Install ...........................................W5-1-2-4 Bell Crank, Removal and Installation ............................W5-1-2-1 Bleeding Air ...........................................................................W1-4-1-1 Bleeding Air from Brake (Axle) ........................................W1-4-1-7 Bleeding Air from Fuel System .......................................W1-4-1-4 Bleeding Air from Hydraulic Oil Tank ...........................W1-4-1-1 Bleeding Air from Hydraulic System.............................W1-4-1-2 Bleeding Air from Radiator ..............................................W1-4-1-6 Brake (Axle), Bleeding Air .................................................W1-4-1-7 Brake Accumulator, Removal and Installation ....... W3-11-3-1

Brake Charge Valve, Removal and Installation ....... W3-11-1-1 Brake Charge Valve, Structure ...................................... W3-11-2-1 Brake Valve, Assembly .......................................................W4-6-2-3 Brake Valve, Disassembly ..................................................W4-6-2-1 Brake Valve, Removal and Installation .........................W4-6-1-1 Bucket Cylinder, Assembly ...............................................W5-2-4-5 Bucket Cylinder, Disassembly .........................................W5-2-4-1 Bucket Cylinder, Position to Install .....................................................W5-1-1-7, W5-1-2-6, W5-2-2-7 Bucket Cylinder, Removal and Installation .................W5-2-2-1 Bucket Link, Position to Install ................... W5-1-2-5, W5-1-3-4 Bucket, Removal and Installation ..................................W5-1-3-1 Bucket, Standard Dimensions .........................................W2-3-2-1 Bushing, Standard ...............................................................W2-3-1-1 C Cab, Removal and Installation ........................................W3-1-1-1 Center Hinge, Removal and Installation .....................W3-3-1-1 Center Hinge, Standard .....................................................W2-1-1-1 Clutch Assembly, Assembly .............................................W4-3-3-3 Clutch Assembly, Disassembly .......................................W4-3-3-1 Clutch Pressure Control Solenoid Valve, Assembly ...........................................................................W4-3-4-3 Disassembly .....................................................................W4-3-4-1 Connecting Hose .................................................................W1-2-1-9 Control Valve, Assembly....................................................W3-9-2-6 Control Valve, Disassembly ..............................................W3-9-2-1 Control Valve, Removal and Installation .....................W3-9-1-1 Cooling Fan System ........................................................ W3-15-1-1 Cover (Lower), Removal and Installation ....................W3-4-2-4 Cylinder, Standard ...............................................................W2-3-3-1 D Deck, Removal and Installation ................................... W3-4-2-10 Differential Housing, Removal ..................................... W4-4-3-11 Differential Housing (LSD), Disassembly.................. W4-4-3-16 Differential Housing (TPD), Disassembly ................. W4-4-3-15 Disassembly of 4-Gear Pump Unit ................................W3-8-3-1 Disassembly of Axle............................................................W4-4-3-1 Disassembly of Brake Valve..............................................W4-6-2-1 Disassembly of Bucket Cylinder .....................................W5-2-4-1 Disassembly of Clutch Assembly ...................................W4-3-3-1 Disassembly of Clutch Pressure Control Solenoid Valve .................................................................W4-3-4-1 Disassembly of Control Valve ..........................................W3-9-2-1 Disassembly of Differential Housing (LSD).............. W4-4-3-16 Disassembly of Differential Housing (TPD) ............. W4-4-3-15 Disassembly of Exhaust Filter....................................... W3-17-2-1 Disassembly of Gear Pump Unit ....................................W3-8-3-1 Disassembly of HST Motors 1, 2 .....................................W4-2-2-1 Disassembly of HST Pump................................................W3-8-2-1 Disassembly of Lift Arm Cylinder...................................W5-2-3-1 Disassembly of Main Pump .............................................W3-8-3-6 Disassembly of Manifold Valve .................................... W3-12-2-1 Disassembly of Multiple Control Valve ........................W3-9-2-1 Disassembly of Pilot Pump ..............................................W3-8-3-5 Disassembly of Pilot Valve ............................................. W3-10-3-1 62Z7(US)D&R

INDEX Disassembly of Pilot Valve (Two Lever Type) .......... W3-10-4-1 Disassembly of Ride Control Valve (Option) ........... W3-16-2-1 Disassembly of Spider .................................................... W4-4-3-10 Disassembly of Steering Cylinder ..................................W4-7-4-1 Disassembly of Steering Pump.......................................W3-8-3-7 Disassembly of Steering Valve ........................................W4-7-2-1 Disassembly of Transmission ..........................................W4-3-2-1 Disassembly of Transmission Charge Pump ..............W3-8-3-3 E Engine Cover, Removal and Installation......................W3-4-2-2 Engine, Removal and Installation ..................................W3-4-1-1 Exhaust Filter Regeneration Control Solenoid Valve, Removal and Installation ......................................... W3-13-1-1 Structure ........................................................................ W3-13-2-1 Exhaust Filter, Assembly................................................. W3-17-2-3 Exhaust Filter, Disassembly ........................................... W3-17-2-1 Exhaust Filter, Removal and Installation .................. W3-17-1-1 Exterior Parts, Removal and Installation .....................W3-4-2-1 F Fan Motor, Removal and Installation......................... W3-15-3-1 Fan Motor, Structure........................................................ W3-15-4-1 Fan Valve, Removal and Installation .......................... W3-15-1-1 Fan Valve, Structure ......................................................... W3-15-2-1 Floating Seal, Precautions ................................................W1-1-1-2 Front Attachment Hydraulic Circuit Pressure Release Procedure .........................................................................W1-5-1-1 Front Attachment, Removal and Installation ............W5-1-1-1 Front Attachment, Standard............................................W2-3-1-1 Front Axle, Removal and Installation............................W4-4-1-1 Front Fender, Removal and Installation ......................W3-4-2-9 Front Tire, Removal and Installation .............................W4-1-1-1 Fuel System, Bleeding Air .................................................W1-4-1-4 Fuel Tank, Removal and Installation .............................W3-7-1-1 G Gear Pump Unit, Assembly ..............................................W3-8-3-8 Gear Pump Unit, Disassembly.........................................W3-8-3-1 H HST Motor, Removal and Installation ...........................W4-2-1-1 HST Motors 1, 2, Assembly ...............................................W4-2-2-3 HST Motors 1, 2, Disassembly .........................................W4-2-2-1 HST Pump, Assembly .........................................................W3-8-2-5 HST Pump, Disassembly ....................................................W3-8-2-1 Housing, Removal ............................................................ W4-4-3-13 Hydraulic Oil Tank, Bleeding Air .....................................W1-4-1-1 Hydraulic Oil Tank, Removal and Installation ............W3-6-1-1 Hydraulic System, Bleeding Air ......................................W1-4-1-2 I Inspection Cover, Removal and Installation ........... W3-4-2-14 Intercooler, Replacement .................................................W3-5-1-1 L Lever, Position to Install ....................................................W5-1-2-4 Lever, Removal and Installation .....................................W5-1-2-1

Lift Arm, Position to Install .......................... W5-1-1-6, W5-1-3-3 Lift Arm, Standard Dimensions ......................................W2-3-2-1 Lift Arm Cylinder, Assembly.............................................W5-2-3-5 Lift Arm Cylinder, Disassembly .......................................W5-2-3-1 Lift Arm Cylinder, Position to Install..............................W5-2-1-4 Lift Arm Cylinder, Removal and Installation ..............W5-2-1-1 Lock of Chassis (Frame) .....................................................W1-6-1-2 Low-Pressure-Hose Clamp Tightening ........................W1-2-1-8 LSD............................................................................................W4-4-3-3 M Machine Position for Inspection and Maintenance (lift arm raise)...................................................................W1-6-1-3 Main Pump, Disassembly..................................................W3-8-3-6 Manifold Valve, Assembly .............................................. W3-12-2-3 Manifold Valve, Disassembly ........................................ W3-12-2-1 Manifold Valve, Removal and Installation ............... W3-12-1-1 Multiple Control Valve, Assembly ..................................W3-9-2-6 Multiple Control Valve, Disassembly ............................W3-9-2-1 Multiple Control Valve, Removal and Installation....W3-9-1-1 N Nut and Bolt Locking .........................................................W1-2-1-3 Nylon Sling, Precautions ...................................................W1-1-1-3 O O-ring Seal Joint ..................................................................W1-2-1-6 Oil Cooler, Replacement ...................................................W3-5-1-1 P Painting ...................................................................................W1-3-1-1 Pilot Pump, Disassembly...................................................W3-8-3-5 Pilot Valve, Assembly....................................................... W3-10-3-4 Pilot Valve, Disassembly ................................................. W3-10-3-1 Pilot Valve, Removal and Installation ........................ W3-10-1-1 Pilot Valve (Two Lever Type), Assembly ........................................................................ W3-10-4-7 Disassembly .................................................................. W3-10-4-1 Removal and Installation ......................................... W3-10-2-1 Pin, Standard .........................................................................W2-3-1-1 Pipe Joint ................................................................................W1-2-1-6 Piping Joint ............................................................................W1-2-1-4 Position of Install (Bucket Link) ................. W5-1-2-5, W5-1-3-4 Position to Install (Bell Crank) .........................................W5-1-2-4 Position to Install (Bucket Cylinder) .....................................................W5-1-1-7, W5-1-2-6, W5-2-2-7 Position to Install (Lever) ..................................................W5-1-2-4 Position to Install (Lift Arm Cylinder)............................W5-2-1-4 Position to Install (Lift Arm) ........................ W5-1-1-6, W5-1-3-3 Precautions for Disassembling and Assembling......W1-1-1-1 Precautions for Split Flange .............................................W1-2-1-3 Precautions for Using Floating Seal ..............................W1-1-1-2 Precautions for Using Nylon Sling .................................W1-1-1-3 Preload Adjustment of Axle Shaft Bearing (Shim Adjustment) .................................................................. W4-4-3-38 Preparation before Inspection and Maintenance....W1-6-1-1 Priority Valve ..................................................................... W3-14-1-1 Priority Valve, Structure .................................................. W3-14-3-1 62Z7(US)D&R

INDEX Priority Valve (with Secondary Steering), Removal and Installation ......................................... W3-14-2-1 Priority Valve (without Secondary Steering), Removal and Installation ......................................... W3-14-1-1 Propeller Shaft, Removal and Installation ..................W4-5-1-1 Pump Device, Removal and Installation .....................W3-8-1-1 Q Quick Coupling ....................................................................W1-2-1-7 R Radiator, Bleeding Air ........................................................W1-4-1-6 Radiator Assembly, Replacement ..................................W3-5-1-1 Rear Axle, Removal and Installation .............................W4-4-2-1 Rear Cover, Removal and Installation...........................W3-4-2-2 Rear Fender (Front), Removal and Installation ...... W3-4-2-10 Rear Fender (Rear), Removal and Installation ...........W3-4-2-7 Rear Grill, Removal and Installation ........................... W3-4-2-13 Rear Tire, Removal and Installation ...............................W4-1-2-1 Releasing Pressure ..............................................................W1-5-1-1 Removal and Installation of Air Cleaner ......................W3-4-3-1 Removal and Installation of Battery Box (With Battery Disconnect Switch) ............................W3-2-3-1 Removal and Installation of Battery Box (Without Battery Disconnect Switch) .....................W3-2-2-1 Removal and Installation of Battery Disconnect Switch.................................................................................W3-2-4-1 Removal and Installation of Bell Crank (Lever) .........W5-1-2-1 Removal and Installation of Brake Accumulator ... W3-11-3-1 Removal and Installation of Brake Charge Valve... W3-11-1-1 Removal and Installation of Brake Valve .....................W4-6-1-1 Removal and Installation of Bucket ..............................W5-1-3-1 Removal and Installation of Bucket Cylinder ............W5-2-2-1 Removal and Installation of Cab ....................................W3-1-1-1 Removal and Installation of Center Hinge .................W3-3-1-1 Removal and Installation of Control Valve .................W3-9-1-1 Removal and Installation of Counterweight .............W3-2-1-1 Removal and Installation of Cover (Lower) ................W3-4-2-4 Removal and Installation of Deck ............................... W3-4-2-10 Removal and Installation of Engine ..............................W3-4-1-1 Removal and Installation of Engine Cover .................W3-4-2-2 Removal and Installation of Exhaust Filter .............. W3-17-1-1 Removal and Installation of Exhaust Filter Regeneration Control Solenoid Valve ................. W3-13-1-1 Removal and Installation of Exterior Parts .................W3-4-2-1 Removal and Installation of Fan Motor .................... W3-15-3-1 Removal and Installation of Fan Valve ...................... W3-15-1-1 Removal and Installation of Front Attachment ........W5-1-1-1 Removal and Installation of Front Axle .......................W4-4-1-1 Removal and Installation of Front Fender ..................W3-4-2-9 Removal and Installation of Front Tire .........................W4-1-1-1 Removal and Installation of Fuel Tank .........................W3-7-1-1 Removal and Installation of HST Motor ......................W4-2-1-1 Removal and Installation of Hydraulic Oil Tank ........W3-6-1-1 Removal and Installation of Inspection Cover ....... W3-4-2-14 Removal and Installation of Lift Arm Cylinder ..........W5-2-1-1 Removal and Installation of Manifold Valve ........... W3-12-1-1

Removal and Installation of Multiple Control Valve ...................................................................................W3-9-1-1 Removal and Installation of Pilot Valve .................... W3-10-1-1 Removal and Installation of Pilot Valve (Two Lever Type) ......................................................... W3-10-2-1 Removal and Installation of Priority Valve (with Secondary Steering) ....................................... W3-14-2-1 (without Secondary Steering) ................................ W3-14-1-1 Removal and Installation of Propeller Shaft ..............W4-5-1-1 Removal and Installation of Pump Device .................W3-8-1-1 Removal and Installation of Rear Axle .........................W4-4-2-1 Removal and Installation of Rear Cover ......................W3-4-2-2 Removal and Installation of Rear Fender (Front) .. W3-4-2-10 Removal and Installation of Rear Fender (Rear) .......W3-4-2-7 Removal and Installation of Rear Grill ....................... W3-4-2-13 Removal and Installation of Rear Tire...........................W4-1-2-1 Removal and Installation of Ride Control Accumulator (Option) ............................................... W3-16-3-1 Removal and Installation of Ride Control Valve (Option) .......................................................................... W3-16-1-1 Removal and Installation of Secondary Steering Pump (Option) ................................................................W4-8-1-1 Removal and Installation of Side Cover ......................W3-4-2-5 Removal and Installation of Steering Accumulator ..............................................................................................W4-7-5-1 Removal and Installation of Steering Cylinder .........W4-7-3-1 Removal and Installation of Steering Valve ...............W4-7-1-1 Removal and Installation of Step (Front) ................. W3-4-2-10 Removal and Installation of Step (Rear) ................... W3-4-2-14 Removal and Installation of Support ...........................W3-4-2-4 Removal and Installation of Transmission ..................W4-3-1-1 Removal of Battery Box (Left)..........................................W3-2-2-2 Removal of Battery Box (Right) ................. W3-2-2-1, W3-2-3-1 Removal of Differential Housing ................................. W4-4-3-11 Removal of Housing ........................................................ W4-4-3-13 Replacement of Intercooler .............................................W3-5-1-1 Replacement of Oil Cooler ...............................................W3-5-1-1 Replacement of Radiator ..................................................W3-5-1-1 Ride Control Accumulator (Option), Removal and Installation..................................................................... W3-16-3-1 Ride Control Accumulator Pressure Release Procedure (Option) .............................................................................W1-5-1-2 Ride Control Valve (Option), Assembly ..................... W3-16-2-4 Ride Control Valve (Option), Disassembly ............... W3-16-2-1 Ride Control Valve (Option), Removal and Installation ........................................................................................... W3-16-1-1 Rotation Resistance Adjustment of Pinion.............. W4-4-3-26 S Screw-In Connection..........................................................W1-2-1-8 Seal Tape Application.........................................................W1-2-1-8 Secondary Steering Device (Option) ............................W4-8-1-1 Secondary Steering Pump (Option), Removal and Installation ........................................................................W4-8-1-1 Side Cover, Removal and Installation ...........................W3-4-2-5 Specified Tightening Torque Chart ...............................W1-2-1-1

62Z7(US)D&R

INDEX Spider, Disassembly ......................................................... W4-4-3-10 Split Flange, Precautions ..................................................W1-2-1-3 Standard Dimensions for Lift Arm and Bucket .........W2-3-2-1 Steering Accumulator, Removal and Installation ....W4-7-5-1 Steering Cylinder, Assembly ............................................W4-7-4-5 Steering Cylinder, Disassembly ......................................W4-7-4-1 Steering Cylinder, Removal and Installation..............W4-7-3-1 Steering Device ...................................................................W4-7-1-1 Steering Pump, Disassembly ...........................................W3-8-3-7 Steering Valve, Assembly ..................................................W4-7-2-4 Steering Valve, Disassembly ............................................W4-7-2-1 Steering Valve, Removal and Installation....................W4-7-1-1 Step (Front), Removal and Installation ..................... W3-4-2-10 Step (Rear), Removal and Installation ....................... W3-4-2-14 Structure of Brake Charge Valve.................................. W3-11-2-1 Structure of Exhaust Filter Regeneration Control Solenoid Valve .............................................................. W3-13-2-1 Structure of Fan Motor ................................................... W3-15-4-1 Structure of Fan Valve ..................................................... W3-15-2-1 Structure of Priority Valve .............................................. W3-14-3-1 Support, Removal and Installation ...............................W3-4-2-4 T Teeth Engagement Adjustment of Ring Gear and Pinion ........................................................................................... W4-4-3-31 Tightening Bolts and Nuts ...............................................W1-2-1-1 Tire ............................................................................................W4-1-1-1 Tire Size .............................................................. W4-1-1-3, W4-1-2-5 TPD ...........................................................................................W4-4-3-1 Transmission Charge Pump, Disassembly ..................W3-8-3-3 Transmission, Assembly ................................................. W4-3-2-10 Transmission, Disassembly ..............................................W4-3-2-1 Transmission, Removal and Installation ......................W4-3-1-1 U Union Joint ............................................................................W1-2-1-5

62Z7(US)D&R